PLC

Micro Application Example
Closed-Loop Positioning Control with standard Drives Micro Automation Set 1
Table of Contents
Micro Automation Set 1 ID Number 21063595
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.
Copyright Siemens AG 2008 All rights reserved Set01_DocTech_2d0_en.doc
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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
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Table of Contents
Table of Contents
Table of Contents ......................................................................................................... 4 1 1.1 1.2 1.3 1.4 2 3 4 4.1 4.2 4.3 4.4 4.4.1 4.4.2 5 5.1 5.2 5.3 5.4 5.5 5.6 6 6.1 6.2 6.3 6.3.1 6.3.2 6.4 6.5 6.5.1 6.5.2 6.6 6.7 7 Fields of Application and Benefits ................................................................ 5 Automation problem.......................................................................................... 5 Automation solution Set 1.............................................................................. 6 Fields of application .......................................................................................... 8 Benefits............................................................................................................. 8 Configuration .................................................................................................. 9 Hardware and Software Components ......................................................... 11 Principle of Operation .................................................................................. 13 Introduction to positioning............................................................................... 13 Block libraries for moving linear and rotary axes ............................................ 19 Configuring the G110 frequency inverter........................................................ 23 Optimizing the positioning operation............................................................... 25 Optimization with regard to the moment of inertia .......................................... 25 Optimization of the travel profile ..................................................................... 27 Configuring the Startup Software ............................................................... 29 Preliminary remark.......................................................................................... 29 Downloading the startup code ........................................................................ 29 Configuring the CPU 224XP PLC ................................................................... 30 Preparing the archiving function ..................................................................... 34 Loading the TP 177micro Touch Panel .......................................................... 35 Parameterizing the G110 frequency inverter .................................................. 36 Live Demo...................................................................................................... 38 Setting up the wire-wound coils ...................................................................... 40 Feeding in the wire ......................................................................................... 41 Automatic mode.............................................................................................. 42 Production of 10 wire rods with a length of 2m ............................................... 42 Premature termination of the production process ........................................... 43 Cutting wire rods of variable length (manual mode) ....................................... 44 Immediate stopping of the feed motion........................................................... 45 Stopping using the stop button of the TP 177micro ........................................ 47 Stopping using the hardware stop button (emergency stop) .......................... 48 Data logging.................................................................................................... 49 Optimizing the positioning process ................................................................. 50 Technical Data .............................................................................................. 53
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Fields of Application and Benefits

1
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 coils 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
Wire-wound coil
Cutter
Type1
Type2
Type3
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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
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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
s
SIMATIC PANEL
TOUC H
5
s
3 4
z 1 2 3 4 5 6 7 8 9 1 0
O J P H M 123 O N z G H
8
7
s
1 8
TP 177 micro
2 LOGO! Power
3 S7-200 CPU 224XP
SIMATIC PXI inductive sensor
5 SINAMICS G110 with BOP 6

WINDOWS-based system
Asynchronous motor with HTL encoder
7 NC contact
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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.
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Configuration
Configuration
Figure 2-1
L1 N PE L+ M
Connection diagram
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+
PROFIBUS cable
3 2 1
L1 L2 L3
B 1 2 3 4 5 6 7 8 9 10 C D E L A M F G
K J H
Connector of the encoder cable contact side (not solder side)
wht
1 L+ M
blu
red blk
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).
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PC/PPI or USB/PPI cable
WINDOWS-based system for configuring and data archiving
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Configuration
The start motor command is applied at digital output Q1.0 of the controller. It is connected to terminal 3 of the inverters signal interface. The reversal signal is applied at digital output Q1.1 of the controller. It is connected to terminal 4 of the inverters 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.
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Hardware and Software Components

