Application about Drive Technology - Siemens AG · PDF fileIntroduction . Warranty, liability...

Application about Drive Technology

Technology CPU “Flying Shears Based on Gearing”

Introduction

Warranty, liability and support

Flying Shears – Introduction ID Number: 21063352

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Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are correctly used. These Application Examples do not relieve you of the responsibility of 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 Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Application Examples and other Siemens publications – e.g. Catalogs – then the contents of the other documents have priority.



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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 Application Example 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 do not imply a change in the burden of proof to your detriment.

Copyright© 2007 Siemens A&D. It is not permissible to transfer or copy these Application Examples or excerpts of them without first having prior authorization from Siemens A&D in writing.

For questions about this document please use the following e-mail address:

mailto:[email protected]

mailto:[email protected]�

Foreword


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Foreword The application described in this document deals with “flying shears”. It shows how an axis can be synchronized to another axis with the aid of the technology CPU so that processing on the fly (cutting, drilling, printing, welding, ...) is enabled.

The core element is the “Flying Shears” technology template which implements the technological functions such as gearing and positioning of an axis. If you want to obtain further information on the technology template, a separate documentation is available. The reference data for this documentation is listed in the appendix of this document.

Objective of the application

This application shows the use of one of the technological functions or of a technology template in the technology CPU.

In order to provide a compact and practical description, a function frequently used in machines is used in a simple example with HMI connection. This ensures that the application can also be used as a demonstration model.

The application illustrates the following:

• How the used components work together

• Which technological functions are used

• How the application is programmed and parameterized

• How the application can be used as a demonstration system

Main contents of this application

The following main points are described in this application:

• Use of the “Gearing” technology function

• Use of the “Flying Shears” technology template

Delimitation

This application does not include a description of…

• …basic knowledge when using STEP 7

• …basic knowledge in the field of motion control

• ...the use of technology functions of the technology CPU

• ...the general handling of the technology CPU

Basic knowledge of these topics is required.

Foreword


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Document structure

The documentation of this application is divided into three documents:

• Introduction

• Extension

• Demonstration

In addition, the STEP7 code is available.

The first document, Introduction, which you are reading right now, is intended for persons who are interested in a quick overview.

Part Description

Introduction Application Description and Principles of Operation

This part provides a general overview of the contents. You are informed on the used components (standard hardware and software components and the specially created user software).

Extension Principles of Operation in Detail and Program Structures

This part describes the detailed functional sequences of the involved hardware and software components, the solution structures and – where useful – the specific implementation of this application. It is required to read this part if you want to familiarize with the interaction of the solution components to use these components, e.g., as a basis for your own developments.

Demonstration Structure, Configuration and Operation of the Application

This part takes you step by step through structure, important configuration steps, startup and operation of the application.

An additional component available is the S7 program code.

Part Description

S7 program code The S7 program code includes the code and a user interface which is also suitable as a demonstration system.

Reference to Automation and Drives Service & Support

This entry is from the internet application portal of Automation and Drives Service & Support. The link below takes you directly to the download page of this document.

http://support.automation.siemens.com/WW/view/en/21063352

http://support.automation.siemens.com/WW/view/en/21063352�

Table of Contents


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Table of Contents Warranty, liability and support ................................................................................... 3 Foreword....................................................................................................................... 4 Table of Contents......................................................................................................... 6 Application Description............................................................................................... 7 1 Essential Information on Processing on the Fly ............................................ 7 2 Automation Problem ......................................................................................... 9

2.1 Flying shears with length selection ...................................................... 9 2.2 Operator control of the process............................................................ 9

3 Process Analysis ............................................................................................. 11 3.1 Process sequence.............................................................................. 11 3.2 Core functions .................................................................................... 11 3.3 Solution structure ............................................................................... 12

4 Automation Solution ....................................................................................... 15 4.1 Solution structure ............................................................................... 15 4.1.1 Overview ............................................................................................ 15 4.1.2 Hardware components ....................................................................... 15 4.1.3 Software components......................................................................... 17 4.2 Functions............................................................................................ 19

Appendix and Bibliographic References................................................................. 20 5 Bibliographic References ............................................................................... 20

5.1 Bibliographic references..................................................................... 20 5.2 Internet links ....................................................................................... 21 5.3 Related documentation ...................................................................... 23

6 History............................................................................................................... 23

Application Description

Essential Information on Processing on the Fly


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1 Essential Information on Processing on the Fly This chapter shows what processing on the fly is, why it is used in machines, the advantages of processing on the fly and the problems that can be solved using processing on the fly.

