Courtesy of CMA/Flodyne/Hydradyne Motion Control Hydraulic Pneumatic Electrical Mechanical (800)

Transcription

1 Electric Drives Linear Motion and Hydraulics Assembly Technologies Pneumatics Service

2 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description Title Type of Documentation Document Typecode Internal File Reference Purpose of Documentation Record of Revision Copyright Validity Published by Note Rexroth IndraMotion 09VRS General Technology Functions Functional Description DOK-IM*ML*-TF*GEN**V09-FK02-EN-P RS-c710071fa4936fde0a6846a0006b3f7d-2-en-US-3 This documentation describes the functions blocks, functions and data types of the libraries for the winder functionality, the register controller functionality and the CrossCutter functionality. Edition Release Date Notes B303-01/EN First edition for 09VRS B303-02/EN Revised for the online help Bosch Rexroth AG, 2009 Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Bosch Rexroth AG Bgm.-Dr.-Nebel-Str Lohr a. Main, Germany Phone +49 (0)93 52/ 40-0 Fax +49 (0)93 52/ BRC/EAM3 (KlGo), BRC/EAY2 (VoHa/MePe) This document has been printed on chlorine-free bleached paper.

3 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG I/III Table of Contents Table of Contents 1 Important Directions for Use Appropriate Use Introduction Areas of Use and Application Inappropriate Use Safety Instructions for Electric Drives Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others How to Employ the Safety Instructions Explanation of Warning Symbols and Degrees of Hazard Seriousness Hazards by Improper Use Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings Protection Against Electric Shock by Protective Extra-Low Voltage Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protection Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Systems RMB_TechWinder.library RMB_TechWinder, Overview Function Blocks for the Closed Loop Dancer Position Control Introduction and Overview MB_DancerControlType Commissioning Closed Loop Dancer Position Control Function Blocks for the Diameter Calculation Introduction and Overview MB_DiameterCalculatorType Commissioning of the Diameter Calculator Function Block to Record an Externally Measured Diameter Introduction and Overview MB_DiameterMeasurementType Diameter Calculator with Dancer Introduction and Overview MB_WinderDancerCtrlType Commissioning the Diameter Calculator with Dancer Diameter Calculator with Open Loop and Closed Loop Tension Control Introduction and Overview MB_WinderTensionCtrlType Commissioning the Diameter Calculator with Closed Loop or Open Loop Tension Control Page

4 II/III Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description Table of Contents Page 3.7 RMB_TechWinder, Supplemental Function Blocks and Data Types Overview MB_CalcInertiaLimitType MB_UnwindMaterialType MB_WIND_CTRL_TYPE MB_WIND_DANCER_LIMITS MB_WIND_DIAMETER MB_WIND_DIAM_CALC_MODE MB_WIND_DIRECTION MB_WIND_FRICTION MB_WIND_TENSION MB_WIND_TENSION_MODE MB_WIND_TENS_DIAG RMB_TechWinder, Parameter Overview ML_TechRegi.library ML_TechRegi, Overview Register Controller Function Blocks MB_RegisterControllerType MB_RegisterControllerType MB_RegisterControllerType Side Register Controller MB_RegisterControllerSideType Measured Value Processing and Regulate Function Blocks MB_RegiMeasuringType MB_RegiMeasuringType MB_RegiRegulateType MB_RegiRegulateType MB_RegiRegulateType Functions Blocks for the Q.I. Camera Sensor Actuation Overview MB_RegiSensor02ConfigType MB_RegiSensor02CycComType MB_REGI_SENSOR02_CFG MB_REGI_SENSOR_DATA RMB_TechCrossCutCrossSeal.library RMB_TechCrossCutCrossSeal, Overview MB_CrossCutSealType MB_CrossCutterCalcType MB_CrossCutterCalcType04, Special Features of IndraMotion MLC MB_CAM_TABLE_DATA MB_CORR_PROFILE MB_RESOLUTION MB_PUSH_OUT_CONFIG

5 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG III/III Table of Contents Page 6 Service and Support Index

6 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description

7 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 1/190 1 Important Directions for Use 1.1 Appropriate Use Introduction WARNING Areas of Use and Application Bosch Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. Personal injury and property damage caused by inappropriate use of the products! The products may only be used in the manner that is defined as appropriate. If they are used in an inappropriate manner, then situations can develop that may lead to property damage or injury to personnel. Bosch Rexroth, as manufacturer, is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks. Before using Bosch Rexroth products, make sure that all the pre-requisites for appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use. If the product takes the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation. The IndraControl of Bosch Rexroth and its function modules are suitable for motion/logic applications. The IndraControl and its function modules may only be used with the accessories and parts specified in this document. If a component has not been specifically named, then it may not be either mounted or connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant function descriptions. IndraControl and its function modules have been developed for use in single or multiple-axis drives and control tasks. To ensure an application-specific use, the machine operator and visualization panels are available with differing equipment and different interfaces. Typical applications of IndraControl and its function modules are: [Handling and assembly systems] [Packaging and foodstuff machines] Important Directions for Use

8 2/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description Important Directions for Use 1.2 Inappropriate Use [Printing and paper processing machines] [Machine tools] IndraControl and its function modules may only be operated under the assembly, installation and ambient conditions as described here (temperature, system of protection, humidity, EMC requirements, etc.) and in the position specified. Using IndraControl and its function modules outside of the above-referenced areas of application or under operating conditions other than described in the document and the technical data specified is defined as "inappropriate use". IndraControl and its function modules may not be used if they are subject to operating conditions that do not meet the above specified ambient conditions. This includes, for example, operation under water, in the case of extreme temperature fluctuations or extremely high maximum temperatures or if Bosch Rexroth has not specifically released them for that intended purpose. Please note the specifications outlined in the general safety instructions!

9 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 3/190 2 Safety Instructions for Electric Drives 2.1 Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others WARNING Do not attempt to install or commission this device without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent immediately to the person or persons responsible for the safe operation of the device. If the device is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the device in the official language of the user's country. Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! Observe the safety instructions! How to Employ the Safety Instructions Safety Instructions for Electric Drives Read these instructions before initial commissioning of the equipment in order to eliminate the risk of bodily harm and/or material damage. Follow these safety instructions at all times. Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before commissioning the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of this device. Only assign trained and qualified persons to work with electrical installations: Only persons who are trained and qualified for the use and operation of the device may work on this device or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the product, as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and devices on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer.

10 4/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description Safety Instructions for Electric Drives Follow all safety regulations and requirements for the specific application as practiced in the country of use. The devices have been designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Only use safety-relevant applications that are clearly and explicitly approved in the Project Planning Manual. If this is not the case, they are excluded. Safety-relevant are all such applications which can cause danger to persons and material damage. The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. Commissioning of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application. Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective documentation (Project Planning Manuals of components and system). The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connection and installation conditions are specified in the product documentation and must be followed at all times. National regulations which the user must take into account European countries: according to European EN standards United States of America (USA): National Electrical Code (NEC) National Electrical Manufacturers Association (NEMA), as well as local engineering regulations regulations of the National Fire Protection Association (NFPA) Canada: Canadian Standards Association (CSA) Other countries: International Organization for Standardization (ISO) International Electrotechnical Commission (IEC) Explanation of Warning Symbols and Degrees of Hazard Seriousness The safety instructions describe the following degrees of hazard seriousness. The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions:

11 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 5/190 Warning symbol Hazards by Improper Use DANGER DANGER WARNING WARNING CAUTION CAUTION Signal word Danger Warning Caution Fig.2-1: Hazard classification (according to ANSI Z 535) Degree of hazard seriousness acc. to ANSI Z Death or severe bodily harm will occur. Death or severe bodily harm may occur. Minor or moderate bodily harm or material damage may occur. High electric voltage and high working current! Risk of death or severe bodily injury by electric shock! Observe the safety instructions! Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! Observe the safety instructions! High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock! Observe the safety instructions! Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Observe the safety instructions! Hot surfaces on device housing! Danger of injury! Danger of burns! Observe the safety instructions! Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting or improper handling of pressurized lines! Observe the safety instructions! Safety Instructions for Electric Drives

12 6/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of batteries! Observe the safety instructions! 2.2 Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings DANGER This section concerns devices and drive components with voltages of more than 50 Volt. Contact with parts conducting voltages above 50 Volts can cause personal danger and electric shock. When operating electrical equipment, it is unavoidable that some parts of the devices conduct dangerous voltage. High electrical voltage! Danger to life, electric shock and severe bodily injury! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain and repair this equipment. Follow general construction and safety regulations when working on power installations. Before switching on the device, the equipment grounding conductor must have been non-detachably connected to all electrical equipment in accordance with the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the equipment grounding conductor is not permanently connected to the mounting points of the components provided for this purpose. Before working with electrical parts with voltage potentials higher than 50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection. With electrical drive and filter components, observe the following: Wait 30 minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the electric voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Do not remove or plug in connectors when the component has been powered. Install the covers and guards provided with the equipment properly before switching the device on. Before switching the equipment on, cover and safeguard live parts safely to prevent contact with those parts. A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device according to the relevant standards. Secure built-in devices from direct touching of electrical parts by providing an external housing, for example a control cabinet.

13 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 7/190 DANGER For electrical drive and filter components with voltages of more than 50 volts, observe the following additional safety instructions. High housing voltage and high leakage current! Risk of death or bodily injury by electric shock! Before switching on, the housings of all electrical equipment and motors must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests. The equipment grounding conductor of the electrical equipment and the devices must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 ma. Over the total length, use copper wire of a cross section of a minimum of 10 mm 2 for this equipment grounding connection! Before commissioning, also in trial runs, always attach the equipment grounding conductor or connect to the ground wire. Otherwise, high voltages may occur at the housing causing electric shock Protection Against Electric Shock by Protective Extra-Low Voltage WARNING Protective extra-low voltage is used to allow connecting devices with basic insulation to extra-low voltage circuits. All connections and terminals with voltages between 5 and 50 volts at Rexroth products are PELV systems. 1) It is therefore allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections and terminals. High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock! If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g. the mains connection) are connected to Rexroth products, the connected extra-low voltage circuits must comply with the requirements for PELV. 2) Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. 1) "Protective Extra-Low Voltage" 2) "Protective Extra-Low Voltage" Safety Instructions for Electric Drives

14 8/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description Safety Instructions for Electric Drives The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

15 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 9/190 DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. These measures have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possible if safety devices are disabled, bypassed or not activated. To avoid accidents, bodily harm and/or material damage: Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: use safety fences use safety guards use protective coverings install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the device if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Additionally secure vertical axes against falling or dropping after switching off the motor power by, for example: mechanically securing the vertical axes, adding an external braking/ arrester/ clamping mechanism or ensuring sufficient equilibration of the vertical axes. The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety! Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: maintenance and repair work cleaning of equipment Safety Instructions for Electric Drives long periods of discontinued equipment use Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such devices cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.

16 10/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description Safety Instructions for Electric Drives Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting WARNING Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious personal danger to those with heart pacemakers, metal implants and hearing aids. Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers and metal implants are not permitted to enter following areas: Areas in which electrical equipment and parts are mounted, being operated or commissioned. Areas in which parts of motors with permanent magnets are being stored, repaired or mounted. If it is necessary for somebody with a pacemaker to enter such an area, a doctor must be consulted prior to doing so. The noise immunity of present or future implanted heart pacemakers differs greatly so that no general rules can be given. Those with metal implants or metal pieces, as well as with hearing aids, must consult a doctor before they enter the areas described above. Otherwise health hazards may occur Protection Against Contact with Hot Parts CAUTION Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns! Do not touch surfaces of device housings and chokes in the proximity of heat sources! Danger of burns! Do not touch housing surfaces of motors! Danger of burns! According to the operating conditions, temperatures can be higher than 60 C, 140 F during or after operation. Before accessing motors after having switched them off, let them cool down for a sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated, the time required for cooling down is five times the thermal time constant specified in the Technical Data. After switching drive controllers or chokes off, wait 15 minutes to allow them to cool down before touching them. Wear safety gloves or do not work at hot surfaces. For certain applications, the manufacturer of the end product, machine or installation, according to the respective safety regulations, has to take measures to avoid injuries caused by burns in the end application. These measures can be, for example: warnings, guards (shielding or barrier), technical documentation Protection During Handling and Mounting In unfavorable conditions, handling and mounting certain parts and components in an improper way can cause injuries.

17 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 11/190 CAUTION Battery Safety CAUTION Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting! Observe the general construction and safety regulations on handling and mounting. Use suitable devices for mounting and transport. Avoid jamming and bruising by appropriate measures. Always use suitable tools. Use special tools if specified. Use lifting equipment and tools in the correct manner. If necessary, use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Do not stand under hanging loads. Immediately clean up any spilled liquids because of the danger of skidding. Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or material damage. Risk of injury by improper handling! Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and cauterization). Do not recharge the batteries as this may cause leakage or explosion. Do not throw batteries into open flames. Do not dismantle batteries. When replacing the battery/batteries do not damage electrical parts installed in the devices. Only use the battery types specified by the manufacturer Protection Against Pressurized Systems Safety Instructions for Electric Drives Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations. Dispose of used batteries separate from other waste. Observe the local regulations in the country of assembly. According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids and cooling lubricating agents. Improper handling of the connected supply systems, supply lines or connections can cause injuries or material damage.

18 12/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of pressurized lines! Do not attempt to disconnect, open or cut pressurized lines (risk of explosion). Observe the respective manufacturer's operating instructions. Before dismounting lines, relieve pressure and empty medium. Use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Immediately clean up any spilled liquids from the floor. Environmental protection and disposal! The agents used to operate the product might not be economically friendly. Dispose of ecologically harmful agents separately from other waste. Observe the local regulations in the country of assembly.

19 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 13/190 3 RMB_TechWinder.library 3.1 RMB_TechWinder, Overview Different function blocks are combined in the RMB_TechWinder.lib library providing the functions for the winding and unwinding of webs of fabric (winders). With the help of these function blocks, the functions of a dancer position controller, diameter calculator with dancer, diameter calculator with closed loop tension control and a diameter calculator with open loop tension control can be implemented. The function blocks required to implement these functions will be described in the following. The following table provides an overview of all the documented function blocks and their respective applications. Complete list of pre-connected winder function blocks Function block Description Application MB_WinderDancerCtrlType01, page 35, MB_WinderTensionCtrlType02, page 44, Function block for winder with dancer (consisting of MB_DancerControlType03, page 16, and MB_DiameterCalculatorType03, page 23. Function block for winder with closed loop tension control and open loop tension control (without sensor) Fig.3-1: Pre-connected winder function blocks Winder with dancer Winder with closed loop tension control (load cell), Winder with open loop tension control The pre-connected function blocks combine all of the functions of the individual blocks and take responsibility away from the operator for the correct connection of the individual function blocks. Function blocks for single functions Function block Description Application MB_DancerControlType03, page 16 MB_DiameterCalculatorType03, page 23. MB_DiameterMeasurement Type01, page 31 Function block for the calculation of a closed loop dancer position control for a tensile axis with dancer or winding axis Function block for the calculation of the current diameter for winding axes with velocity adaptation. Function block to read a measured diameter for winding axes with velocity adaptation Fig.3-2: Individual function blocks RMB_TechWinder.library Tensile axes, Winder with dancer Winder with dancer, winder with closed loop tension control, Winder with open loop tension control (without sensor) Winder with dancer, winder with closed loop tension control, Winder with open loop tension control (without sensor)

20 14/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Function blocks with additional winding functions Designation Type Description MB_CalcInertiaLimitType02, page 61 MB_UnwindMaterialType02, page 63 Fig.3-3: Designation Type Description MB_WIND_CTRL_TYPE, page 68 FB FB ENUM Calculates the maximum moment of inertia of the winding material on the winder Calculates process variables for an unwinder like the unrolled and the remaining length of the web of fabric, the material thickness and the remaining runtime for a splice. Function blocks for additional functionalities for different winder types from the RMB_TechWinder library Allows the selection of the open loop tension control (sensorless) and the closed loop tension control (load cell). MB_WIND_DANCER_LIMITS, page 68 STRUCT Describes the limiter of the controller control variable. MB_WIND_DIAMETER, page 70 STRUCT Describes the data of the diameter calculator. MB_WIND_DIAM_CALC_MODE, page 71 ENUM Allows the selection of the diameter calculation type. MB_WIND_DIRECTION, page 71 ENUM Allows the selection of the winding direction type. MB_WIND_FRICTION, page 72 STRUCT Characterizes the friction torque. MB_WIND_TENSION, page 72 STRUCT Describes the data of the tension controller for closed loop control. MB_WIND_TENSION_MODE, page 73 ENUM Allows the selection of the mode to tension the material web. MB_WIND_TENS_DIAG, page 73 STRUCT Describes the current control deviation of the dancer controller. MLC control - RMB_TechWinder MLD control- MX_TechWinder Fig.3-4: Library dependencies Data types for different winder types from the RMB_TechWinder library The required libraries are automatically included. The following libraries are required: MX_Technology06.lib (MPX06 drive firmware) RIL_LoopControl.lib 3.2 Function Blocks for the Closed Loop Dancer Position Control Introduction and Overview The dancer position controller is used, for example, on tensile axes or winders with dancers. The dancer position controller controls the position of a dancer. The tension will be specified by a force which acts upon the movable part of the dancer. This force can be applied by a weight, a spring or a pneumatic element. The actual value of the dancer position is recorded, for example, over an analog channel, transferred to the control and processed in the process loop. The following figure shows the principle of closed loop dancer position control.

21 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 15/190 Fig.3-5: Principle of closed loop dancer position control The dancer position controller is implemented in the function block MB_DancerControlType03 and designed as PID controller. By setting the controller parameters, the individual controller functions (P part: Proportional part, I part: Integral part, D part: differential part) can be controlled. If a parameter is set to zero, the respective controller part will not be effective either. The following table shows the possible and permitted controller configurations. No. P part I part D part Permitted Note yes Controller ineffective, output = no D controller not defined, error yes pure I controller no DI controller not defined, error yes pure P controller yes PD controller yes PI controller yes PID controller Fig.3-6: Permitted and prohibited controller configurations (1 corresponds to the part set (value 0.0), 0 corresponds to the part not set (value = 0.0) Functional diagram of the dancer position controller RMB_TechWinder.library The following functional diagram illustrates the functions of the dancer position controller on a diagram.

22 16/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Fig.3-7: MB_DancerControlType03 Short description Functional diagram of the dancer position controller The function block cyclically calculates closed loop dancer position control for a draw roll with dancer or for a winding axis with dancer. The cyclical output parameters of the dancer position controller are the speed offset of the respective drive for the draw roll or the winding axis, as well as the current control deviation of the dancer position controller. The output "AddVelocityDancer" of the function block acts on the parameter P0-0690, Additive velocity command value, process controller. If this is not wanted, this can be prevented via the input "Disable CyclicWrites". Then only the output "AddVelocityDancer" will be written to.

23 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 17/190 Interface Description Fig.3-8: MB_DancerControlType03 Name Type Comment VAR_IN_OUT Master AXIS_REF Reference to the master axis RMB_TechWinder.library Slave AXIS_REF Reference to the slave axis (tensile axis) VAR_INPUT Enable BOOL Process enabling of the function block (levelcontrolled) Pause BOOL Dancer controller paused, no velocity adaptation (level-controlled) DisableCyclicWrites BOOL When this input is set, the cyclical data is not written directly into the optional cyclical data container, but only displayed at the output. ControlPolarity BOOL Polarity of the closed loop dancer control is inverted (applied in case of pos. edge at Enable) SetpointDancer REAL Command value for the closed loop dancer control FeedbackDancer REAL Actual value (feedback) for dancer position WindowDancer REAL Window for monitoring the actual dancer position value [%] with regard to the command dancer position value. If the dancer position is different from the command value by a higher value than the specified one, the function block reports this deviation by resetting the output "InWindow". DancerLimits MB_WIND_DANCER_LIMITS MB_WIND_DANCER_LIMITS, page 68 Structure for the automatic actual variable limitation of the dancer PControl REAL Value for the Kp-gain of the closed loop dancer control IControl TIME Value for the integral action time of the closed loop dancer control

24 18/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Comment DControl TIME Value for the derivative time of the closed loop dancer control ReferenceDiameter REAL Reference diameter Dancer position controller only: Diameter of the draw roll [mm] Winder with dancer: Format length REAL Format length [mm] Current winding diameter [mm] from the diameter calculator function block (1 revolution of the reference axis unwound) MinDancerFeedback REAL Lower threshold for the actual dancer value (Only for display with a binary output). MaxDancerFeedback REAL Upper threshold for the actual dancer value VAR_OUTPUT InOperation BOOL Block is working (Only for display with a binary output). Error BOOL Processing completed with error ErrorID ERROR_ CODE Description of the diagnostics in case of error ErrorIdent ERROR_STRUCT Error code, page 20 InPause BOOL Dancer controller pausing InWindow BOOL Actual dancer value within the dancer window MinFeedbackAchieved BOOL Actual value of the dancer position is below the input MinDancerFeedback MaxFeedbackAchieved BOOL Actual value of the dancer position is above the input MaxDancerFeedback AddVelocityDancer REAL Speed offset for the winding drive [rpm] CurrentDancerDeviation REAL Current control deviation of the dancer controller Fig.3-9: Interface description of the MB_DancerControlType03 FB Name Type Min. value Max. value Default value Transfer Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous DisableCyclicWrites BOOL FALSE Rising edge at Enable ControlPolarity BOOL FALSE Rising edge at Enable SetpointDancer REAL 0.0 Not defined 0.0 Continuous FeedbackDancer REAL Not defined Not defined 0.0 Continuous WindowDancer REAL 0.0 Not defined 0.0 Continuous DancerLimits STRUCT PControl REAL 0.0 Not defined 0.0 Continuous IControl TIME 0s Not defined 0s Continuous DControl TIME 0s Not defined 0s Continuous ReferenceDiameter REAL 0.0 Not defined 100 Continuous

25 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 19/190 Name Type Min. value Max. value Default value MinDancerFeedback REAL 0.0 MaxDancer Feedback REAL Actual variable limitation Signal-time diagram Functional Description MaxDancerFeedback MinDancerFeedback Fig.3-10: Transfer 0.0 Continuous Not defined 0.0 Continuous Default values of the MB_DancerControlType03 The actual variable limitation of the dancer position controller is dynamically adjusted according to the reference axis velocity and the diameter ratio ("format length" / Pi * "ReferenceDiameter"). This means that at higher velocity, the limitation of the additive velocity of the dancer position controller is automatically higher than at lower velocity. Consideration of the diameter ratio results in the limitation automatically being adapted to a changing "ReferenceDiameter". The following signal-time diagram represents selected function block signals. The function block will be activated by the "Enable" input, which is signalized at the "InOperation" output. Operational readiness can be interrupted by an error, which is signalized at the "Error" output. The internal controller process can be paused by the "Pause" input. "Pause" is signalized at the "InPause" output. Fig.3-11: RMB_TechWinder.library Signal-time diagram for selected inputs and outputs of the MB_Dancer ControlType02 function block The function block cyclically calculates closed loop dancer position control for a draw roll with dancer or for a winding axis with dancer. The IL_PIDType01 function block from the ML_TechCommon.lib library is used as the controller. The controller has been designed as a PID controller. The cyclical output parameters of the dancer position controller are the speed offset of the respective drive for the draw roll or the winding axis, as well as the current control deviation of the dancer position controller. The "AddVelocityDancer" output of the function block should act on the parameter P , Additive velocity command value, process controller (external connection) for closed loop dancer position control. The current control deviation "CurrentDancerDeviation" is available for analysis purposes. The proportional gain (factor K P ) and the low and high values for actual variable limitation "DancerLimits" are automatically adjusted with the "ReferenceDiameter" input, based on the format length "FormatLength". The diameter of the draw roll "ReferenceDiameter" has to be specified for closed loop dancer position control for a draw roll. "ReferenceDiameter" specifies the current winding diameter with a winder with closed loop dancer position control. If the values for the integral part (integral action timet n, "IControl") and the lead element (lead time T D, "DControl") are zero, the internal memory parameters of the PID controller have been deleted. There has to be a value proportional to the dancer roll adjustment (e.g. an analog tension value) at the "FeedBackDancer" input. The command value and the actual value must have the same unit.

