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Service & Support

Time-efficient, high-precision cutting of moving


materials with the SIMATIC FM 357-2

Applications
The quick way to
the best solution

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The documentation for this application comprises the following main parts:

Part

Description

Part A provides you with an overview. You will learn about the components
(hardware and software) which are used, as well as about their structure.
The key function data displayed shows how efficient this application is.

Part B guides you though the setup and commissioning of the application,
step-by-step.

Part C is of interest if you wish to expand/adapt your system on the basis of this
software.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Contents
Part A

Description of the application

1 The automation problem .......................................................................................... 4


2 The automation solution .......................................................................................... 7
3 Requisite hardware and software elements ........................................................... 9
4 Configuration .......................................................................................................... 10
4.1 Hardware configuration................................................................................... 10
4.2 Program configuration setup........................................................................... 11
5 Key function data.................................................................................................... 13
Part B

Stepby-step instructions

6 Installation instructions ......................................................................................... 14


6.1 Installations..................................................................................................... 14
6.1.1 Installation of the FM firmware from a memory card ................................ 14
6.1.2 Installation of the FM configuration package on the programmer ............ 16
6.1.3 Installation of the Step7 program code..................................................... 17
6.2 Parameterizing the FM 357-2 ......................................................................... 19
7 First steps................................................................................................................ 22
7.1 Simulation of the "Cutting to length" function.................................................. 22
7.2 Simulation of the "Cutting to a synchronous mark" function ........................... 25
Part C

Description of program

8 The code level ......................................................................................................... 28


8.1 Cutting to length.............................................................................................. 28
8.2 Cutting to a synchronous mark ....................................................................... 32
9 Guarantee ................................................................................................................ 36
10

Support .......................................................................................................... 36

11

Please help us to make improvements....................................................... 37

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Part A
1

Description of the application


The automation problem
In many areas of industry materials have to be machined continuously and
endlessly. Possible reasons for this:
The material must be in constant motion for process reasons.
Output must be maximized.
In these cases it is important to guarantee a continuous flow of materials
(the flow of materials must not stop). This can generally be achieved by
synchronizing the machining unit (e.g. the shears) and the material at the
right time (i.e. with the material which is "traveling"), whereby machining
takes place on a flying basis.
This application concerns the "flying shears" whose functions are illustrated
in Figure 1-1. The material being cut to length is fed continuously through
the shears by a main axle and cut.
One example of an application where flying shears are used is in the
manufacture of steel pipes (pipe welding plant):
The belt (sheet metal) is drawn from a coil (roll with several hundred meters
of sheet metal) into the profiling machine (machine with lots of rollers
arranged in series which conduct the sheet metal, bending it gradually into
a pipe as it passes from one roller to the next). Downstream of that is the
welding unit through which the belt has to pass at continuous speed
(approx. 60m/min) in order to perform the continuous welding. After being
welded, the pipes are cut to the product length by flying shears.
S hea rs
C ut-off m ate rial

Ma terial

B elt sensor
B elt motor

S ensor
Mo tor

Figure 1-1

S lid e stroke

Flying shears

A distinction is made between two constituent problems with the "flying


shears"
cutting to length and
cutting to a synchronous mark,
being considered within the scope of this application.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Cutting to length:
The current position of the material is ascertained by the controller via the
"belt sensor" and is compared with the specified parts length (parts
measuring 500 mm in length are continuously cut, for example).
If the parts length/cutting position is moved by the slide, the shear slide
synchronizes itself to the material cutting position. Following
synchronization (the shear slide is now traveling at the same speed as the
material), the separating cut is output (a parts length has been cut off).
Following the cut, the shear slide returns to its start position and waits for
the next length to pass through; the sequence starts all over again.
It should be possible to change the part length during operation, i.e.
during running production.

Description of the system


S hea rs
C ut-off m ate rial

Ma terial

B elt sensor
B elt motor

S ensor
Mo tor

Figure 1-2

S lid e stroke

Cutting to length

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Cutting to a synchronous mark:


The shears wait for the next synchronous mark (cutting position), which is
detected by a synchronous mark sensor. In order to trigger off a cut at only
one specific mark in parts with several marks, the irrelevant marks can be
faded out within this length via the "fade-out length" parameter (see Figure
1-3). The next cutting position is then calculated allowing for the offset
values (distance between the synchronous mark sensor and the cutting
position, synchronous mark sensor and the cutting tool).
Description of the system
Material

Shears
Sensor for synchronous mark

Cut-off material

Belt sensor
Belt motor

Sensor
Motor

Description of parts

distance between the


synchronous mark sensor
and the cutting position

Abstand
Synchron.Marke
bis Trennwkz.

Abstand
distance between the synchronous
Synchron.Marke
mark sensor and the cutting
bis tool
Trennschnitt

irrelevant
hole
auszublendende
Lochung
( "fade-out")

Lochung
hole .
(wird als Synchron.Marke
verwendet)
(used as synchronous
mark)

z trennendes
Material

Material
to cut off

Figure 1-3

Ausblendlnge

"fade-out length"

Cutting to a synchronous mark

If the parts length/cutting position is moved by the slide, the shear slide
synchronizes itself to the material cutting position. Following
synchronization (the shear slide is now traveling at the same speed as the
material), the separating cut is output (a parts length has been cut off).
Following the cut, the shear slide returns to its start position and waits for
the next length to pass through; the sequence starts all over again.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

The automation solution

What will this application teach you?


