Application about Drive Technology - Siemens · • the integrated technology which processes the technological ... Communicating via ... (actual value, setpoint value) read/write

Application about Drive Technology

Technology CPU “Palletizer with simply 3D Interpolating Axes

Based on Cam Discs”

Extension

Warranty, liability and support

Palletizer 3D – Extension ID Number: 21062269

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Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are correctly used. These Application Examples do not relieve you of the responsibility of safely and professionally using, installing, operating and servicing equipment. When using these Application Examples, 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 Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Application Examples and other Siemens publications – e.g. Catalogs – then 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 Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract (“wesentliche Vertragspflichten”). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions do not imply a change in the burden of proof to your detriment.

Copyright© 2007 Siemens A&D. It is not permissible to transfer or copy these Application Examples or excerpts of them without first having prior authorization from Siemens A&D in writing. For questions about this document please use the following e-mail address:

mailto:[email protected]

mailto:[email protected]

Foreword


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Foreword The application described in this document deals with a “palletizer with simply 3D interpolating axes”. It will be shown how a multidimensional positioning as, for instance, required for a palletizer can be realized using the technology CPU or a Microbox 42x-T.

The core element is the “Move3D” technology template which generates the cam discs necessary for a three-dimensional motion from an interpolation point table and which moves the axes at a constant path velocity. If you want to obtain further information on the technology template, a separate documentation is available. The reference data for this documentation is listed in the appendix of this document.

Objective of the application This application shows the use of one of the technological functions or of a technology template in the technology CPU. In order to provide a compact and practical description, a function frequently used in machines is used in a simple example with HMI connection. This ensures that the application can also be used as a demonstration model. The application illustrates the following:

• How the used components work together

• Which technological functions are used

• How the application is programmed and parameterized

• How the application can be used as a demonstration system

Main contents of this application The following main points are described in this application:

• Use of the “Camming” technology function

• Use of the “Move3D” technology template

Delimitation This application does not include a description of…

• …basic knowledge when using STEP 7

• …basic knowledge in the field of motion control

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

• ...the general handling of the technology CPU

Basic knowledge of these topics is required.

Foreword


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Document structure The documentation of this application is divided into three documents:

• Introduction

• Extension

• Demonstration In addition, the STEP7 code is available.

The second document, Extension, which you are reading right now, is intended for persons who want to study the subject in greater detail.

Part Description Introduction Application Description and Principles of Operation

This part provides a general overview of the contents. You are informed on the used components (standard hardware and software components and the specially created user software).

Extension Principles of Operation in Detail and Program Structures

This part describes the detailed functional sequences of the involved hardware and software components, the solution structures and – where useful – the specific implementation of this application. It is required to read this part if you want to familiarize with the interaction of the solution components to use these components, e.g., as a basis for your own developments.

Demonstration Structure, Configuration and Operation of the Application

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

An additional component available is the S7 program code.

Part Description

S7 program code The S7 program code includes the code and a user interface which is also suitable as a demonstration system.

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

http://support.automation.siemens.com/WW/view/en/21062269


Foreword


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Table of Contents

Table of Contents ......................................................................................................... 5

Functional Mechanisms............................................................................................... 8

1 Operating Principle of the Technology CPU ................................................ 8 1.1 Design............................................................................................................... 8 1.1.1 Control unit ....................................................................................................... 9 1.1.2 Integrated technology ....................................................................................... 9 1.2 Interaction of control unit and integrated technology ...................................... 10 1.2.1 Technology data blocks .................................................................................. 11 1.2.2 Technology function blocks ............................................................................ 12 1.2.3 Sequence of a technology job using the example of a positioning ................. 13 1.2.4 Operating principle of the technology function blocks .................................... 14 1.2.5 Replacement of a job by another job .............................................................. 14 1.2.6 List of the PLCopen function blocks ............................................................... 15 1.3 Technology objects of the technology CPU.................................................... 17 1.4 Technology CPU variants ............................................................................... 19 1.4.1 Controller variant ............................................................................................ 19 1.4.2 Embedded variant........................................................................................... 19

2 Operating Principle of the Palletizer ........................................................... 20 2.1 Overview of the operating principle ................................................................ 20 2.2 Detailed description of the function modules .................................................. 22 2.2.1 “Move3D” template, axis X, Y and Z............................................................... 23 2.2.2 Gripper Control ............................................................................................... 25 2.2.3 Pallet Control .................................................................................................. 26

3 Program Structure ........................................................................................ 27 3.1 List of used blocks .......................................................................................... 27 3.2 Overview of the program structure ................................................................. 29 3.2.1 Section: Operation / control ............................................................................ 30 3.2.2 Section: Technology template ........................................................................ 32 3.2.3 Section: Axes.................................................................................................. 32 3.3 Sequential control of the automatic process................................................... 33 3.3.1 Operation and control of the automatic process ............................................. 33 3.3.2 Realization of the interpolated three-dimensional motion............................... 35

Configuration of the Technology CPU...................................................................... 46

4 Configuration Basics.................................................................................... 46 4.1 Introduction ..................................................................................................... 46 4.2 Differences between controller and embedded variant .................................. 46 4.3 Addresses in the application example ............................................................ 46 4.3.1 Controller variant with CPU 31xT-2 DP .......................................................... 47

Foreword


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4.3.2 Embedded variant with Microbox 42x-T ......................................................... 47

5 Hardware Configuration............................................................................... 48 5.1 Configuring the CPU 31xT-2 DP in HW Config .............................................. 48 5.1.1 Integrating the CPU 31xT-2 DP ...................................................................... 48 5.1.2 Parameterizing PROFIBUS DP(Drive) ........................................................... 49 5.1.3 Parameterizing the MPI .................................................................................. 50 5.1.4 Generating the technology system data ......................................................... 51 5.1.5 Completing the configuration of the CPU 31xT-2 DP ..................................... 52 5.2 Configuring the Microbox 42x-T in HW Config ............................................... 52 5.2.1 Integrating the Microbox 42x-T ....................................................................... 53 5.2.2 Parameterizing PROFIBUS DP(Drive) ........................................................... 54 5.2.3 Parameterizing the MPI .................................................................................. 56 5.2.4 Generating the technology system data ......................................................... 57 5.2.5 Completing the configuration of the Microbox T ............................................. 57 5.2.6 Downloading the configuration to the Microbox T........................................... 59 5.3 Configuring the technology objects................................................................. 61 5.3.1 Configuration tools for the technology objects................................................ 61 5.3.2 Calling S7T Config.......................................................................................... 63 5.3.3 Configurations to be performed ...................................................................... 64 5.3.4 Creating the master axis (Axis_Master).......................................................... 64 5.3.5 Creating the virtual master, X, Y, Z axes ........................................................ 66 5.3.6 Cam discs “Cam_VM”, “Cam_X”, “Cam_Y” and “Cam_Z”.............................. 68 5.3.7 Parameterizing the synchronous relationships between the axes.................. 70 5.3.8 Connecting the Axis technology object to a real axis ..................................... 74 5.3.9 Settings for the SINAMICS S120 training case .............................................. 77 5.3.10 Parameterizing an axis ................................................................................... 82 5.3.11 Generation of the technology data blocks ...................................................... 88 5.4 Integration of the PLCopen blocks.................................................................. 90

WinCC flexible Configuration .................................................................................... 91

6 Configuring Aids........................................................................................... 91 6.1 Screen display of the interpolation points ....................................................... 91 6.2 Integration of Runtime on the Microbox 42x-T................................................ 93 6.2.1 Setting the screen resolution .......................................................................... 93 6.2.2 WinCC flexible Runtime installation................................................................ 93 6.2.3 WinCC flexible Runtime Loader settings ........................................................ 94 6.2.4 Transferring the project................................................................................... 95

Appendix and Bibliographic References.................................................................. 97

7 Bibliographic References ............................................................................ 97 7.1 Bibliographic references ................................................................................. 97 7.2 Internet links ................................................................................................... 98 7.3 Related documentation................................................................................. 100

Foreword


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8 History ......................................................................................................... 100

Foreword


Functional Mechanisms

1 Operating Principle of the Technology CPU

1.1 Design

The technology CPU consists of two parts:

• The control unit which processes the control tasks and

• the integrated technology which processes the technological functions.

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To a large extent, both parts operate independently of one another. (The embedded variant (Microbox 42x-T) has only one processor processing both parts. The differences between embedded and controller variant are explained in chapter 1.4.) This ensures that the technological functions are computed in short, equidistant1 cycles without loading the cycle times of the control unit.

Both parts exchange data via technology data blocks and technology function blocks. Figure 1-1 Detail of the technology CPU

OB35 cycle

OB1 cycle

SIEMENS

Communicating via PROFIBUS DP / MPI

Message frame (actual value, setpoint value)read/write via PROFIBUS DP(DRIVE)

Control unit Integrated technology

Technology tasksTechnologyFBs

TechnologyDBs

The technological functions are functions which extend the SIMATIC CPU by MotionControl applications, i.e. drives can be controlled via PROFIBUS.

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

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

1 Equidistant means that something is consistently repeated in a fixed and very exact time frame. This is, for example, required for control systems since it is otherwise not possible or difficult to optimize control loops due to the changing times. In SIMATIC, OB35 is used for equidistant tasks.

Foreword

Palletizer 3D – Extension ID Number: 21062269 1.1.1 Control unit

The control unit behaves like an S7 controller or a WinAC RTX without integrated technology. Via the PROFIBUS interface, the control unit can be connected to other CPUs, HMI or I/O devices.

In the user program, which is processed in the control unit of the technology CPU, technology data blocks and technology function blocks can be used via which the data exchange between the control unit and the integrated technology is realized.

1.1.2 Integrated technology

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

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

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

Chapter 1.3 of this documentation provides a detailed description of all further TOs.

Foreword

Palletizer 3D – Extension ID Number: 21062269 1.2 Interaction of control unit and integrated technology

Figure 1-2 Overview of the data exchange

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Technologyobject

Technology FB

TechnologyDB

DeviceDB

Trigger motion control job

Completed, termination, error message

of the job

Error / status message& actual values

of the technology objects

Job processing timeError of the int. technology

PROFIBUS lifelistDone flags

Status of the integrated I/O

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

These technology function blocks can be used to address and monitor the desired technology objects. The technology object additionally stores general data in a technology data block.

The interface of the technology function blocks is standardized and complies with the PLCopen standard for MotionControl blocks.

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

Foreword


Figure 1-3 Data exchange between one TO and several technology FBs

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Technologyobject

Job

Job statusTechnology

FB

TechnologyDB

Interface tothe

controllerInterface to the

controller

General dataStatus information

TechnologyFB

TechnologyFB

Job

Job status

Job

Job status

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

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

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

1.2.1 Technology data blocks

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

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

The update cycle of the technology DBs can be set. The default setting is 18ms.OB 65 technology synchronous interrupt OB

Foreword


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

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

The Device DB includes the following information:

• Data update status in the TO DBs

• ErrorID of the last detected errors

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• Duration for the job processing of the integrated technology

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

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

1.2.2 Technology function blocks

To be able to address the TOs from the control unit, the “S7-Tech” library is provided for the technology CPU. It includes the function blocks according to the PLCopen standard in the corresponding version, suitable for the firmware version of the integrated technology.

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

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

During a positioning process, e.g. the busy, done and/or error signals are output at the technology FB so that the current status of the positioning job can be monitored directly at the technology FB.

