Manual SIMOTION Rotary Knife V2.0

User Manual Rotary Knife
SIMOTION Rotary Knife V2.0

Application No.: A4027118-A0405
General Notes
SIMOTION Rotary Knife
A4027118-A0405
Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc
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
A4027118-A0405
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

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 customers place of business is in Germany. If customers 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.
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General Notes
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/ Alternative 3: (direct export 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 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:applications.erlf.aud@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 service/maintain the products which are to be used. He or she must have the 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
A4027118-A0405
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 The documentation of this application is sub-divided into the following main section:
Section
Description In the first section you can obtain an overview of this standard application. This Section explains the prerequisites and the objective when using 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. 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. Preparations and parameterizing operations are 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 wish to expand/adapt the functionality of the core functions provided for your particular application. Section Appendix provides you with detailed information including a detailed fault/error description, a description of a test program for the core standard application functions as well as references. A feedback sheet is also provided which you can use to give us your comments and
Note
Prerequisites and objectives
The application example as demosystem
Integrating the core functions
Program description of the technology template
Appendix
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Foreword

Section Description suggestions on this document.
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Note
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Index of contents
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Index of contents
Prerequisites and objectives .................................................................................... 10 1 1.1 1.1.1 1.1.2 1.1.3 1.2 1.2.1 1.2.2 1.2.3 1.3 2 2.1 2.1.1 2.1.2 2.1.3 2.2 2.3 3 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 4 4.1 4.1.1 4.1.2 4.2 4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 5 5.1 5.2 5.3 Basic information................................................................................ 11 Prerequisites ...................................................................................... 11 Target group....................................................................................... 11 Know-how required ............................................................................ 11 Technical environment ....................................................................... 11 Objective and purpose of this standard application ........................... 11 Task.................................................................................................... 11 Application solution using the standard application SIMOTION Rotary Knife ................................................................................................... 13 Advantages of the standard application SIMOTION Rotary Knife ..... 13 Components included in the standard application ............................. 14 Uses ................................................................................................... 15 Applications ........................................................................................ 15 Controls that are permitted................................................................. 15 Tasks that can be implemented using the core functions .................. 15 Properties and features of the core rotary knife functions ............... 16 Exclusions / restrictions...................................................................... 17 Application environment ..................................................................... 18 Structure and function ........................................................................ 19 Geometrical structure of the rotating knife ......................................... 19 Rotary knife cams............................................................................... 21 Design of a cam for cyclic operation .................................................. 21 Segment structure of a rotary knife cam ............................................ 23 Starting and Stop Cam ....................................................................... 24 Linear cutting characteristic ............................................................... 25 Operating states of the application SIMOTION Rotary Knife............. 26 Installing the hardware and software ................................................. 28 Regarding your safety ........................................................................ 28 Safety information and instructions .................................................... 28 Responsibilities of the operator.......................................................... 29 Hardware configuration and installation ............................................. 30 Installing the standard SIEMENS software ........................................ 32 Downloading the user program and parameterizing the drive in the SIMOTION D demonstration case ..................................................... 32 De-archiving the SIMOTION project .................................................. 32 Resetting SIMOTION D435 to the factory settings ............................ 32 Reconfiguration of double-axis motor module from 3A/3A to 5A/5A . 33 Configure Ethernet interface .............................................................. 34 Set the Ethernet address of the PG/PC ............................................. 37 Downloading the hardware configuration after a factory setting........ 39 Downloading the SIMOTION project of the standard application ...... 40 Operator control of the application example ...................................... 42 Structure overview.............................................................................. 44 Brief instructions to demonstrate........................................................ 45 Detailed operating instructions........................................................... 49
The application example as demo system .............................................................. 27
Integrating the core functions .................................................................................. 59
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Index of contents
SIMOTION Rotary Knife 6 6.1 6.1.1 6.1.2 6.1.3 6.2 6.2.1 6.2.2 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 7 7.1 7.2 7.2.1 7.2.2 7.2.3 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6
A4027118-A0405 Program environment and interfaces ................................................. 60 Importing the source code.................................................................. 60 Copying from the application example ............................................... 60 Linking using XML import................................................................... 61 Linking the rotary knife functionality ................................................... 62 Technology objects ............................................................................ 65 Technology objects required and synchronous relationships ............ 65 Synchronous relationships ................................................................. 67 Integrating the SIMOTION Rotary Knife core function....................... 70 Parameterizing the rotary knifes in the startup task........................... 70 Calling FBRotaryKnife in the user program........................................ 70 Calling the FBRKCamCalculation ...................................................... 70 Calling the FBRKIPO in the IPO synchronous task ........................... 71 Global Variables ................................................................................. 71 Program Description........................................................................... 73 Information and warnings................................................................... 73 Type of Data....................................................................................... 73 Overview ............................................................................................ 73 Enumeration types ............................................................................. 74 Data Structures .................................................................................. 75 FBRotaryKnife .................................................................................... 84 Block name......................................................................................... 84 Task.................................................................................................... 84 Integration in the run-time system...................................................... 84 Graphic representation of the block ................................................... 85 Block parameters ............................................................................... 86 Functionality ....................................................................................... 87 Start identification............................................................................... 87 Axis monitoring functions ................................................................... 88 Checking the input parameters and parameterization of the technology settings that are absolutely necessary ............. 88 Automatic mode change sequences .................................................. 91 Error messages ................................................................................ 100 Cam Calculation for rotating shears FBRKCamCalc ....................... 109 Functions in the IPO task FBRKIpo ................................................. 120 Blocks to manage the format length memory .................................. 123 Resetting the format length memory FBFormatLengthBufferReset. 124 Entries in the format length memory FBFormatLengthBufferIn ....... 125 Reading from the format length memory FBFormatLengthBufferRead127 Exporting from the format length memory FBFormatLengthBufferOut129 Measured value memory system blocks used in the rotary knife application ........................................................................................ 130 Deleting and resetting the measured value memory FBCutPositionBufferReset ............................................................... 131 Entries in the measured value memory FBCutPositionBufferIn....... 131 Reading out the measured value memory FBCutPositionBufferRead133 Exporting from the measured value memory FBCutPositionBufferOut135 Extended functions........................................................................... 136 Using the cutting program ................................................................ 136 Using print mark correction .............................................................. 136 General information on the application ............................................ 138
Program Description ................................................................................................. 72
7.3.7 7.4 7.5 7.6 7.6.1 7.6.2 7.6.3 7.6.4 7.7 7.7.1 7.7.2 7.7.3 7.7.4 7.8 7.8.1 7.8.2 8
Appendix................................................................................................................... 138
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Index of contents
SIMOTION Rotary Knife 8.1 8.2 9 10
A4027118-A0405 Scope of supply................................................................................ 138 Revision/Authors .............................................................................. 138 Contact partner................................................................................. 139 Please help us to become even better............................................. 140
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Prerequisites and objectives Basic information SIMOTION Rotary Knife A4027118-A0405
Prerequisites and objectives

Contents This section will provide you with everything that you require to obtain an overview of this standard application. The prerequisites and the objective for using this standard application are presented. The applications shown will give you a good understanding for what this standard application can be used for. 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 This section 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.
Title Content The necessary prerequisites to use the standard application Rotary Knife. The use of this application. Software components and code blocks of the standard application Rotary Knife. Tasks and properties of the core functions of the standard application Rotary Knife Exclusions and restrictions Hardware components required Type of design and physical quantities for which the rotary knife core function can be used. Type of cams that the rotary knife core functions calculate and used. Operating states at the application.
Chap. 1
Basic information and data
Possible uses
Structure and function
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1
1.1
1.1.1
Basic information
Prerequisites
Target group
The standard application is conceived for all programmers and users that wish to quickly and simply implement cross-cutter functionality using SIMOTION.
1.1.2
Know-how required
In order to use this technology template, you should be able to use SCOUT and technology objects and technology function calls in SIMOTION. This document does not provide an introduction into these subjects and is solely restricted to providing information and data on how to use this standard application.
1.1.3
Technical environment
This standard application can only be used, without having to make any changes, in conjunction with SIMOTION D and the SINAMICS demonstration case.
1.2
1.2.1
Objective and purpose of this standard application

Task
Using SIMOTION, a material web fed using the material feed mechanism is to be cut into identical parts and sections. A rotating knife (rotary knife) is to be used in order to achieve high feed velocities and short format lengths of the cut material sections. The cross-cutter comprises a rotating roll. One or several knives are located along the circumference of this roll. While the roll rotates, the knife cuts the material web fed-in below the roll into identical, defined sections.
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Prerequisites and objectives Basic information SIMOTION Rotary Knife

Figure 1-1: Mode of operation of a cross-cutter (rotary knife)
Rotary Knife
A4027118-A0405
material Continous Web
cutted material
When developing a cross-cutter, the rotating cross-cutter axis control must be programmed so that during a cut, the cross-cutter axis motion is synchronized to the material web. The cross-cutter axis is moved with a special velocity profile between the cuts, so that synchronized motion can be resumed in plenty of time for the next cut. The next cut can be made after synchronization.
Additional applications The same sort of solution is also required for similar processes, mainly in packaging machine applications. The motion sequences described above must also be developed for perforating, embossing, sealing etc. with rotating equipment.
Figure 1-2: Application examples (perforating, sealing and cutting)
In the following text, the rotary knife term is used to represent all of the other conceivable machine versions. Definition The term knife is used for all parts of the machine where direct contact is made to the material when cutting.
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1.2.2
Application solution using the standard application SIMOTION Rotary Knife

The standard application SIMOTION Rotary Knife discussed here can be used to implement such applications, and to develop a functioning cross-cutter as quickly as possible. The standard application already includes, as core function, a pre-configured motion control of the rotary knife axis. This can be adapted to the particular application using the appropriate parameters. The core function is responsible for completely controlling the rotary knife axis. 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 Further, this standard application also has the possibility of checking the required format length using a print mark function in conjunction with a sensor.
This function can also be set at the core function and commissioned by simply entering the appropriate parameters.
1.2.3
Advantages of the standard application SIMOTION Rotary Knife

The use of the standard SIMOTION Rotary Knife application offers users the following advantages:
Programs can be quickly generated Comprehensive cross-cutter functionality can be easily and quickly implemented using the standard application SIMOTION Rotary Knife when programming with SIMOTION. The core functions provided in the standard application can be transferred into the application to be generated quickly and simply by copying. The description of this standard application explains the additional configuring steps that are necessary. Automatic motion control The core functions of the standard application SIMOTION Rotary Knife can be used to realize all of the cross-cutter axis motion control using SIMOTION technology functions. The user only programs an execution sequence that corresponds to the actual behavior of the machine function to be implemented. Possibility of adaptation All of the source codes are available in commented form for the standard application SIMOTION Rotary Knife. This means that the existing core functions can be quickly and simply expanded by the user's own particular functions.
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1.3
Components included in the standard application

The standard SIMOTION Rotary Knife application is implemented as SIMOTION project as well as library. The project can be simultaneously used for a (demonstration) machine for a SIMOTION D demonstration case and PC with WinCC Flexible 2008 for visualization. The program fulfills the following tasks: The control of the (demonstration) machine All of the machine functions that are relevant for the demonstration case environment are simulated The (demonstration) machine is displayed on the WinCCflex screen Operating mode manager for the complete (demonstration) machine
This allows the core functions of the standard SIMOTION Rotary Knife application to be quickly and simply integrated in projects that the user has created himself.
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Prerequisites and objectives Uses SIMOTION Rotary Knife A4027118-A0405
2
2.1
2.1.1
Uses
Applications
Controls that are permitted
The standard SIMOTION Rotary Knife application can be used on any SIMOTION control.
2.1.2
Tasks that can be implemented using the core functions

These core functions are used to control rotating equipment and mechanisms to Cut Perforate Emboss Seal etc.
The core rotary knife function completely handles the motion control of the rotating axis used for cutting. The functionality associated with the material feed is implemented outside the core functions in the user program.
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2.1.3
Properties and features of the core rotary knife functions

The following properties and features were taken into account when implementing the core functions, and can also be used in a user program that you generate yourself: Linear cutting characteristic When cutting, the material and cross-cutter axis travel with the same (peripheral) velocity or optionally with the over-velocity. Polynomial cutting characteristic The cutting characteristic is defined by the over-velocities at the start of the cut, at the Zero position within the cut and at the end of the cut. Cam profile Cams are used to control the motion of the cross-cutter axis. The following cam profiles can be parameterized: Linear (constant acceleration), trapezoidal (jerk limiting), polynomial. Print mark correction with adjustable correction speed During operation, deviations in the print marks, identified by the user, can be corrected using a higher-level motion. Multi-knife systems The rotary knife core function can also be used for cross-cutter axes that have more than one knife. The quiescent position of the cross-cutter axis can be set The quiescent position of the knife between two steps can be set using a parameter at the core function. Defined starting and stopping characteristics Special cams are used to implement the starting and stopping characteristics of the cross-cutter axis. This means that the motion control of the cross-cutter axis before and after cutting operations can be precisely determined. Cut length management The additional core functions for cut length management also allow the cams to be calculated with precise segments as a function of the precise segment length previously determined using print marks. This means that formats can also be changed using print marks.
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2.2
Exclusions / restrictions
The following features were not taken into account when implementing the application: Non-linear cutting characteristic The application cannot be used without first making changes if the cut characteristic must be influenced using a non-linear cut characteristic, which cannot be emulated using a polynomial cut characteristic with speed increases. Cutting torque input The application only influences the cross-cutter axis via its speed and position interface. The motor torque cannot be influenced. Seamless continuation of the cut after a fault stop If, during the cut, the cross-cutter goes into a fault condition, then the application function does not permit the cut to be continued. Cross-cutter operation can only be resumed after removing the cause of the fault, acknowledging it and then returning to the initial state. High impetus Motion of the cross-cutter to increase knife impetus for thick materials is not provided in the application.
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2.3
Application environment
The standard application SIMOTION Rotary Knife can be used in the following hardware environment:
Figure 2-1: Application environment of the standard application SIMOTION Rotary Knife
PG / PC
SIMOTION D
Encoder
Sensor
Motor
Cross-cutter Material web

Motor Encoder SIMODRIVE / MASTERDRIVES / SINAMICS
The material feed and the drive control of the rotary knife axis can be controlled from a SIMOTION control system. Alternatively, the rotary knife axis can also be coupled through an encoder mounted on the machine.
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Prerequisites and objectives Structure and function SIMOTION Rotary Knife A4027118-A0405
3
3.1
Structure and function

Geometrical structure of the rotating knife
The rotating knife used as basis for the application comprises a rotating axis, where tools (knives) are located around the circumference. The following geometrical quantities (names in white) are used in the application:
Figure 3-1: Geometrical quantities at the standard Rotary Knife
InflectionPoint
KnifeCircumference
Format range
StartAngle
Sensor
StopAngle
EndSyncAngle
StartSyncAngle
Synchronous range
Sensor Position
Rotary Knife Position

DistanceToSensor
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Prerequisites and objectives Structure and function SIMOTION Rotary Knife

Table 3-1: Explanation of the parameterizable physical quantities Physical quantity
KnifeCircumference [mm] StartAngle [] InflectionPoint [%] StopAngle [] StartSyncAngle []
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Description
Effective circumference of the rotary knife (circle circumference) Start angle of the knife referred to 0 Reverse position (inflection point) of the cyclic cam referred to the length of the format range Stop angle of the knife referred to 0 Start point of the synchronous range referred to 0. From this position onwards, the cutting knife must move in synchronism with the material to be cut. End point of the synchronous range referred to 0. From this point onwards, the knife no longer has to move in synchronism with the material to be cut, and depending on the requirement, can be accelerated or decelerated to adapt the format Number of knives distributed around the circumference. Distance between the cutting position (0) and the sensor to detect the material and print mark
EndSyncAngle []
NumberOfKnives DistanceToSensor [mm]
Synchronous range The synchronous range is located between StartSyncPos and the EndSyncPos. The actual cutting operation occurs within this range and the knife of the rotary knife axis operates with the same velocity as the material web or is synchronized with the material web. Format range The format range is obtained according to the following formula: Format range = KnifeCircumference / NumberOfKnives synchronous range Between two cutting operations, the rotary knife axis moves in the format range. This is the reason that the dynamic values of the rotary knife axis must be selected so that the motion can be controlled within this range between two cuts. This means that the rotary knife axis can move through the length of the format range with all of the appropriate acceleration and braking operations between two cutting operations. It can then have the same velocity as the material web before the next cut.
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3.2
3.2.1
Rotary knife cams

Design of a cam for cyclic operation
The following interrelationship exists when representing the following cams
Note
360 [circumferential angle] = 200 mm [circumference along the knife tips] This representation type means that it is not necessary to convert from Degrees into millimeters when considering the velocity!
Principal design
Figure 3-2: Segments of a rotary knife cam
Cross-cutter circumference
200 mm
Cutting point
Format range
180 mm
Half of the synchronous range at the d f th t

20 mm
?
20 mm Sheet length 20 mm
Half of the synchronous range at the start of the cuts
Cutting point
0 mm 0 mm Sheet length
Material web
The cam has two essential tasks: 1.) Definition of the cutting curve in the synchronous range The shape of the cam in the synchronous range is generated from the specifications of the cutting curve. The cutting curve is independent of the format length. 2.) Adaptation of the format in the format range The shape of the cam in the format range is generated from the difference between the circumference and the format length and is therefore dependent on the format length. This is the reason that the cutting point (defined as position 0) is selected at the changeover point of the cams. The reason for this is that the synchronous range is identical for all of them and can therefore be changed over without any jerk.
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Prerequisites and objectives Structure and function SIMOTION Rotary Knife

Table 3-2 Cam
Circumference, cross-cutter
200 mm
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Description circumference < cut length If the cut length is greater than the rotary knife circumference, then within the format range, the rotary knife must be decelerated, starting from the synchronous velocity, and then be reaccelerated to the synchronous velocity. If the cut length is significantly longer than the rotary knife circumference, then the rotary knife comes to a standstill and if the cut length increases even further, then it has an even longer pause.
180 mm
100 mm
20 mm
0 mm 0 mm 20 mm Cut length 20 mm Cut length
Cross-cutter circumference Cross-cutter circumference

