Micro Application Example

Micro Application Example Closed-Loop Positioning Control with standard Drives Micro Automation Set 1

Table of Contents Note The Micro Automation Sets are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Micro Automation Sets do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are correctly used. These Micro Automation Sets do not relieve you of the responsibility of safely and professionally using, installing, operating and servicing equipment. When using these Micro Automation Sets, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Micro Automation Sets at any time without prior notice. If there are any deviations between the recommendations provided in these Micro Automation Sets and other Siemens publications e.g. Catalogs the contents of the other documents have priority. Warranty, liability and support We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Micro Automation Set shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions does not imply a change in the burden of proof to your detriment. Copyright 2008 Siemens IA and DT. It is not permissible to transfer or copy these Micro Automation Sets or excerpts of them without first having prior authorization from Siemens IA and DT in writing. V2.0 16.07.2008 2/54

Table of Contents Foreword Micro Automation Sets are functional and tested automation configurations based on IA/DT standard products for easy, fast and inexpensive implementation of automation tasks for small-scale automation. Each of the available Micro Automatic Sets covers a frequently occurring subtask of a typical customer problem in the lower performance range. The sets help you obtain answers with regard to required products and the question how they function when combined. However, depending on the system requirements, a variety of other components (e.g. other CPUs, power supplies, etc.) can be used to implement the functionality on which this set is based. For these components, please refer to the respective SIEMENS IA and DT catalogs. The Micro Automation Sets are also available at: http://www.siemens.de/microset V2.0 16.07.2008 3/54

Table of Contents Table of Contents Table of Contents... 4 1 Fields of Application and Benefits... 5 1.1 Automation problem... 5 1.2 Automation solution Set 1... 6 1.3 Fields of application... 8 1.4 Benefits... 8 2 Configuration... 9 3 Hardware and Software Components... 11 4 Principle of Operation... 13 4.1 Introduction to positioning... 13 4.2 Block libraries for moving linear and rotary axes... 19 4.3 Configuring the G110 frequency inverter... 23 4.4 Optimizing the positioning operation... 25 4.4.1 Optimization with regard to the moment of inertia... 25 4.4.2 Optimization of the travel profile... 27 5 Configuring the Startup Software... 29 5.1 Preliminary remark... 29 5.2 Downloading the startup code... 29 5.3 Configuring the CPU 224XP PLC... 30 5.4 Preparing the archiving function... 34 5.5 Loading the TP 177micro Touch Panel... 35 5.6 Parameterizing the G110 frequency inverter... 36 6 Live Demo... 38 6.1 Setting up the wire-wound coils... 40 6.2 Feeding in the wire... 41 6.3 Automatic mode... 42 6.3.1 Production of 10 wire rods with a length of 2m... 42 6.3.2 Premature termination of the production process... 43 6.4 Cutting wire rods of variable length (manual mode)... 44 6.5 Immediate stopping of the feed motion... 45 6.5.1 Stopping using the stop button of the TP 177micro... 47 6.5.2 Stopping using the hardware stop button (emergency stop)... 48 6.6 Data logging... 49 6.7 Optimizing the positioning process... 50 7 Technical Data... 53 V2.0 16.07.2008 4/54

Fields of Application and Benefits 1 Fields of Application and Benefits 1.1 Automation problem A wire cutting machine is to produce a customer-specific number of wire rods with customized length. After equipping the machine with the desired wire-wound coil, the management of the coil s type and available capacity is to be voltage-protected, the positioning axis unwinds the desired length from the wire-wound coil and cuts the wire. This operation is repeated according to the number entered together with a production ID. After completing the production job, voltage-resistant buffering has to be performed for all specific production data to read it from a PC once a day and to archive them there within the scope of quality assurance. After feeding in the wire prior to production, the wire is to be located in front of the cutting device. Figure 1-1 Cutter Wire-wound coil Type1 Type2 Type3 V2.0 16.07.2008 5/54

Fields of Application and Benefits 1.2 Automation solution Set 1 With the aid of the TP177micro Touch Panel, all material data of the available wire-wound coils that is relevant to the production can be stored as a recipe in the voltage-resistant memory module of the S7-200 CPU 224XP. The following information is stored under the designation of the wire-wound coil: Wire size Length of the pieces of wire to be cut of the corresponding job Material capacity of the wire-wound coil (initial value) Production ID of the job (initial value) Prior to production, the wire-wound coil to be used for the production has to be selected via the TP177micro Touch Panel. While feeding in the wire, a block that runs in the S7-200 CPU 224XP controls the G110 frequency inverter via the analog interface in such a way that the wire comes to a standstill after passing an inductive sensor and that the positioning axis is thus homed. An HTL encoder reports the traveled distance of the axis to the S7-200 CPU 224XP in the form of pulses. After entering the production ID and the number of pieces of wire to be produced using the TP177micro Touch Panel, a block running in the S7-200 CPU 224XP causes the frequency inverter to move the positioning axis by the desired wire length. Via a digital output signal, the S7-200 CPU 224XP subsequently controls a cutting device that cuts the wire. This operation is repeated according to the entered number. After completion or premature termination of the job the following production parameters are stored in the voltage-resistant memory module of the S7-200 CPU 224XP. Time and date stamp of the production job Diameters of the wire rods Length of the pieces of wire Quantity of the residual material on the coil A unique production ID for the job Actual number of cut wire rods The thus buffered information can be read out via a serial link, for instance with the aid of a PC/PPI cable and the S7-200 Explorer STEP7 Micro/WIN tool and stored as a csv file. When selecting a new wire-wound coil via the TP177micro Touch Panel, the remaining capacity of the previous coil that has been permanently updated during production is written to the recipe of the relevant material V2.0 16.07.2008 6/54

s Fields of Application and Benefits data. Since the recipe is also stored in the voltage-resistant memory module of the S7-200 CPU 224XP, the remaining capacity of the old wire-wound coil is again available when it is reused in the cutting device. If the remaining capacity of the wire-wound coil falls below a specific value, a warning is displayed on the TP 177micro Touch Panel. And if the amount of wire is not sufficient for the planned job, the entered number of wire rods is reduced to the possible number and this fact is also reported via the TP. Figure 1-2 SIMATIC PANEL TOUC H 5 s 1 2 3 4 F J PM HO N123 O G zh 1234567891 z 0 6 8 1 5 8 s TP 177 micro 2 SINAMICS G110 with BOP WINDOWS-based system LOGO! Power 6 3 7 S7-200 CPU 224XP Asynchronous motor with HTL encoder 7 NC contact 4 SIMATIC PXI inductive sensor V2.0 16.07.2008 7/54

Fields of Application and Benefits 1.3 Fields of application The Micro Automation Set is particularly suitable for industrial applications requiring the positioning of objects. The product combination in conjunction with the software library enables a cost-effective positioning solution, for example, in the following applications: Cutters, for example, for pipes Conveyors Feeders Lifting stages Rotary tables Hoisting devices 1.4 Benefits Simple solution for positioning a linear axis (horizontally or vertically) or a rotary axis. Clearly reduced engineering overhead by providing a command library for STEP 7 Micro/WIN. The use of a particularly sturdy control algorithm ensures that a manual optimization of the position control is not necessary even if there are strong load fluctuations. Realization of the drive task without comprehensive control engineering know-how. The SIMATIC S7-200 takes the position control. Engineering and commissioning of the S7-200 and the position controller with only one software tool: STEP 7 Micro/WIN. Cost-effective and high-performance solution with SINAMICS G110. In addition to your control problem, the S7-200 can also solve multiple automation problems. Visualization and control of the process via the TP 177micro Touch Panel. V2.0 16.07.2008 8/54

