PLC PDF

Micro Application Example
Closed-Loop Positioning Control

with standard Drives
Micro Automation Set 1

Table of Contents
Micro Automation Set 1 ID Number 21063595
Note
The Micro Automation Sets are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The Micro
Automation Sets do not represent customer-specific solutions. They are only
intended to provide support for typical applications. You are responsible for
ensuring that the described products are correctly used. These Micro
Automation Sets do not relieve you of the responsibility of safely and
professionally using, installing, operating and servicing equipment. When using
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in these Micro Automation Sets and other Siemens publications – e.g. Catalogs
– the contents of the other documents have priority.
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We do not accept any liability for the information contained in this document.
Any claims against us – based on whatever legal reason – resulting from the
Copyright © Siemens AG 2008 All rights reserved
use of the examples, information, programs, engineering and performance data

etc., described in this Micro Automation Set shall be excluded. Such an
Set01_DocTech_2d0_en.doc
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Copyright© 2008 Siemens IA and DT. It is not permissible to transfer or
copy these Micro Automation Sets or excerpts of them without first
having prior authorization from Siemens IA and DT in writing.
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Table of Contents
Foreword
Micro Automation Sets are functional and tested automation configurations
based on IA/DT standard products for easy, fast and inexpensive
implementation of automation tasks for small-scale automation. Each of the
available Micro Automatic Sets covers a frequently occurring subtask of a
typical customer problem in the lower performance range.
The sets help you obtain answers with regard to required products and the
question how they function when combined.
However, depending on the system requirements, a variety of other
components (e.g. other CPUs, power supplies, etc.) can be used to
implement the functionality on which this set is based. For these
components, please refer to the respective SIEMENS IA and DT catalogs.
The Micro Automation Sets are also available at:
http://www.siemens.de/microset
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Table of Contents
Table of Contents
Table of Contents ......................................................................................................... 4
1 Fields of Application and Benefits ................................................................ 5
1.1 Automation problem.......................................................................................... 5
1.2 Automation solution – Set 1.............................................................................. 6
1.3 Fields of application .......................................................................................... 8
1.4 Benefits............................................................................................................. 8
2 Configuration .................................................................................................. 9
3 Hardware and Software Components ......................................................... 11
4 Principle of Operation .................................................................................. 13
4.1 Introduction to positioning............................................................................... 13
4.2 Block libraries for moving linear and rotary axes ............................................ 19
4.3 Configuring the G110 frequency inverter........................................................ 23
4.4 Optimizing the positioning operation............................................................... 25
4.4.1 Optimization with regard to the moment of inertia .......................................... 25
4.4.2 Optimization of the travel profile ..................................................................... 27

5 Configuring the Startup Software ............................................................... 29
5.1 Preliminary remark.......................................................................................... 29

5.2 Downloading the startup code ........................................................................ 29
5.3 Configuring the CPU 224XP PLC ................................................................... 30
5.4 Preparing the archiving function ..................................................................... 34
5.5 Loading the TP 177micro Touch Panel .......................................................... 35
5.6 Parameterizing the G110 frequency inverter .................................................. 36
6 Live Demo...................................................................................................... 38
6.1 Setting up the wire-wound coils ...................................................................... 40
6.2 Feeding in the wire ......................................................................................... 41
6.3 Automatic mode.............................................................................................. 42
6.3.1 Production of 10 wire rods with a length of 2m ............................................... 42
6.3.2 Premature termination of the production process ........................................... 43
6.4 Cutting wire rods of variable length (manual mode) ....................................... 44
6.5 Immediate stopping of the feed motion........................................................... 45
6.5.1 Stopping using the stop button of the TP 177micro ........................................ 47
6.5.2 Stopping using the hardware stop button (emergency stop) .......................... 48
6.6 Data logging.................................................................................................... 49
6.7 Optimizing the positioning process ................................................................. 50
7 Technical Data .............................................................................................. 53
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Fields of Application and Benefits
1 Fields of Application and Benefits

1.1 Automation problem
A wire cutting machine is to produce a customer-specific number of wire

rods with customized length.
After equipping the machine with the desired wire-wound coil, the
management of the coil’s type and available capacity is to be
voltage-protected, the positioning axis unwinds the desired length from the
wire-wound coil and cuts the wire. This operation is repeated according to
the number entered together with a production ID.
After completing the production job, voltage-resistant buffering has to be
performed for all specific production data to read it from a PC once a day
and to archive them there within the scope of quality assurance.
After feeding in the wire prior to production, the wire is to be located in front
of the cutting device.
Figure 1-1
Wire-wound coil
Cutter
Type1 Type2 Type3
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1.2 Automation solution – Set 1
With the aid of the TP177micro Touch Panel, all material data of the
available wire-wound coils that is relevant to the production can be stored
as a recipe in the voltage-resistant memory module of the S7-200 CPU
224XP. The following information is stored under the designation of the
wire-wound coil:
• Wire size
• Length of the pieces of wire to be cut of the corresponding job
• Material capacity of the wire-wound coil (initial value)
• Production ID of the job (initial value)
Prior to production, the wire-wound coil to be used for the production has to
be selected via the TP177micro Touch Panel.
While feeding in the wire, a block that runs in the S7-200 CPU 224XP
controls the G110 frequency inverter via the analog interface in such a way
that the wire comes to a standstill after passing an inductive sensor and
that the positioning axis is thus homed.
An HTL encoder reports the traveled distance of the axis to the S7-200
CPU 224XP in the form of pulses.
After entering the production ID and the number of pieces of wire to be

produced using the TP177micro Touch Panel, a block running in the
S7-200 CPU 224XP causes the frequency inverter to move the positioning
axis by the desired wire length. Via a digital output signal, the S7-200 CPU
224XP subsequently controls a cutting device that cuts the wire.
This operation is repeated according to the entered number. After
completion or premature termination of the job the following production
parameters are stored in the voltage-resistant memory module of the
S7-200 CPU 224XP.
• Time and date stamp of the production job
• Diameters of the wire rods
• Length of the pieces of wire
• Quantity of the residual material on the coil
• A unique production ID for the job
• Actual number of cut wire rods
The thus buffered information can be read out via a serial link, for instance
with the aid of a PC/PPI cable and the S7-200 Explorer STEP7 Micro/WIN
tool and stored as a csv file.
When selecting a new wire-wound coil via the TP177micro Touch Panel,
the remaining capacity of the previous coil that has been permanently
updated during production is written to the recipe of the relevant material
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data. Since the recipe is also stored in the voltage-resistant memory

module of the S7-200 CPU 224XP, the remaining capacity of the old
wire-wound coil is again available when it is reused in the cutting device.
If the remaining capacity of the wire-wound coil falls below a specific value,
a warning is displayed on the TP 177micro Touch Panel. And if the amount
of wire is not sufficient for the planned job, the entered number of wire rods
is reduced to the possible number and this fact is also reported via the TP.
Figure 1-2
s
SIMATIC PANEL
H
TOUC
5
s
1 2 3 F
6
MH
J P O
123
O N
G H
z
12345678z91
4 0
8
7
s
1 TP 177 micro 2 LOGO! Power 3 S7-200 CPU 224XP 4 SIMATIC PXI inductive sensor
5 SINAMICS G110 with BOP 6 Asynchronous motor with HTL encoder 7 NC contact
8 WINDOWS-based system
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1.3 Fields of application
The Micro Automation Set is particularly suitable for industrial applications

requiring the positioning of objects. The product combination in conjunction
with the software library enables a cost-effective positioning solution, for
example, in the following applications:
• Cutters, for example, for pipes
• Conveyors
• Feeders
• Lifting stages
• Rotary tables
• Hoisting devices
1.4 Benefits
• Simple solution for positioning a linear axis (horizontally or vertically) or

a rotary axis.
• Clearly reduced engineering overhead by providing a command library