26 20/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Required hardware Required firmware Required software Required parameterization for MLC control Required parameterization for MLD control Error Handling The function block only processes positive command values and actual values. Negative command values result in an error. Negative actual values are limited to zero. Closed loop dancer position control In order to record the dancer position, a measuring element is required, which converts the dancer position into a proportional signal. The actual position of the dancer will be subtracted from a given command value and specified as a control deviation on an internally integrated PID controller. The control variable of the controller acts upon the speed command value by adding this value. Thus, the winding axis rotates faster or slower compared with the master axis. The position of the dancer is thereby controlled. Under normal conditions (e. g. no high speed command value deviations), the circumferential velocity of a winding axis is approximately adjusted by means of the fine adjustment of the gear; the tensile axis is approximately adjusted by means of the electronic gear. In this way, the dancer position controller should only control small deviations. MLC hardware CML65 IndraDrive C or M MLC firmware CML65s-MLs-09 or higher Drive firmware MPX05V12, MPX06 IndraWorks for MLC or MLD The interpolation in the drive must be enabled for the dancer controller axis (Real axis Corresp. axis Properties). The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The Parameter P , Additive velocity command value, process controller has to be entered in the cyclical SERCOS channel of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. Interpolation has to be activated in the drive for the dancer controller axis when using the MLD-S controller with a higher-order MLC controller (Real axes Corresp. axis Properties). This setting does not occur when using MLD-M control. The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The Parameter P , Additive velocity command value, process controller has to be entered in the cyclical channel between the controller and drive of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. (The dialog box is in the project tree below the MLD node AxisData). The following table lists and describes the error codes of the function block.

27 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 21/190 ErrorID Additional1 Additional2 Text Error codes from "F_RELATED table (16#0170)" are used. Error codes from the IL_PIDType01 function block from the RIL_LoopControl.library library and MB_GetCyclicParameterHandle from the ML_TechBase.library or MX_Technologie06.lib libraries can also occur. STATE_MACHINE_ERROR 16# #0020 Error in the state machine 16# #0002 HighLimit < LowLimit 16#0003 FormatLength < #0004 Reference diameter < #0005 Process window < #0006 High limit < #0007 Low limit < #0008 Velocity high limit < #0009 p-gain < #000A Setpoint < #000B Min feedback < #000C Max feedback < #000D Max feedback < MinFeedback 16#000E Number of slave axis wrong 16#000F Number of master axis wrong DEVICE_ERROR 16# #0001 Axis not in operating mode RESSOURCE_ERROR 16# #0000 Wrong drive firmware RESSOURCE_ERROR 16#000F 16#0003 Drive function package "MA" not activated Fig.3-12: Error codes of the MB_DancerControlType03 function block Commissioning Closed Loop Dancer Position Control Commanding the dancer controller axis Basic settings RMB_TechWinder.library The correct operating mode of the drive and the controller enable of the drive have to be set for the dancer controller axis. This can be done in two different ways: Set the "ModeSyncVel" operating mode by means of the axis interface. (recommended) Use the PLC-Open "MC_Power", "MC_GearIn", "MC_Stop" function blocks to command the axis. First of all, the control sense of the dancer position controller is defined depending on the direction of rotation of the tensioning axis. The controller acts in the opposite direction, depending on this setting. The control sense is defined by setting the "ControlPolarity" input. Another important basic setting is the setting of the reference diameter ("ReferenceDiameter" input). The current calculated winding diameter is applied here with winders with dancer. The diameter of the tensile axis is entered with dancer position controllers. Using the "MinDancerFeedback" and "MaxDancerFeedback" inputs, values for the adjustment range of the dancer can be entered, which will then be displayed by the "MinFeedbackAchieved" and "MaxFeedbackA

28 22/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library chieved" outputs. These values should be within the limit positions of the dancer. The process variable window ("WindowDancer") will then be defined. The monitoring process of the dancer command position will be parameterized in this window. If the actual dancer position value differs from the position command value ("SetpointDancer"), in relation to the command value, by more than the specified percentage, the "InWindow" binary output is reset ("InWindow": = FALSE). This allows the higher-value SPS to react to the process accordingly. Exiting the parameterized window initially has no effect on the function of the dancer position controller. If, for example, the command dancer value "SetpointDancer" is and the window size has been set to "WindowDancer" = 10 %, the limits of the window are and Within this value range, the "InWindow" output = TRUE. The format length finally has to be specified. The format length corresponds to an unwound revolution of the reference axis ("FormatLength" input). Parameterization of the dancer position controller The controller parameters are set in the next step. These parameters are the proportional gain (input "PControl"), integral action time ("IControl") and lead time ("DControl"). The Ziegler and Nichols method can be used to set the parameters. The control loop will be closed and the proportional gain ("PControl") will be increased until the output of the control loop performs a constant oscillation with the period T crit at proportional gain K P,crit at a constant input. The setting rules for the gain K p ("PControl"), the integral action time T n ("IControl") and the derivative time T v ("DControl") are as given in the following table. Controller "PControl" "IControl" "DControl" P controller 0.5 K P,crit PI controller 0.45 K P,crit 0,85 T crit PD controller 0.55 K P,crit 0.15 T crit PID controller 0.6 K P,crit 0.5 T crit 0.12 T crit Fig.3-13: Controller parameterization according to Ziegler and Nichols The inputs of the structure MB_WIND_DANCER_LIMITS, page 68, are assigned. The operating range of the dancer position controller is determined here by specifying the upper and lower limit ("LowLimitControl", "HighLimitControl") of the internal limiter. Initial start-up of the dancer position controller Firstly, a value is specified as a command value at the "SetpointDancer" input. Generally, it is helpful if this value corresponds to the central position of the dancer. In this case, the dancer has a comparatively long web distance. After having enabled the dancer position controller ("Enable" = TRUE), the dancer moves to the defined command value position. Now the dancer tries (with the help of the dancer position controller) to balance the variations in the web tension caused by variations of the web speed which act on the dancer

29 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 23/190 position and thus on the control deviation of the dancer position controller by adjusting the drive speed of the tensile axis or the winding axis. These variables are displayed at the "CurrentDancerDeviation" and "AddVelocityDancer" outputs and can thus be monitored. 3.3 Function Blocks for the Diameter Calculation Introduction and Overview MB_DiameterCalculatorType03 Short description Interface Description The MB_DiameterCalculatorType03 function block provides a versatile function block for carrying out diameter calculations. It is used in all diameter calculators described in this manual. For this reason, it is described first and foremost. The function block cyclically calculates the current diameter, the velocity adaptation for the winding axis and the current moment of inertia of the winding material on a winder. The function block is called up for each winding axis. Cyclical output variables are the current winding diameter "CurrentDiameter", the resulting fine adjustment of the gear for the respective winding drive "Gear RatioFineAdjust" and the current moment of inertia of the winding material "CurrentInertia". Fig.3-14: The fine adjustment of the gear "GearRatioFineAdjust" influences the parameter P , Gear ratio fine adjustment, process controller. This parameter is entered in the corresponding cyclical SERCOS channel. Parameterization is carried out in parameterization mode. MB_DiameterCalculatorType03 function block Name Type Comment VAR_IN_OUT Master AXIS_REF Reference to the master axis RMB_TechWinder.library Slave AXIS_REF Reference to the slave axis (tensile axis) VAR_INPUT Enable BOOL Process enabling of the function block (levelcontrolled)

30 24/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Comment Preset BOOL Preset of the current winding diameter Pause BOOL Diameter calculator paused (level-controlled) DisableCyclicWrites BOOL When this input is set, the cyclical data is not written directly into the optional cyclical data container, but only displayed at the output. PresetDiameter REAL CurrentDiameter is set to PresetVal, GearRatioFineAdjust is adjusted accordingly (edgecontrolled) Format length REAL Format length [mm] (corresponds to an unwound revolution of the reference axis) MinDiameter REAL Minimum diameter [mm] Is only used by the "MinAvDiamAchieved" output for display purposes. MaxDiameter REAL Maximum diameter [mm] Is only used by the "MaxAvDiamAchieved" output for display purposes. FeedbackDancer REAL Actual dancer position value (only for the "Winder with dancer" function) DancerConstant REAL Path when adjusting the dancer roll in relation to the unit of the dancer adjustment [mm] Webwidth REAL Web width [mm] Prefix has to be set depending on the structure of the dancer! (only for the "Winder with dancer" function) Density REAL Material density [kg/dm 3 ] AverageValue UINT Number of diameter values averaged. The input is limited to a maximum of 30. HighLimitDiameter REAL Upper limit of the diameter [mm]. The diameter is limited to this value. LowLimitDiameter REAL Lower limit of the diameter [mm]. The diameter is limited to this value. CoreDiameter REAL Core diameter of the winder [mm] DiamCalcRange REAL Range for the calculation of the diameter [degrees]. Specifies the number of degrees after which the diameter should be calculated regularly. Relates to the winding axis. DiamCalcMode MB_WIND_DIAM_CALC_MODE MB_WIND_DIAM_CALC_MODE, page 71 Diameter calculation mode 0x0000: CALC_DIAM_MANUAL Diameter calculation dependent on CalcRange 0x0001: FIRST_REV_AUTO_CALC Diameter calculation is done every 5 degrees for the first revolution and thereafter depending on the CalcRange

31 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 25/190 Name Type Comment PivotVelocity REAL Pivot velocity of the winder (relative velocity to the winder motion) [mm/s] VAR_OUTPUT InOperation BOOL Block is working This corrects the diameter calculation if there is relative motion of the winding axis. Error BOOL Processing completed with error ErrorID ERROR_ CODE Description of the diagnostics in case of error ErrorIdent ERROR_STRUCT Error code, page 29 PresetAck BOOL Preset diameter was applied (is set providing Preset is pending) InPause BOOL Diameter calculation paused MinAvDiamAchieved BOOL Minimum diameter reached (based on the averaged diameter) MaxAvDiamAchieved BOOL Maximum diameter reached (based on the averaged diameter) HighLimitActive BOOL Current calculated diameter has reached the upper limit. (Diameter value is discarded) LowLimitActive BOOL Current calculated diameter has reached the lower limit. (Diameter value is discarded) CurrentDiameter REAL Current winding diameter GearRatioFineAdjust REAL Fine gear adjustment for speed adaptation of the drive [%] CurrentInertia REAL Current total moment of inertia (based on the motor side [kg/m 2 ] MinAvDiamAchieved BOOL Minimum diameter reached (based on the averaged diameter) MaxAvDiamAchieved BOOL Maximum diameter reached (based on the averaged diameter) HighLimitAchieved BOOL Current calculated diameter reached the upper limit (Diameter value is discarded). LowLimitAchieved BOOL Current calculated diameter reached the lower limit (Diameter value is discarded). GearRatioFineAdjust REAL Fine gear adjustment for speed adaptation of the drive [%] Fig.3-15: RMB_TechWinder.library MB_DiameterCalculatorType03 function block interface description

32 26/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Min. value Max. value Default value Transfer Enable BOOL FALSE Continuous Preset BOOL FALSE Continuous Pause BOOL FALSE Continuous DisableCyclicWrites BOOL FALSE rising edge at Enable PresetDiameter REAL > 0.0 Not defined Continuous Format length REAL > 0.0 Not defined rising edge at Enable MinDiameter REAL > 0.0 Not defined Continuous MaxDiameter REAL > 0.0 Not defined Continuous FeedbackDancer REAL 0.0 Not defined 0.0 Continuous DancerConstant REAL Not defined Not defined 0.0 Continuous Webwidth REAL 0.0 Not defined 0.0 Rising edge at Enable Density REAL 0.0 Not defined 1.0 Rising edge at Enable AverageValue UINT Continuous HighLimitDiameter REAL 0.0 Not defined Continuous LowLimitDiameter REAL 0.0 Not defined Continuous CoreDiameter REAL 0.0 Not defined Rising edge at Enable DiamCalcRange REAL 0.0 Not defined Continuous DiamCalcMode ENUM 16#0000 Rising edge at Enable PivotVelocity REAL 0.0 Not defined 0.0 Continuous Signal-time diagram Fig.3-16: Default values of the MB_DiameterCalculatorType03 The following signal-time diagram describes the inputs and outputs of the function block which affect its operation. Operation of the function block is not possible without setting the input "Enable". The operational readiness will be signalized by the output "InOperation" and only interrupted by an error displayed by the output "Error". If there is a positive edge at the "Preset" output, the value at the "PresetDiameter" input will be written as the output of the diameter calculator. This is possible independent of the "Pause" input. The setting of "Preset" is signalized by the "PresetAck" output. The setting of the "Pause" input, which freezes the calculation of the diameter, is signalized at the "In Pause" output. Fig.3-17: Signal/time diagram for selected inputs and outputs of the MB_DiameterCalculatorType03 function block

33 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 27/190 Functional Description Preset of the Diameter Since the calculated diameter directly affects the velocity of the winding axis via the resulting fine adjustment, a meaningful value has to be preset for the diameter prior to the start of the calculation when activating the diameter calculator. Thus, a value for the diameter, which is close to the actual diameter, should be specified at the input "PresetDiameter" and a preset should be performed. With a rewinder, the value should be slightly lower and should be slightly higher for an unwinder. This allows an easier start-up in both cases. With each new roll, a preset off the winding diameter should be performed once at the start. This is done via the "Preset" input. The diameter is set to the value of the "PresetDiameter" input. Setting the diameter with the help of "Preset" is always possible without setting the "Pause" input. After having switched on the controller, the winding diameter, the gear fine adjustment and the moment of inertia all equal zero. This means that a preset should be performed each time the controller is switched on in order to preset the respective variables with meaningful values. If this is not done, no meaningful value can be calculated for the current winding diameter. This may result in a malfunction of the diameter calculator and thus lead to the winder stopping. If it not possible to specify a correct preset value for the starting winding, we would recommend the use of "auto-calc mode" to calculate the diameter (FIRST_REV_AUTO_CALC). In this mode, the range of diameter calculation (DiamCalcRange) is automatically adjusted for the first winding axis revolution after the system has been switched on, in order to obtain more quickly a meaningful starting diameter. Diameter calculation If the current diameter is to be retained after the controller is switched off, the "CurrentDiameter" output has to be copied again to a remaining variable. When the controller is switched on again, a preset can be performed again with this value. The calculation of the diameter is proportional to the quotient from the reference axis velocity n Ref and the winding axis velocity n Winder and to the format length F (corresponding to an unwound revolution of the reference axis). Fig.3-18: Proportionality in diameter calculation The ratio of "Format length" / "CoreDiameter" should not be greater than 25. Otherwise the gear adjustment will not be sufficiently greater than the gear fine adjustment! The calculated winding diameter directly influences the resulting fine adjustment of the gear. In this way the velocity of the winder is adjusted according to the diameter. Average Determination RMB_TechWinder.library The calculated current diameter "CurrentDiameter" can be averaged by setting the "AverageValue" input. The number of the diameter values to be averaged is applied at "AverageValue". Only the current diameters, which have been calculated internally and

34 28/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Required hardware Required firmware Required software Required parameterization for MLC control which are within the limits of "HighLimitDiameter" and "LowLimitDiameter", contribute to generating the average value. Values which are outside these limits are discarded. Values between 1 and 10 are appropriate for "Average Value". For this reason, "AverageValue" is limited to a maximum of 30. If a higher value is entered, "AverageValue" is limited to 30. The higher the number selected, the more precise is the diameter calculated. However, the accuracy of the diameter will be reduced with increasing values for "AverageValue", as this will be adjusted due to "filtering". Thus, the value for "AverageValue" should be selected appropriately. With smaller winding diameters, the variation in the diameter values calculated will be higher. For this reason, the value of the filter should not be too high. Otherwise, the lag of the diameter calculated, caused by the averaging, would result in a distinct "lag" of the diameter calculated. With a winder with dancer, for example, this can result in an undesired displacement of the dancer. Calculation of the Moment of Inertia With the help of the inputs "Webwidth" and "Density", the moment of inertia of the winder will be calculated internally in the diameter calculator and displayed at the output "CurrentInertia". With the help of the moment of inertia depending on the diameter, an adaptation of the K P gain of the speed loop (S ) can be implemented in the PLC project in IndraLogic if required. Preparation of a Splice Finally, the inputs "MinDiameter" and "MaxDiameter" can be set. The variables which are specified here affect the outputs "MinAvDiamAchieved" and "Max AvDiamAchieved" and display a message if the calculated current winding diameter exceeds the specified limits. The respective values should be within the admissible diameter range, defined by the inputs "HighLimitDiameter" and "LowLimitDiameter". Thus, the time for specific process steps, for example, for a splice or the adjustment of the "DiamCalcRange" input, can be detected and displayed in the SPS, on the basis of the specification of the minimum/maximum diameter. MLC hardware CML65 IndraDrive C or M MLC firmware CML65s-MLs-09 or higher Drive firmware MPX05V12 or MPX06 IndraWorks MLC or MLD The interpolation in the drive has to be activated for the winding axis. ((Real axes Corresp. axis Properties) The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The Parameter P , Gear ratio fine adjustment, process controller has to be entered in the cyclical SERCOS channel of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear.

35 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 29/190 Required parameterization for MLD control Error Handling ErrorID Additional1 Additional2 Text The standstill window of the reference axis should be set at as low a value as possible (e.g. 0.1 rpm). When there is a standstill message from the reference axis, the diameter calculator does not calculate! Interpolation has to be activated in the drive for the winding axis when using the MLD-S controller with a higher-order MLC controller (Real axes Corresp. axis Properties). This setting does not occur when using MLD-M control. The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The Parameter P , Fine adjustment gear ratio, process controller has to be entered in the cyclical channel between the controller and drive of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. (The dialog box is in the project tree below the MLD node AxisData.) An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear. The standstill window of the reference axis should be set at as low a value as possible (e.g. 0.1 rpm). When there is a standstill message from the reference axis, the diameter calculator does not calculate! The following table lists and describes the error codes of the function block. Error codes from "F_RELATED table (16#0170)" are used. In addition, the error codes of the MB_GetCyclicParameterHandle function block from the library ML_TechBase.library or MX_Technologie06.lib library can occur. STATE_MACHINE_ERROR 16# #0020 Error in the state machine 16# #0001 HighLimitDiameter < LowLimitDiameter 16#0002 FormatLength < #0003 WebWidth < #0004 Density < #0005 Core diameter < #0006 DiamCalcRange < #0007 Preset diameter < #0008 Minimum diameter < #0009 Maximum diameter < #000A HighLimitDiameter < #000B LowLimitDiameter < #000C DiamCalcMode invalid 16#000D Number of slave axis wrong 16#000E Number of master axis wrong DEVICE_ERROR 16# #0001 No operating mode (no SERCOS phase 4) RESSOURCE_ERROR 16# #0000 Wrong drive firmware RESSOURCE_ERROR 16#000F 16#0003 Drive functional package "MA" not activated Fig.3-19: RMB_TechWinder.library Error codes of the function block MB_DiameterCalculatorType03

36 30/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Commissioning of the Diameter Calculator The following steps are advisable for commissioning of the diameter calculator: Specify the fabric web variables, Specify the winding variables, Specify the cyclically variable inputs, Specify the inputs for manipulation of the diameter calculation and Further specifications. Specify the fabric web variables The fabric web variables refer to the inputs and values, which are related to the dimensions of the fabric web and which can normally be considered as constant values during operation. Exceptions to this are webs of fabric with variable materials or variable dimensions. The following inputs describe fabric web variables: "FormatLength", "Webwidth" and "Density". Since these variables are not read on a cyclical basis, they have to be applied as input values at the inputs prior to activation of the function block. Specify the winding variables Winding variables describe the spatial and general dimensions of the winder. These are the core diameter "CoreDiameter" and the maximum and minimum permissible winding diameter "LowLimitDiameter" and "HighLimitDiameter". With the help of the ratio of the speed of the reference axis and the speed of the winding axis, the current diameter can be determined with the core diameter. The current diameter "CurrentDiameter" is limited to these defined limits. Specify the cyclically variable inputs At the beginning and during the calculation of the diameter, it may be necessary to set the value of the diameter manually. To this end, the "PresetDiameter" input is described. It is read on a cyclical basis and thus becomes effective within a cycle. Specify the inputs for manipulation of the diameter calculation The method for calculation of the diameter is implemented in such a way that the result of the calculation can be influenced with the aid of two inputs of the function block. "AverageValue" specifies the number of diameter values which are to be used for averaging. "DiamCalcRange" allows the frequency of the calculation to be influenced, which, in turn, has an influence on the accuracy of the diameter value. Both variables can be manipulated and adjusted during operation since they are read and processed on a cyclical basis. Further specifications Depending on the respective application, the inputs "DancerConstant", "Feed BackDancer" (both only for a winder with dancer), "MinDiameter" and "Max Diameter" will be connected. If these inputs are not required for the functions to be implemented in the SPS project, it is recommended that the same values are applied to the inputs "MinDiameter" and "MaxDiameter" as to the inputs "LowLimitDiameter" and "HighLimitDiameter". Doing so avoids a corresponding error message.