Configuration 2 Configuration Connection diagram Figure 2-1 L1 N PE L+ M M I V M +A +B 1M 1L+ 0.0 0.1 0.2 0.3 0.4 0.5 2M 2L+ 0.5 0.6 0.7 1.0 1.1 PE M L+ U1 V1 W1 1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 2M 1.0 1.1 1.2 1.3 1.4 1.5 M L+ L+ M PROFIBUS cable PC/PPI or USB/PPI cable 2 1 3 2 1 1 23 4 56 7 89 L1 L2 L3 10 Connector of the encoder cable contact side (not solder side) C D E B L F A M G K wht blu red blk J H WINDOWS-based system for configuring and data archiving SIMATIC S7-200 inputs: Via the preassembled encoder cable, the rotary pulse encoder is connected to the HSC4 high-speed counter that uses the I0.3 and I0.4 inputs. The D-sub connector of the encoder cable was removed. The signal cable of the inductive sensor is connected to I0.6. I0.0 was used for the OFF button. SIMATIC S7-200 outputs: The inverter with analog input receives its frequency setpoint via the analog voltage output of the controller (terminals M, V). A shielded cable has to be used. On the inverter, the analog signal is applied to terminal 9 and the associated analog reference ground is applied to terminal 10 of the signal interface. The analog reference ground and the ground of the 24V supply are jumpered on the inverter (terminals 7, 10). V2.0 16.07.2008 9/54

Configuration The start motor command is applied at digital output Q1.0 of the controller. It is connected to terminal 3 of the inverter s signal interface. The reversal signal is applied at digital output Q1.1 of the controller. It is connected to terminal 4 of the inverter s signal interface. SINAMICS G110 frequency inverter In primary circuit, the connection of the frequency inverter to the 230V mains is a single-phase connection. The asynchronous motor operated in delta connection is connected in secondary circuit. NOTICE Please observe that the phase angle of the encoder pulses A and B correlates with the phase angle L1, L2 and L3 of the motor supply. If correct positioning is not possible, the problem can possibly be solved by reversing the encoder tracks or two motor phases. If the motor does not run in the desired direction, encoder tracks and two motor phases have to be reversed. 24V supply The 24VDC power supply of the devices is provided by a LOGO! Power 1.3A. Protection An RCBO Type A is used for protection. V2.0 16.07.2008 10/54

Hardware and Software Components 3 Hardware and Software Components Products Table 3-1 Component No. MLFB / order number Note RCBO 1 5SU1154-7KK06 LOGO! Power 24V/1.3A 1 6EP1331-1SH02 SIMATIC S7-200 (CPU 1 6ES7214-2BD23-0XB0 224XP) TP 177micro Touch Panel 1 6AV6640-0CA11-0AX0 SINAMICS G110, frequency 6SL3211-0AB12-5UA1 inverter 1 SINAMICS G110, frequency 6SL3211-0AB12-5BA1 inverter with integrated EMC filter Low-voltage asynchronous motor Encoder cable for rotary pulse encoder SIMATIC PXI350 INDUCTIVE SENSOR 40X40MM Alternatively 1 1LA7070-4AB10-Z H57 Motor with rotary pulse encoder, 1024 pulses per revolution 1 6SX7002-0AN30-1AC0 Remove D-sub connector! 1 3RG4141-3AB01 Pushbutton, red, 1NC 1 3SB3203-0AA21 MC 291 MEMORY 1 6ES7291-8GH23-0XA0 MODULE, 256 KBYTES Accessories Table 3-2 Component No. MLFB / order number Note Basic Operator Panel (BOP) for SINAMICS G110 1 6SL3255-0AA00-4BA1 V2.0 16.07.2008 11/54

Hardware and Software Components Configuration software/tools Table 3-3 Component No. MLFB / order number Note WinCC flexible micro 1 6AV6610-0AA01-2CA8 Step 7 Micro/Win 1 6ES7810-2CC03-0YX0 PC/PPI cable USB/PPI cable SINAMICS MICROMASTER SIZER 6ES7901-3CB30-0XA0 Alternatively; can also be used 1 6ES7901-3DB30-0XA0 for loading the TP177 micro 1 6SL3070-0AA00-0AG0 Optional V2.0 16.07.2008 12/54

Principle of Operation 4 Principle of Operation 4.1 Introduction to positioning What does closed-loop controlled positioning mean? In the context of this application, the following definitions can be provided: When positioning, an electrically driven component of a device or plant approaches a defined local point or angle by means of a linear or rotary motion or the component is moved by the distance Δs or the angle Δφ. When the positioning is closed-loop controlled, the motion is performed in a closed control loop in which path and velocity (motor speed) are the controlled variables. The disturbance variables are differing load torques. The SIMATIC S7-200 transfers the velocity controller output to the frequency inverter as an analog voltage that is interpreted by the frequency inverter as a setpoint frequency according to its parameterized V/f characteristic. Considering the slip of the asynchronous motor depending on the load torque, a specific speed is set. According to this speed, the component to be positioned travels a smaller or larger number of path or angle increments. They are detected by the rotary pulse encoder that is located directly on the motor shaft and supplied to the controller via its highspeed counter inputs. From this information and including the setpoint values position, positioning speed and acceleration (torque), a control algorithm counting the encoder pulses calculates the necessary velocity controller output. This results in a velocity profile whose processing finally leads to an exact positioning. Figure 4-1 Position Velocity Acceleration (torque) Reference variable Control with MicroPos blocks Controller Analog value 0 10V Manipulated value Frequency inverter, asynchronous motor Controlled system Load torque Disturbance variable Position Velocity Controlled variable Encoder pulses What is the difference between absolute and relative positioning? When absolute positioning is used, you directly specify the target position to be approached. When relative positioning is used, you enter a path length by which the component is to be moved. V2.0 16.07.2008 13/54

Principle of Operation To enable absolute positioning, it is required that the zero point of your travel path (home position) be defined once in advance. The counter with which the pulses of the rotary pulse encoder are counted is adjusted to the position of the physical axis,.i.e. it is set to a defined value (preferably 0) at a defined local point. Homing is not necessary for relative positioning. Figure 4-2: Example of absolute/relative positioning Absolute positioning Travel range (mm) -300-200 -100 0 100 200 300 400 500 Source position (not relevant) Home position Target position Relative positioning +600mm Source position Target position What is the difference between a linear and a rotary axis? Linear axis: A linear axis is particularly suitable for linear motions in the horizontal or vertical plane. For the distance traveled during positioning, the blocks assume the length dimension. Depending on the velocity or ratios of dimensions, the user applies the corresponding parameters (position, velocity, etc.), for example, to mm, cm or inch. V2.0 16.07.2008 14/54

