application for drive technology · if the motion of several axes depends on the position of a...

Application for Drive Technology

Technology CPU “Feeder for a Press Based on static Cam Discs”

Introduction

Warranty, Liability and Support

Material feed for a press - Introduction Entry ID: 21363677

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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 to use sound practices in application, installation, operation and maintenance. By using these application examples you accept that Siemens is not liable for any damages except for those specified in the above liability clause. 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 – the contents of the other documents have priority.

Warranty, Liability and Support

We accept no liability for 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 “feeder for a press”. It is shown how a rigid synchronization between a master axis, in the example the drive of the press, and a slave axis, here the feeder of the press, can be realized in a simple way without mechanical link.

One central element in this context are the cam discs. With a cam disc a rigid nonlinear synchronization between master and slave axis can easily be implemented.

Objective of this application This application shows the use of one of the technological functions within 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 discussed in this application:

• Use of the “Cam Disc Synchronism” technology function

• Definition of a static cam disc in S7 technology

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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Structure of the document The documentation of this application is divided into two documents:

• Introduction

• Demonstration

The STEP7 code is also 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 Function Principles

Provides a general overview of the contents. You will learn about the components used (standard hardware and software components and the specially created software). The appendix also provides further information on the discussed topic

Demonstration Structure, Configuration and Operation of the Application

This part leads you step by step through the structure, important configuration steps, commissioning 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 may also be used for demonstration purposes.

Reference to Automation and Drives Service & Support This entry originates from the internet application portal of the A&D Service and Support. The following link takes you directly to the download page of this document.

http://support.automation.siemens.com/WW/view/en/21363677


Table of Contents


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Table of Contents Application Description ............................................................................................... 7

1 Synchronization of Axes via Static Cam Discs............................................ 7

2 Automation Task............................................................................................. 9 2.1 Press with feeder .............................................................................................. 9 2.2 Requirements for the press with feeder.......................................................... 10 2.2.1 General requirements ..................................................................................... 10 2.2.2 Design prerequisites ....................................................................................... 10

3 Process Analysis .......................................................................................... 11 3.1 Sequence of processes .................................................................................. 11 3.2 Electronic cam disc and electronic cam switch............................................... 11 3.3 Function structure ........................................................................................... 12

4 Function Mechanisms .................................................................................. 14 4.1 Function Principle of the Technology CPU ..................................................... 14 4.1.1 Setup .............................................................................................................. 14 4.1.2 Control unit ..................................................................................................... 15 4.1.3 Integrated technology ..................................................................................... 15 4.1.4 Interaction between control unit and integrated technology ........................... 15 4.1.5 Technology data blocks .................................................................................. 17 4.1.6 Technology function blocks ............................................................................ 17 4.1.7 Sequence of a technology job using the example of a positioning ................. 18 4.1.8 Operating principle of the technology function blocks .................................... 19 4.1.9 Replacement of a job by another job .............................................................. 20 4.1.10 List of the PLCopen function blocks ............................................................... 20 4.2 Characteristics of the technology CPU ........................................................... 22 4.2.1 Controller version............................................................................................ 23 4.2.2 Embedded version.......................................................................................... 23

5 Automation Solution .................................................................................... 24 5.1 Principle structure of the application example ................................................ 24 5.2 Required technology objects of the technology CPU ..................................... 25 5.3 Development of a simple cam disc ................................................................. 25 5.4 Solution principle ............................................................................................ 27 5.4.1 Overview......................................................................................................... 27 5.4.2 Hardware components.................................................................................... 28 5.4.3 Software components ..................................................................................... 32 5.5 Functions ........................................................................................................ 33

Appendix and List of Further Literature ................................................................... 35

6 Appendix ....................................................................................................... 35 6.1 Basic Information ............................................................................................ 35

Table of Contents


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6.1.1 What are axes with rigid nonlinear synchronization?...................................... 35 6.1.2 Why use rigid synchronization via cam discs?................................................ 36 6.2 Information on the use of cam discs ............................................................... 36 6.2.1 Which options exist to define cam discs? ....................................................... 36 6.2.2 How can a cam disc be defined with the VDI wizzard? .................................. 36 6.2.3 How can a simple cam disc be optimized?..................................................... 38

7 Bibliographic References ............................................................................ 42 7.1 List of further literature.................................................................................... 42 7.2 Internet links ................................................................................................... 43

8 History ........................................................................................................... 46

Application Description

Synchronization of Axes via Static Cam Discs

Material feed for a press - Introduction Beitrags-ID: 21363677

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1 Synchronization of Axes via Static Cam Discs

If the motion of several axes depends on the position of a master axis and if these axes cannot or are not to be synchronized mechanically, the option exists to synchronize the individual axes via a static electronic cam disc. Figure 1-1 Replacing the mechanical synchronization by an electronic cam disc

x

n

x

n

n

x

x = f(n)Master Axis Slave Axis

In the technology CPU, the positioning value of the slave axis is generated from the position of the master axis via the mapping specification of the cam disc.

What are the advantages? Using cam discs for the rigid nonlinear synchronization of axes offers the following advantages:

• Master and slave axis are not mechanically synchronized and can be moved independently of one another also without activated cam disc.

• If the axes are then rigidly synchronized via the static cam disc, the position of the slave axis depending on the master axis is clearly defined at any time.

• Via the cam disc, also nonlinear relations between master and slave axis such as the standstill of the slave axis while the master axis continues moving can easily be specified.

• If different synchronization specifications are to be realized between master and slave axis, e.g. during manufacturing different products, it is also possible to define several cam discs for various rigid nonlinear synchronizations and to activate them correspondingly.