37 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 31/190 Commanding the winding axis The correct operating mode of the drive and the controller enable of the drive have to be set for the winding axis. This can be done in two different ways: Set the "ModeSyncVel" operating mode by means of the axis interface (recommended). Use the PLC-Open "MC_Power", "MC_GearIn", "MC_Stop" function blocks to command the axis. 3.4 Function Block to Record an Externally Measured Diameter Introduction and Overview MB_DiameterMeasurementType01 Short description Interface Description The MB_DiameterMeasurementType01 function block reads a measured diameter and adapts the velocity of the winding drive accordingly. In this case it then replaces the function block MB_DiameterCalculatorType03. It will be used in the function blocks "MB_WinderDancerCtrlType01" and "MB_WinderTensionCtrlType02". The function calculates and reads a measured diameter and calculates the velocity adaptation for the winding axis and the current moment of inertia of the winding material on a winder. The function block is called up for every winding axis, where the diameter is measured. Cyclic output variables are the resulting gear fine adjustment for the associated winding driver "GearRatioFineAdjust" and the current moment of inertia of the winding material "CurrentInertia". The fine adjustment of the gear "GearRatioFineAdjust" influences the parameter P , Gear ratio fine adjustment, process controller. This parameter is entered in the corresponding cyclical SERCOS channel. Parameterization is carried out in parameterization mode. Fig.3-20: Name Type Comment MB_DiameterMeasurementType01 function block interface VAR_IN_OUT Slave AXIS_REF Reference to the slave axis VAR_INPUT Enable BOOL Process enabling of the function block (level-controlled) Pause BOOL FB paused, gear fine adjustment remains "frozen" RMB_TechWinder.library

38 32/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Comment DisableCyclicWrites BOOL When this input is set, the cyclical data is not written directly into the optional cyclical data container, but only displayed at the output. MeasuredDiameter REAL Measured diameter [mm] Format length REAL Format length [mm] (1 revolution of the master axis unwound) MinDiameter REAL Minimum diameter [mm], MaxDiameter REAL Maximum diameter [mm], WebWidth REAL Web width [mm] Density REAL Material density [kg/dm 3 ] is only used by the "MinAvDiamAchieved" output for display purposes. is only used by the "MaxAvDiamAchieved" output for display purposes. AverageValue UINT Number of diameter values averaged. The input is limited to a maximum of 30. HighLimitDiameter REAL Upper limit for the diameter [mm] The diameter is limited to this value. LowLimitDiameter REAL Lower limit for the diameter [mm] The diameter is limited to this value. CoreDiameter REAL Core diameter of the winder [mm] VAR_OUTPUT InOperation BOOL Block is working Error BOOL Processing completed with error ErrorID ErrorIdent ERROR_ CODE ERROR_STR UCT Description of the diagnostics in case of error Error code, page 34 InPause BOOL Dancer controller pausing MinAvDiamAchieved BOOL Minimum diameter reached (based on the averaged diameter) MaxAvDiamAchieved BOOL Maximum diameter reached (based on the averaged diameter) HighLimitActive BOOL Current calculated diameter has reached the upper limit (Diameter value is discarded). LowLimitActive BOOL Current calculated diameter has reached the lower limit (Diameter value is discarded). GearRatioFineAdjust REAL Fine gear adjustment for speed adaptation of the drive [%] CurrentInertia REAL Current total moment of inertia Fig.3-21: (based on the motor side) [kg/m 2 ]. MB_DiameterMeasurementType01 function block interface description

39 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 33/190 Minimum, maximum and default values of the inputs Name Type Min. value Max. value Default value Transfer Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous DisableCyclicWrites BOOL FALSE Rising edge at Enable MeasuredDiameter REAL > 0.0 Not defined Continuous Format length REAL > 0.0 Not defined Rising edge at Enable MinDiameter REAL > 0.0 Not defined Continuous MaxDiameter REAL > 0.0 Not defined Continuous Webwidth REAL 0.0 Not defined 0.0 Rising edge at Enable Density REAL 0.0 Not defined 1.0 Rising edge at Enable AverageValue UINT Continuous HighLimitDiameter REAL 0.0 Not defined Continuous LowLimitDiameter REAL 0.0 Not defined Continuous CoreDiameter REAL 0.0 Not defined Rising edge at Enable Signal-time diagram Functional Description Required hardware Fig.3-22: Fig.3-23: Default value of the MB_DiameterMeasurementType01 Signal-time diagram for selected inputs and outputs of the function block MB_DiameterMeasurementType01 The function block MB_DiameterMeasurementType01 reads a measured diameter value (e.g. by means of an ultra-sound sensor) and ensures the correct velocity adjustment of the respective winding axis based on the diameter measured. The FB is used in the FBs MB_WinderDancerCtrlType01, page 35, and MB_WinderTensionCtrlType02, page 44,. The ratio of "Format length" / "CoreDiameter" should not be greater than 25. Otherwise the gear adjustment will not be sufficiently greater than the gear fine adjustment! MLC hardware CML65 RMB_TechWinder.library

40 34/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Required firmware Required software Required parameterization for MLC control Required parameterization for MLD control Error Handling IndraDrive C or M MLC firmware CML65s-MLs-09 or higher Drive firmware MPX05V12 or MPX06 IndraWorks MLC or MLD The interpolation in the drive has to be activated for the winding axis. ((Real axes Corresp. axis Properties) The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The Parameter P , Gear ratio fine adjustment, process controller has to be entered in the cyclical SERCOS channel of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear. Interpolation has to be activated in the drive for the winding axis when using the MLD-S controller with a higher-order MLC controller (Real axes Corresp. axis Properties). This setting does not occur when using MLD-M control. The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The Parameter P , Fine adjustment gear ratio, process controller has to be entered in the cyclical channel between the controller and drive of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. (The dialog box is in the project tree below the MLD node AxisData.) An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear. The following table lists and describes the error codes of the function block. Error codes from "F_RELATED table (16#0170)" are used. In addition, the error codes of the MB_GetCyclicParameterHandle function block from the library ML_TechBase.library or MX_Technologie06.lib library can occur. ErrorID Additional1 Additional2 Text STATE_MACHINE_ERROR 16# #0020 Error in the state machine 16# #0001 HighLimit < LowLimit 16# #0002 FormatLength < # #0003 Webwidth < # #0004 Density < # #0005 Core diameter < # #0008 MinDiameter < # #0009 MaxDiameter < 0.0

41 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 35/190 ErrorID Additional1 Additional2 Text 16# #000A High limit < # #000B Low limit < # #000C DEVICE_ERROR 16# #0001 Slave axis number wrong No operating mode (no SERCOS phase 4) RESSOURCE_ERROR 16# #0000 Wrong drive firmware RESSOURCE_ERROR 16#000F 16#0003 Fig.3-24: 3.5 Diameter Calculator with Dancer Introduction and Overview Drive functional package "MA" not activated Error codes of the function block MB_DiameterMeasurementType02 The diameter calculator with dancer is used on center winders. The tension will be specified by a force which acts upon the movable part of the dancer. This force can be applied by a weight, a spring or a pneumatic element. The closed loop control of the dancer position is performed in the dancer position controller. The actual value of the dancer position will be recorded, for example by an analog channel, and will be transferred to the control. The current winding diameter is calculated by an internally connected diameter calculator. The velocity of the winding axis will be adjusted with the help of the calculated winding diameter. Thus, the calculated winding diameter replaces an actual diameter recorded via a sensor system. The diameter calculator with dancer thus represents a combination of a winder (represented by the winding axis and the diameter calculator) and a dancer position controller. The diameter calculator influences the fine adjustment of the gear and the dancer position controller influences the additive speed command value. Fig.3-25: MB_WinderDancerCtrlType01 RMB_TechWinder.library Principle of the diameter controller with dancer position controller Function block for winders with dancer (consisting of MB_DancerControl Type03, page 16, and MB_DiameterCalculatorType03, page 23).

42 36/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Fig.3-26: MB_WinderDancerCtrlType01 Name Type Comment VAR_IN_OUT Master AXIS_REF Reference to the master axis Slave AXIS_REF Reference to the slave axis (winding axis) VAR_INPUT Enable BOOL Process enabling of the function block (levelcontrolled) PauseDiameter BOOL Diameter calculator paused; no further measurement of diameter and velocity adjustment (level-controlled). PauseDancer BOOL Dancer controller paused (level-controlled) DisableCyclicWrites BOOL When this input is set, the cyclical data is not written directly into the optional cyclical data container, but only displayed at the output. PresetDiameter BOOL CurrentDiameter is set to PresetVal, GearRatioFineAdj is adjusted accordingly (edge-controlled) ControlPolarity BOOL Polarity of the closed loop dancer control is inverted (applied in case of pos. edge at Enable) SetpointDancer REAL Command value for the closed loop dancer control FeedbackDancer REAL Actual value (feedback) for dancer position WindowDancer REAL Window for monitoring the actual dancer position value [%] based on the command dancer position value. If the dancer position deviates from the command value by more than the given value, the function block reports this deviation by resetting the "InWindow" output. DancerLimits MB_WIND_DANCER_LIMITS MB_WIND_DANCER_LIMITS, page 68,: Structure for the automatic actual variable limitation of the dancer

43 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 37/190 Name Type Comment PControl REAL Value for the Kp-gain of the closed loop dancer control IControl TIME Value for the integral action time of the closed loop dancer control DControl TIME Value for the derivative time of the closed loop dancer control MinDancerFeedback REAL Lower threshold for the actual dancer value (only for display with a binary output). MaxDancerFeedback REAL Upper threshold for the actual dancer value (only for display with a binary output). Diameter MB_WIND_DIAMETER MB_WIND_DIAMETER, page 70 Structure for the diameter calculator VAR_OUTPUT InOperation BOOL Block is working Error BOOL Processing completed with error ErrorID ERROR_ CODE Description of the diagnostics in case of error ErrorIdent ERROR_STRUCT Detailed diagnosis InPauseDancer BOOL Dancer controller pausing InPauseDiam BOOL Diameter calculation paused PresetDiamAck BOOL Preset diameter is applied (is set providing Preset is pending) MinAvDiamAchieved BOOL Minimum diameter reached (based on the averaged diameter) MaxAvDiamAchieved BOOL Maximum diameter reached (based on the averaged diameter) HighLimitDiamActive BOOL Current calculated diameter has reached the upper limit (Diameter value is discarded) LowLimitDiamActive BOOL Current calculated diameter has reached the lower limit (diameter value is discarded). InWindowDancer BOOL Actual dancer value within the dancer window MinFeedbackAchieved BOOL Actual value of the dancer position is below the input MinDancerFeedback MaxFeedbackAchieved BOOL Actual value of the dancer position is above the input MaxDancerFeedback CurrentDiameter REAL Current winding diameter RMB_TechWinder.library GearRatioFineAdjust REAL Fine gear adjustment for speed adaptation of the drive [%] CurrentInertia REAL Current moment of inertia of the winding material + mechanism (based on the motor side) [kg/m 2 ]

44 38/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Comment AddVelocityDancer REAL Speed offset for the winding drive [rpm] CurrentDancerDeviation REAL Current control deviation of the dancer controller Fig.3-27: Name Type Min. value Max. value Default value MB_WinderDancerCtrlType01 function block interface description Transfer Enable BOOL FALSE Continuous PauseDiameter BOOL FALSE Continuous PauseDancer BOOL FALSE Continuous DisableCyclicWrites BOOL FALSE Rising edge at Enable PresetDiameter BOOL FALSE Continuous ControlPolarity BOOL FALSE Rising edge at Enable SetpointDancer REAL 0.0 Not defined 0.0 Continuous FeedbackDancer REAL Not defined Not defined 0.0 Continuous WindowDancer REAL 0.0 Not defined 0.0 Continuous DancerLimits STRUCT PControl REAL 0.0 Not defined 0.0 Continuous IControl TIME 0s Not defined 0s Continuous DControl TIME 0s Not defined 0s Continuous MinDancerFeedback REAL 0.0 MaxDancer Feedback REAL MaxDancerFeedback MinDancerFeedback 0.0 Continuous Not defined 0.0 Continuous Diameter STRUCT depending on the structural element Functional Description Fig.3-28: Diameter calculation Default values of the MB_WinderDancerCtrlType01 The diameter calculation provides the current calculated diameter via the "ML_DiameterCalculatorType03" function block, which is called up cyclically. The additive fine adjustment of the winding axis will be set depending on the diameter. The axis will be moved faster or more slowly in comparison to the reference axis to achieve a constant tension of the web of fabric. A relative movement of the dancer roll will be taken into account in the diameter calculation with the help of the input "DancerConstant". For this purpose, this dancer constant has to be determined once. The following procedure is recommended: 1. Where there is deflection of the dancer from one end position to the other end position, determine the path of the web path (in mm). 2. Determine the difference between both actual dancer values of the respective end position. 3. Calculate the quotients of both values. 4. Determine the prefix of the dancer constant by conducting a practical test. The diameter calculation process will be observed with a slowly rotating

45 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 39/190 winding axis and reference axis for this purpose. Adjustments of the command value to the command dancer value should not have a significant influence on the calculation of the diameter if the prefix is correct. 5. "Subsequently optimize" the calculated value for the dancer constant, as described in step 4 (if required). Splice If the current diameter is to be retained after the controller is switched off, the "CurrentDiameter" output has to be copied again to a remaining variable. When the controller is switched on again, a preset can be performed again with this value. After a splice, the winding diameter generally changes abruptly. The last calculated internal value for the winding diameter then no longer corresponds to the current diameter. To make the diameter calculation function correctly, a preset of the winding diameter may be appropriate. The input value for the Preset should correspond approximately to the actual value of the winding diameter in order to achieve as accurate a resulting fine adjustment as possible. If preset is not performed, this may result in malfunctions. Thus, the preset should be performed before activating the diameter calculator. With a flying splice, it must be ensured that the circumferential velocity of the new roll corresponds to the current one. This has to be ensured with an appropriate SPS project in IndraLogic. The "Pause" input can be used when activating the diameter calculator for the new roll, for example "Pause" can be disabled after having removed the old roll. Closed loop dancer position control To determine the dancer position, a measuring device is required, which converts the dancer position into a proportional signal. The actual position of the dancer will be subtracted from a given command value and specified as a control deviation on an internal PID controller. The control variable of the controller acts upon the speed command value by adding this value. Thus, the winding axis rotates faster or slower compared with the master axis. The tension of the dancer is thereby controlled. Under normal conditions (e. g. no high variations of the speed command value or abrupt changes in the diameter of the winder), the approximate adjustment of the circumferential velocity of the winding axis is performed by the fine adjustment of the gear. The diameter calculator described previously will be used for this. The dancer position controller therefore only has to control small deviations. Functional diagram of the dancer position controller RMB_TechWinder.library The following functional diagram explains the functions of the diameter calculator with dancer diagrammatically.

46 40/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Required hardware Required firmware Required software Required parameterization for the MLC control Fig.3-29: MLC hardware CML65 IndraDrive C or M Functional diagram of the diameter calculator with dancer MLC firmware CML65s-MLs-09 or higher Drive firmware MPX05V12 or MPX06 IndraWorks for MLC or MLD The interpolation in the drive has to be activated for the winding axis. (Real axes Corresp. axis Properties) The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The parameter P , Gear ratio fine adjustment, process controller and parameter P , Additive velocity command value, process controller) have to be entered in the cyclical SERCOS channel of the corresponding drive

47 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 41/190 Required parameterization for the MLD control Error Handling ErrorID Additional1 Additional2 Text ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear. The standstill window of the reference axis should be set at as low a value as possible (e.g. 0.1 rpm). When there is a standstill message from the reference axis, the diameter calculator does not calculate! Interpolation has to be activated in the drive for the winding axis when using the MLD-S controller with a higher-order MLC controller (Real axes Corresp. axis Properties). This setting does not occur when using MLD-M control. The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The parameter P , Gear ratio fine adjustment, process controller and parameter P , Additive velocity command value, process controller) have to be entered in the cyclical SERCOS channel of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. The real axes are parameterized in IndraWorks in parameterization mode. (The dialog box is in the project tree below the MLD node AxisData.) An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear. The standstill window of the reference axis should be set at as low a value as possible (e.g. 0.1 rpm). When there is a standstill message from the reference axis, the diameter calculator does not calculate! The following table lists and describes the error codes of the function block. Error codes from "F_RELATED table (16#0170)" are used. Additionally, the error codes of the function blocks MB_DancerControlType03, page 16, and MB_DiameterCalculatorType03, page 23 and the FB IL_PIDType01 from the library RIL_LoopControl.library and MB_GetCyclicParameterHandle from the library ML_TechBase.library bzw. MX_Technologie06.lib can occur. STATE_MACHINE_ERROR 16# #0020 Error in the state machine Fig.3-30: Error codes of the function block MB_WinderDancerCtrlType Commissioning the Diameter Calculator with Dancer Commanding the winding axis This section describes the commissioning of a diameter calculator with dancer. For this purpose, the following steps are appropriate: Parameterization of the dancer position controller, Parameterization of the diameter calculator and Initial startup of the winding axis. The correct operating mode of the drive and the controller enable of the drive have to be set for the winding axis. This can be done in two different ways: Set the "ModeSyncVel" operating mode by means of the axis interface (recommended). Use the PLC-Open "MC_Power", "MC_GearIn", "MC_Stop" function blocks to command the axis. Parameterization of the dancer position controller RMB_TechWinder.library

48 42/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Since the function of the diameter calculator with dancer is built up on the function of the dancer position controller, the parameterization of the dancer position controller can be performed as described under Introduction and Overview, page 14,. Parameterization for the diameter calculator The individual inputs of the diameter calculator ML_DiameterCalculatorType02 will be activated, as described before. A number of special aspects have to be taken into account when commissioning the diameter calculator with dancer. Due to the parameterization of the dancer position controller, the inputs "FormatLength" and "FeedBackDancer" of the diameter calculator have been preset. Another variable, which affects the the dancer is the dancer constant "Dancer constant". This specifies which path the full displacement of the dancer takes from negative to positive end, based on the unit of dancer adjustment. The "ReferenceDiameter" input should be linked to the current calculated diameter "CurrentDiameter". Since the calculated diameter directly affects the velocity of the winding axis via the resulting fine adjustment, a meaningful value has to be preset for the diameter prior to the start of the calculation when activating the diameter calculator. Thus, a diameter value, which is close to the actual diameter, has to be specified at the "PresetDiameter" input. With a rewinder, the value can be slightly lower and slightly higher with an unwinder. Finally, the inputs "MinDiameter" and "MaxDiameter" can be set. The variables specified here act on the outputs "MinAvDiamAchieved" and "MaxAvDiamAchieved". The respective values should be within the admissible diameter range, defined by the inputs "HighLimitDiameter" and "LowLimitDiameter". Thus, the time for specific process steps, for example, for a splice or adjustment of the "DiamCalcRange", can be detected and displayed in the SPS, based on the specification of the minimum/maximum diameter. The ratio of "Format length" / "CoreDiameter" should not be greater than 25. Otherwise the gear adjustment will not be sufficiently greater than the gear fine adjustment! Initial start-up of the winding axis The dancer position controller and the diameter calculator are activated one after the other. After having activated the closed loop dancer position control, the dancer moves to its command position. As described before, this position should correspond to the central position of the dancer. The angle positions of the winding axis and the reference axis will be added together and, depending on the value of the "DiamCalcRange" input, the diameter will be regularly calculated and displayed as the current diameter value at the "CurrentDiameter" output. After having activated the diameter calculator, "CurrentDiameter" initially displays the zero value until a diameter has been calculated for the first time. A preset has to be performed if another value, apart from zero, is used. The value "PresetDiameter" is applied as the current diameter value when there is a positive edge at "Preset". The period between two calculations depends on the speed of the winding axis and the reference axis. The axis, which last exceeds the angle of "DiamCalcRange", specifies the time at which the diameter will be calculated. Depending on the ratios, the reference axis will therefore be more decisive with small winders (high winding axis speed). This can be the opposite with large winders.

