Automation Days 2015 Workshop Technology/Drives · Challenges for machine builders Increasing production speeds Increasing production accuracy More monitoring and extensive control

Workshop Technology/DrivesAutomation Days 2015

Workshop Technology/Drives

Restricted / © Siemens 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

Program

Time-Based IO- Input

dien

ce

ence

- Output

Control of Motion in PLC- Different types of motion

Possible Sol tions ons

from

aud

stio

ns to

aud

ie

- Possible Solutions- EPOS vs TO- TIA Selection Tool Q

uest

i

Que

s


Challenges for machine builders

SIMATIC Technology

The smart solution for demanding tasks!g

Live-DemoRestricted / © Siemens AG 2015. All Rights Reserved.

Live-Demo

Time-based IOExample for „precise switching“

START! Switch ON!

Goal:Switch ON allSwitch ON all

4 latern exactlyat 19:00

„Switch ON at 19:00“

Transmitmessage!


Time-based IOExample for “precise detecting”

Now it is your turn:

Observe the light in the rack and press your button as fast as you can!y


Basic principle: “Precise detecting”

Light barrierGoal: Calculation of the speed ofmoving objects Light barrier

ttSignal of

light barrier

Programcycle OB1

tRefresh stateof inputs

Signal oflight barrier

Programcycle OB1

tRefresh stateof inputs

cycle OB1

Detectedsignal

t

t

cycle OB1

Detectedsignal

t

t


“Precise detecting” based on Time-based IO

Light barrierNow with Time-based IO

Detection of signal changes withti t

Light barrier

Signal oft

time stamps Information available in the next

program cycle

Signal oft

Signal ofLight barrier

Programcycle OB1

Result:t


Programcycle OB1

t

cycle OB1

Detectedsignal

Evaluation in thenext program cycle

tt

t

High-precision results… application examples: Product detection

cycle OB1

Detectedsignal

Evaluation in thenext program cycle

tt

t


Measuring input

Accurate reaction based on Time-based IO

Light barrierGoal: accurate control of the ejector

EjectorLight barrier Ejector

Si l f

v

Si l f

vs

tSignal oflight barrier

Ejector

t

µs-precise reaction


Ejector

t

t

Ejector

Program

tt3 t4

t1 t2

µ p… application examples: Ejecting Dosing

Ejector

Program

tt3 t4

t1 t2


executiont Output cam executiont

Time-based IO in distributed I/Os

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

ET 200SP TM Ti DIDQ 10 24VET 200SP TM Timer DIDQ 10x24V 4 inputs 6 outputs

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

stamps


stamps

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

?1513 15161512 SP 15181513 15161512 SP

ET 200SPOpen Controller ! EACH SIMATIC S7-1500

1518


Open Controller !

Time-based IO summary

Hi h i i

Added values by Time-based IO

High-precision… independent of transfer times and the cycletime of the user program

Load reduction for PLC and bus systemLoad reduction for PLC and bus system… for increased performance and bigger quantitystructures of I/Os

Reduction of module varietyReduction of module variety… for different applications instead of specificfunction modules (FMs)

Scalability


y… fitting to the size of the application

Why Motion Control within the PLC?

Mechanical Solution

CammingCouplingMain drive OutputcamGearboxGearbox

Motion Integrated& drive systemsare replacing mechanical p gcomponents

Modular machineconcepts

Less wear

Higher flexibility

Better dynamic

Less wear

ON / OFF


Motion Controller Easy maintenance

What is Motion? Speed Control

Interpolation Handling

2)

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)• Pumps, fans, mixers

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

S d

Positioning

Measuring input

Mo 1)

• Conveyors


Speed

What is Motion? Position Control


2)

• Hoists, Lifts

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

• Linear motions

S d

Positioning

Measuring input

Mo 1)

• Feeders palletizers


Speed Feeders, palletizers

What is Motion? Output cams & Measuring Inputs


2)

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)

Gearing(relative)

Measuring

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

S d

Positioning

ginput

Output cams

Mo 1)

S1 S2

S3 S4


Speed

What is Motion? Gearing


2)

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

S d

Positioning

Measuring input

Mo 1)


Speed

What is Motion? Relative Gearing

Scope 1No absolute position relation

Scope 2Gear in during standstill

Scope 3Flying coupling of axis

with non time-critical gear inwith non time critical gear in

Application example:• Longitudinal cutter

Application example:• Hoists, lifts

Application example:• Superimposed operations


Longitudinal cutter• Conveyors

Hoists, lifts• Handling based on several axis• Portals

Superimposed operations• Simple “flying saw” applications

without external encoder

What is Motion?Absolute gearing


2)

Paper

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

S d

Positioning

Measuring input

Mo 1)

Print mark correction


Speed

What is Motion?Camming


2)

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

• Rotary knife

S d

Positioning

Measuring input

Mo 1)


Speed

What is Motion?Interpolation


2)

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)• Deltapickers

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

S d

Positioning

Measuring input

Mo 1)

• Milling, CNC Machining


Speed

When use the different motion solutions?

