Download - Technology Shears Introduction DOKU v321 e

7/30/2019 Technology Shears Introduction DOKU v321 e

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Application about Drive Technology

Technology CPUFlying Shears Based on GearingIntroduction


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Warranty, liability and support

Flying Shears Introduction ID Number: 21063352

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Note The Application Examples are not binding and do not claim to be completeregarding the circuits shown, equipping and any eventuality. The Application

Examples do not represent customer-specific solutions. They are only intendedto provide support for typical applications. You are responsible for ensuring thatthe described products are correctly used. These Application Examples do notrelieve you of the responsibility of safely and professionally using, installing,operating and servicing equipment. When using these Application Examples, yourecognize that Siemens cannot be made liable for any damage/claims beyondthe liability clause described. We reserve the right to make changes to theseApplication Examples at any time without prior notice. If there are any deviationsbetween the recommendations provided in these Application Examples andother Siemens publications e.g. Catalogs then the contents of the otherdocuments have priority.


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We do not accept any liability for the information contained in this document.

Any claims against us based on whatever legal reason resulting from the use ofthe examples, information, programs, engineering and performance data etc.,described in this Application Example shall be excluded. Such an exclusion shallnot apply in the case of mandatory liability, e.g. under the German Product LiabilityAct (Produkthaftungsgesetz), in case of intent, gross negligence, or injury of life,body or health, guarantee for the quality of a product, fraudulent concealment of adeficiency or breach of a condition which goes to the root of the contract(wesentliche Vertragspflichten). However, claims arising from a breach of acondition which goes to the root of the contract shall be limited to the foreseeabledamage 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. Theabove 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 theseApplication Examples or excerpts of them without first having priorauthorization from Siemens A&D in writing.

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

mailto:[email protected]
mailto:[email protected]:[email protected]


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Foreword


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ForewordThe application described in this document deals with flying shears. It shows howan axis can be synchronized to another axis with the aid of the technology CPU sothat processing on the fly (cutting, drilling, printing, welding, ...) is enabled.

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

Objective of the application

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

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

The application illustrates the following:

How the used components work together

Which technological functions are used

How the application is programmed and parameterized

How the application can be used as a demonstration system

Main contents of this application

The following main points are described in this application: Use of the Gearing technology function

Use of the Flying Shears technology template

Delimitation

This application does not include a description of

basic knowledge when using STEP 7

basic knowledge in the field of motion control

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

...the general handling of the technology CPU

Basic knowledge of these topics is required.


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Document structure

The documentation of this application is divided into three documents:

Introduction

Extension

Demonstration

In addition, the STEP7 code is available.

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

Part Description

Introduction

Application Description andPrinciples of Operation

This part provides a general overview of the contents.You are informed on the used components (standardhardware and software components and the speciallycreated user software).

Extension

Principles of Operation inDetail and ProgramStructures

This part describes the detailed functional sequences ofthe involved hardware and software components, thesolution structures and where useful the specificimplementation of this application.

It is required to read this part if you want to familiarizewith the interaction of the solution components to usethese components, e.g., as a basis for your owndevelopments.

Demonstration

Structure, Configuration and

Operation of the Application

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

the application.

An additional component available is the S7 program code.

Part Description

S7 program codeThe S7 program code includes the code and a userinterface which is also suitable as a demonstrationsystem.

Reference to Automation and Drives Service & Support

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

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


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Table of Contents


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Table of ContentsWarranty, liability and support ................................................................................... 3Foreword.......................................................................................................................4Table of Contents......................................................................................................... 6Application Description............................................................................................... 71 Essential Information on Processing on the Fly............................................ 72 Automation Problem ......................................................................................... 9

2.1 Flying shears with length selection ...................................................... 92.2 Operator control of the process............................................................ 9

3 Process Analysis............................................................................................. 113.1 Process sequence.............................................................................. 113.2 Core functions .................................................................................... 113.3 Solution structure ............................................................................... 12

4 Automation Solution ....................................................................................... 154.1 Solution structure ............................................................................... 154.1.1 Overview ............................................................................................ 154.1.2 Hardware components....................................................................... 154.1.3 Software components......................................................................... 174.2 Functions............................................................................................ 19

Appendix and Bibliographic References................................................................. 205

Bibliographic References ............................................................................... 20

5.1 Bibliographic references..................................................................... 205.2 Internet links ....................................................................................... 215.3 Related documentation ...................................................................... 23

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


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Application Description

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1 Essential Information on Processing onthe FlyThis chapter shows what processing on the fly is, why it is used in machines, theadvantages of processing on the fly and the problems that can be solved usingprocessing on the fly.

