manual simotion rotary knife v2.0

User Manual Rotary Knife

SIMOTION Rotary Knife V2.0

Application No.: A4027118-A0405

General Notes

SIMOTION Rotary Knife A4027118-A0405

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We reserve the right to make technical changes to this product.

Copyright Reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration or a utility model or design, are reserved.

General Notes


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General Notes

Note The standard applications are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The standard applications do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible in ensuring that the described products are correctly used. These standard applications do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equipment. When using these standard applications, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these standard applications at any time without prior notice. If there are any deviations between the recommendations provided in these standard applications and other Siemens publications - e.g. catalogs - then the contents of the other documents have priority.

Warranty, liability and support If the application is provided free of charge the following shall apply: We shall not be liable for the information contained in this document. Any and all further rights and remedies against Siemens AG for whatsoever legal reason, shall be excluded; this shall refer in particular to claims for loss of production, loss of use, loss of orders or profit and other direct, indirect or consequential damage. The aforesaid shall not apply if liability is mandatory, e.g. in accordance with the Product Liability Act, in cases of intent, gross negligence by directors and officers of Siemens AG or in the case of willful hiding of a defect. These limitations of liability shall also apply for the benefit of the Siemens AG's subcontractors, suppliers, agents, directors, officers and employees. This Contract shall be subject to German law if customer’s place of business is in Germany. If customer’s place of business is outside of Germany the Contract shall be subject to Swiss law. The application of the UN Convention on Contracts for the International Sale of Goods (CISG) shall be excluded. If the application is provided in return for payment the alternative shall apply which fits the respective business case: / Alternative 1: (internal business) If not explicitly stated otherwise below, the "Terms and Conditions for Deliveries and Services for Siemens Internal Transactions", valid at the time of sale, are applicable. / Alternative 2: (domestic business of Siemens AG) If not explicitly stated otherwise below, the "General License Conditions for Software Products for Automation and Drives for Customers with a Seat or registered Office in Germany", valid at the time of sale, are applicable.

General Notes


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/ Alternative 3: (direct export business of Siemens AG) If not explicitly stated otherwise below, the "General License Conditions for Software Products for Automation and Drives for Customers with a Seat or Registered Office outside of Germany", valid at the time of sale, are applicable. It is not permissible to transfer or copy these standard applications or excerpts of them in unmodified form without first having prior explicit authorization from Siemens Industry Sector in writing.

For questions regarding this application please contact us at the following e-mail address: mailto:[email protected]

Qualified personnel In the sense of this documentation qualified personnel are those who are knowledgeable and qualified to mount/install, commission, operate and service/maintain the products which are to be used. He or she must have the appropriate qualifications to carry-out these activities e.g.: • Trained and authorized to energize and de-energize, ground and tag circuits

and equipment according to applicable safety standards. • Trained or instructed according to the latest safety standards in the care and

use of the appropriate safety equipment. • Trained in rendering first aid. There is no explicit warning information in this documentation. However, reference is made to warning information and instructions in the Operating Instructions for the particular product.

Reference regarding export codes AL: N ECCN: N

Foreword


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Foreword Standard SIMOTION application

A standard SIMOTION application comprises the following components: • One or several software objects or code blocks with defined interfaces that

can be simply integrated into other software projects – without requiring any significant programming – in order to fulfill a precisely defined technology task there (core functions).

• A software project based on a demonstration case to show the functionality and possible uses of the standard application - including the associated WinCCflex screen for demonstration (demonstration project).

• A document to describe the functionality, background information and handling of the standard application. Further, its use as demonstration model is explained (description).

Document structure The documentation of this application is sub-divided into the following main section:

Section Description Note

Prerequisites and objectives

In the first section you can obtain an overview of this standard application. This Section explains the prerequisites and the objective when using this application. Some of the uses of this standard application are explained as well as situations where this application cannot be used.

The application example as

demosystem

Section “Application example as demosystem” is interesting if you wish to use this standard application for demonstration purposes. Here, you are provided with information about how you can download this application from your PC/PG to the demonstration case step-by-step and how it then used.

Integrating the core functions

Section “Integrating the core function” provides you with all of the necessary steps to integrate the core functions of the standard application into your user project. Preparations and parameterizing operations are explained. Further, you are also told how to integrate the core functions into your application step-by-step. In addition, tips are provided on how to use the core functions.

Program description of the technology

template

Section “Program description” is interesting if you wish to expand/adapt the functionality of the core functions provided for your particular application.

Appendix

Section “Appendix” provides you with detailed information including a detailed fault/error description, a description of a test program for the core standard application functions as well as references. A feedback sheet is also provided which you can use to give us your comments and

Foreword


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Section Description Note suggestions on this document.

Index of contents


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Index of contents Prerequisites and objectives .................................................................................... 10

1 Basic information................................................................................ 11 1.1 Prerequisites ...................................................................................... 11 1.1.1 Target group....................................................................................... 11 1.1.2 Know-how required ............................................................................ 11 1.1.3 Technical environment ....................................................................... 11 1.2 Objective and purpose of this standard application ........................... 11 1.2.1 Task.................................................................................................... 11 1.2.2 Application solution using the standard application SIMOTION Rotary

Knife ................................................................................................... 13 1.2.3 Advantages of the standard application SIMOTION Rotary Knife ..... 13 1.3 Components included in the standard application ............................. 14 2 Uses ................................................................................................... 15 2.1 Applications ........................................................................................ 15 2.1.1 Controls that are permitted................................................................. 15 2.1.2 Tasks that can be implemented using the core functions .................. 15 2.1.3 Properties and features of the core “rotary knife” functions ............... 16 2.2 Exclusions / restrictions...................................................................... 17 2.3 Application environment..................................................................... 18 3 Structure and function ........................................................................ 19 3.1 Geometrical structure of the rotating knife ......................................... 19 3.2 Rotary knife cams............................................................................... 21 3.2.1 Design of a cam for cyclic operation .................................................. 21 3.2.2 Segment structure of a rotary knife cam ............................................ 23 3.2.3 Starting and Stop Cam....................................................................... 24 3.2.4 Linear cutting characteristic ............................................................... 25 3.3 Operating states of the application SIMOTION Rotary Knife............. 26

The application example as demo system.............................................................. 27 4 Installing the hardware and software ................................................. 28 4.1 Regarding your safety ........................................................................ 28 4.1.1 Safety information and instructions .................................................... 28 4.1.2 Responsibilities of the operator.......................................................... 29 4.2 Hardware configuration and installation............................................. 30 4.3 Installing the standard SIEMENS software ........................................ 32 4.4 Downloading the user program and parameterizing the drive in the

SIMOTION D demonstration case ..................................................... 32 4.4.1 De-archiving the SIMOTION project .................................................. 32 4.4.2 Resetting SIMOTION D435 to the factory settings ............................ 32 4.4.3 Reconfiguration of double-axis motor module from 3A/3A to 5A/5A . 33 4.4.4 Configure Ethernet interface .............................................................. 34 4.4.5 Set the Ethernet address of the PG/PC ............................................. 37 4.4.6 Downloading the hardware configuration after a factory setting........ 39 4.4.7 Downloading the SIMOTION project of the standard application ...... 40 5 Operator control of the application example ...................................... 42 5.1 Structure overview.............................................................................. 44 5.2 Brief instructions to demonstrate........................................................ 45 5.3 Detailed operating instructions........................................................... 49

Integrating the core functions .................................................................................. 59

Index of contents


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6 Program environment and interfaces ................................................. 60 6.1 Importing the source code.................................................................. 60 6.1.1 Copying from the application example............................................... 60 6.1.2 Linking using XML import ................................................................... 61 6.1.3 Linking the rotary knife functionality ................................................... 62 6.2 Technology objects ............................................................................ 65 6.2.1 Technology objects required and synchronous relationships ............ 65 6.2.2 Synchronous relationships ................................................................. 67 6.3 Integrating the SIMOTION Rotary Knife core function....................... 70 6.3.1 Parameterizing the rotary knifes in the startup task........................... 70 6.3.2 Calling FBRotaryKnife in the user program........................................ 70 6.3.3 Calling the FBRKCamCalculation ...................................................... 70 6.3.4 Calling the FBRKIPO in the IPO synchronous task ........................... 71 6.3.5 Global Variables ................................................................................. 71

Program Description ................................................................................................. 72 7 Program Description........................................................................... 73 7.1 Information and warnings................................................................... 73 7.2 Type of Data....................................................................................... 73 7.2.1 Overview ............................................................................................ 73 7.2.2 Enumeration types ............................................................................. 74 7.2.3 Data Structures .................................................................................. 75 7.3 FBRotaryKnife .................................................................................... 84 7.3.1 Block name......................................................................................... 84 7.3.2 Task.................................................................................................... 84 7.3.3 Integration in the run-time system...................................................... 84 7.3.4 Graphic representation of the block ................................................... 85 7.3.5 Block parameters ............................................................................... 86 7.3.6 Functionality ....................................................................................... 87

Start identification............................................................................... 87 Axis monitoring functions ................................................................... 88 Checking the input parameters and parameterization of the

technology settings that are absolutely necessary ............. 88 Automatic mode change sequences .................................................. 91

7.3.7 Error messages ................................................................................ 100 7.4 Cam Calculation for rotating shears FBRKCamCalc ....................... 109 7.5 Functions in the IPO task FBRKIpo ................................................. 120 7.6 Blocks to manage the format length memory .................................. 123 7.6.1 Resetting the format length memory FBFormatLengthBufferReset. 124 7.6.2 Entries in the format length memory FBFormatLengthBufferIn ....... 125 7.6.3 Reading from the format length memory FBFormatLengthBufferRead127 7.6.4 Exporting from the format length memory FBFormatLengthBufferOut129 7.7 Measured value memory system blocks used in the rotary knife

application ........................................................................................ 130 7.7.1 Deleting and resetting the measured value memory

FBCutPositionBufferReset ............................................................... 131 7.7.2 Entries in the measured value memory FBCutPositionBufferIn....... 131 7.7.3 Reading out the measured value memory FBCutPositionBufferRead133 7.7.4 Exporting from the measured value memory FBCutPositionBufferOut135 7.8 Extended functions........................................................................... 136 7.8.1 Using the cutting program ................................................................ 136 7.8.2 Using print mark correction .............................................................. 136

Appendix................................................................................................................... 138 8 General information on the application ............................................ 138

Index of contents


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8.1 Scope of supply................................................................................ 138 8.2 Revision/Authors .............................................................................. 138 9 Contact partner................................................................................. 139 10 Please help us to become even better............................................. 140


Basic information


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Contents This section will provide you with everything that you require to obtain an overview of this standard application. The prerequisites and the objective for using this standard application are presented. The applications shown will give you a good understanding for what this standard application can be used for. Further, some applications will be listed for which this standard application cannot be used. In addition, the performance limits of this standard application will be shown.

Objective This section should provide the user with the following information • The objective and purpose of this standard application • List several applications • Indicate the performance limits of this standard application.

Chap. Title Content

1 Basic information and data The necessary prerequisites to use the standard application Rotary Knife. The use of this application. Software components and code blocks of the standard application Rotary Knife.

2 Possible uses Tasks and properties of the core functions of the standard application Rotary Knife Exclusions and restrictions Hardware components required

3 Structure and function Type of design and physical quantities for which the rotary knife core function can be used. Type of cams that the rotary knife core functions calculate and used. Operating states at the application.


Basic information


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1 Basic information 1.1 Prerequisites

1.1.1 Target group

The standard application is conceived for all programmers and users that wish to quickly and simply implement cross-cutter functionality using SIMOTION.

1.1.2 Know-how required

In order to use this technology template, you should be able to use SCOUT and technology objects and technology function calls in SIMOTION. This document does not provide an introduction into these subjects and is solely restricted to providing information and data on how to use this standard application.

1.1.3 Technical environment

This standard application can only be used, without having to make any changes, in conjunction with SIMOTION D and the SINAMICS demonstration case.

1.2 Objective and purpose of this standard application

1.2.1 Task

Using SIMOTION, a material web fed using the material feed mechanism is to be cut into identical parts and sections. A rotating knife (rotary knife) is to be used in order to achieve high feed velocities and short format lengths of the cut material sections. The cross-cutter comprises a rotating roll. One or several knives are located along the circumference of this roll. While the roll rotates, the knife cuts the material web fed-in below the roll into identical, defined sections.


Basic information


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Figure 1-1: Mode of operation of a cross-cutter (rotary knife)

Continous Web

cutted material

Rotary Knife

material

When developing a cross-cutter, the rotating cross-cutter axis control must be programmed so that during a cut, the cross-cutter axis motion is synchronized to the material web. The cross-cutter axis is moved with a special velocity profile between the cuts, so that synchronized motion can be resumed in plenty of time for the next cut. The next cut can be made after synchronization.

Additional applications The same sort of solution is also required for similar processes, mainly in packaging machine applications. The motion sequences described above must also be developed for perforating, embossing, sealing etc. with rotating equipment. Figure 1-2: Application examples (perforating, sealing and cutting)

Definition

In the following text, the “rotary knife” term is used to represent all of the other conceivable machine versions.

The term “knife” is used for all parts of the machine where direct contact is made to the material when “cutting”.


Basic information


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1.2.2 Application solution using the standard application SIMOTION Rotary Knife

The standard application SIMOTION Rotary Knife discussed here can be used to implement such applications, and to develop a functioning cross-cutter as quickly as possible. The standard application already includes, as core function, a pre-configured motion control of the rotary knife axis. This can be adapted to the particular application using the appropriate parameters. The core function is responsible for completely controlling the rotary knife axis. The user program only has to control the material feed and to supply the core function with the correct parameters.

Additional function of the standard application Further, this standard application also has the possibility of checking the required format length using a print mark function in conjunction with a sensor. This function can also be set at the core function and commissioned by simply entering the appropriate parameters.

1.2.3 Advantages of the standard application SIMOTION Rotary Knife

The use of the standard SIMOTION Rotary Knife application offers users the following advantages:

Programs can be quickly generated Comprehensive cross-cutter functionality can be easily and quickly implemented using the standard application SIMOTION Rotary Knife when programming with SIMOTION. The core functions provided in the standard application can be transferred into the application to be generated quickly and simply by copying. The description of this standard application explains the additional configuring steps that are necessary.

Automatic motion control The core functions of the standard application SIMOTION Rotary Knife can be used to realize all of the cross-cutter axis motion control using SIMOTION technology functions. The user only programs an execution sequence that corresponds to the actual behavior of the machine function to be implemented.

Possibility of adaptation All of the source codes are available in commented form for the standard application SIMOTION Rotary Knife. This means that the existing core functions can be quickly and simply expanded by the user's own particular functions.


Basic information


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1.3 Components included in the standard application

The standard SIMOTION Rotary Knife application is implemented as SIMOTION project as well as library. The project can be simultaneously used for a (demonstration) machine for a SIMOTION D demonstration case and PC with WinCC Flexible 2008 for visualization. The program fulfills the following tasks: • The control of the (demonstration) machine • All of the machine functions that are relevant for the demonstration case

environment are simulated • The (demonstration) machine is displayed on the WinCCflex screen • Operating mode manager for the complete (demonstration) machine This allows the core functions of the standard SIMOTION Rotary Knife application to be quickly and simply integrated in projects that the user has created himself.


Uses


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2 Uses 2.1 Applications

2.1.1 Controls that are permitted

The standard SIMOTION Rotary Knife application can be used on any SIMOTION control.

2.1.2 Tasks that can be implemented using the core functions

These core functions are used to control rotating equipment and mechanisms to • Cut • Perforate • Emboss • Seal • etc. The core “rotary knife” function completely handles the motion control of the rotating axis used for cutting. The functionality associated with the material feed is implemented outside the core functions in the user program.


Uses


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2.1.3 Properties and features of the core “rotary knife” functions

The following properties and features were taken into account when implementing the core functions, and can also be used in a user program that you generate yourself: • Linear cutting characteristic

When cutting, the material and cross-cutter axis travel with the same (peripheral) velocity or optionally with the over-velocity.

• Polynomial cutting characteristic The cutting characteristic is defined by the over-velocities at the start of the cut, at the “Zero” position within the cut and at the end of the cut.

• Cam profile Cams are used to control the motion of the cross-cutter axis. The following cam profiles can be parameterized: Linear (constant acceleration), trapezoidal (jerk limiting), polynomial.

• Print mark correction with adjustable correction speed During operation, deviations in the print marks, identified by the user, can be corrected using a higher-level motion.

• Multi-knife systems The “rotary knife” core function can also be used for cross-cutter axes that have more than one knife.

• The quiescent position of the cross-cutter axis can be set The quiescent position of the knife between two steps can be set using a parameter at the core function.

• Defined starting and stopping characteristics Special cams are used to implement the starting and stopping characteristics of the cross-cutter axis. This means that the motion control of the cross-cutter axis before and after cutting operations can be precisely determined.

• Cut length management The additional core functions for cut length management also allow the cams to be calculated with precise segments as a function of the precise segment length previously determined using print marks. This means that formats can also be changed using print marks.


Uses


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2.2 Exclusions / restrictions

The following features were not taken into account when implementing the application: • Non-linear cutting characteristic

The application cannot be used without first making changes if the cut characteristic must be influenced using a non-linear cut characteristic, which cannot be emulated using a polynomial cut characteristic with speed increases.

• Cutting torque input The application only influences the cross-cutter axis via its speed and position interface. The motor torque cannot be influenced.

• Seamless continuation of the cut after a fault stop If, during the cut, the cross-cutter goes into a fault condition, then the application function does not permit the cut to be continued. Cross-cutter operation can only be resumed after removing the cause of the fault, acknowledging it and then returning to the initial state.

• “High impetus” Motion of the cross-cutter to “increase knife impetus” for thick materials is not provided in the application.


Uses


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2.3 Application environment

The standard application SIMOTION Rotary Knife can be used in the following hardware environment: Figure 2-1: Application environment of the standard application SIMOTION Rotary Knife

Sen

sor Motor

Encoder

Motor

Encoder

SIMODRIVE / MASTERDRIVES / SINAMICS

PG / PC

SIMOTION D

Material web

Cross-cutter

The material feed and the drive control of the rotary knife axis can be controlled from a SIMOTION control system. Alternatively, the rotary knife axis can also be coupled through an encoder mounted on the machine.


