Application example 10/2016 Print Standard Add-On TRC3000 … · 2016-12-12 · Warranty and liability Print Standard Add-On TRC3000 and TRC7000 Entry-ID: 64896729 , V4.1.0, 10/2016

https://support.industry.siemens.com/cs/ww/en/view/64896729

Application example 10/2016

Print Standard Add-On TRC3000 and TRC7000


Warranty and liability

Print Standard Add-On TRC3000 and TRC7000 Entry-ID: 64896729 , V4.1.0, 10/2016 2

S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Warranty and liability

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 used correctly. These Application Examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these 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 – the contents of the other documents have priority.

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”). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of the Siemens AG.

Security informa-tion

Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions only form one element of such a concept. Customer is responsible to prevent unauthorized access to its plants, systems, machines and networks. Systems, machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures (e.g. use of firewalls and network segmentation) in place. Additionally, Siemens’ guidance on appropriate security measures should be taken into account. For more information about industrial security, please visit http://www.siemens.com/industrialsecurity.

Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly recommends to apply product updates as soon as available and to always use the latest product versions. Use of product versions that are no longer supported, and failure to apply latest updates may increase customer’s exposure to cyber threats. To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under http://www.siemens.com/industrialsecurity.

http://www.siemens.com/industrialsecurity



Table of contents


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Table of contents Warranty and liability ................................................................................................... 2

1 Application description ..................................................................................... 5

1.1 Basic information and data ................................................................... 5 1.1.1 System requirements ........................................................................... 5 1.1.2 Supported Panels (HMI) ....................................................................... 6 1.2 Integrated register control with SIMOTION Print Standard .................. 6 1.2.1 Setpoint integration into the Print Standard ......................................... 7 1.3 Sensor Hardware ................................................................................. 8 1.3.1 TRC3000 .............................................................................................. 9 1.3.2 TRC7000 ............................................................................................ 11 1.4 Mark evaluation principle.................................................................... 12 1.5 Integration of TRC3000/7000 into a machine concept ....................... 13 1.6 Telegram Mark3 / Mark20 .................................................................. 15 1.7 Assignment TRC to PU ...................................................................... 16 1.8 Set value for TRC ............................................................................... 17 1.8.1 Master position or axis/cylinder position ............................................ 17 1.8.2 Actual or command position ............................................................... 17

2 Application structure ....................................................................................... 19

2.1 Structure of the TRC application ........................................................ 20 2.2 Structure of the Register Controller application ................................. 22 2.3 Software parts .................................................................................... 24 2.3.1 Program units ..................................................................................... 24 2.3.2 Used Libraries .................................................................................... 28 2.4 HMI (WinCC TIA) ............................................................................... 31

3 Integration ........................................................................................................ 32

3.1 Hardware integration .......................................................................... 32 3.2 Software integration (libraries and programs) .................................... 40 3.3 Necessary program adaptions ........................................................... 43 3.4 HMI integration ................................................................................... 46 3.4.1 TIA HMI device proxy ......................................................................... 46 3.4.2 Basic settings ..................................................................................... 51 3.5 Necessary settings for TRC3000 oscilloscope .................................. 52 3.6 Necessary settings for TRC7000 camera live image ......................... 54 3.7 Elimination of TRC3000 or TRC7000 from project ............................ 56 3.8 Necessary modifications from Standard mode (mark 3) to End-

Of-Press mode (mark 20) ................................................................... 58

4 Use of the application ..................................................................................... 59

4.1 Overview............................................................................................. 59 4.2 HMI screens ....................................................................................... 61 4.3 Procedure of first sensor config/job setup .......................................... 95

5 Function description ....................................................................................... 97

5.1 Functions and Function blocks ........................................................... 97 5.1.1 FCLTRC3000_Mark3_100Telegram,

FCLTRC3000_Mark20_101Telegram, FCLTRC7000_Mark3_120Telegram, FCLTRC3000_Mark20_121Telegram ................................................ 97

5.1.2 FBLTRC3000BckGrnd, FBLTRCx7000BckGrnd ............................... 98 5.1.3 FBLTRC3000IPO, FBLTRC7000IPO ............................................... 100 5.1.4 FBLTRC3000HMIDataTransfer, FBLTRC7000HMIDataTransfer .... 101 5.1.5 FBLRegCtrlController ....................................................................... 102 5.1.6 FBTech ............................................................................................. 102

Table of contents


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2 Parameter structures ........................................................................ 103 5.2.1 sTRC3000Data ................................................................................. 103

sTRCInterface.sData_Cyclic ............................................................ 104 sTRCInterface.sData_Acyclic .......................................................... 107 sTRCInterface.SensorScopeData .................................................... 111 sSTDcIO…… .................................................................................... 112 sHWSettings ..................................................................................... 118

5.2.2 sTRC7000Data ................................................................................. 119 sTRCInterface.sData_Cyclic ............................................................ 120 sTRCInterface.sData_Acyclic .......................................................... 123 sTRCInterface.sLiveImage ............................................................... 123 sSTDcIO……… ................................................................................ 124 sHWSettings ..................................................................................... 125

5.2.3 sRegCtrlIO ........................................................................................ 126 5.2.4 sHMI_TRC3000_Command ............................................................. 132 5.2.5 sHMI_TRC7000_Command ............................................................. 138 5.2.6 sHMI_RegCtrl_Command ................................................................ 144 5.2.7 sHMI_Application_Command ........................................................... 150 5.2.8 sTRCSetCurveOCX ......................................................................... 151

6 Fault messages .............................................................................................. 153

6.1 Application faults .............................................................................. 154 6.2 Sensor faults .................................................................................... 159 6.3 DRD faults ........................................................................................ 160 6.4 Insetting faults .................................................................................. 163 6.5 Lifesign error .................................................................................... 163 6.6 Register FB error messages ............................................................ 164

7 Sensor calibration ......................................................................................... 165

7.1 Calibration of TRC3000 (white adjustment) ..................................... 165 7.2 Calibration of TRC7000 .................................................................... 165

8 TRC HTML interface ...................................................................................... 166

9 Related literature ........................................................................................... 167

10 History............................................................................................................. 167

11 Contact............................................................................................................ 167

1 Application description


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1 Application description The basic functionality of the application Print Standard Add-On TRC3000 and TRC7000 is the handling of the print mark detector from manufacturer “Eltromat”.

Additionally the application shows how to integrate the functionality of register control and how visualization on a panel or PC can be realized.

Handling of TRC is based on a cyclic and acyclic standard interface between sensor and SIMOTION. Via these interface all necessary functionality is being managed e.g. parameterization, reading of the oscilloscope data and much more.

Moreover to the basic communication functionalities it provides a lot of additional functionalities to make the handling as easy as possible.

Print Standard Add-On TRC functionalities:

Collection of parameterization data and handling of transfer the printing job data to the TRC hardware

Evaluation of the markfield and mark error

Calculation of register errors depending on measuring mode and selected marks

Preparation of analogue oscilloscope curves for graphic display on the HMI screens and gate settings

Evaluation of cyclic communication, monitoring of TRC sign of life, fault handling

TRC mode handling

1.1 Basic information and data

1.1.1 System requirements

This application was developed and tested using:

Software:

SIMOTION SCOUT 4.4 HF 11

WinCC Advanced V13 SP1 Update 7

SIMATIC STEP 7 V5.5 + SP4+ HF5

TRC3000: Eltromat Firmware V1.1.2 (2015-12-15)

TRC7000: Eltromat Firmware P1.0 (2015-05-12)

TRC3000: GSD file RSHPNF-20141117

TRC7000: GSD file RSHPNC-20150319



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.1.2 Supported Panels (HMI)

SIMATIC IPC 277D

SIMATIC Panel PC

NOTE For 20 print units approximately 560 Power Tags are required.

1.2 Integrated register control with SIMOTION Print Standard

In modern printing presses each print unit is individually driven by servo motors and the synchronism is achieved by an electronic line shaft (ELS) with virtual master. The register is adjusted by the offset value (angle) of the synchronism.

Thus the synchronized drive is the actuator of the register adjustment. The register controller needs to manipulate the synchronism between the virtual master and the real axis of the print unit drive.

In order to control the register in a closed loop, a register measured value is required. Therefore register marks are printed additionally to the print view onto the substrate. Depending on the measurement method and printing process different types of marks are used.

In comparison to an external register control system an integrated system provides different advantages:

Faster register control and less startup waste by integration into the electronic line shaft function

Less HW components

Smaller cabinet size

Same HW for motion and register

Integration into machine operation, automation and startup sequence

Open system, extendable by OEM

Same engineering tools for automation, motion control and register control

Clear responsibility: OEM with the support of Siemens

Sensor HW is the only cost addition to integrate a register control

End-user support by OEM possible



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.2.1 Setpoint integration into the Print Standard

The “TechFB” extension of Print Standard offers a possibility to influence the axis basic motion setpoint channel by external or internal created additional values. The figure 2-1 shows this concept basically.

A functionality function block e.g. winder, tension controller or register controller is calculating an additional velocity setpoint value. The value will be switched to the Print Standard “TechFB” for calculation of the entire motion vector. It will be directly connected to the axis addition object which is acting as interface to the axis setpoint channel (as long as the SIMOTION addition object is the interface between user application and SIMOTION axis TO).

Figure 1-1 “TechFB” principle



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.3 Sensor Hardware

Siemens offers different solutions for register control in printing machine concepts with SIMOTION/SINAMICS in combination with the Print Standard application. Separate application examples for each solution are available depending on the sensor type.

Print Standard Add-On TRC1000 (fiber optic sensor solution)

Print Standard Add-On TRC3000 (fiber optic sensor solution)

Print Standard Add-On TRC7000 (camera solution)

Table 1-1 Comparison sensor solution

Feature TRC1000 TRC3000 TRC7000

Manufacturer WIEDEG Elektronik GmbH

www.wiedeg.de

BST eltromat International

www.bst-international.com/

BST eltromat International

www.bst-international.com/

Sensor Type Fiber optic monochrome sensor

Fiber optic RGB sensor RGB camera

Detectable mark types Different types of wedge marks

Different types of wedge marks

dot marks

Communication with SIMOTION

PROFINET IRT PROFINET IRT PROFINET IRT

Max. web speed up to 1000m/min up to 1000m/min up to 1000m/min

Max. number of marks evaluable by one device

2 marks 3/20 marks 19 + 3 for reference

ATEX II 3 G [Ex op is] IIC (Zone 2 for FOC)

II 2 G [Ex op is] IIC (Zone 1 for FOC)

/

Backside printing Extension device 2nd fiber optic cable (different hardware device)

2nd

processing device and camera

Automatic mark recognition

Bar code (3 bars) Bar code (1-4 bars), symmetric mark field

Specific dot arrangement of 3 dots

Mark arrangement

Space requirement

In-line in print free area across with 2

nd FOC

In-line in print free area across with 2

nd FOC

Markfield can be placed within the printed area

Register measurement Integrated Integrated Integrated

Measurement method WebCylinder

WebWeb

WebWeb2 (2nd sensor head)

WebCylinder

WebWeb

WebWeb2 (2nd sensor head)

WebCylinder

WebWeb

Recognition diagnostic 1 trace 3 traces (RGB) Live image

End of press mode no Max 20 marks Max.19 dots

NOTE TRC1000 is provided in a separate example application!

http://www.wiedeg.de/

http://www.bst-international.com/






S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.3.1 TRC3000

NOTE This chapter provides a short summary of the TRC3000 device.

For more detailed information please see the Eltromat user manual.

The TRC3000 is available in two different hardware versions:

“singlehead”- version for a standard markfield

“doublehead”-version for detection of marks on both sides of the web or a mark-arrangement next to each other.

NOTE The singlehead hardware can be extended by a second fiber optical interface.

Figure 1-2 TRC3000 Hardware “single head”-version

Figure 1-3 TRC3000 Hardware “double head” version



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1 Fiber-optical interface with connection for optical waveguide channel 1

2 Option: Fiber-optical interface with connection for optical waveguide channel 2

3 Input for voltage supply cable

4 Output for voltage supply cable (next sensor)

5 Input for field bus

6 Output for field bus (next sensor)

7 Type plate for optical component

8 Sensing head

9 PE connection (equipotential bonding)

10 Status LEDs (see Eltromat user manual “RSH_PN__BA_R1_0_en” for detailed information)

11 Type plate for register sensor

NOTICE Connections which are not required must be closed.

When the optional fiber-optical interface (channel 2 ) is not fitted, a cover plate is provided at this point.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.3.2 TRC7000

NOTE This chapter provides a short summary of the TRC7000 device.

For more detailed information please see the Eltromat user manual.

Figure 1-4 TRC7000 processing unit

NOTE Interface description, see TRC3000

Figure 1-5 TRC7000 measuring camera

The TRC7000 measuring camera is available in two different hardware versions:

RSC-DI.x

RSC-DI-VF.x (device with varnish flash)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.4 Mark evaluation principle

TRC3000

Basically a configured mark stream (maximum 20 marks) will be compared with the actual measured mark stream.

In mode 3 maximum 3 marks, selected in the Job screen, will be transmitted from TRC3000 to SIMOTION. In mode 20 all 20 marks will be transmitted.

Compared with the configured stream every mark has its own mark error in reference to the stream. Depending on the measuring method the application calculates the resulting register error from the mark error and the reference mark error.

Figure 2-2 shows the principle of mark error detection and calculation of the resulting register error. The colored marks are the measured marks, the framed marks are the set marks.

In this case the resulting error for LR of the red mark in “web web”-mode would be red mark error minus reference mark (black) error.

Figure 1-6 Mark stream evaluation example

TRC7000

Basically a configured mark field (maximum 20 dots) will be compared with the actual measured mark field.

In mode 3 maximum 3 marks, selected in the Job screen, will be transmitted from TRC7000 to SIMOTION. In mode 20 all 20 marks will be transmitted.

Compared with the configured mark field every mark has its own mark error in reference to the mark field. Depending on the measuring method the application calculates the resulting register error from the mark error and the reference mark error.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.5 Integration of TRC3000/7000 into a machine concept

The cyclic communication based on PROFINET IRT. Therefore the integration into an existing machine concept is easy. Every TRC-hardware is equipped with two PN-Interfaces for series connection of several devices.

The figure 1-3 shows a TRC3000 standard configuration. Every print unit is equipped with one TRC. The TRC for printing unit #1 is the “doublehead”- version for front and backside detection. All other print units are equipped with the TRCs in “singlehead”-version.

The TRC3000 and TRC7000 are also able to operate in the so called “end of press mode”. This offers the advantage that only one TRC is necessary for the whole machine concept, which is reading all marks (up to 20). This variation is mainly designed for central impression or stack type flexographic machines.

Also a mixed concept of TRCs in End-of-Press-Mode and standard mode with 3 marks is possible.

Also a mixed concept with TRC3000 and TRC7000 is possible.

Figure 1-7 Machine concept example with TRC3000

Figure 1-4 shows the detailed connection between the different system components. The SIMOTION as master device in the PROFINET IO system controls the printing cylinder.

Via PROFINET IRT the cyclic data will be transferred and received from SIMOTION.

Moreover the TRC works with different kinds of acyclic communication. The parameterization will be done by acyclic read/write parameter commands and the analogue oscilloscope data or the live image data will be transferred by TCP/IP-Ethernet communication.

The communication methods are summarized in table 1-3.

PROFINET



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Figure 1-8 System overview with TRC3000

Table 1-2 TRC communication

Communication type Used for e.g.

PROFINET IRT Cyclic communication: Status words, control words, cylinder position, actual mark error

Acyclic Read/Write parameter command Parameterization of TRC (mark field, mark definition, control mode…)

Actual TRC data (Error numbers, actual gate positions, FW version…)

TCP/IP Analogue Oscilloscope data head 1 and 2 (hardware depending) or

Live Image data

The TRC3000 is working with all known types of wedge and block marks. Low contrast ink or reflecting materials are reliable to detect. Also measurement of edges and holes in the material is possible.

Typical applications for the TRC3000 solution are rotogravure printing for packaging, flexographic printing and converting applications.

The TRC7000 is working with dot marks.

The example project contains the preconfigured HMI example screens for TRC parameterization, fault handling and evaluation of the oscilloscope data.

Register Mark Field

Sensor

PROFINET IO

Register Mark Field

Sensor

PROFINET IO



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.6 Telegram Mark3 / Mark20

The TRC3000 can work in two different telegrams:

Mark3: Telegram 100 (46 Byte input / 16 Byte output)


The TRC7000 can work in two different telegrams:



The useable mode depends on the selected telegram in the hardware configuration of the project and can’t be modified later during operation.

NOTE More information about the telegrams is provided in the Eltromat documentation.

Mark 3

Every print unit uses one TRC device. The measurement of 3 marks from a field of 20 marks is possible. The 3 marks are freely selectable by the configuration. TRC3000: “double head” measurement is possible.

Mark 20

One TRC device evaluates the marks of a group of printing units or for the whole machine (end of press mode). Evaluation of 20 marks (maximum) is possible. TRC3000: “double head” measurement is not possible.

The following table shows an overview about the use cases of the different TRC3000 modes.

Table 1-3 Mode overview for TRC3000

Measuring method TRC3000 Mark 3 TRC3000 Mark 20

Web Cylinder X (X)

Web Web X X

Web Web 2 X -

X: possible, (X): possible but not useful, -: not possible



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.7 Assignment TRC to PU

In one machine different TRC sensor types can be used, even in one PU a TRC3000 as well as a TRC7000 device can be installed. Of course it must be selected which device should be used for controlling. The configuration can be done in the HMI “Configuration 2” screen.

Figure 1-9 Assignment TRC to PU

This setting defines which sensor type is installed at each PU (0: Sensor type not installed; x: Sensor type installed) and which sensor is used for controlling (ON/OFF). Furthermore the TRC number for each PU can be defined.

Explanation of the above shown example:

PU1 TRC3000 #0 TRC7000 #0

PU2 TRC3000 #1 ON TRC7000 #1 OFF

PU3 TRC3000 #0 OFF TRC7000 #2 ON





PU1 is not register controlled, printing the key color.

PU2 is using two sensors (TRC3000 & TRC7000), TRC3000 is used for controlling.

PU3 uses a separate TRC7000 for register controlling.

PU4 uses a separate TRC7000 for register controlling.

PU5-7 uses one TRC7000 device to control the 3 PUs.

The setting is done in the structure

HMI_TRC3000_Command.au8TRC3000AssignedToPU and

HMI_TRC7000_Command.au8TRC7000AssignedToPU

The array element represents the printing unit; the array value represents the TRC number.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

1.8 Set value for TRC

1.8.1 Master position or axis/cylinder position

The set value of the web or of the product will be sent via IRT communication to the TRC.

If each printing unit has its TRC and if the printing cylinder runs (like usual) with a constant speed, the set value for TRC normally is Position of the printing cylinder.

If only one TRC at the end of the line is used, or the cylinder doesn’t run with constant speed (like crosscutter or print length correction at corrugated machines) the set value of the cylinder is not suitable. In this case the set value of the virtual master must be used.

The Axis for the set value must be connected in program pTRCx000IPO, see

Figure 1-10 pTRCx000IPO.

Also the variable TRCx000Data.STDcIO.IN.boUseMasterPosition must be set!

NOTE TRCx000Data.STDcIO.IN.boUseMasterPosition

= TRUE : Master position is used = FALSE: Axis position is used

Figure 1-10 pTRCx000IPO

1.8.2 Actual or command position

Generally it is possible to use the actual or the command position for the TRC set value.

If the master position is used, no actual position is available. Therefor the command position must be used.

If the axis position is used, the command position is only recommended, if the following error is small, also during acceleration and deceleration. Finally it should be tried, which value works better. Mostly the differences are not big.

Depending on set or actual value, different compensating times must be set in the TRC.

This can be done manually, by writing the parameters

TRCData.InOut.sData_Acylic.SimotionToTRC.CycleDelay

TRCData.InOut.sData_Acylic.SimotionToTRC.SampleDelay

CycleDelay:

Actual values: 2

Command values: 0



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

SampleDelay:

Actual values: (Ti + 5µs) * 1000

Command values: (-To + 5µs) * 1000

(Ti, To of drive, which is connected to FBLTRC3000IPO as set value for TRC)

The settings can be done also automatically, by setting the variable

TRCx000Data.STDcIO.IN.sDelayData.boAutomaticSetting = TRUE

CycleDelay and SampleDelay will be changed automatically depending the

variable TRCx000Data.STDcIO.IN.boUseCommandPosition , even if

boUseCommandPosition is changed during running!

For the automatic setting Ti and To of the cylinder axis is need to know. This setting must be found out in the hardware configuration

The values must be set in the program pTRCx000Startup.

For example: TRCx000Data.STDcIO.IN.sDelayData.i16Ti_us := 125;// 125µs

TRCx000Data.STDcIO.IN.sDelayData.i16To_us := 250;// 250µs

2 Application structure


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

2 Application structure The application for the TRC3000/TRC7000 is an AddOn to the Print Standard application and is very simple to implement in an existing project.

The sample project shows the implementation of Print Standard, mark recognition (TRC3000 and/or TRC7000) and register control.

It is also possible to use only parts of the application, for example the mark recognition with TRC7000 without HMI and without register control.

The SIMOTION project, the application contains example screens for the visualization with WinCC flexible. Depending on the project philosophy the HMI masks can be integrated and adapted to an existing HMI project or used stand alone as they are in the example project.

NOTE The HMI masks are only examples. They are freely adaptable by the user depending on the project requirements.

NOTE Chapter 4 of this manual contains a more detailed description of the TRC3000 software parts, constants and variables.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

2.1 Structure of the TRC application

Figure 2-1 TRC3000/TRC7000 implementation

Background

Background IPO

SIMOTION

PROFINET IO

HMI TRCx000

FBLTRCx000HMIDataTransfer

sHMI_TRCx000_Command

gasTRCx000DataFCLTRCx000_Mark3_1x0Telegram_IN

OR

FCLTRCx000_Mark20_1x1Telegram_IN

sTRCx000Data

FBLTRCx000BckGrnd[1]

sTRCx000Data

FBLTRCx000IPO[1]

sTRCx000DatagasTRCx000Data[TRC1]


OR


sTRCx000Data


sTRCx000Data

FBLTRCx000IPO[2]



OR


sTRCx000Data


sTRCx000Data

FBLTRCx000IPO[3]


The main part of TRC application part is the handling of cyclic and acyclic communication to the hardware device, the operation mode handling and the print mark evaluation.

Further on the HMI data transfer is implemented.

Background Task


The FBLTRCx000HMIDataTransfer does the data transfer for all used TRCs of one type to HMI and reverse.

This FB must be called only once per TRC type.

FBLTRCx000BckGrnd

For each TRC one FBLTRCx000BckGrnd must be called. The function block FBLTRCx000BckGrnd provides the basic data handling and TRC control.

IPOsynchronous Task

FCLTRCx000_Markxx_xxxTelegram_IN

For each TRC one of the telegram functions must be called. This function copies the cyclic telegram data to the data struct sTRCx000Data of each TRC.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

NOTE The function must be called before the FBLTRCx000_IPO is called!

FBLTRCx000_IPO

For each TRC one FBLTRCx000IPO must be called. The function block FBLTRCx000IPO provides the cyclic data handling, the and TRC control.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

2.2 Structure of the Register Controller application

Figure 2-2 Implementation of Register Controller

BackGround

IPO

SIMOTION

PROFINET IO

HMI TRCx000

FBLRegCtrlDataTransfer

sRegCtrlIO

sHMI_RegCtrl_Command

pPU_01_RegCtrl

FBs Length Register[PU_01]

FBs Side Register[PU_01]

FBLTRC3000DataToRegCtrl

sRegCtrlIO

au8TRC3000AssignedToPU

aboDontUseValOfTRC3000

gasTRC3000Data

FBLTRC7000DataToRegCtrl

sRegCtrlIO



gasTRC7000Data

pPU_02_RegCtrl



pPU_03_RegCtrl



sRegCtrlIO[PU_01]

sRegCtrlIO[PU_02]

sRegCtrlIO[PU_03]

Background Task


The FBLRegCtrlDataTransfer does the data transfer for all register controllers to HMI and reverse.

This FB must be called only once.

IPOsynchronous Task

FBLTRC3000DataToRegCtrl and FBLTRC7000DataToRegCtrl

The function blocks FBLTRC3000DataToRegCtrl and FBLTRC7000DataToRegCtrl copies data between the structures sTRCx000Data and sRegCtrlIO.

Furthermore, if as well TRC3000 and also TRC7000 are used in one PU, depending of the array aboDontUseValOfTRCx000 the right data are used for the register controller of PU.

NOTE The function blocks FBLTRCx000DataToRegCtrl must be called before the register controller sources!



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

pPU_xx_RegCtrl

In the source pPU_xx_RegCtrl the register controller for one PU is implemented. Depending on the requirements the source can/must be adapted.

Normally following functions are called for side and length register controlling:

FBLRegCtrlCharacteristicWithHysteresis for Tension adaption

FBLRegCtrlController

FBLRegCtrlDRD for Dynamic Register Decoupling



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

2.3 Software parts

2.3.1 Program units

The software for the register control is separated in three parts:

TRC3000 (Mark detection with TRC3000)

TRC7000 (Mark detection with TRC7000)

Controller (Register control)

It is possible to use all software parts like in the sample application. If required, the parts can be used standalone also. For example if only the mark recognition of TRC7000 is necessary, but no register control, only the programs in TRC7000 must be used.