3
Products

Table 3-1
Component RCBO LOGO! Power 24V/1.3A SIMATIC S7-200 (CPU 224XP) TP 177micro Touch Panel SINAMICS G110, frequency inverter SINAMICS G110, frequency inverter with integrated EMC filter Low-voltage asynchronous motor
No. 1 1 1 1 1
MLFB / order number 5SU1154-7KK06 6EP1331-1SH02 6ES7214-2BD23-0XB0 6AV6640-0CA11-0AX0 6SL3211-0AB12-5UA1 6SL3211-0AB12-5BA1
Note
Alternatively
1LA7070-4AB10-Z H57
Motor with rotary pulse encoder, 1024 pulses per revolution Remove D-sub connector!
Encoder cable for rotary pulse encoder SIMATIC PXI350 INDUCTIVE SENSOR 40X40MM Pushbutton, red, 1NC MC 291 MEMORY MODULE, 256 KBYTES
1 1
6SX7002-0AN30-1AC0 3RG4141-3AB01
1 1
3SB3203-0AA21 6ES7291-8GH23-0XA0
Accessories
Table 3-2
Component Basic Operator Panel (BOP) for SINAMICS G110
No. 1
MLFB / order number 6SL3255-0AA00-4BA1
Note
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Configuration software/tools
Table 3-3
Component WinCC flexible micro Step 7 Micro/Win PC/PPI cable USB/PPI cable SINAMICS MICROMASTER SIZER
No. 1 1 1 1
MLFB / order number 6AV6610-0AA01-2CA8 6ES7810-2CC03-0YX0 6ES7901-3CB30-0XA0 6ES7901-3DB30-0XA0 6SL3070-0AA00-0AG0
Note
Alternatively; can also be used for loading the TP177 micro Optional
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Principle of Operation
4
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 s or the angle . 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
Load torque Disturbance variable Position Velocity Acceleration (torque) Reference variable Control with MicroPos blocks Controller Frequency inverter, asynchronous motor Analog value 0 10V Controlled system Manipulated value Encoder pulses Position Velocity Controlled variable
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.
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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
400
-300
-200
-100
Source position
Target position
(not relevant)
Home 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.
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100
200
500
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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
40mm Shortest detectable travel path = 40mm / 1024 0.039mm
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 < 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 x0 when homing, the rotation counter has the value +2 in x0. 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.
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Micro Automation Set 1
Figure 4-4: Example of a rotary axis, angle traveled
ID Number 21063595
One motor revolution = 1024 encoder pulses
= 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 ( < 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
Source position
Target position
Positioning to 270 in positive direction
Home position
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
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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.
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Figure 4-7: Travel profile
ID Number 21063595
Forwards/upwards
Velocity
Time
Backwards/downwards
Path
Generator operation
Time
Horizontal axis Vertical axis
Torque
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.
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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

Figure 4-8
Overview of available positioning blocks
MAP_Ind_Lin library for linear axis

Lin_Init_horizontal Lin_Init_vertical Lin_MoveJog Lin_Home Lin_MoveAbs Lin_MoveRel Lin_StopMotion Lin_Control Lin_Com_Monitor
MAP_Ind_Rot library for rotary axis
Rot_Init
Rot_MoveJog Rot_Home Rot_MoveAbs Rot_MoveRel Rot_StopMotion Rot_Control 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.
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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 positionings 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 controllers 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
Upper limits are not even exceeded during operation if higher values are parameterized in the blocks initiating a motion.
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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 End of homing Home position Start of homing
(if feed-in has already been performed)
s(t) Start of homing

(if feed-in has not yet been performed)
1) Detection width
Wire-wound coil Proximity switch for wire detection 1)

Cutter
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.
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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.
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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) 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.
Note
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.
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To parameterize the inverter, we recommend the following procedure:

Table 4-1
No.
Step
1. 2. 3. 4. 5.
Resetting to factory default settings (if condition at delivery from the plant has been changed) Quick commissioning. Application-specific parameterizations. Saving parameters to the inverters EEPROM. 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:
The BOP can be plugged in any inverter mode.
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No. Operator input sequence step
ID Number 21063595
Note
1. 2.
Go to parameterization mode. Select the parameter to be changed.
3. 4.
Display the parameter value. Change the parameter value. When you press FN, you can change each decade individually.
These operations have to be performed for each parameter.
5. 6.
Apply the value. 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 Operating Instructions Parameter List
21696936 22102965 20977026
4.4
4.4.1
Optimizing the positioning operation