This application will enable you to learn about the "Flying Shears" functions
by simulating the axes (belt axis, shear slide). Consequently, this example
can be tested without having to use real axis hardware.
If you use real axes, you need to adjust the machine data. This procedure
is not explained in this description, it is described in the manual for the FM
module being used.
In the course of the application you will be given two fully tested NC
programs which cover the functions, cutting to length and cutting to a
synchronous mark. They are essentially "complete", only the input variables
have to be parameterized. However, if you wish to modify the functionality
of the "Flying Shears", the program code is shown in section 8.
The automation solution
The task described can only be achieved using a controller which supports
this type of function directly or by a controller which can be programmed
very "freely" and provides important basic functions, such as curve table
interpolation.
The SIMATIC FM 357-2 is used in this application. This is a multi-axis
positioning controller which can be used for a wide range of different
positioning tasks through appropriate numerical control programming.
The configuration used is displayed below. The area boxed-in in red (CPU /
FM) is described in the following section, real axes (including sensors,
drives), as mentioned above, are not included.

Important
The two sub-functions (cutting to length/to a synchronous mark) are
described together in this section and in sections 3-6 because the only
difference between them is that there is an additional synchronous mark
sensor in "Cutting to a synchronous mark" (see Figure 1-3).

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Configuration

PS
307

S7-315
CPU

SM
374

FM357-2

Drive
+/-

10V

Synchronous mark sensor *)


Cutting tool

Belt sensor
Sensor
Belt motor

Slide drive

*) Only required for the "Cutting to a synchronous mark" function

Figure 2-1

Configuration

The STEP7 program component, which acts as the interface between S7


and FM and which controls the basic FM functions (operating modes,
overwrite), runs on the CPU. There is always one of the two NC programs,
cutting to length and cutting to a synchronous mark, running on the FM.

Machine data
The following axes are used:
1st axis: belt axis
2nd axis: shear slide
The machine data configuration means that there is no need for a search
for a reference.
The two unused axes (3 and 4) could be used for other functions.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Requisite hardware and software elements

Requisite hardware components


Component

Type

Machine-readable part number


(MLFB) / order details

Qty

Alternatives

You can use a series of other


components (such as other CPUs) to
create the functionality of this
application. Please refer to catalog CA01
for details.

Power supply

PS307

6ES7 307-1EA00-0AA0

CPU

CPU 315

6ES7 315-1AF03-0AB0

Digital I/O module

SM 374

6ES7 374-2XH01-0AA0

Positioning module

FM 357-2

6ES7 357-4AH01-0AE0

Component

Type

Machine-readable part number


(MLFB) / order details

Qty

SIMATIC Manager

V 5.1

6ES7810-4CC05-0YX0

FM357-2 configuration packet

V 4.2

*)

Firmware

FM 357L

6ES7357-4AH03-3AE0

For cutting to length

Firmware

FM 357LX

6ES7357-4BH03-3AE0

For cutting to a synchronous mark

"Flying Shears"

S7 project

Self-compiled software

This project contains:


- S7-CPU/FM communication
- NC-code for "cutting to length"
- NC-code for "cutting to a synchronous
mark"

Requisite software components


Alternatives

*) The configuration packet V4.2 is delivered in combination with the firmware and therefore has no
separate MLFB. Both firmware and configuration packet can be downloaded via Customer Support
(ID: 9836785).

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Configuration

4.1

Hardware configuration
PS S7-315
307 CPU

SM
374

FM357-2

Belt axis on
+24V
"Separated"
response
+24V
Synchronous
mark sensor *)

*) Only required for the "Cutting


to a synchronous mark
function.

Figure 4-1

Hardware configuration

Overview of wiring
Signal

Module / Pin

Comments

+24V

FM 357-2/ pin 1

Supply for digital inputs/outputs

+24V

FM 357-2/ pin 21

Supply for digital inputs/outputs

M (24V)

FM 357-2/ pin 20

Supply for digital inputs/outputs

M (24V)

FM 357-2/ pin 40

Supply for digital inputs/outputs

"Belt axis on" switch

FM 357-2/ pin 28

Input "0"

"Separated" response

FM 357-2/ pin 29

Output "1"

Synchronous mark sensor

FM 357-2/ pin 26

Measurement pulse input 1 (MEPU1).


Simulation with a touch probe is
possible!

Note
This hardware configuration only depicts the components required for the
simulation. Please refer to the manual for further information on a configuration
with "real" axes.

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The following inputs and outputs are used:


Inputs used
Input

Type

Address

nc-reset

BOOL

E 0.0

nc-start

BOOL

E 0.1

nc-stop

BOOL

E 0.2

nc-automatic

BOOL

E 0.3

nc-jog

BOOL

E 0.4

Write_RPA

BOOL

E 0.7

Module

SM 374

Belt axis on

BOOL

Input 0

Separated

BOOL

Input 1

Synchronous mark sensor

BOOL

Measurement pulse input 1

FM 357-2

Outputs used
Output

4.2

Type

Address

Automatic_Mode_active

BOOL

A 4.0

Manual_Mode_active

BOOL

A 4.1

NC_Program_running

BOOL

A 5.0

Separation

BOOL

Output 0

Separation fault

BOOL

Output 1

Module

SM 374

FM 357-2

Program configuration setup


The STEP7 program component, which acts as the interface between S7
and FM and which controls the basic FM functions (operating modes,
overwrite), runs on the CPU. There is always one of the two NC programs,
cutting to length and cutting to a synchronous mark, running on the FM.
CPU S7-315
OB 82

