Rexroth IndraMotion MLC 04VRS

Rexroth IndraMotion MLC 04VRSLinear Motion and Assembly TechnologiesHydraulics
Rexroth IndraMotion MLC 04VRS Library Description ML_Technology
R911321531 Edition 01
Library Description
RS-e3bf7a2813a5fbe60a6846a000599625-1-en-US-7
This documentation describes the function blocks, the functionalities and the data types of the "ML_Technology" library in its version for IndraMotion MLC 04VRS. Furthermore, it contains information with regard to the error responses of the function block.
Edition Release Date Notes
120-2850-B331-01/EN 02.2008 First version, MLC04VRS
© 2007 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availa bility of the product. Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 D-97816 Lohr a. Main Phone +49 (0)93 52/ 40-0 Fax +49 (0)93 52/ 40-48 85 http://www.boschrexroth.com/ BRC/EAM AK (BaWe/MePe) This document has been printed on chlorine-free bleached paper.
Title
Rexroth IndraMotion MLC 04VRS | Library Description
Copyright
Validity
5 General Definitions...................................................................................................... 17
Library Description | Rexroth IndraMotion MLC 04VRS Electric Drives and Controls
| Bosch Rexroth AG I/III
Table of Contents
| Bosch Rexroth AG III/III
1 Introduction and Overview Technology Function Blocks (Tech-FB's) extend the basic functionality of the target systems (like e.g. MLD / MLC) and provide application-specific function alities like e.g. Flying Shear, Cross Cutter, Register Controller etc. The function blocks described here are provided via an internal IEC library (as for example MX_Technology0x.lib for MLD or ML_Technology0x.lib for MLC). These documentation describes the functionality as well as the in- and outputs of the Technology Function Blocks. Technology Function blocks of library ML_Technology0x.lib require the firm ware support of the target system MLC0x. Specific preconditions of the Tech nology Function Blocks are documented in the chapter of the corresponding function blocks.
The library ML_Technology0x.lib uses functions of library RIL_Utilities.lib and ML_TechCommon. Therefore, in addition, the libaries RIL_Utilities.lib and ML_TechCommon must be included in the PLC-Project.
| Bosch Rexroth AG 1/179
2 Further Documentations The following table provides an overview of the available IndraDrive hardware and firmware as well as of MLC documentations.
Title Labeling
DOK-INDRV*-MP*-04VRS**-FK01-EN-P
DOK-INDRV*-GEN-**VRS**-PA03-EN-P
DOK-INDRV*-GEN-**VRS-WA03-EN-P
Rexroth IndraMotion MLC; Functional Description DOK-IM*MLC-SYSTEM**V04-FK01-EN-P
Rexroth IndraMotion MLC04VRS; Axis and Control Parameters DOK-IM*MLC-A*C*PAR*V04-PA01-EN-P
Rexroth IndraMotion MLC04VRS; Analyses DOK-IM*MLC-DIAGN***V04-WA01-EN-P
Rexroth IndraMotion MLC04VRS, PLCopen Function Blocks and Data Types
DOK-IM*MLC-PLCOPEN*V04-FK01-EN-P
Rexroth IndraMotion MLC04VRS, Getting Started DOK-IM*MLC-F*STEP**V04-KB01-EN-P
Rexroth IndraMotion MLC04VRS, ML_TechCommon, ML_TechCam and ML_TechCamIEC libraries
DOK-IM*MLC-TFB-COM*V04-AW01-EN-P
Rexroth IndraMotion MLC04VRS, ML_Packaging Library DOK-IM*MLC*TFB-IMPAV04-AW01-EN-P
Fig.2-1: Further documentations
3 Important Instructions on Use 3.1 Intended Use 3.1.1 Introduction
All Bosch Rexroth controls and drives are developed and tested in accordance with the state of the art technology. It is not possible to track the continuous further improvement of all materials our controls and drives may come into contact with (e.g. lubricants at machine tools). Reactions with the materials used in the Bosch systems cannot generally be excluded. Therefore, before using new lubricants, cleaning agents etc., must be checked for compatibility with the Bosch housing and device materials. The products may only be used for the intended purpose. When they are not used as intended, situations may arise resulting in damage to person or mate rial.
Bosch Rexroth, as the manufacturer of the products, shall not as sume any warranty, liability or payment of damages in case of damage resulting from a non-intended use of the products. If the user fails to use the products as intended, the user shall assume sole responsibility for any resulting risks.
Before using Bosch Rexroth products, the following prerequisites must be ful filled to ensure their proper use: Anyone using our products must read and understand the corresponding
safety notes and intended use of the product. If the products are hardware, they must be kept in their original state, i.e.
no constructional modifications should be made. Software products may not be decompiled; their source codes may not be modified.
Damaged or defective products must not be installed or put into operation. It must be ensured that the products are installed according to the regu
lations specified in the documentation.
3.1.2 Scope of Use and Application Bosch Rexroth drive controllers are intended to control electrical motors and monitor their operation. To control and monitor the motor, it may be necessary to connect additional sensors and actuators.
The drive controllers must only be used with the accessories and mounting parts listed in this documentation. Do not install or con nect components not expressly specified in this documentation. This also applies to cables and lines.
The unit may be operated only with the explicitly specified compo nent configurations and combinations and only with the software and firmware specified in the appropriate functional description.
Before commissioning, every drive controller must be programmed to ensure that the motor executes the appropriate functions for the application.
Important Instructions on Use
The drive controllers have been developed for use in single and multi-axes drive and control tasks. To allow for application-specific requirements in the drive controllers, our prod uct range comprises various device types with different drive powers and interfaces. The drive controller must only be operated under the mounting and installation conditions, the position, and the ambient conditions (temperature, type of pro tection, moisture, EMC, etc.) specified in this documentation.
3.2 Improper Use The use of the drive controllers in applications other than those specified or described in the documentation and the technical data is considered as "im proper". Drive controllers must not be used if they … are subjected to operating conditions not corresponding to the specified
ambient conditions. They must not be operated under water, under ex treme temperature fluctuations, or within extreme maximum tempera tures.
Furthermore, the drive controllers can only be used in applications ap proved by Bosch Rexroth. Please note the specifications outlined in the general safety instructions!
6/179 Bosch Rexroth AG | Electric Drives and Controls
Important Instructions on Use
4 Safety Instructions for Electric Drives and Controls 4.1 Safety Instructions - General Information 4.1.1 Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all doc umentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent im mediately to the person or persons responsible for the safe operation of the device. If the device is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the device in the official lan guage of the user's country.
WARNING
Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product, including disabling of safe ty devices, may result in material damage, bodily harm, electric shock or even death! Observe the safety instructions!
4.1.2 How to Employ the Safety Instructions Read these instructions before initial commissioning of the equipment in order to eliminate the risk of bodily harm and/or material damage. Follow these safety instructions at all times. Bosch Rexroth AG is not liable for damages resulting from failure to ob
serve the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language
before commissioning the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify.
Proper and correct transport, storage, assembly and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of this device.
Only assign trained and qualified persons to work with electrical installa tions: – Only persons who are trained and qualified for the use and operation
of the device may work on this device or within its proximity. The persons are qualified if they have sufficient knowledge of the assem bly, installation and operation of the product, as well as an under standing of all warnings and precautionary measures noted in these instructions.
– Furthermore, they must be trained, instructed and qualified to switch electrical circuits and devices on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safe ty equipment and be trained in first aid.
Only use spare parts and accessories approved by the manufacturer.
Safety Instructions for Electric Drives and Controls
Follow all safety regulations and requirements for the specific application as practiced in the country of use.
The devices have been designed for installation in industrial machinery. The ambient conditions given in the product documentation must be ob
served. Only use safety-relevant applications that are clearly and explicitly ap
proved in the Project Planning Manual. If this is not the case, they are excluded. Safety-relevant are all such applications which can cause dan ger to persons and material damage.
The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applica tions and suggestions. The machine and installation manufacturer must – make sure that the delivered components are suited for his individual
application and check the information given in this documentation with regard to the use of the components,
– make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements.
