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User Manual Rotary Knife

SIMOTION Rotary Knife V2.0


ID: 37706606

General Notes
SIMOTION Rotary Knife ID: 37706606


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We reserve the right to make technical changes to this product.
Copyright
Reproduction, transmission or use of this document or its contents is not permitted
without express written authority. Offenders will be liable for damages. All rights,
including rights created by patent grant or registration or a utility model or design,
are reserved.

General Notes
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General Notes

Note
The standard applications are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The standard
applications do not represent customer-specific solutions. They are only intended
to provide support for typical applications. You are responsible in ensuring that
the described products are correctly used. These standard applications do not
relieve you of the responsibility in safely and professionally using, installing,
operating and servicing equipment. When using these standard applications, you
recognize that we cannot be made liable for any damage/claims beyond the
liability clause described. We reserve the right to make changes to these
standard applications at any time without prior notice. If there are any deviations
between the recommendations provided in these standard applications and other
Siemens publications - e.g. catalogs - then the contents of the other documents
have priority.

Warranty, liability and support
If the application is provided free of charge the following shall apply:

We shall not be liable for the information contained in this document.

Any and all further rights and remedies against Siemens AG for whatsoever legal
reason, shall be excluded; this shall refer in particular to claims for loss of production,
loss of use, loss of orders or profit and other direct, indirect or consequential damage.

The aforesaid shall not apply if liability is mandatory, e.g. in accordance with the
Product Liability Act, in cases of intent, gross negligence by directors and officers of
Siemens AG or in the case of willful hiding of a defect.

These limitations of liability shall also apply for the benefit of the Siemens AG's
subcontractors, suppliers, agents, directors, officers and employees.

This Contract shall be subject to German law if customers place of business is in
Germany. If customers place of business is outside of Germany the Contract shall be
subject to Swiss law. The application of the UN Convention on Contracts for the
International Sale of Goods (CISG) shall be excluded.

If the application is provided in return for payment the alternative shall apply which fits
the respective business case:

/ Alternative 1: (internal business)
If not explicitly stated otherwise below, the "Terms and Conditions for Deliveries and
Services for Siemens Internal Transactions", valid at the time of sale, are applicable.

/ Alternative 2: (domestic business of Siemens AG)
If not explicitly stated otherwise below, the "General License Conditions for Software
Products for Automation and Drives for Customers with a Seat or registered Office in
Germany", valid at the time of sale, are applicable.

General Notes
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/ Alternative 3: (direct export business of Siemens AG)
If not explicitly stated otherwise below, the "General License Conditions for Software
Products for Automation and Drives for Customers with a Seat or Registered Office
outside of Germany", valid at the time of sale, are applicable.

It is not permissible to transfer or copy these standard applications or excerpts of them
in unmodified form without first having prior explicit authorization from
Siemens Industry Sector in writing.


For questions regarding this application please contact us at the following e-mail address:
mailto:applications.erlf.aud@siemens.com


Qualified personnel
In the sense of this documentation qualified personnel are those who are
knowledgeable and qualified to mount/install, commission, operate and
service/maintain the products which are to be used. He or she must have the
appropriate qualifications to carry-out these activities
e.g.:
Trained and authorized to energize and de-energize, ground and tag circuits
and equipment according to applicable safety standards.
Trained or instructed according to the latest safety standards in the care and
use of the appropriate safety equipment.
Trained in rendering first aid.
There is no explicit warning information in this documentation. However, reference
is made to warning information and instructions in the Operating Instructions for the
particular product.

Reference regarding export codes
AL: N
ECCN: N

Foreword
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Foreword
Standard SIMOTION application
A standard SIMOTION application comprises the following components:
One or several software objects or code blocks with defined interfaces that
can be simply integrated into other software projects without requiring
any significant programming in order to fulfill a precisely defined
technology task there (core functions).
A software project based on a demonstration case to show the functionality
and possible uses of the standard application - including the associated
WinCCflex screen for demonstration (demonstration project).
A document to describe the functionality, background information and
handling of the standard application. Further, its use as demonstration
model is explained (description).
Document structure
The documentation of this application is sub-divided into the following main section:

Section Description Note
Prerequisites and
objectives
In the first section you can obtain an overview of this
standard application. This Section explains the
prerequisites and the objective when using this
application.
Some of the uses of this standard application are
explained as well as situations where this application
cannot be used.

The application
example as
demosystem
Section Application example as demosystem is
interesting if you wish to use this standard application
for demonstration purposes.
Here, you are provided with information about how
you can download this application from your PC/PG
to the demonstration case step-by-step and how it
then used.

Integrating the core
functions
Section Integrating the core function provides you
with all of the necessary steps to integrate the core
functions of the standard application into your user
project.
Preparations and parameterizing operations are
explained. Further, you are also told how to integrate
the core functions into your application step-by-step.
In addition, tips are provided on how to use the core
functions.

Program description of
the technology
template
Section Program description is interesting if you
wish to expand/adapt the functionality of the core
functions provided for your particular application.

Appendix
Section Appendix provides you with detailed
information including a detailed fault/error
description, a description of a test program for the
core standard application functions as well as
references. A feedback sheet is also provided which
you can use to give us your comments and


Foreword
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Section Description Note
suggestions on this document.

Index of contents
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Index of contents
Prerequisites and objectives .................................................................................... 10
1 Basic information................................................................................ 11
1.1 Prerequisites ...................................................................................... 11
1.1.1 Target group....................................................................................... 11
1.1.2 Know-how required ............................................................................ 11
1.1.3 Technical environment ....................................................................... 11
1.2 Objective and purpose of this standard application ........................... 11
1.2.1 Task.................................................................................................... 11
1.2.2 Application solution using the standard application SIMOTION Rotary
Knife ................................................................................................... 13
1.2.3 Advantages of the standard application SIMOTION Rotary Knife..... 13
1.3 Components included in the standard application ............................. 14
2 Uses ................................................................................................... 15
2.1 Applications........................................................................................ 15
2.1.1 Controls that are permitted................................................................. 15
2.1.2 Tasks that can be implemented using the core functions.................. 15
2.1.3 Properties and features of the core rotary knife functions............... 16
2.2 Exclusions / restrictions...................................................................... 17
2.3 Application environment ..................................................................... 18
3 Structure and function........................................................................ 19
3.1 Geometrical structure of the rotating knife......................................... 19
3.2 Rotary knife cams............................................................................... 21
3.2.1 Design of a cam for cyclic operation .................................................. 21
3.2.2 Segment structure of a rotary knife cam............................................ 23
3.2.3 Starting and Stop Cam....................................................................... 24
3.2.4 Linear cutting characteristic ............................................................... 25
3.3 Operating states of the application SIMOTION Rotary Knife............. 26
The application example as demo system.............................................................. 27
4 Installing the hardware and software ................................................. 28
4.1 Regarding your safety ........................................................................ 28
4.1.1 Safety information and instructions.................................................... 28
4.1.2 Responsibilities of the operator.......................................................... 29
4.2 Hardware configuration and installation............................................. 30
4.3 Installing the standard SIEMENS software........................................ 32
4.4 Downloading the user program and parameterizing the drive in the
SIMOTION D demonstration case ..................................................... 32
4.4.1 De-archiving the SIMOTION project .................................................. 32
4.4.2 Resetting SIMOTION D435 to the factory settings ............................ 32
4.4.3 Reconfiguration of double-axis motor module from 3A/3A to 5A/5A . 33
4.4.4 Configure Ethernet interface .............................................................. 34
4.4.5 Set the Ethernet address of the PG/PC............................................. 37
4.4.6 Downloading the hardware configuration after a factory setting........ 39
4.4.7 Downloading the SIMOTION project of the standard application ...... 40
5 Operator control of the application example ...................................... 42
5.1 Structure overview.............................................................................. 44
5.2 Brief instructions to demonstrate........................................................ 45
5.3 Detailed operating instructions........................................................... 49
Integrating the core functions .................................................................................. 59

Index of contents
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6 Program environment and interfaces................................................. 60
6.1 Importing the source code.................................................................. 60
6.1.1 Copying from the application example............................................... 60
6.1.2 Linking using XML import ................................................................... 61
6.1.3 Linking the rotary knife functionality................................................... 62
6.2 Technology objects ............................................................................ 65
6.2.1 Technology objects required and synchronous relationships ............ 65
6.2.2 Synchronous relationships ................................................................. 67
6.3 Integrating the SIMOTION Rotary Knife core function....................... 70
6.3.1 Parameterizing the rotary knifes in the startup task........................... 70
6.3.2 Calling FBRotaryKnife in the user program........................................ 70
6.3.3 Calling the FBRKCamCalculation ...................................................... 70
6.3.4 Calling the FBRKIPO in the IPO synchronous task ........................... 71
6.3.5 Global Variables................................................................................. 71
Program Description ................................................................................................. 72
7 Program Description........................................................................... 73
7.1 Information and warnings................................................................... 73
7.2 Type of Data....................................................................................... 73
7.2.1 Overview ............................................................................................ 73
7.2.2 Enumeration types ............................................................................. 74
7.2.3 Data Structures .................................................................................. 75
7.3 FBRotaryKnife.................................................................................... 84
7.3.1 Block name......................................................................................... 84
7.3.2 Task.................................................................................................... 84
7.3.3 Integration in the run-time system...................................................... 84
7.3.4 Graphic representation of the block ................................................... 85
7.3.5 Block parameters ............................................................................... 86
7.3.6 Functionality ....................................................................................... 87
Start identification............................................................................... 87
Axis monitoring functions ................................................................... 88
Checking the input parameters and parameterization of the
technology settings that are absolutely necessary............. 88
Automatic mode change sequences.................................................. 91
7.3.7 Error messages................................................................................ 100
7.4 Cam Calculation for rotating shears FBRKCamCalc ....................... 109
7.5 Functions in the IPO task FBRKIpo ................................................. 120
7.6 Blocks to manage the format length memory .................................. 123
7.6.1 Resetting the format length memory FBFormatLengthBufferReset. 124
7.6.2 Entries in the format length memory FBFormatLengthBufferIn ....... 125
7.6.3 Reading from the format length memory FBFormatLengthBufferRead127
7.6.4 Exporting from the format length memory FBFormatLengthBufferOut129
7.7 Measured value memory system blocks used in the rotary knife
application ........................................................................................ 130
7.7.1 Deleting and resetting the measured value memory
FBCutPositionBufferReset ............................................................... 131
7.7.2 Entries in the measured value memory FBCutPositionBufferIn....... 131
7.7.3 Reading out the measured value memory FBCutPositionBufferRead133
7.7.4 Exporting from the measured value memory FBCutPositionBufferOut135
7.8 Extended functions........................................................................... 136
7.8.1 Using the cutting program................................................................ 136
7.8.2 Using print mark correction .............................................................. 136
Appendix................................................................................................................... 138
8 General information on the application ............................................ 138

Index of contents
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8.1 Scope of supply................................................................................ 138
8.2 Revision/Authors .............................................................................. 138
9 Contact partner................................................................................. 139
10 Please help us to become even better............................................. 140



Prerequisites and objectives
Basic information
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Prerequisites and objectives
Contents
This section will provide you with everything that you require to obtain an overview
of this standard application. The prerequisites and the objective for using this
standard application are presented.
The applications shown will give you a good understanding for what this standard
application can be used for. Further, some applications will be listed for which this
standard application cannot be used. In addition, the performance limits of this
standard application will be shown.
Objective
This section should provide the user with the following information
The objective and purpose of this standard application
List several applications
Indicate the performance limits of this standard application.

Chap. Title Content
1 Basic information and data The necessary prerequisites to use the standard application
Rotary Knife.
The use of this application.
Software components and code blocks of the standard
application Rotary Knife.
2 Possible uses Tasks and properties of the core functions of the standard
application Rotary Knife
Exclusions and restrictions
Hardware components required
3 Structure and function Type of design and physical quantities for which the rotary
knife core function can be used.
Type of cams that the rotary knife core functions calculate
and used.
Operating states at the application.


Prerequisites and objectives
Basic information
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1 Basic information
1.1 Prerequisites
1.1.1 Target group
The standard application is conceived for all programmers and users that wish to
quickly and simply implement cross-cutter functionality using SIMOTION.

1.1.2 Know-how required
In order to use this technology template, you should be able to use SCOUT and
technology objects and technology function calls in SIMOTION.
This document does not provide an introduction into these subjects and is solely
restricted to providing information and data on how to use this standard application.

1.1.3 Technical environment
This standard application can only be used, without having to make any changes,
in conjunction with SIMOTION D and the SINAMICS demonstration case.

1.2 Objective and purpose of this standard application
1.2.1 Task
Using SIMOTION, a material web fed using the material feed mechanism is to be
cut into identical parts and sections.
A rotating knife (rotary knife) is to be used in order to achieve high feed velocities
and short format lengths of the cut material sections.
The cross-cutter comprises a rotating roll. One or several knives are located along
the circumference of this roll. While the roll rotates, the knife cuts the material web
fed-in below the roll into identical, defined sections.


Prerequisites and objectives
Basic information
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Figure 1-1: Mode of operation of a cross-cutter (rotary knife)
Continous Web
cutted material
Rotary Knife
material

When developing a cross-cutter, the rotating cross-cutter axis control must be
programmed so that during a cut, the cross-cutter axis motion is synchronized to
the material web. The cross-cutter axis is moved with a special velocity profile
between the cuts, so that synchronized motion can be resumed in plenty of time for
the next cut. The next cut can be made after synchronization.

Additional applications
The same sort of solution is also required for similar processes, mainly in
packaging machine applications.
The motion sequences described above must also be developed for perforating,
embossing, sealing etc. with rotating equipment.

Figure 1-2: Application examples (perforating, sealing and cutting)

Definition
In the following text, the rotary knife term is used to represent all of the other
conceivable machine versions.
The term knife is used for all parts of the machine where direct contact is
made to the material when cutting.


Prerequisites and objectives
Basic information
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1.2.2 Application solution using the standard application SIMOTION Rotary
Knife
The standard application SIMOTION Rotary Knife discussed here can be used to
implement such applications, and to develop a functioning cross-cutter as quickly
as possible.
The standard application already includes, as core function, a pre-configured
motion control of the rotary knife axis. This can be adapted to the particular
application using the appropriate parameters. The core function is responsible for
completely controlling the rotary knife axis.
The user program only has to control the material feed and to supply the core
function with the correct parameters.

Additional function of the standard application
Further, this standard application also has the possibility of checking the required
format length using a print mark function in conjunction with a sensor.
This function can also be set at the core function and commissioned by simply
entering the appropriate parameters.

1.2.3 Advantages of the standard application SIMOTION Rotary Knife
The use of the standard SIMOTION Rotary Knife application offers users the
following advantages:
Programs can be quickly generated
Comprehensive cross-cutter functionality can be easily and quickly implemented
using the standard application SIMOTION Rotary Knife when programming with
SIMOTION.
The core functions provided in the standard application can be transferred into the
application to be generated quickly and simply by copying. The description of this
standard application explains the additional configuring steps that are necessary.
Automatic motion control
The core functions of the standard application SIMOTION Rotary Knife can be
used to realize all of the cross-cutter axis motion control using SIMOTION
technology functions. The user only programs an execution sequence that
corresponds to the actual behavior of the machine function to be implemented.
Possibility of adaptation
All of the source codes are available in commented form for the standard
application SIMOTION Rotary Knife. This means that the existing core functions
can be quickly and simply expanded by the user's own particular functions.


Prerequisites and objectives
Basic information
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1.3 Components included in the standard application
The standard SIMOTION Rotary Knife application is implemented as SIMOTION
project as well as library.
The project can be simultaneously used for a (demonstration) machine for a
SIMOTION D demonstration case and PC with WinCC Flexible 2008 for
visualization.
The program fulfills the following tasks:
The control of the (demonstration) machine
All of the machine functions that are relevant for the demonstration case
environment are simulated
The (demonstration) machine is displayed on the WinCCflex screen
Operating mode manager for the complete (demonstration) machine

This allows the core functions of the standard SIMOTION Rotary Knife application
to be quickly and simply integrated in projects that the user has created himself.

Prerequisites and objectives
Uses
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2 Uses
2.1 Applications
2.1.1 Controls that are permitted
The standard SIMOTION Rotary Knife application can be used on any SIMOTION
control.
2.1.2 Tasks that can be implemented using the core functions
These core functions are used to control rotating equipment and mechanisms to
Cut
Perforate
Emboss
Seal
etc.
The core rotary knife function completely handles the motion control of the
rotating axis used for cutting. The functionality associated with the material feed is
implemented outside the core functions in the user program.


Prerequisites and objectives
Uses
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2.1.3 Properties and features of the core rotary knife functions
The following properties and features were taken into account when implementing
the core functions, and can also be used in a user program that you generate
yourself:
Linear cutting characteristic
When cutting, the material and cross-cutter axis travel with the same
(peripheral) velocity or optionally with the over-velocity.
Polynomial cutting characteristic
The cutting characteristic is defined by the over-velocities at the start of the cut,
at the Zero position within the cut and at the end of the cut.
Cam profile
Cams are used to control the motion of the cross-cutter axis. The following
cam profiles can be parameterized: Linear (constant acceleration), trapezoidal
(jerk limiting), polynomial.
Print mark correction with adjustable correction speed
During operation, deviations in the print marks, identified by the user, can be
corrected using a higher-level motion.
Multi-knife systems
The rotary knife core function can also be used for cross-cutter axes that
have more than one knife.
The quiescent position of the cross-cutter axis can be set
The quiescent position of the knife between two steps can be set using a
parameter at the core function.
Defined starting and stopping characteristics
Special cams are used to implement the starting and stopping characteristics
of the cross-cutter axis. This means that the motion control of the cross-cutter
axis before and after cutting operations can be precisely determined.
Cut length management
The additional core functions for cut length management also allow the cams
to be calculated with precise segments as a function of the precise segment
length previously determined using print marks. This means that formats can
also be changed using print marks.


Prerequisites and objectives
Uses
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2.2 Exclusions / restrictions
The following features were not taken into account when implementing the
application:
Non-linear cutting characteristic
The application cannot be used without first making changes if the cut
characteristic must be influenced using a non-linear cut characteristic, which
cannot be emulated using a polynomial cut characteristic with speed increases.
Cutting torque input
The application only influences the cross-cutter axis via its speed and position
interface. The motor torque cannot be influenced.
Seamless continuation of the cut after a fault stop
If, during the cut, the cross-cutter goes into a fault condition, then the
application function does not permit the cut to be continued. Cross-cutter
operation can only be resumed after removing the cause of the fault,
acknowledging it and then returning to the initial state.
High impetus
Motion of the cross-cutter to increase knife impetus for thick materials is not
provided in the application.

Prerequisites and objectives
Uses
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2.3 Application environment
The standard application SIMOTION Rotary Knife can be used in the following
hardware environment:

Figure 2-1: Application environment of the standard application SIMOTION Rotary Knife
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Encoder
Motor
Encoder
SIMODRIVE /
MASTERDRIVES /
SINAMICS
PG / PC
SIMOTION D
Material web
Cross-cutter

The material feed and the drive control of the rotary knife axis can be controlled
from a SIMOTION control system. Alternatively, the rotary knife axis can also be
coupled through an encoder mounted on the machine.

Prerequisites and objectives
Structure and function
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3 Structure and function
3.1 Geometrical structure of the rotating knife
The rotating knife used as basis for the application comprises a rotating axis,
where tools (knives) are located around the circumference.
The following geometrical quantities (names in white) are used in the application:

Figure 3-1: Geometrical quantities at the standard Rotary Knife
Rotary Knife Position
Sensor Position
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KnifeCircumference
StartSyncAngle
EndSyncAngle
InflectionPoint
DistanceToSensor
Format range
Synchronous range 0
StartAngle
StopAngle

Prerequisites and objectives
Structure and function
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Table 3-1: Explanation of the parameterizable physical quantities
Physical quantity Description
KnifeCircumference [mm] Effective circumference of the rotary knife (circle circumference)
StartAngle [] Start angle of the knife referred to 0
InflectionPoint [%] Reverse position (inflection point) of the cyclic cam referred to the
length of the format range
StopAngle [] Stop angle of the knife referred to 0
StartSyncAngle [] 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 Number of knives distributed around the circumference.
DistanceToSensor [mm] Distance between the cutting position (0) and the sensor to detect
the material and print mark

Synchronous range
The synchronous range is located between StartSyncPos and the EndSyncPos.
The actual cutting operation occurs within this range and the knife of the rotary
knife axis operates with the same velocity as the material web or is synchronized
with the material web.
Format range
The format range is obtained according to the following formula:
Format range = KnifeCircumference / NumberOfKnives
synchronous range
Between two cutting operations, the rotary knife axis moves in the format range.
This is the reason that the dynamic values of the rotary knife axis must be selected
so that the motion can be controlled within this range between two cuts. This
means that the rotary knife axis can move through the length of the format range
with all of the appropriate acceleration and braking operations between two cutting
operations. It can then have the same velocity as the material web before the next
cut.