200 mm
Material web
180 mm
100 mm
circumference = cut length If the cut length precisely corresponds to the rotary knife circumference, then the cutting knife moves with the velocity of the material web. The format range in this case corresponds to the synchronous range. This is the reason that in principle, there is only one single synchronous range that extends over the complete cut length.
20 mm
Cross-cutter circumference Cross-cutter circumference

200 mm
Material web
180 mm
circumference > cut length If the selected cut length is less than the rotary knife circumference, then the crosscutter, in the format range, must be accelerated starting from the synchronous velocity and then decelerated back down to the synchronous velocity.
100 mm
20 mm
Material web
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3.2.2
Segment structure of a rotary knife cam

As the format length increases, there is a danger that the knife will move backwards into the synchronous range. This can result in damage and must therefore be avoided. The format length from which reverse motion is executed is called the critical length. This is the reason that the format range of the cam is sub-divided into three segments, to allow the knife to dwell at the start position for format lengths greater than the critical length.
Figure 3-3: Diagram showing the segments of the rotary knife cam
200 mm
180 mm
100 mm
20 mm
Material web
Segments I and V define the synchronous range and therefore the specified cutting curve, segments II, III and IV define the format range.
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3.2.3
Table 3-3
Starting and Stop Cam
Cam Type
200 mm
Description
Synchronizing to the starting cam

Using the starting cam, the cutting knife is brought out of its starting position into the cutting position and is accelerated up to the velocity of the material web. This cam is defined over the complete cutting length so that it can be started if the leading material edge reaches the cutting position. For short cutting lengths and knife systems with a high inertia then the cross-cutter can be immediately accelerated. At the cutting position (zero position!) the cam for cyclic operation is selected.
180 mm
Basic position 100 mm
Start
20 mm
Material web
200 mm
De-synchronizing with the stop cam

If the rotary knife is to be stopped, or there is no material under the rotary knife, then to stop a changeover is made to the stop cam when the knife at the cutting position. This means that the cutting knife is kept at the starting position. After this, the rotary knife is taken out of the synchronous group with the material web.
180 mm
Starting position 100 mm
End
20 mm
Material web
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3.2.4
Linear cutting characteristic

Thin materials can be cut essentially at a precise point using a linear cutting characteristic at the cutting point the circumferential velocity of the knife is precisely equal to that of the material. With increasing material thickness, the material bunches up at the entry and exit points of the knife (vector break-down of the circumferential velocity in the direction of the material!).
Table 3-4 cutting characteristic Cam
Knife entry
Knife exit
Cutting point
Example of a velocity profile with linear cutting curve without velocity increase.
Generally, special cutting curves must be developed for thicker materials. These special cutting curves then equalize these velocity differences. The application offers the option of defining cutting curves by increasing the velocity (start of the cut, cut center point, cut end point). A linear interpolation is made between these points.
Table 3-5 cutting characteristic Cam
Knife entry
Knife exit
Cutting point
Example of velocity profile with cutting curve using velocity increase at the start and at the end of the cut.
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3.3
Operating states of the application SIMOTION Rotary Knife

FBRotaryKnife automatic controls the rotating knife to implement the required functionality. This functionality is sub-divided into six operating states so that the sequences at the rotary knife are implemented as a result of the states or also as a result of the transitions between the states. This means the user only influences the rotary knife by specifying the required operating mode with the required parameters
Figure 3-4: Operating modes
4 Manual
1 Disable
0 Error 2 Startposition
6 Sample Cut
3 Automatic
5 Single Cut
Table 3-6 State

ERROR (0)
Description
FBRotaryKnife has detected a fault and has brought the rotary knife axis into a safe state. The fault is still present and can be evaluated by the user. The rotating knife has been stopped and is in the DISABLE mode. FBRotaryKnife is ready for use, but is still in the safe operating state. All of the pending faults have been successfully acknowledged. The rotating knife is in the state after a reset, deactivated and stopped The rotating knife is moving or is already located at the START POSITION and is ready to be synchronized to the material web. The axis waits in the START POSITION operating mode The rotating knife has been synchronized to the material web and is cutting the material according to the specifications The rotating knife is the manual mode; the user can manually move the axis. The axis waits in the MANUAL operating mode. The rotating knife is ready for a single cut. The rotating knife is ready to cut a series of test pieces
DISABLE (1)
STARTPOSITION (2) AUTOMATIC (3) MANUAL (4) SINGLE_CUT (5) SAMPLE_CUT (6)
These operating modes are available to users to implement their cross-cutter functionality in a user program and can be signaled to the FBRotaryKnife using input parameters. The FBRotaryKnife indicates the currently reached status using an output parameter.
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The application example as demo system Structure and function SIMOTION Rotary Knife A4027118-A0405
The application example as demo system

Content All of the necessary steps to commission the rotary knife standard application as presentation system are explained in this section. Preparations and parameterizing operations are explained. Further, you are told how you can use the WinCCflex man-machine interface (screen) of the application example step-by-step. Objective This Section of the document provides the reader with the following
The prerequisites to use this standard SIMOTION application as demonstration system Explains the preparatory activities and parameterizing operations Describes the steps necessary when presenting this standard application. Provides tips for using this standard application.
Title Content Safety information and instructions 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 Brief instructions on how to use the demonstration system Detailed Operating Instructions
Chap.. 4
Installing the hardware and software
Operator control of the application example
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4
4.1
4.1.1
Installing the hardware and software

Regarding your safety
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.
Danger
! ! !
This safety information/instruction indicates an immediate hazard. If the information/instruction is not carefully followed, this results in severe bodily injury or even death.
Warning
This safety information/instruction indicates a potential hazard. If the information/instruction is not carefully followed, this can result in severe bodily injury or even death.
Attention
This safety information/instruction indicates a potentially hazardous situation that can result in slight to average bodily injury. This pictogram/text word can also warn about potential material damage.
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4.1.2
Correct use
Responsibilities of the operator
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. 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. Hardware structure and mounting/installation
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4.2
Overview
Hardware configuration and installation

Figure 4-1: Hardware components (without power cable!)
Ethernet
The demonstration project can be commissioned using a conventional SIMOTION D435 demonstration case and a PC connected via Ethernet.
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The application example as demo system Installing the hardware and software SIMOTION Rotary Knife
Table 4-1: Hardware components Hardware element
SIMOTION D demonstration and training case
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Figure
Order No./MLFB and functions

6ZB2 470-0AE00 The SIMOTION D training case comprises 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 Ethernet.
Training case, SIMOTION D435 with SINAMICS S120
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 Ethernet 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 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
Note
Installing the standard SIEMENS software

If the application is only to be used to demonstrate and present, then it is only necessary to install WinCC Flexible 2008 with 256 power tags.
Minimum required releases

Table 4-3: Versions Component STEP 7 SIMOTON SCOUT WinCC Flexible WinCC Flexible Runtime Version V5.5 V4.2.1 2008 SP2 2008 SP2
4.4
4.4.1
Downloading the user program and parameterizing the drive in the SIMOTION D demonstration case
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 start 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: Once the factory setting has been restored, the SIMOTION D435 has PROFIBUS address 2 and the baud rate is 1.5 Mbit/s. 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
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4.4.3
Reconfiguration of double-axis motor module from 3A/3A to 5A/5A
This Standard Application is configured with a 3A/3A motor module. If this project is used with demonstration racks of a different rated power, e.g. with double motor modules 5A/5A, the configuration in the project has to be changed accordingly:
Change to offline mode Open the drive navigator in the project navigator window By pressing the button device configuration a new window opens Carry out drive configuration, by pressing the relevant button Press continue until you reach the window configuration power unit Select the used power unit in the list, compare serial number at front face of the motor module, e.g. 6SL3120-2TE15-0AA0 (5A/5A) Press continue and acknowledge warnings Press continue , without conducting any further changes, until the button finish appears and finish the configuration by pressing that button Close the window device configuration Reduce parameter p210 separately in both drives (Antrieb rot, Antrieb blau) from 600V to 345V by using the expert list (mark respective drive -> right mouse button -> expert -> expert list) Save and compile project, connect to target system and download your project
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4.4.4
Configure Ethernet interface
Set PG/PC interface

Table 3-5: Setting the PG/PC-interface configuration No. Action Comment
1 Open the interface configuration in SIMOTION SCOUT via EXTRAS SET PG/PC INTERFACE...
2 Among the features by Interface Parameter Assignment Used, please select your Ethernet card / interface of the PG/PC with TCP/IP ...... (e.g. TCP/IP VIA PCI 10/100I Fast Ethernet Adapter).
3 Confirm (possible) warning by Yes.
4 Confirm your changes with OK twice 5 Return to SIMOTION SCOUT and open the net configuration NETPRO by using the button selecting the Menu PROJECT OPEN NETPRO. or by
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6 Double-click on PG/PC(1) to open the properties.
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7 Under the feature Assignment (which has already been selected automatically), the applied ETHERNET interface has to be indicated under Parameter assigned. If this is already the case, you only have to select it and put the tick in the box marked S7ONLINE Access: active. In this case, please skip the steps 8 and 9!
Confirm your entry with OK. After that, the Ethernet line of the PG/PC is marked in yellow.
If the applied ETHERNET interface is not indicated under parameter assigned(but only in that case!), please execute the steps 8 and 9 8 ETHERNET has not been assigned, yet: You can find the configured interface of the control under Configured Interfaces and all available interfaces in the PG/PC under Interface Parameter Assignments in the PG/PC. Select under Interface Parameter Assignment the applied ETHERNET interface (like it has been set in Set Interface in PG/PC) and push the button Assign. If a warning appears, please, confirm it with OK.
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9 After that, the interface of the control is assigned to the interface of the PG/PC. If this assignment has not been selected, yet, please do it now and put the tick in the box marked S7ONLINE Access: Active. Confirm your entry with OK. After that, the Ethernet line of the PG/PC is marked in yellow.
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10 Please, select Compile and check everything. Select the (button ) and confirm with OK.
11 Please close all possible appearing warnings.
12 Before you close the project of loading, please connect NETPRO and adjust the Ethernet address of your PG/PC. For this, please, see the next paragraph
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4.4.5
Set the Ethernet address of the PG/PC
Table 3-6: Ethernet address No.

1
CONNECTIONS
Action
Open the window NETWORK AND DIAL-UP of your PG/PC, select the applied network connection to SIMOTION D435, and open its properties. (Right mouse click mark properties or symbol and then FILE PROPERTIES).
Comment
In the area Components checked are used by this connection, please select the Internet Protocol (TCP/IP) and open its properties.
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3 The standard IP address of the Ethernet interface IE2/OP (X130) for the SIMOTION D435 is 169.254.11.22. Please, select Use the following IP address and enter the IP address 169.254.11.23. Please, enter 255.255.0.0 in the Subnet mask.
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4 The configured address need to be identical with the address of the PG/PC! Check the configured address in the properties of the PG/PC interface and change it if necessary
Confirm your changes by pressing OK twice.
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4.4.6
Downloading the hardware configuration after a factory setting

To download the hardware configuration, please proceed as follows:
Table 4-4: Downloading the hardware configuration according to the factory setting No. Action
1 Change to HW-Config and download the hardware configuration
Comment
2 Confirm with OK
3 Confirm with OK
4 Press No
5 Close the HW-Config and change to SCOUT
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4.4.7
Downloading the SIMOTION project of the standard application
Table 4-5: Downloading the SIMOTION project No.

1.
Action
Before you download the project, in the offline mode, please check under Target system/Select target devices
Comment
2.
Whether both SIMOTION D435 as well as also SINAMICS_Integrated are selected. Please acknowledge changes with OK.
3.
After establishing the ONLINE connection, the operating states of the devices accessed, are displayed in the diagnostics overview.
4.
After starting the download, you will be prompted as to whether you wish to copy RAM to ROM after the download. Always answer this question with Yes as otherwise your program must be again downloaded after power ON/OFF. This copy operation only refers to the SIMOTION part of the project
5.
Once the download has been completed, please acknowledge with OK
6.
Also acknowledge the data that has been successfully copied from the RAM to ROM with OK
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No.
7.
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Action Comment
The system now prompts you whether you wish to also copy the parameters of SINAMICS_Integrated from the RAM to the ROM. Also answer this with Yes
8.
Also acknowledge the data that has been successfully copied from the RAM to ROM with OK
9.
After the download has been completed, youll see the adjacent diagnostics overview.
10.
Now switch the SIMOTION D435 into the RUN state. To do this, click on the SIMOTION-CPU and with the right hand mouse key and target device/operating state, go to the operating state display.
11.
Here, click on the RUN button
The SIMOTION D435 is then in RUN and the demonstration case is now ready to be used for the presentation!
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife A4027118-A0405
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. In the following Chapter 5.2
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Brief instructions to demonstrate you will find brief instructions on how to present and present the application example. You will find detailed descriptions of all operator displays in Chapter 5.3 Detailed operating instructions.
Prerequisites The following prerequisites must be fulfilled in order to use the application example: Note WinCCflex requires the appropriate authorization. Authorization for at least 256 power tags is required. 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 devices have been powered-up. The SIMOTION D435 has been switched into the Run state using the online function of SIMOTION SCOUT. As a minimum, WinCCflex Advanced 2008 SP2 has been installed on the PC/PG.
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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. The SETTINGS and STATUS displays are not required when presenting the application and are therefore not described in the detailed Operating Instructions.
Figure 5-1: Structure overview to demonstrate the application
HOME Manual-Mode
SETTINGS
MANUAL Automatic-Mode
STATUS
AUTO
TECHNOLOGY
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5.2
Brief instructions to demonstrate

Here, in these instructions you will only be shown and explained the steps necessary to demonstrate the application. Not all of the operator screens will be discussed. You will find detailed descriptions of all operator displays in Chapter 5.3 Detailed operating 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 rotary knife application example No.
1.
Action
Call the following file C:\Siemens\Step7\S7Proj\SAP_RotaryKnife\TDOP\ PRO__00.fwd. As an alternative, you can also select the operator panel using Step 7. In the SIMATIC Manager, open the SAP_RotaryKnife project. You will find the HMI object OP1 at the project level. Start the runtime from the context menu (righthand mouse key)
Comment
2.
If the connection to the CPU was able to be established, the screen form appears at the top left mode: Idle At the bottom left, please click on AUTO rd (3 button from the left!)
Please check that your PG/PC is set to MPI with 12 Mbit/s or to automatic.
3.
4.
First activate the print mark simulation by pressing the Print Mark Simulation ON / OFF button.
5.
Next, using the Start Position slider, select the required basic setting and activate the movement to the starting position by pressing the Rotary Knife STARTPOS button
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife
No.
6.
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Action Comment
Once the rotary knife has reached its starting position, the Rotary Knife START button is displayed to activate the rotary knife Before you activate the rotary knife, the required cut length should be selected using the CutLength slider.
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.
Once the material has reached the rotary knife, using the CutLength slider, you can enter a new cut length, and activate with the activate button.
9.
The new cut length is only taken into account after the actual segment has been completely entered. The activate button remains green for this time! Activate the technology screen by pressing the TECHNOLOGY button
10.
The following are displayed in the technology screen: The actual material velocity The actual rotary knife velocity The actual position of the rotary knife The starting position of the rotary knife You can return to the automatic screen by pressing the AUTO button
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No.
11.
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Action Comment
The material can be removed by pressing the Material END button
12.
After the last cut, the rotary knife automatically moves to its starting position and waits for new material.
13.
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 application by pressing the Rotary Knife END button.
14.
After the application has been ended, you can return to the welcome screen by pressing the HOME button
15.
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife Process screen The process screen is the main screen in the automatic mode of the application example to control (operator control) the rotary knife.
Figure 5-2: Process screen in the automatic mode of the rotary knife
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Mode of the application rotary knife
Position and velocity of the material and rotary knife
Operating state (OMAC), application example Velocity input (setpoint)
Rotary Knife Material Random print mark offset

Length scale Start material
Start the rotary knife
Move rotary knife to the starting position End application
Stop/ hold material Allow material to be removed
Basic settings
Manual mode
Automatic mode
Calls the technology screen
To the status display
To the welcome screen
The material and the rotary knife can be started, terminated (exited) and monitored in the process screen. The material (material web) is started, stopped (held) and terminated (exited) on the lefthand side; the rotary knife is started and exited on the righthand side.
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5.3
Detailed operating instructions

A detailed description of the application is provided in these instructions. This is necessary so that you can get to know and test the CPU functions.
Start In the SIMATIC Manager, open the SAP_RotaryKnife project. You will find the HMI object OP1 at the project level. Start the runtime from the context menu (righthand mouse key). Or Call the following file: C:\Siemens\Step7\S7Proj\RotaryKnife_V20\HmiEs\PROJECT_1\ PROJECT_1.OP_Flex.fwx The welcome screen is displayed
Figure 5-3: Welcome screen
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife General screen areas The screen forms of the application are handled using buttons at the lower edge of each of the screen forms. Refer to The name of the actual operator screen form and the presently valid mode are displayed in the upper righthand corner of the screen forms. Refer to A4027118-A0405
The following functions can be selected using the individual buttons:

Table 5-2: General buttons to control/handle the screen forms Button Function You can access the pre-setting screen from every operator screen using the SETTINGS button.
You can access the setting-up screen from every operator screen using the MANUAL button. If the application is in the IDLE or AUTOMATIC-STOPPED modes, the MANUAL mode is selected. You can access the automatic screen from every operator screen using the AUTO button. If the application is in the IDLE or MANUAL modes, the AUTOMATIC-STOPPED mode is selected. You can access the technology screen from every operator screen using the TECHNOLOGY button.
You can access the status screen from every operator screen using the STATUS button.
You can access the welcome screen (home) from every operator screen using the HOME button. If the application is in the MANUAL or AUTOMATIC-STOPPED modes, the IDLE mode is selected.
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife Machine geometry settings The standard application allows the following machine geometry parameters to be adapted: Distance to sensor Distance between the rotary knife axis and the sensor of the material and print mark detection StartSyncPosition Start of the synchronous range EndSyncPosition End of the synchronous range A4027118-A0405
Figure 5-4: SETTINGS operator screen for machine geometry settings
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife Operator functions in the setting-up mode (MANUAL) In the setting-up mode, the material web and the cross-cutter can be manually moved. This standard application does not require any functions that may only be executed in the setting-up mode. This is the reason that we are only providing users with an empty screen form that can be adapted, when required to the specifications and requirements of the users application.
Figure 5-5: MANUAL operator control screen form for the operator functions in the setting-up mode
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife Operator functions for the process in the automatic mode (AUTOMATIC)
Figure 5-6: AUTOMATIC operator screen form for operator functions in the automatic mode
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Note
The automatic mode (AUTOMATIC) is only available, if

