Workshop Motion Control With Siemens PLC (en)

Automation Days 2015

Restricted / © Siemens AG AG 2015. All Rights Reserved.

Challenges for machine builders Increasing production speeds Increasing production accuracy More monitoring and extensive control options inclusive more sensor systems Flexible production: e.g. easy & individual format change Replacement of mechanical solutions thru electronic

Increased complexity and efforts Restricted / © Siemens AG AG 2015. All Rights Reserved.

Program

Time-Based IO - Inpu Inputt - Outp Output ut Control of Motion in PLC - Different Different types of motion motion - o ss

e o u ons

- EPOS vs TO - TIA Selection Tool


e c n e i u a m o r f s n o i t s e u Q

e c n e i d u a o t s n o i t e u Q

Challenges for machine builders

SIMA SIMATIC Technolog echnology y The smart solution for demandin tasks!


Time-based IO Example for „precise switching“ START! Switch ON!

Goal: 4 latern exactly at 19:00 Transmit message!

„Switch ON at 19:00“

Restricted / © Siemens AG 2015. All Rights Reserved.

Time-based IO Example for “precise detecting”

Now it is your turn: Observe the light in the rack and press your button as fast as ou can!


Basic principle: “Precise detecting” Goal: Calculation of the speed of moving objects

Light barrier

t Signal of light barrier Program

t Refresh state of inputs t

Detected signal


t

“Precise detecting” based on Time-based IO Now with Time-based IO

Light barrier



Detection of signal changes with me s amps  Information available in the next program cycle gna o Light barrier

t t

Result: Program

High-precision results … application examples: 

Product detection



Measuring input


t Detected signal

t Evaluation in the next program cycle t

Accurate reaction based on Time-based IO Goal: accurate control of the ejector Light barrier

Ejector

v s Signal of Light light barrier

t

s- recise reaction t

… application examples: 

Ejecting



Dosing



Output cam


t3 Program execution

t1

t4

t2 t

Time-based IO in distributed I/Os

ET 200SP CM 4 x IO link  Up to 4 IO link signals with time stamps

mer

x



4 inputs  6 outputs ET 200MP TM Timer DIDQ 16x24V  8 inputs and 16 outputs  Up to 16 channels configurable with time


Requirement: isochronous real time communication (IRT) actually usable in distributed I/O stations (ET 200) only! Use in central structure planned for the future.

Question to the audience

Which SIMATIC CPU supports Time based IO 1511

1515

1517

1510 SP

ET 200SP


EACH SIMATIC S7-1500

Time-based IO summary Added values by Time-based IO g -prec s on … independent of transfer times and the cycle time of the user program

… for increased performance and bigger quantity structures of I/Os

… for different applications instead of specific function modules (FMs) Scalabilit … fitting to the size of the application Restricted / © Siemens AG 2015. All Rights Reserved.

Why Motion Control within the PLC? Mechanical Solution Main drive

Output Coupling Gearbox Gearbox cam

Camming

Motion Integrated & drive systems are replacing mechanical components Modular machine concepts Higher flexibility

ON / OFF Motion Controller Restricted / © Siemens AG 2015. All Rights Reserved.

Better dynamic Easy maintenance

What is Motion? Speed Control

2)Interpolation

Handling y t i l a n o i t c n u F l o r t n o C n o i t o M

2) Distributed

Motion 1)

• Pumps, fans, mixers

Camming

ab s.

Gearing (absolut)

rel.

Gearing (relative) Output cams Measuring input Positioning

• Conveyors

pee


What is Motion? Position Control

2)Interpolation


• Hoists, Lifts

2) Distributed

Motion 1)

Camming

ab s.

Gearing (absolut)

rel.

Gearing (relative) Output cams Measuring input

• Linear motions

Positioning

pee

•


,

What is Motion? Output cams & Measuring Inputs

2)Interpolation


2) Distributed

Motion 1)

Camming

ab s.

Gearing (absolut)

rel.

Gearing (relative) Measuring input Output cams

S3

Positioning pee


S1

S2

S4

What is Motion? Gearing

2)Interpolation


2) Distributed

Motion 1)

Camming

ab s.

Gearing (absolut)

rel.

Gearing (relative) Output cams Measuring input Positioning pee


What is Motion? Relative Gearing Scope 1

Scope 2

Scope 3

No absolute position relation

Gear in during standstill

Flying coupling of axis with non time-critical ear in

Application example: • • Conveyors Restricted / © Siemens AG 2015. All Rights Reserved.