Structure and function


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3 Structure and function 3.1 Geometrical structure of the rotating knife

The rotating knife used as basis for the application comprises a rotating axis, where tools (knives) are located around the circumference. The following geometrical quantities (names in white) are used in the application: Figure 3-1: Geometrical quantities at the standard “Rotary Knife“

Rotary Knife PositionSensor Position

Sens

or

KnifeCircumference

StartSyncAngle

EndSyncAngle

InflectionPoint

DistanceToSensor

Format range

Synchronous range 0°

StartAngle

StopAngle




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Table 3-1: Explanation of the parameterizable physical quantities

Physical quantity Description

KnifeCircumference [mm] Effective circumference of the rotary knife (circle circumference)

StartAngle [°] Start angle of the knife referred to 0°

InflectionPoint [%] Reverse position (inflection point) of the cyclic cam referred to the length of the format range

StopAngle [°] Stop angle of the knife referred to 0°

StartSyncAngle [°] Start point of the synchronous range referred to 0°. From this position onwards, the cutting knife must move in synchronism with the material to be cut.

EndSyncAngle [°] End point of the synchronous range referred to 0°. From this point onwards, the knife no longer has to move in synchronism with the material to be cut, and depending on the requirement, can be accelerated or decelerated to adapt the format

NumberOfKnives Number of knives distributed around the circumference.

DistanceToSensor [mm] Distance between the cutting position (0°) and the sensor to detect the material and print mark

Synchronous range The synchronous range is located between StartSyncPos and the EndSyncPos. The actual cutting operation occurs within this range and the knife of the rotary knife axis operates with the same velocity as the material web or is synchronized with the material web.

Format range The format range is obtained according to the following formula:

Format range = KnifeCircumference / NumberOfKnives – synchronous range

Between two cutting operations, the rotary knife axis moves in the format range. This is the reason that the dynamic values of the rotary knife axis must be selected so that the motion can be controlled within this range between two cuts. This means that the rotary knife axis can move through the length of the format range with all of the appropriate acceleration and braking operations between two cutting operations. It can then have the same velocity as the material web before the next cut.




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3.2 Rotary knife cams

3.2.1 Design of a cam for cyclic operation

Note

The following interrelationship exists when representing the following cams

360° [circumferential angle] = 200 mm [circumference along the knife tips]

This representation type means that it is not necessary to convert from Degrees into millimeters when considering the velocity!

Principal design Figure 3-2: Segments of a rotary knife cam

Cross-cutter circumference

Material web

?

200 mm

180 mm

20 mm

0 mmSheet lengthSheet length – 20 mm20 mm0 mm

The cam has two essential tasks: 1.) Definition of the cutting curve in the synchronous range The shape of the cam in the synchronous range is generated from the specifications of the cutting curve. The cutting curve is independent of the format length. 2.) Adaptation of the format in the format range The shape of the cam in the format range is generated from the difference between the circumference and the format length and is therefore dependent on the format length. This is the reason that the cutting point (defined as position 0) is selected at the changeover point of the cams. The reason for this is that the synchronous range is identical for all of them and can therefore be changed over without any jerk.

Half of the synchronous range at the

d f th t Half of the synchronous range at the start of the cuts

Format range

Cutting point

Cutting point




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Table 3-2

Cam Description

Circumference, cross-cutter

Material web

200 mm

180 mm

20 mm

0 mmCut lengthCut length – 20 mm20 mm0 mm

100 mm


circumference < cut length If the cut length is greater than the rotary knife circumference, then within the format range, the rotary knife must be decelerated, starting from the synchronous velocity, and then be re-accelerated to the synchronous velocity. If the cut length is significantly longer than the rotary knife circumference, then the rotary knife comes to a standstill and if the cut length increases even further, then it has an even longer pause.


Material web

200 mm

180 mm

20 mm


100 mm


circumference = cut length If the cut length precisely corresponds to the rotary knife circumference, then the cutting knife moves with the velocity of the material web. The format range in this case corresponds to the synchronous range. This is the reason that in principle, there is only one single synchronous range that extends over the complete cut length.


Material web

200 mm

180 mm

20 mm


100 mm


circumference > cut length If the selected cut length is less than the “rotary knife” circumference, then the cross-cutter, in the format range, must be accelerated starting from the synchronous velocity and then decelerated back down to the synchronous velocity.




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3.2.2 Segment structure of a rotary knife cam

As the format length increases, there is a danger that the knife will move backwards into the synchronous range. This can result in damage and must therefore be avoided. The format length from which reverse motion is executed is called the critical length. This is the reason that the format range of the cam is sub-divided into three segments, to allow the knife to dwell at the start position for format lengths greater than the critical length. Figure 3-3: Diagram showing the segments of the rotary knife cam


Material web

200 mm

180 mm

20 mm


100 mm

Segments I and V define the synchronous range and therefore the specified cutting curve, segments II, III and IV define the format range.




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3.2.3 Starting and Stop Cam

Table 3-3

Cam Type Description


Material web

200 mm

180 mm

20 mm


100 mmBasic position

Start

Synchronizing to the starting cam Using the starting cam, the cutting knife is brought out of its starting position into the cutting position and is accelerated up to the velocity of the material web. This cam is defined over the complete cutting length so that it can be started if the leading material edge reaches the cutting position. For short cutting lengths and knife systems with a high inertia then the cross-cutter can be immediately accelerated. At the cutting position (zero position!) the cam for cyclic operation is selected.


Material web

200 mm

180 mm

20 mm


100 mmStarting position

End

De-synchronizing with the stop cam If the rotary knife is to be stopped, or there is no material under the rotary knife, then to stop a changeover is made to the stop cam when the knife at the cutting position. This means that the cutting knife is kept at the starting position. After this, the rotary knife is taken out of the synchronous group with the material web.




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3.2.4 Linear cutting characteristic

Thin materials can be cut essentially at a precise point using a linear cutting characteristic – at the cutting point the circumferential velocity of the knife is precisely equal to that of the material. With increasing material thickness, the material bunches up at the entry and exit points of the knife (vector break-down of the circumferential velocity in the direction of the material!).

Table 3-4

cutting characteristic Cam

0

Knifeentry

Cutting point

Knifeexit

Example of a velocity profile with linear cutting curve without velocity increase.

Generally, special cutting curves must be developed for thicker materials. These special cutting curves then equalize these velocity differences. The application offers the option of defining cutting curves by increasing the velocity (start of the cut, cut center point, cut end point). A linear interpolation is made between these points.

Table 3-5

cutting characteristic Cam

0

Knifeentry

Cutting point

Knifeexit

Example of velocity profile with cutting curve using velocity increase at the start and at the end of the cut.




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3.3 Operating states of the application SIMOTION Rotary Knife

FBRotaryKnife automatic controls the rotating knife to implement the required functionality. This functionality is sub-divided into six operating states so that the sequences at the rotary knife are implemented as a result of the states or also as a result of the transitions between the states. This means the user only influences the rotary knife by specifying the required operating mode with the required parameters Figure 3-4: Operating modes

1Disable

4Manual

0Error

3Auto-matic

5Single

Cut

6Sample

Cut

2Startposi-

tion

Table 3-6

State Description

ERROR (0) FBRotaryKnife has detected a fault and has brought the rotary knife axis into a safe state. The fault is still present and can be evaluated by the user. The rotating knife has been stopped and is in the DISABLE mode.

DISABLE (1) FBRotaryKnife is ready for use, but is still in the safe operating state. All of the pending faults have been successfully acknowledged. The rotating knife is in the state after a reset, deactivated and stopped

STARTPOSITION (2)

The rotating knife is moving or is already located at the START POSITION and is ready to be synchronized to the material web. The axis waits in the START POSITION operating mode

AUTOMATIC (3) The rotating knife has been synchronized to the material web and is cutting the material according to the specifications

MANUAL (4) The rotating knife is the manual mode; the user can manually move the axis. The axis waits in the MANUAL operating mode.

SINGLE_CUT (5) The rotating knife is ready for a single cut.

SAMPLE_CUT (6) The rotating knife is ready to cut a series of test pieces

These operating modes are available to users to implement their cross-cutter functionality in a user program and can be signaled to the FBRotaryKnife using input parameters. The FBRotaryKnife indicates the currently reached status using an output parameter.

The application example as demo system



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Content All of the necessary steps to commission the “rotary knife” standard application as presentation system are explained in this section. Preparations and parameterizing operations are explained. Further, you are told how you can use the WinCCflex man-machine interface (screen) of the application example step-by-step.

Objective This Section of the document provides the reader with the following • The prerequisites to use this standard SIMOTION application as demonstration

system • Explains the preparatory activities and parameterizing operations • Describes the steps necessary when presenting this standard application. • Provides tips for using this standard application.

Chap.. Title Content

4 Installing the hardware and software Safety information and instructions Components and their interconnections required for the presentation Installation of standard SIEMENS software Downloading the user program in SIMOTION D435 Downloading drive parameters in SINAMICS

5 Operator control of the application example

Brief instructions on how to use the demonstration system Detailed Operating Instructions


Installing the hardware and software


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4 Installing the hardware and software 4.1 Regarding your safety

4.1.1 Safety information and instructions

Pictograms, signal words and text Every piece of safety information/instruction in this document is designated by text graphics – comprising pictogram and signal word, and supplemented by explanatory text. A clear classification according to the degree of the potential hazard is provided as a result of the combination of pictogram and signal word. Safety information/instructions are provided in front of the information regarding activities to be executed.

Classification There are three different stages regarding safety information/instructions. These are designated by the same pictogram. They differ by the signal word.

! Danger

This safety information/instruction indicates an immediate hazard. If the information/instruction is not carefully followed, this results in severe bodily injury or even death.

! Warning

This safety information/instruction indicates a potential hazard. If the information/instruction is not carefully followed, this can result in severe bodily injury or even death.

! Attention

This safety information/instruction indicates a potentially hazardous situation that can result in slight to average bodily injury. This pictogram/text word can also warn about potential material damage.




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4.1.2 Responsibilities of the operator

Correct use The correct use of the application components exclusively relates to the open-loop and closed-loop control of test set-ups that were adapted to the power/performance of the application components. In order that the application functions perfectly, the required standard SIMATIC components as well as also the necessary hardware and software components must be installed. The company/person operating the system may only make changes to the application components after having received written authorization from the suppliers.

Misuse The following are considered to be misuse: • Inadmissible loads applied to the application components. • Any application deviating from the use specified above, or applications that go

beyond the specified use. • Non-observance of the safety information and instructions. • If faults, that could have a negative impact on the safety, are not immediately

resolved/removed. • Any changes/modifications to equipment/devices that are used to ensure

perfect function and operation, unrestricted use as well as active or passive safety.

• If recommended hardware and software components are not used. • If the application components are not in a perfect technical condition are not

operated conscious of safety and hazards, and not taking into account all of the instructions provided in the documentation.

The manufacturer assumes no liability for incorrect use (misuse).

Responsible for monitoring The company or person operating the system is responsible in continually monitoring the overall technical status of the application components (defects and damage that can be externally identified as well as changes in the operating behavior). The company/person operating the system is responsible in ensuring that the application is only operated in a perfect state. He must check the state of the application components before they are used and must ensure that any defect is removed before commissioning.

Qualification of personnel The operating company/person may only deploy trained, authorized and reliable personnel. In so doing, all safety regulations must be carefully observed. Personnel must receive special instructions regarding the hazards/dangers that can occur. Hardware structure and mounting/installation




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4.2 Hardware configuration and installation

Overview Figure 4-1: Hardware components (without power cable!)

Ethernet

The demonstration project can be commissioned using a conventional SIMOTION D435 demonstration case and a PC connected via Ethernet.




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Table 4-1: Hardware components

Hardware element Figure Order No./MLFB and functions

Training case, SIMOTION D435 with SINAMICS S120 SIMOTION D demonstration and training case

6ZB2 470-0AE00 The SIMOTION D training case comprises standard components (SIMOTION D435, two SINAMICS axes with motors) and has two axes. These are used to demonstrate the application. The case is already pre-configured and connected-up. It only has to be connected to the HMI system via Ethernet.

Communications Ethernet Cross Link Cable The cable is used to establish a connection

between the HMI system (PG/PC) and the SIMOTION D435 training case.

HMI system PG/PC with Ethernet interface

The PG/ PC is used as the HMI display screen.

Procedure Please proceed as follows to configure and install the hardware components for the application example:

Table 4-2: Hardware configuration and mounting

No. Action Comment

1 Connect the Ethernet interface of your PG/PC with the lower Ethernet interface IE2 (contact X130) of SIMOTION D435 with an Ethernet cable.

2 Connect the SIMOTION D training case to the power supply.

3 Power-up all of the equipment/devices.




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4.3 Installing the standard SIEMENS software

Note If the application is only to be used to demonstrate and present, then it is only necessary to install WinCC Flexible 2008 with 256 power tags.

Minimum required releases Table 4-3: Versions

Component Version

STEP 7 V5.5 SIMOTON SCOUT V4.2.1 WinCC Flexible 2008 SP2 WinCC Flexible Runtime 2008 SP2

4.4 Downloading the user program and parameterizing the drive in the SIMOTION D demonstration case

4.4.1 De-archiving the SIMOTION project

• Open SIMOTION SCOUT • De-archive the SIMOTION project and open it using SIMOTION SCOUT •

4.4.2 Resetting SIMOTION D435 to the factory settings

In order to obtain a fixed start point for the description on how to download the user program into the demonstration case, restore the factory setting at the demonstration case as described below: • Power-down the demonstration case • Set the mode switch SIMOTION D435 to setting 3 (MRES) • Power-up the demonstration case • When RDY lights green and STOP lights orange, set the SIMOTION D435

mode switch to the 0 position (RUN) • RDY and RUN are green • • Once the factory setting has been restored, the SIMOTION D435 has

PROFIBUS address 2 and the baud rate is 1.5 Mbit/s.




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4.4.3 Reconfiguration of double-axis motor module from 3A/3A to 5A/5A

This Standard Application is configured with a 3A/3A motor module. If this project is used with demonstration racks of a different rated power, e.g. with double motor modules 5A/5A, the configuration in the project has to be changed accordingly: • Change to offline mode • Open the “drive navigator” in the project navigator window • By pressing the button “device configuration” a new window opens • Carry out drive configuration, by pressing the relevant button • Press “continue” until you reach the window “configuration power unit” • Select the used power unit in the list, compare serial number at front face of

the motor module, e.g. 6SL3120-2TE15-0AA0 (5A/5A) • Press “continue” and acknowledge warnings • Press “continue” , without conducting any further changes, until the button

“finish” appears and finish the configuration by pressing that button • Close the window “device configuration” • Reduce parameter p210 separately in both drives (Antrieb rot, Antrieb blau)

from 600V to 345V by using the expert list (mark respective drive -> right mouse button -> expert -> expert list)

• Save and compile project, connect to target system and download your project




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4.4.4 Configure Ethernet interface

Set PG/PC interface Table 3-5: Setting the PG/PC-interface configuration

No. Action Comment

1 Open the interface configuration in SIMOTION SCOUT via EXTRAS SET PG/PC INTERFACE...

2 Among the features by “Interface Parameter Assignment Used”, please select your Ethernet card / interface of the PG/PC with „TCP/IP ......“ (e.g. „TCP/IP VIA PCI 10/100I Fast Ethernet Adapter“).

3 Confirm (possible) warning by Yes.

4 Confirm your changes with OK twice

5 Return to SIMOTION SCOUT and open the net configuration NETPRO by using the button or by selecting the Menu PROJECT OPEN NETPRO.




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6 Double-click on PG/PC(1) to open the properties.

7 Under the feature „Assignment“ (which has already been selected automatically), the applied ETHERNET interface has to be indicated under „Parameter assigned“. If this is already the case, you only have to select it and put the tick in the box marked ‘S7ONLINE Access: active’. In this case, please skip the steps 8 and 9! Confirm your entry with OK. After that, the Ethernet line of the PG/PC is marked in yellow. If the applied ETHERNET interface is not indicated under „parameter assigned“(but only in that case!), please execute the steps 8 and 9

8 ETHERNET has not been “assigned”, yet: You can find the configured interface of the control under „Configured Interfaces“ and all available interfaces in the PG/PC under „Interface Parameter Assignments in the PG/PC“. Select under „Interface Parameter Assignment“ the applied ETHERNET interface (like it has been set in „Set Interface in PG/PC“) and push the button Assign. If a warning appears, please, confirm it with OK.




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9 After that, the interface of the control is assigned to the interface of the PG/PC. If this assignment has not been selected, yet, please do it now and put the tick in the box marked „S7ONLINE Access: Active”. Confirm your entry with OK. After that, the Ethernet line of the PG/PC is marked in yellow.

10 Please, select „Compile and check everything”. Select the (button ) and confirm with OK.

11 Please close all possible appearing warnings.

12 Before you close the project of loading, please connect NETPRO and adjust the Ethernet address of your PG/PC. For this, please, see the next paragraph




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4.4.5 Set the Ethernet address of the PG/PC

Table 3-6: Ethernet address

No. Action Comment

1 Open the window NETWORK AND DIAL-UP CONNECTIONS of your PG/PC, select the applied network connection to SIMOTION D435, and open its properties. (Right mouse click mark properties or symbol and then FILE PROPERTIES).

2 In the area „Components checked are used by this connection“, please select the „Internet Protocol (TCP/IP)“ and open its properties.




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3 The standard IP address of the Ethernet interface IE2/OP (X130) for the SIMOTION D435 is 169.254.11.22. Please, select „Use the following IP address“ and enter the IP address 169.254.11.23. Please, enter 255.255.0.0 in the „Subnet mask“.

4 The configured address need to be identical with the address of the PG/PC! Check the configured address in the properties of the PG/PC interface and change it if necessary

5 Confirm your changes by pressing OK twice.




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4.4.6 Downloading the hardware configuration after a factory setting

To download the hardware configuration, please proceed as follows:

Table 4-4: Downloading the hardware configuration according to the factory setting

No. Action Comment

1 Change to HW-Config and download the hardware configuration

2 Confirm with OK

3 Confirm with OK

4 Press No

5 Close the HW-Config and change to SCOUT




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4.4.7 Downloading the SIMOTION project of the standard application

Table 4-5: Downloading the SIMOTION project

No. Action Comment

1. Before you download the project, in the offline mode, please check under Target system/Select target devices

2. Whether both SIMOTION D435 as well as also

SINAMICS_Integrated are selected. Please acknowledge changes with OK.

3. After establishing the ONLINE connection, the

operating states of the devices accessed, are displayed in the diagnostics overview.