FM 357-2

FC 5
Diagnos. interrupt

OB 100

FM
firmware

OB 1 FC 22
FC 1

Start-up
synchronization

Initializ
ation

Transmission of
axes and channels

DB
100

and
NC
code

FB 3
Transmission of
user data

STEP 7
Figure 4-2

Program configuration

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

The DB100 in the STEP7 program contains the interface for the default
values for the FM. It is configured with runnable default values which can,
of course, also be changed.
The following values are of relevance to the two sub-functions (length/
synchronous mark):
Defaults
(DB100)

Cutting to length

Cutting to a synchronous mark

FLIEGSCHERE_LAENGE.MPF

FLIEGSCHERE_SYNCM.MPF

Return speed

Return speed

Max. length of the saw slide

Max. length of the saw slide

Belt speed

Belt speed

Start position of the Y-axis

Start position of the Y-axis

Parts length

Parts length

Distance from synchronous


mark to the cutting tool

Distance from synchronous


mark to the cutting position

Fade-out length

Figure 4-3

Configuration parameters in the DB100

Note
The part length can be changed during production using the "Cut by Length"
function. Here you change the Part Length parameter in DB100 of the S7 program.
In order to transfer the new part length to the FM the parameter Write_RPA
(compare page 11) has to be set. The changed part length will already be
employed for the next cut that follows.

Warning
Inaccurate defaults in the case of real axes can result in damage to the machine.
Pay careful attention to the mechanical conditions!

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

DB100 interface block

Figure 4-4

DB100 data block

Key function data

Parameters

Quantity / Size

Comments

Precision of the parts length

+/- 0.2 mm

These figures are directly linked. If one of them changes, the other
one also changes.

Material speed

80 m/min

Requisite axes

Free axes

CPU cycle

mind. 10 ms

Copyright by Siemens AG, 2000

FM 357-2 possesses four axes

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Part B

Step-by-step instructions

Installation instructions
The following section will guide you through the installation of the software
elements. It will also give you tips on how to configure the software.
At this stage we assume that you know how to install SIMATIC STEP7 or
how to download the project to the CPU.

Requirements
Before the software components can be installed, the hardware must have
been correctly configured, as explained in section 4.1, and version 5.1 or
higher of the SIMATIC Manager must be installed and operational.

6.1

Installations

6.1.1

Installation of the FM firmware from a memory card


Note
FM357 LX firmware is required for the "Cutting to a synchronous mark function.

Table 6-1

Step no.

Installation of the FM firmware from a memory card

Measure

Action/Image

Insert the firmware, which is


being installed, into the
controller, which must be
switched off.

Turn the start-up switch to "0".

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Step no.
3

Measure

Action/Image

Switch on the controller.


(Set the CPU operating mode
selector switch to STOP)

The system software and data are transferred


from the memory card to the controller.
The "SF" LED lights up and the "DIAG" LED
flashes cyclically four times. Wait until the "SF"
LED goes out and the "DIAG" LED flashes
cyclically five times.
If the error/status display behaves differently,
this indicates that there is an error. In this case
refer to the FM manual for further information.

Following transfer, switch off


the controller.

Leave the memory card in the


FM357-2 and turn the start-up
switch to "1".

Switch on the controller.


Note: If you are using older
versions of the firmware, wait a
minute before switching on!

Switch the controller off again


and turn the start-up switch to
"0".

Switch on the controller.


Note: If you are using older
versions of the firmware, wait a
minute before switching on!

The power-up starts with defaults. Wait about


one minute until the "DIAG" LED flashes
cyclically (3 Hz).

The FM 357-2 powers up with the firmware.


During the power-up, the license on the
memory card is checked with the version of the
firmware loaded in the FM.

Note
Refer to section 3.2 of the manual for further information on the installation of the
firmware and to section 7.2 for details on powering up the FM.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

6.1.2

Installation of the FM configuration package on the programmer

Table 6-2

Step no.

Installing the FM configuration package on the programmer

Measure

Action/Image

Insert the CD from the FM


configuration package into the
CD drive.

Run the SETUP.EXE program


from the CD.

Execute the instructions stepby-step which the installation


program displays down to the
"FM 357-2 Toolset:
Components" dialog.

Select the following


components:
FM 357-2 Parameterization
FM 357-2 Basic Functions
V3

Start the installation process by


clicking on the "NEXT" button.
Once the installation is
complete, the installation
program will prompt you to
reboot the computer.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

6.1.3

Installation of the Step7 program code

Table 6-3

Installation of the Step7 program code

Step no.

Measure

Action/Image

Open the SIMATIC Manager


and click on File-> Dearchive...
to extract the
Step7_FliegendeSchere_V10.z
ip file which is included.

Open the extracted project and


select the SIMATIC 300 station.
Click on Edit -> Open Object to
go to the S7 hardware
configuration.

If the hardware configuration is


different, make any changes
that are required.

Highlight the FM357-2


4AxisControl module in the
configuration table. Open the
FM object properties (click on
Edit -> Object Properties).
Switch to the "Addresses" tab.
Refer to the Inputs -> Start field
in the Addresses tab to find out
the initial address of the
module.
Click on OK to confirm.