Program folder “TRC3000”

Figure 2-3 Sources for TRC3000

Table 2-1 Content of units for TRC3000

Unit Content / Description

dTRC3000 Data and FB instances for TRC3000

pTRC3000 Startup program

Assign IP and logical addresses

Port settings

Further presetting

Background program

Data transfer HMI ↔ TRC3000Data

FBTRC3000BckGrnd for each TRC3000

IPO program

Copy telegram to TRC3000Data

FBTRC3000IPO for each TRC3000



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Program folder “TRC7000”

Figure 2-4 Sources for TRC7000

Table 2-2 Content of units for TRC7000


dTRC7000 Data and FB instances for TRC7000

pTRC7000 Startup program for TRC7000

Assign IP and logical addresses

Port settings

Further presetting

Background program for TRC7000

Data transfer HMI ↔ TRC7000Data

FBTRC7000BckGrnd for each TRC7000

IPO program for TRC7000

Copy telegram to TRC7000Data

FBTRC7000IPO for each TRC7000

dTRC7000LiveImages Live image data for each TRC (HMI picture)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Program folder “Controller”

Figure 2-5 Sources for Register Control

Table 2-3 Content of units for Register Control


fLengthRegCtrl Function block which is called in pPU_xx_RegCtrl containing the register controller sub functions for length register (FBController, DRD, Print Standard TechFB)

fSideRegCtrl Function block which is called in pPU_xx_RegCtrl containing the register controller sub functions for side register (FBController, DRD, etc.)

dRegisterControl Definition of numbers of PUs

NUMBER_OF_FIST_PU / NUMBER_OF_LAST_PU

Data declaration for register control

pGlobalRegCtrl StartUp Presetting

Background Data transfer HMI ↔ RegCtrlIO

IPO Copy data from TRC-Struct to RegCtrlIO-Struct

pPU_01_RegCtrl Register controller for PU1

pPU_02_RegCtrl Register controller for PU2

pPU_0x_RegCtrl Register controller for PUx …..

dTRCx000HMI

This data unit contains the global HMI command structures:

HMI_TRC3000_Command

HMI_TRC7000_Command

HMI_RegCtrl_Command

HMI_Application_Command

HMI_SetOCX

Program “pApplicationHMI”

This program contains the general data exchange with HMI which can be assigned neither to TRC nor to register controller part.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

In this example application it is used for the global collective error bits as well as the machine speed and can be adapted to the user requirements.

It can be used for additional user data exchange.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

2.3.2 Used Libraries

Table 2-4 Used Libraries

Library Content / Description

LApplicationHMI Data definitions and functions for HMI, which are special for this application and which cannot be assigned to RegCtrlDataExchange or TRCDataExchange

LCom Standard library for TCP/IP: Used for reading scope or live image data

LConLib Standard library for Converting functions

LDPV1 Standard library for DPV1-Communication

LPrint Standard library for PrintStandard

LRegCtrl Standard library for Register Controlling

LRegCtrlDataExchange Standard library for data exchange with HMI for Register Control

LSafeCast Standard library for safe type cast

LTRC Standard library for TRC3000 and TRC7000

Library LTRC

Table 2-5 Library LTRC


aVersion Version – change log

dTRC Data definitions for TRCData (TRC-Interface)

dTRCHMI Data for TRCCommand (HMI-Interface)

fTRC3000 FCs, FBs for using TRC3000

fTRC3000HMI FBLTRC3000HMIDataTransfer

fTRC3000TcpIpHMI FCs, FBs for getting scope data

fTRC7000 FCs, FBs for using TRC7000

fTRC7000HMI FBLTRC7000HMIDataTransfer

fTRCHMISub Sub FCs, FBs for HMI (for internal use)

fTRCSub Sub FCs, FBs for TRC (for internal use)

xTcpIp TcpIp functions for scope data and live image

Libraries which are grey colored are not relevant for user implementation.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Figure 2-6 LTRC

Only 4 FCs/FBs are important for implementation of TRC:

FCTRCx000_Mark3_1x0Telegram_IN

FCTRCx000_Mark20_1x1Telegram_IN

FBTRCx000BckGrnd

FBTRCx000IPO

One FB is necessary for the data transfer to HMI:




S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Library LRegCtrlDataExchange

Table 2-6 Library LRegCtrlDataExchange



dRegCtrlHMI Data definitions for HMI (HMI-Interface)

dRegCtrlIO Data for Register Controller (Register Controller Interface)

fRegCtrlHMI FBs for user implementation

fRegCtrlSub Sub FCs, FBs for Register Controller (for internal use)


Only 3 FBs are important for implementation of Register Controller:

FBLRegCtrlDataTransfer (Data transfer from/to HMI)

FBLTRC3000DataToRegCtrl (Data transfer from/to TRC3000)

FBLTRC7000DataToRegCtrl (Data transfer from/to TRC7000)

Library LApplicationHMI

Table 2-7 Library LApplicationHMI



dApplicationHMI Data definitions for HMI (HMI-Interface)

fHMI FC for user implementation


This function is made to unload the application program. Only the global Error word for HMI and the status for the register face plate is built there.

If the user wants to expand the HMI functions its recommended to add functions here and call it in the program pApplicationHMI.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

2.4 HMI (WinCC TIA)

The standard application is prepared for maximum 20 print units. The SIMOTION data arrays which are connected to HMI are predefined to this length.

NOTICE The length need to be stable also in machine concepts with less print units!

Within the WinCC TIA HMI application, the user has the possibility to reduce the control elements and internal variables to the exact number of print units used in the machine. This helps to safe internal storage space and calculation time within WinCC TIA scripts.

The setting can be done in properties menu of the TRC3000/7000 start screen in the event list. Click in the black background of the start screen next to the picture and change the value NumberOfPUs in the event list:

Figure 2-7

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3 Integration The following chapters show how to integrate a TRC3000 or TRC7000 device into a new or existing project. Furthermore the integration and adaption of the software parts and the HMI is described.

3.1 Hardware integration

Table 3-1 Integration of TRC3000 and TRC7000 hardware devices

Screenshot Description

1.

Open the hardware configuration of the SIMOTION device in the project

2.

Installing GSD-File:

To integrate the TRC3000 or TRC7000 into the hardware configuration, the GSD-File of the TRC3000 and TRC7000 has to be installed in the engineering-tool SIMOTION Scout.

Go to “Options / install GSD-file”.

Browse to the GSD-file and press “install”.

3.

Insert Profinet Interface:

(If a PN-IO-Interface is already existing (CBE30-2 or X150), step 3 can be skipped.)

Select the suitable PN-IO Option Board from the hardware catalogue on the right side and assign it to a free slot in the SIMOTION hardware rack.

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


4.

Insert I/O-System:

(If there is already an I/O-System existing, step 4 can be skipped.)

Right mouse click on the PROFINET I/O Controller

“Insert PROFINET IO System”

5.

Now I/O devices (e.g. TRC3000 or TRC7000) can be connected to the PROFINET-I/O-System.

6.

Insert TRC3000 or TRC7000 device:

(Premise: GSD file has been installed (step 2!)

Select the TRC3000 or TRC7000 device from the hardware catalogue (“PROFINET IO / additional field devices / Sensors / RSH-PN) and shift it with drag & drop to the PROFINET-IO-System.

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


7.

Define the TRC name and the IP-address.

8.

Select telegram for projected sensor unit:

Chose following telegram:

TRC3000 Fiber-Optic:

Mark3: Telegram 100 or Mark20: Telegram 101

Double head measuring (WebWeb2) is not working with Telegram 101 Mark 20

TRC7000 Camera:

Mark3: Telegram 120 or Mark20: Telegram 121

(The application doesn’t work with Telegram 100 and 101 for TRC7000!)

Telegram Input Output Bytes Bytes

100 16 46

101 16 216

120 16 47

121 16 217

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


9.

Shift the respective telegram from the hardware catalogue to the slot 1.2 of the integrated device.

10.

Define addresses:

Define the TRC addresses by clicking on the telegram in slot 1.2.

NOTE:

Start-Address of input and output data should be the same!

11.

Adjust to the PROFINET IO topology:

Right mouse click on the PROFINET IO system and go to PROFINET IO Topology

12.

Select graphical view and connect the TRC PROFINET interface to a free port of the SIMOTION controller.

Further TRCx000 devices have to be connected from port 2 of the previous device to port 1 of the following device.

NOTE:

This wiring needs to match with the physical wiring!

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


13.

Right mouse click on the PROFINET IO system and go to PROFINET IO Domain Management.

14.

Define the synchronization role for every PN device:

SIMOTION: Sync master

RSH-PN: Sync slave (IRT high performance)

Select the send clock time of the I/O controller to the I/O devices.

(This setting has to match with the DP slave properties of the SINAMICS_Integrated (step 15))

15.

DP slave properties:

Double-click on the SINAMICS_Integrated and check whether the master application cycle and the DP cycle matches with the send clock time of the I/O controller (step 14).

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


16.

SIMOTION properties:

Double click on the SIMOTION device.

In the tab “isosychronous tasks” the interface need to be operated synchronous to servo (set checkbox).

17.

Select IO cycle:

Mark the device, double click on Slot NET “Interface” and go to tab “IO Cycle”.

Select “Servo” at Assign IO

device in isochronous mode

18. Safe and compile the

hardware configuration. Close the hardware configuration and change back to the SCOUT project

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


19.

Define the necessary IO-variables on the address-list of the controller:

Depending on the selected telegram:

Telegram Output Input Bytes Bytes

TRC3000: 100 16 46

101 16 216

TRC7000:

120 16 47

121 16 217

Make sure the start addresses matches with the settings of step 10.

There is no process image necessary! Because of life sign, only IPO process image would be possible!!

20. Safe and compile the project

21.

Assign device names:

Open HW-Config and select the PROFINET-IO-System.

Go to PLC Ethernet Assign Device Name

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


22.

Select the device by MAC-Address, choose the device name from the drop down list and assign the name to the device by clicking the button “Assign name”.

If your device is missing, click the “Update” button.

You can also use the “Flashing on” button to

detect the corresponding device.

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3.2 Software integration (libraries and programs)

The program libraries and program units are separated in TRC3000, TRC7000 and register control. It can be used in combination as well as independent of each other.

NOTICE Axis names

If length and side register is used it is recommended to name the axis like following:

RA_PC_PU_0x RA_SR_PU_0x

In that case the program source of RegCtrl can be copied and adapted easily using the “Find and replace” function.

Table 3-2


1.

Copy the necessary libraries from the example project or via XML-import:

For TRC

LCom

LDPV1

LTRC

For Register Control

LRegCtrl

LRegCtrlDataExchange

LSafeCast

Possibly the used hardware and the version needs to be selected at all library’s first

Accept and compile each library after integration!

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


2.

Integrate necessary program sources for TRC

Units with global variables:

dTRCx000

dTRCx000HMI (if HMI is used)

Program sources

pTRCx000Backgr

pTRCx000IPO

pTRCx000Startup

dTRC7000LiveImages (only for TRC7000)

pApplicationHMI

3.

Integrate necessary program sources for Register Controller

Units with global variables:

dRegisterControl

Program sources

pGlobalRegCtrl

pPU_0x_RegCtrl for each unit with register control

4. Rename the sources pPU_0xRegCtrl with the right PU name

5. Change the sources pPU_0xRegCtrl by find and replace:

Find 0x and replace by 0y (increasing PU number).

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


6.

Assign programs to the respective tasks

Attention:

If already programs for the register control are assigned to IPO task, the TRC programs must be called before the register control programs!

Otherwise the measured values arrive one cycle later at the register controller function blocks.

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3.3 Necessary program adaptions

To adapt the example project to an own machine project or extend the project by further TRC’s the following steps need to be done:

dRegisterControl

The number of the first and last printing unit with register control must be set. Start with NUMBER_OF_FIRST_PU := 2, if first PU in the machine is not register controlled.

pGlobalRegCtrl\pRegCtrlStartUp

Deactivate HMI_axis_stdcIOActivateTestIO

Adapt the settings of the software limit switch for side register movement

pPU_0x_RegCtrl

This unit must be multiplied for each register controlled PU.

The variables can be changed using the find and replace function by replacing the strings “PC_0x” and “PU_0x”.

Ensure r64ActualCylinderFormatLength parameter will be set

Wire the impression off signal as well as the feedback (necessary for large register adjustments in gravure machines)

dTRCx000

The number of the first and last TRCx000 sensor device must be set.

Start with the first register controlled PU number to match numbering (e.g. NUMBER_OF_FIRST_TRCx000 = same number than NUMBER_OF_FIRST_PU).

pTRCx000Startup

Sensor IP address setting

Logical HW address setting

SIMOTION port setting

TRCData settings

Table 3-3

TRCData paramter Description

boUseMasterPosition Setting which axis has to be connected to TRCx000 Background and IPO function block.

FALSE: (Own) printing cylinder axis

TRUE: Master axis, e.g. VA_LM_Format

boUseCommandPosition Setting if axis command or actual motion vector will be send to the sensor device

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

TRCData paramter Description

sDelayData.boAutomaticSetting Sensor delay settings (CycleDelay and SampleDelay)

FALSE: Values need to be set manually by writing on TRCData.SsTRCInterface.sData_Acyclic.SimotionToTRC.CycleDelay / SampleDelay

TRUE: The values will be determined automatically dependent on boUseCommandPosition and Ti/To time.

sDelayData.i16Ti_us Ti time of SINAMICS in HW-Config

sDelayData.i16To_us To time of SINAMICS in HW-Config

boLifeSignAutoAckn TRUE: LifeSignFault will be reset automatically if life sign comes back.

FALSE: LifeSignFault must be acknowledged manually.

Register controller is switched off during life sign faults.

pTRCx000Background

Extend TRCx000 background function block call for every TRC device

The axis which need to be connected to the CylinderInReference input depends on the setting in TRCData.sSTDcIO.In.boUseMasterPosition

Table 3-4

boUseMasterPosition Axis to be connected

FALSE Own printing cylinder axis

TRUE Master axis, e.g. VA_LM_Format

pTRCx000IPO

TRCx000 IPO function block call for every TRC device.

The sensor address list parameters need to be connected here.

The axis which need to be connected to the axis input depends on the setting in TRCData.sSTDcIO.In.boUseMasterPosition

Table 3-5

boUseMasterPosition Axis to be connected

FALSE Own printing cylinder axis

TRUE Master axis, e.g. VA_LM_Format

Telegram copy function call in front of IPO function block call

Dependent on the sensor type and the used sensor telegram, one of the following LTRC library functions must be called:

FCLTRC3000_Mark3_100Telegram_IN




3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

The function copies the data coming from the sensor to the TRCData structure which is being used in the TRCx000 Background and IPO function blocks.

pApplicationHMI

This program can be used to exchange HMI parameter which are not related to TRCx000 or register control.

Furthermore the program is used to transfer fault messages and RegCtrl faceplate values to the HMI.

Depended which sensor type is used one of the following LApplicationHMI library functions has to be called:

FCLApplicationTRC3000



3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3.4 HMI integration

NOTE Before starting the integration of the HMI all necessary variable sources in SIMOTION should be integrated. Otherwise the reconnection of the variables will not match.

NOTICE It is recommended to use the TRC HMI example project as basis!

If a user HMI project already exists, copy these user HMI screens into the TRC example HMI project.

Because of scripts and recipes which are used inside the TRC HMI example project it’s easier to keep the example project as basis.

3.4.1 TIA HMI device proxy

The HMI application is engineered with WinCC TIA. The connection between this TIA project and the SIMOTION classic project is realized via device proxy.

NOTICE In case the global HMI variables have changed inside the SIMOTION classic project, the device proxy data must be updated!

For this complete the following steps.

Table 3-6


1. Close the classic project (SIMOTION Scout and SIMATIC Manager)

2. Open the WinCC TIA example HMI project (TIA Portal) which can be found in the SIMOTION Scout project folder.

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


3.

Right click on the device proxy

Update data of the device proxy

4.

Select the file “project.mcp” from the “u7” folder of the classic project path.

5.

In case the SIMOTION controller type is different (D435-2 -> D445-2) the existing device proxy must be deleted and a new one created.

Continue with step 6!

In case the SIMOTION controller is the same type, the device proxy can be updated.

Continue with step 13!

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


6.

- Delete existing device proxy from the project tree

- Create a new device proxy with “Add new device”

7.

Right click on the device proxy

Initialize device proxy

8.

Select the file “project.mcp” from the “u7” folder of the classic project path.

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


9.

- Go to the “Network view” in “Devices & networks”

10.

- Select “Connections” and choose “HMI connection”

11.

- Wire the HMI station CP port with the correct device proxy port.

The IP address area of the device proxy port must match to the IP address area of the HMI station.

12.

- Go to the “Connections” menu of the HMI station.

- Copy the name of the old, invalid connection shown in red (here “Connection_1”).

- Delete the old, invalid connection shown in red (here “Connection_1”). Delete the complete line.

- Change the name of the new connection to the old name (here “HMI_Connection_1” -> “Connection_1”)

13.

Right click on the folder “HMI tags”

Synchronize with the PLC tag

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


14.

- Select “Paths of the PLC Tags match”

- Remove the checkbox “Replace WinCC tag name with PLC tag name” !

15.

Right click on the HMI runtime

Compile Software (rebuild all)

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3.4.2 Basic settings

For communication between the TRC3000 oscilloscope window and SIMOTION, the SIMOTION IP address must be defined inside the WinCC TIA HMI application.

The setting can be done in properties menu of the TRC3000/7000 start screen in the event list.

To change the IP address or the number of PUs, click in the black background next to the picture and change the value in the event list.

The output filed “TCP/IP connection” on the scope screens shows the connection state of the OCX PrintMarkControls (Green = connected, Red = not connected).

Figure 3-1 Change IP address / number of PUs

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3.5 Necessary settings for TRC3000 oscilloscope

The TRC3000 oscilloscope is realized with an external WinCC control element. It need to be installed on every device the oscilloscope should be displayed (e.g. engineering computer, Panel PC, IPC, …).

Table 3-7


1. Unzip "SetupPrintMarkerControls.zip" to the local hard disk:

e.g C:\Program Files\Siemens\PrintMarkerControls.

2. Close TIA Portal.

Run "SetupPrintMarkerControls.exe"

Two dll files will be registered during the installation.

3. The oscilloscope fields can be used now! No further action necessary!

If a new HMI screen with a new oscilloscope shall be integrated the following steps need to be done first.

4.

Open TIA Portal.

Open one of the HMI screens.

Go to the Toolbox section on the right hand side of TIA Portal.

Go to "My Controls".

Right mouse click in the area “My Controls” opens context menu

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


5.

Select "MCPMControlAnalog.V2 Class".

NOTE To update the PrintMarkerControl, install the latest “SetupPrintMarkerControls.exe” file only. No further steps are necessary!

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3.6 Necessary settings for TRC7000 camera live image

The TRC7000 live image is displayed on an mwsl page on the SIMOTION web server. The TRC7000 TIA HMI application uses an embedded browser window to display the live image from there.

The following steps need to be done to prepare the web pages on the SIMOTION CF card.

Table 3-8


1.

The content of the folder “SIMOTION_Card_Files_TRC7000_Vx.x” which can be downloaded from SIOS need to be copied to the SIMOTION CF card to the path USER/SIMOTION/HMI/FILES/

i. Folder “Applications”

ii. Folder “SIMOTIONIT”

iii. File “USER.mwsl”

2.

Adapt the SIMOTION IP address in the browser

window of each TRC7000 camera screen: 92XX_RegCameraXX

Example for PU2: 192.168.1.1/files/applications/printing/trc7000/eltr

omat.mwsl?PU=2

3.

If SIMOTION Card Files version <= V1.5 are used, the upper selector switch located at the lower front side of the SIMOTION device must be set to position “8” (Web server in security level low)!

Attention: The web server is fully accessible without password protection in this mode!

Remedy: Continue with step 4

4. Using SIMOTION Card Files version >= V1.6 a web server user (username and password) with admin rights must be created to display the camera live image.

The selector switch can remain in position “0” in that way!

5. Creation of the user on IT-Diag:

Open the SIMOTION web server by entering the SIMOTION IP address in a web browser (e.g. Internet Explorer)

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


6.

To create a new user the upper selector switch located at the lower front side of the SIMOTION device must be set to position “8” (Web server in security level low).

7.

Change to “Manage Config” -> “Users & Passwords”

and add a new administrator.

8. Once the user has been created the selector switch can be changed back to position “0”

9.

The new user data (user name and password) need to be defined in the

“TRC7000logManApp.js” file

located on the SIMOTION CF card in the path

USER/SIMOTION/HMI/FILES/Applications/Printing/TRC7000/script

Here the default setting “TRC7000”,”TRC7000” need to be replaced with the new created user name and password.

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3.7 Elimination of TRC3000 or TRC7000 from project

The example project is a combined project containing the TRC3000 as well as the TRC7000 sensor.

If only one sensor type is used, the other one can be removed in a few steps.

The following table describes the removal of the TRC3000 parts. The removal of the TRC7000 can be done in the same way.

There are adaptions in SIMOTION Scout as well as WinCC TIA necessary!

SIMOTION Scout:

HW-Config

– Remove the TRC3000 sensor device

SIMOTION Address List

– Delete the I/O variables of the TRC3000 sensor

TRC3000 (program folder)

– The complete folder must be deleted

pGlobalRegCtrl

– Delete the “USES dTRC3000” command

pGlobalRegCtrl\pRegCtrlIPO

– Delete the function block call FBTRC3000DataToRegCtrl()

SIMOTION Address List

– Delete the I/O variables of the TRC3000 sensor

dTRCx000HMI

– Delete the structure variable HMI_TRC3000_Command

pApplicationHMI

– Change the function call to FCLApplicationTRC7000()

Execution System

– Remove the TRC3000 programs

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

WinCC TIA:

Change the connection setting of the following HMI Tags to <internal tag>

– Reg_External\SIMOTION_IN\OP_TRC3000

– Reg_External\SIMOTION_IN\TRC_Job_TRC3000

– Reg_External\SIMOTION_OUT\OP_TRC3000

– Reg_External\SIMOTION_OUT\Message_TRC3000

Update HMI device proxy as described in chapter 3.4.1 TIA HMI device proxy.

3 Integration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

3.8 Necessary modifications from Standard mode (mark 3) to End-Of-Press mode (mark 20)

First it must be distinguished between to use cases:

(1) The sensor operates in a real End-Of-Press mode, which means one sensor at the end of the machine is detecting all marks and forwarding the respective register deviations to the register controller of each print cylinder axis.

(2) Each print unit has its own sensor, but for evaluation reasons all marks printed up to the respective sensor shall be measured and transferred to SIMOTION.

For both use cases (1) and (2), the following changes have to be made to the program:

The sensor telegram in the HW-Config need to be changed. See chapter 1.6 Telegram Mark3 / Mark20

The length of the SIMOTION Input address list variables need to be changed. See chapter 1.6 Telegram Mark3 / Mark20

For use case (1) the following additional changes have to be made:

pTRCx000Startup

Table 3-9

Parameter Mark 3 Mark 20

STDcIO.IN.boUseMasterPosition FALSE/TRUE TRUE

STDcIO.IN.boUseCommandPosition FALSE/TRUE TRUE

See chapter 1.8 Set value for TRC

pTRCx000Background

Table 3-10


CylinderInReference (TRCx000Background function block)

Print cylinder axis/ VA_LM_Format

VA_LM_Format


pTRCx000IPO

Table 3-11


Axis (TRCx000IPO function block) Print cylinder axis/ VA_LM_Format

VA_LM_Format


4 Use of the application


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

4 Use of the application The example application is made for TRC3000 and TRC7000.

The following part shows the structure of the application, the internal setpoint flow and how to use HMI screens.

4.1 Overview

The following figure shows an overview about the example program for TRC control.

The data for job parameterization will be copied from the HMI (gasHMITRCx000Data) in the background task to the TRC data structure (sTRCx000Data) of the respective TRC. The data values will be used by the TRC function blocks.

Figure 4-1

pPU_0x_RegCtrlIPO

pTRCx000BackGround pTRCx000IPO

SIMOTION

PROFINET IO

HMI TRCx000

FBLTRCx000DataTransfer

sHMI_TRCx000_Command

gasTRCx000Data


OR


sTRCx000Data


sTRCx000Data

FBLTRCx000IPO[1]


pRegCtrlBackgr


sRegCtrlIO

sHMI_RegCtrl_Command

pPU_01_RegCtrl



pRegCtrlIPO

FBLTRCx000DataToRegCtrl

sRegCtrlIO

au8TRCx000AssignedToPU

aboDontUseValOfTRCx000

gasTRCx000Data

FBLTRCx000DataToRegCtrl

sRegCtrlIO

au8TRCx000AssignedToPU

aboDontUseValOfTRCx000

gasTRCx000Data

sRegCtrlIO[PU_01]

Register Mark Field



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Below the cascade of set values and the connection to the adder object is shown.

The velocity correction output of the register controller is converted and transferred to the additional object of the printing cylinder axis and added to the main setpoint from the local master axis.

Figure 4-2

pPU_0x_RegCtrlIPO

TO connection „IPO Task“

fbRA_PU_02RegCtrlLR

fbRA_PU_02TechLR

v set [°/s]

RA_PC_02

+

VA_GM_

Web

1m

----------

Format

VA_LM_

Format

fbRA_PU_02RegDRDLR

r32Output [mm/s]



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

4.2 HMI screens

Start screen

Figure 4-3

Axis control screen (1)

Just for demo case. Button can and respective screen can be removed in real machine project.