Synchronization of Axes via Static Cam Discs

Material feed for a press - Introduction Beitrags-ID: 21363677

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Typical fields of application Nonlinear cam discs are used if slave axes are to be moved coordinated to a master axis and if there is a nonlinear relation between the motional sequences of the two axes.

If e.g. a slave axis is not to be moved during the synchronization via the cam disc although the master axis continues moving, the relation is nonlinear.

The applications in the table below, in which the slave axes have to be synchronized to a continuously moving master axis, are briefly presented as examples: Table 1 -1 Fields of application

Machinery Illustration Problem

Press with load unit

In a press with load unit, the press operates continuously while the load unit must feed material to or remove material from the press only in defined positions.

Packaging machine

When packaging items of all kind, it is mostly required to nonlinearly synchronize the packaging process to the continuous supply of the items.

Food industry

During the production of food it is often necessary to nonlinearly synchronize different processes to the continuously running production process.


Automation Task


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2 Automation Task

The automation problem described in this document is a press with stock feed via a feeder.

The linear axis of the feeder for stock feed is to be synchronized to the continuously moving rotary axis of the press via a static nonlinear cam disc.

This automation problem does not focus on the actual drive of the press and in this application example is only used to generate the master values for the synchronization of the feeder via the cam disc.

2.1 Press with feeder

The rotary axis of a press moves continuously in the range from 0° to 360° and the plunger of the press is moved up and down in the operating range.

Via a load unit, the feeder, material is fed to the press. A fed web is gripped by the gripper of the feeder and inserted into the press with the aid of a linear motion. Figure 2-1 Press with feeder

Press

Load unit

The stock feed may only be performed in specific positions during the continuous motion of the rotary axis of the press operating as master axis in this case:

• 0°...140°: Stock feed by the feeder

• 140°...225°: Waiting until the pressing process is finished

• 225°...270°: Pull-back of the feeder

• 270°...360°: Waiting for the next stock feed

This results in a nonlinear relation between the continuously moving rotary axis of the press as master axis and the motion of the linear axis of the feeder which is synchronized to the rotary axis of the press as slave axis.

Feeder [slave axis]

Rotary axis of the press (0°...360°)

[master axis]

Stamp

Workspace of the press

Material

Gripper


Automation Task


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The required relation between master and slave axis thus has to be mapped via a nonlinear cam disc.

2.2 Requirements for the press with feeder

2.2.1 General requirements

When realizing the press with feeder the following general requirements must be considered:

• The motion sequence described above has to be mapped via a nonlinear cam disc which is then used for the synchronization between master and slave axis.

• Opening and closing the gripper at the feeder is also to be performed depending on the position of the rotary axis of the press. In this process the gripper signal is to be generated by an electronic cam switch1 at the rotary axis of the press.

2.2.2 Design prerequisites

The press with feeder is based on the following design prerequisites which have to be considered when solving the automation problem described here as an example: Table 2-1 Design prerequisites

Variable Value

Press Positioning range of the rotary axis of the press 0 to 360 degrees Initial position of the rotary axis of the press 0 degrees Operating range of the cam switch signal for the gripper Depending on the

active cam disc Feeder Positioning range of the feeder (gripper) 0 to 144 mm Initial position of the linear axis of the feeder 0 mm Max. speed of the feeder 500mm/s

1 A cam switch generates a digital signal depending on the position of the axis assigned to the cam switch


Process Analysis


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3 Process Analysis

In the following, the technological sequence of the application will be analyzed and the required technologies will be illustrated.

3.1 Sequence of processes

The following process sequence is to be implemented for the example application: Table 3-1 Process sequence of the press with feeder

Step Action Note

Start of the press 1 If press and/or feeder are not in initial position,

first the press and then the feeder are moved to the initial position on the nearest distance.

Approach in positive and negative direction possible!

2 The press is accelerated to the set velocity. Start of the feeder

3 Feeder and press are synchronized and moved defined to one another via the cam disc.

4 During operation of the press, the velocity of the press can be varied using the slider.

Feeder also varies via cam disc!

Stop of the feeder 5 The synchronization via the cam disc is released

and the motion of the feeder is thus stopped. Press remains active.

Stop of the press 6 Before the motion of the press is stopped it

moves into the initial position.

3.2 Electronic cam disc and electronic cam switch

To be able to ensure a defined dependence of the motions between press and feeder, the feeder has to be synchronized to the rotary axis of the press via the cam disc. Figure 3-1 Rigid synchronization of master and slave axis and of the gripper

axis

Press

axis

Feedersynchronous

operation

Ma Sl

cam function

cam switch

GripperMaster Axis

Slave AxisCam disc

Camswitch

The gripper of the feeder is also synchronized to the rotary axis of the press via an electronic cam switch. For opening and closing the gripper via the


Process Analysis


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electronic cam switch signal defined positions of the press can be specified at the electronic cam switch.

3.3 Function structure

The functional structure of the example application is shown below. The illustration shows the physical as well as the logical components involved. Table 3-2 Function structure of the application example

PLC

gripper

M G

Axis 2Feeder

program partgripper-control

axis

Press

axis

Feeder

M G

Axis 1Press

synchronous operation

Training Case SINAMICS S120

Ma Sl

cam function

positioning

program partpress-control

program partfeeder-control

program partmain-

control cam out / in

move velo

positioning

cam switch

HMI

Program SignalsTechnology Signals

Program PartPLCopen ObjectTechnology Object

The individual components of the example application perform the following functions: Table 3-2 Functions of the individual components

Program part Function

main-control This program part performs the main control of the program for the control of press and feeder.

press-control This program part controls the press. During the initialization phase of the sequence, the motion to the initial position is controlled via positioning and the velocity of the press is specified via move velocity during process mode.


