Simotion Example for Beginners d435 En

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SIMOTION

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The application examples and the associated documentation contained on

this DVD are made available without cost. The customer receives for the

software the non-exclusive, non transferable, free right to use the

software; this includes the right to change the software, to copy it changed

or unchanged, and to combine it with the customer's own software.

Siemens AG has not subjected the software to the normal system test

otherwise usual for software.

Any liability – irrespective of the legal reason – in particular because of

software errors or the associated documentation or damages resulting

from consulting is excluded, unless, for example, because of

premeditation, gross negligence, risk to life, injury or health, acceptance of

suitability guarantee, malicious concealment of a fault or a violation of

significant contractual obligations, would force liability. A reversal of the

burden of proof to the customer's disadvantage is thus not included.

German legal right applies. Place of jurisdiction is Erlangen.

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Some preliminary comments

Before processing the Example for Beginners, it is advisable to study

”Getting Started with SIMOTION SCOUT" (Menu Help

Getting

Started).

In the example, some elements have been extended more than

necessary in order to demonstrate as many different aspects of

SIMOTION as possible (e.g. a virtual axis as master).

Menu- and context menu commands are shown in italic type as well as

the names of dialogs and tabs etc..

Menu

Sub menu are separated by an arrow.

The screenshots were created with SIMOTION Version 4.2 (05/2011).

Under some circumstances there may be minor changes for future

versions.

The firmware version on the SIMOTION D435 should agree with the

SIMOTION SCOUT version.

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Carton

erector

P

ro

d

u

c

t f

e

e

d

Palletizer

Sensor

Conveyor belt

Package (full)

Package (empty)

Extractor

- Electrical travel

- Eject pneumatically

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Task

Task:

Packages with a protruding machine part are used on a conveyor belt (drive 1).

An empty package is detected by a sensor and should be removed with an

extractor (drive 2). The removal itself is performed pneumatically. When an

emergency off switch is pressed, all drives should be stopped immediately. The

current position of the conveyor belt should be displayed on the operator panel.

The machine diagrams show a machine part, the implementation in

SIMOTION is shown in the following slides.

The solution concept shows only one of many possible solutions. This

particular solution was selected to use as many different SIMOTION

functions as possible:

Cam with CamTool

Gearbox synchronism

Camming

Output cams

Virtual master axis

etc.

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SIMOTION SCOUT

ET 200 *

MICROMASTER 420 *

Profibus DP

D435

1 FK7

HMI

Carton erector *

Feed *

* Not considered in the example, but part of the complete plant

Transport

Extractor

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Execution system

Time triggered Tasks Task 1 Task 2 Task 5

Motion Tasks Motion Task 1 Motion Task 2 Motion Task 20 Run

Startup Task Stop Run

Background Task Background Task

Call Motion Tasks

(se-quential tasks)

1

Synchronous Tasks IPO - sync Task 1 IPO - sync Task 2 Monitor the emergency off criteria

2

System Int Tasks System Int Tasks Interrupt Tasks User Int Task 1 User Int Task 2 System Int Tasks

Response to process signals

3

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Central topic for SIMOTION: Which job do I solve in which task or which

tasks are particularly suitable for specific jobs.

In the example, the background task is used to start sequential tasks

(MotionTasks).

The sequential tasks are used to implement processes and to start

movements.

The UserInterruptTask initiates an incorrect part handling depending on an

external signal.

The IPOsynchronousTask task monitors a protective door.

Another central question in SIMOTION:

Which program sections are programmed cyclically and which are programmed

sequentially. The same result can often be achieved in both ways. For motion

commands, SIMOTION supports the programming in the cyclical context. The

monitoring of the status of a motion command is performed by the system when

sequential programming is used (nextCommand:=WHEN_MOTION_DONE).

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Comparison of cyclical and sequential programming

To simplify the understanding, the comparison on a sample task follows: ”Pos “ should move

to “Target”; the “Finished“ variable is set to TRUE when the position is reached.