What is processing on the fly?

Processing on the fly is characterized by the fact that a product on a material line is

not stopped for processing.

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

Why processing on the fly?

Processing on the fly is required when

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

stopping the material line is not reasonable due to the expenditure of energybecause of the respective forces of deceleration and acceleration.

the individual processing steps are too different so that a uniform waitingtime is economically unacceptable.

What are the advantages?

Processing on the fly makes the entire production procedure

fastersince it is not necessary to wait for the slowest processing procedure.

more energy-optimized since unnecessary deceleration or acceleration isnot required.

more harmonic due to the continuous motion of the material line, whichresults in less wear of the plant.


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Typical fields of application

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

Task

Filling moving containers

Processing, gripping and checking moving

workpieces

Paint spraying / painting movingworkpieces

Cutting to length / cutting a continuousmaterial line


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2 Automation ProblemTo display the application of processing on the fly, flying shears for cutting anendless product to selectable length were selected.

2.1 Flying shears with length selection

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

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

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

Figure 2-1 Flying shears

Axis 1

Shears slide drive

Axis 2Material line drive

Cut mark

Material line

100mm

Synchronization position

Initial position / starting position

Shears slide Shear blades

2.2 Operator control of the process

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

The flying shears can be operated in two modes:


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Setting up with the functions:

Acknowledging errors

Jogging: Moving the axis using a jog button

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

Independent positioning of the axes to a manually selected position

Producing with the function:

Automatic cutting of the material line according to a specified length (cyclicoperation)

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

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


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3 Process AnalysisThis chapter illustrates the technological basics of the flying shears independentlyof the possible hardware.

3.1 Process sequence

Precondition

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

The shears slide is located between the software limit switches

The shears axis was homed

The shear blades are opened

The shears slide is in starting position

Process sequence

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

Synchronizing the shears slide to the velocity of the material line and thecutting position

Closing the shear blades

The actual cutting process

Opening the shear blades

Repositioning the shears slide to the starting position

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

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

3.2 Core functions

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

Synchronization of the shears slide

There are two preconditions for an exact cut:

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

The shear blades are located exactly above the cutting position

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


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

Position

Time

Cutting timeDistance traveled

during cutting

Maximum distance

of the shears slide

Shears slide

position

Material line

position

Defining the cutting position bysetting the axis position = 0

To achieve this mode, the shears axis is connected to the material axis in gearing,i.e. the shears axis directly follows the position information of the material line.Failures are detected and corrected. The simple motion at the same velocity in

velocity gearing is inadequate for this application since failures may causedifferences in position which cannot be detected and corrected.

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

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

Return to starting position

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

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

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

3.3 Solution structure

The following section describes the structure of the solution. The processsequence is realized via the Flying Shears technology template which is used inthis application example and which includes the complete functionality of the flyingshears.


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Figure 3-2 Solution structure of the flying shears

synchronizing

PLC

axis

shears

Cutting simulation

axissynchronousoperation

positioningsynchronousoperation

start

axis

homing

M G

axis 1

shears

M G

axis 2

material

SINAMICS S120 training case

axis

material

Main

Control

Template

Control

move velo

repositioning

cutting

next cut

start material

start shears

Program Signals

Technology Signals

Program Module

PLCopen Object

Technology Object

Technology Template

HMI

Sequence of the overall process

Via the user interface (HMI), the shears slide of the flying shears can first be

moved to starting position in setup mode.Process mode can then be started via Main Control. Via start material, thematerial line is brought to a constant velocity and the flying shears are started viastart shears.