Exit runtime (2)

There are scripts which are executed by pressing this button resp. the “Yes” button in the Pop-Up screen which is being opened with the “Exit” button. It must be guaranteed these scripts will be executed before shutting down the panel! In case there are overall machine screens next to the TRC screens,

these scripts should be executed when going back to the user HMI screen.

Configuration (3)

Alarms (4)

Register error history and statistics (5)

Register error overview of all print units (6)

Print units control screen - camera (7)

Print units control screen – fiber optic sensor (8)

Job and mark field setting - camera (9)

Job and mark field setting – fiber optic sensor (10)

Start screen (11)

1 2 3 4 5 6 7 8 9 10 11



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Machine control screen

NOTE This screen is for register control demo model only!

Figure 4-4

The printing cylinder axes can be switched to mode 60 (gearing) and the global master axis can switched to mode 30 (speed setpoint mode) and can be started with a desired speed setpoint.

NOTE In the example project the speed input is percentage of a web speed of 600 m/min. This depends on the Print Standard setting.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Machine configuration 1

Figure 4-5

Create Configuration dataset recipe (1)

Button Description

With these buttons a recipe can be created and the configuration can be saved into it.

(New, Save, Save as, Delete)

NOTE Each Configuration dataset will be saved in a recipe which is stored on the local hard disk of the runtime PC in the path C:\RECIPES\TRCx000\ConfigSensor

Panel selection (2)

With this selection menu the panel type can be changed from “Main Panel” to “Local Panel”. At the local print unit panel less objects are shown.

TRC Maintenance (3)

After selection of the TRC number, the sensor calibration and the reset to factory settings can be performed.

During calibration the status line shows the necessary operator action.

NOTE For calibration of the FO the reference box (MLFB: 6AU1671-0FA00-0AA0) is necessary.

2

3

4

5

6

7 1



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Factor settings (4)

Table 4-1 Factor settings for oscilloscope screen

Name Unit Default Description

Resolution factor register control view

- 10 Resolution of the register-controller actual value faceplate

10: 0.1 mm per (small) grid line

100: 0.01 mm per (small) grid line

Maculation level mm 0.5 Register error bigger this value is shown in red color in the graphical register error display

Factor register inching LR slow

mm 0,1 Step width (per edge) for printing cylinder inching/register fine correction.

Factor register inching LR fast

mm 2 Step width (per edge) LR fast for printing cylinder inching/register fine correction.

Factor register inching SR slow

mm 0,1 Step width (per edge) SR slow for printing cylinder inching/register fine correction.

Factor register inching SR fast

mm 1 Step width (per edge) SR fast for printing cylinder inching/register fine correction.

Factor insetting gear ratio slow

- 1 Step witch (slow) for gear ration change

Factor insetting gear ratio fast

- 10 Step witch (fast) for gear ration change

Floating averaging of register error for FBController (5)

The number defines the average buffer depth for each print unit controller instance.

Register controller settings (6)

FBController settings

Config Download/Upload (7)

Button Description

With the download button the inputs in the white fields (internal variables) will be copied to the SIMOTION variables (yellow fields).

The upload button copies the SIMOTION variables to the internal variables.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Machine configuration 2

Figure 4-6

Web length setting (1)

In this area the web length between the printing units as well as the web length from sensor measuring point to printing unit can be entered. The inputs are used for controlling.

Sensor type selection and assignment (2)

This setting defines which sensor type is installed at each PU (0: Sensor type not installed; x: Sensor type installed) and which sensor is used for controlling (ON/OFF). Furthermore the TRC number for each PU can be defined.

1

2

3



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Example 1:




…

PU10 TRC3000 #0 OFF TRC7000 #1 ON

PU11 TRC3000 #4 OFF TRC7000 #2 ON

With this configuration PU 1-9 are using TRC3000 devices (one separate device for each PU). PU10 uses a TRC7000 device. At PU11 both devices are installed, however TRC7000 is used for controlling.

This setting is also shown in the Job screen in the column sensor type:

PU1-9 sensor type “F”

PU10 sensor type “C”

PU11 sensor type “C&F”

The sensor type field is colored if the sensor is selected for controlling (ON).

Example 2:







With this configuration no TRC7000 is used at all. The first 3 PUs are using the TRC3000 sensor #1 (first device), the last 3 PUs using the TRC3000 #2 (second device).

Config downlaod (3)

Button Description


By pressing the button the user is asked to save the configurations done on this screen, to the configuration recipe of configuration screen 1.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

PrintMarkControl configuration

In this screen the appearance of the oscilloscope field can be changed. Attributes like zoom area color, grid color, grid width, etc. can be adapted.

As this is just an example, only the columns for PU1, PU2 and PU20 is shown. The values can be changed in the respective column directly. To adapt the values for every print simultaneously the default column can be used. With the “arrow” button the values will be transferred to all print units.

Figure 4-7

Table 4-2 Default settings

Number Symbol Default value / Description

1 - Default settings for OCX PrintMarkControls

1b

Select color from graphic list “OCXColorList”

2

Transfer default setting to OCX PrintMarkControl for sensor 1 to 20

3 settings for sensor1 OCX PrintMarkControl

4 ….

5 settings for sensor20 OCX PrintMarkControl

6 TCP/IP server IP and port address

set in script “OCX_InitPictureAnalogControlTRC”

e.g.

Sensor1 “192.168.0.1:1024”

Sensor2 “192.168.0.1:1025”

…

Sensor20 “192.168.0.1:1043”



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Insetting configuration

Figure 4-8

Create Insetting dataset recipe (1)

Button Description



NOTE Each Insetting dataset will be saved in a recipe which is stored on the local hard disk of the runtime PC in the path C:\RECIPES\TRCx000\ConfigInset

Gearing level pre control (2)

Speed depending format changes can be pre control with this curve

Setting for web cylinder insetting (3)

Web cylinder insetting is that the gear of PU is adjusted and register control is active, where the TRC is connected to.

2

3

4

6

5

1

7



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Setting for key insetting (4)

Key insetting is that the PU is not control where the TRC is connected to. In stat the tension unit is adjusted

Setting for FBLInsetMarkValid (5)

SafetyFactor Tolerance to find the mark. Example: SafetyFactor = 1.5: Waiting for 1.5 printing formats, until the message “NoMarkThisCycle” appears.

MarksPerModulo Number of marks per modulo cycle

Setting for FBLInsetCheckFineCorrection (6)


Button Description



NOTE For detailed information about the “Print Standard Add-On Insetting” application, there is a separate documentation available.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

DRD and tension adaption configuration

Figure 4-9

Create DRD/Tension dataset recipe (1)

Button Description



NOTE Each DRD/Tension setting dataset will be saved in a recipe which is stored on the local hard disk of the runtime PC in the path C:\RECIPES\TRCx000\ConfigDRD

Tension time constant adaption curve (2)

Input values for speed depending adaption for weblength between two PUs. Has influence on register controller on web-cylinder mode and gravure printing. Used for FBTRC1000CharacteristicLR.

Values between two grid points are interpolated and after the last extrapolated. If tension adaption is of or an error in FBTRC1000CharacteristicLR the

adaption factor is 1.0.

2 3

4

5

6

1

7



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

DRD mode selection (3)

Speed depending shift curve (4)

Input values for speed depending shift curve of DRD function speed shift mode.

Values between two grid points are interpolated and after the last extrapolated.

Acceleration depending shift curve (5)

Input values for acceleration depending shift curve of DRD function “accel shift mode”.

Adaption factors for following units (6)

Due to the fact the characteristic for speed depending shift and also the value for acceleration shift is the same except for an factor between the different units, there is only one characteristic. The characteristic of the following units is adjusted by the adaption factors.


Button Description





S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Mark stream TRC3000

Figure 4-10

In this screen the user will be guided through the mark stream configuration.

Step 1: Creating a recipe

Step 2: Selection of AGS block mark for automatic reference mark search

Step 3: Selection of the maximum number of marks

Step 4: Selection of the mark type and geometry input

Step 5: Selection of the distances between the marks

Step 6: Summary and save to recipe

NOTE Each mark field will be saved in a recipe which is stored on the local hard disk of the runtime PC in the path C:\RECIPES\TRCx000\Mark



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Mark stream TRC7000

Figure 4-11

Create mark field dataset recipe (1)

Button Description



NOTE Each mark field will be saved in a recipe which is stored on the local hard disk of the runtime PC in the path C:\RECIPES\TRCx000\Mark

General settings (2)

Mark diameter, clipping size and web running orientation in relation to the camera.

Mark field setting (3)

Definition of mark position x/y value

2

3

1



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Job configuration TRC3000

Figure 4-12

In this screen the job need to be prepared. For each job at least one previously defined mark stream has to be selected. The procedure to create and prepare a new job is described with the following steps.

Create/select job dataset recipe (1)

Button Description



NOTE Each job configuration will be saved in a recipe which is stored on the local hard disk of the runtime PC in the path C:\RECIPES\TRCx000\Job

1

2

3

4

5

8

6

7

9



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Select and copy mark stream to the job (2)

Select a saved mark stream from the drop down menu and copy it with the arrow button to the job recipe. With the number drop down menu it can be selected to which marks stream slot in the job the mark stream will be copied.

NOTE After copying the mark stream to the job and saving it into the job recipe, the mark stream data are part of the job data.

By selection a job from the drop down menu, also the respective mark stream belonging to this job will be displayed in the mark stream drop down menu.

Basic job settings (3)

Name Unit Default value

Description

Machine format mm - Machine format for actual job

Gate width mm 20 Default gate width of the job

Zero to ref pos mm 0 Default distance between zero and gate position for job download

Print unit settings (4)

Button Description

Activate (green) / deactivate (grey) TRC device

Sensor type selection for this print unit

Dependent on the sensor selection in “Configuration 2” screen this field shows which sensor type is installed at the PU.

F: Fiber optic sensor (TRC3000)

C: Camera sensor (TRC7000)

C&F: Both sensor devices installed at this PU

The greyed TRC number field shows which TRC number is used for this print unit. The selection for this is done in the “Configuration 2” screen.

Mark field selection

If there is more than one mark field assigned to this job, the mark field number can be selected here.

With this selection it is possible to use different mark fields for different print units.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Button Description

Mark number selection

Ctrl mark (Own print mark) mark printed by the unit

Ref mark (Reference mark) standard reference mark

Reffo mark (Reference following mark) alternative reference mark; usually the mark of the previous print unit is used for that.

Measuring method

WebCylinder

WebWeb

WebWeb2 (second fiber optic is required)

Insetting WebCylinder

Insetting Key

Insetting WebWeb

Use uploaded data:

With this button the sensor configuration can be switched: Crossed: Use the default job settings which are shown in this screen

Un-Crossed: Use job settings which have been adapted and uploaded with the Job upload button.

Only in WebWeb2 mode!

Selection which sensor head is reading the reference mark.

Orientation of reference mark to control mark.

(Only in WebWeb2 mode!)

(Influence to side register evaluation only!)

Mode 1: Two mark tracks on the same side of the web. Same orientation of reference and control mark.

Mode 2: After web turn, reference mark on the backside, control mark printed in horizontal mirrored orientation to the reference mark.

Mode 3: After web turn, reference mark on the backside, control mark printed in vertical mirrored orientation to the reference mark to have the same orientation of reference and control mark after web turn.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Button Description

Mark number selection for mark center and gate tracking

functionality.

0: print unit mark (WebWeb); reference mark (WebCylinder) 1..x: A random mark of the mark field (WebWeb); always reference mark (WebCylinder) (the number is being ignored if WebCylinder is active)

The “tool factor” specifies the number of formats on the cylinder. If there is more than one format within the cylinder circumference, the sensor is able to measure every format within this revolution.

Color button: With the “color” button the print unit mark color can be selected to get a better overview about the job colors on the HMI screens. This color matches with some background colors on the oscilloscope screen. It for a better overview for the machine operator only. There is no effect to the sensor!

Reverse / mirrored mark field (5)

Button Description

Mirror mark stream horizontal with reading marks in reverse order. The button becomes green if the mirroring is active. The buttons can be used in combination.

Mirror horizontal. The button becomes green if the mirroring is active. The buttons can be used in combination.

Mirror vertical. The button becomes green if the mirroring is active. The buttons can be used in combination.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Mark number selection (6)

Dependent on this selection, the mark numbers for “ctrl mark” (control mark), “ref mark” (reference mark) and “reffo mark” (reference following mark) will be entered automatically. If the numbers should be entered manually, the drop down menu must be set to “manual”.

– 1xxxx: One reference mark, several control marks

– 1x1x1x1: The reference mark is printed again after each control mark

– x1xx1xx1: The reference mark is printed again after every second control mark

– manual: The mark numbers can be entered manually

Mark stream slots (7)

This field shows which mark stream is assigned to which of the 6 mark stream that slots can be used.

To copy a mark stream to one of the mark stream slots, the drop down menu and the copy button next to number “2” in this screenshot must be used.

With the “x” button the mark streams can be removed from the mark stream slots.

If more than one mark stream slot is used, for each print unit the desired mark stream number can be selected with the input field “field nr”.

Job download / upload (8)

After the job definition has been completed the actual job need to be transferred to the TRC device(s) with the download-button.

All data will be transferred to SIMOTION first and following loaded to the TRC devices.

This can take some time!

Color Description

[flashing]

New job download necessary. Start the job download by pressing the download button.

Download from panel to SIMOTION

Download from SIMOTION to TRC device

Download successfully

An error has been occurred. See the error screen for detailed information.

Changed values during the job (e.g. gate width) can be uploaded and saved to the job. Later on this values can be used for download again.

Mark preview refresh (9)

Refresh the color setting in the mark preview bar



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Job configuration TRC7000

Figure 4-13

Create/select job dataset recipe (1)

Button Description



NOTE Each job configuration will be saved in a recipe which is stored on the local hard disk of the runtime PC in the path C:\RECIPES\TRCx000\Job

Select and copy mark field to the job (2)

Select a saved mark field from the drop down menu and copy it with the arrow button to the job recipe. With the number drop down menu it can be selected to which marks field slot in the job the mark field will be copied.

NOTE After copying the mark field to the job and saving it into the job recipe, the mark field data are part of the job data.

By selection a job from the drop down menu, also the respective mark field belonging to this job will be displayed in the mark field drop down menu.

1

2

4 7

5

6

3

8



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Mark field slots (3)

This field shows which mark field is assigned to which of the 6 mark field slots that can be used.

To copy a mark field to one of the mark field slots, the drop down menu and the copy button next to number “2” in this screenshot must be used.

With the “x” button the mark streams can be removed from the mark stream slots.

If more than one mark field slot is used, for each print unit the desired mark field number can be selected with the input field “field nr”.

Copy job settings to mark field (4)

With the arrow to left button, the mark field settings which can be done in the upper right corner of the mark field screen (mark diameter, clipping size, filter threshold, etc. ) can be copied to another mark field configuration.

NOTE To save this configuration in the mark field recipe, the save button on the mark field screen must be pressed!

Basic job settings (5)

Name Unit Default value

Description

Machine format mm - Machine format for actual job

Zero to ref pos mm 0 Default distance between zero and gate position

Print unit settings (6)

Button Description

Activate (green) / deactivate (grey) TRC device

Sensor type selection for this print unit

Dependent on the sensor selection and assignment in “Configuration 2” screen this field shows which sensor type is installed at the PU.

F: Fiber optic sensor (TRC3000)

C: Camera sensor (TRC7000)

C&F: Both sensor devices installed at this PU

The greyed TRC number field shows which TRC number is used for this print unit. The selection for this is done in the “Configuration 2” screen.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Button Description

Mark field selection

If there is more than one mark field assigned to this job, the mark field number can be selected here.

With this selection it is possible to use different mark fields for different print units.

Mark number selection

Ctrl mark (Own print mark) mark printed by the unit

Ref mark (Reference mark) standard reference mark

Reffo mark (Reference following mark) alternative reference mark; usually the mark of the previous print unit is used for that.

Measuring method

WebCylinder

WebWeb

WebWeb2 (second fiber optic is required)

Insetting WebCylinder

Insetting Key

Insetting WebWeb

This field is only a display filed. It shows the camera to mark field orientation in web direction.

The setting itself can be done in the mark field screen.

Camera flash selection.

(1) Standard flash

(2) Varnish flash

(3) Standard and varnish flash

Use uploaded data:

With this button the sensor configuration can be switched: Crossed: Use the default job settings which are shown in this screen

Un-Crossed: Use job settings which have been adapted and uploaded with the Job upload button.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Button Description

The “tool factor” specifies the number of formats on the cylinder. If there is more than one format within the cylinder circumference, the sensor is able to measure every format within this revolution.

Color button: With the “color” button the print unit mark color can be selected to get a better overview about the job colors on the HMI screens. This color matches with some background colors on the oscilloscope screen. It for a better overview for the machine operator only. There is no effect to the sensor!

Mark preview refresh (7)

Refresh the color setting in the mark preview field

Job download / upload (8)

See description of TRC3000 Job configuration



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Oscilloscope TRC3000

Figure 4-14

NOTE The request of the measured values will be started when changing to the scope screen. For measuring the printing cylinder axis need to be angular synchronous. Otherwise no values will be send from the TRC to SIMOTION.

Connection status of OCX PrintMarkControls (sensor oscilloscope) (1)

Green = connected, Red = not connected

OCX is a TCP/IP client which connects to the SIMOTION (TCP/IP server)

OCX needs IP and port address of TCP/IP server

The IP address and the port can be configured in the event list of the TRCx000 start screen.

Print unit selection (2)

With these buttons the oscilloscope screen for each print unit can be selected. The color which is shown in the button depends from the color setting in the job.

Color-Bar and white level adjustment (3)

The color bar shows the real feedback measured by the sensor.

With the button “White level” a pop-up screen to adjust the contrast of the color bar will open.

Mark error (4)

2 1

6

7

7

8 3

9 10 11 12

18 19 17 16

13

14

15

5

3

4

4

20 21



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

The mark error LED on the top right of the screen indicates with a red light a mark error. In the output bar the gate number where the mark error occurs is shown, as well as a mark error text.

NOTE A mark error cannot be solved with the acknowledge button. Rather the reason must be eliminated.

Check the gate position over the mark as well as the entered mark geometry which must fit to the actual mark on the web.

Error/Acknowledge (5)

Button Description

Local error:

Error at this printing unit / sensor device.

Press the button to get detailed information.

Global error:

Error at any printing unit / sensor device.


Fault acknowledge

Analog oscilloscope with cursors (6)

In this diagram the sensor analog signal curve will be displayed. The X-axis represents the format length (millimeter), the Y- axis the sensor analog signal (voltage).

X-Zoom (7)

The zoom curve can be used for a better diagnostic of a specific area of the format length.

The zoom area can be shifted left and right in this area only, the arrow is inserted in the screenshot.

To increase or decrease the zoom area, just grab the right or left edge and shift it.

With a double click in the zoom area, this area can be enlarged. The standard view will become smaller. With a double click in the standard view, the standard view will be enlarged again.

The proportion between the two areas can be defined in the control config screen with the value “RangeFactor”

(default: “60” = 60:40, standard view : zoom area)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Y-Zoom (8)

The y-zoom can be used to adapt the view to display all marks (amplitudes) inside the oscilloscope window.

Grey value curve (9)

Switch between RGB curve and grey value curve in the oscilloscope. This setting is for display only. There is no effect to the measurement.

Gate width (10)

The gate is used to scan a printing mark just within a defined area.

NOTE To calculate the register deviation, the printing marks on which the calculation is based, has to be within the gate!

With the up and down buttons the gate width (which is displayed in the middle field) can be increased/decreased (+/- 0.5 mm).

Gate position (11)

With the up and down buttons the gate position (which is displayed in the middle field) can be shifted to the left and right (+/- 0.5 mm).

Select and set gate Position (12)

With this functionality the gate position (reference mark gate) can be changed just by two clicks.

After pressing the “select gate pos” button (upper button) the button becomes green and the oscilloscope field gets sensitive for selecting a set position. With the next click somewhere in the oscilloscope field, the gate position will be changed to this position.

Alternatively the set value can also be entered into the input filed in between the two buttons or moving the x-cursor to a specific point. With the “set gate pos” button (lower button), the selected gate position will be set.

Set Ref (13)

NOTE This function is mainly applicable using the Print Standard Add-On TRC1000.

The reason is the gate setting procedure is started with print mark gate. After setting up the print mark gate the reference gate can be setup with “Set Ref”.

This functionality can be used if the reference gate is at the right position but the reference mark is not inside the gate. Click on the reference gate (only in the zoom area) and shift it to the reference mark. The value below the button shows the distance the cylinder has to move to bring the mark into the gate. The adjustment can be started by pressing the button “Set-Ref”.

The cylinder will move by the shortest way to bring the mark into the gate.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Set Reg (14)

NOTE This function is mainly applicable using the Print Standard Add-On TRC3000.

The reason is the gate setting procedure is started with reference gate. After setting up the reference gate the print mark gate can be setup with “Set Reg”.

This functionality can be used if the reference gate and reference mark is at the right position (mark inside the gate), the control gate is in the defined distanced to the reference gate but the control mark is not inside the control gate. Click on the control gate (only in the zoom area) and shift it onto the control mark. The value above the button shows the distance the cylinder has to move to bring the mark into the gate. The adjustment can be started by pressing the button “Set-Reg”.

NOTE Just in WebWeb mode and register controller is switched off!

Format counter (15)

Format counter and reset to zero” button

Reference following mark (16)

Switch between two (previously in the job) defined reference marks.

Usually it is used to switch between the reference mark which is printed by the first print unit and the print unit printed by the previous unit as reference.

AMR (Automatic Mark Recognition) (17)

Using a special arrangement of block marks (AMR block mark) at the beginning of the mark stream the sensor is able to detect this AMR block mark and sets the reference gate automatically.

With the “AMR start” button this functionality can be started. The AMR measurement takes 3-4 formats.

A yellow light shows the active measurement, green light the succeeded measurement and red light an error during AGS search.

Center Gate(18)

The printing mark will be centered within the gate. The gate position will be changed in order to that.

The number in the column “mark center” in the job configuration determines which mark (reference or control mark) is being centered.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Table 4-3

Measuring method Mark center value Description

All 0 If 0 is entered, for WebCylinder the reference mark will be centered, for other measuring methods the control mark will be centered.

WebWeb 1..x The respective mark out of the mark field

WebWeb2 1 Control mark

2 Reference mark

WebCylinder x (random) Always reference mark

Gate tracking (19)

The gate tracking functionality moves the gate with a moving print mark in order to maintain the measurement.

The number in the column “mark center” in the job configuration determines which mark (reference or control mark) is used for tracking (see table above).

Register inching and controller buttons (20)

Table 4-4 register controller buttons

Button Description

enable/disable register controller

The jerk buttons have two different functionalities:

Register controller in manual mode (off):

Printing cylinder jerk

Register controller in automatic mode (on):

Register fine correction (offset)

Two jerk steps are available:

jerk slow: (default: 1mm per edge)

jerk fast: (default: 5mm per edge)

The jerk steps can be changed in the “Configuration 1” screen.

Set fine correction offset back to 0.0



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Button Description

Set fine correction offset to the actual register error value

Register Control Faceplate (21)

Figure 4-15

Table 4-5

Number description

1 Register error value for length and side register

2 Graphical register error.

The scale of the diagram can be changed in the “Configuration 1” screen with the value “resolution factor graph. register error”.

3 Maculation level. The value can be changed in “Configuration 1” screen.

4 Fine adjustment value. The value is being adapted with the inch buttons during register controller in automatic mode.

5 The blue bar is showing the “sensor mounting offset”. It determines the lateral offset between mark center and sensor light.

5

2

3

1 1

4 4



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Camera Live image TRC7000

Figure 4-16

Print unit selection (1)

With these buttons the oscilloscope screen for each print unit can be selected. The color which is shown in the button depends from the color setting in the job.

Camera live image (2)

Register Control Faceplate (3)

See description of TRC3000 oscilloscope screen

Register inching and control buttons (4)

See description of TRC3000 oscilloscope screen

Error/Acknowledge (5)

Button Description

Local error:

Error at this printing unit / sensor device.


Global error:

Error at any printing unit / sensor device.


Fault acknowledge

1

2

3

4

5

6

7

8 9

12 10

11



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Zero to ref pos (6)

With the up and down buttons the ZeroToRefPos (defined in the job setting) can be changed.

The value can be changed also by entering a value in the input field and pressing the set button.

Automatic mark field search (7)

This button can be used to find the markfield on the format. The camera activates a continuous flashing for several revolutions to find the reference dot arrangement on the web.

After the markfield has been found the button becomes green for a few seconds.

In case no marks can be found the button becomes red.

Mark field tracking / center mark field (8)

The upper button centers the flashing point to the markfield once, the lower button activates a continuous tracking of the markfield.

Flash selection (9)

With these two buttons the flash light of the camera can be selected.

Dependent on the camera type (RSC-DI / RSC-DI-VF) the standard flash (upper button) or the varnish flash (lower button) can be activated.

Test flash (10)

With this button the camera flashes every 0.5 seconds, even the master axis of the camera is not rotating.

This function can be used during commissioning.

At least one of the two flash selection buttons (see #11) must be switched on!

Brightness (11)

With the up and down buttons the brightness level can be changed.