_pos ( axis:= Pos, position:= Ziel,

nextCommand:= WHEN_MOTION_DONE)

Fertig:= TRUE;

Sequential Task:

Cyclical Task:

Program processing stops until

the target position is reached

Pos_status:=

_getStateOfAxisCommand ( Pos,

PosCommandID) IF (Pos_status <> ACTIVE AND

Fertig = FALSE ) THEN _pos ( axis:= Pos,

position:= Ziel, nextCommand:= IMMEDIATELY, commandID:= PosCommandID); END_IF IF Pos.motionstatedata.motioncommand = MOTION_DONE THEN Fertig:= TRUE; END_IF

Cyclical program section

continued

Advance

command

Query status

pos. command

Pos. command

Advance

command

Query position

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System variables

Technology objects

SIMOTION device

Global user variables

I/O variables

Device global variables

Unit variables

Local user variables

Program variables

FC variables

FB variables

three types of variable groups:

System variables are automatically provided by

the system or from technological objects and do

not need to be created by the user.

Global user variables are defined by the user and

have a wide scope: device global, project global

or unit global.

Local user variables have a limited scope. They

are always valid only within the defining program

unit (program, function or function block).

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Variable model

System variables

Technology objects

SIMOTION device

Global user variables

I/O variables

Device global variables

Unit variables

Local user variables

Program variables

FC variables

FB variables

Variable is assigned to a TO (e.g. actual position of an axis) Variable is assigned to the SIMOTION device

(e.g. system clock)

Variable indicates an input/output area (e.g. Startpos -> P10.1)

Variable can be accessed from anywhere on the device

1. A variable can only be used in programs, functions and function blocks.

2. A specially exported variable can also be used in other units.

Variable can only be used within the declaring program Variable can only be used within the declaring function (FC) Variable can only be used in the declaring function block (FB)

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Current situation

Task (machine diagram)

Topology concept with

SIMOTION

Program concept

Technology objects

Task structure

Task relationships

Variables

System environment

Create device

Specification of the possible DP

cycle clock

Creation of a hardware

configuration

Drives

Parameterization SINAMICS

Axis configuration

Master axis

Conveyorbelt

Extractor

Output cam configuration

Cam configuration

Form

Parameterization

Programming, parameterization

and test

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Technology objects

Virtual master axis

Positioning axis

Rotary axis (modulo)

Real axis - conveyorbelt

Following axis

Rotary axis (modulo)

Gearbox synchronism

Real axis - pusher

Following axis

Linear axis

Camming

Cam - extractor

Not cyclical

Cam controller – pneumatic

extractor

Position-based cams

Interpolator

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Initialization - ST

Background Task

Execution control - FUP

Call the homing task / initial

setting travel - FBD

Call the automatic operation

-FBD

Motion Task 2 (Homing)

Homing (incremental encoder)

and possibly initial setting

travel of the associated axes

-MCC

Motion Task 3 (Automatic

operation)

Start the master axis - MCC

MCC

Trigger the pneumatic valve

-MCC

Motion Task 4

Call the extractor task - MCC

User Interrupt Task 1 (stock outage

detection)

Call the extractor task - MCC

IPO sync Task (Emergency stop

monitoring)

Test protective door - MCC

Tech Fault / Peripheral Fault Task

(fault handling)

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Task relationship / Program start

User Interrupt

IPO Sync Task

Start program pEject

Motion Task 2

Motion Task 3

Interrupts the Task

Startup

Background

Motion Task 3

Motion Task 4

Motion Task 2

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Device-global variables

None

Unit-global variables

Velocity of the leading axis

Open protective door

Program end

Operating mode

Local variables

None

I/O-variables (symbol browser)

Onboard inputs (CU)

ib16DigCU (all inputs)

WORD (DI_0_15)

iboEject (Sensor)

BOOL (DI_2)

iboProtDoor

BOOL (DI_0)

iboStartBelt

BOOL (DI_1)

Onboard outputs (output cam

object)

Onboard outputs (CU)

Extractor active

output cam (DO_8)

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SIMOTION create device

1.

Create new SIMOTION SCOUT project

2.

Create new device (D435 V4.2)

3.

Set the interface for PG to IE2/NET

The networking for PG in NetPro

will be created automatically

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Set system clock for integrated

drive interface

Context menu

SINAMICS_INTEGRATED

Object Properties...