Foreword

Palletizer 3D – Extension ID Number: 21062269 1.2.3 Sequence of a technology job using the example of a positioning

To move an axis by a defined length, the FB 411 “MC_MoveRelative” technology FB is used for the Axis technology object: Figure 1-4 Interfaces of the Axis technology object

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Technologyobject

FB 401“MC_Power”

TechnologyDB

Interface to thecontroller

Interface tothe

controller

axis

Positioning axis

FB 403“MC_Home”

FB 404“MC_Stop”

FB 405“MC_Halt”

FB 410“MC_MoveAbsolute”

FB 411“MC_MoveRelative”

FB 412“MC_MoveAdditive”

FB 413“MC_MoveSuperImposed”

FB 414“MC_MoveVelocity”

FB 415“MC_MoveToEndPos”

Figure 1-5 Interface of FB411 “MC_MoveRelative”

FB 411 “MC_MoveRelative”

AxisExecuteDistanceVelocityAccelerationDecelerationJerkDoneFlag

Reference to theconfiguredtechnology DB of the axis

Technological functionsuccessfully completedDone

BusyCommandAborted

ErrorErrorID

ConstantVelocityAccelerationDeceleration

INTBOOLREALREALREALREALREAL

INT

BOOL

BOOLBOOLBOOL

BOOL

BOOLBOOLWORDStart bit with

which the functionis triggered.

Technological functionactive

Technological functionaborted by another job

Display of an errorwithin the FB

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

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

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

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

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

Foreword


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

1.2.4 Operating principle of the technology function blocks

Basically, the operation of all PLCopen blocks is based on the following principle:

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

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

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

• A job is terminated when

– it has been replaced by another job. If the Execute input is still set to TRUE, the CommandAborted output is set.

– an axis or job error occurs.

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

1.2.5 Replacement of a job by another job

The following example shows how a job is replaced:

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

• It accelerates as set and approaches the target position.

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

Foreword


• The Busy output is now cleared at “MC_MoveAbsolute” and CommandAborted is set. Busy is set at “MC_Halt”. “MC_MoveAbsolute” has been replaced by “MC_Halt”.

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

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

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

1.2.6 List of the PLCopen function blocks

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

Technology object

Technology function block

Description

FB 401 MC_Power Enabling / disabling axis FB 403 MC_Home Homing / setting axis FB 404 MC_Stop Stopping axis FB 405 MC_Halt Normal stop FB 409 MC_ChangeDataset Changing data record FB 410 MC_MoveAbsolute Absolute positioning

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

(e.g., moving axis by 10.0mm) FB 412 MC_MoveAdditive Relative positioning to current

target position FB 413 MC_MoveSuperImposed Superimposed positioning FB 414 MC_MoveVelocity Motion with speed specification FB 415 MC_MoveToEndPos Moving to mechanical endstop /

clamping FB 437 MC_SetTorqueLimit Activating / deactivating torque

limiting

Axis

FB 439 MC_SetCharakteristic Activating hydraulics characteristic

Foreword


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Technology object

Technology function block

Description

FB 420 MC_GearIn Starting gearing

FB 422 MC_GearOut Stopping gearing FB 421 MC_CamIn Starting camming FB 423 MC_CamOut Stopping camming FB 424 MC_Phasing Changing phase shift between

master axis and slave axis FB 441 MC_CamInSuperImposed Starting superimposed camming FB 443 MC_CamOutSuperImposed Stopping superimposed camming FB 440 MC_GearInSuperImposed Starting superimposed gearing FB 442 MC_GearOutSuperImposed Stopping superimposed gearing

Synchronous Operation

FB 444 MC_PhasingSuperImposed Changing superimposed phase shift

FB 430 MC_CamSwitch Position-based cams / operating cams

Cam Switch

FB 431 MC_CamSwitchTime Time-based cams External Encoder

FB 432 MC_ExternalEncoder External encoder

Measuring Input

FB 433 MC_MeasuringInput Measuring input

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

Cam Function

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

Basic Functions

FB 456 MC_WriteDriveParameter Writing drive parameters

Foreword


1.3 Technology objects of the technology CPU

The individual technology objects (TOs) will be briefly explained in the following:

Axis The most important TO is the axis. An axis includes all information on inverter, motor, gear and encoder. When parameterizing the axis, data such as speed and encoder pulses but also max. acceleration and (software) limit switches, etc. are indicated. Below only the axis is controlled. Which type of inverter, motor, gear or encoder is used is no longer relevant after the parameterization of the axis.

axis

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An axis can be individually stopped, moved, positioned or moved in synchronism with other axes or external encoders. Changing between these modes is possible at any time.

It is also possible to create a virtual axis. A virtual axis does not have physical components such as a motor or encoder. It only exists in the controller. Such a virtual axis can, for example, be used as a master axis in a group of synchronized axes.

When creating the axis, one of the following three axis types has to be selected:

• Speed axis: For axes which are only to be used in speed-controlled mode.

• Positioning axis: For axes which are to be used in speed-controlled and/or positioning mode. Axes of this type are suitable as a master axis for synchronous operation applications.

• Synchronized axis: For axes which are to be used in speed-controlled or positioning mode and/or as a slave axis in synchronous operation. Axes of this type are suitable as a master axis for synchronous operation applications.

Note Basically, all axes can be created as synchronized axes. But since the computing time requirement of the technology part increases with an increasing functional scope, the axes should only be created with the type that corresponds to the required functional scope.

Foreword


Cam Switch A cam generates a digital signal depending on the axis position. A typical example is the camshaft in the internal combustion engine. The valves are opened and closed depending on the position of the pistons.

cam switch

The technology CPU not only enables the user to use such position-based cams but also time-based and operating cams. Time-based cam signals remain set for a fixed period after overtravelling the activation position. An operating cam switches at the activation position and remains in the new status.

External Encoder The External Encoder TO allows to read in an external encoder and to use the velocity or position values of this encoder for further functions.

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external encoder

Synchronous Operation Synchronous operation is the synchronous moving of a group of at least two axes. The Synchronous Operation TO is available only for synchronized axes.

synchronous operation

The master value for a group of axes can be provided by an axis or an external encoder. All other axes of the group are slave axes.

The slave axes follow the positioning value (master value) of the master axis. The ratio between master value and position of the slave axis can be a constant (gearing) or a mathematical function (camming). Individual slave axes can be included in or excluded from the group of axes by synchronization or desynchronization processes.

Cam Function The cam function is an option to synchronize axes. However, no fixed, linear gear ratio between master and slave axis is used but a ratio input, for instance, via interpolation points. This enables the realization of nonlinear ratios or ratios defined in segments between master axis and slave axis (axes).

cam function

The cam profile can be defined in different ways. In most cases, interpolation point tables and functional equations are used. The cam profile is partly also stored in segments and each segment is stored in the form which suits it best.

Cam functions can be recalculated during operation. After clearing the previous cam function, the new cam data is read in. With the interpolation the actual cam function is then calculated from the specifications. A large number of points of which the cam function exists are calculated.

Foreword

Palletizer 3D – Extension ID Number: 21062269 Measuring Input

The measuring input is used to store the position value of an axis when receiving a trigger signal (e.g. Bero or zero mark); this measured value is then used, e.g., for positioning.

measuring input

1.4 Technology CPU variants

Two different variants of the technology CPU with specific characteristics are available; the variant to be used should be selected depending on the application use requirements.

• Controller variant

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• Embedded variant

However, the created technology objects can basically be operated on all variants of the technology CPU.

1.4.1 Controller variant

The controller variant is a SIMATIC controller of the S7-300 type. These controllers feature two processors for the control unit and the integrated technology that are independent of one another. These controllers can be extended by SIMATIC S7-300 I/O modules such as input and output modules, communications processors, etc.

The CPU 315T-2 DP and the CPU 317T-2 DP represent the controller variant of the technology CPU.

1.4.2 Embedded variant

The embedded variant is a SIMATIC Box PC of the Microbox type. The Microbox was extended by a PC/104 board for interfacing the equidistant PROFIBUS. A SIMATIC WinAC Soft-PLC runs on the Microbox PC system on which control unit and integrated technology are processed on a processor in time slices with different priorities.

The Microbox 420-T represents the embedded variant of the technology CPU.

Foreword


2 Operating Principle of the Palletizer

What has already been generally described in the Introduction documentation will now be described in detail from the technology CPU’s point of view.

2.1 Overview of the operating principle

This overview describes the structure of the solution approach that is divided into individual function modules and explains their interaction.

Process display Figure 2-1 Palletizer 3D

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Conveyor

Pallet

Walls

Z-axis

Target position

Travel path

X-axis

Y-axis

Starting position

Boxes

Interpolation point 4



(hidden)

Interpolation point 6,7

Interpolation point 1, 2

Solution structure In this application example, the “Palletizer 3D” functionality is realized using the “Move3D” technology template in the technology CPU. The template is responsible for moving the axes.

The task of the higher-level control program is to adequately control the technology template in order to achieve the desired functionality.

Foreword


In the figure below, the functions of the template are shown in pink, the functions of the application example are shown in white. Figure 2-2 Display of all modules relevant to the solution

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HMI


positioning

M G M G

MainControl

TemplateControl

positioning

axis yaxis x axis z

SINAMICS S120 training case

axis x axis y

CalcCam

MoveCam

PalletControl

GripperControl

Ma Sl

cam function



Ma Sl

cam function

Ma Sl

cam function


Ma Sl

cam function

axis

axis

axis axis axis

DB

X Y ZP1234

importpoint tables

interpolation

axis position

velocity correction

interpolationinterpolation

interpolation

Program signalsTechnology signals

Program partPLCopen objectTechnology object

Technology template

Brief description of the function modules Figure 2-2 Display of all modules relevant to the solution shows the functional sequence of the palletizer as an interaction of different function modules.

The following modules determine the sequence:

• “Move3D” technology template “Move3D” generates the trajectory of the palletizer. The interpolation point table, which is adjusted to the respective desired target position on the pallet, is used to generate the necessary cam discs for the travel motion of the three Cartesian axes. After generating the cam discs, the template performs the calculated motion. The “Move3D” technology template consists of three parts.

– Block FB 505 “Move3D” is responsible for the complete functional sequence, initiates the generation of the required cam discs and subsequently starts the travel motion by means of the generated cam discs.

Foreword


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– The FB 509 “MC_CalcCam” function block generates the necessary cam discs from the specified interpolation point table.

– The FB 508 “MoveCam” function block performs the actual axis motions with the aid of the generated cam discs.

• Interpolation point tables The interpolation point table includes the coordinates of the interpolation points used for the interpolation of the cam discs.

• Master axis, virtual master axis The master axis and the virtual master axis have the function of a virtual master axis; the position setpoints of the slave axes are derived from the master value of these axes. The virtual master axis is required for the “interpolated motion with constant path velocity” function.

• X-axis, Y-axis and Z-axis These modules move the palletizer in X, Y or in Z direction. In process mode, the axes are moved in synchronism with a constant path velocity and they follow the position setpoints of the master axis or of the virtual master axis. The axes X, Y, Z are connected to the master axis and the virtual master axis via cam discs.

• Gripper Control This program part simulates the control of the gripper.

• Pallet Control This program part manages the free or occupied locations on the pallet and provides the coordinates of the next target point.

2.2 Detailed description of the function modules

This chapter provides detailed information on the individual function modules of the application. The following areas are explained in greater detail:

• Function of the module

• Components of the module

• Details on this module

The description refers to both the control program and to the technology functions of the modules.