Principle of Operation An important parameter of the linear axis is the correlation between the physical variable distance traveled and a motor or rotary pulse encoder revolution. The parameter thus considers gear, belt, spindles, etc. that eventually convert the rotary motion to a linear motion. Figure 4-3: Example of a linear axis, distance traveled One revolution = 1024 encoder pulses Shortest detectable travel path = 40mm / 1024 0.039mm 40mm The Map_Ind_Lin library is used for the linear axis. The names of all blocks have Lin_ as a prefix. Rotary axis: The rotary axis also referred to as a modulo axis designates a type of positioning where a rotary motion is repeated after each completed motional sequence. Taking this fact into account, the position value of the drive-end, moved component is specified in angular degrees 0 φ < 360.0 and reset to 0 after each rotation. For the unique detection of the absolute position, the rotary axis additionally features a rotation counter that is adjusted each time the axis is moved irrespective of whether the positioning is absolute or relative or whether the rotary axis is moved in jog mode. Without homing, the rotation counter is set to 0 when restarting the controller. With homing, the rotation counter is set to a value that corresponds to the specified reference angle. If you specify, for instance, an angle of +740 for the physical local point x 0 when homing, the rotation counter has the value +2 in x 0. An important parameter of the rotary axis is the correlation between the physical variable angle traveled and a motor or rotary pulse encoder revolution. The parameter thus considers gear, belt, spindles, etc. that finally represent the ratio. V2.0 16.07.2008 15/54

Principle of Operation Figure 4-4: Example of a rotary axis, angle traveled One motor revolution = 1024 encoder pulses φ = 28 Smallest detectable angle of revolution = 28 / 1024 1 38 The following specifics have to be considered for a rotary axis: Absolute positioning with preset direction of rotation At the drive end, the target position has to be approachable with a maximum of one rotation (φ < 360.0 ). Larger angle settings cause a termination of the job. Negative angle settings are also not permissible. The direction of rotation is to be specified by an compared to a linear axis additional direction parameter. Figure 4-5: Example of a rotary axis, absolute positioning Home position Target position 0 Source position Positioning to 270 in positive direction Home position 0 Source position Target position Positioning to 270 in negative direction Absolute positioning on the shortest path The positioning is performed as in the above case. The software V2.0 16.07.2008 16/54

Principle of Operation calculates the shortest path to the target and selects the direction of rotation accordingly. Relative positioning Both angle settings > 360.0 and negative angles are possible. Figure 4-6: Example of a rotary axis, relative positioning Source position Target position Positioning by 630 in positive direction The Map_Ind_Rot library is used for the rotary axis. The names of all blocks have Rot_ as a prefix. What is a travel profile? Depending on the purpose, travel profiles describe various characteristics (path, velocity, acceleration, moment, power, etc.) that describe a desired motional sequence. The time or the path is mostly plotted on the abscissa. The following applies to a positioning operation by means of the MAP Ind blocks: Acceleration is always performed from zero and the component is always decelerated to a standstill. The steepness of acceleration ramp and deceleration ramp is identical The controlled variable for the required acceleration/deceleration is the moment. V2.0 16.07.2008 17/54

Principle of Operation Figure 4-7: Travel profile Forwards/upwards Velocity Backwards/downwards Time Path Generator operation Time Torque Horizontal axis Vertical axis Time For system optimization, the two MAP_Ind_... libraries offer a _Com_Monitor block with which alternatively the dependencies M(t), v(t) and s(t) can be displayed as travel profiles in STEP 7 MicroWin. What is the difference between a horizontal and a vertical axis? While the horizontal axis merely requires that the forces of acceleration/deceleration and the friction forces be considered parallel to the direction of motion for a mass to be moved, the gravitational force of the mass to be moved has to be additionally considered for the vertical axis. This requires the provision of a larger torque from the inverter to achieve the same accelerating/decelerating torques as for the horizontal axis. Figure 4-7 shows a qualitative representation of the torque characteristics of the horizontal and vertical axis for identical accelerations. V2.0 16.07.2008 18/54

Principle of Operation Under which circumstances does the motor become the generator? Whenever energy stored in the system is to be degraded, the motor becomes the generator. The following energies have to be mentioned: Potential energy (due to a suspended load) Kinetic energy (due to moving masses) Energy released when lowering a load or decelerating a flywheel that would drive the motor from the mechanical end has to be degraded by the inverter as power loss. The inverter copes with smaller powers without additional measures. Larger powers require braking resistors or power recovery has to be provided. Figure 4-7 shows the time intervals of generator operation. The hatched areas under the torque characteristics are proportional to the energy to be degraded. 4.2 Block libraries for moving linear and rotary axes Overview of available positioning blocks Figure 4-8 MAP_Ind_Lin library for linear axis Lin_Init_horizontal Lin_Init_vertical Lin_MoveJog MAP_Ind_Rot library for rotary axis Rot_Init Rot_MoveJog Lin_Home Rot_Home Lin_MoveAbs Lin_MoveRel Rot_MoveAbs Rot_MoveRel Lin_StopMotion Rot_StopMotion Lin_Control Rot_Control Lin_Com_Monitor Rot_Com_Monitor The library description also included in Micro Automation Set 1 provides a detailed block description. The MAP_Ind_Lin library for linear axes is used for this application. The following sections briefly describe its blocks. V2.0 16.07.2008 19/54

Principle of Operation Task of the Lin_Init_horizontal block This application describes a horizontal material transport. For this reason, the Lin_Init_horizontal block is used here. The initialization block combines those input and output parameters that refer, so to speak, to all further blocks of the library and that are used by the positioning s control algorithm. Furthermore, the user-specific units of measurement are standardized in this block. Motor characteristics, absolute upper limits for velocity and torque 1 and the transfer factor indicating which feed corresponds to the linear motion of a motor revolution are mainly entered in Lin_Init_horizontal. Lin_Init_horizontal has to be processed once before the remaining blocks which have to be called cyclically are executed for the first time. Trigger Lin_Init_horizontal with SM0.1. Task of the Lin_MoveJog block Using the Lin_MoveJog block, you realize manual mode. The block features two bit inputs for jog mode ( JogPos and JogNeg ). Accelerating/decelerating torque and a limit velocity can be parameterized at the block. Task of the Lin_Home block To enable absolute positioning, the three-dimensional travel path has to be synchronized with the controller s position counter. This is achieved by assigning a specific value to a defined point of your travel path (= home position). This is done during runtime of the automation program. Lin_Home offers two referencing variants: Searching for the home position For searching the motor is started with Execute block parameter =1 and the required direction of rotation ( Direction parameter = ±1). If the moving component is detected by a sensor at the user-defined home position ( RPS signal), a specific reference value ( Home_Position ) is assigned to the current position with this event. The detection of the sensor is performed via its positive or negative edge. The sensor can, for example, be an inductive proximity switch or a photoelectric barrier. Your user program has to be designed in such a way that the sensor is always approached from the same direction when homing to eliminate its detection width. In this wire cutting machine application example, homing is performed when feeding in the wire or before the first cutting operation as shown in the graphic representation below. The distance proximity switch cutter (with minus sign) is entered as a position value of the home 1 Upper limits are not even exceeded during operation if higher values are parameterized in the blocks initiating a motion. V2.0 16.07.2008 20/54