The value of T

determines

the basic cycle of the

SIMOTION task system

Via each factors the settings

can be fine tuned

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The network configuration for PG is created automatically

Use the properties of the PG (Object properties) to

change the access address of the logical PG interface (e.g. IP-address)

(Tab Interfaces) or

change the physical mapping of the logical PG interface

(Tab Assignment)

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Start drive configuration

The configuration assistant (wizard)

obtained all necessary information

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Use unregulated Infeed

Create first drive

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Set drive name for conveyorbelt („conveyor“)

No function modules will enabled

in the drive

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Select Power unit (dual-axis module) according to the rating plate

Wiring operation signal

Note: The drive parameter p0864 at power units with DRIVE-CLiQ have to be wired to the operation signal of the infeed. In all other cases the operating signal have to be wired to a digital input (e.g. CU). The chosen DI is now linked with p0864 via BICO.

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Drive 1 to Connection X1

Drive with DRIVE-CLiQ interface

No further details for motor type

required

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Drive without holding break

Choose encoder for drive control

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Standard communication with drive

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Insert drive

After entering the name of the extractor (“eject”) the configuration wizard

has to be repeated for drive 2. Shown below are just the dialogs that

differ in comparison to drive 1.

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Select the already added dual-axis module

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Motor with SMC

motor type and speed in accordance with rating plate

Encoder in accordance with rating

plate

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For the SIMOTION D training case (single phase connection) the drive

parameter p0210 has to be set from 600V to 345V.

Access via expert list.

This must be carried out for both drives.

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The ratio of bus data cycle clock to servo cycle clock to interpolator

cycle clock (IPO) should be 1 : 1 : 1.

The bus data cycle clock is given

by HW config.

(here: DP cycle T

).

The reduction

of interpolator 2

(IPO_2) can be

chosen freely.

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Create a virtual leading axis („MasterAxis“) as positioning axis

Rotary axis

Virtual axis

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Create a real slave axis („Conveyorbelt“)

Including synchronous operation

Rotary axis

Electrical axis

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Connect the slave axis („Conveyorbelt“) to drive 1 („conveyor“)

Assign encoder for the

positioning controller

Note for the offline configuration: Encoder type (incremental or absolute) by motors with DRIVE-CLiQ interface have to be determined from the motor order number.

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Create a real slave axis („Ejector“)

Including synchronous operation

Linear axis

Electrical axis

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Connect the slave axis („Ejector“) to drive 2 („eject“)

Assign encoder for the

positioning controller

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Synchronous operation between leading axis and conveyorbelt

Via the synchronous object of the axis

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Synchronous operation between conveyorbelt and extractor

By real leading axis (e.g. conveyorbelt) you can choose the setpoint or the actual

value as the set value.

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MasterAxis

No modifications

Conveyorbelt

Position control

Speed precontrol

activated

DSC activated; K

= 50

Ejector

Position control

Speed precontrol

activated

DSC activated; K

= 50

Automatic controller

setting

Via „Controller setting…“

you can reach the automatic

controller setting

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Conveyorbelt

No homing because absolute encoder

Ejector

Homing mode: Encoder zero mark only

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Save and compile project

Either via menu Project

Save and compile all or via

the Toolbar.

Detailed view shows the compile results

The tab Compile / check output shows the results of compiling and checking.

The tab Address setup output shows the automatic performed address assignments.

The set standard settings from the drives and axis were evaluated and suitable

message frame types were chosen (Message frame type 105 and 390 for the Control

Unit). Also the associated address ranges were set.

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Insert output cam to the axis Ejector

Before an output cam can be insert, an I/O of the control unit

has to be configured as output. (DO 8)

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Insert output cam to the axis Ejector

Output cam and track will be added in the directory Output Cam under the relevant

axis (Ejector).

One output cam were created by Insert output cam.

Set name of the output cam and activate Open editor

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Configure the output cam

Proc. cycle clock: IPO

Output cam type: Position based

cam (related to the axis Ejector)

Type of output cam values:

Setpoints

Advantage: Symbolic Access

No absolute address entry

Output cam configuration at the ejector valve

Activate output

Set Cam output to: Fast digital output

Set digital output DO 8 at the control unit.

This output won't be added to the symbol

browser.

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Create I/O-Variables at the symbol browser

iboProtDoor

protection door contact

(input 0 on the switch box of the training case)

iboStartBelt

start conveyorbelt

(input 1)

iboEject

sensor detect bad part

(input 2)

ib16DigCU

Image of the onboard-inputs

of the control unit

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In the general settings of the project is set,

that programs generally can be observed.