Commissioning of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application.
Operation is only permitted if the national EMC regulations for the appli cation are met.
The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective documentation (Project Planning Manuals of components and system). The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations.
Technical data, connection and installation conditions are specified in the product documentation and must be followed at all times.
National regulations which the user must take into account European countries: according to European EN standards United States of America (USA):
– National Electrical Code (NEC) – National Electrical Manufacturers Association (NEMA), as well as
local engineering regulations – regulations of the National Fire Protection Association (NFPA)
Canada: Canadian Standards Association (CSA) Other countries:
– International Organization for Standardization (ISO) – International Electrotechnical Commission (IEC)
4.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness The safety instructions describe the following degrees of hazard seriousness. The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions:
Warning symbol Signal word Degree of hazard serious ness acc. to ANSI Z 535.4-2002
Danger Death or severe bodily harm will occur.
Warning Death or severe bodily harm may occur.
Caution Minor or moderate bodily harm or material damage may occur.
Fig.4-1: Hazard classification (according to ANSI Z 535)
4.1.4 Hazards by Improper Use
DANGER
High electric voltage and high working current! Risk of death or severe bodily injury by electric shock! Observe the safety instructions!
DANGER
Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! Observe the safety instructions!
WARNING
High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock! Observe the safety instructions!
WARNING
Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Observe the safety instructions!
CAUTION
Hot surfaces on device housing! Danger of injury! Danger of burns! Observe the safety instructions!
CAUTION
Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting or improper handling of pressurized lines! Observe the safety instructions!
CAUTION
Risk of injury by improper handling of batteries! Observe the safety instructions!
4.2 Instructions with Regard to Specific Dangers 4.2.1 Protection Against Contact with Electrical Parts and Housings
This section concerns devices and drive components with voltages of more than 50 Volt.
Contact with parts conducting voltages above 50 Volts can cause personal danger and electric shock. When operating electrical equipment, it is unavoid able that some parts of the devices conduct dangerous voltage.
DANGER
High electrical voltage! Danger to life, electric shock and severe bodily injury! Only those trained and qualified to work with or on electrical equipment
are permitted to operate, maintain and repair this equipment. Follow general construction and safety regulations when working on pow
er installations. Before switching on the device, the equipment grounding conductor must
have been non-detachably connected to all electrical equipment in ac cordance with the connection diagram.
Do not operate electrical equipment at any time, even for brief measure ments or tests, if the equipment grounding conductor is not permanently connected to the mounting points of the components provided for this purpose.
Before working with electrical parts with voltage potentials higher than 50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection.
With electrical drive and filter components, observe the following: Wait 30 minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the electric voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch.
Never touch the electrical connection points of a component while power is turned on. Do not remove or plug in connectors when the component has been powered.
Install the covers and guards provided with the equipment properly before switching the device on. Before switching the equipment on, cover and safeguard live parts safely to prevent contact with those parts.
A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device according to the relevant standards.
Secure built-in devices from direct touching of electrical parts by providing an external housing, for example a control cabinet.
For electrical drive and filter components with voltages of more than 50 volts, observe the following additional safety instructions.
DANGER
High housing voltage and high leakage current! Risk of death or bodily injury by electric shock! Before switching on, the housings of all electrical equipment and motors
must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests.
The equipment grounding conductor of the electrical equipment and the devices must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 mA.
Over the total length, use copper wire of a cross section of a minimum of 10 mm2 for this equipment grounding connection!
Before commissioning, also in trial runs, always attach the equipment grounding conductor or connect to the ground wire. Otherwise, high vol tages may occur at the housing causing electric shock.
4.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage Protective extra-low voltage is used to allow connecting devices with basic in sulation to extra-low voltage circuits. All connections and terminals with voltages between 5 and 50 volts at Rexroth products are PELV systems. 1) It is therefore allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections and terminals.
WARNING
High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock! If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g. the mains connection) are connected to Rexroth products, the connected extra-low voltage circuits must comply with the requirements for PELV. 2)
4.2.3 Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation.
1) "Protective Extra-Low Voltage" 2) "Protective Extra-Low Voltage"
The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.
DANGER
Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and tested higher-level
monitoring devices or measures integrated in the installation. These measures have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possi ble if safety devices are disabled, bypassed or not activated.
To avoid accidents, bodily harm and/or material damage: Keep free and clear of the machine’s range of motion and moving parts.
Possible measures to prevent people from accidentally entering the machine’s range of motion: – use safety fences – use safety guards – use protective coverings – install light curtains or light barriers
Fences and coverings must be strong enough to resist maximum possible momentum.
Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don’t operate the device if the emergency stop is not working.
Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start.
Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone.
Additionally secure vertical axes against falling or dropping after switching off the motor power by, for example: – mechanically securing the vertical axes, – adding an external braking/ arrester/ clamping mechanism or – ensuring sufficient equilibration of the vertical axes.
The standard equipment motor brake or an external brake controlled di rectly by the drive controller are not sufficient to guarantee personal safety!
Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: – maintenance and repair work – cleaning of equipment – long periods of discontinued equipment use
Prevent the operation of high-frequency, remote control and radio equip ment near electronics circuits and supply leads. If the use of such devices cannot be avoided, verify the system and the installation for possible mal functions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.
4.2.4 Protection Against Magnetic and Electromagnetic Fields During Oper ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious personal danger to those with heart pacemakers, metal implants and hearing aids.
WARNING
Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers and metal implants are not permitted to
enter following areas: – Areas in which electrical equipment and parts are mounted, being
operated or commissioned. – Areas in which parts of motors with permanent magnets are being
stored, repaired or mounted. If it is necessary for somebody with a pacemaker to enter such an area,
a doctor must be consulted prior to doing so. The noise immunity of pres ent or future implanted heart pacemakers differs greatly so that no general rules can be given.
Those with metal implants or metal pieces, as well as with hearing aids, must consult a doctor before they enter the areas described above. Oth erwise health hazards may occur.
4.2.5 Protection Against Contact with Hot Parts
CAUTION
Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns! Do not touch surfaces of device housings and chokes in the proximity of
heat sources! Danger of burns! Do not touch housing surfaces of motors! Danger of burns! According to the operating conditions, temperatures can be higher than
60 °C, 140°F during or after operation. Before accessing motors after having switched them off, let them cool
down for a sufficiently long time. Cooling down can require up to 140 mi nutes! Roughly estimated, the time required for cooling down is five times the thermal time constant specified in the Technical Data.
After switching drive controllers or chokes off, wait 15 minutes to allow them to cool down before touching them.
Wear safety gloves or do not work at hot surfaces. For certain applications, the manufacturer of the end product, machine or
installation, according to the respective safety regulations, has to take measures to avoid injuries caused by burns in the end application. These measures can be, for example: warnings, guards (shielding or barrier), technical documentation.
4.2.6 Protection During Handling and Mounting In unfavorable conditions, handling and mounting certain parts and compo nents in an improper way can cause injuries.
CAUTION
Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting! Observe the general construction and safety regulations on handling and
mounting. Use suitable devices for mounting and transport. Avoid jamming and bruising by appropriate measures. Always use suitable tools. Use special tools if specified. Use lifting equipment and tools in the correct manner. If necessary, use suitable protective equipment (for example safety gog
gles, safety shoes, safety gloves). Do not stand under hanging loads. Immediately clean up any spilled liquids because of the danger of skidding.
4.2.7 Battery Safety Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or material damage.
CAUTION
Risk of injury by improper handling! Do not attempt to reactivate low batteries by heating or other methods (risk
of explosion and cauterization). Do not recharge the batteries as this may cause leakage or explosion. Do not throw batteries into open flames. Do not dismantle batteries. When replacing the battery/batteries do not damage electrical parts in
stalled in the devices. Only use the battery types specified by the manufacturer.
Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations. Dispose of used batteries separate from other waste. Observe the local regulations in the country of assembly.