49 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 43/190 The diameter calculator affects the fine adjustment of the gear. The respective value is displayed at the "GearRatioFineAdjust" output. 3.6 Diameter Calculator with Open Loop and Closed Loop Tension Control Introduction and Overview The function block provides two different diameter calculators: Diameter calculator with open loop tension control corresponding to a diameter calculator without sensor, Diameter calculator with closed loop tension control corresponding to a diameter calculator with load cell The diameter calculators are implemented in the ML_WinderTensionCtrl Type02 function block. The function block cyclically calculates the current winding diameter, the current moment of inertia of the winder, the corresponding velocity adaptation via the fine adjustment of the gear, an additive speed offset for tensioning the web of fabric and the required torque limit. Diameter calculator with open loop tension control The diameter calculator with tension control is used on center winders. The drive of the winding axis generally operates at its torque limit. The torque limit depends on the current winder diameter and the tension that has been set. Tension control will be generated by setting the torque of the winding axis. Additional measuring elements are not required. Fig.3-31: The winding material can be wound up or wound off from the top and from the bottom. Thus, the direction of rotation of the drive axis should be observed and adjusted when implementing the diameter calculator. This has to be set accordingly using the scaling parameters of the drive. Diameter calculator with open loop tension control Diameter calculator with closed loop tension control RMB_TechWinder.library The diameter calculator with closed loop tension control is used on center winders. The drive of the winding axis generally operates at its torque limit. The torque limit depends on the current winder diameter and the tension that has been set. The torque limit corresponds to the value of the motor torque which is required to rotate the winder with the defined speed. It comprises the load torque, the friction torque and the acceleration torque.

50 44/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Tension control is provided as a PI controller. This includes the function block IL_PIDType01 from the ML_TechCommon.lib library. The actual variable of the controller and the current winding diameter determine the torque limited value of the drive. The command value of the tension should also be scaled and transferred to the controller output (PreControlWeighting not equal to zero). When the scaling is not equal to zero, the tension for the torque configuration consists of the controller output variable added to the scaled command value. Scaling equal to zero means that only the tension controller is active. Thus, the tension controller should only be operated additively (e. g. with a scaling of 1.0). The actual value of the tension will be measured directly with the help of a load cell and transferred to the tension controller as an actual value via an analog channel or via a field bus. With a tensioned web, the diameter calculator can calculate the current winding diameter. Fig.3-32: MB_WinderTensionCtrlType02 Short description The winding material can be wound up or wound off from the top and from the bottom. Thus, the direction of rotation of the drive axis should be observed and adjusted when implementing the diameter calculator. This has to be set accordingly using the scaling parameters of the drive. Diameter calculator with closed loop tension control The function block cyclically calculates the current winding diameter, the current moment of inertia of the winder, the corresponding velocity adaptation via the fine adjustment of the gear, an additive speed offset for tensioning the web of fabric and the required torque limit. Target variables of the function block are the parameters P ,Gear ratio fine adjust, process loop, P , Additive velocity command value, process loop and S , Bipolar torque/force limit value. These parameters have to be incorporated in the cyclical data containers of the MLC.

51 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 45/190 Interface Description Fig.3-33: MB_WinderTensionCtrlType02 Name Type Comment VAR_IN_OUT Master AXIS_REF Reference to the master axis Slave AXIS_REF Reference to the slave axis (winding axis) VAR_INPUT Enable BOOL Process enabling of the function block (levelcontrolled) Pause BOOL Pausing the tension controller and the winding calculator (values will be frozen) DisableCyclicWrites BOOL When this input is set, the cyclical data is not written directly into the optional cyclical data container, but only displayed at the output. WindCtrlType MB_WIND_CTRL_TYPE MB_WIND_CTRL_TYPE, page 68 Winding structure Open loop tension control (without sensor): OPEN_LOOP (16#0000) Open loop tension control (load cell): CLOSED_LOOP (16#0001) WindDirection MB_WIND_DIRECTION MB_WIND_DIRECTION, page 71 Winding direction Rewinder REWIND (16#0000) Unwinder UNWIND (16#0001) RMB_TechWinder.library PauseDiameter BOOL Pausing the diameter calculation Feedback/control of the torque limit remains active PresetDiameter REAL CurrentDiameter is set to PresetVal, GearRatioFineAdj is adjusted accordingly (edge-controlled).

52 46/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Comment TensionMode MB_WIND_TENSION_MODE MB_WIND_TENSION_MODE, page 73 Mode for tensioning the material web Tensioning with a constant speed CONST_SPEED (16#0000) Tensioning with a constant web velocity CONST_WEB_VEL (16#0001) SetpointStandstill REAL Specification of the standstill tension [N] (Changeover between standstill tension and operating tension by means of the standstill message from the drive). SetpointOpMode REAL Specification of the operating tension [N] (Changeover between standstill tension and operating tension by means of the standstill message from the drive). TensionSpeed REAL Tensioning speed in the case of an empty winder [min -1 ] ActTorqueFilter TIME Filter time constant for the actual torque S "Torque/force feedback value" AccelTorqueFilter TIME Filter time constant for the acceleration torque DefaultTorqueLimit REAL Value for the bipolar torque limit after deactivation of "Enable" [%] WindowTension REAL Window for the actual tension value [%] in relation to the command tension value MinTension REAL Lower threshold for the actual tension value (only for a display with binary output "MinTensionAck") MaxTension REAL Upper threshold for the actual tension value (only for a display with binary output "Max TensionAck") Diameter MB_WIND_DIAMETER MB_WIND_DIAMETER, page 70 Structure for the diameter calculator TensionCtrl MB_WIND_TENSION MB_WIND_TENSION, page 72 Structure for tension controller Friction MB_WIND_FRICTION MB_WIND_FRICTION, page 72 Structure for the friction torque VAR_OUTPUT InOperation BOOL Block is working Error BOOL Processing completed with error ErrorID ERROR_ CODE Description of the diagnostics in case of error ErrorIdent ERROR_STRUCT Error handling, page 56 InPause BOOL Tension controller and diameter calculator paused PresetDiamAck BOOL Preset diameter was applied (is set providing Preset is pending) InPauseDiam BOOL Diameter calculator paused MinAvDiamAchieved BOOL Minimum diameter reached (based on the averaged diameter)

53 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 47/190 Name Type Comment MaxAvDiamAchieved BOOL Maximum diameter reached (based on the averaged diameter) HighLimitDiamActive BOOL Current calculated diameter has reached the upper limit (diameter value is discarded). LowLimitDiamActive BOOL Current calculated diameter has reached the lower limit (diameter value is discarded). DiameterEngaged BOOL Diameter "engaged" TRUE: engaged FALSE: disengaged HighLimitTensActive BOOL Output of the tension controller has reached its upper limit. LowLimitTensActive BOOL Output of the tension controller has achieved its lower limit TensionInWindow BOOL Actual tension value is within the tension window. MinTensionAchieved BOOL Tension is below the "MinTension" input MaxTensionAchieved BOOL Tension is below the "MaxTension" input CurrentDiameter REAL Current calculated diameter [mm] GearRatioFineAdjust REAL Resulting fine adjustment of the gear for speed adaptation of the drive [%] CurrentInertia REAL Current moment of inertia of the winding material + mechanism (based on the motor side [kg/m 2 ] SpeedOffset REAL Tensioning speed [rpm] TorqueLimitBiploar REAL Bipolar torque limit [%] WindTensDiag MB_WIND_TENS_DIAG MB_WIND_TENS_DIAG, page 73 Structure of the current control deviation of the dancer controller Fig.3-34: Name Type Min. value MB_WinderTensionCtrlType02 function block interface description Max. value Default value Transfer Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous DisableCyclicWrites BOOL FALSE Rising edge at Enable WindCtrlType MB_WIND_CTRL_TYPE FALSE Rising edge at Enable WindDirection MB_WIND_DIRECTION FALSE Rising edge at Enable PauseDiameter BOOL FALSE Continuous PresetDiameter REAL FALSE Continuous TensionMode MB_WIND_TENSION_MODE FALSE Rising edge at Enable SetpointStandstill REAL 0.0 Not defined SetpointOpMode REAL Not defined Not defined 0.0 Continuous 0.0 Continuous RMB_TechWinder.library

54 48/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Min. value Max. value TensionSpeed REAL 0.0 Not defined ActTorqueFilter TIME 0s Not defined AccelTorqueFilter TIME 0s Not defined DefaultTorqueLimit REAL 0.0 Not defined WindowTension REAL 0.0 Not defined MinTension REAL 0.0 Not defined MaxTension REAL 0.0 Not defined Default value Transfer 0.0 Continuous 0s 0s Continuous Continuous Continuous 0.0 Continuous 0.0 Continuous 0.0 Continuous Diameter MB_WIND_DIAMETER depending on the structural element TensionCtrl MB_WIND_TENSION depending on the structural element Friction MB_WIND_FRICTION depending on the structural element Signal-time diagram Functional Description Fig.3-35: Default values of the MB_WinderTensionCtrlType02 The following signal-time diagram represents selected function block signals. When there is a positive edge at the "Enable" input, which will be signalized at the "InOperation" output, the function block will be activated. Operational readiness can be interrupted by an error, which is signalized at the "Error" output. The internal controller process can be paused by the "Pause" input. "Pause" is signalized at the "InPause" output. The output "CurrentDiameter" will be configured with a preset value ("PresetVal" input in the structure MB_WIND_DI AMETER) via a positive edge at the "PresetDiameter" input, independently of the "Pause" input. However, it is recommended to activate the function block in "Pause". By doing so, the diameter preset can be performed in a more controlled way. Setting the diameter is displayed at the output "PresetDiamAck". Fig.3-36: Signal/time diagram for selected inputs and outputs of the function block ML_WinderTensionCtrlType01 Diameter calculator with open loop tension control, scope of functions

55 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 49/190 The functional scope of the diameter calculator with open loop tension control includes: Tensioning of the untensioned winding material, Friction compensation depending on the speed Compensation of acceleration torque, Separate parameterization of the operating tension and the standstill tension Calculation of diameter-dependent variables (using the ML_DiameterCalculatorType03 function block). RMB_TechWinder.library Functional diagram of the winder calculator with open loop tension control The following functional diagram explains the functions of the diameter calculator with open loop tension control diagrammatically.

56 50/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Fig.3-37: Functional diagram of the winder with open loop tension control Diameter calculator with closed loop tension control, scope of functions The scope of functions of the diameter calculator with closed loop function control includes: Tensioning of the untensioned winding material, Friction compensation depending on the speed Compensation of acceleration torque, Separate parameterization of the operating tension and the standstill tension,

57 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 51/190 PI controller for tension (via IL_PIDType01) and Calculating diameter-dependent variables (via MB_DiameterCalculator Type03). Functional diagram of the winder calculator with closed loop tension control The following functional diagram explains the functions of the diameter calculator with closed loop tension control diagrammatically. Fig.3-38: Functional diagram of the winder with closed loop function control Polarity of the master axis, rewinder/unwinder RMB_TechWinder.library

58 52/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library With the help of an input of the function block, the winder type is set to a rewinder or unwinder type. The direction of rotation of the drive either has to be set by the scaling parameters or by the polarity of the master drive. The following figure shows the principal relations between rewinders. Fig.3-39: Diameter calculation Principles of rewinders and unwinders The torque for the winding drive results from the product of the tension and the winding radius. The radius or the diameter of the winder therefore has to be continually determined. An internal diameter calculator (function block MB_DiameterCalculatorType03 from the RMB_TechWinder.lib library) is always incorporated in the function block. The diameter calculation will only become active when the winding material is tensioned and will be performed cyclically depending on the speed or the position of the winding axis. For diagnostic purposes, the current diameter can be read on the function block. The calculated winding diameter directly influences the resulting fine adjustment of the gear. If the web tension is too low or negative (formation of loops), the diameter calculator will be interrupted since no useful diameter calculation can be performed any longer under these circumstances. If the actual torque of the drive is more than 25 % below the command value, the diameter calculator stops calculating (engaging condition). If the current diameter is to be retained after the controller is switched off, the "CurrentDiameter" output has to be copied again to a remaining variable. When the controller is switched on again, a preset can be performed again with this value. The ratio of "Format length" / "CoreDiameter" should not be greater than 25. Otherwise the gear adjustment will not be sufficiently greater than the gear fine adjustment! Tensioning the winding material When enabling the winding calculator ("Enable" = TRUE), the winding material will initially be tensioned with the tensioning speed. To avoid the formation of loops in the winding material, the master axis should not be rotating. The winding material is tensioned if the torque command value of the drive exceeds a predefined limit and if the relative deviation between the torque command value and the actual torque value is lower than a defined limit. Two different procedures can be used for tensioning the winding material:

59 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 53/190 Tensioning with constant speed and Tensioning with constant web speed. When tensioning the winding material with constant speed, the tensioning speed is maintained on a constant level. Thus, the web velocity increases with an increasing winding diameter. Fig.3-40: Tensioning with constant tensioning speed When tensioning the winding material at a constant web velocity, the tensioning speed will be reduced reciprocally to the winding diameter. The calculation of the winding axis speed is based on the tensioning speed of an empty winder. This has to be applied in accordance with the function block. Fig.3-41: Friction compensation Tensioning with constant web speed RMB_TechWinder.library Different inputs are used to perform friction torque compensation. Friction behavior is approximately defined as follows:

60 54/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library The friction is initially reduced from the standstill friction torque up to a specific speed. Then the friction torque increases linear with the winding axis speed up to the maximum speed (S , Bipolar velocity limit value or A , Positive velocity limit value or A , Negative velocity limit value. This behavior is similar for negative speeds. The curve is reflected at the y axis (friction torque). With the help of this friction torque behavior, the effect of the friction can be counteracted by compensation. Fig.3-42: Friction torque compensation Compensation of acceleration torque Additional acceleration torque is required for the acceleration of the winding axis. This depends on the winding diameter. By specifying certain material and fabric web data, the inertia of the winder will be calculated according to the diameter. The calculated acceleration torque can also be filtered. Splice After a splice, the winding diameter generally changes abruptly. The last calculated internal value for the winding diameter then no longer corresponds to the current diameter. A preset of the winding diameter is required to make the diameter calculation function correctly. The input value for the preset should correspond approximately to the actual value of the winding diameter. If preset is not performed, this may result in malfunctions. The preset should therefore be completed before the diameter calculator becomes active again. The value for the preset should be selected as follows: In the case of a rewinder, it must be slightly smaller or equal to the actual winding diameter and in the case of an unwinder, it must be slightly higher or equal to the actual winding diameter. With a flying splice, it must be ensured that the circumferential velocity of the new roll corresponds to the current one. This should be performed correspondingly in the SPS project in IndraLogic. Filtering the actual torque value With low tensions, an unfiltered actual torque value can result in the diameter calculator disengaging. A filtering process should therefore be performed and

61 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 55/190 Required hardware Required firmware Required software Required parameterization for MLC control Required parameterization for MLD control the corresponding input should be activated. To this end, the actual torque value and command value of the drive will be compared to each other. Additional leading and lagging of the winding axis Additional leading or lagging via the fine adjustment of the gear(presetting fine adjustment "FineAdjust") can be set via the structure variable "qraxisctrl[axis Number].Admin.SyncMode.FineAdjust" of the data structure. MB_AXIS_SYNCHRONISATION of the ML_TechInterface.lib library will be set. With a rewinder, a low positive value (e. g. 5 %) should be set and a low negative value should be set with an unwinder. This results in improved start-up behavior of the respective winding direction. MLC hardware CML65 IndraDrive C or M MLC firmware CML65s-MLs-09 or higher Drive firmware MPX05 and MPX06 IndraWorks MLC The interpolation in the drive has to be activated for the winding axis. ((Real axes Corresp. axis Properties) RMB_TechWinder.library The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The parameter P , Gear ratio fine adjustment, process controller and parameter P , Additive velocity command value, process controller and S , Torque/force limit value bipolar have to be entered in the cyclical SERCOS channel of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode. An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear. The parameters A "Velocity limit value positive" and A "Velocity limit value negative" should be set in accordance with the maximum speed of the winding drive. (This value has to occur in the parameter S "Bipolar velocity limit value"). The standstill window of the reference axis should be set at as low a value as possible (e.g. 0.1 rpm). When there is a standstill message from the reference axis, the diameter calculator does not calculate! Interpolation has to be activated in the drive for the winding axis when using the MLD-S controller with a higher-order MLC controller (Real axes Corresp. axis Properties). This setting does not occur when using MLD-M control. The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The parameter P , Gear ratio fine adjustment, process controller and parameter P , Additive velocity command value, process controller and S , Torque/force limit value bipolar have to be entered in the cyclical SERCOS channel of the corresponding drive ("UserCmdDataA-D"). The real axes are parameterized in IndraWorks in parameterization mode.

62 56/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Error Handling The real axes are parameterized in IndraWorks in parameterization mode. (The dialog box is in the project tree below the MLD node AxisData.) An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear. The parameter S "Bipolar velocity limit value" should be set in accordance with the maximum speed of the winding drive. The standstill window of the reference axis should be set at as low a value as possible (e.g. 0.1 rpm). When there is a standstill message from the reference axis, the diameter calculator does not calculate! The following table lists and describes the error codes of the function block. Error codes from F_RELATED_Table (16#0170) are used. Additionally, the error codes of the function blocks IL_PIDType01 and MB_DiameterCalculator Type03, page 23, and MB_GetCyclicParameterHandle from the library ML_TechBase.library bzw. MX_Technologie06.library can occur. ErrorID Additional1 Additional2 Description STATE_MACHINE_ERROR 16# #20 Error in the state machine 16# #01 Diameter.MechanicInertia < # #02 TensionCtrl.PreControlWeighting < # #03 MaxTension < # #04 MaxTension < MinTension 16# #05 Friction.StandstillTorque < # #06 Friction.MaxTorque < # #07 Friction.MinTorque < # #08 Friction.MinVelocity < # #09 WindowTension < # #0A MinTension < # #0B MaxTension < # #0C Winding axis not in "BB" 16# #0D Wrong torque scaling (A ) Scaling for the motor torque has to be based on the motor side. 16# #0E Axis number of the slave axis incorrect 16# #0F Axis number of the master axis incorrect RESSOURCE_ERROR 16# #0000 Wrong drive firmware RESSOURCE_ERROR 16#000F 16#0003 Drive function package "MA" not activated Fig.3-43: Error numbers for the function block ML_WinderTensionCtrlType Commissioning the Diameter Calculator with Closed Loop or Open Loop Tension Control The commissioning of the diameter calculator is described in the following: Commissioning can be performed in seven steps: Determining the winder type,

63 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 57/190 Commanding the winding axis Determining the standstill friction torque, Determining the friction torque at maximum speed, Determination the minimum friction torque, Determining the direction of rotation of the winding axis, Final settings and Initial start-up of the winding axis. The correct operating mode of the drive and the controller enable of the drive have to be set for the winding axis. This can be done in two different ways: Set the "ModeSyncVel" operating mode by means of the axis interface (recommended). Use the PLC-Open "MC_Power", "MC_GearIn", "MC_Stop" function blocks to command the axis. Determining the winder type First, it must be determined which winder type is available or is to be used. To this end, the winding direction will be defined at the "WindDirection" input (TRUE: Unwinding, FALSE: Rewind). Furthermore, the diameter calculator will be selected with the "WindCtrlType" input (TRUE: Diameter calculator with closed loop tension control, FALSE: Diameter calculator with open loop tension control). When determining the friction torque, the tension command value must be zero, that is to say when the function block is connected, the output for the torque limit value is zero. Determination of the Standstill Friction Torque The friction torque will be parameterized in the following three steps. The "standstill friction torque" ("StandstillTorque" variable in the data structure ML_WIND_TENSION) will be determined when the master axis is at a standstill and the winder is empty (core only). The inputs "Enable" and "PresetDiameter" of the function block are not initially set. A low value is specified at the input "TensionSpeed". In the next step, the diameter calculator will be activated by setting the "Enable" input on the function block. The operating mode "Speed synchronization" has to be selected for the winding axis (slave axis) (in the axis interface of the ML_TechInterface.lib "MODE_SYNC_VEL" library). Now, the value at the "StandstillTorque" input in the data structure ML_WIND_TENSION will be progressively increased until the drive starts to rotate. The last value corresponds to the friction torque at standstill. The entered value also has to appear at the output for the torque limit value. The function block is deactivated again and the axis enable "MODE_SYNCH_VEL" is deactivated. Setting the friction torque at standstill has thus been completed. Determination of the Friction Torque at Maximum Speed RMB_TechWinder.library The "friction torque at maximum speed" ("MaxTorque" variable in the data structure MB_WIND_TENSION) will be determined when the master axis is at a standstill and with an empty winder (core only). The inputs "Enable" and "PresetDiameter" of the function block are not initially set. The maximum value

64 58/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library will be applied at the input "TensionSpeed" (drive parameter S , Bipolar velocity limit value). The input "MaxTorque" receives a value of 100 %. In the next step, the diameter calculator will be activated by setting the "Enable" input on the function block. The operating mode "Speed synchronization" has to be selected for the winding axis (slave axis) (in the axis interface of the ML_TechInterface.lib "MODE_SYNC_VEL" library). Now, the winder drive accelerates until it reaches maximum speed. In the next step, the value at the input "MaxTorque" will be progressively reduced until the speed of the drives starts to reduce as well. The speed of the drive can be traced with the help of the drive parameter S , Actual velocity value or the axis parameter A , Actual velocity value. The last value of "MaxTorque" corresponds to the maximum friction torque at maximum speed. The entered value also has to appear at the output for the torque limit value. The function block and the speed synchronization is deactivated. Thus, setting the friction torque at maximum speed "MaxTorque" has been completed. Determination of the Minimum Friction Torque The minimum friction torque will be determined with the help of a brake check with an empty winder. The winder drive will be decelerated from a constant velocity (e. g. 50 min -1 ) to standstill. At the same time, the drive parameters S "Torque/force command value" (axis parameter A "Bipolar torque/force limit") and S "Actual velocity value" (axis parameter A "Actual velocity value") will be recorded with an oscilloscope or with the trace function in IndraWorks. The minimum value will be read from the torque curve and can be transferred to the structure MB_WIND_TENSION as "MinTorque". The corresponding speed is entered as "MinVelocity". MB_WIND_TENSION Determination of the Rotating Direction of the Winding Axis The direction of rotation of the winder can be set using the drive parameter P , Master drive polarity or the axis parameter A , Polarity master axis position. If the winding axis does not rotate in the desired direction, the parameter P or the axis parameter A have to be reset accordingly. The polarity of the master axis position will only be checked when enabling the function block ("Enable" = TRUE). Thus, modifying the aforementioned parameters during the operation of the function block will not have any effect. Alternatively, the direction of rotation can be changed via the scaling type of the winder drive. This can be done by switching the prefix of the position/acceleration data and the torque/force data (parameters S , A , S , S ). Final settings Finally, the remaining input variables can be determined. This table lists these. Input variable "SetpointOpMode" "SetpointStandstill" Note, Setting Setting the desired operating tension Setting the standstill tension

65 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 59/190 Input variable "TensionMode" Offset in fine adjustment "ActTorqueFilter" "AccelTorqueFilter" Fig.3-44: Note, Setting Selecting the tensioning speed characteristics: TRUE: Tensioning with constant web speed FALSE: Tensioning with constant web speed A fine adjustment presetting can be carried out in the data structure MB_AXIS_SYNCHRONISATION from the library ML_TechInterface.library. Therefore, the "FineAdjust" variable is used. Its value depends on the winding direction. This variable will be cyclically processed if "EnableCyclicScanning" is set to TRUE. As described before, the winding direction is determined with "WindDirection". In the case of an unwinder, a positive value will be used for "FineAdjust". In the case of a rewinder, a negative value will be used. These values should be 5 %. If the actual torque is to be filtered (as measured value), a value not equal to zero has to be applied at this input of the function block as a time constant. This value acts on the standard parameter S "Torque/force feedback value". If the acceleration torque is to be filtered, a value not equal to zero has to be applied at this input of the function block as a time constant. Final determination of the remaining input variables Initial start-up of the winding axis RMB_TechWinder.library The winding material is placed on in an untensioned state (slightly sagging). The winding axis has to be commanded either via the axis interface or via the PLCopen function blocks. The diameter calculator is then activated by setting the "Enable" input. The winding material should now be tensioned with the predefined tensioning speed ("TensionSpeed" input). The "SpeedOffset" output provides the tensioning speed. The process variable window "WindowTension" can be set to a value of from %. The master axis is enabled with a comparatively low speed (e. g. 10 min -1 ). After a number of revolutions, the "DiameterEngaged" output has to be set. It will therefore display that the diameter calculation is active ("engaged"). This depends on the web tension or the actual torque at the winding axis and the torque limit (drive parameter S , Bipolar torque/force limit value or axis parameter A , Bipolar torque/force limit). The torque/force limit is displayed at the "TorqueLimitBipolar" output. When the diameter calculator is engaged, the standstill tension and operating tension can be checked. To do so, the value "CurrentTension" from the data structure ML_WIND_TENS_DIAG is analyzed. In this data structure, the current torque limit "TorqueLimit", the current acceleration torque "Acceleration torque" and the currently applied friction torque "FrictionTorque" can also be observed.