The button next to it enables the automatic brightness control.

Format counter (12)

Format counter and reset to zero” button



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Register overview

With the “register overview” screen the operator gets an overview about all register controlled print units in one screen. The screen shows all print units which have been activated in the selected job.

Figure 4-17

Slide in bar (1)

Switch register control mode (automatic/manual)

Markfield setting (2)

Inch register and fine adjustment buttons

Settings (3)

By clicking in the middle of the hairline cross, the resolution factor of the register error, the musculature level as well as inching factors can be adapted.

1

2

2

2

2 3



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Register error history

The “register error history” screen shows a trend curve of the last 200 register error values.

Figure 4-18

y axis range (1)

The scaling can be changed by adapting the limits for y-axis.

Measuring cursor (2)

With the shift register, every single point can be selected, and the register error value will be displayed.

1 2



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Statistic screen

In the statistic screen the distribution of the register error into different classes can be displayed.

The measurement can be started, stopped and reset for each print unit.

By clicking on the print unit number on the left hand side of the table, the actual chart of the distribution can be displayed.

Figure 4-19

Bar diagram (1)

The number button opens the bar diagram of the respective print unit.

To refresh the values inside the diagram, the diagram must be closed and opened again.

1



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Statistic configuration

In this screen, the classes can be defined for each print unit.

Example:

Class 1: register error > 0.05 mm





Figure 4-20

Copy single (1)

This button copies the class definition form print unit x to y (input fields)

(1): length register, (3): side register

Copy all (2)

This button copies the class definition from PU1 to all other PU’s

(2): length register, (4): side register

Copy all LR & SR (3)

This button copies the class definition from PU1 to all other PU’s

(length and side register)

1 1

2 2 3



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

4.3 Procedure of first sensor config/job setup

NOTICE Before continuing with the config/job setup, the hardware and software integration described in chapter 3 must be completed!

After starting the HMI runtime the very first time the following steps should be followed:

Table 4-6


1.

Go to the machine configuration screen

2.

Create a new configuration dataset

- Press the “new” button

- Define a name

- Save the dataset with the “save” button

3.

Perform a data upload! and save it to the

dataset with the “save” button.

4.

Go to the configuration 2 screen

5.

Define the PU <=> TRC mapping.

It need to be defined which TRC is working on which print unit.

More information are provided in chapter 1.7 Assignment TRC to PU

6.

Perform a data download!

The changes can be saved automatically to the dataset recipe which was defined in configuration 1 screen.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


7.

Go to the Job Screen…

…to create a new mark stream.

8.

After finishing the mark stream wizard, go back to the Job screen.

9.

Create a new Job dataset

- Press the “new” button

- Define a name

- Save the dataset with the “save” button

10.

Define

- job format (mandatory)

- gate width (mandatory)

- ZeroToRefPos (optional)

(There is a similar procedure using TRC7000)

11.

Copy the mark stream data to the job data.

For each job multiple mark streams can be assigned. With the number drop-down menu the mark field number slot can be selected before copying the mark stream.

12.

Define the active print units for this job with the respective settings.

(There is a similar procedure using TRC7000)

13. Save the change to the job dataset with the “save” button.

14.

Perform a job download to the sensor device(s).

5 Function description


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


5.1 Functions and Function blocks

5.1.1 FCLTRC3000_Mark3_100Telegram, FCLTRC3000_Mark20_101Telegram, FCLTRC7000_Mark3_120Telegram, FCLTRC3000_Mark20_121Telegram

Functionality

For each TRC one of the telegram functions must be called. This function copies the cyclic telegram data to the data structure sTRCx000Data of each TRC.

The sTRC3000Data and sTRC7000Data structures are independent of the used telegram. See also chapter 1.6 Telegram Mark3 / Mark20 .

NOTICE For every TRC device one separate FC call is necessary! This function must be called before the FBLTRCx000IPO!

Schematic LAD – Representation

Table 5-1 scheme of FCLTRCx000_Markx_1xxTelegram

FCLTRCx000_Markx_1xxTelegram

ARRAY [0..x] OF BYTE* CyclicDataToSimotion

sTRCx000Data TRCData

*x = Constant TRC_DATA_LENGTH_TO_SIMOTION_M3_100 = 45 or = Constant TRC_DATA_LENGTH_TO_SIMOTION_M20_101 = 215 or = Constant TRC_DATA_LENGTH_TO_SIMOTION_M3_120 = 46 or = Constant TRC_DATA_LENGTH_TO_SIMOTION_M3_121 = 216 or

Input and Output Parameters

Name P-Type Type Unit Description

CyclicDataToSimotion IN ARRAY [0..x] OF BYTE

- cyclic input data from TRC (SIMOTION address list variable)

TRCData IN/OUT sTRCx000Data - TRC data structure (s. structure description)

Task

The function block has to run in a cyclic task before FBLTRC3000IPO / FBLTRC7000IPO



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.1.2 FBLTRC3000BckGrnd, FBLTRCx7000BckGrnd

Functionality

The function block FBLTRC3000BckGrnd and FBLTRC7000BckGrnd provides the basic data handling and TRC control. The main functionalities are:

1. TRC Mode Management

The TRC device has an internal mode manager for different functionalities (s. documentation TRC). The SIMOTION application controls this mode manager and switches the TRC in the right mode for required functionality.

The actual mode will be shown in the variable gasTRCx000Data[x].StdcIO.OUT.eTRCActualMode

and in the cyclic data gasTRCx000Data[x].InOut.sData_Cyclic.TRCToSimotion.

sStatusWord_2.sSW1_OPA.OUT.eActualSensorMode .

2. Error Handling (TRC, Application)

Errors are separated into different error sources (Sensor faults, application faults). The categorization and acknowledgement is handled in this function block.

3. Conversion job settings to TRC structures

The received data for the specific TRC job need to be converted to TRC data sets and every parameter needs to be assigned to a TRC parameter number. The function block distributes the values to the respective data set and prepares the data for the acyclic TRC communication.

4. Acyclic communication (TRC parameterization)

The whole job parameterization on the TRC will be done by acyclic communication. Moreover some operation values (e.g. gate changes) and status values need to be written or read by acyclic communication.

The whole acyclic handling will be done in the background function block.

The commands of the LDPV1 SIMOTION standard library are used for the acyclic communication.

5. Calibration handling

To calibrate the fiber optics a specific routine in the TRC device needs to be started and controlled by the application.

6. TCP/IP handling (scope data reading)

The scope data transfer and the live image transfer from the TRC to SIMOTION are realized by TCP/IP communication (one time per format/ print cylinder rotation). After receiving the data from the TRC device, the scope/image data are sent by FBLTRCx000HMIDataTransfer.

NOTICE For every TRC device one separate FB call is necessary!



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


Table 5-2 scheme of FBLTRCx000BckGrnd

FBLTRCx000BckGrnd

BOOL CylinderInReference

sTRCx000Data TRCData sTRCx000Data


Table 5-3


CylinderInReference IN BOOL - Signal printing cylinder or Master referenced and position data valid


Task

The function block has to run in a cyclic task.

Recommended task: background task



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.1.3 FBLTRC3000IPO, FBLTRC7000IPO

Functionality

The handling of the cyclic data will be done in the FBLTRC3000IPO and FBLTRC7000IPO function block. The main functionalities are:

1. Transfer of control and status word to cyclic interface

The input and output data of the TRC are byte array values. The function block converts the data to the status and control word.

2. Sign of life monitoring

An internal function block does the monitoring of the TRC sign of life error. In case of error an application error will be created.

3. Register error evaluation

One essential job of the cyclic-FB is the register error calculation from the mark error of the TRC. The register error calculation depends on the respective measuring mode and the selected marks.

NOTICE For every TRC device one separate FB call is necessary!


Table 5-4 scheme of FBLTRCx000IPO

FBLTRCx000IPO

posAxis Axis CyclicDataToSensor ARRAY [0..x] OF BYTE*

sTRCx000Data TRCData sTRCx000Data

*x = Constant TRC_DATA_LENGTH_FROM_SIMOTION = 15 (16 Bytes)



Axis IN posAxis - Printing cylinder axis TO

CyclicDataToSensor OUT ARRAY [0..x] OF BYTE

- cyclic output data to TRC (SIMOTION address list variable)


Task


Recommended task: IPO task



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.1.4 FBLTRC3000HMIDataTransfer, FBLTRC7000HMIDataTransfer

Functionality

The function blocks FBLTRC3000HMIDataTransfer and FBLTRC7000HMIDataTransfer copy data between sHMI_TRC3000_Command / sHMI_TRC7000_Command and aTRCData.

For HMI projecting it is much easier and more performant to work with a structure which consists of array variables. The variable structure sHMI_TRCx000_Command is constructed like that.

Most of the HMI variables are indexed by PU number, not by TRC number. The FBLTRCx000HMIDataTransfer assigns the indexes in the right way, depending the PU/TRC assignment.

NOTICE This FB must be called only once per TRC type! Once for all TRC3000 and once for all TRC7000 per Simotion!


Table 5-5 scheme of FBLTRCx000HMIDataTransfer


ARRAY [..] OF sTRCx000Data aTRCData

sHMI_TRCx000_Command DataExchangeHMI



aTRCData IN/OUT ARRAY [..] OF sTRCx000Data

- Array of TRC data structure Dynamic length of array!

DataExchangeHMI IN/OUT sHMI_TRCx000_Command - HMI data exchange structure

Task


Recommended task: background task



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.1.5 FBLRegCtrlController

Functionality

The FBLRegCtrlController (separate library “LRegCtrl”) contains the register control functionality. The function block is used for all register control solutions (TRC1000, TRC3000, TRC7000). A separate documentation of this function block with detailed information is available.

The output signal of the function block is a speed set point signal. The value will be coupled to the addition object of the printing cylinder axis by the function block FBTech. The Print Standard documentation contains a detailed description of the FBTech.

NOTICE For every PU with register control one separate FB call is necessary!

Task



5.1.6 FBTech

Functionality

The functions block calculates the motion vector and transfers the resulting speed value to the addition object of the respective printing cylinder axis.

Further information about the set point coupling to an addition object is available in the Print Standard documentation.

NOTICE For every PU with register control one separate FB call is necessary!

Task





S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2 Parameter structures

5.2.1 sTRC3000Data

The structure sTRC3000Data contains all the data values of a single TRC3000. To provide a clear and useable structure the main structure is divided in 4 parts (s. figure 4-2).

sTRCInterface (communication data to TRC)

o sData_Cyclic (cyclic communication data)

o sData_Acyclic (acyclic communication data)

o sLiveImage (live image)

sStdcIO (TRC application interface)

o IN (Input)

o OUT (Output)

sHWSettings (Communication settings)

Figure 5-1

sTRC3000Data / sTRC7000Data

sTRCInterface (Interface from/to TRC)

sData_Cyclic

SimotionToTRC

TRCToSimotion

sData_Acyclic

SimotionToTRC

TRCToSimotion

SensorScopeData / sLiveImage

sSTDcIO (Interface for application)

IN

OUT

sHWSettings (communication settings)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

sTRCInterface.sData_Cyclic

For a more detailed description of cyclic data functionalities see Eltromat documentation.

Table 5-6 sTRC3000Data.InOut.sData_Cyclic.SimotionToTRC (sTRC3000_DataToSensor)

Name Type Unit Description

sControlWord_1 (sTRC3000CtrlWord1)

boFaultAck BOOL - Acknowledge TRC errors

boControlByPLC BOOL - Control by plc IO data valid

sCW1_OPA (sTRC3000CtrlWord1_OPA)

bo00_ParameterUpdate BOOL - Start parameter update

bo01 BOOL - Not used

bo02_AMRStart BOOL - Start AMR search (Automatic Mark Recognition)

bo03_AMRStop BOOL - Stop AMR search



bo06_CylinderinRef BOOL - Printing cylinder referenced and position data valid

bo07_FaultAcknowledge BOOL - Not used => boFaultAck


bo09_MarkfieldUpdate BOOL - Start markfield update

bo10_ControlByPLC BOOL - Control by plc IO data valid

bo11_GateTrackingStart BOOL - Start gate tracking

bo12_GateTrackingStop BOOL - Stop gate tracking




sCW1_CAL (sTRC3000CtrlWord1_CAL)

bo00_LWL1CalStart BOOL - Start calibration head 1

bo01_LWL2CalStart BOOL - Start calibration head 2



bo04_CalPaperFlag BOOL - [1] calibration reference value white [0] calibration reference value reflecting

bo05 BOOL - not used

bo06_CalCancel BOOL - Cancel calibration


bo08 .. bo15 BOOL - not used


sCW2_ OPA (sTRC7000CtrlWord2_OPA)


bo01_ResetFormatCounter BOOL - Reset TRC format counter

bo02_GateSizeYUp BOOL - Increase gate size by 0.5 mm

bo03_GateSizeYDown BOOL - Decrease gate size by 0.5 mm

bo04_ScopeDataRequest BOOL - Request of scope data



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d



bo06_ZeroToRefPosYUp BOOL - Shift gate position by 0.5mm up

bo07_ZeroToRefPosYDown BOOL - Shift gate position by 0.5mm down

bo08_10_Sensor_Mode eTRCMode - TRC mode change

[1] Go to IDLE

[2] Go to OPERATIONAL

[3] Go to CALIBRATION


bo12_15_Lifesign BYTE - Controller sign of life

General

r32AxisPosition REAL mm Printing cylinder position

r32AxisSpeed REAL mm/s Printing cylinder velocity

r32AxisAcceleration REAL mm/s² Printing cylinder acceleration

Table 5-7 sTRC3000Data.InOut.sData_Cyclic.TRCToSimotion (sTRC3000_DataToSimotion)


sStatusWord_1 (sTRC3000StatusWord1)

boFaultPresent BOOL - TRC error active

boWarningPresent BOOL - TRC warning active

boControlRequested BOOL - TRC ready to control by plc

sSW1_OPA (sTRC3000StatusWord1_OPA)

bo00_ParaUpdateActive BOOL - TRC parameter update active

bo01_MeasureActive BOOL - TRC measuring active

bo02_AMRActive BOOL - AMR search active (Automatic Mark Recognition)

bo03_FaultPresent BOOL - TRC error active

bo04_AMRValid BOOL - AMR valid

bo05_AMRFailure BOOL - AMR failure

bo06_RegisterPrintPositionUpdate

BOOL - New value of CylinderInfo.RegisterPrintPosition

bo07_WarningPresent BOOL - TRC warning active


bo09_ControlRequest BOOL - TRC ready to control by plc

bo10_GateSizeYUpdate BOOL - New value of GateInfo.GateSizeY

bo11_GateTrackingActive BOOL - Gate tracking active





sSW1_CAL (sTRC3000StatusWord1_CAL)

bo00_LWL1CalActive BOOL - Calibration of head 1 active

bo01_LWL2CalActive BOOL - Calibration of head 2 active

bo02_CalActive BOOL - Calibration active



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d



bo04_CalState_Bit0 BOOL - Bit 0 of CalState



bo07_WarningPresent BOOL TRC warning active

bo08_LWL1CurrentWarning BOOL - LED-current warning head 1


bo10_LWL1CurrentMax BOOL - LED-current maximum head 1

bo11_LWL1GainWarning BOOL - Gain warning head 1

bo12_LWL1GainMax BOOL - Gain maximum used head 1

bo13_LWL1Missing BOOL - Head 1 missing

bo14_LWL1CalError BOOL - Head 1 calibration error

bo15_LWL1CalDone BOOL - Head 1 calibration done

CalState eCalState - Calibration state

[0] Idle

[1] detect white adjustment board

[2] detect darken of lens

[3] balance active


eActualSensorMode eTRCActualMode - Actual TRC mode

[0] Init

[1] Idle

[2] Operation

[4] Calibration

b8Lifesign BYTE - TRC sign of life


bo00_LWL2CurrentWarning BOOL - LED-current warning head 2

bo01_LWL2CurrentMax BOOL - LED-current maximum head 2

bo02_LWL2GainWarning BOOL - Gain warning head 2

bo03_LWL2GainMax BOOL - Gain maximum used head 2


bo05_LWL2Missing BOOL - Head 2 missing

bo06_LWL2CalError BOOL - Head 2 calibration error

bo07_LWL2CalDone BOOL - Head 2 calibration done

General

RshStatusWort_0 WORD - Status word 1 for internal use


i32FormatCounter DINT - Format counter increased by 1 with every printing cylinder rotation

i32ZerotoRefPosY DINT µm Distance of mark field to cylinder zero position

i32MarkfieldFormatCounter DINT - Markfield counter is increased by 1 after a new measurement (per format) has been completed.

aui16MarkStatus ARRAY [0..19] OF UINT

- Mark status (mark errors see Eltromat

documentation)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


ar32MarkDeviationX ARRAY [0..19] OF REAL

mm Mark deviation from mark set position in x-direction (side register)

ar32MarkDeviationY ARRAY [0..19] OF REAL

mm Mark deviation from mark set position in y-direction (length register)

sTRCInterface.sData_Acyclic

For a more detailed description see Eltromat documentation.

Table 5-8 sTRC3000Data.InOut.sData_Acyclic.SimotionToTRC (sTRCSetParameter)

Name Type Unit Description/ Parameter name Eltromat

CycleDelay UINT Cycles Delay time between drive data and sensor in bus cycles Actual values: 2 Command values: 0

SampleDelay DINT ns Delay time of sample Actual values: (Ti + 5µs) * 1000 Command values: (-To + 5µs) * 1000 (Ti, To of drive, which is connected to FBLTRC3000IPO as set value for TRC)

SampleSpeedStandstill INT mm/s Below this velocity no measuring will be done

FormatSizeY DINT µm Length of print format

F_ScopeDataCountY *F UINT - Number of data scope data points (maximum 8000)

F_RtiDelay *F ARRAY [0..1] OF UINT

µs not used with RSH-PN device

F_AmrBlock *F (TYPE: sAMRBlock): TRC AMR block definition

AmrType UINT - AmrControl.AmrType

BlockPreSizeY DINT µm AmrBlock.BlockPreSizeY

BlockPostSizeY DINT µm AmrBlock.BlockPostSizeY

BlockTolY DINT µm AmrBlock.BlockTolY

AmrToFirstMarkY DINT µm AmrBlock.AmrToFirstMarkY

AmrBlockSizeY ARRAY [0..6] OF DINT

µm AmrBlock.AmrBlockSizeY Width of blocks and gaps

SymDistanceY DINT µm AmrSym.SymDistanceY

Markfield (TYPE: sMarkfield): TRC Markfield definition

ZeroToRefPosX DINT µm Markfield.ZeroToRefPosX (not used)

ZeroToRefPosY DINT µm Markfield.ZeroToRefPosY



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


F_GateSizeX DINT µm Markfield.GateSizeX (not used)

F_GateSizeY DINT µm Markfield.GateSizeY

GatesUsed UINT - MarkSettings.GatesUsed

MarkSetPosX ai32MarkSetPos: ARRAY [0..19] OF DINT

µm MarkSetPosX

MarkSetPosY ai32MarkSetPos: ARRAY [0..19] OF DINT

µm MarkSetPosY

MarkSettings (TYPE: sMarkSettings): TRC Mark settings

MeasuringMethod UINT - MarkMeasure.MeasuringMethod 1: SINGLEHEAD 2: DOUBLEHEAD (only F) 4: WEB_CYLINDER

MarkSelect ARRAY [0..2] OF UINT

- MarkMeasure.MarkSelect Selection of mark for Mark3

F_MarkCenter UINT - MarkMeasure.MarkCenter (only F) Selection of mark for gate tracking

MarkDef (TYPE: sMarkDef): TRC Mark definition

MarkShape UINT - MarkDef.MarkShape

F_MarkAlign UINT - MarkDef.MarkAlign

MarkSizeX DINT µm MarkDef.MarkSizeX

MarkSizeY DINT µm MarkDef.MarkSizeX

F_MarkRefSizeY DINT µm MarkDef.MarkRefSizeY

F_MarkGapSizeY DINT µm MarkDef.MarkGapSizeY

C_SyncMark *C (TYPE: sTRC7000SyncMark): TRC Sync Mark definition

SetPosX ai32SyncMarkSetPos = ARRAY [0..2] OF DINT

µm SyncMark.SetPosX

SetPosY ai32SyncMarkSetPos = ARRAY [0..2] OF DINT

µm SyncMark.SetPosY

C_LiveImageSettings *C (TYPE: sTRC7000LiveImageSettings): TRC settings of live image

ScaleFactor UINT - LiveImageSettings.ScaleFactor

Rotation UINT - LiveImageSettings.Rotation

ImageFormat UINT - LiveImageSettings.ImageFormat 0: BPM (not allowed in that application) 1: JPEG

C_CameraSettings *C (TYPE: sTRC7000CameraSettings): TRC settings of camera

Brigthness USINT % CamIlluminaationSettings.Brightness

FlashSelect UINT - CamFlashSettings.Select

Rotation UINT ° CamMountingsSettings.Rotation Orientation of camera: 0, 90, 180, 270°

Flags UDINT - CamDiagnosticSettings.Flags Additional informations in live image

C_CameraMeasureSettings *C (TYPE: sTRC7000CamMeasureSettings): TRC settings for measuring manipulation

FilterRadiusInside UINT % CamMeasureSettings.FilterRadiusInside

FilterRadiusOutside UINT % CamMeasureSettings.FilterRadiusOutside



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


FilterThreshold UINT % CamMeasureSettings.FilterThreshold

ZoomTol UINT % CamMeasureSettings.ZoomTol

SyncTol UDINT µm CamMeasureSettings.SyncTol

ClippingSizeX UDINT µm CamMeasureSettings.ClippingSizeX

ClippingSizeY UDINT µm CamMeasureSettings.ClippingSizeY

LifesignTolerance UINT - Tolerated number of missing life signs Default setting = 1

IPPort UINT - Port for connection request via TCP/IP Default setting = 10011

*C Variable only used for TRC7000/Camera

*F Variable only used for TRC3000/Fiberoptic

Table 5-9 sTRC7000Data.InOut.sData_Acyclic.TRCToSimotion (sTRCDataToSimotion)


DeviceInfo (TYPE: sTRCDeviceInfo): Device information (Voltage, current, PN informations)

UnitId ARRAY [0..1] OF UINT

- Extension.UnitId 0: Unused 1: Fiberoptic 5: Camera

DcIn UINT mV Voltage.DcIn

F_DcCh *F ARRAY [0..1] OF UINT

mA Voltage.DcCh Measured LED-Current of head 1 / 2

C_CamFlashInfo UINT - Installed flash combination bit coded Bit 0: Flash 1 installed (standard flash) Bit 1: Flash 2 installed (Varnish flash) Bit 2: Flash 3 installed (not used) Bit 3: Flash 4 installed (not used)

OperatingTime UDINT s OperatingTime.Device

ProfidriveInfo sProfidrive - see Table 5-10 Substructure sProfidrive below

ProfinetInfo sProfinetInfo - see Table 5-11 Substructure sProfinetInfobelow

IpPort UINT - ScopeSocket.IpPort (Default 10011)

ErrorInfo (TYPE: sTRCErrorInfo): TRC error information (General error information, fault code list)

u16FaultMsgCounter UINT - Profidrive.FaultMessageCounter

u16FaultCode ARRAY [0..63] OF UINT

- Profidrive.FaultCode

See chapter 6.2

u16FaultNumber ARRAY [0..63] OF UINT

- Profidrive.FaultNumber

Sub indices for fault code list

u16FaultsAfterLastReset UINT - Profidrive.FaultSituationCounter

F_Status *F (TYPE: sTRC3000Status): Actual TRC status information

RegisterPrintPosition DINT µm CylinderInfo.RegisterPrintPosition Measured distance from zero to end of AMR-mark

GateInfo sTRC3000GateInfo - see Table 5-12 Substructure sTRC3000GateInfo below



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


MarkInfoWidth ARRAY [0..19] OF DINT

µm MarkInfoWidth Measured mark width

AdcCal sTRC3000AdcCal - see Table 5-13 Substructure sTRC3000AdcCalbelow

DacCon sTRC3000DacCon - see Table 5-14 Substructure sTRC3000DacConbelow

CalInfo sTRC3000CalInfo - see Table 5-15 Substructure sTRC3000CalInfobelow

Identification (TYPE: sTRCIdentification): Hardware- and Softwareinfo of TRC

HardwareInfo STRING[128] - Identification.HardwareInfo

SoftwareInfo STRING[160] - Identification.SoftwareInfo



Substructures

Table 5-10 Substructure sProfidrive

Name Type Unit Parameter name Eltromat

TelegramSelection UINT - Profidrive.TelegramSelection 0x0100 RshMark3_100 0x0101 RshMark20_101 0x0120 RshMark3_120 0x0121 RshMark20_100

LifeSignTolerance UINT - Profidrive.LifeSignTolerance

DriveUnitId ARRAY [0..4] OF UINT

- Profidrive.DriveUnitId [0] : Manufacturer = 500 [1] : Drive Unit Type: F=1 C=2 [2] : Version SW [3] : Firmware Date yyyy [4] : Firmware Date ddmm

DoId ARRAY [0..9] OF UINT

- Profidrive.DOId [0] : Manufacturer = 500 [1] : DO type: F=1 FD=2 C=6,7 [2] : Version SW [3] : Firmware Date yyyy [4] : Firmware Date ddmm [5] .. [9]: not important

