User Manual Flying Saw

SIMOTION Flying Saw V2.1

SIROT- ID: 37841424

 General Notes

SIMOTION Flying Saw SIROT- ID: 37841424

2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

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

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

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 General Notes

SIMOTION Flying Saw SIROT- ID: 37841424

General Notes

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

Warranty, liability and support

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Copyright Siemens AG 2014 All rights reserved

If the application is provided free of charge the following shall apply:

We shall not be liable for the information contained in this document.

Any and all further rights and remedies against Siemens AG for whatsoever legal reason, shall
be excluded; this shall refer in particular to claims for loss of production, loss of use, loss of
orders or profit and other direct, indirect or consequential damage.

The aforesaid shall not apply if liability is mandatory, e.g. in accordance with the Product
Liability Act, in cases of intent, gross negligence by directors and officers of Siemens AG or in
the case of willful hiding of a defect.

These limitations of liability shall also apply for the benefit of the Siemens AG's subcontractors,
suppliers, agents, directors, officers and employees.

This Contract shall be subject to German law if customer’s place of business is in Germany. If
customer’s place of business is outside of Germany the Contract shall be subject to Swiss law.
The application of the UN Convention on Contracts for the International Sale of Goods (CISG)
shall be excluded.

If the application is provided in return for payment the alternative shall apply which fits the
respective business case:

/ Alternative 1: (internal business)

If not explicitly stated otherwise below, the "Terms and Conditions for Deliveries and Services
for Siemens Internal Transactions", valid at the time of sale, are applicable.

/ Alternative 2: (domestic business of Siemens AG)

If not explicitly stated otherwise below, the "General License Conditions for Software Products
for Automation and Drives for Customers with a Seat or registered Office in Germany", valid at
the time of sale, are applicable.

/ Alternative 3: (direct export business of Siemens AG)

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 General Notes

SIMOTION Flying Saw SIROT- ID: 37841424

If not explicitly stated otherwise below, the "General License Conditions for Software Products
for Automation and Drives for Customers with a Seat or Registered Office outside of Germany",
valid at the time of sale, are applicable.

It is not permissible to transfer or copy these standard applications or excerpts of them in

unmodified form without first having prior explicit authorization from Siemens Industry Sector in
writing.

For questions regarding this application please contact us at the following e-mail address:
mailto:tech.team.motioncontrol@siemens.com

Qualified personnel
In the sense of this documentation qualified personnel are those who are
knowledgeable and qualified to mount/install, commission, operate and
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

service/maintain the products which are to be used. He or she must have the
Copyright Siemens AG 2014 All rights reserved

appropriate qualifications to carry-out these activities

e.g.:
Trained and authorized to energize and de-energize, ground and tag circuits
and equipment according to applicable safety standards.
Trained or instructed according to the latest safety standards in the care and
use of the appropriate safety equipment.
Trained in rendering first aid.
There is no explicit warning information in this documentation. However, reference
is made to warning information and instructions in the Operating Instructions for the
particular product.

Reference regarding export codes

AL: N
ECCN: N

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 Foreword

SIMOTION Flying Saw SIROT- ID: 37841424

Foreword
Standard SIMOTION application
A standard SIMOTION application comprises the following components:
One or several software objects or code blocks with defined interfaces that can
be simply integrated into other software projects – without requiring any
significant programming – in order to fulfill a precisely defined technology task
there. (Core functions)
A software project based on a demonstration case to show the functionality
and possible uses of the standard application - including the associated
WinCCflex screen for demonstration. (Demonstration project)
A document to describe the functionality, background information and handling
of the standard application. Further, its use as demonstration model is
explained. (Description)

Document structure
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The documentation of this application is sub-divided into the following main section:
Copyright Siemens AG 2014 All rights reserved

Section Description Note

In the first section you can obtain an overview of
this standard application. This Section explains
the prerequisites and the objective when using
Prerequisites and objectives this application.
Some of the uses of this standard application are
explained as well as situations where this
application cannot be used.
Section “Application example as demosystem” is
interesting if you wish to use this standard
application for demonstration purposes.
The application example as
demosystem Here, you are provided with information about
how you can download this application from your
PC/PG to the demonstration case step-by-step
and how it then used.
Section “Integrating the core function” provides
you with all of the necessary steps to integrate
the core functions of the standard application into
your user project.
Integrating the core Preparations and parameterizing operations are
functions explained. Further, you are also told how to
integrate the core functions into your application
step-by-step.
In addition, tips are provided on how to use the
core functions.
Section “Program description” is interesting if you
Program description of the
wish to expand/adapt the functionality of the core
technology template
functions provided for your particular application.

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SIMOTION Flying Saw SIROT- ID: 37841424

Section “Appendix” provides you with detailed

information including a detailed fault/error
description, a description of a test program for the
Appendix core standard application functions as well as
references. A feedback sheet is also provided
which you can use to give us your comments and
suggestions on this document.
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 Index of contents

SIMOTION Flying Saw SIROT- ID: 37841424

Index of contents
Prerequisites and objectives .................................................................................... 10
1 Basic information ................................................................................ 11
1.1 Prerequisites ...................................................................................... 11
1.1.1 Target group ....................................................................................... 11
1.1.2 Knowledge base ................................................................................. 11
1.1.3 Technical environment ....................................................................... 11
1.2 Objective and purpose of this standard application ........................... 11
1.2.1 Task description ................................................................................. 11
1.2.2 Solution using the standard application SIMOTION Flying Saw ........ 12
1.2.3 Advantages of the standard application SIMOTION Flying Saw ....... 13
1.3 Components included in the standard application ............................. 14
2 Areas of use ....................................................................................... 15
2.1 Applications ........................................................................................ 15
2.1.1 Available controls ............................................................................... 15
2.1.2 Tasks that can be implemented using the core functions .................. 15
2.1.3 Properties and features of the core “flying saw” functions ................. 16
2.2 Principle of operation.......................................................................... 17
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2.2.1 Possibilities for determination the cutposition .................................... 17

Copyright Siemens AG 2014 All rights reserved

CP_CALCULATED............................................................................. 17
CP_MEASURED ................................................................................ 18
2.2.2 Synchronizing ..................................................................................... 19
2.3 Application environment ..................................................................... 21
2.3.1 Real Machine (sUsersInterface.boRealMachine = TRUE!) ............... 21
2.3.2 Demo application (sUsersInterface.boRealMachine = FALSE!) ........ 22
3 Structure and function ........................................................................ 23
3.1 Design of the "flying saw" ................................................................... 23
3.1.1 General design ................................................................................... 23
3.2 Operating modes of the application SIMOTION Flying Saw ............. 24
The application example as demonstration system .............................................. 26
4 Installing the hardware and software ................................................. 27
4.1 Regarding your safety ........................................................................ 27
4.1.1 Safety information and instructions .................................................... 27
4.1.2 Responsibilities of the operator .......................................................... 28
4.2 Hardware structure and mounting/installation .................................... 29
4.3 Installing the standard SIEMENS software ........................................ 31
4.4 Downloading the user program and parameterizing the drive in
the SIMOTION D demonstration case ............................................... 31
4.4.1 De-archiving the SIMOTION project .................................................. 31
4.4.2 Resetting SIMOTION D435 to the factory settings ............................ 31
4.4.3 Setting the PG/PC interface ............................................................... 31
4.4.4 Setting the Ethernet address of the PG/PC ....................................... 32
4.4.5 Loading the hardware configuration after the factory setting ............. 32
4.4.6 Loading the SIMOTION project of the standard application .............. 33
5 Operator control of the application example ...................................... 34
5.1 Structure overview .............................................................................. 35
5.2 Brief instructions ................................................................................. 36
6 Operatoration of the TestFB application ............................................ 42
6.1 Structure overview .............................................................................. 43
6.2 Brief instructions ................................................................................. 44

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SIMOTION Flying Saw SIROT- ID: 37841424

Integration of the core functions .............................................................................. 47

7 Integration in the user program .......................................................... 48
7.1 Importing the source code .................................................................. 48
7.1.1 Copying from the application example ............................................... 48
7.1.2 Intergration via XML import ................................................................ 49
7.1.3 Linking the flying saw functionality ..................................................... 50
7.2 Technology objects ............................................................................ 53
7.2.1 Necessary technology objects and synchronism
interconnections ................................................................................. 53
7.2.2 Interconnection of technology objects ................................................ 54
7.3 Integrating the core functions of the application SIMOTION
Flying Saw .......................................................................................... 57
7.3.1 Parameterizing in the startup task ...................................................... 57
7.3.2 Calling FBFlyingSaw in the user program .......................................... 57
7.3.3 Global Variables ................................................................................. 58
Program Description ................................................................................................. 59
8 Program Description........................................................................... 60
8.1 Information and warnings ................................................................... 60
8.2 Type of Data ....................................................................................... 60
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8.2.1 Overview............................................................................................. 60
8.2.2 Enumeration types ............................................................................. 61
8.2.3 Data Structures .................................................................................. 62
sFlyingSawInfoType ........................................................................... 66
8.3 FBFlyingSaw ...................................................................................... 69
8.3.1 Block name ......................................................................................... 69
8.3.2 Task .................................................................................................... 69
8.3.3 Integration in the run-time system ...................................................... 69
8.3.4 Graphic representation of the block ................................................... 70
8.3.5 Block parameters ............................................................................... 71
Input / output parameters ................................................................... 71
Output parameters ............................................................................. 71
8.3.6 Functionality ....................................................................................... 73
Checking the input parameters and parameterization of the
technology settings that are absolutely required (mandatory)75
Axis monitoring ................................................................................... 75
8.3.7 Error messages .................................................................................. 76
8.4 FBCutPositionDetection ..................................................................... 79
8.4.1 Block name ......................................................................................... 79
8.4.2 Task .................................................................................................... 79
8.4.3 Integration in the run-time system ...................................................... 79
8.4.4 Graphic representation of the block ................................................... 80
8.4.5 Block parameters ............................................................................... 80
8.4.6 Functionality ....................................................................................... 81
CP-MEASURED ................................................................................. 81
CP-CALCULATED ............................................................................. 82
8.4.7 Error messages .................................................................................. 82
8.5 Measured value memory system blocks used in the flying saw
application .......................................................................................... 83
8.5.1 Deleting and resetting the measured value memory
FBCutPositionBufferReset ................................................................. 83
8.5.2 Entries in the measured value memory FBCutPositionBufferIn ......... 84
8.5.3 Reading out the measured value memory
FBCutPositionBufferRead .................................................................. 85

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SIMOTION Flying Saw SIROT- ID: 37841424

8.5.4 Exporting from the measured value memory

FBCutPositionBufferOut ..................................................................... 87
Attachment ................................................................................................................. 88
9 Description of the State Changes ...................................................... 88
10 General information on the application .............................................. 92
10.1 Scope of supply .................................................................................. 92
10.2 Revisions/Author ................................................................................ 92
11 Contact partner ................................................................................... 93
12 Please help us to become even better ............................................... 94
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 Prerequisites and objectives
Basic information

SIMOTION Flying Saw SIROT- ID: 37841424

Prerequisites and objectives

Content
Section A will gives a detailed overview about each implemented function or
function block which is ready to apply.
The application presented in this manual provides some use-cases. Further, some
applications will be listed for which this standard application cannot be used. In
addition, the performance limits of this standard application will be shown.

Objective
The part of this document should provide the user with the following information:
The objective and purpose of this standard application
List several applications
Indicate the performance limits of this standard application.

Subjects discussed
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Chap. Title Contents

Copyright Siemens AG 2014 All rights reserved

1 Basic information The necessary prerequisites to use the standard “flying saw”
application.
The use of this application.
Software components and code blocks of the standard “flying saw”
application.
2 Uses Tasks and properties of the core functions of the standard “flying
saw” application
Exclusions and restrictions
Hardware components required
3 Structure and function Type of design and physical quantities for which the “flying saw”
core function can be used.
Type of cams that the “flying saw” core functions calculate and
used.
Operating states at the FlyingSaw FB.

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 Prerequisites and objectives
Basic information

SIMOTION Flying Saw SIROT- ID: 37841424

1 Basic information
1.1 Prerequisites
1.1.1 Target group

The Converting Toolbox standard application “Flying Saw” is intended to provide

SIMOTION programmers and users with help when engineering and programming
flying saw machinery.

1.1.2 Knowledge base

To use this standard application, please make yourself familiar with SCOUT,
technology objects and technology function calls in SIMOTION.
This document does not discuss these a.m. topics and limits itself to provide
information and data how to use this standard application.
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1.1.3 Technical environment

This Flying Saw application can be used unmodified, only at a SIMOTION D- and
SINAMICS-demonstration case.

1.2 Objective and purpose of this standard application

1.2.1 Task description

A continuous web - fed with an infeed unit - shall be cut into identical parts and
sections. Preventing any impacts on the cut the cutting equipment must be
synchronized on the line speed of the web. This allows the web to be cut “on the
fly”.

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Basic information

SIMOTION Flying Saw SIROT- ID: 37841424

Why processing / machining “on the fly”?