There is no fault, Both axes are enabled, and For both of these axes, no manual operator control functions are active.
Standard operator control

Table 5-3: Standard operator control in the automatic mode No.
1.
Action
Initial (starting) situation: The rotary knife is in the AUTOMATIC-STOPPED mode Using the Start Position slider, enter the starting position / basic setting of the rotary knife.
Comment
2.
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No.
3.
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Action Comment
The rotary knife starts to move to the starting position / basic setting by pressing the Rotary Knife STARTPOS button
4.
After the starting position / basic setting has been reached, the rotary knife is in the AUTOMATIC-READY mode
5.
The rotary knife is enabled for operation using the Rotary Knife START button.
6.
The rotary knife is in the AUTOMATIC-STANDBY mode and waits for material.
7.
Select the required material web velocity using the Material Velocity slider.
8.
You can start to thread the material web or continue motion after the material web was stopped by pressing the Material START button.
9.
If the rotary knife has synchronized itself to the motion of the material web, the rotary knife is in the AUTOMATIC-PRODUCING mode. You can stop the material web using the Material BREAK button.
10.
11.
When the material web has been stopped, the rotary knife is in the AUTOMATIC-HELD mode
12.
You can start to remove the material web from the system by pressing the Material END button.
13.
If this symbol appears, then the rotary knife has detected the last segment of the material web and ends its last position with the stop cam in its starting position / basic setting.
14.
The rotary knife then waits in the AUTOMATIC-STANDBY mode for the next material web.
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife Expanded operator control
Table 5-4: Expanded operator control in the automatic mode No.
1.
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Action
If the rotary knife is in the AUTOMATIC-STOPPED, operating mode, you can select one of two possibilities:
Comment
Print Mark Simulation OFF i.e. the demonstration case itself generates print marks using sensors. It is not possible to change the cut lengths Print MARK simulation ON this means that the print marks and therefore also the cut length can be freely selected.
2.
If the print mark simulation has been activated, this character is displayed at the top left edge of the screen.
3.
You can change the cut length with the Cutlength slider.
4.
If the rotary knife is in the AUTOMATIC-PRODUCING mode, you can changeover the print mark simulation using the activate button to the new cut length that you have selected.
5.
Using the button Random Print Marks ON / OFF, you can activate automatic modification of the cut length from print mark to print mark. (presently implemented: The cut length can be modified by +/- 20 mm)
Shift cut function

Figure 5-7: Operator control elements of the shift cut function
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Table 5-5: Using the shift cut function No.
1.
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Action
You can shift the cut by 5 mm to the left using button 5
Comment
2.
You can shift the cut by 1 mm to the left using button -1
3.
You can shift the cut by 1 mm to the right using button +1
4.
You can shift the cut by 5 mm to the right using button +5
5.
Velocity value that is superimposed on the rotary knife velocity for correction motion. Indicates that correction motion is active
6.
Display areas
Figure 5-8: Rotary knife mode
This area informs you about the selected and presently active operating mode of the RotaryKnife-FB.
Figure 5-9: Actual Velocity / Position
In this area, the actual velocity [mm/s] and the actual position [mm] are displayed for the material and rotary knife axis.
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife Technology view The technology view of the application can be selected from every operator screen using the TECHNOLOGY button.
Figure 5-10: Technology view
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Actual cross-cutter position
Material web velocity Starting/basic position of the cross-cutter
Cross-cutter velocity
Controls the trace function
In the technology view, using the trace function of the HMI screen, the actual position of the rotary knife, its starting/basic position and the velocities of the material web and the rotary knife can be monitored and traced (recorded). The modulo jump of the rotary knife can be clearly seen when its position changes from 199.999 mm to 0 mm. The fluctuations in the rotary knife velocity can also be easily seen however, in the cut, the velocity corresponds to precisely that of the material web.
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The application example as demo system Operator control of the application example SIMOTION Rotary Knife Operator control functions in the status display The status display of the application can be selected from every operator screen using the STATUS button.
Figure 5-11: Status display
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You can see the actual state of the RotaryKnife-FB in the status display. You can read about the error number displayed under ErrorID, in Chapter 7.3.7. Errors can be acknowledged using the QUITT button. If the RotaryKnife-FB is in the ERROR state, then the Quitt button should be pressed until the RotaryKnife-FB is in the DISABLE state.
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Integrating the core functions Operator control of the application example SIMOTION Rotary Knife A4027118-A0405
Integrating the core functions

Content All of the steps necessary to integrate the core rotary knife functions into your application are explained in this section. Preparations and parameterizing operations are also explained. Further, you are also told how to integrate the RotaryKnife-FB into your application step-by-step.
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Integrating the core functions Program environment and interfaces SIMOTION Rotary Knife A4027118-A0405
Program environment and interfaces

The SIMOTION Rotary Knife application is part of the LRKLib library. The library is available as standard SIMOTION Rotary Knife application as well as XML export. In order to be able to use the functionality of the library, this must be integrated into the corresponding user project.
6.1 Importing the source code
6.1.1
Copying from the application example

Two instances of SIMOTION SCOUT are opened in order to copy the LRKLib 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 6-1: Copying the library from the application example

No.
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 LRKLib 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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6.1.2
Linking using XML import

With XML import, the LRKLib library and the RK_Progs program unit from their XML files are linked into the existing user project.
Table 6-2: Importing the XML file

No.
1. For the XML import, the LIBRARIES folder must be selected in the user project and then run by clicking on it with the righthand mouse key. 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 file path is specified and therefore the LRKLib library is imported into the user project.
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6.1.3
Linking the rotary knife functionality

The LRKLib library comprises several program units, whereby the units RK_CamCalc (block to calculate the cam), RK_Template (rotary knife block), RK_Tools (internal functions) contain the functionality of the application in the form of function blocks as well as data type definitions and the unit RK_Progs. Reference to the library is established in the unit and the instances of the function blocks and the data structures created. In addition, the unit includes the calls of the instances in the programs that must be integrated in the user project in the task system. The programs are not able to run in the library and may have to be adapted to the particular application (startupRotaryKnife).
Table 6-3: Programs of the RK_Progs unit

Program
StartupRotaryKnife MainRotaryKnife IpoRotaryKnife MTCamCalculation
Description
Initialization and parameterization Main program Status bits and print marks Cam calculation StartupTask
Task
BackgroundTask IPOsynchronousTask MotionTask
After the library has been copied/imported in the library folder, the program unit RK_Progs must be copied from the library folder into the program folder of the application and modified at four positions:
Table 6-4 Copying and modifying the UNIT RK_Progs
No.
1.
The unit is downloaded into the buffer memory by right-clicking on the program unit RK_Progs in the library LRKLib followed by Copy.
2.
The program unit RK_Progs can be inserted if, in the user project, the Program folder is marked and is subsequently run with a righthand mouse click.
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No.
3. Then, in the program unit RK-Progs, in the program container (not in the library!) four program lines must be deleted. Marked with $$$$$$$
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4.
5.
6.
The program unit can now be successfully compiled.
When using the program unit RK_Progs, the user does not have to link the library. The library is linked using the RK_Progs unit.
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User program units that are to access library functions, types, function blocks and data of the standard application, must be linked with the program unit RK_Progs in the interface section.
INTERFACE USES RK_Progs END_INTERFACE // Linking the standard application
Variable access To access variables of the SIMOTION Rotary Knife application, the following instances are set-up in the global data area in the RK_Progs program unit:
Table 6-5: Data interface
Element
gasRotaryKnife gaRotaryKnife
Description
Block interfaces and parameters Instance(s) of the FBRotaryKnife Status bits and print mark detection Instance(s) of the FBRKCamCalculation Number of FB instances
gaFBRKIPO gaFBCamCalculation NUMBER_OR_ROTARY_KNIFES
VAR_GLOBAL CONST NUMBER_OF_ROTARY_KNIFES END_VAR VAR_GLOBAL gasRotaryKnife gaFBRKIpo : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF sRotaryKnifeType; : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF FBRKIpo; gaFBRotaryKnife : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF FBRotaryKnife; gaFBCamCalculation: ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF FBRKCamCalculation; END_VAR : INT := 1; // number of rotary knifes controlled
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6.2
6.2.1
Technology objects
Technology objects required and synchronous relationships
To use the SIMOTION Rotary Knife application, the following technology options must be set-up and interconnected with one another in the described fashion:
Table 6-6: Technology objects required

Object
Material Axis (MaterialAxis, (MaterialEncoder)
Description
To determine the position and velocity of the material web as master (leading) value of the core rotary knife functions and to coordinate the motion of the axis material web from the same control. TO Configuration Real positioning or following axis External encoder Configuration Set the axis type as linear. For accuracy reasons, we recommend that the axis type is parameterized as modulo axis with a modulo length greater than the maximum product length. All of the other parameters should be set corresponding to the drive and encoder data. For the parameter distance per spindle revolution, enter the distance as value that the material web moves through for one revolution of the drive roll. Supplement the additional parameters also corresponding to the geometry and machine design. For this parameter, enter values that correspond to the system/drive relationships Parameterize not required Please set this parameter corresponding to the system relationships.
Mechanical system
Limits Referencing Monitoring, closed-loop control Rotary Knife Axis (RotaryKnifeAxis) Drive for the rotary knife motion. TO Configuration Real following axis Configuration
Parameterize the axis as synchronous axis. Set the axis type as linear. All of the other parameters should be set corresponding to the drive and encoder data. For the parameter distance per spindle revolution enter the distance that the point of the Rotary Knife moves through for one motor revolution. If the Rotary Knife is directly mounted without a gear unit, then knifeCircumference should be entered here. Appropriately supplement the other parameters corresponding to the geometry and the machine design. Please set this parameter corresponding to the drive dynamics Please set this parameter corresponding to the system relationship 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.)
Mechanical system
Pre-assignment Limits Referencing
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Object
Monitoring functions, closedloop control Auxiliary Axis (AuxiliaryAxis)
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Description
Please set this parameter corresponding to the system relationships
Inserting this (virtual) auxiliary axis between the material path motion and the cam makes it easier to correct length errors that are determined by the print mark detection. By correcting the auxiliary axis position, then the knife position is automatically corrected adapted to the cam position. Without the auxiliary axis, the correction motion of the knife corresponding to the length change using the print mark correction must be adapted using the cam. TO Configuration Real following axis Configuration Pre-assignment Limits Monitoring functions Set the axis type as linear Parameterize as virtual axis without drive Please select this parameter so that in operation the virtual axis does not reach the dynamic limits.
Cams (Cam1, Cam2, Cam3)
In operation, two cam Tos are required to recalculate and exchange the cams. The third cam TO is used for travel to the initial position when stopping. TO Cam Cam type, polynomial
Configuration
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6.2.2
Synchronous relationships
Synchronous relationships of the SIMOTION Rotary Knife application:
Figure 6-1: Synchronous relationships required for the FBRotaryKnife
Cam1
Material Axis
1:1
Auxiliary Axis
Cam2
Rotary Knife Axis
Cam3
External Encoder or Positioning Axis
gearing
Following Axis
caming
Following Axis
The material axis (MaterialAxis) is the reference quantity for the rotating knife. This reference quantity can be detected in two different ways: 1. The material path is controlled by the SIMOTION drive system that also controls the rotary knife. In this case, there is an axis TO. The synchronous connection with the auxiliary axis (AuxiliaryAxis) should in this case, access the setpoints of the material path that exist in the system (setpoint coupling) 2. The material path motion is measured using the encoder in the machine itself. In this case, there are no additional setpoints available. The synchronous connection with the auxiliary axis (AuxiliaryAxis) can only access the actual values of the encoder in the machine (actual value coupling). The AuxiliaryAxis as synchronous axis is connected to the MaterialAxis in a 1:1 (gearing) synchronous relationship. There is a camming relationship between the AuxiliaryAxis and the synchronous axis RotaryKnifeAxis, that can be optionally controlled using cam 1 (Cam1) up to cam 3 (Cam3). The synchronous relationship between the RotaryKnifeAxis and AuxiliaryAxis remains during the complete operation from starting to stopping the Rotary Knife; a changeover is only made between the cams. The synchronizing operations when starting and stopping are only executed between the MaterialAxis and the AuxiliaryAxis. Also the print mark correction only operates between the MaterialAxis and AuxiliaryAxis. The technology objects and synchronous operation relationships shown in the diagram above must be set-up and configured by the user in SIMOTION SCOUT. AuxiliaryAxis_GLEICHLAUF(_SYNCHRONOUS_OPERATION) Configuration Either Select the TO Axis MaterialAxis as master (leading) axis Select setpoint as coupling type.
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Figure 6-2 Configuration of MaterialAxis as leading value of AuxiliaryAxis
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 calculated using the calculation tool of the Utility&Applications CD (Scout\CD14\SRC\4_TOOLS\ExtrapolationTimeCalculation).
Figure 6-3 Configuration of MaterialEncoder as leading value of AuxiliaryAxis
Table 6-7
Function / Variable
Dynamic parameters
Value
The dynamic parameters of the time-related synchronization should be selected so when being synchronized and desynchronized, the axis does not reach the dynamic limits.
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Figure 6-4 Configuration of AuxiliaryAxis as leading value of RotaryKnifeAxis
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Select the TO Axis AuxiliaryAxis as master (leading) axis Select setpoint as coupling type. Select Cam1, Cam2 and Cam3 as possible cams
Function / Variable
Dynamic parameters
Table 6-8
Value
The dynamic parameters of the time-related synchronization should be selected so when being synchronized and desynchronized, the axis does not reach the dynamic limits.
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6.3
Integrating the SIMOTION Rotary Knife core function

The SIMOTION Rotary Knife application comprises several functional units that are saved in the program unit RK_Prog :
6.3.1
Parameterizing the rotary knifes in the startup task

It makes sense to combine configuration data assignments that are not changed in operation in a program (StartupRotaryKnife). These are then executed once when starting the control in the StartupTask and therefore assign values to variables. Assignment of the actual TO instances Assignment of the machine-specific parameters Resetting the restart bits. Deleting the format length buffer memory. Resetting all flags in the program.
Generating this program based on the declaration of the variables from Chapter 0 is described in this chapter as an example. The program is already prepared as program instance that can be called in the task manager and saved in the UNIT RK_Progs. The user only has to adapt the parameters to the real machine!
6.3.2
Calling FBRotaryKnife in the user program

The function block of the Rotary Knife core functions can also be called after integration in the user program. The call is already prepared in the program unit RK_Progs in the MainRotaryKnife program. The user only has to integrate this program into a cycle tasks (background, Ipo or Ipo2).
6.3.3
Calling the FBRKCamCalculation

The FBRKCamCalculation call is already prepared. In this case, the user only has to integrate the MTCamCalculation program of unit RK_Progs in a motion task. This motion task should be automatically started with Startup.
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Figure 6-5 Parameterization of MotionTask
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6.3.4
Calling the FBRKIPO in the IPO synchronous task

The FBRKIpo call has already been prepared. The user only has to integrate the IPORotaryKnife program of unit RK_Progs into the IPO_Task.
6.3.5
Global Variables
The FBRotaryKnife function block is influenced by several parameters and interfaces that 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 rotary knife to be connected are communicated to the function block via the block interface in the global data area. In normal rotary knife operation, these quantities are not changed. Further, it includes data areas for communication with the user and for communication of the individual sub-functions in the overall rotary knife system with respect to one another.
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Program Description Program environment and interfaces SIMOTION Rotary Knife A4027118-A0405
Program Description
Content Section Program Description is interesting if you wish to expand/adapt your application based on the technology templates available.
Objective This part of the documentation should Prerequisite