4.2.8 Protection Against Pressurized Systems According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be par tially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids and cooling lubricating agents. Improper handling of the connected supply systems, supply lines or connections can cause injuries or material damage.
CAUTION
Risk of injury by improper handling of pressurized lines! Do not attempt to disconnect, open or cut pressurized lines (risk of explo
sion). Observe the respective manufacturer's operating instructions. Before dismounting lines, relieve pressure and empty medium. Use suitable protective equipment (for example safety goggles, safety
shoes, safety gloves). Immediately clean up any spilled liquids from the floor.
Environmental protection and disposal! The agents used to operate the product might not be economically friendly. Dispose of ecolog ically harmful agents separately from other waste. Observe the local regulations in the country of assembly.
5 General Definitions Each function block contains a continuous "Error"-Structure, as well as general defined in- and outputs with defined behavior. All function blocks with "Execute"-Input and "Done"-Output have the same edge-oriented runtime behavior. With the rising edge at the "Execute"-Input of a function block the processing is activated.
Fig.5-1: Signal-Time-Diagram of Execute, Active, Done and Error When the result is available, "Done" is set to TRUE. When, however, an error case is present, "Error" is set to TRUE and "ErrorID" is set to an error identifi cation. While "Execute" is not canceled, "Done" or "Error" remain on their values. With canceling "Execute", "Done", "Error" and "ErrorID" are reset. If "Execute" is already FALSE when the command is completed, then the in formation "Done" or "Error" and "ErrorID" remain active for exactly one cycle. Function blocks with an "Enable"-Input are working in a level-oriented way. Normally the input "Enable" is passed on to the appropriate functionality (ex ample: "MC_Power").
Fig.5-2: Signal-Time-Diagram of Enable, Active, Done and Error
6 Function Block for Application "Flying Shear" 6.1 Introduction and Overview
With the application "Flying shear", a machining station will be synchronized with regard to a continuously passing material (like, for example, metal, plastic, etc.), and the machining is executed in the synchronous run of the machining station. The material position is usually detected via a measuring wheel and transferred via an optional encoder input to the drive controller. Then, the drive controller synchronizes the connected servo motor on the continuously passing through material when the specified cut length was passed through. The function block chapter 6.2 "MX(L)_FlyingShear" on page 19 or chapter 6.3 "ML_Flying Shear - Special Features of IndraMotion MLC" on page 24 is responsible for the synchronization and sets the output "InSync" once the machining station is running synchronously. In this state, the material can be machined since now the machining station runs synchronously to the material. After having finished the machining process, the synchronous run can be in terrupted with the input "MoveReturn", and the machining station returns to its specified starting position. For test purposes, a virtual axis can be used instead of the measuring wheel. With this virtual axis, it is then possible to simulate the measuring wheel.
6.2 MX(L)_FlyingShear The function block MX(L)_FlyingShear contains the typical procedure of a flying shear and performs the following steps once the input "Start" has been set to TRUE: Moves the slave axis to the starting position „ReturnPos“ and wait until the
axis has reached its position. Synchronizes the slave axis on the master axis over a Lock On cam profile. Sets the output "InSync" once the slave axis (machining station) has been
synchronized on the material. Returns the slave axis to its starting position if the corresponding signal is
set at the input "MoveReturn".
Fig.6-1: Function block MX(L)_FlyingShear
Brief Description
Interface Description
VAR_IN_OUT Master AXIS_REF Reference to the master axis
Slave AXIS_REF Reference to the slave axis (machining station)
FSRetain MB_FS_RETAIN_DATA*1 Reference to the required retain data of this function block
VAR_INPUT Start BOOL Start=TRUE: Starts the FlyingShear function block. Depending on the states of the inputs "ImmediateCut" and "CropCut", the function block performs the following func tions: Start=TRUE and positive edge at the input "Immediate Cut": The machining station will be synchronized immediately and performs the cutting length (Cutlength) once the im mediate cut (ImmediateCut) has been performed. Start=TRUE and positive edge at the input "CropCut": The machining station will be synchronized after the cut ting length (Cutlength) has passed the machine and per forms the cutting length (Cutlength) once the crop cut (CropCut) has been performed. Start=TRUE and no signal "ImmediateCut" and "Crop Cut": The machining station will be synchronized after the cut ting length (Cutlength) has passed the machine (measured from the last cut).
CropCut BOOL In the case of a rising edge, the slave axis starts the syn chronization process after the cutting length has passed the machine. If a cut cycle is currently performed (InCycle=TRUE), the crop cut will be performed in the next cut cycle.
ImmediateCut BOOL (Start = TRUE): This case is intended for an immediate cut on the running material. The immediate cut (ImmediateCut) will be acti vated by a positive edge. The slave axis will be synchron ized immediately. If a cut is currently performed (InCycle = TRUE), the immediate cut will be performed in the next cut cycle. If (Start = FALSE) and (Vmeasuring_wheel < 5 rpm):
This case is intended for an immediate cut on stopped ma terial. The immediate cut (ImmediateCut) will be activated by a positive edge. The slave axis remains in its standstill position and will not be synchronized. The output "In Sync" will be set immediately, and the function block ex pects the input signal "MoveReturn" for finishing the process. After having finished this process, the flying shear is referenced to the material.
MoveReturn BOOL Finishes the synchronous run of the slave axis with the material and returns the slave axis to its starting position "ReturnPos".
ResetCut Counter
Function Block for Application "Flying Shear"
I/O type Name Data type Comment
Cutlength REAL Specified material cutting length*2*3
MWFeedconst REAL Feed constant of the measuring wheel per revolution *2 *3
SyncDist REAL Synchronization distance required by the slave axis for synchronizing on the master axis*2*3. The shorter the syn chronization distance, the higher is the synchronization acceleration.
ReturnPos REAL The slave axis moves to this starting position at the begin ning and after having been synchronized and once the input MoveReturn is set to TRUE *2*3.
ReturnVel REAL The slave axis returns to the starting position "Return Pos" with the velocity ReturnVel *2*3.
ReturnAcc REAL The slave axis returns to the starting position "Return Pos" with the acceleration ReturnAcc *2*3.
PreSyncPos REAL The output signal "PreSyncSignal" is set before the syn chronous position "PreSyncPos" with the distance given here to make preparations before the synchronous run*2 .
PreSyncTime TIME Duration of "PreSyncSignal"
VAR_OUTPUT InSync BOOL The slave axis runs synchronously with the material. It is in its synchronization window (see drive parameter S-0-0228).
InCycle BOOL The slave axis currently performs a cut cycle. An immedi ate or crop cut will be performed in the next cycle (CutCycle = 0).
CropCutDone BOOL The crop cut has been performed
ImmediateCut Done
PreSyncSignal BOOL Presignal before the synchronous position "PreSyncPos"
ShortPrdWarn ing
BOOL The slave axis does not have enough time to reach the starting position "ReturnPos" for the next cut. The return is interrupted and the synchronization ramp starts again. This case should be prevented since the drive might be overloaded and the machining station might move to the carriage bed end. Countermeasures: Increase return velocity (function block input "Re
turnVel") Increase return acceleration (function block input
"ReturnAccl") Reduce synchronization distance (function block in
put "SyncDist") Reduce material feed velocity
MaterialMoving BOOL The speed of the material encoder is higher than 5 rpm. An immediate cut in the case of a material standstill is only possible if MaterialMoving=FALSE.
Reserve DINT Reserved increments of the synchronization procedure for analysis purposes. A synchronization is not possible if Re serve ≤ 0 -> In this case, the function block returns an error message.
I/O type Name Data type Comment
CycleState UINT Current status of the cut cycle: 0: Standstill and waiting phase; 1: Acceleration phase; 2: Synchronous run phase; 3: Return phase.
CutCounter UINT With each cut, the cut counter "CutCounter" will be in creased. With (Start = FALSE) or a positive edge at the input "ResetCutCounter", the counter will be reset.