"On the fly" processing / machining is required if:
Stopping the material web due to sub-processes which would lead to quality
loss, increased waste or lower productivity. (e.g. extrusion line)
It is impossible to stop the material web because associated deceleration- or
acceleration-forces cannot be controlled.
The individual processing / machining steps are too different so that a common
processing step would take too much time and therefore would make the
process ineffective.

Principle design of a "flying saw"

The material is fed-in through a draw unit with a constant velocity.
The position of the cut on the material web is either detected with a print mark
sensor or an adjustable length setpoint is given by the machine controller. At the
same time the synchronous position is defined, wherefrom the cutting equipment
will match with the material speed and the cutting sequence can be started. After
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Copyright Siemens AG 2014 All rights reserved

cutting has been completed, the cutting equipment moves back into start position
where it is waiting for the next cutting position.

Fig. 1-1: Principle of operation of the flying saw

Sensor Starting position

Drive of flying saw

Web drive
or
measuring system

1.2.2 Solution using the standard application SIMOTION Flying Saw

The SIMOTION Flying Saw application introduced in this document helps the user
to meet the assigned requirements for developing a flying saw solution as quickly
as possible.

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Basic information

SIMOTION Flying Saw SIROT- ID: 37841424

The standard application includes a function block which controls the flying saw
and implements the motion control part via parameters corresponding to the
particular application.
The user program only has to control the material feed and to supply the core
function with the correct parameters.

Additional function of the standard application

Furthermore the standard application provides the optional feature to create a gap
with the cutting equipment between the cutted pieces
This function can be activated by setting parameters in the core function.

1.2.3 Advantages of the standard application SIMOTION Flying Saw

The SIMOTION Flying Saw application offers the following advantages:

Quick programming
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The standard application SIMOTION Flying Saw enables simple and quick
implementation of flying saw functionalities.
The core functions provided in the standard application can be copied into the
user’s application. Addional and necessary engineering steps will be explained in
this maual.

Automatic motion control

Using the technology functions of SIMOTION the core motion control functions of
the standard application can be realized The user only programs an execution
sequence which corresponds to required machine function.

Possibility of adaptation
The standard application contains all source codes and comments. Thus existing
core functions can quickly and simply be extended with customized functions.

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 Prerequisites and objectives
Basic information

SIMOTION Flying Saw SIROT- ID: 37841424

1.3 Components included in the standard application

The standard SIMOTION Flying Saw application is implemented as a library.
This library is part of the two projects which will be delivered with the standard
application software package.

The first project can be used for a demonstration machine, on a SIMOTION D

demonstration case and on a PC with WinCC Flexible 2008 for visualization.
The demonstration program fulfills the following tasks:
Operating mode manager for the complete (demonstration) machine
The control of the (demonstration) machine
The core functions of the flying saw functionality with absolute gearing
All of the machine functions that are relevant for the demonstration case
environment can be simulated
The (demonstration) machine is displayed on the WinCCflex screen
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Copyright Siemens AG 2014 All rights reserved

The second project (TestFB) enables the user to get quick access to the standard
application Flying Saw (FB-FlyingSaw) as well as obtaining know how for
commissioning and diagnosting the SIMOTION Flying Saw application.
The TestFB program is limited to the following tasks:
Presentation of FB FlyingSaw from a user’s point of view.
Controlling of all interfaces of the standard application.
Visualization of all relevant data of standard application.
Graphical display of synchronous operations.

In this way the core functions of the standard SIMOTION Flying Saw application
can quickly and simply be integrated into user projects.

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 Prerequisites and objectives
Areas of use

SIMOTION Flying Saw SIROT- ID: 37841424

2 Areas of use
2.1 Applications
2.1.1 Available controls

The standard SIMOTION Flying Saw application can be applied on any SIMOTION
control system.

2.1.2 Tasks that can be implemented using the core functions

The core functions provide interfaces for “on the fly” processes at:
Cutters
Perforators
Embossers
Sealers
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Copyright Siemens AG 2014 All rights reserved

Saws
Drilling machines
Painting machines
Stamping units

Definition In the following text, the flying saw term is used to represent all of the other
conceivable machine versions.
The term saw is used for all parts of the machine where direct contact is made to
the material when “cutting”.

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2.1.3 Properties and features of the core “flying saw” functions

The following properties and features were implemented and can be used in a user
program:
Precisely synchronizing at a specific position
The flying saw is synchronized with the material, so it reaches its velocity at a
parameterized position.
Flying axis
During cutting, the flying saw and the material move with the same velocity.
Adjustable rest position of the flying saw
The rest position of the flying saw can be adjusted between two cuts using a
parameter.
“Cutting” at a print mark
The cutting position is detected using a probe and print mark.
“Cutting” to length
The cut position is determined by comparing the length of material that has
been transported since the last cut with the selected cut length.
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Immediate cut
Copyright Siemens AG 2014 All rights reserved

A cut is initiated using an operator function, independent of the material length

that has been passed since the last cut.
Creating a gap
After a cut has been made, the cutted material will be moved with the cutting
equipment (saw) in the same direction of the material flow until a
parameterizable distance (gap) to the non-cutted material has been achieved.
After this step the cutting unit (saw) returns to its start position.
Gear factor
A gear factor can be set between the measurable material web velocity and the
material web velocity effective when cutting.

E.g. this feature is required when cutting wound paper cores (formers). The
wound material is skewed and therefore the measured material web velocity
(with a measuring wheel) does not match to the resulting core (former) velocity.

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2.2 Principle of operation

2.2.1 Possibilities for determination the cutposition

To determine the cutting postion the block has two different techniques:

CP_CALCULATED: Free cutting. Cut position is calculated by breaking

material web down by cutlength

CP_MEASURED: Detection of cutpositions at a measuring point

including storage of the measured values in a buffer

CAUTION The selection can be changed only when the application is switched off
and the material axis or leading value is switched off.
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CP_CALCULATED
As a matter of principle the material is allways cut at position „cutlength“.

Precondition:
– The material axis is generated as a linear axis without modulo length.

First cut at standstill:

– The material position is set to „cutlength“.
– After the cut carried out, the „cutlength“ will be subtracted from the actual
material position.
( The result is: position = 0 when material keeps at standstill!)

First cut out of the motion:

– The material position is set to a position < „cutlength“ according to the
synchronization requirements, so that the cutting equipment is
synchronized when the material position has reached the „cutLength“.
– After cut and positioning back to startpos is completed, the „cutlength“ will
be subtracted from the actual material position.

All further cuts:

– After the cut and positioning back to startpos has been completed, the
„cutlength“ will be subtracted from the actual material position.

”OnTheSpotCut“ is possible at any time when the Flying Saw (cutting equipment) is
at standstill.

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CP_MEASURED
The positions, onwhich the material shall be cut, are detected with a measuring
sensor in front of the Flying Saw then extrapolated to the synchronizing position
and memorized in a ring buffer. The Flying Saw application will read these position
values from the buffer, starts the synchronizing procedure and deletes the postion
values when the cut has been completed at that position.

Precondition:
– The material axis is generated as a linear axis with modulo length.
– A measuring sensor is mandatory when CPM_DETECTED is activated.
– A ring buffer system is activated.

CPM_DETECTED:
– A measuring sensor is mandatory!
– With the activation of the automatic mode the position of the master value
is set to position = 0.
– The application is waiting for the first measuring value, extrapolates this
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value to the synchronizing position and writes it into the ring buffer.
– Next the measuring system will be prepared for the next measuring value
by extrapolation with the cutlength and activated with a sensivity range.
– Once a measuring value is detected this value will be extrapolated to the
synchronizing position and written into the ring buffer.
– In case a measured value was not detected, an error counter will be
incremented. The last measured value will be increased by the cutlength
and extrapolated to the synchronizing position. This value will be written as
the new measured value into the ring buffer.
– After the next measured value has successfully been detected the error
counter will be set to zero. The counter overflow is monitored.

CPM_SIMULATED:
– No measuring sensor is necessary.
– With the activation of the automatic mode the position of the master value
will be set to position = 0.and automatically the first „measured value“ will
be extrapolated to the synchronizing position and written into the ring
buffer.
– All further „measured values“ will be determined by adding „cutlength“ and
extrapolation to the synchronizing position. The resulting value will be
written into the ring buffer.

“OnTheSpotCuts” to this effect are not possible. As all cuts have to be written into
the ring buffer, these values can only be executed after a certain material run time
which is determined by the synchronizing length and the distance between the
sensor and the Flying Saw.

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Areas of use

SIMOTION Flying Saw SIROT- ID: 37841424

2.2.2 Synchronizing

The user can select one of three synchronization types:

Time related
– BY_TIME

Position-related
– BY_LEADING_AXIS_VALUE
– SYMMETRIC

Time-related synchronization
Synchronization motion is obtained from the dynamic values parameterized at the
axis (velocity, acceleration and jerk).
With dynamic values big enough, the saw will wait for the start of the
synchronization motion and then accelerates to a velocity higher than the material
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velocity in order to catch-up with the synchronous point.

Copyright Siemens AG 2014 All rights reserved

Fig. 2-1: Synchronization with overshooting velocity

With dynamic values too small, the saw won’t be able to start and the error
message „Sync not possible“ appears.

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Position-related synchronization
The characteristic of the synchronizing movement is dependent on “SyncLength”
entered.
If SYMMETRIC is selected, the distance is dimensioned in that way that
symmetrical synchronization will be achieved without any overspeed. The cutting
equipment starts with the synchronization motion so that the synchronous point
only “catches-up” when the material velocity is reached. In this case the
“SyncLength” is set set to 2 x ( SyncPos – StartPos ).

Fig. 2-2: Synchronization with continuous acceleration

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Copyright Siemens AG 2014 All rights reserved

If the „SyncLength“ is selected too short, the saw will not be able to start and the
error message „Sync not possible“ appears.

If the „SyncLength“ is selected too long or the saw doesn’t reach startposition in
time, the saw will not be able to start and the error message „for Sync to late“
appears. In this case the saw will cut automatical the next reachable integer
multiple of cutlength. (e.g. cutlength = 400mm, the next possible cutlength will be
800mm, 1200mm …!) If the operator doesn’t agree with these lengths, he can use
the “on the spot cut” function.

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Areas of use

SIMOTION Flying Saw SIROT- ID: 37841424

2.3 Application environment

The standard application SIMOTION Flying Saw can be used at
– Real machine
– Demo application (e.g demo case or drives/motors without mechanical
coupling to a real machine in test environment!)

CAUTION The User has to select the real application environment by using the bit
sUsersInterface.boRealMachine.

2.3.1 Real Machine (sUsersInterface.boRealMachine = TRUE!)

Fig. 2-3: Application environment of the standard application SIMOTION Flying Saw
Real Machine
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

PG / PC

SIMOTION D

Encoder

Motor
Sensor

Material web

Motor

Encoder

A SIMOTION system can be used to control the material feed and the drive of the
flying saw. As an alternative, it is also possible to couple the flying saw via a
machine encoder.

In this environment modulo parameters of the flying saw axis will be deactivated.

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Areas of use

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2.3.2 Demo application (sUsersInterface.boRealMachine = FALSE!)

Fig. 2-4 Application environment of the standard application SIMOTION Flying Saw
Demo application

PG / PC

SIMOTION D

Encoder

Material web Motor

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Copyright Siemens AG 2014 All rights reserved

Sensor

Motor

Encoder

In this environment the FlyingSaw axis will be configured as a modulo axis with:
modulo length = EndPos + 500.0
startposition = – (distance to sensor +50.0).

Thereby at the demo environment no homing of the FlyingSaw axis is.required.

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Structure and function

SIMOTION Flying Saw SIROT- ID: 37841424

3 Structure and function

3.1 Design of the "flying saw"
3.1.1 General design

The bases of the flying saw application for example consists of a spindle axis, on
which the cutting unit is mounted.
The following physical variables of the flying saw are in use (see white boxes):

Fig 3-1 Physical variables of the application Flying Saw

Startposition Synchronous position Synchronous range end

(Synchronous range)
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Copyright Siemens AG 2014 All rights reserved

Sensor

Synchronous range

Distance to sensor Axis Zero Reversal point

position

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Structure and function

SIMOTION Flying Saw SIROT- ID: 37841424

Table 3-1: Explanation of the parameterizable physical quantities

Physical quantity Description
Distance to Sensor Distance between the axis zero point of the flying saw and the sensor to detect
sUsersInterface. the material and print mark
r64DistanceToSensor
[mm]
Startposition Start position of the cutting unit referred to the axis zero point of the flying saw.
sUsersInterface.
r64StartPos
[mm]
Synchronous position Position at which the cutting unit reaches the specified material position and
sUsersInterface. material velocity. Starting point of the synchronous range
r64SyncPos
[mm]
Synchronous range end End of the synchronous range. If cutting has still not been completed at this
sUsersInterface. position, then the cutting is interrupted.
r64EndSyncPos
[mm]
Reversal point End point of the traversing range of the flying saw (e.g. software limit switch!)
sUsersInterface.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

r64EndPos
Copyright Siemens AG 2014 All rights reserved

[mm]

Synchronous range
The synchronous range and therefore the cutting range are located between the
synchronous position (sUsersInterface.r64SyncPos) and synchronous range end
(sUsersInterface.r64EndSyncPos).