4. After starting the download, you will be prompted as

to whether you wish to “copy RAM to ROM“ after the download. Always answer this question with Yes as otherwise your program must be again downloaded after power ON/OFF. This copy operation only refers to the SIMOTION part of the project

5. Once the download has been completed, please acknowledge with OK

6. Also acknowledge the data that has been successfully copied from the RAM to ROM with OK




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No. Action Comment

7. The system now prompts you whether you wish to also copy the parameters of SINAMICS_Integrated from the RAM to the ROM. Also answer this with Yes

8. Also acknowledge the data that has been successfully copied from the RAM to ROM with OK

9. After the download has been completed, you’ll see the adjacent diagnostics overview.

10. Now switch the SIMOTION D435 into the RUN state.

To do this, click on the SIMOTION-CPU and with the right hand mouse key and target device/operating state, go to the operating state display.

11. Here, click on the RUN button

The SIMOTION D435 is then in RUN and the demonstration case is now ready to be used for the presentation!


Operator control of the application example


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5 Operator control of the application example The application can be used to present SIMOTION D with SINAMICS and get to know and test the functions of the CPU D435. In the following Chapter 5.2




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Brief instructions to demonstrate you will find brief instructions on how to present and present the application example. You will find detailed descriptions of all operator displays in Chapter 5.3 Detailed operating instructions.

Prerequisites The following prerequisites must be fulfilled in order to use the application example: • The SIMOTION project is provided online in SIMOTION D435. • The parameterization for the applications has been downloaded into

SINAMICS. (also included in the SIMOTION project!) • All devices have been powered-up. • The SIMOTION D435 has been switched into the “Run” state using the online

function of SIMOTION SCOUT. • As a minimum, WinCCflex Advanced 2008 SP2 has been installed on the

PC/PG. •

Note WinCCflex requires the appropriate authorization. Authorization for at least 256 power tags is required.




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5.1 Structure overview

Please refer to the following diagram for the basic operator control structure with all of the operator areas of the application. The SETTINGS and STATUS displays are not required when presenting the application and are therefore not described in the detailed Operating Instructions. Figure 5-1: Structure overview to demonstrate the application

Manual-Mode

Automatic-Mode

STATUS

TECHNOLOGY

SETTINGSHOME

MANUAL

AUTO




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5.2 Brief instructions to demonstrate

Here, in these instructions you will only be shown and explained the steps necessary to demonstrate the application. Not all of the operator screens will be discussed. You will find detailed descriptions of all operator displays in Chapter 5.3 Detailed operating instructions Execute the following steps in the sequence as listed in the following table to demonstrate the application example:

Table 5-1: Brief instructions to demonstrate/present the “rotary knife” application example

No. Action Comment

1. Call the following file “C:\Siemens\Step7\S7Proj\SAP_RotaryKnife\TDOP\ PRO__00.fwd”. As an alternative, you can also select the operator panel using Step 7. In the SIMATIC Manager, open the SAP_RotaryKnife project. You will find the HMI object OP1 at the project level. Start the runtime from the context menu (righthand mouse key)

2. If the connection to the CPU was able to be established, the screen form appears at the top left – mode: Idle

Please check that your PG/PC is set to MPI with 12 Mbit/s or to automatic.

3. At the bottom left, please click on AUTO (3rd button from the left!)

4. First activate the print mark simulation by pressing the Print Mark Simulation ON / OFF button.

5. Next, using the Start Position slider, select the required basic setting and activate the movement to the starting position by pressing the Rotary Knife STARTPOS button




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No. Action Comment

6. Once the rotary knife has reached its starting position, the Rotary Knife START button is displayed to activate the rotary knife Before you activate the rotary knife, the required cut length should be selected using the CutLength slider.

7. Now you can start the material feed! Select the Material Velocity using the Material Velocity slider You can start the material feed by pressing the Material START button

8. Once the material has reached the rotary knife, using the CutLength slider, you can enter a new cut length, and activate with the activate button.

9. The new cut length is only taken into account after the actual segment has been completely entered. The activate button remains green for this time! Activate the technology screen by pressing the TECHNOLOGY button

10. The following are displayed in the technology screen: • The actual material velocity • The actual rotary knife velocity • The actual position of the rotary knife The starting position of the rotary knife You can return to the automatic screen by pressing the AUTO button




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No. Action Comment

11. The material can be removed by pressing the Material END button

12. After the last cut, the rotary knife automatically moves to its starting position and waits for new material.

13. Once the material has been completely removed from the screen area, then you can either allow new material to enter by pressing the Material START button and continue with Step 8, or end the application by pressing the Rotary Knife END button.

14. After the application has been ended, you can return to the welcome screen by pressing the HOME button

15.




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Process screen The process screen is the main screen in the automatic mode of the application example to control (operator control) the rotary knife. Figure 5-2: Process screen in the automatic mode of the rotary knife

The material and the rotary knife can be started, terminated (exited) and monitored in the process screen. The material (material web) is started, stopped (held) and terminated (exited) on the lefthand side; the “rotary knife” is started and exited on the righthand side.

Basic settings

Mode of the application rotary

knife

Length scale

Rotary Knife

Operating state (OMAC), application example

Automatic mode

Calls the technology

screen

To the status display

Position and velocity of the material and rotary knife

Velocity input (setpoint)

Manual mode

Material

To the welcome screen

Start material

Stop/ hold

material

Allow material to

be removed

Random print mark

offset

Start the rotary knife

Move rotary knife to the starting

position

End application




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5.3 Detailed operating instructions

A detailed description of the application is provided in these instructions. This is necessary so that you can get to know and test the CPU functions.

Start In the SIMATIC Manager, open the SAP_RotaryKnife project. You will find the HMI object OP1 at the project level. Start the runtime from the context menu (righthand mouse key). Or Call the following file: „C:\Siemens\Step7\S7Proj\RotaryKnife_V20\HmiEs\PROJECT_1\ PROJECT_1.OP_Flex.fwx” The welcome screen is displayed Figure 5-3: Welcome screen




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General screen areas The screen forms of the application are handled using buttons at the lower edge of each of the screen forms. Refer to The name of the actual operator screen form and the presently valid mode are displayed in the upper righthand corner of the screen forms. Refer to The following functions can be selected using the individual buttons: Table 5-2: General buttons to control/handle the screen forms

Button Function

You can access the pre-setting screen from every operator screen using the SETTINGS button.

You can access the setting-up screen from every operator screen using the MANUAL button. If the application is in the IDLE or AUTOMATIC-STOPPED modes, the MANUAL mode is selected.

You can access the automatic screen from every operator screen using the AUTO button. If the application is in the IDLE or MANUAL modes, the AUTOMATIC-STOPPED mode is selected.

You can access the technology screen from every operator screen using the TECHNOLOGY button.

You can access the status screen from every operator screen using the STATUS button.

You can access the welcome screen (home) from every operator screen using the HOME button. If the application is in the MANUAL or AUTOMATIC-STOPPED modes, the IDLE mode is selected.




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Machine geometry settings The standard application allows the following machine geometry parameters to be adapted: • Distance to sensor

Distance between the rotary knife axis and the sensor of the material and print mark detection

• StartSyncPosition Start of the synchronous range

• EndSyncPosition End of the synchronous range

Figure 5-4: SETTINGS operator screen for machine geometry settings




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Operator functions in the setting-up mode (MANUAL) In the setting-up mode, the material web and the cross-cutter can be manually moved. This standard application does not require any functions that may only be executed in the setting-up mode. This is the reason that we are only providing users with an empty screen form that can be adapted, when required – to the specifications and requirements of the user’s application. Figure 5-5: MANUAL operator control screen form for the operator functions in the setting-up mode




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Operator functions for the process in the automatic mode (AUTOMATIC) Figure 5-6: AUTOMATIC operator screen form for operator functions in the automatic mode

Note The automatic mode (AUTOMATIC) is only available, if

• There is no fault, • Both axes are enabled, and • For both of these axes, no manual operator control functions are active.

Standard operator control Table 5-3: Standard operator control in the automatic mode

No. Action Comment

1. Initial (starting) situation: The “rotary knife” is in the AUTOMATIC-STOPPED mode

2. Using the Start Position slider, enter the starting position / basic

setting of the rotary knife.




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No. Action Comment

3. The rotary knife starts to move to the starting position / basic setting by pressing the Rotary Knife STARTPOS button

4. After the starting position / basic setting has been reached, the

rotary knife is in the AUTOMATIC-READY mode

5. The rotary knife is enabled for operation using the Rotary Knife

START button.

6. The rotary knife is in the AUTOMATIC-STANDBY mode and waits

for material.

7. Select the required material web velocity using the Material

Velocity slider.

8. You can start to thread the material web or continue motion after

the material web was stopped by pressing the Material START button.

9. If the rotary knife has synchronized itself to the motion of the

material web, the rotary knife is in the AUTOMATIC-PRODUCING mode.

10. You can stop the material web using the Material BREAK button.

11. When the material web has been stopped, the rotary knife is in the

AUTOMATIC-HELD mode

12. You can start to remove the material web from the system by

pressing the Material END button.

13. If this symbol appears, then the rotary knife has detected the last

segment of the material web and ends its last position with the stop cam in its starting position / basic setting.

14. The rotary knife then waits in the AUTOMATIC-STANDBY mode

for the next material web.




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Expanded operator control Table 5-4: Expanded operator control in the automatic mode

No. Action Comment

1. If the rotary knife is in the AUTOMATIC-STOPPED, operating mode, you can select one of two possibilities: • Print Mark Simulation OFF

i.e. the demonstration case itself generates print marks using sensors. It is not possible to change the cut lengths

• Print MARK simulation ON this means that the print marks – and therefore also the cut length – can be freely selected.

2. If the print mark simulation has been activated, this character is displayed at the top left edge of the screen.

3. You can change the cut length with the Cutlength slider.

4. If the rotary knife is in the AUTOMATIC-PRODUCING mode, you

can changeover the print mark simulation using the activate button to the new cut length that you have selected.

5. Using the button Random Print Marks ON / OFF, you can

activate automatic modification of the cut length from print mark to print mark. (presently implemented: The cut length can be modified by +/- 20 mm)

Shift cut function Figure 5-7: Operator control elements of the shift cut function




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Table 5-5: Using the shift cut function

No. Action Comment

1. You can shift the cut by 5 mm to the left using button –5

2. You can shift the cut by 1 mm to the left using button -1

3. You can shift the cut by 1 mm to the right using button +1

4. You can shift the cut by 5 mm to the right using button +5

5. Velocity value that is superimposed on the rotary knife velocity for

correction motion.

6. Indicates that correction motion is active

Display areas Figure 5-8: Rotary knife mode

This area informs you about the selected and presently active operating mode of the RotaryKnife-FB.

Figure 5-9: Actual Velocity / Position

In this area, the actual velocity [mm/s] and the actual position [mm] are displayed for the material and rotary knife axis.




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Technology view The technology view of the application can be selected from every operator screen using the TECHNOLOGY button. Figure 5-10: Technology view

In the technology view, using the trace function of the HMI screen, the actual position of the rotary knife, its starting/basic position and the velocities of the material web and the rotary knife can be monitored and traced (recorded). The modulo jump of the rotary knife can be clearly seen when its position changes from 199.999 mm to 0 mm. The fluctuations in the rotary knife velocity can also be easily seen – however, in the cut, the velocity corresponds to precisely that of the material web.

Controls the trace function

Actual cross-cutter position

Cross-cutter velocity

Material web velocity

Starting/basic position of the cross-cutter




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Operator control functions in the status display The status display of the application can be selected from every operator screen using the STATUS button. Figure 5-11: Status display

You can see the actual state of the RotaryKnife-FB in the status display. You can read about the error number displayed under ErrorID, in Chapter 7.3.7. Errors can be acknowledged using the QUITT button. If the RotaryKnife-FB is in the ERROR state, then the Quitt button should be pressed until the RotaryKnife-FB is in the DISABLE state.




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Content All of the steps necessary to integrate the core “rotary knife” functions into your application are explained in this section. Preparations and parameterizing operations are also explained. Further, you are also told how to integrate the RotaryKnife-FB into your application step-by-step.


Program environment and interfaces


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6 Program environment and interfaces 6.1 Importing the source code

The SIMOTION Rotary Knife application is part of the LRKLib library. The library is available as standard SIMOTION Rotary Knife application as well as XML export. In order to be able to use the functionality of the library, this must be integrated into the corresponding user project.

6.1.1 Copying from the application example

Two instances of SIMOTION SCOUT are opened in order to copy the LRKLib library. The application example is opened or dearchived in the first window and a new user project is created in the second window, which already includes the global library folder.

Table 6-1: Copying the library from the application example

No.

1. The library is downloaded to the buffer memory by right clicking on the library in the standard application following by Copy.

2. The library LRKLib can be inserted

if, in the user project, the Library folder is selected and is then run by clicking on it with the righthand mouse key.

3. The lower-level objects are also

copied.




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6.1.2 Linking using XML import

With XML import, the LRKLib library and the RK_Progs program unit from their XML files are linked into the existing user project.

Table 6-2: Importing the XML file

No.

1. For the XML import, the LIBRARIES folder must be selected in the user project and then run by clicking on it with the righthand mouse key. Using the Import object menu item, a window opens in which the path of the XML file must be specified.

2. Using the Browse button, the

XML file path is specified and therefore the LRKLib library is imported into the user project.




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6.1.3 Linking the rotary knife functionality

The LRKLib library comprises several program units, whereby the units RK_CamCalc (block to calculate the cam), RK_Template (rotary knife block), RK_Tools (internal functions) contain the functionality of the application in the form of function blocks as well as data type definitions and the unit RK_Progs. Reference to the library is established in the unit and the instances of the function blocks and the data structures created. In addition, the unit includes the calls of the instances in the programs that must be integrated in the user project in the task system. The programs are not able to run in the library and may have to be adapted to the particular application (startupRotaryKnife).

Table 6-3: Programs of the RK_Progs unit

Program Description Task

StartupRotaryKnife Initialization and parameterization StartupTask

MainRotaryKnife Main program BackgroundTask

IpoRotaryKnife Status bits and print marks IPOsynchronousTask

MTCamCalculation Cam calculation MotionTask

After the library has been copied/imported in the library folder, the program unit RK_Progs must be copied from the library folder into the program folder of the application – and modified at four positions:

Table 6-4 Copying and modifying the UNIT RK_Progs

No.

1. The unit is downloaded into the buffer memory by right-clicking on the program unit RK_Progs in the library LRKLib followed by Copy.

2. The program unit RK_Progs can be inserted if, in the

user project, the Program folder is marked and is subsequently run with a righthand mouse click.




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No.

3. Then, in the program unit RK-Progs, in the program container (not in the library!) four program lines must be deleted. Marked with $$$$$$$

4.

5.

6. The program unit can now be

successfully compiled.

When using the program unit RK_Progs, the user does not have to link the library. The library is linked using the RK_Progs unit.




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User program units that are to access library functions, types, function blocks and data of the standard application, must be linked with the program unit RK_Progs in the interface section.

INTERFACE USES RK_Progs // Linking the standard application END_INTERFACE

Variable access To access variables of the SIMOTION Rotary Knife application, the following instances are set-up in the global data area in the RK_Progs program unit: Table 6-5: Data interface

Element Description

gasRotaryKnife Block interfaces and parameters

gaRotaryKnife Instance(s) of the FBRotaryKnife

gaFBRKIPO Status bits and print mark detection

gaFBCamCalculation Instance(s) of the FBRKCamCalculation

NUMBER_OR_ROTARY_KNIFES Number of FB instances

VAR_GLOBAL CONST NUMBER_OF_ROTARY_KNIFES : INT := 1; // number of rotary knifes controlled END_VAR VAR_GLOBAL gasRotaryKnife : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF sRotaryKnifeType; gaFBRotaryKnife : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF FBRotaryKnife; gaFBRKIpo : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF FBRKIpo;

gaFBCamCalculation: ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF FBRKCamCalculation;

END_VAR




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6.2 Technology objects

6.2.1 Technology objects required and synchronous relationships

To use the SIMOTION Rotary Knife application, the following technology options must be set-up and interconnected with one another in the described fashion:

Table 6-6: Technology objects required

Object Description

To determine the position and velocity of the material web as master (leading) value of the core “rotary knife” functions and to coordinate the motion of the axis – material web from the same control.

Real positioning or following axis TO

External encoder

Configuration Set the axis type as linear. For accuracy reasons, we recommend that the axis type is parameterized as modulo axis with a modulo length greater than the maximum product length. All of the other parameters should be set corresponding to the drive and encoder data.

Mechanical system

For the parameter “distance per spindle revolution”, enter the distance as value that the material web moves through for one revolution of the drive roll. Supplement the additional parameters also corresponding to the geometry and machine design.

Limits For this parameter, enter values that correspond to the system/drive relationships

Referencing Parameterize “not required”

Material Axis (MaterialAxis, (MaterialEncoder)

Configuration

Monitoring, closed-loop control

Please set this parameter corresponding to the system relationships.

Drive for the rotary knife motion.

TO Real following axis

Configuration Parameterize the axis as synchronous axis. Set the axis type as linear. All of the other parameters should be set corresponding to the drive and encoder data.

Mechanical system

For the parameter “distance per spindle revolution” enter the distance that the point of the “Rotary Knife” moves through for one motor revolution. If the “Rotary Knife” is directly mounted without a gear unit, then knifeCircumference should be entered here. Appropriately supplement the other parameters corresponding to the geometry and the machine design.

Pre-assignment Please set this parameter corresponding to the drive dynamics

Limits Please set this parameter corresponding to the system relationship

Rotary Knife Axis (RotaryKnifeAxis)

Configuration

Referencing Please set this parameter corresponding to the encoder. (The template assumes a referenced axis. If an incremental encoder is to be used, then the axis must be referenced in the MANUAL mode before additional operating modes are selected.)




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Object Description

Monitoring functions, closed-loop control

Please set this parameter corresponding to the system relationships

Inserting this (virtual) auxiliary axis between the material path motion and the cam makes it easier to correct length errors that are determined by the print mark detection. By correcting the auxiliary axis position, then the knife position is automatically corrected – adapted to the cam position. Without the auxiliary axis, the correction motion of the knife – corresponding to the length change using the print mark correction – must be adapted using the cam.

TO Real following axis

Configuration Set the axis type as linear Parameterize as virtual axis without drive

Pre-assignment

Limits

Auxiliary Axis (AuxiliaryAxis)

Configuration

Monitoring functions

Please select this parameter so that in operation the virtual axis does not reach the dynamic limits.