Error BOOL Indicates an error. Will be deleted if Start=FALSE
ErrorID INT (Enum) ERROR_CODE: Brief error description
ErrorIdent ERROR_STRUCT Detailed error description
*1: MB_FS_RET AIN_DATA*1:
STRUCT (bCutNotCompleted: BOOL, diMasterSyncPosition: DINT, iRevCounter:INT)
*2 : Measuring units according to drive weighting, e. g. mm *3 : New input values will be taken over with the transition from the synchro
nous run phase to the return phase. Due to this reason, a new cutting length which is to be activated in the next cycle has to be copied to the function block input before the axis is moved to its return position.
Fig.6-2: I/O interface of MX(L)_FlyingShear The following diagram shows the signal flow with immediate cut and stopped material (Start = FALSE):
Fig.6-3: Signal/time diagram: Immediate cut with stopped material The following diagram shows the complete signal flow of the function block "Flying shear" with continuously passing material and immediate cut:
Signal/Time Diagram
Fig.6-4: Complete signal flow of the function block „Flying shear“ with immediate cut
The function block "Flying shear" generates the following error messages in Additional1/Additional2 for the table "F_RELATED_TABLE", 16#0170:
ErrorID Additional1 Additional2 Description
RESOURCE_ERROR (16#0003) 16#0001 16#0000 Drive not enabled or drive error
ACCESS_ERROR (16#0004) 16#0003 16#0000 Function block was interrupted by another function block
ACCESS_ERROR (16#0004) 16#0004 16#0000 Unsupported drive firmware
RESOURCE_ERROR (16#0003) 16#0009 16#0000 Selected axis (Axis_Ref) was changed during the pro cessing of the function block
INPUT_RANGE_ERROR (16#0006) 16#0201 16#0001 CutLength <= 0
Troubleshooting
INPUT_RANGE_ERROR (16#0006) 16#0201 16#0002 MWFeedconst <= 0
INPUT_RANGE_ERROR (16#0006) 16#0201 16#0003 SyncDist <= 0
INPUT_RANGE_ERROR (16#0006) 16#0201 16#0004 ReturnAcc <= 0
INPUT_RANGE_ERROR (16#0006) 16#0201 16#0005 ReturnVel <= 0
SYSTEM_ERROR (16#7FFF) 16#0202 16#0000 Synchronization position is too far away. Therefore, synchronization is not possible. Reset error and initiate immediate cut.
ACCESS_ERROR (16#0004) 16#0203 16#0001 S-0-0048 is not configured in the optional cyclical MDT channel of the slave axis.
ACCESS_ERROR (16#0004) 16#0203 16#0002 P-0-0054 is not configured in the optional cyclical MDT channel of the slave axis.
ACCESS_ERROR (16#0004) 16#0203 16#0005 P-0-0052 is not configured in the optional cyclical AT channel of the slave axis.
ACCESS_ERROR (16#0004) 16#0203 16#0008 P-0-1367 bit 6 is not TRUE (the structure AxisData is not updated).
OTHER_ERROR (16#00FE) 16#0204 16#0001 The ELS configuration word (P-0-0086) of the slave axis has been incorrectly configured. The configuration must be as follows: P-0-0086 = 2#xxxx01000.
OTHER_ERROR (16#00FE) 16#0204 16#0002 The parameter P-0-0060 of the slave axis has been incorrectly configured. The value must be: P-0-0060=0.
OTHER_ERROR (16#00FE) 16#0204 16#0005 The parameter P-0-0090 of the slave axis has been incorrectly configured. Bit 2 of P-0-0090 must be FALSE.
SYSTEM_ERROR (16#7FFF) 16#0205 16#0000 Immediate cut (in standstill) has been requested al though the material was moving.
Fig.6-5: Error codes of MX(L)_FlyingShear
6.3 ML_FlyingShear - Special Features of IndraMotion MLC MLC Hardware IndraDrive C or M
Required Hardware
Additional encoder interface card to read in the measuring wheel position if a measuring encoder is to be used (can be omitted if a virtual or real axis is used)
Additional encoder to read in the measuring wheel position (according to IndraDrive planning) if a measuring encoder is to be used (can be omitted if a virtual or real axis is used)
It is recommended to use a high-resolution measuring encoder with a resolution of at least 4096 increments / revolution (possibly sinus encoder). Roughly resolved encoder signals cause low cut accu racies as well as running noises in the synchronous run.
MLC Firmware MPX drive firmware The following functional packages have to be enabled in the drive:
– Closed Loop – Synchronization
IndraWorks MLC The following parameterization has to be accomplished in the drive to ensure a proper functionality of the function block "MX(L)_FlyingShear".
1. Loading the parameter file "FlyingShearSettings.par" By loading the parameter file "FlyingShearSettings.par", important con figurations as well as the cams will automatically be loaded on the flying shear axis. The parameter file will be provided on the IndraWorks MLC 0x installation CD 3 over the path "Add ons\ Tech FB_Parameterfile". The parameter file contains the following information: P-72 Lock On Cam Poly 5 P-92 Run Cam P-750=1 P-693=0 P-60=0 P-86=0x0000.0000.0000.1000 P-90=0x0000.0000.0000.0000 A-500=P-691 A-502=P-692
2. Parameterization of the flying shear axis Parameterization of the flying shear axis according to the application. Weighting should be linear and absolute.
3. Parameterization of the optional encoder IndraWorks Add an encoder axis to the project Weighting should be set to rotary modulo 360°. Setting the encoder parameters according to encoder data
4. Ensuring the encoder motion direction In normal operation, the optional encoder (measuring wheel) has to move in positive direction. The motion direction can be observed via the Indra Works dialog of the encoder axis. The motion sense must be inverted if the encoder moves in the negative direction.
Required Firmware
5. Parameterize the synchronization acceleration (P-0-0142) and synchro nization velocity (P-0-0143) with preferably high values to ensure a dy namic synchronization process IndraWorks Parameter Editor
6. Parameterize the synchronous run window (S-0-0228) preferably small to obtain a possibly high cut accuracy IndraWorks Parameter Editor
The function block "MX(L)_FlyingShear" contains high-prior motion com mands and should therefore be cyclically called in a high-prior, cyclical PLC task with a cycle time ≤ 4ms (MotionTask).
Before starting the function block, "MC_Power" must be processed without errors.
Required IndraLogic Steps
7 Function Blocks for Application "Touch Probe" 7.1 Introduction and Overview
The function blocks chapter 7.2 "MC_TouchProbe" on page 27 and chapter 7.4 "MC_AbortTrigger" on page 31 control and manage the "Touch probe" drive functionality. The function block "MC_TouchProbe" activates the selected touch probe, eval uates the status and provides the measured values once the trigger signal has arrived. The function block "MC_AbortTrigger" cancels a running measurement of "MC_TouchProbe".
7.2 MC_TouchProbe The function block "MC_TouchProbe" is used to detect an axis position, a mas ter position or the touch probe time when the trigger signal arrives.
Before starting the function block "MC_TouchProbe", the "Touch probe cycle" command must be started. The "Touch probe cycle" command will be started by writing the parameter "S-0-0170 = 3". Alternatively, the touch probe function can automatically be activa ted in phase 4 over P-0-0226, bit 9 = TRUE (from MPx04). Thus, writing to S-0-0170 is no longer required.
Fig.7-1: FB MC_TouchProbe
Brief Description
VAR_IN_OUT Axis AXIS_REF Reference to the selected axis
VAR_INPUT Execute BOOL A positive edge at Execute starts the touch probe recording
ProbeType PROBE_DATA_FOR MAT
Defines the recorded data format. AXIS_POS = 0: Position values in drive weighting (e. g. S-0-0051) PROBE_TIME = 1: Touch probe time in µs MASTER_POS = 2: Master position in increments (e. g. P-0-0053)
ProbeSelect PROBE_NUMBER Touch probe selection: PROBE1 = 1: Touch probe 1 PROBE2 = 2: Touch probe 2
PosEdge BOOL Positive touch probe edge will be evaluated
NegEdge BOOL Negative touch probe edge will be evaluated
VAR_OUTPUT Done BOOL The selected edges have been triggered
Active BOOL The function block is active, measurement is running
PosEdgeDe tected
BOOL The positive edge of the selected touch probe has been triggered
NegEdgeDe tected
BOOL The negative edge of the selected touch probe has been triggered
RecordedPo sition
REAL Position value of the axis with positive edge of the selected touch probe This output is only used if "ProbeType = AXIS_POS" has been selec ted.
