Istpid

SoMachine
EIO0000000195 06/2015
SoMachine
Packaging Application Functions
Packaging Library Guide
06/2015
EIO0000000195.08
www.schneider-electric.com
The information provided in this documentation contains general descriptions and/or technical
characteristics of the performance of the products contained herein. This documentation is not
intended as a substitute for and is not to be used for determining suitability or reliability of these
products for specific user applications. It is the duty of any such user or integrator to perform the
appropriate and complete risk analysis, evaluation and testing of the products with respect to the
relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or
subsidiaries shall be responsible or liable for misuse of the information contained herein. If you
have any suggestions for improvements or amendments or have found errors in this publication,
please notify us.
No part of this document may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, without express written permission of Schneider Electric.
All pertinent state, regional, and local safety regulations must be observed when installing and
using this product. For reasons of safety and to help ensure compliance with documented system
data, only the manufacturer should perform repairs to components.
When devices are used for applications with technical safety requirements, the relevant
instructions must be followed.
Failure to use Schneider Electric software or approved software with our hardware products may
result in injury, harm, or improper operating results.
Failure to observe this information can result in injury or equipment damage.
© 2015 Schneider Electric. All rights reserved.
2 EIO0000000195 06/2015
Table of Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
About the Book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Part I Packaging Library System Requirements . . . . . . 17
Chapter 1 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Packaging System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Function Block Location in the Packaging Library . . . . . . . . . . . . . . . . 23
Part II PickAndPlace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 2 MoveJog: Manual Control of a Single Axis in Different
Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MoveJog Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Structured Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Input/Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Function Block Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Quick Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chapter 3 XYPickAndPlace: Moving X- and Y-Axis in a Plane
Coordinate System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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3.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
XYPickAndPlace Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Axis Movement: General Description. . . . . . . . . . . . . . . . . . . . . . . . . . 69
Axis Movement: Non-Optimized Mode Without Approach Point . . . . . 71
Axis Movement: Optimized Mode Without Approach Point . . . . . . . . . 72
Axis Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Function Block Operation: Semi-Auto Mode . . . . . . . . . . . . . . . . . . . . 74
Function Block Operation: Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Detailed Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Input: i_stXYPara . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Input: i_stPItPara . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Input: i_xShiftFrstY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Input: i_uiStepNb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Input: i_uiNbLayr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Input: i_stXYPara.udiApprDist . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Quick Commissioning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Part III TensionControl . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Chapter 4 DigitalTensionControl: Controlling Consistent Film
Tension Between Two Digital Sensors . . . . . . . . . . . . 103
4.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
DigitalTensionControl Function Blocks . . . . . . . . . . . . . . . . . . . 114
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4.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Input: i_stDiaActl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Input: i_stUnwd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Chapter 5 AnalogTensionControl: Controlling Consistent Film
Tension Depending on Analog Sensor Feedback. . . . 135
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
AnalogTensionControl Function Blocks . . . . . . . . . . . . . . . . . . . . 144
5.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Part IV TemperatureControl . . . . . . . . . . . . . . . . . . . . . . . . 157
Chapter 6 TemperatureControl: Monitoring and Controlling of
Temperature-Dependent Packaging Processes . . . . . 159
6.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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TemperatureControl Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Input: i_stPid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Input: i_stTempCtrl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Output: q_sAttnStat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Output: q_stPid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Internal Process Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Part V LateralPositionControl . . . . . . . . . . . . . . . . . . . . . 191
Chapter 7 LateralPositionControl: Controlling Correct Lateral
Film Position with Two Digital Sensors . . . . . . . . . . . . 193
7.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
LateralPositionControl Function Block . . . . . . . . . . . . . . . . . . . 199
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Managing Detected Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Commissioning Procedure in Manual Mode . . . . . . . . . . . . . . . . . . . . 214
Commissioning Procedure in Auto Mode With Symmetric Sensors . . 215
Commissioning Procedure in Auto Mode and Left Placed Sensors. . . 217
Commissioning Procedure in Auto Mode and Right Placed Sensors . 219
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Part VI RotaryKnife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Chapter 8 RotaryKnife_Motion: Synchronization of a Linear
Axis and a Rotary Axis to Perform On The Fly
Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
8.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
RotaryKnife_Motion Function Block . . . . . . . . . . . . . . . . . . . . . . . 235
8.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
8.5 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Operating Mode 0: Continuous Product . . . . . . . . . . . . . . . . . . . . . . . 252
Operating Mode 1: Continuous Product with Mark Compensation . . . 254
Operating Mode 2: Non Continuous Product (Cut on Mark) . . . . . . . . 258
Selection of the Capture Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
8.6 Start, Stop and Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Start and Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Cold Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Warm Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
8.7 Special Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Immediate Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Offset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Oblique Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Shift Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
8.8 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
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Part VII FlyingShear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Chapter 9 FlyingShear_Motion: Synchronization of 2 Linear
Axis to Perform On The Fly Operations . . . . . . . . . . . . 295
9.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Hardware and Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . 299
FlyingShear_Motion Function Block . . . . . . . . . . . . . . . . . . . . . . . 300
9.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
9.5 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
9.6 Start, Stop and Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Start, Stop and Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
9.7 Special Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Special Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Interruption of the Synchronous Phase . . . . . . . . . . . . . . . . . . . . . . . . 307
Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Part VIII GroupingUngrouping . . . . . . . . . . . . . . . . . . . . . . 313
Chapter 10 Grouping - Ungrouping: Synchronization of Linear
Axes to Organize Products on a Conveyor . . . . . . . . . 315
10.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Chapter 11 GroupingAccumulator_Motion . . . . . . . . . . . . . . . . . 331
GroupingAccumulator_Motion Function Block . . . . . . . . . . . . . . 332
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11.2 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Chapter 12 GroupingStripper_Motion . . . . . . . . . . . . . . . . . . . . 341
GroupingStripper_Motion Function Block . . . . . . . . . . . . . . . . . 342
12.2 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Chapter 13 Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . 355
13.1 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Geared Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Triggered Timed Pulsed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Periodic Geared Pulsed Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Triggered Geared Pulsed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
13.2 Start, Stop and Special Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Start and Resume Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Stop and Resume Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Cold Start - GroupingAccumulator_Motion . . . . . . . . . . . . . . . . . 365
Cold Start - GroupingStripper_Motion . . . . . . . . . . . . . . . . . . . . 368
Warm Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Special Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Chapter 14 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . 375
Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Part IX Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Chapter 15 Clamping_Motion: Logical Sequence of Product
Clamping with Torque Limitation . . . . . . . . . . . . . . . . . 381
15.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
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Clamping_motion Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . 386
15.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Structured Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
15.5 Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Selection of the Capture Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
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Safety Information
Important Information
NOTICE
Read these instructions carefully, and look at the equipment to become familiar with the device
before trying to install, operate, or maintain it. The following special messages may appear
throughout this documentation or on the equipment to warn of potential hazards or to call attention
to information that clarifies or simplifies a procedure.
EIO0000000195 06/2015 11
PLEASE NOTE
Electrical equipment should be installed, operated, serviced, and maintained only by qualified
personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of
the use of this material.
A qualified person is one who has skills and knowledge related to the construction and operation
of electrical equipment and its installation, and has received safety training to recognize and avoid
the hazards involved.
BEFORE YOU BEGIN

Do not use this product on machinery lacking effective point-of-operation guarding. Lack of
effective point-of-operation guarding on a machine can result in serious injury to the operator of
that machine.
WARNING
UNGUARDED EQUIPMENT
 Do not use this software and related automation equipment on equipment which does not have
point-of-operation protection.
 Do not reach into machinery during operation.
Failure to follow these instructions can result in death, serious injury, or equipment
damage.
This automation equipment and related software is used to control a variety of industrial processes.
The type or model of automation equipment suitable for each application will vary depending on
factors such as the control function required, degree of protection required, production methods,
unusual conditions, government regulations, etc. In some applications, more than one processor
may be required, as when backup redundancy is needed.
Only you, the user, machine builder or system integrator can be aware of all the conditions and
factors present during setup, operation, and maintenance of the machine and, therefore, can
determine the automation equipment and the related safeties and interlocks which can be properly
used. When selecting automation and control equipment and related software for a particular
application, you should refer to the applicable local and national standards and regulations. The
National Safety Council’s Accident Prevention Manual (nationally recognized in the United States
of America) also provides much useful information.
In some applications, such as packaging machinery, additional operator protection such as point-
of-operation guarding must be provided. This is necessary if the operator’s hands and other parts
of the body are free to enter the pinch points or other hazardous areas and serious injury can occur.
Software products alone cannot protect an operator from injury. For this reason the software
cannot be substituted for or take the place of point-of-operation protection.
12 EIO0000000195 06/2015
Ensure that appropriate safeties and mechanical/electrical interlocks related to point-of-operation
protection have been installed and are operational before placing the equipment into service. All
interlocks and safeties related to point-of-operation protection must be coordinated with the related
automation equipment and software programming.
NOTE: Coordination of safeties and mechanical/electrical interlocks for point-of-operation
protection is outside the scope of the Function Block Library, System User Guide, or other
implementation referenced in this documentation.
START-UP AND TEST

Before using electrical control and automation equipment for regular operation after installation,
the system should be given a start-up test by qualified personnel to verify correct operation of the
equipment. It is important that arrangements for such a check be made and that enough time is
allowed to perform complete and satisfactory testing.
CAUTION
EQUIPMENT OPERATION HAZARD
 Verify that all installation and set up procedures have been completed.
 Before operational tests are performed, remove all blocks or other temporary holding means
used for shipment from all component devices.
 Remove tools, meters, and debris from equipment.
Failure to follow these instructions can result in injury or equipment damage.
Follow all start-up tests recommended in the equipment documentation. Store all equipment
documentation for future references.
Software testing must be done in both simulated and real environments.
Verify that the completed system is free from all short circuits and temporary grounds that are not
installed according to local regulations (according to the National Electrical Code in the U.S.A, for
instance). If high-potential voltage testing is necessary, follow recommendations in equipment
documentation to prevent accidental equipment damage.
Before energizing equipment:
 Remove tools, meters, and debris from equipment.
 Close the equipment enclosure door.
 Remove all temporary grounds from incoming power lines.
 Perform all start-up tests recommended by the manufacturer.
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OPERATION AND ADJUSTMENTS
The following precautions are from the NEMA Standards Publication ICS 7.1-1995 (English
version prevails):
 Regardless of the care exercised in the design and manufacture of equipment or in the selection
and ratings of components, there are hazards that can be encountered if such equipment is
improperly operated.
 It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe
operation. Always use the manufacturer’s instructions as a guide for functional adjustments.
Personnel who have access to these adjustments should be familiar with the equipment
manufacturer’s instructions and the machinery used with the electrical equipment.
 Only those operational adjustments actually required by the operator should be accessible to
the operator. Access to other controls should be restricted to prevent unauthorized changes in
operating characteristics.
14 EIO0000000195 06/2015
About the Book
At a Glance
Document Scope
This document describes the functions of the Packaging Library.
Validity Note
This document has been updated with the release of SoMachine 4.1 SP1.2.
Product Related Information
WARNING
LOSS OF CONTROL
 The designer of any control scheme must consider the potential failure modes of control paths
and, for certain critical control functions, provide a means to achieve a safe state during and
after a path failure. Examples of critical control functions are emergency stop and overtravel
stop, power outage and restart.
 Separate or redundant control paths must be provided for critical control functions.
 System control paths may include communication links. Consideration must be given to the
implications of unanticipated transmission delays or failures of the link.
 Observe all accident prevention regulations and local safety guidelines.1
 Each implementation of this equipment must be individually and thoroughly tested for proper
operation before being placed into service.
damage.
1For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety Guidelines for the
Application, Installation, and Maintenance of Solid State Control" and to NEMA ICS 7.1 (latest
edition), "Safety Standards for Construction and Guide for Selection, Installation and Operation of
Adjustable-Speed Drive Systems" or their equivalent governing your particular location.
EIO0000000195 06/2015 15
WARNING
UNINTENDED EQUIPMENT OPERATION
 Only use software approved by Schneider Electric for use with this equipment.
 Update your application program every time you change the physical hardware configuration.
damage.
16 EIO0000000195 06/2015
SoMachine
System Requirements
EIO0000000195 06/2015
Part I
Packaging Library System Requirements
Packaging Library System Requirements
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System Requirements
18 EIO0000000195 06/2015
SoMachine
System Requirements
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Chapter 1
System Requirements
System Requirements
At a Glance
This chapter describes the system requirements for the Packaging Library function blocks.
What Is in This Chapter?

This chapter contains the following topics:
Topic Page
Packaging System Requirements 20
Function Block Location in the Packaging Library 23
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System Requirements
Packaging System Requirements
Overview
This chapter describes the hardware and the software requirements, and user interface
compatibility for packaging library functions.
For environments, refer to individual function block chapters.
System Requirements
This table describes the system requirements for the following application function blocks:
Application Function Block Requirements

 TemperatureControl  Logic Controller or
 LateralPositionControl  Motion Controller
 MoveJog  Logic Controller

 XYPickAndPlace  Lexium servo drive
 DigitalTensionControlATV  Logic Controller

 AnalogTensionControlATV  Lexium servo drive
 Altivar variable speed drive
 DigitalTensionControlATV_Motion  Motion Controller

 AnalogTensionControlATV_Motion  Lexium servo drive
 Altivar variable speed drive
 RotaryKnife_Motion  Motion Controller

 FlyingShear_Motion  Lexium servo drive
 GroupingAccumulator_Motion
 GroupingStripper_Motion
 Clamping_Motion
 AnalogTensionControlILXM_Motion
The targeted controller for the segment Packaging are:

 M258 Logic Controller
 LMC058 Motion Controller
 LMC078 Motion Controller
The preferred drives are:

 LXM32 Lexium servo drive
 ATV32 Altivar variable speed drive
 ATV71 Altivar variable speed drive
20 EIO0000000195 06/2015
System Requirements
Communication Interface
This table describes the communication interface requirements for the following application
function blocks:
Application Function Block Requirements

 TemperatureControl No communication interface required.
 LateralPositionControl
 MoveJog CANopen protocol is used for

 XYPickAndPlace communication with servo drives.
 DigitalTensionControlATV CANopen protocol is used for
 AnalogTensionControlATV communication with variable speed drive
and servo drive.
 DigitalTensionControlATV_Motion CANopen protocol is used for
 AnalogTensionControlATV_Motion communication with variable speed drive
and CANmotion or Sercos protocol is used
for communication with servo drive.
 Clamping_Motion CANmotion protocol is used for
communication with servo drives.
 RotaryKnife_Motion CANmotion or Sercos protocol is used for
 FlyingShear_Motion communication with servo drives.
 AnalogTensionControlILXM_Motion
NOTE: The LMC078 Motion Controller is using the third generation of Sercos.
User Interface
All parameters can be supplied and modified using Magelis HMI which can be used optionally.
EIO0000000195 06/2015 21
System Requirements
Using the Library
WARNING
 Verify the SoMachine libraries contained in your program are the correct version after updating
SoMachine software.
 Verify that the library versions updated are consistent with your application specifications.
damage.
For more detailed information, see Schneider Electric Libraries.

For IEC 61131-3 compatibility, the ability to add the EN/ENO input/output automatically to Function
Blocks of certain programming languages is available to the programmer. However, for certain
applications that require the complex interaction of multiple function blocks, the use of the
IEC 61131-3 input to disable a function block in a series of interrelated functions affecting a
process may lead to unintended operation of the system as a whole. For the functions contained
in the Library that is the topic of the current document, this is especially true.
The EN/ENO inputs and outputs as defined by IEC 61131-3 are maladapted to, and therefore
inappropriate for, the targeted application of these functions. Suddenly disabling one function by a
falling edge on the EN input would require all outputs of the function block to immediately fall to
their default states, and such an unanticipated action would cause in abrupt change to the entire
process. The implication is that such an event would have deleterious results that may invoke
undesirable consequences. Therefore, the EN/ENO inputs/outputs as defined by IEC 61131-3 are
incompatible with the functions contained within this library.
WARNING
UNINTENDED MACHINE OPERATION
Do not use the EN/ENO functionality defined by IEC 61131-3 to control the behavior of the
Application Function blocks.
damage.
NOTE: Verify that the EN/ENO option is disabled in the compiler options menu of SoMachine.
22 EIO0000000195 06/2015
System Requirements
Function Block Location in the Packaging Library
Function Block Location in the Packaging Library of SoMachine
Folder Sub-Folder Application Function Block

Clamping Clamping_Motion
FlyingShear FlyingShear_Motion
Grouping Ungrouping GroupingAccumulator_Motion
GroupingStripper_Motion
LateralPositionControl LateralPositionControl
PickAndPlace MoveJog
XYPickAndPlace
RotaryKnife RotaryKnife_Motion
TemperatureControl TemperatureControl
TensionControl AnalogTensionControl AnalogTensionControlATV
AnalogTensionControlATV_Motion
AnalogTensionControlLXM_Motion
DigitalTensionControl DigitalTensionControlATV
DigitalTensionControlATV_Motion
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System Requirements
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SoMachine
PickAndPlace
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Part II
PickAndPlace
PickAndPlace
What Is in This Part?

This part contains the following chapters:
Chapter Chapter Name Page
2 MoveJog: Manual Control of a Single Axis in Different Modes 27
3 XYPickAndPlace: Moving X- and Y-Axis in a Plane Coordinate System 59
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PickAndPlace
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SoMachine
MoveJog
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Chapter 2
MoveJog: Manual Control of a Single Axis in Different Modes
MoveJog: Manual Control of a Single Axis in Different

Modes

This chapter contains the following sections:
Section Topic Page
2.1 Functional and Machine Overview 28
2.2 Architecture 32
2.3 Function Block Description 35
2.4 Pin Description 42
2.5 Quick Reference Guide 51
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MoveJog
Section 2.1
Functional and Machine Overview
What Is in This Section?

This section contains the following topics:
Topic Page
Functional Overview 29
Machine Overview 31
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MoveJog
Functional Overview
Functional Description
The MoveJog function block controls a single axis while operating in Manual mode.
Usage of MoveJog Function Block

The MoveJog function is required for moving a single axis in speed mode, position mode and to
home the axis.
Solution with the MoveJog Function Block

The MoveJog function provides the following modes for operating a single axis in Manual mode:
 Speed mode
 Position mode
 Homing mode
Design & Realization Constraints and Assumptions

 Modulo Axis is run as infinite rotation with the Rotary Axis setting at the controller configuration
and there is no hardware/software limit checking.
 Homing is possible when Modulo Axis is selected.
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MoveJog
Functional View for Linear axis

Functional view for linear servo axis on CANopen:
30 EIO0000000195 06/2015
MoveJog
Machine Overview
Machine View
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MoveJog
Section 2.2
Architecture
Architecture

Topic Page
Hardware Architecture 33
Software Architecture 34
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MoveJog
Hardware Architecture
Hardware Architecture Overview
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MoveJog
Software Architecture
DataFlow Overview
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MoveJog
Section 2.3
Function Block Description

Topic Page
MoveJog Function Block 36
Operating Modes 38
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MoveJog
MoveJog Function Block
Pin Diagram
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MoveJog

The MoveJog function block is used for manual control of a single Axis.
This function block includes three modes:
 Speed Mode: the direction and movement commands are given using a single Jog Button. The
axis moves continuously in a specified direction as long as the Jog command is active.
 Position Mode: the direction and movement commands are given using a single Jog button. The
axis moves up a specified distance with a specified direction.
NOTE: Axis must be homed using Homing mode before the MoveJog function block can be
used in Position Mode.
 Homing Mode: after a start Homing command, the axis moves according to the Homing method
selected.
NOTE: Select correct Homing method and parameter for the application. Improper setup or
cabling may cause unintended equipment action.
WARNING
Verify that all configuration parameters are correct and validate cabling before commissioning.
damage.
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MoveJog
Operating Modes
Speed Mode: i_byOpMode=0

In Speed Mode, when the function block is enabled, enabling one of the directional inputs
i_xJogFwd or i_xJogRev starts the axis of motion in the desired direction. The specified axis is
then accelerated at the specified acceleration i_diJogAcc to the specified velocity i_iJogVel.
As long as there are no changes in the state of the direction inputs, the axis moves in the
corresponding direction. The motion is stopped by a falling edge at the respective direction input.
After i_tTimeSwcVelHigh has elapsed in the speed jog mode, the normal i_iJogVel and
i_diJogAcc are increased to i_iJogVelHigh and i_diJogAccHigh as shown in cycle 2 in
the Timing diagram figure below.
If both the direction inputs i_xJogFwd and i_xJogRev are TRUE at same time then the axis is
stopped and displays a detected error. The detected error resets only when one or both of the
direction input is FALSE and the rising edge of i_xAlrmRst is given to function block as shown
in cycle 4 in the timing diagram figure below.
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MoveJog
This figure shows the timing diagram for MoveJog function block in Speed Mode:
Position Mode: i_byOpMode=1

In Position Mode, when the function block is enabled, an enable signal at one of the direction bits
i_xJogFwd or i_xJogRev results in a single motion over a defined path i_diJogDist in the
desired direction. The motion is accelerated at the specified acceleration i_diJogAcc up to the
level i_iJogVel.
The motion is aborted by a falling edge at the respective direction bit before reaching distance as
shown in cycle 3 in the timing diagram figure below.
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MoveJog
If both the direction inputs i_xJogFwd and i_xJogRev are TRUE at same time then the axis does
not move and the function block displays a detected error. The detected error is reset only when
one or both of the direction inputs is FALSE and rising edge of i_xAlrmRst is given to function
block as shown in cycle 4 in the timing diagram figure below.
This figure shows the timing diagram for the MoveJog function block in Position Mode:
40 EIO0000000195 06/2015
MoveJog
Homing Mode: i_byOpMode=2

In Homing Mode, i_xHmngStrt starts the Homing operation according to the Homing method.
After the completion of the Homing operation, the output q_xAxisHome is set to TRUE. During
Homing, additional rising edge at i_xHmngStrt results in a detected Axis error.
NOTE: In Homing Mode, Jog command is not applicable.
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MoveJog
Section 2.4
Pin Description
Pin Description

Topic Page
Input Pin Description 43
Structured Parameter 46
Input/Output Pin Description 48
Output Pin Description 49
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Input Pin Description
Input Data Type Description

i_xEn BOOL TRUE: Enables function block and the parameters are
validated.
FALSE: Disables function block and all outputs are set
to zero. The axis movement is stopped.
i_xJogFwd BOOL TRUE: The jog motion starts in the positive/forward
direction.
FALSE: During jog in forward direction the axis
movement is stopped.
 i_xJogFwd must be TRUE up to the required
position.
 This input is only applicable to Speed and Position
modes.
 When i_xJogFwd and i_xJogRev are TRUE at
the same time, the q_xAlrm is TRUE and the axis
is stopped with a detected error.
i_xJogRev BOOL TRUE: Negative/reverse direction
FALSE: During jog in reverse direction the axis
movement is stopped.
 i_xJogRev must be TRUE up to the desired
position.
 This input is only applicable in Speed and Position
modes.
 When i_xJogFwd and i_xJogRev are TRUE at
the same time, the q_xAlrm is TRUE and the axis
is stopped with a detected error.
i_iJogVel INT In position mode, the axis moves only with i_iJogVel
velocity.
In Speed Mode the axis moves with i_iJogVel
velocity until the i_tTimeVelHigh elapses.
Range: 0...32000 RPM
Factory setting: 20
i_iJogVelHigh INT Jog velocity after the timer elapsed
(i_tTimeVelHigh)
Factory setting: 20
NOTE: Only applicable in Speed Mode
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MoveJog

i_diJogAcc DINT In position mode, the axis moves with i_diJogAcc
acceleration.
In Speed Mode, the axis moves with i_diJogAcc
acceleration until the i_tTimeVelHigh elapses.
Range: 30...3000000 RPM/s
Factory setting: 100
i_diJogDec DINT The axis stops with deceleration time
Range: 750...3000000 RPM/s
i_diJogAccHigh DINT The axis moves with i_diJogAcc acceleration after
the i_tTimeVelHigh elapses.
Range: 30...3000000 RPM/s
NOTE: This is only applicable in Speed Mode
i_tTimeVelHigh TIME This is the time to switch from i_iJogVel to
i_iJogVelHigh and from i_diJogAcc to
i_diJogAccHigh.
Range: 0...4194967295 ms
0: disables timer function
Factory setting: 10 s
 i_tTimeVelHigh is applicable for Speed Mode.
 i_tTimeVelHigh timer is reset after Jog
command FALSE or i_xEn is FALSE.
 When i_tTimeVelHigh = 0, axis moves only with
i_iJogVel and i_diJogAcc.
i_diJogDist DINT Jog distance value
Range: 1...2147483647 user unit
 i_diJogDist is only applicable in position mode.
 Jog distance should be more than zero. If
i_diJogDist is zero, then axis will not move and
position output q_xDone is TRUE.
i_byOpMode BYTE 0: Speed Mode
1: Positioning Mode
2: Homing Mode
i_xHmngStrt BOOL TRUE: Starts the homing operation according to
homing type selected. After the completion of homing
operation, the output q_xAxisHome is set to zero.
 In homing mode, Jog command is not applicable.
 Homing is not possible with modulo axis.
i_xLsEn BOOL TRUE: Enables the hardware limit switch functionality

inside the function block.
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i_xLsFwd BOOL TRUE: Forward / positive direction hardware limit
switch (factory setting)
If enabled and forward / positive direction hardware
limit switch goes low, then axis stops with positive
hardware limit switch active notification.
NOTE: Limit switch is configured as normally closed.
i_xLsRev BOOL TRUE: Reverse / negative direction hardware limit
switch (factory setting)
If enabled and reverse / negative direction hardware
limit switch goes low, then axis stops with negative
hardware limit switch active notification.
NOTE: Limit switch is configured as normally closed.
i_xAxisMode BOOL TRUE: Modulo axis configuration is selected and
hardware/software limit switch functionality is disabled.
FALSE: Linear axis configuration is selected (factory
setting).
Procedure for axis configuration:
 i_xEn input must be TRUE
 Drive must be in ready state
 Change the i_xAxisMode input as per the
requirements
 Set drive to run mode and move the axis.
i_xAlrmRst BOOL TRUE: Reset the detected alarm on a rising edge.

i_stHmngPara HomPara Structure for homing parameter
Refer to i_stHmngPara (see page 46).
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MoveJog
Structured Parameter
i_stHmngPara
This table describes the mandatory parameters for the i_stHmngPara inputs of the MoveJog
function block:
Structure Data Type Description

Parameter
diPos DINT Absolute position when the reference signal is detected
In Homing mode, after successful reference movement, this
position value is automatically set at the axis stop position.
Range: 1...2147483647 User Unit
uiHmngMode UINT Select Homing method
See description in table below
uiHmngVel UINT Velocity for search of reference switch
uiHmngVelOut UINT Velocity for movement back to edge of reference switch
Range: 1...3000 RPM
diHmngPosOut DINT Maximum distance for movement back to edge of reference switch
NOTE: The hardware limit switch must be disabled again inside this
run-off; otherwise the reference movement is aborted.
diHmngDistPos DINT Positioning from edge of reference switch
NOTE: After leaving the switch, the drive is still positioned in the
working range for defined path and this position is defined as a
reference point.
uiHmngMode
This table describes the methods supported by the MoveJog function block:
Method Number Description

1 Limit switch Negative with index pulse
2 Limit switch Positive with index pulse
7 Search Reference switch in Positive direction with index pulse, invert direction
in switch, index pulse/distance outside Switch
8 Search Reference switch in Positive direction with index pulse, invert direction
in switch, index pulse/distance inside Switch
9 Search Reference switch in Positive direction with index pulse, direction in
switch not inverted, index pulse/distance inside Switch
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Method Number Description

10 Search Reference switch in Positive direction with index pulse, direction in
switch not inverted, index pulse/distance outside Switch
11 Search Reference switch in Negative direction with index pulse, invert direction
in switch, index pulse/distance outside Switch
12 Search Reference switch in Negative direction with index pulse, invert direction
in switch, index pulse/distance inside Switch
13 Search Reference switch in Negative direction with index pulse, direction in
switch not inverted, index pulse/distance inside Switch
14 Search Reference switch in Negative direction with index pulse, direction in
switch not inverted, index pulse/distance outside Switch
17 Search Limit switch Negative
18 Search Limit switch Positive
23 Search Reference switch in Positive direction, invert direction in switch, index
pulse/distance outside Switch
24 Search Reference switch in Positive direction, invert direction in switch, index
pulse/distance inside Switch
25 Search Reference switch in Positive direction, direction in switch not inverted,
index pulse/distance inside Switch
26 Search Reference switch in Positive direction, direction in switch not inverted,
index pulse/distance outside Switch
27 Search Reference switch in Negative direction, invert direction in switch, index
pulse/distance outside Switch
28 Search Reference switch in Negative direction, invert direction in switch, index
pulse/distance inside Switch
29 Search Reference switch in Negative direction, direction in switch not inverted,
index pulse/distance inside Switch
30 Search Reference switch in Negative direction, direction in switch not inverted,
index pulse/distance outside Switch
33 Reference movement to the index pulse in Negative direction
34 Reference movement to the index pulse in Positive direction
35 Set dimensions (Direct Homing without movement and set required position to
current position)
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MoveJog
Input/Output Pin Description
Input/Output Data Type Description

iq_stAxis SEM_LXM.Axis_Ref_LXM Servo-axis reference structure
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Output Pin Description
Output Data Type Description

q_xEn BOOL TRUE: Function block enabled. If input i_xEn is TRUE, then
output q_xEn is TRUE.
q_xBusy BOOL TRUE: Axis is accelerating or decelerating.
q_xDone BOOL Only in position mode.
TRUE: Axis moved by jog distance.
q_xVelRchd BOOL Only in speed mode.
TRUE: Velocity reaches jog velocity (i_iJogVel) or jog
velocity high (i_iJogVelHigh).
q_diPosActl DINT Actual position of the axis.
q_xAxisHome BOOL Only in homing mode.
TRUE: Axis homing operation is complete and, after that,
q_xAxisHome is TRUE in all modes.
NOTE: This resets after a controller power on/off or a
detected axis error.
q_xCmdAbort BOOL TRUE: Command aborted
In the event that the motion is aborted due to external
command (for example: detected communication error, Stop
command issued before the completion of a movement,
function block disabled while axis homing) i_xCmdAbort is
set to TRUE.
q_xAlrm BOOL TRUE: Detected alarm
FALSE: No alarm
q_uiAlrmId UINT ID detected alarm
Range: 0, 1, 10, 30, 101, 102, 103, 105, 350-359.
Refer to Notification table (see page 50).
q_sAlrmMsge STRING Refer to Notification table (see page 50).
q_sOpMode STRING Output displays the function block current operating mode.
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MoveJog
Notifications
Detected Notification
Alarm ID
0 Okay
1 Internal function block detected alarm
10 Detected Axis alarm
30 PLCopen function block detected alarm
101 Invalid Acceleration Parameter
102 Invalid Deceleration Parameter
103 Invalid Velocity Parameter
105 Invalid Target Position Parameter
350 Invalid Operation Mode parameter
351 Invalid Absolute Position Parameter
352 Invalid Homing Mode Parameter
353 Invalid Reference Searching Velocity Parameter
354 Invalid Reference Out Velocity Parameter
355 Invalid Maximum Distance Parameter
356 Invalid Distance from Reference Parameter
357 Jog Positive and Jog Negative are Active
358 Positive Limit Switch Active
359 Negative Limit Switch Active
Alarm message:
q_sAlrmMsge: Axis not Homed! Position Mode not Allowed
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Section 2.5
Quick Reference Guide

