Siemens Simotion A4027118 A0414 Users Manual Manual_SIMOTION Flying Saw_V1.4

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2015-02-05

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User Manual Flying Saw

SIMOTION Flying Saw V1.4

Application number: A4027118 -A0414

General Notes

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We reserve the right to make technical changes to this product.

Reproduction, transmission or use of this document or its contents is not

permitted without express written authority. Offenders will be liable for

damages. All rights, including rights created by patent grant or registration

or a utility model or design, are reserved.

General Notes

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General Notes

Note The standard applications are not binding and do not claim to be

complete regarding the circuits shown, equipping and any eventuality.

The standard applications do not represent customer-specific solutions.

They are only intended to pro-vide support for typical applications. You

are responsible in ensuring that the de-scribed products are correctly

used. These standard applications do not relieve you of the responsibility

in safely and professionally using, installing, operating and servicing

equipment. When using these application examples, you recognize that

Siemens cannot be made liable for any damage/claims beyond the

liability clause described. We reserve the right to make changes to these

standard applications at any time without prior notice. If there are any

deviations between the recommendations provided in these standard

applications and other Siemens publications - e.g. Catalogs - then the

contents of the other documents have priority.

Warranty, liability and support

We do not accept any liability for the information contained in this

document.

Any claims against us - based on whatever legal reason - resulting from the

use of the examples, information, programs, engineering and performance

data etc., described in this standard application shall be excluded. Such an

exclusion shall not apply in the case of mandatory liability, e.g. under the

German Product Liability Act (“Produkthaftungsgesetz”), in case of intent,

gross negligence, or injury of life, body or health, guarantee for the quality

of a product, fraudulent concealment of a deficiency or breach of a

condition which goes to the root of the contract (“wesentliche

Vertragspflichten”). However, claims arising from a breach of a condition

which goes to the root of the contract shall be limited to the foreseeable

damage which is intrinsic to the contract, unless caused by intent or gross

negligence or based on mandatory liability for injury of life, body or health

The above provisions does not imply a change in the burden of proof to

your detriment.

these standard applications or excerpts of them without first having prior

authorization from Siemens A&D in writing.

For questions regarding this application please contact us at the following

e-mail address:

mailto:applications.erlf@siemens.com

General Notes

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Qualified personnel

In the sense of this documentation qualified personnel are those who are

knowledgeable and qualified to mount/install, commission, operate and

service/maintain the products which are to be used. He or she must have

the appropriate qualifications to carry-out these activities

e.g.:

• Trained and authorized to energize and de-energize, ground and tag

circuits and equipment according to applicable safety standards.

• Trained or instructed according to the latest safety standards in the care

and use of the appropriate safety equipment.

• Trained in rendering first aid.

There is no explicit warning information in this documentation. However,

reference is made to warning information and instructions in the Operating

Instructions for the particular product.

Reference regarding export codes

AL: N

ECCN: N

Foreword

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Foreword

Standard SIMOTION application

A standard SIMOTION application comprises the following components:

• One or several software objects or code blocks with defined interfaces

that can be simply integrated into other software projects – without

requiring any significant programming – in order to fulfill a precisely

defined technology task there. (Core functions)

• A software project based on a demonstration case to show the

functionality and possible uses of the standard application - including

the associated WinCCflex screen for demonstration. (Demonstration

project)

• A document to describe the functionality, background information and

handling of the standard application. Further, its use as demonstration

model is explained. (Description)

Foreword

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Document structure

The documentation of this application is sub-divided into the following main

section:

Sec-

tion Description Note

A Section A will provide you with everything that

you require to obtain an overview of this

standard application. This Section explains the

prerequisites and the objective when using this

application.

Some of the uses of this standard application are

explained as well as situations where this

application cannot be used.

B Section B is interesting if you wish to use this

standard application for demonstration purposes.

Here, you are provided with information about

how you can download this application from your

PC/PG to the demonstration case step-by-step

and how it then used.

C Section C provides you with all of the necessary

steps to integrate the core functions of the

standard application into your user project.

Preparations and parameterizing operations are

also explained. Further, you are also told how to

integrate the core functions into your application

step-by-step.

In addition, tips are provided on how to use the

core functions.

D Section D is interesting if you wish to

expand/adapt the functionality of the core

functions provided for your particular application.

E Section E “Appendix” provides you with detailed

information including a detailed fault/error

description, a description of a test program for

the core standard application functions as well as

references. A feedback sheet is also provided

which you can use to give us your comments

and suggestions on this document.

List of contents

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List of contents

Section A: Prerequisites and objectives .................................................................. 10

1 Basic information ......................................................................................... 11

1.1 Prerequisites................................................................................................... 11

1.1.1 Target group ................................................................................................... 11

1.1.2 Knowledge base ............................................................................................. 11

1.1.3 Technical environment.................................................................................... 11

1.2 Objective and purpose of this standard application........................................ 11

1.2.1 Task description.............................................................................................. 11

1.2.2 Solution using the standard “flying saw” application....................................... 12

1.2.3 Advantages of the standard "flying saw" application ...................................... 13

1.3 Components included in the standard application.......................................... 13

2 Uses ............................................................................................................... 15

2.1 Applications .................................................................................................... 15

2.1.1 Controls that are permitted ............................................................................. 15

2.1.2 Tasks that can be implemented using the core functions............................... 15

2.1.3 Properties and features of the core “flying saw” functions.............................. 16

2.2 Application environment ................................................................................. 17

3 Structure and function ................................................................................. 18

3.1 Design of the "flying saw" ............................................................................... 18

3.1.1 General design ............................................................................................... 18

3.1.2 Physical quantities that can be parameterized ............................................... 18

3.2 Operating states of the "FlyingSaw-FB".......................................................... 20

Section B: The application example as demonstration system............................ 22

4 Installing the hardware and software ......................................................... 23

4.1 Regarding your safety..................................................................................... 23

4.1.1 Safety information and instructions................................................................. 23

4.1.2 Responsibilities of the operator ...................................................................... 24

4.2 Hardware structure and mounting/installation ................................................ 25

4.3 Installing the standard SIEMENS software..................................................... 28

4.4 Downloading the user program and parameterizing the drive in the SIMOTION

D demonstration case ................................................................................ 28

4.4.1 De-archiving the SIMOTION project ............................................................... 28

4.4.2 Resetting SIMOTION D435 to the factory settings ......................................... 28

4.4.3 Re-configuring the double-axis motor module from 3A/3A to 5A/5A .............. 30

4.4.4 Setting the Ethernet interface of the PG/PC................................................... 32

4.4.5 Downloading the hardware configuration after a factory setting..................... 37

4.4.6 Downloading the SIMOTION project of the standard application ................... 38

5 Operator control of the application example ............................................. 41

List of contents

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5.1 Brief instructions to demonstrate .................................................................... 41

5.1.1 Structure overview.......................................................................................... 42

5.1.2 Brief instructions ............................................................................................. 43

5.2 Detailed operating instructions ....................................................................... 47

5.2.1 Structure overview.......................................................................................... 48

5.2.2 Start ................................................................................................................ 48

5.2.3 Machine parameter settings ........................................................................... 51

5.2.4 Operator control functions in the setting-mode............................................... 53

5.2.5 Operator functions of the process in the automatic mode .............................. 54

5.2.6 Technology view............................................................................................. 59

5.2.7 Operator control functions in the status display.............................................. 60

Section C: Integrating the core “flying saw” functions ......................................... 61

6 Program environment and interfaces ......................................................... 62

6.1.1 Function and identification of the program groups.......................................... 62

6.1.2 Program structure........................................................................................... 63

6.2 Call environment............................................................................................. 65

6.3 Interfaces........................................................................................................ 65

6.3.1 Classifying the interfaces................................................................................ 65

6.3.2 Block interface of the FB_BGD_TEMPLATE_FlyingSaw()............................. 66

6.3.3 Structure of the global data area of the data unit FS_Var .............................. 68

7 Integrating the core “flying saw” functions ............................................... 72

7.1 This is how you integrate core functions into your project.............................. 72

7.2 Prerequisites................................................................................................... 72

7.2.1 SIMOTION SCOUT with SIMATIC STEP 7 .................................................... 72

7.2.2 SIMOTION control .......................................................................................... 73

7.2.3 Technology objects required and synchronous relationships......................... 74

7.3 Preparations ................................................................................................... 75

7.3.1 De-archiving the standard "flying saw" application ......................................... 75

7.3.2 Downloading the core functions into your SCOUT project.............................. 75

7.4 Setting-up the required technology objects .................................................... 76

7.4.1 Flying saw axis ............................................................................................... 76

7.4.2 Axis, material web........................................................................................... 77

7.5 Assigning the synchronous relationships........................................................ 78

7.5.1 FlyingSawAxis_SYNCHRONOUS_OPERATION........................................... 78

7.6 Integrating into your application...................................................................... 79

7.6.1 Calling the “FlyingSaw FB” in the user program ............................................. 79

7.6.2 Integrating the template block in the processing sequence............................ 80

8 Using the "FB_BGD_TEMPLATE_FlyingSaw()"......................................... 81

8.1 General information and instructions.............................................................. 81

8.2 Initial state of the "FB_BGD_TEMPLATE_FlyingSaw()"................................. 81

8.3 Mode changeover sequence .......................................................................... 81

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8.4 Using the restart bit......................................................................................... 83

8.5 Error messages .............................................................................................. 83

8.6 Help functions within the core “flying saw” functions ...................................... 85

Section D: Program description............................................................................... 86

9 Information and instructions to adapt the core “flying saw” functions.. 87

9.1 Information and warnings ............................................................................... 87

10 Description of important program elements.............................................. 88

10.1 Program structure........................................................................................... 88

10.2 Declaration part FS_Var ................................................................................. 88

10.3 Functions of the FB_BGD_Template_FlyingSaw() ("FlyingSaw-FB")............. 89

10.3.1 Declarations.................................................................................................... 89

10.3.2 Start identification, axis monitoring and automatic state change chains ........ 90

10.3.3 Checking the input parameters and parameterization of the technology

settings that are absolutely necessary....................................................... 91

10.3.4 State machine of the “FlyingSaw FB” ............................................................. 91

10.4 Properties/features of startup_SAP ................................................................ 98

10.5 Help routines................................................................................................... 98

10.5.1 Features and characteristics of the MT_FS1_PrintmarkDetection (print mark

sensing)...................................................................................................... 98

10.5.2 Properties/features of the IPO_FS1_IPO_Routine ......................................... 98

10.5.3 SyncPos buffer ............................................................................................... 98

Section E: Appendix................................................................................................100

11 General information on the application.................................................... 100

11.1 Scope of supply ............................................................................................ 100

11.2 Revisions/Author........................................................................................... 100

12 Error messages........................................................................................... 101

12.1 Signaling error events at the “FlyingSaw FB” of the core “flying saw” functions101

12.2 Possible error messages at the error code output ErrorID of the

„FB_BGD_TEMPLATE_FlyingSaw()“ ...................................................... 101

13 Contact partner........................................................................................... 106

14 Please help us to become even better...................................................... 107

Section A: Prerequisites and objectives

Basic information

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Section A: Prerequisites and objectives

Content

Section A will provide you with everything that you require to obtain an

overview of this standard application. The prerequisites and the objective

for using this standard application are presented.

The applications shown will give you a good understanding for what this

standard application can be used for. Further, some applications will be

listed for which this standard application cannot be used. In addition, the

performance limits of this standard application will be shown.

Objective

Section A of this document should provide the user with the following

information:

• The objective and purpose of this standard application

• List several applications

• Indicate the performance limits of this standard application.

Subjects discussed

Chap. Title Contents

1 Basic information

The necessary prerequisites to use the standard “flying saw”

application.

The use of this application.

Software components and code blocks of the standard

“flying saw” application.

2 Uses Tasks and properties of the core functions of the standard

“flying saw” application

Exclusions and restrictions

Hardware components required

3 Structure and

function Type of design and physical quantities for which the “flying

saw” core function can be used.

Type of cams that the “flying saw” core functions calculate

and used.

Operating states at the FlyingSaw FB.