Foreword

Palletizer 3D – Extension ID Number: 21062269 2.2.1 “Move3D” template, axis X, Y and Z

Figure 2-3 Axis X, Y and Z

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HMI


positioning

M G M G

MainControl

TemplateControl

positioning

axis yaxis x axis z

SINAMICS S120training case

axis x axis y

CalcCam

MoveCam

PalletControl

GripperControl

MaSl

cam function



Ma Sl

cam function

Ma Sl

cam function


Ma Sl

cam function

axis

axis

axis axis axis

DB

X Y ZP1234

importpoint tables

interpolation

axis position

velocity correction


interpolation



Technology template

Function of these modules The “Move3D” technology template takes the complete functionality of an interpolated motion at a constant path velocity. This module includes all functional sequences for the realization of a three-dimensional motion. Via an interpolation point table, a defined trajectory is specified for the module which is interpolated and followed with the aid of the technology CPU. During this process it generates cam discs for the control of the axes.

These axes form the Cartesian axes of the actual palletizer. They perform the three-dimensional motion. The axes move in such a way that the load (box) is moved on the selected path at the specified velocity (resulting motion).

Components of these modules All functions for executing an interpolated motion with limited acceleration on a trajectory defined via an interpolation point table are integrated in the FB 505 “Move3D” function block of the template.

The FB 505 “Move3D” function block is responsible for the complete functional sequence, initiates the generation of the required cam discs and subsequently starts the travel motion using the generated cam discs.

Foreword


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The drive side of the module consists of three parts, the modules X- and Y-axis consist of the following components:

• Axis technology object

• Drive

• Motor and encoder

The module for the Z-axis only exists as a virtual axis and therefore consists only of the:

• Axis technology object

These modules include all functions required for moving the axis, e.g. the position control functionality. The position controller calculates the speed setpoint required for the drive; via this setpoint, the motor is set to the desired condition of motion. The “control functionality” only refers to one axis. The interpolated motion of all three axes together is realized in the FB508 “MoveCam” function block.

In addition, the axes are designed as synchronized axes. Via the Synchronous Operation technology object, this axis can be connected to a master axis (virtual master axis) via setpoint or actual value coupling and thus move synchronously to this master axis.

Details on these modules To execute an interpolated motion on a defined path, the FB 505 “Move3D” function block gradually executes the following functions successively:

• Initialization

• Calculation of the required cam discs

• Synchronization of the virtual and real axes.

Block FB 505 “Move3D” is completely processed for each interpolated motion.

In process mode, the axes X, Y and Z are only moved in synchronous operation with the virtual master and they follow the position setpoint generated in the cam disc.

In this application example, the axis X, Y and Z is completely controlled by the “Move3D” technology template.

Foreword

Palletizer 3D – Extension ID Number: 21062269 2.2.2 Gripper Control

Figure 2-4 Gripper Control

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HMI


positioning

M G M G

MainControl

TemplateControl

positioning

axis yaxis x axis z


axis x axis y

CalcCam

MoveCam

PalletControl

GripperControl

Ma Sl

cam function



Ma Sl

cam function

MaSl

cam function


MaSl

cam function

axis

axis

axis axis axis

DB

X Y ZP1234

importpoint tables

interpolation

axis position

velocity correction


interpolation



Technology template

Function of this module • Control of the gripper (simulation)

• Feedback on the gripper status (box gripped or box placed)

Components of this module The module consists of the following components:

• The function of the gripper is simulated using a SIMATIC timer.

Details on this module This module simulates the picking up or putting down of a box with a SIMATIC timer.

Foreword

Palletizer 3D – Extension ID Number: 21062269 2.2.3 Pallet Control

Figure 2-5 Pallet Control

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HMI


positioning

M G M G

MainControl

TemplateControl

positioning

axis yaxis x axis z


axis x axis y

CalcCam

MoveCam

PalletControl

GripperControl

Ma Sl

cam function



Ma Sl

cam function

Ma Sl

cam function


Ma Sl

cam function

axis

axis

axis axis axis

DB

X Y ZP1234

importpoint tables

interpolation

axis position

velocity correction


interpolation



Technology template

Function of this module • Management of the pallet assignment

• Specification of the target position of the next free space on the pallet

Components of this module The module consists of the following components:

• Management of the occupied or free boxes on the pallet.

• Output of the new target position, i.e. the next free put down location on the pallet.

Details on this module This module simulates the control unit for the pallet control. It provides the next free target position on the pallet. This value is copied into the interpolation point tables as a last point.

Foreword


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3 Program Structure

This chapter explains the function of the individual blocks of the STEP 7 program, provides information on the realized program structure and describes the sequential control of the automatic process of the application example.

3.1 List of used blocks

The STEP 7 program of this application example includes the following blocks: Table 3 -1 List of used blocks

Block Symbolic name Function

Blocks of the control program OB 1 CYCL_EXC Cyclic call of the blocks of the application

example and of the “Move3D” technology template.

OB 100 COMPLETE_RESTART Initialization of the status of the application example and of various variables during startup of the CPU.

FB 50 Control_General Higher-level mode control of the application example for changing between manual and automatic mode.

FB 60 Control_axis_manual Manual mode control of the axes of the application example.

FB 70 Control_axis_auto Control of the automatic process execution of the application example. Control of the technology template for realizing the technological execution of the Palletizer3D.

FB 71 Control_pallet Control of the pallet management. It manages the assignment of the boxes on the pallet and outputs the next free put down position for a box.

FB 90 R/W_Parameter Writing and reading technology parameters.

FB 100 AxisControl Enabling the virtual and real axes (master axis, virtual master axis, axis X, Y and Z). Acknowledging error messages on all axes of the application example.

FC72 Scenario_Manager Copying the scenarios depending on the user program mode and on the operation via HMI

Foreword


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Block Symbolic name Function Technology template FB505 Move3D Technology template for the realization of

an interpolated three-dimensional motion at a constant path velocity. This block takes the control of the FB508 and FB509 blocks for the realization of subfunctions of the template.

FB 508 MoveCam Synchronizing the axes via camming and moving the axes with the aid of the virtual master.

FB 509 MC_CalcCam Generating the cam discs required for the interpolated motion using the interpolation point table and the specified parameters.

FC 505 Check_Axes_and_Cams Checking the axes and cam discs defined at the inputs of FB 505.

Technology function blocks FB 401 MC_Power Enabling / disabling axis FB 402 MC_Reset Acknowledging errors / alarms FB 403 MC_Home Homing / setting axis FB 405 MC_Halt Normal stop FB 406 MC_ReadSysParameter Reading parameters FB 407 MC_WriteParameter Changing parameters FB 410 MC_MoveAbsolute Absolute positioning

(e.g. moving axis to position 10.0mm) FB 414 MC_MoveVelocity Motion with speed specification FB 421 MC_CamIn Starting camming FB 434 MC_CamClear Stopping camming FB 435 MC_CamSectorAdd Adding cam segment FB 436 MC_CamInterpolate Interpolating cams FB 438 MC_GetCamPoint Reading point from cam disc System function blocks SFC 20 BLKMOV Copying memory area SFC 24 TEST_DB Checking data blocks SFC 46 STP Setting CPU to STOP

Foreword


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Block Symbolic name Function Technology data blocks DB 1 Axis_Master Technology DB for axis 1 (master axis) DB 2 Axis_VM Technology DB for axis 2 (virtual master

axis) DB 3 Axis_x Technology DB for axis 3 (X-axis) DB 4 Axis_y Technology DB for axis 4 (Y-axis) DB 5 Axis_z Technology DB for axis 5 (Z-axis) DB 9 Trace Technology DB for recording data DB 10 MCDevice Technology DB for the status display of

the technology CPU DB 12 CAM_VM Technology DB for the virtual master cam

disc DB 13 CAM_X Technology DB for cam disc 1 (X-axis) DB 14 CAM_Y Technology DB for cam disc 2 (Y-axis) DB 15 CAM_Z Technology DB for cam disc 3 (Z-axis)

3.2 Overview of the program structure

The figure provides an overview of the call structure of the blocks of the application example’s overall control program.

The program is divided into three sections:

• Operation / control: The higher-level control of the application example is performed in this section. It is also possible to intervene in the functional sequence of the application using the HMI.

• Axes: This section takes the control of the axes of the application. The real axes, i.e. the inverters and motors, are connected to the control program via the “Axis” technology objects.

• Technological functionality: In this section, the “Move3D” technology template is integrated in the program. It performs the interpolated three-dimensional motion. The technology template is parameterized and controlled via the “Operation/control” section.

The individual sections will be explained in greater detail in the following chapters. The used technology function blocks will then also be explained.

Foreword


Figure 3-1 Overview of the program structure

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STL

FB 505 “Move3D”DB 502 “idb_Move3D”

STL

STLOB 1 “CYCL_EXC”

OB 100 “COMPLETE_RESTART”

FBD

STL

FBD

FB 100 “AxisControl”DB 100 “idb_AxisControl ”

FB 90 “R/W_Parameter”DB 90 “idb_R/W_Parameter”

FB 50 “Control_General”DB 50 “idb_Control_General”

FBD

FB 70 “Control_axis_auto”DB 70 “idb_Control_axis_auto”

STL

FB 60 “Control_axis_manual”DB 62 “idb_Control_axis_2”

STL


SFC 46 “STP”

Operationandcontrol

Axes

STL

STL

FB 509 “MC_CalcCam”

FB 508 “MC_MoveCam”

FBDFB 71 “Control_Pallet”

FBDFC 72 “Scenario_Manager”

Technologytemplate

3.2.1 Section: Operation / control

In the “operation / control” section, the inputs via the HMI are converted and the sequential control of the application example is realized from this data.

FB 90 “R/W_Parameter” Accesses to the technology parameters of the CPU from the HMI are realized via this block. FB 406 “MC_ReadSysParameter” is used to read out the desired technology parameters and FB 407 “WriteParameter” is used to write the specified values. Figure 3-2 Structure of FB 90 “R/W_Parameter”

FBD

FB 90 “R/W_Parameter”DB 90 “idb_R/W_Parameter” FB 406 “MC_ReadSysParameter”

FB 407 “MC_WriteParameter”

FB 50 “Control_General” The higher-level mode control of the application example is realized in this block, the manual and automatic modes can be selected via FB 50 “Control_General”.

Foreword


Figure 3-3 Structure of FB 50 “Control_General”

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STL

FB 50 “Control_General”DB 50 “idb_Control_General”

FBD

FB 70 “Control_axis_auto”DB 70 “idb_Control_axis_auto”

STL


SFC 46 “STP”

FB 403 “MC_Home”

SFC 46 “STP”

FB 405 “MC_Halt”

FB 410 “MC_MoveAbsolute”

FB 414 “MC_MoveVelocity”

STL


FB 403 “MC_Home”

SFC 46 “STP”

FB 405 “MC_Halt”

FB 410 “MC_MoveAbsolute”

FB 414 “MC_MoveVelocity”

Mode: Manual

Mode: Automatic

FB 71 “Control_Pallet”

FC 72 “Scenario_Manager”

In manual mode, the FB 60 “Control_axis_manual” block is active and responsible for the control of one axis of the application example. The discrimination between the two axes is achieved by different instance data blocks: DB 61 “idb_Control_axis_1” and DB 62 “idb_Control_axis_2”.

In this mode, different functions are available for the axes for which the following technology function blocks are required:

• Homing axis: Via the FB 403 “MC_Home” function block, the axis can be homed or a position value can be set on the axis.

• Moving axis in JOG mode (jogging +/-): When a button is pressed to move an axis, the axis is set in motion via the FB 414 “MC_MoveVelocity” function block. When releasing the button, the axis is stopped via the FB 405 “MC_Halt” function block.

• Positioning axis: Via the FB 410 “MC_MoveAbsolute” function block, the axis can be moved to a specified position and the block takes control of the complete motional sequence.

In automatic mode, the FB 70 “Control_axis_auto” block is active and responsible for the control of all axes of the application example.

