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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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Contents
Part A
Stepby-step instructions
Description of program
Support .......................................................................................................... 36
11
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Part A
1
Ma terial
B elt sensor
B elt motor
S ensor
Mo tor
Figure 1-1
S lid e stroke
Flying shears
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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.
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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Shears
Sensor for synchronous mark
Cut-off material
Belt sensor
Belt motor
Sensor
Motor
Description of parts
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"
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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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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Configuration
PS
307
S7-315
CPU
SM
374
FM357-2
Drive
+/-
10V
Belt sensor
Sensor
Belt motor
Slide drive
Figure 2-1
Configuration
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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Type
Qty
Alternatives
Power supply
PS307
6ES7 307-1EA00-0AA0
CPU
CPU 315
6ES7 315-1AF03-0AB0
SM 374
6ES7 374-2XH01-0AA0
Positioning module
FM 357-2
6ES7 357-4AH01-0AE0
Component
Type
Qty
SIMATIC Manager
V 5.1
6ES7810-4CC05-0YX0
V 4.2
*)
Firmware
FM 357L
6ES7357-4AH03-3AE0
Firmware
FM 357LX
6ES7357-4BH03-3AE0
"Flying Shears"
S7 project
Self-compiled software
*) 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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Configuration
4.1
Hardware configuration
PS S7-315
307 CPU
SM
374
FM357-2
Belt axis on
+24V
"Separated"
response
+24V
Synchronous
mark sensor *)
Figure 4-1
Hardware configuration
Overview of wiring
Signal
Module / Pin
Comments
+24V
FM 357-2/ pin 1
+24V
FM 357-2/ pin 21
M (24V)
FM 357-2/ pin 20
M (24V)
FM 357-2/ pin 40
FM 357-2/ pin 28
Input "0"
"Separated" response
FM 357-2/ pin 29
Output "1"
FM 357-2/ pin 26
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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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
BOOL
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
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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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
FLIEGSCHERE_LAENGE.MPF
FLIEGSCHERE_SYNCM.MPF
Return speed
Return speed
Belt speed
Belt speed
Parts length
Parts length
Fade-out length
Figure 4-3
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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Figure 4-4
Parameters
Quantity / Size
Comments
+/- 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
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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
Table 6-1
Step no.
Measure
Action/Image
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Step no.
3
Measure
Action/Image
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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6.1.2
Table 6-2
Step no.
Measure
Action/Image
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6.1.3
Table 6-3
Step no.
Measure
Action/Image
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Step no.
Measure
Action/Image
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6.2
Table 6-4
Step no.
Measure
Action/Image
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Step no.
Measure
Action/Image
Load the data into the FM 3572 via Target System ->
Transfer/Activate Data ->
Channel 1.
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Step no.
Measure
10
Action/Image
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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
Table 7-1
Step no.
Measure
Action/Image
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Step no.
Measure
Action/Image
10
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Step no.
Measure
Action/Image
11
12
13
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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7.2
Table 7-2
Step no.
Measure
Action/Image
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Step no.
Measure
Action/Image
10
11
12
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Step no.
Measure
Action/Image
13
14
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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8.1
Cutting to length
Table 8-1
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)
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;************************************************************************
; 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
;************************************************************************
;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.
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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
;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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8.2
Table 8-2
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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;************************************************************************
; 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.
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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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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.
Rev. D - Draft
15.03.02
36/38
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.
11
Sender
D-90327 Nuremberg-Moorenbrunn
Name:
Office:
Place:
Tel.:
E-mail:
- Concept phase
- Project planning/Encoding
- Commissioning
- Layout
- Clarity
Rev. D - Draft
Very poor
Very good
- Scope
no
Not useful
Very useful
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.
Very good
Very poor
6. Is it correctly priced?
yes
yes
no
no
yes
no
yes
no
Rev. D - Draft
15.03.02
38/38