In operation, two cam Tos are required to recalculate and exchange the cams. The third cam TO is used for travel to the initial position when stopping.

TO Cam

Cams (Cam1, Cam2, Cam3)

Configuration Cam type, polynomial




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6.2.2 Synchronous relationships

Synchronous relationships of the SIMOTION Rotary Knife application: Figure 6-1: Synchronous relationships required for the FBRotaryKnife

MaterialAxis

Cam1

1:1

Cam3

External Encoder or

Positioning AxisFollowing Axis Following Axisgearing caming

Cam2RotaryKnifeAxis

AuxiliaryAxis

The material axis (MaterialAxis) is the reference quantity for the rotating knife. This reference quantity can be detected in two different ways: 1. The material path is controlled by the SIMOTION drive system that also

controls the rotary knife. In this case, there is an axis TO. The synchronous connection with the auxiliary axis (AuxiliaryAxis) should in this case, access the setpoints of the material path that exist in the system (setpoint coupling)

2. The material path motion is measured using the encoder in the machine itself. In this case, there are no additional setpoints available. The synchronous connection with the auxiliary axis (AuxiliaryAxis) can only access the actual values of the encoder in the machine (actual value coupling).

The AuxiliaryAxis as “synchronous axis” is connected to the MaterialAxis in a 1:1 (gearing) synchronous relationship. There is a camming relationship between the AuxiliaryAxis and the “synchronous axis” RotaryKnifeAxis, that can be optionally controlled using cam 1 (Cam1) up to cam 3 (Cam3). The synchronous relationship between the RotaryKnifeAxis and AuxiliaryAxis remains during the complete operation from starting to stopping the “Rotary Knife”; a changeover is only made between the cams. The synchronizing operations when starting and stopping are only executed between the MaterialAxis and the AuxiliaryAxis. Also the print mark correction only operates between the MaterialAxis and AuxiliaryAxis. The technology objects and synchronous operation relationships shown in the diagram above must be set-up and configured by the user in SIMOTION SCOUT.

AuxiliaryAxis_GLEICHLAUF(_SYNCHRONOUS_OPERATION) Configuration Either • Select the TO Axis „MaterialAxis“ as master (leading) axis • Select setpoint as coupling type.




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Figure 6-2 Configuration of „MaterialAxis“ as leading value of „AuxiliaryAxis“

• • • or • Select the TO ExternalEncoder „MaterialEncoder“ as master (leading) axis • Select actual value with extrapolation as coupling type. The time constant required for extrapolation is calculated using the calculation tool of the Utility&Applications CD (Scout\CD14\SRC\4_TOOLS\ExtrapolationTimeCalculation). Figure 6-3 Configuration of „MaterialEncoder“ as leading value of „AuxiliaryAxis“

Table 6-7

Function / Variable Value

Dynamic parameters The dynamic parameters of the time-related synchronization should be selected so when being synchronized and desynchronized, the axis does not reach the dynamic limits.




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RotaryKnifeAxis_GLEICHLAUF(_SYNCHRONOUS_OPERATION) Configuration Figure 6-4 Configuration of „AuxiliaryAxis“ as leading value of „RotaryKnifeAxis“

• Select the TO Axis “AuxiliaryAxis” as master (leading) axis • Select setpoint as coupling type. • Select Cam1, Cam2 and Cam3 as possible cams Table 6-8

Function / Variable Value

Dynamic parameters The dynamic parameters of the time-related synchronization should be selected so when being synchronized and desynchronized, the axis does not reach the dynamic limits.




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6.3 Integrating the SIMOTION Rotary Knife core function

The SIMOTION Rotary Knife application comprises several functional units that are saved in the program unit RK_Prog :

6.3.1 Parameterizing the rotary knifes in the startup task

It makes sense to combine configuration data assignments – that are not changed in operation – in a program (StartupRotaryKnife). These are then executed once when starting the control in the StartupTask and therefore assign values to variables. • Assignment of the actual TO instances • Assignment of the machine-specific parameters • Resetting the restart bits. • Deleting the format length buffer memory. • Resetting all flags in the program. Generating this program based on the declaration of the variables from Chapter 0 is described in this chapter as an example. The program is already prepared as program instance that can be called in the task manager and saved in the UNIT RK_Progs. The user only has to adapt the parameters to the real machine!

6.3.2 Calling FBRotaryKnife in the user program

The function block of the Rotary Knife core functions can also be called after integration in the user program. The call is already prepared in the program unit RK_Progs in the MainRotaryKnife program. The user only has to integrate this program into a cycle tasks (background, Ipo or Ipo2).

6.3.3 Calling the FBRKCamCalculation The FBRKCamCalculation call is already prepared. In this case, the user only has to integrate the MTCamCalculation program of unit RK_Progs in a motion task. This motion task should be automatically started with Startup.




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Figure 6-5 Parameterization of MotionTask

6.3.4 Calling the FBRKIPO in the IPO synchronous task

The FBRKIpo call has already been prepared. The user only has to integrate the IPORotaryKnife program of unit RK_Progs into the IPO_Task.

6.3.5 Global Variables

The FBRotaryKnife function block is influenced by several parameters and interfaces that are subdivided into the following areas: • Block interfaces • Block interface in the global data area Changing tasks and modes are communicated to the function block via the block interface. The function block also communicates the actual status – and errors that have possibly occurred – back to the user program via this interface. The parameters of the rotary knife to be connected are communicated to the function block via the block interface in the global data area. In normal rotary knife operation, these quantities are not changed. Further, it includes data areas for communication with the user and for communication of the individual sub-functions in the overall rotary knife system with respect to one another.

Program Description



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Program Description

Content Section “Program Description” is interesting if you wish to expand/adapt your application based on the technology templates available.

Objective This part of the documentation should • Explain to readers the special features/issues when generating a program • Describe in detail the program structure of the rotary knife FB • Illustrate and describe important program elements • Provide information and instructions on how this template can be adapted.

Prerequisite Before possibly expanding this template it is helpful to have read the chapters in Section A and B in order to get to know the basic functions and applications of the template.

Note Before you make changes to the template, please observe the information and warnings listed in the following Chapter as well as the associated restrictions regarding support!

Program DescriptionProgram Description


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7 Program Description 7.1 Information and warnings

Before carrying-out changes Before you carry-out changes to the components included in the core functions, you should get to know how the components function by referring to and reading the ST/MMC documentation. Uncontrolled, incorrect changes and modifications to core functions can result in death and severe bodily injury!

Restrictions regarding support when changing components of the core functions The Application Center can only provide support for core functions that have not been changed If changes have been made to the code, then support can no longer be provided for core functions. This also applies for the revision and adaptation recommendations listed in this Chapter.

7.2 Type of Data

7.2.1 Overview

Enumeration types Enumeration type declarations are prepared for some of the input and output parameters of the function blocks. Various modes and properties can be pre-set using these parameters.

Data structures The function blocks of the “Rotary Knife” application are in some cases parameterized via data structures that should be set-up for the particular block. Structures with the corresponding parameters are provided for each block.



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7.2.2 Enumeration types

Table 7-1

Name of the enumeration type Contents

eOperationModesRotaryKnifeType This enumeration type contains enumerators to select and display the operating states of the function block FBRotaryKnife. Declared in LRKLib.RK_Template:

eTypeOfCamType Defines the cam type for the cam calculation. Declared in: LRKLib.RK_CamCalc

eCamProfileType Defines the travel profile for the cam calculation. Declared in: LRKLib.RK_CamCalc

eOperationModesRotaryKnifeType This enumeration type contains enumerators to select and display the operating state of the FBRotaryKnife function block.

Element Description

OMRK_ERROR FBRotaryKnife is standing in state ERROR

OMRK_DISABLE FBRotaryKnife is standing in state DISABLE

OMRK_START_POSITION FBRotaryKnife is standing in state STARTPOSITION

OMRK_AUTOMATIC FBRotaryKnife is standing in state AUTOMATIC

OMRK_MANUAL FBRotaryKnife is standing in state MANUAL

OMRK_SINGLE_CUT FBRotaryKnife is standing in state SINGLE_CUT

OMRK_SAMPLE_CUT FBRotaryKnife is standing in state SAMPLE_CUT

OMRK_NOTHING_SELECTED FBRotaryKnife has no change of state detected

OMRK_CHANGING FBRotaryKnife is changing state

eTypeOfCamType This enumeration type defines the cam type for the cam calculation:

Element Description

START_CAM Cam for cross-cutter motion from the start position into cyclic operation.

CYCLIC_CAM Cam for cyclic operation

STOP_CAM Cam to stop the cross-cutter from cyclic operation

eCamProfileType This enumeration type defines the travel profile for the cam calculation:

Element Description

LINEAR Acceleration / deceleration profile with constant acceleration

JERK Acceleration / deceleration profile with jerk limiting

POLY_5 Acceleration / deceleration profile as fifth order polynomial



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7.2.3 Data Structures

Name of Structure Content

sRotaryKnifeType This structure contains the complete global data of the Rotary Knife system. Declared in LRKLib.RK_Template

sTOsType This structure contains the definition of all of the axes, external encoders, cams and probes that are used. Declared in LRKLib.RK_Tools

sUsersInterfaceType This structure contains the interface for the user to enter physical limiting conditions (constraints), cam profiles, manual cutting position corrections as well as the input of sequence options – such as a new start, fast start and format change in ongoing operation. Declared in LRKLib.RK_Template

sFormatLengthBufferType This structure contains the format length memory. Declared in LRKLib.RK_Tools

sFormatLengthBuffer ManagementType

This structure contains the internal data area to enter the cut length with a precise position. Declared in LRKLib.RK_Tools

sCutPositionBufferType This structure contains the buffer in which the cut position is saved with the associated position deviations. Declared in LRKLib.RK_Tools

sCutPositionBufferManagementType

This structure contains the internal data area to enter the cut position as a precise position and cut position deviation for the print mark correction. Declared in LRKLib.RK_Tools

sSampleBufferType This structure contains the user area to save cut length sequences in the SAMPLE_CUT operating mode. Declared in LRKLib.RK_Template

sCamCalculationType This structure contains the internal data area to call the cam calculation. Declared in LRKLib.RK_Template

sRotaryKnifeInfoType This structure contains the internal data area to display actual geometry values converted into the peripheral (circumferential) lengths in [mm], actual cut position as well as binary signals for the knife position. Declared in LRKLib.RK_Template

sMeasuringValueType This structure contains the internal data area for the print mark correction. Declared in LRKLib.RK_Tools

Generally applicable for labeling structural elements: [IN]: Values that should be provided by the user [OUT]: Results or feedback signals [IO]: Values, which depending on the block connection, must be supplied by

the user or written by the function

sRotaryKnifeType This structure contains the complete global data of the RotaryKnife system:



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I/O Element Type of Data Description

IN sAxisTOs sTOsType Object references of all technology objects (axes, external encoders, cams and measuring probes).

IN sUsersInterface sUsersInterface Type

Interface for the user to enter physical constraints, cam profiles, manual cutting position corrections as well as the input of sequence options – such as a synchronized start, quick start and format change in ongoing operation.

I/O sFormatLengthBuffer Management

sFormatLength Buffer Management Type

Internal data area to configure processing programs.

I/O sCutPositionBuffer Management

sCutPosition BufferManagementType

Internal data area to enter the cut position as a precise position and cut position deviation for the print mark correction.

I/O sSampleBuffer

sSampleBuffer Type

User area to save cut length sequences in the SAMPLE_CUT mode

I/O sCamCalculation

sCamCalculation Type

Internal data area to call the cam calculation

I/O sRotaryKnifeInfo

sRotaryKnifeInfo Type

Internal data area to display actual geometry values converted into the peripheral (circumferential) lengths in [mm], actual cut position as well as binary signals for the knife position.

I/O sMeasuringValue

sMeasuringValue Type

Internal data area for the print mark correction.

IN r64FormatLength LREAL [ mm ] r64formatLength is the length of the cut material element.

IN boExecute BOOL Activates the mode changeover with the operating mode specified in eMode.

IN eMode eOperationModesRotaryKnife Type

Using eMode the operating mode is preselected that is then activated with the next positive edge at input execute. OMRK_ERROR: Preselects the ERROR mode OMRK_DISABLE: Preselects the DISABLE mode OMRK_AUTOMATIC: Preselects the STARTPOSITION mode OMRK_AUTOMATIC: Preselects the AUTOMATIC mode OMRK_MANUAL: Preselects the MANUAL mode OMRK_SINGLE_CUT: Preselects the SINGLE_CUT mode OMRK_SAMPLE_CUT: Preselects the SAMPLE_CUT mode

IN boStartSingleCut BOOL Starts an individual cut if FB is in the SINGLE_CUT mode.

IN boStartSampleCut BOOL Starts a cut sequence to generate test cuts in the SAMPLE_CUT mode.

IN i16NumberOfInstanz INT Instance number of the actual call.

OUT boDone BOOL TRUE: Selected mode is activated.

OUT boBusy BOOL TRUE: Mode changeover is active.

OUT boError BOOL Indicates errors in the FBs and at the cross-cutter axes.

OUT b32ErrorID DWORD Error code



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OUT eState eOperationModesRotaryKnife Type

Actual mode OMRK_ERROR: ERROR mode OMRK_DISABLE: DISABLE mode OMRK_AUTOMATIC: STARTPOSITION mode OMRK_AUTOMATIC: AUTOMATIC mode OMRK_MANUAL: MANUAL mode OMRK_SINGLE_CUT: SINGLE_CUT mode OMRK_SAMPLE_CUT: SAMPLE_CUT mode OMRK_NOTHING_SELECTED: No mode change OMRK_CHANGING: Mode change active

OUT boAutomaticActive BOOL TRUE: mode AUTOMATIC activated

OUT boSingleCutActive BOOL TRUE: mode SINGLE_CUT activated

OUT boSampleCutActive BOOL TRUE: mode SAMPLE_CUT activated

OUT boCutPosition CorrectionActive

BOOL TRUE: Correction motion for actual cut position is active

OUT boRotaryKnifeAxis Active

BOOL TRUE: rotary knife axis enabled

sTOsType This structure contains the definition of all of the axes, external encoders, cams and measuring probes used (the user must parameterize these):


IN toLeadingValue _AXIS_REF

Reference to the technology object of the leading value. Possible technology objects: - posAxis (real or virtual) - externalEncoderType

IN toAuxiliaryAxis followingAxis Reference to the technology object of the auxiliary axis, this object is mandatory for synchronous operation. Only a virtual axis is permissible.

IN toRotaryKnifeAxis

followingAxis Refer to the technology object of the Rotary Knife axis. Only one real axis is permissible.

IN toCam1 camType Reference to the first cam object.

IN toCam2 camType Reference to the second cam object.

IN toCam3 camType Reference to the third cam object.

IN toPrintmark measuringInput Type

Reference to the technology object of the measuring probe used for print mark detection. The measuring probe must be assigned to the leading value.



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sUsersInterfaceType This structure contains the interface for the user to enter physical constraints, cam profiles, manual cutting position corrections as well as the input of sequence options – such as a synchronized start, quick start and format change in operation (the user must parameterize these):


IN r64KnifeCircumference LREAL [mm] Effective geometrical circumference of the knife roll (circumference of the circle)

IN r64StartSyncAngle LREAL [°] Start angle of the synchronous range (cutting range), i.e. the angle at which the knife enters the material; the center point is defined as 0° (170.0° - 360.0°).

IN r64EndSyncAngle LREAL [°] Final angle of the synchronous range, i.e. the angle at which the knife leaves the cutting range (0.0° - 170.0 °).

IN r64StartAngle LREAL [°] Start position of the knife (start position of the start cam).

IN r64StopAngle LREAL [°] Stop position of the knife (final position of the stop cam).

IN r64InflectionPoint LREAL

[%] Center point of the format range of the cyclic cam . r64inflectionPoint < 50.0 % (min, 10%): Shifts the center point towards r64EndSyncAngle, i.e. the absolute value of the acceleration in the first motion segment after the cut is increased. R64inflectionPoint > 50.0 % (max. 90%): Shifts the centerpoint towards r64StartSyncAngle, i.e. the absolute value of the acceleration in the second motion segment after the cut is higher.

IN i16NumberOfKnives INT Number of knives (max. 6)

IN eCamProfilePhase1 eCamProfileType

Motion profile, phase 1: LINEAR: Curve profile with constant acceleration JERK: Curve profile with constant acceleration and curve limiting POLY_5: Motion profile as fifth order polynomial.

IN r64JerkPhase1 LREAL

[%] Jerk limit component in phase 1 (only for eCamProfilePhase1 = JERK). The valid value range is between 1.0 and 100.0. For 100% a phase is obtained where the acceleration is not constant. The absolute jerk depends on the machine velocity.

IN eCamProfilePhase2 eCamProfileType

Motion profile, phase 2: LINEAR: Curve profile with constant acceleration JERK: Curve profile with constant acceleration and curve limiting POLY_5: Motion profile as fifth order polynomial.

IN r64JerkPhase2 LREAL

[%] Jerk limit component in phase 2 (only for eCamProfilePhase2 = JERK). The valid value range is between 1.0 and 100.0. For 100% a phase is obtained where the acceleration is not constant. The absolute jerk depends on the machine velocity.

IN r64DistanceToSensor LREAL [mm] Distance between the cut position and the sensor to detect the material and printer mark.

IN r64FirstCutCorrection LREAL [mm] Cut offset for the starting cut

IN r64MeasuredValueCutPosAtSensor LREAL [mm] Actual position measured value for the first cut

IN r64ToStartPosVel LREAL [mm/s] Motion velocity when positioning to the start position.

IN r64KnifeOverspeed StartCut

LREAL [%] Overspeed at the transition point to the synchronous range (r64StartSyncAngle) (-20.0% to 20.0%) referred to the synchronous velocity.



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IN r64KnifeOverspeed Zero LREAL

[%] Overspeed at the center position of the synchronous range (0°) (-20.0% - 20.0%) referred to the synchronous velocity.

IN r64KnifeOverspeed EndCut LREAL

[%] Overspeed at the end point of the synchronous range (r64EndSyncAngle) (-20.0% to 20.0%) referred to the synchronous velocity.