for STEP 7 Micro/WIN.
• The use of a particularly sturdy control algorithm ensures that a manual
optimization of the position control is not necessary even if there are
strong load fluctuations.
• Realization of the drive task without comprehensive control engineering
know-how. The SIMATIC S7-200 takes the position control.
• Engineering and commissioning of the S7-200 and the position
controller with only one software tool: STEP 7 Micro/WIN.
• Cost-effective and high-performance solution with SINAMICS G110.
• In addition to your control problem, the S7-200 can also solve multiple
automation problems.
• Visualization and control of the process via the TP 177micro Touch
Panel.
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Configuration
2 Configuration
Connection diagram
Figure 2-1
L1
N
PE
L+
M
M I V M +A +B 1M 1L+ 0.0 0.1 0.2 0.3 0.4 0.5 2M 2L+ 0.5 0.6 0.7 1.0 1.1 PE M L+
U1
V1
W1
1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 2M 1.0 1.1 1.2 1.3 1.4 1.5 M L+
L1
L2
L3
PROFIBUS cable
3
B K
2
C A
1
L
10
1
2
3
4
5
6
7
8
9
J
M
D
E H
Connector of the encoder cable F G
2
contact side (not solder side)
wht blu red blk
1
L+
M
USB/PPI cable
PC/PPI or
WINDOWS-based system for configuring and data archiving
SIMATIC S7-200 – inputs:

Via the preassembled encoder cable, the rotary pulse encoder is connected
to the HSC4 high-speed counter that uses the I0.3 and I0.4 inputs. The
D-sub connector of the encoder cable was removed.
The signal cable of the inductive sensor is connected to I0.6.
I0.0 was used for the OFF button.
SIMATIC S7-200 – outputs:

The inverter with analog input receives its frequency setpoint via the analog
voltage output of the controller (terminals M, V). A shielded cable has to be
used. On the inverter, the analog signal is applied to terminal 9 and the
associated analog reference ground is applied to terminal 10 of the signal
interface. The analog reference ground and the ground of the 24V supply
are jumpered on the inverter (terminals 7, 10).
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Configuration
The “start motor” command is applied at digital output Q1.0 of the

controller. It is connected to terminal 3 of the inverter’s signal interface.
The “reversal” signal is applied at digital output Q1.1 of the controller. It is
connected to terminal 4 of the inverter’s signal interface.
SINAMICS G110 frequency inverter

In primary circuit, the connection of the frequency inverter to the 230V
mains is a single-phase connection.
The asynchronous motor operated in delta connection is connected in
secondary circuit.
NOTICE Please observe that the phase angle of the encoder pulses A and B
correlates with the phase angle L1, L2 and L3 of the motor supply.
If correct positioning is not possible, the problem can possibly be
solved by reversing the encoder tracks or two motor phases.
If the motor does not run in the desired direction, encoder tracks
and two motor phases have to be reversed.
24V supply
The 24VDC power supply of the devices is provided by a LOGO! Power
1.3A.
Protection
An RCBO Type A is used for protection.
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Hardware and Software Components
3 Hardware and Software Components

Products
Table 3-1
Component No. MLFB / order number Note
RCBO 1 5SU1154-7KK06
LOGO! Power 24V/1.3A 1 6EP1331-1SH02
SIMATIC S7-200 (CPU 1 6ES7214-2BD23-0XB0
224XP)
TP 177micro Touch Panel 1 6AV6640-0CA11-0AX0
SINAMICS G110, frequency 6SL3211-0AB12-5UA1
inverter
1
SINAMICS G110, frequency 6SL3211-0AB12-5BA1 Alternatively
inverter with integrated EMC
filter
Low-voltage asynchronous 1 1LA7070-4AB10-Z H57 Motor with rotary
motor pulse encoder,
1024 pulses
per revolution
Encoder cable 1 6SX7002-0AN30-1AC0 Remove D-sub
for rotary pulse encoder connector!

SIMATIC PXI350 1 3RG4141-3AB01
INDUCTIVE SENSOR
40X40MM
Pushbutton, red, 1NC 1 3SB3203-0AA21
MC 291 MEMORY 1 6ES7291-8GH23-0XA0
MODULE, 256 KBYTES
Accessories
Table 3-2
Basic Operator Panel (BOP) 1 6SL3255-0AA00-4BA1
for SINAMICS G110
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Hardware and Software Components
Configuration software/tools
Table 3-3
WinCC flexible micro 1 6AV6610-0AA01-2CA8
Step 7 Micro/Win 1 6ES7810-2CC03-0YX0
PC/PPI cable 6ES7901-3CB30-0XA0 Alternatively;
can also be used
1
USB/PPI cable 6ES7901-3DB30-0XA0 for loading the
TP177 micro
SINAMICS MICROMASTER 1 6SL3070-0AA00-0AG0 Optional
SIZER
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Principle of Operation
4 Principle of Operation
4.1 Introduction to positioning
What does “closed-loop controlled positioning” mean?

In the context of this application, the following definitions can be provided:
When “positioning”, an electrically driven component of a device or plant
approaches a defined local point or angle by means of a linear or rotary
motion or the component is moved by the distance Δs or the angle Δφ.
When the positioning is “closed-loop controlled”, the motion is performed in
a closed control loop in which path and velocity (motor speed) are the
controlled variables. The disturbance variables are differing load torques.
The SIMATIC S7-200 transfers the “velocity” controller output to the
frequency inverter as an analog voltage that is interpreted by the frequency
inverter as a setpoint frequency according to its parameterized V/f
characteristic. Considering the slip of the asynchronous motor depending
on the load torque, a specific speed is set. According to this speed, the
component to be positioned travels a smaller or larger number of path or
angle increments. They are detected by the rotary pulse encoder that is
located directly on the motor shaft and supplied to the controller via its high-
speed counter inputs.
From this information and including the setpoint values “position”,

“positioning speed” and “acceleration (torque)”, a control algorithm counting
the encoder pulses calculates the necessary “velocity” controller output.
This results in a velocity profile whose processing finally leads to an exact
positioning.
Figure 4-1
Load torque
Disturbance variable
Control with Frequency inverter,
Position
MicroPos blocks asynchronous motor
Velocity Analog value Position
Acceleration (torque) 0 – 10V Controlled Velocity
Controller
Reference variable Manipulated system Controlled
value variable
Encoder pulses
What is the difference between absolute and relative positioning?

When absolute positioning is used, you directly specify the target position
to be approached. When relative positioning is used, you enter a path
length by which the component is to be moved.
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To enable absolute positioning, it is required that the zero point of your

travel path (home position) be defined once in advance. The counter with
which the pulses of the rotary pulse encoder are counted is adjusted to the
position of the physical axis, .i.e. it is set to a defined value (preferably 0) at
a defined local point. Homing is not necessary for relative positioning.
Figure 4-2: Example of absolute/relative positioning
Absolute positioning
Travel range (mm)
400
300
500
-300
-200
-100
200
100
0
Source position Target position
(not relevant)
Home position
Relative positioning
+600mm
Source position Target position
What is the difference between a linear and a rotary axis?

• Linear axis:
A linear axis is particularly suitable for linear motions in the horizontal or
vertical plane. For the distance traveled during positioning, the blocks
assume the “length” dimension. Depending on the velocity or ratios of
dimensions, the user applies the corresponding parameters (position,
velocity, etc.), for example, to mm, cm or inch.
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An important parameter of the linear axis is the correlation between the

physical variable “distance traveled” and a motor or rotary pulse
encoder revolution. The parameter thus considers gear, belt, spindles,
etc. that eventually convert the rotary motion to a linear motion.
Figure 4-3: Example of a linear axis, distance traveled
One revolution = 1024 encoder pulses
40mm
Shortest detectable travel path = 40mm / 1024 ≈ 0.039mm

The Map_Ind_Lin library is used for the linear axis. The names of all
blocks have “Lin_” as a prefix.