Foreword


Within the block the following different functions are executed:

• Pallet management The FB71 “Control_Pallet” function block is used for pallet management. After each call the function block supplies the next free pallet location. The coordinates of this pallet location are entered in the interpolation point table.

• Scenario change In the application example, different trajectories or scenarios can be called. By calling the FC72 “Scenario_Manager” block, the coordinates for the selected motional sequence are entered in the interpolation point table.

3.2.2 Section: Technology template

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In the “Technology template” section, the “Move3D” technology template is called which is parameterized via automatic mode and which takes the actual control of the motional sequence. To do this, it calculates the cam discs, synchronizes the axes and executes the travel motion of the axes. Figure 3-4 Structure of the “Move3D” technology template

STL

FB 505 “Move3D”DB 502 “idb_Move3D”

STL

FB 509 “MC_CalcCam”

FB 508 “MC_MoveCam”

STL

Note A separate documentation is available for the “Move3D” technology template in which the functional sequence within the template is explained in detail.

3.2.3 Section: Axes

The “Axes” section takes the control of the axes of the application. The real axes, i.e. the inverters and motors, are connected to the control program via the “Axis” technology objects (DB 3 “Axis_x” and DB 4 “Axis_y”). Figure 3-5 FB 100 “AxisControl”

FBD

FB 100 “AxisControl”DB 100 “idb_AxisControl” FB 401 “MC_Power ”

FB 402 “MC_Reset”

In this section, the FB 401 “MC_Power” technology function block can be used to enable the axes.

Via the FB 402 “MC_Reset” technology function block, error messages on the axes can be acknowledged and the axes can be reset.

Foreword


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3.3 Sequential control of the automatic process

The sequential control of the automatic process is completely realized via the FB70 “Control_axis_auto” block. The “Move3D” technology template is parameterized from FB70 “Control_axis_auto” and subsequently executes the necessary travel motions.

3.3.1 Operation and control of the automatic process

All operations and parameterizations required for the automatic process are operated and monitored via the FB 70 “Control_axis_auto” block.

With the block the Palletizer3D application example and thus the “Move3D” technology template can be started and stopped.

The functions of the individual networks of the block are described in the following table: Table 3-2 Functional description of FB 70

Network Function Remark

1 Providing the TRUE and FALSE signals for the use of these signals in the further program.

The signals are defined via the M0.0 and M0.1 flags so that the desired mode can be applied to the corresponding input directly via the symbols.

2-3 Error control. In the event of an error, the sequencer is set to step 0 which stops the motion process.

4-12 Jump distributor for sequencer control. Jumps to the individual steps depending on the value of the sequencer.

Value 0 – 6 of the Sequencer variable corresponds to step 0 through step 6

Foreword


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13-16 Step 0: Error control

In the event of an error, the start signal of the palletizer is reset. And the program remains in this step. The “Acknowledge” button can be used to reset the technology template in FB 50 and to restart the palletizer.

17-25 Step 1: Initializing the sequential program.

Setting the axes to home position, checking the start position, resetting the “Move3D” technology template and activating a newly selected scenario

26-32 Step 2: Preparing for palletizing, creating the required interpolation point table.

Determining new target position on the pallet, simulation of the gripper control

33-39 Step 3: Moving to target position

Transferring velocity and direction of motion to the “Move3D” technology template and starting the technology template and thus the motion

40-45 Step 4: Putting down the box

Resetting the “Move3D” technology template and putting down the box

46-53 Step 5: Moving to starting position

Transferring velocity and direction of motion to the “Move3D” technology template and starting the technology template and thus the motion

54-57 Step 6: Changing the scenarios

Depending on the selected scenario, the interpolation point tables are copied from the DB 19x data blocks to DB 200 with the current interpolation point table.

Foreword


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58-65 Conversion of the axis positions for display on the HMI

The real values from the control program are adjusted to the graphical resolution of the HMI device.

66-71 Simulation of the box motion on the conveyor.

Start and reset of the box motion, conversion of the real values to the graphical resolution of the HMI device.

72 Display of the scenario selection Display of the currently active and of the selected scenario (1x)

3.3.2 Realization of the interpolated three-dimensional motion

The operations parameterized via the FB 70 “Control_axis_auto” block are then executed via the “Move3D” technology template. This technology template is realized in block FB 505 “Move3D” of the user program of the application example.

Note A separate documentation is available for the “Move3D” technology template in which the functional sequence within the template is explained in detail.

Basic structure of the technology template The technology template is an independent program that was used in the Palletizer3D application example to control the motional sequence of the Cartesian axes X, Y and Z.

The technology template is based on a unique synchronization of axes and cam discs in the integrated technology of the technology CPU.

Three real axes, the three Cartesian axes X, Y and Z of the machine, and two virtual axes, as master axes for the cam disc synchronization, as well as up to four cam discs are required for synchronizing the individual axes.

Foreword


Figure 3-6 Configuration of the axis synchronization via cam discs

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(optional)

CamX

CamY

CamZ

Master Interpolation Slaves

CamVM

AxisX

AxisY

AxisZ

AxisVM

AxisMaster

Velocity adaptation

The Cartesian axes Axis X, Axis Y and Axis Z of the machine are controlled via individual cam discs Cam X, Cam Y and Cam Z in which the respective part of the Cartesian axis in the desired interpolated motion is stored. A virtual axis in the integrated technology of the CPU is used as a master for all three cam discs.

The virtual axis Axis Master is the master for the complete arrangement for the interpolated three-dimensional motion. It is moved from a starting point to an end point at a constant velocity and consequently provides the input value for the cam discs.

If a motion with limited acceleration is desired, an additional cam disc and an additional virtual axis have to be included in the cam disc synchronization. Cam disc Cam VM is responsible for adjusting the input values specified by Axis Master and provides these values to the cam discs Cam X, Cam Y and Cam Z for the interpolated motion via the virtual axis Axis VM.

Operating principle of the technology template All functions for executing an interpolated motion with limited acceleration on a trajectory defined via an interpolation point table are integrated in the FB 505 “Move3D” block of the technology template.

Block FB 505 �Move3D� is responsible for the complete functional sequence, initiates the generation of the required cam discs and subsequently starts the travel motion using the generated cam discs.

Foreword


Figure 3-7 General structure of block FB 505 “Move3D”

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FB 505“Move3D”

FB 509“MC_CalcCam”

FB 508“MoveCam”

Control

ErrorHandle

Output

Override

INPU

T

OU

TPUT

FB 505 “Move3D” uses additional functions realized in independent function blocks. The FB 509 “MC_CalcCam” function blocks for generating the required cam discs from the specified interpolation point table and FB 508 “MoveCam” for executing the actual axis motion with the aid of the generated cam discs are called in this block.

The FB 505 “Move3D” function block is responsible for the complete coordination of the individual block calls.

Figure 3-8 Possible statuses of FB 505 “Move3D”

0Error

StartExecute 0 1

2Calc Cam

3Move Cam(Override)

4

EndOK OK

Quit: Execute 1 0

1Initialize

OK

Foreword


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The individual steps of the block have the following function: Table 3-3 Description of the statuses of FB 505 “Move3D”

Step / status Function 0 – Error If an error occurs during executing the individual

functions of the block, the block branches to this status and outputs an error code for exact localization of the cause of the error.

1 – Initialize In this step the internal variables of the block and the functions called in the block are set to defined values and the input parameters of the block are checked.

2 – Calc Cam In this step the cam discs required for the interpolated motion are generated from the specified interpolation point table in the integrated technology of the CPU.

3 – Move Cam (Override) In this step the synchronization of the real and virtual axes is performed via the just generated cam discs and the travel motion of the interpolated trajectory is executed.

4 – End After successfully processing all functions and executing the travel motion, the block branches to this step and no longer executes functions in this step until the block is terminated or called again.

Each interpolated travel motion requires that block FB 505 “Move3D” is recalled on the technology template with Execute = True.

If the value True is displayed at the Done output of the block, the travel motion on the specified trajectory is completed.

Determining the current block status The current block status or the current step in which block FB 505 “Move3D” is located can be determined via the Sequencer integer variable in the instance data block of FB 505 “Move3D”.

Note The instance data block of FB 505 “Move3D” contains the MoveCam.Sequencer and Sequencer variables!

The Sequencer variable of the “MoveCam” multi-instance represents the current status/step of block FB 508 “MoveCam”.

In contrast, the static Sequencer variable in the associated instance data block of FB 505 “Move3D” displays the current status/step of this block.

Foreword

Palletizer 3D – Extension ID Number: 21062269 Interface of block FB 505 “Move3D”

For operating and parameterizing the functionality of “Move3D”, the following signals are available at the FB 505 “Move3D” block of the technology template.

! Danger

The “Master_Stop” input is used for interrupting an already active motion.

If the input is set before the FB 505 �Move3D� block is started, a motion of the axes may still occur when the cam discs are activated!

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FB 505“Move3D”

Execute

MoveReverseMaster_StopMaster_ContinueMaster_AbortCamIn_Tolerance

AccelerationJerk

DoneBusyCommandAborted

Master_StoppedErrorErrorIDErrorSourceErrorPoint

PosSetPoint_X

PosSetPoint_Y

PosSetPoint_Z

Position_OutOf_Tolerance

DB_PointTable

Velocity

Override

Table 3-4 Block interface

Parameter Data type Initial value Description

Input parameterExecute BOOL False Initiation of a new interpolated

motion, from generating the cam discs from the interpolation point table to executing the motion. When this input is reset, output signals are no longer output at the block.

DB_PointTable INT 0 Number of the data block containing the interpolation point table. The interpolation point table has to be structured according to the specifications of UDT 509.

Foreword


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MoveReverse BOOL False Reversal of the direction of motion. When the signal is set, the interpolation point table is processed from end to start. The signal is newly interpreted before the start of the block or after stopping the travel motion.

Master_Stop BOOL False When the signal is set during the travel motion, the axes are decelerated on the contour and the cam disc synchronization of the axes is released after stopping the axes.

Master_Continue BOOL False Continuation of the template when the CamIn_Tolerance tolerance range or the motion after stopping the motion are exceeded. This requires that the Master_Stop input is no longer set.

Master_Abort BOOL False Terminating the block when the CamIn_Tolerance tolerance range is exceeded or after stopping the travel motion.

CamIn_Tolerance REAL 0.000 Tolerance range (spherical in 3D) in which the axes X, Y and Z have to be located around the starting point of the contour for starting the block. The parameter is processed as an absolute value without observing the sign.

Velocity REAL 0.000 Maximum velocity. An exact assignment of this parameter is available at the end of this table.

Acceleration REAL 0.000 Maximum acceleration. An exact assignment of this parameter is available at the end of this table.

Jerk REAL 0.000 Maximum jerk. An exact assignment of this parameter is available at the end of this table.

Foreword


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Override REAL 100.000 Percentage value for influencing the traversing velocity during the interpolated motion (0…200%).

Output parameterDone BOOL False Processing the block is

completed. The travel motion has been completely executed or the block has been terminated via the Master_Abort input.

Busy BOOL False The block is being processed. CommandAborted BOOL False The technology functions used

in the block and thus the actual block have been replaced by a technology function outside the block. Consequently, the block no longer controls the axes intended for the interpolated motion!

Position_OutOf_Tolerance

BOOL False The position of the axes X, Y and Z is outside the defined tolerance range around the starting point of the motion during the start of the block or during the continuation of a stopped travel motion.

Master_Stopped BOOL False The travel motion has been stopped upon request and the cam disc synchronization has been released.

Error BOOL False An error has occurred during processing the block. Further information on the localization of the cause of the error is made available via the ErrorID, ErrorSource and ErrorPoint outputs.