Explain to readers the special features/issues when generating a program Describe in detail the program structure of the rotary knife FB Illustrate and describe important program elements Provide information and instructions on how this template can be adapted.
Before possibly expanding this template it is helpful to have read the chapters in Section A and B in order to get to know the basic functions and applications of the template. Before you make changes to the template, please observe the information and warnings listed in the following Chapter as well as the associated restrictions regarding support!
Note
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Program Description Program Description SIMOTION Rotary Knife A4027118-A0405
7
7.1
Program Description
Information and warnings
Before you carry-out changes to the components included in the core functions, you should get to know how the components function by referring to and reading the ST/MMC documentation. Uncontrolled, incorrect changes and modifications to core functions can result in death and severe bodily injury!
Before carrying-out changes
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.
7.2
7.2.1
Type of Data
Overview
Enumeration types Enumeration type declarations are prepared for some 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 Rotary Knife 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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7.2.2
Enumeration types
Table 7-1
Name of the enumeration type
eOperationModesRotaryKnifeType
Contents
This enumeration type contains enumerators to select and display the operating states of the function block FBRotaryKnife. Declared in LRKLib.RK_Template: Defines the cam type for the cam calculation. Declared in: LRKLib.RK_CamCalc Defines the travel profile for the cam calculation. Declared in: LRKLib.RK_CamCalc
eTypeOfCamType eCamProfileType
eOperationModesRotaryKnifeType This enumeration type contains enumerators to select and display the operating state of the FBRotaryKnife function block.
Element
Description
FBRotaryKnife is standing in state ERROR FBRotaryKnife is standing in state DISABLE FBRotaryKnife is standing in state STARTPOSITION FBRotaryKnife is standing in state AUTOMATIC FBRotaryKnife is standing in state MANUAL FBRotaryKnife is standing in state SINGLE_CUT FBRotaryKnife is standing in state SAMPLE_CUT FBRotaryKnife has no change of state detected FBRotaryKnife is changing state
OMRK_ERROR OMRK_DISABLE OMRK_START_POSITION OMRK_AUTOMATIC OMRK_MANUAL OMRK_SINGLE_CUT OMRK_SAMPLE_CUT OMRK_NOTHING_SELECTED OMRK_CHANGING
eTypeOfCamType This enumeration type defines the cam type for the cam calculation:
Element
START_CAM CYCLIC_CAM STOP_CAM Cam for cyclic operation Cam to stop the cross-cutter from cyclic operation
Description
Cam for cross-cutter motion from the start position into cyclic operation.
eCamProfileType This enumeration type defines the travel profile for the cam calculation:
Element
LINEAR JERK POLY_5
Description
Acceleration / deceleration profile with constant acceleration Acceleration / deceleration profile with jerk limiting Acceleration / deceleration profile as fifth order polynomial
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7.2.3
Data Structures
Name of Structure
sRotaryKnifeType
Content
This structure contains the complete global data of the Rotary Knife system. Declared in LRKLib.RK_Template This structure contains the definition of all of the axes, external encoders, cams and probes that are used. Declared in LRKLib.RK_Tools This structure contains the interface for the user to enter physical limiting conditions (constraints), cam profiles, manual cutting position corrections as well as the input of sequence options such as a new start, fast start and format change in ongoing operation. Declared in LRKLib.RK_Template This structure contains the format length memory. Declared in LRKLib.RK_Tools This structure contains the internal data area to enter the cut length with a precise position. Declared in LRKLib.RK_Tools This structure contains the buffer in which the cut position is saved with the associated position deviations. Declared in LRKLib.RK_Tools This structure contains the internal data area to enter the cut position as a precise position and cut position deviation for the print mark correction. Declared in LRKLib.RK_Tools This structure contains the user area to save cut length sequences in the SAMPLE_CUT operating mode. Declared in LRKLib.RK_Template This structure contains the internal data area to call the cam calculation. Declared in LRKLib.RK_Template This structure contains the internal data area to display actual geometry values converted into the peripheral (circumferential) lengths in [mm], actual cut position as well as binary signals for the knife position. Declared in LRKLib.RK_Template This structure contains the internal data area for the print mark correction. Declared in LRKLib.RK_Tools
sTOsType
sUsersInterfaceType
sFormatLengthBufferType sFormatLengthBuffer ManagementType sCutPositionBufferType
sCutPositionBufferManagement Type
sSampleBufferType
sCamCalculationType
sRotaryKnifeInfoType
sMeasuringValueType
Generally applicable for labeling structural elements: [IN]: [OUT]: [IO]: sRotaryKnifeType This structure contains the complete global data of the RotaryKnife system: Values that should be provided by the user Results or feedback signals Values, which depending on the block connection, must be supplied by the user or written by the function
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Program Description Program Description SIMOTION Rotary Knife

I/O
IN
A4027118-A0405
Type of Data
sTOsType sUsersInterface Type sFormatLength Buffer Management Type sCutPosition BufferManageme ntType sSampleBuffer Type sCamCalculation Type sRotaryKnifeInfo Type sMeasuringValue Type LREAL BOOL
Element
sAxisTOs
Description
Object references of all technology objects (axes, external encoders, cams and measuring probes). Interface for the user to enter physical constraints, cam profiles, manual cutting position corrections as well as the input of sequence options such as a synchronized start, quick start and format change in ongoing operation.
IN
sUsersInterface
I/O
sFormatLengthBuffer Management sCutPositionBuffer Management sSampleBuffer sCamCalculation
Internal data area to configure processing programs.
I/O
Internal data area to enter the cut position as a precise position and cut position deviation for the print mark correction. User area to save cut length sequences in the SAMPLE_CUT mode Internal data area to call the cam calculation Internal data area to display actual geometry values converted into the peripheral (circumferential) lengths in [mm], actual cut position as well as binary signals for the knife position. Internal data area for the print mark correction. [ mm ] r64formatLength is the length of the cut material element. Activates the mode changeover with the operating mode specified in eMode. Using eMode the operating mode is preselected that is then activated with the next positive edge at input execute. OMRK_ERROR: Preselects the ERROR mode OMRK_DISABLE: Preselects the DISABLE mode OMRK_AUTOMATIC: Preselects the STARTPOSITION mode OMRK_AUTOMATIC: Preselects the AUTOMATIC mode OMRK_MANUAL: Preselects the MANUAL mode OMRK_SINGLE_CUT: Preselects the SINGLE_CUT mode OMRK_SAMPLE_CUT: Preselects the SAMPLE_CUT mode Starts an individual cut if FB is in the SINGLE_CUT mode. Starts a cut sequence to generate test cuts in the SAMPLE_CUT mode. Instance number of the actual call. TRUE: Selected mode is activated. TRUE: Mode changeover is active. Indicates errors in the FBs and at the cross-cutter axes. Error code
I/O I/O
I/O
sRotaryKnifeInfo
I/O IN IN
sMeasuringValue
r64FormatLength boExecute
IN
eMode
eOperationModes RotaryKnife Type
IN IN IN OUT OUT OUT OUT
boStartSingleCut boStartSampleCut i16NumberOfInstanz boDone boBusy boError b32ErrorID
BOOL BOOL INT BOOL BOOL BOOL DWORD
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I/O Element Type of Data Description
Actual mode OMRK_ERROR: ERROR mode OMRK_DISABLE: DISABLE mode OMRK_AUTOMATIC: STARTPOSITION mode OMRK_AUTOMATIC: AUTOMATIC mode OMRK_MANUAL: MANUAL mode OMRK_SINGLE_CUT: SINGLE_CUT mode OMRK_SAMPLE_CUT: SAMPLE_CUT mode OMRK_NOTHING_SELECTED: No mode change OMRK_CHANGING: Mode change active TRUE: mode AUTOMATIC activated TRUE: mode SINGLE_CUT activated TRUE: mode SAMPLE_CUT activated TRUE: Correction motion for actual cut position is active TRUE: rotary knife axis enabled
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OUT
eState
eOperationModes RotaryKnife Type
OUT OUT OUT OUT OUT
boAutomaticActive boSingleCutActive boSampleCutActive boCutPosition CorrectionActive boRotaryKnifeAxis Active
BOOL BOOL BOOL BOOL BOOL
sTOsType This structure contains the definition of all of the axes, external encoders, cams and measuring probes used (the user must parameterize these):
I/O
IN
Element
toLeadingValue
Type of Data
_AXIS_REF
Description
Reference to the technology object of the leading value. Possible technology objects: - posAxis (real or virtual) - externalEncoderType Reference to the technology object of the auxiliary axis, this object is mandatory for synchronous operation. Only a virtual axis is permissible. Refer to the technology object of the Rotary Knife axis. Only one real axis is permissible. Reference to the first cam object. Reference to the second cam object. Reference to the third cam object. Reference to the technology object of the measuring probe used for print mark detection. The measuring probe must be assigned to the leading value.
IN IN IN IN IN IN
toAuxiliaryAxis toRotaryKnifeAxis toCam1 toCam2 toCam3 toPrintmark
followingAxis followingAxis camType camType camType measuringInput Type
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Program Description Program Description SIMOTION Rotary Knife sUsersInterfaceType This structure contains the interface for the user to enter physical constraints, cam profiles, manual cutting position corrections as well as the input of sequence options such as a synchronized start, quick start and format change in operation (the user must parameterize these):
I/O
IN IN IN IN IN
A4027118-A0405
Element
r64KnifeCircumference r64StartSyncAngle r64EndSyncAngle r64StartAngle r64StopAngle
Type of Data
LREAL LREAL LREAL LREAL LREAL
Description
[mm] Effective geometrical circumference of the knife roll (circumference of the circle) [] Start angle of the synchronous range (cutting range), i.e. the angle at which the knife enters the material; the center point is defined as 0 (170.0 - 360.0). [] Final angle of the synchronous range, i.e. the angle at which the knife leaves the cutting range (0.0 - 170.0 ). [] Start position of the knife (start position of the start cam). [] Stop position of the knife (final position of the stop cam). [%] Center point of the format range of the cyclic cam . r64inflectionPoint < 50.0 % (min, 10%): Shifts the center point towards r64EndSyncAngle, i.e. the absolute value of the acceleration in the first motion segment after the cut is increased. R64inflectionPoint > 50.0 % (max. 90%): Shifts the centerpoint towards r64StartSyncAngle, i.e. the absolute value of the acceleration in the second motion segment after the cut is higher. Number of knives (max. 6) Motion profile, phase 1: LINEAR: Curve profile with constant acceleration JERK: Curve profile with constant acceleration and curve limiting POLY_5: Motion profile as fifth order polynomial. [%] Jerk limit component in phase 1 (only for eCamProfilePhase1 = JERK). The valid value range is between 1.0 and 100.0. For 100% a phase is obtained where the acceleration is not constant. The absolute jerk depends on the machine velocity. Motion profile, phase 2: LINEAR: Curve profile with constant acceleration JERK: Curve profile with constant acceleration and curve limiting POLY_5: Motion profile as fifth order polynomial. [%] Jerk limit component in phase 2 (only for eCamProfilePhase2 = JERK). The valid value range is between 1.0 and 100.0. For 100% a phase is obtained where the acceleration is not constant. The absolute jerk depends on the machine velocity. [mm] Distance between the cut position and the sensor to detect the material and printer mark. [mm] Cut offset for the starting cut [mm] Actual position measured value for the first cut [mm/s] Motion velocity when positioning to the start position. [%] Overspeed at the transition point to the synchronous range (r64StartSyncAngle) (-20.0% to 20.0%) referred to the synchronous velocity.
IN
r64InflectionPoint
LREAL
IN
i16NumberOfKnives
INT
IN
eCamProfilePhase1
eCamProfileType
IN
r64JerkPhase1
LREAL
IN
eCamProfilePhase2
eCamProfileType
IN
r64JerkPhase2
LREAL
IN IN IN IN IN
r64DistanceToSensor r64FirstCutCorrection r64MeasuredValueCut PosAtSensor r64ToStartPosVel r64KnifeOverspeed StartCut
LREAL LREAL LREAL LREAL LREAL
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I/O
IN
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Type of Data
LREAL
Element
r64KnifeOverspeed Zero r64KnifeOverspeed EndCut r64CPCorrection Maximum r64CPDeltaTolerance Range r64AdjustCutPosition PositiveValue r64TrimmCutPosition PositiveValue r64AdjustCutPosition NegativeValue r64TrimmCutPosition NegativeValue r64CutPosition CorrectionVelocity i16CutCorrWait boRestart
Description
[%] Overspeed at the center position of the synchronous range (0) (-20.0% - 20.0%) referred to the synchronous velocity. [%] Overspeed at the end point of the synchronous range (r64EndSyncAngle) (-20.0% to 20.0%) referred to the synchronous velocity. [mm] Maximum correction value for the cut position correction [mm] Half the tolerance bandwidth for the activation range of the cut position detection [mm] Coarse correction value of the manual cutting position correction in the positive direction [mm] Fine correction value of the manual cutting position correction in the positive direction [mm] Coarse correction value of the manual cutting position correction in the negative direction [mm] Fine correction value of the manual cutting position correction in the negative direction [mm/s] Velocity value of the higher-level cut position correction Number of cuts without cut position correction Flag restart, the user must set this, it is reset by the application Flag, Quickstart TRUE: The application immediately starts to cut at the start FALSE: Application only starts to cut at the specified start position Flag, enable format length change when the machine is running TRUE: Format length change possible FALSE: Format length change inhibited A positive edge starts a format length change (if format length change is enabled!) Flag, edge selection measuring system TRUE: Rising edge FALSE: Falling edge Flag cut position correction on Flag start coarse correction, positive of the cut position Flag start fine correction, positive of the cut position Flag start coarse correction, negative of the cut position Flag start fine correction, negative of the cut position Start cut to separate scrap and product in the SAMPLE_CUT mode
IN IN IN IN IN IN IN IN IN I/O
LREAL LREAL LREAL LREAL LREAL LREAL LREAL LREAL INT BOOL
IN
boQuickStart
BOOL
IN
boFormatLength ChangePossible
BOOL
IN
boSwitchCAM boMeasuring WithRisingEdge boCutPosition CorrectionOn boAdjustCutPosition Positive boTrimmCutPosition Positive boAdjustCutPosition Negative boTrimmtCutPosition Negative boCleanCut
BOOL
IN
BOOL
IN IN IN IN IN IN
BOOL BOOL BOOL BOOL BOOL BOOL
sFormatLengthBufferType This structure contains the format length memory (this is not relevant for the user):
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I/O
I/O
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Type of Data
ARRAY [0..CLB_MAX-1] OF LREAL ARRAY [0..CLB_MAX-1] OF BOOL ARRAY [0..CLB_MAX-1] OF BOOL
Element
ar64FormatLength
Description
[mm] buffer oh the format length
I/O
aboFormatLengthRead aboFormatLength Entered
buffer of the flags format length read
I/O
buffer of the flags format length entered
sFormatLengthBufferManagementType This structure contains the internal data area to enter the cut length with a precise position (this is not relevant for the user):
I/O
I/O I/O
Element
sFormatLengthBuffer i16BufferIn i16BufferOut i16BufferTest i16BufferInRett boBufferOutTrigger boBufferReadTrigger r64BufferTestFormat Length r64BufferLastFormat Length boBufferTestFL Entered boBufferTestFLRead boBufferResetActive boBufferInActive boBufferOutActive boBufferReadActive
Type of Data
sFormatLength BufferType INT INT INT INT BOOL BOOL LREAL LREAL BOOL BOOL BOOL BOOL BOOL BOOL
Description
data area of format length buffer Pointer to next input position of buffer Pointer to next output position of buffer Pointer to next test position of buffer Buffers the buffer pointer to the next entry position Start trigger to delete the read buffer entry Start trigger to read the next buffer entry Format length currently read from the buffer Previous format length read from the buffer Actual entered flag read from the buffer Actual read flag read from the buffer Reset of buffer active Input of value in buffer active Deletion of buffer value active Reading of buffer value active
I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O
sCutPositionBufferType This structure contains the cut position memory (this is not relevant for the user):
I/O
I/O
Element
ar64CutPosition DeviationMeasured ar64CutPosition Measured aboCutPositionRead aboCutPositionEntered
Type of Data
ARRAY [0..CPB_MAX-1] OF LREAL ARRAY [0..CPB_MAX-1] OF LREAL ARRAY [0..CPB_MAX-1] OF BOOL ARRAY [0..CPB_MAX-1]
Description
[mm] Buffers the deviations between the setpoint and the actual position for the cut at the instant in time of the measurement [mm] Buffer of the measured cut positions
I/O
I/O I/O
Buffer of the flag cut position read Buffer of the flag cut position entered
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I/O Element Type of Data
OF BOOL
A4027118-A0405
Description
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
I/O I/O I/O I/O I/O I/O I/O I/O
Element
sCutPositionBuffer i16BufferIn i16BufferOut i16CutCorrectionWait boBufferOutTrigger boBufferReadTrigger boBufferResetActive boBufferInActive boBufferOutActive boBufferReadActive
Type of Data
sCutPosition BufferType INT INT INT BOOL BOOL BOOL BOOL BOOL BOOL
Description
data area of cut position buffer Pointer to next input position of buffer Pointer to next output position of buffer Number of cuts without cut position correction Start trigger to delete the read buffer entry Start trigger to read the next buffer entry Reset of buffer active Input of value in buffer active Deletion of buffer value active Reading of buffer value active
I/O I/O
sSampleBufferType This structure contains the cut length buffer for the SAMPLE_CUT mode (the user must parameterize this):
I/O
I/O
Element
ar64SampleLength
Type of Data
ARRAY [0..SLB_MAX-1] OF LREAL ARRAY [0..SLB_MAX-1] OF INT INT INT
Description
[mm] Buffer of the format lengths of the samples
I/O I/O I/O
ai16SampleNumberOf Plates i16SampleLengthIn i16SampleLengthOut
Buffer for the number of cuts per sample Pointer to next input position of buffer Pointer to next output position of buffer
sCamCalculationType This structure contains the internal data area to control the cam calculation (this is not relevant for the user):
I/O
IN IN IN
Element
toNextCam toActualCam r64FormatLength Activated
Type of Data
camType camType LREAL
Description
TO Cam of the cam to be actually calculated TO Cam of the presently active cam [mm] Activated format length Type of cam to be calculated START_CAM: Start cam CYCLIC_CAM: Cyclic cam STOP_CAM: Stop cam [] Activated start angle [] Activated stop angle
IN
eTypeOfCam
eTypeOfCam Type LREAL LREAL
IN IN
r64StartAngleActivated r64StopAngleActivated
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I/O
IN OUT OUT OUT OUT
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Type of Data
LREAL DWORD BOOL BOOL BOOL
Element
r64InflectionPoint Activated b32EidCamCalculation boCamCalculation Active boCamCalcualtion Error boCamCalculationOK
Description
[%] Activated center point of the format range of the cyclic cam Transfers the error message of the cam calculation to the error message system of FBRotaryKnife. Flag, cam calculation active Flag, cam calculation interrupted with error Flag, cam calculation successfully completed
sRotaryKnifeTypeInfo This structure contains calculation results and display information relevant for the user that provides information about the state of the rotating knife.
I/O
OUT
Element
r64MechanicalSync Format r64Synchronous Sector r64FormatSector r64CutPosActual r64FormatLength Activated r64StartPos Activated r64StartLength r64StopPos Activated r64StopLength r64MiddlePos Activated r64StartSyncPos r64EndSyncPos boAxisAsLeadingValue toLeadingValueAxis boExternalEncoderAs LeadingValue toLeadingValue ExternalEncoder boKnifeInFormatSector boKnifeInSynchronous Sector boKnifeInSynchronous SectorOld
Type of Data
LREAL LREAL LREAL LREAL LREAL LREAL LREAL LREAL LREAL LREAL LREAL LREAL BOOL posAxis BOOL externalEncoder Type BOOL BOOL BOOL
Description
[mm] Format length that is obtained from the knife running in synchronism with the material web [mm] Length of the range in which the knife is moving in synchronism with the material web [mm] Length of the range in which the knife may make a correction motion to achieve the format length [mm] Position of the material web for the last cut [mm] Activated format length [mm] Activating starting position of the knife referred to the knife axis [mm] Distance that the material web moves when the knife starts from the starting position up to the cut [mm] Activated stop position of the knife referred to the knife axis [mm] Distance that the material web movers when stopping the knife from the cut up to the stop position [mm] Position of the knife referred to the knife axis within the format range with the maximum/minimum knife velocity [mm] Start position of the synchronous range referred to the knife axis [mm] End position of the synchronous range referred to the knife axis TRUE FALSE Leading value is a real or virtual posAxis No posAxis can be entered as leading value
OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT
If the leading value is a real or virtual posAxis, then the name of the TO is the axis otherwise TO#NIL TRUE FALSE Leading value is an external encoder No external encoder entered as leading value
If the leading value is an external encoder, then the name of the TO is the external encoder, otherwise TO#NIL Flag, knife in the format range Flag, knife in the synchronous range Flag, knife in the synchronous range (old value)
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I/O
OUT boCut
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Type of Data
BOOL Flag, cut
Element
Description
sMeasuringValueType This structure contains the internal data area of the measured value detection (this is not relevant for the user):
I/O
OUT OUT
Element
r64MeasuredValueNew r64MeasuredValueOld
Type of data
LREAL LREAL enumMeasured Edge
Description
[mm] Actual measured value [mm] Measured value, old Selects the signal edge that initiates the measurement at the sensor: RISING_EDGE: Rising edge at the sensor FALLING_EDGE: Falling edge at the sensor Flag, wait until the first measured value Flag, wait for measured value Flag, measure starting position Flag, use in the AUTOMATIC mode Flag, cutting position measurement is active First measured cutting position Format length valid at the time the measurement is made Interpolated next cutting position Tolerance bandwidth, next cutting position, start Tolerance bandwidth, next cutting position, end Half of the tolerance bandwidth Cutting position error counter
IN
eMeasuringEdge
I/O I/O
boWaitForFirstCut Position boCutPosition MeasuringActive boStartPosAtSensor Detected boApplicationIn Automatic boCutPosition SwitchedOn r64StartPosAtSensor r64FormatLength ActiveAtSensor r64SollPosNextCut Position r64SollPosTolerance RangeStart r64SollPosTolerance RangeEnd r64DeltaTolerance Range i16CutPositionError Counter
BOOL BOOL BOOL BOOL BOOL LREAL LREAL LREAL LREAL LREAL LREAL INT
I/O IN IN OUT IN OUT OUT OUT IN OUT
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7.3
FBRotaryKnife
Control block of Rotary Knife Functions
7.3.1
Block name
FBRotaryKnife
7.3.2
Task
Control block of the SIMOTION Rotary Knife application. The block includes the following functions: Mode manager of the application, including the following modes ERROR, DISABLE, MANUAL, STARTPOSITION, AUTOMATIC, SAMPLE_CUT, SINGLE_CUT Automatic format change Cutting program (SAMPLE_CUT) Single cut program Control to calculate the travel profile including the following profile types linear (constant acceleration), trapezoidal (defined jerk limiting) and polynomial Print mark correction Synchronization to the material path