RecordedPo sitionNeg
REAL Position value of the axis with negative edge of the selected touch probe This output is only used if "ProbeType = AXIS_POS" has been selec ted.
Recorded Value
DINT Touch probe time (in us) or master axis position (in increments) in the case of a positive edge of the selected touch probe This output is only used if "ProbeType = MASTER_POS" or "PROBE_TIME" has been selected.
RecordedVa lueNeg
DINT Touch probe time (in us) or master axis position (in increments) in the case of a negative edge of the selected touch probe. This output is only used if "ProbeType = MASTER_POS" or "PROBE_TIME" has been selected.
CommandA borted
BOOL Command has been canceled by chapter 7.4 "MC_AbortTrigger" on page 31.
Error BOOL Indicates an error
ErrorID ERROR_CODE Brief error description
ErrorIdent ERROR_STRUCT Detailed error description according to error table
Fig.7-2: Interface of the function block MC_TouchProbe
Function Blocks for Application "Touch Probe"
Fig.7-3: Signal/time diagram according to PLCopen The function block generates the following error messages in Additional1/Ad ditional2 for the table F_RELATED_TABLE, 16#0170:
RESOURCE_ERROR, 16#0003 16#0004 16#0000 Unsupported drive firmware
RESOURCE_ERROR, 16#0003 16#0401 16#0000 Touch probe configuration (S-0-0169) does not corre spond to the inputs of the function block
RESOURCE_ERROR, 16#0003 16#0402 16#0000 Touch probe command (S-0-0170) has not been star ted
RESOURCE_ERROR, 16#0003 16#0403 16#0001 Required touch probe control bit (S-0-0405, bit 0) is not configured in the signal control word
RESOURCE_ERROR, 16#0003 16#0403 16#0002 Required touch probe control bit (S-0-0406, bit 0) is not configured in the signal control word
RESOURCE_ERROR, 16#0003 16#0403 16#0003 Required touch probe status bit (S-0-0409, bit 0) is not configured in the signal status word
RESOURCE_ERROR, 16#0003 16#0403 16#0007 Required touch probe measured value S-0-0130 is not cyclically configured in AT
Signal/Time Diagram
RESOURCE_ERROR, 16#0003 16#0403 16#000A Required touch probe measured value S-0-0133 is not cyclically configured in AT
INPUT_RANGE_ERROR, 16#0006 16#0404 16#0001 The selection of the touch probe at the input "Probe Select" is outside the admissible range
INPUT_RANGE_ERROR, 16#0006 16#0404 16#0002 The input "ProbeType" is outside the admissible range
Fig.7-4: Error numbers caused by MC_TouchProbe
7.3 MC_TouchProbe - Special Features of IndraMotion MLC MLC Hardware IndraDrive C or M MLC Firmware MPX drive firmware The following functional packages have to be enabled in the drive:
– Servo or Synchronization IndraWorks MLC To use the function block "MC_TouchProbe", the touch probe must be para meterized with the help of the following dialog:
Fig.7-5: Touch probe configuration dialog
"Continuous measurement" is not supported by the function block "MC_TouchProbe" and must not be selected in the above dialog.
Depending on the use of TouchProbe1 or TouchProbe2, the following addi tional (cyclical) control bits have to be configured: TouchProbe1: S-0-0405 TouchProbe1 Enable TouchProbe2: S-0-0406 TouchProbe2 Enable IndraWorks Right mouse click on axis Communication Signal control word The above mentioned control bits have to be configured depending on the use of TouchProbe1 or TouchProbe2. The order of the control bits in the
Required Hardware
Required Firmware
Required Software Required Parameterization
additional data containers is arbitrary since the function block scans all chan nels. According to the use of TouchProbe1 (positive or negative edge) or TouchP robe2 (positive or negative edge), the following additional (cyclical) status bits have to be configured: TouchProbe1, pos. edge: S-0-0409 TouchProbe1 pos. detected TouchProbe1, neg. edge: S-0-0410 TouchProbe1 neg. detected TouchProbe2, pos. edge: S-0-0411 TouchProbe2 pos. detected TouchProbe2, neg. edge: S-0-0412 TouchProbe2 neg. detected IndraWorks Right mouse click on axis Communication Signal status word According to the use of the selected touch probe, the corresponding ad ditional status bits have to be configured. The order of the status bits in the additional data containers is arbitrary since the function block scans all chan nels. According to the use of TouchProbe1 (positive or negative edge) or TouchP robe2 (positive or negative edge), the following additional measuring data have to be configured in the cyclical SERCOS channel: TouchProbe1, pos. edge: S-0-0130 Measured value 1 positive edge TouchProbe1, neg. edge: S-0-0131 Measured value 1 negative edge TouchProbe2, pos. edge: S-0-0132 Measured value 2 positive edge TouchProbe2, neg. edge: S-0-0133 Measured value 2 negative edge IndraWorks Right mouse click on axis Communication Cyclical SERCOS data channel According to the use of the selected touch probe, the correspond ing additional data have to be configured in the AT data. The order of the data in the additional containers is arbitrary since the function block scans all chan nels.
1. Integrate "ML_Technology0x.lib" library into the IndraLogic project 2. Set write access to S-0-0170=3 prior to the execution of "MC_TouchP
robe" (over "MB_WriteParameter") or set P-226 bit 9 once 3. Call of "MC_TouchProbe" and positive edge at "Execute" 4. "MC_TouchProbe" should be called until "Done" or "Error" will be returned
7.4 MC_AbortTrigger The function block MC_AbortTrigger aborts a running measurement controlled by MC_TouchProbe.
Fig.7-6: Function block MC_AbortTrigger
Required IndraLogic Steps
VAR_IN_OUT Axis AXIS_REF Reference to the selected axis
VAR_INPUT Execute BOOL A positive signal edge aborts the measurement
ProbeSelect PROBE_NUMBER Specification of the selected touch probe: PROBE1 = 1: Touch probe 1 is selected. PROBE2 = 2: Touch probe 2 is selected
VAR_OUTPUT Done BOOL The selected touch probe events will be aborted
Error BOOL Indicates an error
ErrorID ERROR_CODE Brief error description
ErrorIdent ERROR_STRUCT Detailed error description
Fig.7-7: I/O interface of MC_AbortTrigger Signal/time diagram according to PLCOpen (details see "Signal/Time Diagram" on page 29). The function block generates the following error messages in Additional1/Ad ditional2 for the table F_RELATED_TABLE, 16#0170:
RESOURCE_ERROR (16#0003)
16#0403 16#0001 Required touch probe control bit (S-0-0405, bit 0) is not config ured in the signal control word
RESOURCE_ERROR (16#0003)
16#0403 16#0002 Required touch probe control bit (S-0-0406, bit 0) is not config ured in the signal control word
INPUT_RANGE_ERROR (16#0006)
16#0404 16#0001 The function block input „ProbeSelect“ is outside the admissible range
Fig.7-8: Error codes of MC_AbortTrigger
7.5 MC_AbortTrigger - Special Features of IndraMotion MLC MLC Hardware IndraDrive C or M MLC Firmware MPX drive firmware The following functional packages have to be enabled in the drive:
– Servo or Synchronization IndraWorks MLC See "MC_TouchProbe", "Required Parameterization" on page 30. Include "ML_Technology0x.lib" library into the IndraLogic project Call of "MC_AbortTrigger" in the PLC user program
Signal/Time Diagram
Required Software Required Parameterization Required IndraLogic Steps
8 Function Blocks for Application "Cross Cutter" 8.1 Introduction and Overview
The function blocks mentioned here are intended for cross cutter and cross sealer applications. In this application, the knife or the sealing jaw is mounted on a rotating cylinder. In a definable area (if the knife or the sealing jaw is located on the material), the knife or the sealing jaw has to move with production ve locity. Outside this area, the axis is to perform a compensating motion to produce a respective format length.