4 Program

environment and

interfaces

Call environment of the FlyingSaw FB

Description of the interfaces and the parameters of the

FB_BGD_TEMPLATE_FlyingSaw()

Section A: Prerequisites and objectives

Basic information

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1 Basic information

1.1 Prerequisites

1.1.1 Target group

The standard application is conceived for all programmers and users who

wish to quickly and simply implement a flying saw using SIMOTION.

1.1.2 Knowledge base

In order to use this technology template, you should be able to use SCOUT

and technology objects and technology function calls in SIMOTION.

This document does not provide an introduction into these subjects and is

solely restricted to providing information and data on how to use this

standard application.

1.1.3 Technical environment

This standard application can only be used, without having to make any

changes, in conjunction with SIMOTION D and the SINAMICS

demonstration case.

1.2 Objective and purpose of this standard application

1.2.1 Task description

Using SIMOTION, a material web, fed using the material feed mechanism

is to be cut into identical parts and sections. As a result of the

characteristics of the material, the material cannot be cut at once across

the whole width of the web with just one cut. In order that the motion of the

material web does not have an impact on the cut, either the material web

must be stopped during the cut, or the cutting device must be moved in

synchronism with the material web – i.e. the material web is cut "on the fly".

Why flying processing/machining?

"Flying" processing/machining is required, if

• If the flow of products were to be stopped due to a sub-process

(generally a thermal process) this would result in a reduction in quality

or even waste.

• Stopping the product flow cannot be justified as a result of the energy

demand when decelerating and accelerating.

• The individual processing/machining steps are too different so that a

standard delay time cannot be justified from a cost-effective

perspective.

Section A: Prerequisites and objectives

Basic information

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Principle design of a "flying saw"

The material is fed-in as an endless web (e.g. plastic, sheet steel or fiber

board) using a conveyor belt that runs with a constant velocity.

The position of the cut on the material web is either sensed using a print

mark using a sensor or is specified by the control after a cut length has

been passed that can be adjusted. The synchronous position is

simultaneously defined. From this point onwards, the shears slide of the

flying saw synchronously follows the material at the position to be cut and

the cut can be started. After the cut has been completed, the shears slide is

returned to its starting position where it waits for the next cut position.

Fig. 1-1: Principle of operation of the “flying saw”

Drive of flying saw

Web drive

measuring system

Sensor Starting position

1.2.2 Solution using the standard “flying saw” application

The standard “flying saw” application discussed here can be used to

implement such applications, and to develop a functioning "flying saw" as

quickly as possible.

The standard application already includes, as core function, a pre-

configured motion control of the flying saw axis. This can be adapted to the

particular application using the appropriate parameters. The core function is

responsible for completely controlling the flying saw axis.

Section A: Prerequisites and objectives

Basic information

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The user program only has to control the material feed and to supply the

core function with the correct parameters.

Additional function of the standard application

Further, using this standard application, after the material has been cut with

the cutting device, a gap can be created between the individual cut pieces.

This function can also be set at the core function and commissioned by

simply entering the appropriate parameters.

1.2.3 Advantages of the standard "flying saw" application

When the standard “flying saw” application is used, it offers users the

following advantages:

Programs can be quickly generated

When the standard “flying saw” application is used, it is simple to quickly

implement a "flying saw" functionality when programming with SIMOTION.

The core functions provided in the standard application can be transferred

into the application to be generated quickly and simply by copying. The

description of this standard application explains the additional configuring

steps that are necessary.

Automatic motion control

The core functions of the standard “flying saw” application can be used to

realize all of the flying saw axis motion control using SIMOTION technology

functions. The user only programs a execution sequence that corresponds

to the actual behavior of the machine function to be implemented.

Possibility of adaptation

The standard “flying saw” application includes all of the source codes in a

commented form. This means that the existing core functions can be

quickly and simply expanded by the user's own particular functions.

This description also provides you with an explanation of the background

required to expand the core functions.

1.3 Components included in the standard application

The standard “flying saw” application is implemented as SIMOTION project.

It is a program that can be executed for a (demonstration) machine for the

SIMOTION D and PC demonstration case with WinCCflex for visualization.

Section A: Prerequisites and objectives

Basic information

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The program fulfills the following tasks:

• Operating mode manager for the complete (demonstration) machine

• The control of the (demonstration) machine

• The core functions of the "flying saw" functionality with absolute gearing

• All of the machine functions that are relevant for the demonstration case

environment are simulated

• The (demonstration) machine is displayed on the WinCCflex screen

This means that the user immediately sees which program modules are

required to implement his particular flying saw application; these program

modules are sub-divided into program groups and are appropriately

designated.

This means that the core functions of the standard “flying saw” application

can be quickly and simply integrated into user projects.

Section A: Prerequisites and objectives

Uses

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2 Uses

2.1 Applications

2.1.1 Controls that are permitted

The standard “flying saw” application has only been tested for use in the

following control system:

• SIMOTION D 435

However, it can also be used – without any significant additional costs –

also in the SIMOTION P or SIMOTION C controls.

2.1.2 Tasks that can be implemented using the core functions

These core functions are used to control flying equipment and mechanisms

• Cut

• Perforate

• Emboss

• Seal

• Saw

• Drill

• Paint

• etc.

The core “flying saw” function completely handles the motion control of the

flying axis used for cutting/sawing. The functionality associated with the

material feed is implemented outside the core functions in the user

program.

Definition In the following text, the “flying saw” term is used to represent all of the

other conceivable machine versions.

The term “saw” is used for all parts of the machine where direct contact

is made to the material when “cutting”.

Section A: Prerequisites and objectives

Uses

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2.1.3 Properties and features of the core “flying saw” functions

The following properties and features were taken into account when

implementing the core functions, and can also be used in a user program

that you generate yourself:

• Precisely synchronizing at a specific position

The "flying" axis is accelerated to the velocity of the material web so

that this reaches this velocity above a position on the material that can

be specified.

• Flying axis

The "flying" axis and the material move at the same velocity while

sawing/cutting.

• The starting position of the "flying" axis can be set

The starting position of the "flying" axis between two cuts can be set

using a parameter at the core function.

• "Cutting" at a print mark

The synchronous position is detected using a measuring probe and

print mark.

• "Cutting" to length

The synchronous position is calculated from the distance that the

material has moved through.

• Immediate cut

A cut is initiated by an operator function independently of the distance

that the material has moved. (This function is only possible for "cut" to

length!)

• Creating a gap

After a cut has been made, the cutting unit additionally moves the cut

material in the direction in which the material is moving until a certain

distance is reached to the rest of the material. This distance can be

specified. The cutting unit only returns to its starting position after this

operation has been completed.

• Asymptotic synchronizing

The “flying” axis is accelerated to the velocity of the material web

without overshoot in velocity.

• Gearing Ratio

Ratio between measured and effective velocity of the material web.

Section A: Prerequisites and objectives

Uses

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2.2 Application environment

The standard “flying saw” application can be used in the following hardware

environment:

Fig. 2-1 Application environment of the standard “flying saw” application

Sensor

Motor

Encoder

Motor

Encoder

PG / PC

SIMOTION D

Material web

SIMOTION D used to control the material feed of the material web and to

control the "flying" axis.

Section A: Prerequisites and objectives

Structure and function

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3 Structure and function

3.1 Design of the "flying saw"

3.1.1 General design

The "flying saw", which is based on the "flying saw" core function comprises

a spindle axis that is mounted on the cutting unit.

3.1.2 Physical quantities that can be parameterized

The following physical quantities of the “flying saw” (designations in white)

are used in the “flying saw” core function:

Fig 3-1 Physical quantities for the standard “flying saw”

Sensor

Sync position EndSync-

position

Starting position

DistanceToSensor

Synchronous range

Section A: Prerequisites and objectives

Structure and function

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Table 3-1: Explanation of the parameterizable physical quantities

Physical quantity Description

DistanceToSensor

[mm] Distance (clearance) between the axis zero of the "flying saw"

and the sensor to sense the material and print mark

StartPos

[mm] Starting position of the cutting unit referred to the axis zero

point of the "flying saw".

SyncPos

[mm] Position where the cutting unit reaches the specified material

position and material velocity. Starting point of the

synchronous range

EndSyncPos

[mm]

End point of the synchronous range. If, at this particular

position, sawing/cutting has still not been completed, then it is

now interrupted.

EndPos

[mm] End point (end position) of the traversing range of the "flying

saw"

(software limit switch)

ToStartposVelocity

[mm/s] Velocity for travel to the starting position

ToBackposVelocity

[mm/s]

Velocity with which the flying saw returns to its starting position

GapLength

[mm]

Length of the gap after the cutting unit has made a cut. This

gap is to be additionally created between the cut material and

the material web.

GapVelocity

[mm/s]

Superimposed velocity with which the gap is to be created

GearingRatio Ratio between measured and effective velocity of the material

web.

AccelerationCut

[mm/s²]

Acceleration value for synchronization motion

AccelerationBack

[mm/s²]

Acceleration value for positioning motion back to the starting

position

AccelerationGap

[mm/s²]

Acceleration value for the higher-level positioning to create the

"gap"

Synchronous range

The synchronous range is located between SyncPos and the

EndSyncPos. The material is cut within this range.

Section A: Prerequisites and objectives

Structure and function

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3.2 Operating states of the "FlyingSaw-FB"

The “FlyingSaw FB” automatically controls the “flying saw” axis to

implement the required level of functionality.

This functionality is sub-divided into five operating states so that the

sequences at the “flying saw” are implemented as a result of the states or

also as a result of the transitions between the states.

This means the user only influences the “flying saw” by specifying the

required operating mode with the required parameters.

Fig. 3-2 Operating modes

Disable

Startposi-

tion

Startposi-

tion

Manual

Error

Auto-

matic

Auto-

matic

A differentiation is made between the following operating modes:

• Error (0)

The “FlyingSaw FB” has detected an error and brought the flying saw

axis into a safe state. The fault is still available and the user can

evaluate it.

The flying saw axis is stopped and is in the “disable” state.

• Disable (1)

The “FlyingSaw FB” is already being used but is in the safety operating

state. All of the faults/errors present have been successfully

acknowledged.

After a reset, the flying saw axis is in the disabled and stopped state.

• Starting position (2)

The flying saw axis moves to the starting position or is located at the

Section A: Prerequisites and objectives

Structure and function

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starting position and is ready to synchronize to the material web.

The flying saw axis waits in the “enable” state.

• Automatic (3)

The flying saw axis has been synchronized to the material web and cuts

the material as specified.

• Manual (4)

The flying saw axis is in the manual mode and the user can manually

move the shaft.

The flying saw axis waits in the “enable” state.

These operating modes are available to users to implement their "flying

saw" functionality in a user program and can be signaled to the "FlyingSaw

FB“ using input parameters.

The “FlyingSaw FB” indicates the currently reached status using an output

parameter.

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system

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Section B: The application example as demonstration

system

Contents

All of the necessary steps to commission the standard “flying saw”

application as demonstration system are explained in Section B.

Preparations and parameterizing operations are also explained. Further,

you are told how you can use the WinCCflex Pro man-machine interface

(screen) of the application example step-by-step.

Objective

Section B of this document provides the reader with the following

• The prerequisites to use this standard SIMOTION application as

demonstration system

• Preparations and parameterizing operations are explained

• Describes the steps necessary when presenting this standard

application.

• Provides tips for using this standard application.

Subjects discussed

Chap. Title Contents

5 Installing the

hardware and

software

Safety information and instructions

Components and their interconnections required for the

presentation

Installation of standard SIEMENS software

Downloading the user program in SIMOTION D435

Downloading drive parameters in SINAMICS

6 Operator control of

the application

example

Brief instructions on how to use the demonstration system

Detailed operating instructions

Section B: The application example as demonstration

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4 Installing the hardware and software

4.1 Regarding your safety

4.1.1 Safety information and instructions

Pictograms, signal words and text

Every piece of safety information/instruction in this document is designated

by text graphics – comprising pictogram and signal word, and

supplemented by explanatory text. A clear classification according to the

degree of the potential hazard is provided as a result of the combination of

pictogram and signal word. Safety information/instructions are provided in

front of the information regarding activities to be executed.

