SIMOTION Motion Control technology package

The Motion Control Basic technology functions can be used without a license. Use of the extended functions of the Motion Control technology package is subject to a license.

The comprehensive functions of the Motion Control technology package offer very open and flexible ways of influencing application programming and ensure that you can also implement future Motion Control applications.

Using the Motion Control functions in conjunction with the powerful PLC functionality results in high machine cycles thanks to short response times as well as high product quality thanks to reproducible machine behavior.

Technology functions for Motion Control Basic

The speed-controlled axis technology object

• Speed setpoints are defined in the program (for servo and vector drives)
• In addition, accumulative torque setpoints and torque limits can be defined, for example, for controlling a winder drive with tension control
• Access to status and control words of the drive
  Release sequence of the PROFIdrive units can be specifically controlled (e.g. for braking control signal)
• Reading and writing of drive parameters
• Support for SINAMICS drives which can perform safetyrelated motion monitoring functions such as Safe Operating Stop (SOS), Safely Limited Speed (SLS), Safe Speed Monitor (SSM) and Safe Direction (SDI), safety-related position monitoring such as Safely Limited Position (SLP) and safe position transmission (SP) or safe stop reactions such as Safe Torque Off (STO), Safe Stop 1 (SS1), Safe Stop 2 (SS2).
  The purpose of this support is to prevent stop reactions by the drive, where SIMOTION uses the application to regulate the drive, e.g. within permissible velocity limits (with SLS) or stop the drive (e.g. with SOS).
  Activation and deactivation of SINAMICS Safety Integrated Extended Functions STO, SS1, SS2, SOS, SLS, SDI, SLP as well as their status are indicated on the axis by specific technology alarms and system variables.

Further information about SINAMICS Safety Integrated can be found in section Safety Integrated.

External encoder technology object

External encoders can be used to detect actual position values of axes (on PROFINET/PROFIBUS, onboard for C240 and as a 2nd encoder on the drive).

Cam and cam track technology object

• Generates position-dependent switching signals
• Number of cams and cam tracks depend on available system resources
• Each cam track can have up to 32 cams on one output

The following cam types are available:

• Trip cams
• Position-position cams
• Position-time cams
• Position-time-based cams with maximum ON length
• Counter cams
• Exact time setting of an output, exact time output cams

The cam statuses can be output with:

• Internal variables
• Standard digital outputs
  (SIMATIC ET 200SP, SIMATIC ET 200MP, ...)
• Onboard outputs of SIMOTION C, D and cam outputs on TM15, ET 200SP and ET 200MP TM Timer DIDQ (for high accuracy requirements in the ?s range)
• The output can be inverted

The following can be used as reference points for the switching edges of the cams:

• Setpoints for real and virtual axes
• Actual values of real axes and external encoders

The following functions are available:

• Parameterizable hysteresis and effective direction
• Activation and deactivation times can be specified separately (dead time compensation)
• One-time and cyclic output of cam paths
• Parameterizable start/stop mode for cam tracks (immediately, with next track cycle, etc.)
• The status of each individual cam (activated/deactivated) can be read
• Single output cams on a cam track can also be directly defined as valid/invalid

Measuring input technology object

Measuring inputs can be assigned to positioning and synchronous axes, external encoders or virtual axes and supply the axis position at the time of measuring.

The following functions are available:

• One-time measurement
• Cyclic measurement (2 edges per servo/IPO cycle in conjunction with measuring inputs on ET 200SP and ET 200MP TM Timer DIDQ or SIMOTION C240, D4x5-2)
• Measuring on virtual axes (in conjunction with measuring inputs on TM15, ET 200SP and ET 200MP TM Timer DIDQ, D4xx-2, CX32-2, CUxx or C240)
• Several active measuring inputs on one axis or one measuring input for several axes (in conjunction with measuring inputs on TM15, ET 200SP and ET 200MP TM Timer DIDQ, D4xx-2, CX32-2, CUxx or C240)
• Parameterizable edge evaluation (rising, falling, both edges)
• Dynamic resolution range