Application example: • , • Handling based on several axis • Portals

Application example: • • Simple “flying saw” applications without external encoder

What is Motion? Absolute gearing

2)Interpolation


Paper

2) Distributed

Motion 1)

Camming

ab s.

Gearing (absolut)

rel.


Print mark correction

pee


What is Motion? Camming

2)Interpolation


2) Distributed

Motion 1)

Camming

ab s.

Gearing (absolut)

rel.

Gearing (relative) Output cams Measuring input

• Rotary knife

Positioning pee


What is Motion? Interpolation

2)Interpolation


2) Distributed

Motion 1)

• Deltapickers

Camming

ab s.

Gearing (absolut)

rel.


• Milling, CNC Machining

pee


When use the different motion solutions?

Dedicated


When use the different motion solutions? Motion technology for multiple drives in a separate controller. Stand-alone or with a PLC as “Hi her Level Control”

Dedicated

Simotion Sinumerik FM

Motion Control in extra Controller


When use the different motion solutions?

Motion Control in intelligent drives

Dedicated Motion technology in the drive Control from PLC EPOS Masterdrive technology cards Sinamics S DCB library Restricted / © Siemens AG 2015. All Rights Reserved.

When use the different motion solutions? Motion Control with PLC

Dedicated Motion Technology in PLC Control from PLC -


-

ec no ogy o ec s

When use the different motion solutions? Motion Control with S7-1500 / S7-1200

Motion Control in intelligent drives

Dedicated

Motion Control in extra Controller


When use the different motion solutions? Motion solution vs Motion Technology Siemens Solution 2) Interpolation


2)

1)

abs.

rel.

Distributed Motion s u o i r

Camming Gearing (absolut) Gearing (relative) 1)

Measuring input Positioning pee

V

1)

0 0 2 1 7 S O T

0 0 0 5 0 1 5 7 1 S 7 S O T

U P T 0 0 3

U P C T 0 0 5 1

B C

K I R E M U N I S

N O I T O M I S

S O P E

Legend: 1) Planned for V14

Centralized 2) Planned for higher V14 Restricted / © Siemens AG 2015. All Rights Reserved.

Decentralized

Dedicated

When use the different motion solutions? When to think of a dedicated solution.

Interpolation Handling y t i l a n o i t c n u F l o r t n o C n o i t o M

Siemens Solution Is the customer in a specific industry like CNC or printing. Does the machine match an available 80% solution like Vertical Filler?

Distributed Motion Camming abs.

Gearing (absolut)

rel.

Gearing (relative)

s

Does the application need interpolation, camming u o i or absolute earin ? Are there hi h demands on r V the 1) motion ?

1)



0 0 2 1 7 S O T

0 0 0 5 0 1 5 7 1 S 7 S O T

U U P P C T T 0 Simotion 0 0 0 5 3 1

B C

K I R E M U N I S

N O I T O M I S

or Sinumerik? S O P E

Contact the APC for more information or assistance.


Decentralized

Dedicated

When use the different motion solutions? When think of decentralized solutions (not including EPOS) Siemens Solution 2) Interpolation


2)

1)

abs.

rel.

Application with a lot of basic motion solutions and a few advanced motion solution

Distributed Motion s u o i r

Camming Gearing (absolut) Gearing (relative) 1)



V

1)

0 0 2 1 7 S O T

0 0 0 5 0 1 5 7 1 S 7 S O T

U P T 0 0 3

U P C T 0 0 5 1

B C

K I R E M U N I S

N O I T O M I S

Solution to a specific control-based problem e.g. Winders, distributed load

S O P E



Machine in series production

Decentralized


Dedicated

When use the different motion solutions? S7-technology or EPOS Siemens Solution Interpolation Handling y t i l a n o i t c n u F l o r t n o C n o i t o M

Distributed Motion Camming abs.

Gearing (absolut)

rel.

Gearing (relative) 1)


0 0 2 1 7 S O T

0 0 0 5 0 1 5 7 1 S 7 S O T

S O P E



Decentralized

Dedicated

Decentralized solution Drive Library + EPOS


Centralized Solution Technology Objects


Compare Solutions Decentral Motion Control with SINAMICS G/S (FB) _ FB SINA_POS (EPos)

Axis behaviour Interpolation Position controller

Speed / Positioning axis

Central Motion Control with SIMATIC S7-1500 (TO) open oc s Motion instructions Technology object (TO) Axis behaviour OB MC-Interpolator (OB92) Interpolator OB MC-Servo OB91 Position controller

Speed / Positioning axis

Ready to use programm blocks (FB/PLCopen) for both solutions Restricted / © Siemens AG 2015. All Rights Reserved.