Classification

There are three different stages regarding safety information/instructions.

These are designated by the same pictogram. They differ by the signal

word.

Danger

This safety information/instruction indicates an immediate hazard. If

the information/instruction is not carefully followed, this results in

severe bodily injury or even death.

Warning

This safety information/instruction indicates a potential hazard. If

the information/instruction is not carefully followed, this can result

in severe bodily injury or even death.

Caution

This safety information/instruction indicates a potentially hazardous

situation, which can result in slight to average bodily injury. This

pictogram/text word can also warn about potential material damage.

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4.1.2 Responsibilities of the operator

Correct use

The correct use of the application components exclusively relates to the

open-loop and closed-loop control of test set-ups that were adapted to the

power/performance of the application components. In order that the

application functions perfectly, the required standard SIMATIC components

as well as also the necessary hardware and software components must be

installed.

The company/person operating the system may only make changes to the

application components after having received written authorization from the

suppliers.

Misuse

The following are considered to be misuse:

• Inadmissible loads applied to the application components.

• Any application deviating from the use specified above, or applications

that go beyond the specified use.

• Non-observance of the safety information and instructions.

• If faults that could have a negative impact on the safety are not

immediately resolved/removed.

• Any changes/modifications to equipment/devices that are used to

ensure perfect function and operation, unrestricted use as well as active

or passive safety.

• If recommended hardware and software components are not used.

• If the application components are not in a perfect technical condition are

not operated conscious of safety and hazards, and not taking into

account all of the instructions provided in the documentation.

The manufacturer assumes no liability for incorrect use (misuse).

Responsible for monitoring

The company or person operating the system is responsible in continually

monitoring the overall technical status of the application components

(defects and damage that can be externally identified as well as changes in

the operating behavior).

The company/person operating the system is responsible in ensuring that

the application is only operated in a perfect state. He must check the state

of the application components before they are used and must ensure that

any defect is removed before commissioning.

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Qualification of personnel

The operating company/person may only deploy trained, authorized and

reliable personnel. In so doing, all safety regulations must be carefully

observed.

Personnel must receive special instructions regarding the hazards/dangers

that can occur.

4.2 Hardware structure and mounting/installation

Overview

Fig. 4-1 Hardware components (without power cable!)

MPI/DP

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Table 4-1 Hardware components

Hardware element Diagram Order No./MLFB and functions

Training case, SIMOTION D435 with SINAMICS S120

SIMOTION D

demonstration and

training case

6ZB2 470-0AE00

The SIMOTION D training case comprises

standard components (SIMOTION D435,

two SINAMICS axes with motors) and has

two axes. These are used to demonstrate

the application.

The case is already pre-configured and

connected-up. It only has to be connected

to the HMI system via PROFIBUS.

Communications

PROFIBUS connector

up to 12 Mbit/s

6ES7972-0BA41-0XA0

The connector is used to establish a

connection between the HMI system and

the SIMOTION D435 training case

PROFIBUS cable

6XV1830-0EH10 (sold by the meter, from

20m)

The cable is used to establish a connection

between the HMI system and the

SIMOTION D435 training case

HMI system

PG/PC with MPI

interface

The PG/ PC is used as the HMI display

screen.

Procedure

Please proceed as follows to configure and install the hardware

components for the application example:

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Table 4-2 Hardware configuration and mounting

No. Action Comment

1 Connect the MPI/DP interface of your PG/PC

to the righthand MPI/DP interface (contact

X136) of the SIMOTION D435 using a

PROFIBUS cable and switch the terminating

resistors in the two terminating connectors of

the cable to “On”.

Do not use the standard MPI cable,

supplied with the PG/PC to connect the

PG/PC to the SIMOTION D435!

The connection should be operated with a

12Mbit/s baud rate. Under all

circumstances, a PROFIBUS cable must

be used between the PG/PC and

SIMOTION D435 with the terminating

resistors switched-in. If this is not done,

communication problems can occur

between the PG/PC and the SIMOTION

D435.

2 Connect the SIMOTION D training case to

the power supply.

3 Power-up all of the equipment/devices.

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4.3 Installing the standard SIEMENS software

Minimum required releases

Table 4-3 Versions

Component Version.

STEP 7 V5.4 + SP2

SIMOTON SCOUT V4.1.1.6

WinCCflex Advanced 2007 Hotfix 4

Installation

Please install the following

• Step 7 V5.4 incl. SP2

• SIMOTION SCOUT V4.1.1.6

• WinCCflex 2007 Hotfix 4 Advanced

(with the option: Integration in Step 7)

Please follow the instructions of the installation programs.

4.4 Downloading the user program and parameterizing the drive in

the SIMOTION D demonstration case

4.4.1 De-archiving the SIMOTION project

• Open SIMOTION SCOUT

• De-archive the SIMOTION project and open it using SIMOTION

SCOUT

4.4.2 Resetting SIMOTION D435 to the factory settings

In order to obtain a fixed starting point for the description on how to

download the user program into the demonstration case, restore the factory

setting at the demonstration case as described below:

• Power-down the demonstration case

• Set the mode switch SIMOTION D435 to setting 3 (MRES)

• Power-up the demonstration case

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• When RDY lights green and STOP lights orange, set the SIMOTION

D435 mode switch to the 0 position (RUN)

• RDY and RUN are green

Once the factory setting has been restored, the SIMOTION D435 has

PROFIBUS address 2 and the baud rate is 1.5 Mbit/s.

Fig. 4-2 Mode selector switch, SIMOTION D435

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4.4.3 Re-configuring the double-axis motor module from 3A/3A to 5A/5A

This application example is configured as standard using a 3A/3A motor

module. However, there are demonstration cases in the field, which are still

equipped with a 5A/5A motor module. The hardware should be carefully

checked before the project is downloaded! If a 3A/3A motor module is not

used in the demonstration case, then the project can be re-configured by

following the subsequent instructions:

• Go offline

• In the project tree, open the “Drive Navigator”

• A selection window opens when the “Device configuration” button is

pressed

• Open the Configurator by pressing the “Execute drive configuration"

button

• Scroll in the selection menu of the power unit by pressing the

“Continue” button

• Select the power unit being used from the list – refer to the serial

number on the front of the double motor module, e.g. 6SL3120-2TE15-

0AA0 (5A/5A)

• Press “Continue” and acknowledge the alarm messages

• Press the “Continue” button – without making any additional changes –

until the “Complete” button appears; also press this

• Close the Device Configurator

• In the Expert list of the red and blue drives (select the particular drive ->

righthand mouse key -> Expert -> Expert list), reduce parameter p210

from 600V to 345V

• Compile and save the project, go online and load the project into the

target system

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Fig. 4-3: Re-configuring the motor module

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4.4.4 Setting the Ethernet interface of the PG/PC

Setting the PG/PC interface

Table 3-5: Setting the PG/PC interface

No. Action Comment

1 In SIMOTION SCOUT open the interface

configuration using OPTIONS Æ SET

PG/PC INTERFACE...

2 In the “Interface Parameter Assignment

Used” area, select your Ethernet

card/interface of the PG/PC using the

interface setting “TCP/IP Æ ......”.

(e.g. "TCP/IP Æ VIA PCI 10/100 Fast

Ethernet Adapter“)

3 Acknowledge (possible) warning with

Yes.

Acknowledge your change with OK

5 Now return to SIMOTION SCOUT and

open the network configuration

NETPRO using the button or the

menu PROJECT Æ OPEN NETPRO .

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6 Open Properties by double-clicking on

the PG/PC(1).

7 Under the “Assignment” tab (this is

already automatically selected), the

ETHERNET interface used must be listed

under “Assigned”. If this is already the

case, then select this and set the

checkmark for S7ONLINE access active.

In this case, you skip steps 8 and 9!

Acknowledge your entry with OK.

Under certain

circumstances, the

Ethernet line of the

PG/PC will have a

”yellow border”.

If the ETHERNET interface used is still

not listed under “Assigned” then

execute steps 8 and 9 (but only then!).

8 The ETHERNET interface is still not

“assigned”:

The configured interface of the control is

listed under “Configured Interfaces” and

all of the available interfaces of the

PG/PC are under “Interface Parameter

Assignments in the PG/PC”.

Select the ETHERNET interface to be

used under “Interface Parameter

Assignments in the PG/PC” (just the

same as set in “Set PG/PC interface”)

and press the Assign button.

If a warning is displayed, then

acknowledge this with OK.

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9 The interface of the control is now

assigned the interface of the PG/PC.

Select this and if it has still not been set,

then set the checkmark for S7ONLINE

access Active.

Acknowledge your entry with OK.

Under certain

circumstances, the

Ethernet line of the

PG/PC will have a

”yellow border”.

10 Please select “Compile and check

everything”

(button ) and acknowledge with OK

11 If any references are made to alarms,

then please close.

12 Before you load the project, please close

NETPRO and set the Ethernet address of

your PG/PC.

Refer to the next Section

Setting the Ethernet address of the PG/PC

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Table 3-6: Ethernet address

No. Action Comment

1 Open the window Network and Dial-up

Connections of your PG/PC and select

the network connection to SIMOTION

D435 and open its properties.

(righthand mouse click Æ Properties – or

select the symbol and then FILE Æ

PROPERTIES).

2 In the window “This connection uses the

following items” select “Internet Protocol

(TCP/IP)” and open its properties.

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3 The Ethernet interface IE2 (X130) of

SIMOTION D435 has, as standard, the

IP address 169.254.11.22.

Select “Use the following IP address”

and enter the IP address 169.254.11.23.

Enter 255.255.0.0 as “Subnet mask”.

4 The address set above must be identical

to the address for the PG/PC. Check this

address by selecting the PG/PC

interface in Netpro and, if required,

modify this.

5 Acknowledge your changes by pressing

twice on OK.

4.4.5 Downloading the hardware configuration after a factory setting

To download the hardware configuration, please proceed as follows

Table 4-4: Downloading the hardware configuration after a factory setting

No. Action Comment

1 Now go into the hardware configuration

and press the Download to target

module button

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2 Acknowledge with OK

3 Acknowledge with OK

4 Press No and do not restart

5 Close the hardware configuration and

change to Scout

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4.4.6 Downloading the SIMOTION project of the standard application

Table 4-5: Downloading the SIMOTION project

No. Action Comment

1 Before you download the project, in the offline

mode, please check under Target

system/Select target devices

4 Whether both SIMOTION D435 as well as

also SINAMICS_Integrated are selected.

Please acknowledge changes with OK.

5 After establishing the ONLINE connection,

the operating states of the devices accessed

are displayed in the diagnostics overview.

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6 After starting the download, you will be

prompted as to whether you wish to “copy

RAM to ROM“ after the download. Always

answer this question with Yes as otherwise

your program must be again downloaded

after power ON/OFF.

This copy operation only refers to the

SIMOTION part of the project

7 Once the download has been completed,

please acknowledge with OK

8 Also acknowledge the data that has been

successfully copied from the RAM to ROM

with OK

9 The system now prompts you whether you

wish to also copy the parameters of

SINAMICS_Integrated from the RAM to the

ROM.

Also answer this with Yes

10 Also acknowledge the data that has been

successfully copied from the RAM to ROM

with OK

11 After the download has been completed, you

will see the adjacent diagnostics overview.

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12 Now switch the SIMOTION D435 into the

RUN state.

To do this, click on the SIMOTION-CPU and

with the righthand mouse key and target

device/operating state, go to the operating

state display.

13 Here, click on the RUN button

The SIMOTION D435 is then in RUN and the

demonstration case is now ready to be used

for the presentation!

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5 Operator control of the application example

The application can be used to present SIMOTION D with SINAMICS and

get to know and test the functions of the CPU D435.

You will find brief instructions on how to demonstrate and present the

application in the following Chapter 5.1 Brief instructions to

demonstrate.