Topic Page
Function Block Visualization 52
Quick Commissioning Procedure 53
Troubleshooting 56
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Function Block Visualization
Visualization
This figure shows the visualization of the MoveJog function block:
52 EIO0000000195 06/2015
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Quick Commissioning Procedure
Configuration Procedure
This table explains the procedure to configure the MoveJog function blocks:
Step Action
1 Add the supporting Packaging Library into the application program.
2 Configure the axis on CANopen Master.
3 Enter all parameters in controller configuration.
4 Use MC_Power_LXM for powering up the drive and MC_Reset_LXM for
resetting an axis error (both included in Lexium library based on PLCopen).
5 Load the MoveJog function application on controller.
6 Power on the axis.
7 Enable MC_Power_CAN and MoveJog function blocks and enter all parameters
as per requirements within range in the following tables.
8 In Speed mode, directly give the jog command for movement.
9 For Position mode, first complete the homing operation of axis in homing mode.
10 Start the FB.
Parameterizing in Speed Mode

This table lists the suggested parameters for speed mode:
Parameter Example Value

i_xEn TRUE
i_xJogFwd TRUE
i_xJogRev FALSE
i_iJogVel 100
i_iJogVelHigh 500
i_diJogAcc 100
i_diJogDec 1000
i_diJogAccHigh 500
i_tTimeVelHigh 1000
i_diJogDist 0
i_byOpMode 0
i_xHmngStrt FALSE
i_xLsEn TRUE
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MoveJog

i_xLsFwd TRUE
i_xLsRev TRUE
i_xAxisMode FALSE
i_xAlrmRst FALSE
NOTE: The above values were tested in laboratory conditions and are for illustrative purposes
only. Appropriate values should be entered as per the actual machine setup.
Parameterizing in Position Mode

This table lists the suggested parameters for position mode:

i_xEn TRUE
i_xJogFwd TRUE
i_xJogRev FALSE
i_iJogVel 100
i_iJogVelHigh 500
i_diJogAcc 100
i_diJogDec 1000
i_diJogDist 10000
i_byOpMode 1
i_xHmngStrt FALSE
i_xLsEn TRUE
i_xLsFwd TRUE
i_xLsRev TRUE
i_xAxisMode FALSE
i_xAlrmRst FALSE
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Parameterizing in Homing Mode

This table lists the suggested parameters for homing mode:

i_xEn TRUE
i_byOpMode 2
i_xHmngStrt FALSE
i_xAxisMode FALSE
i_xAlrmRst FALSE
i_stHmngPara.diPos 0
i_stHmngPara.uiHmngMode 17
i_stHmngPara.uiHmngVel 50
i_stHmngPara.uiHmngVelOut 20
i_stHmngPara.diHmngPosOut 0
i_stHmngPara.diHmngDistPos 100
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MoveJog
Troubleshooting
Troubleshooting
This table shows some general issues and their solutions:
Issue Cause Solution

Parameter invalid Function block detected 1.Remove cause of detected error
error. and acknowledge with
i_xAlrmRst
2.Restart the function block.
Inputs invalid The axis movement is 1.Remove cause of detected error
stopped and the detected and acknowledge with
error output is set. i_xAlrmRst
Axis error detected The axis movement is 1.Remove cause of detected error
stopped and the detected 2.Execute the axis reset using
error output is set. MC_Reset function block.
3.Restart the function block.
q_uiAlrmId = 1 Internal detected error Detected error other than the ones
above.
Restart the function block.
q_uiAlrmId = 10 Axis detected alarm Verify the servo drive detected error
and remove the cause of the
detected error.
q_uiAlrmId = 30 PLCopen detected alarm Reset the function block. Give the
power cycle to the controller if a
detected error remains.
q_uiAlrmId = 101 Invalid acceleration Verify that the acceleration
parameter parameter is within the specified
range.
q_uiAlrmId = 102 Invalid deceleration Verify that the deceleration
parameter parameter is within the specified
range.
q_uiAlrmId = 103 Invalid velocity parameter Verify that the speed parameter is
within the specified range.
q_uiAlrmId = 105 Invalid target position Verify that the position parameter is
parameter within the specified range.
q_uiAlrmId = 350 Invalid operation mode Verify that the operation parameter
parameter is within the specified range.
q_uiAlrmId = 351 Invalid absolute position Verify that the absolute position is
Parameter within the specified range.
q_uiAlrmId = 352 Invalid homing mode Verify that the homing mode is
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q_uiAlrmId = 353 Invalid ref. searching velocity Verify that the ref. searching velocity
q_uiAlrmId = 354 Invalid ref. out velocity Verify that the ref. out velocity is
q_uiAlrmId = 355 Invalid max. distance Verify that the max. distance is
q_uiAlrmId = 356 Invalid distance from Verify that the distance from
reference parameter reference is within the specified
range.
q_uiAlrmId = 357 Jog positive and Jog Verify that only one input is ON at a
negative are active time.
q_uiAlrmId = 358 Positive limit switch active Verify the positive limit switch
position.
q_uiAlrmId = 359 Negative limit switch active Verify the negative limit switch
position.
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Chapter 3
XYPickAndPlace: Moving X- and Y-Axis in a Plane Coordinate System
XYPickAndPlace: Moving X- and Y-Axis in a Plane

Coordinate System

Section Topic Page
3.2 Architecture 64
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Section 3.1

Topic Page
Machine Overview 63
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Functional Overview
XYPickAndPlace function is required in the consumer products industry for a wide variety of
product transfer applications. The machine basically takes a product or products from machines
such as wrappers, cartoners or fillers, and stacks them into a case, which is then ready for
palletizing or shipment.
Usage of XYPickAndPlace Function Block

XYPickAndPlace Application involves two functions, one is for the picking and placing of material
and the other is for movement of this material in the XY plane.
The XYPickAndPlace function block involves two linear axes that move the manufactured part
from one assembly station to another station or from a conveyor to pallet.
Solution with the XYPickAndPlace Function Block

Moving the part to the target location can be accomplished in three separate moves:
 Picking the part along the Z axis.
 Moving the part in the XY plane to the target position.
 Placing the part along the Z axis.
This figure shows the PickAndPlace assembly:
The function block is used to reduce process time, increase productivity and efficiency in
packaging.
NOTE: Z Axis Operation is not controlled by the function block.
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 The Shift (Skip) Position is applicable only in the Semi-Auto Mode. This option is not allowed in
Auto Mode.
 In Semi Auto Mode the trigger for each cycle is done by the rising edge of the i_xExe, but the
parameter change is done only with the i_xEn; this is to avoid parameter change during the
cycle.
 New cycle is started once all the boxes (box shifting is counted) in the current cycle are placed
as per the defined matrix. The message "Layer Completed with Skipped Box" is then displayed.
 Presently done: Skipped box can be either manually placed (by operator) or a new semi-
automatic cycle can be started by resetting the Box Count i_xBoxCntRst input and giving
respective skip number through i_uiStepNb to directly reach the box which needs to be
placed (Box or any obstacle on the way to reach this previously skipped box position is not
considered in this FB since Z axis is not controlled).
 If function block is disabled and enabled and the parameters (Direction of Placing, Number of
elements in X and Y, Target, Approach and Start Position) are changed, then the box count is
reset and a fresh cycle is started. If no parameter is changed, then old cycle is continued.
 Direction of Placing, Number of elements in X and Y, Target, Approach and Start Position
cannot be changed when a cycle is running. New values are affected only on the Rising edge
of the i_xEn (FB enable).
Functional View
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Machine Overview
Machine View
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Section 3.2
Architecture
Architecture

Topic Page
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DataFlow Overview
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Section 3.3

Topic Page
XYPickAndPlace Function Block 68
Axis Movement: General Description 69
Axis Movement: Non-Optimized Mode Without Approach Point 71
Axis Movement: Optimized Mode Without Approach Point 72
Axis Movement 73
Function Block Operation: Semi-Auto Mode 74
Function Block Operation: Auto Mode 76
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XYPickAndPlace Function Block
Pin Diagram
The XYPickAndPlace function block encapsulates all necessary functions for controlling the
position of two axes in the XY plane.
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Axis Movement: General Description
At a Glance
The axis are moved in a coordinated linear movement by calculating the ratio of distances travelled
in the X axis and Y axis. The axis with the shorter move is multiplied by this ratio so that the axes
move with the same ratio of velocity, acceleration and deceleration at any point in time.
Approach Point Rules

Selecting the approach point permits decreasing the axes velocity when they reach the approach
position.
If the selected mode is 0, 1 or 2, the resulting axis trajectory is done without an approach point, the
axis moves to the target position in one move.
Following are the 5 modes of axis movement:
0 Non-optimized mode without approach point
1 Optimized mode without approach point
2 Strict optimized mode without approach point
3 Optimized mode with approach point
4 Strict optimized mode with approach point
NOTE: Improper setup or cabling may cause unintended equipment action.
WARNING
damage.
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Linear Axis Movement

This figure shows linear axis movement by starting and stopping both axes at the same time to
achieve a high level of linearity:
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Axis Movement: Non-Optimized Mode Without Approach Point
Description
The non-optimized mode without approach point is selected when i_byAxisMovSel input is 0.
In this mode, if the calculated Acceleration and Deceleration of the short distance move is less than
the lower limit of 30 and 750 respectively, then the Acceleration and Deceleration is set to 30 and
750 and an alarm message of "Non Optimized Mode" is ON and the straight line trajectory is not
assured.
NOTE:
 All calculations are done before the movement of the axes. The mode selection needs to be
done prior to the start of the axis movement.
 In this Mode, the user needs to select the appropriate Acceleration and Deceleration to prevent
from going below the limit required to achieve straight line trajectory.
Axis Movement
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Axis Movement: Optimized Mode Without Approach Point
Description
For axis movement, optimized mode without approach point is selected when i_byAxisMovSel
input is 1.
In this mode, if the short distance movement axis calculated acceleration and deceleration is less
than the lower limit of 30 and 750 respectively then acceleration and deceleration of a long distance
movement axis is increased accordingly to achieve the straight line trajectory.
During this Alarm message "Auto Correction ON" is ON.
Axis Movement
NOTE:
 All the calculations are done before the movement of the axes. The mode selection needs to be
done prior to the start of the axis movement.
 In this mode, the user must set the Maximum Acceleration (diAccMax) and Maximum
Deceleration (diDecMax) so that the calculated Acceleration and Acceleration (of the longer
axis) stays within the acceptable operating limits of the machine.
 In this scenario, the alarm message " Auto Correction On with Acc / Dec Limited" is set and the
straight line trajectory can not be assured.
 In this mode, there is always a movement in X- and in Y- direction and accordingly delta X and
delta Y cannot be zero.
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Axis Movement
Strict Optimized Mode without Approach Point

For axis movement, the Strict Optimized Mode without approach point is selected when
i_byAxisMovSel is 2. In this mode, if the short distance movement axis calculated acceleration
and deceleration is less than the lower limit of 30 and 750 respectively,then function block shows
"Acceleration Value too Low" and "Deceleration Value too Low" respectively and there is no axis
movement.
Strict Optimized Mode with Approach Point

For axis movement, the Strict Optimized Mode with approach point is selected when
i_byAxisMovSel input is 4. In this mode, if the short distance movement axis calculated
acceleration and deceleration is less than the lower limit of 30 and 750 respectively, then function
block shows "Acceleration Value too Low" and "Deceleration Value too Low" respectively and there
is no axis movement.
Optimized Mode with Approach Point

For axis movement, the Optimized Mode with approach point is selected when i_byAxisMovSel
input is 3. In this mode, if the short distance movement axis calculated acceleration and
deceleration is less than the lower limit of 30 and 750 respectively, then acceleration and
deceleration of the long distance movement axis is increased accordingly to achieve a straight line
trajectory. During this, the Alert message "Auto Correction ON" is ON.
NOTE: All calculations are done before the movement of the axis and the mode selection must be
done before the axis starts to move.
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Function Block Operation: Semi-Auto Mode
Description
In Semi-Automatic mode (i_xAutoMode=FALSE), after enabling i_xEn input, the function block
is activated and the structure parameters are validated. After enabling the function block, the first
rising edge of the i_xExe input moves the axis to XYPara.diPosStrtX and
XYPara.diPosStrtY.
Approach Distance
If the approach distance is greater or equal to the target position, then the rising edge of i_xExe
moves the axis to the target positions with XYPara.udiApprVel, XYPara.udiApprAcc and
XYPara.udiApprDec from the start position.
If the approach distance is less than the target position then the rising edge of i_xExe moves the
axis to the target positions with XYPara.udiTrgtVel, XYPara.udiTrgtAcc and
XYPara.udiTrgtDec from the start position.
When the axis is at the end position, the rising edge of i_xExe moves the axis to
XYPara.diPosStrtX and XYPara.diPosStrtY.
NOTE: Movement from the start position to the end position or vice versa happens only on the
rising edge of i_xExe input.
NOTE: Improper setup of acceleration, deceleration, speed parameters, or the approach point is
too close to the target position may cause a position overshoot.
WARNING
TARGET POSITION OVERSHOOT
Verify and validate that the parameters of acceleration, deceleration, speed and approach
distance are correct before executing the function.
damage.
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Timing Chart
This figure shows a timing chart in the Semi-Auto mode:
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Function Block Operation: Auto Mode
Description
In Automatic mode (i_xAutoMode = TRUE), after enabling i_xEn input, the function block is
activated and the structure parameters are validated. In Auto mode, i_xExe input must be TRUE.
After enabling the function block, the first rising edge of the i_xMoveStrt input moves the axis
from any position to XYPara.diPosStrtX and XYPara.diPosStrtY.
Approach Distance
If the approach distance is greater or equal to the target position then a rising edge of
i_xMoveStrt moves the axis to the target positions with XYPara.udiApprVel,
XYPara.udiApprAcc and XYPara.udiApprDec from the start position.
If the approach distance is less than the target position then a rising edge of i_xMoveStrt moves
the axis to the target positions with XYPara.udiTrgtVel, XYPara.udiTrgtAcc and
XYPara.udiTrgtDec from the start position.
When the axis is at the end position, the rising edge of the i_xMoveStrt moves the axis to
XYPara.diPosStrtX and XYPara.diPosStrtY.
NOTE: Movement from the start position to the end position or vice versa happens only on a rising
edge of the i_xMoveStrt input. During this movement, the i_xExe input must be TRUE.
NOTE: When i_xExe is FALSE while the axis is in motion, the axis stops after completing the
current operation.
WARNING
damage.
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Timing Chart
This figure shows a timing chart in Auto mode:
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Section 3.4
Pin Description
Pin Description

Topic Page
Detailed Input Pin Description 81
Input: i_stXYPara 82
Input: i_stPItPara 85
Input: i_xShiftFrstY 86
Input: i_uiStepNb 88
Input: i_uiNbLayr 89
Input: i_stXYPara.udiApprDist 90
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i_xEn BOOL TRUE: Enables function block and the parameters are validated.
FALSE: Disables function block and all outputs are set to zero.
The axis movement is stopped.
i_xExe BOOL TRUE: Axis moves to desired position. Rising edge enables the
Operating Mode selected.
FALSE: If in motion, axis completes the current action and then
stops.
i_xAutoMode BOOL TRUE: Auto Mode, cycle executes for defined layers.
FALSE: Semi-Auto mode.
i_xMoveStrt BOOL TRUE: Starts the Pick and Place cycle in Auto mode. Executes
on rising edge of input.
i_xShiftFrstY BOOL TRUE: Boxes are placed first in Y direction.
FALSE: Boxes are placed first in X direction.
Refer to box placement (see page 86).
i_xEnStepAdd BOOL (*) TRUE: The boxes are shifted by i_iStepNb position
NOTE: The functionality is only applicable in Semi-Auto mode.
i_uiStepNb UINT (*) Number of boxes to be shifted with reference to the last placed
box.
Range:
0...(i_stPltPara.uiElemNbX*i_stPltPara.uiElemNbY)
NOTE: This input is applicable only in Semi-Auto mode and
when i_xEnStepAdd input is TRUE.
i_uiNbLayr UINT Number of layers to be executed
Range: 0...65535
Refer to layer description (see page 89).
i_xCyclNbRst BOOL TRUE: Resets the number of layers executed.
Reset occurs only when axis is in start position.
i_xBoxCntRst BOOL TRUE: Resets the number of box counts.
Reset occurs only when axis is in start position.
i_xAlrmRst BOOL (*) TRUE: Resets the detected alarm (rising edge)
* Optional according to the application mode
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i_byAxisMovSel BYTE Mode selection for Axis movement:
0: Non optimized mode without approach point
1: Optimized mode without approach point
2: Strict optimized mode without approach point
3: Optimized mode with approach point.
4: Strict optimized mode with approach point.
All calculations are done before movement of axis and mode
selection must be done before the axis starts to move.
i_stXYPara XYPara Structure for XY parameters
i_stPltPara PltPara Structure for pallet parameters
* Optional according to the application mode
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Detailed Input Pin Description
Input: i_xExe
Rising edge enables the selected operating mode (Auto / Semi-Auto).
In Auto mode, i_xExe must be TRUE for mode operation. If falling edge of i_xExe is detected
during axis movement, the current operation will be executed and the operation will be stopped.
In Semi-Auto mode, rising edge of i_xExe is required in each cycle to move the axis from start
position to target position or vice versa.
NOTE: After enabling the function block in Semi-Auto mode, the first i_xExe trigger will move the
axis to start position.
Input: i_xMoveStrt
In Auto mode, if i_xExe is TRUE, the function block waits for i_xMoveStrt rising edge to move
the axis to i_stXYPara.diPosStrtX or i_stXYPara.diPosStrtY.
NOTE: i_xMoveStrt input is not applicable in Semi-Automatic mode. After enabling the function
block in Auto mode, the i_xExe trigger is required to select the Auto mode and the first
i_xMoveStrt trigger will move the axis to the start position
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Input: i_stXYPara

diPosStrtX DINT Starting point X
Range: 0...diPosStrtX< diPosEndX
Refer to axis movement figure (see page 84)
diPosStrtY DINT Starting point Y
Range: 0...diPosStrtY< diPosEndY
diPosEndX DINT Ending point X
Range: 0...2147483647
diPosEndY DINT Ending point Y
Range: 0...2147483647
udiApprVel UDINT Velocity from starting point to approach point
Range: 0...3200 units/sec
Factory setting: 20
udiApprAcc UDINT Acceleration from starting point to approach point
Range: 30...3000000 units/sec²
Factory setting: 20
udiApprDec UDINT Deceleration from starting point to approach point
Factory setting: 30
udiApprDist UDINT Approach distance
Range: 0...2147483647
udiTrgtVel UDINT Velocity from approach point to target point
Range: 0...3200 units/sec
Factory setting: 20
udiTrgtAcc UDINT Acceleration from approach point to target point
Factory setting: 30
Only if udiTrgtVel is higher than udiApprVel
* Optional according to the applicable mode
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udiTrgtDec UDINT Deceleration from approach point to target point
xCyclEnd BOOL This pin changes the behavior of cycle count (layer count).
If xCyclEnd is FALSE then q_udiCycINbCmpl will be
incremented with the last box of the layer on the target
position.
If xCyclEnd is TRUE then q_udiCycINbCmpl will be
incremented with the last box of the layer on the start
position.
Factory setting: FALSE
* Optional according to the applicable mode
NOTE: All values for distance, velocity and deceleration/acceleration are depending on the amount
of pulses per one motor revolution. According to this the minimum/maximum values are given by
the following equations:
Acceleration /*min*/= (30 * Motor pulses per revolution)/60
Acceleration /*max*/= (3000000 * Motor pulses per revolution)/60
Deceleration /*min*/= (750 * Motor pulses per revolution)/60
Deceleration /*max*/= (3000000 * Motor pulses per revolution)/60
NOTE: xCyclEnd input status is only latched into internal bit of function block when box count is
0 (q_uiBoxCnt = 0) and can be considered as initial instantiation of the function block. That
means, internal bit is NOT changed during power cycle or disabling of the function block.
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Axis Movement
This figure shows axis movement with udiApprDist:
WARNING
damage.
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Input: i_stPItPara

diShiftX DINT Distance of shifting in X direction
Range: 0...2147483647
Refer to the pallet parameters in figure below.
diShiftY DINT Distance of shifting in Y direction
Range: 0...2147483647
uiElemNbX UINT Total number of boxes in X direction
Range: 0...10000
uiElemNbY UINT Total number of boxes in Y direction
Range: 0...10000
Pallet Parameters
This figure shows the different pallet parameters:
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Input: i_xShiftFrstY
Description
The i_xShiftFrstY input determines whether the boxes are placed first in Y axis by setting this
input to TRUE.
As this priorization for the Y axis can only be accepted at the beginning of an empty pallet layer,
following pre-conditions need to be fulfilled:
1. X and Y axis are at the start (pick) position.
2. The box count of the actual layer is zero (q_uiBoxCnt = 0)
After both conditions have been met a rising edge on i_xExe is required to enable this setting.
Box placement: X or Y Axis
Box Placement: Y Axis
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Box Placement: X Axis
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Input: i_uiStepNb
Description
The i_uiStepNb input refers to the number of positions to be shifted with reference to the last
placed box.
Box Placement Without Shifting
Box Placement With Shifting
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Input: i_uiNbLayr
Description
The i_uiNbLayr input refers to the number of layers to be executed.
This figure shows 4 layers:
NOTE: When layer is completed with skipping, an alarm message "Layer completed with skipping"
will be displayed. Empty space of the layer can be filled manually.
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Input: i_stXYPara.udiApprDist
Description
The approach distance is the distance for which the axes will travel with Target Velocity (usually
less velocity than the i_stXYPara.udiApprVel), Target Acceleration and Target Deceleration.
Target Distance Calculation
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Approach With Normal Values

This figure shows normal and high value approach examples:
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iq_stXaxs SEM_LXM.Axis_Ref_LXM Servo axis reference structure
iq_stYaxs SEM_LXM.Axis_Ref_LXM Servo axis reference structure
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q_xEn BOOL TRUE: function block enabled
If input i_xEn is TRUE, then output q_xEn is TRUE.
q_xBusy BOOL TRUE: Axis in accelerating/decelerating phase
q_xPosStrtRchd BOOL TRUE: Axis in start point
q_xPosStrtRchd output is TRUE when the both X
and Y axis are in pick / start position
q_xPosTargRchd BOOL TRUE: Axis in target point
q_xPosTrgtRchd output will be TRUE when the both
X and Y axis are in place / end position
q_udiCyclNbCmpl UDINT The number of cycles completed will be incremented on
target position if i_stXYPara.xCyclEnd is FALSE.
If i_stXYPara.xCyclEnd is TRUE the number of
cycles will be incremented on start position.
Range: 0...i_uiNbLayer
q_xCyclNbDone BOOL TRUE: Number of cycle reached
q_xCyclNbDone output is TRUE when all layers are
completed in auto mode
q_uiBoxCnt UINT Number of boxes placed
q_xAlrm BOOL TRUE: Alarm detected
Refer to Notifications (see page 94).
q_uiAlrmId UINT Alarm ID
Range: 0, 1, 11, 12, 30, 101...103, 105...107, 336,
340...349
q_sAlrmMsge STRING Notification
q_uiAlrtId UINT Alert ID
Range: 0...9
Refer to Alert messages (see page 94).
q_sAlrtMsge STRING Alert message
Refer to Alert messages (see page 94).
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Notifications
Detected Alarm ID Notification

0 Okay
1 Internal alarm detected
11 Axis X alarm detected
12 Axis Y alarm detected
30 PLCopen alarm detected
101 Invalid acceleration parameter
102 Invalid deceleration parameter
103 Invalid velocity parameter
107 Invalid approach distance parameter
336 Starting point lies further outside the end point
340 Invalid step number parameter
343 Invalid number of elements in XY
345 Invalid axis movement parameter
348 usr/RPM scaling for both the axes is not same
349 Starting point lies inside the XY pallet
Alert Messages
Alert ID Alert Message

0 No alert
2 Layer completed with skipping
3 Skip out of bounds
5 Disable and enable function block
6 Verify layer to be stack
7 No optimized mode
8 Auto correct on
9 Auto correction on with acceleration / deceleration limited
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Section 3.5

Topic Page
Troubleshooting 99
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Visualization
This figure shows a visualization of the XYPickAndPlace function block:
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Process Description
This table describes the quick commissioning procedure for the XYPickAndPlace function block:
Step Action
1 Add following supporting libraries into the application program:
 Packaging Library
2 Configure the axis on CANopen Master.

3 Enter all parameters in controller configuration.
4 Use MC_Power_CAN for powering up the drive.
For homing the axis, one MoveJog FB per axis can be used also.
5 Load the XYPickAndPlace function application on the controller.
6 Power on axis.
7 Enter desired parameter and enable the function block.
Refer to parametrizing table.
8 Select application mode.
9 Start the application.
Parameterizing
This table lists the input parameters to be entered:
Input Auto Mode Semi-Auto Mode

i_xEn TRUE TRUE
i_xExe TRUE TRUE (Rising Edge)
i_uiNbLayer 2 2
i_xAutoMode TRUE FALSE
i_xEnStepAdd FALSE FALSE
i_iStepNb 0 0
i_xShiftFrstY TRUE FALSE
i_xMoveStrt TRUE (Rising Edge) FALSE
i_stXYPara.diPosStrtX 16380 16380
i_stXYPara.diPosStrtY 86100 86100
i_stXYPara.diPosEndX 32760 32760
i_stXYPara.diPosEndY 270600 270600
i_stXYPara.udiApprDist 10000 10000
i_stXYPara.udiApprVel 1000 1000
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Input Auto Mode Semi-Auto Mode

i_stXYPara.udiApprAcc 3000 3000
i_stXYPara.udiApprDec 4000 4000
i_stXYPara.udiTrgtVel 88 88
i_stXYPara.udiTrgtAcc 2000 2000
i_stXYPara.udiTrgtDec 3000 3000
i_stPltPara.uiElemNbX 4 4
i_stPltPara.uiElemNbY 4 4
i_stPltPara.udiShiftX 8190 8190
i_stPltPara.udiShiftY 24600 24600
NOTE: The above values were tested in laboratory conditions and are for sample only. Appropriate
values should be entered as per the actual machine setup.
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Troubleshooting
Troubleshooting
This table describes some general issue and their solutions:

Parameter invalid Function block error detected 1. Remove cause of detected error and acknowledge
with input i_xAlrmRst.
2. Reset the function block with i_xEn.
Inputs invalid The axis movement is stopped and the Remove cause of detected error and acknowledge
detected error output is set. with i_xAlrmRst.
Axis error detected The axis movement is stopped and the 1. Remove cause of detected error.
detected error output is set. 2. Execute the axis reset using MC_Reset function
block.
3. Restart the function block.
Although the input Preconditions for enabling of box Verify that X and Y axis are at the start (pick) position
i_xShiftFrstY is placement in Y axis first are not met. and the box count is zero (q_uiBoxCnt = 0) and give
set to TRUE the a rising edge on input i_xExe.
boxes continue
getting placed in X
axis first.
q_uiAlrmID = 1 Internal alarm detected Restart the function block.
q_uiAlrmID = 11 Alarm detected in X Axis Verify axis power.
q_uiAlrmID = 12 Alarm detected in Y Axis Verify axis power.
q_uiAlrmID = 30 PLCopen alarm detected Reset the function block. Give the power cycle to the
controller if a detected error remains.
q_uiAlrmID = 101 Invalid acceleration parameter Verify that the acceleration parameter is within the
specified range.
q_uiAlrmID = 102 Invalid deceleration parameter Verify that the deceleration parameter is within the
specified range.
q_uiAlrmID = 103 Invalid approach distance parameter Verify that the approach distance parameter is not
greater than the distance between pick position and
place position.
q_uiAlrmID = 105 Invalid target position parameter Verify that the end parameter is within the specified
range.
q_uiAlrmID = 106 Invalid start position parameter Verify that the start parameter is within the specified
range.
q_uiAlrmID = 107 Invalid approach distance parameter Verify that the approach distance parameter is not
greater than the distance between pick position and
place position.
q_uiAlrmID = 336 Invalid starting point Verify that the starting point is below the target
position.
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q_uiAlrmID = 340 Invalid step number parameter Verify that the step number is within the specified
range.
q_uiAlrmID = 341 Invalid approach parameter Verify that the approach parameter is within the
specified range.
q_uiAlrmID = 342 Invalid shift boxes parameter Verify that the shift boxes parameter is within the
specified range.
q_uiAlrmID = 343 Invalid number of elements in XY Verify that the number of elements in XY is within the
specified range
q_uiAlrmID = 345 Invalid axis movement parameter Verify that the axis movement selection parameter is
within the specified range.
q_uiAlrmID = 346 Acceleration value too low Verify the acceleration value and modified as per the
axis movement mode selection.
q_uiAlrmID = 347 Deceleration value too low Verify the deceleration value and modified as per the
axis movement mode selection.
q_uiAlrmID = 348 Axis scaling not the same for both axes Verify that the scaling in terms of drive user units or
RPM scaling is the same for both axes.
q_uiAlrmID = 349 Invalid starting point Verify that the starting point is not placed inside the
pallet.
NOTE: The function block is based on the standard PLCopen library, relying mainly on SDO
communications of CANopen.
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TensionControl
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Part III
TensionControl
TensionControl
Purpose of This Part

This part explains the functionality and implementation of the DigitalTensionControl and the
AnalogTensionControl function block in the packaging industry.

4 DigitalTensionControl: Controlling Consistent Film Tension Between Two 103
Digital Sensors
5 AnalogTensionControl: Controlling Consistent Film Tension Depending on 135
Analog Sensor Feedback
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TensionControl
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DigitalTensionControl
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Chapter 4
DigitalTensionControl: Controlling Consistent Film Tension Between Two Digital Sensors
DigitalTensionControl: Controlling Consistent Film

Tension Between Two Digital Sensors
Overview
This chapter describes the following function blocks:
 DigitalTensionControlATV
 DigitalTensionControlATV_Motion

Section Topic Page
4.2 Architecture 110
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Section 4.1

Topic Page
Machine Overview 107
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Functional Overview
Why Use the DigitalTensionControl Function Block?