3.2 Operating modes of the application

SIMOTION Flying Saw
The application automatically controls the flying saw axis to implement the required
level of functionality.
This functionality is sub-divided into five operating states so that the sequences at
the flying saw are implemented as a result of the modes or also as a result of the
transitions between the states.
This means the user only influences the flying saw by specifying the required
operating mode with the required parameters.

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Fig. 3-2: Operating modes

44
Manual
Manual

11 00
Disable
Disable Error
Error

22
Startposi-
Startposi-
tion
tion

33
Auto-
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Auto-
Copyright Siemens AG 2014 All rights reserved

matic
matic

Table 3-2: Operating modes of the Application SIMOTION Flying Saw

Operating mode Description
ERROR (0) An error was detected and the flying saw was brought into a safe
state. The error is still present and can be evaluated by the user.
The axis of the flying saw is stopped and deactivated.
DISABLE (1) The flying saw is ready for use, but is in the safe operating state. All
errors that are available have been successfully acknowledged.
The axis of the flying saw is in the state after being reset, deactivated
and stopped (disabled).
STARTPOSITION (2) The flying saw is located at the start position and is ready for
synchronization to the material web.
The axis of the flying saw is activated.
The axis waits in the START POSITION operating mode.
AUTOMATIC (3) The flying saw has been synchronized to the material web, and is
cutting the material as specified.
MANUAL (4) The flying saw is in the manual mode, the user can manually move
the axis.
The axis of the flying saw is activated.
The axis waits in the MANUAL operating mode.

These operating modes are available in the user program to implement machine
functions and can be transferred to the FBFlyingSaw function block via input
parameters.
The function block displays the currently reached state using output parameters.

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The application example as demonstration

system
Contents
All of the necessary steps to commission the standard application SIMOTION
Flying Saw as demonstration system are explained in Section B.
Preparations and parameterizing operations are also explained. Further, you are
told how you can use the WinCCflex man-machine interface (screen) of the
application example step-by-step.

Objective
Section B of this document provides the reader with the following
The prerequisites to use this standard SIMOTION application as a
demonstration system
Preparations and parameterizing operations are explained
Describes the steps necessary when presenting this standard application.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

Provides tips for using this standard application.

Subjects discussed
Chap. Title Contents
4 Installing the hardware Safety information and instructions
and software Components and their interconnections required for the
presentation
Installation of standard SIEMENS software
Downloading the user program in SIMOTION D435
Downloading drive parameters in SINAMICS
5 Operator control of the Brief instructions on how to use the demonstration system
application example Detailed operating instructions

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SIMOTION Flying Saw SIROT- ID: 37841424

4 Installing the hardware and software

4.1 Regarding your safety
4.1.1 Safety information and instructions

Pictograms, signal words and text

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

Classification
There are three different stages regarding safety information/instructions. These
are designated by the same pictogram. They differ by the signal word.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

! This safety information/instruction indicates an immediate hazard. If the

Copyright Siemens AG 2014 All rights reserved

information/instruction is not carefully followed, this results in severe

Danger bodily injury or even death.

! This safety information/instruction indicates a potential hazard. If the

information/instruction is not carefully followed, this can result in severe
Warning bodily injury or even death.

! This safety information/instruction indicates a potentially hazardous

situation, which can result in slight to average bodily injury. This
Caution pictogram/text word can also warn about potential material damage.

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4.1.2 Responsibilities of the operator

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

Misuse
The following are considered to be misuse:
Inadmissible loads applied to the application components.
Any application deviating from the use specified above, or applications that go
beyond the specified use.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

Non-observance of the safety information and instructions.

If faults that could have a negative impact on the safety are not immediately
resolved/removed.
Any changes/modifications to equipment/devices that are used to ensure
perfect function and operation, unrestricted use as well as active or passive
safety.
If recommended hardware and software components are not used.
If the application components are not in a perfect technical condition are not
operated conscious of safety and hazards, and not taking into account all of
the instructions provided in the documentation.
The manufacturer assumes no liability for incorrect use (misuse).

Responsible for monitoring

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

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

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4.2 Hardware structure and mounting/installation

Overview

Fig. 4-1: Hardware components (without power cable!)

Ethernet
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Copyright Siemens AG 2014 All rights reserved

The demonstration project can be commissioned using a standard SIMOTION

D435 demonstration case and a PC connected via Ethernet.

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Table 4-1: Hardware components

Hardware element Diagram Order No./MLFB and functions
Training case, SIMOTION D435 with SINAMICS S120
SIMOTION D 6ZB2 470-0AE00
demonstration and training The SIMOTION D training case comprises
case standard components (SIMOTION D435, two
SINAMICS axes with motors) and has two
axes. These are used to demonstrate the
application.
The case is already pre-configured and
connected-up. It only has to be connected to
the HMI system via PROFIBUS.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

Communications
Ethernet Cross Link Cable The cable is used to establish a connection
between the HMI system (PG/PC) and the
SIMOTION D435 training case.

HMI system
PG/PC with MPI interface -
The PG/ PC is used as the HMI display screen.

Procedure
Please proceed as follows to configure and install the hardware components for the
application example:
Table 4-2 Hardware configuration and mounting
No. Action Comment
1 Connect the Ethernet interface of your PG/PC with the
lower Ethernet interface IE2 (contact X130) of
SIMOTION D435 with an Ethernet Cross-Link cable.
2 Connect the SIMOTION D training case to the power
supply.
3 Power-up all of the equipment/devices.

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4.3 Installing the standard SIEMENS software

If the application is only to be used to demonstrate and present, then it is only

Note necessary to install WinCC Flexible 2008 Runtime with 256 power tags.

Minimum required releases

Table 4-3 Versions
Component Version.
STEP 7 V5.5.03.42
SIMOTION SCOUT V4.3.1.17
WinCC Flexible 2008 SP3 HF3
WinCC Flexible Runtime 2008 SP3 HF3

4.4 Downloading the user program and parameterizing the

2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

drive in the SIMOTION D demonstration case

Copyright Siemens AG 2014 All rights reserved

4.4.1 De-archiving the SIMOTION project

Open SIMOTION SCOUT

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

4.4.2 Resetting SIMOTION D435 to the factory settings

In order to obtain a fixed starting point for the description on how to download the
user program into the demonstration case, restore the factory setting at the
demonstration case as described below:
Power-down the demonstration case
Set the mode switch SIMOTION D435 to setting 3 (MRES)
Power-up the demonstration case
When RDY lights green and STOP lights orange, set the SIMOTION D435
mode switch to the 0 position (RUN)
RDY and RUN are green

If the factory setting has been established, (restored), the SIMOTION D435 has the
standard IP address 169.254.11.22 at the Ethernet interface IE2 (X130).

4.4.3 Setting the PG/PC interface

Please proceed as follows to set the PG/PC interface:

In SIMOTION SCOUT open the interface configuration using EXTRAS SET
PG/PC INTERFACE...

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In the area “Interface Parameter Assignment”, select your Ethernet

card/interface of the PG/PC with “TCP/IP ......”.
Acknowledge any (possible) alarm with Yes.
Acknowledge your changes with OK.
Return to SIMOTION SCOUT and open the network configuration NETPRO
using the button or the menu “PROJECT” OPEN NETPRO.
Open the properties by double clicking on PG/PC (1).
The ETHERNET interface being used must be able to be found under the
“Assignment” tab (this is already automatically selected). If this is already the
case, select this and set the checkmark for S7ONLINE access active.
Please select “Compile and check evrything”
Close any messages that may be displayed regarding alarms.
Before you load the project, please close NETPRO and set the Ethernet
address of your PG/PC.

4.4.4 Setting the Ethernet address of the PG/PC

2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

Proceed as follows to set the Ethernet address of the PG/PC:

Open the network connection window of your PG/PC and select the network
connection that is used to SIMOTION and open its properties (righthand
mouse click PROPERTIES or select the symbol and then FILE
PROPERTIES).
In the area “This connection uses the following items” select the protocol
“Internet Protocol (TCP/IP)” and open its properties.
The Ethernet interface IE2 (X130) of SIMOTION D435 has as standard, the IP
address 169.254.11.22.
Select “Use the following IP address” and enter the IP address 169.254.11.23.
As “Subnet mask” enter 255.255.0.0.
The address set above must be identical to the address for the PG/PC. Check
this address by selecting the PG/PC interface in NetPro and if required, adapt
this
Confirm your changes by pressing on OK twice.

4.4.5 Loading the hardware configuration after the factory setting

To load the hardware configuration, please proceed as follows:

Go into the hardware configuration and press the button Load to target device
Acknowledge with OK
Press on No and do not execute a new start
Close the hardware configuration and change to SIMOTION Scout

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4.4.6 Loading the SIMOTION project of the standard application

Proceed as follows to load the SIMOTION project:

Before you load the project, in the offline mode, under Target system/Target
device, select whether both SIMOTION D435 as well as also
SINAMICS_Integrated are selected. Please acknowledge any changes with
OK.
After starting the download, you will be prompted whether you wish to "Copy
RAM to ROM” after you have successfully loaded the project. You must always
answer with Yes, as otherwise your program must be reloaded again after
power ON/OFF. This copying only refers to the SIMOTION part of the project.
Please acknowledge with OK when the loading and copy operations have
been completed.
Acknowledge copy RAM to ROM in SINAMICS_Integrated with Yes and
acknowledge with OK once this has been completed.
Finally, switch SIMOTION D435 into the RUN operating state. To do this, click
on the SIMOTION-CPU and using the righthand mouse key and target
device/operating state, go to the operating state display.
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Copyright Siemens AG 2014 All rights reserved

Here, click on the RUN button.

SIMOTION D435 is then in RUN and the demonstration case is ready for the
presentation/demonstration!

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5 Operator control of the application

example
The application can be used to present SIMOTION D with SINAMICS and get to
know and test the functions of the CPU D435.

Prerequisites
The following prerequisites must be fulfilled to use the application example:
The SIMOTION project is provided online in SIMOTION D435.
The parameterization for the applications has been downloaded into
SINAMICS (also included in the SIMOTION project!).
All of the devices are powered-up.
The SIMOTION D435 has been switched into the “Run” state using the online
function of SIMOTION SCOUT.
At least WinCC Flexible 2008 SP3 Upd2 is installed on the PC/PG.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

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

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5.1 Structure overview

Please refer to the following diagram for the basic operator control structure with all
of the operator areas of the application.

Fig. 5-1: Structure overview to demonstrate the application

HOME SETTINGS

Manual-Mode
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Copyright Siemens AG 2014 All rights reserved

MANUAL STATUS

Automatic-Mode

AUTO TECHNOLOGY

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5.2 Brief instructions

Execute the following steps in the sequence as listed in the following table to
demonstrate the application example:

Table 5-1: Brief instructions to demonstrate/present the “flying saw” application example
No. Action Comment
1 Call the following file
"C:\Siemens\Step7\S7Proj\
FlyingSaw_V20\HmiEs\Project_1\
Project_1.WinCCStation.fwx".
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

2 If the connection to the CPU was able to Check that your PG/PC is set to correct IP-Address.
be established, the screen form appears
at the top left - mode: Idle.
( 169.254.11.23 with "subnet mask“ 255.255.0.0 ).

3 At the bottom left, please click on AUTO

(3rd button from the left!).

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4 First activate the print mark simulation by

pressing the
Print Mark Simulation ON / OFF
button.

When cutting “to print mark”, you can

only set an integer multiple of 200 mm as
cut length (this is inherent to the system).

5 Next, activate the travel to the starting

position using the button Flying Saw
STARTPOS.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

6 Once the flying saw has reached its

starting position, the Flying Saw START
button is displayed to activate the flying
saw.

Before you activate the flying saw, the

required cut length should be selected
using the Cutlength slider.

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7 Now you can start the material feed!

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

8 After the material web starts, the material

enters the unit and the print mark
simulation generates, after the length, set
using the Cutlength slider switch, a print
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

mark. The flying saw then makes a cut.

Copyright Siemens AG 2014 All rights reserved

9 You can immediately generate a print

mark using the on-the-spot CUT button
– which is also then cut by the flying saw.

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10 The red bar

indicates how far the
flying saw must travel with the material
web with the current setting for one cut.

Activate the technology screen

by pressing the TECHNOLOGY button

11 The following contents are displayed in

the technology screen:
The actual material velocity
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

The actual velocity of the flying saw

Copyright Siemens AG 2014 All rights reserved

The actual position of the flying saw

The position of the material referred
to the actual cut

You can return to the

automatic screen by pressing
the AUTO button

12 Machine parameter settings

Machine geometry:
Distance to Sensor
StartPosition
StartSyncPosition
EndSyncPosition
EndPosition
Acceleration:
Cut
Back
Gap
Create a “gap”:
GapVelocity

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13 The actual state of the function block of

the application is displayed in the status
display.
You can read the ErrorID numbers,
which are displayed under ErrorID, under
Chapter 8.3.7 Error messages.
Faults that are present can be
acknowledged by pressing the QUITT
button.
If the function block is in the error state,
then press the Quitt button until it goes
into the disable state.
Using the Restart button, you can reset
the flying saw into the initial state after a
restart.