Principle of Operation position. Thus the current wire position = 0mm if the wire tip is located exactly at the cutter. Figure 4-9: Home position search v(t) RPS signal active Home position End of homing Start of homing (if feed-in has already been performed) Start of homing (if feed-in has not yet been performed) 1) Detection width s(t) Wire-wound coil Cutter Proximity switch for wire detection 1) The offset to the home position at the end of homing is known to the system and will be considered in the next positioning (first wire cut after homing). Setting the home position. When setting the home position, the motor is stopped. 0 has to be specified for the Direction block parameter. If the block detects a positive edge at Execute =1 at the RPS input parameter, the current position is set to a parameterizable reference value ( Home_Position ). In the wire cutting machine application example described in this document, the home position is set to the value 0 whenever the wire tip is located exactly at the cutter after a completed wire cut. For the home position search, accelerating/decelerating torque and a limit velocity can be parameterized at the block. Task of the Lin_MoveAbs block Initiated by a positive edge at the Execute input parameter, the motor starts from the current position for a closed-loop-controlled approach to the end point specified via the Position input parameter. A prerequisite for absolute positioning is previous homing with the Lin_Home block. Accelerating/decelerating torque and a limit velocity can be parameterized at the block. V2.0 16.07.2008 21/54

Principle of Operation Task of the Lin_MoveRel block Initiated by a positive edge at the Execute input parameter, the motor starts at the current position to approach the point whose distance from the starting point is specified by the Distance input parameter on a closedloop-controlled basis. Previous homing using the Lin_Home block is not required in this case. Accelerating/decelerating torque and a limit velocity can be parameterized at the block. Task of the Lin_StopMotion block Lin_StopMotion is used to stop a currently active motion irrespectively of the specific MAP Ind block that triggered it. The block offers two variants for stopping: Stopping via the AUS3 inverter digital input. The steepness of the deceleration ramp is set when parameterizing the inverter. The stop is triggered by a positive edge at the Execute_Off3 input parameter. Stopping via the Lin_StopMotion block. This variant is used in this application. The steepness of the deceleration ramp is set by the Decel_Torque_Ramp input parameter of the block. The stop is triggered by a positive edge at the Execute_Ramp input parameter. It is not only possible to use both variants for stopping alternatively, they can also be used together in one program. The block monitors the deceleration times (separate monitoring of both variants for stopping). The upper limits can be parameterized. When the limits are violated, the Time_Exceeded output bit parameter is set. Task of the Lin_Control block The block uses a status word to inform the user on all system states and limit value violations: Motor stopped Maximum moment reached Axis not synchronized Pulse counter overflow Direction conflict (rotary pulse encoder motor phase angle) Following error exceeded System not initialized The value of the current position is available to the user in the Act_Position output parameter. V2.0 16.07.2008 22/54

Principle of Operation Whenever the motor is stopped from the perspective of the MAP Ind blocks, a Brake bit output is set to a logic 1. For example, a holding brake or the pulse enable for the inverter can then be controlled. Task of the Lin_ComMonitor block In the commissioning phase the Lin_ComMonitor block supports the user in optimizing the dynamic response. The block alternatively records (parameterizable) Note moment velocity position in real time to be able to subsequently represent their time characteristics in the STEP7 Micro/Win trend display. A positive edge at the Start bit input parameter starts the recording. Where the data is to be stored is communicated to the block via the ptablestart input parameter by means of a pointer. The block records 249 REAL values in the 8ms grid. In the trend display, subsequently view the Out output parameter of the block. A parameter description of the MAP Ind blocks is available not only in the library description of this Micro Automation Set, but also in STEP7 Micro/WIN directly as a comment in the relevant protected MicroPos block. 4.3 Configuring the G110 frequency inverter Parameterization steps Due to the universality of the SINAMICS frequency inverters, the adaptation to a specific application requires that the inverter be parameterized. This setting procedure is facilitated by the fact that many applications can be operated with the factory default settings if quick commissioning has previously been performed. If the condition at delivery from the plant of the inverter you are using has been changed, it can be reset to the factory default settings without difficulty. If quick commissioning is set, only the parameters whose adaptation is absolutely necessary can be selected during the parameterization. To meet the specific requirements of this application, application-specific parameterizations are necessary after the reset to factory default settings and after quick commissioning. Finally, save the values to the EEPROM of the inverter and, if necessary, save the entire parameterization to the BOP. This enables you to reload the parameters to the inverter at any time if required without having to reenter them or to transfer the parameters to other identical inverters. V2.0 16.07.2008 23/54

Principle of Operation To parameterize the inverter, we recommend the following procedure: Table 4-1 No. Step 1. Resetting to factory default settings (if condition at delivery from the plant has been changed) 2. Quick commissioning. 3. Application-specific parameterizations. 4. Saving parameters to the inverter s EEPROM. 5. Transferring parameter set to BOP for reuse. Changing parameters All steps listed above are merely sequences of parameter settings. They can be performed, for example, using the Basic Operator Panel (BOP) that is simply plugged onto the inverter 2. Figure 4-10 To change a parameter via the BOP, proceed as follows: 2 The BOP can be plugged in any inverter mode. V2.0 16.07.2008 24/54

Principle of Operation No. Operator input sequence step Note 1. Go to parameterization mode. 2. Select the parameter to be changed. 3. Display the parameter value. 4. Change the parameter value. These operations have to be performed for each parameter. When you press FN, you can change each decade individually. 5. Apply the value. 6. Select the display (0000). 7. Exit parameterization mode. Documents for the SINAMICS G110 The following documents are available for the SINAMICS G110: Table 4-2 Document ID number: Getting Started Guide 21696936 Operating Instructions 22102965 Parameter List 20977026 4.4 Optimizing the positioning operation 4.4.1 Optimization with regard to the moment of inertia Relating to all MAP Ind blocks, the Inertia parameter (moment of inertia) influencing the system dynamics that cannot be easily deduced from motor catalogs or mechanical system requirements like all other input values can be either calculated or determined empirically. The calculation of the moment of inertia of the entire moved system component required by the Lin_Init_horizontal block as an input parameter is difficult. The following sections describe a way to determine the moment of inertia empirically. V2.0 16.07.2008 25/54

Principle of Operation Start value for the moment of inertia Experience has shown that the tenfold mass inertia of the motor is a good start value. Before commissioning, enter this value for the Inertia parameter at the Lin_Init_horizontal block. For the motor s mass inertia, please refer to the motor catalog. Accordingly, a value of 0.00052kgm 2 results for the motor from Table 3-1. Optimization process with the aid of the Lin_ComMonitor block To assess the dynamic response of your system, the graphical representations of the trend curves v(t) and s(t) are alternatively suitable. Consider in particular the end of the positioning operation. If the moment of inertia is set optimally (Figure 4-12), neither distinctive overshoot (Figure 4-11) nor a gradual vanishing (Figure 4-13) of the corresponding curve should occur. Figure 4-11 s(t) Overshoot! v(t) Overshoot! Figure 4-12 s(t) Optimum characteristic Optimum characteristic v(t) V2.0 16.07.2008 26/54