MCC-units can additional be observed in

single step mode.

In the properties of each unit you can

overload this basic settings if necessary.

Programming – Settings for program testing

When you insert a source a

properties dialog displays. In

this you can set the name and

if necessary the compiler

settings.

Later this settings can be

changed by the properties of

the existing source.

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Function

Definition of all unit global variables in the INTERFACE field only in one

ST-unit.

Ensures easy exportability of global variables.

Prevent confusing cross-references (“links” or “USES”).

Retain variables and HMI variables are also declared on a separate

source.

Programming

Insert ST-unit „pDefInit“

Insert keywords VAR_GLOBAL

and END_VAR

Definition of the variables and

default values

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Programming – variable initialization in ST („pDefInit“)

Programming

Insert keywords PROGRAM

„pInit“ and END_PROGRAM

Initialization of the variables at

STOP – RUN transition

Save and compile

Function

With the program “pInit” in the ST-unit “pDefInit” the variables will be set to

a defined value at startup.

The ST-unit “pInit” is to assign to the StartupTask.

The StartupTask is executed at every change of the operating state of the

SIMOTION control from STOP to RUN.

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Basic Procedure

Always when variables from “pDefInit” are used in an other source (e.g.

“pAuto”), “pDefInit” have to be assign to this source.

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Insert MCC-unit “pTecFault” and add it to the

TechnologicalFaultTask after programming.

All alarms of a technological object can be quit (e.g.

Ejector).

Also you can quit a specific alarm (e.g. 30002) of a

technological object (conveyorbelt).

Programming – TechnologicalFaultTask

Function

For fault handling of technological objects

(e.g. axis).

In principle, an empty program can be used. Thus, the SIMOTION control won’t

STOP if errors occurs.

Note: During the commissioning and troubleshooting, it is advisable to acknowledge

as few alarms directly. These alarms often give clues of misconduct.

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Access to I/Os of the drives only when the drive components have also

been ramped up (after Power On)

e.g. onboard inputs of the CU

Test in the program for valid accesses of the I/O variables

Is to be done in all cyclic tasks (e.g. via the variable “gboDriveActive”)

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Programming – BackgroundTask in LAD/FBD

Programming of the BackgroundTask

Insert LAD/FBD-unit “pBckFBD”

Insert a LAD/FBD-program “pLADFBD” in the

LAD/FBD-unit

The homing and the automatic operation

are started depending on the contents of the

gi16Mode variable.

gi16Mode = 0

homing

gi16Mode = 1

automatic

This occurs only when

The protection door is closed and

MotionTask_1 or MotionTask_2

Stopped (performed),

Waiting and has been suspended (emergency stop)

Suspended (emergency stop)

In a LAD/FBD-program you can always switch between the

views LAD and FBD. This is done via the menu or the toolbar.

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Create local variables

b32TaskState : State of MotionTask_2 or MotionTask_3

b32RetStart : Return value of the function „_startTaskID“

boResult : Resultbit of the LAD/FBD-Networks

b32ResAnd : Result of the task state evaluation

boGo: Taskstartbit (TRUE if MotionTask_2 or MotionTask_3 have to be restarted)

sTaskSel : Structure that can contain TaskIDs (e.g. MotionTask_2 or MotionTask_3)

Network 1 – Drives ready

Jump to the end if the drives have not

been ramped up yet

No access possibly to

I/O-variables from SINAMICS.

Jump label “end” is created

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Network 2 – query protection door contact

Jump to the end, if protection door is open

Networks 3 and 4 – selection of the task

Depending on the gi16Mode variable, the sTaskSel variable will be assigned the

value “MotionTask_1“ or “MotionTask_2“, respectively.

The task stored in the sTaskSel variable can be started in network 9.

The block “MOVE” is insert via the

command library - LAD/FBD elements.

Alternatively, an empty box is used. Then

the empty box is filled with the module

name.

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Network 5 and 6 – query task state

You can query the task state with the system function “_GetStateOfTaskId”

(command library – task system). The reported state is always clearly and

consistently.

This is a significant advantage over an application-locking by using boolean

variables.

The variable “sTaskSel” contains the task whose state is to be queried.