• Rotary axis:
The rotary axis – also referred to as a “modulo axis” – designates a type
of positioning where a rotary motion is repeated after each completed
motional sequence. Taking this fact into account, the position value of
the drive-end, moved component is specified in angular degrees
0 ≤ φ < 360.0 and reset to 0 after each “rotation”.
For the unique detection of the absolute position, the rotary axis
additionally features a rotation counter that is adjusted each time the
axis is moved – irrespective of whether the positioning is absolute or
relative or whether the rotary axis is moved in jog mode. Without
homing, the rotation counter is set to 0 when restarting the controller.
With homing, the rotation counter is set to a value that corresponds to
the specified reference angle.
If you specify, for instance, an angle of +740° for the physical local point
x0 when homing, the rotation counter has the value +2 in x0.
An important parameter of the rotary axis is the correlation between the
physical variable “angle traveled” and a motor or rotary pulse encoder
revolution. The parameter thus considers gear, belt, spindles, etc. that
finally represent the ratio.
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Figure 4-4: Example of a rotary axis, angle traveled
One motor revolution = 1024 encoder pulses
φ = 28°
Smallest detectable angle of revolution

= 28° / 1024 ≈ 1′ 38″
The following specifics have to be considered for a rotary axis:

– Absolute positioning with preset direction of rotation
At the drive end, the target position has to be approachable with a
maximum of one “rotation” (φ < 360.0°). Larger angle settings cause
a termination of the job. Negative angle settings are also not
permissible. The direction of rotation is to be specified by an –

compared to a linear axis – additional direction parameter.
Figure 4-5: Example of a rotary axis, absolute positioning
Home position
0° Source position
Target position
Positioning to 270° in positive direction
Home position 0° Source position
Target position
Positioning to 270° in negative direction
– Absolute positioning on the shortest path

The positioning is performed as in the above case. The software
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calculates the shortest path to the target and selects the direction of
rotation accordingly.
– Relative positioning
Both angle settings > 360.0° and negative angles are possible.
Figure 4-6: Example of a rotary axis, relative positioning
Source position
Target position
Positioning by 630° in positive direction
The Map_Ind_Rot library is used for the rotary axis. The names of all
blocks have “Rot_” as a prefix.
What is a travel profile?

Depending on the purpose, travel profiles describe various characteristics

(path, velocity, acceleration, moment, power, etc.) that describe a desired

motional sequence. The time or the path is mostly plotted on the abscissa.
The following applies to a positioning operation by means of the MAP Ind
blocks:
• Acceleration is always performed from zero and the component is
always decelerated to a standstill.
• The steepness of acceleration ramp and deceleration ramp is identical
• The controlled variable for the required acceleration/deceleration is the
moment.
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Figure 4-7: Travel profile
Forwards/upwards
Velocity
Time
Backwards/downwards
Path
Generator operation
Time
Horizontal axis
Vertical axis
Torque
Time
For system optimization, the two “MAP_Ind_...” libraries offer a

“…_Com_Monitor” block with which alternatively the dependencies M(t),
v(t) and s(t) can be displayed as travel profiles in STEP 7 MicroWin.
What is the difference between a horizontal and a vertical axis?

While the “horizontal axis” merely requires that the forces of
acceleration/deceleration and the friction forces be considered parallel to
the direction of motion for a mass to be moved, the gravitational force of
the mass to be moved has to be additionally considered for the vertical
axis. This requires the provision of a larger torque from the inverter to
achieve the same accelerating/decelerating torques as for the horizontal
axis. Figure 4-7 shows a qualitative representation of the torque
characteristics of the horizontal and vertical axis for identical accelerations.
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Under which circumstances does the motor become the generator?

Whenever energy stored in the system is to be degraded, the motor
becomes the generator. The following energies have to be mentioned:
• Potential energy
(due to a suspended load)
• Kinetic energy
(due to moving masses)
Energy released when lowering a load or decelerating a flywheel that would
drive the motor from the mechanical end has to be degraded by the inverter
as power loss. The inverter copes with smaller powers without additional
measures. Larger powers require braking resistors or power recovery has
to be provided. Figure 4-7 shows the time intervals of generator operation.
The hatched areas under the torque characteristics are proportional to the
energy to be degraded.
4.2 Block libraries for moving

linear and rotary axes
Overview of available positioning blocks

Figure 4-8
MAP_Ind_Lin library MAP_Ind_Rot library

for linear axis for rotary axis
Lin_Init_horizontal
Rot_Init
Lin_Init_vertical
Lin_MoveJog Rot_MoveJog
Lin_Home Rot_Home
Lin_MoveAbs Rot_MoveAbs
Lin_MoveRel Rot_MoveRel
Lin_StopMotion Rot_StopMotion
Lin_Control Rot_Control
Lin_Com_Monitor Rot_Com_Monitor
The library description also included in Micro Automation Set 1 provides a

detailed block description. The MAP_Ind_Lin library for linear axes is used
for this application. The following sections briefly describe its blocks.
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Task of the “Lin_Init_horizontal” block

This application describes a horizontal material transport. For this reason,
the “Lin_Init_horizontal” block is used here. The initialization block
combines those input and output parameters that refer, so to speak, to all
further blocks of the library and that are used by the positioning’s control
algorithm. Furthermore, the user-specific units of measurement are
standardized in this block.
Motor characteristics, absolute upper limits for velocity and torque 1 and the
transfer factor indicating which feed corresponds to the linear motion of a
motor revolution are mainly entered in “Lin_Init_horizontal”.
“Lin_Init_horizontal” has to be processed once before the remaining blocks
– which have to be called cyclically – are executed for the first time. Trigger
“Lin_Init_horizontal” with SM0.1.
Task of the “Lin_MoveJog” block

Using the “Lin_MoveJog” block, you realize manual mode. The block
features two bit inputs for jog mode (“JogPos” and “JogNeg”).
Accelerating/decelerating torque and a limit velocity can be parameterized
at the block.
Task of the “Lin_Home” block

To enable absolute positioning, the three-dimensional travel path has to be
synchronized with the controller’s position counter. This is achieved by
assigning a specific value to a defined point of your travel path (= home
position). This is done during runtime of the automation program.
“Lin_Home” offers two referencing variants:
• Searching for the home position
For searching the motor is started with “Execute” block parameter =1
and the required direction of rotation (“Direction” parameter = ±1). If the
moving component is detected by a sensor at the user-defined home
position (“RPS” signal), a specific reference value (“Home_Position”) is
assigned to the current position with this event. The detection of the
sensor is performed via its positive or negative edge. The sensor can,
for example, be an inductive proximity switch or a photoelectric barrier.
Your user program has to be designed in such a way that the sensor is
always approached from the same direction when homing to eliminate
its detection width.
In this “wire cutting machine” application example, homing is performed
when feeding in the wire or before the first cutting operation as shown in
the graphic representation below. The distance “proximity switch –
cutter” (with minus sign) is entered as a position value of the home
1
Upper limits are not even exceeded during operation if higher values are parameterized in the
blocks initiating a motion.
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position. Thus the current wire position = 0mm if the wire tip is located
exactly at the cutter.
Figure 4-9: Home position search
v(t)
RPS signal active
End of homing Start of homing

(if feed-in has already
Home position been performed)
s(t)
1)
Start of homing
(if feed-in has not
yet been performed)
Detection width
Wire-wound coil Cutter
Proximity switch for

wire detection
1)
The offset to the home position at the end of homing is known to the system and will be
considered in the next positioning (first wire cut after homing).
• Setting the home position.