Principle of Operation Figure 4-13 Gradual vanishing! s(t) Gradual vanishing! v(t) The time characteristic v(t) is also suitable for controlling or optimizing the velocity. It shows whether the velocity parameterized at the relevant block is actually reached. 4.4.2 Optimization of the travel profile The travel profile is essentially defined by the technological application and an energetic optimization. Determining factors are the time within which the positioning operation has to be completed, acceleration and deceleration whose upper limits are determined by the motor performance, the application s mechanical system and the actual process and the power demand of the application. The travel profile can be adjusted to the application as follows: Figure 4-14 v(t) Maximum velocity is determined by... Velocity_Limit block parameter (unit of length/s) t Slope is determined by... rated torque of the motor Accel_Torque or Torque_Limit block parameter (0...200%) V2.0 16.07.2008 27/54

Principle of Operation The absolute maximum velocity of the linearly moved component eventually depends on the rated speed relating to the motor frequency. Since the 4-pole motor of this application can be controlled by the inverter with a maximum of 100Hz, its highest speed is 2700 min -1. This speed converted to the linear motion of the application results in the maximum velocity that can be limited with the Velocity_Limit parameter. The Accel_Torque or Torque_Limit block parameters for limiting the motor torque are indicated as percentages of the rated torque. A torque of up to 200% can be used for a 4-pole motor. The example in the figure below shows four possible travel profiles that all position over the same distance, i.e. the integrals over the curves v(t) from the starting point to the end point of the motion are identical. Friction losses are negligible. Figure 4-15: Different travel profiles for the same positioning v(t), M(t) v(t), M(t) v max (at 100Hz) M = 200% v(t), M(t) t v max /2 v(t), M(t) t v max /2 v max /2 M = 100% t M = 50% t Green profile Maximum motor utilization Minimum positioning time Maximum power consumption Yellow, blue and red profile Motor not fully utilized Positioning times extend from yellow to red Power consumption corresponds to half the green profile V2.0 16.07.2008 28/54

Configuring the Startup Software 5 Configuring the Startup Software 5.1 Preliminary remark For the startup, we offer you software examples with test code and test parameters as a download. The software examples support you during the first steps and tests with your Micro Automation Sets. They enable quick testing of the hardware and software interfaces between the products described in the Micro Automation Sets. The software examples are always assigned to the components used in the set and show their basic interaction. However, they are not real applications in the sense of technological problem solving with definable properties. Note At this point, it is assumed that the necessary configuration software has been installed on your development system (PG, PC, laptop computer) as shown in Table 3-3 and that you are familiar with handling this software. The hardware according to Table 3-1 is mounted, wired as shown in Figure 2-1 and the power supply of all involved components is ensured. 5.2 Downloading the startup code The software example is available on the HTML page from which you have downloaded this document. Table 5-1 No. File name Content 1 Set1_s7-200_V1d0_en.zip STEP 7 Micro/WIN project for the wire cutting machine (.mwp file) 2 Set1_WinCCflex_Visu_V1d0_en.zip WinCC flexible project for the TP (.hmi and.ldf files). 3 map_ind_v1.19.zip Libraries of the drive blocks for linear and rotation angle positioning (map_ind_lin.mwl and map_ind_rot.mwl files) Note The map_ind_rot.mwl library is not used in the software example. It is only offered for download to complete the picture. V2.0 16.07.2008 29/54

Configuring the Startup Software 5.3 Configuring the CPU 224XP PLC Step-by-step instructions for configuring the controller Table 5-2 No. Instruction Remark 1. Connect a free COM port or a USB port of the development system to port 0 of the S7-200 controller. Use the PC/PPI or USB/PPI cable for the connection. Use the following switch positions for the PC/PPI cable: Development system 1 2 3 4 5 6 7 8 0 0 0 0 1 0 0 0 PC/PPI or USB/PPI cable 2. In PG/PC Interface, select Start>Settings>Control Panel and make the following settings: Access point of the application: Micro/WIN PC/PPI cable(ppi) Transmission rate: 19.2kbps Local connection: COM or USB (depending on the cable) Advanced PPI deactivated Multi-master network deactivated 3. Start STEP 7 Micro/WIN and open the mwp project file. 4. If you are using a motor type deviating from table 3-1, you have to adjust the input parameters of the Lin_Init_horizontal block (= rated motor data). The block is located in network 1 of the MicroPOS subprogram. Instead of using the control panel, the interface can also be selected from STEP 7 Micro/WIN by selecting Set PG/PC Interface. 5. Check whether the values of the parameters declared in the USER data area are compatible with the mechanical system of your wire cutting machine. The following table provides an explanation of the USER data area (Table 5-3). V2.0 16.07.2008 30/54

Configuring the Startup Software No. Instruction Remark 6. Select File>Download or use the corresponding icon to transfer the project to the S7-200 controller. In the transfer dialog box, ensure that the program blocks, data blocks, system data and recipes are transferred. 7. Select PLC>RUN or the corresponding icon to set the S7-200 controller to RUN mode. 8. In the operation tree, right-click Libraries and open the dialog box for adding/deleting libraries. Add the drive blocks for linear positioning to the library. Follow the explanations in the respective window. It is only necessary to add blocks to the library if you want to add library blocks that have previously not been included in the program code to the user program. In this example, these are, for instance, the Lin_Init_vertical or Lin_MoveAbs blocks. Parameters of the wire cutting machine On the one hand, all technological parameters of the wire cutting machine are declared in the USER data block; on the other hand, they also exist in the Parameters status table for commissioning purposes. Before the first commissioning check whether the values in particular the velocities and torques are suitable for your mechanical system. The following table explains the parameters. V2.0 16.07.2008 31/54

Configuring the Startup Software Table 5-3 Parameter Explanations dist_bero_cutter: VW32 Technological parameters Distance between proximity switch and cutter (mm). The proximity switch is to be installed between the drive wheels and the cutter. dist_bero_cutter has to be entered as a negative value. induktiver Näherungsschalter Schneidemechanismus (cutter) cutter_down_time: VW34 cut_delay: VW40 coil: VW114 minimum: VD76 V_Ref: VD1004 Jog_slow: VD1008 Jog_fast: VD1012 absolute Position 0 + - dist_bero_cutter Indicates how long the cutter remains in the cutting position (value x 10ms). The cutter knows two logic states: Parking position (at top, control with FALSE) Cutting position (at bottom, control with TRUE) In automatic mode, the feed of the next wire rod is started only after this delay (value x 10ms). This is to prevent that the feed starts before the cutter has returned to parking position. The cutter has no end position detection. Other parameters Preset coil (1-4) whose recipe data is used for operation after a data block transfer to the controller. If the remaining capacity of the coil becomes less than this limit value(m), a warning is output on the TP. Velocity parameters Homing velocity (mm/s) Slow jog mode velocity (mm/s) Fast jog mode velocity (mm/s) V2.0 16.07.2008 32/54