66 60/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Finally, the function block provides different process variables at its outputs. The calculated current diameter of the winder ("CurrentDiameter" output) should correspond to the actual diameter of the winder; slight deviations can be disregarded. Furthermore, the fine adjustment of the gear for the speed adaptation of the drive axis of the winder ("GearRatioFineAdjust" output), the current moment of inertia of the winder ("CurrentInertia" output) and the tensioning speed ("SpeedOffset" output) will be displayed. Monitoring the torque limit value When the control is run up for the first time, a drive warning can occur "E2056 Torque limit value = 0", if the winder block is not yet connected. To prevent this, in the start-up phase of the SPS program (e.g. warm start) of the corresponding cyclic data containers, the value for the parameter S "Bipolar torque/force", can be written with a value not equal to zero, such as 100%. If the warning "E8260 Torque - force command value limit active" should arise when the function block is enabled, this warning can be eliminated by setting bit 4 of the parameter P , Axis controller configuration. In rare cases it can be necessary to deactivate velocity control monitoring (set bit 1 of the parameter P , Axis controller configuration). 3.7 RMB_TechWinder, Supplemental Function Blocks and Data Types Overview This section summarizes function blocks, which can add to the functions of the different winding calculators and the dancer position controller. They can also be incorporated into the SPS project in IndraLogic. The following function blocks are available for additional functions (e. g. remaining runtime for a splice): The data types follow the library. Designation Type Description MB_CalcInertiaLimitType02, page 61 MB_UnwindMaterialType02, page 63 Fig.3-45: Designation Type Description MB_WIND_CTRL_TYPE, page 68 FB FB ENUM Calculates the maximum moment of inertia of the winding material on the winder Calculates process variables for an unwinder like the unrolled and the remaining length of the web of fabric, the material thickness and the remaining runtime for a splice. Brief description of additional function blocks for different winder types from the RMB-TechWinder library Allows the selection of the open loop tension control (sensorless) and the closed loop tension control (load cell). MB_WIND_DANCER_LIMITS, page 68 STRUCT Describes the limiter of the controller control variable. MB_WIND_DIAMETER, page 70 STRUCT Describes the data of the diameter calculator. MB_WIND_DIAM_CALC_MODE, page 71 ENUM Allows the selection of the diameter calculation type. MB_WIND_DIRECTION, page 71 ENUM Allows the selection of the winding direction type. MB_WIND_FRICTION, page 72 STRUCT Characterizes the friction torque.

67 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 61/190 Designation Type Description MB_WIND_TENSION, page 72 STRUCT Describes the data of the tension controller for closed loop control. MB_WIND_TENSION_MODE, page 73 ENUM Allows the selection of the mode to tension the material web. MB_WIND_TENS_DIAG, page 73 STRUCT Describes the current control deviation of the dancer controller. Fig.3-46: MB_CalcInertiaLimitType02 Short description Interface Description Short description of the data types for different winder types from the RMB_TechWinder library The function block ML_CalcInertiaLimitType02 represents a non-cyclical function block, as opposed to the other function blocks described in this document. It is systematically retrieved, for example, for the initialization of another function block. In this function block, the material properties and dimensions of the web of fabric will be analyzed and the maximum moment of inertia at the maximum diameter "MaxDiameter" will be calculated for the winding material on the winder. The calculated maximum moment of inertia "MaxInertia" can be used, for example, for a speed controller adaptation (adaptation of the parameter S , Velocity loop proportional gain). Here, the proportional gain between a minimum value and a maximum value can be adapted. For example, a linear increase of the proportional gain factor can be set. Fig.3-47: ML_CalcInertiaLimitType02 function block Range Name Dat Type Description VAR_INPUT Execute BOOL Activating the function block (edge-controlled) WebWidth REAL Width of the web of fabric [mm] Density REAL Material density of the web of fabric [kg/dm 3 ] MaxDiameter REAL Maximum diameter of the winder [mm] CoreDiameter REAL Core diameter of the winder [mm] VAR_OUTPUT Done BOOL Maximum moment of inertia "MaxInertia" calculated Active BOOL Processing, function block active Error BOOL Error occurred ErrorID ERROR_ CODE Error diagnostics ErrorIdent ERROR_STRUCT Error code, page 62 MaxInertia REAL Maximum moment of inertia [kg/dm 3 ] VAR_IN_OUT Slave AXIS_REF Axis structure of the winding axis Fig.3-48: RMB_TechWinder.library I/O configuration of the function block MB_CalcInertiaLimitType02

68 62/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Min. value Max. value Default value Transfer Execute BOOL FALSE Continuous Webwidth REAL 0.0 Not defined FALSE Rising edge at "Execute" Density REAL 0.0 Not defined 1.0 Rising edge at "Execute" MaxDiameter REAL > 0.0 not defined Rising edge at "Execute" CoreDiameter REAL > 0.0 Not defined Rising edge at "Execute" Signal-time diagram Functional Description Required hardware Required firmware Required software Required parameterization Error Handling Fig.3-49: Default values of the MB_CalcInertiaLimitType02 The following signal-time diagram for the operating inputs and outputs displays the flank-controlled behavior. If there is a positive edge at the input "Execute", the function block will be activated. The processing procedure which will, in this example, be specified with two cycles (two boxes in the figure) will be displayed by the output "Active". After having finished the processing procedure, the output will be set to "Done". This state remains if "Execute" remains set and if no error ("Error") occurs. If "Execute" has not been set, "Done" is deleted after one cycle. The output "Error" is set in the case of an error. "Error" remains set until "Execute" is reset. If "Execute" has not been set, the error message at the output "Error" will be deleted after one cycle. Fig.3-50: Signal/time diagram for selected inputs and outputs of the function block ML_CalcInertiaLimitType02 With the core diameter"corediameter" of the winder, the web width "Web Width" and the density of the web of fabric "Density", the moment of inertia "MaxInertia" is calculated for the specified maximum diameter "MaxDiameter". MLC hardware CML65 IndraDrive C or M MLC firmware CML65s-MLs-08T or higher Drive firmware MPX06 IndraWorks MLC An actual existing mechanical gear ratio from the drive axis to the winding axis has to be entered into the parameters S , Input revolutions of load gear and S , Output revolutions of load gear. The following table lists and describes the error codes of the function block. Error codes from "F_RELATED table (16#0170)" are used.

69 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 63/190 ErrorID Additional1 Additional2 Text STATE_MACHINE_ERROR 16# #0020 Error in the state machine 16# #0001 WebWidth < # #0002 Density < # #0003 MaxDiameter < # #0004 CoreDiameter < # #0005 MaxDiameter < CoreDiameter 16# #0006 Number of slave axis wrong RESSOURCE_ERROR 16# #0000 Wrong drive firmware RESSOURCE_ERROR 16#000F 16#0003 Drive function package "MA" not activated Fig.3-51: MB_UnwindMaterialType02 Short description Error codes of the function block MB_CalcInertiaLimitType02 The function block represents a material counter. For an unwinder, it calculates the following cyclical process variables: the unrolled length of the web of fabric"unrolledlength", the remaining length of the web of fabric "RestLength", the material thickness "MaterialThickness" as well as the remaining runtime "RemainRunTime". With the help of this data, a splice can be prepared. The current winding diameter"currentdiameter" and the remaining roll diameter "RestRollDiameter" serve as input variables. Calculating the material variables The remaining length of the web of fabric "RestLength" will be calculated with the help of the current diameter. This means that variations in the current diameter also have to be observed in calculating the remaining length ("Rest Length"). The same applies to the calculation of the material thickness ("MaterialThickness") which, in turn, works with the value of the remaining length, as well as for the calculation of the remaining runtime ("RemainRun Time") which uses the material thickness and velocity of the reference axis. The more precisely the current diameter is determined, the more precise will be the outputs of the function block to be calculated: "UnrolledLength", "Rest Length", "MaterialThickness" and "RemainRunTime". Further input variables are used. In order to obtain physically useful values for the material thickness, this will be limited by "HighLimitThickness" and "Low LimitThickness". This limitation is effective when averaging the material thickness. A fixed number of values "AverageValue" is averaged. A calculation of the material thickness will calculate all "NofRevThickCalc" revolutions of the winding axis. Preset the material variables At the beginning of the material counter process, the outputs are initialized. This is performed with the values "PresetThicknessVal" and "UnrolledLengthVal". These values can also be used as preset values during operation. These are set by the inputs "PresetThickness" and "PresetUnrolledLength". Reset the material variables RMB_TechWinder.library

70 64/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Interface Description Moreover, the material counter can be reset by the "Reset" input. Both resetting ("Reset") and presetting the outputs (Preset) can be performed at any time if the function block is active. Average value generation of the material thickness The calculated material thickness can be averaged by setting the input "AverageValue". The number of material thickness values, which are used for averaging, is entered at "AverageValue". Only the current diameters, which have been calculated internally and which are within the limits of "HighLimitThickness" and "LowLimitThickness" contribute to the average value. Values which are outside these limits are discarded. Values between 1 and 10 are appropriate for "AverageValue". For this reason, "AverageValue" is limited to a maximum of 30. If a higher value is entered, "AverageValue" is set to 30. However, no error message will be displayed, as this does not represent a critical process. The higher the selected number, the more precise will be the calculated value of the material thickness. However, the accuracy will be reduced with increasing values for "AverageValue", since the calculated value will be adjusted due to "filtering". The value for "Average Value" should therefore be selected appropriately. After having deactivated the control, the memory is deleted. The values for " UnrolledLength", "RestLength", "MaterialThickness" and "RemainRunTime" are therefore zero when the control is reactivated. The following inputs can be cyclically changed when a function block is activated: "CurrentDiameter", "PresetThicknessVal", "HighLimitThickness", "LowLimitThickness", "UnrolledLengthVal" and "AverageValue". The inputs "RestRollDiameter", "Master" and "Slave" will only be applied when there is a positive edge at "Enable". This means that these parameters will only be applied internally if a new positive edge is set at "Enable".

71 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 65/190 Fig.3-52: MB_UnwindMaterialType02 function block Range Name Dat Type Description VAR_INPUT Enable BOOL Activating the function block (level-controlled) Pause BOOL Material count paused Reset BOOL Resetting the values for the unrolled length of the web of fabric, remaining length of the web of fabric. PresetThickness BOOL Preset for the material thickness edge-controlled. PresetUnrolledLength BOOL Preset for the unrolled length of the web of fabric edgecontrolled. CurrentDiameter REAL Current winding diameter [mm] from the diameter calculator function block RemainingRollDiameter REAL Remaining roll diameter [mm] Format length REAL Format length [mm] (corresponds to an unwound revolution of the reference axis) PresetThicknessVal REAL Preset value for the material thickness [μm] UnrolledLengthVal REAL Preset value for the unwound length of the web of fabric [mm] HighLimitThickness REAL Upper limit of the material thickness [μm] LowLimitThickness REAL Lower limit of the material thickness [μm] AverageValue UINT Number of the material thickness values which is averaged. The input is limited to a maximum of 30. NofRevThickCalc UINT Number of revolutions, after which the material thickness is calculated. VAR_OUTPUT InOperation BOOL Block is working Error BOOL Error occurred ErrorID ERROR_ CODE Error display ErrorIdent ERROR_STRUCT (see Error code, page 67) InPause BOOL Material calculation paused ResetAck BOOL Reset completed RMB_TechWinder.library

72 66/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Range Name Dat Type Description PresetThicknessAck BOOL Material thickness preset PresetUnrolledLengthAck BOOL Unrolled length preset HighLimitThickAchieved BOOL The current calculated material thickness has achieved the upper limit (value will be discarded) LowLimitThickAchieved BOOL The currently calculated material thickness has achieved the lower limit (value will be discarded) RemainingLength REAL Remaining length of the web of fabric on the winder [mm] MaterialThickness REAL Material thickness of the web of fabric [μm] UnrolledLength REAL Unrolled length of fabric web [mm] RemainRunTime REAL Remaining runtime until the splice (based on the remaining roll diameter) [s] VAR_IN_OUT Master AXIS_REF Axis structure of the reference axis Slave AXIS_REF Axis structure of the winding axis Fig.3-53: Name Type Min. value Max. value I/O configuration of the function block MB_UnwindMaterialType02 Transfer Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Reset BOOL FALSE Continuous PresetThickness BOOL FALSE Continuous Default value PresetUnrolled Length BOOL FALSE Continuous CurrentDiameter REAL 0.0 Not defined 0.0 Continuous RestRollDiameter REAL 0.0 Not defined 0.0 Rising edge at Enable Format length REAL 0.0 Not defined 0.0 Rising edge at Enable PresetThicknessVal REAL > 0.0 Not defined 0.0 Continuous UnrolledLengthVal REAL 0.0 Not defined 0.0 Continuous HighLimitThickness REAL 0.0 Not defined Continuous LowLimitThickness REAL 0.0 Not defined 10.0 Continuous AverageValue UINT Continuous NofRevThickCalc UINT 0 Not defined 50 Continuous Signal-time diagram Fig.3-54: Default values of the function block MB_UnwindMatrialType02 The following explains the signal-time diagram. The function block is activated with the "Enable" input. This is displayed at the "InOperation" output. If an error occurs, the "Error" output will be set and operational readiness will be interrupted. The execution of the function block can be interrupted with the "Pause" input. This is signalized at the "InPause" output. Resetting the function block ("Reset" input) or setting material parameters ("PresetThickness" and "PresetUnrolledLength" inputs) will be performed independently of the "Pause" input. However, it is recommended that the function block is activated in "Pause". By doing so, the preset and the reset can be performed in a more controlled way. Setting and resetting will be displayed at

73 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 67/190 Required hardware Required firmware Required software Required parameterization Error Handling the "ResetAck", "PresetThicknessAck" and "PresetUnrolledLengthAck" outputs. Fig.3-55: Signal/time diagram for selected inputs and outputs of the ML_Unwind MaterialType02 function block MLC hardware CML65 IndraDrive C or M MLC firmware CML65s-MLs-08T or higher Drive firmware MPX06 IndraWorks MLC The interpolation in the drive must be enabled for the winding axis (Real axis Corresp. axis Properties). The type of winding has to be identical for the master axis and the slave axis. Rotatory and preference scaling is recommended. The following table lists and describes the error codes of the function block. Error codes from "F_RELATED table (16#0170)" are used. ErrorID Additional1 Additional2 Description STATE_MACHINE_ERROR 16#11A0 16#20 Error in the state machine 16#11A1 16#01 CurrentDiameter < #11A1 16#02 RestRollDiameter < #11A1 16#03 FormatLength <= #11A1 16#04 PresetThicknessVal < #11A1 16#05 UnrolledLengthVal < #11A1 16#06 HighLimitThickness < #11A1 16#07 LowLimitThickness < #11A1 16#08 HighLimitThickness < LowLimitThickness RMB_TechWinder.library

74 68/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library ErrorID Additional1 Additional2 Description 16#11A1 16#09 AverageValue < 0 16#11A1 16#0A NofRevThickCalc < 0 16#11A1 16#0B Number of slave axis wrong 16#11A1 16#0C Number of master axis wrong RESSOURCE_ERROR 16# #0000 Wrong drive firmware RESSOURCE_ERROR 16#000F 16#0003 Drive functional package "MA" not activated Fig.3-56: MB_WIND_CTRL_TYPE Short description Name Type Min. value Error codes for the function block MB_UnwindMaterialType02 The enumeration type MB_WIND_CTRL_TYPE allows the selection of the open loop tension control (sensorless) and the closed loop tension control (load cell).. Max. value Default value Transfer Description OPEN_LOOP ENUM 16#0000 at a rising edge of Enable Winding type "open loop" without sensor CLOSED_LOOP ENUM 16#0001 at a rising edge of Enable Winding type "closed loop" Fig.3-57: MB_WIND_DANCER_LIMITS Short description Name Type Min. value with load cell Interface description of the MB_WIND_CTRL_TYPE The data structure MB_WIND_DANCER_LIMITS describes the limiter of the controller control variable in the diagram. Max. value LowLimitControl REAL 0.0 Not defined HighLimitControl REAL 0.0 Not defined VelocityHighLimit REAL 0.0 Not defined Fig.3-58: Default value Transfer Description 0.0 Continuous Lower limit of the controller output (at zero speed), bipolar [rpm] 0.0 Continuous Upper limit of the controller output (at VelocityHighLimit speed), bipolar [rpm] 0.0 Continuous Speed of the master for High LimitControl [rpm] Interface description MB_WIND_DANCER_LIMITS

75 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 69/190 RMB_TechWinder.library

76 70/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library MB_WIND_DIAMETER Short description Name Type Min. value The MB_WIND_DIAMETER data structures describes the data required for the diameter calculator. Max. value PresetVal REAL > 0.0 Not defined CoreVal REAL > 0.0 Not defined CalcRange REAL 0.0 Not defined RepeatLength REAL > 0.0 Not defined Webwidth REAL 0.0 Not defined Density REAL 0.0 Not defined Default value Transfer Description Continuous Default value for the preset diameter [mm] Rising edge at Enable Diameter of the core [mm] Continuous Range for calculation of the diameter [degrees] Rising edge at Enable 0.0 Rising edge at Enable 1.0 Rising edge at Enable Format length [mm] (1 revolution of the reference axis unwound) Web width [mm] is required for the moment of inertia Material density [kg/ dm 3 ] is required for the moment of inertia AverageValue UINT Continuous Number of diameter values to be averaged [-] HighLimit REAL LowLimit Not defined Continuous Upper limit for the diameter [mm] LowLimit REAL > 0.0 HighLimit Continuous Lower limit for the diameter [mm] MinDiameter REAL > 0.0 Not defined MaxDiameter REAL > 0.0 Not defined MechanicInertia REAL 0.0 Not defined DancerConstant REAL 0.0 Not defined MeasuredVal REAL 0.0 not defined Continuous Minimum diameter [mm] Continuous Maximum diameter [mm] 0.0 Continuous Moment of inertia of the mechanism [kg/m 2 ] based on the motor side Is required for the resulting moment of inertia. 0.0 Continuous Displacement of the dancer, based on the unit of dancer adjustment [mm/-] Is only required with a winder with dancer. 0.0 Continuous Measured diameter [mm]

77 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 71/190 Name Type Min. value Max. value PivotVelocity REAL 0.0 Not defined DiamCalcMode MB_WIND_DI AM_CALC_MODE Default value Transfer Description 0.0 Continuous Pivot velocity (for relative motion of the winding axis) [mm/s] DiamSource BOOL Rising edge at Enable Fig.3-60: MB_WIND_DIAM_CALC_MODE Short description Name Type Min. value 0x0000 0x0001 0x0000 Rising edge at Enable MB_WIND_DI AM_CALC_MODE, page 71 Diameter calculation mode: 0x0000: 0x0001: CALC_DIAM_MANUAL Diameter calculation dependent on CalcRange FIRST_REV_AU TO_CALC Diameter calculation is performed every 5 degrees for the first revolution and thereafter depending on the CalcRange Determination of diameter: FALSE: Diameter is calculated TRUE: Interface description of the MB_WIND_DIAMETER Diameter is measured (MeasuredVal) The enumeration type MB_WIND_DIAM_CALC_MODE allows the selection of the diameter calculation type. Max. value Default value Transfer Description CALC_DIAM_MANUAL ENUM 16#0000 at a rising edge of Enable Diameter calculation dependent on CalcRange FIRST_REV_AUTO_CALC ENUM 16#0001 at a rising edge of Enable Diameter calculation is done every 3 degrees for the first revolution and thereafter depending on the CalcRange Fig.3-61: MB_WIND_DIRECTION Short description MB_WIND_DIAM_CALC_MODE interface description RMB_TechWinder.library The enumeration type MB_WIND_DIRECTION allows the selection of the diameter direction type.