Save and compile the changes


to the hardware project by
clicking on Station-> Save and
Compile.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Step no.

Measure

Action/Image

Open the OB100 block in the


STEP7 project. Enter the initial
address of the FM module at
the FC1 call in the FMLADDR
parameter.
(in this example, 288)

Save the OB100 block and


close the editor.

Switch the CPU to STOP mode.


Highlight the SIMATIC 300
station(1) in the SIMATIC
Manager and click on Target
System ->Load to load all the
blocks, including the system
data, into your CPU.

Switch the CPU to RUN mode.

Copyright by Siemens AG, 2000

After up to one minute the "DIAG" LED on the


FM 357-2 flashes cyclically to indicate the
successful start-up between the CPU and the
FM 357-2.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

6.2

Parameterizing the FM 357-2

Table 6-4

Step no.

Parameterizing the FM 357-2

Measure

Action/Image

Highlight the SIMATIC 300


station in the SIMATIC
Manager and click on Edit ->
Open Object to open the S7
hardware configuration.

Select the FM357-2 in the


configuration table. Click on
Edit -> Open Object to call up
the "Properties FM357-2
4AxisControl (R0/S6)" dialog.
Click on the Parameters...
button.
Note: This is only possible if the
controller is in RUN or RUN-P
status!

The "New Project" dialog


opens. Click on the Cancel
button to close it.
Now go to the parameterization
interface of the FM357-2
("FM357-2 Parameterization"
dialog).

Click on File -> Open... in the


Step7 project folder to open the
file FM357_2_FliegendeSchere.mcp

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Step no.

Measure

Action/Image

Select the "Machine Data" data


area in the project viewer
window. Double-click on the
block to open the machine data
wizard.

Click on Target System->


Transfer/Activate Data to
transfer the machine data.
Confirm all the dialogs shown
with OK or YES.

Switch the controller off and on


again. Once you have powered
up the FM357-2, you need to
call up Target System->
Establish Connection.

Close the machine data


configuration dialog and switch
to the R-Program data area in
the project viewer window.
Double-click on RP-block1 to
open it.

Load the data into the FM 3572 via Target System ->
Transfer/Activate Data ->
Channel 1.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Step no.

Measure

10

Close the RP-block and switch


to the NC-Programs -> Main
Programs data area. Open the
"FLIEGSCHER_LAENGE.MPF"
program and click on Target
System -> Transfer/Activate
Data to transfer the program.
Execute the two steps once
again with the
"FLIEGSCHERE_SYNCM.MPF
" program.

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Action/Image

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

First steps
The following section will take you step-by-step through the simulation of
the two sub-functions, "Cutting to length" and "Cutting to a synchronous
mark". The simulation can be performed without real axis hardware, i.e. it
enables you to test the NC programs without the need for a real process.

7.1

Simulation of the "Cutting to length" function

Table 7-1

Simulation of the "Cutting to length" function

Step no.

Measure

Action/Image

Set all the switches in the


simulation modules to "0".

Open the DB100 data block in


the STEP7 project and adjust
the default values in the Initial
Value column to your
application (parts length, belt
speed, etc.). Click on View ->
Data View to change to the
data view and then call up Edit> Initialize Data Block.
Save the data block and load it
into the controller.
Note: This is only possible if the
controller is in RUN-P status.

Switch to the FM configuration


window. Click on Test->
Commissioning to go to the
commissioning window.

With a positive edge at input E


0.7, the default values are
written to the FM 357-2.
Note:
The FM module must be in
Reset status in order to accept
the default values.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Step no.

Measure

Action/Image

Press the E0.3 switch.

The FM357-2 switches into automatic mode.

Click on the Test button. Enable


the Automatic mode setting.

Click on the Program Selection


button and, when the "Program
Selection" dialog opens,
highlight the
FLIEGSCHERE_LAENGE.MPF
program.
Click on OK to confirm.

Highlight the X-axis in the left


field.
Select the closed-loop
controller enable and pulse
enable and disable feed rate
stop.
Also perform the two steps for
the Y-axis.

Click on the green start button.


Note:
After pressing the start button,
the FM message "Wait: Help
function response missing".

10

All the preparatory steps have


The movement of the belt axis in the Actual
now been performed. Press the Position field for the X-axis is shown in the
switch at input "0" (belt axis on). commissioning window. Once the belt axis
reaches the parts length configured in the
default values (DB100), the FM 357-2 starts to
move the slide axis (Y-axis). The FM
synchronizes the slide on the cutting position.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Step no.

Measure

Action/Image

11

As soon as output "0" signals


that the completed
synchronization process is
completed, you have to
simulate the cutting tool
"separated" response by setting
input "1" on the FM. (Pulse)

12

If this response is not set within


the length of the saw slide set
in the default values, the axes
are stopped. Output "1" on the
FM indicates that a fault has
occurred.

13

If you click on the "Reset"


button and on the green start
button, the slide axis returns to
the initial position (default
value) and the process starts
again.

Note
If an error occurs as a result of a control mistake, you can reset it by pressing the
"Reset" button in the commissioning window. You can read error messages by
clicking on Test -> Error Evaluation.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

7.2

Simulation of the "Cutting to a synchronous mark" function

Table 7-2

Simulation of the "Cutting to a synchronous mark" function

Step no.

Measure

Action/Image

Set all the switches in the


simulation modules to "0".