When the film reel is unwound, there is a possibility of inconsistent speed or tension variation. This
would result in variation in tension, shifting of film and film cut.
Solution with the DigitalTensionControl Function Block

The purpose of the function block is to control the consistent film tension by the Altivar slave speed
between two digital sensors. The position of the tension arm is controlled and kept constant to
maintain constant film tension.
The position of tension arm is known with the help of two digital sensors:
 SensorArmDown
 SensorArmUp
The function block can be used for both modes, namely slave driven through surface roller and
slave driven axially.
Applications
The function block is applicable for:
 Horizontal bagging machine
 Vertical bagging machine
 Labeling machine

 Normally Diameter calculator requires filter for line speed and roll speed needs to be externally
added.
 Speed gradient is in range of 1 to 5000 RPM.
 Diameter calculation is done by the relation Dact (%) = Dmin (%) *(Line Speed (%) / Motor
Speed (%))
 Hardware (Sensors) Faults are not considered in the Program
 If the Task cycle time less than 5 ms, the velocity of the Slave axis can not be updated after
every scan. In this case, the velocity command to the Slave axis is updated after 3 scans.
NOTE: The tension control function is suitable for a continuous film feeding machine.
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Functional View
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Machine Overview
Purpose
During the film unwinding operation, the arm tends to go towards the SensorArmDown sensor
located at down position (see the machine view figure). The goal of this application function block
template is to maintain the tension of the film between two limits, and this is achieved by controlling
the position of the tension arm.
Sychronization Process
This application function block provides the synchronization between a slave axis (typically the film
roller "machine view figure: motor M1") and a master axis (the pulling film or feeder "machine view
figure: motor M2) with the help of digital sensors. Based on digital sensor inputs, the angular
velocity will be varied to maintaining the position of the tension arm between the two sensors.
This application function block commands the speed of an axis as slave coupled to a master axis.
The master axis can be a physical or virtual axis.
Roll Diameter Control

Since the roll diameter decreases as material unwinds, the linear speed of the film will decrease.
Hence, the slave axis needs to speed up to maintain the constant linear speed.
When the SensorArmDown or SensorArmUp is activated, the function block adjusts the angular
velocity of the roller to maintain the position of tension arm between the sensors which in turn
maintain the film tension.
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Machine View
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Horizontal Bagging Machine

This figure shows a horizontal bagging machine in which the function block can be used for tension
control:
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Section 4.2
Architecture
Architecture

Topic Page
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This figure shows a hardware architecture:
Environment
Based on the axes configuration the DigitalTensionControlATV has the following types of
architecture:
Master Slave Sensor Wiring

Lexium (LXM) on Altivar (ATV) on to the Logic Controller through a digital input module
CANopen CANopen (embedded, expansion or external)
Based on the axes configuration the DigitalTensionControlATV_Motion has the following

types of architecture:

Lexium (LXM) on Altivar (ATV) on to the Motion Controller through a digital input module
 CANmotion or CANopen (embedded, expansion or external)
 Sercos
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Axial Driven
The slave axis is driven directly from the axis.
Surface Driven
The slave axis is driven directly from the surface.
NOTE: The function block is applicable only for Altivar drives as slave.
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DataFlow Overview
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Section 4.3
DigitalTensionControl Function Blocks
Pin Diagram of DigitalTensionControlATV
Pin Diagram of DigitalTensionControlATV_Motion

In a packaging process, the packaging system must be equipped with an efficient tension control
system to ensure that there is a smooth unwinding of the film reel. There must be constant tension
on the film reel when it is unwound. The function block controls the speed of the slave axis, relative
to the master axis to maintain the constant tension on the web.
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Operating Modes
The function block works in two different modes:
 Slave driven through surface roller
 Slave driven axially
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Section 4.4
Pin Description
Pin Description

Topic Page
Input: i_stDiaActl 119
Input: i_stUnwd 121
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Input DataType Description

i_xEn BOOL TRUE: Enables function block and parameters are validated
FALSE: Disables function block and all outputs are set to zero
i_xSenUp BOOL TRUE: Arm up sensor sensed.
If the input is active, the arm is at up position.
It means that the slave speed is less than the master speed,
the slave speed will be increased by the correction factor.
Refer to i_dwCycl (see page 118)
i_xSenDown BOOL TRUE: Arm down sensor sensed.
If the input is active, the arm is at down position. It means that
slave speed is more than master speed, slave speed will be
decreased by the correction factor.
Refer to i_dwCycl (see page 118)
i_rMotRollDia REAL Motor roll diameter (surface roller)
Range: 1.0...2000.0 mm
This parameter will be used only when the surface driven
(i_xSurfMode) mode is selected.
Refer to film roll setup (see page 118) figure
i_rSpdGdnt REAL Speed gradient
Range: 1.0...5000.0 RPM
Speed Gradient input parameter with which the slave speed
will be corrected to maintain the constant tension on the film.
i_dwCycl DWORD Task execution time for speed correction
Range: 1...1000 ms
i_rLineSpd REAL Actual line speed
Range: 0.0...DiaAct.i_rLineSpdMax in m/min
i_xSurfMode BOOL TRUE: Surface driven
FALSE: Axial driven
Driven mode must be selected only while function block is
disabled.
Mode change is not allowed.
i_stDiaActl DiaAct Structure for diameter calculation
Refer to i_stDiaActl (see page 119) description.
i_stUnwd Unwd Structure for unwinder details
Refer to i_stUnwd (see page 121) description.
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Film Roll Setup
Input: i_rSpdGdnt
Slave Axis Speed increase or decrease are calculated based on this value. The Speed correction
is done only if the sensor is active for 60 seconds.
Example:
1000 RPM needs to be decreased or increased according the sensor arm position. For details,
refer below for i_dwCycl description.
Input: i_dwCycl
For effective speed correction, this input should be same as the Target cycle time. This parameter
decides the speed correction per scan.
Example:
i_rSpdGdnt = 1000 RPM and i_dwCycl = 10 ms, then Speed Correction = (1000/60000)*10 =
0.166 revolutions will be added or subtracted from the slave speed.
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Input: i_stDiaActl
Description
This structure is used for the diameter calculation.
When the machine is started with a new film roll, its actual diameter needs to be entered in
i_stDiaActl.rDia and i_stDiaActl.xDiaSet needs to be set TRUE.
Then initially, the slave will start with the speed as per the entered diameter.
Speed ratio (i_stDiaActl.rSpdRto) is the gearing factor for the slave motor. If gear is not used,
set the i_stDiaActl.rSpdRto to 1.0.
NOTE: Whenever the slave speed (actual speed of the drive) is below i_stDiaActl.rSpdMin
and actual Line speed is below i_stDiaActl.rLineSpdMin, then the actual diameter
calculation will stop.
Mathematical Background
Example
If the line speed is 50 % (250 m/min) of the maximum speed (500 m/min), the minimum diameter
is 10 % (100 mm of the maximum diameter (1000 mm) and the un-winder speed is 40 % (636.94
RPM) of the maximum un-winder speed (1592.35 RPM))
Un-winder speed (Max) = (1* 500*1000) / (3.14* 100) = 1592.35 RPM.
Where Speed Ratio = 1, Line Speed (Max) = 500 m/min, Minimum Diameter = (100 mm).
Then the actual diameter value can be calculated as:
Diameter Actual (%) = (50*10)/40= 12.5% of the maximum diameter.
Diameter Actual (mm) = (250)/(3.14*636.94) = 0.125 m = 125 mm
NOTE: i_rLineSpdMax structure parameter is common for surface and axial mode, other
structure parameters of i_stDiaActl are used only for the axial driven mode. The reset of the
diameter calculation in axial driven mode is mandatory in case the film reel is changed. This will be
executed by resetting the internal state machine of the function block by disabling and enabling the
function block.
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Structured Parameters
Structured Data Type Description

Parameter
i_rDiaMin REAL Minimum diameter value
Range: 1.0...i_rDiaMax in mm
i_rDiaMax REAL Maximum diameter value
Range: 1.0...10000.0 mm
i_xDiaSet BOOL TRUE: Set diameter
i_rDia REAL Set diameter value
Range: i_rDiaMin...i_rDiaMax in mm
i_rSpdMin REAL Minimum slave speed to calculate the diameter
Range: 1.0...100.0 RPM
i_rLineSpdMin REAL Minimum line speed to calculate diameter
Range: 1.0...100.0 m/min
i_rLineSpdMax REAL Maximum line speed
Range: 1.0...1000.0 m/min
NOTE: The axis status of the drives can be read via using PLCopen FB (MC_ReadStatus_ATV
& MC_ReadStatus_LXM or MC_ReadStatus). Before starting the machine in axial driven mode,
actual diameter value of unwinder roll (i_stDiaActl.rDia) must be passed to the function block
and this value will be accepted only on the rising edge of i_stDiaActl.xDiaSet.
If the real diameter of the roll is much greater than the parameter setting more material might be
unwound after first cycles and film tension may be too low.
If the real diameter of the roll is much smaller than the parameter setting less material might be
unwound after first cycles and film tension may be too high.
The film might tear or the tension arm might be pulled by the tightened film into its mechanical end
position.
NOTICE
INCORRECT DIAMETER SETTINGS
Be sure that the actual diameter value of the un-winder roll is established (i_stDiaAct1.rDia)
before starting the machine in axial driven mode.
Failure to follow these instructions can result in equipment damage.
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Input: i_stUnwd
Description
This structure is used for setting the following unwinding parameters:
 acceleration time (i_stUnwd.diAcc)
 deceleration time (i_stUnwd.diDec)
 unwinder minimum diameter (i_stUnwd.rUnwdDiaMin) to initiate notification
 time for detecting the film end (i_stUnwd.dwFilmTimeEnd) when the sensor arm is down
The speed ratio (i_rSpdRto) is the ratio to calculate the slave speed in surface driven mode.
Structured Parameters
Structured Parameter Data Type Description

rSpdRto REAL Ratio to calculate to slave speed
Range: 0.01...100.0
diAcc DINT Acceleration time for the slave
Range: 1...6000
Unit: x X Sec
Remarks: X scaling factor
diDec DINT Deceleration time for the slave
Range: 1...6000
Unit: x X Sec
Remarks: X scaling factor
rUnwdDiaMin REAL Minimum diameter to initiate notification
Range: 1.0...300.0 mm
dwFilmTimeEnd DWORD Wait time for film end notification
Range: 1...10000 ms
NOTE: i_stUnwd.diAcc and i_stUnwd.diDec scaling factor (X) is in the drive parameter
setting. Factory setting is 0.1. If i_stUnwd.diAcc is 100 s, then drive interpreted time is 10 s.
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Input/Output Pins of DigitalTensionControlATV

iq_stAxisLxmMstr SEM_LXM.AXIS_REF_LXM Servo axis reference
structure
iq_stAxisAtvSlav SE_ATV.Axis_Ref_ATV ATV axis reference structure
Input/Output Pins of DigitalTensionControlATV_Motion

iq_stAxisLxmMstr SM3_Basic.AXIS_REF_SM3 Servo axis reference
structure
NOTE: The Master’s line speed is always interpreted as absolute value. The direction of rotation
for the Slave will not be changed by inverting the line speed of the Master.
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q_xEn BOOL TRUE: Function block enabled. If input i_xEn is
TRUE, then output q_xEn is TRUE.
q_xAlrm BOOL TRUE: Alarm detected
FALSE: No alarm
Remark: If true, after resetting detected alarm,
rising edge of i_xEn is required to restart the
function block.
q_uiAlrmId UINT 0: Okay
>0: Alarm detected
Range: 0, 1, 11, 12, 20, 30, 40, 101, 102, 116...127
Refer to detailed Notifications (see page 124)
description.
q_xFilmEnd BOOL TRUE: Film end
Remarks: Film end will trigger a notification.
Refer to detailed q_xFlmEnd (see page 123)
description.
q_xFilmStat BOOL TRUE: Min diameter reminder
FALSE: No reminder
q_sAlrmMsge STRING Status of function block display
Refer to detailed Notifications (see page 124)
description.
q_sAlrtMsge STRING Alert message display
Output: q_xFilmEnd
If the line speed is above dead band and if down sensor remains sensed for a predefined time
(i_stUnwd.dwFlmTimeEnd), then the output (q_xFlmEnd) is set TRUE.
NOTE: DeadBand has a constant value of 1.3 m/min in the function block. When the i_xSenDown
is FALSE, the q_sErrMsge will be reset.
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Notifications

0 Okay
11 Master axis alarm detected
12 Slave axis alarm detected
20 Invalid cycle time
30 PLCopen internal alarm detected
40 Incorrect sensor state
101 Invalid acceleration parameter
102 Invalid deceleration parameter
116 Invalid motor roll diameter limit parameter
117 Invalid speed gradient limit parameter
118 Invalid speed ratio value parameter
119 Invalid minimum unwinder diameter parameter
120 Invalid film end time parameter
121 Invalid minimum diameter value parameter
122 Invalid maximum diameter value parameter
123 Invalid set diameter value parameter
124 Invalid minimum unwinder speed value parameter
125 Invalid line speed value parameter
126 Invalid maximum line speed value parameter
127 Invalid minimum line speed value parameter
Alarm Messages
The following alarm message will be displayed as and when required:
"SLAVE POSITIVE FREQ LIMIT REACHED" - When the slave frequency reaches the maximum
frequency set in the drive.
"SLAVE MINIMUM FREQ LIMIT REACHED" - When the slave frequency reaches the minimum
frequency set in the drive.
"DIAMETER SETTING REQUIRED OR MINIMUM DIAMETER REACHED" - When internal
diameter is less than minimum diameter or diameter setting is not done.
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Section 4.5

Topic Page
Troubleshooting 132
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Visualization
This figure shows the HMI visualization for DigitalTensionControl function block:
NOTE: The calculation of the remaining, actual diameter of the unwinding film reel works sensor-
less and based therefore on a mathematical model.
Due to this the following factors describe the limiting effects on reliable results:
 The calculation requires a constant line speed of the film. If the digital tension control function
block is operated in intermittent mode no accurate values can be evaluated.
 In addition to a constant line speed a continuous movement of the unwinding Variable Speed
Drive (VSD) is necessary. As long as the VSD goes into standstill or a setpoint speed close to
0 Hz (high motor slip on asynchronous machines) during operation is caused to regulate the
tension, no appropriate value can be calculated.
 The first calculation of diameter results will be provided after the speed of the VSD has been
monitored and averaged over a certain period. How long this period will last depends on the
mechanical parameters (film reel diameter plus motor/gearbox configuration) and cannot be
given in an absolute time frame in general.
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Commissioning Procedure
This table describes the commissioning procedure for the DigitalTensionControl function
block:
Step Action
1 Add the supporting libraries into the application program:
 Load the Packaging Library for using the DigitalTensionControl
function block in your application.
2 Select the unwinding type:
 Surface driven (Surface Drv)
 Axial driven (Axial Drv)
3 Define the different input parameters for the DigitalTensionControl

function block from the visualization screen.
Refer to:
 mandatory inputs (see page 128) and parameter example
(see page 130) for surface-driven mode and
 mandatory inputs (see page 129) and parameter example
(see page 131) for axial-driven mode.
4 Define the speed of the master and power on the master.
5 Power on the slave drive and enable the DigitalTensionControl
block.
6 If axial-driven mode is selected, set the initial diameter by pressing Set
Diameter once.
7 Start the master in velocity mode.
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Mandatory Inputs in Surface-Driven Mode

The following inputs are mandatory in surface-driven mode:
Input Description
i_xEn Enable or disable the function block
i_xSenUp Sensor arm up sensor is to be connected here.
i_xSenDown Sensor arm down sensor is to be connected here.
i_rMotRollDia The motor roll diameter in terms of millimeter
i_rSpdGdnt The parameter with which the slave speed will be
corrected to maintain the constant tension on the Film.
Example:
i_rSpdGdnt is 1000 RPM and i_dwCycl is 10 ms,
then Speed Correction = (1000 /60000)*10 => 0.166
revolutions will be added to or subtracted from the
slave speed as per SensorArmUp or SensorArmDown
signal.
i_dwCycl Target execution time for speed correction
i_rLineSpd Actual line speed of machine in meters per minute
i_xSurfMode If TRUE then Surface Driven mode is selected
i_stUnwd.rSpdRto Ratio to calculate slave speed
i_stUnwd.diAcc Acceleration time for the slave
i_stUnwd.diDec Deceleration time for the slave
i_stUnwd.rUnwdDiaMin Minimum diameter to raise notification
i_stUnwd.dwFilmTimeEnd Wait time for film end notification
i_stDiaActl.rLineSpdMax Maximum line speed limit
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Mandatory Inputs in Axial-Driven Mode

The following inputs are mandatory in axial-driven mode:
Input Description
i_xEn Enable or disable the function block
i_xSenUp Sensor arm up sensor is to be connected here.
i_xSenDown Sensor arm down sensor is to be connected here.
i_rSpdGdnt The parameter with which the slave speed will be
corrected to maintain the constant tension on the film
i_dwCycl Target execution time for speed correction
i_rLineSpd Actual line speed of machine in meters per minute
i_xSurfMode If FALSE then Axial Driven mode is selected.
i_stUnwdr.rSpdRto Ratio to calculate slave speed
i_stUnwd.diAcc Acceleration time for the slave
i_stUnwd.diDec Deceleration time for the slave
i_stUnwd.rUnwdDiaMin Minimum diameter to raise notification
i_stUnwd.dwFilmTimeEnd Wait time for film end notification
i_stDiaActl.rDiaMin Minimum diameter value
i_stDiaActl.rDiaMax Maximum diameter value
i_stDiaActl.xDiaSet To set the diameter initially
i_stDiaActl.rDia Set diameter value
i_stDiaActl.rSpdMin Minimum slave speed to calculate diameter
i_stDiaActl.rLineSpdMin Minimum line speed to calculate diameter
i_stDiaActl.rLineSpdMax Maximum line speed limit
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Parameter Example for Surface-Driven Mode

This table shows a parameterization example of the function block in surface-driven mode:
Input Description
i_xEn TRUE
i_xSenUp TRUE
i_xSenDown FALSE
i_rMotRollDia 200.00 mm
i_rSpdGdnt 100.00 RPM
i_dwCycl 10 ms
i_xSurfMode TRUE
i_stUnwd.rSpdRto 5
i_stUnwd.diAcc 100 s
i_stUnwd.diDec 100 s
i_stUnwd.rUnwdDiaMin 100.00 mm
i_stUnwd.dwFilmTimeEnd 10000 ms
i_stDiaActl.rLineSpdMax 300.00 m/min
i_stDiaActl.rLineSpdMin 10.00 m/min
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Parameter Example for Axial-Driven Mode

This table shows a parameterization example of the function block in axial-driven mode:
Input Description
i_xEn TRUE
i_xSenUp TRUE
i_xSenDown FALSE
i_rMotRollDia 200.00 mm
i_rSpdGdnt 100.00 RPM
i_dwCycl 5 ms
i_xSurfMode FALSE
i_stUnwd.rSpdRto 5
i_stUnwd.diAcc 100 s
i_stUnwd.diDec 100 s
i_stUnwd.rUnwdDiaMin 100.00 mm
i_stUnwd.dwFilmTimeEnd 10000 ms
i_stDiaActl.rLineSpdMax 300.00 m/min
i_stDiaActl.rLineSpdMin 10.00 m/min
i_stDiaActl.rDiaMin 50.00 mm
i_stDiaActl.rDiaMax 1000.00 mm
i_stDiaActl.rDiaSet TRUE
i_stDiaActl.rDia 900.00 mm
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Troubleshooting
Troubleshooting
This table describes some general issues and their solutions:

Error detected at output Invalid parameter or drive 1. Verify the detected error ID and read the
error detected corresponding notification.
System not responding Invalid value Restart the function block.
Slave not responding Due to CANopen bus traffic / Disable the function block, power off master, slave
PLCopen function block error and restart the system.
detected
Slave axis unwinds too LSP setting is above set point Reduce LSP settings or adjust value to 0.0 Hz.
much material. speed
Slave axis doesn’t stop, LSP setting is above set point Reduce LSP settings or adjust value to 0.0 Hz.
even if set point speed
frequency is 0.0 Hz.
Altivar VSD parameters are Verify the Altivar CHCF parameter for the correct
not properly set setting: command and reference must not be
separated.
Slave frequency doesn’t Changing of axial/surface On the fly mode change is not allowed. For
follow the master. driven mode on the fly. accepting the new drive mode, restart the function
block again.
q_uiAlrmId = 1 Internal alarm detected Restart the function block.
q_uiAlrmId = 11 Master axis alarm detected Verify axis power.
q_uiAlrmId = 12 Slave axis alarm detected Verify axis power.
q_uiAlrmId = 20 Invalid cycle time Verify that the i_dwCycl parameter is within the
specified range.
q_uiAlrmId = 30 PLCopen alarm detected Reset the function block. Give the power cycle to
the controller if a detected error remains.
q_uiAlrmId = 40 Incorrect sensor state Verify that the sensor setup parameter is done
according to the physical configuration on the
machine.
q_uiAlrmId = 101 Invalid acceleration Verify that the acceleration parameter is within the
parameter specified range.
q_uiAlrmId = 102 Invalid deceleration Verify that the deceleration parameter is within the
parameter specified range.
q_uiAlrmId = 116 Invalid motor roll diameter Verify that the
limit parameter i_rMotRollDia
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q_uiAlrmId = 117 Invalid speed gradient limit Verify that the
parameter i_rSpdGdnt parameter is within the specified
range.
q_uiAlrmId = 118 Invalid speed ratio value Verify that the
parameter i_stUnWd.rSpdRto parameter is within the
specified range.
q_uiAlrmId = 119 Invalid minimum unwinder Verify that the
diameter parameter i_stUnWd.rUnwdDiaMin parameter is within the
specified range.
q_uiAlrmId = 120 Invalid film end time Verify that the
parameter i_stUnwd.dwTimeFilmEnd parameter is within
the specified range.
q_uiAlrmId = 121 Invalid minimum diameter Verify that the i_stDiaActl.rDiaMin
value parameter parameter is within the specified range.
q_uiAlrmId = 122 Invalid maximum diameter Verify that the
value parameter i_stDiaActl.rDiaMax parameter is within the
specified range.
q_uiAlrmId = 123 Invalid Set Diameter value Verify that the
parameter i_stDiaActl.rDia parameter is within the
specified range.
q_uiAlrmId = 124 Invalid minimum unwinder Verify that the i_stDiaActl.rSpdMin
speed value parameter parameter is within the specified range.
q_uiAlrmId = 125 Invalid line speed value Verify that the i_rLineSpd parameter is within
parameter the specified range.
q_uiAlrmId = 126 Invalid maximum line speed Verify that the i_stUnwd.rLineSpdMax
value limit parameter parameter is within the specified range.
q_uiAlrmId = 127 Invalid minimum line speed Verify that the i_stUnwd.rLineSpdMin
value limit parameter parameter is within the specified range.
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SoMachine
AnalogTensionControl
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Chapter 5
AnalogTensionControl: Controlling Consistent Film Tension Depending on Analog Sensor Feedback
AnalogTensionControl: Controlling Consistent Film

Tension Depending on Analog Sensor Feedback
Overview
This chapter describes the following function blocks:
 AnalogTensionControlATV
 AnalogTensionControlLXM_Motion
 AnalogTensionControlATV_Motion

Section Topic Page
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Section 5.1

Topic Page
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Functional Overview
Analog tension control makes use of an analog sensor to provide tension feedback to the control
system. The linear speed of the film is determined by the Master axis. Analog feedback from a film
tension sensor is used to adjust the slave axis speed to maintain the desired film tension.
Compatibility
The Function Block is applicable to the following types of packaging machines:
 Labeling machine
NOTE: FB_PID is necessary to use with analog tension control applications.

NOTE: Master axis is not controlled by this function block
Solution With the AnalogTensionControl Function Block

The function block controls the velocity of unwinder.
The function block works as a variable gear box between the master and the unwinder. The
unwinder axis unwinds the film roll in packaging machines.
FB_PID can be used to take tension sensor feedback and generate the variable gear ratio for this
function block.
Design & Realization Constraints and Assumption

1. The configuration of OTB on CANopen is not part of these function blocks. It is assumed that
application developer will do the required configuration and read the analog value of tension
sensor.
2. It is assumed that application developer will do the scaling of analog value of tension sensor and
set point if required.
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Functional View
The function block calculates the velocity of a feeder according to the film velocity and the dancer
position of the unwinder axis.
Depending on the machine, the motor can be located directly on the shaft of the feeder. This
means a large diameter of the roller has a low velocity, whereas a small diameter has a high
velocity.
If the diameter of the roller is not measured by using a dedicated sensor in this the average
diameter of the roller can be specified. The velocity must be completely regulated using the dancer,
from the largest diameter to the smallest diameter.
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Machine Overview
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Section 5.2
Architecture
Architecture

Topic Page
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The figure shows the hardware architecture with a Logic Controller, servo drive and a variable
speed drive on CANopen.
The figure shows the hardware architecture with a Motion Controller, servo drive on CANmotion or
Sercos and a variable speed drive on CANopen.
The figure shows the hardware architecture with a Motion Controller and servor drives on
CANmotion or Sercos.
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Hardware Environments
This table describes the architecture types based on the axes configuration of the AnalogTen-
sionControlATV function block:

Lexium (LXM) on Altivar (ATV) on to the Logic Controller through an
CANopen CANopen  analog input module (embedded, expansion or external)
or
 analog input on drives
This table describes the architecture types based on the axis configuration of the
AnalogTensionControlATV_Motion function block:

Lexium (LXM) on Altivar (ATV) on to the Motion Controller through an
 CANmotion or CANopen  analog input module (embedded, expansion or external)
 Sercos
or
This table describes the architecture types based on the axis configuration of the
AnalogTensionControlLXM_Motion function block:

Lexium (LXM) on Lexium (LXM) on to the Motion Controller through an
 CANmotion or  CANmotion or  analog input module (embedded, expansion or external)
 Sercos  Sercos
or
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DataFlow Overview
In analog tension control, actual tension is measured by a tension sensor which is an analog input
in the form of voltage (0-10 V) or current (0-20 mA, 4-20 mA).
The function block acts as a variable gear box between master and slave axis.
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Section 5.3
AnalogTensionControl Function Blocks
Pin Diagram of AnalogTensionControlATV
Pin Diagram of AnalogTensionControlATV_Motion
Pin Diagram of AnalogTensionControlLXM_Motion
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During operation, the Slave axis follows the Master according to the calculated gear ratio. If there
is any detected parameter error or drive error, then the function block decelerates the Slave axis
to stop and indicates the detected error status and error message.
NOTE: If the Gear Ratio is high, there can be unwanted movement in the Slave Axis even if the
Master Axis appears to be at standstill. This is due to the nonzero instantaneous feedback values
from the Master Axis.
Slave velocity = (master velocity * gear ratio).
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Section 5.4
Pin Description
Pin Description

Topic Page
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The following table describes the input pin description for AnalogTensionControlATV:

i_xEn BOOL TRUE: Enables function block and parameters are
validated.
FALSE: Disables function block and all outputs are set
to zero.
i_xCnstGrMode BOOL TRUE: Gear ratio = i_rCnstGr
FALSE: Gear ratio= (i_rDeltGr * i_rIputCtrl) +
i_rGearOfSt
i_rIputCtrl REAL This pin accepts variable gear ratio.
Range: <=0
PID output will be connected to this input.
i_rCnstGr REAL (*) Gear ratio between master axis and slave axis when
i_xCnstGrMode is TRUE.
i_rDeltGr REAL Scaling factor applicable when i_xCnstGrMode is
FALSE.
-1 <= i_rDeltGr < 0 and 0 < i_rDeltGr <= 1.0
Factory setting: 0.1
0.0 is not allowed.
i_rGearOfSt REAL (*) Offset factor applicable when i_xCnstGrMode is
FALSE.
Example: If i_rIputCtrl = 1.5, i_rDeltGr = 0.8
and i_rGearOfst = 2.0, then Gear ratio =
(1.5*0.8) + 2 = 3.2
i_diAccLim DINT The acceleration limit is used to limit the acceleration
(AnalogTensionControlATV) when the control input (i_rIputCtrl) changes
according to step function. This will help to reduce stress
on the mechanical system of the machine. This
parameter is applicable to slave axis.
Range: 0...6000 (multiplied by X)
Factory setting: 10
X depends on the drive parameter (Inr) of ramp
increment (x0.01, x0.1 or x1)
Unit: s
* Optional according to applicable mode
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i_diDecLim DINT A deceleration ramp or braking ramp can be set
(AnalogTensionControlATV) independently of one another using ramp-down time.
This allows a controlled movement of axis when the
control input (i_rIputCtrl) is changed.
Factory setting: 10
Unit: s
0 < i_rDecLim <= 6000 x X s ; Factory setting: 100
Unit: RPM/s
* Optional according to applicable mode
The following table describes the input pin description for motion blocks:

i_rAccLim REAL The acceleration limit is used to limit the
(AnalogTensionControlLXM_Motion) acceleration when the control input
(i_rIputCtrl) changes according to step
function. This will help to reduce stress on the
mechanical system of the machine. This
0 < i_rAccLim; Factory setting: 100
Unit: RPM/s
i_rDecLim REAL A deceleration ramp or braking ramp can be set
(AnalogTensionControlLXM_Motion) independently of one another using ramp-down
time. This allows a controlled movement of axis
when the control input (i_rIputCtrl) is
changed.
0 < i_rDecLim; Factory setting: 100
Unit: RPM/s
i_diAccLim DINT The acceleration limit is used to limit the
(AnalogTensionControlATV_Motion) acceleration when the control input
(i_rIputCtrl) changes according to step
function. This will help to reduce stress on the
mechanical system of the machine. This
Factory setting: 10
Unit: s
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i_diDecLim DINT A deceleration ramp or braking ramp can be set
(AnalogTensionControlATV_Motion) independently of one another using ramp-down
time. This allows a controlled movement of axis
when the control input (i_rIputCtrl) is
changed.
Factory setting: 10
Unit: s
NOTE: i_rIputCtrl, i_rDeltGr and i_rGearOfSt is applicable only when i_xCnstGrMode

= FALSE. To reset a detected error, a rising edge of i_xEn is required.
NOTE: i_diAccLim and i_diDecLim scaling factor (X) is in the drive parameter setting. Factory
setting is 0.1. Incase i_diAccLim is a value of 100, then drive interpreted time is 10.0 s.
NOTE: To change from Auto Gear mode to Fixed Gear mode and vice versa is possible by using
the input i_xCnstGrMode.
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Input/Output Pins of AnalogTensionControlATV

iq_stAxisLxmMstr SEM_LXM.AXIS_REF_LXM Servo axis reference
structure
NOTE: Both described In/Outputs are mandatory because these inputs link the function block to
the controlled axis.
Input/Output Pins of AnalogTensionControlLXM_Motion

structure
iq_stAxisLxmSlav SM3_Basic.AXIS_REF_SM3 Servo axis reference
structure
Input/Output Pins of AnalogTensionControlATV_Motion

structure
iq_stAxisAtvSlav SE_ATV.Axis_Ref_ATV Servo axis reference
structure
NOTE: The Master’s line speed is always interpreted as absolute value. The direction of rotation
for the Slave will not be changed by inverting the line speed of the Master.
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This table describes the output pins of the AnalogTensionControlATV function block:

q_xEn BOOL TRUE: function block enabled. If input i_xEn is
q_xBusy BOOL TRUE: Function block active and no alarm detected
FALSE: Function block disabled or alarm detected
q_xAlrm BOOL TRUE: Function block detects alarm
FALSE: No alarm detected
q_uiAlrmId UINT Notification when detected alarm output is set.
Refer to Notification (see page 151).
q_sAlrmMsge STRING Notification
q_sAlrtMsge STRING Alert message
This shows the alert message pertaining to slave axis
but does not stop the axis.
Alert message ’Slave frequency limit reached’.
NOTE: "Slave Maximum Frequency Reached" alarm is generated as soon as the command
frequency goes beyond the nominal frequency of the slave axis.
NOTE: The LSP and HSP of the slave axis should be taken into consideration and modified as per
the requirement of the application. It is recommended to set LSP value to 0.0 Hz.
Notifications
This table describes the detected alarm IDs and notifications of the function block:

0 Okay
11 Master axis alarm detected
12 Slave axis alarm detected
30 PLCopen internal alarm detected
31 PLCopen command aborted
108 Invalid gear ratio parameter
110 Invalid acceleration and deceleration parameter
111 Invalid gear ratio calculation parameter
(Only AnalogTensionControlLMX_Motion)
112 Invalid delta gear ratio parameter
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Section 5.5

Topic Page
Troubleshooting 156
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Visualization
This figure shows a visualization for the AnalogTensionControlATV function block:
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This table describes the steps for configuring the AnalogTensionControlATV function block:
Step Action
1 Add the Toolbox library into the application program.
2 Load the FB_PID from Toolbox library and AnalogTensionControlATV
function block in your application.
3 Verify that each CANopen Manager, Master and Slave axis have different node
numbers and same baud rate.
4 Define the different input parameters for the AnalogTensionControlATV
function block from SoMachine Visualization screen or from HMI.
Refer to:
 parameterizing in fixed gear mode
 parameterizing in auto gear mode
5 Power on the Master axis and enter its speed.