Selecting the process mode enables the following process.

Via the synchroniz ingpath, the shears axis is synchronized to the materialaxis in gearing.

If the shears axis is synchronous to the material axis, a cut is triggered via thecut t ingpath. During the cut the gearing of shears slide and material lineprevents the shear blades from canting in the material of the material line.

At the end of the cutting process the shear blades have moved out of the

material of the material line the shears axis is returned to the starting position


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by a positioning via the reposi t ion ingpath.The position value of the material line is simultaneously adjusted to the next

cutting position via the next cutpath.

Gearing

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

Positioning

Positioning is moving an axis from position A to position B. A travel profile is

generated from the specifications target position, velocity and acceleration. Theaxis accelerates to the specified velocity and exactly at that time starts deceleratingto come to a standstill at the target position. During this process the deceleration isperformed with the absolute value of the specified acceleration.


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4 Automation SolutionThis chapter shows the reader how the automation problem can be solved usingthe technology CPU.

4.1 Solution structure

4.1.1 Overview

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

Figure 4-1 Overview of the hardware configuration

Technology CPUPG/PC

WinCC flexible

SINAMICS S120 training case

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

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

4.1.2 Hardware components

The following hardware components are required to realize the applicationexample.

Figure 4-1 Hardware components

Hardware element Picture MLFB/order number and functions

Controller

DIN rail 6ES7390-1AE80-0AA0

The DIN rail is the mechanical rack of an S7-300 and required to set up the controller.

PS307 2Apower supply

6ES7-307-1BA00-0AA0

The power supply provides the required 24VDC


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Technology CPU The technology CPU executes the userprogram and the technological functions.

CPU 317T-2 DP 6ES7317-6TJ10-0AB0

Hardware product version: 02

Firmware revision level: V 3.1.1

Integrated main memory: 512KB

Max. block size: 64KB

or alternatively

CPU 315T-2 DP 6ES7315-6TG10-0AB0

Hardware product version: 01

Firmware revision level: V 3.1

Integrated main memory: 128KB

Max. block size: 16KB

40-pin front connector 6ES7392-1AM00-0AA0

The front connector enables the easy and user-friendly connection of the sensors and actuatorsto the signal modules. It is plugged to themodule and covered by the front door

4MBMicro Memory Card

6ES7953-8LM11-0AA0

The S7 program is stored on the MMC.

Communication and communication via DP(Drive) (optional)

PROFIBUSconnector plug up to12 Mbps

6ES7972-0BA41-0XA0

The plugs are used to connect

PG and technology CPU and

technology CPU and SINAMICS S120training case (optional)

PROFIBUS cable 6XV1830-0EH10 (sold by the meter, min. 20m)

The cable is used to connect

PG and technology CPU and technology CPU and SINAMICS S120

training case (optional)



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HMIPG/PC with MPI andEthernet interface

-

The PG/PC is used for configuring and forexecuting the HMI

Drive (optional)

SINAMICS S120 trainingcase

6ZB2480-0BA00

The SINAMICS S120 training caseconsists of standard components (drivesand motors) and offers two axes. They areused to demonstrate the application.The case is completely configured andwired and is connected to the controller viaPROFIBUS.

4.1.3 Software components

The following software components are required to realize the application.

Standard software

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

Table 4-2 Software components

Component MLFB / order number Functions

STEP7V5.4 SP1

6ES7810-4CC08-0YA7 STEP 7 is the basic package for the othersoftware packages and used for programmingthe SIMATIC S7

S7 Technology

V3.0 SP2

6ES7864-1CC30-0YX0 Tool for parameterizing and programming the

technology objects of the technology CPUWinCC flexible 2005Advancedincl. ServicePack 1and Hotfix 7

6AV6613-0AA01-1CA5incl.S79220-A7890-F

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

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

6AV6613-1DA01-1CA0incl.S79220-A7890-F

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


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Standard software for presentation

