SIMOTION Rotary Knife V3.

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Introduction
The application SIMOTION Rotary Knife was developed with the
objective to address many of the known cross cutter applications
using just one application software.
When required, the application can be configured or also changed
as a result of openness.
Using the SIMOTION control platform the application SIMOTION
Rotary Knife allows to realize cross cutters to be implemented for
the widest range of applications, e.g. foil, film, paper, currogated
etc.

Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

Works in combination with:

SIMOTION Axis Function Block

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Benefits when using the Application
Shorter engineering and service times (same look & feel)

Introduction

Can be used in all programming languages

Benefits when
using the
Application

Industry standards are used

Contents of the
Application

Supported by the various PM Application Centers

Scope of
Functionality

Continuously updated in the Intranet

Function Block
Overview

Essentially open source code so that you can adapt the functions
to your requirements

Example
Configuration

User Manuals in German and English

Test-FB

Demoprojekt

Tools

Simple to learn & get to know using application examples

Free of Charge

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Contents of the Application
PowerPoint presentation (English / German)
Units / libraries (programming in either ST or MCC)
User Manuals (English / German)
Example project for SIMOTION D demonstration case
Feedback sheets (English / German)

Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt

Change log (change history)

Test-FB
Tools

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Converting Toolbox
Scope of Functionality
The goal of the Rotary Knife
The principal requirement of the rotary knife is to respect the
synchronism during the cut the moving web by the knife or by
the tool
The standard Rotary Knife used to divide
into pieces a moving web

Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview

Special tools for

Perforation
Welding
Double cut

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Example
Configuration
Demoprojekt
Test-FB
Tools

Converting Toolbox
Scope of Functionality
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

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Scope of Functionality
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

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Scope of Functionality
Design and characteristic values of the Rotary Knife

Introduction

Synchronous Angle
(Synchronous Range)

Phase1

le

yncA
ngle

stopAngle

inflectionPoint
(Middle Position)

Phase1

gle
ncAn

g
ncAn

start
S

Phase2

Format Range

y
endS

inflectionPoint
(Middle Position)

Phase2

stopAngle

start

ngle
yncA

y
endS

start
Sync
Angle

endS

Format Range

Sync
Angle

knifeCircumference
startAngle

Scope of
Functionality

startAngle

Synchronous Angle
(Synchronous Range)

Description

KnifeCircumference [mm]
StartAngle []
InflectionPoint [%]

Effective circumference of the rotary knife (circle circumference)

Start angle of the knife referred to 0
Reverse position (inflection point) of the cyclic cam referred to the length of the format range

StopAngle []
StartSyncAngle []

Stop angle of the knife referred to 0

Start point of the synchronous range referred to 0.
From this position onwards, the cutting knife must move in synchronism with the material to be cut.

EndSyncAngle []

End point of the synchronous range referred to 0.

From this point onwards, the knife no longer has to move in synchronism with the material to be cut, and depending
on the requirement, can be accelerated or decelerated to adapt the format

NumberOfKnives
DistanceToSensor [mm]

Number of knives distributed around the circumference.

Distance between the cutting position (0) and the sensor to detect the material and print mark

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Contents of the
Application

Function Block
Overview
Material

Physical quantity

Benefits when
using the
Application

Example
Configuration
Demoprojekt
Test-FB
Tools

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Scope of Functionality
The following cam profiles can be selected:
LINEAR
This selection defines a motion profile with constant acceleration..

POLY_5
This selection defines a fifth order polynomial as basis for the motion profile..

Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview

SINUS
This selection defines a sinus as basis for the motion profile..

JERK
This selection defines a profile with constant acceleration and jerk limiting.
Jerk limiting is specified using parameter jerkPhase1 / jerkPhase.
The parameters are only evaluated in this profile.

Example
Configuration
Demoprojekt
Test-FB
Tools

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Scope of Functionality
The following cutting profiles can be selected:
Linear cutting curve:
knifeOverspeedStartCut = 0.0%

Introduction
Benefits when
using the
Application

V
Max. velocity

knifeOverspeedZero = 0.0%
knifeOverspeedEndCut = 0.0%

Synchronous
speed (machine
speed)

Synchronous
range
endSyncAngle

Format range

Synchronous
range
startSyncAngle

Knife
exit

Knife
entry
t

Cycle

Contents of the
Application
Scope of
Functionality

Cutting point

Linear cutting curve with 5% overspeed:

Function Block
Overview

knifeOverspeedStartCut = 5.0%
knifeOverspeedZero = 5.0%
knifeOverspeedEndCut = 5.0%

Example
Configuration
Demoprojekt
Test-FB

Polynomial cutting curve:

Tools

knifeOverspeedStartCut = 5.0%
knifeOverspeedZero = 0.0%
knifeOverspeedEndCut = 5.0%
Knife
exit

Knife
entry

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Cutting point

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Scope of Functionality
Operating mode management:

Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

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Scope of Functionality
Introduction
Description

State
ERROR (0)

FBRotaryKnife has detected a fault and has brought the rotary knife axis into a safe state. The
fault is still present and can be evaluated by the user.
The rotating knife has been stopped and is in the DISABLE mode. .