IN r64CPCorrection Maximum LREAL [mm] Maximum correction value for the cut position

correction

IN r64CPDeltaToleranceRange LREAL [mm] Half the tolerance bandwidth for the activation range

of the cut position detection

IN r64AdjustCutPosition PositiveValue

LREAL [mm] Coarse correction value of the manual cutting position correction in the positive direction

IN r64TrimmCutPosition PositiveValue LREAL [mm] Fine correction value of the manual cutting position

correction in the positive direction

IN r64AdjustCutPosition NegativeValue LREAL [mm] Coarse correction value of the manual cutting position

correction in the negative direction

IN r64TrimmCutPosition NegativeValue

LREAL [mm] Fine correction value of the manual cutting position correction in the negative direction

IN r64CutPosition CorrectionVelocity LREAL [mm/s] Velocity value of the higher-level cut position

correction

IN i16CutCorrWait INT Number of cuts without cut position correction

I/O boRestart BOOL Flag restart, the user must set this, it is reset by the application

IN boQuickStart BOOL

Flag, “Quickstart” TRUE: The application immediately starts to cut at the start FALSE: Application only starts to cut at the specified start position

IN boFormatLength ChangePossible BOOL

Flag, “enable format length change when the machine is running” TRUE: Format length change possible FALSE: Format length change inhibited

IN boSwitchCAM BOOL A positive edge starts a format length change (if format length change is enabled!)

IN boMeasuring WithRisingEdge BOOL

Flag, “edge selection” measuring system TRUE: Rising edge FALSE: Falling edge

IN boCutPosition CorrectionOn BOOL Flag “cut position correction on”

IN boAdjustCutPosition Positive BOOL Flag “start coarse correction, positive of the cut position”

IN boTrimmCutPosition Positive BOOL Flag “start fine correction, positive of the cut position”

IN boAdjustCutPosition Negative BOOL Flag “start coarse correction, negative of the cut position”

IN boTrimmtCutPosition Negative BOOL Flag “start fine correction, negative of the cut position”

IN boCleanCut BOOL Start cut to separate “scrap” and “product” in the SAMPLE_CUT mode

sFormatLengthBufferType This structure contains the format length memory (this is not relevant for the user):



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I/O ar64FormatLength ARRAY [0..CLB_MAX-1] OF LREAL

[mm] buffer oh the format length

I/O aboFormatLengthRead ARRAY [0..CLB_MAX-1] OF BOOL

buffer of the flags „format length read“

I/O aboFormatLength Entered

ARRAY [0..CLB_MAX-1] OF BOOL

buffer of the flags „format length entered“

sFormatLengthBufferManagementType This structure contains the internal data area to enter the cut length with a precise position (this is not relevant for the user):


I/O sFormatLengthBuffer sFormatLength BufferType

data area of format length buffer

I/O i16BufferIn INT Pointer to next input position of buffer

I/O i16BufferOut INT Pointer to next output position of buffer

I/O i16BufferTest INT Pointer to next test position of buffer

I/O i16BufferInRett INT Buffers the buffer pointer to the next entry position

I/O boBufferOutTrigger BOOL Start trigger to delete the read buffer entry

I/O boBufferReadTrigger BOOL Start trigger to read the next buffer entry

I/O r64BufferTestFormat Length

LREAL Format length currently read from the buffer

I/O r64BufferLastFormat Length

LREAL Previous format length read from the buffer

I/O boBufferTestFL Entered

BOOL Actual “entered” flag read from the buffer

I/O boBufferTestFLRead BOOL Actual “read” flag read from the buffer

I/O boBufferResetActive BOOL Reset of buffer active

I/O boBufferInActive BOOL Input of value in buffer active

I/O boBufferOutActive BOOL Deletion of buffer value active

I/O boBufferReadActive BOOL Reading of buffer value active

sCutPositionBufferType This structure contains the cut position memory (this is not relevant for the user):


I/O ar64CutPosition DeviationMeasured

ARRAY [0..CPB_MAX-1] OF LREAL

[mm] Buffers the deviations between the setpoint and the actual position for the cut at the instant in time of the measurement

I/O ar64CutPosition Measured

ARRAY [0..CPB_MAX-1] OF LREAL

[mm] Buffer of the measured cut positions

I/O aboCutPositionRead ARRAY [0..CPB_MAX-1] OF BOOL

Buffer of the flag “cut position read”

I/O aboCutPositionEntered ARRAY [0..CPB_MAX-1] Buffer of the flag “cut position entered”



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I/O Element Type of Data Description OF BOOL

sCutPositionBufferManagementType This structure contains the internal data area to enter the cutting position and to control the cutting position correction as precise position (this is not relevant for the user):


I/O sCutPositionBuffer sCutPosition BufferType

data area of cut position buffer

I/O i16BufferIn INT Pointer to next input position of buffer

I/O i16BufferOut INT Pointer to next output position of buffer

I/O i16CutCorrectionWait INT Number of cuts without cut position correction

I/O boBufferOutTrigger BOOL Start trigger to delete the read buffer entry

I/O boBufferReadTrigger BOOL Start trigger to read the next buffer entry

I/O boBufferResetActive BOOL Reset of buffer active

I/O boBufferInActive BOOL Input of value in buffer active

I/O boBufferOutActive BOOL Deletion of buffer value active

I/O boBufferReadActive BOOL Reading of buffer value active

sSampleBufferType This structure contains the cut length buffer for the SAMPLE_CUT mode (the user must parameterize this):


I/O ar64SampleLength ARRAY [0..SLB_MAX-1] OF LREAL

[mm] Buffer of the format lengths of the samples

I/O ai16SampleNumberOfPlates

ARRAY [0..SLB_MAX-1] OF INT

Buffer for the number of cuts per sample

I/O i16SampleLengthIn INT Pointer to next input position of buffer

I/O i16SampleLengthOut INT Pointer to next output position of buffer

sCamCalculationType This structure contains the internal data area to control the cam calculation (this is not relevant for the user):


IN toNextCam camType TO Cam of the cam to be actually calculated

IN toActualCam camType TO Cam of the presently active cam

IN r64FormatLength Activated LREAL [mm] Activated format length

IN eTypeOfCam eTypeOfCam Type

Type of cam to be calculated START_CAM: Start cam CYCLIC_CAM: Cyclic cam STOP_CAM: Stop cam

IN r64StartAngleActivated LREAL [°] Activated start angle

IN r64StopAngleActivated LREAL [°] Activated stop angle



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IN r64InflectionPoint Activated LREAL [%] Activated center point of the format range of the cyclic

cam

OUT b32EidCamCalculation DWORD Transfers the error message of the cam calculation to the error message system of FBRotaryKnife.

OUT boCamCalculation Active BOOL Flag, cam calculation active

OUT boCamCalcualtion Error BOOL Flag, cam calculation interrupted with error

OUT boCamCalculationOK BOOL Flag, cam calculation successfully completed

sRotaryKnifeTypeInfo This structure contains calculation results and display information – relevant for the user – that provides information about the state of the rotating knife.


OUT r64MechanicalSync Format LREAL [mm] Format length that is obtained from the knife running

in synchronism with the material web

OUT r64Synchronous Sector LREAL [mm] Length of the range in which the knife is moving in

synchronism with the material web

OUT r64FormatSector LREAL [mm] Length of the range in which the knife may make a correction motion to achieve the format length

OUT r64CutPosActual LREAL [mm] Position of the material web for the last cut

OUT r64FormatLength Activated LREAL [mm] Activated format length

OUT r64StartPos Activated LREAL [mm] Activating starting position of the knife referred to the

knife axis

OUT r64StartLength LREAL [mm] Distance that the material web moves when the knife starts from the starting position up to the cut

OUT r64StopPos Activated LREAL [mm] Activated stop position of the knife referred to the knife

axis

OUT r64StopLength LREAL [mm] Distance that the material web movers when stopping the knife from the cut up to the stop position

OUT r64MiddlePos Activated LREAL [mm] Position of the knife referred to the knife axis within

the format range with the maximum/minimum knife velocity

OUT r64StartSyncPos LREAL [mm] Start position of the synchronous range referred to the knife axis

OUT r64EndSyncPos LREAL [mm] End position of the synchronous range referred to the knife axis

OUT boAxisAsLeadingValue BOOL TRUE Leading value is a real or virtual posAxis FALSE No posAxis can be entered as leading value

OUT toLeadingValueAxis posAxis If the leading value is a real or virtual posAxis, then the name of the TO is the axis – otherwise TO#NIL

OUT boExternalEncoderAs LeadingValue

BOOL TRUE Leading value is an external encoder FALSE No external encoder entered as leading value

OUT toLeadingValue ExternalEncoder

externalEncoder Type

If the leading value is an external encoder, then the name of the TO is the external encoder, otherwise TO#NIL

OUT boKnifeInFormatSector BOOL Flag, “knife in the format range”

OUT boKnifeInSynchronousSector BOOL Flag, “knife in the synchronous range”

OUT boKnifeInSynchronousSectorOld BOOL Flag, “knife in the synchronous range (old value)“



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OUT boCut BOOL Flag, “cut”

sMeasuringValueType This structure contains the internal data area of the measured value detection (this is not relevant for the user):

I/O Element Type of data Description

OUT r64MeasuredValueNew LREAL [mm] Actual measured value

OUT r64MeasuredValueOld LREAL [mm] Measured value, old

IN eMeasuringEdge enumMeasured Edge

Selects the signal edge that initiates the measurement at the sensor: RISING_EDGE: Rising edge at the sensor FALLING_EDGE: Falling edge at the sensor

I/O boWaitForFirstCut Position

BOOL Flag, “wait until the first measured value”

I/O boCutPosition MeasuringActive

BOOL Flag, “wait for measured value”

I/O boStartPosAtSensor Detected

BOOL Flag, “measure starting position”“

IN boApplicationIn Automatic

BOOL Flag, “use in the AUTOMATIC mode“

IN boCutPosition SwitchedOn

BOOL Flag, “cutting position measurement is active”

OUT r64StartPosAtSensor LREAL First measured cutting position

IN r64FormatLength ActiveAtSensor

LREAL Format length valid at the time the measurement is made

OUT r64SollPosNextCut Position

LREAL Interpolated next cutting position

OUT r64SollPosTolerance RangeStart

LREAL Tolerance bandwidth, next cutting position, start

OUT r64SollPosTolerance RangeEnd

LREAL Tolerance bandwidth, next cutting position, end

IN r64DeltaTolerance Range

LREAL Half of the tolerance bandwidth

OUT i16CutPositionError Counter

INT Cutting position error counter



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7.3 FBRotaryKnife

Control block of Rotary Knife Functions

7.3.1 Block name

FBRotaryKnife

7.3.2 Task

Control block of the SIMOTION Rotary Knife application. The block includes the following functions: • Mode manager of the application, including the following modes ERROR,

DISABLE, MANUAL, STARTPOSITION, AUTOMATIC, SAMPLE_CUT, SINGLE_CUT

• Automatic format change • Cutting program (SAMPLE_CUT) • Single cut program • Control to calculate the travel profile including the following profile types –

linear (constant acceleration), trapezoidal (defined jerk limiting) and polynomial • Print mark correction • Synchronization to the material path Referencing the axes and setting-up operation (jog) are not included in the application.

7.3.3 Integration in the run-time system

The function block can be called in each cyclic task. The user must link the block.



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7.3.4 Graphic representation of the block

FBRotaryKnifeformatLengthLREAL

executeBOOL

modeeOperationModeRotaryKnifeType

startSingleCutBOOL

done BOOL

busy BOOL

error BOOL

errorId DWORD

measuringValuesMeasuringValueType

sMeasuringValueType

startSampleCutBOOL status eOperationModesRotaryKnifeType

numberOfInstanzINT automaticActive BOOL

singleCutActive BOOL

camCalculationsCamCalculationType

sCamCalculationType

rotaryKnifeInfosRotaryKnifeInfoType

sRotaryKnifeInfoType

cutPositionBufferManagementsCutPositionBufferManagementType


sampleCutActive BOOL

cutPositionCorrectionActive

BOOL

rotaryKnifeAxisActive BOOL

sampleBuffersSampleBufferType

sSampleBufferType

axisTOssTOsType sTOsType

usersInterfacesUserInterfaceType

sUsersInterfaceType



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7.3.5 Block parameters

Input parameters

Name Data type Initial value Description

formatLength REAL 200.0 Cut material element length in mm.

execute BOOL FALSE A pending mode changeover is activated via this input.

Mode eOperation ModesRotary KnifeType

OMRK_ ERROR

With mode, the mode is pre-selected, which is activated with the next positive signal edge at the execute input. OMRK_ERROR: Pre-selection, ERROR mode OMRK_DISABLE : Pre-selection, DISABLE mode OMRK_AUTOMATIC: Pre-selection, STARTPOSITION mode OMRK_AUTOMATIC: Pre-selection, AUTOMATIC mode OMRK_MANUAL: Pre-selection, MANUAL mode OMRK_SINGLE_CUT: Pre-selection, SINGLE_CUT mode OMRK_SAMPLE_CUT: Pre-selection, SAMPLE_CUT mode

startSingleCut BOOL FALSE Start of a single cut if FB is in the SINGLE_CUT mode.

startSampleCut BOOL FALSE Start of a cut sequence to generate sample elements in the SAMPLE_CUT mode.

numberOfInstanz INT 0 Instance number of the actual call.

Output parameters


done BOOL FALSE Selected mode is activated.

Busy BOOL FALSE Mode changeover is active.

Error BOOL FALSE FALSE: No error TRUE: An error has occurred, refer to error identification

errorID WORD 0 Error identification, refer to error messages errorID <= 16#000_8000: warning errorID >= 16#0000_8000: error

state eOperation ModesRotary KnifeType

OMRK_ ERROR

Actual mode OMRK_ERROR: ERROR mode OMRK_DISABLE: DISABLE mode OMRK_AUTOMATIC: STARTPOSITION mode OMRK_AUTOMATIC: AUTOMATIC mode OMRK_MANUAL: MANUAL mode OMRK_SINGLE_CUT: SINGLE_CUT mode OMRK_SAMPLE_CUT: SAMPLE_CUT mode OMRK_NOTHING_SELECTED: No mode change OMRK_CHANGING: Mode change active

automaticActive BOOL FALSE AUTOMATIC mode is active

singleCutActive BOOL FALSE SINGLE_CUT mode is active

sampleCutActive BOOL FALSE SAMPLE_CUT is active

cutPositionCorrection Active

BOOL FALSE Correction motion for the actual cut position is active



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rotaryKnifeAxisActive BOOL FALSE The RotaryKnife axis is active

Input / output parameters


axisTOs sAxisTOs Type

Definition of all of the axes, external encoders, cams and measuring probes being used

usersInterface sUsers Interface

Interface for the user to enter physical constraints, cam profiles, manual cutting position corrections as well as the input of sequence options – such as a new start, fast start and format change in ongoing operation

sampleBuffer sSample BufferType

User area to save cut length sequences in the SAMPLE_CUT operating mode

camCalculation sCam Calculation Type

Internal data area to call the cam calculation

rotaryKnifeInfo sRotary KnifeInfo Type

Internal data area to display actual geometry values converted into the peripheral (circumferential) lengths in [mm], actual cut position as well as binary signals for the knife position.

measuringValue sMeasuring ValueType

Internal data area for print mark correction.

cutPositionBuffer Management

sCutPosition Buffer Management Type

Internal data area to enter the cut position as a precise position and cut position deviation for the print mark correction.

7.3.6 Functionality

Start identification • Identify whether a restart is present.

If yes, then: • Activate the monitoring of the parameterization of the technology objects as

well as auto-parameterization. • Control the state machines in the “manual” state via the state sequence

– ERROR (if activated, the monitoring and auto-parameterization are realized in the ERROR state)

– DISABLE – MANUAL – From any state.

If no, then • Transfer the selected operating state with a positive edge at the execute input • Reset all block outputs with a negative signal edge at the execute input



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Axis monitoring functions If the rotary knife axis or the auxiliary axis has a fault condition, then the FBRotaryKnife is forced into the fault state (ERROR state). However, the monitoring function is only active after the technology objects have been successfully completed.

Checking the input parameters and parameterization of the technology settings that are absolutely necessary

This program function is only active in the ERROR state if it was activated by the user using the restart bit. The following are monitored: • The existence of specified Tos. • The function (positioning axis, synchronous axis, cam …) • Special properties/features required for the template, such as: Modulo axis,

modulo value and cam type. • Deviations with respect to the template are displayed as fault messages. • Parameterization of the technology objects absolutely required is carried-out in

another program part.



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General Notes The FBRotaryKnife function block is the most important element of the application. The connected, rotating knife is parameterized and controlled from this block. The block parameterization (parameter assignment) and the mode changeover must be made in the user program in order to initiate that the FBRotaryKnife executes the required functions. FBRotaryKnife is parameterized as described in Chapter 7. When parameterizing, basic values of the application that generally do not changeare defined; for example, the name of the axis, knifeCircumference, numberOfKnifes, etc. It is only permissible to change these values at standstill – and then FBRotaryKnife must be re-initialized (restart). The individual modes of the FBRotaryKnife are described in Chapter 3.3 Operating states of the application SIMOTION Rotary Knife The procedure when changing the mode is described in more detail in the following sections.

Basic state of FBRotaryKnife After initialization, FBRotaryKnife is in the DISABLE mode. Initialization must be executed each time that the control boots (powers up) by setting the restart bit (gsRotaryKnife.sUsersInterface.boRestart) in the startup task. (This is automatically realized when using the startupRotaryKnife() program in the UNIT RK_Progs). As a consequence, the block is transitioned into its initial stated, important parameters are subject to a plausibility change – if possible adapted and if not possible, a parameterizing error is signaled to the user at the error/fault output.



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Mode changeover sequence The mode manager of the function block is shown in the following diagram. It includes the possible operating states that can be activated and clearly shows the possible transitions, that the user may initiate: Figure 7-1: Possible state transitions at FBRotaryKnife

1Disable

1Disable

2Startposi-

tion

2Startposi-

tion

4Manual

4Manual

0Error

0Error

3Automa-

tic

3Automa-

ticStandard state transition

Fault state transitionAutomatic state change chain

RESTART

5Single

Cut

5Single

Cut6Sample

Cut

6Sample

Cut

The actual block state is displayed at the state output. Figure 7-2: Inputs and outputs of the mode changeover

„FB RotaryK nife()“

Cu tL eng t hEx ecu te

Mode

D on e

B usyE rro r

E rro r ID

S t at e

Changing-over the mode In order to transition the block into a new state, the number of the required target state must be specified at the mode input. The changeover is activated by a rising edge on the execute input. The active changeover is signaled in the new block state with a high signal at the busy output. If all of the actions associated with the changeover have been successfully carried-out and the new state has been reached, this is flagged by a high signal at the done block output. The number of the new state can be read-off at the state output.