What is processing on the fly?

Processing on the fly is characterized by the fact that a product on a material line is not stopped for processing.

To be able to process a defined position on the product, it is required that the processing unit is synchronized to the product velocity and that it is moved synchronously with the product during the processing phase.

Why processing on the fly?

Processing on the fly is required when…

• …stopping the material line due to a subprocess (mostly a thermal process) could cause quality loss or scrap.

• …stopping the material line is not reasonable due to the expenditure of energy because of the respective forces of deceleration and acceleration.

• …the individual processing steps are too different so that a uniform waiting time is economically unacceptable.

What are the advantages?

Processing on the fly makes the entire production procedure…

• …faster since it is not necessary to wait for the slowest processing procedure.

• …more energy-optimized since unnecessary deceleration or acceleration is not required.

• …more harmonic due to the continuous motion of the material line, which results in less wear of the plant.


Essential Information on Processing on the Fly


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Typical fields of application

Table 1-1 Fields of application for processing on the fly

Task

Filling moving containers

Processing, gripping and checking moving workpieces

Paint spraying / painting moving workpieces

Cutting to length / cutting a continuous material line


Automation Problem


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2 Automation Problem To display the application of processing on the fly, flying shears for cutting an endless product to selectable length were selected.

2.1 Flying shears with length selection

A conveyor running at a constant velocity is used to feed the product via the material line as an endless board (e.g. plastic, sheet metal or chip board).

When the cutting process is started, the shears slide is synchronized to the velocity of the material line and positioned to the cutting position. As soon as the synchronous operation between shears slide and material line is reached, the shear blades are located directly above the cutting position and the cut is triggered. During the cut the velocity of the shears slide is identical to the velocity of the material line.

When the cut is finished, the shear blades are opened and the shears slide is returned to the initial position.

Figure 2-1 Flying shears

Axis 1Shears slide drive

Axis 2Material line drive

Cut mark

Material line

100mm

Synchronization position

Initial position / starting position

Shears slide Shear blades

2.2 Operator control of the process

For presenting and operating, the flying shears feature an HMI attached to the application example; this HMI was created with WinCC flexible.

The flying shears can be operated in two modes:


Automation Problem


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• Setting up with the functions:

– Acknowledging errors

– Jogging: Moving the axis using a jog button

– Homing: Synchronizing the axis with a reference point switch or setting the current position.

– Independent positioning of the axes to a manually selected position

• Producing with the function:

– Automatic cutting of the material line according to a specified length (cyclic operation)

In this application, the cutting process of the shears is simulated with the aid of the HMI.

Note For details on operating and presenting the application, please refer to the Demonstration document.


Process Analysis


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3 Process Analysis This chapter illustrates the technological basics of the flying shears independently of the possible hardware.

3.1 Process sequence

Precondition

The process can only be started if the flying shears are within the permissible operating range and if they have been homed:

• The shears slide is located between the software limit switches

• The shears axis was homed

• The shear blades are opened

• The shears slide is in starting position

Process sequence

Once the flying shears have been started in automatic mode, they pass the following cycle until they are deactivated:

• Synchronizing the shears slide to the velocity of the material line and the cutting position

• Closing the shear blades

• The actual cutting process

• Opening the shear blades

• Repositioning the shears slide to the starting position

• Adjusting the position of the material line to the next cutting position

The position of the material line is influenced in such a way that each cut occurs at the 0 position of the material line. This is achieved by setting the position value of the material line on the fly.

3.2 Core functions

The following sections describe the technological core functions required to realize the application.

Synchronization of the shears slide

There are two preconditions for an exact cut:

• The shears slide and the material on the material line move at exactly the same velocity

• The shear blades are located exactly above the cutting position

These preconditions are achieved by synchronizing the shears slide to the material line and have to be maintained during the entire cutting process.


Process Analysis


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Figure 3-1 Positions of material line and shears slide during a cycle

Position

Time

Cutting timeDistance traveled

during cuttingMaximum distance of the shears slide

Shears slideposition

Material lineposition

Defining the cutting position bysetting the axis position = 0

To achieve this mode, the shears axis is connected to the material axis in gearing, i.e. the shears axis directly follows the position information of the material line. Failures are detected and corrected. The simple motion at the same velocity in velocity gearing is inadequate for this application since failures may cause differences in position which cannot be detected and corrected.