Referencing the axes and setting-up operation (jog) are not included in the application.
7.3.3
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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7.3.4
Graphic representation of the block FBRotaryKnife

LREAL BOOL formatLength execute mode startSingleCut startSampleCut numberOfInstanz done busy error errorId status automaticActive singleCutActive sampleCutActive cutPositionCorrection Active rotaryKnifeAxisActive sTOsType axisTOs usersInterface sampleBuffer camCalculation rotaryKnifeInfo measuringValue cutPositionBufferManagement BOOL BOOL BOOL DWORD eOperationModes RotaryKnifeType BOOL BOOL BOOL BOOL BOOL sTOsType sUsersInterface Type sSampleBuffer Type sCamCalculation Type sRotaryKnifeInfo Type sMeasuringValue Type sCutPositionBuffer ManagementType
eOperationMode RotaryKnifeType BOOL BOOL INT
sUserInterface Type sSampleBuffer Type sCamCalculation Type sRotaryKnifeInfo Type sMeasuringValue Type sCutPositionBuffer ManagementType
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7.3.5
Block parameters
Input parameters
Name Data type
REAL BOOL
Initial value
200.0 FALSE
Description
Cut material element length in mm. 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. OMRK_ERROR: Pre-selection, ERROR mode OMRK_DISABLE : Pre-selection, DISABLE mode OMRK_AUTOMATIC: Pre-selection, STARTPOSITION mode OMRK_AUTOMATIC: Pre-selection, AUTOMATIC mode OMRK_MANUAL: Pre-selection, MANUAL mode OMRK_SINGLE_CUT: Pre-selection, SINGLE_CUT mode OMRK_SAMPLE_CUT: Pre-selection, SAMPLE_CUT mode Start of a single cut if FB is in the SINGLE_CUT mode. Start of a cut sequence to generate sample elements in the SAMPLE_CUT mode. Instance number of the actual call.
formatLength execute
Mode
eOperation ModesRotary KnifeType
OMRK_ ERROR
startSingleCut startSampleCut numberOfInstanz
BOOL BOOL INT
FALSE FALSE 0
Output parameters
Name
done Busy Error
Data type
BOOL BOOL BOOL
Initial value
FALSE FALSE FALSE
Description
Selected mode is activated. Mode changeover is active. FALSE: No error TRUE: An error has occurred, refer to error identification Error identification, refer to error messages errorID <= 16#000_8000: warning errorID >= 16#0000_8000: error Actual mode OMRK_ERROR: ERROR mode OMRK_DISABLE: DISABLE mode OMRK_AUTOMATIC: STARTPOSITION mode OMRK_AUTOMATIC: AUTOMATIC mode OMRK_MANUAL: MANUAL mode OMRK_SINGLE_CUT: SINGLE_CUT mode OMRK_SAMPLE_CUT: SAMPLE_CUT mode OMRK_NOTHING_SELECTED: No mode change OMRK_CHANGING: Mode change active AUTOMATIC mode is active SINGLE_CUT mode is active SAMPLE_CUT is active Correction motion for the actual cut position is active
errorID
WORD
state
eOperation ModesRotary KnifeType
OMRK_ ERROR
automaticActive singleCutActive sampleCutActive cutPositionCorrection Active
BOOL BOOL BOOL BOOL
FALSE FALSE FALSE FALSE
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Name
rotaryKnifeAxisActive
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Initial value
FALSE
Data type
BOOL
Description
The RotaryKnife axis is active
Input / output parameters

Name
axisTOs
Data type
sAxisTOs Type sUsers Interface sSample BufferType sCam Calculation Type sRotary KnifeInfo Type sMeasuring ValueType sCutPosition Buffer Management Type
Initial value
Description
Definition of all of the axes, external encoders, cams and measuring probes being used Interface for the user to enter physical constraints, cam profiles, manual cutting position corrections as well as the input of sequence options such as a new start, fast start and format change in ongoing operation User area to save cut length sequences in the SAMPLE_CUT operating mode Internal data area to call the cam calculation Internal data area to display actual geometry values converted into the peripheral (circumferential) lengths in [mm], actual cut position as well as binary signals for the knife position. Internal data area for print mark correction. Internal data area to enter the cut position as a precise position and cut position deviation for the print mark correction.
usersInterface
sampleBuffer
camCalculation
rotaryKnifeInfo
measuringValue
cutPositionBuffer Management
7.3.6
Functionality
Start identification Identify whether a restart is present. If yes, then: Activate the monitoring of the parameterization of the technology objects as well as auto-parameterization. Control the state machines in the manual state via the state sequence ERROR (if activated, the monitoring and auto-parameterization are realized in the ERROR state) DISABLE MANUAL From any state.
If no, then Transfer the selected operating state with a positive edge at the execute input Reset all block outputs with a negative signal edge at the execute input
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Program Description Program Description SIMOTION Rotary Knife Axis monitoring functions If the rotary knife axis or the auxiliary axis has a fault condition, then the FBRotaryKnife is forced into the fault state (ERROR state). However, the monitoring function is only active after the technology objects have been successfully completed. Checking the input parameters and parameterization of the technology settings that are absolutely necessary This program function is only active in the ERROR state if it was activated by the user using the restart bit. The following are monitored:
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The existence of specified Tos. The function (positioning axis, synchronous axis, cam ) Special properties/features required for the template, such as: Modulo axis, modulo value and cam type. Deviations with respect to the template are displayed as fault messages. Parameterization of the technology objects absolutely required is carried-out in another program part.
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Program Description Program Description SIMOTION Rotary Knife General Notes The FBRotaryKnife function block is the most important element of the application. The connected, rotating knife is parameterized and controlled from this block. The block parameterization (parameter assignment) and the mode changeover must be made in the user program in order to initiate that the FBRotaryKnife executes the required functions. FBRotaryKnife is parameterized as described in Chapter 7. When parameterizing, basic values of the application that generally do not changeare defined; for example, the name of the axis, knifeCircumference, numberOfKnifes, etc. It is only permissible to change these values at standstill and then FBRotaryKnife must be re-initialized (restart). The individual modes of the FBRotaryKnife are described in Chapter 3.3 Operating states of the application SIMOTION Rotary Knife The procedure when changing the mode is described in more detail in the following sections. Basic state of FBRotaryKnife
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After initialization, FBRotaryKnife is in the DISABLE mode. Initialization must be executed each time that the control boots (powers up) by setting the restart bit (gsRotaryKnife.sUsersInterface.boRestart) in the startup task. (This is automatically realized when using the startupRotaryKnife() program in the UNIT RK_Progs). As a consequence, the block is transitioned into its initial stated, important parameters are subject to a plausibility change if possible adapted and if not possible, a parameterizing error is signaled to the user at the error/fault output.
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Program Description Program Description SIMOTION Rotary Knife 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 7-1: Possible state transitions at FBRotaryKnife
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RESTART
4 4 Manual Manual
1 1 Disable Disable 2 2 StartposiStartposition tion

0 0 Error Error
6 6 Sample Sample Cut Cut
3 3 AutomaAutomatic tic
5 5 Single Single Cut Cut

Standard state transition Fault state transition Autom atic state change chain
The actual block state is displayed at the state output.

Figure 7-2: Inputs and outputs of the mode changeover
C ut L eng t h E x ecu t e Mode D on e B usy E rr or E rr o rI D S t at e
FB RotaryK n ife()
Changing-over the mode 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 at the state output.
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Program Description Program Description SIMOTION Rotary Knife Automatic mode change sequences The following automatic mode change sequences have been implemented: From the ERROR mode into the STARTPOSITION mode. ERROR DISABLE STARTPOSITION From the ERROR mode into the AUTOMATIC mode. ERROR DISABLE STARTPOSITION AUTOMATIC From the ERROR mode into the MANUAL mode. ERROR DISABLE MANUAL From the AUTOMATIC mode into the MANUAL mode. AUTOMATIC ERROR DISABLE MANUAL A4027118-A0405
The following table describes the function sequences that are hidden behind the modes and the mode changes.
Table 7-2: Description of the sequences at the state change (state transition) in the FBRotaryKnife
Step
Function
Comment
0 Error
ERROR (0)
ERROR DISABLE
0 All ErrorID memories are reset
0 Error
1 Disable
Step
Function
1 _resetAxisError() is called for the specified axes _resetFollowingObject() is called for the specified axes _resetCamError() is called for cam1, cam 2 and cam3 If the axis, cams and synchronous objects have no error condition, then the DISABLE mode is activated.
Comment
DISABLE (1)
1 Disable
DISABLE DISABLE
0 The stop command is prepared 1 _move() with velocity = 0.0 is called for the auxiliary axis 2 _move() with velocity = 0.0 is called for the rotary knife axis 3 Calls the _disableAxis() for the specified axes If all of the axes are deactivated, then the DISABLE mode is activated.
1 Disable
1 Disable
DISABLE ERROR
0 Preparation 1 Calls the _disableAxis() for the specified axes If the axes are deactivated, then the ERROR mode is activated
1 Disable
0 Error
DISABLE STARTPOSITION
1 Disable
2 Startposition
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0 The enable command is prepared 1 _resetAxisError() is called for the specified axes If all axes are OK, then progress (advance) to step 2 2 _enableAxis() is called for the specified axes If the axes are enabled, then the direction of rotation to reach the starting position is determined without moving through the material and progressing (advancing) to step 3 3 _pos() is called with the direction of rotation determined in step 0 If the starting position is reached, then the STARTPOSITION mode is activated
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DISABLE MANUAL
0 The enable command is prepared 1 _enableAxis() is called for the specified axes If the axes are enabled, then the MANUAL mode is activated
1 Disable
4 Manual
STARTPOSITION (2)
2 Startposition
2 Startposition 0 Error
STARTPOSITION ERROR
0 Preparation 1 _disableAxis() is called for the specified axes If the axes are disabled, then the ERROR mode is activated.
STARTPOSITION DISABLE
0 The stop command is prepared 1 _move() with velocity = 0.0 is called for the auxiliary axis 2 _move() with velocity = 0.0 is called for the rotary knife axis 3 _disableAxis() is called for the specified axes If the axes are disabled, then the DISABLE mode is activated.
2 Startposition
1 Disable
STARTPOSITION AUTOMATIC
0 The calculation of the start cam is initiated 1 Wait for the start cam 2 The calculation of the cyclic cam is initiated 3 The technology parameter is set userdefault.cammingsettings.synchronizingmode = IMMEDIATELY 4 The technology parameter is set userdefault.cammingsettings.syncpositionslave 5 The auxiliary axis is reset to 0 when _homing() is called. If OK, then the start mode is defined 6 The technology parameter is set userdefault.gearingsettings.synchronizingmode = IMMEDIATELY or ON_MASTER_POSITION 7 The technology parameter is set userdefault.gearingsettings.syncpositonmaster = r64DistanceToSensor 8 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the start cam.
2 Startposition
3 Automatic
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9 If OK, then _enableGearing() is called to synchronize the auxiliary axis to the material web 10 Wait for cyclic cam 11 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the cyclic cam. If the cyclic cam is in synchronism, then the AUTOMATIC mode is activated
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STARTPOSITION MANUAL
For an automatic mode change sequence this mode change is achieved when the MANUAL mode is reached via the DISABLE mode.
2 Startposition
4 Manual
STARTPOSITION SINGLE_CUT
2 Startpo sition
5 Single Cut
0 The calculation of the start cam is initiated 1 Wait for the start cam 2 The calculation of the stop cam is initiated 3 The technology parameter userdefault.cammingsettings.synchronizingmode = IMMEDIATELY
4 The technology parameter is set userdefault.cammingsettings.syncpositionslave 5 The auxiliary axis is reset to 0 when _homing() is called. If OK, then the start mode is defined (synchronous or immediately) 6 Wait for the stop cam
STARTPOSITION SAMPLE_CUT
2 Startpo sition
6 Sample Cut
0 The calculation of the start cam is initiated 1 Wait for the start cam 2 The technology parameter userdefault.cammingsettings.synchronizingmode = IMEEDIATELY 3 The technology parameter is set userdefault.cammingsettings.syncpositionslave 4 The auxiliary axis is reset to 0 when _homing() is called. If OK, then the start mode is defined (synchronous or immediately)
AUTOMATIC (3)
3 Automatic
Re-calculation and activation of a cyclic cam in operation

If a cam may be changed-over and is requested, then the calculation of a new cyclic cam is initiated and step 0 is activated 0 Wait until the cyclic cam is calculated 1 _enableCaming() is called to synchronize a new cyclic cam at the end of the old cyclic cam.
Print mark correction

_pos() is called with the print mark deviation determined by the user and the merge mode SUPERIMPOSED_MOTION_MERGE
AUTOMATIC ERROR
_disableAxis() is called for the auxiliary axis and the rotary knife axis. If the axes are disabled, then the ERROR mode is activated.
3 Automatic
0 Error
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AUTOMATIC STARTPOSITION
0 The calculation of the stop cam is initiated 1 Wait for the stop cam 2 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the stop cam. 3 Wait for a rotary knife axis stop 4 De-couple the rotary knife axis from the synchronous operation group with the rotary knife axis by calling _disableCaming(). 5 De-couple the auxiliary axis from the synchronous operation group with the material web by calling _disableGearing() 6 The direction of rotation to approach the start position without passing through the cut position is determined. 7 Call _pos() to position to the starting position
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3 Automatic 2 Startposition
MANUAL (4)
4 Manual
MANUAL ERROR
4 Manual
0 Error
_disableAxis()is called for the auxiliary axis and the rotary knife axis. If the axes are disabled, then the ERROR mode is activated.
MANUAL DISABLE
0 The stop command is prepared 1 _move() with velocity = 0.0 is called for the auxiliary axis 2 _move() with velocity = 0.0 is called for the rotary knife axis 3 _disableAxis()is called for the auxiliary axis and the rotary knife axis. If the axes are disabled, then the DISABLE mode is activated.
4 Manual
1 Disable
MANUAL STARTPOSITION
0 Preparation 1 _move() with velocity = 0.0 is called for the auxiliary axis 2 _move() with velocity = 0.0 is called for the rotary knife axis 3 The direction of rotation to approach the start position without passing through the cut position is determined. 4 Call _pos() to position to the starting position
4 Manual
2 Startposition
SINGLE_CUT (5)
5 Single Cut
Executing a single cut

0 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the start cam. 1 Wait for a positive edge at input startSingleCut 2 If the quickstart bit = TRUE, then the setting of the technology parameter userdefault.gearingsettings.synchronizingmode = IMMEDIATELY and continue with step 4 Or If the quickstart bit = FALSE, then the setting of the technology parameters userdefault.gearingsettings.synchronizingmode = ON_MASTER_POSITION and continue with step 3
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3 The technology parameter is et to the geometry parameter userdefault.gearingsettings.syncpositonmaster = r64DistanceToSensor 4 If OK, then _enableGearing() is called to synchronize the auxiliary axis to the material web 5 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the stop cam. 6 Wait for a rotary knife axis stop 7 De-couple the auxiliary axis from the synchronous operation group with the material web by calling _disableGearing() 8 De-couple the rotary knife axis from the synchronous operation group with the rotary knife axis by calling _disableCaming(). 9 The auxiliary axis is reset to 0 when _homing() is called. 10 The direction of rotation to approach the start position without passing through the cut position is determined. 11 Call _pos() to position to the starting position. Please continue with step 0.
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SINGLE_CUT ERROR
5 Single Cut
0 Error
SINGLE_CUT STARTPOSITION
5 Single Cut
2 Startposi tion
If SINGLE_CUT inactive, then

1 De-couple the rotary knife axis from the synchronous operation group with the rotary knife axis by calling _disableCaming().
If SINGLE_CUT active, then