You will find a detailed description of all of the operator screens in Chapter

5.2 Detailed operating instruction

5.1 Brief instructions to demonstrate

Here, in these instructions you will only be shown and explained the steps

necessary to demonstrate the application. Not all of the operator screens

are discussed.. A detailed description of all operator screens is provided in

Chapter 5.2 Detailed operating instruction.

Prerequisites

The following prerequisites must be fulfilled to use the application example:

• The SIMOTION project is provided online in SIMOTION D435.

• The parameterization for the applications has been downloaded into

SINAMICS. (also included in the SIMOTION project!)

• All of the devices are powered-up.

• The SIMOTION D435 has been switched into the “Run” state using the

online function of SIMOTION SCOUT.

• At least WinCCflex Advanced 2007 Hotfix 4 is installed on the PC/PG.

Note WinCCflex requires the appropriate authorization. Authorization for at

least 256 power tags is required.

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5.1.1 Structure overview

Please refer to the following diagram for the basic operator control structure

with all of the operator areas of the application.

The SETTINGS, STATUS and MANUAL displays are not required when

presenting the application and are therefore not described in the detailed

Operating Instructions.

Fig. 5-1 Structure overview to demonstrate the application

Manual-Mode

Automatic-Mode

STATUS

TECHNOLOGY

SETTINGS

HOME

MANUAL

AUTO

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5.1.2 Brief instructions

Execute the following steps in the sequence as listed in the following table

to demonstrate the application example:

Table 5-1: Brief instructions to demonstrate/present the “flying saw” application example

No. Action Comment

1 Call the following file

"C:\Siemens\Step7\S7Proj\SAP_FlyingSaw\TDOP\

PRO__00.fwd".

As an alternative, you can also select the operator panel

using Step 7. In the SIMATIC Manager, open the

SAP_FlyingSaw project. You will find the HMI object

OP1 at the project level. Start the runtime from the

context menu (righthand mouse key).

2 If the connection to the CPU was able to be established,

the screen form appears at the top left - mode: Idle Check that your PG/PC is set

to PROFIBUS with 12 Mbit/s.

3 At the bottom left, please click on AUTO

(3rd button from the left!)

4 First activate the print mark simulation by pressing the

Print Mark Simulation ON / OFF

button.

5 Next, activate the travel to the starting position using the

button Flying Saw STARTPOS

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6 Once the “flying saw” has reached its starting position,

the Flying Saw START button is

displayed to activate the “flying saw”

Before you activate the “flying saw”, the required cut

length should be selected using the Cutlength

slider.

7 Now you can start the material feed!

Select the Material Velocity

using the

Material Velocity slider

You can start the

material feed by pressing

the Material START button

8 After the material web starts, the material enters the unit

and the print mark simulation generates, after the length,

set using the Cutlength slider switch, a print mark. The

flying saw then makes a cut.

You can immediately generate a print mark using the on-

the-spot CUT button – which is also then cut by the flying

saw.

9 The red bar

indicates how far the

flying saw must travel with the material web with the

current setting for one cut.

Activate the technology screen

by pressing the TECHNOLOGY button

10 The following are displayed in the technology screen:

• The actual material velocity

• The actual velocity of the "flying saw"

• The actual position of the "flying saw"

• The position of the material referred to the actual cut

•

You can return to the

automatic screen by pressing

the AUTO button

11 The material can be removed

by pressing the

Material END button

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12 After the last cut, the “flying saw” automatically moves to

its starting position and waits for new material.

13 Once the material has been completely removed

from the screen area, then you can

either

allow new material to enter by pressing

the Material START button

and continue with Step 8,

end the “flying saw” by pressing

the Flying Saw END button.

14 After the “flying saw” has been ended, you can

return to the welcome screen

by pressing the

HOME button

Process screen

The process screen is the main screen in the automatic mode of the

application example to control (operator control) the “flying saw”.

Fig. 5-2 Process screen in the automatic mode of the “flying saw”

Mode of the

"FlyingSaw FB“

Flying Saw

Operating state (OMAG)

application example

Position and velocity of the

material and "Flying Saw“

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The material and the “flying saw” can be started, terminated (exited) and

monitored in the process screen.

The material (material web) is started, stopped (held) and terminated

(exited) on the righthand side; the “flying saw” is started and exited on the

lefthand side.

Basic

settings Automatic

mode Calls-up the

technology

screen

To the

status

display

Manual

mode

Material

To the

start

screen

Start

Material

Stop

Material

Allow

material to

run-out

Random print

mark offset

Start flying

saw

Move flying saw

to the starting

position

Terminate

flying saw

(end)

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5.2 Detailed operating instructions

A detailed description of the application is provided in these instructions.

This is necessary so that you can get to know and test the CPU functions.

Prerequisites

The following prerequisites must be fulfilled to use the application example:

• The STEP7 project is available online in the S7-CPU.

• The parameterization for the application has been downloaded into

SIMODRIVE.

• All of the devices are powered-up.

• At least WinCCflex Advanced 2007 Hotfix 4 is installed on the PC/PG.

Note WinCCflex requires the appropriate authorization. Authorization for at

least 256 power tags is required.

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5.2.1 Structure overview

Please refer to the following diagram for the basic operator control structure

with all of the operator areas of the application.

Fig. 5-3 Structure overview

Manual-Mode

Automatic-Mode

STATUS

TECHNOLOGY

SETTINGS

HOME

MANUAL

AUTO

5.2.2 Start

In the SIMATIC Manager, open the SAP_FlyingSaw project. You will find

the HMI object OP1 at the project level. Start the runtime from the context

menu (righthand mouse key).

Call the following file

C:\Siemens\Step7\S7Proj\SAP_FlyingSaw\TDOP\PRO__00.fwd".

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The welcome screen is displayed

Fig. 5-4 Welcome screen

General screen areas

The screen forms of the application are handled using buttons at the lower

edge of each of the screen forms.

Refer to

The name of the actual operator screen form and the presently valid mode

are displayed in the upper righthand corner of the screen forms.

Refer to

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The following functions can be selected using the individual buttons:

Table 5-2 General buttons to control/handle the screen forms

Button Function

You can access the pre-setting screen from every operator

screen using the SETTINGS button.

You can access the setting-up screen from every operator

screen using the MANUAL button.

If the application is in the IDLE or AUTOMATIC-STOPPED

modes, the MANUAL mode is selected

You can access the automatic screen from every operator

screen using the AUTO button.

If the application is in the IDLE or MANUAL modes, the

AUTOMATIC-STOPPED mode is selected

You can access the technology screen from every operator

screen using the TECHNOLOGY button.

You can access the status screen from every operator

screen using the STATUS button.

You can access the welcome screen (home) from every

operator screen using the HOME button.

If the application is in the MANUAL or AUTOMATIC-

STOPPED modes, the IDLE mode is selected

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5.2.3 Machine parameter settings

The standard application allows the following parameters to be adapted:

Machine geometry

• Distance to sensor

Distance between the flying saw axis and the sensor of the material and

print mark detection

• StartPosition

Position from which the flying saw starts motion to achieve synchronism

(with the material web)

• StartSyncPosition

Position at which the flying saw is synchronized, start of the

synchronous traversing range

• EndSyncPosition

End of the synchronous traversing range

• EndPosition

Maximum traversing range of the flying saw

Flying Saw Axis Accelerations

• Cut

Acceleration value for synchronization

• Back

Acceleration value for return motion

• Gap

Acceleration value for creating a "gap".

Creating a "gap"

• GapVelocity

Additional velocity in order to create a gap between the material and the

cut piece

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Fig. 5-5 SETTINGS operator screen for machine geometry settings

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5.2.4 Operator control functions in the setting-mode

In the manual mode, the material web and flying saw can be manually

moved.

This standard application does not require any functions that may only be

executed in the setting-up mode. This is the reason that we are only

providing users with an empty screen form that can be adapted, when

required - to the specifications and requirements of the user’s application.

Fig. 5-6 MANUAL operator control screen form for the operator functions in the setting-up mode

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5.2.5 Operator functions of the process in the automatic mode

Note The automatic mode is only available, if

• There is no fault,

• Both axes are enabled, and

• For both of these axes, no manual operator control functions are

active.

Fig. 5-7 AUTOMATIC operator screen form for operator functions in the automatic mode

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Standard operator control

Table 5-3: Standard operator control in the automatic mode

No. Action Comment

1 Initial situation:

The “flying saw” is in the AUTOMATIC-STOPPED mode

2 Using the Sync Position slider switch, enter the position

at which the flying saw reaches the position where the

material web is to be cut.

3 The flying saw starts to move to the starting position by

pressing the Flying Saw STARTPOS button

4 After the starting position has been reached, the flying

saw is in the AUTOMATIC-READY mode

5 The flying saw is enabled for operation using the Flying

Saw START button.

6 The flying saw is in the AUTOMATIC-STANDBY mode

and waits for material.

7 Select the required material web velocity using the

Material Velocity slider.

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8 Depending on the material velocity and the cutting

duration, an actual maximum position of the flying saw is

obtained, which is identified by a

red bar.

9 You can start to thread the material web or continue

motion after the material web was stopped by pressing

the Material START button.

10 If the flying saw has synchronized itself to the motion of

the material web, the flying saw is in the AUTOMATIC-

PRODUCING mode.

11 Here, you can select whether a cutting position is to be

generated at each print mark (sensor signal) or only after

n print marks.

12 You can stop the material web using the Material BREAK

button.

13 When the material web has been stopped, the flying saw

is in the AUTOMATIC-HELD mode

14 You can start to remove the material web from the system

by pressing the Material END button.

15 The flying saw then waits in the AUTOMATIC-STANDBY

mode for the next material web.

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Expanded operator control

Table 5-4: Expanded operator control in the automatic mode

No. Action Comment

1 If the flying saw is in the AUTOMATIC-STOPPED,

operating mode, you can select one of two possibilities:

1. Print Mark Simulation OFF

i.e. the demonstration case itself

generates print marks using sensors. The

cut length can only be changed in steps

of complete revolutions.

2. Print MARK simulation ON

this means that the print marks – and

therefore also the cut length – can be

freely selected .

2 If the print mark simulation has been activated, this

character is displayed at the top left edge of the screen.

3 You can change the cut length with the Cutlength slider.

The system automatically calculates the minimum cut

length from the data specified for the material velocity, cut

duration, velocity for return positioning and the actual

acceleration values. The maximum cut length is obtained

from the minimum plus 1000!

4 You can enter the cutting time using sel

For act

the remaining

cutting time is displayed during the cut itself.

5 You can activate/deactivate the "gap" function using the

Gap ON / OFF button

You can define the size of the gap by entering

Gap Length

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6 Here, you can set the velocities for the return to the

starting position and also when returning to the starting

position in the automatic mode

Display areas

Fig. 5-8: Flying saw mode

This area informs you about the selected and presently active operating

mode of the FlyingSaw FB.

Fig. 5-9: Actual velocity / position

In this area, the actual velocity [mm/s] and the actual position [mm] are

displayed for the material and flying saw axis.

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5.2.6 Technology view

The technology view of the application can be selected from every operator

screen using the TECHNOLOGY button.

Fig. 5-10 Technology view of the flying saw

Using the trace function on the HMI screen, the actual position and velocity

of the flying saw, the starting position, its velocities and position of the

material web referred to the particular cut can be monitored and traced in

the technology view.

It can also be easily seen how the position of the flying saw precisely

corresponds to that of the material web during the cut itself.

Using the trace-

record function

Actual position of the

flying saw

Velocity of the flying

saw

Velocity of the

material web

Quiescent position of

the flying saw

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5.2.7 Operator control functions in the status display

The status display of the application can be selected from every operator

screen using the STATUS button.

Fig. 5-11: Status

You can see the actual state of the FlyingSaw FB in the status display.

The error numbers that are displayed under ErrorID can be viewed under

Chapter 12.2 Possible error messages at the error output ErrorID of the

„FB_BGD_TEMPLATE_FlyingSaw()“.

Errors can be acknowledged using the QUITT button.

If the FlyingSaw-FB is in the “error” state, then the Quitt button should be

pressed until the FlyingSaw-FB is in the “disable” state.