6 Power on the Slave axis and enable the AnalogTensionControlATV
function block.
7 Start the master in velocity mode.
Parameterizing in Fixed Gear Mode

This table describes the applicable parameters in fixed gear mode:
Input Description Example

i_xEn Enables function block TRUE
i_xCnstGrMode Enables fixed gear mode TRUE
i_rCnstGr Value of fix gear ratio 2.0
i_diAccLim Value of acceleration 10
Unit: xX sec
i_diDecLim Value of deceleration 10
Unit: xX sec
iq_stAxisLxmMstr Specify Master axis in function block
iq_stAxisAtvSlav Specify Slave axis in function block
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Parameterizing in Auto Gear Mode

This table describes the applicable parameter values in fixed gear mode:
Input Description Example

i_xEn Enables function block TRUE
i_xCnstGrMode Enables fixed gear mode FALSE
i_rIputCtrl Tension sensor feedback 1.0
i_rDeltGr Value of delta gear 0.2
i_rGearOfst Value of offset gear ratio 1.00
i_diAccLim Value of acceleration 10
Unit: xX sec
i_diDecLim Value of deceleration 10
Unit: xX sec
iq_stAxisLxmMstr Specify Master axis in function block
iq_stAxisAtvSlav Specify Slave axis in function block
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Troubleshooting
Troubleshooting

Alarm is raised Invalid parameter or drive alarm Please verify the detected alarm ID and read the
detected corresponding notification.
Slave not responding Due to CANopen bus traffic / Disable the function block, switch power off
PLCopen function block detected Master, Slave and restart the system.
alarm
System not responding Possible invalid value Disable and enable the function block.
Slave axis unwinds too LSP setting is above set point speed Reduce LSP settings or adjust value to 0.0 Hz.
much material.
Slave axis unwinds less HSP setting is below set point speed Increase HSP setting
material.
Slave axis doesn’t stops, LSP setting is above set point speed Reduce LSP settings or adjust value to 0.0 Hz.
even if set point
Altivar parameters are not properly set Verify the Altivar CHCF parameter for the correct
frequency is 0.0 Hz setting: command and reference must not be
separated.
q_uiAlrmId = 1 Internal alarm detected Reset the function block.
q_uiAlrmId = 11 Master axis alarm detected Verify for detected alarm in Master axis.
q_uiAlrmId = 12 Slave axis alarm detected Verify for alarms in Slave axis.
q_uiAlrmId = 30 PLCopen internal alarm detected Reset the function block. Give the power cycle to
the controller if a detected alarm remains.
q_uiAlrmId = 31 PLCopen command aborted Reset the axis.
q_uiAlrmId = 108 Invalid variable gear ratio parameter Verify the parameter i_rIputCtrl is in the
specified range.
q_uiAlrmId = 110 Invalid acceleration and deceleration Verify the parameter i_diAccLim / i_rAccLim
parameter and i_diDecLim / i_rDecLim are in the
specified range.
q_uiAlrmId = 112 Invalid delta gear ratio parameter. Verify the parameter i_rDeltGr is in the
specified range.
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TemperatureControl
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TemperatureControl
TemperatureControl
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TemperatureControl
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Chapter 6
TemperatureControl: Monitoring and Controlling of Temperature-Dependent Packaging Processes
TemperatureControl: Monitoring and Controlling of

Temperature-Dependent Packaging Processes
Overview
This chapter explains the functionality and implementation of the TemperatureControl function
block in the packaging industry.

Section Topic Page
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Section 6.1

Topic Page
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Functional Overview
Why Use the TemperatureControl Function Block?

The Packaging machines require precise temperature control. For more accurate control of
temperature, Proportional, Integral and Derivative functions (PID) should be applied.
The TemperatureControl function block incorporates a PID control algorithm for more accurate
temperature control in packaging machines.
Solution with the TemperatureControl Function Block

The TemperatureControl function block is equipped with an AutoTuning algorithm to find the
initial parameters for PID loop. The temperature can be effectively controlled by the PID control
algorithm when the AutoTuning fixes the parameters.
TemperatureControl uses FB_PID to generate the control value. FB_PID is equipped with an
anti reset windup which holds the integral component when PID output reaches the maximum limit.
NOTE: The TemperatureControl function block was developed for heating purpose only.
Application
The TemperatureControl function block is applicable to the following machines:
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Functional View
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Machine Overview
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Section 6.2
Architecture
Architecture

Topic Page
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The FB_PID function block operates according to the transfer function:
The SetPointGenerator generates "SetPoint1" (temperature setting point) and "SetPoint2"

(standby set value). Internally it uses a RampGenerator to ramp the setpoint.
The PWM function block transforms FB_PID output into a pulse train with a constant period by
modulating the pulse width. Optionally, digital filters are used to reduce the noise in the process
value.
The AutoTuning function block operates on the Ziegler-Nichols inflectional tangent method. This
function block evaluates the process and provides calculated parameters to the FB_PID function
block.
DataFlow Overview
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Section 6.3
TemperatureControl Function
Pin Diagram

The TemperatureControl function block is designed for monitoring and controlling a wide
variety of temperature dependant processes. It includes the functionality of AutoTuning and the
FB_PID function block with anti-reset windup.
The function block has three modes of operation:
 Automatic mode (closed loop with PID control or OnOff control)
 Manual mode (open loop)
 Auto tuning mode
In Automatic mode, the control output is generated by FB_PID.

In Manual mode, the control output is the desired value entered by you.
In Autotuning mode, only the autotuning function is executed and all other function except the filters
are disabled.
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Temperature Measurement
A thermocouple or a resistance thermometer (for example, Pt100) is used to measure the process
temperature. The set value for the FB_PID function block is limited by SetPoint high and low value,
and it can be ramped optionally. The control output is available in the form of an analog output and
a PWM output.
AutoTuning Algorithm
The AutoTuning algorithm is based on the Ziegler-Nichols inflectional tangent method. With this
method, the maximum response rate and dead time of the process is calculated. After calculating
the time constant, the PID parameters are calculated. There are different monitoring parameters
which conditions can be monitored as follows:
 Temperature Low Low
 Temperature Low
 Temperature High High
 Temperature High
Integrated Sub Functions

The TemperatureControl function has the following integrated sub functions:
 AutoTuning
 Digital Filter
 PWM
Auto Tuning
 Functional Description
AutoTuning once enabled disables the PID action or output from the Process.
A step signal is applied through AutoTuning the process value will be sampled and checked for
the steady state by comparing the process value stability within tolerance limits.
Once the process value reaches the steady state, then the dead time, delay time and the
response rate are calculated.
Based on these values the PID parameters are calculated. These PID values calculated through
AutoTuning can be accepted / rejected for executing the PID.
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 Time Constant Function

This figure shows AutoTuning calculating the time constant:
 PID Parameter Calculation

The PID parameters Kp, Tn and Tv will be calculated by the conditions measured during
autotuning phase.
PID Parameters Formula

Kp 0.60 [TimeConstant/(Dead Time*Ks)]
Tn 1.00 * TimeConstant
Tv 0.50 * TimeConstant
Digital Filter
This function incorporates the functionality of digital filter to reduce the noise at the input.
PWM
The internal PWM Heating function generates pulse width modulation output (q_xPwm) based on
the FB_PID output and FB_PID maximum limit.
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TemperatureControl
This figure shows the timing diagram for the PWM Heating function block:
NOTE: If time period = 5 s and PID output is 20 % (PID high limit = 100) then the q_xPwm is high
for 1 s and low for 4 s.
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Section 6.4
Pin Description
Pin Description

Topic Page
Input: i_stPid 173
Input: i_stTempCtrl 177
Output: q_sAttnStat 183
Output: q_stPid 184
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i_xEn BOOL TRUE: Enables function block and parameters
(All modes) are validated.
FALSE: Disables function block and all outputs
are set to zero
i_xExe BOOL TRUE: Accepts new input parameters at the rising
edge.
FALSE: Does not accept new input parameters.
i_xSpSel BOOL(*) TRUE: Selects i_rSp2
(Auto and Manual FALSE: Selects i_rSp1
modes)
i_rSp1 REAL Value of the actual SetPoint1. The actual setpoint
(Auto and Manual is the temperature that needs to be maintained in
modes) the system.
Range: i_rLowSp...i_rHighSp
Factory setting: 0.0 user temperature unit
i_rSp2 REAL(*) Value of SetPoint 2 in standby mode. The standby
(Auto and Manual setpoint is used to reduce the temperature of the
modes) system when the actual temperature control
operation is not running.
Range: i_rLowSp...i_rSp1
i_rPv REAL Temperature value from the process.
(Auto and Manual Range: 0.0 .. 3.4 e+38
modes)
i_xAlrmRst BOOL This pin is used to reset the detected errors. To
(Auto and Manual perform the reset you have to change the
modes) parameter value which caused the detected error
and then initiate a rising edge at this pin. After
reset, the rising edge of i_xExe is not required to
accept the parameter change.
TRUE: Detected error is reset on rising edge
FALSE: Detected error is not reset
i_stTempCtrl stTempCtrl Includes various parameters needed for
temperature control
Refer to i_stTempCtrl (see page 177) table.
i_stPid PidParameters Includes all the PID parameters
Refer to i_stPid (see page 173) table.
(*) Optional, according to the applicable mode.
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Input: i_stPid
Input: i_stPid
This structured input consists of PID and AutoTuning parameters. This table describes the input
details:
Structure Parameter Data Type Description

xHold BOOL (*) TRUE: Holds the FB_PID action.
(Auto and Manual modes) FALSE: Resumes the FB_PID action.
rKp REAL Proportional Gain for heating or hysteresis value if On
(Auto mode) Off Control is active.
Range: 0.0...3.4e+38
rTn REAL Integral time for heating
(Auto mode) Range: 0.0...3.4e+38 s
Factory setting:152
rTv REAL Derivative time for heating
(Auto mode) Range: 0.0...3.4e+38 s
Factory setting: 32
rTd REAL Damping time for heating
(Auto mode) Range: CycleTime...3.4e+38 s
Factory setting: 3
xManMode BOOL(*) TRUE: Enables Manual mode
(Manual mode) FALSE: Disables Manual mode
rManVal REAL(*) Manual mode PID output

(Manual mode) Range: 0...rHighLim
rTargCyclTime REAL Cycle time of controller
(All modes) Range: 0...60000 ms
Factory setting: 20 ms
rLowLim REAL Low limit of FB_PID output. This value is generally
(Auto and Manual modes) configured to the analog output module specifications.
Range: 0.0...less than rHighLim
rHighLim REAL High limit of FB_PID output. This value is generally
(Auto and Manual modes) configured to the analog output module specifications.
Range: Greater than rLowLim...3.4e+38
rInerWdo REAL Inner window for reduced I-part
(Auto and Manual modes) Range: 0.0...less than rOterwdo
rOterWdo REAL Outer window for disabling I-part
(Auto and Manual modes) Range: Greater than rInerWdo...3.4e+38
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rDbnd REAL(*) Deadband for detected error and is generally used to
(Auto mode) make the PID output to settle down.
Range: 0.0...100.0
NOTE: Any deadband value higher than 0 negatively
influences the precision of temperature control.
xAttn BOOL(*) TRUE: Enables AutoTuning
(Auto tuning mode) FALSE: Disables AutoTuning
Range: 0...1
rTnce REAL Tolerance value for checking the initial steady state to
enter Auto tuning procedure.
Range: 0...3.4e+38
uiCycl UINT Number of cycles to a sample the process value during
Auto Tuning
Range: 0...65535
xAcptPara BOOL(*) TRUE: Accepts new PID parameters given by
(Auto tuning mode) AutoTuning.
FALSE: No action
xRjctPara BOOL(*) TRUE: Rejects new PID parameters given by
(Auto tuning mode) AutoTuning.
FALSE: No action
xOnOffCtrl BOOL TRUE: OnOff control is active.
NOTE: If xOnOffCtrl is TRUE, the rKp parameter
become the hystersis value.
tPwmTimePrd TIME In time period for PWM, the heater remains steadily
switched on as the process temperature is below the set
point temperature.
Range: i_stPid.rTarg...4194967295 ms
Factory setting: 5 s
rPwmTimeOnMin REAL If this pin has been set to at least 1 ms, the binary output
will be switched on for at least this time. The controller
will still attempt to keep to the defined PWM cycle time,
but the minimum rPwnMinOnTime will have priority.
Range: 0...4194967295 s
Factory setting: 0.0 s
rPwmTimeOnMax REAL If this pin has been set to less than tPwmTimePeriod,
the binary output will be switched on for at least this time.
Range: 0...4194967295 s
Factory setting: 5.0 s
(*) Optional, according to the applicable mode.
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 rKp: The proportional term of PID changes the output proportional to process error. The
proportional output is adjusted by multiplying the process error with gain Kp. The value of gain
is defined at the pin rKp.
 rTn: The integral term contribution to PID output is proportional to both the magnitude of
process error and duration of process error. Integral term will sum the process error over time
(Integrate the process error).The integrated value of process error is divided by integral time.
The magnitude of integral output is adjusted by Proportional gain. The value of integral time is
defined in variable rTn.
 rTv: Derivative term determines the rate of change of process error over time and multiplying
it with derivative time is the derivative output. The derivative term output is adjusted by
derivative time. The value of derivative time is defined at the pin rTv.
NOTE: The value of Td should not be less than cycletime. If it is less than cycletime then Td
value will be overwritten with the value of cycletime. Parameters uiCycl or rTargCyclTime
have an influence on the calculated results of the PID parameters. If parameters uiCycl or
rTargCyclTime will be changed afterwards a new execution of the AutoTuning process is
mandatory.
 rInerWdo: If the absolute value of the process error is less than rInerWdo then integral
calculations are scaled by factor [ABS (process error value) / Inner Window]. The process error
value is the difference between the setpoint and the actual process value. If process error value
is greater than rInerWdo and less than rOterWdo, normal integral calculations are performed.
This window slows down the change in FB_PID output caused by integral part.
Process error value = Set Point - Process value
 rOterWdo: If the absolute value of the process error is greater than rOterWdo, integral
calculations are stopped and integral output is held at the last value. This prevents the integral
part from winding up too high and helps to avoid overshoot and oscillation of the controlled
system.
Example: With rInerWdo=10 and rOterWdo=200.
If Setpoint=250 and Process value=100, then process error value=150 and it is within the range
mentioned by window parameters, so normal integral calculation is executed.
If Setpoint=250 and Process value=245, then process error value=5 and it is less than
rInerWdo, so integral calculation is scaled.
If Setpoint=250 and Process value=30, then process error value=220 which is above
rOterWdo, so integral calculation is hold with the previous value.
NOTE: The rInerWdo and rOterWdo parameters should not be configured to have the same
value. If these parameters values are configured equally, then the FB will generate a
configuration error. The corresponding Error ID is 16 and the notification is INVALID I WINDOW
PARAMETER.
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 i_xAcptPara,i_xRjctPara: These inputs are used to accept or reject the PID parameters
calculated by the AutoTuning function block. To accept the parameters, you have to enable
i_xAcptPara followed by a rising edge signal on the i_xExe pin. Then the FB_PID function
block will generate an output based on the new PID parameters.
To reject the parameters, enable the i_xRjctPara pin followed by the rising edge signal on
the i_xExe pin.The FB_PID function block will generate an output based on the PID
parameters provided by the user.
NOTE: Once the parameters are accepted, the PID function block uses the new parameters
calculated by Auto Tuning function block. After this if for any other parameter change,
execute rising edge is given then PID will use parameters provided through i_stPid.rKp,
i_stPid.rTn, i_stPid.rTv.
xOnOffCtrl
If xOnOffCtrl is true, the PID is ignored and the control output of the heater system is based on
On Off control. The Kp parameter became the hysteresis of On Off control.
An On Off control function acts like a thermostat. If the process is below the setpoint, it closes the
output contact, and the heating runs at full power. If the setpoint is reached, the power is set to 0%,
i.e switched off. If the process value now falls, when it goes below the level (setpoint minus
switching differential hysteresis), the output will be switched on again.
If a On Off control is operated in a first order process, then the heating is switched on if the actual
temperature of the system is less than the setpoint. Since there is only one component to store the
heater energy, the temperature will instantly start to rise. If the setpoint is reached, the power is set
to 0%, i.e. switched off, and the process value will not go above the setpoint.
Theoretically, the process value instantly starts to fall and after a certain time it will have fallen to
the lower switching point.
The heating is switched on again, and the process value starts to rise again. In the first order
process, the process value moves within the band defined by the switching differential. The
switching frequency is higher and the controlled becomes faster as the hysteresis is set smaller.
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Input: i_stTempCtrl
Input: i_stTempCtrl
This structured input consists of function block parameters other than PID and AutoTuning:

rSpHigh REAL High limit for setpoint
(Auto mode) Range: > rSpLow2...3.4e+38 user temperature unit
rSpLow REAL Low limit for setpoint
(Auto mode) Range: 0.0...rSpHigh user temperature unit
xStup BOOL(*) TRUE: Enables startup function
(Manual mode) FALSE: Disables startup function
rStupVal REAL(*) Percentage of output to the process when startup

(Manual mode) function is enabled
Range: 0.0...100.0%
Factory setting: 0.0 %
tStupTime TIME(*) Startup function active for this time
(Manual mode) Range: 0...4194967295 ms
Factory setting: 0 ms
xRampEn BOOL(*) TRUE: Enables RampGenerator
(Auto mode) FALSE: Disables RampGenerator
rRampGdntRise REAL(*) Value in temperature units/s of ramping time from

(Auto mode) a lower value to high value
Range: 1.0...i_rSp1 or 1.0...i_rSp2 if i_xSelSp
is TRUE.
Factory setting: 0.0 degree per second
rRampGdntFall REAL(*) Value in temperature units/s of ramping time from
(Auto mode) a higher value to low value.
Range: 1.0...i_rSp1 or 1.0...i_rSp2 if i_xSelSp
is TRUE.
Factory setting: 0.0 degree per second
rFltrTime REAL Filter Time for the Digital Filter (Noise reduction) in
ms. If no value is given the filter is not activated.
Range: 0.0...3.4e+38
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rTempLow REAL Low value of temperature in inner band given in
(Auto and user temperature unit. This limit is related to the
Manual modes) actual setpoint and represents the delta below the
setpoint value.
Example: If i_rSp1=100 degree and
rTempLow=10 degree then the low temperature
limit will be 90 degree.
Range: 0.0...rTempLL
rCnst REAL The constant for the Digital Filter (Noise reduction)
is without any unit. The filter is deactivated if no
value given for rFltrTime.
Increasing of rCnst will reduce noise level but will
slow down the change rate of the filtered process
value.
Range: 1.0...3.4e+38
rTempLL REAL Low (LL) value of temperature in outer band given
(Auto and in user temperature unit. This limit is related to the
Manual mode) actual setpoint and represents the LL delta below
the setpoint value.
rTempLow=20 degree then the low temperature
limit will be 80 degree.
Range: r_TempLow...3.4e+38
rTempHigh REAL High value of temperature in outer band given in
(Auto and user temperature unit. This limit is related to the
Manual mode) actual setpoint and represents the delta above the
setpoint value.
rTempHigh=10 degree then the high (HH)
temperature limit will be 110 degree.
Range: 0.0..rTempHH
rTempHH REAL High (HH) value of temperature in outer band given
(Auto and in user temperature unit. This limit is related to the
Manual mode) actual setpoint and represents the HH delta above
the setpoint value.
rTempHH=20 degree then the high (HH)
temperature limit will be 120 degree.
Range: rTempHigh...3.4e+38
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xAlrtSel2 BOOL TRUE: The function block will confirm the value of
TempAbsLow and rTempAbsHigh.
FALSE:The function block will confirm the value of
rTempAbsLow.
The value of rTempAbsLow and rTempAbsHigh
is Alarm 1 and Alarm 2 in the visualization.
rTempAbsLow REAL Low value of absolute temperature
(Auto and Range: 0.0...3.4e+38 user temperature unit
Manual mode)
rTempAbsHigh REAL High value of absolute temperature
(Auto and Range: 0.0...3.4e+38 user temperature unit
Manual mode)
(*)
Optional, according to the applicable mode.
NOTE: User temperature units can be in Celsius, Fahrenheit, or Kelvin.

rSpHigh, rSpLow
These values decide the range of i_rSp1. These values will be decided with the minimum and
maximum temperature which can be applied to the process, so that it acts as a safeguard to stop
the temperature from increasing or decreasing than the desired limits.
xStup, tStupTime
xStup enables the startup function. When this is enabled the percentage of output mentioned in
rStupVal is applied to the process till tStupTime. This functionality is used at the initial stage to
maintain the temperature at lower level before the actual setpoint is effective. During the startup
function FB_PID is in manual mode.
rRampGdntRise, rRampGdntFall
These pins are used for RampGenerator function. RampGenerator changes its internal setpoint
from any present value at the input of i_rPv until the selected setpoint, given by i_rSp1 or
i_rSp2 is reached. The value is incremented/decremented once per second by rRampGdntRise
for increasing ramp or rRampGdntFall for decreasing ramp.
Ramping functionality is used to increase or decrease the set point gradually so that there will not
be sudden increase or decrease in the control value.
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TemperatureControl

q_xEn BOOL TRUE: Function block enabled, if input i_xEn is
q_rAna REAL Analog form of FB_PID output
Range: i_rPidHighLim...i_rPidLowLim
q_xPwm BOOL This is the digital form of FB_PID output
TRUE: PWMHeating output high
FALSE: PWMHeating output low
q_xAlrm BOOL TRUE: Alarm detected in temperature control
FALSE: No alarm detected (factory setting)
q_uiAlrtId UINT This gives the alert status of TemperatureControl
function block and the unique number for alert.
Range: [1...10]
Factory setting: 0
q_xAlrt BOOL TRUE: Presence of alert in temperature control
FALSE: No alerts (factory setting)
q_uiAlrmId UINT Gives unique notification for detected alarms.
Range: [0...340]
Factory setting: 0
q_sAlrmMsge STRING Displays the notification according to the detected
alarm ID.
q_sAlrtMsge STRING Displays the alert message according to the alert ID.
q_sAttnStat STRING This is the string output which gives the status
message of the Auto Tuning process.
Refer to structured output q_sAttnStat
(see page 183) table.
factory setting string: Inactive
q_iAttnStat INT This gives the AutoTuning status.
Range: 0...8
Factory setting: 0
q_stPid stNewPmts This structured input includes the PID parameters
calculated by Auto Tuning.
Refer to structured output q_stPid (see page 184)
table.
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TemperatureControl
Notifications
This structured output provides the detected alarm status of TemperatureControl function
block:
Detected Notification
Alarm ID
0 Okay
1 INTERNAL ALARM
20 INVALID CYCLETIME
115 INVALID DEADBAND VALUE
200 INVALID PID PARAMETER
202 INVALID I WINDOW PARAMETER
203 INVALID PID LIMIT PARAM
204 ALL PID PARAMETERS ARE ZERO
300 PWM TIME PERIOD INVALID
301 PWM MINIMUM ONTIME INVALID
302 PWM MAXIMUM ONTIME INVALID
310 RAMP GDNT RISE GREATER THAN SP1 OR SP2 OR EQUAL TO ZERO
311 RAMP GDNT FALL GREATER THAN SP1 OR SP2 OR EQUAL TO ZERO
320 SETPOINT HIGH LIMIT VALUE LESS THAN LOW SETPOINT
322 STARTUP TIME INVALID
323 STARTUP VALUE INVALID
331 TEMP LOWLOW VALUE INVALID
332 TEMP HIGH VALUE INVALID
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TemperatureControl
Alert Messages
This structured output provides the alert status of TemperatureControl function block:
Alert ID Alert Message

1 SETPOINT1 GREATER THAN HIGH SETPOINT
2 SETPOINT1 LESS THAN LOW SETPOINT
3 SETPOINT2 GREATER THAN SETPOINT1 OR LESS
THAN LOW SETPOINT
4 TEMP ABS LOW AND HIGH VALUES INVALID
5 ABSOLUTE TEMPERATURE LOW
6 ABSOLUTE TEMPERATURE HIGH
7 TEMPERATURE LOW LOW
8 TEMPERATURE LOW
9 TEMPERATURE HIGH
10 TEMPERATURE HIGH HIGH
11 STARTUP FUNCTION CANNOT BE ENABLED AT
THIS TIME.
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TemperatureControl
Output: q_sAttnStat
Output: q_sAttnStat
This is the string output which gives the status message of the AutoTuning process:
q_iAttnStat q_sAttnStat Description

0 NO ERROR DETECTED AutoTuning is checking the steady
1 FB ERROR DETECTED AutoTuning is not running due to detected
AUTOTUNING COULD FB error
NOT PROCEED
2 CHECKING THE STEADY AutoTuning is checking the steady state of
STATE process before going to apply step output to
the process
3 TIME OUT Process is not in steady state
4 WAIT AutoTuning is calculating the PID
parameters
5 CANCELLED New steady state not reached
6 READY AutoTuning has calculated the PID
parameters
7 OK The new PID parameters are accepted by
the user
8 PARAMETERS ARE NOT The new PID parameters are rejected by
ACCEPTED the user
NOTE: If the status message is displayed as "CANCELLED" and "TIME OUT", then to restart
AutoTuning, you have to disable and enable the FB.
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TemperatureControl
Output: q_stPid
Output: q_stPid
This structured output includes the PID parameters calculated by AutoTuning. The structure details
are explained in the given table:

rKp REAL Value of proportional gain calculated by AutoTuning
Range: 0.0...3.4e+38
rTn REAL Value of integral time calculated by AutoTuning
Range: 0.0...3.4e+38
Scaling/unit: s
rTv REAL Value of derivative time calculated by AutoTuning
Range: 0.0...3.4e+38
Scaling/unit: s
NOTE: In the event of a detected error, the function block will be initialized. To execute the function
block again, correct the detected error and enable i_xRst.
Structure elements i_stPid.uiCycl or i_stPid.rTargCyclTime have an influence on the
calculated results of the PID parameters. If parameters uiCycl or rTargCyclTime will be
changed afterwards a new execution of the AutoTuning process is mandatory.
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TemperatureControl
Section 6.5

Topic Page
Internal Process Diagram 190
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TemperatureControl
Introduction
In the following figures, you will see the visualization of the function block in the software:
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TemperatureControl
Commissioning Procedure
This table describes the quick commissioning procedure for the TemperatureControl function
block:
Step Action
1 Add the Packaging Library into the application program.
2 Load the TemperatureControl function block in your application.
3 Enter all parameters in the controller configuration.
4 Connect to the function block input i_rPv the variable assigned to the temperature sensor.
5 Connect the function block output q_xPwm to the variable assigned to the heater module.
6 Enable the function block with i_xEn.
7 Enable AutoTuning with parameter i_stPid.xAttn.
8 Accept all new inputs with a rising edge signal on i_xExe.
9 AutoTuning is running. The status must be verified at the output q_iAttnStat and
q_sAttnStat.
10 After AutoTuning has calculated the PID parameter (state 6), you have to accept
(i_stPid.xAcptPara) or reject (i_stPid.xRjctPara) them, followed by a rising edge
signal on the i_xExe pin.
11 Disable the parameter i_stPid.xAttn and i_stPid.xAcptPara.
12 After verification of the Auto Tuning result, use the calculated PID parameter at q_stPid as the
input parameter for i_stPid.
NOTE: For commissioning, it is helpful to use the function block visualization and also to create a
trace with the parameter i_rSp1, i_rPv, q_rAna and q_xPwm.
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TemperatureControl
Parameterizing
This table lists the input parameters to be entered:

i_xSpSel FALSE
i_rSp1 145
i_rSp2 120
i_stTempCtrl.xAlrtSel2 TRUE
i_stTempCtrl.rSpHigh 200
i_stTempCtrl.rSpLow 20
i_stTempCtrl.xStup FALSE
i_stTempCtrl.rStupVal 0
i_stTempCtrl.tStupTime 0
i_stTempCtrl.xRampEn FALSE
i_stTempCtrl.rRampGdntRise 1
i_stTempCtrl.rRampGdntFall 1
i_stTempCtrl.rFltrTime 0
i_stTempCtrl.rCnst 1
i_stTempCtrl.rTempLow 5
i_stTempCtrl.rTempLL 10
i_stTempCtrl.rTempHigh 5
i_stTempCtrl.rTempHH 10
i_stTempCtrl.rTempAbsLow 10
i_stTempCtrl.rTempAbsHigh 180
i_stPid.xHold FALSE
i_stPid.xOnOffCtrl FALSE
i_stPid.rKp 8
i_stPid.rTn 152
i_stPid.rTd 3
i_stPid.xManMode FALSE
i_stPid.rManVal 0
i_stPid.rTargCyclTime 20
i_stPid.rLowLim 0
i_stPid.rHighLim 100
i_stPid.rInerWdow 0
i_stPid.rOterWdow 0
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TemperatureControl

i_stPid.rDbnd 0
i_stPid.uiCycl 200
i_stPid.rTnce 10
i_stPid.xAcptPara FALSE
i_stPid.xRjctPara FALSE
i_stPid.tPwmTimePrd 10 000
i_stPid.rPwmTimeOnMin 0
i_stPid.rPwmTimeOnMax 10
NOTE: The values above were tested under laboratory conditions and are for illustrative purposes
It is important that the task cycletime is given to i_stPid.rTargCyclTime. Otherwise, the
calculation of the PID output will be imprecise (I-part).
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TemperatureControl
Internal Process Diagram
Execution Order of TemperatureControl Function Block

This figure shows the execution order of internal functions in TemperatureControl function
block:
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SoMachine
LateralPositionControl
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Part V
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SoMachine
EIO0000000195 06/2015
Chapter 7
LateralPositionControl: Controlling Correct Lateral Film Position with Two Digital Sensors
LateralPositionControl: Controlling Correct Lateral Film

Position with Two Digital Sensors
Overview
This chapter describes the LateralPositionControl function block.