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.
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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 motors mass inertia, please refer to the motor catalog. Accordingly, a value of 0.00052kgm2 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!
Overshoot! v(t)
Figure 4-12
s(t) Optimum characteristic
Optimum characteristic v(t)
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Figure 4-13
ID Number 21063595
s(t) Gradual vanishing!
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 applications 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%)
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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)
vmax (at 100Hz)
v(t), M(t)
M = 200%
vmax/2
v(t), M(t)
vmax/2 M = 100%
v(t), M(t)
vmax/2
M = 50%
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
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Configuring the Startup Software

5
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
Set1_s7-200_V1d0_en.zip
STEP 7 Micro/WIN project for the wire cutting machine (.mwp file) WinCC flexible project for the TP (.hmi and .LDF files). Libraries of the drive blocks for linear and rotation angle positioning (map_ind_lin.mwl and map_ind_rot.mwl files)
2 3
Set1_WinCCflex_Visu_V1d0_en.zip map_ind_V1.19.zip
Note
The map_ind_rot.mwl library is not used in the software example. It is only offered for download to complete the picture.
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5.3
Table 5-2
Configuring the CPU 224XP PLC
Step-by-step instructions for configuring the controller

No. Instruction Remark
Development syst em
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:
12345678 00001000
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 Start STEP 7 Micro/WIN and open the mwp project file. 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.
3. 4.
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).
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No. Instruction
ID Number 21063595
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. Select PLC>RUN or the corresponding icon to set the S7-200 controller to RUN mode.

7.
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.
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Table 5-3
ID Number 21063595
Parameter
Explanations Technological parameters
dist_BERO_cutter: VW32
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 Nherungsschalter
Schneidemechanismus (cutter)
absolute Position
dist_BERO_cutter
cutter_down_time: VW34
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
cut_delay: VW40
coil: VW114 minimum: VD76
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
V_Ref: VD1004 Jog_slow: VD1008 Jog_fast: VD1012
Homing velocity (mm/s) Slow jog mode velocity (mm/s) Fast jog mode velocity (mm/s)
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Parameter
V_Pos: VD1016
ID Number 21063595
Explanations
Positioning velocity (mm/s)

Torque parameters 3
T_Ref: VD1028 Torque_Jog_slow: VD1032 Torque_Jog_fast: VD1036 T_Pos: VD1040 T_Stop: VD1048
Accelerating/decelerating torque for homing (%) Accelerating/decelerating torque for slow jog mode (%) Accelerating/decelerating torque for fast jog mode (%) Accelerating/decelerating torque for positioning (%) 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. 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. 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. Moment of inertia; see chapter 4.4
Velocity_Limit: VD1108
s_per_rev: VD1112
Inertia: VD1116
The percentage data of the torque refers to the motors 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 0200% are possible for the torque.
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5.4
Table 5-4
Preparing the archiving function
No.
Instruction
Remark
Development syst em
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:
12345678 00001000
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. 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)
3.
4.
A shortcut to the Data-Log file in the 256 KB memory module is now automatically created on the desktop. 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 when double-clicking path as a csv file .
5.
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5.5
Table 5-5
Loading the TP 177micro Touch Panel
No.
Instruction
Remark
TP 177micro
Development system
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:
12345678 11000000
2. 3.
Start WinCC flexible and open the hmi project file. Call the transfer dialog box by selecting Project>Transfer>Transfer Settings or by using the respective icon. 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. 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.
4.
5.
6. 7.
Start the project file transfer. 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
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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 P0970 P0003

30 1 3 1 1.34 0.25 0.78 50 1350 100.00 0.00 0.00 1 3 200.00 0 1 30 1 1
Commissioning parameter: Factory setting Start of the reset of all parameters to default values
Quick commissioning
Access level: Expert Commissioning parameter: Quick commissioning Rated motor current (A) (for delta connection), see rating plate Rated motor power (kW), see rating plate Rated power factor of the motor (cos ), see rating plate Rated motor frequency (Hz) for the specific motor data, see rating plate Rated motor speed (min-1), see rating plate Maximum frequency (Hz) (100Hz for 4-pole motor, 50Hz for 2-pole motor) Acceleration time (determined by the controller) Deceleration time (determined by the controller) End of quick commissioning (among other things, resets P0003 to 1)
Application-specific parameterizations
P0010 P0305 P0307 P0308 P0310 P0311 P1082 P1120 P1121 P3900 P0003 P0760 P1240 P0971 P0010 P0802 P0003
Access level: Expert y2 value ADC scaling (%) (100% for 2-pole motors) Configuration of Vdc controller: Vdc controller disabled
Saving parameters to the inverters EEPROM
Transfer of values from RAM to EEPROM