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Automatic mode change sequences The following automatic mode change sequences have been implemented: • From the ERROR mode into the STARTPOSITION mode.

ERROR DISABLE STARTPOSITION • From the ERROR mode into the AUTOMATIC mode.

ERROR DISABLE STARTPOSITION AUTOMATIC • From the ERROR mode into the MANUAL mode.

ERROR DISABLE MANUAL • From the AUTOMATIC mode into the MANUAL mode.

AUTOMATIC ERROR DISABLE MANUAL The following table describes the function sequences that are hidden behind the modes and the mode changes.

Table 7-2: Description of the sequences at the state change (state transition) in the FBRotaryKnife

Step Function Comment

ERROR (0) 0

Error

ERROR DISABLE

0Error

1Disable

0 All ErrorID memories are reset

Step Function Comment

1 _resetAxisError() is called for the specified axes _resetFollowingObject() is called for the specified axes _resetCamError() is called for cam1, cam 2 and cam3 If the axis, cams and synchronous objects have no error condition, then the DISABLE mode is activated.

DISABLE (1) 1

Disable

DISABLE DISABLE

1 Disable 1

Disable

0 The stop command is prepared

1 _move() with velocity = 0.0 is called for the auxiliary axis

2 _move() with velocity = 0.0 is called for the rotary knife axis

3 Calls the _disableAxis() for the specified axes If all of the axes are deactivated, then the DISABLE mode is activated.

DISABLE ERROR

1Disable

0Error

0 Preparation

1 Calls the _disableAxis() for the specified axes If the axes are deactivated, then the ERROR mode is activated

DISABLE STARTPOSITION

1Disable

2Startpo-

sition



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0 The enable command is prepared

1 _resetAxisError() is called for the specified axes If all axes are OK, then progress (advance) to step 2

2 _enableAxis() is called for the specified axes If the axes are enabled, then the direction of rotation to reach the starting position is determined without moving through the material and progressing (advancing) to step 3

3 _pos() is called with the direction of rotation determined in step 0 If the starting position is reached, then the STARTPOSITION mode is activated

DISABLE MANUAL

1Disable

4Manual

0 The enable command is prepared

1 _enableAxis() is called for the specified axes If the axes are enabled, then the MANUAL mode is activated

STARTPOSITION (2)

2Startpo-

sition STARTPOSITION ERROR

2Startpo-

sition

0Error

0 Preparation

1 _disableAxis() is called for the specified axes If the axes are disabled, then the ERROR mode is activated.

STARTPOSITION DISABLE

2Startpo-

sition

1Disable




3 _disableAxis() is called for the specified axes If the axes are disabled, then the DISABLE mode is activated.

STARTPOSITION AUTOMATIC

2Startpo-

sition

3Automa-

tic 0 The calculation of the start cam is initiated

1 Wait for the start cam

2 The calculation of the cyclic cam is initiated

3 The technology parameter is set userdefault.cammingsettings.synchronizingmode = IMMEDIATELY

4 The technology parameter is set userdefault.cammingsettings.syncpositionslave

5 The auxiliary axis is reset to 0 when _homing() is called. If OK, then the start mode is defined

6 The technology parameter is set userdefault.gearingsettings.synchronizingmode = IMMEDIATELY or ON_MASTER_POSITION

7 The technology parameter is set userdefault.gearingsettings.syncpositonmaster = r64DistanceToSensor

8 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the start cam.



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9 If OK, then _enableGearing() is called to synchronize the auxiliary axis to the material web

10 Wait for cyclic cam

11 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the cyclic cam. If the cyclic cam is in synchronism, then the AUTOMATIC mode is activated

STARTPOSITION MANUAL

2Startpo-

sition

4Manual

For an automatic mode change sequence – this mode change is achieved

when the MANUAL mode is reached via the DISABLE mode.

STARTPOSITION SINGLE_CUT

0 The calculation of the start cam is initiated


2 The calculation of the stop cam is initiated

3 The technology parameter userdefault.cammingsettings.synchronizingmode = IMMEDIATELY


5 The auxiliary axis is reset to 0 when _homing() is called. If OK, then the start mode is defined (synchronous or immediately)

6 Wait for the stop cam

STARTPOSITION SAMPLE_CUT



2 The technology parameter userdefault.cammingsettings.synchronizingmode = IMEEDIATELY


4 The auxiliary axis is reset to 0 when _homing() is called. If OK, then the start mode is defined (synchronous or immediately)

AUTOMATIC (3)

3Automa-

tic Re-calculation and activation of a cyclic cam in operation

If a cam may be changed-over and is requested, then the calculation of a new cyclic cam is initiated and step 0 is activated

0 Wait until the cyclic cam is calculated

1 _enableCaming() is called to synchronize a new cyclic cam at the end of the old cyclic cam.

Print mark correction _pos() is called with the print mark deviation determined by the user and

the merge mode SUPERIMPOSED_MOTION_MERGE

AUTOMATIC ERROR

3Automa-

tic

0Error

_disableAxis() is called for the auxiliary axis and the rotary knife axis.

If the axes are disabled, then the ERROR mode is activated.

2 Startpo -

sition 6

Sample Cut

2 Startpo -

sition 5

Single Cut



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AUTOMATIC STARTPOSITION

3Automa-

tic

2Startposi-

tion 0 The calculation of the stop cam is initiated

1 Wait for the stop cam

2 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the stop cam.

3 Wait for a rotary knife axis stop

4 De-couple the rotary knife axis from the synchronous operation group with the rotary knife axis by calling _disableCaming().

5 De-couple the auxiliary axis from the synchronous operation group with the material web by calling _disableGearing()

6 The direction of rotation to approach the start position without passing through the cut position is determined.

7 Call _pos() to position to the starting position

MANUAL (4)

4Manual

MANUAL ERROR

4Manual

0Error

_disableAxis()is called for the auxiliary axis and the rotary knife axis.


MANUAL DISABLE

4Manual

1Disable




3 _disableAxis()is called for the auxiliary axis and the rotary knife axis. If the axes are disabled, then the DISABLE mode is activated.

MANUAL STARTPOSITION

4Manual

2Startposi-

tion 0 Preparation





SINGLE_CUT (5)

Executing a single cut


1 Wait for a positive edge at input startSingleCut

2 If the quickstart bit = TRUE, then the setting of the technology parameter userdefault.gearingsettings.synchronizingmode = IMMEDIATELY and continue with step 4 Or If the quickstart bit = FALSE, then the setting of the technology parameters userdefault.gearingsettings.synchronizingmode = ON_MASTER_POSITION and continue with step 3

5Single

Cut



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3 The technology parameter is et to the geometry parameter userdefault.gearingsettings.syncpositonmaster = r64DistanceToSensor






9 The auxiliary axis is reset to 0 when _homing() is called.


11 Call _pos() to position to the starting position. Please continue with step 0.

SINGLE_CUT ERROR



SINGLE_CUT STARTPOSITION

If SINGLE_CUT inactive, then


If SINGLE_CUT active, then 0 Preparation






SAMPLE_CUT (6)

Executing a sequence of cuts to generate samples


1 Wait for a positive edge at input startSampleCut

2 If the quickstart bit = TRUE, then the setting of the technology parameter userdefault.gearingsettings.synchronizingmode = IMMEDIATELY and continue with step 4 Or If the quickstart bit = FALSE, then the setting of the technology parameters userdefault.gearingsettings.synchronizingmode = ON_MASTER_POSITION and continue with step 3

3 The technology parameter is set to userdefault.gearingsettings.syncpositonmaster” = r64DistanceToSensor

6Sample

Cut

5 Single Cut

2 Startposi -

tion

5Single

Cut 0

Error



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5 If a valid value is saved in the sample store, then continue with step 6. If not, then continue with step 10

6 A cyclic cam is calculated with the length currently saved in the sample store (formatLength).

7 Wait until the cyclic cam is calculated.

8 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the cyclic cam at the end of the cam cycle.

9 If the cut position is reached and an additional valid value is saved in the sample store, then continue with step 6. If the cut position is reached, and there is no additional valid value saved in the sample store, then continue with step 10.

10 The calculation of the stop cam is initiated

11 Wait for stop cam.





16 The auxiliary axis is reset to 0 when _homing() is called.


18 Call _pos() to position to the starting position.


20 Wait for stop cam. If OK, please continue with step 0.

SAMPLE_CUT ERROR



SAMPLE_CUT STARTPOSITION

If Sample Cut inactive, then


If SAMPLE_CUT active, then 0 Preparation






6Sample

Cut 0

Error

6 Sample Cut

2 Startposi -

tion



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Using the restart bit (sUsersInterface. boRestart) The restart bit must be set at each new start of the SIMOTION or when changing the parameterization. This is the reason that an initialization routine is run in the FBRotaryKnife and a parameter check is made and the block is brought into a defined state.

Note

We recommend that the program startupRotaryKnife of the unit RK_Progs is used in the startup task in order to initialize the block FBRotaryKnife.

The restart bit should also be set there in order to bring the block into a defined state!

Note At restart, the block checks essential technology parameters as well as the existence of saved technology objects.

After the block has been successfully initialized, the restart bit is automatically reset.

Using the quick start bit (sUsersInterface. boQuickstart)

Task The standard, starting situation of the FBRotaryKnife is to synchronize at the start of the material. However, if the cross-cutter is started with the material already threaded/entered and must be synchronized, then the program must run-through another synchronizing mechanism. The quick start bit is used to select which synchronizing mechanism the user wishes to apply.

Mode of Operation Table 7-3: Mode of operation of the quick start bit

boQuickstart Description = 1 The rotating knife immediately synchronizes with mode = 3 and

execute = true, independent of the actual material position. = 0 The rotating knife synchronizes with mode = 3 and execute = true only

if the material position has reached the position entered under r64DistancetoSensor.

Synchronizing Mechanism

Task Description The task of the example is to synchronize the rotating knife to the start of the material that should run so that the first cut is precisely made after the specified cut length after the start of the material.



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Procedure Tabelle 7-4: Synchronizing the rotary knife

Phase Graphic representation What actually happens

Initial situation: • No material in the cutting range • The knife is at the zero position • The user has switched FBRotaryKnife

into the DISABLE mode

1

Sen

sor

0

User task: • The mode changes to

STARTPOSITION

Initial situation: • No material in the cutting range • The knife is located at its starting

position • The START POSITION mode is active

2

Sens

or

0

Startposition

User task: • Wait for material



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Initial situation: • The material has reached the sensor

and the measuring probe function has received the first measured value of the material web position

• The knife is at its start position • The START POSITION mode is active

3

Sen

sor

Distance to Sensor

Startposition

0 Referenzpunkt Warenbahn

User task: • In order to assign the position of the

rotating knife to the material web position, the user must set the material path position back by the measured value, or: add the measured value to r64DistanceToSensor and save as new value.

• The mode changes to AUTOMATIC

Initial situation: • The material has reached the rotary

knife • When this synchronous position is

reached, the starting cam was started

4

Sen

sor

Distance to Sensor

Startposition

0 Referenzpunkt WarenbahnSynchronposition

User task: • None

Initial situation: • The first cut length has passed below

the rotating knife • The rotating knife is at the zero position • When the position is reached, a

change has been made to the cyclic cam.

• The AUTOMATIC mode is active 5

Sen

sor

CutLength

Result: The rotary knife has started in synchronism with the start of the material and cuts the material to the required length



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Error handling If faults occur in the block itself or in technology objects and technology functions involved while FBRotaryKnife is operational, then these are signaled using the block outputs error and errorID.

Figure 7-3: Block outputs for fault messages

FBRotaryKnife()

CutLengthExecuteMode

DoneBusyErrorErrorIDState

The error bit signals an error while an error code is output at output errorID; this can be analyzed using the error analysis function.

Note The error output is only set if the execute input is set. The errorID and state 0 (ERROR) are still output even after execute has been reset!

7.3.7 Error messages

Table 7-5: List of the possible error priorities

ErrorID Priority Description 16#xxxx_0xxxx Lowest priority Warning

16#xxxx_4xxx Low priority Warning, execution possible with error

16#xxxx_8xxx High priority Error, no execution possible

16#xxxx_Cxxx Highest priority Critical error

Warnings Warnings are indicated by the status of the outputs error and errorID: error = FALSE and errorID <> 16#0000_0000. Table 7-6: Warnings

ErrorID Description 16#0000_0000 No warning

16#050B_4000 Parameter r64KnifeCircumference not accepted (invalid value) (AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)

16#050B_4001 Parameter i16NumberOfKnives not accepted (invalid value) (AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)

16#050B_4002 Parameter r64StartSyncWinkel not accepted (invalid value) (AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)

16#050B_4003 Parameter r64EndSyncWinkel not accepted (invalid value) (AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)

ErrorID Description 16#050B_4005 Inpug formatLength not accepted (invalid value)

(Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)



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16#050B_4006 Parameter r64InflectionPoint replaced by a substitute value (invalid value) (substitute value = 50 %)

16#050B_4007 Parameter r64StartAngle replaced by a substitute value (invalid value) (substitute value = 90°)

16#050B_4008 Parameter r64StopAngle replaced by a substitute value (invalid value) (substitute value = 270°)

16#050B_4009 Parameter r64OverspeedStartCut not accepted (invalid value) (Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)

16#050B_400A Parameter r64OverspeedZero not accepted (invalid value) (Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)

16#050B_400B Parameter r64OverspeedEndCut not accepted (invalid value) (Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)

16#050B_400C Parameter r64JerkPhase1 replaced by a substitute value (invalid value) (substitute value = 0%)

16#050B_400D Parameter r64JerkPhase2 replaced by a substitute value (invalid value) (substitute value = 0%)

16#050C_4002 RotaryKnife axis changed over to modulo axis

16#050C_4003 Modulo length of the RotaryKnife Axis is adapted to (Fsymech = r64KnifeCircumference / i16NumberOfKnives)

16#050C_4006 Auxiliary axis changed over to modulo axis

16#050C_4007 Modulo length of the auxiliary axis adapted to (Fsymech = r64KnifeCircumference / i16NumberOfKnives )

Errors Error messages are indicated by the status of the outputs error and errorID: error = TRUE and errorID <> 16#0000_0000. If the error was caused by a TO-specific command called from the RotaryKnife FB, then its return parameter (RetDINT or FR) is kept in the internal data area of the FB for further evaluation by the user. Table 7-7 Errors

Error ID Description

16#050A_8001 Error at the rotary knife axis

16#050A_8002 Error at the auxiliary axis

16#050A_8003 Error at the rotary knife axis and at the auxiliary axis

16#050A_8004 Error at the rotary knife axis synchronous operation

16#050B_8000 Invalid parameter: r64knifeCircumference <= 0.0

16#050B_8001 Invalid parameter i16numberOfKnives < 1 or i16numberOfKnives > 6

16#050B_8002 Invalid parameter r64startSyncAngle < START_SYNC_ANGLE_MIN / i16numberOfKnives or r64startSyncAngle > 360.0° / i16numberOfKnives

16#050B_8003 Invalid parameter r64endSyncAngle < 0.0° or r64endSyncAngle > (START_SYNC_ANGLE_MIN – FORMAT_ANGLE_MIN) / i16numberOfKnives

16#050B_8004 Invalid parameter: i16numberOfKnifes * Synchrounous angle >= 360° or Synchrounous angle < 0°

16#050B_8005 Invalid parameter:



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Error ID Description formatLength <= Synchronous length * FACTOR_SYNCLENGTH_FOR_MIN_CUTLENGTH

16#050B_8006 Invalid parameter r64inflectionPoint < MIN_VAL_INFLECTION_POINT or r64inflectionPoint > 100.0 – MIN_VAL_INFLECTION_POINT

16#050B_8007 Invalid parameter: r64startAngle <= r64endSyncAngle or r64startAngle >= r64startSyncAngle – ACC_DCC_ANGLE_MIN

16#050B_8008 Invalid parameter: r64stopAngle <= endSyncAngle + ACC_DCC_ANGLE_MIN or r64stopAngle >= r64startSyncAngle

16#050B_8009 Invalid parameter: r64knifeOverspeedStartCut < - MAXIMUM_OVERSPEED_KNIFE or r64knifeOverspeedStartCut > MAXIMUM_OVERSPEED_KNIFE

16#050B_800A Invalid parameter r64knifeOverspeedZero < - MAXIMUM_OVERSPEED_KNIFE or r64knifeOverspeedZero > MAXIMUM_OVERSPEED_KNIFE

16#050B_800B Invalid parameter r64knifeOverspeedEndCut < - MAXIMUM_OVERSPEED_KNIFE or r64knifeOverspeedEndCut > MAXIMUM_OVERSPEED_KNIFE

16#050B_800C Invalid parameter r64jerkPhase1 < 0.0 or r64jerkPhase1 > 100.0

16#050B_800D Invalid parameter r64jerkPhase2 < 0.0 or r64jerkPhase2 > 100.0

16#050C_8001 The TO axis Rotary Knife Axis is not set-up

16#050C_8004 The TO axis Auxiliary Axis is not set-up

16#050C_8005 The TO axis Auxiliary Axis is not set-up as a virtual axis

16#050C_8008 There is no TO set-up as leading value

16#050C_8009 There is no TO cam Cam1 set-up

16#050C_800A There is no TO cam Cam2 set-up

16#050C_800B There is no TO cam Cam3 set-up

16#050C_800C There is no TO measuring input set-up

16#050C_800D The TO measuring input is not connected to leading value 16#050F_8001 Invalid mode selection from the ERROR mode 16#050F_8002 Invalid mode selection from the DISABLE mode 16#050F_8003 Invalid mode selection from the STARTPOSITION mode 16#050F_8004 Invalid mode selection from the AUTOMATIC mode 16#050F_8005 Invalid mode selection from the MANUAL mode 16#050F_8006 Invalid mode selection from the SINGLE_CUT mode 16#050F_8007 Invalid mode selection from the SAMPLE_CUT mode

16#050F_8008 Wrong mode

16#0511_8001 DISABLE to DISABLE



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Error ID Description Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA

16#0511_8002 DISABLE to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA

16#0511_8003 DISABLE to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ), Details in i32RetDINTStopRKA

16#0511_8004 DISABLE to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA

16#0512_8001 DISABLE to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA

16#0512_8002 DISABLE to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA

16#0521_8001 STARTPOSITION to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA

16#0521_8002 STARTPOSITION to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA

16#0521_8003 STARTPOSITION to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA

16#0521_8004 STARTPOSITION to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA

16#0522_8001 STARTPOSITION to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA

16#0522_8002 STARTPOSITION to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA

16#0523_8001 STARTPOSITION to AUTOMATIC Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA

16#0523_8002 STARTPOSITION to AUTOMATIC Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA

16#0523_8003 STARTPOSITION to AUTOMATIC Error when activating camming of the Rotary Knife Axis [ start cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA

16#0523_8004 STARTPOSITION to AUTOMATIC Error when activating gearing of the Auxiliary Axis ( _enablegearing ) Details in i32RetDINTEnableGearingAA

16#0523_8005 STARTPOSITION to AUTOMATIC Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming )



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Error ID Description Details in i32RetDINTEnableCammingRKA

16#0525_8001 STARTPOSITION to SINGLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA

16#0525_8002 STARTPOSITION to SINGLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA

16#0526_8001 STARTPOSITION to SAMPLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA

16#0526_8002 STARTPOSITION to SAMPLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA

16#0503_8001 Change FormatLength Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA

16#0503_8002 Change FormatLength Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming ) Details in i32FREnableCammingRKA

16#0532_8002 AUTOMATIC to STARTPOSITION Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32FREnableCammingRKA

16#0532_8003 AUTOMATIC to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA

16#0532_8004 AUTOMATIC to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA

16#0532_8005 AUTOMATIC to STARTPOSITION Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32RetDINTDisableGearingAA

16#0532_8006 AUTOMATIC to STARTPOSITION Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32FRDisableGearingAA

16#0532_8007 AUTOMATIC to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA

16#0532_8008 AUTOMATIC to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA

16#0541_8001 MANUAL to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA

16#0541_8002 MANUAL to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 )



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Error ID Description Details in i32FRStopAA

16#0541_8003 MANUAL to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA

16#0541_8004 MANUAL to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA

16#0542_8001 MANUAL to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA

16#0542_8002 MANUAL to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA

16#0542_8003 MANUAL to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA

16#0542_8004 MANUAL to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA

16#0542_8005 MANUAL to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA

16#0542_8006 MANUAL to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA

16#0505_8001 SINGLE_CUT Error when activating camming of the Rotary Knife Axis [ start cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA

16#0505_8002 SINGLE_CUT Error when activating gearing of the Auxiliary Axis ( _enablegearing ) Details in i32RetDINTEnableGearingAA

16#0505_8003 SINGLE_CUT Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA

16#0505_8004 SINGLE_CUT Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32FREnableCammingRKA

16#0505_8005 SINGLE_CUT Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32RetDINTDisableGearingAA

16#0505_8006 SINGLE_CUT Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32FRDisableGearingAA

16#0505_8007 SINGLE_CUT Error when de-activating camming of the Rotary Knife Axis ( _disablecamming )



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Error ID Description Details in i32RetDINTDisableCammingRKA

16#0505_8008 SINGLE_CUT Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA

16#0505_8009 SINGLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA

16#0505_800A SINGLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA

16#0505_800B SINGLE_CUT Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINT_pos_RKA

16#0505_800C SINGLE_CUT Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA

16#0552_8001 SINGLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA

16#0552_8002 SINGLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA

16#0552_8003 SINGLE_CUT to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA

16#0552_8004 SINGLE_CUT to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA

16#0552_8005 SINGLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA

16#0552_8006 SINGLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA

16#0552_8007 SINGLE_CUT to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA

16#0552_8008 SINGLE_CUT to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA

16#0552_8009 SINGLE_CUT to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA

16#0552_800A SINGLE_CUT to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA



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Error ID Description

16#0506_8001 SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ start cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA

16#0506_8002 SAMPLE_CUT Error when activating gearing of the Auxiliary Axis ( _enablegearing ) Details in i32RetDINTEnableGearingAA

16#0506_8003 SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA

16#0506_8004 SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming ) Details in i32FREnableCammingRKA

16#0506_8005 SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA

16#0506_8006 SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32FREnableCammingRKA

16#0506_8007 SAMPLE_CUT Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA

16#0506_8008 SAMPLE_CUT Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA

16#0506_8009 SAMPLE_CUT Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32RetDINTDisableGearingAA

16#0506_800A SAMPLE_CUT Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32FRDisableGearingAA

16#0506_800B SAMPLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA

16#0506_800C SAMPLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA

16#0506_800D SAMPLE_CUT Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA

16#0506_800E SAMPLE_CUT Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA

16#0562_8001 SAMPLE_CUT to STARTPOSITION



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Error ID Description Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA

16#0562_8002 SAMPLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA

16#0562_8003 SAMPLE_CUT to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA

16#0562_8004 SAMPLE_CUT to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA

16#0562_8005 SAMPLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA

16#0562_8006 SAMPLE_CUT to STARTPOSITION Error when de-activating camming of the r Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA

16#0562_8007 SAMPLE_CUT to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA

16#0562_8008 SAMPLE_CUT to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA

16#0562_8009 SAMPLE_CUT to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA

16#0562_800A SAMPLE_CUT to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA

16#05CC_8100 Cam calculation Error when deleting the actual cam ( _resetCam )

16#05CC_8200 Cam calculation Error when adding new segments ( _addSegmentToCam )

16#05CC_8300 Cam calculation Error when interpolating the actual cam ( _interpolateCam )

16#05DD_8001 Print mark correction Error when positioning the rotary knife axis ( _pos ) Details in i32RetDINTPosRKA

16#05DD_8002 AUTOMATIC to STARTPOSITION Error when activating camming of the rotary knife axis [ stop cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA



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7.4 Cam Calculation for rotating shears FBRKCamCalc

Block name FBRKCamCalculation

Task This function block generates cams for rotating shears based on the specified geometrical parameters and velocity profiles.

Integration in run-time system The function block can be linked into a cycle or sequential task.

Graphic representation of the block

FBRKCamCalcexecuteBOOL

formatLengthLREAL

nextCamcamType

typeOfCameTypeOfCamType

knifeCircumferenceLREAL

startSyncAngleLREAL

endSyncAngleLREAL

startAngleLREAL

stopAngleLREAL

inflectionPointLREAL

numberOfKnivesINT

knifeOverspeedStartCutLREAL

knifeOverspeedZeroLREAL

knifeOverspeedEndCutLREAL

camProfilePhase1eCamProfileType

jerkPhase1LREAL

camProfilePhase2eCamProfileType

jerkPhase2LREAL

done BOOL

busy BOOL

error BOOL

errorId DWORD



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Block parameters

Input parameters


execute BOOL FALSE Start of calculation

formatLength LREAL 200 [mm] length of format

nextCam camType TO#NIL Reference to the technology object of the cam If no cam is specified, then only a parameter check

typeOfCam eTypeOfCam Type

START_ CAM

START_CAM Cam to move the cross-cutter from the starting position into cyclic operation. CYCLIC_CAM Cam for cyclic operation of a cross-cutter. STOP_CAM Cam to stop the cross-cutter from cyclic operation.

knifeCircumference LREAL 200.0 [mm] circumference of the knife

startSyncAngle LREAL 345.0

[°] Starting angle of the synchronous range (cutting range), i.e. the angle at which the knife enters the material, the knife center point is defined at 0° (The permissible value range lies between START_SYNC_ANGLE_MIN and 360.0°). StartSyncAngle and endSyncAngle together define the synchronous range.

endSyncAngle LREAL 15.0

[°] End angle of the synchronous range, i.e. the angle at which the knife exits the cutting range (The permissible value range lies between 0.0° and START_SYNC_ANGLE_MIN – FORMAT_ANGLE_MIN). StartSyncAngle and endSyncAngle together define the synchronous range.

startAngle LREAL 90.0

[°] Knife start position (The permissible value range lies between endSyncAngle and startSyncAngle – ACC_DCC_ANGLE_MIN) (Start position of the start cam)

stopAngle LREAL 270.0

[°] Knife stop position. (The permissible value range lies between endSyncAngle + ACC_DCC_ANGLE_MIN and startSyncAngle) (End position of the stop cam)

inflectionPoint LREAL 50.0

[%] Center point of the cyclic cam. inflectionPoint < 50.0 % [min. MIN_VAL_INFLECTION_POINT (10%)]: Offset of the center point in the direction endSyncAngle, i.e. the absolute value of the acceleration in the first motion segment after the cut is higher. inflectionPoint > 50.0 % [max. 100% - MIN_VAL_INFLECTION_POINT]: Offset of the centerpoint in the direction startSyncAngle, i.e. the absolute value of the acceleration in the second motion segment after the cut is higher.

numberOfKnives INT 1 Number of knifes (max. 6)



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knifeOverspeedStartCut LREAL 0.0

[%] Knife overspeed at the transition point to the synchronous range (startSyncAngle) [-MAXIMUM_OVERSPEED_KNIFE (%) to MAXIMUM_OVERSPEED_KNIFE (%)] referred to the synchronous velocity of the knife.

knifeOverspeedZero LREAL 0.0

[%] Knife overspeed at the center position of the synchronous range (0°) [-MAXIMUM_OVERSPEED_KNIFE (%) to MAXIMUM_OVERSPEED_KNIFE (%)] referred to the synchronous velocity of the knife.

knifeOverspeedEnd Cut LREAL 0.0

[%] Knife overspeed at the end point of the synchronous range (endSyncAngle) [-MAXIMUM_OVERSPEED_KNIFE (%) to MAXIMUM_OVERSPEED_KNIFE (%)] referred to the synchronous velocity of the knife.

camProfilePhase1 eCamProfile Type

POLYNOM_5

Motion profile, phase 1 (endSyncAngle – inflectionPoint) LINEAR Curve profile with constant acceleration JERK Curve profile with constant acceleration and jerk limiting POLY_5 Motion profile as fifth order polynomial.

jerkPhase1 LREAL 0.0

[%] Jerk limiting component in phase 1 (only for camProfilePhase1 = JERK). The valid value range is 1.0 up to 100.0. For 100%, there is no constant acceleration for the phase. The absolute jerk depends on the machine velocity

camProfilePhase2 eCamProfile Type

POLYNOM_5

Motion profile, phase 2 (inflectionPoint – startSyncAngle) LINEAR Curve profile with constant acceleration JERK Curve profile with constant acceleration and jerk limiting POLY_5 Motion profile as fifth order polynomial.

jerkPhase2 LREAL 0.0

[%] Jerk limiting component in phase 2 (only for camProfilePhase2 = JERK). The valid value range lies between 1.0 and 100.0. For 100%, there is no constant acceleration for the phase. The absolute jerk depends on the machine velocity.

Output parameters


done BOOL FALSE TRUE: The cam generation has been completed

busy BOOL FALSE FALSE: No cam calculation TRUE: The cam generation is active

error BOOL FALSE FALSE: No error TRUE: An error has occurred, refer to error identification

errorId DWORD 16#0000_0000 Error identification, refer to error messages errorID <= 16#000_8000: warning errorID >= 16#0000_8000: error



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Functionality The function block generates the cam for the specified cross-cutter geometry for the parameterized cut length. The reference to the cam object is defined using input nextCam. The block is started with a rising edge at input execute; the input parameters are then checked for plausibility. If the input parameters are not valid, block processing is interrupted and a corresponding error message (error and errorID) is output. Once the cam generation has been completed, this is signaled with a rising edge at the done output.



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When initiating the cam calculation, the following actions are executed in the individual steps: Figure 7-4: Sequence of cam calculation

0error

1wait

2gen.

calcula-tions

3startcam

4cycliccam

5stopcam

6deletecam

7add

segmentsto cam

8interpolate

cam

Calculations

Gen

erat

ion

of c

am

General properties and characteristic quantities of a rotating shears

System with one knife System with two knives

endSyncAngle

star

tSyn

cAng

leendSyncAngle

star

tSyn

cAng

le



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Table 7-8: Overview of the parameters and characteristic quantities for the cam calculation

Parameter Description

Synchronous range The synchronous range is defined by the synchronous angle referred to the knife circumference or the knife geometry. The synchronous angle is obtained from the parameters startSyncAngle und stopSyncAngle. The synchronous angle is the range in which the knife moves in synchronism with the material web velocity. The velocity in the synchronous range can be adapted for special applications or for special cutting geometries using parameter knifeOverspeedStartCut, knifeOverspeedZero, knifeOverspeedEndCut. The point, at which the knife is located perpendicular to the material is defined as the center point of the synchronous range and is at 0°.

Format range The format range is the range of the rotating shears, where the knife is not located in the synchronous range, i.e. is not in the cutting range. As the velocity in the synchronous range is defined by the material itself and the overspeed, equalization motion (format changes, print mark correction, etc.) can only be executed in the format range. For multi-knife systems, the format range is obtained according to the following formula: Format range = knifeCircumference / numberOfKnifes – synchronous range

Phase1 / Phase2 Phase 1 describes the range of the rotating shears between endSyncAngle and inflectionPoint. Depending on the characteristic quantities and format length, in this phase, the rotating shears must either be accelerated or decelerated: cutLength < synchronous range + format range: Acceleration cutLength > synchronous range + format range: Deceleration Phase 2 defines the range of the rotating shears between inflectionPoint and startSyncAngle. The acceleration and deceleration behavior is opposite to that of phase 1: cutLength < synchronous range + format range: Deceleration cutLength > synchronous range + format range: Acceleration

startSyncAngle / endSyncAngle

Parameter startSyncAngle defines the start angle of the synchronous angle, i.e. the start point of the cutting range referred to the geometry. The point at which the knife is perpendicular to the material is defined as the zero point (0°). Parameter endSyncAngle defines the end point of the synchronous angle and therefore the synchronous range. The angle between startSyncAngle and endSyncAnlge is the synchronous angle. If the two parameters are not identical, then the knife center position is automatically shifted into the format range, so that at inflectionPoint = 50%, the knife is always located at the geometrical center.

knifeOverspeedStartCut, knifeOverspeed Zero, knifeOverspeedEndCut

In the standard configuration, a rotating shears operates with a linear cutting curve, i.e. a velocity characteristic that for the circumferential (peripheral) velocity of the shears corresponds to the material velocity. However, the knife and material are only perpendicular to one another at the cutting center point. This means that at the remaining points of the synchronous range, there are velocity differences between the tool and material, the magnitude of which depends on the material thickness respectively shears diameter – or shears geometry. The velocity of the knife in the synchronous range can be specifically adapted using the mentioned parameters.


knifeOverspeedStartCut Defines the velocity offset of the knife when entering the synchronous range, corresponding to parameter startSyncAngle.

knifeOverspeedZero Defines the velocity offset at the zero position.

knifeOverspeedEndCut Defines the velocity offset at the end point of the synchronous range, corresponding to parameter endSyncAngle.

A fifth order polynomial is interpolated between the individual points. The parameter values are correspondingly interpreted as offset to the synchronous velocity.



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Cutting profile Diagram

Linear cutting curve: knifeOverspeedStartCut = 0.0% knifeOverspeedZero = 0.0% knifeOverspeedEndCut = 0.0%

Linear cutting curve with 5% overspeed: knifeOverspeedStartCut = 5.0% knifeOverspeedZero = 5.0% knifeOverspeedEndCut = 5.0%

Polynomial cutting curve: knifeOverspeedStartCut = 5.0% knifeOverspeedZero = 0.0% knifeOverspeedEndCut = 5.0%

inflectionPoint

The changeover point between phase 1 and phase 2 is defined using parameter inflectionPoint. The value is entered as a percentage and is referred to the format range, i.e. a value of 50% represents the center point of the format range.

inflectionPoint = 30 % inflectionPoint = 50 % inflectionPoint = 70 %

startAngle / stopAngle

For rotating shears, the start position, the center position and the stop position are generally identical. In order to achieve a certain machine behavior, in spite of this, it may be necessary



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Parameter Description (e.g. for single cut programs to reduce the load on the motor) to separate these positions. As already described, the center position is defined using parameter inflectionPoint, the start position by startAngle and the stop position by stopAngle. If the start position is shifted from the center position using the parameter startAngle, the acceleration distance of the rotating shears increases, which reduces the motor load and can therefore result in higher operating velocities. The maximum value for startAngle is theoretically endSyncAngle, otherwise the knife would move in the cutting range. The same consideration also applies to parameter stopAngle, which is limited by the value of parameter startSyncAngle.

jerkPhase1 / jerkPhase2

These parameters define the percentage component of the phase that is used for jerk limiting. The absolute jerk is obtained from the machine velocity based on the specified motion profile. Values between 1.0 % and 100 % are permitted for this parameter; the value 0.0 stands for the profile with constant acceleration.

jerkPhase1 / jerkPhase2 = 10%



camProfilePhase1 / camProfilePhase2

These parameters define the motion profile in phase1 or in phase 2. The parameters do not have to be assigned the same value.

LINEAR This selection defines a motion profile with constant acceleration.

Phase 1 Phase 2

endSyncAngle(Synchronous range)

startSyncAngle(Synchronous range)

Format range

inflectionPoint

knifeCircumference

Format length JERK This selection defines a profile with constant acceleration and jerk limiting. Jerk limiting is specified using parameter jerkPhase1 / jerkPhase. The parameters are only evaluated in this profile.



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POLY_5 This selection defines a fifth order polynomial as basis for the motion profile.

Phase 1 Phase 2

endSyncAngle(Synchronous range)

startSyncAngle(Synchronous range)

Format range

inflectionPoint

knifeCircumference

Format length typeOfCam

This parameter specifies the cam type that should be calculated.

Type Description

START_CAM The start cam defines the starting behavior of the rotating shears from the start point (startAngle) up to the cutting point (0°). The profile selection is also taken into account in the calculation of the starting cam.

CYCLIC_CAM Motion profile of the shears in cyclic operation.

STOP_CAM The stop cam defines the transition from cyclic operation to standstill of the rotating knife, i.e. the distance from the cutting point to the stop position (corresponding to stopAngle).



