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Technological tasks with SIMATIC

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1 Technological tasks with SIMATIC
IMATIC Technology Technological tasks with SIMATIC

2 SIMATIC Technology – solves the following technological functions
Events can be counted continuously, one-shot or periodically, e.g. for dosing. Lengths, frequencies, speeds and periods (e.g. for speed control) can be measured. Counting and measuring The methods cover rapid traverse/creep feed, position control, up to multi-axis continuous-path controls and synchronized applications, e.g. for positioning axes, palletizers. Positioning Cam controls are used to trigger position-dependent or time-dependent functions, e.g. with presses or packaging machines. Cam control Various control structures can be designed for highly versatile applications. PID controls are typical for analog variables such as temperature, pressure and flow. Closed-loop control Functions

3 Counting and measuring
Event counting Continuous One-shot Periodic e.g. for dosing Measurement of Lengths Frequencies Speeds Periods e.g. for speed control Counting and measuring

4 Counting and measuring with SIMATIC
Function Product Solution Counting up to 30 kHz Counting up to 60 kHz Counting up to 100 kHz (24 V) or 500 kHz (5 V) Counting up to 500 kHz (1 ch.) Pos. meas. with SSI encoders Counting up to 20 kHz (8 ch.) Counting (freely-progr.) Counting (freely-config.) S7-200 S compact CPUs, C7 1 COUNT FM 350-1, 450-1 SM 338 FM 350-2 FM 352-5 1 SSI FM DP Integr. function Integral function ET 200S module Funct. module Applic. module Counting and measuring

5 Counting and measuring with function modules
Counter module FM 350-1 One counting channel with two DI/DO each 24 volts, 5 volt sensor Maximum counting frequency 500 kHz (5 V) / 200 kHz (24 V) Latch function Counter module FM 350-2 Eight counting channels with one DI/DO each or 2 proportioning channels with / 4 DI/DO 24 volts (ext. power supply), NAMUR sensor Maximum counting frequency 10 kHz with 24V incremental encoders, otherwise 20 kHz Counting and measuring

6 Operating modes – Overview
BA 0: Continuous counting BA 1: One-shot counting BA 2: Periodic counting BA 3: Frequency measurement BA 4: Speed measurement BA 5: Period measurement BA 6: Proportioning FM only Operating modes BA 0 to BA 5 (all modes except proportioning) can be allocated to any channel independently of one another (8 channels). In "Proportioning" mode, channels 0 to 3 and 4 to 7 are combined into groups (2 proportioning channels). Counting and measuring

7 Continuous counting (BA 0)
Once the gate has been enabled, continuous counting begins with the start value. When the counter reaches the upper counting limit during up counting, it jumps to the lower counting limit and continues counting from there without any pulse loss. When the counter reaches the lower counting limit during down counting, it jumps to the upper counting limit and continues counting from there without any pulse loss. When the comparison value is reached, a digital output can be set or reset and/or a process interrupt triggered without regard to parameter settings. Counting width: 32 bits Counting and measuring Upper limit Lower limit Count Timer Current count Gate start Gate stop 5

8 Single-shot counting (BA 1)
When the gate is opened, the pulse trains are counted once only. If the main counting direction is up, the count proceeds from zero toward the end of the counting range. If the main counting direction is down, the count proceeds from the beginning of the counting range toward zero. When the comparison value is reached, a digital output can be set or reset and/or a process interrupt triggered without regard to parameter settings. Counting width: 32 bits Counting and measuring End value Start value Count Timer G. stop Gate start G. start 6

9 Periodic counting (BA 2)
When the gate is enabled, periodic counting begins within the configured counting range. When the counter reaches the end of the counting range during up counting, it jumps back to zero and counts from there periodically without any pulse loss. When the counter reaches zero during down counting, it jumps back to the specified start value and counts periodically from there without loosing any pulse. When the comparison value is reached, a digital output can be set or reset and/or a process interrupt triggered without regard to the parameter settings. Counting width: 32 bits Counting and measuring 7

10 Frequency measurement (BA 3)
When the gate is enabled, all pulses occurring within a specifiable time window are counted. Each time a time window expires, the computed frequency is updated. It is possible to specify 2 frequency comparison values: Lower limiting value Upper limiting value Frequency range: max. 10 kHz Time window: 10 ms to 10 s (programmable) Counting and measuring 8