14 The material can be removed

by pressing the
Material END button
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Copyright Siemens AG 2014 All rights reserved

15 After the last cut, the flying saw

automatically moves to its starting
position and waits for new material.

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16 Once the material has been completely

removed from the screen area, then you
can either allow new material to enter by
pressing the Material START button
and continue with Step 8,
or
end the “flying saw” by pressing
the Flying Saw END button.

17 After the flying saw has been ended, you

can
return to the welcome screen
by pressing the
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

HOME button.
Copyright Siemens AG 2014 All rights reserved

18

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SIMOTION Flying Saw SIROT- ID: 37841424

6 Operatoration of the TestFB application

The pupose of this application is to learn the functionality of the FB-FlyingSaw as it
should be installed in any user application and how to run the FB. This application
also is prepared for the demo suitcase, and can be adapted also directly to the
user hardware.

Prerequisites
The following prerequisites must be fulfilled to use the application example:
The SIMOTION project is provided online in SIMOTION D435.
The parameterization for the applications has been downloaded into
SINAMICS (also included in the SIMOTION project!).
All of the devices are powered-up.
The SIMOTION D435 has been switched into the “Run” state using the online
function of SIMOTION SCOUT.
At least WinCC Flexible 2008 SP3 Upd2 is installed on the PC/PG.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

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

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6.1 Structure overview

Please refer to the following diagram for the basic operator control structure with all
of the operator areas of the application.
Fig 6-1: Structure overview to demonstrate the application

FS-Operating
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Copyright Siemens AG 2014 All rights reserved

FS-Data1 (UI) FS-Data2 (CPB-MI-FSI)

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6.2 Brief instructions

Execute the following steps in the sequence as listed in the following table to
demonstrate the application example:

Table 6-1: Brief instructions to demonstrate/present the TestFB-Application SIMOTION Flying Saw
Nr. Aktion Anmerkung
1 Start screen after activation of WinCC RT
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

2 Activation of „Auto Cutting“

If „Auto Cutting“ is activated, all the
control signals for the knife will be
automatically generated and must not be
activated t by the user. This simplifies the
handling of the application.
This function is activated via the button
„Auto Cutting“.

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3 Run FlyingSaw to startposition

Select mode „STARTPOS“
Activate button „Execute“
(Edge 0 1!)

4 Switch FlyingSaw into mode „automatic“

Select mode „AUTO“
Activate button „Execute“
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

(Edge 0 1!)
Copyright Siemens AG 2014 All rights reserved

5 Activation of material movement

Switch on material axis
Select speed value
Start movement

(Stop movement)

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6 Switchover from the indication of the

application state to the indication of the
movement curves
Switching over will be done with the
button „Mode / Graphic“

7 Have fun with trying out

the application !!!!!!!
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 Integration of the core functions
Operatoration of the TestFB application

SIMOTION Flying Saw SIROT- ID: 37841424

Integration of the core functions

Content
The section “Intergration of core functions” gives an overview of all necessary
steps for implementing the SIMOTION Flying Saw applications into the user’s
program.
Preparatory activities and parameterizing works will be defined. Moreover this
section also explains step by step how to integrate the application library into the
user’s application.
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7 Integration in the user program

7.1 Importing the source code
The SIMOTION Flying Saw application is part of the LFSLib library. The library is
available within the SIMOTION project “SIMOTION Flying Saw” as well as XML
export. In order to be able to use the functionality of the library, this library must be
integrated into the corresponding user project.

7.1.1 Copying from the application example

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

Table 7-1: Copying the library from the application example

No.
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1. The library is downloaded to the buffer memory by

right clicking on the library in the standard
application following by Copy.

2. The library LFSLib can be inserted if, in the user

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

3. The lower-level objects are also copied.

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7.1.2 Intergration via XML import

Using XML import, the LFSLib library and the FS_Progs program unit will be linked
to the existing user project.
Table 7-2: Importing the XML file
No.
1. For the XML import, the LIBRARIES
folder must be selected in the user
project and then executed by right-
clicking. Using the Import object
menu item, a window opens in
which the path of the XML file must
be specified.

2. Using the Browse button, the XML

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file path is specified and therefore

Copyright Siemens AG 2014 All rights reserved

the LFSLib library is imported into

the user project.

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7.1.3 Linking the flying saw functionality

The LFSLib library comprises several program units, whereby the unit
FS_Template contains the functionality of the application in the form of function
blocks as well as data type definitions. The reference to the library is established in
the unit FS_Progs as well as the instances of the function blocks and the data
structures will be created. In addition, the unit includes the calls of the instances in
those programs which must be integrated in the task system of the user project.
The programs are not able to run in the library and may have to be adapted to the
particular application (startupFlyingSaw).

Table 7-3: Programs of the RK_Progs unit

Program Description Task
startupFlyingSaw Initialization and parameterization StartupTask
mainFlyingSaw Main program BackgroundTask

After the library has been copied / imported in the library folder, the program unit
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FS_Progs must be copied from the library folder into the program folder of the
Copyright Siemens AG 2014 All rights reserved

application – and modified at four positions:

Table 7-4: Copying and modifying the UNIT FS_Progs
No.
1. The unit is downloaded into the
buffer memory by right-clicking on
the program unit FS_Progs in the
library LFSLib followed by Copy.

2. Mark the Program folder in the user

project. Insert the program unit
FS_Progs by right-clicking Paste

3. Then, in the program unit FS-Progs,

within the program container (not in
the library!) four program lines must
be deleted.

Marked with $$$$$$$

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No.
4.

5.

6. Now the program unit can be

compiled.
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When using the program unit FS_Progs, the user must not link the library by
himself. The library is linked using the FS_Progs unit.
User program units requiring access to library-functions, library-types, library-
function blocks and to data of the standard application, must be linked with the
program unit FS_Progs in the interface section.

INTERFACE
USES FS_Progs // Linking the standard application
END_INTERFACE

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Variable access
To access variables of the SIMOTION Flying Saw application, the following
instances are set-up in the global data area in the FS_Progs program unit:

Table 7-5: Data interface

Element Description
gasFlyingSaw Block interfaces and parameters
gaFBFlyingSaw Instance(s) of the FBFlyingSaw
NUMBER_OF_FLYING_SAWS Number of FB instances

VAR_GLOBAL CONST
NUMBER_OR_FLYING_SAWS : INT := 1; // number of flying saws
END_VAR
VAR_GLOBAL
gasFlyingSaw : ARRAY[0.. NUMBER_OR_FLYING_SAWS -1] OF sFlyingSawType;
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gaFBFlyingSaw : ARRAY[0.. NUMBER_OR_FLYING_SAWS -1] OF FBFlyingSaw;

END_VAR

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7.2 Technology objects

7.2.1 Necessary technology objects and synchronism interconnections

To use the SIMOTION Flying Saw application, the following technology objects
must be set-up and interconnected as described..
Please take into account the way the cutposition (CP) has to be detected and the
way the actual application is used (to control a real machine or for test pruposes at
a demo case):

Table 7-6: Technology objects required

Object Description
Web Axis To determine the position and velocity of the material web as leading value of the
(MaterialAxis, SIMOTION Flying Saw application and to coordinate the motion of the material web axis
(MaterialEncoder) from the same control.
TO Real positioning or following axis
Machine encoder (external encoder)
Configuration Configuration When CP Generation Mode = CP_CALCULATED
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Set the axis type as linear without modulo length.

When CP Generation Mode = CP_MEASURED
For accuracy reasons, we recommend that the axis
type is parameterized as modulo linear axis with a
modulo length greater than three times the
maximum product length.
All of the other parameters should be set
corresponding to the drive and encoder data.
Mechanical For the parameter “distance per spindle revolution”,
system enter the distance as that value the material web
travels within one revolution of the drive roll.
Complete other parameters accordingly to the
geometry and machine design.
Limits For this parameter, enter values that correspond to
the system/drive specifications
Referencing Parameterize “not required”
Monitoring, Please set this parameter corresponding to the
closed-loop system specifications.
control
Flying Saw Axis Drive for the flying saw motion.
(FlyingSawAxis) TO Real following axis
Configuration Configuration If the application is used in a “Real Machine”
sUsersInterface.boRealMachine = TRUE.
Parameterize the axis as a synchronous axis.
Set the axis type as linear without modulo.
If the application is used in a test arrangement (e.g.
demo case)
sUsersInterface.boRealMachine = FALSE
Parameterize the axis as a synchronous axis.
Set the axis type as linear with modulo
Using modulo length value
sUsersInterface.r64EndPos + 500.0
Using startvalue value
- ( sUsersInterface.r64DistanceToSensor + 50.0 )
Thus the axis always is in the actual operating range
and must not be referenced at test mode.

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Object Description
All of the other parameters should be set
corresponding to the drive and encoder data.
Mechanical For the parameter “distance per spindle revolution”
system enter that distance the “Flying Saw”(cutting
equipment) is travelling along the web within one
motor revolution.
Complete other parameters corresponding to the
geometry and the machine design.
Pre-assignment Please set this parameter corresponding to the drive
dynamics
Limits Please set this parameter corresponding to the
system specifications
Referencing Please set this parameter corresponding to the
encoder.
(The template assumes a referenced axis. If an
incremental encoder is to be used, then the axis
must be referenced in the MANUAL mode before
additional operating modes are selected.)
Monitoring Please set this parameter corresponding to the
functions, closed- system specifications
loop control
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7.2.2 Interconnection of technology objects

Synchronism interconnections of the SIMOTION Flying Saw application:

Figure 7-1: Synchronism interconnections required for the FBFlying Saw

Flying
Material
1:n Saw
Axis
Axis

External Encoder
or Positioning Gearing Gearing axis
axis

The material axis (MaterialAxis) is the reference value for the flying saw. This
reference value can be detected in two different ways:
1. The material path is controlled by the SIMOTION drive system which also
controls the flying saw. In this case, a TO axis is provided. The synchronous
connection with the axis of the flying saw (FlyingSawAxis) should have access
to the setpoints of the material path which are existing in the system (setpoint
coupling)
2. The speed of the material is measured with a machine encoder. In this case,
there are no additional setpoints available. The synchronous connection with

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the flying saw (FlyingSawAxis) can only access the actual values of the
machine encoder (actual value coupling).
The FlyingSawAxis as “synchronous axis” is connected to the MaterialAxis in a 1:n
(gearing) synchronous interconnections.
The technology objects and synchronous interconnections (shown in the diagram
above) must be set-up and configured by the user in SIMOTION SCOUT.
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Configuration of Synchronous Operation

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

Figure 7-2: Configuration of the synchronous interconnections between the master axis
(material web) and flying saw as setpoint coupling
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or
Select the TO ExternalEncoder „MaterialEncoder“ as master (leading) axis
Select actual value with extrapolation as coupling type.
The time constant required for extrapolation is determined by using the
calculation tool on the Utility&Applications CD.
(Scout\CD14\SRC\4_TOOLS\ExtrapolationTimeCalculation).

Figure 7-3: Configuration of the synchronous interconnection between the master value
(machining encoder) and the flying saw as actual value coupling

Table 7-7
Function / Variable Value
Dynamic parameters During synchonizing and desynchronizing the dynamic
parameters of the time-related synchronization should be
selected subject to the condition that the axis must not
reach its dynamic limits.

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7.3 Integrating the core functions of the application

SIMOTION Flying Saw
The SIMOTION Flying Saw application comprises several functional units that are
saved in the program unit FS_Prog.

7.3.1 Parameterizing in the startup task

It is useful to combine configuration data assignments – which won’t be changed

during operation - in one program (startupFlyingSaw). When starting the control in
the startupTask these data need to be executed once and the values will be
assigned to the variables.
Assignment of the actual TO instances
Assignment of machine-specific parameters
Setting the restart bits.
The program is already prepared in the execution system as a program instance
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and is included in the UNIT FS_Progs.

Copyright Siemens AG 2014 All rights reserved

The user only has to adapt the parameters to the real machine.
If several instances of the flying saw are used in the user program then the
parameter assignments must be correspondingly supplemented.

7.3.2 Calling FBFlyingSaw in the user program

The function block of the flying saw core functions can be called after the
integration in the user program.
The call is already prepared in the program unit FS_Progs in the mainFlyingSaw
program. The user only has to integrate this program into one of the cycle tasks
(preferably into the background task).

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7.3.3 Global Variables

The FBFlyingSaw function block is influenced by several parameters and interfaces

which are subdivided into the following areas:
Block interfaces
Block interface in the global data area
Changing tasks and modes are communicated to the function block via the block
interface. The function block also communicates the actual status - and errors that
have possibly occurred - back to the user program via this interface.
The parameters of the flying saw to be connected are communicated to the
function block via the block interface in the global data area. In normal flying saw
operation, these values will not change. Further, it includes data areas for
communication with the user and for communication among the individual sub-
functions in the overall.
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Program Description
Content
The section “Program Description” is only then of interest if you wish to
expand/adapt your application by using the technology templates..