Table 5-11 Substructure sProfinetInfo


IpOfStation UDINT - Profinet.IpOfStation

MacOfStation ARRAY [0..5] OF BYTE

- Profinet.MacOfStation

StandardGatewayOfStation UDINT - Profinet.StandardGatewayOfStation

SubnetMaskOfStation UDINT - Profinet.SubnetMaskofStation



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Table 5-12 Substructure sTRC3000GateInfo


GateSizeY DINT µm GateInfo.GateSizeY

ZeroToRefPosY DINT µm GateInfo.ZeroToRefPosY

GateCenterPosY ARRAY [0..2] OF DINT

µm GateInfo.GateCenterPosY

Table 5-13 Substructure sTRC3000AdcCal


Roffset ARRAY [0..1] OF DINT

- AdcCal.Roffset Offset of red channels after calibration

Rgain ARRAY [0..1] OF DINT

- AdcCal.Rgain Gain of red channels after calibration

Goffset ARRAY [0..1] OF DINT

- AdcCal.Goffset Offset for green channels after calibration

Ggain ARRAY [0..1] OF DINT

- AdcCal.Ggain Gain of green channels after calibration

Boffset ARRAY [0..1] OF DINT

- AdcCal.Boffset Offset of blue channels after calibration

Bgain ARRAY [0..1] OF DINT

- AdcCal.Bgain Gain of blue channels after calibration

Table 5-14 Substructure sTRC3000DacCon


LedCurrent ARRAY [0..1] OF USINT

- DacCon.LedCurrent Index = Extension

RefVoltage ARRAY [0..1] OF USINT

- DacCon.RefVoltage Index = Extension

Table 5-15 Substructure sTRC3000CalInfo


Enable UINT - CalInfo.Enable 0x0001: Head 1 calibrated 0x0002: Head 2 calibrated

LWL ARRAY [0..1] OF UINT

- CalStatus.LWL Index = Extension

CalDate UDINT s CalDate Operating time at the time of calibration

sTRCInterface.SensorScopeData

Scope data of channel 1 and 2.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Table 5-16 sTRC3000Data.InOut.SensorScopeData.sSensorScopeData_TCP[1]/[2] (sRSH_ChannelScopeData)


bo_NewData BOOL - New scope data available

u16_JobNumber UINT - Jobnumber, will be increased which each new data

u16_Channel UINT - Channel number of scope data (head1 or head2)

u16_DataCountY UINT - Number of data counts

u16_OffsetR UINT - Offset value red

u16_OffsetG UINT - Offset value green

u16_OffsetB UINT - Offset value blue

i32_FormatCounter DINT - Actual number of formats

ui16_Min UINT - Scope transfer minimum value

ui16_Max UINT - Scope transfer maximum value

i32_GateSizeY DINT µm Actual gate size

i32_ZeroToRefPosY DINT µm Actual distance zero to reference position

aui8_DataR ARRAY[1..8000] OF USINT

- Data of red curve

aui8_DataG ARRAY[1..8000] OF USINT

- Data of green curve

aui8_DataB ARRAY[1..8000] OF USINT

- Data of blue curve

sSTDcIO……

sSTDcIO.IN

Table 5-17 sTRC3000/7000Data.sStdcIO.IN (sTRCIn)


boTRCActive BOOL - TRC active

boFaultAcknowledge BOOL - Acknowledge of TRC faults, application errors of this TRC

boModeCalibration BOOL - Switch TRC to calibration

boUseMasterPosition BOOL . TRUE: Use master position (f.e. Mark20) FALSE: Use printing cylinder position

boUseCommandPosition BOOL - TRUE: Use printing cylinder command position as TRC reference values FALSE: Use actual values Note: Dead time compensation

boReadScopeLiveImgData BOOL - Start reading live image data by Tcp/Ip

boWriteTRCParameter BOOL - Start parameter transfer to TRC

boChangeZeroToRefPos BOOL - Set ZeroToRefPos (Flashposition) => Write Par Markfield.ZeroToRefPosY HMI-Par ai32TRC7000ZeroToRefPosY



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


boChangeGateWidth *F BOOL - Set gate width => Write Par Markfield.F_GateSizeY HMI-Par ai32GateSizeY

boStatusUpdate BOOL - Get status update of TRC

boDeviceInfoUpdate BOOL - Get device info update

boInfoError BOOL - Get error info update (read TRC fault information)

boWriteDelayData BOOL - Set delay setting of TRC => Write Par CycleDelay and SampleDelay

boLifeSignAckn BOOL - Acknowledge of application LifeSignError (internal use)

boLifeSignAutoAckn BOOL - TRUE: LifeSignErrors will be reset automatically, after connection is established again.

i16LifesignTolerance UINT - Number of tolerated sign of life faults

boResetTRC BOOL - Start TRC hardware reset

boAMRStart BOOL - Start AMR search (Automatic Mark Recognition)

boAMRCancel BOOL - Cancel AMR search (Automatic Mark Recognition)

boConsiderZeroToRefPos BOOL - For WebCylinder with GateTracking: TRUE: Consider automatic or manual adjustments of ZeroToRefPosY in TRCData.sSTDcIO.OUT.ar32RegActValueLR

boBrightnessCtrl *C BOOL - Brightness control on

boGateTracking BOOL - Gate tracking on

boCentreGate BOOL - Start center gate

boFlashSelect1 *C BOOL - Flash 1 on (LED bar – standard flash)

boFlashSelect2 *C BOOL - Flash 2 on (varnish flash)

boGateSizeUp *F BOOL - Increase gate by +0.5mm per tip

boGateSizeDown *F BOOL - Decrease gate by -0.5mm per tip

boFormatCountReset BOOL - Reset TRC format counter

boBrightnessUp *C BOOL - Increase brightness by +1% per tip

boBrightnessDown *C BOOL - Decrease brightness by -1% per tip

boTestTrigger *C BOOL - Testtrigger (flash) on

boZeroToRefPosUp BOOL - Increase ZeroToRefPos by +0.5mm per tip (gate position)

boZerotoRefPosDown BOOL - Decrease ZeroToRefPos by -0.5mm per tip (gate position)

boDoubleheadReverse *F BOOL - Setting of double head mode: Which head detects the reference mark.

FALSE: Doublehead forward Head 1 = Reference mark = gate Head 2 = Print mark TRUE: Doublehead reverse Head 1 = Print mark = gate Head 2 = Reference mark



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


u8WebWeb2Type *F USINT - Calculate side register error, dependent on web guide line.

Job setting “Orientation reference mark to control mark in WebWeb2 mode”


0: same mark orientation

1: horizontal mirrored mark orientation (after web turn)

2: vertically mirrored mark orientation (after web turn)

MarkTypeDefine sMarkDefine - Geometric mark definition for TRC parameterization see Table 5-19 Substructure sMarkDefine below

u8PUAssignedToTRC USINT - Only mode 3: PU number, which is assigned to that TRC

aboActivePUS

ARRAY[1..20] OF BOOL

- Active printing units Index 1 = PU1 …

au8PUMark ARRAY[1..20] OF USINT

- Own print mark of PU

au8RefMark ARRAY[1..20] OF USINT

- Ref mark of PU

au8RefMarkFollw ARRAY[1..20] OF USINT

- Reference mark for following control of PU

aboRegFollowLR ARRAY[1..20] OF BOOL

- Switch LR to following control of PU

aboRegFollowSR ARRAY[1..20] OF BOOL

- Switch SR to following control of PU

r32DegreesPerRotation REAL ° Degrees per rotation (production cycle) of machine. Default = 360° Only possible, if lead axis of TRC has a modulolength >= r32DegreesPerRotation!

u16CutsPerRotation UINT - Tool factor: number of formats per cylinder rotation (Default = 1)

eMeasuringMethod eTRCMeasMode - Measuring method of that TRC [1]: Singlehead [2]: Doublehead [4]: Web_Cylinder

sReadScopeLiveImg (TYPE: sReadScopeLiveImg): Settings for token handling or timer to reduce communication load

u32TimeReadCycle UDINT [ms] Cycle time for reading LiveImage or ImageData (only, if boTokenActive = FALSE)

boToken BOOL - Token for token handling (only, if boTokenActive = TRUE) 1: TRC is allowed to request new data 0: No rights for this TRC

boTokenActive BOOL - 1: Token handling is active 0: Token handling is not active



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


sDelayData (TYPE: sDelayData):

boAutomaticSetting BOOL - FALSE: CycleDelay and SampleDelay can/must be changed manually TRUE: CycleDelay and SampleDelay will be changed automatically, even if boUseCommandPosition is changed during running!

boDelayOneCycle BOOL - FALSE: (Default setting) Velocity and Position will be sent immediately to TRC

TRUE: Velocity and Position will be sent one cycle delayed to TRC. Only necessary for special applications!

i16Ti_us INT [µs] Ti of drive Printing Unit (see in HW-Config)

i16To_us INT [µs] To of drive Printing Unit (see in HW-Config)



sStdcIO.OUT

Table 5-18 sTRC3000Data.sStdcIO.OUT (sTRC3000Out)


eTRCActualMode eTRCActualMode - Actual TRC mode [0] INIT [1] IDLE [2] OPA (OPERATION) [4] CAL (CALIBRATION)

boLDPV1_Busy BOOL - Acyclic channel to TRC device is already used (only one transfer can be active)

boLifesignError BOOL - TRC sign of life error (from application)

boApplicationError BOOL - Application error

u16ApplicationErrorID UINT - Application error number

u32Parameter1 DINT - Additional parameter 1 application error number


boTRCError BOOL - TRC device error

boTRCWarning BOOL - TRC device warning

boTRCStandStill BOOL - Axis speed < SampleSpeedStandstill TRUE: No mark measuring is done

u16TRCErrorID UINT - TRC device error number (detailed information s. TRC documentation)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


b8TRCUpdateActive BYTE - Status “TRC job download” [1] TRC Update started [yellow] [4] TRC download done [green] [5] TRC update failed [red]

b8ChangeZeroToRefPos BYTE - Status “change ZeroToRefPos” [1] gate position update started [4] gate position update done [5] gate position update failed

b8ChangeGateWidth BYTE - Status “change GateWidth” [1] Change GateWidth started [4] Change GateWidth done [5] Change GateWidth failed

b8ParameterRead BYTE - Status “Status Update” [1] Status Update started [4] Status Update done [5] Status Update failed

b8InfoParameterRead BYTE - Status “info update of TRC” [1] TRC info update started [4] TRC info update done [5] TRC info update failed

b8InfoErrorRead BYTE - Status “read error parameter of TRC” [1] TRC error update started [4] TRC error update done [5] TRC error update failed

b8TRCReset BYTE - Status “TRC reset” [1] TRC reset started [4] TRC reset done [5] TRC reset failed

b8CentreGate BYTE - Status “centre gate” [0] - [1] centre gate function active [4] centre gate function done

b8GateTracking BYTE - Status “gate tracking” [0] gate tracking inactive [4] gate tracking active

b8AMRStatus BYTE - Status “AMR (Automatic Mark Recognition)” [0] AMR search inactive [4] AMR valid [5] AMR failure

b8CalibrationStatus BYTE - Status “TRC calibration” [1] Use reference box head 1 [2] Use reference box head 2 [3] Measuring active [4] Remove reference box [5] IDLE

sCalibrationState STRING[25] - Response of calibration as STRING (see b8CalibrationStatus)

boCalibrationActive BOOL - Calibration active

boCalibrationDone BOOL - Calibration done

boNewMeasureValues BOOL - New measured values (TRUE for one cycle)

r32SensorMoutingOffsetSide REAL mm Head 1: Mounting offset in side direction

r32SensorMoutingOffsetSideK2

REAL mm Head 2: Mounting offset in side direction



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


ar32RegActValueLR

ARRAY [0..20] OF REAL

mm LR register value of print unit 1..20 depending on selected marks [0]: Deviation of Reference Mark

ar32RegActValueSR


mm SR register value of print unit 1..20 depending on selected marks [0]: Deviation of Reference Mark

aboMarkError ARRAY [0..20] OF BOOL

- Mark error active per PU Collective fault of marks belonging to that PU [0]: Mark error of Reference Mark

aMarkStatus (TYPE: asMarkStatus = ARRAY [0..20] OF sMarkStatus): Mark status Index = Mark number 1..19 [0]: Mark status of Reference Mark

boMarkError BOOL - Mark Error

boMarkWarning BOOL - Mark Warning

u16ErrorNumer UINT - Mark status (Error Number) (see Eltromat docu “Mark3Status”)

sgErrorTxt STRING[30] - Error as text

aMarkFieldStatus UINT - Mark status (Error Number) (see Eltromat docu “Mark2Status”) Index = Mark number 1..19 [0]: Mark status of Reference Mark

Substructures

Table 5-19 Substructure sMarkDefine


MarkType eMarkType Parameter defines the used mark type:

Wedge_Mark_1 …4, Double_Wedge_Mark_5 …6,

Double_Block_Mark_7 …10,

AMR_Mark,

Edge_1 …3,

DoubleEdge_1 …3,

Dot

r32Width_Blockmark REAL [mm] These parameters are used to define the mark geometry.

Usually the values are coming from HMI via the HMIDataTransfere structure.

The value can be written from application (e.g. Startup Task program) if no HMI is used.

From here the values will be converted into the TRC3000 parameter names using the function FCLTRCMarkSettings and copied to the sTRCData.sTRCInterface.sData_Acyclic structure to send the values to the

r32Width_WedgeMark_Min REAL [mm]

r32Width_WedgeMark_Max REAL [mm]

r32EdgeLength_WedgeMark REAL [mm]

r32Width_DoubleWedgeMark_Min REAL [mm]

r32Width_DoubleWedgeMark_Max REAL [mm]

r32MiddleWidth_DoubleWedgeMark REAL [mm]

r32Width_DoubleWedgeMark REAL [mm]

r32EdgeLength_DoubleWedgemark REAL [mm]

r32Width_DoubleBlockMark_Min REAL [mm]

r32Width_DoubleBlockMark_Max REAL [mm]



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


r32WidthBar_DoubleBlockmark REAL [mm] sensor device.

r32EdgeLength_DoubleBlockmark REAL [mm]

r32AGSDistToFirstMark REAL [mm]

r32AGSTolerance REAL [mm]

r32AGSBlockPreSize REAL [mm]

r32AGSBlockPostSize REAL [mm]

r32Width_AGSMark_1 REAL [mm]




r32Chasm_AGSMark_1 REAL [mm]



sHWSettings

The structure sHWSettings contains all ports/addresses from the hardware configuration.

Table 5-20 sHWSettings


u16SimotionPort UINT - Simotion Port for TCP/IP communication to TRC (Read scope data and live image) TRC1: 12000 TRC2: 12001 …

i32LogAddress DINT - Logical I/O-address of TRC

au8IPAddress ARRAY [0..3] OF USINT

- IP address of TRC [0] 1. Number of IP address [1] 2. Number of IP address [2] 3. Number of IP address [3] 4. Number of IP address



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2.2 sTRC7000Data

The structure sTRC7000Data contains all the data values of a single TRC7000. To provide a clear and useable structure the main structure is divided in 4 parts (s. figure 4-2).

sTRCInterface (communication data to TRC)

o sData_Cyclic (cyclic communication data)

o sData_Acyclic (acyclic communication data)

o sLiveImage (live image)

sStdcIO (TRC application interface)

o IN (Input)

o OUT (Output)


Figure 5-2

sTRC3000Data / sTRC7000Data

sTRCInterface (Interface from/to TRC)

sData_Cyclic

SimotionToTRC

TRCToSimotion

sData_Acyclic

SimotionToTRC

TRCToSimotion

SensorScopeData / sLiveImage

sSTDcIO (Interface for application)

IN

OUT




S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

sTRCInterface.sData_Cyclic

For a more detailed description of cyclic data functionalities see Eltromat documentation.

Table 5-21 sTRC7000Data.InOut.sData_Cyclic.SimotionToTRC (sTRC7000_DataToSensor)



boFaultAck BOOL - Acknowledge TRC errors

boControlByPLC BOOL - Control by plc IO data valid

sCW1_OPA (sTRC7000CtrlWord1_OPA)

bo00_ParameterUpdate BOOL - Start parameter update


bo02_AMRStart BOOL - Start AMR search (Automatic Mark Recognition)

bo03_AMRStop BOOL - Stop AMR search

bo04_BrightnessControlStart BOOL - Start Brigthnesscontrol

bo05_BrightnessControlStop BOOL - Stop Brigthnesscontrol

bo06_CylinderinRef BOOL - Printing cylinder referenced and position data valid



bo09_MarkfieldUpdate BOOL - Start markfield update

bo10_ControlByPLC BOOL - Control by plc IO data valid

bo11_GateTrackingStart BOOL - Start gate tracking

bo12_GateTrackingStop BOOL - Stop gate tracking

bo13_FlashSelect1 BOOL - Select Flash 1



sCW1_CAL (sTRC7000CtrlWord1_CAL)

bo00_CalStart BOOL - Start calibration


bo06_CalCancel BOOL - Cancel calibration



sCW2_ OPA (sTRC7000CtrlWord2_OPA)


bo01_ResetFormatCounter BOOL - Reset TRC format counter

bo02_BrightnessUp BOOL - Increase brightness by +1%

bo03_BrightnessDown BOOL - Decrease brightness by -1%

bo04_TestTriggerStart BOOL - Test trigger on (test flash)

bo05_TestTriggerStop BOOL - Test trigger off (test flash)

bo06_ZeroToRefPosYUp BOOL - Shift ZeroToRefPos (flash position) by 0.5mm up

bo07_ZeroToRefPosYDown BOOL - Shift ZeroToRefPos (flash position) by 0.5mm down



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


bo08_10_Sensor_Mode eTRCMode - TRC mode change [1] Go to IDLE [2] Go to OPERATIONAL [3] Go to CALIBRATION


bo12_15_Lifesign BYTE - Controller sign of life

General

r32AxisPosition REAL mm Printing cylinder position

r32AxisSpeed REAL mm/s Printing cylinder velocity

r32AxisAcceleration REAL mm/s² Printing cylinder acceleration

Table 5-22 sTRC7000Data.InOut.sData_Cyclic.TRCToSimotion (sTRC7000_DataToSimotion)



boFaultPresent BOOL - TRC error active

boWarningPresent BOOL - TRC warning active

boControlRequested BOOL - TRC ready to control by plc

sSW1_OPA (sTRC7000StatusWord1_OPA)

bo00_ParaUpdateActive BOOL - TRC parameter update active

bo01_MeasureActive BOOL - TRC measuring active

bo02_AMRActive BOOL - AMR search active (Automatic Mark Recognition)


bo04_AMRValid BOOL - AMR valid

bo05_AMRFailure BOOL - AMR failure


bo07_WarningPresent BOOL - TRC warning active




bo11_GateTrackingActive BOOL - Gate tracking active

bo12_CamIlluminationInfoUpdate

BOOL - The value CamIlluminationInfo.Brightness has changed

bo13_BrightnessControlActive

BOOL - Brightness control active

bo14_TestTriggerActive BOOL - Test trigger (test flash) active





bo02_CalActive BOOL - Calibration active







S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


bo07_WarningPresent BOOL TRC warning active





bo12_GainMax BOOL Gain maximum used

bo13_Missing BOOL Camera not connected

bo14_CalError BOOL Calibration error

bo15_CalDone BOOL Calibration done

CalState eCalState - Calibration state [0] Idle [1] detect white adjustment board [2] detect darken of lens [3] balance active


eActualSensorMode eTRCActualMode - Actual TRC mode [0] Init [1] Idle [2] Operation [4] Calibration

b8Lifesign BYTE - TRC sign of life


bo00..bo07 BOOL - not used

General



i32FormatCounter DINT - Format counter increased by 1 with every printing cylinder rotation

i32ZerotoRefPosY DINT µm Distance of mark field to cylinder zero position

ui8Brightness USINT % Brightness actual value


aui16MarkStatus ARRAY [0..19] OF UINT

- Mark status (mark errors see Eltromat

documentation)

ar32MarkDeviationX ARRAY [0..19] OF REAL

mm Mark deviation from mark set position in x-direction (side register)

ar32MarkDeviationY ARRAY [0..19] OF REAL

mm Mark deviation from mark set position in y-direction (length register)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

sTRCInterface.sData_Acyclic

NOTE Same structure like sTRC3000Data.sTRCInterface.sData_Acyclic

sTRCInterface.sLiveImage

Table 5-23 sTRC7000Data.InOut.sLiveImage (sRSH_LiveImageData)


bo_NewData BOOL - New live image data available

ui16_JobNumber UINT - Jobnumber, will be increased which each new data

ui32_Id UDINT - Number of live image

ui32_Size UDINT Bytes Size of image data

ui32_Offset UDINT Bytes Offset from image structure to Image.data

i32_FormatCounter DINT - Actual number of formats

ui16_ScaleFactor UINT - Scale factor of image

ui16_Rotation UINT ° Rotation of image 0°, 90°, 180°, 270°

ui16_ImageFormat UINT - Data format of image 0=BMP, 1= JPEG

i32_ZeroToRefPosY DINT µm Actual distance zero to reference position

aui8_Data ARRAY[1..24000] OF BYTE

- Image data (JPEG)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

sSTDcIO………

sStdcIO.IN

NOTE Same structure like sTRC3000Data.sStdcIO.IN

sStdcIO.OUT

Table 5-24 sTRC7000Data.sStdcIO.OUT (sTRC7000Out)


eTRCActualMode eTRCActualMode - Actual TRC mode [0] INIT [1] IDLE [2] OPA (OPERATION) [4] CAL (CALIBRATION)

boLDPV1_Busy BOOL - Acyclic channel to TRC device is already used (only one transfer can be active)

boLifesignError BOOL - TRC sign of life error (from application)

boApplicationError BOOL - Application error

u16ApplicationErrorID UINT - Application error number



boTRCError BOOL - TRC device error

boTRCWarning BOOL - TRC device warning

boTRCStandStill BOOL - Axis speed < SampleSpeedStandstill TRUE: No mark measuring is done

u16TRCErrorID UINT - TRC device error number (detailed information s. TRC documentation)

b8TRCUpdateActive BYTE - Status “TRC job download” [1] TRC Update started [yellow] [4] TRC download done [green] [5] TRC update failed [red]

b8ChangeZeroToRefPos BYTE - Status “change ZeroToRefPos” [1] gate position update started [4] gate position update done [5] gate position update failed

b8InfoParameterRead BYTE - Status “info update of TRC” [1] TRC info update started [4] TRC info update done [5] TRC info update failed

b8InfoErrorRead BYTE - Status “read error parameter of TRC” [1] TRC error update started [4] TRC error update done [5] TRC error update failed

b8TRCReset BYTE - Status “TRC reset” [1] TRC reset started [4] TRC reset done [5] TRC reset failed



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


b8CentreGate BYTE - Status “centre gate” [0] - [1] centre gate function active [4] centre gate function done

b8GateTracking BYTE - Status “gate tracking” [0] gate tracking inactive [4] gate tracking active

b8AMRStatus BYTE - Status “AMR (Automatic Mark Recognition)” [0] AMR search inactive [4] AMR valid [5] AMR failure

b8CalibrationStatus BYTE - Status “TRC calibration” [1] Use reference box head 1 [2] Use reference box head 2 [3] Measuring active [4] Remove reference box [5] IDLE

sCalibrationState STRING - Response of calibration as STRING (see b8CalibrationStatus)

boCalibrationActive BOOL - Calibration active

boCalibrationDone BOOL - Calibration done

boNewMeasureValues BOOL - New measured values (TRUE for one cycle)

ar32RegCtrlRegErrorLR


mm Resulting LR register error of print unit 1..20 depending on selected marks [0]: Deviation of Reference Mark

ar32RegCtrlRegErrorSR


mm Resulting SR register error of print unit 1..20 depending on selected marks [0]: Deviation of Reference Mark

aboMarkError ARRAY [0..20] OF BOOL

- Mark error active per PU Collective fault of marks belonging to that PU [0]: MarkError of Reference Mark

aMarkStatus (TYPE: asMarkStatus = ARRAY [0..20] OF sMarkStatus): Mark status Index = Mark number 1..19; [0]: Mark status of Reference Mark

boMarkError BOOL - Mark Error

boMarkWarning BOOL - Mark Warning

u16ErrorNumer UINT - Mark status (Error Number) (see Eltromat docu “Mark2Status”)

sgErrorTxt STRING[30] - Error as text

aMarkFieldStatus UINT - Mark status (Error Number) (see Eltromat docu “Mark2Status”) Index = Mark number 1..19 [0]: Mark status of Reference Mark

sHWSettings

NOTE Same structure like sTRC3000Data.sHWSettings



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2.3 sRegCtrlIO

The structure sRegCtrlIO contains all the data values for the register controller.

sRegCtrlIO (interface register controller)

o IN (Input)

o OUT (Output)

The structure is used for data exchange between:

FBLRegCtrlDataTransfer (communication to HMI)

FBLTRC3000DataToRegCtrl (communication to TRC3000)

FBLTRC7000DataToRegCtrl (communication to TRC3000)

Register control application

Figure 5-3 sRegCtrlIO

The structure for all printing units in the application is an array. The index of the array is the PU number: gasRegCtrlIO:= ARRAY [NR_OF_FIRST_PU..NR_OF_LAST_PU] OF sRegCtrlIO;

sRegCtrIO.IN

Table 5-25 sRegCtrlIO.IN


boMarkError BOOL - Mark error Depending on measuring method WebCyl: only reference mark WebWeb: reference and control mark

boNewMeasureValues BOOL - New measure values MarkfieldFormatCounter was increased

boTRCReadyForMeasure BOOL - TRUE: No LifeSignError and State=OPA

boTRCStandStill BOOL - TRC is in standstill mode Actual speed < SampleSpeedStandstill of TRC



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


boTRCUsesMasterPosition BOOL - TRUE: TRC gets position values from master axis FALSE: TRC gets position values from own axis Used for measuring method web cylinder!

boImpressionOff BOOL - TRUE: Impression OFF FALSE: Impression ON Connect with Impression-On/Off signal of machine in case of gravure machines. In case of flexo machines, connect with TRUE! If FALSE, Set_Ref- and Set_Reg-funcions will not be done.

boRegCtrlEnableInsetting BOOL - Enable register controller from insetting

i32FormatCounter DINT - Format counter, increased by 1 with every printing cylinder rotation


boMarkErrorRefMark BOOL - Mark error only of reference mark

r32ActValueRefMarkLR REAL - Mark deviation of reference mark LR

r32ActValueRefMarkSR REAL - Mark deviation of reference mark SR

sRegInLR sRegIn - Interface to register controller LR

sRegInSR sRegIn - Interface to register controller SR

sRegInPU sLRegCtrlPrintinUnit

- Mechanical and technological settings of register controller of PU

sInsettingIn sInsettingInType - Interface to insetter

sDRDInLR sLRegCtrlDRDIn - Interface to DRD LR

sDRDInSR sLRegCtrlDRDIn - Interface to DRD SR

Substructures

sRegIN

Used for side register (sRegInLR) and for length register (sRegInSR).