The return value is a DWORD (“b32TaskState”) that can be processed bitwise.

In Network 6 is a bitwise AND link of the return value with the value 16#0022.

This corresponds to the OR link of the two states “TASK_STATE_STOPPED” and

“TASK_STATE_SUSPENDED”.

Note: The different task state information can be

found in the manual SIMOTION SCOUT basic

functions.

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Network 7 and 8 – evaluate task state

The result of the bit AND logical operation is evaluated in this network.

If the return value is larger than 16#0000, the associated task must be restarted

(boGo = TRUE).

If the return value matches 16#0000, boGo becomes FALSE. This bypasses

restarting the task. Jump label is “end“ (network 9).

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Network 9 and 10 – start task

This network becomes active as soon as a task needs to be restarted.

To start the task the system function “_restartTaskId” (command library – task

system) is used. This function can only be used to MotionTasks.

The return value is a DWORD (“b32RetStart”), which reports about success or

failure.

In Network 10 is a jump label “end”. This jump label is at the end of the block, so that

jumps to this position will end the block.

A jump label can be switched on or off. To do this you have to select the label and

switch it on or off via the toolbar or the menu.

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Programming - BackgroundTask (FBD)

The status of the FBD

program can be monitored

in this snapshot (monitor

online).

Network 2: The protection

door is closed.

Network 3 and 4: The

operating mode is

“automatic“ (gi16Mode = 1).

Consequently, Motiontask_3

is stored in the sTaskSel

variable.

Aktueller Wert

zur Laufzeit

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Connect with “pDefInit”

Declare a local variable

“i32RetResetAxis” (Variable type

VAR, Data type DINT)

Reset axes in the “ST-Zoom” (after

emergency stop):

„i32RetResetAxis := _resetAxis

(Axis := MasterAxis);“

„i32RetResetAxis := _resetAxis

(Axis := Conveyorbelt);“

„i32RetResetAxis := _resetAxis

(Axis := Ejector);“

Alternatively, the axis enable can

also be removed and reapplied.

Set gboProtDoorOpen to “false”

Set gr64VMasterAxisOld to 0

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Programming – Homing (Motion Task 2 MCC) 2/2

Homing:

Zeros on the “MasterAxis”

Enable “Conveyorbelt”

Enable “Ejector”

Deactivate “Valve” output cam

If necessary: active homing conveyorbelt (if an

incremental encoder is used).

Command can be displayed in case of need

again.

Active homing ejector

Use default settings

Optionally, an initial position motion can also

be connected here

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a double click

Use the arrow buttons to

assign previously created

programs to the execution

levels

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Programming – First Test

Open the “Homing“ program (SCOUT must

be online) and start monitoring

Switch SIMOTION D435 to RUN

Depending on the configuration either both

or only one of these axes perform homing

Optionally, the program can also be run in

single-step mode

The axes are homed after passage through

the program

Note for the execution:

The “pBckFBD” program in the background task starts

the automatic operation as soon as the “gi16Mode”

variable is set to 1.

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Insert MCC Chart “pAuto”

Connect with “pDefInit”

Enable “MasterAxis”

The conveyor belt starts with the positive edge of

the “iboStartBelt“ signal

Synchronize the conveyorbelt

see parameterization (following slides)

Activate the “Valve” output cam

see parameterization (following slides)

If the set velocity changes, switch continue

gr64VMasterAxis <> gr64VMasterAxisOld

Start master axis position-controlled with

“gr64VMasterAxis” velocity

For comparison, save the current velocity in

“gr64VMasterAxisOld := gr64VMasterAxis”

Until-loop with “gboProgEnd” condition

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Parameterization - Automatic (MCC)

Switch on the gearbox

synchronism of the

Conveyorbelt

“Synchronize immediately”

Synchronization length 1

Synchronization reference

master axis

Relative to the start

position (Parameters tab)

Activate the “Valve“ output cam

Switch-on position

0.1 mm

Switch-off position

0.4 mm

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The “gr64VMasterAxis” set velocity can

be controlled in the symbol browser or

in a watch table (control immediately)

The automatic program responds only

to a change of the set velocity

execution system

As previously, the monitoring is now activated

Operation:

Once the axes have been homed, the “Conveyorbelt“ starts

to turn as soon as a positive edge of “iboStartBelt“ is

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Programming – Test using trace