Selecting the appropriate synchronization mode ensures that the shear blades are located exactly above the cutting position when reaching the material line velocity.

This solution ensures that modifications of the material line velocity do not affect the actual cutting length and the cutting quality.

Return to starting position

When the cutting process is finished, the shears slide has to be returned to its initial position.

This is done by a positioning to the starting position of the shears slide at a defined velocity.

The synchronous operation between material line and shears slide is terminated, the shears slide is brought to a standstill with a specified deceleration and returned to the starting position at a defined velocity.

3.3 Solution structure

The following section describes the structure of the solution. The process sequence is realized via the “Flying Shears” technology template which is used in this application example and which includes the complete functionality of the flying shears.


Process Analysis


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Figure 3-2 Solution structure of the flying shears

synchronizing

PLC

axisshears

Cutting simulation

axissynchronous operation

positioningsynchronous operation

start

axis

homing

M G

axis 1shears

M G

axis 2material

SINAMICS S120 training case

axismaterial

MainControl

TemplateControl

move velo

repositioning

cutting

next cut

start material

start shears

Program Signals

Technology Signals

Program Module

PLCopen Object

Technology Object

Technology Template

HMI

Sequence of the overall process

Via the user interface (HMI), the shears slide of the flying shears can first be moved to starting position in setup mode.

Process mode can then be started via Main Control. Via start material, the material line is brought to a constant velocity and the flying shears are started via start shears.

Selecting the process mode enables the following process.

• Via the synchronizing path, the shears axis is synchronized to the material axis in gearing.

• If the shears axis is synchronous to the material axis, a cut is triggered via the cutting path. During the cut the gearing of shears slide and material line prevents the shear blades from canting in the material of the material line.

• At the end of the cutting process – the shear blades have moved out of the material of the material line – the shears axis is returned to the starting position


Process Analysis


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by a positioning via the repositioning path. The position value of the material line is simultaneously adjusted to the next cutting position via the next cut path.

Gearing

Gearing is the moving of a group of at least two axes with a fixed reference to speed and rotation angle. The axis providing the master value is the master axis. All further axes of the group of axes are slave axes. The slave axes follow the position selection of the master axis in a fixed but adjustable ratio. Individual slave axes can be included in or excluded from the group of axes by means of synchronization or desynchronization processes.

Positioning

Positioning is moving an axis from position A to position B. A travel profile is generated from the specifications target position, velocity and acceleration. The axis accelerates to the specified velocity and exactly at that time starts decelerating to come to a standstill at the target position. During this process the deceleration is performed with the absolute value of the specified acceleration.


Automation Solution


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4 Automation Solution This chapter shows the reader how the automation problem can be solved using the technology CPU.

4.1 Solution structure

4.1.1 Overview

Technological tasks with medium to high PLC performance and medium motion control requirements can easily be realized using the technology CPU.

Figure 4-1 Overview of the hardware configuration

Technology CPUPG/PC

WinCC flexible


Note The automation solution presented in this document is available as a STEP 7 archive with virtual axes, i.e. without real drive.

However, the connection of a SINAMICS S120 training case can later be performed based on the provided STEP 7 archive.

4.1.2 Hardware components

The following hardware components are required to realize the application example.

Figure 4-1 Hardware components

Hardware element Picture MLFB/order number and functions

Controller

DIN rail

6ES7390-1AE80-0AA0 The DIN rail is the mechanical rack of an S7-300 and required to set up the controller.

PS307 2A power supply

6ES7-307-1BA00-0AA0 The power supply provides the required 24VDC


Automation Solution


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Technology CPU The technology CPU executes the user program and the technological functions.

CPU 317T-2 DP 6ES7317-6TJ10-0AB0 Hardware product version: 02 Firmware revision level: V 3.1.1 Integrated main memory: 512KB

Max. block size: 64KB

or alternatively

CPU 315T-2 DP 6ES7315-6TG10-0AB0 Hardware product version: 01 Firmware revision level: V 3.1 Integrated main memory: 128KB Max. block size: 16KB

40-pin front connector

6ES7392-1AM00-0AA0 The front connector enables the easy and user-friendly connection of the sensors and actuators to the signal modules. It is plugged to the module and covered by the front door

4MB Micro Memory Card

6ES7953-8LM11-0AA0 The S7 program is stored on the MMC.