Table 5-26 sRegIN


boEnable BOOL - Enable register control

boReset BOOL - Reset for register control (connected to several FBs)

boResetOutMm BOOL - Reset output r32OutputMm of FBRegCtrl

boIntActionEnable BOOL - Enable/Disable integral part of register control modes with integral part

boDifActionEnable BOOL - Enable/Disable differential part of register control modes with differential part



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


boRegInchNegative BOOL - Not used anymore! Used for register inching via print standard: Connect to StdcIO.IN.boNegativeRelRegister

boSpdPreCtrl BOOL - Not used yet Enable speed pre control of register controller

boRampMode BOOL - Enable ramp mode of register controller

boInchMode BOOL - FALSE: Inching via FBRegCtrl TRUE: Inching via PrintStandard (not used anymore)

boSetAdderValue BOOL - Set position value of adder to 0

boEnableMove BOOL - TRUE: Enable PWM outputs

boFastReactionAxis BOOL - TRUE: A fast reaction of controller is needed. u8FilterDepth will be forced to 1 internal. (E.g. when axis accelerate)

boFastReactionSplice BOOL - TRUE: A fast reaction of controller is needed. u8FilterDepth will be forced to 1 internal. (E.g. splice)

u8FilterDepth USINT - Averaging over the parameterized number of register error values

r32InchDistMM REAL mm Inch value for FBRegCtrl

r32SetValue REAL mm Register controller set value / Fine correction

r32ActValue REAL mm Actual register value

r32WebCylLatchPosition REAL mm Latched position of register axis, when register controller changes to On. Necessary for WebCylinder

r32KpWebWeb REAL - Register controller gain value for WebWeb mode

r32KpWebCyl REAL - Register controller gain value for WebCylinder mode

r32TiWebWeb REAL s Register controller reset time for WebWeb mode

r32TiWebCyl REAL s Register controller reset time for WebCylinder mode

r32DampingA REAL Damping factor

r32VPosMax REAL mm/s Positive speed limit of register motion

r32VnegMin REAL mm/s Negative speed limit of register motion

r32LimitNegPosition REAL Unit Negative limit for register own limit switch

r32LimitPosPosition REAL Unit Positive limit for register own limit switch

r32FiltThresh REAL mm Threshold for noise reduction Values < r32FiltThresh are reduced

r32vMove REAL mm/s Speed of external motor for register adjustment

eControlAlg eLRegCtrlControlAlg

- not used yet

etechnology eLRegCtrlTechnology

- not used yet



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

sLRegCtrlPrintingUnit – sPU

Find description in manual “LregCtrl FBController” https://support.industry.siemens.com/cs/ww/de/view/109475398

sInsettingInType

Find description in manual “Print Standard Add-On Insetting” https://support.industry.siemens.com/cs/ww/de/view/109475398

sLRegCtrlDRD

Find description of parameters in manual “Print Standard Add-On DRD” https://support.industry.siemens.com/cs/ww/de/view/109475398

sRegCtrlIO.OUT

Table 5-27 sRegCtrlIO.OUT


boRequestImpressionOff BOOL - Request “Impression off” from register control. If the function “SetRef” or “SetReg” from HMI is chosen, the request will be set.

sRegOutLR sRegOut Interface from register controller LR

sRegOutSR sRegOut Interface from register controller LR

sInsettingOut sInsettingOutType Interface from insetter

sDRDOutLR sLRegCtrlDRDOut Interface from DRD LR

sDRDOutSR sLRegCtrlDRDOut Interface from DRD SR

Substructures

sRegOut

Used for side register (sRegOutLR) and for length register (sRegOutSR).

Table 5-28 sRegOut


boFBRegCtrlActive BOOL - State of input FBRegCtrl boEnableCtrl

boFBRegCtrlError BOOL - State of output FBRegCtrl boSeriousError FALSE: u16FBRegCtrlErrorID = 0 TRUE: u16FBRegCtrlErrorID <> 0 Register controller is inactive

boFBRegCtrlInchingActive BOOL - TRUE: Inching via FBRegCtrl active

boLimitSwitchPos BOOL - TRUE: Positive limit of axis position reached (only important for SR) Register motion in negative direction is inhibited

boLimitSwitchNeg BOOL - TRUE: Negative limit of axis position reached (only important for SR) Register motion in positive direction is inhibited

boPwmPlus BOOL - Plus signal for external motors for register adjustment

https://support.industry.siemens.com/cs/ww/de/view/109475398





S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


boPwmMinus BOOL - Minus signal for external motors for register adjustment

r32FBRegCtrlDeviation REAL mm Deviation of register = FBRegCtrl.r32SetValue - FBRegCtrl.r32ActValue

r32FBRegCtrlOut REAL mm/s Output of register controller Additional speed

r32FBRegCtrlOutMm REAL mm Integrated value of controller output Position

r32RegisterValueAdder REAL Unit of Axis

Position value, connected to adder (modulo)

u16FBRegCtrlErrorID UINT - ErrorID of register controller See under Register FB error messages



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

sLRegCtrlPrintingUnit - sPU

Find description in manual “LRegCtrl FBController” https://support.industry.siemens.com/cs/ww/de/view/109475398

sInsettingOutType

Find description in manual “Print Standard Add-On Insetting” https://support.industry.siemens.com/cs/ww/de/view/109475398

sLRegCtrlDRD

Find description of parameters in manual “Print Standard Add-On DRD” https://support.industry.siemens.com/cs/ww/de/view/109475398






S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2.4 sHMI_TRC3000_Command

There is a structure of the HMI interface for TRC3000 and also for TRC7000.

The HMI screens will be connected via the sHMI_TRC3000_Command variables to the sTRC3000Data interface. The function blocks “FBLTRC3000DataTransfer” copy the sHMI_TRC3000_Command variable to the StdcIO variables and reverse.

In case of using the Application without HMI it is also possible to delete this structure and the conversion function block “FBLTRC3000DataTransfer”. In this case the application can/must be controlled via the StdcIO interface directly.

In the sHMI_TRC3000_Command structure all printing unit depending variables are collected in array form to realize the HMI connection as easy as possible. The sHMI_TRC3000_Command structure is prepared to provide a standard solution with a maximum of 20 print units. If the number of print units is less than twenty the HMI part and the array length of the sHMI_TRC_Command should be still at 20 (constant NUMBER_OF_PUS in dTRC). Otherwise the HMI masks needs to be adapted.

The complete data structure sHMI_TRC_Command is as retain implemented, so that all settings are saved. The index number of the arrays is always the PU number. PU 1..20 is index 1..20, index 0 is unused.

sHMI_TRC3000_Command.IN

Table 5-29 sHMI_TRC3000_Command.IN


i32 TRC3000FormatSize DINT µm Length of print format

au8 TRC3000FormatCounterReset

ARRAY [0..20] OF BYTE

- Reset TRC format counter

ab8TRC3000FaultAckn ARRAY [0..20] OF BYTE

- Acknowledge of TRC faults, application errors and register controller errors of this unit

ab8TRC3000Reset ARRAY [0..20] OF BYTE

- Start hardware reset of TRCs, which are assigned to the PU

au16TRC3000CutsPerRotation

ARRAY [0..20] OF UINT

- Tool factor

number of formats per cylinder rotation

boTRC3000JobDownload BOOL - Start job download for all TRC3000

aboTRC3000ObjRequest ARRAY [0..20] OF BOOL

- Request from HMI: TRC3000 of PU[x] must send curve

au8TRC3000AssignedToPu ARRAY [0..20] OF USINT

- Number of TRC3000 which is assigned to PU[x]

aboTRC3000SelectPUactive ARRAY [0..20] OF BOOL

- PU[x] is active/inactive

aboDontUseValOfTRC3000 ARRAY [0..20] OF BOOL

- Only important if TRC3000 and TRC7000 are assigned to that PU: TRUE: Don’t use values of TRC3000 for register controller

aboTRC3000RegFollowLR ARRAY [0..20] OF BOOL

- Switch LR of PU[x] to following control

aboTRC3000RegFollowSR ARRAY [0..20] OF BOOL

- Switch SR of PU[x] to following control



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


aboTRC3000AMRStart ARRAY [0..20] OF BOOL

- Start AMR search (Automatic Mark Recognition) of TRC which is assigned to PU[x]

sTRC3000MarkTypeDefine (sHMIFMarkDefine)

Geometric mark definitions for TRC3000 parameterization. 6 mark fields are possible [1..6]

aboTurnMarkField ARRAY [0..6] OF BOOL

- TRUE: Mark geometry is flipped by 180° for example, if cylinders are mounted reverse!

au16GatesUsed ARRAY [0..6] OF UINT

- Number of valid MarkSetPosY-values or Number of defined Marks

MarkType ARRAY [0..6] OF eMarkType

- Parameter defines used mark type:

Wedge_Mark_1 …4, Double_Wedge_Mark_5 …6,

Double_Block_Mark_7 …10,

AMR_Mark,

Edge_1 …3,

DoubleEdge_1 …3,

Dot

r32Width_Blockmark ARRAY [0..6] OF REAL

mm

These parameters are connected to the HMI mark setting screens. (The parameter names are used from TRC1000 application to have a uniform interface) Dependent on the selected mark type, the respective mark geometry parameters are used to describe the physical dimensions of the marks. The values here will be copied to the sTRCData.sSTDcIO.In.sMarkTypeDefine structure in the HMIDataTransfere function block using the function FCLTRC3000FillMarkfield function. From there the values will be converted into the TRC3000 parameter names using the function FCLTRCMarkSettings and copied to the sTRCData.sTRCInterface.sData_Acyclic

r32Width_WedgeMark_Min ARRAY [0..6] OF REAL

mm

r32Width_WedgeMark_Max ARRAY [0..6] OF REAL

mm

r32EdgeLength_WedgeMark ARRAY [0..6] OF REAL

mm

r32Width_DoubleWedgeMark_Min


mm

r32Width_DoubleWedgeMark_Max


mm

r32MiddleWidth_DoubleWedgeMark


mm

r32Width_DoubleWedgeMark ARRAY [0..6] OF REAL

mm

r32EdgeLength_DoubleWedgemark


mm

r32Width_DoubleBlockMark_Min


mm

r32Width_DoubleBlockMark_Max


mm

r32WidthStraight_DoubleBlockmark


mm

r32WidthBevel_DoubleBlockMark


mm

r32EdgeLength_DoubleBlockmark


mm

r32Distance_AGSMarktoRefMark


mm

r32Tolerance_AGSMark ARRAY [0..6] OF REAL

mm



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


r32Width_AGSMark_1 ARRAY [0..6] OF REAL

mm structure to send the values to the sensor device.


mm


mm


mm

r32Chasm_AGSMark_1 ARRAY [0..6] OF REAL

mm


mm


mm

aai32MarkSetPosY ARRAY [0..6] OF ai32MarkSetPos ai32MarkSetPos=ARRAY [0..20] OF DINT

mm Mark position within the format

au8TRC3000MarkfieldNr ARRAY [0..20] OF USINT

- mark field number of PU[x]

au8TRC3000PUMark ARRAY [0..20] OF USINT

- Own print mark of PU[x]

au8TRC3000RefMark ARRAY [0..20] OF USINT

- Reference mark of PU[x]

au8TRC3000RefMarkFollw ARRAY [0..20] OF USINT

- Reference mark for following control of PU[x]

ab8TRC3000CentreGate ARRAY [0..20] OF BYTE

- Start centre gate function of PU[x]

ab8TRC3000ChangeZeroToRefPos


- Set ZeroToRefPos (gate position) of TRC3000 assigned to PU[x]

ab8TRC3000ZeroToRefPosYUp


- Shift gate position by 0.5mm up of TRC3000 assigned to PU[x]

ab8TRC3000ZeroToRefPosYDown


- Shift gate position by -0.5mm down of TRC3000 assigned to PU[x]

ab8TRC3000GateTracking ARRAY [0..20] OF BYTE

- Start gate tracking of TRC3000 assigned to PU[x]

ab8TRC3000ModeCalibration


- Switch TRC3000 assigned to PU[x] to mode calibration

ai32TRC3000ZeroToRefPosY

ARRAY [0..20] OF DINT

µm Set distance of cylinder zero to first mark of TRC3000 assigned to PU[x]

aeTRC3000RegCtrlMode ARRAY [0..20] OF eHMICtrlMode

- Register control mode of PU[x] Mode will be converted to Measuring method of TRC [0] Web_Cylinder → Web_Cylinder [1] Web_Web → Singlehead [2] Web_Web_2 → Doublehead [3] Inset_Web_Cylinder → Web_Cylinder [4] Inset_Key → Web_Cylinder [5] Inset_Web_Web → Singlehead

aboTRC3000DoubleheadReverse

ARRAY [0..20] OF BOOL

- Setting of double head mode: Which head detects the reference mark.



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


FALSE: Doublehead forward Head 1 = Reference mark = gate Head 2 = Print mark TRUE: Doublehead reverse Head 1 = Print mark = gate Head 2 = Reference mark

au8TRC3000WebWeb2Type ARRAY [0..20] OF USINT

- Calculate side register error of PU[x], dependent on web guide line.

Job setting “Orientation reference mark to control mark in WebWeb2 mode”


0: same mark orientation

1: horizontal mirrored mark orientation (after web turn)

2: vertically mirrored mark orientation (after web turn)

au8TRC3000MarkCenter ARRAY [0..20] OF USINT

- Mark number for center and tracking function of PU[x]

Singlehead: Any mark of markfield Doublehead: 1: print mark 2: reference mark WebCylinder: Always reference mark

ab8TRC3000GateSizeYUp ARRAY [0..20] OF BYTE

- Increase gate size by 0.5mm of TRC3000 assigned to PU[x]

ab8TRC3000GateSizeYDown


- Decrease gate size by 0.5mm of TRC3000 assigned to PU[x]

ai32TRC3000GateSizeY ARRAY [0..20] OF DINT

µm Set Gate size of TRC3000 assigned to PU[x]

ai32TRC3000GatePosY ARRAY [0..20] OF DINT

mm Set Gate position of TRC3000 assigned to PU[x]

sHMI_TRC3000_Command.OUT

Table 5-30 sHMI_TRC3000_Command.OUT


b8TRC3000UpdateActiveGlobal

BYTE - Status “job download” for all TRC3000

[1] Download started [3] Load data from HMI to Simotion [4] Download done [5] Download failed

ab8TRC3000UpdateActive ARRAY [0..20] OF BYTE

- State TRC update of TRC assigned to PU[x] (Parameter writing to TRC) [1] Download started [3] Load data from HMI to Simotion [4] Download done [5] Download failed

aboTRC3000CalibrationActive


- Calibration active of TRC assigned to PU[x]



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


aboTRC3000LifesignError ARRAY [0..20] OF BOOL

- LifesignError monitored by Simotion application of TRC assigned to PU[x]

aboTRC3000ApplicationError ARRAY [0..20] OF BOOL

- Application error of TRC assigned to PU[x]

aboTRC3000Warning ARRAY [0..20] OF BOOL

- Warning of TRC device assigned to PU[x]

aboTRC3000Error ARRAY [0..20] OF BOOL

- Error of TRC device assigned to PU[x]

aboTRC3000Standstill ARRAY [0..20] OF BOOL

- Standstill of TRC device assigned to PU[x] Axis speed < SampleSpeedStandstill TRUE: No mark measuring is done

aboTRC3000UseMasterPosition


- Set value of TRC device assigned to PU[x]

TRUE: Use master position (f.e. Mark20) FALSE: Use printing cylinder position

au16TRC3000ErrorID ARRAY [0..20] OF UINT

- TRC device Error ID of TRC assigned to PU[x]

au16TRC3000ApplicationErrorID


- Application error number of TRC assigned to PU[x]

ai32TRC3000ErrorParameter1


- Additional parameter 1 application error number of TRC assigned to PU[x]




ai32TRC3000FormatCounter ARRAY [0..20] OF DINT

- Format counter of TRC assigned to PU[x]

ar32TRC3000ZeroToRefPos ARRAY [0..20] OF REAL

mm Distance of mark field to cylinder zero position of TRC assigned to PU[x]

aau16TRC3000MarkStatus ARRAY [0..20] OF au16MarkStatus

au16MarkStatus = ARRAY [0..20] OF UINT

- MarkStatus of all Marks of one TRC, which is assigned to PU[x]

ab8TRC3000Mode ARRAY [0..20] OF BYTE

- Actual mode of TRC assigned to PU[x] [0] Init [1] Idle [2] Operation [4] Calibration

aboTRC3000MarkError ARRAY [0..20] OF BOOL

- Mark error active per PU Collective fault of marks belonging to PU[x]



- Status “change ZeroToRefPos” of TRC assigned to PU[x] [1] gate position update started [4] gate position update done [5] gate position update failed


- Status “Reset” of TRC assigned to PU[x] [1] reset started [4] reset done [5] reset failed



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d



- Status “Centre Gate” of TRC assigned to PU[x] [0] - [1] centre gate function active [4] centre gate function done


- Status “gate tracking” of TRC assigned to PU[x] [0] gate tracking inactive [4] gate tracking active

ab8TRC3000AMRStatus ARRAY [0..20] OF BYTE

- Status “AMR (Automatic Mark Recognition)” of TRC assigned to PU[x] [0] AMR search inactive [4] AMR valid [5] AMR failure

ab8TRC3000CalibrationStatus


- Status “TRC calibration” of TRC assigned to PU[x] [1] Use reference box head 1 [2] Use reference box head 2 [3] Measuring active [4] Remove reference box [5] IDLE

ab8TRC3000MarkFiledMode ARRAY [0..20] OF BYTE

- Chosen mark field/telegram of TRC assigned to PU[x] 2: MARK 3 (max. 3 register marks)

19: MARK 20 (max. 20 register marks)

ar32SensorMountingOffsetSide


mm Mounting offset in side direction of head 1 of TRC assigned to PU[x]

ar32SensorMountingOffsetSideK2


mm Mounting offset in side direction of head 2 of TRC assigned to PU[x]

ar32ActualGatePosition ARRAY [0..20] OF REAL

mm Actual gate position of TRC assigned to PU[x]

ar32ActualGateWidth ARRAY [0..20] OF REAL

mm Actual gate width of TRC assigned to PU[x]

ab8ChangeGateWidth ARRAY [0..20] OF BYTE

- Status “change gate width” of TRC assigned to PU[x] [1] gate width update started [4] gate width update done [5] gate width update failed

aai16GatePosForControl ARRAY [0..20] OF aiGatePositions

- HMI scope gate positions of PU[x]



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2.5 sHMI_TRC7000_Command

There is a structure of the HMI interface for TRC3000 and also for TRC7000.

The HMI screens will be connected via the sHMI_TRC7000_Command variables to the sTRC7000Data interface. The function blocks “FBLTRC7000DataTransfer” copy the sHMI_TRC7000_Command variable to the StdcIO variables and reverse.

In case of using the Application without HMI it is also possible to delete this structure and the conversion function block “FBLTRC7000DataTransfer”. In this case the application can/must be controlled via the StdcIO interface directly.

In the sHMI_TRC7000_Command structure all printing unit depending variables are collected in array form to realize the HMI connection as easy as possible. The sHMI_TRC7000_Command structure is prepared to provide a standard solution with a maximum of 20 print units. If the number of print units is less than twenty the HMI part and the array length of the sHMI_TRC_Command should be still at 20 (constant NUMBER_OF_PUS in dTRC). Otherwise the HMI masks needs to be adapted.

The complete data structure sHMI_TRC_Command is as retain implemented, so that all settings are saved. The index number of the arrays is always the PU number. PU 1..20 is index 1..20, index 0 is unused.

Only for the measuring settings of the camera the mark field index is used. The measuring settings belong to the mark field.

sHMI_TRC7000_Command.IN

Table 5-31 sHMI_TRC7000_Command.IN


i32TRC7000FormatSize DINT µm Length of print format

au8TRC7000FormatCounterReset


- Reset TRC format counter

ab8TRC7000FaultAckn ARRAY [0..20] OF BYTE

- Acknowledge of TRC faults, application errors and register controller errors of this unit


- Start hardware reset of TRCs, which are assigned to the PU

au16TRC7000CutsPerRotation


- Tool factor

number of formats per cylinder rotation

boTRC7000JobDownload BOOL - Start job download for all TRC7000

ab16TRC7000ObjRequest ARRAY [0..20] OF BOOL

- Request from HMI: TRC7000 of PU[x] must send live image


ARRAY [0..20] OF USINT

- Number of TRC7000 which is assigned to PU[x]

aboTRC7000SelectPUactive


- PU[x] is active/inactive



- Only important if TRC3000 and TRC7000 are assigned to that PU: TRUE: Don’t use values of TRC7000 for register controller

aboTRC7000RegFollowLR ARRAY [0..20] OF BOOL

- Switch LR of PU[x] to following control



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


aboTRC7000RegFollowSR ARRAY [0..20] OF BOOL

- Switch SR of PU[x] to following control

aboTRC7000AMRStart ARRAY [0..20] OF BOOL

- Start AMR search (Automatic Mark Recognition) of TRC which is assigned to PU[x]

sTRC7000MarkTypeDefine sHMICMarkDefine - Geometric mark definitions for TRC7000 parameterization. 6 mark fields are possible [1..6]

sTRC7000MarkTypeDefine (sHMICMarkDefine)

Geometric mark definitions for TRC7000 parameterization. 6 mark fields are possible [1..6]

au16GatesUsed ARRAY [0..6] OF UINT

- Number of valid MarkSetPosY-values or Number of defined Marks

ai32TRCMarkSizeY ARRAY [0..6] OF DINT

µm MarkSizeY Diameter of dot marks

aai32SyncMarkSetPosX ARRAY [0..6] OF ai32SyncMarkSetPos

ai32SyncMarkSetPos = ARRAY [0..2] OF DINT

µm X-Position of SyncMark

aai32SyncMarkSetPosY ARRAY [0..6] OF ai32SyncMarkSetPos

µm Y-Position of SyncMark

aai32MarkSetPosX ARRAY [0..6] OF ai32MarkSetPos

ai32MarkSetPos = ARRAY [0..20] OF DINT

µm X-Position of Mark

aai32MarkSetPosY ARRAY [0..2] OF ai32MarkSetPos

µm Y-Position of Mark

au8TRC7000MarkfieldNr ARRAY [0..20] OF USINT

- mark field number of PU[x]

au8TRC7000PUMark ARRAY [0..20] OF USINT

- Own print mark of PU[x]

au8TRC7000RefMark ARRAY [0..20] OF USINT

- Reference mark of PU[x]

au8TRC7000RefMarkFollw ARRAY [0..20] OF USINT

- Reference mark for following control of PU[x]


- Start centre gate function of PU[x]



- Set ZeroToRefPos (flash position) of TRC7000 assigned to PU[x]

ab8TRC7000ZeroToRefPosYUp


- Shift gate position by 0.5mm up of TRC7000 assigned to PU[x]

ab8TRC7000ZeroToRefPosYDown


- Shift gate position by -0.5mm down of TRC7000 assigned to PU[x]


- Start gate tracking of TRC7000 assigned to PU[x]

ab8TRC7000ModeCalibration


- Switch TRC7000 assigned to PU[x] to mode calibration



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


ai32TRC7000ZeroToRefPosY


µm Set distance of cylinder zero to first mark of TRC7000 assigned to PU[x]

aeTRC7000RegCtrlMode ARRAY [0..20] OF eHMICtrlMode

- Register control mode of PU[x] Mode will be converted to Measuring method of TRC [0] Web_Cylinder → Web_Cylinder [1] Web_Web → Singlehead [2] Web_Web_2 → Doublehead [3] Inset_Web_Cylinder → Web_Cylinder [4] Inset_Key → Web_Cylinder [5] Inset_Web_Web → Singlehead

aboTRC7000TestTrigger ARRAY [0..20] OF BOOL

- Test trigger (flash) on/off of TRC assigned to PU[x] If standstill speed is exceeded, test trigger stops automatically

aboTRC7000BrightnessCtrl


- Automatic brightness control on/off of TRC assigned to PU[x]

aboTRC7000FlashSelect1 ARRAY [0..20] OF BOOL

- Flash 1 on (LED bar – standard flash) of TRC assigned to PU[x]