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

Prerequisite
Before possibly expanding this template it is helpful to read the chapters in Section
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1 to 3 and 7 in order to learn the basic functions and applications of the template.

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

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8 Program Description
8.1 Information and warnings
Before making changes
Before you start modifying components included in the core functions, please
inform yourself about the component features in the ST/MMC documentation.
Uncontrolled, incorrect changes and modifications to core functions may result in
death and severe bodily injury!

Restrictions regarding support when changing components of the core functions

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

8.2.1 Overview

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

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

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8.2.2 Enumeration types

Name of the enumeration type Contents

eOperationModesFlyingSawType This enumerator type contains enumerators to
select and display the operating state of the
FBFlyingSaw function block.
Declared in LFSLib.FS_Template:
eCutPositionGenerationModesType Defines the method to determine the cutting
position.
Declared in: LFSLib.FS_Template
eCutPositionMeasureModesType Defines the method to detect the measured
values
Declared in: LFSLib.FS_Template
eTypeOfSynchronizationType Defines the synchronizing behavior of the knife
slide on the motion of the material web.
Declared in: LFSLib.FS_Template

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

Element Description
OMFS_ERROR FBFlyingSaw is standing in state ERROR
OMFS_DISABLE FBFlyingSaw is standing in state DISABLE
OMFS_START_POSITION FBFlyingSaw is standing in state STARTPOSITION
OMFS_AUTOMATIC FBFlyingSaw is standing in state AUTOMATIC
OMFS_MANUAL FBFlyingSaw is standing in state MANUAL
OMFS_NOTHING_SELECTED FBFlyingSaw has no change of state detected
OMFS_CHANGING FBFlyingSaw is changing state

eCutPositionGenerationModesType
This enumerator type defines how the cutting position is determined:
Element Description
CP_MEASURED The cutting position is determined using sensor and print mark or is calculated
and stored into the CutPositionBuffer.
CP_CALCULATED The cutting position keeps constant, the material position is reduced by cutlength
after each cut. This method doesn’t need any stored position data.

eCutPositionMeasureModesType
This enumerator type defines how the measured value is detected:
Element Description
CPM_DETECTED The cutting position is detected using a sensor and a print mark.
CPM_SIMULATED The cutting position is calculated from the given cut length.

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eTypeOfSynchronizationType
This enumerator type defines the synchronizing characteristics of the cutting
equipment to the material web motion:
Element Description
BY_TIME Synchronization by dynamic values
BY_LEADING_AXIS_VALUE Synchronization through distance.
The distance used will be stored in the variable “usersInterface.r64SyncLength”.
SYMMETRIC The distance is dimensioned so that symmetrical synchronization is achieved
without any overshoot.

8.2.3 Data Structures

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Name of Structure Content

Copyright Siemens AG 2014 All rights reserved

sFlyingSawType This structure contains the complete global data of the

SIMOTION Flying Saw application.
Declared in: LFSLib.FS_Template
sTOsType This structure contains the definition of all technology objects
used (axes, machine encoders and measuring probes).
Declared in: LFSLib.FS_Template
sUsersInterfaceType This structure contains the interface for the user to enter
geometry and motion data of the shears mechanical system, as
well as to enter operating versions.
Declared in: LFSLib.FS_Template
sCutPositionBufferType This structure contains the memory in which the cutting
positions are saved with associated position deviations.
Declared in: LFSLib.FS_Template
sCutPositionBufferManagement This structure contains the internal data area to precisely enter
Type the cutting position – and cutting position deviation for print
mark correction.
Declared in: LFSLib.FS_Template
sFlyingSawInfoType This structure contains data about the actual leading value, the
actual position of the leading value as well as its position from
the perspective of the flying saw.
Declared in: LFSLib.FS_Template
sMeasuringValueType This structure contains the internal data area to determine the
cutting position.
Declared in: LFSLib.FS_Template

Generally applicable for labeling structural elements:

[IN]: Values that should be provided by the user
[OUT]: Results or feedback signals
[IO]: Values, depending on the block connection, must be supplied by the
user or will be supplied by the function

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sFlyingSawType
This structure contains the complete global data of the application SIMOTION
Flying Saw:
I/O Element Type of Data Description
Object references of all technology objects (axes,
IN sAxisTOs sTOsType
external encoders and measuring probes).
Interface for the user to enter geometry and motion
sUsersInterface data of the shears mechanical system – as well as to
IN sUsersInterface
Type enter sequence options such as a restart in ongoing
operation.
sCutPositionBuffer sCutPosition Internal data area to enter the cut position as a precise
I/O Management BufferManageme position and cut position deviation for the print mark
ntType correction.

sFlyingSawInfo sFlyingSawInfo Data area to display the actual leading value

I/O interconnection as well as the actual leading value
Type position.
sMeasuringValue sMeasuringValue
I/O Internal data area to detect the cutting position.
Type
[ mm ] r64formatLength is the length of the cut material
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IN r64FormatLength LREAL
Copyright Siemens AG 2014 All rights reserved

element.
Activates the mode changeover with the operating
IN boExecute BOOL
mode specified in eMode.
Using eMode the operating mode is preselected that is
then activated with the next positive edge at input
boExecute.
OMFS_ERROR: Preselects the ERROR mode
eOperationModes OMFS_DISABLE: Preselects the DISABLE mode
IN eMode
FlyingSawType OMFS_START_POSITION: Preselects the
STARTPOSITION mode
OMFS_AUTOMATIC: Preselects the AUTOMATIC
mode
OMFS_MANUAL: Preselects the MANUAL mode
Feedback signal from the cutting device:
IN boStopCutting BOOL
TRUE: Cutting has been completed
Feedback signal from the cutting device:
IN boKnifeOut BOOL
TRUE: Cutting device withdrawn from the material web
IN boGap BOOL TRUE: Create gap has been selected
IN boOnTheSpotCut BOOL TRUE: Start “Immediate cut“
OUT boDone BOOL TRUE: Selected mode is activated..
OUT boBusy BOOL TRUE: Mode changeover is active.
Indicates errors in the FBFlyingSaw and at the
OUT boError BOOL
FlyingSawAxis.
Signal to the cutting device
OUT boCut BOOL TRUE: Flying saw is in synchronism to the material
web, the cutting device can cut
OUT boFlyingSawInStartPos BOOL TRUE: Flying saw is in initial position (Startposition)
TRUE: The end of the synchronous range has been
OUT boEndSyncPosReached BOOL
reached or exceeded
OUT boOnTheSpotCutPossible BOOL TRUE: An “Immediate cut” is possible
OUT boOnTheSpotCutDone BOOL TRUE: An “Immediate cut” was executed
TRUE: The last synchronization operation was not
OUT boSyncNotPossible BOOL
successful

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I/O Element Type of Data Description

TRUE: The flying saw has not reached the start
position in time for the next cut. The saw will cut
OUT boForSyncToLate BOOL
automatical the next reachable integer multiple
of cutlength.
OUT b32ErrorID DWORD Error code
Actual mode
OMFS_ERROR: ERROR mode
OMFS_DISABLE: DISABLE mode
eOperationModes OMFS_START_POSITIONC: STARTPOSITION mode
OUT eState
FlyingSawType OMFS_AUTOMATIC: AUTOMATIC mode
OMFS_MANUAL: MANUAL mode
OMFS_NOTHING_SELECTED: No mode change
OMFS_CHANGING: Mode change active
OUT boFlyingSawAxisActive BOOL TRUE: flying saw axis enabled

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

Copyright Siemens AG 2014 All rights reserved

I/O Element Type of Data Description

Reference to the technology object of the leading value.
Possible technology objects:
IN toLeadingValue _AXIS_REF - posAxis (real or virtual)
- externalEncoderType
Refer to the technology object of the Flying Saw axis. Only
IN toFlyingSawAxis followingAxis
one real axis is permissible

measuringInput Reference to the technology object of the measuring probe

IN toPrintmark used for print mark detection. The measuring probe must be
Type assigned to the leading value.

sUsersInterfaceType
This structure includes the interface for the user to enter physical boundary
conditions, operating mode versions as well as to enter a restart during operation
(this function must be parameterized by the user):
I/O Element Type of Data Description
[mm] Distance between the sensor for the material and print
mark detection and the axis zero point of the distance-
IN r64DistanceToSensor LREAL
reference system of the flying saw
(distance to the sensor).
[mm] Start position within the distance reference system of
IN r64StartPos LREAL
the flying saw.
[mm] Position within the distance-reference system of the
IN r64SyncPos LREAL flying saw where synchronization is completed
(synchronous position).
[mm] Maximum position within the distance-reference
IN r64EndSyncPos LREAL system of the flying saw where synchronous motion must
have been completed (end of the synchronous range)
[mm] Reversal point in the distance-reference position of the
IN r64EndPos LREAL
flying saw.
IN r64ToStartPosVel LREAL [mm/s] Velocity when positioning to the start position.

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I/O Element Type of Data Description

[mm/s] Velocity when positioning back to the start position
IN r64ToBackPosVel LREAL
after a cut.
[mm/s] Velocity after executing the higher-level gap
IN r64GapVelocity LREAL
positioning (“creating a gap!).
[mm/s²] Acceleration when synchronizing for the cut (only if
IN r64CutAcceleration LREAL
eTypeOfSynchronisation = BY_TIME!) .
[mm/s²] Acceleration when positioning back to the start
IN r64BackAcceleration LREAL
position after a cut.
[mm/s] Acceleration when executing the higher-level gap
IN r64GapAcceleration LREAL
positioning (“creating a gap!).
IN r64GearingRatio LREAL Ratio between the measured and real material motion.
r64CPDeltaTolerance [mm] Half the tolerance bandwidth for the activation range
IN LREAL
Range of the cut position detection
Flag restart, the user must set this, it is reset by the
I/O boRestart BOOL
application
interrupt production of FlyingSaw without leaving automatic
I/O boInterruptProduction BOOL
mode (e.g. to activate STO!)
continue production of FlyingSaw after interrupt production
I/O boContinueProduction BOOL
in automatic mode (e.g. after STO!)
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Method to determine the cut position:

eCutPosition CP_CALCULATED: Cut position is calculated by cutting
eCutPosition
IN GenerationMode to length of material position
GenerationMode
Type CP_MEASUERED: Cut position is detected using the
measuring probe
Method to measure cut position, only valid when
CP_MEASURED active:
eCutPosition CPM_DETECTED: Cut position is detected with sensor
eCutPosition and print mark and then entered in
IN MeasureMode
MeasureMode CutPositionBuffer.
Type
CPM_SIMULATED: Cut position is calculated by
cutlength and entered in
CutPositionBuffer
Synchronizing method to synchronize to the material axis:
eTypeOf BY_TIME: Referred to time
eTypeOf
IN Synchronisation BY_LEADING_VALUE: Referred to distance
Synchronisation
Type SYMMETRIC: Referred to distance, without
overshoot in velocity
[mm] length of the synchronization-distance at
IN r64SyncLength LREAL
distance-related synchronization
TRUE: drives connected with real machine
IN boRealMachine BOOL FALSE: drives connected with test arrangement
(e.g. demo case)

sCutPositionBufferType
This structure contains the cut position memory (this is not relevant for the user):
I/O Element Type of Data Description
ARRAY
ar64CutPosition [0..CPB_MAX-1]
I/O [mm] Buffer of the measured cut position
Measured
OF LREAL
ar64CutPosition
ARRAY [-] Buffer of the measured cut position number of
I/O MeasuredNumber
[0..CPB_MAX-1] modulo cycles
Modulo

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I/O Element Type of Data Description

OF DINT
ARRAY
I/O aboCutPositionRead [0..CPB_MAX-1] Buffer of the flag “cut position read”
OF BOOL
ARRAY
I/O aboCutPositionEntered [0..CPB_MAX-1] Puffer of the flag “cut position entered”
OF BOOL
ARRAY
aboOnTheSpotCut [0..CPB_MAX-1]
I/O Buffer of the flag “OnTheSpotCut Position entered”
PositionEntered
OF BOOL

sCutPositionBufferManagementType
This structure contains the internal data area to enter the cutting position and to
control the cutting position correction as precise position (this is not relevant for the
user):
I/O Element Type of Data Description
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

sCutPosition
I/O sCutPositionBuffer data area of cut position buffer
BufferType
I/O i16BufferIn INT Pointer to next input position of buffer
I/O i16BufferOut INT Pointer to next output position of buffer
I/O i16CutCorrectionWait INT Number of cuts without cut position correction
I/O boBufferOutTrigger BOOL Start trigger to delete the read buffer entry
I/O boBufferReadTrigger BOOL Start trigger to read the next buffer entry
I/O boBufferResetActive BOOL Reset of buffer active
I/O boBufferInActive BOOL Input of value in buffer active
I/O boBufferOutActive BOOL Deletion of buffer value active
I/O boBufferReadActive BOOL Reading of buffer value active

sFlyingSawInfoType
This structure contains calculation results and display information – relevant for the
user – that provides information about the state of the flying saw.
I/O Element Type of Data Description
TRUE Leading value is a real or virtual posAxis
OUT boAxisAsLeadingValue BOOL
FALSE No posAxis can be entered as leading value
If the leading value is a real or virtual posAxis, then the
OUT toLeadingValueAxis posAxis
name of the TO is the axis - otherwise TO#NIL
boExternalEncoderAs TRUE Leading value is an external encoder
OUT BOOL
LeadingValue FALSE No external encoder entered as leading value
toLeadingValue externalEncoder If the leading value is an external encoder, then the name of
OUT
ExternalEncoder Type the TO is the external encoder, otherwise TO#NIL
boTOLeadingValue
OUT BOOL TRUE TO master value active
Active
boLeadingValue
OUT BOOL TRUE ,Master value in standstill
Standstill
OUT toActiveFollowing followingObject Active following object of the FlyingSaw axis