Open the DB100 data block in


the STEP7 project and adjust
the default values in the Initial
Value column to youre your
application (parts length, belt
speed, etc.). Click on View ->
Data View to change to the
data view and then call up Edit> Initialize Data Block.
Click on YES to confirm.
Save the data block and load it
into the controller.

Switch to the FM configuration


window. Click on Test->
Commissioning to go to the
commissioning window.

With a positive edge at input E


0.7, the default values are
written to the FM 357-2.
Note:
The FM module must be in
Reset status in order to accept
the default values.

Press the input E0.3 switch.

Click on the Test button. Enable


the Automatic mode setting.

Copyright by Siemens AG, 2000

The FM357-2 switches into automatic mode.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Step no.

Measure

Action/Image

Click on the Program Selection


button and, when the "Program
Selection" dialog opens,
highlight the
FLIEGSCHERE_SYNCM.MPF
program.
Click on OK to confirm.

Highlight the X-axis in the left


field.
Select the closed-loop
controller enable and pulse
enable and disable feed rate
stop.
Also perform the two steps for
the Y-axis.

Click on the green start button.

10

All the preparatory steps have


The movement of the belt axis in the Actual
now been performed. Press the Position field for the X-axis is shown in the
switch at input "0" (belt axis on). commissioning window.

11

Enter a pulse at the


synchronous mark sensor.
Once the belt axis reaches the
cutting position calculated from
the default values (DB100), the
FM 357-2 starts to synchronize
the slide axis (Y-axis) to the
cutting position.

12

As soon as output "0" signals


that the completed
synchronization process is
completed, you have to
simulate the cutting tool
"separated" response by setting
input "1" on the FM. (Pulse)

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Step no.

Measure

Action/Image

13

If this response is not set within


the length of the saw slide set
in the default values, the axes
are stopped. Output "1" on the
FM indicates that a fault has
occurred.

14

If you click on the "Reset"


button and on the green start
button, the slide axis returns to
the initial position (default
value) and the process starts
again.

Note
If an error occurs as a result of a control mistake, you can reset it by pressing the
"Reset" button in the commissioning window. You can read error messages by
clicking on Test -> Error Evaluation.

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Part C Description of program


8

The code level


The code, with explanatory comments, below enables you to adapt to your
requirements. This is the NC code which is used on the FM 357-2.
The comments in the code are always printed in green.

8.1

Cutting to length

Table 8-1

NC program code for "Cutting to length"

Flying Shears

Shears
Material

Belt motor

Cut-off material

Belt sensor

Position

Position

Sensor

Slide
axis (Y)
Schlittenachse
(Y)

SlideSchlittenlnge
length
= R2 -R4=
R2-R4

Teilelnge
Parts
length
= R5
= R5

Motor
PointPunk
2 t2

Area of
synchronicity,
waitingderfor
Bereich
Synchronitt,
warteen
auf getrennt
seperated
Bandachse (X)

Belt axis (X)

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

;************************************************************************
; This program creates the "flying cutting to length" function.
;
;
; Function:
; Once the belt has passed through the default parts length, the
; slide axis is synchronized to the belt cutting position.
; Following synchronization, the "separate" signal is output. Once the
; separation process is over ("separated" input signal), the SHEARS
; return to their start position and wait for the parts length to pass
; through again.
;
; Inputs:
IN 1 = Start belt axis (not with external sensor)
;
IN 2 = Separated
; Outputs:
;
OUT 1 = Separate
;
OUT 2 = Fault
;
02/2001 A&D AS CS2
;************************************************************************

;**** Default values ****


;This data is defaulted by the CPU (DB100)
;R1=40000 ;Reverse speed of SHEARS
;R2=5000 ;Max. slide end position
;R3=20000 ;Belt axis speed
;R4=0 ;Start position of SHEARS axis
;R5=1000 ;Parts length, this variable has to be used for the parts length
R9=5
; Synchronizes window in mm
R10=0 ; ext. sensor=0 / internal axis=1(belt)

;Ideal configuration of the control loop is very important in highly dynamic cycles!!!
;Some of these parameters are: amplification factor, speed controller adjustment, speed ;precontrol, max. acceleration.
;In order to keep the fluctuations in accuracy as low as possible when changing the belt speed ;and likewise the Synchronized
range, you must minimize the following error of the shears to ;practically 0mm using the speed pre-control.

;External sensor/belt axis?


;This program can be used both if the belt is an external sensor and if there is an internal axis available.
;Settings for the external sensor:
;Deactivate loop controller release and pulse release in PLC, activate follow-up mode, machine data movement connection
setpoint connection (preset R10 to 0)
;Settings for internal axis:
;Activate loop controller release and pulse release in PLC, deactivate follow-up mode, machine data movement connection
setpoint connection (preset R10 to 1)
;An internally calculated belt axis is preferable to an external sensor in the case of highly dynamic applications with high accuracy
requirements!