Dedicated



Motion technology for multiple drives in a separate controller.

Stand-alone or with a PLC as “HigherStand alone or with a PLC as HigherLevel Control”

Dedicated

SimotionSinumerikFM

Motion Control in extra Controller


C C


Motion Control in intelligent drives

DedicatedMotion technology in the driveControl from PLC

EPOS


Masterdrive technology cardsSinamics S DCB library


Motion Control with PLC

Dedicated

Motion Technology in PLCControl from PLC

S7 1200 / S7 1500 T h l bj t


S7-1200 / S7-1500 Technology objects


Motion Control in intelligent drivesMotion Control with S7-1500 / S7-1200

Dedicated

Motion Control in extra Controller


C C

When use the different motion solutions? Motion solution vs Motion Technology


2)

Siemens Solution

2)

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)

ario

us

2)

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

SIM

OTI

ON

SIN

UM

ERIK

DC

B

Va

CPU

CPU

1)

S d

Positioning

Output camsMeasuring input

Mo 1) D

EPO

S300T

-C

S7-

1200

1500

T-C

S7-1

500

S7-1

500

1)

Restricted / © Siemens AG 2015. All Rights Reserved.Centralized Decentralized Dedicated

Speed

1) Planned for V142) Planned for higher V14

Legend:

TO TO

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


Siemens Solution

2)

Is the customer in a specific industry likeCNC or printing. Does the machine match an

available 80% solution like Vertical Filler?

Camming

DistributedMotion

Func

tiona

lity

ario

us

2)

Does the application need interpolation, cammingor absolute gearing? Are there high demands on

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

SIM

OTI

ON

SIN

UM

ERIK

DC

B

Va

CPU

CPU

1)

g g gthe motion ?

Does the customer already have experience with

S d

Positioning


Mo D

EPO

S300T

-C

S7-

1200

1500

T-C

S7-1

500

S7-1

500

1)Does the customer already have experience with

Simotion or Sinumerik?


Speed


Legend:

TO TO

Contact the APC for more information or assistance.

When use the different motion solutions?When think of decentralized solutions (not including EPOS)


2)

Siemens Solution

2)

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

solution

Camming

DistributedMotion

2)

Func

tiona

lity

1)

1)

ario

us

2)

Machine in series production

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

SIM

OTI

ON

SIN

UM

ERIK

DC

B

Va

CPU

CPU

1)

Solution to a specific control-based

S d

Positioning


Mo 1) D

EPO

S300T

-C

S7-

1200

1500

T-C

S7-1

500

S7-1

500

1) problem e.g. Winders, distributed load


Speed


Legend:

TO TO

Contact the APC for more information or assistance. Contact the APC for more information or assistance.

When use the different motion solutions?S7-technology or EPOS


Siemens Solution

Camming

DistributedMotion

Func

tiona

lity

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

S d

Positioning


Mo

EPO

S

S7-

1200

S7-1

500

S7-1

500

1)


Speed


Legend:

TO TO

Decentralized solutionDrive Library + EPOS


Centralized SolutionTechnology Objects


Compare Solutions

PLC Bl kFB SINA SPEED

CentralMotion Control with SIMATIC S7-1500 (TO)

DecentralMotion Control with SINAMICS G/S (FB)

Technology object (TO)Axis behaviour

PLCopen BlocksMotion instructions

FB SINA_SPEED

FB SINA_POS (EPos)

Axis behaviour

Interpolation

OB MC-Interpolator (OB92)Interpolator

OB MC-Servo (OB91)Position controller

( )Position controller

Speed / Positioning axis Speed / Positioning axis


Ready to use programm blocks (FB/PLCopen) for both solutions

Advantages of both solutions

Decentral CentralLow 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)

Axis behavior and dynamics instantaneously NOT changeableAxis behavior and dynamics instantaneously NOT changeable

Highest usability and engineering efficiency without special drive

technology knowledgetechnology knowledge

Extensive drive & technology diagnostics and messages

Axis behavior and dynamics instantaneously changeable

Motion programming with PLC-Open Standard


Higher PLC load

System LoadNumber of Axes

DecentralMotion Control with SINAMICS G/S (FB)

CentralMotion Control with SIMATIC S7-1500 (TO)

How many TO axis can be calculatedHow many EPos axis can be controlled How many TO axis can be calculatedin maximum by S7-1500 (FW1.6)?