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Section C: Integrating the core “flying saw” functions

Content

All of the steps necessary to integrate the core “flying saw” functions into

your application are explained in Section C.

Preparations and parameterizing operations are also explained. Further,

you are also told how to integrate the “FlyingSaw FB” into your application

step-by-step.

Objective

Section C of this document is intended to provide the user with

• The prerequisites to use this standard SIMOTION application

• Preparations and parameterizing operations are explained

• The necessary steps to integrate this standard application into their

application.

• Information and references to possible error messages and tips on how

to use this standard application.

Subjects discussed

Chap. Title Contents

6 Program

environment and

interfaces

Structure of the standard application

Function and identification of the program groups

Call environment of the FlyingSaw FB

Description of the interfaces and the parameters of the

FB_BGD_TEMPLATE_FlyingSaw()

7 Integrating the core

“flying saw”

functions

Prerequisites that are absolutely necessary to use the core

“flying saw” functions

Preparations to use the core functions in your application

Technology objects required and their parameterization

Synchronous objects required and their parameterization

Integrating core functions into your application

8 Using the

„FB_BGD_TEMPLA

TE_FlyingSaw()“

General information and instructions

Basic state of the function block

“FB_BGD_TEMPLATE_FlyingSaw()” and when this state occurs.

Mode changeover at the "FB_BGD_TEMPLATE_FlyingSaw()".

Using the restart bit of the block.

Function of the "immediate cut" of

FB_BGD_TEMPLATE_FlyingSaw()“.

Function of the "create gap" of the

FB_BGD_TEMPLATE_FlyingSaw()“.

Display of block errors

Function of the synchronizing mechanism of the

FB_BGD_TEMPLATE_FlyingSaw ()

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6 Program environment and interfaces

6.1.1 Function and identification of the program groups

The standard “flying saw” application is sub-divided into the following

program groups:

• OMAC

• SAP

• FS

• SIM

• HMI

OMAC

In the OMAC program group, the operating mode manager is used

according to the OMAC standard of the standard SIMOTION Easy Basics

(SEB) application.

SAP

Program group to solve automation tasks (demo) machine with the

application example of the standard “flying saw” application. Based on the

SIMOTION D demonstration case, the mode of operation and core

functions of the standard application are presented/demonstrated in

conjunction with a WinCCflex-base visualization system.

Program group with the core functions of the standard “flying saw”

application.

This program group includes the "flying saw" TEMPLATE and

supplementary functions to manage the synchronous position.

SIM

Program group to simulate system signals in the demonstration case

environment

HMI

Program group to display system sequences on the WinCCflex operator

interface (screen)

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6.1.2 Program structure

All of the functions, implemented in the standard “flying saw” application are

listed in the following table according to their assignment to a particular

program group and program unit.

Table 6-1: Program structure of the standard “flying saw” application

Pro-

gram

Section

Program

unit Program

module Data

unit

OmacMain OmacMain()

OmacVar

OMAC

OmacStUp OmacStUp()

SAP SAP_FS

BGD_SAP_FlyingSaw()

Startup_SAP()

SAP_Var

SAP SAPState FC_SAP_FlyingSaw_AutomaticAborted()

FC_SAP_FlyingSaw_AutomaticAborting()

FC_SAP_FlyingSaw_AutomaticHeld()

FC_SAP_FlyingSaw_AutomaticHolding()

FC_SAP_FlyingSaw_AutomaticProducing()

FC_SAP_FlyingSaw_AutomaticStandby()

FC_SAP_FlyingSaw_AutomaticReady()

FC_SAP_FlyingSaw_AutomaticStarting()

FC_SAP_FlyingSaw_AutomaticStopping()

FC_SAP_FlyingSaw_AutomaticStopped()

FC_SAP_FlyingSaw_AutomaticManual()

FC_SAP_FlyingSaw_AutomaticIdle()

FC_SAP_FlyingSaw_AutomaticEStop()

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Pro-

gram

Section

Program

unit Program

module

Data

unit

FS_TEMPL FB_BGD_TEMPLATE_FlyingSaw()

FS_Var

FS_PMIPO MT_FS1_PrintmarkDetection()

IPO_FS1_IPO_routine()

FS_SPB FB_BGD_FS_SPB_in()

FB_BGD_FS_SPB_reset()

FB_BGD_FS_SPB_read()

FB_BGD_FS_SPB_out()

SIM SIM_PM IPO_SIM_Printmarks()

Startup_SIM()

SIM_Var

HMI HMI_SAP BGD_HMI_FlyingSaw()

Startup_HMI()

FB_BGD_HMI_Printmarks()

FB_BGD_HMI_Cuts()

FB_BGD_HMI_Material()

HMI_Var

The meanings are as follows:

FB: The program module is programmed as function block

FC: The program module is programmed as function

MT: The program must be called in the motion task

BGD: Programming function or function block is used to make a call in

the background task.

IPO: Program is used to make a call in the IPO task.

Startup Program is used to make a call in the start-up task.

Core functions, which the user can use, unchanged in his

application.

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6.2 Call environment

The function block FB_BGD_TEMPLATE_FlyingSaw() of the “flying saw”

core function must be cyclically called in the user program. This is the

reason that the call can only be made from a program that is incorporated

in the background task.

Fig. 6-1 Call environment of the FB_BGD_TEMPLATE_FlyingSaw()

SIMOTION

„FB_BGD_

TEMPLATE_

FlyingSaw()“ TO

TO specific

commands

TO specific

commands

in mode (4)

Manual only

Flying Saw Axis

other Axes

Central Function Flying Saw

Unit „FS_Var“

The technology object “FlyingSawAxis”, influenced by the function block

FB_BGD_TEMPLATE_FlyingSaw(), may only be addressed by the user

program if, beforehand, the user switched the core “flying saw” function into

Mode 4 “Manual”. In all of the other modes, it is not permissible that the

user program influences the technology object “FlyingSawAxis”.

6.3 Interfaces

6.3.1 Classifying the interfaces

The function block FB_BGD_TEMPLATE_FlyingSaw() can be influenced

using several parameters and interfaces that are classified/sub-divided into

the following areas:

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• Block interfaces

• User interface in the global data area (data unit FS_Var)

The function block is signaled changing tasks and modes using the block

interface. The function block signals the actual status and possibly

occurring faults back to the user program also via this interface.

The function block is mainly signaled the physical quantities of the “flying

saw” to be controlled via the user interface in the global data area. In

normal “flying saw” operation, these quantities are not changed.

6.3.2 Block interface of the FB_BGD_TEMPLATE_FlyingSaw()

The following interfaces are provided at the block to control the flying saw

using the function block FB_BGD_TEMPLATE_FlyingSaw():

FB_BGD_TEMPLATE_FlyingSaw()

Execute

Mode

Done

Busy

Error

ErrorID

State

StopCutting

Gap

OnTheSpotCut

Cut

OnTheSpotCutPossible

OnTheSpotCutDone

IN OUT

IN / OUT

UsersInterface

ErrorInterface

InternalData

SyncPosManagement

TimeCalc

KnifeOut EndSyncPosReached

PMGenerationMode

TypeOfSynchronization

Table 6-2 Interfaces of the FB_BGD_TEMPLATE_FlyingSaw()

Parameter Data type Initial value Description

Input parameter (IN)

Execute BOOL False

A queued mode changeover is

activated using this input.

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Parameter Data type Initial value Description

Mode INT 0 Using Mode, the mode is pre-

selected that is activated with

the next positive signal edge at

the execute input.

StopCutting BOOL False When this bit is set, the module

is informed that cutting has

been completed and a gap can

be created or the cutting device

can be withdrawn from the

material.

KnifeOut BOOL False

When this bit is set, the module

is signaled that the cutting

device is no longer in contact

with the material and the

cutting device can be returned

to its starting position.

Gap BOOL False

If this bit is set, after a cut, the

flying saw generates a gap

between the cut piece of

material web and the material

web using a superimposed

motion of the cutting device.

OnTheSpotCut BOOL False When this bit is set, a

synchronous position is

immediately generated on the

material web for the next cut.

PMGenerationMod

e INT PM_CALCULA

TED PM_CALCULATED:

The next cut position is defined

automatically after running one

cutlength.

PM_MEASURED:

The next cut position is defined

by printmark detection.

TypeOfSynchronis

ation INT BY_TIME

BY_TIME:

The synchronizing is done

according to dynamic values

entered.

BY_LEADING_AXIS_VALUE:

The synchronizing is done

according to leading axis

values. The master synclength

is set to a value as twice as

slave synclength automatically.

This causes an asymptotic

synchronization.

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Parameter Data type Initial value Description

Input/output parameter (IN/OUT)

UsersInterface STRUCT User interface

ErrorInterface STRUCT ErrorID of the technology

functions

InternalData STRUCT Internal data of the sequence

control

SyncPos

Management STRUCT Data of the synchronous

position management

TimeCalc STRUCT Time calculation data

Output parameter (OUT)

Done BOOL False

Selected mode has been

activated.

Busy BOOL False Mode changeover is active.

Error BOOL False

Indicates faults/errors within

the FBs and at the cross-cutter

axes.

Cut BOOL False

The flying saw moves in

synchronism with the material

web – cutting can start.

EndSyncPos

Reached BOOL False Alarm, if the flying saw

passes/exceeds the upper limit

value of the synchronous range

when in the automatic mode

OnTheSpotCut

Possible BOOL False The flying saw is in its starting

position and an immediate cut

is possible

OnTheSpotCut

Done BOOL False The immediate cut was carried-

out

SyncNotPossible BOOL False The last synchronization

operation could not be

executed with the secondary

conditions/constraints present.

ErrorID WORD 0 Fault code

State INT 0 Actual operating mode

6.3.3 Structure of the global data area of the data unit FS_Var

The interconnection and links with the technology objects required and the

physical reference quantities and control information are saved in the user

interface of the instance data area.

The parameters saved here are generally not changed during fault-free

operation of the “flying saw”.

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Fig. 6-2 Structure of the global data area of the core “flying saw” function

Internal data of the

sequence control

Unit FS_Var

User rinterface

Data of the synchronous

position management

Data of the time calculation

TOs used

Physical quantities

Control information

User must adapt values

User may not change values

ErrorID of the technology

functions

DW24

DW34

DW58

DW60

Table 6-3 User interface in the global data area of the unit FS_Var

Parameter Data type Initial

value Description

User interface

Matrix of the TOs used

FS_AxesTOs StructAxesTOs

Matrix to reference the

technology objects

relevant for the “flying

saw”.

Physical quantities

DistanceToSensor [mm] LREAL 200.0 Clearance between

the sensor and zero

position of the

FlyingSawAxis

StartPos [mm] LREAL 0.0 Circumference of the

cross-cutter / number

of knives

SyncPos [mm] LREAL 100.0 Position from where

the flying saw moves

in synchronism with

the material web.

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Parameter Data type Initial

value Description

EndSyncPos [mm] LREAL 20.0 End position of the

synchronous range

EndPos [mm] LREAL 125.0 Starting position of the

cross-cutter

ToStartposVelocity [mm/s] LREAL 100.0 Velocity of the travel

back to the starting

position

ToBackposVelocity [mm/s] LREAL 150.0 Velocity of the travel

back to the starting

position

AccelerationCut [mm/s²] LREAL 100.0 Acceleration value for

synchronization motion

AccelerationBack [mm/s²] LREAL 100.0 Acceleration value for

return motion to the

starting position

AccelerationGap [mm/s²] LREAL 100.0 Acceleration value for

motion to create a

"gap".

GearingRatio LREAL 1.0

Ratio between

measured and

effective velocity of the

material web.

CutEverySensorSignal DINT 1 Specifies after how

many sensor signals a

synchronous position

is to be generated.

GapLength LREAL 10.0

Length of the gap that

should be located

between the cut pieces

GapVelocity LREAL 50.0

Higher-level velocity

with which the gap is

to be created

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Parameter Data type Initial

value Description

Control information

Restart BOOL false

If the bit is set (e.g. in

the StartUp task), then

the template executes

a re-initialization and

resets the bit.

This bit must be set

for each new start!