Foreword


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ErrorID WORD 0 Error code of the block or of an internally called technology function. The error location in the block can additionally be read via the ErrorSource output.

ErrorSource WORD 0 Indication of an additional error code for localizing the cause of the error in the block.

ErrorPoint INT 0 Index of the incorrect point in the interpolation point table when generating the cam discs using the FB 509 “MC_CalcCam” function block.

PosSetPoint_X REAL 0.000 If the position of the axes X, Y and Z is outside the tolerance range, the required position for the start or the continuation of the motion for axis X is output.

PosSetPoint_Y REAL 0.000 If the position of the axes X, Y and Z is outside the tolerance range, the required position for the start or the continuation of the motion for axis Y is output.

PosSetPoint_Z REAL 0.000 If the position of the axes X, Y and Z is outside the tolerance range, the required position for the start or the continuation of the motion for axis Z is output.

Interpolation point table, transfer of the interpolation point table The individual interpolation points for the trajectory of the axes X, Y and Z are stored in the interpolation point table.

The trajectory between two interpolation points is on a straight line. A tolerance range (radius) can be defined around the interpolation points within which the trajectory may deviate from the straight line. This enables a smooth motion of the axes and a short-time standstill of the axes at the interpolation points can be avoided.

From the transferred interpolation point table, the “Move3D” technology template generates three cam discs for the interpolated motion of the three Cartesian axes and one cam disc for the velocity adaptation for generating an interpolated three-dimensional motion.

The cam discs form the link between the position of the master axis and the slave axis. Using a cam disc, the setpoint position for the X-, Y- and Z axis is determined from the master value of the virtual master.

Foreword


The cam discs are recalculated for each target position of the palletizer. The interpolation points stored in the interpolation point table for the X-, Y- and Z-axis are imported and then interpolated.

An example of an interpolation point table is shown below: Table 3-5 Example of an interpolation point table Interpolation point

X-axis Y-axis Z-axis Radius

1 0.0 0.0 0.0 0.0 2 0.0 0.0 100.0 0.0 3 0.0 250.0 100.0 50.0 4 350.0 400.0 100.0 50.0 5 300.0 550.0 100.0 50.0 6 450.0 1200.0 100.0 0.0 7 450.0 1200.0 0.0 0.0

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This means that the path of each axis is defined by 7 points. These interpolation points are transferred to the “Move3D” technology template. The interpolation points are used as a basis for the cam disc calculation.

When you read out the individual cam discs CAM_X, CAM_Y and CAM_Z from the technology CPU and enter them in the same coordinate system, the following chart ensues. Figure 3-9 Imported cam disc

-100

100

300

500

700

900

1100

1300

0 200 400 600 800 1000 1200 1400 1600

Y-axis

X-axis

Z-axis

Interpolation point table structure The interpolation point table is the basis of the interpolated motion. It is stored in a data block with the following structure:

• One array element exists for each spatial point (7 field groups).

• Input boxes for the spatial coordinates X, Y and Z are available for each spatial point.

Foreword


• For each spatial point, a tolerance range can be defined within which the interpolated trajectory may be adapted in such a way that smooth motion control without standstill of individual axes or without exceeding dynamic limits is enabled.

Figure 3-10 Interpolation point table structure

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Intermediate points

Target point

Starting point

To keep the application example as simple as possible, only the target position is adjusted to the position on the pallet. The corresponding values have to be entered in the interpolation points 6 and 7. All other points remain unchanged.

Foreword


Figure 3-11 Adaptation of the interpolation points 6 and 7

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1200.0

1200.0

550.0

400.0

250.0

0.0

0.0

Axis Y

450.0

450.0

300.0

350.0

0.0

0.0

0.0

Axis X

0.07

100.06

100.04

100.05

100.03

100.02

0.01

Axis ZPoint

Virtual master for slave axis for box 1Interpolation point tables:

Pallet with 13 placed boxes

Applying the pallet position

Above the pallet

At the put down position of the box

When a box is picked up, the target position is determined by the Pallet Control program part and the coordinates are then copied into the interpolation point tables.

• Interpolation point 6 above (100mm) the put down position X=450.0mm; Y=1200.0mm; Z=100.0mm; radius 100.0mm

• Interpolation point 7 on the put down position X=450.0mm; Y=1200,0mm; Z=0.0mm; radius 0.0mm

Foreword


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Configuration of the Technology CPU

4 Configuration Basics

4.1 Introduction

To enable the use of the technology CPU in a plant, several basic configurations are necessary which are already included in this application example.

To familiarize you with the required configuration steps, the necessary configuration sequences for using the technology CPU will be briefly explained specifically for this application example:

• Configuration of the technology CPU in HW Config to enable the integration of the CPU into a project.

• Configuration of the technology objects of the technology CPU with the aid of S7T Config and generation of the technology data blocks as an interface to the technology objects in the STEP 7 program to make available axes, encoders, cam discs, cams, etc. in the CPU.

• Integration of the PLCopen blocks from the STEP 7 S7 Technology block library to enable the user to control the configured technology objects via the STEP 7 program.

4.2 Differences between controller and embedded variant

Depending on whether you are using the controller variant with CPU 31xT-2 DP or the embedded variant with Microbox 42x-T, differences exist in configuring the technology CPU in HW Config.

For this reason, the configurations of the technology CPU for controller and embedded variant are described in separate chapters:

• For configuring the CPU 31xT-2 DP, please refer to chapter 5

• For configuring the Microbox 42x-T, please refer to chapter 5.2

4.3 Addresses in the application example

The connection of the components via the different bus systems and the associated assignment of the bus addresses also differ between controller and embedded variant.

Foreword

Palletizer 3D – Extension ID Number: 21062269 4.3.1 Controller variant with CPU 31xT-2 DP

When using the controller variant, the CPU 31xT-2 DP is connected to the PG/PC on which Runtime of the application example’s HMI is operated via MPI. The figure below lists the MPI and DP addresses of the components.

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Figure 4-1 Configuration in controller variant of the application example

CPU 31xT-2 DPHMI station / PC/PG

PROFIBUS – DP(Drive)

Addr.:2

Addr.:2


Addr.:3

Optional

MPI

Addr.:1

4.3.2 Embedded variant with Microbox 42x-T

When using the embedded variant, the Microbox 42x-T is connected to the PG/PC via Industrial Ethernet. Runtime of the HMI of the application example is operated on the Microbox 42x-T.

The following figure lists the configured IP and DP addresses. Figure 4-2 Configuration in embedded variant of the application example

Foreword


5 Hardware Configuration

5.1 Configuring the CPU 31xT-2 DP in HW Config

The CPU 31xT-2 DP is integrated into a new or already existing STEP 7 project as a SIMATIC S7-300 station exactly like any other SIMATIC CPU of the 300 series.

After creating the S7-300 station, the hardware of this station can be configured via HW Config and the CPU 31xT-2 DP can be integrated.

Open HW Config and in the hardware catalog open the SIMATIC Technology-CPU profile to display the components available for use with the CPU 31xT-2 DP in the hardware catalog. Figure 5-1 Activation of the “SIMATIC Technology-CPU” profile in HW Config

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You can now select the desired components from the hardware catalog and configure them in HW Config as usual.

Selection of the Technology-CPU profile

5.1.1 Integrating the CPU 31xT-2 DP

In the HW Config station window, position a Rack-300 and equip it with a PS-300 power supply. Select the desired CPU 31xT-2 DP from the hardware catalog and use drag & drop to move it to the rack. Make sure to select the correct firmware revision level for the CPU you are using.

Note If a CPU 31xT-2 DP is already configured in HW Config, the CPU can be replaced by the version with the correct firmware using drag & drop.

Foreword


Adapting the interface speed When inserting the technology CPU into the hardware configuration in HW Config, a dialog box informs you to set the interface speed to a value ≥ 1.5 Mbaud. Figure 5-2 Message box on increasing the transmission rate

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Setting a high transmission rate is necessary since the execution code of the integrated technology is also transferred to the CPU when downloading the configuration to the CPU 31xT-2 DP. If the interface speed is set too low, the download of this large data volume may take a lot of time.

5.1.2 Parameterizing PROFIBUS DP(Drive)

When integrating the CPU 31xT-2 DP into the configuration, the screen form for setting the PROFIBUS DP(Drive) parameters opens.

In this screen form, you can make the interface settings for the drives and I/O devices connected to the technology CPU. Figure 5-3 PROFIBUS DP(Drive) interface settings

Foreword


Perform the following actions:

• Use the New… button to create a new PROFIBUS connection.

• In Properties, set the interface speed of this PROFIBUS connection to 12 Mbps.

• In Options, also set the equidistance of this PROFIBUS connection as shown in the figure below.

Figure 5-4 Setting the equidistance on PROFIBUS DP(Drive)

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Activation of the equidistance

Setting of the equidistant

DP cycle time

Activation of the slave

synchronization

Setting of the Ti and To times

Drives such as SINAMICS S120 can now be connected to the equidistant PROFIBUS generated as shown above for the control via CPU 31xT-2 DP.

Connecting a SINAMICS S120 to the CPU 31xT-2 DP Especially for connecting the SINAMICS S120 drive system, an FAQ is available on the internet at the following link:


5.1.3 Parameterizing the MPI

When integrating the CPU 31xT-2 DP into the configuration, a message box has already informed you of the setting of the MPI to a data transmission rate of ≥ 1.5 Mbaud.


Foreword


! Warning

Before changing the interface speed, check which maximum speed is supported by your CP or interface adapter. If the value set for the transmission rate in HW Config is too high and if you download this configuration to the CPU, you can no longer access the CPU!

To set the MPI, proceed as follows:

• In HW Config, double-click the X1 (MPI/DP) interface of the configured CPU 31xT-2 DP.

• Select Properties.

• Set the desired address, e.g. address 2.

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• Select the MPI bus to which the controller is to be connected, e.g. MPI(1)

• Select Properties and Network Settings.

• Set the desired interface speed, e.g. 12 Mbps

• Close all dialog boxes by clicking OK

• Save and compile everything and download the configuration to the CPU.

Note Make sure that the correct station address is set for the MPI connection on the CPU.

For the connection establishment from PG/PC to CPU 31xT-2 DP, please observe the following:

• In the SIMATIC Manager in Options / Set PG/PC Interface, set the interface of your PG/PC to CPxxxx_(Auto) to ensure that it is automatically set to the baud rate of the MPI bus and that it can communicate with the controller.

• Do not use the standard MPI cable for a transmission rate of 12 Mbps but a PROFIBUS cable to avoid failures on the bus connection.

5.1.4 Generating the technology system data

To be able to use the technology part of the CPU 31xT-2 DP, it is required to generate the system data of the technology firmware when saving and compiling the hardware configuration.

Foreword


To achieve this, proceed as follows:

• In HW Config, double-click Technology of the configured CPU 31xT-2 DP

• Activate the Generate technology system data setting

• Click OK to close the dialog box

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Figure 5-5 Generating technology system data

5.1.5 Completing the configuration of the CPU 31xT-2 DP

When all configuration steps have been successfully performed in HW Config and when the settings of the parameters have been completed, Save and Compile this configuration and use PLC / Download… to download it to the CPU 31xT-2 DP.

5.2 Configuring the Microbox 42x-T in HW Config

Since the Microbox 42x-T is a PC-based system on which the WinAC-T Soft-PLC is operated, the WinAC-T has to be integrated into a new or an already existing STEP 7 project as a SIMATIC PC station.

After creating the PC station, the hardware of this station can be configured via HW Config and the Microbox 42x-T can be integrated.