Section Topic Page
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Section 7.1
Functional Overview
Why Use the LateralPositionControl Function Block ?

When the film reel is unwound, there is a possibility of a lateral shift in position due to uneven
thickness of the film or inconsistent speed and tension variation.
The function block checks the lateral shift and corrects the film position.
Lateral film position correction is required to:
 Avoid a film break-up,
 Have a constant product quality,
 Help increase the cutting accuracy by keeping the print mark detection under the photo cell.
Solution with the LateralPositionControl Function Block

The function block reads film sensor inputs from the field. It checks the sensors’ status and
generates control outputs (digital or analog) to command the movement of film to its correct
position.

Constraints
1. The function block does not consider the inoperable state of sensors; it is assumed that sensors
are always in healthy state.
2. The function block allows any change in input parameters, as well as the operating mode on the
fly. However any errors caused due to this will not be handled by the function block.
Assumptions
1. Sensor inputs are active high when the sensor is detecting the film directly above/below it..
2. A positive value of q_rOputAna output will move the film leftwards and likewise a negative
value of q_rOputAna will move the film rightwards.
Application
In packaging machines LateralPositionControl function block verifies the correct lateral
position of the film.
The function block is applicable to the following types of packaging machines:
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Functional View
This figure shows the LateralPositionControl function block generating digital outputs:
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This figure shows the LateralPositionControl function block generating analog outputs:
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Section 7.2
Architecture
Architecture
DataFlow Overview
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Section 7.3

Topic Page
LateralPositionControl Function Block 199
Automatic Mode 201
Managing Detected Errors 204
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LateralPositionControl Function Block
Pin Diagram

LateralPositionControl system consists of film position sensors and digital or analog
actuators (variable speed drives) to control movement of the film reel.
The function block has two operating modes:
 Automatic
 Manual
The output of the function block can be selected to:

 Digital or
 Analog
NOTE: The operating modes as well as the output modes can be changed on-the-fly.
Manual Inputs
In Manual mode with no detected error, manual input i_xManLeftMove is used to control the left
movement of the film. Similarly, manual input i_xManRighMove is used to control right movement
of the film.
NOTE: In Manual mode if both i_xManRighMove and i_xManLeftMove are TRUE, then
i_xManRighMove is given priority. In Automatic mode, the manual inputs are ignored and only
sensor inputs are taken into account.
Lateral Position of Film

Position sensors feed in the current position of the film reel. Based upon this feedback, the function
block activates the digital actuators via digital outputs or the analog actuator (example: Altivar
variable speed drive) via analog output through CANopen to correct the lateral position of film.
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Position Configuration
The function block support 3 sensor position configurations.
This figure shows symmetrically placed sensors:
This figure shows asymmetrically places sensors:
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Automatic Mode
De-bouncing
In Automatic mode of operation, to avoid the sensor signals bouncing due to film vibration, the
signals are continuously monitored for inactivity for a time greater than
i_stCmdPara.dwTimeWait before the position correction outputs (q_xFilmLeftMove,
q_xFilmRighMove or q_rOputAna) are activated.
This diagram shows the timing diagram for digital output:
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Digital Output
While operating in Automatic mode with digital outputs, film position has to be corrected within
i_stCmdPara.dwTimePosCorr time. If correction is not achieved, the function block displays
timeout alarm. The value of i_stCmdPara.dwPosCorrTime must be set greater than zero in
Automatic mode.
In Manual mode, the i_stCmdPara.dwPosCorrTime value can be set to zero to disable the
functionality.
NOTE: The value of the i_stCmdPara.dwRampTime must be set greater than zero in Automatic
mode. If it is not configured greater than zero, then function block detects an error.
Analog Output
The analog output (q_rOputAna) from the function block follows a ramp with
i_stCmdPara.dwRampTime as the ramp time and i_stCmdPara.rOputAnaMax as maximum
attainable value. To command left movement, q_rOputAna is positive and to command right
movement, it is negative.
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This timing diagram is for analog output:
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Managing Detected Errors
Description
Errors detected inside the function block are displayed at the output pin q_xAlrm.
Additionally, the notification ID will be set at the output pin q_uiAlrmld to indicate the type of error
detected.
Detected errors are acknowledged with the falling edge of i_xEn input.
An unacknowledged detected error resets all outputs.
Symmetric Sensor External Error Detected

Both sensors are inactive as shown in the figure below.
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Asymmetric Sensor External Error Detected

If both sensors are inactive, so there will be left movement of the film. When the film is moving
leftwards and the left sensor signal becomes active without right sensor becoming active first.
If both sensors are inactive, so there will be right movement of the film. When the film is moving
rightwards and the right sensor signal becomes active without left sensor becoming active first.
NOTE: The LateralPositionControl function block allows changes in control parameters

while it is enabled. But it is recommended not to explicitly do so on-the-fly this may result in
incorrect operation.
NOTICE
MISFEEDS CAUSING MATERIAL DAMAGE
You must ensure that the sensor placement configuration matches the mechanical system.
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Section 7.4
Pin Description
Pin Description

Topic Page
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i_xEn BOOL TRUE: Enables function block and parameters
are validated.
FALSE: Disables function block and all outputs
are set to zero(factory setting)
i_xAutoMode BOOL Selects between Automatic and Manual modes.
TRUE: Corrects automatically the lateral
position of the film depending upon the feedback
from the 2 sensors.
FALSE: The adjustment of the film position is
achieved through input pins i_xManLeftMove
and i_xManRighMove.(factory setting)
i_xSenLeft BOOL Left sensor Input
(*)Auto
mode FALSE: No input
TRUE: Active high input from sensor
i_xSenRigh BOOL Right sensor input
(*)
Auto mode TRUE: Active high input from sensor
FALSE: No input
i_xManLeftMove BOOL Manual move command to move the film left
(*)Manual
mode without checking the sensor feedback.
TRUE: Move left command
FALSE: No command
i_xManRighMove BOOL Manual move command to move the film right
(*)
Manual mode without checking the sensor feedback.
TRUE: Move right command
FALSE: No command
i_stCmdPara CmdParameterFilmPos Includes various control parameters for sensor
position, output selction and position correction.
Refer to the structured input
CmdParameterFilmPos (see page 208).
(*)
Optional according to the application mode
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Input: CmdParameterFilmPos
This table describes the CmdParameterFilmPos structured input:
Structure Element Data Type Description

xOputAnaMode BOOL Selects between analog and digital output.
TRUE: The function block corrects the film
position via an analog output q_rOputAna.
FALSE: The function block corrects the film
position via digital outputs q_xFilmLeftMove
and q_xFilmRighMove.
xSenPosSym BOOL Selects between the two types of sensor position
(*)
Auto mode configuration.
TRUE: Sensors placed at both sides of the film.
FALSE: Both sensors placed at the same side of
the film.
xSenPosLeft BOOL If xSenPosSym = FALSE, this parameter will
(*)
Auto mode select which side of the film sensors are placed.
TRUE: Sensors located on left.
FALSE: Sensors located on right.
rOputAnaMax REAL Maximum generated value of the analog output at
(*)Auto
mode the function block output q_rOputAna
Range: 0.0...1e32.
dwTimePosCorr DWORD Time to correct the position of film.
(*)Auto mode Range: 0...4294967295 ms.
0: Functionality is disabled. Not allowed in Auto
mode with digital outputs.
dwRampTime DWORD Represents the time in which q_rOputAna
(*)
Auto mode should achieve the maximum analog output.
Range: 0...4294967295 ms.
0: Functionality is disabled. Not allowed in Auto
mode with analog output.
dwTimeWait DWORD Represents the time in which the sensor signal is
(*)
Auto mode inactive to start the position correction.
Range: 0...4294967295 ms.
(*)
Optional according to the application mode
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q_xEn BOOL TRUE: Function block enabled if input i_xEn is
q_xFilmLeftMove BOOL Output to the left actuator
TRUE: ON
FALSE: OFF
q_xFilmRighMove BOOL Output to the right actuator
TRUE: ON
FALSE: OFF
q_rOputAna REAL Value of analog output.
Range: - i_stCmdPara.rOputAnaMax...
+ i_stCmdPara.rOputAnaMax
q_xTmot BOOL This pin will be set when operating in Automatic
mode with:
 digital outputs and film position is not
corrected within the specified time,
i_stCmdPara.dwPosCorrTime
 analog output and the film position is not
corrected within the specified ramp time
i_stCmdPara.dwRampTime.
TRUE: Error detected
FALSE: Ok
q_xAlrm BOOL Indicates that a detected alarm has occurred
inside the block
TRUE: Alarm detected
FALSE: Ok
q_uiAlrmId UINT Displays the notification number when the
detected alarm output is set, see table
q_uiAlrmId and q_sAlrmMsge.
q_sAlrmMsge STRING(40) Displays the function block notification message
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Notifications
Detected Alarm ID Notification Description

0 Okay Function block is in healthy state
1 Internal alarm Function block in unknown state
detected
40 External alarm Incorrect state or positioning of sensors
detected
70 Time-out alarm Indicates a timeout when film position is not
detected corrected within the specified time in Automatic
mode.
100 Invalid For example: input parameter values to the
parameter function block are out of range.
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Section 7.5

Topic Page
Commissioning Procedure in Manual Mode 214
Commissioning Procedure in Auto Mode With Symmetric Sensors 215
Commissioning Procedure in Auto Mode and Left Placed Sensors 217
Commissioning Procedure in Auto Mode and Right Placed Sensors 219
Troubleshooting 221
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Visualization
This figure shows the visualization of the LateralPositionControl function block:
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Commissioning Procedure Overview

This table explains the procedure on how to configure the LateralPositionControl function
block:
Step Action
1 Add the Packaging.library in the library manager.
2 Load the LateralPositionControl function block from Packaging library
included in your application.
3 Determine the type of sensor position configuration.
4 Connect the outputs to the corresponding output fields.
5 Perform a sensor input test.
6 Start the system.
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Commissioning Procedure in Manual Mode
Running in Manual Mode

To run the LateralPositionControl function block in Manual mode, configure the following
parameters:
 i_xEn = TRUE,
 i_xAutoMode = FALSE.
Performing a Right Move

To perform a right move operation make
i_xManRighMove = TRUE.
The lateral position of film starts moving to the right side while i_xManRighMove is TRUE.
When i_xManRighMove = FALSE, the movement of lateral position of the film is stopped.
Performing a Left Move

To perform a left move operation make
i_xManLeftMove = TRUE.
The lateral position of film starts moving to the left side while i_xManLeftMove is TRUE.
When i_xManLeftMove = FALSE, the movement of lateral position of the film is stopped.
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Commissioning Procedure in Auto Mode With Symmetric Sensors
Symmetric sensors configuration with digital output

To execute the function block in symmetric sensors configuration, configure the following
parameters:
 i_stCmdPara.xSenPosSym = TRUE,
 i_stCmdPara.xOputAnaMode = FALSE,
 i_stCmdPara.dwTimePosCorr = 5000ms,
 i_stCmdPara.dwTimeWait = 3000ms.
This figure shows the visualization for the above configuration:
Then enable the function block.

In this configuration, both i_xSenRigh and i_xSenLeft should be always TRUE . If any of the
sensor i_xSenRigh or i_xSenLeft is FALSE, then after i_stCmdPara.dwTimeWait the
lateral position of the film is moved to the corresponding side by enabling q_xFilmLeftMove or
q_xFilmRighMove.
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Symmetric sensors configuration with analog output

To execute the function block in symmetric sensors configuration, configure the following
parameters:
 i_stCmdPara.xSenPosSym = TRUE,
 i_stCmdPara.xOputAnaMode = TRUE,
 i_stCmdPara.dwTimeWait = 3000ms,
 i_stCmdPara.dwRampTime = 5000ms,
 i_stCmdPara.rOputAnaMax = 10.0.
This figure shows the visualization for the configuration:

In this configuration both i_xSenRigh and i_xSenLeft should be always TRUE. If any of the
sensor i_xSenRigh or i_xSenLeft is FALSE, then after i_stCmdPara.dwTimeWait the
lateral position of the film is moved to the corresponding side by providing analog output through
q_rOputAna.
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Commissioning Procedure in Auto Mode and Left Placed Sensors
Asymmetric left placed sensors configuration with digital output

To execute the function block in asymmetric left sensors configuration, configure the following
parameters:
 i_stCmdPara.xSenPosSym = FALSE,
 i_stCmdPara.xSenPosLeft = TRUE,

In this configuration i_xSenRigh should be TRUE and i_xSenLeft should be FALSE.
If i_xSenRigh is FALSE, then after i_stCmdPara.dwTimeWait function block will enable
q_xFilmLeftMove. If both the sensors are TRUE, then after i_stCmdPara.dwTimeWait
function block will enable q_xFilmRighMove.
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Asymmetric left placed sensors configuration with analog output

To execute the function block in asymmetric left placed sensors configuration, configure the
following parameters:
 i_stCmdPara.xSenPosLeft = TRUE,
 i_stCmdPara.dwRampTime = 5000ms.

If i_xSenRigh is FALSE, then after i_stCmdPara.dwTimeWait function block will provide
analog output through q_rOputAna. In this case, the value of q_rOputAna is positive to move
the lateral position of the film in left side.
If both the sensors are TRUE, then function block will provide analog output through q_rOputAna.
In this case, the value of q_rOputAna is negative to move the lateral position of the film in right
side.
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Commissioning Procedure in Auto Mode and Right Placed Sensors
Asymmetric right placed sensors configuration with digital output

To execute the function block in asymmetric right placed sensors configuration, configure the
 i_stCmdPara.xSenPosLeft = FALSE,
 i_stCmdPara.xOputAnaMode = FALSE,

If i_xSenRigh is FALSE, then after i_stCmdPara.dwTimeWait function block will provide
analog output through q_rOputAna. In this case, the value of q_rOputAna is positive to move
the lateral position of the film in left side.
In this case, the value of q_rOputAna is negative to move the lateral position of the film in right
side.
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Asymmetric right placed sensors configuration with analog output

To execute the function block in asymmetric right placed sensors configuration, configure the
 i_stCmdPara.xSenPosLeft = FALSE,
 i_stCmdPara.dwTimeWait = 3000ms,
 i_stCmdPara.dwRampTime = 5000ms,

In this configuration i_xSenRigh should be FALSE and i_xSenLeft should be TRUE.
If i_xSenLeft is FALSE, then after i_stCmdPara.dwTimeWait function block will provide
analog output through q_rOputAna. In this case, the value of q_rOputAna is negative to move
the lateral position of the film in right side.
In this case, the value of q_rOputAna is positive to move the lateral position of the film in left side.
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Troubleshooting
Troubleshooting
This table shows some general issues and their solutions:

No sensor feedback Inoperative sensors Inoperative sensors will not be detected
by the function block. The user must
verify that the sensors are always in
good condition.
Unpredictable Parameter change on-the-fly You should avoid in this case to
behavior leading to explicitly change the control parameters
improper position of function block without disabling the
correction function block. To do so, disable the
function block, feed new parameter
values and then re-enable the function
block.
q_uiAlrmld = 1 Internal alarm detected Restart the function block.
q_uiAlrmld = 70 Alarm detected due to q_xTmot 1. Change the input parameters
(i_stCmdPara.dwPosCorrTime for
digital output mode or
i_stCmdPara.dwRampTime for
analog output mode) to suitable values.
q_uiAlrmld = 100 Parameters such as Configure the value of parameters
i_stCmdPara.dwPosCorrTime, greater than zero.
i_stCmdPara.dwRampTime,
i_stCmdPara.dwWaitTime,
i_stCmdPara.rAnaOputMax is
configured less than zero or equal to zero
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RotaryKnife
RotaryKnife
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Chapter 8
RotaryKnife_Motion: Synchronization of a Linear Axis and a Rotary Axis to Perform On The Fly Operations
RotaryKnife_Motion: Synchronization of a Linear Axis

and a Rotary Axis to Perform On The Fly Operations

Section Topic Page
8.5 Operating Modes 251
8.6 Start, Stop and Starting Modes 262
8.7 Special Modes 278
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Section 8.1

Topic Page
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Functional Overview
Why Use the RotaryKnife_Motion Function Block?

The RotaryKnife_Motion function block controls a machine that performs operations on a
moving part.
Typical operations can include:
 Cutting
 Sealing
 Marking
Solution with the RotaryKnife_Motion Function Block?

The RotaryKnife_Motion function is required for moving the operational axis to synchronize it
with the forward motion of the part.
This introduces the concept of master and slave axis.
 Master: moves the part forward
 Slave: performs the operation
NOTE: Although the Rotary Knife function can be used for many different applications, the
examples shown in this document will refer to a typical cutting application.
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Machine Overview
Machine View
The figure below gives an example of a Rotary Knife application. Master axis is a linear axis type
whereas the axis slave is a rotary axis.
Rotary Knife
With the application function blocks it is possible to handle Multi Blade Rotary Knife. The condition
is to have equidistant knifes.
In this case the parameter lrPeri is defined as the distance between the blades.
Note
Please also refer to:
 Master Axis (see page 230)
 Slave Axis (see page 231)
 Cutting Tool (see page 231)
 Capture Position of the Product (see page 231)
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Section 8.2
Architecture
Architecture

Topic Page
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Master Axis
NOTE: This architecture is valid for the RotaryKnife_Motion and FlyingShear_Motion
function blocks.
The master axis moves a product forward continuously. It is an infinite axis.
The master axis can be of the following type:
 servo drive (Lexium) on CANmotion or Sercos
 any type of axis (Altivar or Lexium) coupled with a master encoder
 virtual axis
Example: Tube cutting

The forward motion of the tube is managed by the rolling mill and thus by the device which controls
it. Therefore the movement of this axis is not controlled by the RotaryKnife/FlyingShear functions.
The master and the slave axis can both be on CANmotion or Sercos.
Master and slave on CANmotion or Sercos
If the master axis is not a servo drive on the same CANmotion or Sercos as the slave, then the
position of the master is determined by an encoder signal connected to the input of the Motion
Controller:
Example of a master axis controlled with an Altivar via CANopen communication protocol
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Slave Axis
The slave axis has to be a servo drive on CANmotion/Sercos or stepper drive on CANmotion.
According to the length to cut (input i_lrLentoCut), the slave axis synchronizes itself with the
master, remains synchronized during the cut (or another operation) and finally returns to its resting
position (parameter lrPosRest) and/or continues with a new cut.
Synchronization may correspond to:
 A positioning of the slave in relation to the master according to the cutting point. This position is
defined as position 0 of the slave.
 A speed of the slave proportional to the speed of the master.
Cutting Tool
If needed, the knife starts its movement after the beginning of the synchronization phase (of the
master and the slave). It must have completed its movement before the end of synchronization
phase and return to its original position before a new cut is begun.
The movement of the cutting tool is managed by the application, rather than the
RotaryKnife_Motion/FlyingShear_Motion application function blocks. However, the
functions provide a "Beginning of Synchronization" signal (q_xInSync) which can be used by the
application to control the start of the cutting tool.
Capture Position of the Product

In certain applications the product is not continuous (e.g. individual parts to be labeled), or may not
be rigid which presents a possibility of stretching (e.g. plastic film). In these cases, a sensor is
placed on the master axis to capture the position of labels on the product.
Rotary Knife: Principle of operation sensor wiring
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Flying Shear: Principle of operation sensor wiring
Sensor Wiring
If... Then...
the master is the encoder the sensor may be wired to a Touch Probe input
input (TP1, TP2…) of the Motion Controller. The TP inputs
have an acquisition time of 30µs.
the master is a servo drive on the sensor may be wired to one of the capture inputs
CANmotion or Sercos bus of the drive. (See configuration of capture inputs in
documentation of the drive.)
The standard inputs of the Motion Controller can also be used. In this case however, the acquisition
time is related to the cycle time of the Motion Controller.
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Requirements for Configuration

NOTE: This architecture is valid for the RotaryKnife_Motion and FlyingShear_Motion
function blocks.
Configuration of the axes with the Motion Controller.
Master:
 Even if the master axis is considered to be a linear axis (e.g. a conveyor) being infinite, it
must nonetheless be configured as a modulo axis.
NOTICE
UNSATISFACTORY EQUIPMENT OPERATION
Set the modulo value higher than the maximum possible length to cut plus Touch Probe
distance to the synchronization point (greater than the sum of max i_lrLentoCut and
lrTpDistToSypt).
Slave:
 For Rotary Knife:
The slave axis has to be configured as a rotary axis.
 For Flying Shear:
The slave axis has to be configured as a linear axis.
NOTICE
UNSATISFACTORY EQUIPMENT OPERATION
Set the modulo value of the slave greater than or equal to than 2 times the distance between the
knife blades (perimeter) (greater than or equal to 2*lrPeri).
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The axis type and the modulo is configured in the device configuration.
Configuration of the Slave Axis Servo Drive.

In addition to the communication parameters (addresses on the bus, speed transmission), the
following parameter adjustments should be made to the drive in order to optimize the response of
the servo drive that controls the slave axis:
 increase the maximum slopes of acceleration and deceleration
 set the parameter N_ref_Filter to OFF
 various loop parameters. They include proportional gain speed loop, integral time speed loop
and the proportional gain position.
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Section 8.3
RotaryKnife_Motion Function Block
Pin Diagram
Profiles of Master/Slave Positions

The curves (see case 1 and 2) show the position profile of the slave axis in relation to the master
during the execution of the Rotary Knife function.
A Rotary Knife cycle consists of 3 phases:
Phase Description
Start Phase The slave accelerates up to the master velocity to be
synchronized at the beginning of the synchronous phase.
 The start phase distance on the slave is equal to:
Slave Start Phase Distance = ABS (lrPeri -lrPosRest)
 The start phase distance on the master can be calculated
with the following formula:
Master Start Phase Distance = (ABS (lrPeri -
lrPosRest) / lrM) * 1.875
Synchronous Phase The cut (or the operation) is performed. The synchronous phase
always starts with position 0 of the slave.
Return Phase The slave returns, makes a half-turn before it begins a new
synchronous phase.
Depending on the length to cut and the perimeter of the Rotary Knife different cases are to be
distinguished:
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At the end of the synchronous phase, the slave decelerates and enters a new synchronous phase
(see figure below).
At the end of the synchronous phase, the slave decelerates, stops at the resting position and
awaits a new cut position (see figure below).
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At the end of the synchronous phase, the slave accelerates to enter a new synchronous phase as
fast as possible (see figure below).
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The length to cut is equal to the perimeter of the knife (see figure below).
The distance covered by the master during this cycle corresponds to the length to cut
(i_lrLentoCut).
The distance covered by the slave during this cycle corresponds to the perimeter of the knife
(lrPeri).
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Backward Movement with a Rotary Knife

Depending upon the machine, a backward movement of the slave (Rotary Knife) is prohibited
during the synchronous phase therefore please pay attention to the following information:
Inside the synchronous phase, a backward movement of the slave is possible with the following
situations:
 If the master moves backward. In this case the slave will follow the master backward and stop
at 0. Do not move the master backward to avoid this situation.
 With warm start mode 1, 2, 4. Use warm start 3 or 5 to avoid this situation.
Outside the synchronous phase, a backward movement of the slave is possible with the following
situations:
 If the master moves backward. In this case the slave will follow the master backward and stop
at 0. Do not move the master backward to avoid this situation.
 With warm start 1 to 5 outside the synchronous phase
 If the slaves has to return to rest position (lrPosRest) when its position is included between
lrPosRest and lrPeri. This is to prevent the salve to cross the synchronous phase (see
figure below).
CAUTION
ASYNCHRONOUS OPERATION OF CUTTING TOOL
Use additional measures to avoid backward movement of the slave (Rotary Knife) unless the
application accounts for such motion.
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Section 8.4
Pin Description
Pin Description

Topic Page
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Inputs/outputs are linked directly to the application function block interface. The main difference
with the parameters is that inputs/outputs are refreshed cyclically, therefore they can be modified
on the fly.
NOTE: These inputs are valid for the RotaryKnife_Motion and FlyingShear_Motion
function block.

i_xActv BOOL Activate:
TRUE: Application function block is activated.
FALSE: Application function block is de-activated.
Start and Stop (see page 263)
i_xExe BOOL Execute:
TRUE: Movement is started depending on the
operating mode and the starting mode.
FALSE: Movement is stopped.
NOTE: If the slave is inside the synchronous phase,
the movement will not be stopped immediately.
Start and Stop (see page 263)
i_uiStrtMode UINT Start mode:
0 warm start mode 0
1 warm start mode 1
2 warm start mode 2
3 warm start mode 3
4 warm start mode 4
5 warm start mode 5
Factory setting: 0
Starting Modes (see page 266)
i_xSyncAbort BOOL Abort synchronization:
(for FlyingShear only) TRUE: Interruption of the synchronization phase.
Interruption of the Synchronous Phase
(see page 307)
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i_xSyncImdt BOOL Immediate synchronization:
TRUE: Synchronize the slave immediately to the
master.
This input is considered only when the slave is in
resting position (lrPosRest). Only significant for
operating modes 0.
i_lrLentoCut LREAL Length to cut:
Can be modified on the fly. Only significant for
operating modes 0 and 1.
Factory setting: 0
Range: lrLentoCutMin ≤..≤9999999 [Master
User Unit]
i_xAlrmRst BOOL Alarm quit:
TRUE: Reset detected alarm.
If (and only if) i_xAlrmRst is triggered whereas the
function block is OK, it will reset q_diTpAlrmCnt
Troubleshooting (see page 288)
i_xTpUseNext BOOL Use next TP:
TRUE: The following position capture will be accepted
as a valid capture even if it is outside of lrTpWdow.
Only significant for operating modes 1.
i_xTpIputStd BOOL TP standard input:
Standard input used for the master position capture.
Only significant if diCptrNb = 0.
Selection of the Capture Mode (see page 261)
i_lrShift LREAL Shift:
Value of the shift to apply on the cutting point.
Factory setting: 0
Range: -lrPosSyncEnd ≤..≤ +lrPosSyncEnd
[Master User Unit]
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i_lrShiftStepSize LREAL Shift step size:
Maximum value of the shift to apply on the cutting
point in 1 slave cycle.
0: Shift interruption. The shift of the tool stays constant
at the current value even if the final shift: i_lrShift
has not been reached.
NOTE: If i_lrShiftStepSize is greater than
i_lrShift the shift is applied in one step.
Factory setting: 0
Range (according to operating mode):
Op. mode Range
0 0 ≤..≤ (i_lrLentoCut-
lrPosSyncEnd/lrM)*0.9)
1 0 ≤..≤ (i_lrLentoCut-
lrPosSyncEnd/lrM-
lrTpWdow/2)*0.9)
2 0 ≤..
[Master User Unit]
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Inputs/outputs are linked directly to the application function block interface. The main difference
with the parameters is that inputs/outputs are refreshed cyclically, therefore they can be modified
on the fly.
NOTE: These outputs are valid for the RotaryKnife_Motion and FlyingShear_Motion
function blocks.

q_xActv BOOL Active:
TRUE: Application function block is initialized and
activated.
FALSE: Application function block is inactive.
q_xCoup BOOL Coupled:
TRUE: Slave is coupled with the master on the
Rotary Knife/FlyingShear profile curve.
q_xInSync BOOL In synchronization:
TRUE: Slave is in synchronous phase of the curve
and synchronized to the master.
q_xAlrm BOOL Detected Alarm:
TRUE: An interruption occurred
q_diAlrmId DINT Detected Alarm ID:
Range: 0 ≤..≤ 99999
q_xWsPosRchd BOOL Warm start position reached:
TRUE: Slave has reached the warm start position.
q_diTpAlrmCnt DINT TP alarm counter:
Number of successive missed position captured.
One valid TP will reset q_diTpAlrmCnt
Only significant for operating modes 1.
Range: 0 ≤..≤ 99999
q_lrShiftActl LREAL Current shift:
Current applied shift.
Range: Master User Unit
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NOTE: These inputs/outputs are valid for the RotaryKnife_Motion and
FlyingShear_Motion function blocks.

iq_stDrvMstr SM3_Basic.AXIS_REF_SM3 master axis reference structure
iq_stDrvSlav SM3_Basic.AXIS_REF_SM3 slave axis reference structure
iq_stPara STRUCT ST_FSRK_PARAMETER block parameters structure
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iq_stPara
Parameters are entered to the application function block via the structure iq_stPara.
The main difference with inputs/outputs is that parameters are only refreshed after activation of the
application function block (i_xActv=TRUE). Therefore parameters are only taken into account
after a re-activation of the application function block.
Inputs - iq_stPara
NOTE: These parameters are valid for the RotaryKnife_Motion and FlyingShear_Motion
function blocks.

lrPeri LREAL Knife Perimeter
(for the Rotary Knife only) Perimeter of the Rotary Knife.
Distance between the blades for Multi Blade Rotary Knifes.
Factory setting: 0
Range: 0 ≤..≤ 999999 [Slave User Unit]
lrPosRest LREAL Rest Position:
Rest position of the slave
Factory setting: 0
Range: -999999 ≤..≤ 999999 [Slave User Unit]
lrSyncPosEnd LREAL Synchronization end position:
Final position of the synchronous phase (related to the slave axis).
Synchronous phase start at position 0 until position lrPosSyncEnd.
Factory setting: 0
Range: 0 ≤..≤ 999999 [Slave User Unit]
WARNING
 Set the modulo value of the master axis at least 25 times greater than the lrSyncPosEnd
parameter.
 Verify that the modulo value of the master axis is as large as possible.
damage.
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lrDecStop LREAL Stop deceleration:

Deceleration ramp to stop the slave in case of:
 detected alarm
 deactivation of the application function block (falling edge of
i_xActv).
Range: 0 ≤..≤ max acc of the drive [Slave User Unit]
lrWsWdow LREAL Warm start window:
Tolerance window for warm start. Only significant for warm start mode
2, 3, 4, 5.
Factory setting: 30
Range: 0 ≤..≤ 999999 [Master User Unit]
lrVel LREAL Velocity:
Slave speed used for the following movement:
 in warm start mode to move to the warm start position
 in cold start to move to rest position
 With a falling edge of i_xExe to move to rest position

Range: 0 ≤..≤ max speed of the drive [Slave User Unit]
lrAccDec LREAL Acceleration / Deceleration:
Acceleration and deceleration used for the following movement:
 in warm start mode to move to the warm start position
 during a cold start to move to rest position
 with a falling edge of i_xExe to move to rest position

Range: 0 ≤..≤ max acc of the drive [Slave User Unit]
diCptrNb DINT Capture number:
Selection of the input for the position capture:
0 position capture is made on a standard input. In this case the
input has to be wired to input i_xTpIputStd
1 position capture is made on the Touch Probe 1 (TP1)
2 position capture is made on the Touch Probe 2 (TP2)
NOTE: The edge (rising edge or falling edge) can be changed using the
configuration dialog of the encoder or by means of the drive setup tool.
Factory setting: 0
Range: 0 ≤..≤ 2
Selection of the Capture Mode (see page 261)
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lrTpDistToSypt LREAL TP distance to the synchronization point:

Distance between the position capture sensor and the starting point of
the synchronous phase.
Only significant for operating mode 1 and 2.
Range: lrTpDistToSyptMin ≤... ≤ 999999 [Master User
Unit]
lrTpWdow LREAL TP Window:
Tolerance window of the position capture.
For operating mode 1: Range within the captured position are valid.
For operating mode 2: Range in which, after an active TP, no other TP
will be accepted.
Factory setting: 50
Range (for operating mode 1 and 2): lrTpWdow > ((lrPerim-
lrPosRest)/lrm)*1,875
diOpMode DINT Operating mode:
Selection of the operating mode.
0 continuous product
1 continuous product with mark compensation
2 non continuous product (cut on the mark)
Factory setting: 0
Range: 0 ≤...≤ 2
Operating Modes (see page 251)
diTpMisdMax DINT TP missed maximum:
Maximum number of captures outside the tolerance window (defined
with lrTpWdow).
An alarm is generated if q_diTpAlrmCnt > diTpMisdMax.
Only significant in operating mode 1
Factory setting: 3
Range: 0 ≤...≤ 999999
lrM LREAL RM:
Introduce a slope coefficient in the synchronous phase.
Allows the definition of a different speed ratio during this phase.
Factory setting: 1
Range: 0 ≤...≤ 10
xOfstMode BOOL Offset mode:
TRUE: Activate offset mode
FALSE: Deactivate offset mode
Range: FALSE / TRUE [Slave User Unit]
lrCamOfst LREAL CAM offset:
Offset added to the original slave profile.
Only relevant if offset.
Factory setting: 0
Range: 0 ≤...≤ lrPosSyncEnd/2 [Slave User Unit]
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lrPosOfstStrt LREAL Offset start position:

Slave position from where the offset distance is added.
Only relevant if offset mode is activated (xOfstMode=TRUE)
Factory setting: 0
Range: 0 <...< lrPosOfstStrt [Slave User Unit]
lrPosOfstEnd LREAL Offset end position:
Slave position where the offset distance is reached.
Only relevant if offset mode is activated (xOfstMode=TRUE)
Factory setting: 0
Range: lrPosOfstStrt <...< lrPosSyncEnd [Slave User
Unit]
Outputs - iq_stPara

lrTpDistToSyptMin LREAL TP minimum distance:
Calculated by the application function block for information.
Minimum distance between the position capture sensor and the
starting point of the synchronous phase (position 0 of the slave).
Only relevant in Operating mode 1 and 2.
Calculation for Rotary Knife:
 lrTpDistToSyptMin = ABS (lrPeri - lrPosRest / lrM)
*1.875) + lrTpWdow / 2
Calculation for Flying Shear:
 lrTpDistToSyptMin = ABS (lrPosRest / lrM) *1.875) +
lrTpWdow / 2
Range: [Master Unit]
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lrLentoCutMin LREAL Minimum length to cut:
Calculated by the application function block.
Minimum possible value of length to cut.
Calculation for Rotary Knife:
 in operating mode 0: lrLentoCutMin = lrPosSyncEnd
 in operating mode 1: lrLentoCutMin = lrPosSyncEnd +
lrTpWdow / 2
 in operating mode 2: lrLentoCutMin = lrPosSyncEnd + ABS
((lrPeri - lrPosRest / lrM) * 1.875)
Calculation for Flying Shear:
 in operating mode 0: lrLentoCutMin = lrSyncPosEnd
 in operating mode 1: lrLentoCutMin = lrSyncPosEnd +
lrTpWdow / 2
 in operating mode 2: lrLentoCutMin = lrSyncPosEnd + ABS
((lrPosRest / lrM) * 1.875)
NOTE: This minimum length to cut value is theoretical and cannot be
reached. Practically, reducing the length to cut increase the velocity,
acceleration and deceleration constraints on the slave axis. Therefore
the minimum length to cut depends on the velocity, acceleration and
deceleration that the drive and the mechanic can handle.
If the maximum master velocity is known as well as the maximum
velocity supported by the slave axis then it is possible to calculate the
real minimum length to cut with the following formulas:
Formula for Rotary Knife:
Formula for Flying Shear:
NOTE: These formulas do not take into account the acceleration.

Range: [Master Unit]
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Section 8.5
Operating Modes
Operating Modes

Topic Page
Operating Mode 0: Continuous Product 252
Operating Mode 1: Continuous Product with Mark Compensation 254
Operating Mode 2: Non Continuous Product (Cut on Mark) 258
Selection of the Capture Mode 261
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Operating Mode 0: Continuous Product
Overview
NOTE: This operating mode description is valid for the RotaryKnife_Motion and
Operating mode 0 is used to process products with a constant length. This distance corresponds
to the length of one process cycle and is defined via the input variable i_lrLentoCut.
The parameter i_lrLentoCut can be modified during the movement. The modification is
accepted for the next cycle.
Rotary Knife Representation
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Flying Shear Representation
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Operating Mode 1: Continuous Product with Mark Compensation
Overview
This operating mode description is valid for the RotaryKnife_Motion and
Operating mode 1 has basically the same functionality as operating mode 0, extended with an
automatic correction of the product length, calculated from a position capture.
The product length correction is principally interesting in case of flexible product (with risk of
deformation, stretching, etc.). In this case a label or a mark is needed on the product.
The cutting condition is then related to the length to cut parameter (i_lrLentoCut) which can be
corrected according to the position captured at the time of label detection.
If a mark is detected inside the tolerance window, the measured length is used for cutting. Any
mark before the tolerance window will be ignored. If the position leaves the window without seeing
a mark, the default length is used and the output q_diTpAlrmCnt is incremented by 1.
The parameter i_lrLentoCut can be modified during the movement. The modification is
accepted for the next the cycle.
The parameter lrTpDistToSypt corresponds to the distance between the sensor for position
capture and the beginning of the synchronous phase (position 0 of the slave).
Depending upon this distance, several labels may be located between the sensor and the
beginning of the synchronous phase. Those captures are stored in a buffer. The
RotaryKnife/FlyingShear functions allow the storage of up to 15 positions. Over 15 positions an
alarm is detected.
To improve the accuracy, lrTpDistToSypt has to be reduced to a minimum. However,
depending upon the length to cut, this distance must be chosen higher than the minimum value,
calculated by the block function and given by parameter output lrTpDistToSyptMin.
A tolerance capture window, lrTpWdow, can be used to define an interval of valid position.
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Tolerance Capture Window (Operating Mode 1)

In help to avoid interfering signals (detection of false labels) or limit the stretching tolerance of
elastic products, a tolerance window for capturing can be defined by lrTpWdow:
i_lrLentoCut - lrTpWdow /2< Range of tolerance < i_lrLentoCut + lrTpWdow /2
If... Then...
a mark is detected inside this the measured length is used for cutting. Any mark before
range, this range will be ignored.
the position leaves this range the default length is used and the output q_diTpAlrmCnt
without seeing a mark, is incremented by 1.
A maximum number of successive captures outside this range can be configured with the
parameter diTpMisdMax.
An alarm occurs if q_diTpAlrmCnt > diTpMisdMax. The slave is stopped with the ramp
lrDecStop.
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The alarm counter q_diTpAlrmCnt is set back to 0 with the following conditions:
 a valid capture signal before an alarm occurs
 the function block is de-activated
 with rising edge of input i_xAlrmRst while no alarm is active
With a rising edge of the input i_xTpUseNext the next capture signal is valid without any
consideration to the lrTpWdow and the alarm counter q_diTpAlrmCnt is set back to 0.
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Operating Mode 2: Non Continuous Product (Cut on Mark)
Overview
This operating mode description is valid for the RotaryKnife_Motion and
In the operating mode 2, the product arrives on the conveyor in a discontinuous and random way.
The size and the format can vary. The cutting condition is started exclusively by the position
capture.
The parameter lrTpDistToSypt corresponds to the distance between the sensor for position
capture and the beginning of the synchronous phase (position 0 of the slave).
Depending upon this distance, several labels may be located between the sensor and the
beginning of the synchronous phase. Those captures are stored in a buffer. The
RotaryKnife/FlyingShear functions allow the storage of up to 15 positions. In case more than 15
positions are detected an alarm will be raised.
lrTpDistToSypt has to be higher than the minimum value lrTpDistToSyptMin calculated by
the function block.
A capture ignorance window can be used to define an interval of valid position.
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Capture Ignorance Window (Operating Mode 2)

In order to avoid detection of false signals, a tolerance for position captures can be defined by
lrTpWdow. The range begins with the previous captured position.
To be a valid mark, the position has to be greater then the last accepted mark + lrTPWdow:
position of previous + lrTpWdow.
If a mark is detected inside this range, the product length is calculated depending on this mark.
Any detection outside this range is ignored.
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Selection of the Capture Mode

NOTE: This mode description is valid for the RotaryKnife_Motion and
Position capture is used with operating mode 1 and 2.
According to the architecture and the requirements of precision for the application, several capture
modes are possible.
Mode Description
Detection with standard input The sensor is wired to a standard input. The capturing is
within the cycle of the motion controller.
Detection with fast input The sensor is wired to a Touch Probe input
 TP1, TP2, … if the master is an external encoder
 a capture input of a servo drive, if the master is a drive
Capture input can be configured with parameter diCptrNb:
diCptrNb i_xTpIputStd
0: Associated standard input. If input DI3 is used, then DI3 is
Capture is done with a wired to i_xTpIputStd.
standard input
1 to 2: No effect
Capture is done on Touch
Probe 1 to 2
If a Touch Probe is selected, the edge (rising edge or falling edge) has to be selected outside the
application function block.
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Section 8.6
Start, Stop and Starting Modes

Topic Page
Start and Stop 263
Starting Modes 266
Cold Start 267
Warm Start 268
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Start and Stop
Overview
NOTE: This description is valid for the RotaryKnife_Motion and FlyingShear_Motion
function blocks.
The correct sequence for the application function block is as follows:
 activate the application function block (i_xActv=TRUE)
 start the movement (i_xExe=TRUE)
 de-execute the application function block (i_xExe=FALSE)
 de-activate the application function block (i_xActvFALSE)
Activate the Application Function Block

The function block is activated with a rising edge of i_xActv.
 the input parameters (defined in iq_stParam) are confirmed for consistency.
 q_xActv is set to TRUE
 in case of incorrect or inconsistent inputs or input parameters, output q_xAlrm becomes TRUE.
WARNING
Do not send any other commands to the slave axis when it is under control of the
RotaryKnife_Motion/FlyingShear_Motion application function blocks.
damage.
Start the Movement

Movement is started with a rising edge of i_xExe.
 verify slave axis state (slave has to be standstill)
 inputs are confirmed for validity
 if no alarm occurred, movement is started depending on the following conditions Starting Modes
(see page 266):
 with the first rising edge of i_xExe after activation of the application application function
block (rising edge of i_xActv) a cold start is automatically executed. Input i_uiStrtMode
is ignored.
 with every following rising edge of i_xExe a warm start is executed depending on the input
i_uiStrtMode
 output q_xCoup is set to TRUE when the slave is coupled to the master.
 in case of incorrect or inconsistent inputs, output q_xAlrm becomes TRUE. Troubleshooting
(see page 288)
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Stop the Movement

On a falling edge of i_xExe the movement is stopped under the following conditions:
 If outside the synchronous phase (q_xInSync=FALSE), the slave is uncoupled from the
master and returns directly to its rest position (lrPosRest).
 If inside the synchronous phase (q_xInSync=TRUE), the slave remains coupled with the
master until the end of synchronous phase. Then the slave is uncoupled from the master and
returns directly to its rest position (lrPosRest).
Therefore, i_xExe= FALSE does not guarantee that the slave stops immediately or remain
stationary. To stop immediately or to block any movement of the slave controlled by the application
function block, i_xActv has to be FALSE.
NOTE: In operating mode 1 and 2 and with a falling edge of i_xExe, the application function block
continues to capture and buffer positions as long as the application function block is activated.
Other conditions that stop the slave:
 when the slave is coupled with the master (q_xCoup=TRUE), the slave stops if the master
stops. Nevertheless, the slave remains coupled and restarts if the master restarts.
 on a falling edge of i_xActv the slave is stopped with the deceleration ramp lrDecStop. The
master / slave synchronization is lost.
 if an alarm occurs, the slave is stopped with the deceleration ramp lrDecStop. The master /
slave synchronization is lost.
De-Activate the Application Function Block

On a falling edge of i_xActv the block is de-activated and:
 if moving, the slave is stopped with the deceleration ramp lrDecStop
 when the slave is stopped, all outputs are reset
 the current shift is reset (q_lrShiftActl)
 the position capture is stopped and the position capture buffer (for operating mode 1 and 2) is
reset.
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Slave Movement to Rest Position (lrPosRest)

NOTE: For Rotary Knife only.
The slave goes to its rest position in the following situations:
Inside the synchronous phase:
 with a cold start
 with a warm start 0 if the master and slave are uncoupled
Outside the synchronous phase:

 with a cold start
 with a warm start 0 if the master and slave are uncoupled
 with a falling edge of execute input
The following rules are applied:

 In any case the slave does not cross the synchronous phase to move to its rest position (case
1 and 2, see figure below). In case 2 the slave moves backward.
 If the slave is in the synchronous phase, it moves forward to its rest position (case 3, see figure
below).
The following figure shows the slave movement to the rest position.
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Starting Modes
Overview
NOTE: This description is valid for the RotaryKnife_Motion and the FlyingShear_Motion
function blocks.
There are 2 different types of starting modes:
Mode Description
Cold Start is the starting method automatically used for the first execution of the
application function block after activation. A cold start is necessary when there
is no context coming from a previous execution of the application function block
(No position captured inside the buffer, no shift applied, no output
information…).
Warm Start is the starting method used for a re-start of the application function block,
following a temporary interruption (with a falling edge on i_xExe), an error-
stop or an emergency stop without de-activation of the application function
block. In this case the previous context is kept and considered for the re-start
of the movement.
Main differences between cold start and warm start:

In operating mode 1 and 2:
 at cold start the position buffered is empty. The first product to be cut will be the first detected
product. Therefore, if the position sensor is 5 products before the cutting tool, the 5 intermediate
products will not be cut.
 at warm start, the buffer is kept active. Therefore the application can restart immediately without
loosing any product.
With a rising edge of i_xExe the movement is started depending on the following conditions:
 with the first rising edge of i_xExe after activation of the application function block (rising edge
of i_xActv) a cold start is automatically executed. Input i_uiStrtMode is ignored
 with every following rising edge of i_xExe a warm start is executed depending on the input
i_uiStrtMode
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Cold Start
Overview
function blocks.
A cold start is the starting method used for the first execution of the
RotaryKnife_Motion/FlyingShear_Motion application function blocks after activation. In
other word a cold start is necessary when there is no context coming from a previous execution of
the application function block (No position captured inside the buffer, no shift applied, no outputs
information…).
Therefore, with the first rising edge of i_xExe after activation of the application function block
(rising edge of i_xActv) a cold start is automatically executed. Input i_uiStrtMode is ignored.
At cold start the slave moves to the rest position (lrPosRest). When the rest position has been
reached, the slave is coupled to the master (using the start phase) depending on the operating
mode (diOpMode) and the position capture buffer.
Modes Description
Operating Mode 0 the slave will start immediately the Rotary
Knife/FlyingShear profile when the master is started.
Operating Mode 1 and 2 the first product to be cut will be the first detected product.
Therefore, if the position capture sensor is placed 5
products before the cutting tool the 5 intermediates
products will not be cut.
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Warm Start
Overview
function blocks.
A warm start is the starting method used for a re-start of the application function block following a
temporary interruption (with a falling edge on i_xExe), an error-stop or an emergency stop without
de-activation of the application function block.
In this case the previous context is kept (buffer is still active, shift is maintained, outputs are
relevant). Therefore in operating mode 1 and 2, the application can restart using valid positions
from the buffer.
Six warm start modes are available depending on the application requirements. For each warm
start mode there are certain conditions to be fulfilled. Warm start mode is selected with input
i_uiStrtMode.
How to select a warm start mode:
Mode Description
Warm Start 0 is the only warm start possible with a moving master.
(i_uiStrtMode=0)
has no tolerance window and can be used if warm start 1 to 5 is
not possible (if slave is outside the tolerance window…). In this
case the slave goes first to the rest position.
Warm Start 1 to 5 only possible if the master is stopped otherwise an alarm is
(i_uiStrtMode=1 to 5) created.
is mainly used when there is a mechanical constraint between
master and slave during the synchronization phase (a blade into
a metal sheet…). In case of accidental de-coupling of the master
and slave during the synchronization phase (emergency stop…)
the slave can be re-coupled with the master following different
conditions.
For warm start modes 1 to 5, output q_xPosWsRch indicates that the warm start position has been
reached. It signals to the application, that the master can be started.
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Warm Start 0 (i_uiStrtMode = 0)

NOTE: Warm start 0 is the only warm start possible with a moving master.
With a rising edge of i_xExe:
If... Then...
the slave is still coupled to the master (ex: i_xExe=FALSE the slave stays coupled to the master and
with a master stopped into the synchronous phase) restarts normally.
the slave is in rest position (lrPosRest) the slave restarts with the next cycle if the
distance is long enough to accomplish the start
phase.
the slave is not coupled and not in rest position (in or out of the slave goes to rest position and restart with
the synchronous phase) the next cycle if the distance is long enough to
accomplish the start phase.

With a rising edge at i_xExe:
 The slave returns to the curve position regardless where (inside or outside synchronous phase)
it has been stopped.
RotaryKnife Representation
Warm start 1 allows backward movement of the slave into the synchronous phase.
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WARNING
Use warm start mode 3 or 5, if the machine design does not account for a backward movement
of the slave (Rotary Knife).
damage.
FlyingShear Representation
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RotaryKnife FlyingShear If.. Then..

Case Case
1 and 2 1 the slave is in the synchronous phase and located the slave returns to its curve
inside the tolerance window defined by lrWsWdow position.
 slave position ≥ curve position - lrWsWdow / 2
AND
 slave position ≤ curve position + lrWsWdow / 2
3 2 the slave is in the synchronous phase and located the slave remains in position
outside the tolerance window defined by lrWsWdow and an alarm is produced.
 slave position > curve position + lrWsWdow / 2 Troubleshooting
OR (see page 288)
 slave position < curve position - lrWsWdow / 2
4 3 the slave is outside the synchronous phase the slave returns to its curve
position.
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WARNING
damage.
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Case Case
1 and 3 1 the slave is in the synchronous phase and located the slave remains in position
outside the tolerance window defined by lrWsWdow and an alarm is detected.
 LREAL position > curve position (see figure Troubleshooting
RotaryKnife, case 1) (see page 288)
OR
 LREAL position < curve position - lrWsWdow (see
figure RotaryKnife, case 3)
2 2 the slave is in the synchronous phase and located the slave returns to its curve
inside the tolerance window defined by lrWsWdow position.
 slave position ≤ curve position
AND
 slave position ≥ curve position - lrWsWdow
4 3 the slave is outside the synchronous phase the slave returns to its curve
(see figure RotaryKnife, case 4) position.
NOTE: In this warm start mode, the slave can move only in the positive direction in the event of a
stop within the synchronous phase.
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Case Case
1 2 the slave is in the synchronous phase and located the slave returns to its curve
inside the tolerance window defined by lrWsWdow (see position.
 LREAL position ≤ curve position + lrWsWdow
AND
 LREAL position ≥ curve position
 LREAL position ≥ curve position + lrWsWdow (see Troubleshooting
figure RotaryKnife, case 1) (see page 288):
OR
 LREAL position < curve position (see figure
RotaryKnife, case 3)
4 3 the slave is outside the synchronous phase (see figure the slave returns to its curve
RotaryKnife, case 4) position.
NOTE: With this warm start mode, the slave can move only in the negative direction in the event
of a stop within the synchronous phase.
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WARNING
damage.
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Case Case
 LREAL position > curve position + lrWsWdow / 2 Troubleshooting
(see figure RotaryKnife, case 1) (see page 288):
OR
 LREAL position < curve position - lrWsWdow / 2 (see
2 and 3 1 the slave is in the synchronous phase and located the slave remains on its
inside the tolerance window defined by lrWsWdow position and follow the
 LREAL position ≥ curve position - lrWsWdow / 2 (see master as with a normal
figure RotaryKnife, case 2) profile until the end of the
synchronous phase.
AND
 LREAL position ≤ curve position + lrWsWdow / 2 (see
5 3 the slave is outside the synchronous phase (see figure the slave returns to its curve
RotaryKnife, case 5) position.
NOTE: In this warm start mode, the slave keeps its position shift with the master until the end of
synchronous phase in the event of a stop within the synchronous phase.
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Section 8.7
Special Modes
Special Modes

Topic Page
Immediate Cut 279
Offset Mode 280
Oblique Cut 281
Shift Function 282
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Immediate Cut
General
function blocks.
With input i_xSyncImdt it is possible to engage an immediate cut in operating mode 0.
The slave does not await the end of the cycle in progress. It begins immediately a new cycle with
the start phase. The length of this new cycle will be equal to the length lrLentoCut.
The input reacts on a rising edge and is considered only if the slave is in lrPosRest.This input
will be ignored in operating mode 1 and 2.
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Offset Mode
General
function blocks.
The offset mode:
 allows the shift of the slave axis a certain distance (lrCamOfst) during the synchronous phase.
 can only be activated when the application function block is de-activated.
 When activated, the offset mode is applied at every cycle.
 is activated with the parameter input xOfstMode.
 does not influence the length of the process cycle.
 value is defined with the parameter input lrCamOfst.
 output q_xInSync is TRUE during the complete synchronous phase although slave and
master are not synchronized during the transition phase needed to apply the offset.
The start and end positions of this transition are defined by the following parameters:
 lrPosOfstStrt
 lrPosOfstEnd
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Oblique Cut
General
function blocks.
With the parameter rm, it is possible to adjust the ratio of the position between the slave and the
master during the synchronous phase.
rm = ΔY / ΔX
This coefficient should be used in the applications, in which the paths of master and slave are not
parallel.
Irm can only be modified when the application function block is de-activated.
 Irm = 1, the speed of slave and master are equal
 Irm < 1, slaves moves slower than the master
 Irm > 1, slave moves quicker than the master
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Shift Function
General
function blocks.
The shift function allows to adjust manually the cut on the product. This shift (i_lrShift) is
applied to the master position in order to shift the starting point of cutting on the product.
NOTE:
The shift necessarily creates a variation of the i_lrLentoCut during the transition phase:
 a positive shift leads to a shorter product during the transition and moves the start point of the
synchronous phase in the direction of the master movement.
 a negative shift leads to a longer product during the transition and moves the start point of the
synchronous phase against the direction of the master movement.
In order to limit the i_lrLentoCut variation during the transition phase, it is possible to apply the
total shift divided into several steps.
This can be set-up with i_lrShiftStepSize.
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Example
Example with a positive shift
Length to cut: i_lrLentoCut = 100
Steps 1-4 refer to figure below
Step Description
1 Length of the product = 100, the product is cut normally
i_lrShift = + 10 user units
i_lrShiftStepSize = 5 user units
NOTE: In this case the total shift will be applied in 2 steps, corresponding to 2
slave cycles.
2 Length of the product = 95, the product is shorter.
3 Length of the product = 95, the product is shorter.
The length of the product comes back to the normal length.
4 Length of the product = 100
The product is cut to the normal length but the starting point of the tool has
been shifted of 10 user units.
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Start Modes
Depending on the start mode (cold start or warm start), the behavior of the shift is different:
If... Then...
the slave is restarted with a cold start the current shift is set to zero. No initial shift is applied.
the slave is restarted with a warm start the current shift is kept and is applied as soon as the
slave restarts. The positioning of the slave on the curve
(depending on i_uiStrtMode) is done with the shift.
Remarks:
The following positions and distances are not affected by the shift function:
 length to cut
 rest position
The following windows are not affected by the shift function:

 Touch Probe window
 warm start window
NOTE: i_lrShift and i_lrShiftStepSize are checked with every rising edge on i_xActv
and i_xExe. When the slave is running (AFB active) i_lrShift and i_lrShiftStepSize are
checked at every machine cycle.
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Section 8.8

Topic Page
Visualization 286
Troubleshooting 288
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Visualization
Overview
Visualization screens are embedded in the Rotary Knife library. They allow to configure and to start
the application function block very easily and quickly.
All the inputs/outputs and all the parameters are accessible.
For more information please refer to How to Integrate the Visualization into an Application
(see page 395).
Rotary Knife template visualization
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Rotary Knife parameters visualization
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Troubleshooting
Troubleshooting
NOTE: This description is valid for the RotaryKnife_Motion and FlyingShear_Motion
function blocks.
Issue q_diAlrmId Offset Example Remark

Application function 10000 (Factory Application function blocks alarm If several application libraries are
block alarm detection setting) Id 451 ("Length to cut invalid") used in the same application, this
will be: q_diAlrmId = 10000 + offset can be modified with the
451 = 10451 global variable:
GC_MotionLib_ErrorOffset
Other alarms No offset SoftMotion alarm Id 12 ("The -
(SoftMotion, Motion position limits of the axis have
Controller…) been exceeded") will be:
q_diAlrmId = 12
Notification
When an alarm is detected:
 the slave is stopped immediately with the deceleration ramp lrDecStop. The master and slave
synchronization is lost.
 q_xAlrm is set to TRUE
 q_diAlrmId display the notification number according to the table below
 detected alarms have to be reset with a rising edge on the input i_xAlrmRst
NOTE: Output q_diAlrmId only displays the first detected alarm. Therefore a new problem is
reported only if the last active problem has been reset.
Detected AlrmId Notification

14 Slave axis state is not in standstill at execution.
Enable slave axis with MC_Power.
50 Invalid capture input (parameter diCptrNb).
Verify parameter.
Range: 0 ≤ diCptrNb ≤ 2
51 Invalid operating mode (parameter diOpMode).
Verify parameter.
Range: 0 ≤ diOpMode ≤ 2
52 Invalid start mode (input i_uiStrtMode)
Verify input.
Range: 0 ≤ i_uiStrtMode ≤ 5
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53 Master moved at warm start.
Start modes 1 to 5 (i_uiStrtMode = 1 to 5) are only possible if the master is stopped.
Stop the master or switch to start mode 0.
55 Slave is outside warm start window configured with parameter lrWsWdow. Start
modes 2 to 5 (i_uiStrtMode = 2 to 5) are not possible.
56 Application function blocks runs on wrong controller.
This application function block requires a Motion Controller.
129 Invalid deceleration ramp (parameter lrDecStop).
Verify parameter.
Range: 0 ≤ lrDecStop
130 Invalid warm start window (parameter lrWsWdow).
Verify parameter.
Range: 0 ≤ lrWsWdow
131 Invalid velocity (parameter lrVel).
Verify parameter.
Range: 0 ≤ lrVel
132 Invalid acceleration / deceleration (parameter lrAccDec)
Verify parameter.
Range: 0 ≤ lrAccDec
451 Invalid length to cut (input i_lrLentoCut).
Verify input.
Range: lrLentoCutMin ≤ i_lrLentoCut
Operating mode 0: lrLentoCutMin = lrSyncPosEnd
Operating mode 1: lrLentoCutMin = lrSyncPosEnd + lrTpWdow/2
Operating mode 2:
 For Rotary Knife: lrLentoCutMin = lrSyncPosEnd + ABS (((lrPeri -
lrPosRest) / lrM) * 1.875)
 For Flying Shear: lrLentoCutMin = lrSyncPosEnd + ABS ((lrPosRest / lrM)
* 1.875)
452 Invalid synchronization end position (parameter lrSyncPosEnd).
Verify parameter.
Range: 0 ≤ lrSyncPosEnd
453 Invalid TP distance (parameter lrTpDistToSypt).
Verify parameter.
Range: lrTpDistToSyptMin ≤ lrTpDistToSypt
 For Rotary Knife:
lrTpDistToSyptMin = ABS (((lrPeri - lrPosRest) / lrM) * 1.875) +
lrTpWdow/2
 For Flying Shear
lrTpDistToSyptMin = ABS ((lrPosRest / lrM) * 1.875) + lrTpWdow/2
454 Invalid TP window (parameter lrTpWdow).
Verify parameter.
Range: lrTpWdow > ((lrPerim-lrPosRest)/lrm)*1,875
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455 There are more than 15 products between the position capture sensor and the knife,
the position buffer is full. Reduce the distance between the sensor and the knife.
456 Invalid RM (slope of oblique cut, parameter lrM).
Verify parameter.
Range: 0 ≤ lrM ≤ 10
457 Invalid CAM offset (parameter lrCamOfst).
Verify parameter.
Range: 0 ≤ lrCamOfst ≤ lrSyncPosEnd/2
458 Invalid TP missed max. (parameter diTpMisdMax).
Verify parameter.
Range: 0 ≤ diTpMisdMax
459 Invalid offset start position (parameter lrPosOfstStrt).
Verify parameter.
Range: 0 < lrPosOfstStrt < lrPosOfstEnd
460 Invalid offset end position (parameter lrPosOfstEnd).
Verify parameter.
Range: lrPosOfstStrt < lrPosOfstEnd < lrSyncPosEnd
461 Invalid shift (input i_lrShift).
Verify input.
Range: - lrSyncPosEnd ≤ i_lrShift ≤ + lrSyncPosEnd
462 Invalid shift step size (input i_lrShiftStepSize).
Verify input.
Range:
Operating mode 0: 0 ≤ i_lrShiftStepSize < (i_lrLentoCut-
lrSyncPosEnd/lrM)*0.9)
Operating mode 1: 0 ≤ i_lrShiftStepSize < (i_lrLentoCut -
lrSyncPosEnd/lrM - lrTpWdow/2)*0.9)
Operating mode 1: 0 ≤ i_lrShiftStepSize
463 Number of missed marks (out of the TP window). Exceeded the maximum value
defined by parameter diTpMisdMax (q_diTpAlrmCnt > diTpMisdMax)
Only for operating mode 1.
Verify the product / verify the position sensor / increase parameter diTpMisdMax
465 Invalid knife perimeter (input lrPeri).
(for Rotary Knife Verify input.
only) Range: lrPeri ≥ 0
466 Invalid rest position (parameter lrPosRest).
Verify parameter.
Range:
 For Rotary Knife: lrSyncPosEnd ≤ lrPosRest ≤ lrPeri
 For Flying Shear: lrPosRest ≤ 0
467 Invalid Rotary Knife slave axis configuration. Rotary Knife slave axis must be
(for Rotary Knife configured as a modulo axis.
only)
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468 Invalid Flying Shear slave axis configuration. Flying Shear slave axis must be
(for Flying Shear configured as a linear axis, not as a modulo axis
only)
469 Invalid Rotary Knife slave axis configuration. Rotary Knife slave axis must be
(for Rotary Knife configured as a modulo axis with a modulo higher than 2 times the knife perimeter
only) (Slave modulo ≥ 2*lrPeri).
470 Invalid master axis configuration. Master axis has to be configured as a modulo axis,
with a modulo higher than maximum possible length to cut + TP distance to the
synchronization point. (> max i_lrLentoCut + lrTpDistToSypt).
471 The function block was interrupted by a PLCopen function block.
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FlyingShear
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FlyingShear
FlyingShear
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FlyingShear_Motion
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Chapter 9
FlyingShear_Motion: Synchronization of 2 Linear Axis to Perform On The Fly Operations
FlyingShear_Motion: Synchronization of 2 Linear Axis

to Perform On The Fly Operations

Section Topic Page
9.6 Start, Stop and Starting Modes 304
9.7 Special Modes 305
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Section 9.1

Topic Page
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Functional Overview
Why Use the FlyingShear_Motion Function Block?