Process Analysis


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feeder-control

The feeder-control controls the feeder. During initialization, the initial position is moved to via positioning while the cam disk (cam function) is activated via cam in during process mode and the feeder is synchronized to the rotary axis of the press. The synchronization can be revoked via cam out.

gripper-control This program part controls the gripper. It receives a switch signal from the electronic cam switch (cam switch) and controls the gripper for the stock feed depending on the mode of the press with feeder.

The rotary axis of the press and the linear axis of the feeder are combined in the SINAMICS S120 training case for the example application.

Operator control and monitoring of the application can be performed via the HMI which runs on the PG/PC and which is connected to the controller.

Application DescriptionFunction Mechanisms


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4 Function Mechanisms

4.1 Function Principle of the Technology CPU

4.1.1 Setup

The technology CPU consists of two parts:

• The control unit which processes the control tasks and

• the integrated technology which processes the technological functions.

Both parts are mainly independent of each other and each is equipped with its own processor. The embedded variant (Microbox 42x-T) only contains one processor which processes both parts. The differences between embedded and controller variant are described in chapter 4.2). This is to ensure that the technological functions will be calculated at short equidistant 2 cycles without affecting the cycle times of the control section.

Both parts exchange data via technology data blocks and technology function blocks. Figure 4-1 Detailed technology CPU

OB35 cycleOB1 cycle

SIEMENS

Communicating via PROFIBUS DP / MPI

Telegram (actual value, setpointvalue) read/write via PROFIBUS DP(DRIVE)

Technology tasks

Controller Integrated technology

TechnologyFBs

TechnologyDBs

With these technological functions, the usual functions of a SIMATIC CPU are extended by MotionControl applications, i.e. drives can be controlled via a PROFIBUS connection.

An equidistant PROFIBUS (PROFIBUS DP(Drive)) is used for the drives. This enables clock-synchronized operation of the integrated technology of the controller, PROFIBUS and all connected drives, i.e. the clock cycles of all devices connected to the bus start at the same time.

This isochrone mode enables to use centralized positioning control for the drives despite a distributed automation structure.

2 The term 'equidistant' (or 'isochrone') refers to the repeat of operations on a strict and very accurate time basis. This is, for example, required for optimized control loops in control processes which could otherwise be optimized only with great difficulty or not at all. In SIMATIC applications such equidistant tasks are processed by the block OB35.



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4.1.2 Control unit

The control unit behaves like an S7 controller or a WinAC RTX without integrated technology. The PROFIBUS interface of the control unit enables establishing a connection with other CPUs, HMI or I/O devices.

Technology data blocks and technology function blocks can be used in the user program, which is edited in the technology CPU. Data exchange between control unit and integrated technology is realized via these blocks.

4.1.3 Integrated technology

The integrated technology processes the MotionControl functions of the technology CPU. In equidistant mode the drives can be connected to the integrated technology via the second PROFIBUS interface DP(Drive).

The integrated technology must be configured for processing the MotionControl functions. This includes the creation and configuration of technology objects, referred to as TOs.

The most important TO is the axis. An axis includes all information on inverter, motor, gear and encoder. If e.g. a positioning job is transferred to an axis, the inverter is controlled in such a way that the motor accelerates, runs and then decelerates so that it reaches the desired position when reaching the standstill.

All further TOs are discussed in greater detail in chapter 4.1.5 of this documentation.

4.1.4 Interaction between control unit and integrated technology

Figure 4-2 Data exchange – overview


DeviceDB

Technology DB

Technologyfunction

block

Trigger motion control job Technology object

Completed, termination,error message

of the job

Error/status messages & actual valuesof the technology objects

Job processing timeerror of the integr. techn.,

PROFIBUS Lifelist,DoneFlags, status of the

integrated I/O

The technology function blocks and the technology data blocks form the interface between controller section and integrated technology.



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The desired technology objects can be addressed and monitored via these technology function blocks. Additionally, the technology object files general data in a technology data block.

The interface of the technology function blocks is standardized and corresponds to the PLCopen standard for MotionControl blocks.

Data exchange between a TO and several technology FBs A technology object can be addressed by different technology FBs. For instance, an axis can be enabled, positioned or synchronized. A different technology FB is used for each of these functions. Figure 4-3 Data exchange between one technology object and several technology FBs

Technologyobject

TechnologyFB

TechnologyFB

Technology FB

TechnologyDB

Interface tothe

controllerInterface to the

controller

Job

Job status

Job

Job status

Job

Job status

General data


Only a suitable chronological order of the technology FB calls in the control program ensures a technologically effective use of the TO. For this reason we recommend using a sequencer in the user program from which the technology function blocks are called according to the PLCopen standard.

The job status is updated with each call of the technology FB in the control unit.



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A further data transfer between the technology part and the control unit is performed via data blocks, the technology data blocks. One data block is assigned to each technology object.

4.1.5 Technology data blocks

After generating the technology objects in the integrated technology via the configuration tool S7T-Config, technology data blocks are automatically created. The TO status and further TO-typical information are entered asynchronously to the cyclic user program at regular intervals; for an axis e.g. the current position and velocity.

The control unit can (read) access the technology data block like any normal data block.

The update cycle of the technology DBs can be set. The default setting is 18ms.