MaterialIn BOOL false

If the bit is set, the

material web is in the

flying saw area.

MaterialInMotion BOOL false

If the bit is set, the

material web in the

flying saw area.is

moving.

Fig. 6-3 Matrix of the relevant technology objects (TOs)

Axis_FlyingSawAxis_Material

Pos_Axis

Following_Axis

External_Encoder

Following_Objekt

Printmark

X--

-- X

(X) --

-- X

X--

(X) In realen Anwendungen kann auch auf einen

externen Geber zugegriffen werden

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7 Integrating the core “flying saw” functions

7.1 This is how you integrate core functions into your project

Please proceed as follows to integrated core functions into your project:

• Check whether your equipment fulfills the software and hardware

prerequisites listed in Chapter 7.2 Prerequisites.

• De-archive and load the relevant project sections as described in

Chapter 7.3 Preparations.

• Set-up the required technology objects as described in Chapter 7.4

Setting-up the required technology objects.

• Assign the synchronous relationships as described in Chapter 7.5

Assigning the synchronous relationships.

• Call-up the core functions as listed in Chapter 7.6 Integrating into

your application.

• Information and instructions on how you must integrate core functions

into the sequence of your user program are provided in Chapter 8

Using the "FB_BGD_TEMPLATE_FlyingSaw()".

7.2 Prerequisites

7.2.1 SIMOTION SCOUT with SIMATIC STEP 7

In order to use this standard SIMOTION application, the SIMOTION

SCOUT programming interface must be correctly installed on your

computer.

You have two possibilities to do this:

• You can install SIMOTION SCOUT in its standalone version - the STEP

7 functions required will be automatically installed.

Table 7-1 Software components

Software Diagram Order No./MLFB and functions Version used

SIMOTION

SCOUT

standalone

6AU1810-0CA40-0XA0

SCOUT standalone is the engineering

tool to program all SIMOTION controls

without STEP 7

V4.0.0

• You install STEP 7 followed by SIMOTION SCOUT.

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Table 7-2 Software components

Software Diagram Order No./MLFB and functions Version used

STEP 7

6ES7810-4CC07-0YA5

Step7 is the basis package for all

optional software packages and is used

to program the SIMATIC S7.

V5.3 SP3 HF1

SIMOTION

SCOUT

6AU1810-0BA40-0XA0

SCOUT is the engineering tool to

program all SIMOTION controls

V4.0.0

This form of the installation has been used when generating the standard

“flying saw” application and should therefore be the preferred one for users.

7.2.2 SIMOTION control

A SIMOTION control is required to operate the core “flying saw” functions.

All SIMOTION D, SIMOTION P and SIMOTION C controls can be used.

Note The application example has been developed and tested for use in

conjunction with the SIMOTION D training case with CPU D435.

Modifications and changes may have to be made when used in another

hardware environment

In order to correctly use the program elements in this document, you should

be knowledgeable about handling, and programming the control being used

as well as its functions.

Table 7-3 Hardware components of the core “flying saw” functions

Hardware element Diagram Order No./MLFB and functions

SIMOTION CPU

D435

6AU1435-0AA00-0AA0 Version C

The CPU D435 processes the user

program, the technology and checks the

drives.

SIMOTION

D435

32MB CF-Card

6AU1400-2JA00-0AA0

The SIMOTION program and the

SINAMICS configuring are saved on the

CF card.

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7.2.3 Technology objects required and synchronous relationships

The following technology objects must be set-up and interconnected with

one another in the following fashion in order to use the core “flying saw”

functions:

Technology objects

The required technology objects are listed according to their function within

the core “flying saw” functions in the following:

• Generating the master (leading) value from the motion of the material

web:

– TO Achse “MaterialAxis” as real positioning or synchronous axis

(maximum configuration)

To determine the position and velocity of the material web as

master (leading) value of the core “flying saw” functions and to

coordinate the motion of the axis – material web from the same

control.

• Coordinating the flying saw axis

– TO axis “FlyingSawAxis” as real synchronous axis

Synchronous relationships

The "flying saw" core functions require the following synchronous

relationships:

Fig. 7-1 Synchronous relationship required for the “FlyingSaw FB”

Material

Axis

Flying

Saw

Axis

1:1

External encoder

or positioning

axis

Synchronous

axis

Gearing

The MaterialAxis is the reference quantity for the “flying saw”. For this

purpose, it must be made available to the “flying saw FB” as “positioning

axis”.

Section C: Integrating the core “flying saw” functions

Integrating the core “flying saw” functions

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The FlyingSawAxis is connected, for the cut, as “synchronous axis” with the

MaterialAxis in a 1:1 (gearing) synchronous relationship.

The technology objects and synchronous relationships listed above must

be set-up and configured/engineered by the user in SIMOTION SCOUT.

7.3 Preparations

7.3.1 De-archiving the standard "flying saw" application

The standard “flying saw” application is supplied as STEP 7/SCOUT

project. In order to use the template, this project must be de-archived either

using STEP 7 or SCOUT.

7.3.2 Downloading the core functions into your SCOUT project

In order to quickly and simply transfer the core “flying saw” functions into

your SCOUT project, you should proceed as shown in the following steps.

Table 7-4 This is how you download the core functions into your project

No Action Comment

1 Open the standard “flying saw” application using SCOUT

2 Open your user project with SCOUT SCOUT is opened a second

time!

3 Copy the program units

FS_SPB

FS_PMIPO

FS_TEMPL

FS_VAR

from the standard application into your user project

By dragging and dropping

4 Close SCOUT using the standard application Ready!

Section C: Integrating the core “flying saw” functions

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7.4 Setting-up the required technology objects

Prerequisite

SIMOTION SCOUT has been started.

The user knows how to apply the SIMOTION SCOUT program.

7.4.1 Flying saw axis

Configuration

• Insert a new axis with the name FlyingSawAxis

• Parameterize the axis as synchronous axis

• Set the axis type as linear

• Parameterize as modulo axis with a modulo length greater than the

maximum traversing distance (this is monitored from the FlyingSaw-FB

Æ “parameterizing error”)

• All of the additional parameters should be set corresponding to the drive

and encoder data.

Mechanical system

• For the parameter “distance for each spindle revolution” enter the

distance that the knife tip of the “flying saw” moves through for one

motor revolution.

• Appropriately supplement the other parameters as well as geometry

and design.

Pre-assignment

• Please enter this parameter corresponding to the drive dynamic

performance.

Limits

• Please enter these parameters corresponding to the system layout and

configuration.

Referencing (homing)

• Please enter these parameters corresponding to the encoder

(the template assumes a referenced/homed axis). If an incremental

encoder is used, it is necessary to reference/home the axis in mode 4

“Manual” before additional operating modes are selected. )

Section C: Integrating the core “flying saw” functions

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Monitoring functions – closed-loop control

• Please set these parameters corresponding to the system layout and

configuration.

7.4.2 Axis, material web

Configuration

• Insert a new axis with the name MaterialAxis

• Parameterize the axis as positioning axis

• Set the axis type as linear

• Parameterize as modulo axis with a modulo length greater than the

maximum product length

• All of the additional parameters should be set corresponding to the drive

and encoder data.

Mechanical system

• For the parameter “distance for each spindle revolution”, the distance

that the material web moves through for one revolution of the drive roll

should be entered.

• Appropriately supplement the other parameters as well as geometry

and design.

Pre-assignment - limits

• Please enter these parameters corresponding to the system / drive

relationships.

Referencing (homing)

• Parameterize “not required”

Monitoring functions – closed-loop control

• Please set these parameters corresponding to the system layout and

configuration.

Section C: Integrating the core “flying saw” functions

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7.5 Assigning the synchronous relationships

7.5.1 FlyingSawAxis_SYNCHRONOUS_OPERATION

Configuration

• Select the MaterialAxis as master (leading) axis

• Select setpoint coupling as coupling type.

Pre-assignment (gear synchronization)

• Synchronizing:

Enter the synchronizing position of the master (leading) axis and

slave (following) axis

(this is checked and corrected by the FlyingSaw FB)

• Position reference:

Synchronize before the synchronizing position

(this is checked and corrected by the FlyingSaw FB)

• SyncPos master (leading) value:

0.0

(the FlyingSaw FB enters the actual value)

• SyncPos slave (following) axis:

0.0

(the FlyingSaw FB enters the actual value)

• The other values are no longer relevant.

Pre-assignment (dynamic)

• Profile input: Time-related synchronizing profile

(this is checked and corrected by the FlyingSaw FB)

• Please select the dynamic parameters of the time-related

synchronization so that the FlyingSawAxis does not reach the dynamic

limits when synchronizing and de-synchronizing.

Section C: Integrating the core “flying saw” functions

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7.6 Integrating into your application

7.6.1 Calling the “FlyingSaw FB” in the user program

The function block of the core “flying saw” functions can also be simply

called in the program after integration into your SIMOTION project.

Calling the “FB_BGD_TEMPLATE_FlyingSaw()” in ST and FBD

As an example, the calls of the function block

“FB_BGD_TEMPLATE_FlyingSaw()” of the core “flying saw” functions in

the ST and FBD programming languages are shown here:

Table 7-5 Calling the function block “_BGD_TEMPLATE_FlyingSaw()“

FB_BGD_TEMPLATE_FlyingSaw()

FUP

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Assigning the instance

In the calling user program, the function block

“FB_BGD_TEMPLATE_FlyingSaw()” must be assigned an instance. The

following table includes examples in ST and FBD.

Table 7-6 Generating an instance of the “FB_BGD_TEMPLATE_FlyingSaw()”

Instance

FUP

7.6.2 Integrating the template block in the processing sequence

The core “flying saw” function is integrated in the processing sequence

using a simple function block call and transferring the required parameters.

This call strategy corresponds to that of PLC-Open standard function

blocks.

Section C: Integrating the core “flying saw” functions

Using the "FB_BGD_TEMPLATE_FlyingSaw()"

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8 Using the "FB_BGD_TEMPLATE_FlyingSaw()"

8.1 General information and instructions

The most important element of the technology template is the function

block “FB_BGD_TEMPLATE_FlyingSaw()”. The connected “flying saw” is

parameterized and controlled using this block.

In the user program, the block must therefore be parameterized and the

block mode changed-over in order to initiate that the

“FB_BGD_TEMPLATE_FlyingSaw()” executes the required functions.

The "FB_BGD_TEMPLATE_FlyingSaw()“ is parameterized as described in

Chapter 6.3 Interfaces. When parameterizing (assigning parameter

values), basic values of the “flying saw” are defined that normally do not

change; for example, the name of the flying saw axis, the starting position,

the synchronous position etc. These values may only be changed when the

system is at a standstill and changes require a re-initialization (restart) of

the "FB_BGD_TEMPLATE_FlyingSaw()“!

The individual modes of the"FB_BGD_TEMPLATE_FlyingSaw()“ are

described in Chapter 3.2 Operating states of the "FlyingSaw-FB". The

procedure to change over the mode is described in more detail in the

following Chapters.

8.2 Initial state of the "FB_BGD_TEMPLATE_FlyingSaw()"

After a “restart”, the “FB_BGD_TEMPLATE_FlyingSaw()” is in the “disable”

state.

Each time that the control is started, “restart” must be run by setting the

restart bit in the startup task. (this is realized automatically when using the

program startup_SAP() in the UNIT SAP_FS)

This means that the template is transitioned into its initial state and

important technology parameters are checked regarding plausibility, if

possible adapted, and if not possible, parameterizing errors are flagged to

the user at the fault output.

8.3 Mode changeover sequence

The functions of the function block “FB_BGD_TEMPLATE_FlyingSaw()”

and therefore the functions of the connected “flying saw” are controlled

using the various state modes of the block.

The following state modes and status transitions can be called at the block:

Section C: Integrating the core “flying saw” functions

Using the "FB_BGD_TEMPLATE_FlyingSaw()"

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Fig. 8-1 Possible state transitions at the "FB_BGD_TEMPLATE_FlyingSaw()"

Disable

Startposi-

tion

Startposi-

tion

Manual

Error

Automa-

tic

Automa-

tic Standard Zustandsübergang

Fehlerzustandsübergang

Automatische Zustandswechselkette

RESTART

The actual block state is displayed at the state output.