When setting the home position, the motor is stopped. 0 has to be
specified for the “Direction” block parameter. If the block detects a
positive edge at “Execute”=1 at the “RPS” input parameter, the current
position is set to a parameterizable reference value (“Home_Position”).
In the “wire cutting machine” application example described in this
document, the home position is set to the value 0 whenever the wire tip
is located exactly at the cutter after a completed wire cut.
For the home position search, accelerating/decelerating torque and a limit
velocity can be parameterized at the block.
Task of the “Lin_MoveAbs” block

Initiated by a positive edge at the “Execute” input parameter, the motor
starts from the current position for a closed-loop-controlled approach to the
end point specified via the “Position” input parameter. A prerequisite for
absolute positioning is previous homing with the “Lin_Home” block.
at the block.
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Task of the “Lin_MoveRel” block

Initiated by a positive edge at the “Execute” input parameter, the motor
starts at the current position to approach the point whose distance from the
starting point is specified by the “Distance” input parameter on a closed-
loop-controlled basis. Previous homing using the “Lin_Home” block is not
required in this case.
at the block.
Task of the “Lin_StopMotion” block

“Lin_StopMotion” is used to stop a currently active motion – irrespectively
of the specific MAP Ind block that triggered it. The block offers two variants
for stopping:
• Stopping via the “AUS3” inverter digital input.
The steepness of the deceleration ramp is set when parameterizing the
inverter. The stop is triggered by a positive edge at the “Execute_Off3”
input parameter.
• Stopping via the “Lin_StopMotion” block.
This variant is used in this application. The steepness of the

deceleration ramp is set by the “Decel_Torque_Ramp” input parameter
of the block. The stop is triggered by a positive edge at the
“Execute_Ramp” input parameter.

It is not only possible to use both variants for stopping alternatively, they
can also be used together in one program.
The block monitors the deceleration times (separate monitoring of both
variants for stopping). The upper limits can be parameterized. When the
limits are violated, the “Time_Exceeded” output bit parameter is set.
Task of the “Lin_Control” block

• The block uses a status word to inform the user on all system states
and limit value violations:
– Motor stopped
– Maximum moment reached
– Axis not synchronized
– Pulse counter overflow
– Direction conflict (rotary pulse encoder ↔ motor phase angle)
– Following error exceeded
– System not initialized
• The value of the current position is available to the user in the
“Act_Position” output parameter.
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• Whenever the motor is stopped from the perspective of the MAP Ind
blocks, a “Brake” bit output is set to a logic “1”. For example, a holding
brake or the pulse enable for the inverter can then be controlled.
Task of the “Lin_ComMonitor” block

In the commissioning phase the “Lin_ComMonitor” block supports the user
in optimizing the dynamic response. The block alternatively records
(parameterizable)
• moment
• velocity
• position
in real time to be able to subsequently represent their time characteristics in
the STEP7 Micro/Win trend display.
A positive edge at the “Start” bit input parameter starts the recording.
Where the data is to be stored is communicated to the block via the
“pTableStart” input parameter by means of a pointer. The block records 249
REAL values in the 8ms grid. In the trend display, subsequently view the
“Out” output parameter of the block.
Note A parameter description of the MAP Ind blocks is available not only in the
library description of this Micro Automation Set, but also in STEP7

Micro/WIN directly as a comment in the relevant protected MicroPos
block.
4.3 Configuring the G110 frequency inverter
Parameterization steps
Due to the universality of the SINAMICS frequency inverters, the adaptation
to a specific application requires that the inverter be parameterized. This
setting procedure is facilitated by the fact that many applications can be
operated with the factory default settings if quick commissioning has
previously been performed. If the condition at delivery from the plant of the
inverter you are using has been changed, it can be reset to the factory
default settings without difficulty. If quick commissioning is set, only the
parameters whose adaptation is absolutely necessary can be selected
during the parameterization. To meet the specific requirements of this
application, application-specific parameterizations are necessary after
the reset to factory default settings and after quick commissioning. Finally,
save the values to the EEPROM of the inverter and, if necessary, save
the entire parameterization to the BOP. This enables you to reload the
parameters to the inverter at any time if required without having to reenter
them or to transfer the parameters to other identical inverters.
V2.0 16.07.2008 23/54

To parameterize the inverter, we recommend the following procedure:

Table 4-1
No. Step
1. Resetting to factory default settings (if condition at delivery from the plant
has been changed)
2. Quick commissioning.
3. Application-specific parameterizations.
4. Saving parameters to the inverter’s EEPROM.
5. Transferring parameter set to BOP for reuse.
Changing parameters
All steps listed above are merely sequences of parameter settings. They
can be performed, for example, using the Basic Operator Panel (BOP) that
is simply plugged onto the inverter 2.
Figure 4-10
To change a parameter via the BOP, proceed as follows:
2
The BOP can be plugged in any inverter mode.
V2.0 16.07.2008 24/54

No. Operator input sequence step Note

1. Go to parameterization mode.
2. Select the parameter to be changed.
3. Display the parameter value.

These operations
4. Change the parameter value. have to be performed
for each parameter.
When you press FN, you can

change each decade individually.
5. Apply the value.
6. Select the display (0000).
7. Exit parameterization mode.

Documents for the SINAMICS G110

The following documents are available for the SINAMICS G110:

Table 4-2
Document ID number:
Getting Started Guide 21696936
Operating Instructions 22102965
Parameter List 20977026
4.4 Optimizing the positioning operation
4.4.1 Optimization with regard to the moment of inertia
Relating to all MAP Ind blocks, the Inertia parameter (moment of inertia)
influencing the system dynamics that cannot be easily deduced from motor
catalogs or mechanical system requirements like all other input values can
be either calculated or determined empirically. The calculation of the
moment of inertia of the entire moved system component required by the
Lin_Init_horizontal block as an input parameter is difficult. The following
sections describe a way to determine the moment of inertia empirically.
V2.0 16.07.2008 25/54

Start value for the moment of inertia

Experience has shown that the tenfold mass inertia of the motor is a good
start value. Before commissioning, enter this value for the Inertia parameter
at the Lin_Init_horizontal block. For the motor’s mass inertia, please refer to
the motor catalog. Accordingly, a value of 0.00052kgm2 results for the
motor from Table 3-1.
Optimization process with the aid of the “Lin_ComMonitor” block

To assess the dynamic response of your system, the graphical
representations of the trend curves v(t) and s(t) are alternatively suitable.
Consider in particular the end of the positioning operation. If the moment of
inertia is set optimally (Figure 4-12), neither distinctive overshoot
(Figure 4-11) nor a “gradual vanishing” (Figure 4-13) of the corresponding
curve should occur.
Figure 4-11
s(t)
Overshoot!
Overshoot!
v(t)
Figure 4-12
s(t)
Optimum characteristic
Optimum characteristic
v(t)
V2.0 16.07.2008 26/54

Figure 4-13
s(t)
Gradual vanishing!
Gradual vanishing!
v(t)
The time characteristic v(t) is also suitable for controlling or optimizing the
velocity. It shows whether the velocity parameterized at the relevant block
is actually reached.
4.4.2 Optimization of the travel profile

The travel profile is essentially defined by the technological application and

an energetic optimization. Determining factors are

• the time within which the positioning operation has to be completed,
• acceleration and deceleration whose upper limits are determined by the
motor performance, the application’s mechanical system and the actual
process and
• the power demand of the application.
The travel profile can be adjusted to the application as follows:
Figure 4-14
v(t)
Maximum velocity is determined by...

•Velocity_Limit block parameter (unit of length/s)
Slope is determined by...