Open HW Config and in the hardware catalog open the SIMATIC Technology-CPU profile to display the components available for use with the Microbox 42x-T in the hardware catalog.

Foreword


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Figure 5-6 Activation of the “SIMATIC Technology-CPU” profile in HW Config

5.2.1 Integrating the Microbox 42x-T

After integrating the PC station into your STEP 7 project, this station already includes a virtual rack in HW Config in which you can enter the components required for your project.

Select the desired Microbox T from the hardware catalog and use drag & drop to move it to the rack. Make sure to select the correct firmware revision level for the PC station you are using. Figure 5-7 Setting the IP address

Selection of the Technology-CPU profile

Foreword


Note The default address of Ethernet port 2 is 192.168.0.1

After inserting the Microbox T into the virtual rack, you are automatically prompted to enter IP address and subnet mask as shown in the above figure.

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Figure 5-8 Integrating WinLC-T

5.2.2 Parameterizing PROFIBUS DP(Drive)

To be able to connect drives to the Microbox T, the PROFIBUS DP(Drive) interface of the Microbox T has to be parameterized.

Double-click DP(Drive) in the virtual rack of HW Config.

Foreword


Figure 5-9 PROFIBUS DP(Drive) interface settings

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In this screen form, the interface settings for the drives and I/O devices connected to the Microbox T can be made:

• Use the New… button to create a new PROFIBUS connection.

• In Properties, set the interface speed of this PROFIBUS connection to 12 Mbps.

• In Options, also set the equidistance of this PROFIBUS connection as shown in the figure below.

Figure 5-10 Setting the equidistance on PROFIBUS DP(Drive)

Activation of the equidistance

Setting of the equidistant

DP cycle time

Activation of the slave

synchronization

Setting of the Ti and To times

Foreword


Drives such as SINAMICS S120 can now be connected to the equidistant PROFIBUS generated as shown above for the control via the Microbox T.

Connecting a SINAMICS S120 to the Microbox T Especially for connecting the SINAMICS S120 drive system to the CPU 31xT-2 DP, an FAQ that can be used analogously for the Microbox T is available on the internet at the following link:


5.2.3 Parameterizing the MPI

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To use the application example, it is not necessary to parameterize the MPI/DP interface of the Microbox T. The communication of the Microbox T is handled via Industrial Ethernet of the Microbox T.

If, however, further nodes are to be connected to the MPI/DP interface, the settings of this interface can be made by double-clicking DP as described in chapter 5.1.3. Figure 5-11 Setting the MPI/DP interface


Foreword

Palletizer 3D – Extension ID Number: 21062269 5.2.4 Generating the technology system data

When using the Microbox T, it is not required to explicitly select the generation of the technology system data via a check box as known from the controller variant.

The technology system data of the Microbox T are automatically generated when saving and compiling the hardware configuration. A separate tab for calling the parameterization dialog box in the Technology Properties that can be opened by double-clicking the virtual rack does not exist. Figure 5-12 Properties of the integrated technology

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The tab for parameterizing the technology system data is missing since they area

generated by default.

5.2.5 Completing the configuration of the Microbox T

When all configuration steps have been successfully performed in HW Config and when the settings of the parameters have been completed, Save and Compile this configuration.

Additional PG/PC settings before downloading the configuration To download the configuration to the Microbox T via the Ethernet interface of the PG/PC, the PG/PC interface must be set to a fixed IP address.

For the configuration of the application example, IP address 192.168.000.003 is used for the PG/PC.

Foreword


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ATTENTION A connection between PG/PC and Microbox T via Industrial Ethernet can only be established when the same subnet mask is set for both systems. In the application example, the following subnet mask is used:

255.255.255.000

Note You can set a fixed IP address for a PG/PC with the Microsoft Windows operating system as follows:

• Select: Start Settings Control Panel • Section: Network Connections • Select the desired LAN connection or set up a new connection via the

desired network card. • In the context menu, select the connection properties. • Select Internet Protocol (TCP/IP) and its properties. • Via the “Use the following IP address” setting, set the desired IP address and

subnet mask.

It is additionally required that the correct interface is selected in the SIMATIC Manager for downloading the configuration. In Set PG/PC Interface, select the TCP/IP connection via the desired network card.

Foreword


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Figure 5-13 PG/PC interface settings

5.2.6 Downloading the configuration to the Microbox T

Download the configuration to the Microbox T using PLC / Download…

Note However, you can also download the configuration to the Microbox T via the MPI/DP interface. The instructions are the same as the ones for downloading the controller variant with CPU 31xT-2 DP.

Setting the station name When downloading the configuration to the Microbox T, the station name of the Microbox T is compared to the configured station name of the STEP 7 project. If the names differ, an acknowledgeable warning is output when downloading; this warning does not affect the operating capability of the application example.

In the STEP 7 project, the station name of the Microbox T can be set via the PC station properties.

Foreword


Figure 5-14 Setting the station name in the STEP 7 project

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On the actual Microbox T, the station name has to be set via the Station Configuration Editor of the Microbox T:

• Open the Station Configuration Editor by selecting Start Station Configurator.

• Subsequently, select the Station Name… button

• Enter the same station name as configured in the STEP 7 project.

Foreword


Figure 5-15 Station Configuration Editor of the Microbox T

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5.3 Configuring the technology objects

5.3.1 Configuration tools for the technology objects

The following two tools are available for configuring the technology objects of the technology CPU and the Microbox 42x-T:

• S7T Config For creating and parameterizing the desired technology objects such as axes, cam discs, cams, etc.

• Technology Objects Management (TOM) For generating the technology data blocks to provide the technology objects generated with the aid of S7T Config in the STEP 7 program.

Foreword


In the SIMATIC-Manager, the S7 program of the technology CPU includes a Technology folder in addition to the Sources and Blocks folders.

Via the Technological Objects entry in this folder, the configuration tools for the technology objects can be called.

S7T Config S7T Config is called via the Configure Technology context menu of Technological Objects. Figure 5-16 Call of S7T Config

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Technology Objects Management (TOM) To call the Technology Objects Management (TOM), double-click Technological Objects or click the Open Object entry in the context menu of Technological Objects. Figure 5-17 Call of the Technology Objects Management (TOM)

Foreword


Note If no technology objects have been configured yet, S7T Config is opened in addition to the Technology Objects Management (TOM) to enable the user to create and parameterize technology objects.

5.3.2 Calling S7T Config

For the “Palletizer3D” application example the following technology objects have to be created in the technology part of the technology CPU:

• Axes:

– Axis_Master - Master axis

– Axis_VM - Virtual master axis

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– Axis_X - X-axis

– Axis_Y - Y-axis

– Axis_Z - Z-axis

• Cam discs:

– CAM_VM - Cam disc velocity adaptation

– CAM_X - Cam disc X-axis

– CAM_Y - Cam disc Y-axis

– CAM_Z - Cam disc Z-axis

Call the S7T Config configuration tool and create the five axes and four cam discs for the application example as explained in detail in the following.

S7T Config user interface The user interface of S7T Config is divided into three sections: Figure 5-18 Sections of the S7T Config user interface

Workspace

Detail Display

Navigator

Foreword


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The individual sections of S7T Config have the following functions:

• Navigator: The Navigator provides an overview of the entire technology. All defined technology objects are displayed in a clear tree structure.

• Workspace: The Workspace displays all called screen forms for configuring, parameterizing, etc. Using tabs, the active screen forms can be placed in the foreground.

• Detail Display: The Detail Display displays more detailed information on the element selected in the Navigator or Workspace.

5.3.3 Configurations to be performed

Depending on the configuration, i.e. with or without SINAMICS S120 training case, the configuration of the axes can differ for the “Palletizer 3D” application example.

The master axis (Axis_Master) and the virtual master axis (Axis_VM) always have to be created as a virtual axis and the axes X, Y, Z have to be created as virtual or electrical axes depending on the number of available real axes. Table 5-1 Structure, configuration of the application example

Axis Virtual/electrical Technology Master axis (Axis_Master)

Virtual Positioning axis

Virtual master axis (Axis_VM)

Virtual Synchronized axis

X-axis (Axis_X) Virtual, electrical optional

Synchronized axis

Y-axis (Axis_Y) Virtual, electrical optional

Synchronized axis

Z-axis (Axis_Z) Virtual, electrical optional

Synchronized axis

5.3.4 Creating the master axis (Axis_Master)

First the master axis (Axis_Master) is configured. It is created as a positioning axis and then used as a master axis for the virtual master axis (Axis_VM), the axis X, Y and Z (Axis_VM, Axis_X, Axis_Y and Axis_Z).

Foreword


Table 5-2 Configuration of the master axis

No. Instruction Remark

1. Start the configuration of the axis by double-clicking Insert axis in the Navigator of S7T Config.

2. Assign the name Axis_Master to

the master axis.

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For a positioning axis activate the check boxes of the Drive axis and Positioning axis technologies.

3. For the Axis type of the axis select

Linear and Virtual if no real drive exists. Note: If you want to connect a real axis, please observe chapter 5.3.8 Connecting the Axis technology object to a real axis.

4. Check the set units.

Foreword



Since the master axis is a continuously moving linear axis, confirm the settings window for a modulo axis without changes.

5.

6. Click the Finish button to complete

the configuration of the master axis.

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Since the motion of the master axis is independent of the motion of the other axis, a configuration of this axis as a positioning axis is sufficient. This restriction ensures that computing time can be saved in the technology part of the technology CPU and that the technology can be operated with shorter cycle times if required.

5.3.5 Creating the virtual master, X, Y, Z axes

Now the axes virtual master (Axis_VM), X-axis (Axis_X), Y-axis (Axis_Y) and Z-axis (Axis_Z) are created. These axes are configured as a synchronized axis to the master axis (Axis_Master) or to the virtual master axis (Axis_VM).

In the next section, the configuration of the virtual master axis (Axis_VM) is shown as an example. The axes X, Y, Z have to be configured in the same way.

Foreword


Table 5-3 Configuration of the master axis


1. Double-click Insert axis in the Navigator of S7T Config to create an additional axis.

2. Assign the name Axis_VM to the axis.

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For a synchronized axis activate the check boxes of the Drive axis, Positioning axis and Following axis technologies.

3. For the Axis type of the axis select

Linear and Virtual if no real drive exists. Note: If you want to connect a real axis, please observe chapter 5.3.8 Connecting the Axis technology object to a real axis.

4. Check the set units.

Foreword



Since the virtual master axis is also a continuously moving linear axis, confirm the settings window for a modulo axis without changes.

5.


the configuration of the virtual master axis.

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5.3.6 Cam discs “Cam_VM”, “Cam_X”, “Cam_Y” and “Cam_Z”

To be able to synchronize the synchronized axes via cam discs, a cam disc has to be created for each synchronous relationship. The transfer specification of the cam discs is generated from the interpolation point table by the “Move3” technology template via the FB509 “MC_CalcCam” function block. For this reason, the cam discs only have to be created when configuring.

The cam discs must be created to ensure that “Move3D” can synchronize the axes.

Foreword


Figure 5-19 Creating a cam disc

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The cam discs “Cam_VM”, “Cam_X”, “Cam_Y” and “Cam_Z” have to be created for the “Palletizer 3D” application.

In the next section, the creation of cam disc “CAM_VM” is shown as an example. The cam discs “CAM_X”, “CAM_Y” and “CAM_Z” then have to be created in the same way. Table 5-4 Configuration of CAM_VM

Instruction Remark

1. Double-click Insert cam in S7T Config to create a cam disc.

2. Assign the name CAM_VM, CAM_X, CAM_Y or CAM_Z to the cam disc.

Select Interpolation point table as cam disc type.