Configuring the Startup Software V_Pos: VD1016 Parameter Positioning velocity (mm/s) Torque parameters 3 Explanations T_Ref: VD1028 Accelerating/decelerating torque for homing (%) Torque_Jog_slow: VD1032 Accelerating/decelerating torque for slow jog mode (%) Torque_Jog_fast: VD1036 Accelerating/decelerating torque for fast jog mode (%) T_Pos: VD1040 Accelerating/decelerating torque for positioning (%) T_Stop: VD1048 Decelerating torque when stopping by means of stop button on the TP or hardware stop button during homing or a positioning operation (%). Parameters for the Lin_Init_horizontal initialization block Torque_Limit: VD1100 Maximum permissible accelerating/decelerating torque (%). The torque parameter values of the other drive blocks always have to be smaller than/equal to this value. Otherwise, the relevant drive block reports an error. Velocity_Limit: VD1108 Maximum permissible velocity (mm/s). The velocity parameter values of the other drive blocks always have to be smaller than/equal to this value. Otherwise, the relevant drive block reports an error. s_per_rev: VD1112 The feed of the wire per motor revolution has to be entered here (mm/rev). For a positioning accuracy < 1mm, s_per_rev < 40 mm/rev should apply. Inertia: VD1116 Moment of inertia; see chapter 4.4 3 The percentage data of the torque refers to the motor s rated torque that is listed in the motor data sheets and that the MAP Ind blocks calculate from the further motor rating parameterized at the Lin_Init_horizontal block. Entries from 0 200% are possible for the torque. V2.0 16.07.2008 33/54

Configuring the Startup Software 5.4 Preparing the archiving function Table 5-4 No. Instruction Remark 1. Connect a free COM port or a USB port of the development system to port 0 of the S7-200 controller. Use the PC/PPI or USB/PPI cable for the connection. Use the following switch positions for the PC/PPI cable: Development system 1 2 3 4 5 6 7 8 0 0 0 0 1 0 0 0 PC/PP or USB/PPI cable 2. In Windows, start S7-200 Explorer by selecting Start>SIMATIC>S7-200 Explorer or by double-clicking the corresponding icons. 3. Click the S7-200 CPU and select the 256 KB memory module. In the right window, right-click DAT Configuration 0(DAT0) and select Create Shortcut. (The Open File on Upload option has to be deactivated) 4. A shortcut to the Data-Log file in the 256 KB memory module is now automatically created on the desktop. 5. On the desktop, create a link to the Micro/WIN installation path (default: Drive : Program Files\Siemens\MicroSystems\Data Logs). The logged data from the memory module is moved to the path as a csv file when double-clicking. V2.0 16.07.2008 34/54

Configuring the Startup Software 5.5 Loading the TP 177micro Touch Panel Table 5-5 No. Instruction Remark 1. Connect a free COM port or a USB port of the development system to the RS485 interface of the TP 177micro. Use the PC/PPI cable or the USB/PPI cable. On the PC/PPI cable, set a baud rate of 115200 baud. This corresponds to the following switch positions: 1 2 3 4 5 6 7 8 1 1 0 0 0 0 0 0 TP 177micro PC/PPI or USB/PPI cable Development system 2. Start WinCC flexible and open the hmi project file. 3. Call the transfer dialog box by selecting Project>Transfer>Transfer Settings or by using the respective icon. 4. Adjust the transfer settings according to the cable you are using. When using the PC/PPI cable, select the used COM port of your development system and set the baud rate to 115200 baud. 5. Set the TP 177 Micro to Transfer mode. This is done by selecting the Transfer button after the bootloader sequence. The download of the WinCC flexible project can be started when a Transfer. dialog box is displayed on the TP. 6. Start the project file transfer. 7. Use the PROFIBUS cable to connect the RS485 interface of the touch panel to port 1 of the S7-200 controller. S7-224 XP CPU TP 177micro PROFIBUS cable V2.0 16.07.2008 35/54

Configuring the Startup Software 5.6 Parameterizing the G110 frequency inverter For the procedure, please refer to chapter 4.3. The following section lists only the parameters you have to change with regard to the factory default settings for this application example. For the parameterization, please follow the order specified in the table below. Parameter changes in the SINAMICS G110 Table 5-6 Parameter No. Value Remark Resetting to factory default settings P0010 30 Commissioning parameter: Factory setting P0970 1 Start of the reset of all parameters to default values Quick commissioning P0003 3 Access level: Expert P0010 1 Commissioning parameter: Quick commissioning P0305 1.34 Rated motor current (A) (for delta connection), see rating plate P0307 0.25 Rated motor power (kw), see rating plate P0308 0.78 Rated power factor of the motor (cos φ), see rating plate P0310 50 Rated motor frequency (Hz) for the specific motor data, see rating plate P0311 1350 Rated motor speed (min -1 ), see rating plate P1082 100.00 Maximum frequency (Hz) (100Hz for 4-pole motor, 50Hz for 2-pole motor) P1120 0.00 Acceleration time (determined by the controller) P1121 0.00 Deceleration time (determined by the controller) P3900 1 End of quick commissioning (among other things, resets P0003 to 1) Application-specific parameterizations P0003 3 Access level: Expert P0760 200.00 y2 value ADC scaling (%) (100% for 2-pole motors) P1240 0 Configuration of Vdc controller: Vdc controller disabled Saving parameters to the inverter s EEPROM P0971 1 Transfer of values from RAM to EEPROM Transferring parameter set to BOP for reuse P0010 30 Commissioning parameter: Factory setting P0802 1 Parameter transfer from SINAMICS BOP P0003 1 Access level: Standard V2.0 16.07.2008 36/54

Configuring the Startup Software NOTICE If you are using a motor type that differs from the ones listed in Table 3-1, the following parameters have to be additionally considered during quick commissioning: P0304 rated motor voltage (V) (for delta connection), see rating plate P0335 rotor cooling: 1 = self-ventilated, 2 = separately ventilated In this application example, the values of these parameters are already covered by the factory default settings and thus not listed in the above table. Parameter transfer from BOP SINAMICS G110 Table 5-7 Parameter No. When you have transferred the inverter parameter set to the BOP as shown in Table 5-6, you can reload it from the BOP to the inverter very easily if required or distribute it to other inverters. Value Remark Transferring parameter set from the BOP to the frequency inverter P0003 3 Access level: Expert P0010 30 Commissioning parameter: Factory setting P0803 1 Parameter transfer from BOP SINAMICS Saving parameters to the inverter s EEPROM P0971 1 Transfer of values from RAM to EEPROM P0003 1 Access level: Standard V2.0 16.07.2008 37/54

Live Demo 6 Live Demo Overview To facilitate understanding, the functions and features of Micro Automation Set 1 are shown in the form of a sample application. If the components have been correctly configured as described in chapter 5, the program code can be tested. Figure 6-1: Live demo overview Start Setting up the wire-wound coils Feeding in the wire Producing 10 wire rods with a length of 2m (automatic mode) Cutting wire rods of variable length (manual mode) Immediate stopping of the feed motion using the stop button of the TP 177micro Immediate stopping of the feed motion using the hardware stop button (e.g. emergency stop) Data logging Optimizing the dynamic response End Basic information on operating the TP 177micro Table 6-1 Definition Input values: Input or input/output fields are designated by a white background. Output values: Mere output fields are marked by a gray background. Example Input/output field Output field V2.0 16.07.2008 38/54

Live Demo Definition Grayed out buttons: Buttons with grayed out labeling indicate that the action associated with the button is locked for programming reasons. For example, automatic mode can only be set after the wire has been fed in. Not grayed out Example Grayed out Navigation buttons: The navigation buttons for changing the screens/statuses are located on the bottom screen edge. The screens are structured as shown on the right. In case of voltage recovery or restart of the controller, the system branches to the feed in screen. In the currently selected screen, the background of the navigation buttons is black and they cannot be operated. Graphic: A graphic in the TP screens shows the wire cutting machine s condition of motion. settings recipe admin. production feed in automatic manual Automatic mode selected Standstill Feed active (the sectors within the coils rotate and the wire moves forward.) Cut Deleting old archive data Delete any old logged data from the memory module and old csv log files before the live demo scenarios. V2.0 16.07.2008 39/54