• rated torque of the motor
•Accel_Torque or Torque_Limit block parameter (0...200%)
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The absolute maximum velocity of the linearly moved component

eventually depends on the rated speed relating to the motor frequency.
Since the 4-pole motor of this application can be controlled by the inverter
with a maximum of 100Hz, its highest speed is 2700 min-1. This speed –
converted to the linear motion of the application – results in the maximum
velocity that can be limited with the Velocity_Limit parameter.
The Accel_Torque or Torque_Limit block parameters for limiting the motor
torque are indicated as percentages of the rated torque. A torque of up to
200% can be used for a 4-pole motor.
The example in the figure below shows four possible travel profiles that all
position over the same distance, i.e. the integrals over the curves v(t) from
the starting point to the end point of the motion are identical. Friction losses
are negligible.
Figure 4-15: Different travel profiles for the same positioning
v(t), M(t) v(t), M(t)

vmax
(at 100Hz)
M = 200% vmax/2
t t
v(t), M(t) v(t), M(t)

vmax/2 vmax/2
M = 100%
M = 50%
t t
• Green profile
– Maximum motor utilization
– Minimum positioning time
– Maximum power consumption
• Yellow, blue and red profile
– Motor not fully utilized
– Positioning times extend from yellow to red
– Power consumption corresponds to half the green profile
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Configuring the Startup Software
5 Configuring the Startup Software

5.1 Preliminary remark
For the startup, we offer you software examples with test code and test
parameters as a download. The software examples support you during the
first steps and tests with your Micro Automation Sets. They enable quick
testing of the hardware and software interfaces between the products
described in the Micro Automation Sets.
The software examples are always assigned to the components used in the
set and show their basic interaction. However, they are not real applications
in the sense of technological problem solving with definable properties.
Note At this point, it is assumed that the necessary configuration software has
been installed on your development system (PG, PC, laptop computer)
as shown in Table 3-3 and that you are familiar with handling this
software.
The hardware according to Table 3-1 is mounted,
wired as shown in Figure 2-1 and the power supply of all involved
components is ensured.
5.2 Downloading the startup code
The software example is available on the HTML page from which you have
downloaded this document.
Table 5-1
No. File name Content
1 Set1_s7-200_V1d0_en.zip STEP 7 Micro/WIN project
for the wire cutting machine
(….mwp file)
2 Set1_WinCCflex_Visu_V1d0_en.zip WinCC flexible project for the TP
(….hmi and ….LDF files).
3 map_ind_V1.19.zip Libraries of the drive blocks for
linear and rotation angle
positioning
(map_ind_lin.mwl and
map_ind_rot.mwl files)
Note The map_ind_rot.mwl library is not used in the software example. It is

only offered for download to complete the picture.
V2.0 16.07.2008 29/54

5.3 Configuring the CPU 224XP PLC
Step-by-step instructions for configuring the controller

Table 5-2
No. Instruction Remark
1. Connect a free COM port or a USB port of Development
syst em
the development system to port 0 of the
S7-200 controller. Use the PC/PPI or
USB/PPI cable for the connection.
Use the following switch positions for the
PC/PPI cable:
12345678
PC/PPI or USB/PPI cable
00001000
2. In “PG/PC Interface”, select Instead of using the control panel, the

“Start>Settings>Control Panel” and make interface can also be selected from
the following settings: STEP 7 Micro/WIN by selecting
• Access point of the application: “Set PG/PC Interface”.
Micro/WIN Æ PC/PPI cable(PPI)
• Transmission rate:
19.2kbps
• Local connection: COM or USB

(depending on the cable)
• Advanced PPI deactivated
Multi-master network deactivated
3. Start STEP 7 Micro/WIN and open the
mwp project file.
4. If you are using a motor type deviating
from table 3-1, you have to adjust the
input parameters of the Lin_Init_horizontal
block (= rated motor data). The block is
located in network 1 of the MicroPOS
subprogram.
5. Check whether the values of the The following table provides an

parameters declared in the “USER” data explanation of the “USER” data area
area are compatible with the mechanical (Table 5-3).
system of your wire cutting machine.
V2.0 16.07.2008 30/54


6. Select “File>Download…”
or use the corresponding icon to
transfer the project to the S7-200
controller.
In the transfer dialog box, ensure that the
• program blocks,
• data blocks,
• system data and
• recipes
are transferred.
7. Select “PLC>RUN” or the corresponding
icon to set the S7-200 controller to “RUN”
mode.
8. • In the operation tree, right-click

“Libraries” and open the dialog box for
adding/deleting libraries.
• Add the drive blocks for linear
positioning to the library. Follow the

explanations in the respective
window.
It is only necessary to add blocks to the

library if you want to add library blocks
that have previously not been included in
the program code to the user program. In
this example, these are, for instance, the
“Lin_Init_vertical” or “Lin_MoveAbs”
blocks.
Parameters of the wire cutting machine

On the one hand, all technological parameters of the wire cutting machine
are declared in the USER data block; on the other hand, they also exist in
the “Parameters” status table for commissioning purposes. Before the first
commissioning check whether the values – in particular the velocities and
torques – are suitable for your mechanical system. The following table
explains the parameters.
V2.0 16.07.2008 31/54

Table 5-3
Parameter Explanations
Technological parameters
dist_BERO_cutter: VW32 Distance between proximity switch and cutter (mm).
The proximity switch is to be installed between the drive
wheels and the cutter.
dist_BERO_cutter has to be entered as a negative value.
induktiver Näherungsschalter
Schneidemechanismus
(cutter)
absolute Position 0
+ -
dist_BERO_cutter
cutter_down_time: VW34 Indicates how long the cutter remains in the cutting position
(value x 10ms).
The cutter knows two logic states:
• Parking position (at top, control with FALSE)
• Cutting position (at bottom, control with TRUE)
cut_delay: VW40 In automatic mode, the feed of the next wire rod is started
only after this delay (value x 10ms).
This is to prevent that the feed starts before the cutter has
returned to parking position. The cutter has no end position
detection.
Other parameters
coil: VW114 Preset coil (1-4) whose recipe data is used for operation
after a data block transfer to the controller.
minimum: VD76 If the remaining capacity of the coil becomes less than this
limit value(m), a warning is output on the TP.
Velocity parameters
V_Ref: VD1004 Homing velocity (mm/s)
Jog_slow: VD1008 Slow jog mode velocity (mm/s)
Jog_fast: VD1012 Fast jog mode velocity (mm/s)
V2.0 16.07.2008 32/54

Parameter Explanations
V_Pos: VD1016 Positioning velocity (mm/s)
Torque parameters 3
T_Ref: VD1028 Accelerating/decelerating torque for homing (%)
Torque_Jog_slow: VD1032 Accelerating/decelerating torque for slow jog mode (%)
Torque_Jog_fast: VD1036 Accelerating/decelerating torque for fast jog mode (%)
T_Pos: VD1040 Accelerating/decelerating torque for positioning (%)
T_Stop: VD1048 Decelerating torque when stopping by means of stop
button on the TP or hardware stop button during homing or
a positioning operation (%).
Parameters for the Lin_Init_horizontal initialization block
Torque_Limit: VD1100 Maximum permissible accelerating/decelerating torque (%).
The torque parameter values of the other drive blocks
always have to be smaller than/equal to this value.
Otherwise, the relevant drive block reports an error.
Velocity_Limit: VD1108 Maximum permissible velocity (mm/s). The velocity
parameter values of the other drive blocks always have to
be smaller than/equal to this value. Otherwise, the relevant
drive block reports an error.

s_per_rev: VD1112 The feed of the wire per motor revolution has to be entered
here (mm/rev). For a positioning accuracy < 1mm,

s_per_rev < 40 mm/rev should apply.
Inertia: VD1116 Moment of inertia;
see chapter 4.4
3
The percentage data of the torque refers to the motor’s rated torque that is listed in the motor
data sheets and that the MAP Ind blocks calculate from the further motor rating parameterized
at the “Lin_Init_horizontal” block. Entries from 0…200% are possible for the torque.
V2.0 16.07.2008 33/54

5.4 Preparing the archiving function

Table 5-4
1. Connect a free COM port or a USB port of Development
syst em
the development system to port 0 of the
S7-200 controller. Use the PC/PPI or
USB/PPI cable for the connection.
Use the following switch positions for the
PC/PPI cable:
12345678
PC/PP or USB/PPI cable
00001000
2. In Windows, start
S7-200 Explorer by selecting
“Start>SIMATIC>S7-200 Explorer” or by
double-clicking the corresponding icons.
3. Click the S7-200 CPU and select the
256 KB memory module.
In the right window, right-click
“DAT Configuration 0(DAT0)” and select