Benefits when
using the
Application
Contents of the
Application

DISABLE (1)

FBRotaryKnife is ready for use, but is still in the safe operating state.
All of the pending faults have been successfully acknowledged. The rotating knife is in the state
after a reset, deactivated and stopped

Scope of
Functionality

STARTPOSITION (2)

The rotating knife is moving or is already located at the START POSITION and is ready to be
synchronized to the material web. The axis waits in the START POSITION operating mode

Function Block
Overview

AUTOMATIC (3)

The rotating knife has been synchronized to the material web and is cutting the material according
to the specifications

MANUAL (4)

The rotating knife is the manual mode; the user can manually move the axis.
The axis waits in the MANUAL operating mode.

Example
Configuration
Demoprojekt
Test-FB
Tools

SINGLE_CUT (5)

The rotating knife is ready for a single cut.

SAMPLE_CUT (6)

The rotating knife is ready to cut a series of test pieces.

(Number and length of pieces has to be entered in SampleBuffer before starting!)

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Scope of Functionality

Parameterization instead of programming

Open Source
Linear cut curve with adaptable over speed
Different Profiles: Const. acceleration, jerk limitation,
polynomial 5th, Sinus and polynomial 6th
Print mark correction with settable correction speed:
Correction movement in the format range
Shift register
Multi knife system
Settable Standby position of the knife
Predefined start and stop behavior
Dynamic change of the cut length on the fly
Operating mode manager
Single cut and sample cut (cut program) functionality.

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Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

Converting Toolbox
Scope of Functionality
Additional functionality in version 3.0:
Pre control of acceleration torque
Pre control of cutting torque
Pre control of DC-Link voltage
(only by using ALM and capacitors connected to DC-Link!)
Increasing the functionality of CAM calculation
- new profiles in format section: POLY_6, SINUS
- profiles in synchronous section: CONST (conform to V2.0!)
LINEAR (kick out)
- pendulum cut possible when
formatlength > 4 * knifecircumference
Interrupt / Continue Production
Vmax-Calculation
- calculation of maximal web speed at a certain formatlength
- calculation of performance curves

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Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

Converting Toolbox
Function Block Overview
The Rotary Knife functionality is part of the
Library LRKLib and included in the
application SIMOTION Rotary Knife:
The Library consists of 9 Units:
aVersion
cPublic
RK_CamCalc
RK_Progs
RK_ProgsVmax
RK_Template
RK_TemplateVmax
RK_Tools
RK_ToolsVmax

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Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

Converting Toolbox
Example Configuration
SIMOTION D445
(Technology and Machine Control)

Example Configuration:
SIMOTION D445
SINAMICS S120 DC/AC
SINAMICS ALM
Capacitor Module
TM17
1FW3 Motors

Standards:
SIMOTION Rotary Knife
SIMOTION Line Axis or
SIMOTION Axis Function Block

Infeed ALM

SIMOTION D445

(High End, Machine control or stand alone)

Introduction
Benefits when
using the
Application
Contents of the
Application

Motor Modules

Rotary Knife
1FW3

Scope of
Functionality
Function Block
Overview

PM External
TM17Encoder
Evaluation
SMC
Aux. Axis

Example
Configuration
Demoprojekt
Test-FB
Tools

Benefits:
High hardware integration (no special controller required)
Standard Hardware No Black Box solution or special components
Machine Control and Technology in one controller
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Higher
Efficiency through Energy buffer

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Example Configuration
SIMOTION D4x5
(Technology and Machine Control)

Example Configuration:

Introduction
Benefits when
using the
Application

(Medium Performance, Machine control or stand alone)

Standards:
SIMOTION Rotary Knife
SIMOTION Line Axis or
SIMOTION Axis Function Block

Contents of the
Application

Motor Modules

SIMOTION D4x5
SINAMICS S120 DC/AC
SINAMICS SLM/BLM
Breaking Resistor (optional)
1FK/1FT or 1FW3 Motor

Infeed
SLM/BLM
SIMOTION D4x5

Scope of
Functionality
Function Block
Overview
PM
TM17

Rotary Knife

External
Encoder
Evaluation
SMC

Aux. Axis

Example
Configuration
Demoprojekt
Test-FB
Tools

Benefits:
High hardware integration (no special controller required)
Standard Hardware No Black Box solution or special components
Modular Solution with scalable performance
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Flexible
infeed concepts

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Example Configuration
Example Configuration:

Introduction

HMI

(Low Cost / Low Performance)

SIMOTION D410
SINAMICS S120 AC/AC
Breaking Module (optional)
1FK7 Motor

Standards:
SIMOTION Rotary Knife
SIMOTION Line Axis or
SIMOTION Axis Function Block

SIMOTION D410

Ethernet / PROFIBUS
SIMOTION D410
(Technology and
Machine Control)
PM340
Rotary Knife
1FK7

Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview

External
Machine Encoder

Example
Configuration
Demoprojekt
Test-FB
Tools

Benefits:
Cheap and simple stand alone solution (no special controller required)
Onboard I/O inclusive fast inputs (printmark detection)
Onboard TTL/HTL/SSI Encoder interface for Machine Encoder
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Standard Hardware No Black Box solution or special components

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Demoprojekt
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

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Test-FB
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

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Tools - Auslegung
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

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Converting Toolbox
Tools - Auslegung
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Demoprojekt
Test-FB
Tools

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Thank you for your attention!

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