Fig.8-1: Cross cutter construction The following function blocks are available: MB_CrossCutterCalcType04
→ Calculating a motion profile for cross cutter and cross sealer applications MB_CrossCutSealType01
→ Calculating, loading and activating a motion profile for cross cutter and cross sealer applications
MX(L)_CrossCutter → Activating a cross cutter and cross sealer point table (function block is only contained due to compatibility reasons; the above MB_ function blocks should be used for new applications)
8.2 MB_CrossCutterCalcType04 8.2.1 General
The function block MB_CrossCutterCalcType04 provides all required data at its outputs which have to be loaded into the motion profile of an axis to operate a cross cutter or a cross sealer with the functions selected in the parameters of the function block. All inputs of the function block will be taken over by "Exe cute" once in the case of a rising edge. In addition, the function block writes directly into the arrays specified by the pointers during its runtime. The written data are only valid if the function block has been processed without any errors and if it returns "Done".
Brief Description
Name Type Comment
VAR_IN_OUT MasterAxisInitialPo sAdr
POINTER TO REAL Pointer to an array with three elements to be created by the user in which the function block stores the starting positions of the master axis of the generated motion pro file segments
DistanceAdr POINTER TO REAL Pointer to an array with three elements to be created by the user in which the function block stores the distances of the generated motion profile segments
SlaveAxisVelocityAdr POINTER TO REAL Pointer to an array with three elements to be created by the user in which the function block stores the velocities of the slave axis at the segment limits of the motion profile segments
StepModeAdr POINTER TO MC_STEP_MODE
Pointer to an array with three elements to be created by the user in which the function block stores the step modes of the generated motion profile segments
CamTableAdr POINTER TO MB_CAM_TABLE_DA TA
Pointer to an array with three elements to be created by the user in which the function block stores cam tables as well as meta data of the cams which are inserted as seg ments in the motion profile
Function Blocks for Application "Cross Cutter"
ModuloValue REAL Modulo value of the cross cutter axis in [°]
FormatRatio REAL Format ratio of the product to be cut (no unit)
CutAngle REAL Length of the cutting area in [°]
PendelumFactor REAL Maximum pendulum radius in [%] (0%: No pendular motion; 100%: Maximum pendular motion (pendular motion up to the edges of the cutting area)).
CorrectionProfile MB_CORR_PROFILE Selection of a special profile. The inputs "Overspeed" or "PushOut" have to be used for the parameterization of the special profile. Further information with regard to the selection options of the enumeration type MB_CORR_PROFILE can be found in the respective section.
Overspeed REAL Constant overspeed or reduction of the master axis speed in the cutting area in [%] (0%: No overspeed; 100%: Twice the master axis speed; -50%: Half the master axis speed) In "CorrectionProfile", the option CORR_PROFILE_OVERSPEED has to be selected. Otherwise, "Overspeed" is deactivated and thus ineffec tive.
PushOut MB_PUSH_OUT_CON FIG
Structure for the definition of a push out motion during the cut In "CorrectionProfile", the option CORR_PROFILE_PUSH_OUT or CORR_PROFILE_COS_COMP_AND_PUSH_OUT has to be selected. Otherwise, "PushOut" is deactivated and thus ineffective. Further detailed information concerning the structure MB_PUSH_OUT_CONFIG can be found in the respective section.
Resolution MB_RESOLUTION Specification of the resolution of the cam calculation by determining the number of supporting points in three stages. Further information with regard to the selection options of the enumeration type MB_RESOLUTION can be found in the respective section.
Name Type Comment
VAR_OUTPUT Done BOOL Processing completed without errors, output data valid
Active BOOL Processing active, output data are invalid
Error BOOL Processing completed with errors
ErrorID ERROR_CODE In the case of a set "Error" output, this output contains a rough classification of the error
ErrorIdent ERROR_STRUCT In the case of a set "Error" output, this output contains detailed information concerning this error
NumberOfSteps USINT Number of the generated motion profile segments and number of the motion profile segments to be downloaded
NumberOfCams USINT Number of the generated cams and number of the cams to be downloaded
Fig.8-3: Interface description of the function block: MB_CrossCutterCalcType04 . .
Name Type Mini mum value
Maximum value Default value Acceptance
Execute BOOL FALSE Continuous
ModuloValue REAL >0.0° Not defined 360.0° For rising edge at "Exe cute"
FormatRatio REAL 0.2 30.0 1.0 For rising edge at "Exe cute"
CutAngle REAL 0.0° < "ModuloValue" 12.0° For rising edge at "Exe cute"
PendelumFactor REAL 0.0% 100.0% 0.0% For rising edge at "Exe cute"
CorrectionProfile MB_CORR_PROFILE CORR_PROFILE_NON E
For rising edge at "Exe cute"
Overspeed REAL -50.0% 100.0% 0.0% For rising edge at "Exe cute"
PushOut MB_PUSH_OUT_CONFIG For rising edge at "Exe cute"
Resolution MB_RESOLUTION RESOLUTION_HIGH For rising edge at "Exe cute"
Fig.8-4: Minimum/maximum and default values of the function block: MB_Cross CutterCalcType04
Minimum, Maximum and Default Values of the Inputs
Fig.8-5: Signal/time diagram function block: MB_CrossCutterCalcType04 On the basis of the operating mode "electronic motion profile", the function block calculates profiles for the "cross cutter" application. The individual seg ments either consist of analytical segments or of cam tables. After having enabled the processing with "Execute", an "electronic motion profile" consisting of three segments will be calculated once on the basis of the input variables. The parameters describing the profile will be saved in the respective arrays which have to be created by pointers at the inputs of the function block "MB_CrossCutterCalcType04". The arrays have to be large enough to be able to save the number of calculated motion steps (currently three steps). The han dling of the pointers is similar to the function blocks "MB_ChangeProfileStep" / "MB_ChangeProfileSet" since these function blocks have to be called by the user after the calculation to be able to write the calculated profile to the re spectively free record of the "electronic motion profile". The following list describes the meaning of the individual inputs of the function block "MB_CrossCutterCalcType04" in more detail: The input "ModuloValue" specifies the modulo value of the cross cutter
axis. By standard, 360.0° are specified here. The input "FormatRatio" specifies the product length to be cut. It describes
the ratio of the desired product length and the circumference of the cross cutter cylinder. This means that in the case of "FormatRatio==1", the length of the cut product corresponds to the circumference of the cross cutter cylinder (synchronous format). In the case of "FormatRatio==5", however, the length of the cut product is five times the circumference of the cross cutter cylinder.
The input "CutAngle" specifies the cutting area of the cross cutter. In the cutting area, the cross cutter either rotates with the material feed velocity or with a (selectable) correction motion.
The input "PendelumFactor" specifies the maximum pendular motion of the cross cutter axis in percent. This means that in the case of "Pende
Signal/Time Diagram
Functional Description
lumFactor==0%", the cross cutter axis will never rotate with a negative velocity (backwards); in the case of "PendelumFactor==100%", the cross cutter axis will rotate to the end of the cutting area to minimize the energy loss and the required accelerations. This provides special benefits in the case of higher values for "FormatRatio". In the case of "PendelumFac tor==100%", the cross cutter does not generally rotate to the end of the cutting area since this is not always advantageous. The respective opti mum utilization of the available area will always be automatically calcula ted by the function block.
The input "CorrectionProfile" allows several correction motions in the cut ting area which are required depending on the respective application. The following correction motions can be selected: – "CorrectionProfile==CORR_PROFILE_NONE"
(no correction: cross cutter axis rotates with the velocity of the master axis),
– "CorrectionProfile==CORR_PROFILE_OVERSPEED" (constant overspeed of the cross cutter axis in the cutting area),
– "CorrectionProfile==CORR_PROFILE_COS_COMP" (constant velocity vector in material direction, e. g. for guillotine cut ters),
– "CorrectionProfile==CORR_PROFILE_PUSH_OUT" (push out of the material), as well as
– CorrectionProfile==CORR_PROFILE_COS_COMP_AND_PUSH_O UT (constant velocity vector in material direction as well as parallel push out, e. g. for guillotine cutters).