“Create Shortcut”.
(The “Open File on Upload” option has to

be deactivated)
4. A shortcut to the “Data-Log” file in the 256

KB memory module is now automatically
created on the desktop.
5. On the desktop, create a link to the The logged data from the memory module
Micro/WIN installation path (default:
“Drive”: Program is moved to the path as a csv file
Files\Siemens\MicroSystems\Data Logs).
when double-clicking .
V2.0 16.07.2008 34/54

5.5 Loading the TP 177micro Touch Panel

Table 5-5
1. Connect a free COM port or a USB port of TP 177micro
Development
system
the development system to the RS485
interface of the TP 177micro.
Use the PC/PPI cable or the USB/PPI
cable.
On the PC/PPI cable, set a baud rate of
115200 baud. This corresponds to the
following switch positions:
PC/PPI or USB/PPI cable
12345678
11000000
2. Start WinCC flexible and open the hmi

project file.
3. Call the transfer dialog box by selecting
“Project>Transfer>Transfer Settings…” or by
using the respective icon.
4. Adjust the transfer settings according to

the cable you are using.
When using the PC/PPI cable, select the

used COM port of your development
system and set the baud rate to
115200 baud.
5. Set the TP 177 Micro to Transfer mode.
This is done by selecting the “Transfer”
button after the “bootloader” sequence.
The download of the WinCC flexible
project can be started when a
“Transfer….” dialog box is displayed on
the TP.
6. Start the project file transfer.
7. Use the PROFIBUS cable to connect the

S7 - 224 XP CPU TP 177micro
RS485 interface of the touch panel to port
1 of the S7-200 controller.
PROFIBUS cable
V2.0 16.07.2008 35/54

5.6 Parameterizing the G110 frequency inverter
For the procedure, please refer to chapter 4.3. The following section lists
only the parameters you have to change with regard to the factory default
settings for this application example. For the parameterization, please
follow the order specified in the table below.
Parameter changes in the SINAMICS G110

Table 5-6
Parameter
Remark
No. Value
Resetting to factory default settings

P0010 30 Commissioning parameter: Factory setting
P0970 1 Start of the reset of all parameters to default values
Quick commissioning
P0003 3 Access level: Expert
P0010 1 Commissioning parameter: Quick commissioning
P0305 1.34 Rated motor current (A) (for delta connection), see rating plate
P0307 0.25 Rated motor power (kW), see rating plate
P0308 0.78 Rated power factor of the motor (cos φ), see rating plate
P0310 50 Rated motor frequency (Hz) for the specific motor data, see rating plate
P0311 1350 Rated motor speed (min-1), see rating plate
P1082 100.00 Maximum frequency (Hz) (100Hz for 4-pole motor, 50Hz for 2-pole motor)
P1120 0.00 Acceleration time (determined by the controller)
P1121 0.00 Deceleration time (determined by the controller)
P3900 1 End of quick commissioning (among other things, resets P0003 to 1)
Application-specific parameterizations
P0760 200.00 y2 value ADC scaling (%) (100% for 2-pole motors)
P1240 0 Configuration of Vdc controller: Vdc controller disabled
Saving parameters to the inverter’s EEPROM
P0971 1 Transfer of values from RAM to EEPROM
Transferring parameter set to BOP for reuse
P0802 1 Parameter transfer from SINAMICS → BOP
P0003 1 Access level: Standard
V2.0 16.07.2008 36/54

NOTICE If you are using a motor type that differs from the ones listed in Table 3-1,
the following parameters have to be additionally considered during quick
commissioning:
• P0304 rated motor voltage (V) (for delta connection), see rating plate
• P0335 rotor cooling: 1 = self-ventilated, 2 = separately ventilated
In this application example, the values of these parameters are already
covered by the factory default settings and thus not listed in the above
table.
Parameter transfer from BOP → SINAMICS G110

When you have transferred the inverter parameter set to the BOP as shown
in Table 5-6, you can reload it from the BOP to the inverter very easily if
required or distribute it to other inverters.
Table 5-7
Parameter
Remark
No. Value
Transferring parameter set from the BOP to the frequency inverter


P0803 1 Parameter transfer from BOP → SINAMICS
Saving parameters to the inverter’s EEPROM
P0971 1 Transfer of values from RAM to EEPROM
P0003 1 Access level: Standard
V2.0 16.07.2008 37/54

Live Demo
6 Live Demo
Overview
To facilitate understanding, the functions and features of Micro Automation
Set 1 are shown in the form of a sample application.
If the components have been correctly configured as described in chapter
5, the program code can be tested.
Figure 6-1: Live demo overview
Start
Setting up the wire-wound coils
Feeding in the wire
Producing 10 wire rods with a length of 2m (automatic mode)
Cutting wire rods of variable length (manual mode)

Immediate stopping of the feed motion using the stop button of the TP 177micro
Immediate stopping of the feed motion using the hardware stop button (e.g. emergency stop)
Data logging
Optimizing the dynamic response
End
Basic information on operating the TP 177micro

Table 6-1
Definition Example
Input values: Input/output field
Input or input/output fields are
designated by a white background.
Output values: Output field
Mere output fields are marked by a

gray background.
V2.0 16.07.2008 38/54

Live Demo
Definition Example
Grayed out buttons: Not grayed out
Buttons with grayed out labeling
indicate that the action associated
with the button is locked for
programming reasons. For example,
automatic mode can only be set after Grayed out
the wire has been fed in.
Navigation buttons:
The navigation buttons for changing settings
the screens/statuses are located on
the bottom screen edge. The screens
recipe admin.
are structured as shown on the right.
In case of voltage recovery or restart
production
of the controller, the system
branches to the “feed in” screen.
In the currently selected screen, the feed in
background of the navigation buttons
is black and they cannot be automatic
operated.
manual
Automatic mode selected
Graphic:
A graphic in the TP screens shows Standstill
the wire cutting machine’s condition
of motion.
Feed active
(the sectors within the coils
rotate and the wire moves
forward.)
Cut
Deleting old archive data

Delete any old logged data from the memory module and old csv log files
before the live demo scenarios.
V2.0 16.07.2008 39/54

Live Demo
Table 6-2
No. Step Remark
1.
Double-click .
Ö Memory module is read out and deleted. The logging was configured in such a way
that the log data in the memory module is
2.
deleted when reading out the 256 KB
Double-click . memory module in a csv file.
Ö Directory of csv log files is opened.
3. Delete all csv files in the directory.
6.1 Setting up the wire-wound coils
Setting up the wire-wound coil means defining the recipe data of the
individual material types and selecting the coil to be used for the current
operation.
Procedure
Table 6-3
No. Step Remark

1. On the TP 177micro, select the “recipe

admin.” screen.
2. Use the arrow keys to select the
wire-wound coil you want to use. Four data
records (recipes) are available.
3. If necessary, change the recipe data of the
selected wire-wound coil.
Core rod diameter:
Merely used as a material characteristic. Its
value is not included in any calculation.
Core rod length:
Indicates the length of the steel rods that
are cut in automatic mode when selecting
the corresponding recipe.
Residual material:
Depending on the material consumption,
the controller automatically reduces the
displayed residual material quantity. It can
be overwritten by the user at any time, e.g.
when changing the coil.
Production ID:
Each production job, consisting of n steel
rods, is given a production ID. The user
enters an initial value the controller
automatically increments per job. The initial
value must be > 0 since production ID 0 is
reserved for manual production.
V2.0 16.07.2008 40/54

Live Demo
No. Step Remark

4. If required, change the residual material
quantity on the coil; when the quantity is
less than this value, a message not
requiring acknowledgement is triggered on
the TP. The limit value of the residual
material quantity is independent of the
selected wire-wound coil.
Reading and writing the recipe data

Each time a wire-wound coil is newly selected, the remaining coil capacity
of the previous coil is saved to its recipe stored in the memory module and
the recipe data of the new coil is loaded from the memory module to the
controller.
Manual recipe data modifications are transferred to the PLC and written to
the memory module with leaving the recipe administration.
6.2 Feeding in the wire

Procedure
Table 6-4
No. Step Remark
1. On the TP 177micro, select the
“production” screen + “feed in”.
The text “not yet fed in!” flashes.