78 72/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Name Type Min. value Max. value Default value Transfer Description REWIND ENUM 16#0000 at a rising edge of Enable Rewinder UNWIND ENUM 16#0001 at a rising edge of Enable Unwinder Fig.3-62: MB_WIND_FRICTION Short description Name Type Min. value Interface description of the MB_WIND_DIRECTION The data structure of the MB_WIND_FRICTION characterizes the friction torque. Max. value StandstillTorque REAL 0.0 Not defined MaxTorque REAL 0.0 Not defined MinTorque REAL 0.0 Not defined MinTorqueVelocity REAL 0.0 Not defined Fig.3-63: MB_WIND_TENSION Short description Name Type Min. value Default value Transfer Description 0.0 Continuous Friction torque at standstill 0.0 Continuous Friction torque at S , Bipolar velocity limit value 0.0 Continuous Minimum friction torque 0.0 Continuous Velocity at minimum friction torque Interface description of the MB_WIND_FRICTION The data structure MB_WIND_TENSION describes the data of the tension controller. Max. value PControl REAL 0.0 Not defined IControl REAL 0.0 Not defined FeedbackVal REAL 0.0 Not defined PreControlWeighting REAL 0.0 Not defined Default value Transfer Description 0.0 Continuous Kp-gain of the tension controller 0.0 Continuous Tn Integral action time of the tension controller 0.0 Continuous Actual value of the tension 1.0 Continuous Scaling of the command value injection

79 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 73/190 Name Type Min. value Max. value HighLimit REAL 0.0 Not defined LowLimit REAL 0.0 Not defined Fig.3-64: Default value MB_WIND_TENSION_MODE Short description Name Type Min. value Transfer Description 0.0 Continuous Upper limit of the tension controller 0.0 Continuous Lower limit of the tension controller Interface description of the MB_WIND_TENSION The enumeration type MB_WIND_TENSION_MODE allows the selection of the mode to tension the material web. Max. value Default value Transfer Description CONST_SPEED ENUM 16#0000 at a rising edge of Enable Tensioning method: constant tensioning speed CONST_WEB_VEL ENUM 16#0001 at a rising edge of Enable Tensioning method: Fig.3-65: MB_WIND_TENS_DIAG Short description Name Type Min. value TensionCtrlOutput REAL Not defined TorqueLimit REAL Not defined AccelerationTorque REAL Not defined FrictionTorque REAL Not defined constant web velocity Interface description of the MB_WIND_TENSION_MODE The data structure MB_WIND_TENS_DIAG describes the current control deviation of the dancer controller. Max. value Not defined Not defined Not defined Not defined Fig.3-66: Default value Transfer Description 0.0 Continuous Output of the tension controller [N] 0.0 Continuous Prefixed torque limit [%] 0.0 Continuous current acceleration torque [%] 0.0 Continuous current friction torque [%] Interface description of the MB_WIND_TENS_DIAG 3.8 RMB_TechWinder, Parameter Overview This sections lists the parameters used in the documentation. RMB_TechWinder.library There are axis parameters (A-parameters) for the MLC control and productspecific parameters (P-parameters) and standard parameters (S-parameters) for the respective drive. There are only product-specific parameters (P-parameters) and standard parameters (S-parameters) for the MLD control.

80 74/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechWinder.library Parameters A A A A A A A A A A A A A Fig.3-67: Parameters S S S S S S S S S S S Fig.3-68: Parameters P P P P Fig.3-69: Parameters P P P P Designation Position polarity Bipolar torque/force limit Torque/force data scaling type Actual velocity value Configuration user defined commanded data A Configuration user defined commanded data B Configuration user defined commanded data C Configuration user defined commanded data D Configuration user defined actual data A Configuration user defined actual data B Configuration user defined actual data C Configuration user defined actual data D Polarity master axis position MLC axis parameters (A parameters) Designation Actual velocity value Velocity polarity parameter Position polarity Torque/force command value Actual torque/force Torque/force polarity parameter Bipolar velocity limit value Bipolar torque/force limit Velocity regulator - proportional gain Input revolutions of load gear Output revolutions of load gear Default parameters (S parameters) Designation Master drive polarity Axis controller configuration Additive velocity command value, process loop Gear ratio fine adjust, process loop Product-specific parameters (P parameter) Designation CCD: Configuration master command values CCD: Configuration slave actual values CCD: Configuration list slave command values CCD: Configuration list slave actual values

81 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 75/190 RMB_TechWinder.library Parameters Designation P CCD: MDT Real-time container 1, master P CCD: MDT Real-time container 1, slave n (n = 1-9) P CCD: MDT Real-time container 2, master P CCD: MDT Real-time container 2, slave n (n = 1-9) P CCD: MDT Real-time container 3, master P CCD: MDT Real-time container 3, slave n (n = 1-9) P CCD: MDT Real-time container 4, master P CCD: MDT Real-time container 4, slave n (n = 1-9) P CCD: AT Real-time container 1, master P CCD: AT Real-time container 1, slave n (n = 1-9) P CCD: AT Real-time container 2, master P CCD: AT Real-time container 2, slave n (n = 1-9) P CCD: AT Real-time container 3, master P CCD: AT Real-time container 3, slave n (n = 1-9) P CCD: AT Real-time container 4, master P CCD: AT Real-time container 4, slave n (n = 1-9) Fig.3-70: Product-specific parameters (P parameter)

82 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description

83 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 77/190 4 ML_TechRegi.library 4.1 ML_TechRegi, Overview Function blocks and data types MB_RegisterControllerType02, page 77 MB_RegisterControllerType03, page 88 MB_RegisterControllerType04, page 100 MB_RegisterControllerSideType01, page 114 MB_RegiMeasuringType01, page 119 MB_RegiMeasuringType02, page 121 MB_RegiRegulateType01, page 125 MB_RegiRegulateType02, page 128 MB_RegiRegulateType04, page 136 MB_RegiSensor02ConfigType01, 151 The ML_TechRegi library contains the data types and function blocks necessary for the realization of register controller functionality of MLC systems. Description Closed loop register controller The FB is used for the closed loop register control of a pressure mark and contains a PI controller with an adjustable correction window. The FB is used for the closed loop register control of a pressure mark and contains a PI controller with an adjustable correction window, a shift register PT1 filter and a dead band Kp characteristic curve. The FB is used for the closed loop register control of a pressure mark and contains a PI controller with an adjustable correction window, a shift register PT1 filter, a dead band Kp characteristic curve and a mark gating feature. Side register controller The FB is used for the side register controller of a sphenoidal pressure mark and contains a PI controller. Measured value processing and regulate function blocks The FB is used to process the measured touch probe signal. The FB is used to process the measured touch probe signal. The FB is used to write a control value to the drive. The FB is used to write a control value to the drive. If the correction window is active, the control deviations are corrected within one parameterized correction window. The FB is used to write a control value to up to eight drives. If the correction window is active, the control deviations are corrected within one parameterized correction window. Function blocks and data types for the Q.I. camera sensor actuation page MB_RegiSensor02CycComType01, page 153 MB_REGI_SENSOR02_CFG, page 155 MB_REGI_SENSOR_DATA, page 156 Fig.4-1: The FB configures a Q.I. Press Control camera sensor to use it as measurement source in the register controller chain. The FB evaluates the measured values of the Q.I. Press Control camera sensor and provides the deviations in the registration mark for the controller chain. Configuration data of a Q.I. camera sensor Measured data of a sensor ML_TechRegi library, Overview 4.2 Register Controller Function Blocks MB_RegisterControllerType02 Short Description The MB_RegisterControllerType02 register controller function block supports the following functionality: Calculate a correction value based on both measured and setpoint value using a P or PI control loop Preset feature ML_TechRegi.library

84 78/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Interface Description Pause feature Min/Max limiting of the calculated control value Correction window feature Lock setpoint on demand Fig.4-2: I/O Type Name Data Type Comment MB_RegisterControllerType02 Function Block VAR_IN_OUT Setpoint REAL Desired value. Will be compared to "RecordedPosition" MeasuredAxis AXIS_REF Reference to the measured axis ControlledAxis AXIS_REF Reference to the controlled axis VAR_INPUT Enable BOOL Enables the Register Controller Pause BOOL The "Pause" input will only be evaluated while the "Enable" input is active. Pause is intended to keep the "ControlValue" and "ParameterControlValue" constant in a steady state. Preset BOOL The "Preset" input will only be evaluated while "Enable" is TRUE. A positive edge of this input forces the control loop to "PresetValue". In addition, this function sets the controlled parameter to the value of "PresetValue" Step UINT Edge detection for example from MB_TouchProbeContinuous DisableCyclicWrites BOOL Disable writing to the "ControlledValueIDN" internally from the FB. If TRUE the user has to link the output "Parameter ControlValue" for the control functionality PresetValue REAL This is the value passed to the system when the Preset function becomes active SetpointLock BOOL Enables set point lock. If TRUE, the next measured mark will be latched. ControlPolarity BOOL The polarity of the control value is inverted while this input is TRUE

85 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 79/190 I/O Type Name Data Type Comment ControlledValueIDN MB_IDN Sercos-IDN of the controlled parameter (e.g. P ).The following IDN s are supported: MLD: P , P , P , P , P , P MLC: A , P , A , P , A , P , A , P , A , P , A PControl REAL Proportional gain of the PI controller. If set to 0, the proportional part of the controller is disabled and the proportional gain is set internally to 1 in order to work as an I-Controller. IControl REAL Integral time Tn of the PI controller. If set to 0, the integral part of the PI-controller is disabled. ModuloValue REAL ModuloValue from measured probe signal HighLimit REAL This is the maximum value for "ControlValue" LowLimit REAL This is the minimum value for "ControlValue" CorrectionMode MB_CORREC TION_MODE CORR_ABS = absolute correction window within [CorrectionStart.. CorrectionEnd]. A modulo value is considered. CORR_REL = correction start relative after measured value detection, end of correction relative. Correction window is [measured value + CorrectionStart.. measured value + CorrectionEnd] CORR_REL_ABS = Correction start relative after measured value detection, end of correction absolute. Correction window is [measured value + CorrectionStart.. CorrectionEnd] CORR_ABS_REL = Correction start absolute value, end of correction relative to measured value detection. Correction window is [CorrectionStart.. measured value + CorrectionEnd] CORR_WIN_DISABLED = Correction window is disabled CorrectionStart REAL Start of the correction window: Is an absolute angle or an offset to the measured value. CorrectionEnd REAL End of the correction window: Is an absolute angle or an offset to the measured value. RecordedPosition REAL Position where edge occurred (in technical units). VAR_OUTPUT InOperation BOOL Registration controller is running Error BOOL Indicates an error. Clear error with Enable = FALSE ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL Register controller is in pause PresetAck BOOL Preset function is done ActStep UINT Step Value, counting with every new value on the output "ControlValue" SetpointLockAck BOOL Setpoint lock is done ML_TechRegi.library HighLimitActive BOOL High limit is active. "ControlValue" would be higher, but is limited to "HighLimit"

86 80/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library I/O Type Name Data Type Comment LowLimitActive BOOL Low limit is active."controlvalue" would be lower, but is limited to "LowLimit" ControlValue REAL Control value calculated by the registration controller CurrentValue REAL Actual value used in the register controller Deviation REAL "Deviation" = ("Setpoint" - "CurrentValue") of the register controller ParameterControlValue REAL Fig.4-3: This calculated value is written to the drive or control parameter set in input "ControlledValueIDN". MB_RegisterControllerType02 I/O Interface Min/Max Values and Default Values of the Inputs Name Type Min Value Max Value Default Value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Preset BOOL FALSE Step UINT DisableCyclic Writes "Enable TRUE (continuous) Continuous. Starts on rising edge of Enable and falling edge of Pause BOOL FALSE Continuous SetpointLock BOOL FALSE Continuous PresetValue REAL n.def n.def 0.0 Rising edge on Preset ControlPolarity BOOL FALSE Continuous ControlledValueIDN DINT n.def n.def 0 Rising edge on Enable Setpoint REAL n.def n.def 0.0 Change of "Step" PControl REAL 0.0 n.def 1.0 Continuous IControl REAL 0.0 n.def 0.0 Continuous ModuloValue REAL 0.0 n.def 0.0 HighLimit REAL LowLimit n.def 0.0 Continuous LowLimit REAL n.def HighLimit 0.0 Continuous CorrectionMode Rising edge of Enable MB_CORREC TION_MODE CORR_REL Continuous CorrectionStart REAL 0.0 ModuloValue 0.0 Continuous CorrectionEnd REAL 0.0 ModuloValue 0.0 Continuous RecordedPosition REAL n.def n.def 0.0 Change of Step Timing Diagram Fig.4-4: Overview Min/Max Values and Default Values of the Inputs The following diagram shows the signal timing of MB_RegisterController Type02 including Pause and Preset functions.

87 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 81/190 Functional Description Fig.4-5: ML_TechRegi.library Timing Diagram of MB_RegisterControllerType02 with Pause and Preset Function A sensor detects marks, perforations, cuts or pasted joints on the material and provides a (binary) signal to the drive. The probe feature of the drive determines the edge of the sensor signal and latches the following positions, depending on the signal selection of the probe. Drive feedback position parameters: S , S , P Master axis position parameters: P , P , P , P , P The probe function records positional data with a resolution of 0.5 µs. The sensor must provide a 24V signal with a rise time in the µs range. The sensor specific delay time can be compensated using the "DeadTimePosEdge" or "DeadTimeNegEdge" inputs of the MB_InitTouchProbe function block. The register controller calculates the control deviation between the measured and setpoint positions and determines the required correction value once a new edge of the sensor signal is detected. Changes of the correction value become active via the trapezoidal profile, velocity ramp, PT1-filter or instantaneously, depending on the selected control parameter ("ControlledValueIDN") input of the function block. The following table shows the available control parameters ("ControlledValueIDN") as well the resulting motion profile of all available drive operation modes with synchronization.

88 82/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Initialization PresetValue Fig.4-6: Supported Control Parameter and Behavior An Integration is done for the following "ControlledValueIDN" values: P , A P , A P , A P , A During initialization, the Setpoint and RecordedPosition inputs must have valid data. An uninterrupted start of the the controller outputs "ControlValue" and "CommandPosition require that the "Preset" input be set before the "Enable" input is activated. During this period, the Setpoint and RecordedPosition inputs must have valid data. In addition, the upper limits and lower limits are monitored

89 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 83/190 Pause Lock Setpoint Correction Window ML_TechRegi.library for activation to ensure a limitation of the ControlValue output if the set value for PresetValue is outside the limits of HighLimit or LowLimit. PresetAck is active, if the value on PresetValue is taken into account. Preset has the priority over Pause. The value PresetValue is taken into account on a rising edge at Preset, if Enable is active. If successful, the output PresetAck is set TRUE. The "Pause" input is only evaluated as long as the Enable input is active. In this case, the deviation ( "Setpoint" "RecordedPosition") is set to 0. This causes "ControlValue" and "CommandPosition" to be fixed. This can be used in addition to constantly hold the output in a stable state. The ActStep output gets updated even if the Pause input is active. As long as Pause is active, the InPause output is TRUE. To achieve a manual/automatic mode changeover (use the actual control value RecordedPosition as setpoint), the lock setpoint feature is present. If the input becomes TRUE the value of Setpoint is overwritten with the value of RecordedPosition at the next change of the Step input. This feature allows the user e.g. to enable and pause the register controller function and then to jog the system so that it is in register. Then activate the SetpointLock input to use the next latched RecordedPosition as Setpoint. The correction window is an angular range relating to the measuring axis. The register controller regulates the control deviations within this window. The position and size of the correction window are set with the help of the following inputs: The CorrectionMode input sets the correction window either absolute or relative. If the "CorrectionMode is set to CORR_WIN_DISABLED, the correction window is inactive. The "CorrectionStart input defines the start of the correction window. The CorrectionEnd input defines the end of the correction window. The correction window supports only a positive number of revolutions of the measuring axis.

90 84/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library a: Start correction window b: End correction window c: Correction window d: Expectation window Fig.4-7: Correction Window Absolute

91 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 85/190 a: Start correction window = measuring end b: Relative end of correction window to measuring end c: Correction window d: Expectation window Fig.4-8: Correction Window Relative ML_TechRegi.library

92 86/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library a: Start correction window = measuring end b: End of correction window = perm. angle c: Correction window d: Expectation window Fig.4-9: Correction Window Relative Start Absolute End The RegisterController function block only calculates a new value if the Step input changes. The controller parameter PControl, IControl and can be changed continuously. The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR RESOURCE_ERROR STATE_MA CHINE_ERROR (16#0005) RESOURCE_ERROR Normal Operation Error Handling 16# #0000 Drive is not enabled or drive error 16# #0000 Drive firmware not supported 16# #0000 Invalid state of function block 16# #0000 Selected Axis (Axis_Ref) was changed while FB is in operation 16#000D 16#0000 AxisRef is outside valid range(measured/controlled) 16# #0002 Input "Setpoint" > "ModuloValue" 16# #0003 Input "Setpoint" < 0

93 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 87/190 ErrorID Additional1 Additional2 Description INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVA LID_ERROR(16#0001) INPUT_INVALID_ERROR (16#0001) 16# #0004 Input "RecordedPosition" > "ModuloValue" 16# #0005 Input "RecordedPosition" < 0 16# #0006 Input "ModuloValue" < 0 16#0C01 16#0001 "LowLimit" > "HighLimit' 16#0C01 16#0002 Selection of controller typ isn't supported. Check Inputs "IControl" and "PControl" 16#0C02 16#0003 Input "IControl" isn't valid 16#0C02 16#0004 Input "PControl" isn't valid 16# #0001 "CorrectionEnd" < "Correction Start" 16# #0002 Input "CorrectionStart" < 0 16# #0003 Input "CorrectionEnd" < 0 16# #0004 Value < 0 Input "ModuloValue" 16# #0005 Value < 0 Input "RecordedPosition" 16# #0006 Input "CorrectionStart" > "ModuloValue" 16# #0007 Input "CorrectionEnd" > "ModuloValue" 16# #0008 Input "RecordedPosition" > "ModuloValue" 16# #0009 Correction path > "ModuloValue" 16# #000A S of Controlled Axis out of range 16# #000B S of Controlled Axis out of range 16# #000C P of Controlled Axis out of range 16# #0001 "HighLimit" < "LowLimit" 16# #0002 "PControl" < 0 16# #0001 Selected "ControlledValueIDN" is not supported 16# #0002 Input invalid "CorrectionMode" ML_TechRegi.library

94 88/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library ErrorID Additional1 Additional2 Description INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) ACCESS_ERROR 16# #0003 "CorrectionStart" = "CorrectionEnd" 16# #0004 Input "ModuloValue" invalid 16# #0008 Measured or Controlled axis is an MLD-M slave, but Parameter P , Bit 6 is not TRUE Fig.4-10: MB_RegisterControllerType03 Short Description Interface Description MB_RegisterControllerType02 Error Codes The MB_RegisterControllerType03 register controller function block supports the following functionality: Calculate a correction value based on both measured and setpoint value using a P or PI control loop Preset feature Pause feature Min/Max limiting of the calculated control value Correction window feature Shifting register Dead band Kp characteristic curve PT1 element Lock setpoint on demand Fig.4-11: I/O Type Name Data Type Comment Interface RegisterControllerType03 Function Block VAR_IN_OUT Setpoint REAL Desired value. Will be compared to "RecordedPosition" MeasuredAxis AXIS_REF Reference to the measured axis ControlledAxis AXIS_REF Reference to the controlled axis

95 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 89/190 I/O Type Name Data Type Comment VAR_INPUT Enable BOOL Enables the Register Controller Pause BOOL The "Pause" input will only be evaluated while the "Enable" input is active. Pause is intended to keep the "ControlValue" and "ParameterControlValue" constant in a steady state. Preset BOOL The "Preset" input will only be evaluated while "Enable" is TRUE. A positive edge of this input forces the control loop to "PresetValue". In addition, this function sets the controlled parameter to the value of "PresetValue" Step UINT Edge detection for example from MB_TouchProbeContinuous DisableCyclicWrites BOOL Disable writing to the "ControlledValueIDN" internally from the FB. If TRUE the user has to link the output "Parameter ControlValue" for the control functionality PresetValue REAL This is the value passed to the system when the Preset function becomes active SetpointLock BOOL Enables set point lock. If TRUE, the next measured mark will be latched. ClearMeasValMem BOOL Clear the memory for the measured values which is used by the probe distance function ControlPolarity BOOL The polarity of the control value is inverted while this input is TRUE ControlledValueIDN MB_IDN Sercos-IDN of the controlled parameter (e.g. P ).The following IDN s are supported: MLD: P , P , P , P , P , P MLC: A , P , A , P , A , P , A , P , A , P , A PControl REAL Proportional gain of the PI controller. If set to 0, the proportional part of the controller is disabled and the proportional gain is set internally to 1 in order to work as an I-Controller. IControl REAL Integral time Tn of the PI controller. If set to 0, the integral part of the PI-controller is disabled. TControl REAL Filter constant for the input "RecordedPosition" ModuloValue REAL ModuloValue from measured probe signal HighLimit REAL This is the maximum value for "ControlValue" LowLimit REAL This is the minimum value for "ControlValue" ML_TechRegi.library

96 90/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library I/O Type Name Data Type Comment CorrectionMode MB_CORREC TION_MODE CORR_ABS = absolute correction window within [CorrectionStart.. CorrectionEnd]. A modulo value is considered. CORR_REL = correction start relative after measured value detection, end of correction relative. Correction window is [measured value + CorrectionStart.. measured value + CorrectionEnd] CORR_REL_ABS = Correction start relative after measured value detection, end of correction absolute. Correction window is [measured value + CorrectionStart.. CorrectionEnd] CORR_ABS_REL = Correction start absolute value, end of correction relative to measured value detection. Correction window is [CorrectionStart.. measured value + CorrectionEnd] CORR_WIN_DISABLED = Correction window is disabled CorrectionStart REAL Start of the correction window: Is an absolute angle or an offset to the measured value. CorrectionEnd REAL End of the correction window: Is an absolute angle or an offset to the measured value. RecordedPosition REAL Position where edge occurred (in technical units). ResponseCurve ARRAY[0..3] OF IL_COORD Characteristic curve ProbeDistance UINT The distance between marks sensor and regulated axis in format lengths (master axis revolutions, formats). MissedMarksCnt UNIT Counter missing marks if using expectation window VAR_OUTPUT InOperation BOOL Registration controller is running Error BOOL Indicates an error. Clear error with Enable = FALSE ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL Register controller is in pause PresetAck BOOL Preset function is done ActStep UINT Step Value, counting with every new value on the output "ControlValue" SetpointLockAck BOOL Setpoint lock is done ClearMeasValMemAck BOOL Clearing the memory of the measured values is done HighLimitActive BOOL High limit is active. "ControlValue" would be higher, but is limited to "HighLimit" LowLimitActive BOOL Low limit is active."controlvalue" would be lower, but is limited to "LowLimit" ControlValue REAL Control value calculated by the registration controller CurrentValue REAL Current value used in the register controller. It is equal to Input "RecordedPosition" if "ProbeDistance" and "MarkGating" are disabled.