Fig. 8-2 Inputs and outputs of the mode changeover

FB_BGD_TEMPLATE_FlyingSaw()

Execute

Mode

Done

Busy

Error

ErrorID

State

StopCutting

Gap

OnTheSpotCut

Cut

OnTheSpotCutPossible

OnTheSpotCutDone

IN OUT

KnifeOut

Changing-over the mode

In order to transition the block into a new state, the number of the required

target state must be specified at the mode input. The changeover is

activated using a high signal at Execute input. The block signals the active

changeover into the new state using a high signal at the Busy output. If all

of the actions associated with the changeover have been successfully

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carried-out and the new state has been reached, this is flagged by a high

signal at the done block output. The number of the new state can be read-

off at the state output.

The sequences and actions that are executed during the changeover are

described in detail in Chapter 10.3.4 of this document.

8.4 Using the restart bit

Restart after a new start

The restart bit must be set at each new start of the SIMOTION D435 or

when changing the parameterization. This is the reason that an initialization

routine is run in the “FB_BGD_TEMPLATE_FlyingSaw()” and a parameter

check is made and the block is brought into a defined state.

Note In the startup task, we recommend that the program startup_SAP() of the

unit SAP_FS is used in order to initialize the

"FB_BGD_TEMPLATE_FlyingSaw()" block.

The restart bit should also be set there in order to bring the block into a

defined state!

Note At restart, the block checks essential technology parameters as well as

the existence of saved technology objects

After the block has been successfully initialized, the restart bit is

automatically reset.

8.5 Error messages

If faults occur in the block itself or in technology objects and technology

functions involved while FB_BGD_TEMPLATE_FlyingSaw() is operational,

then these are signaled using the block outputs error and ErrorID.

Section C: Integrating the core “flying saw” functions

Using the "FB_BGD_TEMPLATE_FlyingSaw()"

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Fig. 8-3 Block outputs for fault messages

FB_BGD_TEMPLATE_FlyingSaw()

Execute

Mode

Done

Busy

Error

ErrorID

State

StopCutting

Gap

OnTheSpotCut

Cut

OnTheSpotCutPossible

OnTheSpotCutDone

IN OUT

KnifeOut

The error bit signals an error while an error code is output at output

ErrorID; this can be analyzed using the error analysis function.

A list of the possible error codes with a description of the error causes is

provided in the Appendix of this document, Chapter 12.2.

Note The error output is only set if the execute input is set. The ErrorID and

state 0 are still output even after execute has been reset!

Section C: Integrating the core “flying saw” functions

Using the "FB_BGD_TEMPLATE_FlyingSaw()"

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8.6 Help functions within the core “flying saw” functions

As part of the core functions, there are also help functions that make it

easier for you to implement your “flying saw” application.

It provides you with solutions for the following functions:

• The synchronous position is sensed using sensors/measuring probes

• Buffer to save the measured synchronous positions for sequential

execution of several cuts by the "flying saw".

The names and description of these functions are listed in Chapter 10.5

Help routines.

Section D: Program description

Using the "FB_BGD_TEMPLATE_FlyingSaw()"

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Section D: Program description

Content

Section D is interesting if you wish to expand/adapt your application based

on the technology templates available.

Objectives

This part of the documentation should

• Explain to readers the special features/issues when generating a

program

• Describe in detail the program structure of the FlyingSaw FB

• Illustrate and describe important program elements

Provide information and instructions on how this template can be adapted.

Prerequisite

Before possibly expanding this template it is helpful to have read the

chapters in Section A and B in order to get to know the basic functions and

applications of the template.

Subjects discussed

Chap. Title Contents

9 Information and instructions to adapt the core “flying saw”

functions

10 Description of important program elements

Note Before you make changes to the template, please observe the

information and warnings listed in the following Chapter as well as the

associated restrictions regarding support!

Section D: Program description

Information and instructions to adapt the core “flying saw”

fti

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9 Information and instructions to adapt the core “flying

saw” functions

9.1 Information and warnings

Before carrying-out changes

Before you carry-out changes to the components included in the core

functions, you should get to know how the components function by referring

to and reading the ST/MMC documentation.

Uncontrolled, incorrect changes and modifications to core functions can

result in death and severe bodily injury!

Restrictions regarding support when changing components of the core functions

The Application Center can only provide support for core functions that

have not been changed

If changes have been made to the code, then support can no longer be

provided for core functions.

This also applies for the revision and adaptation recommendations listed in

this Chapter.

Section D: Program description

Description of important program elements

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10 Description of important program elements

10.1 Program structure

The core functions of the standard “flying saw” application are sub-divided

into two sections

• Declaration section

• Instruction section

All of the interfaces, constants, instance data and multi-instance of the

function blocks called from the block are described in the Declaration

section. Er besteht aus der Unit FS_Var.

All program instructions of the code that can be run are provided in the

Instruction section. This Section is sub-divided into four units.

• FS_TEMPL with the "FlyingSaw FB“.

• FS_PMIPO with the print mark sensing and the ipo-synchronous

functions.

• FS_SPB with the FBs to manage the synchronous positions in the

SyncPo buffer

10.2 Declaration part FS_Var

The structure of all of the data required for the FlyingSaw FB is saved in the

unit FS_Var. Instances will be the data in the user unit SAP_Var. When

required, in this unit, this data area can also be instantiated several times

so that the FlySaw FB can also be called for several flying saws within one

project.

Constants

• Axis numbers

• Operating states of the flying saw

• Sequence phases of the parameter check

• Sequence phases of the automatic parameterization

• Sequence phases when changing from the “error” to “disable”

• Sequence phases when changing from the “error” to “disable” state

• Sequence phases when changing from the “disable” to “error”

• Sequence phases when changing from the “disable” to “starting

position”

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Description of important program elements

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• Sequence phases when changing from the “disable” to “manual”

• Sequence phases when changing from the “starting position” to

“disable”

• Sequence phases when changing from the “starting position” to “error”

• Sequence phases when changing from the “starting position” to

“automatic”

• Sequence phases when changing from the “automatic” to “disable”

• Sequence phases when changing from the “automatic” to “starting

position”

• Sequence phases when changing from the “manual” to “disable”

• Sequence phases in "automatic" operation.

• Maximum length of the SyncPos buffer

Static variables

• Description of the data structure of the TO parameters

• Description of the data structure of the user interface with the geometry,

machine data and control bits

• Description of the data structure of the error interface with the error IDs

of the state change and the RetDINT and FR values of the system

commands.

• Description of the data structure of the internal data area of the

FlyingSaw FBs. Under no circumstances may users change these

values.

• Description of the data structure to manage synchronous positions.

• Description of the data structure for time calculations within the

FlyingSaw FBs

• Description of the data structure of the synchronous position detection

using measuring function.

10.3 Functions of the FB_BGD_Template_FlyingSaw()

("FlyingSaw-FB")

10.3.1 Declarations

• Input interface

• Input/output interface

• Output interface

• Internal program data

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Description of important program elements

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10.3.2 Start identification, axis monitoring and automatic state change

chains

Start identification

Identify whether a restart is present.

If yes, then

• Activate the monitoring of the parameterization of the technology

objects as well as auto-parameterization.

• Control the state machines in the “manual” state via the state sequence

– Error

(if activated, the monitoring and auto-parameterization are realized

in the error state)

– Disable

– Manual

From any state.

If no, then

• Transfer the selected operating state with a positive edge at the

execute input

• Reset all block outputs with a negative signal edge at the execute input

Axis monitoring functions

The flying saw axis has an error, the "FlyingSaw FB“ is forced into the error

state.

However, the monitoring function is only active after the technology objects

have been successfully completed.

Automatic state change sequences

The following automatic state change sequences have been implemented:

• From the “error” state into the “starting position” state.

“Error“ Æ “Disable” Æ “Starting position”

• From the “error” state into the “automatic” state.

“Error“ Æ “Disable” Æ “Starting position” Æ “Automatic”

• From the “error” state into the “manual” state.

“Error“ Æ “Disable” Æ “Manual”

• From the “starting position” state into the “manual” state.

“Starting position” Æ “Disable” Æ “Manual”

• From the “automatic” state into the “manual” state.

“Automatic” Æ “Error” Æ “Disable” Æ “Manual”

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• From the “manual” state into the “starting position” state.

“Manual” Æ “Disable” Æ “Starting position”

10.3.3 Checking the input parameters and parameterization of the

technology settings that are absolutely necessary

This program function is only active in the error state if it was activated by

the user using the restart bit.

The following are monitored:

• The existence of specified TOs.

• The function (positioning axis, synchronous axis, …)

• Special properties/features required for the template, such as: Modulo

axis and modulo value.

Deviations with respect to the template are displayed as fault messages.

Parameterization of the technology objects absolutely required is carried-

out in another program part.

The parameters that are therefore changed are described in Chapter 7.4

Setting-up the required technology objects and Chapter 7.5 Assigning

the synchronous relationships.

10.3.4 State machine of the “FlyingSaw FB”

The state machines of the “FlyingSaw FB” are described in the following

diagram. It includes possible operating states that can be activated and

clearly shows the possible state transitions that may be initiated by the

user.

Section D: Program description

Description of important program elements

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Fig. 10-1 State model of the "FlyingSaw FB"

Disable

Startposi-

tion

Startposi-

tion

Manual

Error

Automa-

tic

Automa-

tic

RESTART

Standard Zustandsübergang

Fehlerzustandsübergang

Automatische Zustandswechselkette

The functional sequences that are hidden behind the states and state

changes (transitions) are listed in the following table.

Table 10-1 Description of the sequences at the state change (state transition) in the “FlyingSaw FB”

Step Function Comment

Mode Error (0)

Error

Error Æ Disable

Error 1

Disable

0 All ErrorID memories are reset

1 Calls the _resetAxisError() for the flying saw axis

Calls the _resetFollowingObject() for the flying saw axis

If the axis and the synchronous object have no error

condition, then the "disable“ mode is activated.

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Step

Function Comment

Mode Disable (1)

Disable

Disable Æ Disable

Disable 1

Disable

0 The stop command is prepared

1 _stop() is called for the flying saw axis

2 _disableAxis() is called for the flying saw axis

If the axis is disabled, then the “disable” mode is activated.

Disable Æ Error

Disable 0

Error

0 Preparation

1 _disableAxis() is called for the flying saw axis

If the axis is disabled, then the “error” mode is activated

Disable Æ Starting position

Disable

Startpo-

sition

0 The enable command is prepared

1 _enableAxis() is called for the flying saw axis

If the axis is enabled, then advance to step 2

2 _resetAxisError() is called for the flying saw axis

If the axis is OK, advance to step 3

3 _pos() is called for the flying saw axis with the direction of

rotation for the shortest path

If the starting position is reached, then the “starting

position” mode is activated.

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Description of important program elements

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Step

Function Comment

Disable Æ Manual

Disable 4

Manual

0 The enable command is prepared.

1 _enableAxis() is called for the flying saw axis

If the axis is enabled, then the “manual” mode is activated

Mode, starting position (2)

Startpo-

sition

Starting position Æ Error

Startpo-

sition

Error

0 Preparation

1 _disableAxis() is called for the flying saw axis

If the axes are disabled, then the “error” mode is activated

Starting position Æ Disable

Startpo-

sition

Disable

0 The stop command is prepared.

1 _stop() is called for the flying saw axis

2 _disableAxis() is called for the flying saw axis

If the axis is disabled, then the “disable” mode is activated

Starting position Æ Automatic

Startpo-

sition

Automa-

tic

0 The SyncPosBuffer is reset

1 Wait until a valid synchronous position is available

If yes, then advance to step 2

2 _enableGearing() is called to synchronize the flying saw

axis to the material web at the master and slave positions

If successfully synchronized, then advance with step 4,

if not, then advance with step 3

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Step

Function Comment

3 _disableGearing() is called to delete (clear) the command

from the command queue.