Advantages of both solutions

Decentral

Low PLC load and very high numbers of axis feasible

Extensive drive diagnostics and messages Harmonized Standard-FBs with intuitive interface Additional drive integrated functions feasible (monitoring and compensation functions)

Highest usability and engineering efficiency without special drive technolo

knowled e

Extensive drive & technology diagnostics and messages Axis behavior and dynamics instantaneously changeable Motion programming with PLC-Open Standard Higher PLC load


Central

System Load Number of Axes Decentral Motion Control with SINAMICS G/S (FB)

Central Motion Control with SIMATIC S7-1500 (TO)

in maximum by S7-1500?

in maximum by S7-1500 (FW1.6)?

Number of I/O Devices depending on PROFINET RT-Communication: S7-1511/13: 128 Drive CUs *) *) S7-1517/18: 512 Drive CUs *)

1510 SP

c

s are su a e

Every PLC including PROFINET– Controller or PROFIBUS-Master interface, especially SIMATIC PLCs. (S7-300, S7-400, S7-1200, S7-1500).

1512 SP

15111513 1515

c

1516

1517

1518

r ves are su a e

Every drive with PROFIdrive or analog interface, especially SINAMICS G/S.

The number of axis is the elementary factor Restricted / © Siemens AG 2015. All Rights Reserved.

*) Note: Each SINAMICS S120 CU320-2 operates with up to 6 axis (Multiaxissystem)

Cost of components Application example for 6 positioning axis:

Decentral

Decentral CPU Type

Number of axis

Central CPU Type

S7-1511

1 up to 6

S7-1511/13

31 up to 96

S7-1517

S7-1511

97 up to 128

S7-1518

S7-1515

129 up to 256

---

-

-

S7-1511

SIMATIC S7-15xx

Decentral SINAMICS G120 CU250S-2 PN & Extended Functions SAFETY

Pcs.

1x

Hardware

L-Price/ Piece [EUR]


S7-1511 1PN





Hardware

Pcs..

S7-1511 1PN

1x

6ES7510-1AK00-0AB0

PM240-2

PM240-2

6SL3210-1PB13-8AL0

6SL3210-1PB13-8AL0

CU250S-2 PN

SIMATIC S7-15xx

Central

6ES7510-1AK00-0AB0

6x

Central









CU250S-2 PN 6SL3246-0BA22-1FA0

SINAMICS G120 CU250S-2 PN & Extended Functions SAFETY

6x

6SL3246-0BA22-1FA0

EPos position controller: 8ms

6x

Ʃ 6-

Axis

EPOS& Safety Lizenz 6SL3054-4AG00-2AA0-Z E01 + F01

Safety Lizenz 6SL3054-4AG00-2AA0-Z F01

6x

Ʃ 6-

Axis

The customer and the application determine the best applicable configuration Restricted / © Siemens AG 2015. All Rights Reserved.

TO position controller: 8ms

Cost of components Application example for 8 positioning axis:

Decentral

Decentral CPU Type

Number of axis

Central CPU Type

S7-1511

1 up to 6

S7-1511/13

31 up to 96

S7-1517

S7-1511

97 up to128

S7-1518

S7-1515

129 up to256

---

-

-

S7-1511

SIMATIC S7-15xx

Decentral SINAMICS G120 CU250S-2 PN & Extended Functions SAFETY

Pcs.

1x

Hardware

L-Price Piece [EUR]


S7-1511 1PN





Hardware

Pcs..

S7-1515 2PN

1x

6ES7515-2AM00-0AB0

PM240-2

PM240-2

6SL3210-1PB13-8AL0

6SL3210-1PB13-8AL0

CU250S-2 PN

SIMATIC S7-15xx

Central

6ES7510-1AK00-0AB0

8x

Central









CU250S-2 PN 6SL3246-0BA22-1FA0

SINAMICS G120 CU250S-2 PN & Extended Functions SAFETY

8x

6SL3246-0BA22-1FA0

EPos position controller: 8ms

8x

Ʃ 8-

Axis

EPOS& Safety Lizenz 6SL3054-4AG00-2AA0-Z E01 + F01

Safety Lizenz 6SL3054-4AG00-2AA0-Z F01

8x

Ʃ 8-

Axis

The customer and the application determine the best applicable configuration Restricted / © Siemens AG 2015. All Rights Reserved.