Technology synchronous interrupt OB (OB 65) The technology synchronous interrupt OB OB 65 is available for the consistent evaluation of the technology data blocks. OB 65 is called by the integrated technology after the update of the technology data blocks. This ensures that the content of the technology data blocks can be evaluated synchronously to the integrated technology and that changes in the technology data blocks can be reacted to timely.

Device datablock status of the integrated technology The status of the actual integrated technology is also stored in a technology data block. The symbolic name of this technology DB is “MCDevice”.

The device DB contains the following information:

• Status of the data update in the technology DBs

• ErrorID of the last recognized error

• Duration for the job processing of the integrated technology.

• List of the accessible nodes on PROFIBUS DP(DRIVE).

• Status of the technology CPU’s integrated inputs and outputs

4.1.6 Technology function blocks

To enable to address the TOs from the control unit, the S7-Tech library is provided for the technology CPU. It contains the function blocks according to the PLCopen Standard in the respective version, suited for the firmware version of the integrated technology.

The technology function blocks form the interface between the control unit and the integrated technology. The functional sequences of the TOs are controlled by the consistent call of individual technology function blocks (mostly via step sequences). Different functions can be caused via the order of the calls.



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In addition, the technology function blocks return the current function call status to the controller (not to be confused with the general status of the TO which is signaled via the technology data block).

During a positioning procedure, for example, the outputs of the technology FB signal busy, done or error, so that the current status of the positioning job can be monitored directly at the technology FB.

4.1.7 Sequence of a technology job using the example of a positioning

To move an axis by a defined length, the technology-FB FB 411 “MC_MoveRelative” is used for the technology object Axis: Figure 4-4 Interfaces of the technology object Axis

Technologyobject

Positioningaxis

TechnologyDB

Interface tothe

controllerInterface to

thecontroller

MC_PowerFB 401

MC_HomeFB 403

MC_StopFB 404

MC_HaltFB 405

MC_MoveAbsoluteFB 410

MC_MoveRelativeFB 411

MC_MoveAdditiveFB 412

MC_MoveSuperImposedFB 413

MC_MoveVelocityFB 414

MC_MoveToEndPosFB 415

axis



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Figure 4-5 Interface of FB411 “MC_MoveRelative” FB 411 „MC_MoveRelative“

AxisExecuteDistanceVelocityAccelerationDecelerationJerkDoneFlag

DoneBusy

CommandAbortedError

ErrorIDConstantVelocity

AccelerationDecelration

INTBOOLREALREALREALREALREAL

INT

BOOLBOOLBOOLBOOLWORDBOOLBOOLBOOL

Reference to configured technology DB of the axis

Start bit which triggers the function

Technology function has been completed successfully

Technological functionactive

Technological function cancelled by other job

Display of an error within the FB

When the technology function block FB 411 “MC_MoveRelative” is called, the following parameters have to be supplied with values:

• The Axis input of the FB indicates the number of the axis to be positioned and the Distance input specifies the distance to be traveled.

• A positive edge at the Execute input starts the axis and the positioning.

• The Busy output bit of the FB indicates that the positioning process is active.

• When the target has been reached, Busy is cleared and Done is set.

• If an error occurs, Busy and Done are cleared and Error is set. The error is specified in greater detail via the ErrorID output.

4.1.8 Operating principle of the technology function blocks

Basically all PLCopen blocks are based on the following principle:

• A rising edge at the Execute input triggers the job (depending on the used PLCopen block).

• As long as the Execute input is set to TRUE, the job status is indicated at the status outputs of the FB (Busy, Done, Error, CommandAborted, etc.).

• While a job is processed, the output parameter Busy shows the value TRUE; if the job is completed, Busy shows the value FALSE. The remaining output parameters indicate the status for at least one cycle. While the input parameter Execute is set to TRUE, the display of these status messages is latching If the input parameter Execute is set to FALSE and if the job is not yet completed (Busy = TRUE), the Done output is set to TRUE for one cycle after the job is completed!

• A job is terminated if

– it has been replaced by another job. If the Execute input is still set to 1, the Command/Aborted output is set.

– an axis or job error occurs.



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– the target has been reached (e.g. positioning target or standstill reached or parameter value read) and the Done output has been set. Some jobs run endlessly and consequently do not stop themselves. These jobs include e.g. synchronous operation commands or (endless) travel at constant velocity. For this reason the corresponding PLCopen blocks do not have a Done output but are instead equipped with a status output, for example, In_sync or In_velocity.

4.1.9 Replacement of a job by another job

The following example shows how a job is replaced:

• An axis receives a job to move to position 500.0 mm. (“MC_MoveAbsolute”)

• It accelerates as set and approaches the target position.

• It now receives the job to stop (“MC_Halt”).

• Output Busy is now deleted at “MC_MoveAbsolute” and CommandAborted is set. Busy is set at “MC_Halt”. “MC_MoveAbsolute” was replaced with “MC_Halt”.

• The axis decelerates according to the settings and comes to a standstill.

• Busy is cleared at “MC_Halt” and Done is set.

• The positioning job has now been replaced by the halt job via the “MC_MoveAbsolute” and the halt job terminated itself upon reaching standstill.