Prerequisites and objectives
Structure and function
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3.2 Rotary knife cams
3.2.1 Design of a cam for cyclic operation
Note
The following interrelationship exists when representing the following cams
360 [circumferential angle] = 200 mm [circumference along the knife tips]
This representation type means that it is not necessary to convert from Degrees
into millimeters when considering the velocity!

Principal design
Figure 3-2: Segments of a rotary knife cam
Cross-cutter circumference
Material web
?
200 mm
180 mm
20 mm
0 mm
Sheet length Sheet length 20 mm 20 mm 0 mm


The cam has two essential tasks:
1.) Definition of the cutting curve in the synchronous range
The shape of the cam in the synchronous range is generated from the
specifications of the cutting curve. The cutting curve is independent of the format
length.
2.) Adaptation of the format in the format range
The shape of the cam in the format range is generated from the difference between
the circumference and the format length and is therefore dependent on the format
length.
This is the reason that the cutting point (defined as position 0) is selected at the
changeover point of the cams. The reason for this is that the synchronous range is
identical for all of them and can therefore be changed over without any jerk.
Half of the
synchronous
range at the
d f th t
Half of the synchronous range
at the start of the cuts
Format range
Cutting point
Cutting point

Prerequisites and objectives
Structure and function
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Table 3-2
Cam Description
Circumference, cross-cutter
Material web
200 mm
180 mm
20 mm
0 mm
Cut length Cut length 20 mm 20 mm 0 mm
100 mm
Cross-cutter circumference

circumference < cut length
If the cut length is greater than the rotary knife
circumference, then within the format range,
the rotary knife must be decelerated, starting
from the synchronous velocity, and then be re-
accelerated to the synchronous velocity. If the
cut length is significantly longer than the rotary
knife circumference, then the rotary knife
comes to a standstill and if the cut length
increases even further, then it has an even
longer pause.
Cross-cutter circumference
Material web
200 mm
180 mm
20 mm
0 mm
Cut length Cut length 20 mm 20 mm 0 mm
100 mm
Cross-cutter circumference

circumference = cut length
If the cut length precisely corresponds to the
rotary knife circumference, then the cutting
knife moves with the velocity of the material
web. The format range in this case
corresponds to the synchronous range. This is
the reason that in principle, there is only one
single synchronous range that extends over
the complete cut length.
Cross-cutter circumference
Material web
200 mm
180 mm
20 mm
0 mm
Cut length Cut length 20 mm 20 mm 0 mm
100 mm
Cross-cutter circumference

circumference > cut length
If the selected cut length is less than the
rotary knife circumference, then the cross-
cutter, in the format range, must be
accelerated starting from the synchronous
velocity and then decelerated back down to
the synchronous velocity.


Prerequisites and objectives
Structure and function
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3.2.2 Segment structure of a rotary knife cam
As the format length increases, there is a danger that the knife will move
backwards into the synchronous range. This can result in damage and must
therefore be avoided. The format length from which reverse motion is executed is
called the critical length.
This is the reason that the format range of the cam is sub-divided into three
segments, to allow the knife to dwell at the start position for format lengths greater
than the critical length.
Figure 3-3: Diagram showing the segments of the rotary knife cam
Cross-cutter circumference
Material web
200 mm
180 mm
20 mm
0 mm
Cut length Cut length 20 mm 20 mm 0 mm
100 mm

Segments I and V define the synchronous range and therefore the specified cutting
curve, segments II, III and IV define the format range.



Prerequisites and objectives
Structure and function
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3.2.3 Starting and Stop Cam
Table 3-3
Cam Type Description
Cross-cutter circumference
Material web
200 mm
180 mm
20 mm
0 mm
Cut length Cut length 20 mm 20 mm 0 mm
100 mm
Basic position
Start

Synchronizing to the starting cam

Using the starting cam, the cutting knife is brought
out of its starting position into the cutting position
and is accelerated up to the velocity of the material
web.

This cam is defined over the complete cutting
length so that it can be started if the leading
material edge reaches the cutting position. For
short cutting lengths and knife systems with a high
inertia then the cross-cutter can be immediately
accelerated.

At the cutting position (zero position!) the cam for
cyclic operation is selected.

Cross-cutter circumference
Material web
200 mm
180 mm
20 mm
0 mm
Cut length Cut length 20 mm 20 mm 0 mm
100 mm
Starting position
End

De-synchronizing with the stop cam

If the rotary knife is to be stopped, or there is no
material under the rotary knife, then to stop a
changeover is made to the stop cam when the
knife at the cutting position. This means that the
cutting knife is kept at the starting position. After
this, the rotary knife is taken out of the
synchronous group with the material web.






Prerequisites and objectives
Structure and function
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3.2.4 Linear cutting characteristic
Thin materials can be cut essentially at a precise point using a linear cutting
characteristic at the cutting point the circumferential velocity of the knife is
precisely equal to that of the material. With increasing material thickness, the
material bunches up at the entry and exit points of the knife (vector break-down of
the circumferential velocity in the direction of the material!).
Table 3-4
cutting characteristic Cam
0
Knife
entry
Cutting point
Knife
exit


Example of a velocity profile with linear cutting curve
without velocity increase.

Generally, special cutting curves must be developed for thicker materials. These
special cutting curves then equalize these velocity differences. The application
offers the option of defining cutting curves by increasing the velocity (start of the
cut, cut center point, cut end point). A linear interpolation is made between these
points.
Table 3-5
cutting characteristic Cam
0
Knife
entry
Cutting point
Knife
exit


Example of velocity profile with cutting curve using
velocity increase at the start and at the end of the cut.



Prerequisites and objectives
Structure and function
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3.3 Operating states of the application SIMOTION Rotary
Knife
FBRotaryKnife automatic controls the rotating knife to implement the required
functionality.
This functionality is sub-divided into six operating states so that the sequences at
the rotary knife are implemented as a result of the states or also as a result of the
transitions between the states.
This means the user only influences the rotary knife by specifying the required
operating mode with the required parameters

Figure 3-4: Operating modes
1
Disable
4
Manual
0
Error
3
Auto-
matic
5
Single
Cut
6
Sample
Cut
2
Startposi-
tion

Table 3-6
State Description
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.
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
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
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.
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

These operating modes are available to users to implement their cross-cutter
functionality in a user program and can be signaled to the FBRotaryKnife using
input parameters.
The FBRotaryKnife indicates the currently reached status using an output
parameter.

The application example as demo system
Structure and function
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The application example as demo system
Content
All of the necessary steps to commission the rotary knife standard application as
presentation system are explained in this section.
Preparations and parameterizing operations are explained. Further, you are told
how you can use the WinCCflex man-machine interface (screen) of the application
example step-by-step.
Objective
This Section of the document provides the reader with the following
The prerequisites to use this standard SIMOTION application as demonstration
system
Explains the preparatory activities and parameterizing operations
Describes the steps necessary when presenting this standard application.
Provides tips for using this standard application.

Chap.. Title Content
4 Installing the hardware and software Safety information and instructions
Components and their interconnections required for
the presentation
Installation of standard SIEMENS software
Downloading the user program in SIMOTION D435
Downloading drive parameters in SINAMICS
5 Operator control of the application
example
Brief instructions on how to use the demonstration
system
Detailed Operating Instructions


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4 Installing the hardware and software
4.1 Regarding your safety
4.1.1 Safety information and instructions
Pictograms, signal words and text
Every piece of safety information/instruction in this document is designated by text
graphics comprising pictogram and signal word, and supplemented by
explanatory text. A clear classification according to the degree of the potential
hazard is provided as a result of the combination of pictogram and signal word.
Safety information/instructions are provided in front of the information regarding
activities to be executed.
Classification
There are three different stages regarding safety information/instructions. These
are designated by the same pictogram. They differ by the signal word.

!

Danger
This safety information/instruction indicates an immediate hazard. If the
information/instruction is not carefully followed, this results in severe
bodily injury or even death.



!

Warning
This safety information/instruction indicates a potential hazard. If the
information/instruction is not carefully followed, this can result in severe
bodily injury or even death.



!

Attention
This safety information/instruction indicates a potentially hazardous
situation that can result in slight to average bodily injury. This
pictogram/text word can also warn about potential material damage.



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4.1.2 Responsibilities of the operator
Correct use
The correct use of the application components exclusively relates to the open-loop
and closed-loop control of test set-ups that were adapted to the power/performance
of the application components. In order that the application functions perfectly, the
required standard SIMATIC components as well as also the necessary hardware
and software components must be installed.
The company/person operating the system may only make changes to the
application components after having received written authorization from the
suppliers.
Misuse
The following are considered to be misuse:
Inadmissible loads applied to the application components.
Any application deviating from the use specified above, or applications that go
beyond the specified use.
Non-observance of the safety information and instructions.
If faults, that could have a negative impact on the safety, are not immediately
resolved/removed.
Any changes/modifications to equipment/devices that are used to ensure
perfect function and operation, unrestricted use as well as active or passive
safety.
If recommended hardware and software components are not used.
If the application components are not in a perfect technical condition are not
operated conscious of safety and hazards, and not taking into account all of
the instructions provided in the documentation.
The manufacturer assumes no liability for incorrect use (misuse).
Responsible for monitoring
The company or person operating the system is responsible in continually
monitoring the overall technical status of the application components (defects and
damage that can be externally identified as well as changes in the operating
behavior).
The company/person operating the system is responsible in ensuring that the
application is only operated in a perfect state. He must check the state of the
application components before they are used and must ensure that any defect is
removed before commissioning.
Qualification of personnel
The operating company/person may only deploy trained, authorized and reliable
personnel. In so doing, all safety regulations must be carefully observed.
Personnel must receive special instructions regarding the hazards/dangers that
can occur.
Hardware structure and mounting/installation


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4.2 Hardware configuration and installation
Overview
Figure 4-1: Hardware components (without power cable!)
Ethernet

The demonstration project can be commissioned using a conventional SIMOTION
D435 demonstration case and a PC connected via Ethernet.

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Table 4-1: Hardware components
Hardware element Figure Order No./MLFB and functions
Training case, SIMOTION D435 with SINAMICS S120
SIMOTION D demonstration
and training case
6ZB2 470-0AE00
The SIMOTION D training case comprises standard
components (SIMOTION D435, two SINAMICS axes
with motors) and has two axes. These are used to
demonstrate the application.
The case is already pre-configured and connected-up.
It only has to be connected to the HMI system via
Ethernet.
Communications
Ethernet Cross Link Cable The cable is used to establish a connection
between the HMI system (PG/PC) and the
SIMOTION D435 training case.
HMI system
PG/PC with Ethernet
interface
The PG/ PC is used as the HMI display screen.
Procedure
Please proceed as follows to configure and install the hardware components for the
application example:
Table 4-2: Hardware configuration and mounting
No. Action Comment
1 Connect the Ethernet interface of your PG/PC with the
lower Ethernet interface IE2 (contact X130) of
SIMOTION D435 with an Ethernet cable.

2 Connect the SIMOTION D training case to the power
supply.

3 Power-up all of the equipment/devices.

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4.3 Installing the standard SIEMENS software
Note
If the application is only to be used to demonstrate and present, then it is only
necessary to install WinCC Flexible 2008 with 256 power tags.

Minimum required releases
Table 4-3: Versions
Component Version
STEP 7 V5.5.2.0
SIMOTON SCOUT V4.3.1
WinCC Flexible 2008 SP2 Upd12
WinCC Flexible Runtime 2008 SP2 Upd10

4.4 Downloading the user program and parameterizing the
drive in the SIMOTION D demonstration case
4.4.1 De-archiving the SIMOTION project
Open SIMOTION SCOUT
De-archive the SIMOTION project and open it using SIMOTION SCOUT

4.4.2 Resetting SIMOTION D435 to the factory settings
In order to obtain a fixed start point for the description on how to download the user
program into the demonstration case, restore the factory setting at the
demonstration case as described below:
Power-down the demonstration case
Set the mode switch SIMOTION D435 to setting 3 (MRES)
Power-up the demonstration case
When RDY lights green and STOP lights orange, set the SIMOTION D435
mode switch to the 0 position (RUN)
RDY and RUN are green

Once the factory setting has been restored, the SIMOTION D435 has
PROFIBUS address 2 and the baud rate is 1.5 Mbit/s.

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4.4.3 Reconfiguration of double-axis motor module from 3A/3A to 5A/5A

This Standard Application is configured with a 3A/3A motor module. If this project
is used with demonstration racks of a different rated power, e.g. with double motor
modules 5A/5A, the configuration in the project has to be changed accordingly:
Change to offline mode
Open the drive navigator in the project navigator window
By pressing the button device configuration a new window opens
Carry out drive configuration, by pressing the relevant button
Press continue until you reach the window configuration power unit
Select the used power unit in the list, compare serial number at front face of
the motor module, e.g. 6SL3120-2TE15-0AA0 (5A/5A)
Press continue and acknowledge warnings
Press continue , without conducting any further changes, until the button
finish appears and finish the configuration by pressing that button
Close the window device configuration
Reduce parameter p210 separately in both drives (Antrieb rot, Antrieb blau)
from 600V to 345V by using the expert list (mark respective drive -> right
mouse button -> expert -> expert list)
Save and compile project, connect to target system and download your project





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4.4.4 Configure Ethernet interface
Set PG/PC interface
Table 3-5: Setting the PG/PC-interface configuration
No. Action Comment
1 Open the interface configuration in SIMOTION
SCOUT via EXTRAS SET PG/PC INTERFACE...
2 Among the features by Interface Parameter
Assignment Used, please select your Ethernet
card / interface of the PG/PC with TCP/IP ......
(e.g. TCP/IP VIA PCI 10/100I Fast Ethernet
Adapter).

3 Confirm (possible) warning by Yes.
4 Confirm your changes with OK twice


5 Return to SIMOTION SCOUT and open the net
configuration

NETPRO by using the button or by
selecting the
Menu PROJECT OPEN NETPRO.


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6 Double-click on PG/PC(1) to open the properties.
7 Under the feature Assignment (which has already
been selected automatically), the applied
ETHERNET interface has to be indicated under
Parameter assigned. If this is already the case,
you only have to select it and put the tick in the box
marked S7ONLINE Access: active.
In this case, please skip the steps 8 and 9!

Confirm your entry with OK.

After that, the Ethernet
line of the PG/PC
is marked in yellow.




If the applied ETHERNET interface is not
indicated under parameter assigned(but only
in that case!), please execute the steps 8 and 9
8 ETHERNET has not been assigned, yet:
You can find the configured interface of the control
under Configured Interfaces and all available
interfaces in the PG/PC under Interface Parameter
Assignments in the PG/PC.

Select under Interface Parameter Assignment the
applied ETHERNET interface (like it has been set in
Set Interface in PG/PC) and push the button
Assign.

If a warning appears, please, confirm it with OK.

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9 After that, the interface of the control is assigned to
the interface of the PG/PC. If this assignment has
not been selected, yet, please do it now and put the
tick in the box marked S7ONLINE Access:
Active.

Confirm your entry with OK.

After that, the Ethernet
line of the PG/PC
is marked in yellow.





10 Please, select Compile and check everything.
Select the (button ) and confirm with OK.
11 Please close all possible appearing warnings.
12 Before you close the project of loading, please
connect NETPRO and adjust the Ethernet address
of your PG/PC.
For this, please, see the next paragraph






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4.4.5 Set the Ethernet address of the PG/PC
Table 3-6: Ethernet address
No. Action Comment
1 Open the window NETWORK AND DIAL-UP
CONNECTIONS of your PG/PC, select the applied
network connection to SIMOTION D435, and open
its properties.
(Right mouse click mark properties or symbol
and then FILE PROPERTIES).
2 In the area Components checked are used by this
connection, please select the Internet Protocol
(TCP/IP) and open its properties.

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3 The standard IP address of the Ethernet interface
IE2/OP (X130) for the SIMOTION D435 is
169.254.11.22.

Please, select Use the following IP address and
enter the IP address 169.254.11.23.
Please, enter 255.255.0.0 in the Subnet mask.

4 The configured address need to be identical with
the address of the PG/PC!
Check the configured address in the properties of
the PG/PC interface and change it if necessary
5 Confirm your changes by pressing OK twice.







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4.4.6 Downloading the hardware configuration after a factory setting
To download the hardware configuration, please proceed as follows:

Table 4-4: Downloading the hardware configuration according to the factory setting
No. Action Comment
1 Change to HW-Config and download the hardware
configuration

2 Confirm with OK

3 Confirm with OK

4 Press No

5 Close the HW-Config and change to SCOUT



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4.4.7 Downloading the SIMOTION project of the standard application
Table 4-5: Downloading the SIMOTION project
No. Action Comment
1. Before you download the project, in the offline mode,
please check under Target system/Select target
devices


2. Whether both SIMOTION D435 as well as also
SINAMICS_Integrated are selected.

Please acknowledge changes with OK.

3. After establishing the ONLINE connection, the
operating states of the devices accessed, are
displayed in the diagnostics overview.


4. After starting the download, you will be prompted as
to whether you wish to copy RAM to ROM after the
download. Always answer this question with Yes as
otherwise your program must be again downloaded
after power ON/OFF.

This copy operation only refers to the SIMOTION
part of the project
5. Once the download has been completed, please
acknowledge with OK
6. Also acknowledge the data that has been
successfully copied from the RAM to ROM with OK

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No. Action Comment
7. The system now prompts you whether you wish to
also copy the parameters of SINAMICS_Integrated
from the RAM to the ROM.

Also answer this with Yes
8. Also acknowledge the data that has been
successfully copied from the RAM to ROM with OK
9. After the download has been completed, youll see
the adjacent diagnostics overview.


10. Now switch the SIMOTION D435 into the RUN state.

To do this, click on the SIMOTION-CPU and with the
right hand mouse key and target device/operating
state, go to the operating state display.


11. Here, click on the RUN button


The SIMOTION D435 is then in RUN and the
demonstration case is now ready to be used for the
presentation!



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5 Operator control of the application
example
The application can be used to present SIMOTION D with SINAMICS and get to
know and test the functions of the CPU D435.
In the following Chapter 5.2

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SIMOTION Rotary Knife ID: 37706606


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Brief instructions to demonstrate you will find brief instructions on how to
present and present the application example.
You will find detailed descriptions of all operator displays in Chapter 5.3 Detailed
operating instructions.

Prerequisites
The following prerequisites must be fulfilled in order to use the application example:
The SIMOTION project is provided online in SIMOTION D435.
The parameterization for the applications has been downloaded into
SINAMICS. (also included in the SIMOTION project!)
All devices have been powered-up.
The SIMOTION D435 has been switched into the Run state using the online
function of SIMOTION SCOUT.
As a minimum, WinCCflex Advanced 2008 SP2 Upd12 has been installed on
the PC/PG.

Note
WinCCflex requires the appropriate authorization. Authorization for at least 256
power tags is required.



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SIMOTION Rotary Knife ID: 37706606


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5.1 Structure overview
Please refer to the following diagram for the basic operator control structure with all
of the operator areas of the application.
The SETTINGS and STATUS displays are not required when presenting the
application and are therefore not described in the detailed Operating Instructions.

Figure 5-1: Structure overview to demonstrate the application
Manual-Mode
Automatic-Mode
STATUS
TECHNOLOGY
SETTINGS HOME
MANUAL
AUTO



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SIMOTION Rotary Knife ID: 37706606


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5.2 Brief instructions to demonstrate
Here, in these instructions you will only be shown and explained the steps
necessary to demonstrate the application. Not all of the operator screens will be
discussed. You will find detailed descriptions of all operator displays in Chapter 5.3
Detailed operating instructions
Execute the following steps in the sequence as listed in the following table to
demonstrate the application example:
Table 5-1: Brief instructions to demonstrate/present the rotary knife application example
No. Action Comment
1. Call the following file
"C:\Siemens\Step7\S7Proj\SAP_RotaryKnife\TDOP\
PRO__00.fwd".