TO position controller: 8ms

Performance Accuracy and Dynamics Positioning accuracy >1 °

Positioning accuracy <1 °

Positioning dynamic low

Positioning dynamic medium

Positioning dynamic high

(Movement cycle > 1s)

(Movement cycle < 1s)

(Movement cycle < 100ms)

,

) O G120 CU240B/E-2 T ( l G120D CU240D-2 a r G120 CU250S-2 t n e C S120

) s o P ( l a r t n e c e D

G110M, G120C G120 CU240B/D/E-2 G120 CU250D-2 G120D CU250S-2 S110 S120

Technology Objects offer new possibilities for price sensitive positioning applications Restricted / © Siemens AG 2015. All Rights Reserved.

Legend:

Isochronous communication

Technically feasible / recommended

NON isochronous communication

Technically NOT feasible / recommended

Restricted recommended, because of range limitations or overdimension

Optimal Solution What to consider Customer has experience with PLC or Drives?

Possible configuration suitable for application?

Price of components?

For further information: contact APC/SSS


Motion Control with SIMATIC S7-1500

• Technology Object Positioning • Basic Positioner with SINA_POS


Motion Control with SIMATIC S7-1500 Identical Motion Control functionality in each PLC

1510 SP 1512 SP

1517 ET 200SP Open Controller Restricted / © Siemens AG 2015. All Rights Reserved.

1518

TIA Selection Tool 1. Click: New device 11

2. Click: SIMATIC S7 3. Click: SIMATIC S7-1500 4. Click: Setup device

7 9

8 2

3

5. Activate: Motion Integrated .

1

Application specific PLC load due to

4

Attention: This is a mistake in the pre-version! 5 This should be 188,8 s

10 Restricted / © Siemens AG 2015. All Rights Reserved.

NEW Version available in April 2015!

.

e ec : - Type of axis - Number of axis - Motion cycle time c :

on gure

8. Select: Type of CPU 9. Drag&Drop the chosen CPU onto the rack 10. Click: Project view 11. Click: Limits

Motion Control with SIMATIC S7-1500

Dimensioning of a PLC with TIA Selection Tool


Technology Object Interfaces for the control of drives

S7-1200

S7-1500

U/I

Puls Train Output PTO

Analog Signal

U/I

Puls Train Output Restricted / © Siemens AG 2015. All Rights Reserved.

Analog Signal

U/I

Puls Train Output PTO (in the future)

Analog Signal

Usable drive types

SINAMICS

Standard frequency converter, servo converter

SINAMICS G/S

Standard frequency converter, servo converter

Every SINAMICS

Step drives, servo converter

SINAMICS V60, V90, S110

Unique Selling Point (USP): S7-1500 Motion Control & Safety Principle within S7-1500

MCProgramm

Safety Programm

Technology Safety OB

What happens, if the safety program controls the drive with an operation that conflicts with the TO? TO always reacts in the right way!

MC OBs Standard Tele ramm

Safet Tele ramm

… across the complete system from the PLC down to the drive


Outlook: Motion Integrated within the S7-1500/1500T Portfolio S7-1511

S7-1513

S7-1515

S7-1516

S7-1517

S7-1518

2) Interpolation


2)

1)

Distributed Motion

Technology PLC

Camming

S7-15xxT, S7-15xxTF

abs.

Gearing (absolut)

rel.

Gearing (relative) Measuring input

PLC

Positioning

S7-15xx, S7-15xxF

1)

1)

1)

1)

1)

pee Legend: 1) Planned for V14

2) Planned for higher V14


Price / Performance / Number of axis

1)

Motion Control with SIMATIC S7-1500 Integration of SINAMICS in TIA Portal SINAMICS G110M, G120x via Startdrive

SINAMICS S120 via Starter and GSD-File

HW configuration

SINAMICS S120 usable

Commisioning wizards

PROFINET IRT communication & DSC*)

System diagnosis for drives

System diagnosis for drives

Librar conce t for drives

Automatic generation -

Identical Look & Feel for SIMATIC & SINAMICS

*) Dynamic Servo Control

1. Configure drive 2. Generate GSD-File

HMI direct access Restricted / © Siemens AG 2015. All Rights Reserved.

3. Import GSD-File in TIA Portal

Overview of the drive types Drive type

Example

Servo drives + servomotors

Frequency converters + induction motors


Benefit

Disadvantage

• rec se pos on ng • High dynamic • Precise even at low speed

• High motor price

• Low motor price • Robust

• Turbulent behavior at low speeds • Separate fan necessary for low speeds

Workshop Motion Control With Siemens PLC (en)

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