POS – Positioning technology functions

The positioning axis technology object

• Contains the functions of the drive axis technology object
• Supported axis types:
  • Linear axis, rotary axis
  • Modulo axis for linear and rotary axes
  • Real and virtual axis
  • Simulation axis
• Position control for:
  • Electrical drives
    Position control with digital setpoint output:
    The following PROFINET/PROFIBUS DP protocol is used for this purpose: Drive technology profile, PROFIdrive, version 4 (isochronous mode)
    Highly dynamic movements can be programmed using Dynamic Servo Control (DSC and DSC with spline) in combination with the position control in the drive in a cycle of 125 µs, for example
    Position control with analog setpoint output:
    Onboard I/Os for C240, ADI 4, IM 174
  • Hydraulic drives
    Position control with analog setpoint output:
    Onboard I/Os for C240, ADI 4, IM 174, analog outputs in the I/O range, e.g. in combination with ET 200 High Speed I/Os
    The characteristics of the hydraulic valves are specified with cams
  • Stepper motors
    Position control with pulse direction output for stepper drives:
    Onboard I/Os for C240, IM 174
    Alternatively, stepper drives can be linked with a PROFINET/PROFIBUS interface provided that they support the PROFIdrive profile. Stepper drives can be operated without an encoder or be position-controlled with an encoder.
• Position-controlled positioning:
  Axes can be manipulated individually without interpolation context by specifying, for example:
  • Axis name
  • Position
  • Velocity
  • Acceleration/delay, jerk
  • Transition behavior to next motion
• Speed-controlled operation of positioning axes
• Monitoring and limiting (standstill, positioning, dynamic following error, standstill signal, controlled variables, hardware/software end positions, encoder limit frequency, velocity error, measuring system difference/slip, limits for the dynamic response)
• Reversing block (prevents the output of setpoints which would cause a reversing motion)
• Movement profiles on axis defined over cams:
  • Path over time
  • Velocity over time
  • Velocity over path
• Force and pressure control of an axis:
  • On-the-fly switchover from position to pressure-controlled operation and vice versa
  • Several pressure sensors possible
  • Pressure difference measurement
• Force and pressure limitation of an axis:
• Force and pressure profiles specifiable by means of cams:
  • For closed-loop control and limitation
  • Force/pressure over time
  • Force/pressure over path
• Traveling to a fixed stop point
  • Stop on reaching a following error limit
  • Stop on reaching a torque limit
  • Stop with defined torque
• Traversing with additive torque, adjustable torque limiting and flexible torque limits B+/B-
• Transition behavior of successive motions:
  • attach, i.e. each motion is completed and the axis stops between motions (exact stop)
  • continuous move, i.e. the transition to the next motion begins when braking starts.
  • replace, i.e. the programmed motion is performed immediately. The active command is aborted.
• An additional motion can be performed during an active motion, for example, an active positioning motion can be performed simultaneously to a compensation motion.
• Concurrent start of positioning axes
• Homing:
  The following homing types are currently supported:
  • Active homing (reference point approach)/passive homing (homing on-the-fly)
      o  With reference cam and encoder zero mark
      o  With external zero mark only
      o  With encoder zero mark only
      o  BERO proximity switch and hardware limit switch as reversing cam
      o  Hardware limit switch as reference cam
  • Direct homing / setting the home position
  • Relative direct homing (shift by specified offset)
  • Absolute encoder homing / absolute encoder calibration
• Compensations and reference points:
  • Reference point offset
  • Backlash compensation
  • Static friction compensation
  • Sliding friction compensation for hydraulics
  • Drift compensation for analog drives
• Print mark correction
• Encoder switchover:
  Up to 8 encoders can be specified for an axis:
  • For the position control, only one encoder is active at any one time.
  • The switchover between encoders can be performed on-thefly (with a change-over smoothing filter).
  • The actual value of the non-active encoder can be read with the user program and used for specific monitoring, for example.
• Override:
  • Factors can be superimposed online on the current traverse velocity and acceleration/deceleration.