4.1.10 List of the PLCopen function blocks

The table below lists all technology function blocks: Table 4-1 Technology objects and PLCopen function blocks

Technology object

Technology function block

Description

FB 401 MC_Power Achse freigeben / sperren

FB 403 MC_Home Homing / setting axis

FB 404 MC_Stop Stopping axis

FB 405 MC_Halt Normal stop

FB 409 MC_ChangeDataset Changing data record

FB 410 MC_MoveAbsolute Absolute positioning (e.g. moving axis to 10.0 mm)

FB 411 MC_MoveRelative Relative positioning (e.g. moving axis by 10.0 mm)

Axis

FB 412 MC_MoveAdditive Relative positioning to current target position



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Technology object


Description

FB 413 MC_MoveSuperImposed Superimposed positioning

FB 414 MC_MoveVelocity Motion with speed specification

FB 415 MC_MoveToEndPos Moving to mechanical endstop / clamping

FB 437 MC_SetTorqueLimit Activating / deactivating torque limiting

FB 439 MC_SetCharakteristic Activating hydraulic characteristic



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Technology object


Description

FB 420 MC_GearIn Starting gear synchronism

FB 422 MC_GearOut Terminating gear synchronism FB 421 MC_CamIn Starting cam synchronism FB 423 MC_CamOut Terminating cam synchronism FB 424 MC_Phasing Changing phase shift between

master axis and slave axis FB 441 MC_CamInSuperImposed Starting superimposed cam

synchronism FB 443 MC_CamOutSuperImposed Terminating superimposed cam

synchronism FB 440 MC_GearInSuperImposed Starting superimposed gear

synchronism FB 442 MC_GearOutSuperImposed Terminating superimposed gear

synchronism

Synchronous Operation

FB 444 MC_PhasingSuperImposed Changing superimposed phase shift

FB 430 MC_CamSwitch Position-based cams / operating cams

Cam Switches

FB 431 MC_CamSwitchTime Time-based cams Ext. Encoder FB 432 MC_ExternalEncoder External encoder Measuring Input

FB 433 MC_MeasuringInput Measuring Input

FB 434 MC_CamClear Clearing cam FB 435 MC_CamSectorAdd Adding cam segment FB 436 MC_CamInterpolate Interpolating cam

Cam Function

FB 438 MC_GetCamPoint Reading points from cam disc FB 402 MC_Reset Acknowledge errors / commands FB 406 MC_ReadSysParameter Reading parameters FB 407 MC_WriteParameter Changing parameters FB 450 MC_ReadPeriphery Reading technology I/O FB 451 MC_WritePeriphery Writing technology I/O FB 453 MC_ReadRecord Read data record FB 454 MC_WriteRecord Write data record FB 455 MC_ReadDriveParameter Reading drive parameters

Basic functions

FB 456 MC_WriteDriveParameter Writing drive parameters

4.2 Characteristics of the technology CPU

The technology CPUs are available in two different versions, each with various characteristics, and which should be selected according to the usage requirements:



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• Controller version

• Embedded version

Principally, however, only the generated technology objects can be operated on all variants of the technology CPU.

4.2.1 Controller version

The controller version is a SIMATIC controller of the S7-300 series. These controllers have two independent processors for control unit and integrated technology. These controllers can be expanded with I/O modules of SIMATIC S7-300, such as input and output modules, communication processors, etc.. CPU 315T-2 DP and CPU 317T-2 DP are representatives of the technology CPU in the controller version.

4.2.2 Embedded version

The embedded version is a SIMATIC Box-PC of the Microbox type. The Microbox was expanded by a PC/104 board for connecting the equidistant PROFIBUS. A SIMATIC Soft-PLC WinAC is running on the PC system of the Microbox on which control unit and integrated technology are processed on a processor in time slices of different priority.

A representative of the technology CPU in the embedded version is the Microbox 420-T.


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5 Automation Solution

This chapter shows the reader how the introduced automation task can be realized with the technology CPU.

5.1 Principle structure of the application example

The basic structure of the example application shown below is necessary to implement the design and general requirements of the application example “Press with Feeder”. Figure 5-1 Basic structure of the example application with controller version

Motor

Encoder

PG / PC

Technology-CPU

Mot

or

Enco

der

Press

Feeder

Slave Axis

Master Axis

SINAMICS S120

Difference compared to real applications To demonstrate the example application, the motor of the press and the motor of the feeder are both controlled by the technology CPU via SINAMICS S120.

If only the feeder for a press is to be realized with the technology CPU in a real application, it is also possible to use only one encoder on the rotary axis of the press as master value specification for the synchronization of the feeder via the cam disc.

The press is then controlled by a different controller.


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5.2 Required technology objects of the technology CPU

The technology objects of the technology CPU listed in the table below are required for the solution of the described automation problem: Table 5-1 Technology objects necessary in the technology CPU

Technology object Note

Technology object - axis It is required to create one technology object Axis in the technology part of the technology CPU for the rotary axis of the press and one for the linear axis of the feeder.

In addition, the linear axis of the feeder has to be defined as synchronization axis. If this is not done, a synchronization of the linear axis of the feeder to the rotary axis of the press is not possible.

Technology object – cam disc The cam disc for the synchronization of the two axes is created as separate technology object and linked to the two axes. During cam disc configuration, the type of relation between master and slave axis is defined also.

Technology object cam switch The cam switch signal for the control of the gripper is generated via an electronic cam switch which is connected to the rotary axis of the press as technology object.

The technology objects are created using the S7T Config configuration tool in the technology part of the technology CPU and addressed from the control unit via special function calls.

5.3 Development of a simple cam disc

The successive development of a simple cam disc for the press with feeder will now be explained in greater detail.

The processing and motion sequence of the press with feeder is examined step by step and the respective elements of the cam disc are determined:


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Table 5-2 Development of a simple cam disc for the feeder

Press Cam Function Gripper The gripper is closed

0° ... 5°

closed

Stock is inserted into the press via the feeder

5° ...

135°

closed

The material motion is stopped

135° ...