0 Preparation 1 _move() with velocity = 0.0 is called for the auxiliary axis 2 De-couple the rotary knife axis from the synchronous operation group with the rotary knife axis by calling _disableCaming(). 3 _move() with velocity = 0.0 is called for the rotary knife axis 4 The direction of rotation to approach the start position without passing through the cut position is determined. 5 Call _pos() to position to the starting position
SAMPLE_CUT (6)
6 Sample Cut
Executing a sequence of cuts to generate samples

0 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the start cam. 1 Wait for a positive edge at input startSampleCut 2 If the quickstart bit = TRUE, then the setting of the technology parameter userdefault.gearingsettings.synchronizingmode = IMMEDIATELY and continue with step 4 Or If the quickstart bit = FALSE, then the setting of the technology parameters userdefault.gearingsettings.synchronizingmode = ON_MASTER_POSITION and continue with step 3 3 The technology parameter is set to userdefault.gearingsettings.syncpositonmaster = r64DistanceToSensor
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4 If OK, then _enableGearing() is called to synchronize the auxiliary axis to the material web 5 If a valid value is saved in the sample store, then continue with step 6. If not, then continue with step 10 6 A cyclic cam is calculated with the length currently saved in the sample store (formatLength). 7 Wait until the cyclic cam is calculated. 8 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the cyclic cam at the end of the cam cycle. 9 If the cut position is reached and an additional valid value is saved in the sample store, then continue with step 6. If the cut position is reached, and there is no additional valid value saved in the sample store, then continue with step 10. 10 The calculation of the stop cam is initiated 11 Wait for stop cam. 12 _enableCaming() is called to synchronize the rotary knife axis to the auxiliary axis with the stop cam. 13 Wait for a rotary knife axis stop 14 De-couple the auxiliary axis from the synchronous operation group with the material web by calling _disableGearing()
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15 De-couple the rotary knife axis from the synchronous operation group with the rotary knife axis by calling _disableCaming(). 16 The auxiliary axis is reset to 0 when _homing() is called. 17 The direction of rotation to approach the start position without passing through the cut position is determined. 18 Call _pos() to position to the starting position. 19 The calculation of the start cam is initiated 20 Wait for stop cam. If OK, please continue with step 0.
SAMPLE_CUT ERROR
6 Sample Cut
0 Error
SAMPLE_CUT STARTPOSITION
6 Sample Cut
2 Startposi tion
If Sample Cut inactive, then

1 De-couple the rotary knife axis from the synchronous operation group with the rotary knife axis by calling _disableCaming().
If SAMPLE_CUT active, then

0 Preparation 1 _move() with velocity = 0.0 is called for the auxiliary axis 2 De-couple the rotary knife axis from the synchronous operation group with the rotary knife axis by calling _disableCaming(). 3 _move() with velocity = 0.0 is called for the rotary knife axis 4 The direction of rotation to approach the start position without passing through the cut position is determined. 5 Call _pos() to position to the starting position
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Program Description Program Description SIMOTION Rotary Knife 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 FBRotaryKnife and a parameter check is made and the block is brought into a defined state. We recommend that the program startupRotaryKnife of the unit RK_Progs is used in the startup task in order to initialize the block FBRotaryKnife. Note The restart bit should also be set there in order to bring the block into a defined state! A4027118-A0405
Note
At restart, the block checks essential technology parameters as well as the existence of saved technology objects.
After the block has been successfully initialized, the restart bit is automatically reset. Using the quick start bit (sUsersInterface. boQuickstart) Task The standard, starting situation of the FBRotaryKnife is to synchronize at the start of the material. However, if the cross-cutter is started with the material already threaded/entered and must be synchronized, then the program must run-through another synchronizing mechanism. The quick start bit is used to select which synchronizing mechanism the user wishes to apply. Mode of Operation
Table 7-3: Mode of operation of the quick start bit
boQuickstart
=1 =0
Description
The rotating knife immediately synchronizes with mode = 3 and execute = true, independent of the actual material position. The rotating knife synchronizes with mode = 3 and execute = true only if the material position has reached the position entered under r64DistancetoSensor.
Synchronizing Mechanism Task Description The task of the example is to synchronize the rotating knife to the start of the material that should run so that the first cut is precisely made after the specified cut length after the start of the material.
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Program Description Program Description SIMOTION Rotary Knife Procedure

Tabelle 7-4: Synchronizing the rotary knife
Phase Graphic representation What actually happens
Initial situation: No material in the cutting range The knife is at the zero position The user has switched FBRotaryKnife into the DISABLE mode
Sensor
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User task: The mode changes to STARTPOSITION
Startposition Sensor
Initial situation: No material in the cutting range The knife is located at its starting position The START POSITION mode is active User task: Wait for material
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Initial situation: The material has reached the sensor and the measuring probe function has received the first measured value of the material web position The knife is at its start position The START POSITION mode is active User task: In order to assign the position of the rotating knife to the material web position, the user must set the material path position back by the measured value, or: add the measured value to r64DistanceToSensor and save as new value. The mode changes to AUTOMATIC Initial situation: The material has reached the rotary knife When this synchronous position is reached, the starting cam was started User task: None
3
Distance to Sensor 0 Referenzpunkt Warenbahn
Distance to Sensor 0 Referenzpunkt Warenbahn
Synchronposition
Sensor
Initial situation: The first cut length has passed below the rotating knife The rotating knife is at the zero position When the position is reached, a change has been made to the cyclic cam. The AUTOMATIC mode is active Result: The rotary knife has started in synchronism with the start of the material and cuts the material to the required length
CutLength
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Program Description Program Description SIMOTION Rotary Knife Error handling If faults occur in the block itself or in technology objects and technology functions involved while FBRotaryKnife is operational, then these are signaled using the block outputs error and errorID.
Figure 7-3: Block outputs for fault messages
CutLength E xecute Mode Done Bu sy Err or Err orID State
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FBRotaryKnife()
The error bit signals an error while an error code is output at output errorID; this can be analyzed using the error analysis function.
Note
The error output is only set if the execute input is set. The errorID and state 0 (ERROR) are still output even after execute has been reset!
7.3.7
Error messages
Table 7-5: List of the possible error priorities
ErrorID
16#xxxx_0xxxx 16#xxxx_4xxx 16#xxxx_8xxx 16#xxxx_Cxxx Low priority High priority Highest priority
Priority
Lowest priority Warning
Description
Warning, execution possible with error Error, no execution possible Critical error
Warnings Warnings are indicated by the status of the outputs error and errorID: FALSE and errorID <> 16#0000_0000.
Table 7-6: Warnings
ErrorID
16#0000_0000 16#050B_4000 16#050B_4001 16#050B_4002 16#050B_4003 No warning Parameter r64KnifeCircumference not accepted (invalid value) (AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode) Parameter i16NumberOfKnives not accepted (invalid value) (AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode) Parameter r64StartSyncWinkel not accepted (invalid value) (AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode) Parameter r64EndSyncWinkel not accepted (invalid value) (AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)
error =
Description
ErrorID
16#050B_4005
Description
Inpug formatLength not accepted (invalid value) (Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)
Version 2.0
Release 06.05.2011
100/140

16#050B_4006 16#050B_4007 16#050B_4008 16#050B_4009 16#050B_400A 16#050B_400B 16#050B_400C 16#050B_400D 16#050C_4002 16#050C_4003 16#050C_4006
A4027118-A0405
Parameter r64InflectionPoint replaced by a substitute value (invalid value) (substitute value = 50 %) Parameter r64StartAngle replaced by a substitute value (invalid value) (substitute value = 90) Parameter r64StopAngle replaced by a substitute value (invalid value) (substitute value = 270) Parameter r64OverspeedStartCut not accepted (invalid value) (Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT) Parameter r64OverspeedZero not accepted (invalid value) (Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT) Parameter r64OverspeedEndCut not accepted (invalid value) (Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT) Parameter r64JerkPhase1 replaced by a substitute value (invalid value) (substitute value = 0%) Parameter r64JerkPhase2 replaced by a substitute value (invalid value) (substitute value = 0%) RotaryKnife axis changed over to modulo axis Modulo length of the RotaryKnife Axis is adapted to (Fsymech = r64KnifeCircumference / i16NumberOfKnives) Auxiliary axis changed over to modulo axis Modulo length of the auxiliary axis adapted to (Fsymech = r64KnifeCircumference / i16NumberOfKnives )
16#050C_4007
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 RotaryKnife 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 7-7 Errors
Error ID
16#050A_8001 16#050A_8002 16#050A_8003 16#050A_8004 16#050B_8000 16#050B_8001 16#050B_8002 Error at the rotary knife axis Error at the auxiliary axis Error at the rotary knife axis and at the auxiliary axis Error at the rotary knife axis synchronous operation Invalid parameter: r64knifeCircumference <= 0.0 Invalid parameter i16numberOfKnives < 1 or i16numberOfKnives > 6 Invalid parameter r64startSyncAngle < START_SYNC_ANGLE_MIN / i16numberOfKnives or r64startSyncAngle > 360.0 / i16numberOfKnives Invalid parameter r64endSyncAngle < 0.0 or r64endSyncAngle > (START_SYNC_ANGLE_MIN FORMAT_ANGLE_MIN) / i16numberOfKnives Invalid parameter: i16numberOfKnifes * Synchrounous angle >= 360 or Synchrounous angle < 0 Invalid parameter:
Description
16#050B_8003
16#050B_8004
16#050B_8005
Version 2.0
Release 06.05.2011
101/140

Error ID Description
formatLength <= Synchronous length * FACTOR_SYNCLENGTH_FOR_MIN_CUTLENGTH 16#050B_8006 Invalid parameter r64inflectionPoint < MIN_VAL_INFLECTION_POINT or r64inflectionPoint > 100.0 MIN_VAL_INFLECTION_POINT Invalid parameter: r64startAngle <= r64endSyncAngle or r64startAngle >= r64startSyncAngle ACC_DCC_ANGLE_MIN Invalid parameter: r64stopAngle <= endSyncAngle + ACC_DCC_ANGLE_MIN or r64stopAngle >= r64startSyncAngle Invalid parameter: r64knifeOverspeedStartCut < - MAXIMUM_OVERSPEED_KNIFE or r64knifeOverspeedStartCut > MAXIMUM_OVERSPEED_KNIFE Invalid parameter r64knifeOverspeedZero < - MAXIMUM_OVERSPEED_KNIFE or r64knifeOverspeedZero > MAXIMUM_OVERSPEED_KNIFE Invalid parameter r64knifeOverspeedEndCut < - MAXIMUM_OVERSPEED_KNIFE or r64knifeOverspeedEndCut > MAXIMUM_OVERSPEED_KNIFE Invalid parameter r64jerkPhase1 < 0.0 or r64jerkPhase1 > 100.0 Invalid parameter r64jerkPhase2 < 0.0 or r64jerkPhase2 > 100.0 The TO axis Rotary Knife Axis is not set-up The TO axis Auxiliary Axis is not set-up The TO axis Auxiliary Axis is not set-up as a virtual axis There is no TO set-up as leading value There is no TO cam Cam1 set-up There is no TO cam Cam2 set-up There is no TO cam Cam3 set-up There is no TO measuring input set-up The TO measuring input is not connected to leading value Invalid mode selection from the ERROR mode Invalid mode selection from the DISABLE mode Invalid mode selection from the STARTPOSITION mode Invalid mode selection from the AUTOMATIC mode Invalid mode selection from the MANUAL mode Invalid mode selection from the SINGLE_CUT mode Invalid mode selection from the SAMPLE_CUT mode Wrong mode DISABLE to DISABLE
A4027118-A0405
16#050B_8007
16#050B_8008
16#050B_8009
16#050B_800A
16#050B_800B
16#050B_800C
16#050B_800D
16#050C_8001 16#050C_8004 16#050C_8005 16#050C_8008 16#050C_8009 16#050C_800A 16#050C_800B 16#050C_800C 16#050C_800D 16#050F_8001 16#050F_8002 16#050F_8003 16#050F_8004 16#050F_8005 16#050F_8006 16#050F_8007 16#050F_8008 16#0511_8001
Version 2.0
Release 06.05.2011
102/140

Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA 16#0511_8002 DISABLE to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA DISABLE to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ), Details in i32RetDINTStopRKA DISABLE to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA DISABLE to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA DISABLE to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA STARTPOSITION to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA STARTPOSITION to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA STARTPOSITION to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA STARTPOSITION to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA STARTPOSITION to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA STARTPOSITION to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA STARTPOSITION to AUTOMATIC Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA STARTPOSITION to AUTOMATIC Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA STARTPOSITION to AUTOMATIC Error when activating camming of the Rotary Knife Axis [ start cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA STARTPOSITION to AUTOMATIC Error when activating gearing of the Auxiliary Axis ( _enablegearing ) Details in i32RetDINTEnableGearingAA STARTPOSITION to AUTOMATIC Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming )
A4027118-A0405
16#0511_8003
16#0511_8004
16#0512_8001
16#0512_8002
16#0521_8001
16#0521_8002
16#0521_8003
16#0521_8004
16#0522_8001
16#0522_8002
16#0523_8001
16#0523_8002
16#0523_8003
16#0523_8004
16#0523_8005
Version 2.0
Release 06.05.2011
103/140

Error ID
16#0525_8001
A4027118-A0405
Description
Details in i32RetDINTEnableCammingRKA STARTPOSITION to SINGLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA STARTPOSITION to SINGLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA STARTPOSITION to SAMPLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA STARTPOSITION to SAMPLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA Change FormatLength Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA Change FormatLength Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming ) Details in i32FREnableCammingRKA AUTOMATIC to STARTPOSITION Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32FREnableCammingRKA AUTOMATIC to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA AUTOMATIC to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA AUTOMATIC to STARTPOSITION Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32RetDINTDisableGearingAA AUTOMATIC to STARTPOSITION Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32FRDisableGearingAA AUTOMATIC to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA AUTOMATIC to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA MANUAL to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA MANUAL to DISABLE Error when stopping the Auxiliary Axis ( _move v=0 )
16#0525_8002
16#0526_8001
16#0526_8002
16#0503_8001
16#0503_8002
16#0532_8002
16#0532_8003
16#0532_8004
16#0532_8005
16#0532_8006
16#0532_8007
16#0532_8008
16#0541_8001
16#0541_8002
Version 2.0
Release 06.05.2011
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Error ID
Details in i32FRStopAA 16#0541_8003 MANUAL to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA MANUAL to DISABLE Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA MANUAL to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA MANUAL to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA MANUAL to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA MANUAL to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA MANUAL to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA MANUAL to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA SINGLE_CUT Error when activating camming of the Rotary Knife Axis [ start cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA SINGLE_CUT Error when activating gearing of the Auxiliary Axis ( _enablegearing ) Details in i32RetDINTEnableGearingAA SINGLE_CUT Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA SINGLE_CUT Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32FREnableCammingRKA SINGLE_CUT Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32RetDINTDisableGearingAA SINGLE_CUT Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32FRDisableGearingAA SINGLE_CUT Error when de-activating camming of the Rotary Knife Axis ( _disablecamming )
A4027118-A0405
Description
16#0541_8004
16#0542_8001
16#0542_8002
16#0542_8003
16#0542_8004
16#0542_8005
16#0542_8006
16#0505_8001
16#0505_8002
16#0505_8003
16#0505_8004
16#0505_8005
16#0505_8006
16#0505_8007
Version 2.0
Release 06.05.2011
105/140

Error ID
16#0505_8008
A4027118-A0405
Description
Details in i32RetDINTDisableCammingRKA SINGLE_CUT Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA SINGLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA SINGLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA SINGLE_CUT Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINT_pos_RKA SINGLE_CUT Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA SINGLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA SINGLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA SINGLE_CUT to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA SINGLE_CUT to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA SINGLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA SINGLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA SINGLE_CUT to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA SINGLE_CUT to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA SINGLE_CUT to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA SINGLE_CUT to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA
16#0505_8009
16#0505_800A
16#0505_800B
16#0505_800C
16#0552_8001
16#0552_8002
16#0552_8003
16#0552_8004
16#0552_8005
16#0552_8006
16#0552_8007
16#0552_8008
16#0552_8009
16#0552_800A
Version 2.0
Release 06.05.2011
106/140

Error ID
16#0506_8001
A4027118-A0405
Description
SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ start cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA SAMPLE_CUT Error when activating gearing of the Auxiliary Axis ( _enablegearing ) Details in i32RetDINTEnableGearingAA SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ cyclic cam] ( _enablecamming ) Details in i32FREnableCammingRKA SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA SAMPLE_CUT Error when activating camming of the Rotary Knife Axis [ stop cam] ( _enablecamming ) Details in i32FREnableCammingRKA SAMPLE_CUT Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA SAMPLE_CUT Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA SAMPLE_CUT Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32RetDINTDisableGearingAA SAMPLE_CUT Error when de-activating gearing of the Auxiliary Axis ( _disablegearing ) Details in i32FRDisableGearingAA SAMPLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32RetDINTHomingAA SAMPLE_CUT Error when referencing the Auxiliary Axis ( _homing ) Details in i32FRHomingAA SAMPLE_CUT Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA SAMPLE_CUT Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA SAMPLE_CUT to STARTPOSITION
16#0506_8002
16#0506_8003
16#0506_8004
16#0506_8005
16#0506_8006
16#0506_8007
16#0506_8008
16#0506_8009
16#0506_800A
16#0506_800B
16#0506_800C
16#0506_800D
16#0506_800E
16#0562_8001
Version 2.0
Release 06.05.2011
107/140

Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA 16#0562_8002 SAMPLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA SAMPLE_CUT to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32RetDINTStopAA SAMPLE_CUT to STARTPOSITION Error when stopping the Auxiliary Axis ( _move v=0 ) Details in i32FRStopAA SAMPLE_CUT to STARTPOSITION Error when de-activating camming of the Rotary Knife Axis ( _disablecamming ) Details in i32RetDINTDisableCammingRKA SAMPLE_CUT to STARTPOSITION Error when de-activating camming of the r Rotary Knife Axis ( _disablecamming ) Details in i32FRDisableCammingRKA SAMPLE_CUT to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32RetDINTStopRKA SAMPLE_CUT to STARTPOSITION Error when stopping the Rotary Knife Axis ( _move v=0 ) Details in i32FRStopRKA SAMPLE_CUT to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32RetDINTPosRKA SAMPLE_CUT to STARTPOSITION Error when positioning the Rotary Knife Axis ( _pos ) Details in i32FRPosRKA Cam calculation Error when deleting the actual cam ( _resetCam ) Cam calculation Error when adding new segments ( _addSegmentToCam ) Cam calculation Error when interpolating the actual cam ( _interpolateCam ) Print mark correction Error when positioning the rotary knife axis ( _pos ) Details in i32RetDINTPosRKA AUTOMATIC to STARTPOSITION Error when activating camming of the rotary knife axis [ stop cam] ( _enablecamming ) Details in i32RetDINTEnableCammingRKA
A4027118-A0405
16#0562_8003
16#0562_8004
16#0562_8005
16#0562_8006
16#0562_8007
16#0562_8008
16#0562_8009
16#0562_800A
16#05CC_8100 16#05CC_8200 16#05CC_8300 16#05DD_8001
16#05DD_8002
Version 2.0
Release 06.05.2011
108/140
7.4
Block name
Cam Calculation for rotating shears FBRKCamCalc

FBRKCamCalculation
Task This function block generates cams for rotating shears based on the specified geometrical parameters and velocity profiles. Integration in run-time system The function block can be linked into a cycle or sequential task. Graphic representation of the block
FBRKCamCalc
BOOL LREAL camType eTypeOfCamType LREAL LREAL LREAL LREAL LREAL LREAL INT LREAL LREAL LREAL eCamProfileType LREAL eCamProfileType LREAL
execute formatLength nextCam typeOfCam knifeCircumference startSyncAngle endSyncAngle startAngle stopAngle inflectionPoint numberOfKnives knifeOverspeedStartCut knifeOverspeedZero knifeOverspeedEndCut camProfilePhase1 jerkPhase1 camProfilePhase2 jerkPhase2
done busy error errorId
BOOL BOOL BOOL DWORD
Version 2.0
Release 06.05.2011
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Program Description Program Description SIMOTION Rotary Knife Block parameters Input parameters
Name
execute formatLength nextCam
A4027118-A0405
Data type
BOOL LREAL camType
Initial value
FALSE 200 TO#NIL Start of calculation
Description
[mm] length of format Reference to the technology object of the cam If no cam is specified, then only a parameter check START_CAM Cam to move the cross-cutter from the starting position into cyclic operation. CYCLIC_CAM Cam for cyclic operation of a cross-cutter. STOP_CAM Cam to stop the cross-cutter from cyclic operation. [mm] circumference of the knife [] Starting angle of the synchronous range (cutting range), i.e. the angle at which the knife enters the material, the knife center point is defined at 0 (The permissible value range lies between START_SYNC_ANGLE_MIN and 360.0). StartSyncAngle and endSyncAngle together define the synchronous range. [] End angle of the synchronous range, i.e. the angle at which the knife exits the cutting range (The permissible value range lies between 0.0 and START_SYNC_ANGLE_MIN FORMAT_ANGLE_MIN). StartSyncAngle and endSyncAngle together define the synchronous range. [] Knife start position (The permissible value range lies between endSyncAngle and startSyncAngle ACC_DCC_ANGLE_MIN) (Start position of the start cam) [] Knife stop position. (The permissible value range lies between endSyncAngle + ACC_DCC_ANGLE_MIN and startSyncAngle) (End position of the stop cam) [%] Center point of the cyclic cam. inflectionPoint < 50.0 % [min. MIN_VAL_INFLECTION_POINT (10%)]: Offset of the center point in the direction endSyncAngle, i.e. the absolute value of the acceleration in the first motion segment after the cut is higher. inflectionPoint > 50.0 % [max. 100% - MIN_VAL_INFLECTION_POINT]: Offset of the centerpoint in the direction startSyncAngle, i.e. the absolute value of the acceleration in the second motion segment after the cut is higher. Number of knifes (max. 6)
typeOfCam
eTypeOfCam Type
START_ CAM
knifeCircumference
LREAL
200.0
startSyncAngle
LREAL
345.0
endSyncAngle
LREAL
15.0
startAngle
LREAL
90.0
stopAngle
LREAL
270.0
inflectionPoint
LREAL
50.0
numberOfKnives
INT
Version 2.0
Release 06.05.2011
110/140

Name Data type Initial value
A4027118-A0405
Description
[%] Knife overspeed at the transition point to the synchronous range (startSyncAngle) [-MAXIMUM_OVERSPEED_KNIFE (%) to MAXIMUM_OVERSPEED_KNIFE (%)] referred to the synchronous velocity of the knife. [%] Knife overspeed at the center position of the synchronous range (0) [-MAXIMUM_OVERSPEED_KNIFE (%) to MAXIMUM_OVERSPEED_KNIFE (%)] referred to the synchronous velocity of the knife. [%] Knife overspeed at the end point of the synchronous range (endSyncAngle) [-MAXIMUM_OVERSPEED_KNIFE (%) to MAXIMUM_OVERSPEED_KNIFE (%)] referred to the synchronous velocity of the knife. Motion profile, phase 1 (endSyncAngle inflectionPoint) LINEAR Curve profile with constant acceleration JERK Curve profile with constant acceleration and jerk limiting POLY_5 Motion profile as fifth order polynomial. [%] Jerk limiting component in phase 1 (only for camProfilePhase1 = JERK). The valid value range is 1.0 up to 100.0. For 100%, there is no constant acceleration for the phase. The absolute jerk depends on the machine velocity Motion profile, phase 2 (inflectionPoint startSyncAngle) LINEAR Curve profile with constant acceleration JERK Curve profile with constant acceleration and jerk limiting POLY_5 Motion profile as fifth order polynomial. [%] Jerk limiting component in phase 2 (only for camProfilePhase2 = JERK). The valid value range lies between 1.0 and 100.0. For 100%, there is no constant acceleration for the phase. The absolute jerk depends on the machine velocity.
knifeOverspeedStartCut
LREAL
0.0
knifeOverspeedZero
LREAL
0.0
knifeOverspeedEnd Cut
LREAL
0.0
camProfilePhase1
eCamProfile Type
POLYNOM_5
jerkPhase1
LREAL
0.0
camProfilePhase2
eCamProfile Type
POLYNOM_5
jerkPhase2
LREAL
0.0
Output parameters
Name
done busy
Data type
BOOL BOOL
Initial value
FALSE FALSE
Description
TRUE: The cam generation has been completed FALSE: No cam calculation TRUE: The cam generation is active FALSE: No error TRUE: An error has occurred, refer to error identification Error identification, refer to error messages errorID <= 16#000_8000: warning errorID >= 16#0000_8000: error
error
BOOL
FALSE
errorId
DWORD
16#0000_0000
Version 2.0
Release 06.05.2011
111/140
Program Description Program Description SIMOTION Rotary Knife Functionality The function block generates the cam for the specified cross-cutter geometry for the parameterized cut length. The reference to the cam object is defined using input nextCam. The block is started with a rising edge at input execute; the input parameters are then checked for plausibility. If the input parameters are not valid, block processing is interrupted and a corresponding error message (error and errorID) is output. Once the cam generation has been completed, this is signaled with a rising edge at the done output. A4027118-A0405
Version 2.0
Release 06.05.2011
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When initiating the cam calculation, the following actions are executed in the individual steps:
Figure 7-4: Sequence of cam calculation
0 error
3 start cam 2 gen. calculations
1 wait
4 cyclic cam
6 delete cam Generation of cam
5 stop cam Calculations

7 add segments to cam
8 interpolate cam
General properties and characteristic quantities of a rotating shears

System with one knife System with two knives
start Sync Angle
Version 2.0
Release 06.05.2011
start S y endS gle ncAn
yncA ngle
y endS gle ncAn
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Table 7-8: Overview of the parameters and characteristic quantities for the cam calculation
Parameter
Synchronous range
Description
The synchronous range is defined by the synchronous angle referred to the knife circumference or the knife geometry. The synchronous angle is obtained from the parameters startSyncAngle und stopSyncAngle. The synchronous angle is the range in which the knife moves in synchronism with the material web velocity. The velocity in the synchronous range can be adapted for special applications or for special cutting geometries using parameter knifeOverspeedStartCut, knifeOverspeedZero, knifeOverspeedEndCut. The point, at which the knife is located perpendicular to the material is defined as the center point of the synchronous range and is at 0.
Format range
The format range is the range of the rotating shears, where the knife is not located in the synchronous range, i.e. is not in the cutting range. As the velocity in the synchronous range is defined by the material itself and the overspeed, equalization motion (format changes, print mark correction, etc.) can only be executed in the format range. For multi-knife systems, the format range is obtained according to the following formula: Format range = knifeCircumference / numberOfKnifes synchronous range
Phase1 / Phase2
Phase 1 describes the range of the rotating shears between endSyncAngle and inflectionPoint. Depending on the characteristic quantities and format length, in this phase, the rotating shears must either be accelerated or decelerated: cutLength < synchronous range + format range: Acceleration cutLength > synchronous range + format range: Deceleration Phase 2 defines the range of the rotating shears between inflectionPoint and startSyncAngle. The acceleration and deceleration behavior is opposite to that of phase 1: cutLength < synchronous range + format range: Deceleration cutLength > synchronous range + format range: Acceleration
startSyncAngle / endSyncAngle
Parameter startSyncAngle defines the start angle of the synchronous angle, i.e. the start point of the cutting range referred to the geometry. The point at which the knife is perpendicular to the material is defined as the zero point (0). Parameter endSyncAngle defines the end point of the synchronous angle and therefore the synchronous range. The angle between startSyncAngle and endSyncAnlge is the synchronous angle. If the two parameters are not identical, then the knife center position is automatically shifted into the format range, so that at inflectionPoint = 50%, the knife is always located at the geometrical center.
knifeOverspeedStart Cut, knifeOverspeed Zero, knifeOverspeedEnd Cut
In the standard configuration, a rotating shears operates with a linear cutting curve, i.e. a velocity characteristic that for the circumferential (peripheral) velocity of the shears corresponds to the material velocity. However, the knife and material are only perpendicular to one another at the cutting center point. This means that at the remaining points of the synchronous range, there are velocity differences between the tool and material, the magnitude of which depends on the material thickness respectively shears diameter or shears geometry. The velocity of the knife in the synchronous range can be specifically adapted using the mentioned parameters. Parameter knifeOverspeedStartCut Description Defines the velocity offset of the knife when entering the synchronous range, corresponding to parameter startSyncAngle. Defines the velocity offset at the zero position. Defines the velocity offset at the end point of the synchronous range, corresponding to parameter endSyncAngle.
knifeOverspeedZero knifeOverspeedEndCut
A fifth order polynomial is interpolated between the individual points. The parameter values are correspondingly interpreted as offset to the synchronous velocity.
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Parameter
Cutting profile Linear cutting curve: knifeOverspeedStartCut = 0.0% knifeOverspeedZero = 0.0% knifeOverspeedEndCut = 0.0%
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Description
Diagram
Linear cutting curve with 5% overspeed: knifeOverspeedStartCut = 5.0%

knifeOverspeedZero = 5.0% knifeOverspeedEndCut = 5.0%
Polynomial cutting curve: knifeOverspeedStartCut = 5.0% knifeOverspeedZero = 0.0% knifeOverspeedEndCut = 5.0%
inflectionPoint
The changeover point between phase 1 and phase 2 is defined using parameter inflectionPoint. The value is entered as a percentage and is referred to the format range, i.e. a value of 50% represents the center point of the format range.
inflectionPoint = 30 % startAngle / stopAngle
inflectionPoint = 50 %
inflectionPoint = 70 %
For rotating shears, the start position, the center position and the stop position are generally identical. In order to achieve a certain machine behavior, in spite of this, it may be necessary
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Parameter Description
(e.g. for single cut programs to reduce the load on the motor) to separate these positions. As already described, the center position is defined using parameter inflectionPoint, the start position by startAngle and the stop position by stopAngle. If the start position is shifted from the center position using the parameter startAngle, the acceleration distance of the rotating shears increases, which reduces the motor load and can therefore result in higher operating velocities. The maximum value for startAngle is theoretically endSyncAngle, otherwise the knife would move in the cutting range. The same consideration also applies to parameter stopAngle, which is limited by the value of parameter startSyncAngle. jerkPhase1 / jerkPhase2 These parameters define the percentage component of the phase that is used for jerk limiting. The absolute jerk is obtained from the machine velocity based on the specified motion profile. Values between 1.0 % and 100 % are permitted for this parameter; the value 0.0 stands for the profile with constant acceleration.
A4027118-A0405
jerkPhase1 / jerkPhase2 = 10% camProfilePhase1 / camProfilePhase2
jerkPhase1 / jerkPhase2 = 50%
jerkPhase1 / jerkPhase2 = 100%
These parameters define the motion profile in phase1 or in phase 2. The parameters do not have to be assigned the same value. LINEAR This selection defines a motion profile with constant acceleration.
Phase 1
Phase 2
knifeCircumference startSyncAngle (Synchronous range)
Format range
endSyncAngle (Synchronous range) inflectionPoint
Format length
JERK This selection defines a profile with constant acceleration and jerk limiting. Jerk limiting is specified using parameter jerkPhase1 / jerkPhase. The parameters are only evaluated in this profile.
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Parameter Description
A4027118-A0405
POLY_5 This selection defines a fifth order polynomial as basis for the motion profile.
Phase 1
Phase 2
knifeCircumference startSyncAngle (Synchronous range)
Format range
endSyncAngle (Synchronous range) inflectionPoint
Format length
typeOfCam
This parameter specifies the cam type that should be calculated. Type START_CAM Description The start cam defines the starting behavior of the rotating shears from the start point (startAngle) up to the cutting point (0). The profile selection is also taken into account in the calculation of the starting cam. Motion profile of the shears in cyclic operation. The stop cam defines the transition from cyclic operation to standstill of the rotating knife, i.e. the distance from the cutting point to the stop position (corresponding to stopAngle).
CYCLIC_CAM STOP_CAM
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Program Description Program Description SIMOTION Rotary Knife Error messages

ErrorID
16#xxxx_0xxxx 16#xxxx_4xxx 16#xxxx_8xxx 16#xxxx_Cxxx Low priority High priority Highest priority
A4027118-A0405
Priority
Lowest priority Warning
Description
Warning, execution possible with error Error, no execution possible Critical error
Warnings Warnings are indicated by the status of the outputs error and errorID: FALSE and errorID <> 16#0000_0000.
Table 7-9: Warnings
ErrorID
16#0000_0000 No warning
error =
Description
Errors
Error messages are indicated by the status of the outputs error and errorID: error = TRUE and errorID <> 16#0000_0000.
Table 7-10 Errors
ErrorID
16#05CC_8000 16#05CC_8001 Invalid parameter: knifeCircumference <= 0.0 Invalid parameter: numberOfKnives < 1 or numberOfKnives > 6 Invalid parameter: startSyncAngle < START_SYNC_ANGLE_MIN / numberOfKnives or startSyncAngle > 360.0 / numberOfKnives Invalid parameter: endSyncAngle < 0.0 or endSyncAngle > (START_SYNC_ANGLE_MIN FORMAT_ANGLE_MIN) / numberOfKnives Invalid parameter: numberOfKnifes * Synchrounous angle >= 360 or Synchrounous angle < 0 Invalid parameter: formatLength <= Synchronous length * FACTOR_SYNCLENGTH_FOR_MIN_CUTLENGTH Invalid parameter: inflectionPoint < MIN_VAL_INFLECTION_POINT or inflectionPoint > 100.0 MIN_VAL_INFLECTION_POINT Invalid parameter: startAngle <= endSyncAngle or startAngle >= startSyncAngle ACC_DCC_ANGLE_MIN Invalid parameter: stopAngle <= endSyncAngle + ACC_DCC_ANGLE_MIN or stopAngle >= startSyncAngle
Description
16#05CC_8002
16#05CC_8003
16#05CC_8004
16#05CC_8005
16#05CC_8006
16#05CC_8007
16#05CC_8008
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ErrorID
16#05CC_8009
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Description
Invalid parameter: knifeOverspeedStartCut < - MAXIMUM_OVERSPEED_KNIFE or knifeOverspeedStartCut > MAXIMUM_OVERSPEED_KNIFE Invalid parameter: knifeOverspeedZero < - MAXIMUM_OVERSPEED_KNIFE or knifeOverspeedZero > MAXIMUM_OVERSPEED_KNIFE Invalid parameter: knifeOverspeedEndCut < - MAXIMUM_OVERSPEED_KNIFE or knifeOverspeedEndCut > MAXIMUM_OVERSPEED_KNIFE Invalid parameter: jerkPhase1 < 0.0 or jerkPhase1 > 100.0 Invalid parameter: jerkPhase2 < 0.0 or jerkPhase2 > 100.0 Invalid parameter: nextCam = TO#NIL This error is only signaled if the parameter check was OK!!!! Error when deleting the actual cam ( _resetCam ) Error when adding new segments to actual cam ( _addSegmentToCam ) Error when interpolating the actual cam ( _interpolateCam )
16#05CC_800A
16#05CC_800B
16#05CC_800C
16#05CC_800D
16#05CC_800E 16#05CC_8100 16#05CC_8200 16#05CC_8300
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7.5
Functions in the IPO task FBRKIpo