GEAR – Synchronous operation/electronic gear technological functions

Synchronized axis technology object

• Contains the functions of the positioning axis technology object
• Synchronized speed for position-controlled axes
• Angular synchronization, electronic gear:
  Stable, long-time angular synchronization over several axes is ensured. The gear ratio can be adjusted in small steps.
• Absolute and relative gearbox synchronism
• Offset of the following axis
• Leading axis:
  The master value can be changed immediately between master value sources (transition dynamics must be specified). ?The following can be used as a leading axis or master value sources for the following axes:
  • Virtual axis:
    The virtual axis only exists in the control and therefore does not have a real drive, motor or encoder. A virtual axis can be controlled with commands in the same way as a real axis. The motion control calculates the setpoints with the interpolator which can be used as a master value for synchronous operation, for example.
  • Real axis:
    The real axis is a leading axis which is part of the SIMOTION system and can be coupled over a setpoint and actual value.
  • External encoder:
    The actual value is detected with an external encoder and supplied as a master value after conditioning.
• Setpoint value linkage as well as actual-value linkage with compensation of dead times.
• Angular position and electronic gear ratio for axes can also be changed during operation.
• Engaging/disengaging:
  Following axes can be stopped for one cycle or moved for only one cycle to remove a faulty component, for example. This can be flexibly implemented with the programmable synchronism functionality.
• Synchronization and desynchronization:
  • Following axes can be synchronized and desynchronized while the leading axis is in motion or standing still.
  • The synchronous position of the master value and the following axis can be specified.
• Different synchronization modes are available:
  • Synchronization via a specifiable master value distance
  • Synchronization based on specifiable dynamic response parameters (jerk-limited)
  • Synchronizing position for synchronization and desynchronization at a precision position
  • Position of synchronizing range (before, after and symmetrically with synchronous position)
• Terminating synchronized operation of/to positioning
• Comprehensive synchronized operation monitoring functions
• External synchronization:
  Material slip can be corrected, for example, by flying measurement of, for example, a print-mark and a superimposed positioning function.
• Simultaneous motion during synchronous operation:
  A positioning motion or other synchronous operation can be performed during synchronous operation.
• Distributed synchronous operation and the option to implement synchronous operation beyond device limits.
  • PROFIBUS: Leading axis to PROFIBUS master, following axes to PROFIBUS slaves.
  • PROFINET: Changeover possible between leading axes on different SIMOTION controllers. Cascading of the synchronous operations over several SIMOTION controllers.
  • Dead times are compensated automatically.
  • Also possible across different projects (independent projects)

CAM - Cam technology functions

Cam technology object

• The number of cams depends on the available system resources
• The number of support points or segments per cam depends on the available system resources
• Cam functions:
  • Definition using table interpolation points or polynomials up to the 6th order with trigonometric component
  • Motion laws can be implemented in accordance with VDI 2143
  • Transition between support points/polynomials: Linear, continuous, spline

Technology object synchronous axis with camming

• Contains the functions of the synchronous axis technology object
• Scalability, cam functions can be offset and switched even during operation:
  • The leading and following axis positions of the cam functions can be scaled and offset during operation.
  • The active cam function can be defined and switched during operation.
• Non-cyclic and cyclic editing of cams
• Absolute and relative camming
• Absolute and relative master value referencing
• Synchronization and desynchronization
  (see synchronized axis technology object)
• Overriding of 2 synchronized cams
• Cams can be defined and modified with the SIMOTION SCOUT engineering system or with an application program during runtime.