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Error messages

ErrorID Priority Description 16#xxxx_0xxxx Lowest priority Warning

16#xxxx_4xxx Low priority Warning, execution possible with error

16#xxxx_8xxx High priority Error, no execution possible

16#xxxx_Cxxx Highest priority Critical error

Warnings Warnings are indicated by the status of the outputs error and errorID: error = FALSE and errorID <> 16#0000_0000. Table 7-9: Warnings

ErrorID Description 16#0000_0000 No warning

Errors Error messages are indicated by the status of the outputs error and errorID: error = TRUE and errorID <> 16#0000_0000. Table 7-10 Errors

ErrorID Description

16#05CC_8000 Invalid parameter: knifeCircumference <= 0.0

16#05CC_8001 Invalid parameter: numberOfKnives < 1 or numberOfKnives > 6

16#05CC_8002

Invalid parameter: startSyncAngle < START_SYNC_ANGLE_MIN / numberOfKnives or startSyncAngle > 360.0° / numberOfKnives

16#05CC_8003

Invalid parameter: endSyncAngle < 0.0° or endSyncAngle > (START_SYNC_ANGLE_MIN – FORMAT_ANGLE_MIN) / numberOfKnives

16#05CC_8004

Invalid parameter: numberOfKnifes * Synchrounous angle >= 360° or Synchrounous angle < 0°

16#05CC_8005 Invalid parameter: formatLength <= Synchronous length * FACTOR_SYNCLENGTH_FOR_MIN_CUTLENGTH

16#05CC_8006

Invalid parameter: inflectionPoint < MIN_VAL_INFLECTION_POINT or inflectionPoint > 100.0 – MIN_VAL_INFLECTION_POINT

16#05CC_8007

Invalid parameter: startAngle <= endSyncAngle or startAngle >= startSyncAngle – ACC_DCC_ANGLE_MIN

16#05CC_8008

Invalid parameter: stopAngle <= endSyncAngle + ACC_DCC_ANGLE_MIN or stopAngle >= startSyncAngle



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ErrorID Description

16#05CC_8009

Invalid parameter: knifeOverspeedStartCut < - MAXIMUM_OVERSPEED_KNIFE or knifeOverspeedStartCut > MAXIMUM_OVERSPEED_KNIFE

16#05CC_800A

Invalid parameter: knifeOverspeedZero < - MAXIMUM_OVERSPEED_KNIFE or knifeOverspeedZero > MAXIMUM_OVERSPEED_KNIFE

16#05CC_800B

Invalid parameter: knifeOverspeedEndCut < - MAXIMUM_OVERSPEED_KNIFE or knifeOverspeedEndCut > MAXIMUM_OVERSPEED_KNIFE

16#05CC_800C

Invalid parameter: jerkPhase1 < 0.0 or jerkPhase1 > 100.0

16#05CC_800D

Invalid parameter: jerkPhase2 < 0.0 or jerkPhase2 > 100.0

16#05CC_800E Invalid parameter: nextCam = TO#NIL This error is only signaled if the parameter check was OK!!!!

16#05CC_8100 Error when deleting the actual cam ( _resetCam )

16#05CC_8200 Error when adding new segments to actual cam ( _addSegmentToCam )

16#05CC_8300 Error when interpolating the actual cam ( _interpolateCam )



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7.5 Functions in the IPO task FBRKIpo

Measuring the actual position using a measuring probe. Displays in which range (synchronous or format) the knife is presently moving. Displays whether the knife is currently moving in the cutting range.

Block name FBRKIpo

Task If the print mark correction has been enabled, using a measuring probe, the function block determines the specified cutting position using print marks, calculates the position deviation from the difference between two consecutive cutting positions and the specified cutting length – and saves the position measured value and position deviation in the measured value memory. The block determines the first cutting position using the first measuring cycle. Generally, the function block determines the range in which the knife is presently located by comparing the position – and whether the knife is currently in the cutting range. It indicates the result using status flags.

Integration in run-time system The user must call the block in the IPO synchronous task.


FBRKIpomodeEnabledeOperationModes

RotaryKnifeTypemodeSelectedeOperationModes

RotaryKnifeType

formatLengthBufferManagementsFormatLengthBufferManagementType

sFormatLengthBufferManagementType

rotaryKnifeInfosRotaryKnifeInfoType

sRotaryKnifeInfoType



measuringValuesMeasuringValueType

sMeasuringValueType

axisTOssTOsType sTOsType

usersInterfacesUsersInterfaceType

sUsersInterfaceType



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Block parameters

Input parameter


modeEnabled eOperationModesRotaryKnifeType

OMRK_ NOTHING_ SELECTED

Aktive state of FBRotaryKnife OMRK_ERROR: State ERROR OMRK_DISABLE: State DISABLE OMRK_AUTOMATIC: State STARTPOSITION OMRK_AUTOMATIC: State AUTOMATIC OMRK_MANUAL: State MANUAL OMRK_SINGLE_CUT: State SINGLE_CUT OMRK_SAMPLE_CUT: State SAMPLE_CUT OMRK_NOTHING_SELECTED: No change of state selected OMRK_CHANGING: Change of state active

modeSelected eOperationModesRotaryKnifeType

OMRK_ NOTHING_ SELECTED

Selected state of FBRotaryKnife OMRK_ERROR: Selected state ERROR OMRK_DISABLE: Selected state DISABLE OMRK_AUTOMATIC: Selected state STARTPOSITION OMRK_AUTOMATIC: Selected state AUTOMATIC OMRK_MANUAL: Selected state MANUAL OMRK_SINGLE_CUT: Selected state SINGLE_CUT OMRK_SAMPLE_CUT: Selected state SAMPLE_CUT



axisTOs sTOsType Structure of axes and TO management

usersInterface sUsersInterface Type

Structure with all of the machine data that the user can adapt – such as startSyncPos and endSyncPos (refer to chapter, data types).

rotaryKnifeInfo sRotaryKnifeInfoType Structure with all of the information signals of the

RotaryKnife (refer to chapter, data types).



Structure of the CutPositionBuffer with all of the required control signals and pointers (refer to chapter, data types).

formatlengthBuffer Management

sFormatlength Buffer Management Type

Structure of the FormatlengthBuffer with all of the required control signals and pointers (refer to chapter, data types).

measuringValue sMeasuringValue Type

Structure of the measured value detection



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Functionality The block fulfills the following functions depending on the operating phase of the system with the print mark detection switched-in: Table 7-11: Sequence, print mark detection

Phase Description

Phase 1 Activates the measuring probe to measure the “FirstCutPosition”

Phase 2 The first measured position is saved as startPosAtSensor and the setpoint position is calculated for the next cutting operation from the measured position plus the format length.

Phase 3 The measuring probe is activated to measure the next cutting position with activated activation range.

Phase 4 The next measured position is saved in the measured value memory together with its deviation from the setpoint position.

Phase 5 If a measured value is not found in the actual active range (fault 40003), then the reference position – with its activation range – is shifted one format length further.

The block compares the actual knife position with startSyncPos and endSyncPos, which are defined in the user interfaces and depending on the position sets the following bits in the RotaryKnifeInfo structure: In the synchronous range knifeInSynchronousSector = TRUE knifeInFormatSector = FALSE In the format range knifeInSynchronousSector = FALSE knifeInFormatSector = TRUE The block compares the actual knife position with 0.0 and endSyncPos and sets In the cutting range rotaryKnifeInfo.cut = TRUE cutPositionBufferManagement.bufferOutTrigger = TRUE Outside the cutting range rotaryKnifeInfo.cut = FALSE cutPositionBufferManagement.bufferOutTrigger = FALSE

Error messages No errors are generated.



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7.6 Blocks to manage the format length memory

Users must use the blocks described in this chapter if they must change the cut length by precisely one cut. The user program section of the demonstration application is used here as application example. If the application has a dynamic cut length detection, to enter the cut lengths at the standard Rotary Knife application, then the following blocks should be used.



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7.6.1 Resetting the format length memory FBFormatLengthBufferReset

Deleting and resetting the format length memory.

Block name FBFormatLengthBufferReset

Task Deleting and resetting the format length memory.

Integration in run-time system This block can be called in any task. The block is used by the SIMOTION Rotary Knife application and does not have to be linked-in by the user.


FBFormatLengthBufferReset



Block parameters

Input / output Parameters


formatLengthBuffer Management

sFormatLength BufferManagementType

Structure of the format length memory with all of the required control signals and pointers (refer to chapter, data types)

• Deletes all of the memory contents by overwriting the memory elements with 0.0 and FALSE

• Resets all pointers to 0 • Resets all status signals to FALSE




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7.6.2 Entries in the format length memory FBFormatLengthBufferIn

Enters a format length in the format length memory.

Name of the block FBFormatLengthBufferIn

Task With each call, the format length present at the block is entered into a free location in the format length memory. In addition, a “processing completed” ID can be set for the last segment.

Integration in run-time system The block can be called in any task. The block is used by the SIMOTION Rotary Knife application and does not have to be linked-in by the user.




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Block parameters

Input parameters


lastSegment BOOL FALSE “Cutting completed” detection

formatLength LREAL 0.0 [mm] Format length




sFormat Length Buffer Manage-mentType

Structure of the format length memory with all of the required control signals and pointers (refer to chapter, data types)

Functionality A new format length is entered into the format length memory. If the input parameter lastSegment = TRUE – and if the format length last entered from the RotaryKnife system has still not been read – then the format length last entered is set to 0.0 and the buffer pointer is not increased (incremented). If it was already read-in, then an additional format length is entered with 0.0 and the buffer pointer is increased (incremented) by “1”.




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7.6.3 Reading from the format length memory FBFormatLengthBufferRead

Reads a format length from the format length memory.

Block name FBFormatLengthBufferRead

Task At each call, a check is made as to whether a new format length was entered. If yes, then it is read-out and a cam change initiated. The format length is not deleted from the buffer.



Block parameters



switchCAM BOOL FALSE Initiates that a new cam is calculated


sFormatLength BufferManagement Type

Structure of the format length memory with all of the required control signals and pointers (refer to the chapter, data types)

Output parameters


formatLength LREAL 0.0 [mm] Format length

lastSegment BOOL FALSE “Processing ended” detection

switchCAMActive BOOL FALSE Cam change being prepared



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Functionality The block only executes the following activities, if a format length has been entered, but has still not been read out – and if a cam changeover has not been activated. Reads out the next format length to be activated. The format length remains saved in the buffer, however it is tagged as if it has been read out. If the format length that is read out is zero, then the output flag lastSegment is set to TRUE and a cam changeover is not activated. If a format length that has been read-out is not equal to zero, then a cam changeover is activated.




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7.6.4 Exporting from the format length memory FBFormatLengthBufferOut

Exporting a format length from the format length memory.

Name of Block FBFormatLengthBufferOut

Task After the next processing operation, the function block deletes the last format length that was entered from the format length memory and releases the memory cell for memory management purposes.


Graphic representation of the Block

FBFormatLengthBufferOut



Block parameters

Input / Output parameters



sFormatLength BufferManagementType

Structure of the format length memory with all of the required control signals and pointers (refer to the chapter, data types)

Functionality The block monitors the processing operation of the Rotary Knife. With the next step after reading-out the particular format length, this is deleted in the buffer.




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7.7 Measured value memory system blocks used in the rotary knife application

The Rotary Knife system uses these blocks. As standard, the user does not have to access them!



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7.7.1 Deleting and resetting the measured value memory FBCutPositionBufferReset

Deleting and resetting the measured value memory.

Block name FBCutPositionBufferReset

Task Deleting and resetting the measured value memory.

Integration in run-time system The block can be called in any task. The block is used by the SIMOTION Rotary Knife or SIMOTION Flying Saw application and does not have to be linked-in by the user.


FBCutPositionBufferReset



Block parameters





Structure of the measured value memory with all of the required control signals and pointers (refer to the chapter, data types)

Functionality • Deletes all of the memory contents by overwriting memory elements with 0.0 or

FALSE • Resets all pointers to 0 • Resets all status signals to FALSE

Error Messages No errors are generated.

7.7.2 Entries in the measured value memory FBCutPositionBufferIn

Enters a measured value (position measured value and/or position deviation) in the measured value memory.



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Block name FBCutPositionBufferIn

Task With each call, the values present at the block (position measured value and position deviation) are entered into a free location of the measured value memory.



Block parameters

Input parameters


positionDeviation LREAL 0.0 [mm] Position deviation (deviation between the reference position and actual position)

actPosition LREAL 0.0 [mm] Position measured value




sCutPositionBuffer ManagementType

Structure of the measured value memory with all of the required control signals and pointers (refer to the chapter, data types)

Functionality • The position measured value is entered into the measured value memory. • The position deviation is entered into the measured value memory.




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7.7.3 Reading out the measured value memory FBCutPositionBufferRead

Reading measured values from the measured value memory.

Block name FBCutPositionBufferRead

Task If the block is being used in the SIMOTION Rotary Knife application, then it detects whether a new position deviation was entered and initiates a corresponding position correction. If the block is being used in the SIMOTION Flying Saw application, then it detects as to whether a new position measured value was entered and initiates an additional processing cycle.



Block parameters

Input parameters


operatingForRotaryKnife BOOL TRUE

= TRUE Block is being used for the “Rotary Knife” application = FALSE Block is being used for the “Flying Saw” application

Output parameters


positionDeviationValid BOOL FALSE A position deviation has been defined

positionDeviation Maesured

LREAL 0.0 [mm] Position correction value



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flyingSawStart BOOL FALSE Start condition of the flying saw

positionMeasured LREAL 0.0 [mm] next sync position

Input / output Parameters




Structure of the measured value memory with all of the required control signals and pointers (refer to the chapter, data types).

Functionality Depending on the calling application, the block executes the following activities: If the block is being used in a “Rotary Knife” application (operatingForRotaryKnife = TRUE), then at each call, a check is made as to whether a new position deviation (cutPositionDeviation) was entered. If yes, the cutPositionDeviationValid flag is set and the position deviation (cutPositionDeviation) is transferred as correction value. If the block is used in a “Flying Saw” application (operatingForRotaryKnife = FALSE) at each call, a check is made as to whether a new position measured value (cutPosition) was entered. If yes, the flag “flyingSawStart” is set and the measured position is transferred as synchronous position for the next processing cycle.




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7.7.4 Exporting from the measured value memory FBCutPositionBufferOut

A measured value (position measured value and position deviation) are exported from the measured value memory.

Block name FBCutPositionBufferOut

Task After the processing operation, the function block deletes the last measured value (position measured value and position deviation) from the measured value memory and releases the memory for memory management.



FBCutPositionBufferOut



Block parameters

Input / output parameter



sCutPositionBuffer ManagementType

Structure of the CutPositionBuffer with all of the required control signals and pointers (refer to the chapter, data types)

Functionality When the block is called, the actual measured value (position measured value and position deviation) are deleted from the measured value memory.

Error messages No messages are generated.



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7.8 Extended functions

7.8.1 Using the cutting program

Cutting programs are used in the steel industry to cut samples of different lengths from the sheet steel. For this purpose, the SIMOTION RotaryKnife has the SAMPLE_CUT mode.

How is the memory filled? The user enters the required cut lengths into the SAMPLEBUFFER with the associated number of cuts.

Which blocks do I have to call? None

How does all of this function? The user switches FBRotaryKnife into the SAMPLE_CUT mode. The cutting program then automatically and immediately starts (Bit quickstart = TRUE!) or at the specified starting position (bit quickstart = FALSE!) and executes the cut lengths – saved in the SAMPLEBUFFER – with their associated number of cuts. The entries that are saved are deleted after execution. If there is no further entry in the buffer, the FB exits the program in the start position.

7.8.2 Using print mark correction

The print mark correction is switched-in by setting the “CutPosition CorrectionOn” bits to TRUE. (sUsersInterface. boCutPositionCorrectionOn)

How is the memory filled? The print mark correction has an intermediate buffer memory (CUTPOSITIONBUFFER) to enter the correction values precisely for the cut. The correction values are measured, saved and entered automatically after the print mark correction has been activated. The user does not have to intervene.

Which blocks do I have to call? None

How does all of this function? The print mark correction is realized automatically. However, users have parameters to influence its mode of operation. These parameters are located in the structure UsersInterface. Table 7-12 Parameter of Printmark Correction

Name Description

sUsersInterface.

boMeasuringWithRisingEdge Flag, “edge selection, measuring system” TRUE: Rising edge FALSE: Falling edge



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Name Description

boCutPositionCorrectionOn Flag, “cut position correction on”

boAdjustCutPositionPositive Flag, “start coarse correction positive of the cutting position”

boTrimmCutPositionPositive Flag, “start fine correction positive of the cutting position”

boAdjustCutPositionNegative Flag, “start coarse correction negative of the cutting position”

boTrimmtCutPositionNegative Flag, “start fine correction negative of the cutting position”

r64CPCorrectionMaximum [mm] Maximum correction value for the cut position correction

r64CPDeltaToleranceRange [mm] Half the tolerance bandwidth for the activation range of the cut position detection

r64AdjustCutPositionPositiveValue [mm] Coarse correction value of the manual cut position correction in the positive direction

r64TrimmCutPositionPositiveValue [mm] Fine correction value of the manual cut position correction in the positive direction

r64AdjustCutPositionNegativeValue [mm] Coarse correction value of the manual cut position correction in the negative direction

r64TrimmCutPositionNegativeValue [mm] Fine correction value of the manual cut position correction in the negative direction

r64CutPositionCorrectionVelocity [mm/s] Velocity value of the higher-level cut position correction

i16CutCorrWait Number of cuts without cut position correction

Appendix

General information on the application


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Appendix

8 General information on the application 8.1 Scope of supply

The package “Rotary Knife in SIMOTION” comprises the following: • Program

S7/Scout project as ZIP file: SIMOTION_Rotary Knife_V2.0.zip

• Documentation Implementation/Operating Instructions as PDF file Manual_SIMOTION_Rotary Knife_V2.0.pdf

8.2 Revision/Authors Table 8-1: Revision/Author

Version Date/Revision Author

V 1.0 28.02.2005 / first edition H.-E. Böhm V 1.1 3rd cam H.-E. Böhm V 1.2 03/13/06 Changes „General

Notes“ A. Hagelauer

V 1.3 04/13/06 SCOUT V4.0 H.-E. Böhm V 1.4 06/06/08 SCOUT V4.1.1.6

and WinCCflex P. Tabori H.-E. Böhm

V 2.0 09.08.06 expanded by the SINGLE_CUT and SAMPLE_CUT modes, change to the instance assignment capability (instanceability). Adapted to the “Converting” standards, expanded by the cam profile “Linear” and “Jerk”.

H.-E. Böhm

06.05.2011 Adaptions for Scout V4.2

H.-E. Böhm

Appendix

Contact partner


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9 Contact partner Applicationcenter

SIEMENS Siemens AG Industry Sector Drives Technologies Division Motion Control Systems A&D MC PM APC Frauenauracher Str. 80 91056 Erlangen Fax: +49 (0) 9131-98–1297 mailto: [email protected]

Appendix

Please help us to become even better


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10 Please help us to become even better I DT MC PM APC Sender: Application Center Name: Department: D – 91056 Erlangen City: Fax: +49 (0) 9131/98–1297 Telephone: E-Mail: [email protected] E-Mail:

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manual simotion rotary knife v2.0

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