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

Table 4-3 Software components required for presentation

Component MLFB / order number Functions

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

6AV6613-1DA01-1CA0incl.S79220-A7890-F

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

Application software

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

Table 4-4 Application software for use without drives

File Functions

21063352_CPU315T_Shears_v_CODE_v30.zip Archived Step 7 project for theCPU 315T-2 DP with virtualaxes, does not require drives

21063352_CPU317T_Shears_v_CODE_v30.zip Archived Step 7 project for theCPU 317T-2 DP with virtualaxes, does not require drives


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4.2 Functions

PG/PC

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

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

Technology CPU

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

Realization of the program flow with a step sequence

Management of the modes

Communication with HMI

Management and coordination of the technology jobs

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

The technology part performs the following tasks:

Implementation of the technology jobs

Motion control of the axes

Motion monitoring

DriveAs a drive system for tests, the optional SINAMICS S120 training case with twoaxes takes over the axis functions. It is completely wired so that it can be directlyused for this application example.

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


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Bibliographic References


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5 Bibliographic References

5.1 Bibliographic references

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

Table 5-1

Topic Title

/1/ STEP7 Automating with STEP7 in STL and SCL

Hans BergerPublicis MCD Verlag - 2004

ISBN 3-89578-242-4

/2/ Technology CPU SIMATIC S7-300 CPU Data: CPU 315T-2DP

Siemens Manual

Edition 11/2006

MLFB: A5E00427932-03

/3/ Technology CPU SIMATIC S7-300 CPU Data: CPU 317T-2DP

Siemens Manual

Edition 11/2006

MLFB: A5E00251769-05

/4/ Technology CPU SIMATIC S7 Technology

Siemens Manual

Edition 11/2006

MLFB: A5E00251797-05

/5/ Technology CPU CPU 317T-2DP: Controlling a SINAMICS S120

Getting Started

Edition 11/2006

MLFB: A5E00480390-02

/6/ Technology CPU CPU 317T-2DP: Controlling a virtual axis

Getting Started

Edition 11/2006

MLFB: A5E00266283-04

/7/ Technology CPU CPU 317T-2DP: Controlling a physical axisGetting Started

Edition 11/2006

MLFB: A5E00251785-04

/8/ SINAMICS S120 SINAMICS S120 Installation and Start-Up Manual (IH1)

Manufacturer / Service Documentation

Edition 04/2006

MLFB: 6SL3 097-2AF00-0AP5


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Topic Title

/9/ SINAMICS S120 SINAMICS S120 Equipment Manual (GH1)

Control Units and Additional System Components

Edition 03/2006

MLFB: 6SL3097-2AH00-0AP3

/10/ SINAMICS S120 SINAMICS S120 Equipment Manual (GH2)

Booksize Power Sections

Edition 03/2006

MLFB: 6SL3097-2AC00-0AP3

/11/ SINAMICS S120 SINAMICS S List Manual (LH1)

Manual

Edition 03/2006

MLFB: 6SL3 097-2AP00-0AP4

/12/ SINAMICS S120 SINAMICS S120 Function Manual (FH1)Function Manual Drive Functions

Manufacturer / Service Documentation

Edition 03/2006

MLFB: 6SL3 097-2AB00-0AP2

5.2 Internet links

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

Table 5-2

Topic Title

\1\ Reference to theentry


\2\ Siemens A&DCustomer Support

www.ad.siemens.de/support

\3\ Siemens A&DApplications &Tools

http://support.automation.siemens.com/WW/view/en/21063352http://support.automation.siemens.com/WW/view/en/21063352http://www.ad.siemens.de/supporthttp://support.automation.siemens.com/WW/view/en/20208582http://support.automation.siemens.com/WW/view/en/20208582http://support.automation.siemens.com/WW/view/en/20208582http://support.automation.siemens.com/WW/view/en/20208582http://www.ad.siemens.de/supporthttp://support.automation.siemens.com/WW/view/en/21063352http://support.automation.siemens.com/WW/view/en/21063352


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Topic Title

\4\ Applicationexamples for thetechnology CPU

(a selection)