Live Demo Table 6-2 No. Step Remark 1. 2. Double-click. Memory module is read out and deleted. Double-click. Directory of csv log files is opened. 3. Delete all csv files in the directory. The logging was configured in such a way that the log data in the memory module is deleted when reading out the 256 KB memory module in a csv file. 6.1 Setting up the wire-wound coils Setting up the wire-wound coil means defining the recipe data of the individual material types and selecting the coil to be used for the current operation. Procedure Table 6-3 No. Step Remark 1. On the TP 177micro, select the recipe admin. screen. 2. Use the arrow keys to select the wire-wound coil you want to use. Four data records (recipes) are available. 3. If necessary, change the recipe data of the selected wire-wound coil. Core rod diameter: Merely used as a material characteristic. Its value is not included in any calculation. Core rod length: Indicates the length of the steel rods that are cut in automatic mode when selecting the corresponding recipe. Residual material: Depending on the material consumption, the controller automatically reduces the displayed residual material quantity. It can be overwritten by the user at any time, e.g. when changing the coil. Production ID: Each production job, consisting of n steel rods, is given a production ID. The user enters an initial value the controller automatically increments per job. The initial value must be > 0 since production ID 0 is reserved for manual production. V2.0 16.07.2008 40/54

Live Demo No. Step Remark 4. If required, change the residual material quantity on the coil; when the quantity is less than this value, a message not requiring acknowledgement is triggered on the TP. The limit value of the residual material quantity is independent of the selected wire-wound coil. Reading and writing the recipe data Each time a wire-wound coil is newly selected, the remaining coil capacity of the previous coil is saved to its recipe stored in the memory module and the recipe data of the new coil is loaded from the memory module to the controller. Manual recipe data modifications are transferred to the PLC and written to the memory module with leaving the recipe administration. 6.2 Feeding in the wire Procedure Table 6-4 No. Step Remark 1. On the TP 177micro, select the production screen + feed in. 2. Use the start button (transport wheels start) and put the end of wire between the transport wheels. The text not yet fed in! flashes. When the end of wire reaches the proximity switch, the feed is stopped. The flashing text changes to a permanent display of fed in!. From now on, the current feed is also always displayed on the top of the screen. V2.0 16.07.2008 41/54

Live Demo Display of the current feed The current feed is the distance between the wire tip and the cutter. Since the proximity switch referring to the normal conveying direction is located in front of the cutter, the value of the current feed after completing the feed-in operation is negative and slightly smaller than the distance between the proximity switch and the cutter. When cutting the first wire rod to length in automatic mode, the already existing negative feed resulting from the feed-in operation is considered. Repetition of the feed-in operation If a feed-in operation is to be performed when the proximity switch is already occupied by the wire this can, for instance, be the case after power off/on of the controller the drive wheels start backwards when pressing the start button. If the proximity switch then detects the start of the wire (negative edge), it is reversed and stopped when the wire tip is detected again (positive edge). 6.3 Automatic mode 6.3.1 Production of 10 wire rods with a length of 2m Procedure Table 6-5 No. Step Remark 1. Go to automatic production and enter 10 for the number of core rods. Subsequently, start the production using the start button. The distance between steel rod tip position and cutter position is always displayed as current feed (here -198mm). In this case, the first steel rod is thus moved forward by 2198mm and then cut. V2.0 16.07.2008 42/54

Live Demo No. Step Remark 2. As soon as the job has started, the production ID of the batch is displayed. While processing the job, the number of already cut steel rods (actual value) is permanently updated and displayed. The steel rod is cut when the current feed corresponds to the required rod length (here 2000mm). With each new feed after cutting, the feed value is reset to 0. The remaining capacity on the coil is updated after each cut. 3. After the cutting job has been completely processed, setpoint and actual value of the cut steel rods are identical (here =10). The production job is terminated with the Protocol button. The production data of the job is then written to the memory module. Alternatively, you can later increase the number of steel rods to be cut before the job is logged. If you enter, for example, 15 as a new setpoint and restart the job, 5 additional rods are cut. The production ID remains unchanged. The above figure graphically indicates the feed and cut operations. After pressing the Protocol button, the controller is ready for the entry of a new job. 6.3.2 Premature termination of the production process Procedure Table 6-6 No. Step Remark 1. Start a cutting job in automation mode as described in section 6.3.1. Select the number of steel rods to be cut, for example again =10. V2.0 16.07.2008 43/54

Live Demo No. Step Remark 2. Before completing the job for instance during the feed of the sixth rod press the End button. The End button flashes and thus indicates the premature termination of the job. The currently processed rod is still cut to the defined length. The cutting process is interrupted. 3. Terminate the production job by selecting the Protocol button. The production data of the job is then written to the memory module. Alternatively, you can undo the termination of the production by again pressing the End button and by selecting the start button to continue the original job. 6.4 Cutting wire rods of variable length (manual mode) Aside from automatic mode, the application also offers manual production. In manual mode, the wire feed is realized by a jog mode (both forwards and backwards) with two velocities. Cutting is performed by a button on the TP. Also manual mode requires that the steel wire be fed in (scenario as shown in section 6.2). This enables the user to accurately display the current feed or the desired wire length on the TP 177micro and to set the feed or length using jogging. V2.0 16.07.2008 44/54

Live Demo Procedure Table 6-7 No. Step Remark 1. Go to manual production mode (only possible if wire has previously been fed in ). 2. To cut a steel rod with a length of 2000mm also in this mode, use the jog buttons to move the wire in such a way that a current feed of 2000mm is displayed on the TP. 3. Press the cut button. The cutting tool is controlled while you keep the button pressed. The displayed current feed indicates the distance between wire tip position and cutter. If the wire tip is located exactly at the cutting tool (e.g., immediately after a cut), the feed = 0mm. You can move forward or backward, jog quickly or slowly and make corrections as often as desired. If the current feed 0, i.e. if no wire is under the cutting tool, the cut button cannot be used. After completing the cut, the residual material is updated on the TP. The cut is automatically logged with production ID 0. 6.5 Immediate stopping of the feed motion In the feed in and automatic production modes, a triggered feed motion can be stopped immediately using a stop button on the TP 177micro, hardware button. In both cases, the stopping is realized by the Lin_StopMotion block whose decelerating torque can be parameterized. While, after a stop via the TP 177micro, the original motion can be continued using the start button on the TP, the program branches to a fault condition requiring acknowledgement ( Emergency Stop message) when stopping by means of the hardware button; after acknowledgement this condition inevitably leads to feed in. V2.0 16.07.2008 45/54

Live Demo! WARNING The hardware stop button must not necessarily be used as an actuating element of an emergency stop circuit, even if this is provided by its mechanical and electrical design. The hardware button merely intervenes in the control software. It does not interrupt the voltage of the motor circuit. Please observe the safety philosophy to be applied in your plant. V2.0 16.07.2008 46/54