As an alternative, you can also select the operator panel using Step 7.
In the SIMATIC Manager, open the SAP_RotaryKnife project. You will
find the HMI object OP1 at the project level. Start the runtime from the
context menu (righthand mouse key)
2. If the connection to the CPU was able to be established, the screen
form appears at the top left - mode: Idle
Please check that your PG/PC
is set to MPI with 12 Mbit/s or to
automatic.
3. At the bottom left, please click on AUTO
(3
rd
button from the left!)
4. First activate the print mark simulation by pressing the
Print Mark Simulation ON / OFF
button.
5. Next, using the
Start Position slider,
select the required
basic setting
and activate the movement to the starting position
by pressing the Rotary Knife STARTPOS button

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Operator control of the application example
SIMOTION Rotary Knife ID: 37706606


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No. Action Comment
6. Once the rotary knife has reached its starting position, the Rotary
Knife START button is
displayed to activate the rotary knife

Before you activate the rotary knife, the required cut length
should be selected using the CutLength
slider.
7. Now you can start the material feed!
Select the Material Velocity
using the
Material Velocity slider
You can start the
material feed by pressing
the Material START button
8. Once the material has reached the rotary knife, using the CutLength
slider,
you can enter a new
cut length, and activate
with the activate
button.
9. The new cut length is only taken into account after the actual segment
has been completely entered. The activate button remains green for
this time!

Activate the technology screen
by pressing the TECHNOLOGY button
10. The following are displayed in the technology screen:
The actual material velocity
The actual rotary knife velocity
The actual position of the rotary knife
The starting position of the rotary knife
You can return to the
automatic screen by pressing
the AUTO button

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SIMOTION Rotary Knife ID: 37706606


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No. Action Comment
11. The material can be removed
by pressing the Material END button
12. After the last cut, the rotary knife automatically moves to its starting
position and waits for new material.
13. Once the material has been completely removed
from the screen area, then you can
either
allow new material to enter by pressing
the Material START button
and continue with Step 8,
or
end the application by pressing
the Rotary Knife END button.
14. After the application has been ended, you can
return to the welcome screen
by pressing the HOME button
15.


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Process screen
The process screen is the main screen in the automatic mode of the application
example to control (operator control) the rotary knife.

Figure 5-2: Process screen in the automatic mode of the rotary knife








The material and the rotary knife can be started, terminated (exited) and monitored
in the process screen.
The material (material web) is started, stopped (held) and terminated (exited) on
the lefthand side; the rotary knife is started and exited on the righthand side.

Basic
settings
Mode of the
application rotary
knife
Length scale
Rotary Knife
Operating state (OMAC),
application example
Automatic
mode
Calls the
technology
screen
To the
status
display
Position and velocity of the
material and
rotary knife
Velocity input
(setpoint)
Manual
mode
Material
To the
welcome
screen
Start
material
Stop/
hold
material
Allow
material to
be removed
Random
print mark
offset
Start the
rotary knife
Move rotary knife
to the starting
position
End
application

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Operator control of the application example
SIMOTION Rotary Knife ID: 37706606


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5.3 Detailed operating instructions
A detailed description of the application is provided in these instructions. This is
necessary so that you can get to know and test the CPU functions.
Start
In the SIMATIC Manager, open the SAP_RotaryKnife project. You will find the
HMI object OP1 at the project level. Start the runtime from the context menu
(righthand mouse key).
or
Call the following file:
C:\Siemens\Step7\S7Proj\RotaryKnife_V20\HmiEs\PROJECT_1\
PROJECT_1.OP_Flex.fwx"

The welcome screen is displayed

Figure 5-3: Welcome screen





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SIMOTION Rotary Knife ID: 37706606


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General screen areas
The screen forms of the application are handled using buttons at the lower edge of
each of the screen forms.
Refer to

The name of the actual operator screen form and the presently valid mode are
displayed in the upper righthand corner of the screen forms.
Refer to


The following functions can be selected using the individual buttons:
Table 5-2: General buttons to control/handle the screen forms
Button Function


You can access the pre-setting screen from every operator screen
using the SETTINGS button.


You can access the setting-up screen from every operator screen
using the MANUAL button.
If the application is in the IDLE or AUTOMATIC-STOPPED modes,
the MANUAL mode is selected.


You can access the automatic screen from every operator screen
using the AUTO button.
If the application is in the IDLE or MANUAL modes, the
AUTOMATIC-STOPPED mode is selected.


You can access the technology screen from every operator screen
using the TECHNOLOGY button.


You can access the status screen from every operator screen using
the STATUS button.


You can access the welcome screen (home) from every operator
screen using the HOME button.
If the application is in the MANUAL or AUTOMATIC-STOPPED
modes, the IDLE mode is selected.


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Machine geometry settings
The standard application allows the following machine geometry parameters to be
adapted:
Distance to sensor
Distance between the rotary knife axis and the sensor of the material and print
mark detection
StartSyncPosition
Start of the synchronous range
EndSyncPosition
End of the synchronous range

Figure 5-4: SETTINGS operator screen for machine geometry settings


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Operator functions in the setting-up mode (MANUAL)
In the setting-up mode, the material web and the cross-cutter can be manually
moved.
This standard application does not require any functions that may only be executed
in the setting-up mode. This is the reason that we are only providing users with an
empty screen form that can be adapted, when required - to the specifications and
requirements of the users application.

Figure 5-5: MANUAL operator control screen form for the operator functions in the setting-up
mode


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SIMOTION Rotary Knife ID: 37706606


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Operator functions for the process in the automatic mode (AUTOMATIC)
Figure 5-6: AUTOMATIC operator screen form for operator functions in the automatic mode



Note
The automatic mode (AUTOMATIC) is only available, if
There is no fault,
Both axes are enabled, and
For both of these axes, no manual operator control functions are active.

Standard operator control
Table 5-3: Standard operator control in the automatic mode
No. Action Comment
1. Initial (starting) situation:
The rotary knife is in the AUTOMATIC-STOPPED mode


2. Using the Start Position slider, enter the starting position / basic
setting of the rotary knife.



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No. Action Comment
3. The rotary knife starts to move to the starting position / basic
setting by pressing the Rotary Knife STARTPOS button


4. After the starting position / basic setting has been reached, the
rotary knife is in the AUTOMATIC-READY mode


5. The rotary knife is enabled for operation using the Rotary Knife
START button.


6. The rotary knife is in the AUTOMATIC-STANDBY mode and waits
for material.


7. Select the required material web velocity using the Material
Velocity slider.


8. You can start to thread the material web or continue motion after
the material web was stopped by pressing the Material START
button.


9. If the rotary knife has synchronized itself to the motion of the
material web, the rotary knife is in the AUTOMATIC-PRODUCING
mode.


10. You can stop the material web using the Material BREAK button.


11. When the material web has been stopped, the rotary knife is in the
AUTOMATIC-HELD mode


12. You can start to remove the material web from the system by
pressing the Material END button.


13. If this symbol appears, then the rotary knife has detected the last
segment of the material web and ends its last position with the
stop cam in its starting position / basic setting.


14. The rotary knife then waits in the AUTOMATIC-STANDBY mode
for the next material web.



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Operator control of the application example
SIMOTION Rotary Knife ID: 37706606


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Expanded operator control
Table 5-4: Expanded operator control in the automatic mode
No. Action Comment
1. If the rotary knife is in the AUTOMATIC-STOPPED, operating
mode, you can select one of two possibilities:
Print Mark Simulation OFF
i.e. the demonstration case itself generates print
marks using sensors. It is not possible to change the
cut lengths
Print MARK simulation ON
this means that the print marks and therefore also
the cut length can be freely selected.


2. If the print mark simulation has been activated, this character is
displayed at the top left edge of the screen.


3. You can change the cut length with the Cutlength slider.


4. If the rotary knife is in the AUTOMATIC-PRODUCING mode, you
can changeover the print mark simulation using the activate
button to the new cut length that you have selected.


5. Using the button Random Print Marks ON / OFF, you can
activate automatic modification of the cut length from print mark to
print mark.
(presently implemented: The cut length can be modified by +/- 20
mm)



Shift cut function
Figure 5-7: Operator control elements of the shift cut function




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Table 5-5: Using the shift cut function
No. Action Comment
1. You can shift the cut by 5 mm to the left using button 5


2. You can shift the cut by 1 mm to the left using button -1


3. You can shift the cut by 1 mm to the right using button +1


4. You can shift the cut by 5 mm to the right using button +5


5. Velocity value that is superimposed on the rotary knife velocity for
correction motion.


6. Indicates that correction motion is active



Display areas
Figure 5-8: Rotary knife mode


This area informs you about the selected and presently active operating mode
of the RotaryKnife-FB.

Figure 5-9: Actual Velocity / Position


In this area, the actual velocity [mm/s] and the actual position [mm] are
displayed for the material and rotary knife axis.

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Technology view
The technology view of the application can be selected from every operator screen
using the TECHNOLOGY button.

Figure 5-10: Technology view



In the technology view, using the trace function of the HMI screen, the actual
position of the rotary knife, its starting/basic position and the velocities of the
material web and the rotary knife can be monitored and traced (recorded).
The modulo jump of the rotary knife can be clearly seen when its position changes
from 199.999 mm to 0 mm.
The fluctuations in the rotary knife velocity can also be easily seen however, in
the cut, the velocity corresponds to precisely that of the material web.

Controls the trace
function
Actual cross-cutter
position
Cross-cutter velocity
Material web
velocity
Starting/basic position
of the cross-cutter

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Operator control functions in the status display
The status display of the application can be selected from every operator screen
using the STATUS button.

Figure 5-11: Status display


You can see the actual state of the RotaryKnife-FB in the status display.
You can read about the error number displayed under ErrorID, in
Chapter 7.3.7.
Errors can be acknowledged using the QUITT button.
If the RotaryKnife-FB is in the ERROR state, then the Quitt button should be
pressed until the RotaryKnife-FB is in the DISABLE state.

Integrating the core functions
Operator control of the application example
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Integrating the core functions
Content
All of the steps necessary to integrate the core rotary knife functions into your
application are explained in this section.
Preparations and parameterizing operations are also explained. Further, you are
also told how to integrate the RotaryKnife-FB into your application step-by-step.


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Program environment and interfaces
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6 Program environment and interfaces
6.1 Importing the source code
The SIMOTION Rotary Knife application is part of the LRKLib library. The library is
available as standard SIMOTION Rotary Knife application as well as XML export.
In order to be able to use the functionality of the library, this must be integrated into
the corresponding user project.
6.1.1 Copying from the application example
Two instances of SIMOTION SCOUT are opened in order to copy the LRKLib
library. The application example is opened or dearchived in the first window and a
new user project is created in the second window, which already includes the
global library folder.

Table 6-1: Copying the library from the application example
No.
1. The library is downloaded to the
buffer memory by right clicking on
the library in the standard
application following by Copy.


2. The library LRKLib can be inserted
if, in the user project, the Library
folder is selected and is then run by
clicking on it with the righthand
mouse key.


3. The lower-level objects are also
copied.



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6.1.2 Linking using XML import
With XML import, the LRKLib library and the RK_Progs program unit from their
XML files are linked into the existing user project.
Table 6-2: Importing the XML file
No.
1. For the XML import, the
LIBRARIES folder must be
selected in the user project and
then run by clicking on it with the
righthand mouse key. Using the
Import object menu item, a
window opens in which the path
of the XML file must be specified.


2. Using the Browse button, the
XML file path is specified and
therefore the LRKLib library is
imported into the user project.



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6.1.3 Linking the rotary knife functionality
The LRKLib library comprises several program units, whereby the units
RK_CamCalc (block to calculate the cam), RK_Template (rotary knife block),
RK_Tools (internal functions) contain the functionality of the application in the form
of function blocks as well as data type definitions and the unit RK_Progs.
Reference to the library is established in the unit and the instances of the function
blocks and the data structures created. In addition, the unit includes the calls of the
instances in the programs that must be integrated in the user project in the task
system. The programs are not able to run in the library and may have to be
adapted to the particular application (startupRotaryKnife).
Table 6-3: Programs of the RK_Progs unit
Program Description Task
StartupRotaryKnife Initialization and parameterization StartupTask
MainRotaryKnife Main program BackgroundTask
IpoRotaryKnife Status bits and print marks IPOsynchronousTask
MTCamCalculation Cam calculation MotionTask

After the library has been copied/imported in the library folder, the program unit
RK_Progs must be copied from the library folder into the program folder of the
application and modified at four positions:
Table 6-4 Copying and modifying the UNIT RK_Progs
No.
1.
The unit is downloaded into the buffer memory by
right-clicking on the program unit RK_Progs in the
library LRKLib followed by Copy.

2. The program unit RK_Progs can be inserted if, in the
user project, the Program folder is marked and is
subsequently run with a righthand mouse click.


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No.
3. Then, in the program unit RK-Progs,
in the program container (not in the
library!) four program lines must be
deleted.

Marked with $$$$$$$

4.


5.


6. The program unit can now be
successfully compiled.


When using the program unit RK_Progs, the user does not have to link the library.
The library is linked using the RK_Progs unit.

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User program units that are to access library functions, types, function blocks and
data of the standard application, must be linked with the program unit RK_Progs in
the interface section.

INTERFACE
USES RK_Progs // Linking the standard application
END_INTERFACE

Variable access
To access variables of the SIMOTION Rotary Knife application, the following
instances are set-up in the global data area in the RK_Progs program unit:

Table 6-5: Data interface
Element Description
gasRotaryKnife Block interfaces and parameters
gaRotaryKnife Instance(s) of the FBRotaryKnife
gaFBRKIPO Status bits and print mark detection
gaFBCamCalculation Instance(s) of the FBRKCamCalculation
NUMBER_OR_ROTARY_KNIFES Number of FB instances


VAR_GLOBAL CONST
NUMBER_OF_ROTARY_KNIFES : INT := 1; // number of rotary knifes controlled
END_VAR
VAR_GLOBAL
gasRotaryKnife : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF sRotaryKnifeType;
gaFBRotaryKnife : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF FBRotaryKnife;
gaFBRKIpo : ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF FBRKIpo;
gaFBCamCalculation: ARRAY[0.. NUMBER_OF_ROTARY_KNIFES -1] OF
FBRKCamCalculation;
END_VAR

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6.2 Technology objects
6.2.1 Technology objects required and synchronous relationships
To use the SIMOTION Rotary Knife application, the following technology options
must be set-up and interconnected with one another in the described fashion:
Table 6-6: Technology objects required
Object Description
To determine the position and velocity of the material web as master (leading) value of the
core rotary knife functions and to coordinate the motion of the axis material web from the
same control.
Real positioning or following axis TO
External encoder
Configuration Set the axis type as linear. For accuracy reasons,
we recommend that the axis type is parameterized
as modulo axis with a modulo length greater than
the maximum product length.
All of the other parameters should be set
corresponding to the drive and encoder data.
Mechanical
system
For the parameter distance per spindle revolution,
enter the distance as value that the material web
moves through for one revolution of the drive roll.
Supplement the additional parameters also
corresponding to the geometry and machine design.
Limits For this parameter, enter values that correspond to
the system/drive relationships
Referencing Parameterize not required
Material Axis
(MaterialAxis,
(MaterialEncoder)
Configuration
Monitoring,
closed-loop
control
Please set this parameter corresponding to the
system relationships.
Drive for the rotary knife motion.
TO Real following axis
Configuration Parameterize the axis as synchronous axis. Set the
axis type as linear.
All of the other parameters should be set
corresponding to the drive and encoder data.
Mechanical
system
For the parameter distance per spindle revolution
enter the distance that the point of the Rotary Knife
moves through for one motor revolution. If the
Rotary Knife is directly mounted without a gear
unit, then knifeCircumference should be entered
here.
Appropriately supplement the other parameters
corresponding to the geometry and the machine
design.
Pre-assignment Please set this parameter corresponding to the drive
dynamics
Limits Please set this parameter corresponding to the
system relationship
Rotary Knife Axis
(RotaryKnifeAxis)
Configuration
Referencing Please set this parameter corresponding to the
encoder.
(The template assumes a referenced axis. If an
incremental encoder is to be used, then the axis
must be referenced in the MANUAL mode before
additional operating modes are selected.)

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Program environment and interfaces
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Object Description
Monitoring
functions, closed-
loop control
Please set this parameter corresponding to the
system relationships
Inserting this (virtual) auxiliary axis between the material path motion and the cam makes it
easier to correct length errors that are determined by the print mark detection. By correcting
the auxiliary axis position, then the knife position is automatically corrected - adapted to the
cam position. Without the auxiliary axis, the correction motion of the knife corresponding
to the length change using the print mark correction must be adapted using the cam.
TO Real following axis
Configuration Set the axis type as linear
Parameterize as virtual axis without drive
Pre-assignment
Limits
Auxiliary Axis
(AuxiliaryAxis)
Configuration
Monitoring
functions
Please select this parameter so that in operation the
virtual axis does not reach the dynamic limits.
In operation, two cam TOs are required to recalculate and exchange the cams. The third
cam TO is used for travel to the initial position when stopping.
TO Cam
Cams
(Cam1, Cam2, Cam3)
Configuration Cam type, polynomial


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6.2.2 Synchronous relationships
Synchronous relationships of the SIMOTION Rotary Knife application:
Figure 6-1: Synchronous relationships required for the FBRotaryKnife
Material
Axis
Cam1
1:1
Cam3
External Encoder
or
Positioning Axis
Following Axis Following Axis gearing caming
Cam2
Rotary
Knife
Axis
Auxiliary
Axis

The material axis (MaterialAxis) is the reference quantity for the rotating knife. This
reference quantity can be detected in two different ways:
1. The material path is controlled by the SIMOTION drive system that also
controls the rotary knife. In this case, there is an axis TO. The synchronous
connection with the auxiliary axis (AuxiliaryAxis) should in this case, access the
setpoints of the material path that exist in the system (setpoint coupling)
2. The material path motion is measured using the encoder in the machine itself.
In this case, there are no additional setpoints available. The synchronous
connection with the auxiliary axis (AuxiliaryAxis) can only access the actual
values of the encoder in the machine (actual value coupling).
The AuxiliaryAxis as synchronous axis is connected to the MaterialAxis in a 1:1
(gearing) synchronous relationship.
There is a camming relationship between the AuxiliaryAxis and the synchronous
axis RotaryKnifeAxis, that can be optionally controlled using cam 1 (Cam1) up to
cam 3 (Cam3).
The synchronous relationship between the RotaryKnifeAxis and AuxiliaryAxis
remains during the complete operation from starting to stopping the "Rotary Knife;
a changeover is only made between the cams.
The synchronizing operations when starting and stopping are only executed
between the MaterialAxis and the AuxiliaryAxis. Also the print mark correction only
operates between the MaterialAxis and AuxiliaryAxis.
The technology objects and synchronous operation relationships shown in the
diagram above must be set-up and configured by the user in SIMOTION SCOUT.
AuxiliaryAxis_GLEICHLAUF(_SYNCHRONOUS_OPERATION)
Configuration
Either
Select the TO Axis MaterialAxis as master (leading) axis
Select setpoint as coupling type.

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Figure 6-2 Configuration of MaterialAxis as leading value of AuxiliaryAxis


or
Select the TO ExternalEncoder MaterialEncoder as master (leading) axis
Select actual value with extrapolation as coupling type.
The time constant required for extrapolation is calculated using the calculation tool
of the Utility&Applications CD
(Scout\CD14\SRC\4_TOOLS\ExtrapolationTimeCalculation).
Figure 6-3 Configuration of MaterialEncoder as leading value of AuxiliaryAxis


Table 6-7
Function / Variable Value
Dynamic parameters The dynamic parameters of the time-related
synchronization should be selected so when being
synchronized and desynchronized, the axis does not
reach the dynamic limits.



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RotaryKnifeAxis_GLEICHLAUF(_SYNCHRONOUS_OPERATION)
Configuration
Figure 6-4 Configuration of AuxiliaryAxis as leading value of RotaryKnifeAxis

Select the TO Axis AuxiliaryAxis as master (leading) axis
Select setpoint as coupling type.
Select Cam1, Cam2 and Cam3 as possible cams
Table 6-8
Function / Variable Value
Dynamic parameters The dynamic parameters of the time-related
synchronization should be selected so when being
synchronized and desynchronized, the axis does not
reach the dynamic limits.


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6.3 Integrating the SIMOTION Rotary Knife core function
The SIMOTION Rotary Knife application comprises several functional units that are
saved in the program unit RK_Prog :

6.3.1 Parameterizing the rotary knifes in the startup task
It makes sense to combine configuration data assignments - that are not changed
in operation - in a program (StartupRotaryKnife). These are then executed once
when starting the control in the StartupTask and therefore assign values to
variables.
Assignment of the actual TO instances
Assignment of the machine-specific parameters
Resetting the restart bits.
Deleting the format length buffer memory.
Resetting all flags in the program.
Generating this program based on the declaration of the variables from Chapter 0
is described in this chapter as an example.
The program is already prepared as program instance that can be called in the task
manager and saved in the UNIT RK_Progs.
The user only has to adapt the parameters to the real machine!

6.3.2 Calling FBRotaryKnife in the user program
The function block of the Rotary Knife core functions can also be called after
integration in the user program.
The call is already prepared in the program unit RK_Progs in the MainRotaryKnife
program. The user only has to integrate this program into a cycle tasks
(background, Ipo or Ipo2).