11 Speed measurement (BA 4)
When the gate is enabled, all pulses arriving within a specifiable time window are collected. Each time a time window expires, the computed speed is updated. It is possible to specify 2 speed comparison values: Lower limiting value Upper limiting value Frequency range: max. 10 kHz Time window: 10 ms to 10 s (programmable) Counting and measuring 9

12 Period measurement (BA 5)
Acquires the exact amount of time between rising counter edges A positive edge at the gate input starts the period measurement, a falling edge terminates it, and the computed value is retained until the next enable. It is possible to specify 2 period comparison values: Lower limiting value Upper limiting value Measuring range: 100 µs to 120 s Counting and measuring 10

13 Proportioning (BA 6) (FM 350-2 only)
When the gate is opened, the proportioning functions are counted on a one-shot basis. In this mode, 4 of the module's counting channels are combined into one proportioning channel. When the main counting direction is up, the count proceeds from zero toward the end of the counting range. Four comparison values may be specified for each proportioning channel. When the comparison values are reached, the 4 digital outputs can be set or reset and/or process interrupts triggered in dependence on the parameter settings. Counting width: 32 bits Counting and measuring Timer Count End value Start value Gate start Gate start G. stop CMP1 CMP2 CMP3 CMP4 stop 11

14 Counting and measuring with application modules
FM 352-5 FM 352-5 High-speed Boolean processor Integral I/O Cycle time 1 µs Counting and measuring

15 Positioning Positioning methods Control of drives
Rapid traverse/creep feed Position control Multi-axis continuous- path controls Synchronized applications, e.g. for positioning axes and palletizers Control of drives Servo motors Stepper motors Asynchronous motors Positioning

16 Positioning with SIMATIC
Function Product Solution Controlled positioning, rapid traverse/creep feed procedure Positioning with pulse/direction interface Rapid trav./creep feed proc. Stepper/servo motors Multi-axis interpolation Stepper motors Multi-axis synchronization Positioning and synchr. oper. Pos.-controlled positioning CPU 314C, C7-635 1 STEP 1 POS Inc, 1 POS SSI FM 351, 451 FM 353, 354, 453 FM 357-2 EM 253 FM DP CPU 317T-2 DP Easy motion control Integr. function ET 200S module Funct. module Applic. module Loadable block Positioning

17 Positioning with FM 351, 451 rapid traverse/creep feed drives
4 outputs per axis Rapid traverse/creep feed Forwards, backwards Low price Through use of low-cost rapid traverse/creep feed drives Positioning FM 451 For 3 axes FM 351 For 2 axes FM351是通过快速接近和爬行进给两个不同速度间的切换来实现简单的定位功能,它最典型的应用是连接双速电机。

18 System overview MPI SIMATIC S7-300 P & P HMI Machine FM 351 Field PG
OP Positioning . M C P U STEP 7 programming FM parameter initialization Sequential control Start/stop positioning S7 CPU interfaced to FM via technology function block Position encoder SSI absolute, incremental HMI Error diagnostics

19 Positioning with FM 353, 354 stepper/servo motors
Exact positioning with stepper motors (pulse/direction interface) FM 353 (1 axis) Positioning Position control with maximum precision and dynamic response using servo motors (+/-10 V) FM 354 (1 axis) FM353和FM354分别用于连接步进驱动器和伺服驱动器实现定位功能。他们和FM351最大的区别之一就是FM351只有两档速度,快速和慢速。而FM353和FM354可以使用驱动器和电机支持的任意的速度

20 Functional Diagram --- FM353
Power section for stepper motors MPI CPU FM 353 FM STEPDRIVE PG, PC OP Positioning SIMOSTEP stepper motor Human-machine interface Fault diagnosis Drive interface STEP Pulses, direction signal STEP 7 programming FM parameterizing Sequence control Starting/stopping of positioning

21 Functional Diagram --- FM354
MPI CPU FM 354 PG/PC OP Positioning SIMODRIVE 611U Human-machine interface Fault diagnosis Encoder interface SSI/incremental servo motor STEP 7 programming FM parameterizing Drive interface +/- 10V Sequence control Starting/stopping of positioning