Measuring the actual position using a measuring probe. Displays in which range (synchronous or format) the knife is presently moving. Displays whether the knife is currently moving in the cutting range.
Block name FBRKIpo Task If the print mark correction has been enabled, using a measuring probe, the function block determines the specified cutting position using print marks, calculates the position deviation from the difference between two consecutive cutting positions and the specified cutting length and saves the position measured value and position deviation in the measured value memory. The block determines the first cutting position using the first measuring cycle.
Generally, the function block determines the range in which the knife is presently located by comparing the position and whether the knife is currently in the cutting range. It indicates the result using status flags. Integration in run-time system The user must call the block in the IPO synchronous task. Graphic representation of the block
FBRKIpo
eOperationModes RotaryKnifeType eOperationModes RotaryKnifeType sTOsType sUsersInterface Type sRotaryKnifeInfo Type sCutPositionBuffer ManagementType sFormatLengthBuffer ManagementType sMeasuringValue Type modeEnabled modeSelected axisTOs usersInterface rotaryKnifeInfo cutPositionBufferManagement formatLengthBufferManagement measuringValue sTOsType sUsersInterface Type sRotaryKnifeInfo Type sCutPositionBuffer ManagementType sFormatLengthBuffer ManagementType sMeasuringValue Type
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Program Description Program Description SIMOTION Rotary Knife Block parameters Input parameter
Name Data type Initial value Description
Aktive state of FBRotaryKnife OMRK_ERROR: State ERROR OMRK_DISABLE: State DISABLE OMRK_AUTOMATIC: State STARTPOSITION OMRK_AUTOMATIC: State AUTOMATIC OMRK_MANUAL: State MANUAL OMRK_SINGLE_CUT: State SINGLE_CUT OMRK_SAMPLE_CUT: State SAMPLE_CUT OMRK_NOTHING_SELECTED: No change of state selected OMRK_CHANGING: Change of state active Selected state of FBRotaryKnife OMRK_ERROR: Selected state ERROR OMRK_DISABLE: Selected state DISABLE OMRK_AUTOMATIC: Selected state STARTPOSITION OMRK_AUTOMATIC: Selected state AUTOMATIC OMRK_MANUAL: Selected state MANUAL OMRK_SINGLE_CUT: Selected state SINGLE_CUT OMRK_SAMPLE_CUT: Selected state SAMPLE_CUT
A4027118-A0405
modeEnabled
eOperationModesRotary KnifeType
OMRK_ NOTHING_ SELECTED
modeSelected
eOperationModesRotary KnifeType
OMRK_ NOTHING_ SELECTED

Name
axisTOs usersInterface rotaryKnifeInfo
Data type
sTOsType sUsersInterface Type sRotaryKnifeInfo Type sCutPosition Buffer Management Type sFormatlength Buffer Management Type sMeasuringValue Type
Initial value
Description
Structure of axes and TO management Structure with all of the machine data that the user can adapt such as startSyncPos and endSyncPos (refer to chapter, data types). Structure with all of the information signals of the RotaryKnife (refer to chapter, data types). Structure of the CutPositionBuffer with all of the required control signals and pointers (refer to chapter, data types).
formatlengthBuffer Management
Structure of the FormatlengthBuffer with all of the required control signals and pointers (refer to chapter, data types). Structure of the measured value detection
measuringValue
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Program Description Program Description SIMOTION Rotary Knife Functionality The block fulfills the following functions depending on the operating phase of the system with the print mark detection switched-in:
Table 7-11: Sequence, print mark detection
Phase
Phase 1 Phase 2
A4027118-A0405
Description
Activates the measuring probe to measure the FirstCutPosition The first measured position is saved as startPosAtSensor and the setpoint position is calculated for the next cutting operation from the measured position plus the format length. The measuring probe is activated to measure the next cutting position with activated activation range. The next measured position is saved in the measured value memory together with its deviation from the setpoint position. If a measured value is not found in the actual active range (fault 40003), then the reference position with its activation range is shifted one format length further.
Phase 3 Phase 4 Phase 5
The block compares the actual knife position with startSyncPos and endSyncPos, which are defined in the user interfaces and depending on the position sets the following bits in the RotaryKnifeInfo structure: In the synchronous range knifeInSynchronousSector = TRUE knifeInFormatSector = FALSE In the format range knifeInSynchronousSector = FALSE knifeInFormatSector = TRUE The block compares the actual knife position with 0.0 and endSyncPos and sets In the cutting range rotaryKnifeInfo.cut cutPositionBufferManagement.bufferOutTrigger Outside the cutting range rotaryKnifeInfo.cut cutPositionBufferManagement.bufferOutTrigger Error messages No errors are generated. = TRUE = TRUE = FALSE = FALSE
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7.6
Blocks to manage the format length memory

Users must use the blocks described in this chapter if they must change the cut length by precisely one cut. The user program section of the demonstration application is used here as application example. If the application has a dynamic cut length detection, to enter the cut lengths at the standard Rotary Knife application, then the following blocks should be used.
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7.6.1
Resetting the format length memory FBFormatLengthBufferReset

Deleting and resetting the format length memory.
Block name FBFormatLengthBufferReset Task Deleting and resetting the format length memory. Integration in run-time system This block can be called in any task. The block is used by the SIMOTION Rotary Knife application and does not have to be linked-in by the user. Graphic representation of the block
FBFormatLengthBufferReset
sFormatLengthBuffer ManagementType formatLengthBufferManagement sFormatLengthBuffer ManagementType
Block parameters Input / output Parameters

Name
formatLengthBuffer Management
Data type
sFormatLength BufferManagement Type
Initial value
Description
Structure of the format length memory with all of the required control signals and pointers (refer to chapter, data types)
Deletes all of the memory contents by overwriting the memory elements with 0.0 and FALSE Resets all pointers to 0 Resets all status signals to FALSE
Error messages No errors are generated.
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7.6.2
Entries in the format length memory FBFormatLengthBufferIn

Enters a format length in the format length memory.
Name of the block FBFormatLengthBufferIn Task With each call, the format length present at the block is entered into a free location in the format length memory. In addition, a processing completed ID can be set for the last segment. Integration in run-time system The block can be called in any task. The block is used by the SIMOTION Rotary Knife 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 Rotary Knife Block parameters Input parameters
Name
lastSegment formatLength
A4027118-A0405
Data type
BOOL LREAL
Initial value
FALSE 0.0 [mm] Format length
Description
Cutting completed detection

Name Data type
sFormat Length Buffer ManagementType
Initial value
Description
Structure of the format length memory with all of the required control signals and pointers (refer to chapter, data types)
Functionality
A new format length is entered into the format length memory. If the input parameter lastSegment = TRUE and if the format length last entered from the RotaryKnife system has still not been read then the format length last entered is set to 0.0 and the buffer pointer is not increased (incremented). If it was already read-in, then an additional format length is entered with 0.0 and the buffer pointer is increased (incremented) by 1. Error messages No errors are generated.
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7.6.3
Reading from the format length memory FBFormatLengthBufferRead

Reads a format length from the format length memory.
Block name FBFormatLengthBufferRead Task At each call, a check is made as to whether a new format length was entered. If yes, then it is read-out and a cam change initiated. The format length is not deleted from the buffer. Integration in run-time system The block can be called in any task. The block is used by the SIMOTION Rotary Knife application and does not have to be linked-in by the user.
Block parameters Input / output parameters

Name
switchCAM formatLengthBuffer Management
Data type
BOOL sFormatLength BufferManagement Type
Initial value
FALSE
Description
Initiates that a new cam is calculated Structure of the format length memory with all of the required control signals and pointers (refer to the chapter, data types)
Output parameters
Name
formatLength lastSegment switchCAMActive
Data type
LREAL BOOL BOOL
Initial value
0.0 FALSE FALSE
Description
[mm] Format length Processing ended detection Cam change being prepared
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Program Description Program Description SIMOTION Rotary Knife Functionality The block only executes the following activities, if a format length has been entered, but has still not been read out and if a cam changeover has not been activated. Reads out the next format length to be activated. The format length remains saved in the buffer, however it is tagged as if it has been read out. If the format length that is read out is zero, then the output flag lastSegment is set to TRUE and a cam changeover is not activated. If a format length that has been read-out is not equal to zero, then a cam changeover is activated. Error messages No errors are generated. A4027118-A0405
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7.6.4
Exporting from the format length memory FBFormatLengthBufferOut

Exporting a format length from the format length memory.
Name of Block FBFormatLengthBufferOut Task After the next processing operation, the function block deletes the last format length that was entered from the format length memory and releases the memory cell for memory management purposes. Integration in run-time system The block can be called in any task. The block is used by the SIMOTION Rotary Knife application and does not have to be linked-in by the user.
Graphic representation of the Block
FBFormatLengthBufferOut
sFormatLengthBuffer ManagementType formatLengthBufferManagement sFormatLengthBuffer ManagementType
Block parameters Input / Output parameters

Name
Data type
sFormatLength BufferManagement Type
Initial value
Description
Structure of the format length memory with all of the required control signals and pointers (refer to the chapter, data types)
Functionality The block monitors the processing operation of the Rotary Knife. With the next step after reading-out the particular format length, this is deleted in the buffer. Error messages No errors are generated.
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7.7
Measured value memory system blocks used in the rotary knife application
The Rotary Knife system uses these blocks. As standard, the user does not have to access them!
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7.7.1
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. 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
FBCutPositionBufferReset
sCutPositionBuffer ManagementType cutPositionBufferManagement sCutPositionBuffer ManagementType
Block parameters Input / output parameters

Name
Data type
sCutPositionBuffer ManagementType
Initial value
Description
Structure of the measured value memory with all of the required control signals and pointers (refer 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.
7.7.2
Entries in the measured value memory FBCutPositionBufferIn

Enters a measured value (position measured value and/or position deviation) in the measured value memory.
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Program Description Program Description SIMOTION Rotary Knife 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 A4027118-A0405
Block parameters Input parameters

Name
positionDeviation actPosition
Data type
LREAL LREAL
Initial value
0.0 0.0
Description
[mm] Position deviation (deviation between the reference position and actual position) [mm] Position measured value

Name
Data type
Initial value
Description
Structure of the measured value memory with all of the required control signals and pointers (refer to the chapter, data types)
Functionality The position measured value is entered into the measured value memory. The position deviation is entered into the measured value memory.
Error messages No errors are generated.
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7.7.3
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 position correction. 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
Block parameters Input parameters

Name
operatingForRotaryKnife
Data type
BOOL
Initial value
= TRUE TRUE = FALSE
Description
Block is being used for the Rotary Knife application Block is being used for the Flying Saw application
Output parameters
Name
positionDeviationValid positionDeviation Maesured
Data type
BOOL LREAL
Initial value
FALSE 0.0
Description
A position deviation has been defined [mm] Position correction value
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Name
flyingSawStart positionMeasured
A4027118-A0405
Data type Initial value
FALSE 0.0
Description
Start condition of the flying saw [mm] next sync position
BOOL LREAL
Input / output Parameters

Name
Data type
sCutPosition Buffer Management Type
Initial value
Description
Structure of the measured value memory with all of the required control signals and pointers (refer to the chapter, data types).
Functionality Depending on the calling application, the block executes the following activities: If the block is being used in a Rotary Knife application (operatingForRotaryKnife = TRUE), then at each call, a check is made as to whether a new position deviation (cutPositionDeviation) was entered. If yes, the cutPositionDeviationValid flag is set and the position deviation (cutPositionDeviation) is transferred as correction value.
If the block is used in a Flying Saw application (operatingForRotaryKnife = FALSE) at each call, a check is made 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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7.7.4
Exporting from the measured value memory FBCutPositionBufferOut

A measured value (position measured value and position deviation) are 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.
FBCutPositionBufferOut
sCutPositionBuffer ManagementType cutPositionBufferManagement sCutPositionBuffer ManagementType
Block parameters Input / output parameter

Name
Data type
Initial value
Description
Structure of the CutPositionBuffer with all of the required control signals and pointers (refer to the 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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7.8
7.8.1
Extended functions
Using the cutting program
Cutting programs are used in the steel industry to cut samples of different lengths from the sheet steel. For this purpose, the SIMOTION RotaryKnife has the SAMPLE_CUT mode.
How is the memory filled? The user enters the required cut lengths into the SAMPLEBUFFER with the associated number of cuts. Which blocks do I have to call? None How does all of this function? The user switches FBRotaryKnife into the SAMPLE_CUT mode.
The cutting program then automatically and immediately starts (Bit quickstart = TRUE!) or at the specified starting position (bit quickstart = FALSE!) and executes the cut lengths saved in the SAMPLEBUFFER with their associated number of cuts. The entries that are saved are deleted after execution. If there is no further entry in the buffer, the FB exits the program in the start position.
7.8.2
Using print mark correction

The print mark correction is switched-in by setting the CutPosition CorrectionOn bits to TRUE. (sUsersInterface. boCutPositionCorrectionOn)
How is the memory filled? The print mark correction has an intermediate buffer memory (CUTPOSITIONBUFFER) to enter the correction values precisely for the cut. The correction values are measured, saved and entered automatically after the print mark correction has been activated. The user does not have to intervene. Which blocks do I have to call? None How does all of this function? The print mark correction is realized automatically. However, users have parameters to influence its mode of operation. These parameters are located in the structure UsersInterface.
Table 7-12 Parameter of Printmark Correction
Name Description
Flag, edge selection, measuring system TRUE: Rising edge FALSE: Falling edge
sUsersInterface.
boMeasuringWithRisingEdge
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Name
boCutPositionCorrectionOn boAdjustCutPositionPositive boTrimmCutPositionPositive boAdjustCutPositionNegative boTrimmtCutPositionNegative r64CPCorrectionMaximum r64CPDeltaToleranceRange r64AdjustCutPositionPositiveValue r64TrimmCutPositionPositiveValue r64AdjustCutPositionNegativeValue r64TrimmCutPositionNegativeValue
A4027118-A0405
Description
Flag, cut position correction on Flag, start coarse correction positive of the cutting position Flag, start fine correction positive of the cutting position Flag, start coarse correction negative of the cutting position Flag, start fine correction negative of the cutting position [mm] Maximum correction value for the cut position correction [mm] Half the tolerance bandwidth for the activation range of the cut position detection [mm] Coarse correction value of the manual cut position correction in the positive direction [mm] Fine correction value of the manual cut position correction in the positive direction [mm] Coarse correction value of the manual cut position correction in the negative direction [mm] Fine correction value of the manual cut position correction in the negative direction [mm/s] Velocity value of the higher-level cut position correction Number of cuts without cut position correction
r64CutPositionCorrectionVelocity i16CutCorrWait
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Appendix General information on the application SIMOTION Rotary Knife A4027118-A0405
Appendix 8
8.1
General information on the application

Scope of supply
The package Rotary Knife in SIMOTION comprises the following: Program S7/Scout project as ZIP file: SIMOTION_Rotary Knife_V2.0.zip Documentation Implementation/Operating Instructions as PDF file Manual_SIMOTION_Rotary Knife_V2.0.pdf
8.2
Revision/Authors
Table 8-1: Revision/Author
Version Date/Revision Author
V 1.0 V 1.1 V 1.2 V 1.3 V 1.4 V 2.0
28.02.2005 / first edition 3rd cam 03/13/06 Changes General Notes 04/13/06 SCOUT V4.0 06/06/08 SCOUT V4.1.1.6 and WinCCflex 09.08.06 expanded by the SINGLE_CUT and SAMPLE_CUT modes, change to the instance assignment capability (instanceability). Adapted to the Converting standards, expanded by the cam profile Linear and Jerk. 06.05.2011 Adaptions for Scout V4.2
H.-E. Bhm H.-E. Bhm A. Hagelauer H.-E. Bhm P. Tabori H.-E. Bhm H.-E. Bhm
H.-E. Bhm
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Appendix Contact partner SIMOTION Rotary Knife A4027118-A0405
Contact partner
Applicationcenter
SIEMENS Siemens AG Industry Sector Drives Technologies Division Motion Control Systems A&D MC PM APC Frauenauracher Str. 80 91056 Erlangen Fax: +49 (0) 9131-981297 mailto: applications.erlf@siemens.com
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Appendix Please help us to become even better SIMOTION Rotary Knife A4027118-A0405
10
Please help us to become even better

Sender: Name: Department: City: Telephone: E-Mail:
I DT MC PM APC Application Center D 91056 Erlangen Fax: +49 (0) 9131/981297 E-Mail: applications.erlf@siemens.com
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

conceptual phase engineering/writing code commissioning How is this application from the didactic perspective?
Very high Very poor
scope layout/design clarity Can the application be transferred to your own application?
Very easily Not easily
Do you require support for this application? Other comments
Yes
No
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Manual SIMOTION Rotary Knife V2.0

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SIMOTION Rotary Knife

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SIMOTION Rotary Knife

Warranty, liability and support

SIMOTION Rotary Knife

Reference regarding export codes AL: N ECCN: N

SIMOTION Rotary Knife

Prerequisites and objectives

The application example as demosystem

Integrating the core functions

Program description of the technology template

SIMOTION Rotary Knife

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

SIMOTION Rotary Knife

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

The application example as demo system .............................................................. 27

Integrating the core functions .................................................................................. 59

Program Description ................................................................................................. 72

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

SIMOTION Rotary Knife 8.1 8.2 9 10

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Prerequisites and objectives Basic information SIMOTION Rotary Knife A4027118-A0405

Prerequisites and objectives

Basic information and data

Structure and function

Prerequisites and objectives Basic information SIMOTION Rotary Knife A4027118-A0405

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

Objective and purpose of this standard application

Prerequisites and objectives Basic information SIMOTION Rotary Knife

material Continous Web

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

Prerequisites and objectives Basic information SIMOTION Rotary Knife A4027118-A0405

Application solution using the standard application SIMOTION Rotary Knife

Advantages of the standard application SIMOTION Rotary Knife

Prerequisites and objectives Basic information SIMOTION Rotary Knife A4027118-A0405

Components included in the standard application

Prerequisites and objectives Uses SIMOTION Rotary Knife A4027118-A0405

Tasks that can be implemented using the core functions

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

Prerequisites and objectives Uses SIMOTION Rotary Knife A4027118-A0405

Properties and features of the core rotary knife functions

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

Prerequisites and objectives Uses SIMOTION Rotary Knife A4027118-A0405

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

Prerequisites and objectives Uses SIMOTION Rotary Knife A4027118-A0405

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

Cross-cutter Material web

Structure and function

Rotary Knife Position

Prerequisites and objectives Structure and function SIMOTION Rotary Knife

NumberOfKnives DistanceToSensor [mm]

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

Rotary knife cams

Half of the synchronous range at the d f th t

Half of the synchronous range at the start of the cuts

Prerequisites and objectives Structure and function SIMOTION Rotary Knife

0 mm 0 mm 20 mm Cut length 20 mm Cut length

Cross-cutter circumference Cross-cutter circumference

Copyright Siemens AG 2011 All rights reserved Manual_SIMOTION_Rotary_Knife_V2.0.doc

0 mm 0 mm 20 mm Cut length 20 mm Cut length

Cross-cutter circumference Cross-cutter circumference

0 mm 0 mm 20 mm Cut length 20 mm Cut length