6.3.3 Calling the FBRKCamCalculation
The FBRKCamCalculation call is already prepared. In this case, the user only has
to integrate the MTCamCalculation program of unit RK_Progs in a motion task.
This motion task should be automatically started with Startup.


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Figure 6-5 Parameterization of MotionTask


6.3.4 Calling the FBRKIPO in the IPO synchronous task
The FBRKIpo call has already been prepared. The user only has to integrate the
IPORotaryKnife program of unit RK_Progs into the IPO_Task.

6.3.5 Global Variables
The FBRotaryKnife function block is influenced by several parameters and
interfaces that are subdivided into the following areas:
Block interfaces
Block interface in the global data area
Changing tasks and modes are communicated to the function block via the block
interface. The function block also communicates the actual status - and errors that
have possibly occurred - back to the user program via this interface.
The parameters of the rotary knife to be connected are communicated to the
function block via the block interface in the global data area. In normal rotary knife
operation, these quantities are not changed. Further, it includes data areas for
communication with the user and for communication of the individual sub-functions
in the overall rotary knife system with respect to one another.


Program Description
Program environment and interfaces
SIMOTION Rotary Knife ID: 37706606


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Program Description
Content
Section Program Description is interesting if you wish to expand/adapt your
application based on the technology templates available.

Objective
This part of the documentation should
Explain to readers the special features/issues when generating a program
Describe in detail the program structure of the rotary knife FB
Illustrate and describe important program elements
Provide information and instructions on how this template can be adapted.
Prerequisite
Before possibly expanding this template it is helpful to have read the chapters in
Section A and B in order to get to know the basic functions and applications of the
template.

Note
Before you make changes to the template, please observe the information and
warnings listed in the following Chapter as well as the associated restrictions
regarding support!



Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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7 Program Description
7.1 Information and warnings
Before carrying-out changes
Before you carry-out changes to the components included in the core functions,
you should get to know how the components function by referring to and reading
the ST/MMC documentation.
Uncontrolled, incorrect changes and modifications to core functions can result in
death and severe bodily injury!

Restrictions regarding support when changing components of the core functions
The Application Center can only provide support for core functions that have not
been changed
If changes have been made to the code, then support can no longer be provided
for core functions.
This also applies for the revision and adaptation recommendations listed in this
Chapter.

7.2 Type of Data
7.2.1 Overview
Enumeration types
Enumeration type declarations are prepared for some of the input and output
parameters of the function blocks. Various modes and properties can be pre-set
using these parameters.
Data structures
The function blocks of the Rotary Knife application are in some cases
parameterized via data structures that should be set-up for the particular block.
Structures with the corresponding parameters are provided for each block.


Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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7.2.2 Enumeration types
Table 7-1
Name of the enumeration type Contents
eOperationModesRotaryKnifeType This enumeration type contains enumerators to select and
display the operating states of the function block
FBRotaryKnife.
Declared in LRKLib.RK_Template:
eTypeOfCamType Defines the cam type for the cam calculation.
Declared in: LRKLib.RK_CamCalc
eCamProfileType Defines the travel profile for the cam calculation.
Declared in: LRKLib.RK_CamCalc
eOperationModesRotaryKnifeType
This enumeration type contains enumerators to select and display the operating
state of the FBRotaryKnife function block.
Element Description
OMRK_ERROR FBRotaryKnife is standing in state ERROR
OMRK_DISABLE FBRotaryKnife is standing in state DISABLE
OMRK_START_POSITION FBRotaryKnife is standing in state STARTPOSITION
OMRK_AUTOMATIC FBRotaryKnife is standing in state AUTOMATIC
OMRK_MANUAL FBRotaryKnife is standing in state MANUAL
OMRK_SINGLE_CUT FBRotaryKnife is standing in state SINGLE_CUT
OMRK_SAMPLE_CUT FBRotaryKnife is standing in state SAMPLE_CUT
OMRK_NOTHING_SELECTED FBRotaryKnife has no change of state detected
OMRK_CHANGING FBRotaryKnife is changing state
eTypeOfCamType
This enumeration type defines the cam type for the cam calculation:
Element Description
START_CAM Cam for cross-cutter motion from the start position into cyclic operation.
CYCLIC_CAM Cam for cyclic operation
STOP_CAM Cam to stop the cross-cutter from cyclic operation
eCamProfileType
This enumeration type defines the travel profile for the cam calculation:
Element Description
LINEAR Acceleration / deceleration profile with constant acceleration
JERK Acceleration / deceleration profile with jerk limiting
POLY_5 Acceleration / deceleration profile as fifth order polynomial

Program Description
Program Description
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7.2.3 Data Structures
Name of Structure Content
sRotaryKnifeType This structure contains the complete global data of the Rotary
Knife system.
Declared in LRKLib.RK_Template
sTOsType This structure contains the definition of all of the axes, external
encoders, cams and probes that are used.
Declared in LRKLib.RK_Tools
sUsersInterfaceType This structure contains the interface for the user to enter
physical limiting conditions (constraints), cam profiles, manual
cutting position corrections as well as the input of sequence
options - such as a new start, fast start and format change in
ongoing operation.
Declared in LRKLib.RK_Template
sFormatLengthBufferType This structure contains the format length memory.
Declared in LRKLib.RK_Tools
sFormatLengthBuffer
ManagementType
This structure contains the internal data area to enter the cut
length with a precise position.
Declared in LRKLib.RK_Tools
sCutPositionBufferType This structure contains the buffer in which the cut position is
saved with the associated position deviations.
Declared in LRKLib.RK_Tools
sCutPositionBufferManagement
Type
This structure contains the internal data area to enter the cut
position as a precise position and cut position deviation for the
print mark correction.
Declared in LRKLib.RK_Tools
sSampleBufferType This structure contains the user area to save cut length
sequences in the SAMPLE_CUT operating mode.
Declared in LRKLib.RK_Template
sCamCalculationType This structure contains the internal data area to call the cam
calculation.
Declared in LRKLib.RK_Template
sRotaryKnifeInfoType This structure contains the internal data area to display actual
geometry values converted into the peripheral (circumferential)
lengths in [mm], actual cut position as well as binary signals for
the knife position.
Declared in LRKLib.RK_Template
sMeasuringValueType This structure contains the internal data area for the print mark
correction.
Declared in LRKLib.RK_Tools

Generally applicable for labeling structural elements:
[IN]: Values that should be provided by the user
[OUT]: Results or feedback signals
[IO]: Values, which depending on the block connection, must be supplied by
the user or written by the function
sRotaryKnifeType
This structure contains the complete global data of the RotaryKnife system:

Program Description
Program Description
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I/O Element Type of Data Description
IN sAxisTOs sTOsType
Object references of all technology objects (axes, external
encoders, cams and measuring probes).
IN sUsersInterface
sUsersInterface
Type
Interface for the user to enter physical constraints, cam
profiles, manual cutting position corrections as well as the
input of sequence options - such as a synchronized start,
quick start and format change in ongoing operation.
I/O
sFormatLengthBuffer
Management
sFormatLength
Buffer
Management
Type
Internal data area to configure processing programs.
I/O
sCutPositionBuffer
Management

sCutPosition
BufferManageme
ntType
Internal data area to enter the cut position as a precise
position and cut position deviation for the print mark
correction.
I/O
sSampleBuffer

sSampleBuffer
Type
User area to save cut length sequences in the
SAMPLE_CUT mode
I/O
sCamCalculation

sCamCalculation
Type
Internal data area to call the cam calculation
I/O
sRotaryKnifeInfo

sRotaryKnifeInfo
Type
Internal data area to display actual geometry values
converted into the peripheral (circumferential) lengths in
[mm], actual cut position as well as binary signals for the
knife position.
I/O
sMeasuringValue

sMeasuringValue
Type
Internal data area for the print mark correction.
IN r64FormatLength LREAL
[ mm ] r64formatLength is the length of the cut material
element.
IN boExecute BOOL
Activates the mode changeover with the operating mode
specified in eMode.
IN eMode
eOperationModes
RotaryKnife
Type
Using eMode the operating mode is preselected that is then
activated with the next positive edge at input execute.
OMRK_ERROR: Preselects the ERROR mode
OMRK_DISABLE: Preselects the DISABLE mode
OMRK_AUTOMATIC: Preselects the STARTPOSITION
mode
OMRK_AUTOMATIC: Preselects the AUTOMATIC mode
OMRK_MANUAL: Preselects the MANUAL mode
OMRK_SINGLE_CUT: Preselects the SINGLE_CUT mode
OMRK_SAMPLE_CUT: Preselects the SAMPLE_CUT
mode
IN boStartSingleCut BOOL Starts an individual cut if FB is in the SINGLE_CUT mode.
IN boStartSampleCut BOOL
Starts a cut sequence to generate test cuts in the
SAMPLE_CUT mode.
IN i16NumberOfInstanz INT Instance number of the actual call.
OUT boDone BOOL TRUE: Selected mode is activated.
OUT boBusy BOOL TRUE: Mode changeover is active.
OUT boError BOOL Indicates errors in the FBs and at the cross-cutter axes.
OUT b32ErrorID DWORD Error code

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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I/O Element Type of Data Description
OUT eState
eOperationModes
RotaryKnife
Type
Actual mode
OMRK_ERROR: ERROR mode
OMRK_DISABLE: DISABLE mode
OMRK_AUTOMATIC: STARTPOSITION mode
OMRK_AUTOMATIC: AUTOMATIC mode
OMRK_MANUAL: MANUAL mode
OMRK_SINGLE_CUT: SINGLE_CUT mode
OMRK_SAMPLE_CUT: SAMPLE_CUT mode
OMRK_NOTHING_SELECTED: No mode change
OMRK_CHANGING: Mode change active
OUT boAutomaticActive BOOL TRUE: mode AUTOMATIC activated
OUT boSingleCutActive BOOL TRUE: mode SINGLE_CUT activated
OUT boSampleCutActive BOOL TRUE: mode SAMPLE_CUT activated
OUT
boCutPosition
CorrectionActive
BOOL TRUE: Correction motion for actual cut position is active
OUT
boRotaryKnifeAxis
Active
BOOL TRUE: rotary knife axis enabled
sTOsType
This structure contains the definition of all of the axes, external encoders, cams
and measuring probes used (the user must parameterize these):
I/O Element Type of Data Description
IN toLeadingValue _AXIS_REF
Reference to the technology object of the leading value.
Possible technology objects:
- posAxis (real or virtual)
- externalEncoderType
IN toAuxiliaryAxis followingAxis
Reference to the technology object of the auxiliary axis, this
object is mandatory for synchronous operation. Only a
virtual axis is permissible.
IN
toRotaryKnifeAxis

followingAxis
Refer to the technology object of the Rotary Knife axis. Only
one real axis is permissible.
IN toCam1 camType Reference to the first cam object.
IN toCam2 camType Reference to the second cam object.
IN toCam3 camType Reference to the third cam object.
IN toPrintmark
measuringInput
Type
Reference to the technology object of the measuring probe
used for print mark detection. The measuring probe must be
assigned to the leading value.

Program Description
Program Description
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sUsersInterfaceType
This structure contains the interface for the user to enter physical constraints, cam
profiles, manual cutting position corrections as well as the input of sequence
options - such as a synchronized start, quick start and format change in operation
(the user must parameterize these):
I/O Element Type of Data Description
IN r64KnifeCircumference LREAL
[mm] Effective geometrical circumference of the knife roll
(circumference of the circle)
IN r64StartSyncAngle LREAL
[] Start angle of the synchronous range (cutting range), i.e.
the angle at which the knife enters the material; the center
point is defined as 0 (170.0 - 360.0).
IN r64EndSyncAngle LREAL
[] Final angle of the synchronous range, i.e. the angle at
which the knife leaves the cutting range (0.0 - 170.0 ).
IN r64StartAngle LREAL [] Start position of the knife (start position of the start cam).
IN r64StopAngle LREAL [] Stop position of the knife (final position of the stop cam).
IN r64InflectionPoint LREAL
[%] Center point of the format range of the cyclic cam .
r64inflectionPoint < 50.0 % (min, 10%):
Shifts the center point towards r64EndSyncAngle, i.e. the
absolute value of the acceleration in the first motion
segment after the cut is increased.
r64inflectionPoint > 50.0 % (max. 90%): Shifts the
centerpoint towards r64StartSyncAngle, i.e. the absolute
value of the acceleration in the second motion segment
after the cut is higher.
IN i16NumberOfKnives INT Number of knives (max. 6)
IN eCamProfilePhase1 eCamProfileType
Motion profile, phase 1:
LINEAR: Curve profile with constant acceleration
JERK: Curve profile with constant acceleration and curve
limiting
POLY_5: Motion profile as fifth order polynomial.
IN r64JerkPhase1 LREAL
[%] Jerk limit component in phase 1 (only for
eCamProfilePhase1 = JERK).
The valid value range is between 1.0 and 100.0. For 100%
a phase is obtained where the acceleration is not constant.
The absolute jerk depends on the machine velocity.
IN eCamProfilePhase2 eCamProfileType
Motion profile, phase 2:
LINEAR: Curve profile with constant acceleration
JERK: Curve profile with constant acceleration and curve
limiting
POLY_5: Motion profile as fifth order polynomial.
IN r64JerkPhase2 LREAL
[%] Jerk limit component in phase 2 (only for
eCamProfilePhase2 = JERK).
The valid value range is between 1.0 and 100.0. For 100%
a phase is obtained where the acceleration is not constant.
The absolute jerk depends on the machine velocity.
IN r64DistanceToSensor LREAL
[mm] Distance between the cut position and the sensor to
detect the material and printer mark.
IN r64FirstCutCorrection LREAL [mm] Cut offset for the starting cut
IN
r64MeasuredValueCut
PosAtSensor
LREAL [mm] Actual position measured value for the first cut
IN r64ToStartPosVel LREAL [mm/s] Motion velocity when positioning to the start position.
IN
r64KnifeOverspeed
StartCut
LREAL
[%] Overspeed at the transition point to the synchronous
range (r64StartSyncAngle) (-20.0% to 20.0%) referred to
the synchronous velocity.

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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I/O Element Type of Data Description
IN
r64KnifeOverspeed
Zero
LREAL
[%] Overspeed at the center position of the synchronous
range (0) (-20.0% - 20.0%) referred to the synchronous
velocity.
IN
r64KnifeOverspeed
EndCut
LREAL
[%] Overspeed at the end point of the synchronous range
(r64EndSyncAngle) (-20.0% to 20.0%) referred to the
synchronous velocity.
IN
r64CPCorrection
Maximum
LREAL
[mm] Maximum correction value for the cut position
correction
IN
r64CPDeltaTolerance
Range
LREAL
[mm] Half the tolerance bandwidth for the activation range
of the cut position detection
IN
r64AdjustCutPosition
PositiveValue
LREAL
[mm] Coarse correction value of the manual cutting position
correction in the positive direction
IN
r64TrimmCutPosition
PositiveValue
LREAL
[mm] Fine correction value of the manual cutting position
correction in the positive direction
IN
r64AdjustCutPosition
NegativeValue
LREAL
[mm] Coarse correction value of the manual cutting position
correction in the negative direction
IN
r64TrimmCutPosition
NegativeValue
LREAL
[mm] Fine correction value of the manual cutting position
correction in the negative direction
IN
r64CutPosition
CorrectionVelocity
LREAL
[mm/s] Velocity value of the higher-level cut position
correction
IN i16CutCorrWait INT Number of cuts without cut position correction
I/O boRestart BOOL
Flag restart, the user must set this, it is reset by the
application
IN boQuickStart BOOL
Flag, Quickstart
TRUE: The application immediately starts to cut at the start
FALSE: Application only starts to cut at the specified start
position
IN
boFormatLength
ChangePossible
BOOL
Flag, enable format length change when the machine is
running
TRUE: Format length change possible
FALSE: Format length change inhibited
IN boSwitchCAM BOOL
A positive edge starts a format length change (if format
length change is enabled!)
IN
boMeasuring
WithRisingEdge
BOOL
Flag, edge selection measuring system
TRUE: Rising edge
FALSE: Falling edge
IN
boCutPosition
CorrectionOn
BOOL Flag cut position correction on
IN
boAdjustCutPosition
Positive
BOOL Flag start coarse correction, positive of the cut position
IN
boTrimmCutPosition
Positive
BOOL Flag start fine correction, positive of the cut position
IN
boAdjustCutPosition
Negative
BOOL Flag start coarse correction, negative of the cut position
IN
boTrimmtCutPosition
Negative
BOOL Flag start fine correction, negative of the cut position
IN boCleanCut BOOL
Start cut to separate scrap and product in the
SAMPLE_CUT mode
sFormatLengthBufferType
This structure contains the format length memory (this is not relevant for the user):

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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I/O Element Type of Data Description
I/O ar64FormatLength
ARRAY
[0..CLB_MAX-1]
OF LREAL
[mm] buffer oh the format length
I/O aboFormatLengthRead
ARRAY
[0..CLB_MAX-1]
OF BOOL
buffer of the flags format length read
I/O
aboFormatLength
Entered
ARRAY
[0..CLB_MAX-1]
OF BOOL
buffer of the flags format length entered
sFormatLengthBufferManagementType
This structure contains the internal data area to enter the cut length with a precise
position (this is not relevant for the user):
I/O Element Type of Data Description
I/O sFormatLengthBuffer
sFormatLength
BufferType
data area of format length buffer
I/O i16BufferIn INT Pointer to next input position of buffer
I/O i16BufferOut INT Pointer to next output position of buffer
I/O i16BufferTest INT Pointer to next test position of buffer
I/O i16BufferInRett INT Buffers the buffer pointer to the next entry position
I/O boBufferOutTrigger BOOL Start trigger to delete the read buffer entry
I/O boBufferReadTrigger BOOL Start trigger to read the next buffer entry
I/O
r64BufferTestFormat
Length
LREAL Format length currently read from the buffer
I/O
r64BufferLastFormat
Length
LREAL Previous format length read from the buffer
I/O
boBufferTestFL
Entered
BOOL Actual entered flag read from the buffer
I/O boBufferTestFLRead BOOL Actual read flag read from the buffer
I/O boBufferResetActive BOOL Reset of buffer active
I/O boBufferInActive BOOL Input of value in buffer active
I/O boBufferOutActive BOOL Deletion of buffer value active
I/O boBufferReadActive BOOL Reading of buffer value active
sCutPositionBufferType
This structure contains the cut position memory (this is not relevant for the user):
I/O Element Type of Data Description
I/O
ar64CutPosition
DeviationMeasured
ARRAY
[0..CPB_MAX-1]
OF LREAL
[mm] Buffers the deviations between the setpoint and the
actual position for the cut at the instant in time of the
measurement
I/O
ar64CutPosition
Measured
ARRAY
[0..CPB_MAX-1]
OF LREAL
[mm] Buffer of the measured cut positions
I/O aboCutPositionRead
ARRAY
[0..CPB_MAX-1]
OF BOOL
Buffer of the flag cut position read
I/O aboCutPositionEntered
ARRAY
[0..CPB_MAX-1]
Buffer of the flag cut position entered

Program Description
Program Description
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I/O Element Type of Data Description
OF BOOL
sCutPositionBufferManagementType
This structure contains the internal data area to enter the cutting position and to
control the cutting position correction as precise position (this is not relevant for the
user):
I/O Element Type of Data Description
I/O sCutPositionBuffer
sCutPosition
BufferType
data area of cut position buffer
I/O i16BufferIn INT Pointer to next input position of buffer
I/O i16BufferOut INT Pointer to next output position of buffer
I/O i16CutCorrectionWait INT Number of cuts without cut position correction
I/O boBufferOutTrigger BOOL Start trigger to delete the read buffer entry
I/O boBufferReadTrigger BOOL Start trigger to read the next buffer entry
I/O boBufferResetActive BOOL Reset of buffer active
I/O boBufferInActive BOOL Input of value in buffer active
I/O boBufferOutActive BOOL Deletion of buffer value active
I/O boBufferReadActive BOOL Reading of buffer value active
sSampleBufferType
This structure contains the cut length buffer for the SAMPLE_CUT mode (the user
must parameterize this):
I/O Element Type of Data Description
I/O ar64SampleLength
ARRAY
[0..SLB_MAX-1]
OF LREAL
[mm] Buffer of the format lengths of the samples
I/O
ai16SampleNumberOf
Plates
ARRAY
[0..SLB_MAX-1]
OF INT
Buffer for the number of cuts per sample
I/O i16SampleLengthIn INT Pointer to next input position of buffer
I/O i16SampleLengthOut INT Pointer to next output position of buffer
sCamCalculationType
This structure contains the internal data area to control the cam calculation (this is
not relevant for the user):
I/O Element Type of Data Description
IN toNextCam camType TO Cam of the cam to be actually calculated
IN toActualCam camType TO Cam of the presently active cam
IN
r64FormatLength
Activated
LREAL [mm] Activated format length
IN eTypeOfCam
eTypeOfCam
Type
Type of cam to be calculated
START_CAM: Start cam
CYCLIC_CAM: Cyclic cam
STOP_CAM: Stop cam
IN r64StartAngleActivated LREAL [] Activated start angle
IN r64StopAngleActivated LREAL [] Activated stop angle