The input "Overspeed" allows the exact setting of the overspeed in [%] in the cutting area with "CorrectionProfile==CORR_PROFILE_OVERSPEED". Thus, entering a value of 10 [%] increases the velocity of the cross cutter axis in the cutting area by 10% compared to the material velocity.
The input "PushOut" parameterizes the push out correction. The input will only be processed with "CorrectionProfile==CORR_PROFILE_PUSH_OUT" or "CorrectionProfile==CORR_PROFILE_COS_COMP_AND_PUSH_OUT".
The input "Resolution" allows the resolution of the used cam tables in three steps. On the one hand, this saves a lot of calculating time, and on the other hand, the accuracy of the calculation will be increased.
The successful calculation of a profile will be signaled by the output "Done". The parameters will be written to the data fields addressed by the created pointers. Subsequently, these have to be written to a free motion profile with the help of "MB_ChangeProfileSet"/"MB_ChangeProfileStep". The same pro cedure applies for the cams. It must be observed that the table into which the cams have to be loaded will be defined in the structure "MB_CAM_TABLE_DA TA". In the following, the loaded motion profile has to be activated by using "MB_MotionProfile". The exact cutting length will be defined with the electronic drive at "MB_MotionProfile". The gear ratio corresponds to the value of "For matRatio". This means that a new profile will be calculated for each possible product length; this profile takes into account the exact input parameters (es pecially "CutAngle" and "PendelumFactor"). fig. 8-6 "Sequence diagram for
using MB_CrossCutterCalcType04" on page 39 shows a sequence diagram describing the use of the function block MB_CrossCutterCalcType04.
Fig.8-6: Sequence diagram for using MB_CrossCutterCalcType04 To use several equidistantly distributed knives, a mechanical gear has to be planned in IndraWorks with reference to the load side. The number of input revolutions will be set to 1, whereas the number of output revolutions will be set to the number of the used knives n. Since, however, no real mechanical gear is existent, the drive will only perform one n-fold revolution. Thus, the velocity of the slave axis in one revolution is n times identical with the velocity of the master axis. Example:
Configuration of the Mechanical Gear When Using a Cross Cutter With Four Equidistantly Distributed Knives on the Cross Cutter Axis
Input variables: Mechanical gear at the motor, input revolutions ninput = 10 Mechanical gear at the motor, output revolutions noutput = 1 Number of knives per circumference nknife = 4
Calculation of the required gear setting:
S-0-0121 = 10 S-0-0122 = 4
If, with this parameterization, the cutting cylinder moves mechanically by 90°, this corresponds to an electrical movement of 360° ( = modulo value of the slave axis).
To adjust the velocity of the master axis and the slave axis in the cutting area to the same value, the feed constant between the measuring wheel and the internal virtual master axis has to be adjusted as well. In this context, the cir cumference of the internal virtual master axis will be specified with the length between two knives of the real slave axis. With this parameterization, it is pos sible to cut each product with a different length with a corresponding lead time.
Fig.8-7: Master axis structure when operating a cross cutter The function block uses the error table F_RELATED_TABLE, 16#061x. It can generate the following error messages in Additional1 and Additional2:
INPUT_RANGE_ERROR, 16#0006 16#0610 16#0001 Invalid value of the input "ModuloValue"
INPUT_RANGE_ERROR, 16#0006 16#0610 16#0002 Invalid value of the input "FormatRatio"
Troubleshooting
INPUT_RANGE_ERROR, 16#0006 16#0610 16#0003 Invalid value of the input "CutAngle"
INPUT_RANGE_ERROR, 16#0006 16#0610 16#0004 Invalid value of the input "CutAngle" in combination with cosine compensation
INPUT_RANGE_ERROR, 16#0006 16#0610 16#0005 Invalid value of the input "PendulumFactor"
INPUT_INVALID_ERROR, 16#0001 16#0610 16#0006 Invalid value of the input "CorrectionProfile"
INPUT_INVALID_ERROR, 16#0001 16#0610 16#0007 Invalid value of the input "Overspeed"
INPUT_INVALID_ERROR, 16#0001 16#0610 16#0008 Invalid starting point for the push out function
INPUT_INVALID_ERROR, 16#0001 16#0610 16#0009 Invalid value for "Overspeed_At_Cut" in the structure "MB_PUSH_OUT_CONFIG"
INPUT_INVALID_ERROR, 16#0001 16#0610 16#000A Invalid value for "Overspeed_Max" in the structure "MB_PUSH_OUT_CONFIG"
INPUT_INVALID_ERROR, 16#0001 16#0610 16#000B Invalid combination of "Overspeed_At_Cut" and "Overspeed_Max"
INPUT_INVALID_ERROR, 16#0001 16#0610 16#000C Value of the input "CutAngle" too small in combination with PushOut.
INPUT_INVALID_ERROR, 16#0001 16#0610 16#000D Invalid value of the input "Resolution"
INPUT_INVALID_ERROR, 16#0001 16#0610 16#000E Invalid values of the "POINTER" inputs
STATE_MACHINE_ERROR, 16#0005 16#0006 xxyy Invalid status of the finite state machine xx specifies the invalid step. yy specifies the invalid status.
Fig.8-8: Error numbers caused by MB_CrossCutterCalcType04
8.2.2 Special Features of IndraMotion MLC With regard to the system IndraMotion MLC, the following start-up instructions have to be taken into account for operating the technology function block MB_CrossCutterCalcType04, downloading the generated motion profiles and cams as well as for linking the cross cutter axis with the master axis: Modulo weighting with the modulo value 360° has to be activated for the
cross cutter axis. The function block MB_MotionProfile always has to be operated with the
setting "0: absolute synchronization without resynchronization" for the in put "StartMode" to ensure the exact exchange of the profiles.
For the electronic gear, the function block MB_MotionProfile only allows integral values from 1 to 65535 for the numerator and the denominator of the gear ratio. Thus, a maximum cutting length deviation will result due to the quantization. This can be minimized by multiplication with a big con stant to be able to almost completely use the value range.
The generated motion profile can be downloaded on the MLC with the function block MB_ChangeProfileSet, and the generated cams can be downloaded with the function blocks MB_ChangeCamData or MB_Write ListParameter. In contrast to MB_WriteListParameter, the function block MB_ChangeCamData is faster; however, the cam will not be saved per sistently and has to be reloaded after a reboot of the control. When downloading the cams, it must be observed that the respective cam is loaded at its assigned position (described in the structure MB_CAM_TABLE_DATA, element "CamTableID").
Start-up Instructions
A small format ratio (< 1) should be selected carefully since the cross cutter axis reaches very high velocities in the compensation range (up to eight times the velocity of the master axis).
Bit 1 has to be set in the parameter A-0-2930 of the cross cutter axis so that the gear will be exchanged at a switching angle of 0° analog to the motion profile and not when calling the function block MB_MotionProfile.
Format ratio Ratio of the slave axis velocity to the ve locity of the master axis
1 1
0,8 1,5
0,6 2,2
0,4 3,7
0,2 8
Fig.8-9: Effects of the format ratio on the maximum velocity of the cross cutter axis in the compensation range
8.2.3 MB_CAM_TABLE_DATA The structure MB_CAM_TABLE_DATA is used by the function block chapter 8.2 "MB_CrossCutterCalcType04" on page 33. It contains an array with a cam table as well as meta data which describe the number of supporting points of the array as well as the position at which the table has to be loaded into the control / the drive.