Creating a cam disc

Foreword


Instruction Remark

3. It is not required to make further settings for the cam discs since the cam disc is generated and interpolated by the FB 509 “MC_CalcCam” function block.

5.3.7 Parameterizing the synchronous relationships between the axes

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If the axes X, Y or Z were created as real axes, further screen forms are then available for this axis in S7T Config; these screen forms can be used to make different default selections and settings on the axes. For a detailed explanation of these screen forms, please refer to chapter 5.3.10 Parameterizing an axis.

In addition, further screen forms are available for a synchronized axis for parameterizing the synchronous relationship between a master and a slave axis. They can be called below the synchronized axis, e.g., via Axis_X_Gleichlauf in the Navigator of S7T Config. Figure 5-20 Parameterizing the synchronous relationships of a synchronized axis

Parameterization of the synchronous relationships

Configuration In the synchronous relationship, the synchronized axis operates as a slave axis that is synchronized to the position of a master axis.

Foreword


Via the configuration of the synchronous relationship, a master axis providing the position for the synchronization can be assigned to the slave axis. Figure 5-21 Synchronous relationship for the “Palletizer 3D”

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CamX

CamY

CamZ

Master Interpolation Slaves

CamVM

AxisX

AxisY

AxisZ

AxisVM

AxisMaster

Velocity adaptation

Synchronous relationship 1Synchronous relationship 2

Slave axis

Master axis

Slave axisMaster axis

Setpoint couplin

g

Setpoint coupling

Setpoint coupling is selected as coupling type so that the setpoint of the slave axis can be synchronized to the setpoint of the master axis.

The synchronous relationship between master axis and virtual master axis and between virtual master axis and X-axis is shown as an example. The relationship to the axes Y and Z has to be established accordingly. Figure 5-22 Synchronous relationship between master axis and virtual master axis

Master axis as a master axis

Synchronization of the two axes via the setpoints

Cam discs CAM_VM for setpoint coupling

Virtual master axis as a slave axis

Foreword


Figure 5-23 Synchronous relationship between virtual master axis and X-axis

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X-axis as a slave axis

Virtual master axis as a master axis

Synchronization of the two axes via the setpoints

Cam discs CAM_X for setpoint coupling

Preassignment In the “Palletizer 3D” application example, camming is selected for the synchronous coupling of the two axes, i.e. the axes are synchronized via a cam disc.

For this reason, only the Cam synchronization and Dynamic response screen forms are relevant for the preassignment for parameterizing the synchronous relationship.

The presetting for the synchronization of the axis to the cam disc defines how the axis reacts in case of a request of the cam disc synchronization.

The cam disc synchronization is requested in the technology template via the FB 421 “MC_CamIn” technology function block. Table 5-5 Presetting of the synchronous operation conditions of the axes

Parameter Setting Note

Synchronization Effective immediately As a result, all further settings for the synchronization are ineffective.

Desynchronization Effective immediately As a result, all further settings for the synchronization are ineffective.

The “Effective immediately” setting ensures that the synchronization or desynchronization process is started immediately upon request of the cam disc synchronization. Then the synchronization process takes place according to the dynamic presettings of the cam disc synchronization.

Foreword


Figure 5-24 Example of the presetting of the synchronization conditions of the axes

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The “Synchronization effective immediately” setting may cause a compensating motion of the slave axes when starting the master axis. This compensating motion occurs when the current position is not equal to the setpoint position according to the master specification!

Note

Presetting – dynamics Table 5-6 Presetting of the dynamics for the synchronous operation conditions


Profile setting Time-related synchronization profile

Synchronization and desynchronization are performed according to the specified dynamic values.

Velocity Jerk Acceleration

The values entered here are not relevant for the use of the technology template

Foreword



Deceleration since the values specified at the block input of FB 505 “Move3D” are used for cam disc synchronization in the template.

Velocity profile Trapezoidal velocity profile

Figure 5-25 Example of presetting the dynamics for the synchronous operation conditions

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Time-related synchronization profile means that the synchronization of the axes via the cam discs does not, as in the master axis-related synchronization profile, depend on the position of the master axis but that the synchronization is performed via the set dynamic values after calling FB 421 �MC_CamIn�. For the synchronization of the axes, the slave axis moves to the position which is specified by the current position of the master axis via the cam disc.

In the technology template, the dynamic values defined at FB 421 “MC_CamIn” are used and not the values set in S7T Config (selection via the mode input of FB 421 “MC_CamIn”).

5.3.8 Connecting the Axis technology object to a real axis

If a real drive with real axes has been configured in the hardware configuration of the application example, the Axis technology object can also be connected to this drive. When configuring the corresponding technology object, this requires additional inputs which will be explained in greater detail in the following.

Foreword


Note A connection of the technology object to a real drive, e.g. to a SINAMICS S120, is only possible if the drive has already been completely commissioned and if it is functional.

The additional inputs are made after step 6 of the configuration of the virtual axis, of axis X, Y and Z shown above. If a real axis is configured, the configuration of the axis is again to be repeated up to step 5. When setting the axis type in step 3, a linear, electrical axis has to be selected.

In the next section, the configuration of the X-axis is shown as an example. Table 5-7 Additional inputs for connecting the axis to a drive

No. Instruction

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Remark

1. For the Axis type of the axis select Linear and Electrical. The configured axis can thus be connected to a real axis of a drive.

Foreword


2. If a drive unit is not yet offered for selection in the screen form, click the Align Sinamics devices… button to perform an alignment with the configured drives.

3. Select the desired drive for the alignment from the displayed list.

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4. You can now select the drive unit

you want to connect to the Axis technology object from the drop-down list.

5. Select the corresponding drive of

the device, define the message frame for the PROFIBUS communication and set the maximum speed of the connected motor. For optimum dynamics also activate Dynamic Servo Control (DSC).

6. Set Encoder type, Encoder mode

and Measuring system type at the selected drive.

Foreword


Set the Encoder pulses per revolution and the Multiplication factor of the cyclic actual value of the encoder.

7.


the configuration of the material axis.

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Note If Dynamic Servo Control (DSC) is activated on the drive, at least PROFIBUS message frame 105 has to be set for the communication between technology CPU and drive.

5.3.9 Settings for the SINAMICS S120 training case

If you are using the SINAMICS S120 training case as a drive system, the screen shots below show all necessary settings: Figure 5-26 Connecting the SINAMICS S120 training case

MPI/DP

Industrial Ethernet

DP (Drive)

DP (Drive)

Microbox T

CPU 31xT-2 DPPG/PC

PG/PC

SINAMICS S120

SINAMICS S120

Con

trol

ler v

aria

ntEm

bedd

ed v

aria

nt

Foreword

Palletizer 3D – Extension ID Number: 21062269 Settings for the X-axis

In our example, the axis with the red disk is used on the training case for the X-axis.

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Figure 5-27 SINAMICS S120 training case – Drive assignment Selection of the drive

Selection of PROFIBUS

message frame 105

Setting of the maximum

motor speed

Activation of Dynamic Servo

Control Figure 5-28 SINAMICS S120 training case – Encoder assignment

The encoder is connected

directly to the drive

Setting of the encoder mode

Setting of the measuring system type

Setting of the encoder type

Foreword


Figure 5-29 SINAMICS S120 training case – Encoder data

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Setting of the multiplication factor

Setting of the multiplication factors

Setting of the encoder pulses per revolution

Note For setting the encoder assignment and the encoder data, a list with the required data is available on the internet.

Foreword


Settings for the Y-axis In our example, the axis with the blue disk is used on the training case for the Y-axis.

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Figure 5-30 SINAMICS S120 training case – Drive assignment

Selection of the drive

Selection of the PROFIBUS

message frame 105

Activation of Dynamic Servo

Control

Setting of the maximum

motor speed

Note If Dynamic Servo Control (DSC) is activated on the drive, at least PROFIBUS message frame 105 has to be set for the communication between technology CPU and drive.

Foreword


Figure 5-31 SINAMICS S120 training case – Encoder assignment

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The encoder is connected

directly to the drive

Setting of the encoder mode

Setting of the encoder type

Setting of the measuring system type

Figure 5-32 SINAMICS S120 training case – Encoder data

Setting of the number of data bits

Setting of the encoder pulses per revolution

Note For setting the encoder assignment and the encoder data, a list with the required data is available on the internet.

Foreword

Palletizer 3D – Extension ID Number: 21062269 5.3.10 Parameterizing an axis

After the axis has been successfully created, further screen forms are available in S7T Config via which different default selections and settings can be made on the axis.

Mechanics In the Mechanics section, the axis created in the controller can be adjusted to the real conditions on the machine. The direction of rotation of the measuring system can be changed, settings for load and measuring gearbox can be made and the traveled distance per motor revolution can be entered.

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In addition, a backlash compensation can be performed via which the mechanical backlash of the drive spindle can be compensated in the event of a reversal of the axis. Figure 5-33 Parameterization – Mechanics

Preassignment In the Preassignment section, the default values of the axis are defined which can be used when controlling the axis via the STEP 7 program.

A velocity profile for the axis motion with values for jerk and acceleration can be defined.

Foreword


Figure 5-34 Parameterization – Preassignment

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Limitations In the Limitations section, the maximum values for the motion of the corresponding axis can be defined.

The Position and Velocity section includes boxes for defining the hardware and software limit switches of the axis and for defining the maximum axis velocity. Figure 5-35 Parameterization – Limitations (position and velocity)

Foreword


In the Dynamic Response section, the maximum acceleration and the maximum jerk can be set.

Acceleration and deceleration of the axis can be specified separately for the software limits. Figure 5-36 Parameterization – Limitations (dynamic response)

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Homing In the Homing section, it can be set whether the corresponding axis has to be homed or not. Figure 5-37 Parameterization – Homing (active homing)

Foreword


In active homing, homing is performed according to the set mode via a motion initiated by the homing command in the STEP 7 program. Different modes can be defined for the homing process and different velocities can be preset for the reference cam approach, the motion into the reference point and the deactivation at the reference point. The position of the reference point and an additional offset which is assigned to the axis position in the reference point can also be defined here.

In passive homing, homing is performed according to the set mode via a motion which is not initiated by the homing command in the STEP 7 program. Homing is virtually performed “on the fly” during a currently active motion as soon as the reference mark is detected or passed. Figure 5-38 Parameterization – Homing (passive homing)

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Monitoring In the Monitoring section, different monitoring values can be defined for the corresponding axis which control the execution of the axis motion and possibly output an error message if the axis leaves the defined tolerance range.

In the Positioning and Standstill Monitoring section, tolerance ranges can be defined for the compliance with the specified axis position and the monitoring of the axis standstill. This enables the user to monitor the execution of a positioning command if disturbance variables occur which externally affect the axis.

Foreword


Figure 5-39 Parameterization – Monitoring (positioning and standstill)

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In the Following Error Monitoring section, the inertia of the axis can be monitored. The following error is the difference between the setpoint position specified by the controller and the actual position of the axis during the motion. Figure 5-40 Parameterization – Monitoring (following error monitoring)

Foreword


In the Standstill Signal section, a velocity threshold can be defined below which the “Standstill drive” signal is set in the technology data block of the axis. In the STEP 7 program, this signal can be used to check the axis standstill. Figure 5-41 Parameterization – Monitoring (standstill signal)

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Control In the Control section, the parameters of the position controller in the technology part of the technology CPU can be influenced.

The signs for actual value and setpoint value can be inverted and consequently the control loop can be adjusted to the hardware conditions of the machine.

The servo gain factor represents the gain of the position control loop via which the response of the control to deviations between setpoint and actual value can be influenced. If the servo gain factor is set too low, the actual value follows the setpoint value only very slowly. If, however, the servo gain factor is set too high, an overshoot of the controller may occur.