How many EPos axis can be controlledin maximum by S7-1500?

Number of I/O Devices depending onPROFINET RT-Communication:S7-1511/13: 128 Drive CUs *)S7-1515/16: 256 Drive CUs *)

Whi h d i it bl ?Whi h PLC it bl ?

S7 1515/16: 256 Drive CUs )

S7-1517/18: 512 Drive CUs *)

15111513 1515 1516 15171518

1512 SP

1510 SP

Which drives are suitable?

Every drive with PROFIdrive oranalog interface, especiallySINAMICS G/S.

Which PLCs are suitable?

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


The number of axis is the elementary factor

( )

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

Cost of componentsApplication example for 6 positioning axis:

DecentralCPU Type Number of axis Central

CPU Type

S7-1511 1 up to 6 S7-1511/13

S7 1511 7 up to 30 S7 1515/16

Decentral

EPos

Central

TO

Decentral Central

S7-1511 7 up to 30 S7-1515/16

S7-1511 31 up to 96 S7-1517

S7-1511 97 up to 128 S7-1518

S7-1515 129 up to 256 ---

EPos TO

SIMATICS7-15xx

SIMATICS7-15xx

Pcs. HardwareL-Price/Piece[EUR]

L-Price/Piece[EUR]

Hardware Pcs..

1xS7-1511

1PN6ES7510-1AK00-0AB0

S7-1511

1PN6ES7510-1AK00-0AB0

1x

6x PM240-2 PM240-2 6x

SINAMICSG120

CU250S-2 PN&

Extended FunctionsSAFETY& EPOS

SINAMICSG120

CU250S-2 PN&

Extended FunctionsSAFETY

6x 06SL3210-1PB13-8AL0 0

6SL3210-1PB13-8AL06x

6xCU250S-2

PN6SL3246-0BA22-1FA0

CU250S-2 PN6SL3246-0BA22-1FA0

6x

6xEPOS & Safety Lizenz6SL3054-4AG00-2AA0-Z E01 +

F01

SafetyLizenz

6SL3054-4AG00-2AA0-ZF01

6x

Ʃ 6- Axis Ʃ 6- Axis

& EPOS

EPos position controller: 8ms TO position controller: 8ms


The customer and the application determine the best applicable configuration

Cost of componentsApplication example for 8 positioning axis:

Decentral

EPos

Central

TO

DecentralCPU Type Number of axis Central

CPU Type

S7-1511 1 up to 6 S7-1511/13

S7 1511 7 up to 30 S7 1515/16EPos TO

SIMATICS7-15xx

SIMATICS7-15xx

Decentral Central

S7-1511 7 up to 30 S7-1515/16

S7-1511 31 up to 96 S7-1517

S7-1511 97 up to128 S7-1518

S7-1515 129 up to256 ---

SINAMICSG120

CU250S-2 PN&

Extended FunctionsSAFETY& EPOS

SINAMICSG120

CU250S-2 PN&

Extended FunctionsSAFETY

Pcs. HardwareL-PricePiece[EUR]

L-Price/Piece[EUR]

Hardware Pcs..

1xS7-1511

1PN6ES7510-1AK00-0AB0

S7-1515

2PN6ES7515-2AM00-0AB0

1x

8x PM240-2 PM240-2 8x

EPos position controller: 8ms TO position controller: 8ms

& EPOS 8x 06SL3210-1PB13-8AL0 0

6SL3210-1PB13-8AL08x

8xCU250S-2

PN6SL3246-0BA22-1FA0

CU250S-2 PN6SL3246-0BA22-1FA0

8x

8xEPOS & Safety Lizenz6SL3054-4AG00-2AA0-Z E01 +

F01

SafetyLizenz

6SL3054-4AG00-2AA0-ZF01

8x

Ʃ 8- Axis Ʃ 8- Axis


The customer and the application determine the best applicable configuration

PerformanceAccuracy and Dynamics

Positioningaccuracy

> 1°

Positioningaccuracy

< 1°

Positioningdynamic

low(Movement cycle > 1s)

Positioningdynamicmedium

(Movement cycle < 1s)

Positioningdynamic

high(Movement cycle < 100ms)

G110M G120CG110M, G120C

G120 CU240B/E-2

G120D CU240D-2

G120 CU250S-2

S110entr

al (T

O)

S110

S120

G110M, G120C

G120 CU240B/D/E-2EPos

)C

e

G120 CU250D-2

G120D CU250S-2

S110

S120Dec

entr

al(E


Technology Objects offer new possibilities for price sensitive positioning applicationsIsochronous communication Technically feasible / recommended

NON isochronous communication Technically NOT feasible / recommendedRestricted recommended, because ofrange limitations or overdimensionLegend:

Optimal SolutionWhat to consider

Customer has experiencewith PLC or Drives?