22 Intelligent motion control FM 357-2
Interpolation, synchronization for four axes Low wear through jerk limitation Safety and precision through "look-ahead" Optional drive interface +/- 10 V analog Pulse/direction PROFIBUS DP Programming according to DIN or in high-level language Positioning S7-300的功能模块中,功能最强的要数FM357-2. FM357-2可以实现最多4轴的同步或插补 它的功能已不仅仅是定位,它更倾向与运动控制。这也是PLC发展的一个趋势,就是向运动控制领域迈进。

23 Automation concept for multi-axis operation
CPU315-2 DP MPI/PROFIBUS DP OP/PC FM 357-2 POSMO CD/CA POSMO SI SIMODRIVE 611U PROFIBUS DP analog Positioning

24 Possible configurations
FM 357-2 CPU I/O Local I/O IM360 IM361 S7-300, S7-400 Operation with an IM153-2 should only be used with low performance requirements ! IM153-2 DP CPU315-2DP Multi-tier configuration Single-tier configuration Distributed configuration Positioning Max. 3 FM per CPU (max. 1 FM with Firmware version H) Central or distributed configuration Local bus segment with up to 2 I/O modules for fast reaction (on right side of FM only !)

25 Ordering Data FM 357-2 Hardware 6ES7357-4AH01-0AE0
FM L Systemfirmware 6ES7357-4AH03-3AE0 on coded memory card* + configuration package FM LX Systemfirmware 6ES7357-4BH03-3AE0 on coded memory card* + configuration package FM H Systemfirmware 6ES7357-4CH03-3AE0 on coded memory card* + configuration package Configuration Package (german, english, french, italian) contains parameterization tool, electronic documentation, S7-Technology blocks, OP-Example masks Printed Manual 6ES7357-4AH00-8?G0 (german=A, english=B, french=C, italian=E) Edit-FM Program editor (stand-alone) 6FC5263-0AA03-0AB0 (suitable for FM 353/354, FM 357 and FM 357-2) * copy protected, including backup-function for series commissioning and module exchange without PG/PC Positioning 在使用FM357-2的时候,除了要购买模块本身,还需要购买一个firmware,这个firmware就保存在FM357的存储卡上 FM357-2提供三种不同的firmware来满足不同的应用。分别是L,LX和H。LX是可以完全替代L的,但是要贵500欧元。

26 Superimposed master value
Synchronization of axes – Master value coupling and table interpolation FM 357-2 Belt drive Encoder (master value) Drive for X-axis Drive for Y-axis X-axis Material Belt movement Interpolation-table Superimposed master value L, LX, H Positioning

27 On-the-fly measurement with Hot-spot area
Encoder FM 357-2 LX, H 10240 10230 10220 10210 10200 10190 10180 10170 - = 40 Memory 1 Memory 2 Meas. result: length of cartons Position values from encoder Light barrier Skip area „Hot-Spot“ area Trigger 1 Trigger 2 Belt drive Positioning

28 Restart after emergency stop Rapid restart
Operator presses emergency stop NC-Stop Enables are deactivated FM goes to „follow-up mode“ Drives are decelerated as fast as possible Automatic program Obstacle located within path Obstacle is removed Operator presses "Start“ NC-Start Drives are enabled Program is resumed FM goes to restart point and continues the movement from this position L, LX, H Positioning

29 Spline interpolation Complex path control using points
...directly through interpol. points ...approximatedpath ...continuous transitions through points FM 357-2 P1 X30 Y20 P2 X50 Y40 P3 X70 Y20 P4 X90 Y10 P5 X120 Y50 P6 X170 Y30 P7 X200 Y20 ASPLINE BSPLINE CSPLINE Spline type Resulting path Interpolation points LX, H Positioning

30 Gantry function High-quality portal movement without canting
FM 357-2 LX, H - + Actual pos. value 1 Actual pos. value 2 Position controller 1 Position controller 2 Program Position setting independently of operating mode Portal Motor 1 Motor 2 Canting monitor Canting Working area Positioning

31 Path velocity dependent analog output
LX, H adhesive nozzle Resulting path velocity s Output value = Quantity of adhesive FM357-2LX control valve Analog-module Path (adhesive) Positioning

32 Synchronous actions Motion control with Interrupts
FM 357-2 Obstacle Start position End position “dangerous" LX, H WHENEVER Position = dangerous AND Obstacle = true DO Velocity = 0 Positioning