Live Demo 6.5.1 Stopping using the stop button of the TP 177micro Procedure Table 6-8 No. Step Remark 1. Go to feed in mode (section 6.2) or to automatic production (section 6.3). 2. During the relevant mode, press the Stop button on the TP. a. Response when feed active: The motor is immediately decelerated to a standstill with the decelerating torque parameterized at the Lin_StopMotion block (T_Stop variable in the Parameters status table). Response when feed motor stopped: This is, for example, the case when the cut is currently being performed in automatic mode. The subsequent feed motion that normally follows the cut is not performed. 3. Continue the original operation using the Start button. In automatic production, the current job cannot be aborted by means of the stop button on the TP. If you want to cancel the job after the currently fed rod is cut to length, use the End button (flashes after the selection) to select the abort and to subsequently restart the drive using the start button. Use the hardware stop button for an immediate abort of the current job and automatic production (see section 6.5.2). V2.0 16.07.2008 47/54

Live Demo 6.5.2 Stopping using the hardware stop button (emergency stop) Procedure Table 6-9 No. Step Remark 1. Go to feed in mode (section 6.2) or to automatic production (section 6.3). 2. During the corresponding mode, press the hardware stop button. a. Response when feed active: The motor is immediately decelerated to a standstill with the decelerating torque parameterized at the Lin_StopMotion block (T_Stop variable in the Parameters status table). Response when feed motor stopped: This is, for example, the case when the cut is currently being performed in automatic mode. The subsequent feed motion that normally follows the cut is not performed. 3. An Emergency Stop message is displayed on the TP 177micro. 4. If you have used a latching (emergency stop) button instead of the hardware stop button, release it. 5. Acknowledge the message on the TP. 6. Feed in the wire as described in section 6.2. Acknowledgement After acknowledging the message, it disappears and the feed-in screen is displayed on the TP. Log data When stopping with the hardware stop button, forced logging of the job data is performed. All rods of the respective job cut until the stop event are considered. Please check this within the scope of the data logging in chapter 6.6. V2.0 16.07.2008 48/54

Live Demo 6.6 Data logging Read out the log data from the memory module at regular intervals. Procedure Table 6-10 No. Step Remark 1. 2. Double-click. Directory of csv log files is opened. A file with current date/time stamp in the file name does not yet exist. Double-click. The memory module is read out and deleted. The log data is written to the above directory as a csv file. If the directory is opened, it can be directly checked whether the csv file is created (may take several seconds). 3. Open the csv log file. (Example): The csv log file has a date/time stamp in the file name: (2) DAT Configuration 0 (DAT0) tt.mm.jjjj hh-mm.csv V2.0 16.07.2008 49/54

Live Demo 6.7 Optimizing the positioning process Note The process is optimized by examining the trend curves v(t) and/or s(t).as described in chapter 4.4. The optimization is performed for a positioning in automatic mode. The trend curves are triggered by pressing the start button in automatic mode. In the case described in the following table, the motor was operated without additional external moments of inertia. Procedure Table 6-11 No. Step Remark 1. Open the Parameters variable table and select a positioning speed for the optimization that is as large as possible (V_Pos=400.0). Set the speed in the Parameters status table. Please note that the V_Pos parameter is smaller than/equal to the Velocity_Limit parameter. Start the optimization process with the tenfold moment of inertia (inertia) of the motor. This value (10*0.00052=0.0052kgm 2.) has already been stored in VD1116. 2. Select the Test variable table. Activate Lin_Com_Monitor. In selected_value, specify what you want to monitor (2=v(t), 3=s(t)). Enable Lin_Com_Monitor with Com_Monitor =1. 3. In recipe administration, select a steel rod length of 400mm for the wire-wound coil used for optimization. On the one hand, this ensures that the specified positioning speed is reached and, on the other hand, that the entire positioning process is short enough (< 1.992s) to be completely monitored by the Lin_Com_Monitor block. V2.0 16.07.2008 50/54

Live Demo No. Step Remark 4. A requirement for recording a trend curve is that the Done output of the Lin_Com_Monitor block has 1 status (does not apply to the first recording process). 5. Go to automatic production and enter 1 for the number of core rods. Subsequently, start the production using the start button. The positioning starts and Lin_Com_Monitor is triggered. 6. Go to the Optimization status table and use to go to the trend view. By selecting, you can stop the recording to make, for example, a screen shot. 7. Go to the Parameters status table and change the following parameters: Inertia: 0.00416kgm 2 M10.0: 1 (is reset automatically) To ensure that the Inertia parameter takes effect at the Lin_Init_horizontal block, the init block has to be processed once. You achieve this with a positive edge at the M10.0 flag. This makes a system restart with renewed feed in unnecessary. V2.0 16.07.2008 51/54

Live Demo No. Step Remark 8. To move the axis again, proceed as follows: Press the Protocol button Enter number of core rods = 1 Press the Start button As can be seen in the marked frame, the overshoot behavior could be optimized. 9. If necessary, repeat steps 7 and 8 with changed inertia and iteratively approach the optimum. Note The smaller the inertia, the smaller its influence on the system dynamics. Thus the trend curves for your application may deviate more or less strongly from the pictures in this application. V2.0 16.07.2008 52/54

Technical Data 7 Technical Data LOGO! Power 24V 1.3 Table 7-1 Supply voltage Criterion Technical data Additional note 85 to 264VAC Output voltage 24VDC (setting range 22.2 to 26.4VDC ) Output current 1.3A Dimensions (W x H x D) mm 54 x 90 x 55 SIMATIC S7-200 CPU 224XP Table 7-2 Criterion Technical data Additional note Supply voltage 20.4 to 28.8VDC Current consumption 900mA Inputs/outputs 14DI/10DO + 2AI EPROM user data 16 Kbytes Dimensions (W x H x D) mm 140 x 80 x 62 SINAMICS G110 Table 7-3 Criterion Technical data Additional note Supply voltage 1 200-240VAC ±10% Input frequency 47-63Hz Output frequency 0-650Hz Output power 0.25kW Rated output current 1.7A Efficiency 90-94% Overload capability 150% Dimensions (H x W x D) mm 150 X 90 X 116 4-pole asynchronous motor Table 7-4 Criterion Technical data Additional note Rated power 0.25kW Rated voltage Δ/Y 230/400V Rated current Δ/Y 1.34/0.77A Rated frequency 50Hz V2.0 16.07.2008 53/54

Technical Data Criterion Technical data Additional note Rated speed 1350min -1 Moment of inertia 0.00052kg m 2 Shaft height 71mm Weight Approx. 5kg Proximity switch Table 7-5 Criterion Technical data Additional note Number of conductors Type of design Connector 3 conductors Cubic 40mm x 40mm M12 connector Rated operating distance s n 25 or 40mm Selectable Operating voltage Rated operational current I e 10-65VDC 300mA Displays for Switching status, supply voltage Degree of protection IP 65 TP 177micro Touch Panel Table 7-6 Criterion Technical data Additional note Supply voltage 24VDC 20.4 28.8V Nominal current 0.24A Memory Flash 256 KB usable for user Required configuration tool WinCC flexible Micro V 2004 SP1 and higher Display STN, 4 blue levels 5.7" 320 x 240 pixels (W x H) Interface RS485 (max. 0.1875Mbps) Dimensions (W x H) 212mm x 156mm Degree of protection (front/rear) IP 65/20 V2.0 16.07.2008 54/54