PATH - Path interpolation technology functions

Path interpolation technology object

The path interpolation technology object is primarily intended for the automation of handling kinematics and features the following functions:

• Linear, circular and polynomial interpolation in 2D and 3D
• Transformation for standard kinematics
• Synchronization with conveyor belts (conveyor tracking)
• Dynamic planning across three traversing blocks
• The path dynamics (acceleration, jerk) are specified on the path, axis limits are generally applicable regardless of the path limits
• Continuous geometric movement between two traversing blocks
• Intuitive operation with SIMOTION SCOUT (path control panel for efficient traversing of the path axes, screens to support the calibration procedure of the coordinate system)
• Interconnection of a path object is possible with:
  • Up to 3 interpolating path axes
  • One positioning axis for path-synchronized motion
  • One cam for specifying velocity profiles
• Connection of path-based cams, cam tracks and measuring inputs over the positioning axis for path-synchronized motion
• Interconnection of the Cartesian path coordinates with positioning axes is possible. Cams, cam tracks and measuring inputs can also be implemented on the path
• Kinematic transformations for:
  • Swivel arm
  • SCARA L
  • Cartesian gantries (2D/3D)
  • Articulated arm (toploader)
  • Cylindrical robot
  • Roller pickers (2D/3D)
  • Delta pickers (2D/3D)
  • Spare transformation interface for customer-specific kinematics
• Programming in ST and MCC

A pre-configured standard application can be used for easy implementation of handling kinematics, which allows both jog mode and the creation of motion programs (see SIMOTION Utilities & Applications which is supplied with SIMOTION SCOUT).

Kinematics in the Motion Control technology package

Kinematics in the Motion Control technology package

Interpolation in machines for material machining is covered by the SINUMERIK machine tool controllers. (Further information about SINUMERIK control systems can be found in Catalogs NC 62 and NC 82).

Supplementary technology functions

Fixed gear technology object

You can use the "Fixed gear" technology object to implement a fixed synchronous operation (without synchronization/desynchronization) using a specified gear ratio. Fixed gearing converts an input variable to an output variable with a configured transmission ratio (gear ratio). ?A Fixed gear technology object can be used as follows, for example:

• To make allowance for diameters in a master variable.
• To implement a fixed gear ratio without coupling
• For speed synchronization on speed-controlled axes
• As a motion-coupled gear on master value, following axes are engaged or disengaged. In this way, the gear is always synchronized with the master value. Example: A paper web runs synchronously with the master.

Summator technology object

The addition object can be used to add up to four input vectors (motion vectors) to one output vector. An addition object can be used as follows, for example:

• To add up superimpositions/offsets in the main signal path, e.g. color register, cut-off register on the paper web

Formula technology object

Formula object for scalable variables and motion vectors. A formula object can be used between interconnected objects to modify scalar variables in the main signal path, e.g.:

• Superimposition of torque
• Superimposition of master velocity
• Modification of torque variables B+, B-
• Enabling of torque limitations
• Enabling of torque

Sensor technology object

The sensor object can be used to acquire scalar measuring values. A sensor object reads out a value from the I/O and supplies an actual value as an output signal in standardized formats.

Controller technology object

The controller object can be used to prepare and control scalar variables.
A controller object can be used as a universal PIDT1 controller for scalar control variables as well as a PI and P controller.

Interconnection of technology objects

The individual technology objects can be interconnected. The supplementary technology functions, for example, can be used to implement tension-controlled winder applications directly on the system level.

Note:
No license is necessary for using the supplementary technology functions.

SIMOTION TControl technology package

TControl – Temperature controller technology functions

Temperature channel technology object

The controller core of the temperature technology package has a DPID structure. Pure heating controllers and cooling controllers as well as combined heating/cooling controllers can be configured and parameterized.