33 Handling functions Teach in
Positioning Teach in of robots and handling machines using the PHG or HT 6

34 Handling functions Coordinate transformation
SCARA H Positioning Coordinate transformation for SCARA- or Articulated-arm systems like robots and handling machines

35 Closed-loop control Miscellaneous closed-loop control structures
Fixed setpoint control Follow-up control Cascade controls Ratio controls Automatic blending controls Analog variables Pressure Flow Temperature Closed-loop control

36 Closed-loop control with SIMATIC
Function Product Solution PID controller Predefined closed-loop control structure Modular system with closed-loop control function blocks Online self-optimization PID temperature controller Dosing, adjustment Closed-loop control modules with self-optimization High-performance control Temperature control module with online self-optimization S7-200, STEP 7, CFC Standard PID control Modular PID control PID self-tuner STEP 7 V5.1 and later 2 PULSE FM 355, 455 FM DP FM 355-2 Integr. function Loadable blocks Loadable blocks ET 200S module Function module Applic. module Closed-loop control

37 Why to use a hardware controller? FM 355 PID Control
SIMATIC FM355 controller offers a lot of benefits Backup facility Continuation of closed-loop control in the event of stop or CPU failure, function module continuous work with follow-up mode or safety mode Saves CPU-Resources like e.g. Memory Suitable Peripheries „onboard“ A lot of possibilities for value acquisition All current types for control elements Control structures and processing functions can be adapted comfortable through parameter assignment Closed-loop control

38 FM 355, FM 355-2 backup controllers with self-optimization
FM 355 C 4/16 closed-loop controllers, each with 1 analog output For actuators with proportional action (continuous output) FM 355 S 4/16 closed-loop controllers, each with 2 digital outputs Either for actuators with integral action Or binary trigger actuators with proportional action With/without position feedback signal (step controller) FM specialized for temperature control PID controller with integral self-optimization Enhanced accuracy Cycle times and Resolution fix on 100 ms and 14 Bit Closed-loop control

39 PID temperature control Application example – thermoform molding
Pilot use in heat-sealing machine A) Temperature control of the mold heating plates Pt100 Plastic sheet Blister Cardboard Seal with heat sealer B) Temperature control of the heat sealer Closed-loop control

40 Cam controls Function switch depending on
Position Time Speed Integral I/O guarantees fast response Examples Presses Packaging machines Wood processing Cam controls

41 Cam controls with SIMATIC
Electronic cam controller Boolean high-speed links Complex cam controls CPU 317T-2 DP FM 352-5 FM DP FM 352, 452 Function module Application module Function Product Solution Cam controls

42 FM 352, electronic cam controllers
128 cams on 32 traces Onboard digital outputs 13 for FM 352 Highly flexible Online modification of parameters Many different encoders can be connected Super-fast 20 µs response time for maximum accuracy and repeatability Cam controls Technische Folien

43 FM 352-5 high-speed Boolean processor
Cycle time 1 µs Integral digital I/O 16 DI, 8 DO Connection facility for position encoder SSI, incremental 5 V /24 V Programming In LAD or FBD with command/block library Cam controls Technische Folien

44 System integration Cam controls

45 Comparison of Program Execution between an FPGA and a PLC
& <1 Inputs Outputs 1 µs FPGA Parallel execution Sequential Execution Network 1 Network 2 SPS 1 ms Cam controls

46 Fields of Application Fast response speed applications
For example, for equipment automation with high clock-pulse rates (cigarette manufacturing, packaging industry, etc.) Applications with a maximum absence of jitter Applications that for performance reasons can no longer be accomplished using a standard PLC Cam controls

47 Speed Measurement Objective
Determine vehicle speeds of up to 300 km/hr using two photoelectric barriers Accuracy <0.1% (<5 µs) Light scanner 1 Light scanner 2 0.5 m Cam controls

48 Solution for example Speed Measurement
How speed measurement is accomplished: An internal base frequency of 500 kHz is generated A detection by the first light scanner triggers a counter with the generated base frequency A detection by the second light scanner stops the counter The count can be read and be converted into speed Cam controls Light scanner 1 Light scanner 2 0.5 m

49 Homepage www.siemens.com/simatic-technology
Internet


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