Structural element Type Description
CamTableID DINT Number of the cam table into which the described cam has to be loaded
NumberOfElements UINT Number of supporting points of the described cam
CamTable ARRAY[0..1023] OF DINT Array with the supporting points of the cam
Fig.8-10: Interface description structure MB_CAM_TABLE_DATA
Name Type Minimum val ue
Maximum value Default value
CamTableID DINT 0 0
Fig.8-11: Minimum, maximum and default values of the structure MB_CAM_TABLE_DATA
In the structural element "CamTableID", the number of the cam table has been saved in the format required by the function blocks MB_ChangeCamData, MB_ChangeProfileStep and MB_ChangeProfileSet. fig. 8-12 "Allocation of CamTableID to parameter numbers" on page 42 shows the mappings be tween "CamTableID" and the corresponding parameter number in MLC and MLD.
CamTableID Parameter number MLC Parameter number MLD
1 C-0-2001 P-0-0072
2 C-0-2002 P-0-0092
3 C-0-2003 P-0-0780
Brief Description
4 C-0-2004 P-0-0781
5 C-0-2005 P-0-0784
6 C-0-2006 P-0-0785
7-99 C-0-2007 - C-0-2099 Not available
Fig.8-12: Allocation of CamTableID to parameter numbers The following diagram shows how to use the data of the structure MB_CAM_TABLE_DATA to load the cam into the control or the drive, respec tively.
Fig.8-13: Connection plan structure MB_CAM_TABLE_DATA
8.2.4 MB_CORR_PROFILE The enumeration MB_CORR_PROFILE is used by the function block chapter 8.2 "MB_CrossCutterCalcType04" on page 33 to define a correction motion in the cutting area. The possible elements of the enumeration type MB_CORR_PROFILE as well as their meanings are described in the following description.
Brief Description
Element Val ue Description
CORR_PROFILE_NONE 0 No correction in the cutting area. The veloc ity of the cross cutter axis corresponds to the velocity of the master axis.
CORR_PROFILE_OVERSPEED 1
Constant overspeed or reduction of the ve locity of the cross cutter axis in the cutting area. The velocity of the cross cutter axis is then faster or slower than the velocity of the mas ter axis by the value parameterized at the input "Overspeed" of the function block MB_CrossCutterCalcType04.
CORR_PROFILE_COS_COMP 2
Correction of the cross cutter axis velocity The velocity is changed in a way so that the cross cutter axis in the direction of the ma terial (the x component of the velocity vector) rotates with constant speed. The speed of the cross cutter axis has to be adapted de pending on the current position in the cut.
CORR_PROFILE_PUSH_OUT 3
Performing a push out motion at the end of the cut. Parameterization with the input "PushOut" of the function block MB_Cross CutterCalcType04. The speed of the cross cutter axis has to be adapted depending on the current position in the cut. See also the description of the structure "MB_PUSH_OUT_CONFIG".
CORR_PROFILE_COS_COMP_ AND_PUSH_OUT 4
Fig.8-14: Elements of the enumeration type MB_CORR_PROFILE
8.2.5 MB_PUSH_OUT_CONFIG The structure MB_PUSH_OUT_CONFIG is used by the function block chapter 8.2 "MB_CrossCutterCalcType04" on page 33. With this structure, a defined push out can be parameterized at the end of the cut. The elements of the struc ture MB_PUSH_OUT_CONFIG as well as their minimum, maximum and default values are described in the following interface description.
Structural element Type Description
PushOutBegin REAL Beginning of the push out area (parameter A). The value must not be equal to 0. Unit in [°].
Overspeed_At_Cut REAL Overspeed during a cut (parameter B). The value must not be equal to 0. Unit in [%].
Overspeed_Max REAL Maximum overspeed (parameter C). Unit in [%].
Fig.8-15: Interface description structure MB_PUSH_OUT_CONFIG
Elements of the Enumeration Type
Brief Description
PushOutBegin REAL -5.0°
Fig.8-16: Minimum, maximum and default values of the structure MB_PUSH_OUT_CONFIG
The following diagrams display the velocity characteristics of the cross cutter cylinder in the cutting area. The individual parameters can be adjusted with the elements of the structure MB_PUSH_OUT_CONFIG. A curve profile with a cut angle of 20° has been assumed for the graphics. The degree of the velocity adjustment will be determined with the help of the two variables "Overspeed_At_Cut" and "Overspeed_Max". The beginning of the velocity increase will be determined with the help of "PushOutBegin". For a clear parameterization, it is required that "PushOutBegin" and "Overspeed_At_Cut" are not equal to zero. Both figures show an example of the parameterization. The green line characterizes the degree of the increase and can be determined by connecting the points A, B and C.
Fig.8-17: Definition of PushOut.PushOutBegin < 0
Minimum, Maximum and Default Values of the Inputs
Fig.8-18: Definition of PushOut. PushOutBegin > 0
8.2.6 MB_RESOLUTION The enumeration MB_RESOLUTION is used by the function block chapter 8.2 "MB_CrossCutterCalcType04" on page 33. With this enumeration, the number of supporting points of the cam tables and thus the required calculation time can be changed. The elements of the enumeration MB_RESOLUTION as well as their meanings are described in the following description.
Element Val ue
Description Number of supporting points (cutting seg ment + compensating segment + cutting segment)
RESOLUTION_LOW 1 Low resolution, short calculation time required (faster by approx. factor 3 in contrast to medium resolution)
10 + 100 + 10
RESOLUTION_MIDDLE 2 Medium resolution, mean calculation time required (faster by approx. factor 3 in contrast to high res olution)
25 + 300 + 25
50 + 1000 + 50
Fig.8-19: Elements of the enumeration type MB_RESOLUTION With the enumeration MB_RESOLUTION, the number of supporting points of the cam tables and thus the required calculation time can be changed. For short formats and little lead time for a format change, the calculation time of the function block can be reduced by selecting the option "RESOLUTION_LOW". However, it must be taken into account that the reso lution of the generated cams is reduced and that the machine might not be running smoothly. In the case of long formats and high lead times for format
Brief Description
changes, the option "RESOLUTION_HIGH" can be selected to generate the created cams with the highest possible resolution. Basically, this setting ("RESOLUTION_HIGH") should be preferred. The option to be selected here strongly depends on the used application and should be determined through tests during the initial start-up.
8.3 MB_CrossCutSealType01 The function block MB_CrossCutSealType01 calculates, loads and activates a motion profile for cross sealer or cross cutter applications. The function block internally uses the function block "MB_CrossCutterCalcType04" for the calcu lation. With the calculated motion profile, the slave axis moves with product velocity within the sealing or cutting area. Other functions like, for example, OverSpeed, PushOut or cosine correction can be optionally added within this area. Outside the sealing or cutting area, an almost optimum compensating motion (with regard to acceleration and energy loss) will be performed if the specified format length does not correspond to the distance of the knife or the sealing jaw. Furthermore, a pendular motion of the cross sealer or cross cutter axis within freely selectable limits can be predefined to optimally use the accelera tion capacity of the drive in the case of large format lengths. During operation, input variables like, for example, the format length, can be changed to automatically calculate a new motion profile in the background. The newly calculated motion profile will then be activated and takes effect at the switching angle. In the case of a negative edge at Enable, the cross sealer or cross cutter will be deactivated. The axis will be immediately stopped over the predefined de celeration ramp.
Fig.8-20: Interface function block MB_CrossSealType01
Brief Description
VAR_IN_OUT Master AXIS_REF Reference to master axis
Slave AXIS_REF Reference to slave axis ( = cross cutter axis / cross sealer axis) The modulo value is 360° (electrical) and is mechanically de fined as the distance between two knives / sealing jaws.
VAR_INPUT Enable BOOL Enabling the function block for processing
CrossCutter BOOL If CrossCutter = TRUE, the cross cutter application (see the fol lowing detailed description) will be selected. In this case of application, the master axis has to be standar dized in a way so that the material to be cut covers the distance in one revolution that corresponds to the distance of the knives. In this case, the used electronic gear of the motion profile is set to the gear transmission ratio "FormatLength / KnifeDistance". Furthermore, the input CutSealArea functions as the cut angle of the cross cutter whereas the input var

Rexroth IndraMotion MLC 04VRS

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