- Flash 2 on (varnish flash) of TRC assigned to PU[x]

ab8TRC7000BrightnessUp ARRAY [0..20] OF BYTE

- Increase brightness by 1% of TRC7000 assigned to PU[x]

ab8TRC7000BrightnessDown


- Decrease brightness by -1% of TRC7000 assigned to PU[x]

au8TRC7000CamSetBrightness

ARRAY [0..20] OF USINT

% Brightness setting of TRC7000 assigned to PU[x]

au16TRC7000CamFlashSettings


- Selection of flash of TRC7000 assigned to PU[x] 0: Flash 1..2 off 1: Flash 1 on (LED bar – standard flash) 2: Flash 2 on (Varnish flash)

Index [1..6] : Mark field number (Measure settings are done in mark settings page)

au16TRC7000CamMountSetRotation


° Mounting orientation of camera of TRC7000 assigned to PU[x] 0°, 90°, 180° or 270°

au16TRC7000CamMeasSetFilterRadiusInside

ARRAY [0.. 6] OF UINT

% Measuring settings: FilterRadiusInside (default = 40%)

au16TRC7000CamMeasSetFilterRadiusOutside


% Measuring settings: FilterRadiusOutside (default = 40%)

au16TRC7000CamMeasSetFilterThreshold


% Measuring settings: FilterThreshold (default = 93%)

au16TRC7000CamMeasSetZoomTol


% Measuring settings: ZoomTol (default = 15%) Value must be increased at web flutter or not accurate print

au16TRC7000CamMeasSetSyncTol


µm Measuring settings: SyncTol (default = 150µm) Value must be increased at web flutter or not accurate print

au16TRC7000CamMeasSetClippingSizeX


µm Measuring settings: ClippingSizeX (default = 5000µm) Frame around mark field which is free of other print



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


au16TRC7000CamMeasSetClippingSizeY


µm Measuring settings: ClippingSize> (default = 5000µm) Frame around mark field which is free of other print

au32TRC7000CamDiagSetFlags

ARRAY [0.. 6] OF UDINT

- Cam diagnostic setting: Flags (default = 0x0030.0000) 0x0010.0000 Marks with rectangle 0x0020.0000 Marks with mark number 0x0040.0000 meaure result in Live Img 0x0080.0000 Dot-Filter result on

Index PU-Number

au16TRC7000LiveImgSetScaleFactor


- Live Image Settings: ScaleFactor (default = 2)

au16TRC7000LiveImgSetRotation


° Live Image Settings: Rotation (default = 0°) 0°, 90°, 180°, 270°

au16TRC7000LiveImgSetImageFormat


- Live Image Settings: ImageFormat (default = 1 = JPEG)

0=BMP, 1= JPEG

sHMI_TRC7000_Command.OUT

Table 5-32 sHMI_TRC7000_Command.OUT


b8TRC7000UpdateActiveGlobal

BYTE - Status “job download” for all TRC7000

[1] Download started [3] Load data from HMI to Simotion [4] Download done [5] Download failed

ab8TRC7000UpdateActive ARRAY [0..20] OF BYTE

- State TRC update of TRC assigned to PU[x] (Parameter writing to TRC) [1] Download started [3] Load data from HMI to Simotion [4] Download done [5] Download failed

aboTRC7000CalibrationActive


- Calibration active of TRC assigned to PU[x]

aboTRC7000LifesignError ARRAY [0..20] OF BOOL

- LifesignError monitored by Simotion application of TRC assigned to PU[x]

aboTRC7000ApplicationError ARRAY [0..20] OF BOOL

- Application error of TRC assigned to PU[x]

aboTRC7000Warning ARRAY [0..20] OF BOOL

- Warning of TRC device assigned to PU[x]

aboTRC7000Error ARRAY [0..20] OF BOOL

- Error of TRC device assigned to PU[x]

aboTRC7000Standstill ARRAY [0..20] OF BOOL

- Standstill of TRC device assigned to PU[x] Axis speed < SampleSpeedStandstill TRUE: No mark measuring is done



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


aboTRC7000UseMasterPosition


- Set value of TRC device assigned to PU[x]

TRUE: Use master position (f.e. Mark20) FALSE: Use printing cylinder position

aboTRC7000LiveImgOrientation


- LiveImage orientation for HMI 0: Cross 1: Upright

au16TRC7000ErrorID ARRAY [0..20] OF UINT

- TRC device Error ID of TRC assigned to PU[x]

au16TRC7000ApplicationErrorID


- Application error number of TRC assigned to PU[x]







ai32TRC7000FormatCounter ARRAY [0..20] OF DINT

- Format counter of TRC assigned to PU[x]

ar32TRC7000ZeroToRefPos ARRAY [0..20] OF REAL

mm Distance of mark field to cylinder zero position of TRC assigned to PU[x]

aau16TRC7000MarkStatus ARRAY [0..20] OF au16MarkStatus au16MarkStatus = ARRAY [0..20] OF UINT

- MarkStatus of all Marks of one TRC, which is assigned to PU[x]

ab8TRC7000Mode ARRAY [0..20] OF BYTE

- Actual mode of TRC assigned to PU[x] [0] Init [1] Idle [2] Operation [4] Calibration

aboTRC7000MarkError ARRAY [0..20] OF BOOL

- Mark error active per PU Collective fault of marks belonging to PU[x] [0]: MarkError of Reference Mark



- Status “change ZeroToRefPos” of TRC assigned to PU[x] [1] gate position update started [4] gate position update done [5] gate position update failed


- Status “Reset” of TRC assigned to PU[x] [1] reset started [4] reset done [5] reset failed


- Status “Centre Gate” of TRC assigned to PU[x] [0] - [1] centre gate function active [4] centre gate function done


- Status “gate tracking” of TRC assigned to PU[x] [0] gate tracking inactive [4] gate tracking active



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


ab8TRC7000AMRStatus ARRAY [0..20] OF BYTE

- Status “AMR (Automatic Mark Recognition)” of TRC assigned to PU[x] [0] AMR search inactive [4] AMR valid [5] AMR failure

ab8TRC7000CalibrationStatus


- Status “TRC calibration” of TRC assigned to PU[x] [1] Use reference box head 1 [2] Use reference box head 2 [3] Measuring active [4] Remove reference box [5] IDLE

ab8TRC7000MarkFiledMode ARRAY [0..20] OF BYTE

- Chosen mark field/telegram of TRC assigned to PU[x] 2: MARK 3 (max. 3 register marks)

19: MARK 20 (max. 20 register marks)


- Flash 1 on (LED bar – standard flash) of TRC assigned to PU[x]


- Flash 2 on (varnish flash) of TRC assigned to PU[x]

aboTRC7000TestTrigger ARRAY [0..20] OF BOOL

- Testtrigger (flash) on of TRC assigned to PU[x]

aboTRC7000BrightnessCtrl ARRAY [0..20] OF BOOL

- Brightnesscontrol on of TRC assigned to PU[x]

au8TRC7000Brightness ARRAY [0..20] OF USINT

% Brightness actual value of TRC assigned to PU[x]

au16TRC7000CamFlashInfo ARRAY [0..20] OF UINT

- Installed flash combination bit coded of TRC assigned to PU[x] Bit 0: Flash 1 installed Bit 1: Flash 2 installed (Varnish flash) Bit 2: Flash 3 installed (not used) Bit 3: Flash 4 installed (not used)



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2.6 sHMI_RegCtrl_Command

The HMI screens will be connected via the sHMI_RegCtrl_Command variables to the sRegCtrlIO interface. The function block “FBLRegCtrlDataTransfer” copies the sHMI_RegCtrl_Command variable to the sRegCtrlIO variables and reverse.

In case of using the Application without HMI it is also possible to delete this structure and the conversion function block “FBLRegCtrlDataTransfer”. In this case the application can/must be controlled via the sRegCtrlIO interface directly.

The sHMI_RegCtrl_Command structure contains all printing unit depending variables. They are collected in array form to realize the HMI connection as easy as possible. The sHMI_RegCtrl_Command structure is prepared to provide a standard solution with a maximum of 20 print units. If the number of print units is less than twenty the HMI part and the array length of the sHMI_TRC_Command should be still at 20 (constant NUMBER_OF_PUS in dTRC). Otherwise the HMI masks needs to be adapted.

The complete data structure sHMI_RegCtrl_Command is as retain implemented, so that all settings are saved. The index number of the arrays is always the PU number. PU 1..20 is index 1..20, index 0 is unused.

sHMI_RegCtrl_Command.IN

Table 5-33 sHMI_RegCtrl_Command.IN


boRegCtrlJobDownload BOOL - Job download of register controller (Take fine correction (RegCtrlSetValue) and RegCtrlMode from Job)

boIntActionEnableLR BOOL - Enable/Disable integral part of register control modes with integral part

boIntActionEnableSR BOOL - Enable/Disable integral part of register control modes with integral part

i16RegErrorHistoryTRCNo INT - PU number for history curve

b16RegErrorHistoryRequest WORD - Request for register error history

r32FormatSize REAL mm Length of print format

r32RegInchLRFactorSlow REAL mm Factor for register inching steps per edge LR slow

r32RegInchSRFactorSlow REAL mm Factor for register inching steps per edge SR slow

r32RegInchLRFactorFast REAL mm Factor for register inching steps per edge LR fast

r32RegInchSRFactorFast REAL mm Factor for register inching steps per edge SR fast

r32ExtInchSpeed REAL mm/s Speed level for external manual register inching (e.g. joystick)

Inch distance is calculated with r32ExtInchSpeed and time duration bits aboExtInchLR/SRForward/Backward are TRUE



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


r32RegFactorGraphic REAL - Resolution factor for graphical register error representation Scale (20 tick marks) = 20mm/r32RegFactorGraphic

r32RegMakuLevel REAL mm Threshold for maku (red/green)

r32LRRegCtrlKPWebWeb REAL - Register controller gain value for WebWeb mode

r32LRRegCtrlKPWebCyl REAL - Register controller gain value for WebCylinder mode

r32LRRegCtrlIWebWeb REAL s Register controller reset time for WebWeb mode

r32LRRegCtrlIWebCyl REAL s Register controller reset time for WebCylinder mode

r32LRRegCtrlDampingA REAL - Damping factor for symmetrical optimum

r32LRRegCtrlVPosMax REAL mm/s Positive speed limit of register motion and inching

r32LRRegCtrlVNegMax REAL mm/s Negative speed limit of register motion and inching

r32LRRegCtrlVPosMaxInch REAL mm/s Positive speed limit for “SetReg” and “SetRef”

r32LRRegCtrlVNegMaxInch REAL mm/s Negative speed limit for “SetReg” and “SetRef”

r32SRRegCtrlKPWebWeb REAL - Register controller gain value for WebWeb mode

r32SRRegCtrlKPWebCyl REAL - Register controller gain value for WebCylinder mode

r32SRRegCtrlIWebWeb REAL s Register controller reset time for WebWeb mode

r32SRRegCtrlIWebCyl REAL s Register controller reset time for WebCylinder mode

r32SRRegCtrlDampingA REAL - Damping factor for symmetrical optimum

r32SRRegCtrlVPosMax REAL mm/s Positive speed limit of register motion and inching

r32SRRegCtrlVNegMax REAL mm/s Negative speed limit of register motion and inching

r32SRRegCtrlVPosMaxInch REAL mm/s Positive speed limit for “SetReg” and “SetRef”

r32SRRegCtrlVNegMaxInch REAL mm/s Negative speed limit for “SetReg” and “SetRef”

eLRTechnology eLRegCtrlTechnology

- not used yet

eLRControlAlg eLRegCtrlControlAlg

- not used yet

eSRTechnology eLRegCtrlTechnology

- not used yet

eSRControlAlg eLRegCtrlControlAlg

- not used yet

eDRDMode eLRegCtrlDecouplingMode

- Selection of DRD decoupling mode Selection of the DRD mode

ab8FaultAckn ARRAY [0..20] OF BYTE

- Reset of FBRegCtrl and insetting



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


aboLRRegCtrlEnable ARRAY [0..20] OF BOOL

- Enable register controller LR

aboSRRegCtrlEnable ARRAY [0..20] OF BOOL

- Enable register controller SR

aboExtInchLRForward ARRAY [0..20] OF BOOL

- Input for external register inching (e.g. joystick)

Time duration this bit is TRUE is multiplied with r32ExtInchSpeed to calculate inch distance

aboExtInchLRBackward ARRAY [0..20] OF BOOL



aboExtInchSRForward ARRAY [0..20] OF BOOL



aboExtInchSRBackward ARRAY [0..20] OF BOOL



ab8RegInchLRBackwardFast ARRAY [0..20] OF BYTE

- Register inching LR backward fast

ab8RegInchLRForwardFast ARRAY [0..20] OF BYTE

- Register inching LR forward fast

ab8RegInchLRBackwardSlow


- Register inching LR backward slow

ab8RegInchLRForwardSlow ARRAY [0..20] OF BYTE

- Register inching LR forward slow

ab8RegInchSRBackwardFast ARRAY [0..20] OF BYTE

- Register inching SR backward fast

ab8RegInchSRForwardFast ARRAY [0..20] OF BYTE

- Register inching SR forward fast

ab8RegInchSRBackwardSlow


- Register inching SR backward slow

ab8RegInchSRForwardSlow ARRAY [0..20] OF BYTE

- Register inching SR forward slow

ab8SetRegStarted ARRAY [0..20] OF BYTE

- Function “SetReg” has been started from HMI

ab8SetRefStarted ARRAY [0..20] OF BYTE

- Function “SetRef” has been started from HMI

au8FilterDepthLR ARRAY [0..20] OF USINT

- Averaging over the parameterized number of LR register error values

au8FilterDepthSR ARRAY [0..20] OF USINT

- Averaging over the parameterized number of SR register error values



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


aeRegCtrlMode ARRAY [0..20] OF eHMICtrlMode

- Register control mode of PU[x] [0] Web_Cylinder [1] Web_Web [2] Web_Web_2 [3] Inset_Web_Cylinder [4] Inset_Key [5] Inset_Web_Web

ab8RegCtrlSetFromActValueLR


- Set FBController LR set value to current register error

ab8RegCtrlSetValueZeroLR ARRAY [0..20] OF BYTE

- Set FBController LR set value back to 0

ab8RegCtrlSetFromActValueSR


- Set FBController SR set value to current register error

ab8RegCtrlSetValueZeroSR ARRAY [0..20] OF BYTE

- Set FBController SR set value back to 0

ar32RegCtrlSetValueLR ARRAY [0..20] OF REAL

mm fine correction value LR

ar32RegCtrlSetValueSR ARRAY [0..20] OF REAL

mm fine correction value SR

ar32TRC1PosToPU ARRAY [0..20] OF REAL

m Distance head 1 to print unit (FO to nip) sPU.s_sensor1

ar32PUtoPU ARRAY [0..20] OF REAL

m Machine geometry, distance from print unit to previous print unit or nip (nip to nip)

asStatisticIn ARRAY [0..20] OF sLRegCtrlStatisticIn

- Substructure for register error statistic

sHMIPrintingUnit sHMIPrintingUnitStruct

- Substructure for tension adaption curve and speed level curve

sHMIInsettingCommandIn sHMIInsettingCommandInType

- Find description in manual “Print Standard Add-On Insetting”



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

sHMI_RegCtrl_Command.OUT

Table 5-34 sHMI_RegCtrl_Command.OUT


u8MakuLevel USINT mm Maku level for register error face plate Color switching green/red

r32Scale REAL mm Scale of 10. tick mark of register error face plate

aboFBRegCtrlErrorLR ARRAY [0..20] OF BOOL

- FBRegCtrl LR error

aboFBRegCtrlErrorSR ARRAY [0..20] OF BOOL

- FBRegCtrl SR error

au16FBRegCtrlErrorIDLR ARRAY [0..20] OF UINT

- FBRegCtrl LR error id

au16FBRegCtrlErrorIDSR ARRAY [0..20] OF UINT

- FBRegCtrl SR error id

aboSetRefActive ARRAY [0..20] OF BOOL

- Function “SetRef” has been started from HMI

aboSetRegActive ARRAY [0..20] OF BOOL

- Function “SetReg” has been started from HMI

aboRegCtrlActiveLR ARRAY [0..20] OF BOOL

- LR State of input FBRegCtrl boEnableCtrl

aboRegCtrlActiveSR ARRAY [0..20] OF BOOL

- SR State of input FBRegCtrl boEnableCtrl

ar32ActualRegSetValueLR ARRAY [0..20] OF REAL

mm Actual set value fine correction LR

ar32ActualRegSetValueSR ARRAY [0..20] OF REAL

mm Actual set value fine correction SR

ar32ActualRegErrorLR ARRAY [0..20] OF REAL

mm Actual register error LR

ar32ActualRegErrorSR ARRAY [0..20] OF REAL

mm Actual register error SR

ar32ActualRegErrorLRGraphic


- Actual register error LR scaled

ar32ActualRegErrorSRGraphic


- Actual register error SR scaled

au8ActualMakuLevelLR ARRAY [0..20] OF USINT

- Actual Maku Level LR 0: total red .. 20

au8ActualMakuLevelSR ARRAY [0..20] OF USINT

- Actual Maku Level SR 0: total red .. 20

ar32FBRegCtrlOutputMmLR ARRAY [0..20] OF REAL

mm Integration of LR controller output

ar32FBRegCtrlOutputMmSR ARRAY [0..20] OF REAL

mm Integration of SR controller output

ar32FBDRDOutputMmLR ARRAY [0..20] OF REAL

mm Integration of LR DRD shift function output

ar32FBDRDOutputMmSR ARRAY [0..20] OF REAL

mm Integration of SR DRD shift function output

abodecouplingerrorLR ARRAY [0..20] OF BOOL

- LR DRD Decoupling Error

au16decouplingerrnoLR ARRAY [0..20] OF UINT

- LR DRD Decoupling Error number



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d


aboshifterrorLR ARRAY [0..20] OF BOOL

- LR DRD Shift function Error

au16shifterrnoLR ARRAY [0..20] OF UINT

- LR DRD Shift function Error number

abodecouplingerrorSR ARRAY [0..20] OF BOOL

- SR DRD Decoupling Error

au16decouplingerrnoSR ARRAY [0..20] OF UINT

- SR DRD Decoupling Error number

aboshifterrorSR ARRAY [0..20] OF BOOL

- SR DRD Shift function Error

au16shifterrnoSR ARRAY [0..20] OF UINT

- SR DRD Shift function Error number

sHMIInsettingCommandOut sHMIInsettingCommandOutType

- Find description in manual “Print Standard Add-On Insetting”

b16RegErrorHistoryTransfer WORD - Bit 0: Curve update LR Bit 1: Curve update SR Bit 15: Object update

ar32RegisterErrorHistoryLR ar32RegErrorHistory

- LR Error History Values

ar32RegisterErrorHistorySR ar32RegErrorHistory

- SR Error History Values

asStatisticOut ARRAY [0..20] OF sLRegCtrlStatisticOut

- Statistic values



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2.7 sHMI_Application_Command

The structure sHMI_Application_Command is used for HMI-Variables, which cannot be assigned directly to RegCtrl and not to TRC. The variables used in this structure, are especially for this sample application.

The structure is defined in the library LApplicationHMI.

sHMI_Application_Command.IN

Table 5-35 sHMI_Application_Command.IN


au16UsedTRCTypes ARRAY [0..20] OF UINT

- HMI internal variable – don’t write!

au8PUColor ARRAY [0..20] OF USINT

- HMI internal variable – don’t write!

sHMI_Application_Command.OUT

Table 5-36 sHMI_Application_Command.OUT


i32MachineActualSpeed DINT m/min Machine speed

b32GlobalError DWORD - Bit 0: Global error of all PUs Bit 1: Collective error of PU1 Bit 2: Collective error of PU2 …

au8RegCtrlStatus ARRAY [0..20] OF USINT

- Comprehensive status of register control (Index = PU) 1: Mark error (TRC3000/7000) 3: AMR active (TRC3000/7000) 4: Error of FBRegCtrl (LR and SR) 5: Decoupling error (LR and SR) 6: Insetting error 7: Shift error (LR and SR) 8: Vel < Limit



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

5.2.8 sTRCSetCurveOCX

Settings for scope data control. The definition should be retain, to keep changed settings.

Table 5-37 sTRCSetCurveOCX

Name Type Description

ai32AxisColor ARRAY [0..20] OF DINT

Color of X-Axis [OLE_COLOR] Value range: R,Y,B 0..255 Default: 16#00A8_A8A8

ai32AxisFontColor ARRAY [0..20] OF DINT

Color of marking of X-Axis [OLE_COLOR] Value range: R,Y,B 0..255 Default: 16#00A8_A8A8

ai32AxisFontSize ARRAY [0..20] OF DINT

Font size for marking of X-Axis [Pixel] Default: 8

ai32AxisLineWidth ARRAY [0..20] OF DINT

Line width of X-Axis [Pixel] Default: 1

ai32StartZoomRange ARRAY [0..20] OF DINT

Start point of zoom range Value range: 0..MaxRange Default: 1000

ai32EndZoomRange ARRAY [0..20] OF DINT

Start point of zoom range Value range: 0..MaxRange Default: 5000

ai32GridColor ARRAY [0..20] OF DINT

Color of grid [OLE_COLOR] Value range: R,Y,B 0..255 Default: 16#00A8_A8A8

ai16GridSize ARRAY [0..20] OF INT

Line width of grid-Axis [Pixel] Default: 1

ai32MainGridCount ARRAY [0..20] OF DINT

Number of main lines of grid Default: 5

ai32MaxRangeX ARRAY [0..20] OF DINT

Range of X-Axis [0,1mm] Default: 6180 = 618mm

ai32MaxRangeY ARRAY [0..20] OF DINT

Range of Y-Axis [0,1mm] Default: 100 = 10mm

ai32MaxZoomRangeY ARRAY [0..20] OF DINT

Max. range of zoom of Y-Axis [0,1mm] Default: 100 = 10mm

ai32MinZoomRangeY ARRAY [0..20] OF DINT

Min. range of zoom of Y-Axis [0,1mm] Default: 0

ai32RangeWeight1 ARRAY [0..20] OF DINT

Proportion of standard to zoom range [%] Value range: 10..90 Default: 60

ai32ReadValuesCycle ARRAY [0..20] OF DINT

Cycle time of refreshing scope data [ms] Default: 1000

ai32SensorTypeTRC1 ARRAY [0..20] OF DINT

0: Grey value curve of 1-head sensor 1: Color value curve of 1-head sensor 2: Grey value curve of 2-head sensor 3: Color value curve of 2-head sensor 4: Grey value curve Ex of 1-head sensor 5: Grey value curve Ex of 2-head sensor Default: 1

ai32ShowColorCodes ARRAY [0..20] OF DINT

Show color code range 1: Color code displayed 0: Color code not displayed Default: 1



S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Name Type Description

ai32ShowCursor ARRAY [0..20] OF DINT

Show cursor of X-Axis 1: Cursor on 0: Cursor off Default: 1

ai32ShowCursorY ARRAY [0..20] OF DINT

Show cursor of X-Axis 1: Cursor on 0: Cursor off Default: 1

ai32ShowMainGrid ARRAY [0..20] OF DINT

Show grid lines 1: grid on 0: grid off Default: 1

ai32ShowZoomRange ARRAY [0..20] OF DINT

Show zoom range 1: zoom range on 0: zoom range off Default: 1

ai32SubGridCount ARRAY [0..20] OF DINT

Number of graduation lines of sub grid Default: 5

ai32Timeout ARRAY [0..20] OF DINT

Timeout for communication with Simotion [ms] Default: 30000

ai32WhiteColorSensor1 ARRAY [0..20] OF DINT

Color value for white balance of sensor 1 Value range: 0..100 Default: 30

ai32WhiteColorSensor2 ARRAY [0..20] OF DINT

Color value for white balance of sensor 2 Value range: 0..100 Default: 30

ai32YMainGridCount ARRAY [0..20] OF DINT

Number of main lines of grid of Y-Axis Default: 3

ai32YSubGridCount ARRAY [0..20] OF DINT

Number of graduation lines of sub grid of Y-Axis Default: 2

ai32ZoomBackgroundColor ARRAY [0..20] OF DINT

Color of background of zoom [OLE_COLOR] Value range: R,Y,B 0..255 Default: 16#0080_FFFF

ai32ZoomColor ARRAY [0..20] OF DINT

Color of zoom [OLE_COLOR] Value range: R,Y,B 0..255 Default: 16#0080_FFFF

ai32HeightColorCodeActive ARRAY [0..20] OF DINT

Height of color code range of active range [Pixel] Default: 32

ai32HeightColorCodeInActive ARRAY [0..20] OF DINT

Height of color code range of inactive range [Pixel] Default: 16

ai32CursorCatchRangeWidth ARRAY [0..20] OF DINT

Number of pixels for catching the object Default: 16 This setting must be adapted depending the panel!

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

6 Fault messages The fault messages are separated into the following categories:

Application faults

Sensor faults

Register FB faults

Insetting faults

DRD faults

LifeSign fault

The error bits and errorIDs of TRC will be shown in the respective variables in the

data structure gasTRCx000Data[ ].StdcIO.OUT.