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I/O Element Type of Data Description

Object Type
r64MaterialPosActual
OUT LREAL [mm] Actual material position at start of FlyingSaw activity
Start
i32MaterialPosActual [-] Number of modulo cycles at actual material position
OUT DINT
StartNumberModulo at start of FlyingSaw activity
OUT r64MaterialPosActual LREAL [mm] Actual material position
i32MaterialPosActual
OUT DINT [-] Number of modulo cycles at actual material position
NumberModulo
boOnTheSpotCut
OUT BOOL TRUE: On the spot cut selected
Selected
[mm] Actual synchronous position referred to the material
OUT r64MASyncPos LREAL
axis
i32MASyncPos [-] Number of modulo cycles at actual synchronous
OUT DINT
NumberModulo position referred to the material axis
[mm] Actual shift between the reference systems –
OUT r64MASyncOffset LREAL
material-axis and axis of the flying saw
r64MAPosFor [mm] Actual position of the material axis in the reference
OUT LREAL
Technologie system of the flying saw axis
r64CutLength
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

OUT LREAL [mm] aktivated cutlength in mode „CP_CALCULATED“

Copyright Siemens AG 2014 All rights reserved

Activated
r64MaterialPosition [mm] maximum material position before „Redefine
OUT LREAL
Maximum Position“
[mm] Knife positions error (caused by following error) at
OUT r64Delta LREAL start cut
(accuracy +/- Vmat akt * Backgroundcycle)
boInterruptProduction
OUT BOOL TRUE: interrupt active
Activated
boContinueProduction
OUT BOOL TRUE: continue active
Activated
boProduction TRUE: FlyingSaw is deactivated in automatic mode and
OUT BOOL
Interrupted ready for STO.
boProduction TRUE: FlyingSaw is reactivated and ready for start
OUT BOOL
Continued operation again.
OUT r64UpperLimitToLate LREAL [mm] Maximum material position to start FlyingSaw
i32UpperLimitToLate [-] Number of modulo cycles at maximum material
OUT DINT
NumberModulo position to start FlyingSaw
r64UpperLimitNot
OUT LREAL [mm] Material position for abort synchronization
Possible
i32UpperLimitNot
[-] A Number of modulo cycles at material position to
OUT PossibleNumber DINT
abort synchronization
Modulo
Method to determine the cut position:
eCutPosition CP_CALCULATED: Cut position is calculated by cutting
eCutPosition
IN GenerationMode to length of material position
GenerationMode
Type CP_MEASUERED: Cut position is detected using the
measuring probe
Method to measure cut position, only valid when
CP_MEASURED activ:
eCutPosition CPM_DETECTED: Cut position is detected using the
eCutPosition sensor and the print mark and
IN MeasureMode
MeasureMode entered in CutPositionBuffer.
Type
CPM_SIMULATED: Cut position is culculated by
cutlength and entered in
CutPositionBuffer

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sMeasuringValueType
This structure contains the internal data area of the measured value detection (this
is not relevant for the user):
I/O Element Type of Data Description
I/O boStartMeasuring BOOL Flag “Start measured value generation”
OUT r64CutlengthActivated LREAL [mm] Actual cut length
OUT r64MeasuredValueNew LREAL [mm] Measured value, actual
i32MeasuredValueNew
OUT DINT [-] Number of modulo cycles at actual measured value
NumberModulo
OUT r64MeasuredValueOld LREAL [mm] Measured value, old
i32MeasuredValueOld
OUT DINT [-] Number of modulo cycles at old measured value
NumberModulo
[mm] Difference between the new and old measured
OUT r64MVDelta LREAL
value
Enum Selects the measurement-initiating edge at the sensor:
IN eMeasuringEdge Measured RISING_EDGE: Rising edge at the sensor
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

Edge FALLING_EDGE: Falling edge at the sensor

Copyright Siemens AG 2014 All rights reserved

boWaitForFirstCut
I/O BOOL Flag “Wait for the first measured value”
Position
boWaitForCyclCut
I/O BOOL Flag “Wait for the next measured value”
Position
boCutPosition
I/O BOOL Flag “Wait for measured value”
MeasuringActive
boStartPosAtSensor
I/O BOOL Flag “Start position measured”
Detected
boApplicationIn
IN BOOL Flag “Application in the AUTOMATIC mode”
Automatic
boNewCutPosition
OUT BOOL Flag “New value entered in the CutPositionBuffer”
Entered
r64LeadingValueModulo
OUT LREAL [mm] Modulo length of the leading value
Length
r64SetPosNextCut
OUT LREAL [mm] Interpolated next cutting position at the sensor
PosAtSensor
i32SetPosNextCutPosAt [-] Number modulo cycles at interpolated next cutting
OUT DINT
SensorNumberModulo position at the sensor
r64SetPosTolerance [mm] Tolerance bandwidth of the next cutting position,
OUT LREAL
RangeStart start
r64SetPosTolerance [mm] Tolerance bandwidth of the next cutting position,
OUT LREAL
RangeEnd end
r64DeltaTolerance
IN LREAL [mm] Half the tolerance bandwidth
Range
i16CutPositionError
OUT INT Cut position fault counter
Counter
OUT r64CutLengthMeasured LREAL [mm] Actually measured cut length
[mm] Actual measured material position if the cutting
OUT r64CutPosAtSensor LREAL
position is at the measuring point
[-] Number modulo cycles at actual measured material
r64CutPosAtSensor
OUT DINT position if the cutting position is at the measuring
NumberModulo
point

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I/O Element Type of Data Description

[mm] Interpolated material position if the cutting position
OUT r64CutPosAtSyncPos LREAL
coincides with the synchronous point.
[-] Number modulo cycles at interpolated material
r64CutPosAtSyncPos
OUT DINT position if the cutting position coincides with the
NumberModulo
synchronous point.

8.3 FBFlyingSaw
Control block of the SIMOTION Flying Saw application.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

8.3.1 Block name

Copyright Siemens AG 2014 All rights reserved

FBFlyingSaw

8.3.2 Task

Control block of the SIMOTION Flying Saw application. The block includes the
following functions:
Mode manager of the application, including the following modes ERROR,
DISABLE, MANUAL, STARTPOSITION, AUTOMATIC
Determining the cutting position either using a print mark and measuring
sensor or a parameterizable cut length
Synchronizing to the material web
Controlling the cutting device during synchronous motion
Possibility of “creating a gap”
Referencing the axes and setting-up operation (jog) are not included in the
application.

8.3.3 Integration in the run-time system

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

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8.3.4 Graphic representation of the block

FBFlyingSaw
LREAL cutLength done BOOL

BOOL execute busy BOOL

eOperationMode mode error BOOL

FlyingSawType
BOOL stopCutting cut BOOL

flyingSawInStartPos BOOL
BOOL knifeOut
endSyncPosReached BOOL
LREAL gapLength
onTheSpotCutPossible BOOL
BOOL gap
onTheSpotCutDone BOOL
BOOL onTheSpotCut
syncNotPossible BOOL
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

forSyncToLate BOOL

errorId DWORD

status eOperationModes
FlyingSawType
rotaryKnifeAxisActive BOOL

sTOsType axisTOs sTOsType

sUserInterface usersInterface sUsersInterface

Type Type
sFlyingSawInfo flyingSawInfo sFlyingSawInfo
Type Type
sCutPositionBuffer cutPositionBufferManagement sCutPositionBuffer
ManagementType ManagementType
sMeasuringValue measuringValue sMeasuringValue
Type Type

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8.3.5 Block parameters

Input parameters
Name Data type Initial value Description
cutLength LREAL 800.0 Cut material element length in mm
execute BOOL FALSE A pending mode changeover is activated via this input.
With mode, the mode is pre-selected, which is
activated with the next positive signal edge at the
execute input.
OMFS_ERROR: Pre-selection, ERROR mode
eOperation
OMFS_ OMFS_DISABLE: Pre-selection, DISABLE mode
mode ModesFlying
ERROR OMFS_AUTOMATIC: Pre-selection, STARTPOSITION
SawType
mode
OMFS_AUTOMATIC: Pre-selection, AUTOMATIC
mode
OMFS_MANUAL: Pre-selection, MANUAL mode
By setting this signal, the block is signaled that the
cutting operation has been completed and a gap can
stopCutting BOOL FALSE
be created - or the cutting equipment (knife) can be
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

withdrawn from the material.

Copyright Siemens AG 2014 All rights reserved

By setting this bit, the block is signaled that the cutting

equipment is no longer connected to the material and
knifeOut BOOL FALSE
the cutting device (knife) can be withdrawn to the start
position
gapLength LREAL 10.0 [mm] Length of the gap to be created
TRUE: A gap with length gapLength is created
Gap BOOL FALSE
FALSE: No gap is created
By setting this signal, a synchronous position is
onTheSpotCut BOOL FALSE immediately generated on the material web at the
“sensor position” for the next cutting operation.

Input / output parameters

Name Data type Initial value Description
Defines the axes, machine encoder, and measuring
axisTOs sTOsType
probe being used
sUsersInter
usersInterface Interface to enter dynamic and geometrical parameters
faceType
sFlyingSawInfo
flyingSawInfo Internal data area for display
Type
sCutPosition
cutPositionBuffer Internal data area to enter precise data for the cutting
Buffer
position and cutting position deviation for the cut
Management Management
position determination.
Type
sMeasuring
measuringValue Internal data area to determine the cutting position.
ValueType

Output parameters
Name Data type Initial value Description

done BOOL FALSE Selected mode is activated.

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Name Data type Initial value Description

busy BOOL FALSE Mode changeover is active.

FALSE: No error
TRUE: There is an error, refer to error ID
Error BOOL FALSE
Processing and calculating the process values is not
interrupted in the case of an error.
FALSE: The flying saw is stationary, is
synchronizing or is moving back to the
cut BOOL FALSE start position.
TRUE: The flying saw is moving in synchronism
with the material web, cutting can start.
TRUE: FlyingSaw is in initial position
flyingSawInStartPos BOOL FALSE (startposition)
FALSE: FlyingSaw is out of initial position.
Warning, if the flying saw passes the upper limit value
endSyncPosReached BOOL FALSE
of the synchronous range in the automatic mode
FALSE: No “On the spot cut” possible
onTheSpotCutPossible BOOL FALSE TRUE: The flying saw is in its start position,
an “On the spot cut” is possible
onTheSpotCutDone BOOL FALSE The “On the spot cut” was executed
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

FALSE: The last synchronizing operation was

successful
syncNotPossible BOOL FALSE
TRUE: The last synchronizing operation was not able
to be executed under the specified conditions
FALSE: The last synchronizing operation was
successful
forSyncToLate BOOL FALSE
TRUE: The flying saw did not reach the start position
in time for the next cut.
Error identification, refer to error messages
errorID WORD 0 errorID <= 16#000_8000: warning
errorID >= 16#0000_8000: error
Actual mode
OMFS_ERROR: ERROR mode
OMFS_DISABLE: DISABLE mode
eOperation OMFS_ OMFS_AUTOMATIC: STARTPOSITION mode
state ModesFlying
SawType ERROR OMFS_AUTOMATIC: AUTOMATIC mode
OMFS_MANUAL: MANUAL mode
OMFS_NOTHING_SELECTED: No mode change
OMFS_CHANGING: Mode change active
flyingSawAxisActive BOOL FALSE The FlyingSaw axis is active

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8.3.6 Functionality

The FBFlyingSaw function block is the most important element of the application.
The connected flying saw is parameterized and controlled using this block.
The block and the operating mode changeover must be parameterized in the user
program in order that the FBFlyingSaw executes the required functions.
The FBFlyingSaw is parameterized as explained in Chapter 8 Program
Description. When parameterizing, basic values of the application are defined,
which generally do not change, such as e.g. specifying the name of the axis or all
geometrical data, such as r64DistanceToSensor, r64StartPos, r64StartSyncPos,
etc. It is only permissible to change these values at standstill (zero speed) - and
they require a re-initialization (restart) of the FBFlyingSaw.
The individual operating modes of the FBFlyingSaw are described in Chapter 3.2
Operating modes of the application
SIMOTION Flying Saw. The procedure to change over the operating mode is
described in more detail here in the following sections.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

Basic state of the FBFlyingSaw

Copyright Siemens AG 2014 All rights reserved

After being initialized, FBFlyingSaw is in the DISABLE operating mode.