Transferring parameter set to BOP for reuse
Commissioning parameter: Factory setting Parameter transfer from SINAMICS BOP Access level: Standard
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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 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.
Table 5-7
Parameter No.
Value
Remark
Transferring parameter set from the BOP to the frequency inverter
P0003 P0010 P0803 P0971 P0003
3 30 1 1 1
Access level: Expert Commissioning parameter: Factory setting Parameter transfer from BOP SINAMICS
Saving parameters to the inverters EEPROM
Transfer of values from RAM to EEPROM Access level: Standard
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Live Demo
6
Overview
Live Demo
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
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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. 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.
Not grayed out
ID Number 21063595
Example
Grayed out
settings recipe admin. production feed in automatic manual
Automatic mode selected
Graphic: A graphic in the TP screens shows the wire cutting machines condition of motion.
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.
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Live Demo
Table 6-2
ID Number 21063595
No.
Step
Remark
1. . Double-click Memory module is read out and deleted. 2. 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. 2.
On the TP 177micro, select the recipe admin. screen. Use the arrow keys to select the wire-wound coil you want to use. Four data records (recipes) are available. 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.
3.
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Live Demo
No. Step
ID Number 21063595
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.
The text not yet fed in! flashes. 2. Use the start button (transport wheels start) and put the end of wire between the transport wheels. 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.
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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
6.3.1 Procedure
Table 6-5
Automatic mode
Production of 10 wire rods with a length of 2m
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.
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Live Demo
No. Step
ID Number 21063595
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. The above figure graphically indicates the feed and cut operations.
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. After pressing the Protocol button, the controller is ready for the entry of a new job.
6.3.2 Procedure
Table 6-6
Premature termination of the production process
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.
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Live Demo
No. Step
ID Number 21063595
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.
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Live Demo
Procedure
Table 6-7
No.
Step
Remark
1.
Go to manual production mode (only possible if wire has previously been fed in).
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. 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. 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.
3.
Press the cut button. The cutting tool is controlled while you keep the button pressed.
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.
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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.
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Live Demo
6.5.1 Procedure
Table 6-8
Stopping using the stop button of the TP 177micro
No.
Step
Remark
1. 2.
Go to feed in mode (section 6.2) or to automatic production (section 6.3). 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).
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Live Demo
6.5.2 Procedure
Table 6-9
Stopping using the hardware stop button (emergency stop)
No.
Step
Remark
1. 2.
Go to feed in mode (section 6.2) or to automatic production (section 6.3). 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. 4.
An Emergency Stop message is displayed on the TP 177micro. If you have used a latching (emergency stop) button instead of the hardware stop button, release it. Acknowledge the message on the TP. Feed in the wire as described in section 6.2.
Acknowledgement
5. 6.
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.
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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. Double-click . Directory of csv log files is opened. A file with current date/time stamp in the file name does not yet exist. 2. 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
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Live Demo
6.7
Optimizing the positioning process

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.
Note
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=0.0052kgm2.) has already been stored in VD1116. 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.
2.
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.
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Live Demo
No. Step
ID Number 21063595
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: 0.00416kgm2 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.
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Live Demo
No. Step
ID Number 21063595
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.
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Technical Data
7
Table 7-1
Technical Data
LOGO! Power 24V 1.3

Criterion Technical data Additional note
Supply voltage Output voltage Output current Dimensions (W x H x D) mm
85 to 264VAC 24VDC (setting range 22.2 to 26.4VDC ) 1.3A 54 x 90 x 55
SIMATIC S7-200 CPU 224XP

Table 7-2
Criterion
Technical data
Additional note
Supply voltage Current consumption

20.4 to 28.8VDC 900mA 14DI/10DO + 2AI 16 Kbytes 140 x 80 x 62
Inputs/outputs EPROM user data Dimensions (W x H x D) mm
SINAMICS G110
Table 7-3
Criterion
Technical data
Additional note
Supply voltage Input frequency Output frequency Output power Rated output current Efficiency Overload capability Dimensions (H x W x D) mm
1 200-240VAC 10% 47-63Hz 0-650Hz 0.25kW 1.7A 90-94% 150% 150 X 90 X 116
4-pole asynchronous motor