2. Use the start button (transport wheels start) When the end of wire reaches the
and put the end of wire between the proximity switch, the feed is stopped. The
transport wheels. flashing text changes to a permanent
display of “fed in!”. From now on, the
current feed is also always displayed on
the top of the screen.
V2.0 16.07.2008 41/54

Live Demo
Display of the current feed

The current feed is the distance between the wire tip and the cutter. Since
the proximity switch – referring to the normal conveying direction – is
located in front of the cutter, the value of the current feed after completing
the feed-in operation is negative and slightly smaller than the distance
between the proximity switch and the cutter. When cutting the first wire rod
to length in automatic mode, the already existing negative feed resulting
from the feed-in operation is considered.
Repetition of the feed-in operation

If a feed-in operation is to be performed when the proximity switch is
already occupied by the wire – this can, for instance, be the case after
power off/on of the controller – the drive wheels start backwards when
pressing the start button. If the proximity switch then detects the start of the
wire (negative edge), it is reversed and stopped when the wire tip is
detected again (positive edge).
6.3 Automatic mode

6.3.1 Production of 10 wire rods with a length of 2m

Procedure
Table 6-5
No. Step Remark
1. Go to automatic production and enter 10
for the “number of core rods”.
Subsequently, start the production using
the start button.
The distance between steel rod tip position
and cutter position is always displayed as
current feed (here -198mm). In this case,
the first steel rod is thus moved forward by
2198mm and then cut.
V2.0 16.07.2008 42/54

Live Demo
No. Step Remark

2. As soon as the job has started, the
production ID of the batch is displayed.
While processing the job, the number of
already cut steel rods (actual value) is
permanently updated and displayed.
The steel rod is cut when the “current feed”
corresponds to the required rod length
(here 2000mm). With each new feed after
cutting, the feed value is reset to 0.
The remaining capacity on the coil is
updated after each cut.
The above figure graphically indicates the

feed and cut operations.
3. After the cutting job has been completely
processed, setpoint and actual value of the
cut steel rods are identical (here =10).
The production job is terminated with the
Protocol button. The production data of the
job is then written to the memory module.
Alternatively, you can later increase the

number of steel rods to be cut before the
job is logged. If you enter, for example, 15

as a new setpoint and restart the job, 5
additional rods are cut. The production ID
remains unchanged.
After pressing the Protocol button, the
controller is ready for the entry of a new
job.
6.3.2 Premature termination of the production process
Procedure
Table 6-6
No. Step Remark
1. Start a cutting job in automation mode as
described in section 6.3.1. Select the
number of steel rods to be cut, for example
again =10.
V2.0 16.07.2008 43/54

Live Demo
No. Step Remark

2. Before completing the job – for instance
during the feed of the sixth rod – press the
“End” button.
Ö The “End” button flashes and thus
indicates the premature termination of
the job.
Ö The currently processed rod is still cut to
the defined length. The cutting process
is interrupted.
3. Terminate the production job by selecting

the Protocol button. The production data of
the job is then written to the memory
module.
Alternatively, you can undo the termination
of the production by again pressing the
“End” button and by selecting the start
button to continue the original job.
6.4 Cutting wire rods of variable length (manual mode)
Aside from automatic mode, the application also offers manual production.
In manual mode, the wire feed is realized by a jog mode (both forwards and
backwards) with two velocities. Cutting is performed by a button on the TP.
Also manual mode requires that the steel wire be “fed in” (scenario as
shown in section 6.2). This enables the user to accurately display the
current feed or the desired wire length on the TP 177micro and to set the
feed or length using jogging.
V2.0 16.07.2008 44/54

Live Demo
Procedure
Table 6-7
No. Step Remark
1. Go to “manual production” mode (only
possible if wire has previously been
“fed in”).
The displayed “current feed” indicates the

distance between wire tip position and
cutter. If the wire tip is located exactly at
the cutting tool (e.g., immediately after a
cut), the feed = 0mm.
2. To cut a steel rod with a length of 2000mm You can move forward or backward, jog
also in this mode, use the jog buttons to quickly or slowly and make corrections as
move the wire in such a way that a “current often as desired.

feed” of 2000mm is displayed on the TP. If the “current feed” ≤ 0, i.e. if no wire is
under the cutting tool, the “cut” button
cannot be used.
3. Press the “cut” button. After completing the cut, the “residual
Ö The cutting tool is controlled while you material” is updated on the TP. The cut is
keep the button pressed. automatically logged with production ID 0.
6.5 Immediate stopping of the feed motion
In the “feed in” and “automatic production” modes, a triggered feed motion
can be stopped immediately using a…
• stop button on the TP 177micro,
• hardware button.
In both cases, the stopping is realized by the “Lin_StopMotion” block whose
decelerating torque can be parameterized. While, after a stop via the TP
177micro, the original motion can be continued using the start button on the
TP, the program branches to a fault condition requiring acknowledgement
(“Emergency Stop” message) when stopping by means of the hardware
button; after acknowledgement this condition inevitably leads to “feed in”.
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Live Demo
! The hardware stop button must not necessarily be used as an

actuating element of an emergency stop circuit, even if this is
WARNING provided by its mechanical and electrical design. The hardware
button merely intervenes in the control software. It does not
interrupt the voltage of the motor circuit. Please observe the safety
philosophy to be applied in your plant.
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Live Demo
6.5.1 Stopping using the stop button of the TP 177micro
Procedure
Table 6-8
No. Step Remark
1. Go to “feed in” mode (section 6.2) or to
“automatic production” (section 6.3).
2. During the relevant mode, press the “Stop”
button on the TP.
a. Response when feed active:
The motor is immediately decelerated to
a standstill with the decelerating torque
parameterized at the “Lin_StopMotion”
block (T_Stop variable in the
“Parameters” status table).
Ö Response when feed motor stopped:
This is, for example, the case when the
cut is currently being performed in
automatic mode. The subsequent feed
motion that normally follows the cut is

not performed.
3. Continue the original operation using the

“Start” button.
In automatic production, the current job

cannot be aborted by means of the stop
button on the TP. If you want to cancel
the job after the currently fed rod is cut to
length, use the “End” button (flashes after
the selection) to select the abort and to
subsequently restart the drive using the
start button.
Use the hardware stop button for an
immediate abort of the current job and
automatic production (see section 6.5.2).
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Live Demo
6.5.2 Stopping using the hardware stop button (emergency stop)
Procedure
Table 6-9
No. Step Remark
1. Go to “feed in” mode (section 6.2) or to
“automatic production” (section 6.3).
2. During the corresponding mode, press the
hardware stop button.
a. Response when feed active:
The motor is immediately decelerated to
a standstill with the decelerating torque
parameterized at the “Lin_StopMotion”
block (T_Stop variable in the
“Parameters” status table).
Ö Response when feed motor stopped:
This is, for example, the case when the
cut is currently being performed in
automatic mode. The subsequent feed
motion that normally follows the cut is
not performed.
3. An Emergency Stop message is displayed

on the TP 177micro.
4. If you have used a latching (emergency Acknowledgement
stop) button instead of the hardware stop
button, release it. After acknowledging the message, it
disappears and the “feed-in” screen is
5. Acknowledge the message on the TP. displayed on the TP.
6. “Feed in” the wire as described in section
6.2.
Log data
When stopping with the hardware stop button, forced logging of the job
data is performed. All rods of the respective job cut until the stop event are
considered. Please check this within the scope of the data logging in
chapter 6.6.
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Live Demo
6.6 Data logging
Read out the log data from the memory module at regular intervals.
Procedure
Table 6-10
No. Step Remark
1.
Double-click .
Ö Directory of csv log files is opened. A file
with current date/time stamp in the file
name does not yet exist.
2. The csv log file has a date/time stamp in
the file name:
Double-click .
(2) – DAT Configuration 0 (DAT0) – tt.mm.jjjj hh-mm.csv
Ö The memory module is read out and
deleted. The log data is written to the
above directory as a csv file. If the
directory is opened, it can be directly
checked whether the csv file is created
(may take several seconds).
3. Open the csv log file.