Initialization must be executed each time after the control has booted by setting the
restart bit (gasFlyingSaw[0].sUsersInterface.boRestart) in the startup task. (This is
realized automatically when using the startupFlyingSaw() program in the UNIT
FS_Progs)
As a consequence, the block is brought into its initial state, important parameters
are checked for plausibility, if possible adapted, and if not possible, parameterizing
errors are displayed for user information at the error output.

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Mode changeover sequence

The mode manager of the function block is shown in the following diagram. It
includes the possible operating states that can be activated and clearly shows the
possible transitions, that the user may initiate:
Figure 8-1: Possible state transitions at FBFlyingSaw

RESTART
44
Manual
Manual

11 00
Disable
Disable Error
Error

22
Startposi-
Startposi-
tion
tion
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

33
Automa-
Automa-
tic
Standard Zustandsübergang
tic Fehlerzustandsübergang
Automatische Zustandswechselkette

The actual block state is displayed at the state output

.
Figure 8-2: Inputs and outputs of the mode changeover

IN OUT

cutLength Done
execute Busy
Error
mode
Cut
stopCutting endSyncPosReached
FBFlyingSaw() OnTheSpotCutPossible
knifeOut
OnTheSpotCutDone
gapLength syncNotPossible
gap ErrorID
onTheSpotCut State

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

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at the state output.

Checking the input parameters and parameterization of the technology settings that are
absolutely required (mandatory)
This program function is only executed after a “Restart” or if it was activated by the
user using the restart bit of the UsersInterface.
The following are monitored:
The existance and the type of specified TOs.
Deviations with respect to what has been specified are displayed as error
messages.
Parameter assignments of the technology objects that are absolutely required
are executed in an additional program section.

Axis monitoring
The function block is switched into the error state (ERROR operating mode) if there
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

is an error at the technology object axis of the flying saw.

Copyright Siemens AG 2014 All rights reserved

However, the monitoring function is only active if the parameterization check of the
technology objects was successfully completed.

Using the restart bit (sUsersInterface. boRestart)

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

We recommend that the program startupFlyingSaw of the unit FS_Progs is used

in the startup task in order to initialize the block FBFlyingSaw.
Note
The restart bit should also be set there in order to bring the block into a defined
state!

At restart, the block checks essential technology parameters as well as the

Note existence of saved technology objects.

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

Error handling
If faults occur in the block itself or in technology objects and technology functions
involved while FB FlyingSaw is operational, then these are signaled using the block

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outputs error and errorID.

Figure 8-3: Block outputs for fault messages

IN OUT

cutLength Done
execute Busy
Error
mode
Cut
stopCutting endSyncPosReached
FBFlyingSaw() OnTheSpotCutPossible
knifeOut
OnTheSpotCutDone
gapLength syncNotPossible
gap ErrorID
onTheSpotCut State

The error bit signals an error while an error code is output at output errorID; this
can be analyzed using the error analysis function.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

The error output is only set if the execute input is set. The errorID and state = 0
Copyright Siemens AG 2014 All rights reserved

Note (ERROR) are still output even after execute has been reset!

8.3.7 Error messages

Table 8-1: List of the possible error priorities

ErrorID Priority Description
16#xxxx_0xxxx Lowest priority Warning
16#xxxx_4xxx Low priority Warning, execution possible with error
16#xxxx_8xxx High priority Error, no execution possible
16#xxxx_Cxxx Highest priority Critical error

Warnings
Warnings are indicated by the status of the outputs error and errorID: error =
FALSE and errorID <> 16#0000_0000.
Table 8-2: Warnings
ErrorID Description
16#0000_0000 No warning
16#060C_4002 FlyingSawAxis changed over to modulo axis
16#060C_4003 Modulo length of the FlyingSawAxis is adapted to ( r64EndPos + 500.0 )
Only valid when using test environment (e.g. demo case!)
16#060C_4004 StartValue of the FlyingSawAxis is adapted to
- ( r64DistanceToSensor + 50.0 )
Only valid when using test environment (e.g. demo case!)
16#060C_4005 The axis as master value was switched to linear without modulo
16#060C_4006 The axis as master value was switched to linear with modulo
16#060C_4007 The external encoder as master value was switched to linear without modulo

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16#060C_4008 The external encoder as master value was switched to linear with modulo
16#060C_4009 Modulo length of axis as master value was set to 0.0
16#060C_400A Modulo length of axis as master value was set to MAXIMUM_CUTLENGTH * 3000
16#060C_400B Modulo length of external encoder as master value was set to 0.0
16#060C_400C Modulo length of external encoder as master value was set to
MAXIMUM_CUTLENGTH * 3000

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

Table 8-3: Errors

Error ID Description
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

16#0000_0000 No error
Copyright Siemens AG 2014 All rights reserved

16#060A_8001 Error at the FlyingSawAxis

16#060A_8002 Error at the FlyingSawAxis synchronous operation
16#060A_8003 Actual position of FlyingSawAxis > r64EndPos
16#060C_8001 The TO axis FlyingSawAxis is not set-up
16#060C_8002 There is no TO set-up as master value
16#060C_8003 There is no TO measuring input set-up
16#060C_8004 The TO measuring input is not connected to leading value
16#060C_8005 TO Flying Saw Axis - Error adaption drive data
16#060C_8006 TO Master Value Axis - Error adaption drive data
16#060C_8007 TO Master Value External Encoder – Error adaption drive data
16#060C_8008 Error modulo settings master value
16#060F_8001 Invalid mode selection from the ERROR mode
16#060F_8002 Invalid mode selection from the DISABLE mode
16#060F_8003 Invalid mode selection from the STARTPOSITION mode
16#060F_8004 Invalid mode selection from the AUTOMATIC mode
16#060F_8005 Invalid mode selection from the MANUAL mode
16#060F_8006 Wrong mode
16#0611_8001 DISABLE to DISABLE
Error when stopping the FlyingSawAxis ( _move v=0 ),
Details in i32RetDINTStopFSA
16#0611_8002 DISABLE to DISABLE
Error when stopping the FlyingSawAxis ( _move v=0 )
Details in i32FRStopFSA
16#0612_8001 DISABLE to STARTPOSITION
Error when positioning the FlyingSawAxis ( _pos )
Details in i32RetDINTPosFSA
16#0612_8002 DISABLE to STARTPOSITION
Error when positioning the FlyingSawAxis ( _pos )
Details in i32FRPosFSA

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Error ID Description
16#0621_8001 STARTPOSITION to DISABLE
Error when stopping the FlyingSawAxis ( _move v=0 )
Details in i32RetDINTStopFSA
16#0621_8002 STARTPOSITION to DISABLE
Error when stopping the FlyingSawAxis ( _move v=0 )
Details in i32FRStopFSA
16#0622_8001 STARTPOSITION to STARTPOSITION
Error when positioning the FlyingSawAxis ( _pos )
Details in i32RetDINTPosFSA
16#0622_8002 STARTPOSITION to STARTPOSITION
Error when positioning the FlyingSawAxis ( _pos )
Details in i32FRPosFSA
16#0603_8001 AUTOMATIC RUN
Error when activating gearing of the FlyingSawAxis ( _enablegearing )
Details in i32RetDINTEnableGearingFSA
16#0603_8002 AUTOMATIC RUN
Error when deactivating gearing of the FlyingSawAxis ( _disablegearing )
Details in i32RetDINTDisableGearingFSA
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

16#0603_8003 AUTOMATIC RUN

Error when deactivating gearing of the FlyingSawAxis ( _disablegearing )
Details in i32FRDisableGearingFSA
16#0603_8004 AUTOMATIC RUN
Error when superimposed positioning the FlyingSawAxis for Gap ( _pos )
Details in i32RetDINTPosSuperimposedFSA
16#0603_8005 AUTOMATIC RUN
Error when superimposed positioning the FlyingSawAxis for Gap ( _pos )
Details in i32FRPosSuperimposedFSA
16#0603_8006 AUTOMATIC RUN
Error when positioning the FlyingSawAxis back to start position ( _pos )
Details in i32RetDINTPosFSA
16#0603_8007 AUTOMATIC RUN
Error when positioning the FlyingSawAxis back to start position ( _pos )
Details in i32FRPosFSA
16#0631_8001 AUTOMATIC to DISABLE
Error when stopping the FlyingSawAxis ( _move v=0 )
Details in i32RetDINTStopFSA
16#0631_8002 AUTOMATIC to DISABLE
Error when stopping the FlyingSawAxis ( _move v=0 )
Details in i32FRStopFSA
16#0632_8001 AUTOMATIC to STARTPOSITION
Error when positioning the FlyingSawAxis ( _pos )
Details in i32RetDINTPosFSA
16#0632_8002 AUTOMATIC to STARTPOSITION
Error when positioning the FlyingSawAxis ( _pos )
Details in i32FRPosFSA
16#0641_8001 MANUAL to DISABLE
Error when stopping the FlyingSawAxis ( _move v=0 )
Details in i32RetDINTStopFSA
16#0641_8002 MANUAL to DISABLE
Error when stopping the FlyingSawAxis ( _move v=0 )
Details in i32FRStopFSA

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Error ID Description
16#0642_8001 MANUAL to STARTPOSITION
Error when positioning the FlyingSawAxis ( _pos )
Details in i32RetDINTPosFSA
16#0642_8002 MANUAL to STARTPOSITION
Error when positioning the FlyingSawAxis ( _pos )
Details in i32FRPosFSA
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

8.4 FBCutPositionDetection
Block to determine the cutting position of the flying saw.

8.4.1 Block name

FBCutPositionDetection

8.4.2 Task

Determining the cutting positions

8.4.3 Integration in the run-time system

The function block can be called in each cyclic task.

The block is used by the SIMOTION Flying Saw application and does not have to
be linked-in by the user.

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SIMOTION Flying Saw SIROT- ID: 37841424

8.4.4 Graphic representation of the block

2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

8.4.5 Block parameters

Input Parameters
Name Data type Initial value Description
cutLength LREAL 800.0 [mm] Element length of the cut material.
By setting this signal, a synchronous position is
onTheSpotCut BOOL FALSE immediately generated for the next cut on the material
web at the “sensor position”.
There are two techniques to generate cutting positions:
CP_CALCULATED: Cut position is calculated by
eCutPositionG breaking material web down by
CutPositionGeneration CP_
enerationMode cutlength
Mode CALCULATED
Type CP_MEASUERED: Cut position is detected using
the measuring probe and
stored in the CutPositionBuffer
Method to measure cut position, only valid when
CP_MEASURED activ:
CPM_DETECTED: Cut position is detected using
eCutPosition
CutPositionMeasure CPM_ sensor and prink mark and
MeasureMode
Mode SIMULATED entered in CutPositionBuffer.
Type
CPM_SIMULATED: Cut position is culculated by
cutlength and entered in
CutPositionBuffer

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 Program Description
Program Description

SIMOTION Flying Saw SIROT- ID: 37841424

Input / output Parameters

Name Data type Initial value Description
Definition of the axes, external encoders and
axisTOs sTOsType
measuring probes
sUsers
usersInterface Interface to input dynamic and geometrical parameters
InterfaceType
sCutPosition
cutPositionBuffer Buffer Internal data area to enter precise cutting position and
cutting position deviation for the cutting position
Management Management determination.
Type
sMeasuring
measuringValue Internal data area to determine the cutting position.
ValueType

8.4.6 Functionality

To determine the cutting position, the block has two different techniques:
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

CP-MEASURED: The presetting of cut position setpoints is done via

Copyright Siemens AG 2014 All rights reserved

CutPositionBuffer

CP-CALCULATED: The cut position of material web remains constant.

The presetting of cut position setpoint is done by
breaking material web position down by actual
cutlength.

CP-MEASURED
To determine the cutting position put in the CutPositionBuffer, the block has two
different techniques:
CPM_DETECTED: The cutting position is detected using the measuring
function with an activated sensitivity range at the distance of the cut length
from the last measured position.
After being activated, the cutting position determination function initially waits
for the first sensor signal. Its position (measuringValue.r64CutPosAtSensor) is
interpolated using the geometrical data usersInterface.r64DistanceToSensor
and usersInterface.r64StartSyncPos to the cutting position
(measuringValue.r64CutPosAtSyncPos) and is entered in the cutting position
buffer as the first cutting position. For all additional cutting positions, a
sensitivity range is now placed around the possible cutting position. To do this,
the next cutting position expected is interpolated using the actual cut length to
measuringValue.r64NextCutPosAtSensor and a tolerance bandwidth of
usersInterface. r64CPDeltaToleranceRange is applied. If a measured value is
determined, then this is interpolated as new cutting position and entered in the
cutting position buffer. If a cutting position was not able to be measured within
the range that had been selected, then the interpolated cutting position
measuringValue.r64NextCutPosAtSensor is interpolated as new cutting
position and entered in the cutting position buffer. At the same time,
measuringValue i16CutPositionError is incremented by 1. Users can utilize this

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 Program Description
Program Description

SIMOTION Flying Saw SIROT- ID: 37841424

variable for diagnostics/error monitoring. This counter is reset to 0 if the

measurement was successful.
CPM_SIMULATED: With the activation, the cutting position determination
function immediately keeps one of the “measured values” referred to a fictitious
sensor. Activating an “immediate cut” (OnTheSpotCut) initiates the same
procedure as when activating the cutting position determination function – a
“measured value” referred to the fictitious sensor is immediately kept.
Its position (measuringValue.r64CutPosAtSensor) is, using the geometrical
data usersInterface.r64DistanceToSensor and usersInterface.r64StartSyncPos
interpolated to the cutting position (measuringValue.r64CutPosAtSyncPos) and
is entered as the first cutting position into the cutting position buffer.
For all additional cutting positions, the position value that was last saved is
subtracted from the actual position value of the material web. If this difference
is greater than the actual cut length, the new cutting position is determined
from the sum of the position value saved and the actual cut length - and saved
as position value.