Palletizer with simply Interpolating Axes:


Feeder for a Press:


\5\ Technology CPUmanual

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

Select Product Support

Open the following directories in theProduct Information tree:

Automation systems

SIMATIC Industrial Automation Systems

PLC SIMATIC S7

S7-300/S7-300F

CPUs

Click the Manual tab to open a list with related documents orclick the following links:

S7 Technology:


CPU manual 317T-2 DP:


993483CPU manual 315T-2 DP:


\6\ SINAMICSS120instruction manual

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

Select Product Support

Open the following directories in theProduct Information tree:

Drive technology

AC Converter

Low voltage converters

Built-in and cabinet system SINAMICS S120

Click the Manual tab in the right window to open a list withrelated documents

or select the following link:

http://www.automation.siemens.com/doconweb
http://support.automation.siemens.com/WW/view/en/21062269http://support.automation.siemens.com/WW/view/en/21062269http://support.automation.siemens.com/WW/view/en/21363677http://support.automation.siemens.com/WW/view/en/21363677http://www.ad.siemens.de/supporthttp://support.automation.siemens.com/WW/view/en/22639716http://support.automation.siemens.com/WW/view/en/22639716http://support.automation.siemens.com/WW/view/en/17993483http://support.automation.siemens.com/WW/view/en/17993483http://support.automation.siemens.com/WW/view/en/21362915http://support.automation.siemens.com/WW/view/en/21362915http://www.ad.siemens.de/supporthttp://www.automation.siemens.com/doconwebhttp://www.automation.siemens.com/doconwebhttp://www.ad.siemens.de/supporthttp://support.automation.siemens.com/WW/view/en/21362915http://support.automation.siemens.com/WW/view/en/21362915http://support.automation.siemens.com/WW/view/en/17993483http://support.automation.siemens.com/WW/view/en/17993483http://support.automation.siemens.com/WW/view/en/22639716http://support.automation.siemens.com/WW/view/en/22639716http://www.ad.siemens.de/supporthttp://support.automation.siemens.com/WW/view/en/21363677http://support.automation.siemens.com/WW/view/en/21363677http://support.automation.siemens.com/WW/view/en/21062269http://support.automation.siemens.com/WW/view/en/21062269


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History


CopyrightS

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mensAG2


21063352_

Technology

_Shears_

Introduction_

DOKU_

v321_

e.d

oc

Topic Title

\7\ FAQ

CPU 317T-2 DPapplicableencoders

Applicable encoders for the technology CPU 31xT inconnection with the drive systemsSIMODRIVE 611U, MASTERDRIVES MC


\8\ FAQtechnology CPUversion overview

Which versions of the S7 Technology option package areavailable and which SINAMICS S120 drive firmware can youuse with which of these versions?


5.3 Related documentationThis list includes a summary of related documentations which you can obtain fromSiemens Customer Support or your Siemens contact person.

Table 5-3

Topic Title

/A/ Technologytemplate

Flying Shears Technology Template

Technology CPU Documentation

ID number: 21062270


6 HistoryTable 6-1 History

Version Date Modification

V3.2 06/05/07 Adaptation of the documentation to the S7 Technology V3.0SP2 technology package.

Added Microbox 420-T.

Added Runtime.

V3.21 08/2010 Removed Microbox 420-T
http://support.automation.siemens.com/WW/view/en/19968954http://support.automation.siemens.com/WW/view/en/19968954http://support.automation.siemens.com/WW/view/en/23411204http://support.automation.siemens.com/WW/view/en/23411204http://support.automation.siemens.com/WW/view/en/21062270http://support.automation.siemens.com/WW/view/en/21062270http://support.automation.siemens.com/WW/view/en/21062270http://support.automation.siemens.com/WW/view/en/21062270http://support.automation.siemens.com/WW/view/en/23411204http://support.automation.siemens.com/WW/view/en/23411204http://support.automation.siemens.com/WW/view/en/19968954http://support.automation.siemens.com/WW/view/en/19968954

Download - Technology Shears Introduction DOKU v321 e

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