User-assignable functions are available for each temperature channel:

• Each temperature channel can either be configured as a heating or cooling section or as a combined heating/cooling section.
• The controllers either use a PID or DPID control algorithm or use the optional control zone functionality.
• In manual output mode, a replacement value can be output.
• You can select the operating mode for each controller channel separately. In this way, for example, you can switch the output to a fixed control variable.
  The following operating modes are available:
  • Closed-loop control for operating setpoint
  • Actual value acquisition and output of the manual manipulated variable value
  • Actual value acquisition and output of "0"
  • Self tuning
• Actual value acquisition and processing
  • Plausibility check for each new actual value and correction before corresponding filter measures
  • Filtering (by PT1 element)
• Actuating signal preparation and output
  • Digital, pulse-length modulated actuating signal
  • Prevention of minimal pulse durations for I/O cycles by integration of lost pulses
  • Manual actuating value (for manual output mode)
  • Output value limitation
  • Replacement value (calculated dynamically)
• Self-tuning for heating controllers
  • This ensures fast startup without overshooting and maintains the setpoint value without lasting system deviations.
  • Self-tuning can be used in parallel for all desired channels to ensure optimal parameter acquisition even for strongly coupled temperature sections.
• Monitoring and alarm functions
  • Actual value monitoring by definition of tolerance bands. The inner and outer tolerance bands can be defined independently as absolute or relative tolerance bands.
  • Measuring circuit monitoring for increased operational safety of a plant
  • Plausibility check
  • Alarm functions

The use of the TControl technology package is clarified by an application example. The application example provides functional expansions, function interfaces to the application and data interfaces to the HMI. It is contained in the Utilities & Applications which are supplied with SIMOTION SCOUT.

SIMOTION technology package for Drive Control Chart (DCC)

Technology functions for Drive Control Chart

With Drive Control Chart (DCC), open-loop and closed-loop control functions can be easily configured graphically. For this purpose, multi-instance function blocks are selected from a block library using drag and drop, and then graphically interconnected and parameterized.

The control structures are presented clearly. DCC is not available for SIMOTION in the TIA Portal (SCOUT TIA).

The block library comprises a large selection of

• control blocks,
• calculation blocks, and
• logic blocks as well as
• comprehensive open-loop and closed-loop control functions.

Further functions:

• For logically combining, evaluating and acquiring binary signals, all commonly used logic functions are available for selection including, for example,
  • AND - XOR
  • On/Off delays
  • RS flip-flops or counters
• For monitoring and evaluating numerical values, numerous arithmetic functions are available, such as:
  • Summation
  • Divider
  • Minimum/maximum evaluation
• Apart from the automatic speed control, winders, PI controls, ramp-function generators and wobble generators can easily be configured.

More information about Drive Control Chart (DCC) can be found in section Optional packages for SIMOTION SCOUT.

SIMOTION technology package Multipurpose Information Interface (MIIF)

The SIMOTION technology package MIIF (Multipurpose Information Interface) functions as a server to permit symbolic access to SIMOTION data and makes them available to clients (e.g. operator panel) via Ethernet.

Access to SIMOTION variables is purely symbolic. The client application is not in any way dependent on the SIMOTION application. The communication is TCP/IP-based. Several controllers and HMI stations can be operated on an Ethernet line.

The server is active after being loaded to the controller. The server does not need to be configured in the application.

Symbolic access to SIMOTION data with MIIF

The server allows variables to be read and written within SIMOTION RT. System variables of the device, system variables of technology objects and UNIT global variables are supported here. Global device variables and I/O variables are not supported in the OAMIIF V1.0. If these are displayed/changed, they need to be copied by the application.

SIMOTION Vibration Extinction (VIBX) technology package

The VIBX (VIBration eXtinction) technology package provides vibration damping functionality in the form of a setpoint filter (axis setpoint filter) that is applied to SIMOTION axes. By altering the setpoint for an axis, the technology package reduces the vibrations caused by the natural frequency of the moving mechanical components. Axes can be positioned without vibration and wear on mechanical components is reduced. This increases the availability of the machine and improves the rate of part production and thus overall productivity. Structural changes or additional sensors or actuators are not required.

SIMOTION OACAMGEN technology package

The SIMOTION technology package OACAMGEN can be used to calculate motion profiles and dimension drives for servo presses. It enables motion profiles to be calculated taking account of boundary conditions, such as maximum eccentric speed, maximum ram velocity and maximum acceleration, while simultaneously minimizing the drive load.