The FlyingShear_Motion function block controls a machine that performs an operation, on the
fly, on a moving part.
Typical operations can include:
 Cutting
 Clamping
 Stamping
 Marking
Solution with the FlyingShear_Motion Function Block

The Flying Shear function is required for moving the operational axis to synchronize it with the
forward motion of the part.
This introduces the concept of master and slave axes.
 Master: moves the part forward
 Slave: performs the operation
NOTE: Although the Flying Shear function can be used for many different applications, the
examples shown in this document refer to a typical cutting application.
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Machine Overview
Machine View
The figure below gives an example of a Flying Shear application. Both master and slave axes are
linear axis types.
Note
Please also refer to:
 Master Axis (see page 230)
 Slave Axis (see page 231)
 Cutting Tool (see page 231)
 Capture Position of the Product (see page 231)
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Section 9.2
Architecture
Architecture
Hardware and Software Architecture
Note
For the hardware and software architecture please refer to the Architecture chapter
(see page 229).
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Section 9.3
FlyingShear_Motion Function Block
Pin Diagram
Profiles of Master/Slave Positions

The curves (see case 1 and 2 below) show the position profile of the slave axis in relation to the
master during the execution of the Flying Shear function.
A Flying Shear cycle consists of 3 phases:
Phase Description
Start Phase The slave accelerates up to the master velocity to be synchronized
at the beginning of the synchronous phase.
 The start phase distance on the slave is equal to:
Slave Start Phase Distance = ABS (lrPosRest)
 The start phase distance on the master can be calculated with
the following formula:
Master Start Phase Distance = (ABS (lrPosRest) / lrM) * 1.875
Synchronous Phase The cut (or the operation) is performed. The synchronous phase
always starts at position 0 of the slave.
Return Phase The slave returns and makes a half-turn before it begins a new
synchronous phase.
According to the length to be cut and the length of the synchronous
phase, 2 cases are distinguished.
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FlyingShear_Motion
Case 1: return to resting position (long cut)
When the ratio i_lrLentoCut / lrSyncPosEnd is > 3, the slave returns, crosses its position of
origin (position 0) and stops at its resting position (lrPosRest) before it begins a new cycle.
The duration of the stop depends on the length to cut (i_lrLentoCut) and the speed of the
master.
Case 2: sequence of cuts (short cut)
When the ratio i_lrLentoCut / lrSyncPosEnd is < 3, the slave returns, crosses its position of
origin and begins a new cycle immediately.
The distance covered by the master during this cycle corresponds to the length to cut
(i_lrLentoCut).
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FlyingShear_Motion
Section 9.4
Pin Description
Pin Description
Pin Description
Notes
For the input pin description, please refer to the Input Pin Description (see page 241) of
RotaryKnife_Motion function block.
For the output pin description, please refer to the Output Pin Description (see page 244) of
For input/output pin description, please refer to the Input/Output Pin Description (see page 245) of
For structured parameter description, please refer to the Structured Parameter (see page 246) of
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FlyingShear_Motion
Section 9.5
Operating Modes
Operating Modes
Operating Modes
Note
For the description of operating modes, please refer to the Operating Modes chapter
(see page 251).
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FlyingShear_Motion
Section 9.6
Note
For the descriptions of start, stop and starting modes, refer to the Start, Stop and Starting Modes
chapter (see page 262).
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FlyingShear_Motion
Section 9.7
Special Modes
Special Modes

Topic Page
Special Modes 306
Interruption of the Synchronous Phase 307
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FlyingShear_Motion
Special Modes
Note
For the descriptions of other special modes, refer to the Special Modes chapter (see page 278).
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FlyingShear_Motion
Interruption of the Synchronous Phase
Overview
With the input i_xSyncAbort, it is possible to prematurely interrupt the synchronous phase of the
cycle. Depending upon the length of the return path, the slave returns to its resting position
(lrPosRest) or begins a new cycle.
The input reacts on a rising edge and is considered only when the cycle is in the synchronous
phase.
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FlyingShear_Motion
Section 9.8

Topic Page
Visualization 309
Troubleshooting 311
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Visualization
Overview
Visualization screens are embedded in the FlyingShear library. They allow configuring and starting
the application function block easily and quickly.
For more information please refer to How to Integrate the Visualization into an Application
(see page 395).
Flying Shear template visualization
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FlyingShear_Motion
Flying Shear parameters visualization
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FlyingShear_Motion
Troubleshooting
Note
For troubleshooting, please refer to the Troubleshooting section (see page 288).
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FlyingShear_Motion
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SoMachine
GroupingUngrouping
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Part VIII
GroupingUngrouping
GroupingUngrouping

10 Grouping - Ungrouping: Synchronization of Linear Axes to Organize Products 315
on a Conveyor
11 GroupingAccumulator_Motion 331
12 GroupingStripper_Motion 341
13 Operation Description 355
14 Quick Reference Guide 375
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GroupingUngrouping
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SoMachine
Grouping - Ungrouping
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Chapter 10
Grouping - Ungrouping: Synchronization of Linear Axes to Organize Products on a Conveyor
Grouping - Ungrouping: Synchronization of Linear Axes to

Organize Products on a Conveyor

Section Topic Page
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Section 10.1

Topic Page
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Functional Overview
Usage of Grouping/Ungrouping Function

Grouping/Ungrouping involves the synchronization of several conveyors to sort and organize
products in a predefined way (groups).
Solution with the Grouping/Ungrouping Function

Appropriate function blocks allow a storing and a subsequent delivery of products. A desired
distance between the products can be set and be modified at each cycle.
Those function blocks are:
Function Description
The Grouping function blocks can be used separately or together. In combination they form an
unsteady product flow into an evenly spaced product flow. This introduces the concept of master
and slave.
For further information, refer to Machine Overview (see page 318).
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Machine Overview
Machine View
General Overview:
Principle of Operation
Conveyor Figure Product delivery Description Controlled by AFB

to following
conveyor
Input Input conveyor The input conveyor No
Conveyor Velocity delivers products with a
> random product flow.
Accumulator The velocity of the input
Velocity conveyor must be greater
than the velocity of a
following accumulation
conveyor.
A too high back pressure
however may push the
products on the
accumulation conveyor.
Accumulator Delivery The accumulation GroupingAccumulator_
Conveyor dependent on conveyor generates a Motion (see page 332)
iOpMode product jam.
Product Delivery Ensure that no gaps occur
(see page 321) as they are not managed
by the function block.
Product delivery to the
following conveyor can be
set with iOpMode = 0..3.
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Conveyor Figure Product delivery Description Controlled by AFB

to following
conveyor
Stripper During delivery: The stripper is the master GroupingStripper_
Conveyor Distance = of the accumulator. Motion (see page 342)
i_lrDistTarg At the start position of the
Velocity = stripper, the accumulator
MasterVelocity generates an evenly
Product Delivery spaced product flow which
(see page 321) is approximately the final
target distance.
At the end the stripper has
corrected these distances
to the accurate target
distance and delivers the
products with a
synchronous speed to the
target conveyor.
Target - The target conveyor is the No
Conveyor master of the stripper, or
the accumulator if no
stripper is used.
On this conveyor the
products must have a
defined distance, and/or
position where
compartments are used.
Compartments on the Target Conveyor
If compartments are used on the target conveyor, the position of this conveyor at the beginning of
a movement is important for correct product placement. The parameter lrMstrOfst must be
determined once before the first start-up.
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Its value remains constant if with every restart of the system a reference movement is executed:
 After a system start-up, execute a reference movement of the master (target conveyor) to an
arbitrary compartment edge. The position of the target conveyor is then 0.
NOTICE
INOPERABLE EQUIPMENT
For a proper referencing in the controller configuration, set the modulo value of the target
conveyor to the value of i_lrDistTarg.
 Measure the distance x as the distance from the start of delivery position to the first
compartment edge on the target conveyor (see figure Compartments on the Target Conveyor).
Calculate the lrMstrOfst as a function of x and d:
If... Then...
x>d rMsterOfst = i_lrDistTarg - x + d
x<d rMsterOfst = d - x
d = desired distance of the product from the compartment edge
When using compartments, xCmpt must be set TRUE. However this parameter is only evaluated
with a cold start. Then the virtual encoder is set to the actual position of the target conveyor minus
lrMstrOfst.
For an accumulator (if no stripper is used), only iOpMode = 2 (periodic geared pulsed mode) is
allowed.
For further information refer to Cold Start Accumulator (see page 365) and Cold Start Stripper
(see page 368).
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Product Delivery (Stripper)
Requirements:
 The stripping conveyor must deliver each product with an accurate distance (i_lrDistTarg)
to its predecessor.
 For the duration of the delivery, the stripper and the target conveyor must have exactly the same
velocity (Velocity = MasterVelocity).
To fulfill both requirements even high-dynamically, the accumulator conveyor must deliver the
products to the stripper conveyor with a distance i_lrDistTarg.
For this you can select between 4 different delivery modes (iOpMode = 0..3).
The stripper only requires the position information (where compartments are on the target
conveyor) and velocity information of the target conveyor (using a cam). Therefore, the master can
be an encoder.
For further information, refer to Curve Diagrams (see page 343), Input Pin Description
(see page 347), Output Pin Description (see page 349) and Parameter (see page 352).
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Sensor for Product Detection (Accumulator, optional)
The sensor becomes active with the arrival of the first product. Therefore, this sensor is relevant
only for a cold start. The parameter lrTpDistToSypt sets the distance between the touch probe
sensor (TP) and the point of delivery (SyncPt) from which a product is started to be delivered to
the following stripper and/or target conveyor. The delivery mode can be selected with iOpMode.
Sensor for Product Detection (Stripper)
The sensor becomes active with every arrival of a product. The parameter lrTpDistToSypt sets
the distance between the sensor (TP) and the point of delivery (SyncPt) from which a product is
started to be delivered to the following target conveyor.
During the delivery the stripper conveyor moves synchronously with the target conveyor
(see page 384).
Up to 15 parts may be buffered between TP and SyncPt.
When the distance between the signals is greater than i_lrTpDistMin, the product detection is
accepted.
For the compartments on the target conveyor: if the signal distance is greater than i_lrDistTarg
+ i_lrTpDistMin, a compartment is left out and the product detected is delivered to a next
compartment.
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By applying i_lrTpDistMin with the TP detection, the following type of grouping can be
accomplished:
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Section 10.2
Architecture
Architecture

Topic Page
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Configuration of the Axes with the Motion Controller

The master axis must be configured as a rotary axis.
The modulo value must be set higher than the application’s maximum i_lrDistTarg. The
modulo value is a configuration parameter and cannot be modified by the application
All inputs/outputs for position, velocity and acceleration in user units are defined in the controller
configuration.
Example:
Gear ratio = 1: 1
1 motor revolution = 360 mm
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Configuration of the Slave Axis with the Drive

In addition to the communication parameters (addresses on the bus, speed transmission), the
following parameter adjustments should be made to optimize the response of the servo drive that
controls the slave axis:
 increase the maximum slopes of acceleration and deceleration.
 set the parameter N_ref_Filter to OFF.
 set various loop parameters. They include proportional gain speed loop, integral time speed
loop and the proportional gain position.
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The target conveyor (master axis) moves the products forward continuously. It is an infinite axis.
The controller of this axis can be of any type (servo drive, variable speed drive, etc.). The
movement of this axis is not controlled by a Grouping function block.
Both master and slave may be axes on CANmotion or Sercos:
If the master axis is not a servo drive on the same CANmotion or Sercos as the slave, then the
position of the master is determined by an encoder signal connected to the input of the Motion
Controller:
Sensor Wiring (Accumulator)

The sensor is evaluated at a cold start and only once with the arrival of the first product.
Sensor wiring (accumulator) is only possible over a standard input by wiring one of the digital inputs
to i_xTpIputStd.
NOTE: The accuracy depends on the master velocity and the program cycle time and/or the cycle
time of the Motion Controller.
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Sensor Wiring (Stripper)

Perform the sensor wiring (stripper) over a TP input as follows.
A TP input is used where a short acquisition time is required. The TP position is captured via
CANmotion or Sercos. The attainable accuracy is higher than with the capturing over a standard
input (see below).
 Set the parameter xTpMode to TRUE.
 Connect the sensor to one of the capture inputs (CAP1 or CAP2) of the Lexium servo drive.
NOTE: The TP inputs of the Controller cannot be used as they can only trigger encoder positions
(master) and not drive positions.
 Set the parameter iCptrNb to 0 or 1.
 The input i_xTpIputStd is unused.
The edge to be evaluated must configured directly in the Lexium drive.
Using for Sercos:
 the FB_SercosWriteServiceDataAsync
Using for CANmotion either:

 the SMC3_CAN_WriteParameter
 the CAN Drive list in the Controller configuration
 Configure the parameter Cap1Config for capture unit 1, or Cap2Config for capture unit 2.
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The Sercos identification number (IDN) for Cap1Config is P-O-3010.0.2
The Sercos identification number (IDN) for Cap2Config is P-O-3010.0.3

NOTE: This parameter cannot be saved in the Lexium persistent Memory (EEPROM).
Perform the sensor wiring (stripper) over a standard input as follows:
Alternatively to a TP input, an digital input of the controller may be used. However, in this case the
attainable accuracy depends on the master velocity and the program cycle time and/or the cycle
time of the Motion Controller. A captured position will be evaluated by the function block.
 sets the parameter xTpMode to FALSE.
 wire 1 of the digital inputs to i_xTpIputStd.
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SoMachine
GroupingAccumulator_Motion
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Chapter 11

Section Topic Page
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Section 11.1
GroupingAccumulator_Motion Function Block
Pin Diagram
The Accumulator function block is made up of:
 Inputs and outputs (they can be changed on the fly.)
 Parameters of inputs / outputs
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Section 11.2
Pin Description
Pin Description

Topic Page
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Input Data Description

Type
i_xEn BOOL TRUE: Enables the function block
 With a rising edge, the parameters are checked for
validity and consistency.
 A falling edge stops a movement with deceleration
lrDecEmgy.
 The parameters defined in iq_stPara are checked.
Incorrect or inconsistent input parameters affect the
outputs q_xAlrm and q_diAlrmId.
FALSE: The current movement stops with lrDecEmgy
 The output q_xActv stays TRUE until stopping is
finished.
 While q_xActv = TRUE, the function block must be
called cyclically.
i_xExe BOOL TRUE: The movement starts (steady signal required)·
lrAccDecStrt.
i_xWsSel BOOL FALSE: Cold start
TRUE: Warm start
Different cold and warm start modes are available, see
i_lrProdLen LREAL Length of product
 Must be << slave modulo (configured in Controller
configuration)·
 Must be ≤ i_lrDistTarg, otherwise an interruption
is generated.
Factory setting: 0
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Type
i_lrDistTarg LREAL Desired distance for products (length of product plus gap)
on master (stripper or target conveyor) of accumulator.
 Must be << slave modulo (configuration in Controller

configuration).
 Must be >= i_lrProdLen, otherwise an interruption
is generated
Factory setting: 0
Range: > 0
i_xAlrmRst BOOL TRUE: Detected alarm is acknowledged, function block
leaves alarm state.
i_xTpIputStd BOOL For product detection (first product edge at cold start),
see Sensor Wiring (see page 327)
i_xPulsIput BOOL Only with iOpMode = 1 or 3 pulse for product delivery.
i_lrPrdActlMstr LREAL The position period of the master has to be set here as
input. The master cannot make any position jumps
(because of modulo or set pos) different from this input or
the slave can not run.
Range: > 0
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q_xActv BOOL TRUE: Function block is active.
q_xPosStrtRchd BOOL TRUE: Cold / warm start position reached.
Reset with function block disabled (i_xEn = FALSE)
q_xCyclofSlavActv BOOL Only with iOpMode = 1 or 3
TRUE: While a slave cycle is in progress.
FALSE: When slave is ready to start a new cycle.
q_lrPrdActlSlav LREAL On this output the actual period of the CAM curve is
given.
If the drive is a master for another drive, this signal
has to be given to the control function block of the
slave.
q_xAlrm BOOL TRUE: Not OK
q_diAlrmId DINT Notification number:
Range: 0..99999
Troubleshooting
There are 2 types of notifications given on the output of the function block.
The first types of notifications come from internal (SoftMotion (SM3 library)) function blocks. These
notifications are given directly to the output q_diAlrmId. For these notifications see the
notifications list of the SoftMotion (SM3 library) function blocks.
The second types of notifications are generated by the function block itself. These notifications are
added to the global constant GC_MotionLib_ErrorOffset (standard 1000).
Detected Alarm ID (added to Notification

GC_MotionLib_ErrorOffset)
10 controller axis detected alarm
14 controlled axis in wrong state
15 controlled axis is not a modulo axis
50 invalid capture input
51 invalid iOpMode
52 invalid iWsMode
53 master moved during start
54 warm start not possible
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55 position outside warm start window
129 invalid lrDecEmgy
130 invalid lrWsWdow
453 lrTpDistToSypt < 0
455 FIFO full - too many products detected
501 FIFO empty - no products detected
502 no TP found
504 invalid i_lrSyncLen
505 invalid i_lrTpDistMin
506 invalid i_lrProdLen
507 invalid i_lrDistTarg
508 i_lrProdLen greater i_lrDistTarg
509 i_lrSyncLen greater i_lrDistTarg
510 i_lrSyncLen greater i_lrDistDflt
511 invalid i_lrDistDflt
512 lrTpDistToSypt smaller i_lrDistDflt plus
i_lrTpDistMin
513 i_lrTpDistMin smaller i_lrSyncLen
514 invalid iCsMode
515 invalid lrCsDistMax
516 invalid lrVelStrt
517 invalid lrAccDecStrt
519 invalid lrVelOpMode1
520 invalid lrAccOpMode1
521 invalid lrDecOpMode1
522 invalid lrPulsSyncPhas
523 invalid Slop
524 invalid lrVelStsl
525 invalid lrCorrMax
526 invalid lrMstrOfst
527 invalid warm start data
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iq_stDrvMstr AXIS_REF_SM3 Master axis (stripper or
target conveyor)
reference
iq_stDrvSlav AXIS_REF_SM3 Slave axis
(accumulator)
reference
iq_stPara STRUCT Block parameters
ST_GroupingAccumulatorParameter For further information,
refer to Structured
Parameters
(see page 339).
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iq_stPara

iCsMode INT Cold start mode
0: first product is moved to delivery position
1: dimension setting (no movement)
Cold Start Mode (see page 365)
Factory setting: 0
iWsMode INT Selecting warm start mode (see page 370).
Factory setting: 0
iOpMode INT 0: Geared mode (see page 358)
1: Triggered timed pulsed mode (see page 359)
2: Periodic geared pulsed mode (see page 360)
3: Triggered geared pulsed mode (see page 361)
Factory setting: 0
lrCsDistMax LREAL Maximum position allowed for detecting the first product
(i_xTpIputStd = TRUE)
= 0: no limitation
> 0: axis moves maximum this distance
lrWsWdowFwd LREAL Only with iWsMode = 1 or 4.
Maximum position that the slave is allowed to move
forward to return to the cam position.
lrWsWdowBack LREAL Only with iWsMode = 1 or 4.
Maximum position that the slave is allowed to move
backwards in order to return to the cam position.
Factory setting: 10
lrVelStrt LREAL Start velocity
lrAccDecStrt LREAL Start acceleration / deceleration (also for falling edge at
i_xExe)
lrTpDistToSypt LREAL Distance between TP (sensor) and SyncPt (start of
delivery).
Must be greater than master modulo (i_lrDistTarg) +
lrMstrOfst
lrDecEmgy LREAL Stop ramp for detected error stop or falling edge at
i_xEn.
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lrVelOpMode1 LREAL Only with iOpMode = 1
Maximum velocity for moving to the cam position.
lrAccOpMode1 LREAL Only with iOpMode = 1.
Maximum acceleration for moving to the cam position.
lrDecOpMode1 LREAL Only with iOpMode = 1.
Maximum deceleration for moving to the cam position.
lrSlop LREAL Only with iOpMode = 2 or 3.
Gear ratio between master and slave during the
synchronous phase.
Examples:
1: velocity ratio between accumulator and stripper is 1:1.
2: velocity ratio between accumulator and stripper is 2:1
(accumulator delivers the products to the stripper faster
than with 1:1).
Factory setting: 1
lrPulsSyncPhas LREAL Only with iOpMode = 2 or 3.
Length of the synchronous phase in percentage of the
product length.
Factory setting: 80
Range: 0..99%
lrMstrOfst LREAL Only with cold start and xCmpt = TRUE.
Product distance from a compartment edge.
Factory setting: 0
xCmpt BOOL Only with cold start
TRUE: Target conveyor with compartments.
FALSE: Target conveyor without compartments.
Compartments on the Target Conveyor (see page 319).
lrVelStsl LREAL Velocity window in which the drive is considered to be
standing still.
Factory setting: 10
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Chapter 12

Section Topic Page
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Section 12.1
GroupingStripper_Motion Function Block
Pin Diagram
The Stripper function block is made up of:
 Inputs and outputs (they can be changed on the fly.)
 Parameters of inputs / outputs
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Curve Diagrams
Trajectory for correcting the product distance:
The motion profile indicates how products are passed from the stripper to the target conveyor.
The distance of a product to its predecessor measured by the TP sensor of the stripper is
corrected. This is done so that the distance is exactly = i_lrDistTarg at the position of delivery
to the target conveyor. During the delivery (i_lrSyncLen) the stripper (slave) and the target
conveyor (master) move synchronously (Velocity = MasterVelocity). The TP sensor may have
detected another product (a maximum of 15 are possible) during this time.
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Special case: No product on conveyor
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Special case: Changing i_lrDistTarg on the fly
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Section 12.2
Pin Description
Pin Description

Topic Page
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Type
i_xEn BOOL TRUE: Enables the function block
 With a rising edge, the parameters are checked for validity and
consistency.
lrDecEmgy.
 The parameters defined in iq_stPara are checked. Incorrect
or inconsistent input parameters will affect the outputs
q_xAlrm and q_diAlrmId.
FALSE: The current movement stops with lrDecEmgy
 The output q_xActv stays TRUE until a stopping is finished.
 While q_xActv = TRUE, the function block must be called
cyclically.
i_xExe BOOL TRUE: The movement starts (steady signal required)
lrAccDecStrt.
FALSE: Stripper in cyclic (automatic) mode
 The stripper axis stops at the end of the synchronous phase
(position > i_rLenSync).
 If i_xExe goes TRUE again within the same synchronous
phase, the previous FALSE will be ignored.
i_xWsSel BOOL FALSE: Cold start
TRUE: Warm start
Different cold and warm start modes are available, refer
Cold Start (see page 368) and Warm Start (see page 370)
i_lrDistTarg LREAL Desired distance for products (length of product plus gap) on
master (stripper or target conveyor) of accumulator.
 Must be << slave modulo (configured in controller
configuration).
Factory setting: 0
Range: > 0
i_lrDistDflt LREAL Default distance on stripper. It should be equal to i_lrDistTarg
of accumulator and is used if a part is missing.
Factory setting: 0
Range: > 0
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Type
i_lrSyncLen LREAL Distance that the slave (stripper) moves synchronously with the
master (target conveyor).
Factory setting: 0
Range: > 0
i_lrTpDistMin LREAL Minimum distance between 2 edges at the TP input.
Factory setting: 0
Range: > 0
i_xAlrmRst BOOL TRUE: Detected alarm is acknowledged, function block leaves
alarm state.
i_xTpIputStd BOOL Standard input is used for product detection if xTpMode = FALSE.
Sensor Wiring (see page 328)
i_lrPrdActlMstr LREAL The position period of the master has to be set here as input. The
master cannot make any position jumps (because of modulo or set
pos) different from this input or the slave can not run.
Factory setting: 0
Range: > 0
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Output Data Description

Type
q_xActv BOOL TRUE: Function block is active.
q_xPosStrtRchd BOOL TRUE: Cold / warm start position reached.
Reset with function block disabling (i_xEn = FALSE)
q_xCorrMax BOOL TRUE: The current product would require a correction > lrCorrMax.
Instead a backward correction is executed (=> empty place on the
target conveyor) and this output q_xCorrMax is set.
q_iTpMisd INT Number of consecutive missing parts.
Range: 0...n
q_lrPrdActlSlav LREAL On this output the actual period of the CAM curve is given.
If the drive is a master for another drive, this signal has to be given to
the control function block of the slave.
E.g. to the input i_lrPrdActlMstr of the Accumulator function block.
q_xAlrm BOOL TRUE: Not OK
q_diAlrmId DINT Notification number:
Notification (see page 377)
Range: 0...99999
Troubleshooting
There are 2 types of notifications given on the output of the function block.
The first types of notifications are coming from internal used SoftMotion (SM3 library) function
blocks. These notifications are given directly to the output q_diAlrmId. For these notifications
see the notifications list of the SoftMotion (SM3 library) function blocks.