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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I/O Element Type of Data Description
IN
r64InflectionPoint
Activated
LREAL
[%] Activated center point of the format range of the cyclic
cam
OUT b32EIdCamCalculation DWORD
Transfers the error message of the cam calculation to the
error message system of FBRotaryKnife.
OUT
boCamCalculation
Active
BOOL Flag, cam calculation active
OUT
boCamCalcualtion
Error
BOOL Flag, cam calculation interrupted with error
OUT boCamCalculationOK BOOL Flag, cam calculation successfully completed

sRotaryKnifeTypeInfo
This structure contains calculation results and display information relevant for the
user that provides information about the state of the rotating knife.
I/O Element Type of Data Description
OUT
r64MechanicalSync
Format
LREAL
[mm] Format length that is obtained from the knife running
in synchronism with the material web
OUT
r64Synchronous
Sector
LREAL
[mm] Length of the range in which the knife is moving in
synchronism with the material web
OUT r64FormatSector LREAL
[mm] Length of the range in which the knife may make a
correction motion to achieve the format length
OUT r64CutPosActual LREAL [mm] Position of the material web for the last cut
OUT
r64FormatLength
Activated
LREAL [mm] Activated format length
OUT
r64StartPos
Activated
LREAL
[mm] Activating starting position of the knife referred to the
knife axis
OUT r64StartLength LREAL
[mm] Distance that the material web moves when the knife
starts from the starting position up to the cut
OUT
r64StopPos
Activated
LREAL
[mm] Activated stop position of the knife referred to the knife
axis
OUT r64StopLength LREAL
[mm] Distance that the material web movers when stopping
the knife from the cut up to the stop position
OUT
r64MiddlePos
Activated
LREAL
[mm] Position of the knife referred to the knife axis within
the format range with the maximum/minimum knife velocity
OUT r64StartSyncPos LREAL
[mm] Start position of the synchronous range referred to the
knife axis
OUT r64EndSyncPos LREAL
[mm] End position of the synchronous range referred to the
knife axis
OUT boAxisAsLeadingValue BOOL
TRUE Leading value is a real or virtual posAxis
FALSE No posAxis can be entered as leading value
OUT toLeadingValueAxis posAxis
If the leading value is a real or virtual posAxis, then the
name of the TO is the axis - otherwise TO#NIL
OUT
boExternalEncoderAs
LeadingValue
BOOL
TRUE Leading value is an external encoder
FALSE No external encoder entered as leading value
OUT
toLeadingValue
ExternalEncoder
externalEncoder
Type
If the leading value is an external encoder, then the name of
the TO is the external encoder, otherwise TO#NIL
OUT boKnifeInFormatSector BOOL Flag, knife in the format range
OUT
boKnifeInSynchronous
Sector
BOOL Flag, knife in the synchronous range
OUT
boKnifeInSynchronous
SectorOld
BOOL Flag, knife in the synchronous range (old value)

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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I/O Element Type of Data Description
OUT boCut BOOL Flag, cut

sMeasuringValueType
This structure contains the internal data area of the measured value detection (this
is not relevant for the user):
I/O Element Type of data Description
OUT r64MeasuredValueNew LREAL [mm] Actual measured value
OUT r64MeasuredValueOld LREAL [mm] Measured value, old
IN eMeasuringEdge
enumMeasured
Edge
Selects the signal edge that initiates the measurement at
the sensor:
RISING_EDGE: Rising edge at the sensor
FALLING_EDGE: Falling edge at the sensor
I/O
boWaitForFirstCut
Position
BOOL Flag, wait until the first measured value
I/O
boCutPosition
MeasuringActive
BOOL Flag, wait for measured value
I/O
boStartPosAtSensor
Detected
BOOL Flag, measure starting position"
IN
boApplicationIn
Automatic
BOOL Flag, use in the AUTOMATIC mode
IN
boCutPosition
SwitchedOn
BOOL Flag, cutting position measurement is active
OUT r64StartPosAtSensor LREAL First measured cutting position
IN
r64FormatLength
ActiveAtSensor
LREAL Format length valid at the time the measurement is made
OUT
r64SollPosNextCut
Position
LREAL Interpolated next cutting position
OUT
r64SollPosTolerance
RangeStart
LREAL Tolerance bandwidth, next cutting position, start
OUT
r64SollPosTolerance
RangeEnd
LREAL Tolerance bandwidth, next cutting position, end
IN
r64DeltaTolerance
Range
LREAL Half of the tolerance bandwidth
OUT
i16CutPositionError
Counter
INT Cutting position error counter

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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7.3 FBRotaryKnife
Control block of Rotary Knife Functions
7.3.1 Block name
FBRotaryKnife
7.3.2 Task
Control block of the SIMOTION Rotary Knife application. The block includes the
following functions:
Mode manager of the application, including the following modes ERROR,
DISABLE, MANUAL, STARTPOSITION, AUTOMATIC, SAMPLE_CUT,
SINGLE_CUT
Automatic format change
Cutting program (SAMPLE_CUT)
Single cut program
Control to calculate the travel profile including the following profile types
linear (constant acceleration), trapezoidal (defined jerk limiting) and polynomial
Print mark correction
Synchronization to the material path
Referencing the axes and setting-up operation (jog) are not included in the
application.
7.3.3 Integration in the run-time system
The function block can be called in each cyclic task. The user must link the block.

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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7.3.4 Graphic representation of the block
FBRotaryKnife
formatLength LREAL
execute BOOL
mode eOperationMode
RotaryKnifeType
startSingleCut BOOL
done BOOL
busy BOOL
error BOOL
errorId DWORD
measuringValue sMeasuringValue
Type
sMeasuringValue
Type
startSampleCut BOOL status eOperationModes
RotaryKnifeType
numberOfInstanz INT automaticActive BOOL
singleCutActive BOOL
camCalculation sCamCalculation
Type
sCamCalculation
Type
rotaryKnifeInfo sRotaryKnifeInfo
Type
sRotaryKnifeInfo
Type
cutPositionBufferManagement sCutPositionBuffer
ManagementType
sCutPositionBuffer
ManagementType
sampleCutActive BOOL
cutPositionCorrection
Active
BOOL
rotaryKnifeAxisActive BOOL
sampleBuffer sSampleBuffer
Type
sSampleBuffer
Type
axisTOs sTOsType sTOsType
usersInterface sUserInterface
Type
sUsersInterface
Type


Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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7.3.5 Block parameters
Input parameters
Name Data type Initial value Description
formatLength REAL 200.0 Cut material element length in mm.
execute BOOL FALSE A pending mode changeover is activated via this input.
mode
eOperation
ModesRotary
KnifeType
OMRK_
ERROR
With mode, the mode is pre-selected, which is
activated with the next positive signal edge at the
execute input.
OMRK_ERROR: Pre-selection, ERROR mode
OMRK_DISABLE: Pre-selection, DISABLE mode
OMRK_AUTOMATIC: Pre-selection,
STARTPOSITION mode
OMRK_AUTOMATIC: Pre-selection, AUTOMATIC
mode
OMRK_MANUAL: Pre-selection, MANUAL mode
OMRK_SINGLE_CUT: Pre-selection, SINGLE_CUT
mode
OMRK_SAMPLE_CUT: Pre-selection, SAMPLE_CUT
mode
startSingleCut BOOL FALSE Start of a single cut if FB is in the SINGLE_CUT mode.
startSampleCut BOOL FALSE
Start of a cut sequence to generate sample elements
in the SAMPLE_CUT mode.
numberOfInstanz INT 0 Instance number of the actual call.
Output parameters
Name Data type Initial value Description
done BOOL FALSE Selected mode is activated.
busy BOOL FALSE Mode changeover is active.
error BOOL FALSE
FALSE: No error
TRUE: An error has occurred, refer to error
identification
errorID WORD 0
Error identification, refer to error messages
errorID <= 16#000_8000: warning
errorID >= 16#0000_8000: error
state
eOperation
ModesRotary
KnifeType
OMRK_
ERROR
Actual mode
OMRK_ERROR: ERROR mode
OMRK_DISABLE: DISABLE mode
OMRK_AUTOMATIC: STARTPOSITION mode
OMRK_AUTOMATIC: AUTOMATIC mode
OMRK_MANUAL: MANUAL mode
OMRK_SINGLE_CUT: SINGLE_CUT mode
OMRK_SAMPLE_CUT: SAMPLE_CUT mode
OMRK_NOTHING_SELECTED: No mode change
OMRK_CHANGING: Mode change active
automaticActive BOOL FALSE AUTOMATIC mode is active
singleCutActive BOOL FALSE SINGLE_CUT mode is active
sampleCutActive BOOL FALSE SAMPLE_CUT is active
cutPositionCorrection
Active
BOOL FALSE Correction motion for the actual cut position is active

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Name Data type Initial value Description
rotaryKnifeAxisActive BOOL FALSE The RotaryKnife axis is active

Input / output parameters
Name Data type Initial value Description
axisTOs
sAxisTOs
Type

Definition of all of the axes, external encoders, cams
and measuring probes being used
usersInterface
sUsers
Interface

Interface for the user to enter physical constraints, cam
profiles, manual cutting position corrections as well as
the input of sequence options - such as a new start,
fast start and format change in ongoing operation
sampleBuffer
sSample
BufferType

User area to save cut length sequences in the
SAMPLE_CUT operating mode
camCalculation
sCam
Calculation
Type
Internal data area to call the cam calculation
rotaryKnifeInfo
sRotary
KnifeInfo
Type

Internal data area to display actual geometry values
converted into the peripheral (circumferential) lengths
in [mm], actual cut position as well as binary signals for
the knife position.
measuringValue
sMeasuring
ValueType
Internal data area for print mark correction.
cutPositionBuffer
Management
sCutPosition
Buffer
Management
Type

Internal data area to enter the cut position as a precise
position and cut position deviation for the print mark
correction.

7.3.6 Functionality
Start identification
Identify whether a restart is present.
If yes, then:
Activate the monitoring of the parameterization of the technology objects as
well as auto-parameterization.
Control the state machines in the manual state via the state sequence
ERROR
(if activated, the monitoring and auto-parameterization are realized in the
ERROR state)
DISABLE
MANUAL
From any state.
If no, then
Transfer the selected operating state with a positive edge at the execute input
Reset all block outputs with a negative signal edge at the execute input


Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Axis monitoring functions
If the rotary knife axis or the auxiliary axis has a fault condition, then the
FBRotaryKnife is forced into the fault state (ERROR state).
However, the monitoring function is only active after the technology objects have
been successfully completed.
Checking the input parameters and parameterization of the technology settings that are
absolutely necessary
This program function is only active in the ERROR state if it was activated by the
user using the restart bit.
The following are monitored:
The existence of specified TOs.
The function (positioning axis, synchronous axis, cam )
Special properties/features required for the template, such as: Modulo axis,
modulo value and cam type.
Deviations with respect to the template are displayed as fault messages.
Parameterization of the technology objects absolutely required is carried-out in
another program part.


Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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General Notes
The FBRotaryKnife function block is the most important element of the application.
The connected, rotating knife is parameterized and controlled from this block.
The block parameterization (parameter assignment) and the mode changeover
must be made in the user program in order to initiate that the FBRotaryKnife
executes the required functions.
FBRotaryKnife is parameterized as described in Chapter 7. When parameterizing,
basic values of the application that generally do not changeare defined; for
example, the name of the axis, knifeCircumference, numberOfKnifes, etc. It is only
permissible to change these values at standstill - and then FBRotaryKnife must be
re-initialized (restart).
The individual modes of the FBRotaryKnife are described in Chapter 3.3
Operating states of the application SIMOTION Rotary Knife
The procedure when changing the mode is described in more detail in the following
sections.
Basic state of FBRotaryKnife
After initialization, FBRotaryKnife is in the DISABLE mode.
Initialization must be executed each time that the control boots (powers up) by
setting the restart bit (gsRotaryKnife.sUsersInterface.boRestart) in the startup task.
(This is automatically realized when using the startupRotaryKnife() program in the
UNIT RK_Progs).
As a consequence, the block is transitioned into its initial stated, important
parameters are subject to a plausibility change - if possible adapted and if not
possible, a parameterizing error is signaled to the user at the error/fault output.

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Mode changeover sequence
The mode manager of the function block is shown in the following diagram. It
includes the possible operating states that can be activated and clearly shows the
possible transitions, that the user may initiate:
Figure 7-1: Possible state transitions at FBRotaryKnife
1
Disable
1
Disable
2
Startposi-
tion
2
Startposi-
tion
4
Manual
4
Manual
0
Error
0
Error
3
Automa-
tic
3
Automa-
tic
Standard state transition
Fault state transition
Automatic statechange chain
RESTART
5
Single
Cut
5
Single
Cut 6
Sample
Cut
6
Sample
Cut

The actual block state is displayed at the state output.
Figure 7-2: Inputs and outputs of the mode changeover

FB RotaryK ni fe()
Cu tL eng t h
Ex ecu te
Mode
Don e
B usy
E r ro r
E r ro r ID
S t at e

Changing-over the mode
In order to transition the block into a new state, the number of the required target
state must be specified at the mode input. The changeover is activated by a rising
edge on the execute input.
The active changeover is signaled in the new block state with a high signal at the
busy output. If all of the actions associated with the changeover have been
successfully carried-out and the new state has been reached, this is flagged by a
high signal at the done block output. The number of the new state can be read-off
at the state output.

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Automatic mode change sequences
The following automatic mode change sequences have been implemented:
From the ERROR mode into the STARTPOSITION mode.
ERROR DISABLE STARTPOSITION
From the ERROR mode into the AUTOMATIC mode.
ERROR DISABLE STARTPOSITION AUTOMATIC
From the ERROR mode into the MANUAL mode.
ERROR DISABLE MANUAL
From the AUTOMATIC mode into the MANUAL mode.
AUTOMATIC ERROR DISABLE MANUAL

The following table describes the function sequences that are hidden behind the
modes and the mode changes.
Table 7-2: Description of the sequences at the state change (state transition) in the FBRotaryKnife
Step Function Comment
ERROR (0)

0
Error

ERROR DISABLE

0
Error
1
Disable

0 All ErrorID memories are reset
Step Function Comment
1 _resetAxisError() is called for the specified axes

_resetFollowingObject() is called for the specified axes

_resetCamError() is called for cam1, cam 2 and cam3

If the axis, cams and synchronous objects have no error condition, then
the DISABLE mode is activated.


DISABLE (1)

1
Disable

DISABLE DISABLE

1
Disable
1
Disable

0 The stop command is prepared
1 _move() with velocity = 0.0 is called for the auxiliary axis
2 _move() with velocity = 0.0 is called for the rotary knife axis
3 Calls the _disableAxis() for the specified axes
If all of the axes are deactivated, then the DISABLE mode is activated.

DISABLE ERROR

1
Disable
0
Error

0 Preparation
1 Calls the _disableAxis() for the specified axes
If the axes are deactivated, then the ERROR mode is activated

DISABLE STARTPOSITION

1
Disable
2
Startpo-
sition


Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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0 The enable command is prepared
1 _resetAxisError() is called for the specified axes

If all axes are OK, then progress (advance) to step 2

2 _enableAxis() is called for the specified axes

If the axes are enabled, then the direction of rotation to reach the starting
position is determined without moving through the material and
progressing (advancing) to step 3

3 _pos() is called with the direction of rotation determined in step 0

If the starting position is reached, then the STARTPOSITION mode is
activated

DISABLE MANUAL

1
Disable
4
Manual

0 The enable command is prepared
1 _enableAxis() is called for the specified axes
If the axes are enabled, then the MANUAL mode is activated

STARTPOSITION (2)

2
Startpo-
sition

STARTPOSITION ERROR

2
Startpo-
sition
0
Error

0 Preparation
1 _disableAxis() is called for the specified axes
If the axes are disabled, then the ERROR mode is activated.

STARTPOSITION DISABLE

2
Startpo-
sition
1
Disable

0 The stop command is prepared
1 _move() with velocity = 0.0 is called for the auxiliary axis
2 _move() with velocity = 0.0 is called for the rotary knife axis
3 _disableAxis() is called for the specified axes
If the axes are disabled, then the DISABLE mode is activated.

STARTPOSITION AUTOMATIC

2
Startpo-
sition
3
Automa-
tic

0 The calculation of the start cam is initiated
1 Wait for the start cam
2 The calculation of the cyclic cam is initiated
3 The technology parameter is set
userdefault.cammingsettings.synchronizingmode = IMMEDIATELY

4 The technology parameter is set
userdefault.cammingsettings.syncpositionslave

5 The auxiliary axis is reset to 0 when _homing() is called.
If OK, then the start mode is defined

6 The technology parameter is set
userdefault.gearingsettings.synchronizingmode = IMMEDIATELY or
ON_MASTER_POSITION

7 The technology parameter is set
userdefault.gearingsettings.syncpositonmaster = r64DistanceToSensor

8 _enableCaming() is called to synchronize the rotary knife axis to the
auxiliary axis with the start cam.


Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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9 If OK, then _enableGearing() is called to synchronize the auxiliary axis to
the material web
10 Wait for cyclic cam
11 _enableCaming() is called to synchronize the rotary knife axis to the
auxiliary axis with the cyclic cam.

If the cyclic cam is in synchronism, then the AUTOMATIC mode is
activated

STARTPOSITION MANUAL

2
Startpo-
sition
4
Manual

For an automatic mode change sequence - this mode change is achieved
when the MANUAL mode is reached via the DISABLE mode.

STARTPOSITION SINGLE_CUT


0 The calculation of the start cam is initiated
1 Wait for the start cam
2 The calculation of the stop cam is initiated
3 The technology parameter
userdefault.cammingsettings.synchronizingmode = IMMEDIATELY

4 The technology parameter is set
userdefault.cammingsettings.syncpositionslave

5 The auxiliary axis is reset to 0 when _homing() is called.
If OK, then the start mode is defined (synchronous or immediately)

6 Wait for the stop cam
STARTPOSITION SAMPLE_CUT


0 The calculation of the start cam is initiated
1 Wait for the start cam
2 The technology parameter
userdefault.cammingsettings.synchronizingmode = IMEEDIATELY

3 The technology parameter is set
userdefault.cammingsettings.syncpositionslave

4 The auxiliary axis is reset to 0 when _homing() is called.
If OK, then the start mode is defined (synchronous or immediately)

AUTOMATIC (3)

3
Automa-
tic

Re-calculation and activation of a cyclic cam in operation
If a cam may be changed-over and is requested, then the calculation of a
new cyclic cam is initiated and step 0 is activated

0 Wait until the cyclic cam is calculated
1 _enableCaming() is called to synchronize a new cyclic cam at the end of
the old cyclic cam.

Print mark correction
_pos() is called with the print mark deviation determined by the user and
the merge mode SUPERIMPOSED_MOTION_MERGE

AUTOMATIC ERROR

3
Automa-
tic
0
Error

_disableAxis() is called for the auxiliary axis and the rotary knife axis.
If the axes are disabled, then the ERROR mode is activated.

2
Startpo -
sition
6
Sample
Cut
2
Startpo -
sition
5
Single

Cut

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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AUTOMATIC STARTPOSITION

3
Automa-
tic
2
Startposi-
tion

0 The calculation of the stop cam is initiated
1 Wait for the stop cam
2 _enableCaming() is called to synchronize the rotary knife axis to the
auxiliary axis with the stop cam.

3 Wait for a rotary knife axis stop
4 De-couple the rotary knife axis from the synchronous operation group with
the rotary knife axis by calling _disableCaming().

5 De-couple the auxiliary axis from the synchronous operation group with
the material web by calling _disableGearing()

6 The direction of rotation to approach the start position without passing
through the cut position is determined.

7 Call _pos() to position to the starting position
MANUAL (4)

4
Manual

MANUAL ERROR

4
Manual
0
Error

_disableAxis()is called for the auxiliary axis and the rotary knife axis.
If the axes are disabled, then the ERROR mode is activated.

MANUAL DISABLE

4
Manual
1
Disable

0 The stop command is prepared
1 _move() with velocity = 0.0 is called for the auxiliary axis
2 _move() with velocity = 0.0 is called for the rotary knife axis
3 _disableAxis()is called for the auxiliary axis and the rotary knife axis.
If the axes are disabled, then the DISABLE mode is activated.