(Example):
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Live Demo
6.7 Optimizing the positioning process
The process is optimized by examining the trend curves v(t) and/or s(t).as
described in chapter 4.4. The optimization is performed for a positioning in
automatic mode. The trend curves are triggered by pressing the start button
in automatic mode.
Note
In the case described in the following table, the motor was
operated without additional external moments of inertia.
Procedure
Table 6-11
No. Step Remark
1. Open the “Parameters” variable table and
select a positioning speed for the
optimization that is as large as possible
(V_Pos=400.0). Set the speed in the
“Parameters” status table. Please note that
the “V_Pos” parameter is smaller
than/equal to the “Velocity_Limit”

parameter.
Start the optimization process with the

tenfold moment of inertia (inertia) of the
motor. This value
(10*0.00052=0.0052kgm2.) has already
been stored in VD1116.
2. Select the “Test” variable table.

Activate Lin_Com_Monitor. In
“selected_value”, specify what you want to
monitor (2=v(t), 3=s(t)). Enable
Lin_Com_Monitor with “Com_Monitor =1”.
3. In “recipe administration”, select a steel rod

length of 400mm for the wire-wound coil
used for optimization.
On the one hand, this ensures that the
specified positioning speed is reached and,
on the other hand, that the entire
positioning process is short enough
(< 1.992s) to be completely monitored by
the Lin_Com_Monitor block.
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Live Demo
No. Step Remark

4. A requirement for recording a trend curve is
that the “Done” output of the
“Lin_Com_Monitor” block has “1” status
(does not apply to the first recording
process).
5. Go to automatic production and enter 1 for

the “number of core rods”. Subsequently,
start the production using the start button.
The positioning starts and
Lin_Com_Monitor is triggered.
6. Go to the “Optimization” status table and

use
to go to the trend view. By selecting
,
you can stop the recording to make, for
example, a screen shot.
7. Go to the “Parameters” status table and To ensure that the “Inertia” parameter
change the following parameters: takes effect at the “Lin_Init_horizontal”
• Inertia: 0.00416kgm2 block, the init block has to be processed
once. You achieve this with a positive
• M10.0: “1” (is reset automatically)
edge at the M10.0 flag. This makes a
system restart with renewed feed in
unnecessary.
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Live Demo
No. Step Remark

8. To move the axis again, proceed as
follows:
• Press the “Protocol” button
• Enter “number of core rods” = 1
• Press the “Start” button
As can be seen in the marked frame, the

overshoot behavior could be optimized.
9. If necessary, repeat steps 7 and 8 with

changed inertia and iteratively approach
the optimum.
Note
The smaller the inertia, the smaller its influence on the system dynamics. Thus the trend
curves for your application may deviate more or less strongly from the pictures in this
application.
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Technical Data
7 Technical Data
LOGO! Power 24V 1.3
Table 7-1
Criterion Technical data Additional note
Supply voltage 85 to 264VAC
Output voltage 24VDC (setting range 22.2 to
26.4VDC )
Output current 1.3A
Dimensions (W x H x D) mm 54 x 90 x 55
SIMATIC S7-200 CPU 224XP

Table 7-2
Supply voltage 20.4 to 28.8VDC
Current consumption 900mA
Inputs/outputs 14DI/10DO + 2AI
EPROM user data 16 Kbytes

Dimensions (W x H x D) mm 140 x 80 x 62
SINAMICS G110
Table 7-3
Supply voltage 1 200-240VAC ±10%
Input frequency 47-63Hz
Output frequency 0-650Hz
Output power 0.25kW
Rated output current 1.7A
Efficiency 90-94%
Overload capability 150%
Dimensions (H x W x D) mm 150 X 90 X 116
4-pole asynchronous motor

Table 7-4
Rated power 0.25kW
Rated voltage Δ/Y 230/400V
Rated current Δ/Y 1.34/0.77A
Rated frequency 50Hz
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Technical Data

Rated speed 1350min-1
Moment of inertia 0.00052kg m2
Shaft height 71mm
Weight Approx. 5kg
Proximity switch
Table 7-5
Number of conductors 3 conductors
Type of design Cubic 40mm x 40mm
Connector M12 connector
Rated operating distance sn 25 or 40mm Selectable
Operating voltage 10-65VDC
Rated operational current Ie 300mA
Displays for Switching status,

supply voltage
Degree of protection IP 65
TP 177micro Touch Panel

Table 7-6
Supply voltage 24VDC 20.4…28.8V
Nominal current 0.24A
Memory Flash
256 KB usable for user
Required configuration tool WinCC flexible Micro V 2004 SP1 and
higher
Display STN, 4 blue levels
5.7"
320 x 240 pixels (W x H)
Interface RS485 (max. 0.1875Mbps)
Dimensions (W x H) 212mm x 156mm
Degree of protection IP 65/20
(front/rear)
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Micro Application Example

Closed-Loop Positioning Control

Micro Automation Set 1

Micro Automation Set 1 ID Number 21063595

Warranty, liability and support

use of the examples, information, programs, engineering and performance data

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Micro Automation Set 1 ID Number 21063595

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Micro Automation Set 1 ID Number 21063595

4.4.2 Optimization of the travel profile ..................................................................... 27

5.1 Preliminary remark.......................................................................................... 29

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Micro Automation Set 1 ID Number 21063595

1 Fields of Application and Benefits

A wire cutting machine is to produce a customer-specific number of wire

Type1 Type2 Type3

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Micro Automation Set 1 ID Number 21063595

1.2 Automation solution – Set 1

After entering the production ID and the number of pieces of wire to be

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Micro Automation Set 1 ID Number 21063595

data. Since the recipe is also stored in the voltage-resistant memory

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Micro Automation Set 1 ID Number 21063595

1.3 Fields of application

The Micro Automation Set is particularly suitable for industrial applications

• Simple solution for positioning a linear axis (horizontally or vertically) or

• Clearly reduced engineering overhead by providing a command library

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Micro Automation Set 1 ID Number 21063595

WINDOWS-based system for configuring and data archiving

SIMATIC S7-200 – inputs:

SIMATIC S7-200 – outputs:

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Micro Automation Set 1 ID Number 21063595

The “start motor” command is applied at digital output Q1.0 of the

SINAMICS G110 frequency inverter

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Micro Automation Set 1 ID Number 21063595

3 Hardware and Software Components

for rotary pulse encoder connector!

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Micro Automation Set 1 ID Number 21063595

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Micro Automation Set 1 ID Number 21063595

What does “closed-loop controlled positioning” mean?

From this information and including the setpoint values “position”,

What is the difference between absolute and relative positioning?

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Micro Automation Set 1 ID Number 21063595

To enable absolute positioning, it is required that the zero point of your

Travel range (mm)

Source position Target position

What is the difference between a linear and a rotary axis?

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Micro Automation Set 1 ID Number 21063595

An important parameter of the linear axis is the correlation between the

One revolution = 1024 encoder pulses

Shortest detectable travel path = 40mm / 1024 ≈ 0.039mm

blocks have “Lin_” as a prefix.

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