190°

closed

Waiting until completion of the pressing process and the gripper is open

190° ...

225°

open

The feeder is pulled back

225° ...

270°

open

The feeder waits for the next stock feed

270° ...

360°

open

Zange = Feeder, Presse = Press


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The cam disc developed as described above can now be displayed via an interpolation table and configured in the technology CPU.

The interpolation points of the master axis (press) are entered as master and the corresponding points of the slave axis (feeder) are entered as slave in the table: Table 5-3 Interpolation table from the cam disc (press = master, feeder = slave)

Interpolation table

Master Slave

0 0 5 0

135 144 225 144 270 0

360 0

5.4 Solution principle

5.4.1 Overview

Technological tasks with medium to high PLC performance and medium motion control requirements can easily be realized with the technology CPU. Figure 5-2 Overview

Technology-CPUPG/PC

WinCC flexible

SINAMICS S120 training case

Note The automation solution presented in this document is available as 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.

Feeder

Press


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5.4.2 Hardware components

The following hardware components are required for realizing the application whereby two versions are possible.

• Controller solution Hardware setup of the application example with technology controllers of the SIMATIC S7-300 series.

• Embedded PC solution Hardware setup of the application example with the Microbox 42x-T as Embedded PC version of the technology CPU.

Hardware components of the controller solution The following hardware components are required for realizing the controller solution of the application example.

Table 5 -4 Hardware components – controller solution

Hardware element Illustration MLFB/Order number and functions

Controller Mounting 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 24 VDC

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

CPU 317T2 DP 6ES7317-6TJ10-0AB0 Hardware product version: 02 Firmware revision level: V 3.1.1 Integrated main memory: 512kB Max. block size: 64kB

or alternative


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Hardware element Illustration MLFB/Order number and functions

CPU 315T-2 DP

6ES7315-6TG10-0AB0 Hardware product version: 01 Technology firmware revision level: V 3.1 Integrated main memory: 128kB Max. block size: 16kB

40-pole front connector

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

Micro Memory Card 4MB

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

Communication and communication via DP(Drive) (optional) PROFIBUS connecting plug up to 12 MBit/s

6ES7972-0BA41-0XA0 Used for connection between • PG and technology CPU and • technology CPU and SINAMICS S120

training case (optional) PROFIBUS cable

6XV1830-0EH10 (yard ware, as of 20m) Used for connection between • PG and technology CPU and • technology CPU and SINAMICS S120

training case (optional)

Hardware components of the embedded PC solution The following hardware components are required for realizing the embedded solution of the application example.

Table 5 -5 Hardware components – PC-based solution

Hardware component Illustration MLFB/Order number and functions

Controller Standard mounting rail

6ES5710-8MA11 SIMATIC standard mounting rail 35mm 483mm length for 19“ cabinets.


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Power supply SITOP Modular 5A

6EP1333-3BA00 The power supply provides the required 24 VDC


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Technology CPU

The technology CPU processes the user program and the technological functions.

Microbox 420-T

6ES7675-3AG30-0PA0 Hardware product version: 01 Firmware revision level: V 1.0 Processor: P III 933MHz Main memory: 512MB RAM Compact flash cards: 2GB Operating system: Windows XP embedded Control: WinAC T

Communication SIMATIC NET cable

6XV1850-2HH20 Crossed Industrial Ethernet cable TP XP Cord CAT6, 2xRJ45, length: 2m The Ethernet cable connects the Microbox 42x-T with the PG/PC.

USB keyboard

Fujitsu-Siemens S26381-K340-V120 USB/PS2 keyboard KBPC-PX D The keyboard is used for the input for windows at the Microbox 42x-T. A keyboard is necessary for commissioning the Microbox 42x-T.

USB mouse

Fujitsu-Siemens S26381-K340-V120 TOUCHBIRD Optical Mouse MB The mouse facilitates operating Windows during commissioning.

Communication via DP(Drive) (optional) PROFIBUS connecting plug up to 12 MBit/s

6ES7972-0BA41-0XA0 The connector serves for connecting the Microbox 42x-T with the SINAMICS S120.

PROFIBUS cable

6XV1830-0EH10 (yard ware, as of 20m) The cable serves for connecting the Microbox 42x-T with the SINAMICS S120.

Hardware components for both solutions The following hardware components are required for realizing both solution options of the application example.


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Figure 5-6 Hardware components for both solution options


HMI PG/PC with MPI and Ethernet interface

- The PG or PC is used for configuring and running the HMI.

Drive (optional) SINAMICS S120 training case

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.

5.4.3 Software components

The following software components are required to use the application.

Standard software Performing the technological functions of the application requires the following SIEMENS standard software components:

Table 5-7 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 512 PowerTags

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

WinCC flexible Runtime enables to use a PG/PC or the Microbox 42x-T (with screen, mouse and keyboard) as operator panel.


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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 necessary that the application has already been loaded into the CPU, e.g. by means of another PG/PC.

Table 5-8 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 to use a PG/PC or the Microbox 42x-T (with screen, mouse and keyboard) as operator panel.

Application software Application software refers to an archived Step 7 project which contains the code of the application for the respective technology CPU.

Table 5-9 Application software to be used without drives

File Functions

21363677_CPU315T_Feeder_v_CODE_v30.zip Archived Step 7 project for the CPU 315T-2 DP with virtual axes, requires no drives

21363677_CPU317T_Feeder_v_CODE_v30.zip Archived Step 7 project for the CPU 317T-2 DP with virtual axes, requires no drives

21363677_MicroboxT_Feeder_v_CODE_v30.zip Archived Step 7 project for the Microbox 42x-T with virtual axes, requires no drives

5.5 Functions

PG/PC

Operator control and monitoring of press and feeder is performed via a WinCC flexible 2005 interface on the PG/PC.