MANUAL STARTPOSITION

4
Manual
2
Startposi-
tion

0 Preparation
1 _move() with velocity = 0.0 is called for the auxiliary axis
2 _move() with velocity = 0.0 is called for the rotary knife axis
3 The direction of rotation to approach the start position without passing
through the cut position is determined.

4 Call _pos() to position to the starting position
SINGLE_CUT (5)


Executing a single cut
0 _enableCaming() is called to synchronize the rotary knife axis to the
auxiliary axis with the start cam.

1 Wait for a positive edge at input startSingleCut
2 If the quickstart bit = TRUE, then the setting of the technology parameter
userdefault.gearingsettings.synchronizingmode = IMMEDIATELY and
continue with step 4
Or
If the quickstart bit = FALSE, then the setting of the technology
parameters userdefault.gearingsettings.synchronizingmode =
ON_MASTER_POSITION and continue with step 3

5
Single

Cut

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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3 The technology parameter is et to the geometry parameter
userdefault.gearingsettings.syncpositonmaster = r64DistanceToSensor

4 If OK, then _enableGearing() is called to synchronize the auxiliary axis to
the material web

5 _enableCaming() is called to synchronize the rotary knife axis to the
auxiliary axis with the stop cam.

6 Wait for a rotary knife axis stop
7 De-couple the auxiliary axis from the synchronous operation group with
the material web by calling _disableGearing()

8 De-couple the rotary knife axis from the synchronous operation group with
the rotary knife axis by calling _disableCaming().

9 The auxiliary axis is reset to 0 when _homing() is called.
10 The direction of rotation to approach the start position without passing
through the cut position is determined.

11 Call _pos() to position to the starting position.
Please continue with step 0.

SINGLE_CUT ERROR


_disableAxis()is called for the auxiliary axis and the rotary knife axis.
If the axes are disabled, then the ERROR mode is activated.

SINGLE_CUT STARTPOSITION


If SINGLE_CUT inactive, then
1 De-couple the rotary knife axis from the synchronous operation group with
the rotary knife axis by calling _disableCaming().

If SINGLE_CUT active, then
0 Preparation
1 _move() with velocity = 0.0 is called for the auxiliary axis
2 De-couple the rotary knife axis from the synchronous operation group with
the rotary knife axis by calling _disableCaming().

3 _move() with velocity = 0.0 is called for the rotary knife axis
4 The direction of rotation to approach the start position without passing
through the cut position is determined.

5 Call _pos() to position to the starting position
SAMPLE_CUT (6)


Executing a sequence of cuts to generate samples
0 _enableCaming() is called to synchronize the rotary knife axis to the
auxiliary axis with the start cam.

1 Wait for a positive edge at input startSampleCut
2 If the quickstart bit = TRUE, then the setting of the technology parameter
userdefault.gearingsettings.synchronizingmode = IMMEDIATELY and
continue with step 4
Or
If the quickstart bit = FALSE, then the setting of the technology
parameters userdefault.gearingsettings.synchronizingmode =
ON_MASTER_POSITION and continue with step 3

3 The technology parameter is set to
userdefault.gearingsettings.syncpositonmaster = r64DistanceToSensor

6
Sample

Cut
5
Single

Cut
2
Startposi -
tion
5
Single
Cut
0
Error

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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4 If OK, then _enableGearing() is called to synchronize the auxiliary axis to
the material web

5 If a valid value is saved in the sample store, then continue with step 6.
If not, then continue with step 10

6 A cyclic cam is calculated with the length currently saved in the sample
store (formatLength).

7 Wait until the cyclic cam is calculated.
8 _enableCaming() is called to synchronize the rotary knife axis to the
auxiliary axis with the cyclic cam at the end of the cam cycle.

9 If the cut position is reached and an additional valid value is saved in the
sample store, then continue with step 6.
If the cut position is reached, and there is no additional valid value saved
in the sample store, then continue with step 10.

10 The calculation of the stop cam is initiated
11 Wait for stop cam.
12 _enableCaming() is called to synchronize the rotary knife axis to the
auxiliary axis with the stop cam.

13 Wait for a rotary knife axis stop
14 De-couple the auxiliary axis from the synchronous operation group with
the material web by calling _disableGearing()

15 De-couple the rotary knife axis from the synchronous operation group with
the rotary knife axis by calling _disableCaming().

16 The auxiliary axis is reset to 0 when _homing() is called.
17 The direction of rotation to approach the start position without passing
through the cut position is determined.

18 Call _pos() to position to the starting position.
19 The calculation of the start cam is initiated
20 Wait for stop cam.
If OK, please continue with step 0.

SAMPLE_CUT ERROR


_disableAxis()is called for the auxiliary axis and the rotary knife axis.
If the axes are disabled, then the ERROR mode is activated.

SAMPLE_CUT STARTPOSITION


If Sample Cut inactive, then
1 De-couple the rotary knife axis from the synchronous operation group with
the rotary knife axis by calling _disableCaming().

If SAMPLE_CUT active, then
0 Preparation
1 _move() with velocity = 0.0 is called for the auxiliary axis
2 De-couple the rotary knife axis from the synchronous operation group with
the rotary knife axis by calling _disableCaming().

3 _move() with velocity = 0.0 is called for the rotary knife axis
4 The direction of rotation to approach the start position without passing
through the cut position is determined.

5 Call _pos() to position to the starting position

6
Sample
Cut
0
Error
6
Sample
Cut
2
Startposi -
tion

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Using the restart bit (sUsersInterface. boRestart)
The restart bit must be set at each new start of the SIMOTION or when changing
the parameterization. This is the reason that an initialization routine is run in the
FBRotaryKnife and a parameter check is made and the block is brought into a
defined state.

Note
We recommend that the program startupRotaryKnife of the unit RK_Progs is
used in the startup task in order to initialize the block FBRotaryKnife.
The restart bit should also be set there in order to bring the block into a defined
state!


Note
At restart, the block checks essential technology parameters as well as the
existence of saved technology objects.


After the block has been successfully initialized, the restart bit is automatically
reset.
Using the quick start bit (sUsersInterface. boQuickstart)
Task
The standard, starting situation of the FBRotaryKnife is to synchronize at the start
of the material. However, if the cross-cutter is started with the material already
threaded/entered and must be synchronized, then the program must run-through
another synchronizing mechanism.
The quick start bit is used to select which synchronizing mechanism the user
wishes to apply.
Mode of Operation
Table 7-3: Mode of operation of the quick start bit
boQuickstart Description
= 1
The rotating knife immediately synchronizes with mode = 3 and
execute = true, independent of the actual material position.
= 0
The rotating knife synchronizes with mode = 3 and execute = true only
if the material position has reached the position entered under
r64DistancetoSensor.

Synchronizing Mechanism
Task Description
The task of the example is to synchronize the rotating knife to the start of the
material that should run so that the first cut is precisely made after the specified cut
length after the start of the material.

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Procedure
Tabelle 7-4: Synchronizing the rotary knife
Phase Graphic representation What actually happens
Initial situation:
No material in the cutting range
The knife is at the zero position
The user has switched FBRotaryKnife
into the DISABLE mode
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User task:
The mode changes to
STARTPOSITION
Initial situation:
No material in the cutting range
The knife is located at its starting
position
The START POSITION mode is active
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Startposition

User task:
Wait for material

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Initial situation:
The material has reached the sensor
and the measuring probe function has
received the first measured value of the
material web position
The knife is at its start position
The START POSITION mode is active
3
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Distance to Sensor
Startposition
0 Referenzpunkt Warenbahn

User task:
In order to assign the position of the
rotating knife to the material web
position, the user must set the material
path position back by the measured
value,
or:
add the measured value to
r64DistanceToSensor and save as new
value.
The mode changes to AUTOMATIC
Initial situation:
The material has reached the rotary
knife
When this synchronous position is
reached, the starting cam was started
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Startposition
0 Referenzpunkt Warenbahn
Synchronposition

User task:
None
Initial situation:
The first cut length has passed below
the rotating knife
The rotating knife is at the zero position
When the position is reached, a
change has been made to the cyclic
cam.
The AUTOMATIC mode is active
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CutLength

Result:
The rotary knife has started in
synchronism with the start of the
material and cuts the material to the
required length






Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Error handling
If faults occur in the block itself or in technology objects and technology functions
involved while FBRotaryKnife is operational, then these are signaled using the
block outputs error and errorID.
Figure 7-3: Block outputs for fault messages
FBRotaryKnife()
CutLength
Execute
Mode
Done
Busy
Err or
Err orID
State

The error bit signals an error while an error code is output at output errorID; this
can be analyzed using the error analysis function.


Note
The error output is only set if the execute input is set. The errorID and state 0
(ERROR) are still output even after execute has been reset!


7.3.7 Error messages
Table 7-5: List of the possible error priorities
ErrorID Priority Description
16#xxxx_0xxxx Lowest priority Warning
16#xxxx_4xxx Low priority Warning, execution possible with error
16#xxxx_8xxx High priority Error, no execution possible
16#xxxx_Cxxx Highest priority Critical error

Warnings
Warnings are indicated by the status of the outputs error and errorID: error =
FALSE and errorID <> 16#0000_0000.
Table 7-6: Warnings
ErrorID Description
16#0000_0000 No warning
16#050B_4000 Parameter r64KnifeCircumference not accepted (invalid value)
(AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)
16#050B_4001 Parameter i16NumberOfKnives not accepted (invalid value)
(AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)
16#050B_4002 Parameter r64StartSyncWinkel not accepted (invalid value)
(AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)
16#050B_4003 Parameter r64EndSyncWinkel not accepted (invalid value)
(AUTOMATIC, SINGLE_CUT or SAMPLE_CUT mode)
ErrorID Description
16#050B_4005 Inpug formatLength not accepted (invalid value)
(Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)

Program Description
Program Description
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16#050B_4006 Parameter r64InflectionPoint replaced by a substitute value (invalid value)
(substitute value = 50 %)
16#050B_4007 Parameter r64StartAngle replaced by a substitute value (invalid value)
(substitute value = 90)
16#050B_4008 Parameter r64StopAngle replaced by a substitute value (invalid value)
(substitute value = 270)
16#050B_4009 Parameter r64OverspeedStartCut not accepted (invalid value)
(Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)
16#050B_400A Parameter r64OverspeedZero not accepted (invalid value)
(Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)
16#050B_400B Parameter r64OverspeedEndCut not accepted (invalid value)
(Betriebsart AUTOMATIC, SINGLE_CUT or SAMPLE_CUT)
16#050B_400C Parameter r64JerkPhase1 replaced by a substitute value (invalid value)
(substitute value = 0%)
16#050B_400D Parameter r64JerkPhase2 replaced by a substitute value (invalid value)
(substitute value = 0%)
16#050C_4002 RotaryKnife axis changed over to modulo axis
16#050C_4003 Modulo length of the RotaryKnife Axis is adapted to
(Fsymech = r64KnifeCircumference / i16NumberOfKnives)
16#050C_4006 Auxiliary axis changed over to modulo axis
16#050C_4007 Modulo length of the auxiliary axis adapted to
(Fsymech = r64KnifeCircumference / i16NumberOfKnives )
Errors
Error messages are indicated by the status of the outputs error and errorID: error =
TRUE and errorID <> 16#0000_0000.
If the error was caused by a TO-specific command called from the RotaryKnife FB,
then its return parameter (RetDINT or FR) is kept in the internal data area of the
FB for further evaluation by the user.
Table 7-7 Errors
Error ID Description
16#050A_8001 Error at the rotary knife axis
16#050A_8002 Error at the auxiliary axis
16#050A_8003 Error at the rotary knife axis and at the auxiliary axis
16#050A_8004 Error at the rotary knife axis synchronous operation
16#050B_8000 Invalid parameter:
r64knifeCircumference <= 0.0
16#050B_8001 Invalid parameter
i16numberOfKnives < 1 or i16numberOfKnives > 6
16#050B_8002 Invalid parameter
r64startSyncAngle < START_SYNC_ANGLE_MIN / i16numberOfKnives
or
r64startSyncAngle > 360.0 / i16numberOfKnives
16#050B_8003 Invalid parameter
r64endSyncAngle < 0.0
or
r64endSyncAngle > (START_SYNC_ANGLE_MIN FORMAT_ANGLE_MIN) /
i16numberOfKnives
16#050B_8004 Invalid parameter:
i16numberOfKnifes * Synchrounous angle >= 360
or
Synchrounous angle < 0
16#050B_8005 Invalid parameter:

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Error ID Description
formatLength <= Synchronous length *
FACTOR_SYNCLENGTH_FOR_MIN_CUTLENGTH
16#050B_8006 Invalid parameter
r64inflectionPoint < MIN_VAL_INFLECTION_POINT
or
r64inflectionPoint > 100.0 MIN_VAL_INFLECTION_POINT
16#050B_8007 Invalid parameter:
r64startAngle <= r64endSyncAngle
or
r64startAngle >= r64startSyncAngle ACC_DCC_ANGLE_MIN
16#050B_8008 Invalid parameter:
r64stopAngle <= endSyncAngle + ACC_DCC_ANGLE_MIN
or
r64stopAngle >= r64startSyncAngle
16#050B_8009 Invalid parameter:
r64knifeOverspeedStartCut < - MAXIMUM_OVERSPEED_KNIFE
or
r64knifeOverspeedStartCut > MAXIMUM_OVERSPEED_KNIFE
16#050B_800A Invalid parameter
r64knifeOverspeedZero < - MAXIMUM_OVERSPEED_KNIFE
or
r64knifeOverspeedZero > MAXIMUM_OVERSPEED_KNIFE
16#050B_800B Invalid parameter
r64knifeOverspeedEndCut < - MAXIMUM_OVERSPEED_KNIFE
or
r64knifeOverspeedEndCut > MAXIMUM_OVERSPEED_KNIFE
16#050B_800C Invalid parameter
r64jerkPhase1 < 0.0
or
r64jerkPhase1 > 100.0
16#050B_800D Invalid parameter
r64jerkPhase2 < 0.0
or
r64jerkPhase2 > 100.0
16#050C_8001 The TO axis Rotary Knife Axis is not set-up
16#050C_8004 The TO axis Auxiliary Axis is not set-up
16#050C_8005 The TO axis Auxiliary Axis is not set-up as a virtual axis
16#050C_8008 There is no TO set-up as leading value
16#050C_8009 There is no TO cam Cam1 set-up
16#050C_800A There is no TO cam Cam2 set-up
16#050C_800B There is no TO cam Cam3 set-up
16#050C_800C There is no TO measuring input set-up
16#050C_800D The TO measuring input is not connected to leading value
16#050F_8001
Invalid mode selection from the ERROR mode
16#050F_8002
Invalid mode selection from the DISABLE mode
16#050F_8003
Invalid mode selection from the STARTPOSITION mode
16#050F_8004
Invalid mode selection from the AUTOMATIC mode
16#050F_8005
Invalid mode selection from the MANUAL mode
16#050F_8006
Invalid mode selection from the SINGLE_CUT mode
16#050F_8007
Invalid mode selection from the SAMPLE_CUT mode
16#050F_8008 Wrong mode
16#0511_8001 DISABLE to DISABLE

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Error ID Description
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32RetDINTStopAA
16#0511_8002 DISABLE to DISABLE
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32FRStopAA
16#0511_8003 DISABLE to DISABLE
Error when stopping the Rotary Knife Axis ( _move v=0 ),
Details in i32RetDINTStopRKA
16#0511_8004 DISABLE to DISABLE
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32FRStopRKA
16#0512_8001 DISABLE to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32RetDINTPosRKA
16#0512_8002 DISABLE to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32FRPosRKA
16#0521_8001 STARTPOSITION to DISABLE
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32RetDINTStopAA
16#0521_8002 STARTPOSITION to DISABLE
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32FRStopAA
16#0521_8003 STARTPOSITION to DISABLE
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32RetDINTStopRKA
16#0521_8004 STARTPOSITION to DISABLE
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32FRStopRKA
16#0522_8001 STARTPOSITION to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32RetDINTPosRKA
16#0522_8002 STARTPOSITION to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32FRPosRKA
16#0523_8001 STARTPOSITION to AUTOMATIC
Error when referencing the Auxiliary Axis ( _homing )
Details in i32RetDINTHomingAA
16#0523_8002 STARTPOSITION to AUTOMATIC
Error when referencing the Auxiliary Axis ( _homing )
Details in i32FRHomingAA
16#0523_8003 STARTPOSITION to AUTOMATIC
Error when activating camming of the Rotary Knife Axis [ start cam]
( _enablecamming )
Details in i32RetDINTEnableCammingRKA
16#0523_8004 STARTPOSITION to AUTOMATIC
Error when activating gearing of the Auxiliary Axis
( _enablegearing )
Details in i32RetDINTEnableGearingAA
16#0523_8005 STARTPOSITION to AUTOMATIC
Error when activating camming of the Rotary Knife Axis [ cyclic cam]
( _enablecamming )

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Error ID Description
Details in i32RetDINTEnableCammingRKA
16#0525_8001 STARTPOSITION to SINGLE_CUT
Error when referencing the Auxiliary Axis ( _homing )
Details in i32RetDINTHomingAA
16#0525_8002 STARTPOSITION to SINGLE_CUT
Error when referencing the Auxiliary Axis ( _homing )
Details in i32FRHomingAA
16#0526_8001 STARTPOSITION to SAMPLE_CUT
Error when referencing the Auxiliary Axis ( _homing )
Details in i32RetDINTHomingAA
16#0526_8002 STARTPOSITION to SAMPLE_CUT
Error when referencing the Auxiliary Axis ( _homing )
Details in i32FRHomingAA
16#0503_8001 Change FormatLength
Error when activating camming of the Rotary Knife Axis [ cyclic cam]
( _enablecamming )
Details in i32RetDINTEnableCammingRKA
16#0503_8002 Change FormatLength
Error when activating camming of the Rotary Knife Axis [ cyclic cam]
( _enablecamming )
Details in i32FREnableCammingRKA
16#0532_8002 AUTOMATIC to STARTPOSITION
Error when activating camming of the Rotary Knife Axis [ stop cam]
( _enablecamming )
Details in i32FREnableCammingRKA
16#0532_8003 AUTOMATIC to STARTPOSITION
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32RetDINTDisableCammingRKA
16#0532_8004 AUTOMATIC to STARTPOSITION
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32FRDisableCammingRKA
16#0532_8005 AUTOMATIC to STARTPOSITION
Error when de-activating gearing of the Auxiliary Axis
( _disablegearing )
Details in i32RetDINTDisableGearingAA
16#0532_8006 AUTOMATIC to STARTPOSITION
Error when de-activating gearing of the Auxiliary Axis
( _disablegearing )
Details in i32FRDisableGearingAA
16#0532_8007 AUTOMATIC to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32RetDINTPosRKA
16#0532_8008 AUTOMATIC to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32FRPosRKA
16#0541_8001 MANUAL to DISABLE
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32RetDINTStopAA
16#0541_8002 MANUAL to DISABLE
Error when stopping the Auxiliary Axis ( _move v=0 )

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Error ID Description
Details in i32FRStopAA
16#0541_8003 MANUAL to DISABLE
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32RetDINTStopRKA
16#0541_8004 MANUAL to DISABLE
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32FRStopRKA
16#0542_8001 MANUAL to STARTPOSITION
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32RetDINTStopAA
16#0542_8002 MANUAL to STARTPOSITION
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32FRStopAA
16#0542_8003 MANUAL to STARTPOSITION
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32RetDINTStopRKA
16#0542_8004 MANUAL to STARTPOSITION
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32FRStopRKA
16#0542_8005 MANUAL to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32RetDINTPosRKA
16#0542_8006 MANUAL to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32FRPosRKA
16#0505_8001 SINGLE_CUT
Error when activating camming of the Rotary Knife Axis [ start cam]
( _enablecamming )
Details in i32RetDINTEnableCammingRKA
16#0505_8002 SINGLE_CUT
Error when activating gearing of the Auxiliary Axis
( _enablegearing )
Details in i32RetDINTEnableGearingAA
16#0505_8003 SINGLE_CUT
Error when activating camming of the Rotary Knife Axis [ stop cam]
( _enablecamming )
Details in i32RetDINTEnableCammingRKA
16#0505_8004 SINGLE_CUT
Error when activating camming of the Rotary Knife Axis [ stop cam]
( _enablecamming )
Details in i32FREnableCammingRKA
16#0505_8005 SINGLE_CUT
Error when de-activating gearing of the Auxiliary Axis
( _disablegearing )
Details in i32RetDINTDisableGearingAA
16#0505_8006 SINGLE_CUT
Error when de-activating gearing of the Auxiliary Axis
( _disablegearing )
Details in i32FRDisableGearingAA
16#0505_8007 SINGLE_CUT
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Error ID Description
Details in i32RetDINTDisableCammingRKA
16#0505_8008 SINGLE_CUT
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32FRDisableCammingRKA
16#0505_8009 SINGLE_CUT
Error when referencing the Auxiliary Axis ( _homing )
Details in i32RetDINTHomingAA
16#0505_800A SINGLE_CUT
Error when referencing the Auxiliary Axis ( _homing )
Details in i32FRHomingAA
16#0505_800B SINGLE_CUT
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32RetDINT_pos_RKA
16#0505_800C SINGLE_CUT
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32FRPosRKA
16#0552_8001 SINGLE_CUT to STARTPOSITION
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32RetDINTDisableCammingRKA
16#0552_8002 SINGLE_CUT to STARTPOSITION
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32FRDisableCammingRKA
16#0552_8003 SINGLE_CUT to STARTPOSITION
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32RetDINTStopAA
16#0552_8004 SINGLE_CUT to STARTPOSITION
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32FRStopAA
16#0552_8005 SINGLE_CUT to STARTPOSITION
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32RetDINTDisableCammingRKA
16#0552_8006 SINGLE_CUT to STARTPOSITION
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32FRDisableCammingRKA
16#0552_8007 SINGLE_CUT to STARTPOSITION
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32RetDINTStopRKA
16#0552_8008 SINGLE_CUT to STARTPOSITION
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32FRStopRKA
16#0552_8009 SINGLE_CUT to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32RetDINTPosRKA
16#0552_800A SINGLE_CUT to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32FRPosRKA