Open the trace

Variables from the program

and from technological

objects (e.g. axes) can be

recorded in the trace

Procedure:

Select trace D435

Select variables

Load Trace in the D435

Start D435

Start trace

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3 elements

1 interpolation point

left

1 straight line at 45°

1 interpolation point

right

Note: CAM Tool have to be

installed

Segment 1: Synchronize

to the conveyorbelt

Segment 2: Synchronous

operation with

conveyorbelt

Segment 3:

Desynchronize and return

to the initial position (wait

for the next defect part)

Segment 1

Segment 2

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Cam - Parameterization

Curve elements (straight line, interpolation point)

are selected in the CAMtool function bar.

Properties (right mouse click on the curve

element)

Straight line

x1 = y1 = 0.1

x2 = y2 = 0.4

Interpolation point left (create with symbol)

x = y = 0.0

Interpolation point right (create with symbol)

x = 0.8

y = 0.0

Scaling (Cam – “Target Device Parameter“ menu

Master

Base scaling 360

Slave

Base scaling 10

Note: The mouse pointer must be active in order to move

curve elements with the mouse. A decimal point must be

used for floating point numbers.

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Insert MCC Chart “pEject”

Synchronize the cam

This motion task is started

with a user interrupt

The cam is processed

acyclically

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Programming – Stock outage detection (user interrupt in MCC)

Stock outage detection:

Insert program “pEject”

Specify condition for user interrupt in the

execution system

Sensor at DI 2 (iboEject) at TRUE means

“eject” is coming (Input 2 on the switch box

of the D435 training case)

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Monitoring the protection door:

Insert MCC Chart “pProtDoor”

Connect with “pDefInit”

Query whether protection door is

closed (true = closed)

If open , set “gboProtDoorOpen” bit,

because axes must be explicitly

reset after an emergency stop (see

automatic operation (MotionTask 3

in MCC) 1/2)

Query all MotionTasks using

“_GetStateOfTask (MotionTask_x)

<> 16#0002“ (where x = 1 to 3)

(test whether task “stopped”)

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Programming – Protection door (IPO synchronous in MCC) 2/2

Monitoring the protection door:

Query the axes for stoppage using

„MasterAxis.motionstatedata.

motionstate <> standstill“

„Conveyorbelt.motionstatedata.

motionstate <> standstill“

„Ejector.motionstatedata.

motionstate <> standstill“

If the axes are moving

Deactivate “Valve” output cam

Stop axes using “Fast stop with

maximum deceleration”

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Information

Create a “watch table“. The variable can be moved with a

_{right click in the symbol browser.}

Recording object variables

such as actual position and

actual velocity of an axis

using “Trace“

Test the program execution of a Motion Task using

“Monitor” and “Single Step”

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FAQ

After STOP-RUN transition nothing moves, what is the problem?

Have the tasks been correctly added to the execution system?

Is the protective door (DI 0) closed?

The extractor output cam does not come!

An output cam must be activated. Are the limits correctly parameterized in the “Switch on

SW output cam“ mask ?

The homing task “hangs“ on the axis enable of the real axes. Why is this?

The axis enable does not arrive. Possible causes:

In the HW configuration, the “Master application cycle“ in the slave properties does

not agree with the position control cycle in the SCOUT under “Execution system –

Expert settings“. They must be identical!

The axes homing is not correct. What can be the error cause?

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Connectable variables:

Ethernet

HMI (WinCC flexible)

Data exchange

Global user variables

I/O-variables

Device global variables

Unit variables

System variables

Technology objects

SIMOTION device

Example needs a

display resolution of

1280x1024

D435

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© Siemens AG 2011. All Rights Reserved.

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© Siemens AG 2011. All Rights Reserved.

WinCC flexible - Connection

Open NetPro

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WinCC flexible - Connection

After selecting, the SIMATIC HMI Station appears in NetPro.

By double clicking on the station,

the HW Config opens.

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IP address: 169.254.11.1

Subnet mask: 255.255.0.0

Save and compile

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WinCC flexible - Connection

After inserting, the HMI IE interface appears in the station.

Save and compile

Close NetPro

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Open existing project

double click on project

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WinCC flexible - Connection

WinCC flexible opens the project

At this point you can edit the WinCC flexible project.

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