The PG/PC can also be used for loading the programs for the technology CPU and for parameterizing the optional SINAMICS S120 training case.


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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

– Managing the operating mode

– Communication with HMI

– Managing and coordinating the technology orders

– Calling the technology orders 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

– Monitoring of movements

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 List of Further Literature

Appendix


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6 Appendix

6.1 Basic Information

This chapter provides further background information and answers to basic questions on the topic dealt with.

6.1.1 What are axes with rigid nonlinear synchronization?

The use of interpolating axes3 with nonlinear coupling is required when several axes shall be moved interdependently with nonlinear travel path behavior of the individual axis. The axes are not synchronized mechanically; however, they are still moved coordinated to each other via a virtual synchronization, the cam disc.

A rigid synchronization requires that the cam disc defining the virtual synchronization of several axes is not modified during the runtime of the application (see application example dealing with technology CPU “palletizer”) but defined statically during the configuration (as in the application example described in this document).

A nonlinear synchronization requires that the synchronized axes do not move in a fixed relationship to each other as would e.g. be the case in a mechanical gear, but if the position of the slave axes ensues from the position of the master axis via a defined nonlinear mapping specification – the cam disc. Such applications frequently occur when linear and rotary axes are to be synchronized. Figure 6-1 Linear and nonlinear synchronization between rotary and linear axis

x = a n

n

x

x

n

x = f(n)

n

x

n

x

3 The term 'axis' refers to the combination of drive, motor and mechanical components affected by position and/or torque control.


Appendix


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6.1.2 Why use rigid synchronization via cam discs?

A rigid synchronization between several axes is important if the position of the slave axes directly depends on the position of the master axis and has to be complied with as defined.

If the cam disc has already been defined during the configuration phase and not changed during the runtime of the application, the cam disc represents a clearly defined mapping specification between master and slave axis.

6.2 Information on the use of cam discs

This chapter provides basic information on the use of cam discs in the technology CPU.

6.2.1 Which options exist to define cam discs?

There are different options to define nonlinear cam discs:

• Interpolation table: The cam disc is defined via interpolation points at which the relation between master axis and slave axis is uniquely defined and which are entered in an interpolation table. An interpolation specification is defined for the areas between the interpolation points; linear interpolation, cubic splines or Bezier splines can be selected. According to this specification, the points are generated between the interpolation points during creating the cam disc in the S7T Config configuration tool.

• Polynomial or polynomial coefficient: The cam disc is defined using a higher-order polynomial or via the coefficient of this polynomial. The graph of this polynomial represents the cam disc. The actual polynomial is the mapping specification of the cam disc so that the position value of the slave axis can be determined from the position of the master axis via the polynomial.

The desired method for the definition of a new cam disc can be selected in the S7T Config configuration tool.

6.2.2 How can a cam disc be defined with the VDI wizzard?

The polynomial coefficients of a cam disc can easily be determined using the VDI wizzard of the S7T Config configuration tool. Complex cam discs can also be created relatively easy according to VDI guideline 2143.

The VDI wizzard particularly offers advantages when points defined via the cam disc are to be approached by the slave axis and when no discontinuous transitions, e.g. “corners”, must occur in the cam disc. Such points cause a high stress of the mechanical components of a machine.

For instance the following cam disc is to be created with soft accelerating and braking processes:


Appendix


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Figure 6-2 Cam disc with soft accelerating and braking processes

0

144

5 270225135

Feeder

Press

360

The transitions at start (0) and end position (144) of the feeder are to be tangential so that a continuous travel path with soft accelerating and braking processes is created.

The following inputs are required in the VDI wizzard: Table 6-1 Definition of the cam disc using the VDI wizzard

Element Action Note

Range 0°…5°

Symmetical

Range 5°…135° Definition as 5th order polynomial Symmetric configuration

Range 135°…225°


Appendix


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Element Action Note

Symmetical

Range 225°…270° Definition as fifth-order polynomial Symmetric configuration

Range 270°…360°

6.2.3 How can a simple cam disc be optimized?

The simple cam disc developed in chapter 5.3 can still be optimized to reduce the mechanical stress of the feeder and to achieve higher velocities.

This chapter shows several options of improving the developed cam disc with simple means.

All cam discs described here can be called and monitored in the HMI of the application example in expert mode. The permissible velocity limits of the press are adapted by means of the selected cam disc.

Note The names of the cam discs are derived from the data blocks used in the application.

Example: CAM 6 corresponds to data block DB6 in the Step7 code.


Appendix


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Table 6-2 Optimized cam discs

Cam Function Remarks

CAM 4: The simple cam disc displayed here and developed in chapter 5.3 is used as starting point for the optimization described below. Advantage:

• Can easily be developed from the desired motional sequence.

Disadvantage: • “Sudden changes of speed” at the

“corner points” of the cam disc. CAM 5: Symmetric configuration of feeder and pull-back motion of the gripper. Advantage:

• Can easily be developed from the desired motional sequence.

• Symmetric configuration of stock feed and pull-back of the gripper reduce the pull-back velocity and thus enable a higher velocity of the press.

Disadvantage: • “Sudden changes of speed” at the

“corner points” of the cam disc. CAM 6: Soft motion control during accelerating and braking the feeder. Advantage:

• Protection of the mechanical system due to soft motion.

Disadvantage: • High velocity and acceleration during

pull-back of the feeder.