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

;****Internally used items****


R20=0 ;Result memory calculation new position belt axis
R22=0 ; Step number sequence
R23=0 ; Damping clock pulse counter
R24=0 ;As status display, deviation of Belt actual value to Shears actual value (should be ;approximately 0mm after synchronization
and optimum setting of the speed controller)
R25=0 ;Mean value for aging correction
R26=0 ;Mean value for belt speed
R27=R5 ;Uses variable in the program for the part length (it is therefore possible to make ;changes to the length while the program
is running)
R28=0 ;Calculated smoothing deviation
;R31-$R40 Shift register for mean value generation for aging correction

;**** Move to start position/Reset the positions ****


N1100 LEADOF(SCHERE,BAND) ; Delete existing coupling
N1200 PRESETON(BAND1,-R27) ; PRESET at the start
N1300 $A_OUT[1]=0 ; Reset of "Separate" if still ON
N1400 $A_OUT[2]=0 ; Reset of "Fault"
N1500 POS[SCHERE]=R4 FA[SCHERE]=R1 ; Start pos. of SHEARS axis

MA1:
;**** Table definition ****
N1600 CTABDEF(SCHERE,BAND,1,0) ; Table definition
N1700 BAND=0 SCHERE=R4 ; Pairs of values, point 1 (BAND=parts length, SCHERE=start position)
N1800 BAND=(R2-R4) SCHERE=R4+(R2-R4) ; point 2 (BAND= parts length + slide length (R2-R4), SCHERE=start position + slide
length
N1900 CTABEND ; End of table definition
STOPRE

;**** Synchronous actions ****


;Switch on coupling
N10 ID=1 EVERY ($R22==0) AND ($AA_COUP_ACT[SCHERE]==0) DO LEADON(SCHERE,BAND,1) $R22=1 ; Couple SCHERE
to BAND via table 1
;Synchronized
N20 ID=2 EVERY ($R22==1) AND ($AA_IM[BAND]>0) AND ($AA_VACTM[SCHERE]>$R26*0.9) AND (($R24<$R9)AND ($R24>$R9)) DO $R22=2 ; Separate ($AA_SYNC[SCHERE]==3)
;Start damping time when synchronized is done
N40 ID=3 WHENEVER ($R22==2) DO $R23=$R23+1
;Separate
N40 ID=4 EVERY ($R22==2) AND ($R23>=20) DO $A_OUT[1]=1 $R22=3 $R23=0 ; Separate on
N50 ID=5 EVERY ($R22==3)AND ($A_IN[2]==1) DO $A_OUT[1]=0 $R22=4
; Separate off
;If separated, couple, position, reset belt axis, set auxiliary memory marker (ID No. must be ;higher)
N60 ID=8 EVERY ($R22==4) DO LEADOF(SCHERE,BAND) $R27=$R5 $R20=($AA_IW[BAND]-$R27) PRESETON(BAND1,$R20)
$R22=5
;Return to start position
N70 ID=6 EVERY ($R22==5) DO POS[SCHERE]=$R4 FA[SCHERE]=$R1 $R22=6
;Slide is back again
N80 ID=7 EVERY ($R22==6) AND ($AA_IW[SCHERE]==$R4) DO $R22=0

;Fault
N90 ID=9 WHENEVER ($AA_IW[SCHERE]>=$R2) OR ($AA_IW[BAND]>=$R27) DO $A_OUT[2]=1 $A_OUT[1]=0
;Switch on the belt axis (makes sense only if belt is internal FM357 axis)
N100 ID=10 EVERY $A_IN[1]==1 DO MOV[BAND]=1 FA[BAND]=$R3 ; Set belt axis into constant motion N110 ID=11 WHENEVER
(($A_IN[1]==0) OR ($A_OUT[2]==1)) AND ($AA_STAT[BAND]==1) DO MOV[BAND]=0 ;Stop belt axis
;As status display, deviation of Belt actual value to Shears actual value (should be ;approximately 0mm after synchronization and
optimum setting of the speed controller)
N140 ID=14 WHENEVER TRUE DO $R24=$VA_IM[BAND]-($VA_IM[SCHERE]-$R4)

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;******** These actions must be executed (partly for calculating when using an external sensor)

;Calculate mean value for aging correction (10 steps via shift register)
N150 ID=15 WHENEVER $VA_IM[BAND]>=$AC_PARAM[2] DO $R31=$R32 $R32=$R33 $R33=$R34 $R34=$R35 $R35=$R36
$R36=$R37 $R37=$R38 $R38=$R39 $R39=$R40
N160 ID=16 WHENEVER $VA_IM[BAND]>=$AC_PARAM[2] DO $R40=($VA_IM[BAND] - $AC_PARAM[2])
$R25=($R31+$R32+$R33+$R34+$R35+$R36+$R37+$R38+$R39+$R40)/10
;Calculate mean value for belt speed
N170 ID=17 WHENEVER TRUE DO $R26=$R25/$MN_IPO_CYCLE_TIME*60
;Calculate smoothing deviation
N170 ID=18 WHENEVER TRUE DO $R28=($R26/60)*($R26/60)/($MA_MAX_AX_ACCEL[SCHERE]*1000)/2
;Master axis with "aging correction" and "smoothing correction"
N180 ID=19 WHENEVER $R10==0 DO $$SA_LEAD_OFFSET_IN_POS[SCHERE]= $R25*3+$R28
;Save aging correction actual value
N190 ID=20 WHENEVER TRUE DO $AC_PARAM[2]= $VA_IM[BAND]
N2200 M30

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

8.2

Cutting to a synchronous mark

Table 8-2

NC program code for "Cutting to a synchronous mark"

Flying Shears
Description of the system
Shears
Synchronous mark sensor

Material

Belt sensor
Belt motor

Cut-off material

Sensor
Motor

Description of parts
Distance from
synchronous mark
to cutting tool
Distance from
synchronous mark
to cutting position