Possible configurationsuitable for application?

Price of components?

For further information: contact APC/SSS


Motion Control with SIMATIC S7-1500

Realization of gearing based onRealization of gearing based on

• Technology Object Positioning• Basic Positioner with

SINA_POS

Live DemoRestricted / © Siemens AG 2015. All Rights Reserved.

Live-Demo


Scalability in amount of axis

Identical Motion Control functionality in each PLC

Scalability in amount of axis

1511 1513 1515 1516

1512 SP1510 SP


1511 1513 1515 1516 15171518ET 200SP Open Controller

TIA Selection Tool

1. Click: New device2. Click: SIMATIC S7

3. Click: SIMATIC S7-1500

11

2

3

4. Click: Setup device

5. Activate:Motion Integrated

6 S l t

789

1

47 Cli k C fi

6. Select:- Type of axis- Number of axis- Motion cycle time

Application specificPLC load due to

Motion Integrated 7. Click: Configure

5

6

8. Select: Type of CPU

9. Drag&Drop the chosen CPU onto the rack

Motion IntegratedAttention: This is a mistake

in the pre-version!This should be 188,8 s


610. Click: Project view

10 11. Click: LimitsNEW Version available in April 2015!


Dimensioning of a PLC withTIA Selection Tool

Live DemoRestricted / © Siemens AG 2015. All Rights Reserved.

Live-Demo

Technology Object Interfaces for the control of drives

S7-1200 S7-1500

U/IU/I

Analog Signal

Puls Train OutputPTO

(in the future)

Analog Signal

Puls Train Output

PTO

Usable drive types SINAMICSyp

Standard frequency converter,servo converter SINAMICS G/S

Standard frequency converter,servo converter Every SINAMICSAnalog Signal U/I


Step drives,servo converter SINAMICS V60, V90, S110Puls Train Output

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

Principle within S7-1500

MC-Programm

TechnologyObject

Safety Programm What happens, if the safety program controls the drive

with an operation that conflicts with the TO?

Standard Telegramm Safety Telegramm

Object

MC OBsSafety OB TO always reacts in the right way!

Motion Control and Safety in parallel

Standard Telegramm Safety Telegramm Motion Control and Safety in parallel… across the complete systemfrom the PLC down to the drive


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


2)

S7-1511 S7-1513 S7-1515 S7-1516 S7-1517 S7-1518

TechnologyPLC

S7-15xxT, S7-15xxTF

Camming

DistributedMotion 1) 1)1) 1)1)

2)

Func

tiona

lity

1)

1)

1)

Standard

Gearing(relative)

Output cams

Gearing(absolut)

abs.

rel.

otio

n C

ontr

ol

1)

1)

StandardPLC

S7-15xx, S7-15xxF

S d

Positioning


Mo 1)


Speed

1) Planned for V14 Price / Performance / Number of axis2) Planned for higher V14Legend:

Motion Control with SIMATIC S7-1500Integration of SINAMICS in TIA Portal

SINAMICS G110M, G120x via Startdrive

Fast & Easy network and

SINAMICS S120via Starter and GSD-File

S7 1500 Motion Control with

Commisioning wizards

Fast & Easy network andHW configuration

PROFINET IRT communication & DSC*)

S7-1500 Motion Control withSINAMICS S120 usable

Library concept for drives

System diagnosis for drives

Automatic generationof GSD Files in Starter

System diagnosis for drives

2. Generate GSD-File

1. Configure driveIdentical Look & Feel forSIMATIC & SINAMICS

y p of GSD-Files in Starter*) Dynamic Servo Control


3. Import GSD-File in TIA PortalHMI direct access

Overview of the drive types

P i iti i

BenefitDrive type Example Disadvantage

Servo drives + servomotors

• Precise positioning• High dynamic• Precise even at low speed

• High motor price

• Low motor price• Robust

Frequency converters + induction motors

• Turbulent behaviorat low speeds

• Separate fan necessaryfor low speeds

• Big motor size• Big motor size


Thank you for your attention!

Team Technology

Automation Days 2015

Application Center / Simatic System [email protected]


y @

Documents

Automation Days 2015 Workshop Technology/Drives · Challenges for machine builders Increasing production speeds Increasing production accuracy More monitoring and extensive control