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Error ID Description
16#0506_8001 SAMPLE_CUT
Error when activating camming of the Rotary Knife Axis [ start cam]
( _enablecamming )
Details in i32RetDINTEnableCammingRKA
16#0506_8002 SAMPLE_CUT
Error when activating gearing of the Auxiliary Axis
( _enablegearing )
Details in i32RetDINTEnableGearingAA
16#0506_8003 SAMPLE_CUT
Error when activating camming of the Rotary Knife Axis [ cyclic cam]
( _enablecamming )
Details in i32RetDINTEnableCammingRKA
16#0506_8004 SAMPLE_CUT
Error when activating camming of the Rotary Knife Axis [ cyclic cam]
( _enablecamming )
Details in i32FREnableCammingRKA
16#0506_8005 SAMPLE_CUT
Error when activating camming of the Rotary Knife Axis [ stop cam]
( _enablecamming )
Details in i32RetDINTEnableCammingRKA
16#0506_8006 SAMPLE_CUT
Error when activating camming of the Rotary Knife Axis [ stop cam]
( _enablecamming )
Details in i32FREnableCammingRKA
16#0506_8007 SAMPLE_CUT
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32RetDINTDisableCammingRKA
16#0506_8008 SAMPLE_CUT
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32FRDisableCammingRKA
16#0506_8009 SAMPLE_CUT
Error when de-activating gearing of the Auxiliary Axis ( _disablegearing )
Details in i32RetDINTDisableGearingAA
16#0506_800A SAMPLE_CUT
Error when de-activating gearing of the Auxiliary Axis
( _disablegearing )
Details in i32FRDisableGearingAA
16#0506_800B SAMPLE_CUT
Error when referencing the Auxiliary Axis ( _homing )
Details in i32RetDINTHomingAA
16#0506_800C SAMPLE_CUT
Error when referencing the Auxiliary Axis ( _homing )
Details in i32FRHomingAA
16#0506_800D SAMPLE_CUT
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32RetDINTPosRKA
16#0506_800E SAMPLE_CUT
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32FRPosRKA
16#0562_8001 SAMPLE_CUT to STARTPOSITION

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Error ID Description
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32RetDINTDisableCammingRKA
16#0562_8002 SAMPLE_CUT to STARTPOSITION
Error when de-activating camming of the Rotary Knife Axis ( _disablecamming )
Details in i32FRDisableCammingRKA
16#0562_8003 SAMPLE_CUT to STARTPOSITION
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32RetDINTStopAA
16#0562_8004 SAMPLE_CUT to STARTPOSITION
Error when stopping the Auxiliary Axis ( _move v=0 )
Details in i32FRStopAA
16#0562_8005 SAMPLE_CUT to STARTPOSITION
Error when de-activating camming of the Rotary Knife Axis
( _disablecamming )
Details in i32RetDINTDisableCammingRKA
16#0562_8006 SAMPLE_CUT to STARTPOSITION
Error when de-activating camming of the r Rotary Knife Axis
( _disablecamming )
Details in i32FRDisableCammingRKA
16#0562_8007 SAMPLE_CUT to STARTPOSITION
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32RetDINTStopRKA
16#0562_8008 SAMPLE_CUT to STARTPOSITION
Error when stopping the Rotary Knife Axis ( _move v=0 )
Details in i32FRStopRKA
16#0562_8009 SAMPLE_CUT to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32RetDINTPosRKA
16#0562_800A SAMPLE_CUT to STARTPOSITION
Error when positioning the Rotary Knife Axis ( _pos )
Details in i32FRPosRKA
16#05CC_8100 Cam calculation
Error when deleting the actual cam ( _resetCam )
16#05CC_8200 Cam calculation
Error when adding new segments ( _addSegmentToCam )
16#05CC_8300 Cam calculation
Error when interpolating the actual cam ( _interpolateCam )
16#05DD_8001 Print mark correction
Error when positioning the rotary knife axis ( _pos )
Details in i32RetDINTPosRKA
16#05DD_8002 AUTOMATIC to STARTPOSITION
Error when activating camming of the rotary knife axis
[ stop cam] ( _enablecamming )
Details in i32RetDINTEnableCammingRKA

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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7.4 Cam Calculation for rotating shears
FBRKCamCalc
Block name
FBRKCamCalculation
Task
This function block generates cams for rotating shears based on the specified
geometrical parameters and velocity profiles.
Integration in run-time system
The function block can be linked into a cycle or sequential task.
Graphic representation of the block
FBRKCamCalc
execute BOOL
formatLength LREAL
nextCam camType
typeOfCam eTypeOfCamType
knifeCircumference LREAL
startSyncAngle LREAL
endSyncAngle LREAL
startAngle LREAL
stopAngle LREAL
inflectionPoint LREAL
numberOfKnives INT
knifeOverspeedStartCut LREAL
knifeOverspeedZero LREAL
knifeOverspeedEndCut LREAL
camProfilePhase1 eCamProfileType
jerkPhase1 LREAL
camProfilePhase2 eCamProfileType
jerkPhase2 LREAL
done BOOL
busy BOOL
error BOOL
errorId DWORD


Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Block parameters
Input parameters
Name Data type Initial value Description
execute BOOL FALSE Start of calculation
formatLength LREAL 200 [mm] length of format
nextCam camType TO#NIL
Reference to the technology object of the cam
If no cam is specified, then only a parameter check
typeOfCam
eTypeOfCam
Type
START_
CAM
START_CAM
Cam to move the cross-cutter from the starting
position into cyclic operation.
CYCLIC_CAM
Cam for cyclic operation of a cross-cutter.
STOP_CAM
Cam to stop the cross-cutter from cyclic operation.
knifeCircumference LREAL 200.0 [mm] circumference of the knife
startSyncAngle LREAL 345.0
[] Starting angle of the synchronous range (cutting
range), i.e. the angle at which the knife enters the
material, the knife center point is defined at 0
(The permissible value range lies between
START_SYNC_ANGLE_MIN and 360.0).
StartSyncAngle and endSyncAngle together define
the synchronous range.
endSyncAngle LREAL 15.0
[] End angle of the synchronous range, i.e. the
angle at which the knife exits the cutting range
(The permissible value range lies between
0.0 and START_SYNC_ANGLE_MIN -
FORMAT_ANGLE_MIN).
StartSyncAngle and endSyncAngle together define
the synchronous range.
startAngle LREAL 90.0
[] Knife start position
(The permissible value range lies between
endSyncAngle and startSyncAngle -
ACC_DCC_ANGLE_MIN)
(Start position of the start cam)
stopAngle LREAL 270.0
[] Knife stop position.
(The permissible value range lies between
endSyncAngle + ACC_DCC_ANGLE_MIN and
startSyncAngle)
(End position of the stop cam)
inflectionPoint LREAL 50.0
[%] Center point of the cyclic cam.
inflectionPoint < 50.0 %
[min. MIN_VAL_INFLECTION_POINT (10%)]:
Offset of the center point in the direction
endSyncAngle, i.e. the absolute value of the
acceleration in the first motion segment after the cut
is higher.
inflectionPoint > 50.0 %
[max. 100% - MIN_VAL_INFLECTION_POINT]:
Offset of the centerpoint in the direction
startSyncAngle, i.e. the absolute value of the
acceleration in the second motion segment after the
cut is higher.
numberOfKnives INT 1 Number of knifes (max. 6)

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Name Data type Initial value Description
knifeOverspeedStartCut LREAL 0.0
[%] Knife overspeed at the transition point to the
synchronous range (startSyncAngle)
[-MAXIMUM_OVERSPEED_KNIFE (%) to
MAXIMUM_OVERSPEED_KNIFE (%)]
referred to the synchronous velocity of the knife.
knifeOverspeedZero LREAL 0.0
[%] Knife overspeed at the center position of the
synchronous range (0)
[-MAXIMUM_OVERSPEED_KNIFE (%) to
MAXIMUM_OVERSPEED_KNIFE (%)]
referred to the synchronous velocity of the knife.
knifeOverspeedEnd
Cut
LREAL 0.0
[%] Knife overspeed at the end point of the
synchronous range (endSyncAngle)
[-MAXIMUM_OVERSPEED_KNIFE (%) to
MAXIMUM_OVERSPEED_KNIFE (%)]
referred to the synchronous velocity of the knife.
camProfilePhase1
eCamProfile
Type
POLYNOM_5
Motion profile, phase 1 (endSyncAngle
inflectionPoint)
LINEAR
Curve profile with constant acceleration
JERK
Curve profile with constant acceleration and jerk
limiting
POLY_5
Motion profile as fifth order polynomial.
jerkPhase1 LREAL 0.0
[%] Jerk limiting component in phase 1 (only for
camProfilePhase1 = JERK).
The valid value range is 1.0 up to 100.0. For 100%,
there is no constant acceleration for the phase. The
absolute jerk depends on the machine velocity
camProfilePhase2
eCamProfile
Type
POLYNOM_5
Motion profile, phase 2 (inflectionPoint -
startSyncAngle)
LINEAR
Curve profile with constant acceleration
JERK
Curve profile with constant acceleration and jerk
limiting
POLY_5
Motion profile as fifth order polynomial.
jerkPhase2 LREAL 0.0
[%] Jerk limiting component in phase 2 (only for
camProfilePhase2 = JERK).
The valid value range lies between 1.0 and 100.0.
For 100%, there is no constant acceleration for the
phase. The absolute jerk depends on the machine
velocity.
Output parameters
Name Data type Initial value Description
done BOOL FALSE TRUE: The cam generation has been completed
busy BOOL FALSE
FALSE: No cam calculation
TRUE: The cam generation is active
error BOOL FALSE
FALSE: No error
TRUE: An error has occurred, refer to error
identification
errorId DWORD 16#0000_0000
Error identification, refer to error messages
errorID <= 16#000_8000: warning
errorID >= 16#0000_8000: error

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Functionality
The function block generates the cam for the specified cross-cutter geometry for
the parameterized cut length. The reference to the cam object is defined using
input nextCam.
The block is started with a rising edge at input execute; the input parameters are
then checked for plausibility. If the input parameters are not valid, block processing
is interrupted and a corresponding error message (error and errorID) is output.
Once the cam generation has been completed, this is signaled with a rising edge at
the done output.

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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When initiating the cam calculation, the following actions are executed in the
individual steps:
Figure 7-4: Sequence of cam calculation
0
error
1
wait
2
gen.
calcula-
tions
3
start
cam
4
cyclic
cam
5
stop
cam
6
delete
cam
7
add
segments
to cam
8
interpolate
cam
Calculations
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General properties and characteristic quantities of a rotating shears
System with one knife System with two knives

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Program Description
Program Description
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Table 7-8: Overview of the parameters and characteristic quantities for the cam calculation
Parameter Description
Synchronous range
The synchronous range is defined by the synchronous angle referred to the knife
circumference or the knife geometry. The synchronous angle is obtained from the parameters
startSyncAngle und stopSyncAngle.
The synchronous angle is the range in which the knife moves in synchronism with the material
web velocity. The velocity in the synchronous range can be adapted for special applications or
for special cutting geometries using parameter knifeOverspeedStartCut, knifeOverspeedZero,
knifeOverspeedEndCut.
The point, at which the knife is located perpendicular to the material is defined as the center
point of the synchronous range and is at 0.
Format range
The format range is the range of the rotating shears, where the knife is not located in the
synchronous range, i.e. is not in the cutting range.
As the velocity in the synchronous range is defined by the material itself and the overspeed,
equalization motion (format changes, print mark correction, etc.) can only be executed in the
format range. For multi-knife systems, the format range is obtained according to the following
formula:
Format range = knifeCircumference / numberOfKnifes synchronous range
Phase1 / Phase2
Phase 1 describes the range of the rotating shears between endSyncAngle and inflectionPoint.
Depending on the characteristic quantities and format length, in this phase, the rotating shears
must either be accelerated or decelerated:
cutLength < synchronous range + format range: Acceleration
cutLength > synchronous range + format range: Deceleration
Phase 2 defines the range of the rotating shears between inflectionPoint and startSyncAngle.
The acceleration and deceleration behavior is opposite to that of phase 1:
cutLength < synchronous range + format range: Deceleration
cutLength > synchronous range + format range: Acceleration
startSyncAngle /
endSyncAngle
Parameter startSyncAngle defines the start angle of the synchronous angle, i.e. the start point
of the cutting range referred to the geometry. The point at which the knife is perpendicular to
the material is defined as the zero point (0).
Parameter endSyncAngle defines the end point of the synchronous angle and therefore the
synchronous range. The angle between startSyncAngle and endSyncAnlge is the synchronous
angle.
If the two parameters are not identical, then the knife center position is automatically shifted
into the format range, so that at inflectionPoint = 50%, the knife is always located at the
geometrical center.
knifeOverspeedStart
Cut, knifeOverspeed
Zero,
knifeOverspeedEnd
Cut
In the standard configuration, a rotating shears operates with a linear cutting curve, i.e. a
velocity characteristic that for the circumferential (peripheral) velocity of the shears
corresponds to the material velocity. However, the knife and material are only perpendicular to
one another at the cutting center point. This means that at the remaining points of the
synchronous range, there are velocity differences between the tool and material, the
magnitude of which depends on the material thickness respectively shears diameter or
shears geometry.
The velocity of the knife in the synchronous range can be specifically adapted using the
mentioned parameters.
Parameter Description
knifeOverspeedStartCut Defines the velocity offset of the knife when entering the
synchronous range, corresponding to parameter
startSyncAngle.
knifeOverspeedZero Defines the velocity offset at the zero position.
knifeOverspeedEndCut Defines the velocity offset at the end point of the synchronous
range, corresponding to parameter endSyncAngle.

A fifth order polynomial is interpolated between the individual points. The parameter values are
correspondingly interpreted as offset to the synchronous velocity.

Program Description
Program Description
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Parameter Description
Cutting profile Diagram
Linear cutting curve:
knifeOverspeedStartCut = 0.0%
knifeOverspeedZero = 0.0%
knifeOverspeedEndCut = 0.0%

Linear cutting curve with 5%
overspeed:
knifeOverspeedStartCut = 5.0%
knifeOverspeedZero = 5.0%
knifeOverspeedEndCut = 5.0%

Polynomial cutting curve:
knifeOverspeedStartCut = 5.0%
knifeOverspeedZero = 0.0%
knifeOverspeedEndCut = 5.0%


inflectionPoint

The changeover point between phase 1 and phase 2 is defined using parameter
inflectionPoint. The value is entered as a percentage and is referred to the format range, i.e. a
value of 50% represents the center point of the format range.

inflectionPoint = 30 % inflectionPoint = 50 % inflectionPoint = 70 %

startAngle /
stopAngle
For rotating shears, the start position, the center position and the stop position are generally
identical. In order to achieve a certain machine behavior, in spite of this, it may be necessary

Program Description
Program Description
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Parameter Description
(e.g. for single cut programs to reduce the load on the motor) to separate these positions. As
already described, the center position is defined using parameter inflectionPoint, the start
position by startAngle and the stop position by stopAngle.
If the start position is shifted from the center position using the parameter startAngle, the
acceleration distance of the rotating shears increases, which reduces the motor load and can
therefore result in higher operating velocities. The maximum value for startAngle is
theoretically endSyncAngle, otherwise the knife would move in the cutting range.
The same consideration also applies to parameter stopAngle, which is limited by the value of
parameter startSyncAngle.
jerkPhase1 /
jerkPhase2
These parameters define the percentage component of the phase that is used for jerk limiting.
The absolute jerk is obtained from the machine velocity based on the specified motion profile.
Values between 1.0 % and 100 % are permitted for this parameter; the value 0.0 stands for the
profile with constant acceleration.

jerkPhase1 / jerkPhase2 =
10%
jerkPhase1 / jerkPhase2 =
50%
jerkPhase1 / jerkPhase2 =
100%

camProfilePhase1 /
camProfilePhase2
These parameters define the motion profile in phase1 or in phase 2. The parameters do not
have to be assigned the same value.
LINEAR
This selection defines a motion profile with constant acceleration.
Phase 1 Phase 2
endSyncAngle
(Synchronous range)
startSyncAngle
(Synchronous range)
Format range
inflectionPoint
knifeCircumference
Format length

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.

Program Description
Program Description
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Parameter Description

POLY_5
This selection defines a fifth order polynomial as basis for the motion profile.
Phase 1 Phase 2
endSyncAngle
(Synchronous range)
startSyncAngle
(Synchronous range)
Format range
inflectionPoint
knifeCircumference
Format length

typeOfCam

This parameter specifies the cam type that should be calculated.

Type Description
START_CAM The start cam defines the starting behavior of the rotating shears from
the start point (startAngle) up to the cutting point (0). The profile
selection is also taken into account in the calculation of the starting
cam.
CYCLIC_CAM Motion profile of the shears in cyclic operation.
STOP_CAM The stop cam defines the transition from cyclic operation to standstill of
the rotating knife, i.e. the distance from the cutting point to the stop
position (corresponding to stopAngle).