Marking to
fade out

Mark used

Fade-out length

Material being
separated

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

;************************************************************************
; This program creates the "flying cutting to a synchronous mark" function.
; Function:
; If the synchronous mark signal occurs after the fade-out length
; (default value), the slide axis (Y-axis) is synchronized to the belt
; speed after the cutting position is reached (synchronous mark
; position + calculated distance values).
; Following synchronization, the "separate" signal is output. Once the
; separation process is over ("separated" input signal), the Y-axis
; returns to its start position and waits for a new synchronous mark.
;
; In order to record the synchronous mark, measurement input 1 is used
; and calculated in the program in order to achieve higher precision.
;
; Inputs:
IN 1 = Belt axis on (if no external sensor is used)
;
IN 2 = Separated
;
MEPU1 PIN 26 = Synchronous mark sensor
; Outputs:
;
OUT 1 = Separate
;
OUT 2 = Fault
;
5/2000 A&D AS CS2
;************************************************************************
;**** Default values ****
;This data is defaulted by the CPU (DB100)
;R1=30000 ;Reverse speed of SHEARS axis
;R2=5000 ;Max. slide length
;R3=20000 ;Belt axis speed
;R4=0 ;Start position of SHEAR axis
;R6=0 ;Distance from synchronous mark to middle of cutting tool
;R7=100 ;Distance from synchronous mark to cutting position on the part (must be at least ;Vmax*50ms)
;R8=0 ;Fade-out length
R9=5
;Synchronizes window in mm
R10=0 ;external sensor =0 / internal axis =1 (belt)

;Ideal configuration of the control loop is very important in highly dynamic cycles!!!
;Some of these parameters are: amplification factor, speed controller adjustment, speed precontrol,
;max. acceleration.
;In order to keep the fluctuations in accuracy as low as possible when changing the belt speed ;and ;likewise the Synchronized range,
you must minimize the following error of the shears to ;practically 0mm using the speed pre-control.

;External sensor/belt axis?


;This program can be used both if the belt is an external sensor and if there is an internal axis ;available.
;Settings for the external sensor:
;Deactivate loop controller release and pulse release in PLC, activate follow-up mode, machine data ;movement connection setpoint
connection (preset R10 to 0)
;Settings for internal axis:
;Activate loop controller release and pulse release in PLC, deactivate follow-up mode, machine data movement connection setpoint
connection (preset R10 to 1)
;An internally calculated belt axis is preferable to an external sensor in the case of highly dynamic applications with high accuracy
requirements!

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

;****Internally used items****


R20=0 ;Result memory calculation new position belt axis
R21=3 ; Set waiting time after setting of actual value
R22=0 ; Step number sequence
R23=0 ; Counter1 damping clock pulse shears synchronous
R24=0 ;As status display, deviation of Belt actual value to Shears actual value (should be ;approximately 0mm after synchronization
and optimum setting of the speed controller)
R25=0 ; Mean value for aging correction
R26=0 ;Mean value for belt speed
R27=0 ; Counter 2 waiting time after setting of actual value is set
R28=0 ;Calculated smoothing deviation
;R31-$R40 Shift register for mean value generation for aging correction

;**** Move to start position/Reset the positions ****


N1100 LEADOF(SCHERE,BAND) ; Delete existing coupling
N1200 PRESETON(BAND,0)
; PRESET at the start
N1300 $A_OUT[1]=0 ; Reset of "Separate" output if still ON
N1400 $A_OUT[2]=0 ; Reset of "Fault" output
N1500 POS[SCHERE]=R4 FA[SCHERE]=10000 ; Start pos. of SHEARS axis

;**** Table definition ****


N1600 CTABDEF(SCHERE,BAND,1,0)) ; Table definition
N1700 BAND=R6+R7 SCHERE=R4; Pairs of values
N1800 BAND=(R2+R6+R7)-R4 SCHERE=(R4+R2)-R4
N1900 CTABEND; End of table definition
STOPRE

;**** Synchronous actions ****


;Restart measuring task after each measurement
N10 ID=1 EVERY ($AC_MARKER[2]==0) AND ($A_PROBE[1]==0) AND ($R22==0) DO MEAWA[BAND]=(3,1)$AC_MARKER[2]=1
N20 ID=2 EVERY ($AA_MEAACT[BAND]==0) AND ($AC_MARKER[2]==1) DO $AC_MARKER[1]=1
$AC_MARKER[2]=0
;Measuring task completed => Calculate measured value with actual value to be set => Set value
N30 ID=3 EVERY $AC_MARKER[1]==1 DO $AC_MARKER[1]=0 $R22=1 PRESETON(BAND,($AA_IW[BAND]-$AA_MM1[BAND]))
;Waiting time after setting of actual value is set
N40 ID=4 WHENEVER ($R22==1 )DO $R27=$R27+1
;Switch on connection
N50 ID=5 EVERY ($R22==1) AND ($R27==$R21) DO LEADON(SCHERE,BAND,1) $R27=0 $R22=2 ; Connect shears to belt via
table1
;Synchronized
N60 ID=6 EVERY ($R22==2) AND ($AA_IM[BAND]>$R6+$R7) AND ($AA_VACTM[SCHERE]>$R26*0.9) AND (($R24<$R9)AND
($R24>-$R9)) DO $R22=3
;Start settling time after Synchronized
N70 ID=7 WHENEVER ($R22==3) DO $R23=$R23+1
;Separate
N80 ID=8 EVERY ($R22==3) AND ($R23>=20) DO $A_OUT[1]=1 $R22=4 $R23=0 ; Separate on
N90 ID=9 EVERY ($R22==4)AND ($A_IN[2]==1) DO $A_OUT[1]=0 $R22=5 ; Separate off
;Disconnect when separated, position, reset belt axis, set auxiliary flag (ID number must be higher)
N100 ID=12 EVERY ($R22==5) DO LEADOF(SCHERE,BAND) $R22=6
;Return to initial position
N110 ID=10 EVERY ($R22==6) DO POS[SCHERE]=$R4 FA[SCHERE]=$R1 $R22=7
;Slide is returned
N120 ID=11 EVERY ($R22==7) AND ($AA_IW[SCHERE]==$R4) DO $R22=0