The errors of the register controller can be found in the data structure gasRegCtrlIO[ ].OUT.

Actual errors will be shown on the HMI screen with number and text (s. figure 6-1).

Pressing the respective error box, a window appears which shows the error massage in clear text. The error texts of the different errorID’s are defined in the WinCC flexible project.

By pressing the “reset” button, all faults related to this print unit are being acknowledged.

Figure 6-1 Alarm screen (HMI)

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

6.1 Application faults

Variables:

TRCx000Data.OUT.

boApplicationError

u16ApplicationErrorID

u32Parameter1 (function/parameter result) (see table 6-2, 6-3)

u32Parameter2 (parameter number) (see Eltromat manual)

The following table shows FBTRCx000Backgr internal errors. (HMI: Application ErrorID).

Table 6-1 Application error messages

Error ID Description

3001 TcpIp: buffer overflow

3002 TcpIp: undefined header type received

3003 TcpIp: watchdog

3004 TcpIp: too many y data received

3005 TcpIp: received channel number out of range

3006 TcpIp: open client failed

3009 TcpIp: Unknown error number

3010 Calibration error

3020 parameter download: No valid Parameter number of Error of FBWriteDriveMultiParameter (see ErrorID)

3022 status update

3023 device info update

3024 TRC reset

3025 update gate position / ZeroToRefpos

3026 update gate width

3027 read TRC error information

3028 parameter download value out of limits

3029 write delay data

3030 WebWeb2 not possible in mode 20

3031 TRC Lifesignerror

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

The following table shows the errorID of the system function _writedDriveMultiParameter displayed in u32Parameter1 (HMI: “Para1”).

The function FCGetWriteDriveMPError of the LTRC3000 library reads out the errorID of the system function in “Para1” (and if available, the parameter number which causes the error in “Para2”).

If “Para2” is 0, a function internal error occurred (function result).

Table 6-2 function/parameter result of system function _writeDriveMultiParameter

Para1 Description

function result = function internal error

16#00007001 Must be repeated in the next program cycle. Initial call, initiation of writing of parameters okay (only when command is issued asynchronously).

16#00007002 Must be repeated in the next program cycle. Intermediate call, writing of parameters is still active (only when command is issued asynchronously).

16#00007003 Writing of parameters aborted.

16#FFFF8110 Internal error, job aborted. The sum of the lengths specified by the user exceeds the maximum transferable length.

16#FFFF8111 Internal error, job aborted. The length specified by the user does not match the length calculated from the data type and number of elements in the case of at least one parameter.

16#FFFF8112 Internal error, job aborted. A valid format could not be found for at least one parameter.

16#FFFF8190 Internal error, job aborted. Specified logical base address invalid: No assignment is available in SDBs, or there is no base address.

16#FFFF8191 Internal error, job aborted. The _writeDriveMultiParameter function cannot reach the specified logical base address.

16#FFFF8192 Internal error, job aborted. Error in response identifier.

16#FFFF8193 Internal error, job aborted. The number of parameters to be read is not permissible.

16#FFFF819D Internal error, job aborted. An I slave/I device interface is unable to issue a parameter job to the higher-level master/controller.

16#FFFF819E Internal error, job aborted. Attempt to abort a non-active function.

16#FFFF819F Internal error, job aborted. Function not executable.

16#FFFF81C3 Error, can be repeated in the next program cycle. Required resources are presently occupied:

- In the _writeDriveMultiParameter function

- In the module

16#FFFF81C5 Error, can be repeated in the next program cycle. Distributed I/O not available.

16#FFFF81C7 Error, can be repeated in the next program cycle. Another parameter job has already been issued to the DP station.

- based on the user program

- from a system-internal component

16#FFFF81CF Error, can be repeated in the next program cycle. Another parameter job call is currently active under this ‘commandId’.


16#FFFF8291 Internal error, job aborted. The _writeDriveMultiParameter function cannot reach the specified logical base address.

16#FFFF82A2 Error during data set transfer, job aborted. Error in Layer2:

- Station failure

- Timeout

16#FFFF82A3 Error during data set transfer, job aborted. Error in user interface/user:

- Protocol error

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Para1 Description

- Station failure

- Timeout

16#FFFF82B0 Error during data set transfer, job aborted. Parameter jobs are not supported by the addressed module.

16#FFFF82B2 Error during data set transfer, job aborted. Module reports access to an invalid slot/subslot.

16#FFFF82B5 Error during data set transfer, can be repeated in the next program cycle. The system function cannot be executed due to an internal operating state of the module.

16#FFFF82B7 Error during data set transfer, job aborted. The job could not be dispatched due to a job error.

16#FFFF82C1 Error during data set transfer, command can be repeated immediately. Data of the preceding write job on the module for the same data set has not yet been processed by the module.

16#FFFF82C2 Error during data set transfer, command can be repeated immediately. The module is currently executing the maximum possible jobs for one CPU.

16#FFFF82C3 Error during data set transfer, command can be repeated immediately. Required resources are presently occupied: - In the _writeRecord function – In the module

16#FFFF82C4 Error during data set transfer, command can be repeated immediately. Communication errors:

- Parity error – SW Ready not set – Error in block length administration

- Checksum error on CPU side – Checksum error on module side

16#FFFF82C5 Error during data set transfer, can be repeated in the next program cycle.

Distributed I/O not available.

16#FFFF82C6 Error during data set transfer, can be repeated in the next program cycle.

Data record transfer has been aborted due to priority class abort (restart or background).

Parameter result = parameter specific error

16#FFFF8000 Parameter error, job aborted. Access to a non-existent parameter.

16#FFFF8001 Parameter error, job aborted. Change access to a parameter that cannot be modified.

16#FFFF8002 Parameter error, job aborted. Change access with value outside value limits.

16#FFFF8003 Parameter error, job aborted. Access to a non-existent subindex.

16#FFFF8004 Parameter error, job aborted. Access with subindex to non-indexed parameter (not an array parameter).

16#FFFF8005 Parameter error, job aborted. Change access with value that does not match the parameter data type.

16#FFFF8006 Parameter error, job aborted. Modification access with value other than 0 where this is not allowed.

16#FFFF800B Parameter error, job aborted. Change access without parameter change rights.

16#FFFF8011 Parameter error, job aborted. Job cannot be executed due to operating state.

16#FFFF8014 Parameter error, job aborted. Modification access with value that is within value limits, but illegal for some other sustainable reason (parameter with defined individual values).

16#FFFF8016 Parameter error, job aborted. Illegal or unsupported value for attribute, number of elements, parameter number, or subindex, or a combination of these.

16#FFFF8017 Parameter error, job aborted. Illegal format.

16#FFFF8018 Parameter error, job aborted. Number of values of parameter data does not match the number of elements in the parameter address.

16#FFFF8019 Parameter error, job aborted. Access to a non-existing axis or an invalid drive object.

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

The following table shows the errorID of the system function _readDriveMultiParameter displayed in u32Parameter1 (HMI: “Para1”).

The function FCGetReadDriveMPError of the LTRC3000 library reads out the errorID of the system function in “Para1” (and if available, the parameter number which causes the error in “Para2”).

If “Para2” is 0, an function internal error occurred (function result).

Table 6-3 function/parameter result of system function _readDriveMultiParameter

Para1 Description

function result = function internal error

16#00007001 Must be repeated in the next program cycle. Initial call, initiation of reading of parameters okay (only when command is issued asynchronously).

16#00007002 Must be repeated in the next program cycle. Intermediate call, reading of parameter description

is still active (only when command is issued asynchronously).

16#00007003 Reading of parameters aborted.


16#FFFF8191 Internal error, job aborted. The _readDriveMultiParameter function cannot reach the specified logical base address.

16#FFFF8192 Internal error, job aborted. Error in response identifier.

16#FFFF8193 Internal error, job aborted. The number of parameters to be read is not permissible.

16#FFFF819D Internal error, job aborted. An I slave/I device interface is unable to issue a parameter job to the higher-level master/controller.

16#FFFF819E Internal error, job aborted. Attempt to abort a non-active function.

16#FFFF819F Internal error, job aborted. Function not executable.

16#FFFF81C3 Error, can be repeated in the next program cycle. Required resources are presently occupied:

- In the _readDriveMultiParameter function

- In the module

16#FFFF81C5 Error, can be repeated in the next program cycle. Distributed I/O not available.

16#FFFF81C7 Error, can be repeated in the next program cycle. Another parameter job has already been issued to the DP station.

- based on the user program

- from a system-internal component

16#FFFF81CF Error, can be repeated in the next program cycle. Another parameter job call is currently active under this ‘commandId’.


16#FFFF8291 Internal error, job aborted. The _readDriveMultiParameter function cannot reach the specified logical base address.

16#FFFF82A2 Error during data set transfer, job aborted. Error in Layer2: - Station failure – Timeout

16#FFFF82A3 Error during data set transfer, job aborted. Error in user interface/user:

- Protocol error – Station failure

- Timeout

16#FFFF82B0 Error during data set transfer, job aborted. Parameter jobs are not supported by the addressed module.

16#FFFF82B2 Error during data set transfer, job aborted. Module reports access to an invalid slot/subslot.

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Para1 Description

16#FFFF82B5 Error during data set transfer, can be repeated in the next program cycle. The system function cannot be executed due to an internal operating state of the module.

16#FFFF82B7 Error during data set transfer, job aborted. The job could not be dispatched due to a job error.

16#FFFF82C0 Error during data set transfer, can be repeated in the next program cycle. The module is feeding the data record, but the module does not yet have any read data.

16#FFFF82C2 Error during data set transfer, command can be repeated immediately. The module is currently executing the maximum possible jobs for one CPU.

16#FFFF82C3 Error during data set transfer, command can be repeated immediately. Required resources are

presently occupied: - In the _readRecord function – In the module

16#FFFF82C4 Error during data set transfer, command can be repeated immediately. Communication errors:

- Parity error – SW Ready not set

- Error in block length administration – Checksum error on CPU side – Checksum error on module side

16#FFFF82C5 Error during data set transfer, Can be repeated in the next program cycle. Distributed I/O not available.

16#FFFF82C5 Error during data set transfer, Can be repeated in the next program cycle. Distributed I/O not available.

Parameter result = parameter specific error

16#FFFF8000 Parameter error, job aborted. Access to a non-existent parameter.

16#FFFF8003 Parameter error, job aborted. Access to a non-existent subindex.

16#FFFF8004 Parameter error, job aborted. Access with subindex to non-indexed parameter (not an array parameter).

16#FFFF800B Parameter error, job aborted. Change access without parameter change rights.

16#FFFF8015 Parameter error, job aborted. The length of the current response exceeds the maximum transferable length.

16#FFFF8016 Parameter error, job aborted. Illegal or unsupported value for attribute, number of elements, parameter number, or subindex, or a combination of these.

16#FFFF8017 Parameter error, job aborted. Illegal or unsupported parameter format.

16#FFFF8019 Parameter error, job aborted. Access to a non-existing axis or an invalid drive object.

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

6.2 Sensor faults

sStdcIO.out variables:

boTRCWarning

The sStdcIO.out variable boTRCWarning indicates a sensor warning (warning in service or maintenance parameter) which is transferred in status word 1. Acknowledge is not necessary!

boTRCError

u16TRCErrorID

Table 6-4 TRC3000 error messages

Error ID Description

1100 Measuring unit fault

1200 FPGA boot error

1300 Internal software error

1301 Internal FPGA error

1400 Extension unit error – no or wrong extension unit detected

1500 Communication error

1501 Sign of life error

2100 NV data memory error – failure in flash memory

2200 Parameter error

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

6.3 DRD faults

Table 6-5 Register controller error messages

Table 6-6

Error ID

Error message Corrective

5002 lineSpeedOverflow Machine velocity is too high.

Input r32LineSpeed < LREGCTRL_CONST_LINE_SPEED_MAX = 100000 mm/s

5003 lineSpeedUnderflow Machine velocity is too low.

Input r32LineSpeed > LREGCTRL_CONST_LINE_SPEED_MIN = 0.0 mm/s

5004 webLengthOverflow Weblength is too long.

Input r64WebLength < LREGCTRL_CONST_WEB_LENGTH_MAX = 100000 mm

5005 webLengthUnderflow Weblength is too short.

R64WebLength > LREGCTRL_CONST_WEB_LENGTH_MIN = 100 mm

5006 sampleTimeOverflow Sample time is too big.

R64SampleTime < LREGCTRL_CONST_SAMPLE_TIME_MAX = 4 s

5007 sampleTimeUnderflow Sample time is too small.

R64SampleTime > LREGCTRL_CONST_SAMPLE_TIME_MIN = 0.0005 s

5008 DcpTimeUnderflow Sample time too big or time constant too small.

Try following inputs:

Increase r64rateInputT

Increase r64Weblength

Decrease r32LineSpeed

Decrease r64SampleTime

5009 modeInvalidMN Invalid decoupling mode.

Switch input eDecouplingMode to…

Static

Dynamic1

Dynamic2

Direct

5010 actuatorInvalid Invalid actuator chosen.

Switch input eActuator to…

compensator

printingCylMd

5011 accelOffsetOverflow shiftMode “accelMode or “speedAccelMode””: Acceleration register offset too big.

Input r32AccelOffset > LREGCTRL_CONST_MAX_ACCEL_OFFSET = 1000 mm

5012 accelOffsetUnderflow shiftMode “accelMode” or “speedAccelMode”: Acceleration register offset too small.

Input r32AccelOffset < LREGCTRL_CONST_MIN_ACCEL_OFFSET = - 1000 mm

5013 offsetOverflow shiftMode “speedMode” or “speedAccelMode”: Speed register offset too big.

One element of input ar32SpeedOffset > LREGCTRL_CONST_MAX_SHIFT_OFFSET = 300 mm

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Error ID


5014 offsetUnderflow shiftMode “speedMode” or “speedAccelMode”: Speed register offset too small.

One element of input ar32SpeedOffset < LREGCTRL_CONST_MIN_SHIFT_OFFSET = - 300 mm

5015 speedAdaptOverflow shiftMode “speedMode” or “speedAccelMode”: Speed adaption too big.

Input ar32SpeedOffset > LREGCTRL_CONST_MAX_SPEED_ADAPT = 3

5016 speedAdaptUnderflow shiftMode “speedMode” or “speedAccelMode”: Speed adaption too small.

Input ar32SpeedOffset < LREGCTRL_CONST_MIN_SPEED_ADAPT = 1/3

5017 accelAdaptOverflow shiftMode “accelMode” or “speedAccelMode”: Acceleration adaption too big.

Input r32AccelAdapt > LREGCTRL_CONST_MAX_ACCEL_ADAPT = 10

5018 accelAdaptUnderflow shiftMode “accelMode” or “speedAccelMode”: Acceleration adaption too big.

Input r32AccelAdapt < LREGCTRL_CONST_MIN_ACCEL_ADAPT = 1/10

5019 speedLevelOverflow shiftMode “speedMode” or “speedAccelMode”: Speed level too big.

One element of input ar32SpeedLevel > LREGCTRL_CONST_MAX_SPEED_LEVEL = 3000 m/min

5020 speedLevelUnderflow shiftMode “speedMode” or “speedAccelMode”: Speed level too small.

One element of input ar32SpeedLevel < LREGCTRL_CONST_MIN_SPEED_LEVEL = 0.1 m/min

5021 speedLevelStepSize shiftMode “speedMode” or “speedAccelMode”: Step size between two sequent speed level is too small.

One element of input ar32SpeedLevel[index + 1] < ar32SpeedLevel[index] + LREGCTRL_CONST_MIN_SPEED_STEP

LREGCTRL_CONST_MIN_SPEED_STEP = 0.1 m/min

5022 accelTimeUnderflow shiftMode “accelMode” or “speedAccelMode”: Sample time too big or time constant acceleration mode too small.


Increase r32AccelTimeAdapt

Set r32AccelTimeAdapt = 0 (deactivates delay)



Decrease r32LineSpeed

5023 accelTimeAdaptOverflow shiftMode “accelMode” or “speedAccelMode”: Acceleration time constant too big.

Input r32AccelTimeAdapt > LREGCTRL_CONST_MAX_ACCEL_TIME_ADAPT = 20

5024 accelTimeAdaptUnderflow

shiftMode “accelMode” or “speedAccelMode”: Acceleration time constant too small.

Input r32AccelTimeAdapt < LREGCTRL_CONST_MIN_ACCEL_TIME_ADAPT = 0

5025 gridPointsOverflow shiftMode “speedMode” or “speedAccelMode”: Too many grid points.

Input u8GridPoints > LREGCTRL_CONST_MAX_GRID_POINTS = 8

5026 gridPointsUnderflow shiftMode “speedMode” or “speedAccelMode”: Too less grid points.

Input u8GridPoints < LREGCTRL_CONST_MIN_GRID_POINTS = 1

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

Error ID


5027 accelLevelOverflow shiftMode “accelMode” or “speedAccelMode”: Acceleration level too big.

Input r32AccelLevel > LREGCTRL_CONST_MAX_ACCEL_LEVEL = 100 m/s²

5028 accelLevelUnderflow shiftMode “accelMode” or “speedAccelMode”: Acceleration level too small.

Input r32AccelLevel > LREGCTRL_CONST_MIN_ACCEL_LEVEL = 100 m/s²

5029 axisConfigError No axis is assigned.

Input toName = TO#NIL

5030 formatUnderflow Format length is too short.

Input r64FormatLengthMA < LREGCTRL_CONST_MIN_FORMAT = 300 mm

5031 formatOverflow Format length is too long.

Input r64FormatLengthMA > LREGCTRL_CONST_MAX_FORMAT = 5000 mm

5032 speedLevelMonotony shiftMode “speedMode” or “speedAccelMode”: Speed level is not monotonically increasing.

One element of input ar32SpeedLevel[index + 1] < ar32SpeedLevel[index]

5033 resetActive Reset is active.

Input boReset = TRUE

5034 speedTimeAdaptOverflow

shiftMode “speedMode” or “speedAccelMode”: Speed time constant too big.

Input r32SpeedTimeAdapt > LREGCTRL_CONST_MAX_SPEED_TIME_ADAPT = 20

5035 speedTimeAdaptUnderflow

shiftMode “speedMode” or “speedAccelMode”: Speed time constant too small.

Input r32SpeedTimeAdapt < LREGCTRL_CONST_MIN_SPEED_TIME_ADAPT = 0

5036 speedTimeUnderflow shiftMode “speedMode” or “speedAccelMode”: Sample time too big or time constant speed mode too small.


Increase r32SpeedTimeAdapt

Set r32SpeedTimeAdapt = 0 (deactivates delay)



5037 notReadyLowSpeed Speed too low to work correctly.

5038 maxVeloTooLow Maximum velocity is smaller than 0.0. Use a sensible value. Standard value = 100.0 mm/s

5039 minVeloTooHigh Minimum velocity is larger than 0.0: Use a sensible value. Standard value = - 100 mm/s.

5040 CompensatorAndStaticInvalid

If you want to use compensator as actuator: Do not select static as decoupling mode.

If you want to use the static mode: Select printingCylMd as actuator.

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

6.4 Insetting faults

NOTE A list of all error and warning messages can be found in the respective Add-On documentation.

6.5 Lifesign error

Variable TRCx000Data.STDcIO.OUT.boLifesignError:

In the sensor control word and status word there are respectively 4 bits (bit 12..15)

to observe the communication between sensor and controller (SIMOTION). This is

realized by a counter (Sing-Of-Life Counter).

In case of communication timeout the error bit

TRCx000Data.STDcIO.OUT.boLifesignError becomes TRUE.

In the error screen of HMI the life sign error box becomes red.

The number of LifesignErrors, which are tolerated before an error appears, can be set:

TRCx000Data.STDcIO.IN.i16LifesignTolerance

The default setting of the variable is 1. The value range is from 0 .. 100.

NOTICE A lifesign error causes the disabling of the register controller!

To enable the register controller automatically after the connection is established again, use

TRCx000Data.STDcIO.IN.boLifeSignAutoAckn := TRUE;

If the register controller is allowed to be enabled again only after faultacknowledge, use

TRCx000Data.STDcIO.IN.boLifeSignAutoAckn := FALSE;

6 Fault messages


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

6.6 Register FB error messages

Variables:

RegCtrlIO.OUT.sRegOutLR.boFBRegCtrlError

RegCtrlIO.OUT.sRegOutLR.u16FBRegCtrlErrorID

RegCtrlIO.OUT.sRegOutSR.boFBRegCtrlError

RegCtrlIO.OUT.sRegOutSR.boFBRegCtrlError

Table 6-7 Register controller error messages

Error ID Description b32DiagStatus

2050 T_A out of range bit 0

2051 sPu.v_setpoint > CONST_V_MAX bit 1

2052 sPu.s_web_Length out of range bit 2

2053 T_mot out of range bit 3

2054 sPu.s_format out of range bit 4

2055 r32TIWebWeb out of range bit 5

2056 transport delay error bit 6

2057 input or output filter error bit 7

2058 controller disabled: amplitude x1_k exceeds bounds bit 8

2059 controller disabled: amplitude x3_k exceeds bounds bit 9

2060 Prediction output invalid x4 bit 10

2061 fast rate differentiation of predictor output error bit 11

2062 paramError OR oFiltOutputLimited OR

iFiltOutputLimited

bit 12

2063 Output filter invalid value x6 bit 13

2064 warning integrator overflow bit 16

2065 warning buffer size (transport delay) bit 17

2066 warning negative time (transport delay) bit 18

2067 warning initial ramp up bit 19

2068 output filter k_outLtd: x5 is out of range and limited. Bit 20

2069 output P-controller k_intLtd: x_int out of range and limited bit 21

2070 requested ramp time is active after controller enable bit 24

2071 predictEnabled bit 25

2072 DSRP output limited by maxspeed bit 26

2073 r32damping_a out of range and limited bit 27

2074 u8FilterDepth out of range and limited bit 28

2075 u8FilterDepth for fast reaction out of range and limited bit 29

7 Sensor calibration


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

7 Sensor calibration

7.1 Calibration of TRC3000 (white adjustment)

Before using the TRC3000 for printing mark detection, the sensor needs to be

calibrated with a special gauge. The white adjustment should be repeated after

several hours of operation. Lighting wear can be compensated and a fault free

operation is achievable by doing this.

The calibration can be executed on the “config data” HMI screen.

To start the calibration the respective TRC need to be selected in the drop down menu.

After starting the calibration the TRC mode should be change to calibration and the calibration status shows the user what to do (use reference box, remove reference box etc.).

NOTICE A detailed instruction how to calibrate the TRC3000 sensor can be found in the Eltromat user manual “RSH_PN__BA_R1_0_en” in chapter “Adjustment of the register sensor”!

After calibration the TRC changes back to operation state automatically.

7.2 Calibration of TRC7000

The calibration of the TRC7000 is already done by factory and normally not

necessary to repeat.

The calibration can be executed on the “config data” HMI screen.

To start the calibration the respective TRC need to be selected in the drop down menu.

After starting the calibration the TRC mode should be change to calibration and the calibration status shows the user what to do (use reference box, remove reference box etc.).

NOTICE A detailed instruction how to calibrate the TRC7000 camera can be found in the Eltromat user manual “RSC_DI__BA_R1_0_1_en” in chapter “Adjustment of the measuring camera”!

After calibration the TRC changes back to operation state automatically.

8 TRC HTML interface


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

8 TRC HTML interface The TRC3000 and the TRC7000 provide a HTML access via browser and device IP-address.

Figure 8-1: HTML access start mask

Start

Contains important hardware and software information (e.g. Software-Package, MAC-Address, Serial-Number, etc.)

Configuration

On this page all important network parameters of the sensor are displayed.

With the button “Reset Factory Settings” the displayed parameters can be reset to factory settings. The changes are applied after a reboot of the sensor.

With the button “Reset FSH-Sensor” (hardware reset) a reboot will be performed.

Firmware

Sensor firmware upgrade can be done from here.

CAUTION

Do not switch off the register sensor RSH-PN during the firmware update. Otherwise the register sensor might be damaged.

NOTE For more information see Eltromat documentation.

9 Related literature


S

iem

en

s A

G 2

01

6 A

ll ri

gh

ts r

ese

rve

d

9 Related literature

Table 9-1

Topic

\1\ Siemens Industry Online Support

https://support.industry.siemens.com

\2\ Link to this entry


\3\ SIMOTION Print Standard


10 History

Table 10-1

Version Date Modifications

Version < V4.00 contains TRC3000 only!

V4.0.0 08/2016 TRC3000 and TRC7000 combined in one application

V4.0.1 09/2016 Description of Variables for external inching added to structure sHMI_RegCtrl_Command.IN;

Chapter 3.6 Necessary settings for TRC7000 camera live image adapted, because new TRC7000 card files;

V4.1.0 10/2016 New variables added; Updates in HMI screenshots

11 Contact

Application Center

SIEMENS

Siemens AG

DF FA PMA APC

Frauenauracher Str. 80

91056 Erlangen

Fax: 09131-98-1297

mailto: [email protected]

https://support.industry.siemens.com/



mailto:[email protected]

Documents

Application example 10/2016 Print Standard Add-On TRC3000 … · 2016-12-12 · Warranty and liability Print Standard Add-On TRC3000 and TRC7000 Entry-ID: 64896729 , V4.1.0, 10/2016