If required, then continue with step 1

4 The "cut" output bit is set

The actual synchronous position is deleted (cleared) from

the SyncPosBuffer

5 Wait until "StopCutting" signal appears

If the "Gap" signal is present, then continue with step 6

If not, then continue with step 7

6 _pos() is called for the flying saw axis with the

"superimposed" merge mode in order to create a gap with

the superimposed motion.

When completed, then continue with step 7.

7 If the "KnifeOut" signal appears, then _pos() is called for

the flying saw axis to position back to the starting position.

When completed, then continue with step 1.

Starting position Æ Manual

Startpo-

sition

Manual

This state change is achieved using an automatic state

change sequence that reaches the manual state through

the disable state.

Mode, automatic (3)

Automa-

tic

Automatic cycle

0 Wait until a valid synchronous position is available

If yes, then advance to step 1

Section D: Program description

Description of important program elements

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Step

Function Comment

1 _enableGearing() is called to synchronize the flying saw

axis to the material web at the master and slave positions

If synchronization was successful, then continue with step

if not, then continue with step 2

2 _disableGearing() is called to delete (clear) the command

from the command queue.

If this is successful, then continue with step 0

3 The "cut" output bit is set

The actual synchronous position is deleted (cleared) from

the SyncPosBuffer

4 Wait until "StopCutting" signal appears

If the "Gap" signal is present, then continue with step 5

If not, then continue with step 6

5 _pos() is called for the flying saw axis using the merge

mode "SUPERIMPOSED_MOTION_MERGE" in order to

create a gap with the superimposed motion.

When completed, then continue with step 6.

6 If the "KnifeOut" signal appears, then _pos() is called for

the flying saw axis to return to the starting position.

When completed, then continue with step 1.

Automatic Æ Error

Automa-

tic

Error

_disableAxis() is called for the flying saw axis

If the axis is disabled, then the “error” mode is activated

Automatic Æ Disable

Automa-

tic

Error

0 The stop command is prepared

Section D: Program description

Description of important program elements

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Step

Function Comment

1 _stop() is called for the flying saw axis

If the axis is disabled, then advance to step 2

2 _disableAxis() is called for the flying saw axis

If the axis is disabled, then the “disable” mode is activated

Automatic Æ Starting position

Automa-

tic

Startposi-

tion

0 Resets the "cut" output bit

If the "KnifeOut" signal is present, then prepare the

position command and advance to step 1

1 _pos() is called to return the flying saw axis back to its

starting position.

Mode, manual (4)

Manual

Manual Æ Error

Manual 0

Error

_disableAxis() is called for the auxiliary axis and the flying

saw axis

If the axes are disabled, then the “error” mode is activated.

Manual Æ Disable

Manual 1

Disable

0 The stop command is prepared

2 _stop() is called for the flying saw axis

3 _disableAxis() is called for the flying saw axis

If the axes are disabled, then the “disable” mode is

activated

Manual Æ Starting position

Manual

Startposi-

tion

This state change is achieved using an automatic state

change sequence where the starting position state is

reached via the disable state.

Section D: Program description

Description of important program elements

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10.4 Properties/features of startup_SAP

The startup_SAP program is located in the unit SAP_FS

• Assigns the actual TO instances

• Assigns the machine-specific parameters

• Resets the restart bit.

• Deletes the SyncPos buffer.

• Resets all internal program flags.

10.5 Help routines

10.5.1 Features and characteristics of the MT_FS1_PrintmarkDetection

(print mark sensing)

The program MT_FS1_PrintmarkDetection is in the unit RK_PMIPO and

must be called from a motion task.

The following functions are executed:

• Waits for a valid measured value

• Determines the synchronous position for the actual print mark

• Enters the synchronous position into the SyncPos buffer

10.5.2 Properties/features of the IPO_FS1_IPO_Routine

The program IPO_FS1_IPO_Routine is located in the RK_PMIPO unit and

must be called from the IPO task.

• Calculates the position of the MaterialAxis referred to the flying saw

• Edge detection.

10.5.3 SyncPos buffer

Using the following FBs of the FS_SPB unit,

the SyncPos buffer is managed

• FB_BGD_FS_SPB_reset()

• FB_BGD_FS_SPB_in()

Section D: Program description

Description of important program elements

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• FB_BGD_FS_SPB_out()

• FB_BGD_FS_SPB_read()

FB_BGD_FS_SPB_reset()

The SyncPos buffer is deleted (cleared) using this FB.

FB_BGD_FS_SPB_in()

Using this FB, when the print mark is sensed, a new synchronous position

is entered into the buffer.

FB_BGD_FS_SPB_out()

Using this FB, after every cut, a synchronous position is deleted (cleared)

from the buffer (FIFO)

FB_BGD_FS_SPB_read()

This FB is used to check as to whether a new synchronous position is

available for the next cut and the flying saw must be synchronized.

Section E: Appendix

General information on the application

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Section E: Appendix

11 General information on the application

11.1 Scope of supply

The "flying saw" package comprises:

• Program

S7/Scout project as ZIP file:

FlyingSaw_for_SIMOTION_V4.1.1_V1.4.zip

• Documentation

Implementation/Operating Instructions as PDF file

FlyingSaw_with_SIMOTION_V4.1.1_V1.4.pdf

11.2 Revisions/Author

Table 11-1: Revisions/Author

Version Date/Revision Author

V 1.0 Generation H.-E. Böhm

V 1.1 Change-over Ethernet H.-E. Böhm

V 1.2 Protool templates trilingual Ch. Pabst

H.-E. Böhm

V 1.2 Changes General Notes A. Hagelauer

V 1.3 13.04.06 Scout V4.0 H.-E. Böhm

V 1.3

(V 2.0!)

04.04.07 Functional Changes:

- synchronization according to

leading axis values.

(asymptotic synchronization)

- Ratio between measured and

effective velocity of material web

H.-E. Böhm

V 1.4 06.06.08 Replacing ProTool by

WinCflex / SCOUT V4.1.1.6 P. Tabori

H.-E. Böhm

Section E: Appendix

Error messages

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12 Error messages

12.1 Signaling error events at the “FlyingSaw FB” of the core “flying

saw” functions

If an error occurs when calling the “FB_BGD_TEMPLATE_FlyingSaw()” of

the core “flying saw” functions, then this is displayed using an error code at

output ErrorID of the FB.

If the error is caused by a TO-specific command called from the Flying Saw

FB, then its RetDINT or FR is documented in the data area FS_Var for

evaluation by the user.

12.2 Possible error messages at the error code output ErrorID of the

„FB_BGD_TEMPLATE_FlyingSaw()“

A reference is made to the internal block error source of the “FlyingSaw FB”

in the Explanation column.

Table 12-1 Error codes of the flying saw template

ErrorID

error code Explanation

C001 There is an error at a flying saw axis

C005 Position of the flying saw axis greater than that specified under

UsersInterface.g_r_EndPos.

C011 Disable to Disable

Error when stopping the FlyingSawAxis ( _stop )

Details in FS_Var structure under RetDINT_stop_FSA

C012 Disable to disable

Error when stopping the FlyingSawAxis ( _stop )

Details in FS_Var structure under FR_stop_FSA

Section E: Appendix

Error messages

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ErrorID

error code Explanation

C021 Disable to starting position

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under RetDINT_pos_FSA

C022 Disable to starting position

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under FR_pos_FSA

C031 Starting position to disable

Error when stopping the FlyingSawAxis ( _stop )

Details in FS_Var structure under RetDINT_stop_FSA

C032 Starting position to disable

Error when stopping the FlyingSawAxis ( _stop )

Details in FS_Var structure under FR_stop_FSA

C041 Starting position to Startpos

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under RetDINT_pos_FSA

C042 Starting position to Startpos

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under FR_pos_FSA

C051 Starting position to automatic

Error when activating gearing of the FlyingSawAxis

( _enablegearing )

Details in FS_Var structure under RetDINT_enablegearing_FSA

C052 Starting position to automatic

Error when de-activating gearing after unsuccessful

synchronization of the FlyingSawAxis

( _disablegearing )

Details in FS_Var structure under RetDINT_disablegearing_FSA

C053 Starting position to automatic

Error when de-activating gearing after unsuccessful

synchronization of the FlyingSawAxis

( _disablegearing )

Details in FS_Var structure under FR_disablegearing_FSAFSA

C054 Starting position to automatic

Error for superimposed positioning of the FlyingSawAxis to create

"gap" ( _pos )

Details in FS_Var structure under RetDINT_possuperimp_FSA

Section E: Appendix

Error messages

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C055

Starting position to automatic

Error for superimposed positioning of the FlyingSawAxis to create

"gap" ( _pos )

Details in FS_Var structure under FR_possuperimp_FSA

C056 Starting position to automatic

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under RetDINT_pos_FSA

C057 Starting position to automatic

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under FR_pos_FSA

Section E: Appendix

Error messages

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ErrorID

error code Explanation

C061 Automatic Run

Error when activating gearing of the FlyingSawAxis

( _enablegearing )

Details in FS_Var structure under RetDINT_enablegearing_FSA

C062 Automatic Run

Error when de-activating gearing after unsuccessful

synchronization of the FlyingSawAxis ( _disablegearing )

Details in FS_Var structure under RetDINT_disablegearing_FSA

C063 Automatic Run

Error when de-activating gearing after unsuccessful

synchronization of the FlyingSawAxis ( _disablegearing )

Details in FS_Var structure under FR_disablegearing_FSAFSA

C064 Automatic Run

Error for superimposed positioning of the FlyingSawAxis to create

"gap" ( _pos )

Details in FS_Var structure under RetDINT_possuperimp_FSA

C065 Automatic Run

Error for superimposed positioning of the FlyingSawAxis to create

"gap" ( _pos )

Details in FS_Var structure under FR_possuperimp_FSA

C066 Automatic Run

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under RetDINT_pos_FSA

C067 Automatic Run

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under FR_pos_FSA

C071 Automatic to Disable

Error when stopping the FlyingSawAxis ( move mit v=0)

Details in FS_Var structure under RetDINT_stop_FSA

C072 Automatic to Disable

Error when stopping the FlyingSawAxis ( move mit v=0)

Details in FS_Var structure under FR_stop_FSA

C081 Automatic to Starting position

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under RetDINT_pos_FSA

C082 Automatic to Starting position

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under FR_pos_FSA

Section E: Appendix

Error messages

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ErrorID

error code Explanation

C091 Manual to Disable

Error when stopping the FlyingSawAxis ( move mit v=0)

Details in FS_Var structure under RetDINT_stop_FSA

C092 Manual to Disable

Error when stopping the FlyingSawAxis ( move mit v=0)

Details in FS_Var structure under FR_stop_FSA

C0A1 Manual to Starting position

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under RetDINT_pos_FSA

C0A2 Manual to Starting position

Error when positioning the FlyingSawAxis ( _pos )

Details in FS_Var structure under FR_pos_FSA

C0F1 Incorrect mode selection from “error” mode

C0F2 Incorrect mode selection from “disable” mode

C0F3 Incorrect mode selection from “starting position” mode

C0F4 Incorrect mode selection from “automatic” mode

C0F5 Incorrect mode selection from “manual” mode

C101 Parameterizing error at the flying saw axis

Axis is not parameterized as synchronous axis.

C201 Parameterizing error at the material axis/external encoder

The material master (leading) value is neither a positioning axis

nor an external encoder

Section E: Appendix

Contact partner

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13 Contact partner

Applicationcenter

SIEMENS

Siemens AG

Automation & Drives

A&D MC PM APC

Frauenauracher Str. 80

Erlangen

Fax: 09131-98-1297

mailto: applications.erlf@siemens.com

Section E: Appendix

Please help us to become even better

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14 Please help us to become even better

A&D MC PM APC From:

Application Center Name:

Department:

D – 91056 Erlangen City:

Fax: +49 (0) 9131/98–1297 Telephone:

E-Mail: applications@erlf.siemens.de E-Mail:

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Siemens Simotion A4027118 A0414 Users Manual Manual_SIMOTION Flying Saw_V1.4

A4027118-A0414 to the manual 384a7547-433c-4eb9-a6d9-8f1227985e67

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