97 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 91/190 I/O Type Name Data Type Comment Deviation REAL "Deviation" = ("Setpoint" - "CurrentValue") of the register controller ParameterControlValue REAL Fig.4-12: This calculated value is written to the drive or control parameter set in input "ControlledValueIDN". MB_RegisterControllerType03 I/O Interface Min/Max Values and Default Values of the Inputs Name Type Min Value Max Value Default Value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Preset BOOL FALSE Step UINT DisableCyclic Writes "Enable TRUE (continuous) Continuous. Starts on rising edge of Enable and falling edge of Pause BOOL FALSE Continuous SetpointLock BOOL FALSE Continuous ClearMeasValMem BOOL FALSE Continuous PresetValue REAL n.def n.def 0.0 Rising edge on Preset ControlPolarity BOOL FALSE Continuous ControlledValueIDN DINT n.def n.def 0 Rising edge on Enable Setpoint REAL n.def n.def 0.0 Change of "Step" PControl REAL 0.0 n.def 1.0 Continuous IControl REAL 0.0 n.def 0.0 Continuous TControl REAL 0.0 n.def 0.0 Continuous ModuloValue REAL 0.0 n.def 0.0 HighLimit REAL LowLimit n.def 0.0 Continuous LowLimit REAL n.def HighLimit 0.0 Continuous CorrectionMode Rising edge of Enable MB_CORREC TION_MODE CORR_REL Continuous CorrectionStart REAL 0.0 ModuloValue 0.0 Continuous CorrectionEnd REAL 0.0 ModuloValue 0.0 Continuous RecordedPosition REAL n.def n.def 0.0 Change of Step ResponseCurve ARRAY[0..3] OF IL_COORD n.def n.def 0.0 Continuous ProbeDistance UINT Continuous MissedMarksCnt UINT Continuous Fig.4-13: ML_TechRegi.library Overview Min/Max Values and Default Values of the Inputs

98 92/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Timing Diagram Functional Description The following diagram shows the signal timing of MB_RegisterController Type03 including Pause and Preset functions. Fig.4-14: Timing Diagram of MB_RegisterControllerType03 with Pause and Preset Function A sensor detects marks, perforations, cuts or pasted joints on the material and provides a (binary) signal to the drive. The probe feature of the drive determines the edge of the sensor signal and latches the following positions, depending on the signal selection of the probe. Drive feedback position parameters: S , S , P Master axis position parameters: P , P , P , P , P The probe function records positional data with a resolution of 0.5 µs. The sensor must provide a 24V signal with a rise time in the µs range. The sensor specific delay time can be compensated using the "DeadTimePosEdge" or "DeadTimeNegEdge" inputs of the MB_InitTouchProbe function block. The register controller calculates the control deviation between the measured and setpoint positions and determines the required correction value once a new edge of the sensor signal is detected. Changes of the correction value become active via the trapezoidal profile, velocity ramp, PT1-filter or instantaneously, depending on the selected control parameter ("ControlledValueIDN") input of the function block. The following table shows the available control parameters ("ControlledValueIDN") as well the resulting motion profile of all available drive operation modes with synchronization.

99 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 93/190 Initialization PresetValue Fig.4-15: Supported Control Parameter and Behavior An Integration is done for the following "ControlledValueIDN" values: P , A P , A P , A P , A ML_TechRegi.library During initialization, the Setpoint and RecordedPosition inputs must have valid data. An uninterrupted start of the the controller outputs "ControlValue" and "CommandPosition require that the "Preset" input be set before the "Enable" input is activated. During this period, the Setpoint and RecordedPosition inputs must have valid data. In addition, the upper limits and lower limits are monitored

100 94/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Pause Lock Setpoint Correction Window for activation to ensure a limitation of the ControlValue output if the set value for PresetValue is outside the limits of HighLimit or LowLimit. PresetAck is active, if the value on PresetValue is taken into account. Preset has the priority over Pause. The value PresetValue is taken into account on a rising edge at Preset, if Enable is active. If successful, the output PresetAck is set TRUE. The "Pause" input is only evaluated as long as the Enable input is active. In this case, the deviation ( "Setpoint" "RecordedPosition") is set to 0. This causes "ControlValue" and "CommandPosition" to be fixed. This can be used in addition to constantly hold the output in a stable state. The ActStep output gets updated even if the Pause input is active. As long as Pause is active, the InPause output is TRUE. To achieve a manual/automatic mode changeover (use the actual control value RecordedPosition as setpoint), the lock setpoint feature is present. If the input becomes TRUE the value of Setpoint is overwritten with the value of RecordedPosition at the next change of the Step input. This feature allows the user e.g. to enable and pause the register controller function and then to jog the system so that it is in register. Then activate the SetpointLock input to use the next latched RecordedPosition as Setpoint. The correction window is an angular range relating to the measuring axis. The register controller regulates the control deviations within this window. The position and size of the correction window are set with the help of the following inputs: The CorrectionMode input sets the correction window either absolute or relative. If the "CorrectionMode is set to CORR_WIN_DISABLED, the correction window is inactive. The "CorrectionStart input defines the start of the correction window. The CorrectionEnd input defines the end of the correction window. The correction window supports only a positive number of revolutions of the measuring axis.

101 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 95/190 a: Start correction window b: End correction window c: Correction window d: Expectation window Fig.4-16: Correction Window Absolute ML_TechRegi.library

102 96/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library a: Start correction window = measuring end b: Relative end of correction window to measuring end c: Correction window d: Expectation window Fig.4-17: Correction Window Relative

103 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 97/190 Smoothing ProbeDistance a: Start correction window = measuring end b: End of correction window = perm. angle c: Correction window d: Expectation window Fig.4-18: Correction Window Relative Start Absolute End ML_TechRegi.library The "TControl" input is the attenuation constant for the RecordedPosition input. If set to 0, smoothing is inactive. In the simplest case, the measuring axis is a format cylinder ( = regulated axis) and the distance of the sensor to the measuring (= regulated) axis is less than the format length. Measurement and correction relate to the same product. Many times it is necessary to mount the mark reader (sensor) further away from the measuring axis, e.g., hazardous areas in printing facilities. If the distance is greater than the format length, then the measured register error cannot be corrected until the product has reached the format cylinder. The correction must be delayed by as many formats as there are formats between the regulated axis and the sensor. The ProbeDistance input is the distance between the mark reader (sensor) and the regulated axis in format lengths (master axis revolutions, formats). If set to 0, the distance of the sensor to the measuring axis is less than the format length.

104 98/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Fig.4-19: Probe Distance Clearing the Internal Memory of Measured Values The probe distance feature contains an internal memory that stores measured values (like a shift register). This internal memory can be cleared (set to 0 ) using the ClearMeasValMem input. The differential signal from the filtered RecordedPosition input and the Setpoint input is weighted via the ResponseCurve input. A characteristic curve is used in order to pause the register controller within small registration errors. The RegisterController only calculates a new value if the Step input changes. The PControl, IControl and TControl controller parameters can be changed continuously. In the event that the controlled axis is a real axis, the used "ControlledValueIDN" (P-Parameter must be used) has to be configured in the MDT of the controlled axis. In the event of a virtual axis, the A-Parameter must be used as "ControlledValueIDN". The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR RESOURCE_ERROR STATE_MA CHINE_ERROR (16#0005) RESOURCE_ERROR DeadBand Normal Operation Necessary Parameterization Error Handling 16# #0000 Drive is not enabled or drive error 16# #0000 Drive firmware not supported 16# #0000 Invalid state of function block 16# #0000 Selected Axis (Axis_Ref) was changed while FB is in operation 16#000D 16#0000 AxisRef is outside valid range(measured) 16#000D 16#0001 AxisRef is outside valid range(controlled) 16# #0001 Input "ProbeDistance" isn't in valid range (0<= ProbeDistance <=30) 16# #0002 Input "Setpoint" > "ModuloValue" 16# #0003 Input "Setpoint" < 0 16# #0004 Input "Feedback" > "ModuloValue"

105 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 99/190 ErrorID Additional1 Additional2 Description INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) 16# #0005 Input "Feedback" < 0 16# #0006 Input "ModuloValue" < 0 16#0C01 16#0001 "LowLimit" > "HighLimit' 16#0C01 16#0002 Selection of controller typ isn't supported. Check Inputs "IControl" and "PControl" 16#0C02 16#0001 Input "TControl" isn t valid 16#0C02 16#0003 Input "IControl" isn't valid 16#0C02 16#0004 Input "PControl" isn't valid 16#0C05 16#0001 X-Value in ResponseCurve not in ascending order 16#0C05 16#0002 More than one value for one X-Position in ResponseCurve 16#0C05 16#0003 Negative X-Value in ResponseCurve" 16# #0001 "CorrectionEnd" < "Correction Start" 16# #0002 Input "CorrectionStart" < 0 16# #0003 Input "CorrectionEnd" < 0 16# #0004 Value < 0 Input "ModuloValue" 16# #0005 Value < 0 Input "RecordedPosition" 16# #0006 Input "CorrectionStart" > ModuloValue 16# #0007 Input "CorrectionEnd" > "ModuloValue" 16# #0008 Input "RecordedPosition" > "ModuloValue" 16# #0009 Correction path > "ModuloValue" 16# #000A S or A of Controlled Axis out of range 16# #000B S or A of Controlled Axis out of range 16# #000C P of Controlled Axis out of range ML_TechRegi.library

106 100/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library ErrorID Additional1 Additional2 Description INPUT_INVA LID_ERROR(16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR 16# #0001 "HighLimit" < "LowLimit" 16# #0002 "PControl" < 0 16# #0001 Selected "ControlledValueIDN" is not supported 16# #0002 Input invalid "CorrectionMode" 16# #0003 "CorrectionStart" = "CorrectionEnd" 16# #0004 Input "ModuloValue" invalid 16# #0002 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0003 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0004 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0005 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0006 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0007 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0008 Measured or Controlled axis is an MLD-M slave, but Parameter P , Bit 6 is not TRUE Fig.4-20: MB_RegisterControllerType04 Short Description MB_RegisterControllerType03 Error Codes The MB_RegisterControllerType04 register controller function block supports the following functionality: Calculate a correction value based on both measured and setpoint value using a P or PI control loop Preset feature Pause feature Min/Max limiting of the calculated control value Correction window feature Shifting register Dead band Kp characteristic curve PT1 element Lock setpoint on demand Mark gating feature

107 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 101/190 Interface Description Fig.4-21: I/O Type Name Data Type Comment MB_RegisterControllerType04. Function Block VAR_IN_OUT Setpoint REAL Desired value. Will be compared to "RecordedPosition" MeasuredAxis AXIS_REF Reference to the measured axis ControlledAxis AXIS_REF Reference to the controlled axis VAR_INPUT Enable BOOL Enables the Register Controller ML_TechRegi.library Pause BOOL The "Pause" input will only be evaluated while the "Enable" input is active. Pause is intended to keep the "ControlValue" and "ParameterControlValue" constant in a steady state. Preset BOOL The "Preset" input will only be evaluated while "Enable" is TRUE. A positive edge of this input forces the control loop to "PresetValue". In addition, this function sets the controlled parameter to the value of "PresetValue" Step UINT Edge detection for example from MB_TouchProbeContinuous DisableCyclicWrites BOOL Disable writing to the "ControlledValueIDN" internally from the FB. If TRUE the user has to link the output "Parameter ControlValue" for the control functionality SetpointLock BOOL Enables set point lock. If TRUE, the next measured mark will be latched. PresetValue REAL This is the value passed to the system when the Preset function becomes active ClearMeasValMem BOOL Clear the memory for the measured values which is used by the probe distance function ControlPolarity BOOL The polarity of the control value is inverted while this input is TRUE

108 102/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library I/O Type Name Data Type Comment ControlledValueIDN MB_IDN Sercos-IDN of the controlled parameter (e.g. P ).The following IDN s are supported: MLD: P , P , P , P , P , P MLC: A , P , A , P , A , P , A , P , A , P , A PControl REAL Proportional gain of the PI controller. If set to 0, the proportional part of the controller is disabled and the proportional gain is set internally to 1 in order to work as an I-Controller. IControl REAL Integral time Tn of the PI controller. If set to 0, the integral part of the PI-controller is disabled. TControl REAL Filter constant for the input "RecordedPosition" ModuloValue REAL ModuloValue from measured probe signal HighLimit REAL This is the maximum value for "ControlValue" LowLimit REAL This is the minimum value for "ControlValue" CorrectionMode MB_CORREC TION_MODE CORR_ABS = absolute correction window within [CorrectionStart.. CorrectionEnd]. A modulo value is considered. CORR_REL = correction start relative after measured value detection, end of correction relative. Correction window is [measured value + CorrectionStart.. measured value + CorrectionEnd] CORR_REL_ABS = Correction start relative after measured value detection, end of correction absolute. Correction window is [measured value + CorrectionStart.. CorrectionEnd] CORR_ABS_REL = Correction start absolute value, end of correction relative to measured value detection. Correction window is [CorrectionStart.. measured value + CorrectionEnd] CORR_WIN_DISABLED = Correction window is disabled CorrectionStart REAL Start of the correction window: Is an absolute angle or an offset to the measured value CorrectionEnd REAL End of the correction window: Is an absolute angle or an offset to the measured value RecordedPosition REAL Position where edge occurred (in technical units) ResponseCurve ARRAY[0..3] OF IL_COORD Characteristic curve ProbeDistance UINT The distance between marks sensor and regulated axis in format lengths (master axis revolutions, formats). MissedMarksCnt UNIT Counter missing marks if using expectation window MarkGating UINT Every N-th mark will be used for registration. VAR_OUTPUT InOperation BOOL Registration controller is running Error BOOL Indicates an error. Clear error with Enable = FALSE ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL Register controller is in pause

109 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 103/190 I/O Type Name Data Type Comment PresetAck BOOL Preset function is done ActStep UINT Step Value, counting with every new value on the output "ControlValue" SetpointLockAck BOOL Setpoint lock is done ClearMeasValMemAck BOOL Clearing the memory of the measured values is done HighLimitActive BOOL High limit is active. "ControlValue" would be higher, but is limited to "HighLimit" LowLimitActive BOOL Low limit is active."controlvalue" would be lower, but is limited to "LowLimit" ControlValue REAL Control value calculated by the registration controller CurrentValue REAL Current value used in the register controller. It is equal to Input "RecordedPosition" if "ProbeDistance" and "MarkGating" are disabled. Deviation REAL "Deviation" = ("Setpoint" - "CurrentValue") of the register controller ParameterControlValue REAL Fig.4-22: This calculated value is written to the drive or control parameter set in input "ControlledValueIDN". MB_RegisterControllerType04 I/O Interface Min/Max Values and Default Values of the Inputs Name Type Min Value Max Value Default Value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Preset BOOL FALSE Step UINT DisableCyclic Writes "Enable TRUE (continuous) Continuous. Starts on rising edge of Enable and falling edge of Pause BOOL FALSE Continuous SetpointLock BOOL FALSE Continuous ClearMeasValMem BOOL FALSE Continuous PresetValue REAL n.def n.def 0.0 Rising edge on Preset ControlPolarity BOOL FALSE Continuous ControlledValueIDN DINT n.def n.def 0 Rising edge on Enable Setpoint REAL n.def n.def 0.0 Change of "Step" PControl REAL 0.0 n.def 1.0 Continuous IControl REAL 0.0 n.def 0.0 Continuous TControl REAL 0.0 n.def 0.0 Continuous ModuloValue REAL 0.0 n.def 0.0 ML_TechRegi.library Rising edge of Enable

110 104/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Name Type Min Value Max Value Default Value Effective HighLimit REAL LowLimit n.def 0.0 Continuous LowLimit REAL n.def HighLimit 0.0 Continuous CorrectionMode MB_CORREC TION_MODE CORR_REL Continuous CorrectionStart REAL 0.0 ModuloValue 0.0 Continuous CorrectionEnd REAL 0.0 ModuloValue 0.0 Continuous RecordedPosition REAL n.def n.def 0.0 Change of Step ResponseCurve ARRAY[0..3] OF IL_COORD n.def n.def 0.0 Continuous ProbeDistance UINT Continuous MissedMarksCnt UINT MarkGating UINT Timing Diagram Functional Description Fig.4-23: Overview Min/Max Values and Default Values of the Inputs Continuous. Init on rising edge of "Enable" and falling edge of "Pause" Rising edge on "Enable". A value of "0" disables mark gating (identical to a value of "1") The following diagram shows the signal timing of MB_RegisterController Type04 including Pause and Preset functions. Fig.4-24: Timing Diagram of MB_RegisterControllerType04 with Pause and Preset Function A sensor detects marks, perforations, cuts or pasted joints on the material and provides a (binary) signal to the drive. The probe feature of the drive determines the edge of the sensor signal and latches the following positions, depending on the signal selection of the probe.

111 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 105/190 ML_TechRegi.library Drive feedback position parameters: S , S , P Master axis position parameters: P , P , P , P , P The probe function records positional data with a resolution of 0.5 µs. The sensor must provide a 24V signal with a rise time in the µs range. The sensor specific delay time can be compensated using the "DeadTimePosEdge" or "DeadTimeNegEdge" inputs of the MB_InitTouchProbe function block. The register controller calculates the control deviation between the measured and setpoint positions and determines the required correction value once a new edge of the sensor signal is detected. Changes of the correction value become active via the trapezoidal profile, velocity ramp, PT1-filter or instantaneously, depending on the selected control parameter ("ControlledValueIDN") input of the function block. The following table shows the available control parameters ("ControlledValueIDN") as well the resulting motion profile of all available drive operation modes with synchronization.

112 106/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Initialization PresetValue Fig.4-25: Supported Control Parameter and Behavior An Integration is done for the following "ControlledValueIDN" values: P , A P , A P , A P , A During initialization, the Setpoint and RecordedPosition inputs must have valid data. An uninterrupted start of the the controller outputs "ControlValue" and "CommandPosition require that the "Preset" input be set before the "Enable" input is activated. During this period, the Setpoint and RecordedPosition inputs must have valid data. In addition, the upper limits and lower limits are monitored

113 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 107/190 Pause Lock Setpoint Correction Window ML_TechRegi.library for activation to ensure a limitation of the ControlValue output if the set value for PresetValue is outside the limits of HighLimit or LowLimit. PresetAck is active, if the value on PresetValue is taken into account. Preset has the priority over Pause. The value PresetValue is taken into account on a rising edge at Preset, if Enable is active. If successful, the output PresetAck is set TRUE. The "Pause" input is only evaluated as long as the Enable input is active. In this case, the deviation ( "Setpoint" "RecordedPosition") is set to 0. This causes "ControlValue" and "CommandPosition" to be fixed. This can be used in addition to constantly hold the output in a stable state. The ActStep output gets updated even if the Pause input is active. As long as Pause is active, the InPause output is TRUE. To achieve a manual/automatic mode changeover (use the actual control value RecordedPosition as setpoint), the lock setpoint feature is present. If the input becomes TRUE the value of Setpoint is overwritten with the value of RecordedPosition at the next change of the Step input. This feature allows the user e.g. to enable and pause the register controller function and then to jog the system so that it is in register. Then activate the SetpointLock input to use the next latched RecordedPosition as Setpoint. The correction window is an angular range relating to the measuring axis. The register controller regulates the control deviations within this window. The position and size of the correction window are set with the help of the following inputs: The CorrectionMode input sets the correction window either absolute or relative. If the "CorrectionMode is set to CORR_WIN_DISABLED, the correction window is inactive. The "CorrectionStart input defines the start of the correction window. The CorrectionEnd input defines the end of the correction window. The correction window supports only a positive number of revolutions of the measuring axis.