Program Description
Program Description
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Error messages
ErrorID Priority Description
16#xxxx_0xxxx Lowest priority Warning
16#xxxx_4xxx Low priority Warning, execution possible with error
16#xxxx_8xxx High priority Error, no execution possible
16#xxxx_Cxxx Highest priority Critical error
Warnings
Warnings are indicated by the status of the outputs error and errorID: error =
FALSE and errorID <> 16#0000_0000.
Table 7-9: Warnings
ErrorID Description
16#0000_0000 No warning
Errors
Error messages are indicated by the status of the outputs error and errorID: error =
TRUE and errorID <> 16#0000_0000.
Table 7-10 Errors
ErrorID Description
16#05CC_8000
Invalid parameter:
knifeCircumference <= 0.0
16#05CC_8001
Invalid parameter:
numberOfKnives < 1 or numberOfKnives > 6
16#05CC_8002
Invalid parameter:
startSyncAngle < START_SYNC_ANGLE_MIN / numberOfKnives
or
startSyncAngle > 360.0 / numberOfKnives
16#05CC_8003
Invalid parameter:
endSyncAngle < 0.0
or
endSyncAngle > (START_SYNC_ANGLE_MIN - FORMAT_ANGLE_MIN) /
numberOfKnives
16#05CC_8004
Invalid parameter:
numberOfKnifes * Synchrounous angle >= 360
or
Synchrounous angle < 0
16#05CC_8005
Invalid parameter:
formatLength <= Synchronous length *
FACTOR_SYNCLENGTH_FOR_MIN_CUTLENGTH
16#05CC_8006
Invalid parameter:
inflectionPoint < MIN_VAL_INFLECTION_POINT
or
inflectionPoint > 100.0 - MIN_VAL_INFLECTION_POINT
16#05CC_8007
Invalid parameter:
startAngle <= endSyncAngle
or
startAngle >= startSyncAngle - ACC_DCC_ANGLE_MIN
16#05CC_8008
Invalid parameter:
stopAngle <= endSyncAngle + ACC_DCC_ANGLE_MIN
or
stopAngle >= startSyncAngle

Program Description
Program Description
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ErrorID Description
16#05CC_8009
Invalid parameter:
knifeOverspeedStartCut < - MAXIMUM_OVERSPEED_KNIFE
or
knifeOverspeedStartCut > MAXIMUM_OVERSPEED_KNIFE
16#05CC_800A
Invalid parameter:
knifeOverspeedZero < - MAXIMUM_OVERSPEED_KNIFE
or
knifeOverspeedZero > MAXIMUM_OVERSPEED_KNIFE
16#05CC_800B
Invalid parameter:
knifeOverspeedEndCut < - MAXIMUM_OVERSPEED_KNIFE
or
knifeOverspeedEndCut > MAXIMUM_OVERSPEED_KNIFE
16#05CC_800C
Invalid parameter:
jerkPhase1 < 0.0
or
jerkPhase1 > 100.0
16#05CC_800D
Invalid parameter:
jerkPhase2 < 0.0
or
jerkPhase2 > 100.0
16#05CC_800E
Invalid parameter:
nextCam = TO#NIL
This error is only signaled if the parameter check was OK!!!!
16#05CC_8100 Error when deleting the actual cam ( _resetCam )
16#05CC_8200 Error when adding new segments to actual cam ( _addSegmentToCam )
16#05CC_8300 Error when interpolating the actual cam ( _interpolateCam )


Program Description
Program Description
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7.5 Functions in the IPO task FBRKIpo
Measuring the actual position using a measuring probe.
Displays in which range (synchronous or format) the knife is presently moving.
Displays whether the knife is currently moving in the cutting range.
Block name
FBRKIpo
Task
If the print mark correction has been enabled, using a measuring probe, the
function block determines the specified cutting position using print marks,
calculates the position deviation from the difference between two consecutive
cutting positions and the specified cutting length and saves the position
measured value and position deviation in the measured value memory. The block
determines the first cutting position using the first measuring cycle.
Generally, the function block determines the range in which the knife is presently
located by comparing the position - and whether the knife is currently in the cutting
range. It indicates the result using status flags.
Integration in run-time system
The user must call the block in the IPO synchronous task.
Graphic representation of the block
FBRKIpo
modeEnabled eOperationModes
RotaryKnifeType
modeSelected eOperationModes
RotaryKnifeType
formatLengthBufferManagement sFormatLengthBuffer
ManagementType
sFormatLengthBuffer
ManagementType
rotaryKnifeInfo sRotaryKnifeInfo
Type
sRotaryKnifeInfo
Type
cutPositionBufferManagement sCutPositionBuffer
ManagementType
sCutPositionBuffer
ManagementType
measuringValue sMeasuringValue
Type
sMeasuringValue
Type
axisTOs sTOsType sTOsType
usersInterface sUsersInterface
Type
sUsersInterface
Type


Program Description
Program Description
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Block parameters
Input parameter
Name Data type Initial value Description
modeEnabled
eOperationModesRotary
KnifeType
OMRK_
NOTHING_
SELECTED
Aktive state of FBRotaryKnife
OMRK_ERROR: State ERROR
OMRK_DISABLE: State DISABLE
OMRK_AUTOMATIC: State STARTPOSITION
OMRK_AUTOMATIC: State AUTOMATIC
OMRK_MANUAL: State MANUAL
OMRK_SINGLE_CUT: State SINGLE_CUT
OMRK_SAMPLE_CUT: State SAMPLE_CUT
OMRK_NOTHING_SELECTED: No change of
state selected
OMRK_CHANGING: Change of state active
modeSelected
eOperationModesRotary
KnifeType
OMRK_
NOTHING_
SELECTED
Selected state of FBRotaryKnife
OMRK_ERROR: Selected state ERROR
OMRK_DISABLE: Selected state DISABLE
OMRK_AUTOMATIC: Selected state
STARTPOSITION
OMRK_AUTOMATIC: Selected state
AUTOMATIC
OMRK_MANUAL: Selected state MANUAL
OMRK_SINGLE_CUT: Selected state
SINGLE_CUT
OMRK_SAMPLE_CUT: Selected state
SAMPLE_CUT
Input / output parameters
Name Data type Initial value Description
axisTOs sTOsType Structure of axes and TO management
usersInterface
sUsersInterface
Type

Structure with all of the machine data that the user
can adapt - such as startSyncPos and endSyncPos
(refer to chapter, data types).
rotaryKnifeInfo
sRotaryKnifeInfo
Type

Structure with all of the information signals of the
RotaryKnife (refer to chapter, data types).
cutPositionBuffer
Management
sCutPosition
Buffer
Management
Type

Structure of the CutPositionBuffer with all of the
required control signals and pointers (refer to
chapter, data types).
formatlengthBuffer
Management
sFormatlength
Buffer
Management
Type

Structure of the FormatlengthBuffer with all of the
required control signals and pointers (refer to
chapter, data types).
measuringValue
sMeasuringValue
Type
Structure of the measured value detection


Program Description
Program Description
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Functionality
The block fulfills the following functions depending on the operating phase of the
system with the print mark detection switched-in:

Table 7-11: Sequence, print mark detection
Phase Description
Phase 1 Activates the measuring probe to measure the FirstCutPosition
Phase 2 The first measured position is saved as startPosAtSensor and the setpoint
position is calculated for the next cutting operation from the measured
position plus the format length.
Phase 3 The measuring probe is activated to measure the next cutting position with
activated activation range.
Phase 4 The next measured position is saved in the measured value memory
together with its deviation from the setpoint position.
Phase 5 If a measured value is not found in the actual active range (fault 40003),
then the reference position with its activation range is shifted one format
length further.

The block compares the actual knife position with startSyncPos and endSyncPos,
which are defined in the user interfaces and depending on the position sets the
following bits in the RotaryKnifeInfo structure:
In the synchronous range
knifeInSynchronousSector = TRUE
knifeInFormatSector = FALSE
In the format range
knifeInSynchronousSector = FALSE
knifeInFormatSector = TRUE

The block compares the actual knife position with 0.0 and endSyncPos and sets
In the cutting range
rotaryKnifeInfo.cut = TRUE
cutPositionBufferManagement.bufferOutTrigger = TRUE
Outside the cutting range
rotaryKnifeInfo.cut = FALSE
cutPositionBufferManagement.bufferOutTrigger = FALSE
Error messages
No errors are generated.

Program Description
Program Description
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7.6 Blocks to manage the format length memory
Users must use the blocks described in this chapter if they must change the cut
length by precisely one cut.
The user program section of the demonstration application is used here as
application example.
If the application has a dynamic cut length detection, to enter the cut lengths at the
standard Rotary Knife application, then the following blocks should be used.


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Program Description
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7.6.1 Resetting the format length memory FBFormatLengthBufferReset
Deleting and resetting the format length memory.
Block name
FBFormatLengthBufferReset
Task
Deleting and resetting the format length memory.
Integration in run-time system
This block can be called in any task.
The block is used by the SIMOTION Rotary Knife application and does not have to
be linked-in by the user.
Graphic representation of the block
FBFormatLengthBufferReset
formatLengthBufferManagement sFormatLengthBuffer
ManagementType
sFormatLengthBuffer
ManagementType

Block parameters
Input / output Parameters
Name Data type Initial value Description
formatLengthBuffer
Management
sFormatLength
BufferManagement
Type

Structure of the format length memory with all of
the required control signals and pointers (refer to
chapter, data types)
Deletes all of the memory contents by overwriting the memory elements with
0.0 and FALSE
Resets all pointers to 0
Resets all status signals to FALSE
Error messages
No errors are generated.


Program Description
Program Description
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7.6.2 Entries in the format length memory FBFormatLengthBufferIn
Enters a format length in the format length memory.
Name of the block
FBFormatLengthBufferIn
Task
With each call, the format length present at the block is entered into a free location
in the format length memory. In addition, a processing completed ID can be set
for the last segment.
Integration in run-time system
The block can be called in any task.
The block is used by the SIMOTION Rotary Knife application and does not have to
be linked-in by the user.
Graphic representation of the block



Program Description
Program Description
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Block parameters
Input parameters
Name Data type Initial value Description
lastSegment BOOL FALSE Cutting completed detection
formatLength LREAL 0.0 [mm] Format length
Input / output parameters
Name Data type Initial value Description
formatLengthBuffer
Management
sFormat
Length
Buffer
Manage-
mentType

Structure of the format length memory with all of the
required control signals and pointers (refer to chapter,
data types)
Functionality
A new format length is entered into the format length memory.
If the input parameter lastSegment = TRUE - and if the format length last entered
from the RotaryKnife system has still not been read - then the format length last
entered is set to 0.0 and the buffer pointer is not increased (incremented).
If it was already read-in, then an additional format length is entered with 0.0 and
the buffer pointer is increased (incremented) by 1.
Error messages
No errors are generated.


Program Description
Program Description
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7.6.3 Reading from the format length memory FBFormatLengthBufferRead
Reads a format length from the format length memory.
Block name
FBFormatLengthBufferRead
Task
At each call, a check is made as to whether a new format length was entered. If
yes, then it is read-out and a cam change initiated. The format length is not deleted
from the buffer.
Integration in run-time system
The block can be called in any task.
The block is used by the SIMOTION Rotary Knife application and does not have to
be linked-in by the user.
Graphic representation of the block

Block parameters
Input / output parameters
Name Data type Initial value Description
switchCAM BOOL FALSE Initiates that a new cam is calculated
formatLengthBuffer
Management
sFormatLength
BufferManagement
Type

Structure of the format length memory with all of the
required control signals and pointers (refer to the
chapter, data types)
Output parameters
Name Data type Initial value Description
formatLength LREAL 0.0 [mm] Format length
lastSegment BOOL FALSE Processing ended detection
switchCAMActive BOOL FALSE Cam change being prepared

Program Description
Program Description
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Functionality
The block only executes the following activities, if a format length has been
entered, but has still not been read out - and if a cam changeover has not been
activated.
Reads out the next format length to be activated. The format length remains saved
in the buffer, however it is tagged as if it has been read out.
If the format length that is read out is zero, then the output flag lastSegment is set
to TRUE and a cam changeover is not activated. If a format length that has been
read-out is not equal to zero, then a cam changeover is activated.
Error messages
No errors are generated.

Program Description
Program Description
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7.6.4 Exporting from the format length memory FBFormatLengthBufferOut
Exporting a format length from the format length memory.
Name of Block
FBFormatLengthBufferOut
Task
After the next processing operation, the function block deletes the last format
length that was entered from the format length memory and releases the memory
cell for memory management purposes.
Integration in run-time system
The block can be called in any task.
The block is used by the SIMOTION Rotary Knife application and does not have to
be linked-in by the user.
Graphic representation of the Block
FBFormatLengthBufferOut
formatLengthBufferManagement sFormatLengthBuffer
ManagementType
sFormatLengthBuffer
ManagementType

Block parameters
Input / Output parameters
Name Data type Initial value Description
formatLengthBuffer
Management
sFormatLength
BufferManagement
Type

Structure of the format length memory with all of
the required control signals and pointers (refer to
the chapter, data types)
Functionality
The block monitors the processing operation of the Rotary Knife. With the next step
after reading-out the particular format length, this is deleted in the buffer.
Error messages
No errors are generated.

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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7.7 Measured value memory system blocks used in the
rotary knife application
The Rotary Knife system uses these blocks. As standard, the user does not have
to access them!


Program Description
Program Description
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7.7.1 Deleting and resetting the measured value memory
FBCutPositionBufferReset
Deleting and resetting the measured value memory.
Block name
FBCutPositionBufferReset
Task
Deleting and resetting the measured value memory.
Integration in run-time system
The block can be called in any task.
The block is used by the SIMOTION Rotary Knife or SIMOTION Flying Saw
application and does not have to be linked-in by the user.
Graphic representation of the block
FBCutPositionBufferReset
cutPositionBufferManagement sCutPositionBuffer
ManagementType
sCutPositionBuffer
ManagementType

Block parameters
Input / output parameters
Name Data type Initial value Description
cutPositionBuffer
Management
sCutPositionBuffer
ManagementType

Structure of the measured value memory with all
of the required control signals and pointers (refer
to the chapter, data types)
Functionality
Deletes all of the memory contents by overwriting memory elements with 0.0 or
FALSE
Resets all pointers to 0
Resets all status signals to FALSE
Error Messages
No errors are generated.

7.7.2 Entries in the measured value memory FBCutPositionBufferIn
Enters a measured value (position measured value and/or position deviation) in the
measured value memory.

Program Description
Program Description
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Block name
FBCutPositionBufferIn
Task
With each call, the values present at the block (position measured value and
position deviation) are entered into a free location of the measured value memory.
Integration in run-time system
The block can be called in any task.
The block is used by the SIMOTION Rotary Knife or SIMOTION Flying Saw
application and does not have to be linked-in by the user.
Graphic representation of the block

Block parameters
Input parameters
Name Data type Initial value Description
positionDeviation LREAL 0.0
[mm] Position deviation (deviation between the
reference position and actual position)
actPosition LREAL 0.0 [mm] Position measured value
Input / output parameters
Name Data type Initial value Description
cutPositionBuffer
Management
sCutPositionBuffer
ManagementType

Structure of the measured value memory with all of
the required control signals and pointers (refer to the
chapter, data types)
Functionality
The position measured value is entered into the measured value memory.
The position deviation is entered into the measured value memory.
Error messages
No errors are generated.


Program Description
Program Description
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7.7.3 Reading out the measured value memory FBCutPositionBufferRead
Reading measured values from the measured value memory.
Block name
FBCutPositionBufferRead
Task
If the block is being used in the SIMOTION Rotary Knife application, then it detects
whether a new position deviation was entered and initiates a corresponding
position correction.
If the block is being used in the SIMOTION Flying Saw application, then it detects
as to whether a new position measured value was entered and initiates an
additional processing cycle.
Integration in run-time system
The block can be called in any task.
The block is used by the SIMOTION Rotary Knife or SIMOTION Flying Saw
application and does not have to be linked-in by the user.
Graphic representation of the block

Block parameters
Input parameters
Name Data type Initial value Description
operatingForRotaryKnife BOOL TRUE
= TRUE Block is being used for the Rotary
Knife application
= FALSE Block is being used for the Flying Saw
application
Output parameters
Name Data type Initial value Description
positionDeviationValid BOOL FALSE A position deviation has been defined
positionDeviation
Maesured
LREAL 0.0 [mm] Position correction value

Program Description
Program Description
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Name Data type Initial value Description
flyingSawStart BOOL FALSE Start condition of the flying saw
positionMeasured LREAL 0.0 [mm] next sync position
Input / output Parameters
Name Data type Initial value Description
cutPositionBuffer
Management
sCutPosition
Buffer
Management
Type

Structure of the measured value memory with all of
the required control signals and pointers (refer to the
chapter, data types).
Functionality
Depending on the calling application, the block executes the following activities:
If the block is being used in a Rotary Knife application (operatingForRotaryKnife =
TRUE), then at each call, a check is made as to whether a new position deviation
(cutPositionDeviation) was entered. If yes, the cutPositionDeviationValid flag is set
and the position deviation (cutPositionDeviation) is transferred as correction value.
If the block is used in a Flying Saw application (operatingForRotaryKnife =
FALSE) at each call, a check is made as to whether a new position measured
value (cutPosition) was entered. If yes, the flag flyingSawStart is set and the
measured position is transferred as synchronous position for the next processing
cycle.
Error messages
No errors are generated.


Program Description
Program Description
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7.7.4 Exporting from the measured value memory FBCutPositionBufferOut
A measured value (position measured value and position deviation) are exported
from the measured value memory.
Block name
FBCutPositionBufferOut
Task
After the processing operation, the function block deletes the last measured value
(position measured value and position deviation) from the measured value memory
and releases the memory for memory management.
Integration in run-time system
The block can be called in any task.
The block is used by the SIMOTION Rotary Knife or SIMOTION Flying Saw
application and does not have to be linked-in by the user.
Graphic representation of the block
FBCutPositionBufferOut
cutPositionBufferManagement sCutPositionBuffer
ManagementType
sCutPositionBuffer
ManagementType

Block parameters
Input / output parameter
Name Data type Initial value Description
cutPositionBuffer
Management
sCutPositionBuffer
ManagementType

Structure of the CutPositionBuffer with all of the
required control signals and pointers (refer to the
chapter, data types)
Functionality
When the block is called, the actual measured value (position measured value and
position deviation) are deleted from the measured value memory.
Error messages
No messages are generated.


Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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7.8 Extended functions
7.8.1 Using the cutting program
Cutting programs are used in the steel industry to cut samples of different lengths
from the sheet steel. For this purpose, the SIMOTION RotaryKnife has the
SAMPLE_CUT mode.
How is the memory filled?
The user enters the required cut lengths into the SAMPLEBUFFER with the
associated number of cuts.
Which blocks do I have to call?
None
How does all of this function?
The user switches FBRotaryKnife into the SAMPLE_CUT mode.
The cutting program then automatically and immediately starts (Bit quickstart =
TRUE!) or at the specified starting position (bit quickstart = FALSE!) and executes
the cut lengths saved in the SAMPLEBUFFER with their associated number of
cuts. The entries that are saved are deleted after execution. If there is no further
entry in the buffer, the FB exits the program in the start position.

7.8.2 Using print mark correction
The print mark correction is switched-in by setting the CutPosition
CorrectionOn bits to TRUE.
(sUsersInterface. boCutPositionCorrectionOn)
How is the memory filled?
The print mark correction has an intermediate buffer memory
(CUTPOSITIONBUFFER) to enter the correction values precisely for the cut. The
correction values are measured, saved and entered automatically after the print
mark correction has been activated. The user does not have to intervene.
Which blocks do I have to call?
None
How does all of this function?
The print mark correction is realized automatically. However, users have
parameters to influence its mode of operation. These parameters are located in the
structure UsersInterface.
Table 7-12 Parameter of Printmark Correction
Name Description
sUsersInterface.
boMeasuringWithRisingEdge
Flag, edge selection, measuring system
TRUE: Rising edge
FALSE: Falling edge

Program Description
Program Description
SIMOTION Rotary Knife ID: 37706606


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Name Description
boCutPositionCorrectionOn Flag, cut position correction on
boAdjustCutPositionPositive
Flag, start coarse correction positive of the cutting
position
boTrimmCutPositionPositive Flag, start fine correction positive of the cutting position
boAdjustCutPositionNegative
Flag, start coarse correction negative of the cutting
position
boTrimmtCutPositionNegative Flag, start fine correction negative of the cutting position
r64CPCorrectionMaximum
[mm] Maximum correction value for the cut position
correction
r64CPDeltaToleranceRange
[mm] Half the tolerance bandwidth for the activation
range of the cut position detection
r64AdjustCutPositionPositiveValue
[mm] Coarse correction value of the manual cut position
correction in the positive direction
r64TrimmCutPositionPositiveValue
[mm] Fine correction value of the manual cut position
correction in the positive direction
r64AdjustCutPositionNegativeValue
[mm] Coarse correction value of the manual cut position
correction in the negative direction
r64TrimmCutPositionNegativeValue
[mm] Fine correction value of the manual cut position
correction in the negative direction
r64CutPositionCorrectionVelocity
[mm/s] Velocity value of the higher-level cut position
correction
i16CutCorrWait Number of cuts without cut position correction



Appendix
General information on the application
SIMOTION Rotary Knife ID: 37706606


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Appendix
8 General information on the application
8.1 Scope of supply
The package Rotary Knife in SIMOTION comprises the following:
Program
S7/Scout project as ZIP file:
SIMOTION_Rotary Knife_V2.0.zip
Documentation
Implementation/Operating Instructions as PDF file
Manual_SIMOTION_Rotary Knife_V2.0.pdf


8.2 Revision/Authors
Table 8-1: Revision/Author
Version Date/Revision Author
V 1.0 02/28/05 first edition H.-E. Bhm
V 1.1 3
rd
cam H.-E. Bhm
V 1.2 03/13/06 Changes General
Notes
A. Hagelauer
V 1.3 04/13/06 SCOUT V4.0 H.-E. Bhm
V 1.4 06/06/08 SCOUT V4.1.1.6
and WinCCflex
P. Tabori
H.-E. Bhm
V 2.0 08/06/09 expanded by the
SINGLE_CUT and
SAMPLE_CUT modes,
change to the instance
assignment capability
(instanceability). Adapted to
the Converting standards,
expanded by the cam profile
Linear and Jerk.
05/05/11 SCOUT V4.2.1
02/10/12 SCOUT V4.3.1
H.- E. Bhm



Appendix
Contact partner
SIMOTION Rotary Knife ID: 37706606


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9 Contact partner
Applicationcenter


SIEMENS
Siemens AG
Industry Sector
Drives Technologies Division
Motion Control Systems
I DT MC PMA APC
Frauenauracher Str. 80
91056 Erlangen
Fax: +49 (0) 9131-981297
mailto: tech.team.motioncontrol@siemens.com




Appendix
Please help us to become even better
SIMOTION Rotary Knife ID: 37706606


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10 Please help us to become even better
I DT MC PM APC Sender:
Application Center Name:
Department:
D 91056 Erlangen City:
Fax: +49 (0) 9131/981297 Telephone:
E-Mail: applications.erlf@siemens.com E-Mail:

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