Table 7-4
Criterion
Technical data
Additional note
Rated power Rated voltage Rated current Rated frequency
0.25kW /Y 230/400V /Y 1.34/0.77A 50Hz
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Technical Data
Criterion Technical data
ID Number 21063595
Additional note
Rated speed Moment of inertia Shaft height Weight
1350min-1 0.00052kg m2 71mm Approx. 5kg
Proximity switch
Table 7-5
Criterion
Technical data
Additional note
Number of conductors Type of design Connector Rated operating distance sn Operating voltage Rated operational current Ie
3 conductors Cubic 40mm x 40mm M12 connector 25 or 40mm 10-65VDC 300mA Switching status, supply voltage IP 65 Selectable
Displays for Degree of protection
TP 177micro Touch Panel

Table 7-6
Criterion
Technical data
Additional note
Supply voltage Nominal current Memory Required configuration tool Display
24VDC 0.24A Flash 256 KB usable for user WinCC flexible Micro STN, 4 blue levels 5.7" 320 x 240 pixels (W x H) RS485 (max. 0.1875Mbps) 212mm x 156mm IP 65/20
20.428.8V
V 2004 SP1 and higher
Interface Dimensions (W x H) Degree of protection (front/rear)
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Micro Application Example

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

Warranty, liability and support

Copyright Siemens AG 2008 All rights reserved Set01_DocTech_2d0_en.doc

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Fields of Application and Benefits

Fields of Application and Benefits

Copyright Siemens AG 2008 All rights reserved Set01_DocTech_2d0_en.doc

Fields of Application and Benefits

Automation solution Set 1

Copyright Siemens AG 2008 All rights reserved Set01_DocTech_2d0_en.doc

Fields of Application and Benefits

3 S7-200 CPU 224XP

SIMATIC PXI inductive sensor

5 SINAMICS G110 with BOP 6

Asynchronous motor with HTL encoder

Fields of Application and Benefits

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Connector of the encoder cable contact side (not solder side)

PC/PPI or USB/PPI cable

WINDOWS-based system for configuring and data archiving

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Hardware and Software Components

Hardware and Software Components

MLFB / order number 5SU1154-7KK06 6EP1331-1SH02 6ES7214-2BD23-0XB0 6AV6640-0CA11-0AX0 6SL3211-0AB12-5UA1 6SL3211-0AB12-5BA1

Component Basic Operator Panel (BOP) for SINAMICS G110

MLFB / order number 6SL3255-0AA00-4BA1

Hardware and Software Components

MLFB / order number 6AV6610-0AA01-2CA8 6ES7810-2CC03-0YX0 6ES7901-3CB30-0XA0 6ES7901-3DB30-0XA0 6SL3070-0AA00-0AG0

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One revolution = 1024 encoder pulses

40mm Shortest detectable travel path = 40mm / 1024 0.039mm

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One motor revolution = 1024 encoder pulses

Smallest detectable angle of revolution = 28 / 1024 1 38

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Figure 4-5: Example of a rotary axis, absolute positioning

Positioning to 270 in positive direction

Positioning to 270 in negative direction

Source position Target position

Positioning by 630 in positive direction

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Horizontal axis Vertical axis

Block libraries for moving linear and rotary axes

Overview of available positioning blocks

MAP_Ind_Lin library for linear axis

MAP_Ind_Rot library for rotary axis

Rot_MoveJog Rot_Home Rot_MoveAbs Rot_MoveRel Rot_StopMotion Rot_Control Rot_Com_Monitor

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s(t) Start of homing

Wire-wound coil Proximity switch for wire detection 1)

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Configuring the G110 frequency inverter

To parameterize the inverter, we recommend the following procedure:

To change a parameter via the BOP, proceed as follows:

The BOP can be plugged in any inverter mode.

Go to parameterization mode. Select the parameter to be changed.

These operations have to be performed for each parameter.

Apply the value. Select the display (0000).

Exit parameterization mode.

Getting Started Guide Operating Instructions Parameter List