Communication and communication via DP(Drive) (optional)

PROFIBUS connector plug up to 12 Mbps

6ES7972-0BA41-0XA0 The plugs are used to connect

• PG and technology CPU and

• technology CPU and SINAMICS S120 training case (optional)

PROFIBUS cable

6XV1830-0EH10 (sold by the meter, min. 20m) The cable is used to connect

• PG and technology CPU and

• technology CPU and SINAMICS S120 training case (optional)



Automation Solution


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HMI

PG/PC with MPI and Ethernet interface

- The PG/PC is used for configuring and for executing the HMI

Drive (optional)


6ZB2480-0BA00

The SINAMICS S120 training case consists of standard components (drives and motors) and offers two axes. They are used to demonstrate the application. The case is completely configured and wired and is connected to the controller via PROFIBUS.

4.1.3 Software components

The following software components are required to realize the application.

Standard software

If the technological functions of the application are to be reconstructed, the following SIEMENS standard software components are necessary:

Table 4-2 Software components

Component MLFB / order number Functions

STEP7 V5.4 SP1

6ES7810-4CC08-0YA7 STEP 7 is the basic package for the other software packages and used for programming the SIMATIC S7

S7 Technology V3.0 SP2

6ES7864-1CC30-0YX0 Tool for parameterizing and programming the technology objects of the technology CPU

WinCC flexible 2005 Advanced incl. ServicePack 1 and Hotfix 7

6AV6613-0AA01-1CA5 incl. S79220-A7890-F

WinCC flexible is used to program the HMI. Without this software, it is not possible to modify the HMI.

WinCC flexible 2005 Runtime incl. ServicePack 1 and Hotfix 7 with 256 PowerTags

6AV6613-1DA01-1CA0 incl. S79220-A7890-F

WinCC flexible Runtime enables the use of a PG/PC as an operator panel.


Automation Solution


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Standard software for presentation

If the application is only to be presented, it is sufficient to install the following software components on the demonstration PG/PG. However, it is required that the application has already been loaded into the CPU, e.g. with another PG/PC.

Table 4-3 Software components required for presentation

Component MLFB / order number Functions

WinCC flexible 2005 Runtime incl. ServicePack 1 and Hotfix 7 with 512 PowerTags

6AV6613-1DA01-1CA0 incl. S79220-A7890-F

WinCC flexible Runtime enables the use of a PG/PC as an operator panel.

Application software

The application software is an archived Step 7 project that contains the code of the application for the respective technology CPU.

Table 4-4 Application software for use without drives

File Functions

21063352_CPU315T_Shears_v_CODE_v30.zip Archived Step 7 project for the CPU 315T-2 DP with virtual axes, does not require drives

21063352_CPU317T_Shears_v_CODE_v30.zip Archived Step 7 project for the CPU 317T-2 DP with virtual axes, does not require drives


Automation Solution


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4.2 Functions

PG/PC

Operator control and monitoring of the flying shears is performed via a WinCC flexible 2005 user interface on the PG/PC.

This platform can also be used for loading the programs for the technology CPU and for parameterizing the optional SINAMICS S120 training case.

Technology CPU

The technology CPU features a control unit like each conventional CPU and an integrated technology. The following tasks are realized in the control unit:

– Realization of the program flow with a step sequence

– Management of the modes

– Communication with HMI

– Management and coordination of the technology jobs

– Call of the technology jobs via motion control blocks according to the PLCopen standard

The technology part performs the following tasks:

– Implementation of the technology jobs

– Motion control of the axes

– Motion monitoring

Drive

As a drive system for tests, the optional SINAMICS S120 training case with two axes takes over the axis functions. It is completely wired so that it can be directly used for this application example.

The training case is equipped with a clocked Profibus interface via which the drive is connected to the controller.

Appendix and Bibliographic References

Bibliographic References


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5 Bibliographic References

5.1 Bibliographic references

This list is by no means complete and only provides a selection of appropriate sources.