Via the drift compensation, the integration component of the position controller can be activated; this enables the user to compensate steady-state deviations during positioning.

The use of Dynamic Servo Control (DSC) enables the user to set a larger servo gain factor for the position control loop. This increases the dynamics for the reference variable sequence and disturbance variable control in highly dynamic drives.

Note If Dynamic Servo Control (DSC) is activated, at least PROFIBUS message frame 105 has to be set for the communication between technology CPU and drive.

Foreword


Figure 5-42 Parameterization – Control

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Axis test via control panel When the axis has been successfully created and parameterized in the technology of the controller, it can be moved in test mode from S7T Config via the control panel of the technology.

Figure 5-43 Control panel

5.3.11 Generation of the technology data blocks

Step 2: Setting enable

Step 3: Selecting function

Step 4: Starting motion

Step 1: Assuming control priority

After completing the configuration and parameterization of the Axis and Cam Functions technology objects, it is now required to generate the technology data blocks of these technology objects via the Technology

Foreword


Objects Management (TOM). These data blocks form the interface of the technology objects to the STEP 7 program.

The following data blocks are used in the application example: Table 5-8 Data block numbers

Technology object DB no.: Symbol

Master axis DB1 Axis_Master Virtual master axis DB2 Axis_VM X-axis DB3 Axis_X Y-axis DB4 Axis_Y Z-axis DB5 Axis_Z Trace DB9 Trace Technology CPU status display DB10

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MCDevice Cam disc virtual master DB12 Cam_VM Cam disc X DB13 Cam_X Cam disc Y DB14 Cam_Y Cam disc Z DB15 Cam_Z

Call the Technology Objects Management (TOM) as described in chapter 5.3.1 Configuration tools for the technology objects, define the desired data block numbers, select all lines and then generate the data blocks of the technology objects. Figure 5-44 Technology Objects Management (TOM)

Select all lines.

Use this button to generate all selected data blocks.

Define DB number.

Foreword

Palletizer 3D – Extension ID Number: 21062269 5.4 Integration of the PLCopen blocks

Different function blocks according to the PLCopen standard are available for controlling the configured technology objects by the STEP 7 program. These blocks are combined in the S7-Tech block library. From there they can be integrated into the user program and called. Figure 5-45 S7-Tech block library in FBD Editor

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Foreword


WinCC flexible Configuration

6 Configuring Aids

6.1 Screen display of the interpolation points

When the HMI device was configured with WinCC flexible, a WinCC flexible script was used for the display of the interpolation points and for the variable display of the radii around the interpolation points.

Note The WinCC flexible script is only required for the display of the trajectory on the HMI and does not influence the program execution in the CPU.

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With the aid of this script, the 7 interpolation points and the corresponding radii are set in the motional sequence of the palletizer. The script is started when the box is picked up and put down. It reads out the interpolation point table and calculates a position in the display for each interpolation point. Figure 6-1 Display of the interpolation points

Display of the position

Interpolation point table as a basis for

the script editing

Foreword

Palletizer 3D – Extension ID Number: 21062269 Script description

In the script for the display of the interpolation point position, the variables, e.g. PT_Interpol.Point[1].X, of the individual coordinates are read out from the interpolation point table and multiplied by a factor and an offset is added.

The multiplication and the addition adjust the variable contents to the graphics resolution of the WinCC flexible project. The following result is, for example, saved in the x_point1 variable. In the WinCC flexible properties, the x_point1 variable is interconnected with the position offset of the interpolation point graphics object.

For the display of the radius around the interpolation point, the value of the radius is read out from the interpolation point table, e.g. PT_Interpol.Point[1].R, converted to the LongInteger numerical format and saved on a local variable.

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Figure 6-2 Script for display of the interpolation points, radii

' Position of the Point 1 to 7 by expertmode'

SmartTags("x_point1") = CLng(SmartTags("PT_Interpol.Point[1].X") * -0.233) + 120SmartTags("y_point1") = CLng(SmartTags("PT_Interpol.Point[1].Y") * -0.2615) - 55SmartTags("r_point1") = CLng(SmartTags("PT_Interpol.Point[1].R"))

SmartTags("x_point2") = CLng(SmartTags("PT_Interpol.Point[2].X") * -0.233) + 100SmartTags("y_point2") = CLng(Smart …….…………

Foreword


6.2 Integration of Runtime on the Microbox 42x-T

6.2.1 Setting the screen resolution

To enable optimum display of the HMI on the Microbox 42x-T, set the screen resolution of the Microbox to 1024x768 pixels.

In addition, select a medium color quality of 16 bits which is sufficient for the display of the HMI and does not cause a high load of the Microbox 42x-T processor. Figure 6-3 Setting the screen resolution

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Color quality setting

of the display

Screen resolution setting

In the Windows Control Panel, select the Display settings to go to the screen resolution and color quality settings.

Note

6.2.2 WinCC flexible Runtime installation

To be able to operate the HMI on the Microbox 42x-T, you have to install WinCC flexible Runtime on the Microbox 42x-T.

To install WinCC flexible Runtime on the Microbox 42x-T, the following options are available:

Foreword


• Installation via an external USB CD drive Insert the WinCC flexible Runtime installation CD in the CD drive and follow the instructions on the screen.

• Installation via a shared network drive On another PG/PC in the network, share a folder or the CD drive and access this drive from the Microbox. Copy the installation files for WinCC flexible Runtime to this folder or insert the installation CD in the shared CD drive and start the installation from the Microbox. Follow the instructions on the screen.

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• Installation via an external USB hard disk or a USB flash drive On another PG/PC, copy the WinCC flexible installation files to the external USB hard disk or the USB flash drive. Connect the hard disk or the flash drive to the Microbox and start the included installation. Follow the instructions on the screen.

Please note that no USB drive or other USB storage medium must be connected to the Microbox in productive mode of the Microbox 42x-T!

ATTENTION

6.2.3 WinCC flexible Runtime Loader settings

To be able to transfer the HMI to the Microbox 42x-T, it is required that WinCC flexible Runtime Loader has been parameterized and started.

To parameterize and start Runtime Loader, proceed as follows: Table 6-1 WinCC flexible Runtime Loader settings


1. Start Runtime Loader via the Microbox start menu. Start Simatic WinCC flexible Runtime Loader

Foreword



2. Use the Settings button to call the Runtime Loader settings.

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3. Make the following settings for

Channel 2: • Ethernet • Activate • Remote Control Use the OK button to close the Runtime Loader settings.

4.

Select the Transfer button to make the Microbox 42x-T ready to receive.

6.2.4 Transferring the project

The WinCC flexible can now be transferred from the configuration computer to the Microbox 42x-T. Start WinCC flexible and select Transfer mode:

To go to this mode, select: Project Transfer Transfer Settings

Foreword


Now set the parameters for the data transfer of WinCC flexible Runtime to the Microbox 42x-T as follows:

• Mode: Ethernet

• Computer name or IP Address: 192.168.0.1

Figure 6-4 Data transfer settings

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Subsequently, select the Transfer button to start the data transfer.

After a successful data transfer, the HMI starts automatically. Close the display window to exit WinCC flexible Runtime on the Microbox 42x-T. Runtime can be restarted by selecting the Runtime Loader Start button. Figure 6-5 Operating WinCC flexible Runtime Loader

Starting “ready-to-receive” for the transfer of WinCC flexible Runtime

Starting WinCC flexible Runtime (HMI)

Calling the transfer settings

Exiting WinCC flexible Runtime Loader

Foreword


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Appendix and Bibliographic References

7 Bibliographic References

7.1 Bibliographic references

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

Topic Title /1/ STEP7 Automating with STEP7 in STL and SCL

Hans Berger Publicis MCD Verlag - 2004 ISBN 3-89578-242-4

/2/ Technology CPU

SIMATIC – S7-300 CPU Data: CPU 315T-2DP Siemens Manual Edition 11/2006 MLFB: A5E00427932-03

/3/ Technology CPU

SIMATIC – S7-300 CPU Data: CPU 317T-2DP Siemens Manual Edition 11/2006 MLFB: A5E00251769-05

/4/ Technology CPU

SIMATIC – S7 Technology Siemens Manual Edition 11/2006 MLFB: A5E00251797-05

/5/ Technology CPU

Installing SIMATIC Microbox 420-T Siemens Manual Edition 06/2006 MLFB: A5E00495804-01

/6/ Technology CPU

Operating SIMATIC Microbox 420-T Siemens Manual Edition 06/2006 MLFB: A5E00495966-01

/7/ Technology CPU

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

/8/ Technology CPU

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

Foreword


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Topic Title /9/ Technology

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

/10/ SINAMICS S120

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

/11/ SINAMICS S120

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

/12/ SINAMICS S120

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

/13/ SINAMICS S120

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

/14/ SINAMICS S120

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

7.2 Internet links

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

Topic Title \1\ Reference to

the entry http://support.automation.siemens.com/WW/view/en/21062269

\2\ Siemens A&D Customer Support

www.ad.siemens.de/support

\3\ Siemens A&D Applications & Tools




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



Foreword


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Topic Title \4\ Application

examples for the technology CPU (a selection)

Feeder for a Press: http://support.automation.siemens.com/WW/view/en/21363677Flying Shears with Print-Mark Synchronization Based on Gear Synchronism: http://support.automation.siemens.com/WW/view/en/21063352

\5\ Technology CPU manual

http://www.ad.siemens.de/supportSelect “Product Support” Open the following directories in the Product Information tree: • Automation systems • SIMATIC Industrial Automation Systems • PLC • SIMATIC S7 • S7-300/S7-300F • CPUs Click the Manual tab to open a list with related documents or click the following links: S7 Technology: http://support.automation.siemens.com/WW/view/en/22639716CPU manual 317T-2 DP: http://support.automation.siemens.com/WW/view/en/17993483CPU manual 315T-2 DP: http://support.automation.siemens.com/WW/view/en/21362915Installing Microbox 420-T: http://support.automation.siemens.com/WW/view/en/23999776Operating Microbox 420-T: http://support.automation.siemens.com/WW/view/en/23999030

\6\ SINAMICS S120 instruction manual

http://www.ad.siemens.de/supportSelect “Product Support” Open the following directories in the Product Information tree: • Drive technology • AC Converter • Low voltage converters • Built-in and cabinet system SINAMICS S120 Click the Manual tab in the right window to open a list with related documents or select the following link: http://www.automation.siemens.com/doconweb

















http://www.automation.siemens.com/doconweb

Foreword


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Topic Title \7\ FAQ

CPU 317T-2 DP applicable encoders

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

\8\ FAQ technology CPUversion overview

Which versions of the S7 Technology option package are available and which SINAMICS S120 drive firmware can you use with which of these versions? http://support.automation.siemens.com/WW/view/en/23411204

7.3 Related documentation

This list includes a summary of related documentations which you can obtain from Siemens Customer Support or your Siemens contact person. Table 7-3

Topic Title /A/ Technology

template “Move3D” Technology Template Technology CPU – Documentation ID number: 21364022 http://support.automation.siemens.com/WW/view/en/21364022

8 History Table 8-1 History

Version Date Modification

V3.1 12/05/06 Adaptation of the documentation to the S7 Technology V3.0 SP1 technology package. Adding of the Microbox 420-T.

V3.2 09/11/07 Adaptation of the documentation to the S7 Technology V3.0 SP2 technology package. Adding of the Microbox 420-T. Adding of Runtime.







Documents

Application about Drive Technology - Siemens · • the integrated technology which processes the technological ... Communicating via ... (actual value, setpoint value) read/write