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;Fault
N130 ID=13 WHENEVER ($AA_IW[SCHERE]>=$R2) DO $A_OUT[2]=1 $A_OUT[1]=0
;Switch on the belt axis (makes sense only if belt is internal FM357 axis)
N140 ID=22 EVERY $A_IN[1]==1 DO MOV[BAND]=1 FA[BAND]=$R3 ;Set belt axis into constant motion
N150 ID=23 WHENEVER (($A_IN[1]==0) OR ($A_OUT[2]==1)) AND ($AA_STAT[BAND]==1) DO MOV[BAND]=0 ;belt axis stop
;As status display, deviation of Belt actual value to Shears actual value (should be approximately ;0mm after synchronization and
optimum setting of the speed controller)
N180 ID=24 WHENEVER TRUE DO $R24=($VA_IM[BAND]-$R6-$R7)-($VA_IM[SCHERE]-$R4)

;******** These actions must be executed (partly for calculating when using an external sensor)
;Calculate mean value for aging correction (10 steps via shift register)
N190 ID=25 WHENEVER $VA_IM[BAND]>=$AC_PARAM[2] DO $R31=$R32 $R32=$R33 $R33=$R34 $R34=$R35 $R35=$R36
$R36=$R37 $R37=$R38 $R38=$R39 $R39=$R40
N200 ID=26 WHENEVER $VA_IM[BAND]>=$AC_PARAM[2] DO $R40=($VA_IM[BAND] - $AC_PARAM[2])
$R25=($R31+$R32+$R33+$R34+$R35+$R36+$R37+$R38+$R39+$R40)/10
;Calculate mean value for belt speed
N210 ID=27 WHENEVER TRUE DO $R26=$R25/$MN_IPO_CYCLE_TIME*60
;Calculate smoothing deviation
N220 ID=28 WHENEVER TRUE DO $R28=($R26/60)*($R26/60)/($MA_MAX_AX_ACCEL[SCHERE]*1000)/2
;Master axis with "aging correction" and "smoothing correction"
N230 ID=29 WHENEVER $R10==0 DO $$SA_LEAD_OFFSET_IN_POS[SCHERE]= $R25*3+$R28
;Save aging correction actual value
N240 ID=30 WHENEVER TRUE DO $AC_PARAM[2]= $VA_IM[BAND]

N2200 M30

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Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Guarantee
Siemens AG accepts no liability, regardless of the legal grounds, for
damages arising from the use of the application, apart from the statutory
liability accepted, for example, for damage to items used for personal
purposes, personal accident or for malicious intent or gross negligence.

10

Support
If you have any queries regarding this application,
please e-mail them to us at:
simatic.fachkomm@nbgm.siemens.de
Please enter the article ID number in the subject line.
We can then forward your query immediately to the appropriate person.

Copyright by Siemens AG, 2000

Rev. D - Draft

15.03.02

36/38

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om the SIM
ATIC Expert
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references e
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be invalid.

Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

11

Please help us to make improvements

SIMATIC Systems Support

Sender

D-90327 Nuremberg-Moorenbrunn

Name:

Fax: 0911/ 895 - 4316

Office:
Place:
Tel.:
E-mail:

Assessment of the application


"Time-efficient, high-precision cutting of moving materials
with the SIMATIC FM 357-2"

1. Is the topic helpful/useful to you?

2. How useful is this application to you


in the following phases of work?

- Concept phase
- Project planning/Encoding
- Commissioning

3. How good is the training manual


for this application?

- Layout
- Clarity

Copyright by Siemens AG, 2000

Rev. D - Draft

Very poor

Very good

- Scope

no

Not useful

Very useful

- Own training / information

yes

15.03.02

37/38

This entry ha
sb
unchanged fr een taken directly and
om the SIM
ATIC Expert
Communicati
on, so conta
c
references e
tc. might now ts,
be invalid.

Time-efficient, high-precision cutting of moving materials with the SIMATIC FM 357-2

Very good

4. Transferability of the application to

Very poor

your own application?

5. Do you need advice on the application?

6. Is it correctly priced?

yes

yes

no

no

--> If not, suggest an alternative price: ...............................................................................

7. Is payment using the SIMATIC CARD acceptable?

yes

no

--> If not, suggest an alternative: .....................................................................................

8. Is the Internet adequate as a source of reference?

yes

no

--> If not, suggest an alternative: ....................................................................................

I would also be interested in the following topics: ...............................................................

Other suggestions: .................................................................................................................

Many thanks for your assistance!

Copyright by Siemens AG, 2000

Rev. D - Draft

15.03.02

38/38

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