Table 5-1

Topic Title

/1/ STEP7 Automating with STEP7 in STL and SCL Hans Berger Publicis MCD Verlag - 2004 ISBN 3-89578-242-4

/2/ Technology CPU SIMATIC – S7-300 CPU Data: CPU 315T-2DP Siemens Manual Edition 11/2006 MLFB: A5E00427932-03

/3/ Technology CPU SIMATIC – S7-300 CPU Data: CPU 317T-2DP Siemens Manual Edition 11/2006 MLFB: A5E00251769-05

/4/ Technology CPU SIMATIC – S7 Technology Siemens Manual Edition 11/2006 MLFB: A5E00251797-05

/5/ Technology CPU CPU 317T-2DP: Controlling a SINAMICS S120 Getting Started Edition 11/2006 MLFB: A5E00480390-02

/6/ Technology CPU CPU 317T-2DP: Controlling a virtual axis Getting Started Edition 11/2006 MLFB: A5E00266283-04

/7/ Technology CPU CPU 317T-2DP: Controlling a physical axis Getting Started Edition 11/2006 MLFB: A5E00251785-04

/8/ SINAMICS S120 SINAMICS S120 – Installation and Start-Up Manual (IH1) Manufacturer / Service Documentation Edition 04/2006 MLFB: 6SL3 097-2AF00-0AP5




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/9/ SINAMICS S120 SINAMICS S120 – Equipment Manual (GH1) Control Units and Additional System Components Edition 03/2006 MLFB: 6SL3097-2AH00-0AP3

/10/ SINAMICS S120 SINAMICS S120 – Equipment Manual (GH2) Booksize Power Sections Edition 03/2006 MLFB: 6SL3097-2AC00-0AP3

/11/ SINAMICS S120 SINAMICS S – List Manual (LH1) Manual Edition 03/2006 MLFB: 6SL3 097-2AP00-0AP4

/12/ SINAMICS S120 SINAMICS S120 – Function Manual (FH1) Function Manual Drive Functions Manufacturer / Service Documentation Edition 03/2006 MLFB: 6SL3 097-2AB00-0AP2

5.2 Internet links

This list is by no means complete and only provides a selection of appropriate sources.

Table 5-2

Topic Title

\1\ Reference to the entry


\2\ Siemens A&D Customer Support

www.ad.siemens.de/support

\3\ Siemens A&D Applications & Tools




http://www.ad.siemens.de/support�






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\4\ Application examples for the technology CPU (a selection)

Palletizer with simply Interpolating Axes:


Feeder for a Press:


\5\ Technology CPU manual

http://www.ad.siemens.de/support Select “Product Support” Open the following directories in the Product Information tree:

• Automation systems

• SIMATIC Industrial Automation Systems

• PLC

• SIMATIC S7

• S7-300/S7-300F

• CPUs Click the Manual tab to open a list with related documents or click the following links: S7 Technology:


CPU manual 317T-2 DP:


CPU manual 315T-2 DP:


\6\ SINAMICS S120 instruction manual

http://www.ad.siemens.de/support Select “Product Support” Open the following directories in the Product Information tree:

• Drive technology

• AC Converter

• Low voltage converters

• Built-in and cabinet system SINAMICS S120 Click the Manual tab in the right window to open a list with related documents or select the following link:

http://www.automation.siemens.com/doconweb













http://www.automation.siemens.com/doconweb�


History


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\7\ FAQ CPU 317T-2 DP applicable encoders

Applicable encoders for the technology CPU 31xT in connection with the drive systems SIMODRIVE 611U, MASTERDRIVES MC


\8\ FAQ technology CPU version overview

Which versions of the S7 Technology option package are available and which SINAMICS S120 drive firmware can you use with which of these versions?


5.3 Related documentation

This list includes a summary of related documentations which you can obtain from Siemens Customer Support or your Siemens contact person.

Table 5-3

Topic Title

/A/ Technology template

“Flying Shears” Technology Template Technology CPU – Documentation ID number: 21062270


6 History Table 6-1 History

Version Date Modification

V3.2 06/05/07 Adaptation of the documentation to the S7 Technology V3.0 SP2 technology package. Added Microbox 420-T. Added Runtime.

V3.21 08/2010 Removed Microbox 420-T







Application about Drive Technology - Siemens AG · PDF fileIntroduction . Warranty, liability...

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Transcript of Application about Drive Technology - Siemens AG · PDF fileIntroduction . Warranty, liability...