CP-CALCULATED
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

In this operation mode there is no activity necessary.

Copyright Siemens AG 2014 All rights reserved

8.4.7 Error messages

No errors are generated.

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 Program Description
Program Description

SIMOTION Flying Saw SIROT- ID: 37841424

8.5 Measured value memory system blocks used in the

flying saw application
The flying saw system uses these blocks. As standard, the user does not have to
access them!

8.5.1 Deleting and resetting the measured value memory

FBCutPositionBufferReset

Deleting and resetting the measured value memory.

Block name
FBCutPositionBufferReset

Task
Deleting and resetting the measured value memory.
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Copyright Siemens AG 2014 All rights reserved

Integration in run-time system

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

Graphic representation of the block

Block parameters

Input / output parameters

Name Data type Initial value Description

cutPositionBuffer Structure of the measured value memory with all

sCutPositionBuffer
of the required control signals and pointers (refer
Management ManagementType
to the chapter, data types)

Functionality
Deletes all of the memory contents by overwriting memory elements with 0.0 or
FALSE
Resets all pointers to 0
Resets all status signals to FALSE

Error Messages
No errors are generated.

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Program Description

SIMOTION Flying Saw SIROT- ID: 37841424

8.5.2 Entries in the measured value memory FBCutPositionBufferIn

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

Block name
FBCutPositionBufferIn

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

Integration in run-time system

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

Graphic representation of the block

2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

Block parameters

Input parameters
Name Data type Initial value Description
cutPosition LREAL 0.0 [mm] Position measured value
cutPositionNumber [-] Number modulo cycles of position
DINT 0
Modulo measured value
onTheSpotCut BOOL FALSE “Immediate cut” active (on the spot cut)

Input / output parameters

Name Data type Initial value Description

cutPositionBuffer sCutPositionBuffer Structure of the measured value memory with all of

the required control signals and pointers (refer to the
Management ManagementType chapter, data types)

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

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Program Description

SIMOTION Flying Saw SIROT- ID: 37841424

The number of modulo cycles of the actual postion is entered into the measured
value memory.

Error messages
No errors are generated.

8.5.3 Reading out the measured value memory FBCutPositionBufferRead

Reading measured values from the measured value memory.

Block name
FBCutPositionBufferRead

Task
If the block is being used in the SIMOTION Rotary Knife application, then it detects
whether a new position deviation was entered and initiates a corresponding
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

position correction.
Copyright Siemens AG 2014 All rights reserved

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

Integration in run-time system

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

Graphic representation of the block

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 Program Description
Program Description

SIMOTION Flying Saw SIROT- ID: 37841424

Block parameters

Output parameters
Name Data type Initial value Description
flyingSawStart BOOL FALSE Start condition of the flying saw
positionMeasured LREAL 0.0 [mm] next sync position
positionMeasuredNumber
DINT 0 [-] Number modulo cycle of next sync position
Modulo
onTheSpotCut BOOL FALSE TRUE: On the spot cut active

Input / output Parameters

Name Data type Initial value Description
sCutPosition
cutPositionBuffer Buffer Structure of the measured value memory with all of
the required control signals and pointers (refer to the
Management Management chapter, data types).
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

Type
Copyright Siemens AG 2014 All rights reserved

Functionality
Depending on the calling application, the block executes the following activity:
The block checks as to whether a new position measured value (cutPosition) was
entered. If yes, the flag “flyingSawStart” is set and the measured position is
transferred as synchronous position for the next processing cycle.

Error messages
No errors are generated.

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Program Description

SIMOTION Flying Saw SIROT- ID: 37841424

8.5.4 Exporting from the measured value memory FBCutPositionBufferOut

A measured value (position measured value and position deviation) is exported

from the measured value memory.

Block name
FBCutPositionBufferOut

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

Integration in run-time system

The block can be called in any task.
The block is used by the SIMOTION Rotary Knife or SIMOTION Flying Saw
application and does not have to be linked-in by the user.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

Graphic representation of the block

Block parameters

Input / output parameter

Name Data type Initial value Description

cutPositionBuffer sCutPositionBuffer Structure of the CutPositionBuffer with all of the

required control signals and pointers (refer to the
Management ManagementType chapter, data types)

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

Error messages
No messages are generated.

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 Attachment
Description of the State Changes

SIMOTION Flying Saw SIROT- ID: 37841424

Attachment

9 Description of the State Changes

The following table describes the function sequences that are hidden behind the
modes and the mode changes.
Table 9-1 Description of the sequences at the state change (state transition) in the FBFlyingSaw
Step Function Comment
Mode ERROR (0)
0
Error

ERROR DISABLE 0 1
Error Disable

0 All ErrorID memories are reset

1 Calls the _resetAxisError() for the flying saw axis

Calls the _resetFollowingObject() for the flying saw axis

2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

If the axis and the synchronous object have no error condition, then the
DISABLE mode is activated.
Mode DISABLE (1)
1
Disable

DISABLE DISABLE 1 1
Disable Disable

0 The stop command is prepared

1 _move() with velocity = 0.0 is called for the flying saw axis
2 _disableAxis() is called for the flying saw axis

If the axis is disabled, then the DISABLE mode is activated.

DISABLE ERROR 1 0
Disable Error

0 Preparation
1 _disableAxis() is called for the flying saw axis

If the axis is disabled, then the ERROR mode is activated

DISABLE STARTPOSITION 1
2
Startpo-
Disable
sition

0 The enable command is prepared

1 _enableAxis() is called for the flying saw axis

If the axis is enabled, then advance to step 2

2 _resetAxisError() is called for the flying saw axis

If the axis is OK, advance to step 3

3 _pos() is called for the flying saw axis with the direction of rotation for
the shortest path

If the starting position is reached, then the “starting position” mode is

activated.

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Description of the State Changes

SIMOTION Flying Saw SIROT- ID: 37841424

DISABLE MANUAL 1 4
Disable Manual

0 The enable command is prepared.

1 _enableAxis() is called for the flying saw axis

If the axis is enabled, then the MANUAL mode is activated

Mode, STARTPOSITION (2) 2
Startpo-
sition

STARTPOSITION ERROR 2
0
Startpo-
Error
sition

0 Preparation
1 _disableAxis() is called for the flying saw axis

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

STARTPOSITION DISABLE 2
1
Startpo-
Disable
sition

0 The stop command is prepared.

2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

1 _move() with velocity = 0.0 is called for the flying saw axis
Copyright Siemens AG 2014 All rights reserved

2 _disableAxis() is called for the flying saw axis

If the axis is disabled, then the DISABLE mode is activated

STARTPOSITION AUTOMATIC 2 3
Startpo- Automa-
sition tic

0 Resetting the CutPosBuffer

Activation of the measuring system is required.
Activation the AUTOMATIC operating mode
STARTPOSITION MANUAL 2
4
Startpo-
Manual
sition

0 This state change is achieved using an automatic state change

sequence that reaches the manual state through the disable state.
Mode, AUTOMATIC (3) 3
Automa-
tic

Automatic cycle
0 Wait until a valid synchronous position is available

If yes, then advance to step 1

1 _enableGearing() is called to synchronize the flying saw axis to the
material web at the master and slave positions

If synchronization was successful, then continue with step 3,

if not, then continue with step 2
2 _disableGearing() is called to delete (clear) the command from the
command queue.

If this is successful, then continue with step 0

3 The cut output bit is set

The actual synchronous position is deleted (cleared) from the

CutPosBuffer

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Description of the State Changes

SIMOTION Flying Saw SIROT- ID: 37841424

4 Wait until stopCutting signal appears

If the gap signal is present, then continue with step 5

If not, then continue with step 6

5 _pos() is called for the flying saw axis using the merge mode
SUPERIMPOSED_MOTION_MERGE in order to create a gap with the
superimposed motion.

When completed, then continue with step 6.

6 If the knifeOut signal appears, then _pos() is called for the flying saw
axis to return to the starting position.

When completed, then continue with step 1.

AUTOMATIC ERROR 3
0
Automa-
Error
tic

_disableAxis() is called for the flying saw axis

If the axis is disabled, then the ERROR mode is activated

AUTOMATIC DISABLE 3
0
Automa-
Error
tic
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc

0 The stop command is prepared

Copyright Siemens AG 2014 All rights reserved

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

If the axis is disabled, then advance to step 2

2 _disableAxis() is called for the flying saw axis

If the axis is disabled, then the DISABLE mode is activated

AUTOMATIC STARTPOSITION 3 2
Automa- Startposi-
tic tion

0 Resets the cut output bit

If the knifeOut signal is present, then prepare the position command and
advance to step 1
1 _pos() is called to return the flying saw axis back to its starting position.
Mode, MANUAL (4) 4
Manual

MANUAL ERROR 4 0
Manual Error

_disableAxis() is called for the auxiliary axis and the flying saw axis

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

MANUAL DISABLE 4 1
Manual Disable

0 The stop command is prepared

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

2 _disableAxis() is called for the flying saw axis

If the axes are disabled, then the DISABLE mode is activated

MANUAL STARTPOSITION 4
2
Startposi-
Manual
tion

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Description of the State Changes

SIMOTION Flying Saw SIROT- ID: 37841424

0 _pos() is called for the flying saw axis with the direction of rotation for the
shortest path

If the starting position is reached, then the “starting position” mode is

activated.
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

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 Attachment
General information on the application

SIMOTION Flying Saw SIROT- ID: 37841424

10 General information on the application

10.1 Scope of supply
The "flying saw" package comprises:
Program
S7/Scout project as ZIP file:
SIMOTION_FlyingSaw _V2.1.zip
TestFB-Program
S7/Scout-Projekt as ZIP-File:
SIMOTION_FlyingSaw _TestFB_V2.1.zip
Library
HTML-Export as ZIP-File:
SIMOTION_FlyingSaw _LFSLib_V2.1.zip
Documentation
Implementation/Operating Instructions as PDF file
Manual_SIMOTION_FlyingSaw_V2.1.pdf
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

10.2 Revisions/Author
Table 10-1: Revisions/Author
Version Date/Revision Author
V 1.0 Generation H.-E. Böhm
V 1.1 Change-over Ethernet H.-E. Böhm
V 1.2 Protool templates trilingual Ch. Pabst
H.-E. Böhm
V 1.2 Changes General Notes A. Hagelauer
V 1.3 13.04.06 Scout V4.0 H.-E. Böhm
V 1.3 04.04.07 Functional Changes: H.-E. Böhm
(V 2.0!) - synchronization according to
leading axis values.
(asymptotic synchronization)
- Ratio between measured and
effective velocity of material web
V 1.4 06.06.08 Replacing ProTool by P. Tabori
WinCflex / SCOUT V4.1.1.6 H.-E. Böhm
V 2.0 March 2010 changeover to the H.-E. Böhm
StyleGuide
Adapt to ongoing projects
Essential simplifications
V2.1 2011 up to September 2014 H.-E. Böhm
Extension by break down process
Error correction
Improvements error detection
Adaption to CutToLength-Line
requirements

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 Attachment
Contact partner

SIMOTION Flying Saw SIROT- ID: 37841424

11 Contact partner
Application Center

SIEMENS
Siemens AG
Industry Sector
Drives Technologies Division
Motion Control Systems
DF FA PMA APC
Frauenauracher Str. 80
91056 Erlangen
Fax: +49 (0) 9131-98–1297
mailto: tech.team.motioncontrol@siemens.com
2014-11-05-Manual_SIMOTION_Flying_Saw_V2.1.doc
Copyright Siemens AG 2014 All rights reserved

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 Attachment
Please help us to become even better

SIMOTION Flying Saw SIROT- ID: 37841424

12 Please help us to become even better

DF FA PMA APC Sender:
Application Center Name:
Department:
D – 91056 Erlangen City:
Fax: +49 (0) 9131/98–1297 Telephone:
E-Mail: tech.team.motioncontrol@siemens.com E-Mail:

Evaluation of the document

Is this subject helpful/ beneficial for you? Yes No

How high are the benefits of this application for you in the following working phases?
Very high Very low

– own training/ information

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– conceptual phase
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– engineering/writing code

– commissioning

How is this application from the didactic perspective?

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– scope

– layout/design

– clarity

Can the application be transferred to your own application?

Very easily Not easily

Do you require support for this application? Yes No

Other comments ..............................................................
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