10 controlled axis not working
15 controlled axis is no modulo axis
51 invalid iOpMode
52 invalid iWsMode
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53 master moved during start
54 warm start not poosible
55 position outside warm start window
129 invalid lrDecEmgy
130 invalid lrWsWdow
453 lrTpDistToSypt < 0
455 FIFO full - too much products detected
501 FIFO empty - no products detected
502 no TP found
504 invalid i_lrSyncLen
505 invalid i_lrTpDistMin
507 invalid i_lrDistTarg
509 i_lrSyncLen greater i_lrDistTarg
510 i_lrSyncLen greater i_lrDistDflt
511 invalid i_lrDistDflt
512 lrTpDistToSypt smaller i_lrDistDflt plus
i_lrTpDistMin
513 i_lrTpDistMin smaller i_lrSyncLen
514 invalid iCsMode
515 invalid lrCsDistMax
516 invalid lrVelStrt
517 invalid lrAccDecStrt
519 invalid lrVelOpMode1
520 invalid lrAccOpMode1
521 invalid lrDecOpMode1
522 invalid lrPulsSyncPhas
523 invalid Slop
524 invalid lrVelStsl
525 invalid lrCorrMax
526 invalid lrMstrOfst
527 invalid warm start data
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iq_stDrvMstr AXIS_REF_SM3 Master axis (stripper or
target conveyor) reference
iq_stDrvSlav AXIS_REF_SM3 Slave axis (accumulator)
reference
ST_GroupingStripperParameter For further information refer
to Structured Parameters
(see page 339).
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iq_stPara
Changes of parameters are accepted with a positive edge at input i_xEn
At the same time the parameters are checked. If their values are invalid or inconsistent, an
interruption is generated which affects the outputs q_xAlrm and q_diAlrmId.

iWsMode INT Selecting warm start mode (see page 370).
Factory setting: 0
lrCsDistMax LREAL Maximum distance allowed for detecting the first
product (i_xTpIputStd = TRUE)
= 0: no limitation
> 0: axis maximum distance
lrCorrMax LREAL Maximum distance for forward correction.
If the distance to the next product is to high
(correction > lrCorrMax), a place on the target
conveyor is left empty.
This prevents excessive stripper acceleration
and velocity.
Factory setting: 20
lrWsWdowFwd LREAL Only with iWsMode = 1 or 4.
Maximum distance that the slave is allowed to
move forward in order to return to the cam
position.
lrWsWdowBack LREAL Only with iWsMode = 1 or 4.
Maximum distance that the slave is allowed to
move backwards in order to return to the cam
position.
Factory setting: 10
lrVelStrt LREAL Start velocity
lrAccDecStrt LREAL Start acceleration / deceleration (also for falling
edge at i_xExe)
xTpMode BOOL TRUE: Use TP input (iCptrNb)
FALSE: Use standard input (i_xTpIputStd)
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lrTpDistToSypt LREAL Distance between TP (sensor) and SyncPt (start
of delivery).
Must be greater than master modulo
(i_lrDistTarg) + lrMstrOfst
lrDecEmgy LREAL Stop ramp for error stop or falling edge at i_xEn.
lrMstrOfst LREAL Only with cold start and xCmpt = TRUE.
Product distance from a compartment edge.
xCmpt BOOL Only with cold start
TRUE: Target conveyor with compartments
FALSE: Target conveyor without compartments
Compartments of the Target Conveyor
(see page 319)
lrVelStsl LREAL Velocity window in which the drive is regarded as
standing still
Factory setting: 10
iCptrNb INT Number of the TP (0 or 1) to be used.
Factory setting: 0
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Operation Description
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Chapter 13

Section Topic Page
13.2 Start, Stop and Special Modes 362
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Section 13.1
Operating Modes
Operating Modes

Topic Page
General Description 357
Geared Mode 358
Triggered Timed Pulsed Mode 359
Periodic Geared Pulsed Mode 360
Triggered Geared Pulsed Mode 361
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General Description
Overview
iOpMode sets how the products are passed from the accumulator to the stripper (and/or the target
conveyor).
iOpMode Name Principle Description

0 Geared Mode Master/slave have constant velocity
ratio (during delivery master and slave
run with different velocities).
1 Triggered Timed Pulse triggered delivery of one product
Pulsed Mode length (independent of master; no
synchronous phase)
2 Periodic Geared Master/slave mode with synchronous
Pulsed Mode phase (during delivery master and
slave run with the same velocity).
The delivery is triggered cyclically and
depends on i_lrDistTarg.
3 Triggered Geared Master/slave mode with synchronous
Pulsed Mode phase (as with iOpMode = 2).
Here a pulse triggers the synchronous
+ phase
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Geared Mode
Overview
The accumulator follows its master with the velocity ratio:
i_lrProdLen and i_lrTargDis are both inputs of the GroupingAccumulator_Motion

block.
The master may be a stripper or target conveyor. The change of the velocity is accepted cyclically.
With a rising edge at i_xExe, the accumulator synchronizes with its master axis.
If i_lrProdLen or i_lrDistTarg are changed on the fly (during the movement), a (Poly5)
transition cam is used.
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Triggered Timed Pulsed Mode
Overview
On a rising edge at i_xPulsIput (and i_xExe = TRUE) one product is delivered. I.e., the
accumulator is positioned i_lrProdLen forward. There is no synchronization with the master.
Repetitive pulses (rising edges at i_xPulsIput) during one cycle are ignored.
The motion of the accumulator is defined by the following parameters:
 lrVelOpMode1 (velocity)
 lrAccOpMode1 (acceleration)
 lrDecOpMode1 (deceleration)
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Periodic Geared Pulsed Mode
Overview
When i_xExe = TRUE, the accumulator executes a periodic movement. With every master period
i_lrDistTarg one product is delivered.
Setting the delivery cam.
The accumulator follows its master over an electronic cam:
 X-Factor is i_lrDistTarg
 Y-Factor is i_lrProdLen
Within a master period (i_lrDistTarg) the slave movement is divided into 3 phases:
 acceleration phase
 synchronous phase
 deceleration phase
These curves can be adjusted by lrPulsSyncPhas and lrSlop. Their values must be
consistent. For further informations refer to Special Modes (see page 372).
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Triggered Geared Pulsed Mode
Overview
+
On a rising edge at i_xPulsIput (and i_xExe = TRUE) one product is delivered. The
accumulator performs one motion cycle and is positioned i_lrProdLen forward. Here if iOpMode
≠ 1, the motion cycle is defined by an electronic cam.
Repetitive pulses (rising edges at i_xPulsIput) during one cycle are ignored.
The delivery movement is the same as with iOpMode = 2.
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Section 13.2
Start, Stop and Special Modes
Start, Stop and Special Modes

Topic Page
Start and Resume Modes 363
Stop and Resume Modes 364
Cold Start - GroupingAccumulator_Motion 365
Cold Start - GroupingStripper_Motion 368
Warm Start 370
Special Modes 372
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Start and Resume Modes
Start and Resume Modes

When the input i_xEn is activated, the parameters defined in iq_stPara are checked for
consistency. With incorrect or inconsistent input parameters, q_xAlrm becomes TRUE. In
q_diAlrmId the notification number is indicated.
When the input i_xEn is activated, the control of the slave is managed by the Grouping function
block.
When the input i_xExe is activated, the slave is launched according to the start mode defined by
the input i_xWsSel.
WARNING
Grouping/Ungrouping application function block.
damage.
The start modes describe the slave behavior on a rising edge at i_xExe.
For the Accumulator, refer to Cold Start (see page 365) and Warm Start (see page 370).
For the Stripper, refer to Cold Start (see page 368) and Warm Start (see page 370).
The axes behavior when starting is dependent upon the conditions for stopping, which include:
 Falling edge at input i_xEn
 Falling edge at i_xExe
 Detected alarm in the block function
For further details, refer to Stop and Resume Modes (see page 364).
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Stop and Resume Modes
Stop and Resume Modes

The stop and resume modes describe the slave behavior according to the cause of the stop.
With normal execution of the function, when the master stops, the slave stops following the master
slope.
With the restart of the master (without modification of the block inputs) the slave will follow
accordingly.
Other causes for a stop may be:
Cause for Stop Stop Ramp Possible Resume Modes

Falling Edge at i_xEn lrDecEmgy Cold start or warm start
Falling Edge at i_xExe lrAccDecStrt Cold start or warm start
Block Problem lrDecEmgy Cold start
In all 3 cases the master (target conveyor and/or stripper) must be stopped immediately.
If this is not possible, the following events may occur:
If... Then...
conveyors are within SyncPhase with a standing or moving conveyor, the product
currently being delivered may be shifted in an
undefined manner.
conveyors are outside SyncPhase at the next warm start the next product can be
pushed onto a standing master conveyor.
Take into consideration the actions and events listed in the following table for a restart.
With an... Then...

cold start within SyncPhase you have to remove the products from the delivery
position before the cold start, otherwise a collision
may occur.
cold start outside SyncPhase the start can be managed without any specific
consideration.
warm start within SyncPhase after the the start can be managed without any specific
master stopped immediately consideration.
warm start within SyncPhase after the the product currently being delivered may be shifted
master had moved on in an undefined manner.
warm start outside SyncPhase after the start can be managed without any specific
the master stopped immediately consideration.
warm start outside SyncPhase after during the warm start the products may be pushed
the master had moved on onto a standing master conveyor.
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Cold Start - GroupingAccumulator_Motion
Overview
There are 2 different cold start modes for the behavior of the accumulator (see iCsMode in the
table below).
When the cold start is finished, q_xPosStrtRchd becomes TRUE.
For further informations refer to Warm Start Modes (see page 370).
Requirements for a Cold Start

A cold start is the first start after switching on the machine. The master (stripper or target conveyor)
must wait for the arrival of the first product before moving. Otherwise, at the end of the cold start
movement an interrupt is generated.
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Settings for a Cold Start

For a cold start, the following inputs and parameters must be set:
Input and/or Description

Parameter
i_xWsSel TRUE: Warm start
FALSE: Cold start
iCsMode Cold start mode
Setting Description
0 the axis moves until the TP sensor detects the first product
(i_xTpIputStd = TRUE). Then the axis moves forward
lrTpDistToSypt:
 When exceeding the lrCsDistMax for detecting a

product, an alarm is generated.
 When iOpMode = 1 or iOpMode = 3 and there is a
rising edge at i_xPulsIput, the conveyor moves
forward i_lrProdLen.
For further informations, refer to Sensor Wiring
(see page 327), Geared Mode (see page 358) and
Triggered Geared Pulsed Mode (see page 361).
1 setting dimension: the axis is set to a defined start position
(constant internal value). There is no movement taking
place.
 This mode is used where no TP sensor exists or is

taken into account. The user positions the first product
at the delivery position.
 The axis is set to the calculated slave position
(iOpMode = 1 or iOpMode = 3) and/or to
i_lrDistTarg (iOpMode = 0 or iOpMode = 2).
For further informations, refer to Geared Mode
(see page 358), Triggered Timed Pulsed Mode
(see page 359), Periodic Geared Pulsed Mode
(see page 360) and Triggered Geared Pulsed Mode
(see page 361).
lrTpDistToSypt Measured distance between the sensor (TP) and the synchronous
start point (SyncPt, end of conveyor, start of delivery)
lrCsDistMax maximum permissible distance for detecting the first product
Setting Description
=0 no limitation
>0 maximum axis movement
lrVelStrt start velocity
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Parameter
lrAccDecStrt start acceleration / deceleration
lrMstrOfst only if no stripper is used
only with xCmpt = TRUE
Product distance from a compartment edge
xCmpt only if no stripper is used
TRUE: Compartments on target conveyor. Refer to Compartments of
the Target Conveyor (see page 319)
FALSE: No compartments on target conveyor. The synchronization
starts immediately.
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Cold Start - GroupingStripper_Motion
Overview
The stripper moves until the TP sensor detects a product. Then q_xPosStrtRchd becomes
TRUE.
Requirements for a Cold Start

A cold start is the first start after switching on the machine. The position of the products are
unknown.
The cold start of the accumulator (if applicable) must be finished, i.e., the accumulator operates in
automatic mode. For further information, refer to Cold Start Accumulator (see page 365) and
Sensor Wiring (see page 328).
The master (target conveyor) must wait for the arrival of the first product.
Otherwise, at the end of the cold start movement an interruption is generated.
If compartments are used, the target conveyor must wait in its start position.
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Settings for a Cold Start

For a cold start, the following inputs and parameters must be set:

Parameter
i_xWsSel TRUE: Warm start
FALSE: Cold start
lrTpDistToSypt Measured distance between the sensor (TP) and the synchronous
start point (SyncPt, end of conveyor, start of delivery)
lrCsDistMax maximum permissible distance for detecting the first product
Setting Description
=0 no limitation
>0 maximum axis movement
lrVelStrt start velocity
lrAccDecStrt start acceleration / deceleration
lrMstrOfst only with xCmpt = TRUE
Product distance from a compartment edge
xCmpt TRUE: Compartments on target conveyor. Refer to Compartments
of the Target Conveyor (see page 319)
FALSE: No compartments on target conveyor. The synchronization
starts immediately.
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Warm Start
Requirements for a Warm Start

You execute a warm start in order to continue an interrupted cycle at the current position of the
master (after an emergency stop, for example). The master (stripper or target conveyor) has
stopped and its position is known. The slave (accumulator or stripper) usually stops outside of its
cam position.
Settings for a Warm Start

 At start of the movement i_xWsSel must be TRUE.
 The warm start mode is selected. (see below)
 The master axis must not be moved.
 A warm start is not possible with iOpMode = 1. Refer to Tiggered Timed Pulsed Mode
(see page 359)
Warm Start Behavior

 The slave (accumulator) returns to its cam position that depends on the warm start mode.
 When the cam position is reached, q_xPosStrtRchd becomes TRUE.
For further informations, refer to Accumulator Cold Start (see page 365) and Selecting Warm Start
Mode.
Selecting a Warm Start Mode

The parameter iWsMode selects between 3 different warm start modes:
iWsMode Description Representation

0 The slave moves directly to
its cam position.
NOTE: The slave may go
backwards to reach its cam
position.
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iWsMode Description Representation

1 The slave moves to its cam
position only if it is within the
range lrWsWdowBack <
warm start window <
lrWsWdowFwd
If slave position is outside of
this warm start window an
alarm is generated.
4 The slave keeps its distance

to the cam. A position alarm
on target conveyor must be
acceptable.
The initial slave position
must be within the warm start
window, otherwise an alarm
is generated.
This warm start window is
the range between
lrWsWdowFwd and
lrWsWdowBack in relation
to the initial master position.
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Special Modes
lrPulsSyncPhas
The length of the synchronous phase is configured by the parameter lrPulsSyncPhas, which
represents a percentage of i_lrProdLen.
The remainder of i_lrProdLen is evenly divided between acceleration and deceleration.
Example:
lrPulsSyncPhas = 80 means that the accumulator conveyor moves synchronously (to be exact:
they have the same velocity only if lrSlop= 1) with its master for 80% of i_lrProdLen. 10% is
used for acceleration and 10% for deceleration.
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lrSlop
The master/slave velocity ratio during the synchronous phase is configured with the parameter
lrSlop. The cam may then have a dwell phase. lrSlop does not affect the length of the
synchronous phase. This is set with lrPulsSyncPhas.
Examples:
lrSlop = 1 means a velocity ratio between accumulator and stripper of 1:1.
lrSlop = 2 increases this ratio to 2:1. The accumulator delivers the products to the stripper faster.
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Chapter 14

This chapter contains the following topics:
Topic Page
Visualization 376
Troubleshooting 377
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Visualization
Overview
Visualization screens are embedded in the Packaging library. They help to configure and to start
the application function blocks easily and quickly.
For more information please refer to How to integrate the Visualization into an Application
(see page 395).
Stripper visualization
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Troubleshooting
Troubleshooting

The cycle is Parameter is invalid or
stopped and inconsistent.  Correct the parameter.
detected alarm  Set new rising edge at i_xEn.
outputs are set.
Inputs are invalid or
inconsistent.  Correct the inputs and acknowledge
with i_xAlrmRst.
 Set new rising edge at i_xExe.
Application during operation

(general alarm)  Correct the application and
acknowledge with i_xAlrmRst.
 After i_xEn -> FALSE, execute a
warm start and/or a cold start.
For further information, refer to Starting
Modes (see page 365).
The SoftMotion SoftMotion (SM3 library)
(SM3 library) (e.g., incorrect following)  Correct the SoftMotion (SM3 library)
function block function block and acknowledge with
detected alarm is i_xAlrmRst.
passed on to the  Restart SoftMotion (SM3 library)
alarm outputs of function block.
the Grouping  After i_xEn -> FALSE, execute a
function block. warm start and/or a cold start.
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Clamping
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Part IX
Clamping
Clamping
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Clamping
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Clamping_Motion
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Chapter 15
Clamping_Motion: Logical Sequence of Product Clamping with Torque Limitation
Clamping_Motion: Logical Sequence of Product

Clamping with Torque Limitation

Section Topic Page
15.5 Operating Mode 394
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Clamping_Motion
Section 15.1
Functional Overview
Usage of Clamping_Motion Function Block?

The Clamping_Motion function block is required for clamping arbitrary products.
Solution with the Clamping_Motion Function Block

When i_xCls is activated, the clamping starts a fast positioning up to a defined position or until
the recognition of an input signal. After this, the axis brakes and continues driving slowly until a set
reference current or the goal position is reached. With the signal i_xOpen, the clamping returns
to a specified position.
NOTE: The function block only runs on type S controllers.
NOTE: The closing movement must be in positive direction of the drive.
CAUTION
UNITENDED EQUIPMENT OPERATION
The Clamping function works only with drives of type Lexium 05 or Lexium 32.
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Clamping_Motion
Section 15.2
Architecture
Architecture
Profile in Principle
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Clamping_Motion
Motion Profile
Clamping without Product Detection
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Clamping with Product Detection
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Clamping_Motion
Section 15.3
Clamping_motion Function Block
Pin Diagram

When i_xEn is activated, the block is activated. The parameters defined in iq_stPara are
examined. If the input parameters are incorrect or inconsistent, q_xAlrm becomes TRUE.
q_diAlrmId indicates the alarm number.
When i_xCls is activated, the axis is started and moves with lrVelHigh until it reaches
lrPosNear. After this, the axis decelerates and moves with the slow speed lrVelLow. When the
current specified in dwCurrLim is reached, the axis stops. Alternatively, switching to slow speed
can be accomplished with a TP input or a standard input (i_xTpIputStd).
WARNING
Clamping_Motion application function block.
damage.
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Clamping_Motion
Section 15.4
Pin Description
Pin Description

Topic Page
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Clamping_Motion

i_xEn BOOL TRUE: Block is activated
i_xCls BOOL TRUE: Closing block function is started (edge
evaluation)
i_xOpen BOOL TRUE: Opening block function is started (edge
evaluation)
i_xTeach BOOL TRUE: Start of teach procedure
i_xAlrmRst BOOL TRUE: Alarm reset on rising edge.
i_xTpIputStd BOOL Capture input (standard) of master position.
Significant only if xTpMode = FALSE
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q_xActv BOOL TRUE: Block is activated
q_xBusy BOOL TRUE: Cycle is in progress
q_xCls BOOL TRUE: Jaw is in closed position. Torque is constant
and product is clamped
q_xInfd BOOL TRUE: Axis has reached lrInfdPos position
q_xOutfd BOOL TRUE: Axis has reached lrOutfdPos position
q_xPosBhndRchd BOOL TRUE: Axis has reached lrPosBhnd position (no
product for clamping found)
q_xAlrm BOOL TRUE: There is a detected alarm
q_diAlrmld DINT Notification number.
For detailed information see table below.
Notifications
There are 2 types of notifications numbers given on the output q_diAlrmId of the function block.
The first types of notifications are coming from internal used (SoftMotion (SM3 library)) function
blocks. These notifications are given directly to the output q_diAlrmId. For these notifications
see the list of notifications of the SoftMotion (SM3 library) function blocks.

10 controlled axis not working
15 controlled axis is no modulo axis
16 invalid drive - the Clamping_Motion function block
supports only the LXM05, LXM32A and LXM32M
drive
400 teach not possible
401 invalid dwCurrLim
403 invalid lrAccHigh
404 invalid lrDecHigh
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Clamping_Motion

405 invalid lrVelHigh
406 invalid lrAccLow
407 invalid lrDecLow
408 invalid lrVelLow
409 invalid lrPosNear
410 invalid lrAccOpen
411 invalid lrDecOpen
412 invalid lrVelOpen
413 invalid lrPosBhnd
414 invalid teach input
415 close speed too fast
416 close speed too slow
418 lrPosNear reached without detecting TP signal
419 lrTpDistNearPnt greater than lrPosBhnd -
IrPosOpen
420 invalid lrInfdPos
421 invalid lrOutfdPos
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iq_iTeachPara INT Position for the teaching
0 (none)
1 OutFeed position
2 InFeed position
3 Near position
4 Open position
ST_ClampingParameter Refer to the input structured
parameter iq_stPara
(see page 392).
iq_stDrv SM3_Basic.AXIS_REF_SM3 Axis to be controlled.
Axis has to be configured as
linear axis.
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Clamping_Motion
iq_stPara

dwCurrLim DWORD Value of current limitation during clamping
procedure in steps of 1/100 A
Factory setting: 25
lrPosOpen REAL Position when the clamping is opened
Factory setting: 0
lrInfdPos REAL Position for display of output q_xInfd (only
displayed on opening)
Can be used to start infeed of the product.
Factory setting: 50
lrOutfdPos REAL Position for display of output q_xOutfd (only
displayed on opening)
Can be used to start outfeed of the product.
Factory setting: 80
lrPosBhnd REAL Virtual behind position. If this position is reached,
q_xPosBhndRchd goes to TRUE and an alarm
notification is generated.
It means that no product has been found.
Range: >lrPosNear, <lrPosOpen
lrPosNear REAL Near position: position for changeover from fast to
slow speed on closing. This parameter is used only
when clamping is done without product detection
(xTpUse = FALSE).
Range: >lrPosOpen
lrVelHigh REAL Speed for fast movements (closing)
Range: >= 0.1
lrAccHigh REAL Acceleration for fast movements (closing)
Range: >= 0.1
lrDecHigh REAL Brake ramp for fast movements (closing)
Range: >= 0.1
lrVelLow REAL Speed for slow movements (closing)
Factory setting: 10
Range: >= 0.1
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lrAccLow REAL Acceleration for slow movements (closing)
Range: >= 0.1
lrDecLow REAL Brake ramp for slow movements (closing)
Range: >= 0.1
lrVelOpen REAL Speed for opening the clamping
Range: >= 0.1
lrAccOpen REAL Acceleration for opening the clamping
Range: >= 0.1
lrDecOpen REAL Brake ramp for opening the clamping
Range: >= 0.1
lrDecEmgy REAL Brake ramp in case of interruption or block de-
selection
Range: >= 0.1
xTpUse BOOL TRUE: Clamping with product detection.
Use product detection (TP) to start slow approach.
xTpMode BOOL Used only if xTpUse = TRUE
FALSE: TP over standard input (i_xTpIputStd)
TRUE: TP over TP input
iCptrNb INT Touch Probe number
Used only if xTpUse = TRUE and xTpMode = TRUE.
Factory setting: 1
Range: 0...1
xTpEdge BOOL Used only if xTpUse = TRUE
FALSE = negative edge
TRUE = positive edge
lrTpDistNearPnt REAL Used only if xTpUse = TRUE
Distance between sensor (captor) and slow
approach position.
Factory setting: 20
If no product detection is used, then due to movement behavior, the parameters have to fulfil the
following formulas:
lrPosNear - lrPosOpen < lrVelLow² / (2 * lrAccHigh)
lrPosBhnd - lrPosOpen < lrVelLow² / (2* lrAccHigh)
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Clamping_Motion
Section 15.5
Operating Mode
Operating Mode
Overview
According to the architecture and the precision requirements of the application, several capture
modes are possible:
Capture Mode Description

Detection with standard The sensor is wired to a standard input. The capturing is done in the cycle of
input the motion task in which the function block is called.
Detection with special input The sensor is wired to a special input:
 The inputs of the controller are captured if the master axis is an encoder.
 A input of a servo drive is captured if the master is a servo drive.
xTpMode iCptrNb i_xTpIputStd

FALSE: Capturing with No effect Associated with the standard input.
standard input The digital input has to be connected to the
input i_xTpStdIput.
TRUE: Capturing with Touch Probe input number. If TP2 is No effect
special input used, then iCptrNb = 1
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Section 15.6
Visualization
Overview
Visualization screens are in the Clamping folder. They help to configure and start the application
function block easily and quickly. All the inputs/outputs and all the parameters are accessible.
How to start the visualization is described in the following.
How to Integrate the Visualization into an Application

The following table describes the procedure of integrating the visualization into an application:
Step Action
1 In the Tools Tree right click Application.
2 Select Add Object.
3 Select the Visualization object and give it a name (e.g., MyVisualization) and press Add.
Result: The visualization and the Visualization Manager are added to the project.
4 In the screen of MyVisualization add a new frame by selecting Frame in the toolbox. Drag the
Frame onto the visualization screen.
Result: The Frame Configuration window appears.
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Clamping_Motion
Step Action
5 Select for the visualization ClampingVis and move it with the Add button and press OK.
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Clamping_Motion
Step Action
6 To avoid deformation of the visualization, set the scale type in the properties of the frame to FIXED.
To connect the visualization to the project set 3 references to the instances of your project:
 refClampingFb -> the instance of the function block Clamping_Motion.
 refClampingParam -> the instance of the structure which is connected to the input iq_stPara
of the clamping instance.
 refTeachParam -> the instance of the variable which is connected to the input
iq_iTeachPara of the clamping instance.
Result: The visualization is ready to work.
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SoMachine
Glossary
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Glossary
A
AFB
(application function block)
analog output
Converts numerical values within the logic controller and sends out proportional voltage or current
levels.
C
CANmotion
A CANopen-based motion bus with an additional mechanism that provides synchronization
between the motion controller and the drives.
CANopen
An open industry-standard communication protocol and device profile specification (EN 50325-4).
closed loop
A closed loop control is a motion control system that used both positional feedback and velocity
feedback to generate a correction signal. It does this by comparing its position and velocity to the
values of specified parameters. The devices providing the feedback are typically encoders,
resolvers, LVTDs, and tachometers.
See also: open loop
closing on stack
process of filling the grab with bulk cargo
configuration
The arrangement and interconnection of hardware components within a system and the hardware
and software parameters that determine the operating characteristics of the system.
E
EEPROM
(electrically erasable programmable read-only memory) A type of non-volatile memory to store
required data even when power is removed.
element
The short name of the ARRAY element.
equipment
A part of a machine including sub-assemblies such as conveyors, turntables, and so on.
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Glossary
F
FB
(function block) A convenient programming mechanism that consolidates a group of programming
instructions to perform a specific and normalized action, such as speed control, interval control, or
counting. A function block may comprise configuration data, a set of internal or external operating
parameters and usually 1 or more data inputs and outputs.
function
A programming unit that has 1 input and returns 1 immediate result. However, unlike FBs, it is
directly called with its name (as opposed to through an instance), has no persistent state from one
call to the next and can be used as an operand in other programming expressions.
Examples: boolean (AND) operators, calculations, conversions (BYTE_TO_INT)
H
HMI
(human machine interface) An operator interface (usually graphical) for human control over
industrial equipment.
HSP
(high speed) The motor frequency at maximum reference of a drive.
I
ID
(identifier/identification)
input/output
The index of the ARRAY.
K
Kp
The proportional gain parameter of a PID controller.
L
LSP
The motor frequency at minimum reference of a drive.
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Glossary
M
machine
Consists of several functions and/or equipment.
master/slave
The single direction of control in a network that implements the master/slave mode.
ms
(millisecond)
N
node
An addressable device on a communication network.
O
open loop
Open loop control refers to a motion control system with no external sensors to provide position or
velocity correction signals.
See also: closed loop.
OTB
(optimized terminal block) Used in the context of STB I/O distributed modules.
P
pallet
A portable platform, which is used for storing or moving goods.
PID
(proportional, integral, derivative) A generic control loop feedback mechanism (controller) widely
used in industrial control systems.
PLCopen
The standard that brings efficiency, flexibility, and manufacturer independence to the automation
and control industry through the standardization of tools, libraries, and modular approaches to
software programming.
program
The component of an application that consists of compiled source code capable of being installed
in the memory of a logic controller.
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Glossary
protocol
A convention or standard definition that controls or enables the connection, communication, and
data transfer between 2 computing system and devices.
Pt100/Pt1000
(platinum 100/1000) Resistance thermometers, also referred to as resistance temperature
detectors, are sensors used to measure temperature by correlating electrical resistance with
temperature. As the temperature changes, the resistance to an electrical current passing through
them predictably changes likewise. They are characterized by their nominal resistance R0 at a
temperature of 0 ° C.
 Pt100 (R0 = 100 Ω)
 Pt1000 (R0 = 1 kΩ)
PWM
(pulse width modulation) A fast output that oscillates between off and on in an adjustable duty
cycle, producing a rectangular wave form (though you can adjust it to produce a square wave). The
PTO is well adapted to simulate or approximate an analog output in that it regulates the voltage of
the output over its period making it useful in light dimming or speed control applications, among
others.
R
RPM
(revolutions per minute)
run
A command that causes the controller to scan the application program, read the physical inputs,
and write to the physical outputs according to solution of the logic of the program.
S
scan
A function that includes:
 reading inputs and placing the values in memory
 executing the application program 1 instruction at a time and storing the results in memory
 using the results to update outputs
SDO
(service data object) A message used by the field bus master to access (read/write) the object
directories of network nodes in CAN-based networks. SDO types include service SDOs (SSDOs)
and client SDOs (CSDOs).
402 EIO0000000195 06/2015

Glossary
Sercos
(serial real-time communications system) A digital control bus that interconnects, motion controls,
drives, I/Os, sensors, and actuators for numerically controlled machines and systems. It is a
standardized and open controller-to-intelligent digital device interface, designed for high-speed
serial communication of standardized closed-loop real-time data.
setpoint
In a PID controller, the target value set by the user. The main objective of the PID controller is to
ensure that the process value reaches the setpoint.
See also process value.
STOP
A command that causes the controller to stop running an application program.
T
task
A group of sections and subroutines, executed cyclically or periodically for the MAST task or
periodically for the FAST task.
A task possesses a level of priority and is linked to inputs and outputs of the controller. These I/O
are refreshed in relation to the task.
A controller can have several tasks.
TP
(touch probe) A position capture that is triggered by a fast input signal (quick sensor). On the rising
edge of the touch probe input, the position of an encoder is captured.
For example, this is used for packaging machines to capture the position of a printmark on a film
to cut on the same position.
V
variable
A memory unit that is addressed and modified by a program.
VSD
(variable speed drive) An equipment that makes a variable and regulates the speed and rotational
force, or torque output, of an electric motor.
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Glossary
404 EIO0000000195 06/2015

SoMachine
Index
EIO0000000195 06/2015
Index
A P
AnalogTensionControlATV, 135 Packaging
AnalogTensionControlATV_Motion, 135 AnalogTensionControlATV, 135
AnalogTensionControlLXM_Motion, 135 AnalogTensionControlATV_Motion, 135
AnalogTensionControlLXM_Motion, 135
Clamping_motion, 381
C DigitalTensionControlATV, 103
Clamping_motion, 381 DigitalTensionControlATV_Motion, 103
FlyingShear_Motion, 295
function block location in the Packaging li-
D brary, 23
DigitalTensionControlATV, 103 grouping - ungrouping, 315
DigitalTensionControlATV_Motion, 103 GroupingAccumulator_Motion, 331
GroupingStripper_Motion, 341
LateralPositionControl, 193
F MoveJog, 27
FlyingShear_Motion, 295 RotaryKnife_Motion, 225
system requirements, 20
TemperatureControl, 159
G XYPickAndPlace, 59
grouping - ungrouping, 315
GroupingAccumulator_Motion, 331
GroupingStripper_Motion, 341
R
RotaryKnife_Motion, 225
L
LateralPositionControl, 193
S
system requirements, 20
M
material movement, 25
T
MoveJog, 27 TemperatureControl, 159
X
XYPickAndPlace, 59
EIO0000000195 06/2015 405

Index
406 EIO0000000195 06/2015

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SoMachine

BEFORE YOU BEGIN

START-UP AND TEST

Product Related Information

Packaging Library System Requirements

What Is in This Chapter?

Packaging System Requirements

Application Function Block Requirements

 MoveJog  Logic Controller

 DigitalTensionControlATV  Logic Controller

 DigitalTensionControlATV_Motion  Motion Controller

 RotaryKnife_Motion  Motion Controller

The targeted controller for the segment Packaging are:

The preferred drives are:

Application Function Block Requirements

 MoveJog CANopen protocol is used for

Using the Library

For more detailed information, see Schneider Electric Libraries.

Function Block Location in the Packaging Library

Function Block Location in the Packaging Library of SoMachine

Folder Sub-Folder Application Function Block

What Is in This Part?

MoveJog: Manual Control of a Single Axis in Different

What Is in This Chapter?

Functional and Machine Overview

What Is in This Section?

Usage of MoveJog Function Block

Solution with the MoveJog Function Block

Design & Realization Constraints and Assumptions

Functional View for Linear axis

What Is in This Section?

Hardware Architecture Overview

Function Block Description

What Is in This Section?

MoveJog Function Block

Function Block Description

Speed Mode: i_byOpMode=0

Position Mode: i_byOpMode=1

Homing Mode: i_byOpMode=2

What Is in This Section?

Input Pin Description

Input Pin Description

Input Data Type Description

Input Data Type Description

i_xLsEn BOOL TRUE: Enables the hardware limit switch functionality

Input Data Type Description

i_xAlrmRst BOOL TRUE: Reset the detected alarm on a rising edge.

Structure Data Type Description

Method Number Description

Method Number Description

Input/Output Pin Description

Input/Output Pin Description

Input/Output Data Type Description

Output Pin Description

Output Pin Description

Output Data Type Description

Quick Reference Guide

What Is in This Section?