Appendix


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Cam Function Remarks

CAM 7: Time-optimized distribution of stock feed and pull-back motion during the motion of the press. Advantage:

• Optimum distribution of stock feed and pull-back motion over the overall motion of the press.

• Stock feed already shortly after the pressing process.

Disadvantage: • Higher development effort.

Characteristic features of cam disc CAM 7 Despite the very complex design of cam disc CAM 7 it can be created very easily in the S7T Config configuration tool. Figure 6-3 Creation of cam disc CAM 7

0

144

0 27018090

Feeder

Press

360

0

144

0 27018090

Feeder

Press

-90

Offset-90°

0

144

0 27018090

Feeder

Press

360

Start of materialfeed

Normalized Display

Offset

In order to make the input of the cam disc as simple as possible, the cam disc is defined in the range between 0° and 360° of the master axis in the S7T Config configuration tool and subsequently moved by –90° by specifying an offset value. This offset is automatically performed in S7T Config.


Appendix


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Due to this offset the start of the stock feed by the feeder is moved forward from 0° by 90° and thus already starts at the position 270° of the master axis.

Since the synchronization of master and slave axis no longer starts at 0°, the synchronization points for connecting and disconnecting also have to be reset between master and slave axis. The Sync Position and the SyncOff Position of the cam disc also have to be set to the position 270°.

The same applies to the control of the gripper. Since the gripper is not controlled via the cam disk but via the cam switch signals of the electronic cam switch, the electronic cam switch also has to be moved forward by 90°. This requires to reset the switch-on and switch-off position of the cam switch signal. Since the switch-on length of the cam switch signal of 140° does not change, the new switch-on position at 270° and the new switch-off position at 50° ensue after the electronic cam switch has been moved forward by 90°.

All modifications to be made at the synchronization positions of the cam disc and the cam switch signals of cam disc CAM 7 are combined in the following table:

Table 6-3 Adapting the parameters for the activation of cam disc CAM 7

Parameter Value

Sync Position SyncPositionMaster [4268] 270° SyncOff Position SyncOffPositionMaster [4321] 270° Cam switch signal on CamSwitch.OnPosition 270° Cam switch signal off CamSwitch.OffPosition 50°


Bibliographic References


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7 Bibliographic References

7.1 List of further literature

This list is by no means exhaustive and only gives a selection of appropriate sources. Table 7-1

Topic Title /1/ STEP7 Automatisieren mit STEP7 in AWL und SCL

[Automation 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

SIMATIC Microbox 420-T setup Siemens Manual Issue 06/2006 MLFB: A5E00495804-01

/6/ Technology CPU

SIMATIC Microbox 420-T operation Siemens Manual Issue 06/2006 MLFB: A5E00495966-01

/7/ Technology CPU

CPU 317T-2DP: Controlling a SINAMICS S120 Getting started Issued 11/2006 MLFB: A5E00480390-02

/8/ Technology CPU

CPU 317T-2DP: Controlling a virtual axis Getting started Issued 11/2006 MLFB: A5E00266283-04




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Topic Title /9/ Technology

CPU

CPU 317T-2DP: Controlling a physical axis Getting started Issued 11/2006 MLFB: A5E00251785-04

/10/ SINAMICS S120

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

/11/ SINAMICS S120

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

/12/ SINAMICS S120

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

/13/ SINAMICS S120

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

/14/ SINAMICS S120

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

7.2 Internet links

This list is by no means exhaustive and only gives a selection of appropriate sources. Table 7-2

Topic Title \1\ Reference to

this documentation


\2\ Siemens A&D Customer Support

www.ad.siemens.de/support

\3\ Siemens A&D Applications &



http://www.ad.siemens.de/support





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Topic Title Tools




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Topic Title \4\ Application

examples for the technology CPU (a selection)

Palletizer with simply 3D Interpolating Axes Based on Cam Discs http://support.automation.siemens.com/WW/view/en/21062269Flying Shears with Print-Mark Synchronization Based on Gear Synchronism: http://support.automation.siemens.com/WW/view/en/21063352

\5\ Technology CPU manual

http://www.ad.siemens.de/support Select Product Support Open the following directories in the tree: • Automation technology • Industrial automation systems SIMATIC • Controllers • 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: http://support.automation.siemens.com/WW/view/en/22639716CPU-Handbuch 317T-2 DP: http://support.automation.siemens.com/WW/view/en/17993483CPU-Handbuch 315T-2 DP: http://support.automation.siemens.com/WW/view/en/21362915Installing Microbox 420-T: http://support.automation.siemens.com/WW/view/en/23999776Operating Microbox 420-T: http://support.automation.siemens.com/WW/view/en/23999030

\6\ SINAMICS S120 instruction manual

http://www.ad.siemens.de/support Select Product Support Open the following directories in the tree: • Drive technology • AC converter • Low voltage converter • Built-in and cabinet system SINAMICS S120 Click the tab Manual 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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Topic Title \7\ FAQCPU 317T-

2 DP applicable encoders

Applicable encoders for the technology CPU 31xT in connection with the drive systems SIMODRIVE 611U, MASTERDRIVES MC http://support.automation.siemens.com/WW/view/en/19968954

\8\ FAQ CPU 317T-2 DP 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? http://support.automation.siemens.com/WW/view/en/23411204

8 History Table 8-1 History

Version Date Modification

V3.2 28.09.07 Adjusting the documentation to the technology package of the S7-Technology V3.0 SP2. Supplementation of the Microbox 420-T Supplementation Runtime



application for drive technology · if the motion of several axes depends on the position of a...

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