114 108/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library a: Start correction window b: End correction window c: Correction window d: Expectation window Fig.4-26: Correction Window Absolute

115 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 109/190 a: Start correction window = measuring end b: Relative end of correction window to measuring end c: Correction window d: Expectation window Fig.4-27: Correction Window Relative ML_TechRegi.library

116 110/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Smoothing ProbeDistance a: Start correction window = measuring end b: End of correction window = perm. angle c: Correction window d: Expectation window Fig.4-28: Correction Window Relative Start Absolute End The "TControl" input is the attenuation constant for the RecordedPosition input. If set to 0, smoothing is inactive. In the simplest case, the measuring axis is a format cylinder ( = regulated axis) and the distance of the sensor to the measuring (= regulated) axis is less than the format length. Measurement and correction relate to the same product. Many times it is necessary to mount the mark reader (sensor) further away from the measuring axis, e.g., hazardous areas in printing facilities. If the distance is greater than the format length, then the measured register error cannot be corrected until the product has reached the format cylinder. The correction must be delayed by as many formats as there are formats between the regulated axis and the sensor. The ProbeDistance input is the distance between the mark reader (sensor) and the regulated axis in format lengths (master axis revolutions, formats). If set to 0, the distance of the sensor to the measuring axis is less than the format length.

117 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 111/190 Fig.4-29: Probe Distance Clearing the Internal Memory of Measured Values The probe distance feature contains an internal memory that stores measured values (like a shift register). This internal memory can be cleared (set to 0 ) using the ClearMeasValMem input. The differential signal from the filtered RecordedPosition input and the Setpoint input is weighted via the ResponseCurve input. A characteristic curve is used in order to pause the register controller within small registration errors. This feature allows the user to control the registration only every N-th mark by gating invalid marks. This can be used e.g. if the marks on the web were printed with a cliche where the printed image appears several times. In this situation, the mark distances between consecutive marks are not constant. For example, the mark distances between every N-th consecutive mark is constant. The register controller then only uses every N-th mark for the register control. Fig.4-30: Mark Gating The RegisterController only calculates a new value if the Step input changes. The PControl, IControl and TControl controller parameters can be changed continuously. In the event that the controlled axis is a real axis, the used "ControlledValueIDN" (P-Parameter must be used) has to be configured in the MDT of the controlled axis. In the event of a virtual axis, the A-Parameter must be used as "ControlledValueIDN". The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR RESOURCE_ERROR DeadBand MarkGating Normal Operation Necessary Parameterization Error Handling 16# #0000 Drive is not enabled or drive error 16# #0000 Drive firmware not supported ML_TechRegi.library

118 112/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library ErrorID Additional1 Additional2 Description STATE_MA CHINE_ERROR (16#0005) RESOURCE_ERROR INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) 16# #0000 Invalid state of function block 16# #0000 Selected Axis (Axis_Ref) was changed while FB is in operation 16#000D 16#0000 AxisRef is outside valid range(measured) 16#000D 16#0001 AxisRef is outside valid range(controlled) 16# #0001 Input "ProbeDistance" isn't in valid range (0<= ProbeDistance <=30) 16# #0002 Input "Setpoint" > "ModuloValue" 16# #0003 Input "Setpoint" < 0 16# #0004 Input "Feedback" > "ModuloValue" 16# #0005 Input "Feedback" < 0 16# #0006 Input "ModuloValue" < 0 16# #0007 Input "MarkGating" < 0 16#0C01 16#0001 "LowLimit" > "HighLimit' 16#0C01 16#0002 Selection of controller typ isn't supported. Check Inputs "IControl" and "PControl" 16#0C02 16#0001 Input "TControl" isn t valid 16#0C02 16#0003 Input "IControl" isn't valid 16#0C02 16#0004 Input "PControl" isn't valid 16#0C05 16#0001 X-Value in ResponseCurve not in ascending order 16#0C05 16#0002 More than one value for one X-Position in ResponseCurve 16#0C05 16#0003 Negative X-Value in ResponseCurve" 16# #0001 "CorrectionEnd" < "Correction Start" 16# #0002 Input "CorrectionStart" < 0 16# #0003 Input "CorrectionEnd" < 0 16# #0004 Value < 0 Input "ModuloValue"

119 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 113/190 ErrorID Additional1 Additional2 Description INPUT_INVA LID_ERROR(16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR 16# #0005 Value < 0 Input "RecordedPosition" 16# #0006 Input "CorrectionStart" > ModuloValue 16# #0007 Input "CorrectionEnd" > "ModuloValue" 16# #0008 Input "RecordedPosition" > "ModuloValue" 16# #0009 Correction path > "ModuloValue" 16# #000A S or A of Controlled Axis out of range 16# #000B S or A of Controlled Axis out of range 16# #000C P of Controlled Axis out of range 16# #0001 "HighLimit" < "LowLimit" 16# #0002 "PControl" < 0 16# #0001 Selected "ControlledValueIDN" is not supported 16# #0002 Input invalid "CorrectionMode" 16# #0003 "CorrectionStart" = "CorrectionEnd" 16# #0004 Input "ModuloValue" invalid 16# #0002 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0003 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0004 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0005 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0006 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0007 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0008 Measured or Controlled axis is an MLD-M slave, but Parameter P , Bit 6 is not TRUE Fig.4-31: MB_RegisterControllerType04 Error Codes ML_TechRegi.library

120 114/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library 4.3 Side Register Controller MB_RegisterControllerSideType01 Short Description Interface Description The The MB_RegisterControllerSideType01 register controller function block supports the following functionality: Calculate a correction value based on both measured and setpoint values using a P or PI control loop Preset feature Pause feature Min/Max limiting of the calculated control value Setpoint lock feature Fig.4-32: I/O Type Name Data Type Comment MB_RegisterControllerSideType01 Function Block VAR_IN_OUT SetpointWidth REAL Desired value (in technical units) ControlledAxis AXIS_REF Reference to the controlled axis VAR_INPUT Enable BOOL The function block is active while the input is TRUE. Pause BOOL The "Pause" input will only be evaluated while the "Enable" input is active. Pause is intended to keep the "ControlValue" and "CommandPosition" constant in a steady state. Preset BOOL The "Preset" input will only be evaluated while "Enable" is TRUE. A positive edge of this input forces the control loop to "PresetValue". In addition, this function sets the controlled parameter to the value of "PresetValue" Step UINT Edge detection for example from MB_TouchProbeContinuous PresetValue REAL The value in this input is passes to the system when the Preset function becomes active. SetpointLock BOOL Enables set point lock. If TRUE, the next measured mark will be latched.

121 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 115/190 I/O Type Name Data Type Comment ControlPolarity BOOL The polarity of the control value is inverted while this input is TRUE. ControlledValueIDN MB_IDN The following control IDN is supported: S PControl REAL Proportional gain of the PI controller. If set to 0, the proportional part of the controller is disabled and the proportional gain is set internally to 1 in order to work as an I-Controller. IControl REAL Integral time Tn of the PI controller. If set to 0, the integral part of the PI-controller is disabled. TControl REAL Filter constant for the "RecordedPositionWidth" input HighLimit REAL This is the maximum value for "ControlValue" LowLimit REAL This is the minimum value for "ControlValue" RecordedPosition Width ResponseCurve REAL ARRAY[0..3] OF IL_COORD Width of measured mark (in technical units). Characteristic curve FormatLength REAL Length of the format in mm TriangleTangent REAL Value of tan α = ( opposite leg length / adjacent leg length ) VAR_OUTPUT InOperation BOOL Side register controller is in operation Error BOOL Indicates an error Clear error with Enable = FALSE ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL Side register controller is paused PresetAck BOOL Preset function is done ActStep UINT Step Value, counting with every new value on the "Control Value" output. SetpointLockAck BOOL Setpoint lock is done Note: The process controller is paused and output "ActStep" is still counting with every new value on input "Step". HighLimitActive BOOL High limit is active. ControlValue would be higher, but is limited to "HighLimit" LowLimitActive BOOL Low limit is active. ControlValue would be lower, but is limited to "LowLimit" ControlValue REAL Control value calculated by the registration controller. CurrentValue REAL Actual value used in the register controller side. Note: Transformed RecordedPositionWidth value. Deviation REAL Difference SetpointSide ( transformed SetpointWidth ) - "CurrentValue" of the side register controller (mm) CommandPosition REAL Calculated command position for the drive. Fig.4-33: MB_RegisterControllerSideType01 I/O Interface ML_TechRegi.library

122 116/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Min/Max Values and Default Values of the Inputs Name Type Min Value Max Value Default Value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Preset BOOL FALSE Step UINT PresetValue REAL n.def n.def 0.0 "Enable TRUE (continuous) Continuous. Starts on rising edge of "Enable" and falling edge of "Pause" Rising edge on Preset ControlPolarity BOOL FALSE Continuous ControlledValueIDN DINT n.def n.def 0 PControl REAL 0.0 n.def 1.0 Continuous IControl REAL 0.0 n.def 0.0 Continuous TControl REAL 0 n.def 0.0 Continuous HighLimit REAL LowLimit n.def 0.0 Continuous LowLimit REAL n.def HighLimit 0.0 Continuous Rising edge on Enable RecordedPosition Width ResponseCurve REAL n.def n.def 0.0 Change of Step ARRAY[0..3] OF IL_COORD n.def n.def 0.0 Continuous FormatLength REAL 0.0 n.def 0.0 TriangleTangent REAL 0.0 n.def 1.0 Timing Diagram Fig.4-34: Overview Min/Max Values and Default Values of the Inputs Rising edge of "Enable" Rising edge of "Enable" The following diagram shows the signal timing of MB_RegisterControllerSide Type01 including the Pause and Preset functions.

123 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 117/190 Initialization PresetValue Pause Smoothing DeadBand FormatLength TriangleTangent Fig.4-35: Functional Description Timing Diagram of MB_RegisterControllerSideType01 with Pause and Preset Function During initialization, the Setpoint and RecordedPosition inputs must have valid data. An uninterrupted start of the the controller outputs "ControlValue" and "CommandPosition require that the "Preset" input be set before the "Enable" input is activated. During this period, the Setpoint and RecordedPosition inputs must have valid data. In addition, the upper limits and lower limits are monitored for activation to ensure a limitation of the ControlValue output if the set value for PresetValue is outside the limits of HighLimit or LowLimit. PresetAck is active, if the value on PresetValue is taken into account. Preset has the priority over Pause. The value PresetValue is taken into account on a rising edge at Preset, if Enable is active. If successful, the output PresetAck is set TRUE. The "Pause" input is only evaluated as long as the Enable input is active. In this case, the deviation ( "Setpoint" "RecordedPosition") is set to 0. This causes "ControlValue" and "CommandPosition" to be fixed. This can be used in addition to constantly hold the output in a stable state. The ActStep output gets updated even if the Pause input is active. As long as Pause is active, the InPause output is TRUE. The "TControl" input is the attenuation constant for the RecordedPosition input. If set to 0, smoothing is inactive. The differential signal from the filtered RecordedPosition input and the Setpoint input is weighted via the ResponseCurve input. A characteristic curve is used in order to pause the register controller within small registration errors. The length of the format (master axis revolutions, formats) in mm. The mark length between opposite leg and adjacent leg (tan α). ML_TechRegi.library

124 118/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Fig.4-36: Normal Operation Right Triangle Mark and Conical Frustum Mark The register controller side only calculates a new value if Input Step is changes. Controller parameters PControl, IControl and TControl can be continuously changed. The controlled axis must be an absolute linear axis. The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR STATE_MA CHINE_ERROR (16#0005) RESOURCE_ERROR RESOURCE_ERROR INPUT_INVA LID_ERROR(16#0001) IN PUT_RANGE_ERROR(16 #0006) IN PUT_RANGE_ERROR(16 #0006) IN PUT_RANGE_ERROR(16 #0006) Error Handling 16# #0000 Drive firmware not supported 16# #0000 Invalid state of function block 16#000D 16#0000 AxisNo of "ControlledAxis" is out of range 16# #0000 Axis has no power "ControlledAxis" 16# #0000 AxisRef has changed "ControlledAxis" 16# #0001 Selected "ControlledValueIDN" is not supported 16# #0001 "HighLimit" < "LowLimit" 16# #0002 "PControl" < 0 16# #0001 Input "SetpointWidth" < 0

125 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 119/190 ErrorID Additional1 Additional2 Description IN PUT_RANGE_ERROR(16 #0006) IN PUT_RANGE_ERROR(16 #0006) IN PUT_RANGE_ERROR(16 #0006) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) ACCESS_ERROR (16#0004) 16# #0002 Input "RecordedPositionWidth" < 0 16# #0003 Input "TriangleTangent" isn't in valid range 16# #0004 Input "FromatLength" isn't in valid range 16#0C01 16#0001 "LowLimit" > "HighLimit' 16#0C01 16#0002 Selection of controller typ isn't supported. Check Inputs "IControl" and "PControl" 16#0C02 16#0001 Input "TControl" isn t valid 16#0C02 16#0003 Input "IControl" isn't valid 16#0C02 16#0004 Input "PControl" isn't valid 16#0C05 16#0001 X-Value in ResponseCurve not in ascending order 16#0C05 16#0002 More than one value for one X-Position in ResponseCurve 16#0C05 16#0003 Negative X-Value in ResponseCurve" 16# #0007 Controlled axis is an MLD-M slave, but Parameter P , Bit 6 is not TRUE Fig.4-37: MB_RegisterControllerSideType01 Error Codes 4.4 Measured Value Processing and Regulate Function Blocks MB_RegiMeasuringType01 Short Description Interface Description The MB_RegiMeasuringType01 function block is used to process the measured probe signal. Fig.4-38: MB_RegiMeasuringType01 Function Block ML_TechRegi.library

126 120/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library I/O Type Name Data Type Comment VAR_INPUT VAR_OUTPUT Enable Pause Step BOOL BOOL UINT Setpoint REAL Desired value The Measuring function becomes active when this input is TRUE. The "Pause" input will only be evaluated while the "Enable" input is active. New values will only be calculated if this input changes. Feedback REAL The measured probe signal ModuloValue InOperation Error REAL BOOL BOOL ModuloValue from measured probe signal Measuring function is In Operation Indicates an error occurred during function block operation ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL The function block is paused. ActStep UINT Step Value, counting with every new value on the "Deviation" output Deviation REAL "Setpoint - Feedback" Fig.4-39: MB_RegiMeasuringType01 I/O Interface Min/Max Values and Default Values of the Inputs Name Type Min Value Max-value Default-value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Step UINT Continuous. Starts on rising edge of Enable and falling edge of Pause Setpoint REAL 0 ModuloValue 0.0 Change of Step Feedback REAL 0 ModuloValue 0.0 Change of Step ModuloValue REAL 0 n.def 0.0 Timing Diagram Fig.4-40: Overview Min/Max Values and Default Values of the Inputs Timing diagram according to PLCopen specification. Rising edge of Enable

127 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 121/190 Fig.4-41: Timing Diagram of MB_RegiMeasuringType02 The MB_RegiMeasuringType01 function block subtracts the "Setpoint" and "Feedback" inputs (Setpoint-Feedback). The result of the subtraction is the value of the "Deviation" output. The "Pause" input is only evaluated as long as the Enable input is active. The ActStep output is updated even if the Pause input is active. While Pause is active, the InPause output is true and the "Deviation" output is paused. The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR Functional Description STATE_MACHINE_ERROR (16#0005) RE SCOURCE_ERROR(16#000 3) Pause Error Handling 16# #0000 Drive firmware not supported 16# #0000 Invalid state of function block 16# # # #0002 Selected Axis (Axis_Ref) was changed while FB is in operation Input "Setpoint" > "ModuloValue" 16# #0003 Input "Setpoint" < 0 16# #0004 Input "Feedback" > "Modulo Value" 16# #0005 Input "Feedback" < 0 16# #0006 Input "ModuloValue" < 0 Fig.4-42: MB_RegiMeasuringType02 Short Description Interface Description MB_RegiMeasuringType01 Error Codes ML_TechRegi.library The MB_RegiMeasuringType02 function block is used to process the measured probe signal.

128 122/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Fig.4-43: MB_RegiMeasuringType02 Function Block I/O Type Name Data Type Comment VAR_IN_OUT MeasuredAxis AXIS_REF VAR_INPUT Enable BOOL Pause Preset Step BOOL BOOL UINT Reference to the measured axis Setpoint REAL Desired value The Measuring function becomes active when this input is TRUE. The "Pause" input will only be evaluated while the "Enable" input is active. The "Preset" input will only be evaluated while "Enable" is TRUE. A positive edge of this input forces the shift register memory to 0. New values will only be calculated when Step changes. Feedback REAL The measured probe signal ModuloValue ProbeDistance MissedMarksCnt REAL UINT UINT VAR_OUTPUT InOperation BOOL Error BOOL ModuloValue from measured probe signal The distance between mark sensor and measuring (= regulated) axis in master axis revolutions (format lengths) Counter for the missed marks if using a expectation window Measuring function is in Operation Indicates an error occurred during function block operation ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL RegiMeasuring function block is paused

129 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 123/190 I/O Type Name Data Type Comment PresetAck BOOL Preset function is done ActStep Deviation Fig.4-44: UINT REAL MB_RegiMeasuringType02 I/O Interface Min/Max Values and Default Values of the Inputs Step Value, counting with every new value on the output Deviation Delayed "Setpoint - Feedback", if shifting register is active Name Type Min Value Max Value Default Value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Preset BOOL FALSE Step UINT "Enable TRUE (continuous) Continuous. Starts on rising edge of Enable and falling edge of Pause Setpoint REAL 0 ModuloValue 0.0 Change of Step Feedback REAL 0 ModuloValue 0.0 Change of Step ModuloValue REAL 0 n.def 0.0 Rising edge of Enable ProbeDistance UINT Continuous MissedMarksCnt UINT Continuous Timing Diagram Functional Description Pause Preset Fig.4-45: Overview Min/Max Values and Default Values of the Inputs Timing diagram according to PLCopen specification. Fig.4-46: Timing Diagram of MB_RegiMeasuringType02 ML_TechRegi.library The MB_RegiMeasuringType02 function block subtracts the "Setpoint" and "Feedback" inputs (Setpoint-Feedback). The result of the subtraction is the value of the "Deviation" output when the shifit register is deactivated. If the shift register is activated, it will be the delayed by the number of "ProbeDistance". The "Pause" input is only evaluated as long as the Enable input is active. The ActStep output is updated even if the Pause input is active. While Pause is active, the InPause output is true and the "Deviation" output is paused. The shift register can be pre written with the Preset input. In order to pre write the shift register memory, Enable must be active. A zero value is written to

130 124/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library the memory on a rising edge of the Preset" input if Enable is active. If successful, the PresetAck output is set to TRUE. The ProbeDistance input is the distance between the mark sensor and the measuring (= regulated) axis, in master axis revolutions (format lengths). The maximum number of format lengths is 30. If ProbeDistance is 0, the shifting register is deactivated. The Deviation output is set to "Setpoint" "Feedback". If ProbeDistance is not 0, then the shift register is activated. This means that the values at the Deviation output are delayed by the number of master axis revolutions (format lengths) on input ProbeDistance. Fig.4-47: Setting Input "ProbeDistance" This is the missed mark counter if using an expectation window. If a mark is missed, a zero is written to the shift register if activated. In the event of a deactivated shifitng register, the zero is written to the "Deviation" output. The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR STATE_MACHINE_ERROR (16#0005) RE SCOURCE_ERROR(16#000 3) ProbeDistance MissedMarkCnt Error Handling 16# #0000 Drive firmware not supported 16# #0000 Invalid state of function block 16# # # # # #0002 Selected Axis (Axis_Ref) was changed while FB is in operation Input ProbeDistance isn t in valid range (0 <= "ProbeDistance" <= 30) Input "Setpoint" > "ModuloValue" 16# #0003 Input "Setpoint" < 0 16# #0004 Input "Feedback" > "Modulo Value" 16# #0005 Input "Feedback" < 0 16# #0006 Input "ModuloValue" < 0 Fig.4-48: MB_RegiMeasuringType02 Error Codes

131 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 125/ MB_RegiRegulateType01 Short Description Interface Description The MB_RegiRegulateType01 function block is used to write a control value to the drive. Fig.4-49: I/O Type Name Data Type Comment MB_RegiRegulateType01 Function Block VAR_IN_OUT ControlledAxis AXIS_REF Reference to the controlled axis VAR_INPUT Enable BOOL Enables the MB_RegiRegulateType01 FB Pause BOOL The "Pause" input will only be evaluated while the "Enable" input is active. Preset BOOL The "Preset" input will only be evaluated while "Enable" is TRUE. A positive edge of this input forces the Parameter ControlValue to PresetValue. Step UINT Edge detection DisableCyclicWrites BOOL Disable writing to the "ControlledValueIDN" internally from the FB. If TRUE, the user has to link to the "ParameterControlValue" output for the control functionality. PresetValue REAL A preset value that the "ParameterControlValue" output is set to on a rising edge of "Preset". ControlPolarity BOOL The polarity of the control value is inverted while this input is TRUE. ControlledValueIDN MB_IDN Sercos IDN of the controlled parameter (e.g. P ).The following IDN s are supported: MLD: P , P , P , P , P , P MLC: A , P , A , P , A , P , A , P , A , P , A ControlValue REAL Calculated control parameter from, for example, IL_PIType02 ModuloValue REAL ModuloValue from measured probe signal VAR_OUTPUT InOperation BOOL Function block is running ML_TechRegi.library

132 126/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library I/O Type Name Data Type Comment Error BOOL Indicates an error. Clear error with Enable = FALSE ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL Function block is paused. PresetAck BOOL Preset function is finished. ActStep UINT Step Value, counting with every new value on the output ParameterControlValue ParameterControlValue REAL Fig.4-50: This calculated value is written to the drive or control parameter set in input "ControlledValueIDN". MB_RegiMeasuringType01 I/O Interface Min/Max Values and Default Values of the Inputs Name Type Min Value Max Value Default Value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Preset BOOL FALSE Continuous Step UINT DisableCyclic Writes BOOL FALSE PresetValue REAL n.def n.def 0.0 Continuous. Starts on rising edge of Enable and falling edge of Pause Rising edge on Preset ControlPolarity BOOL FALSE Continuous Rising edge of "Enable" ControlledValueIDN DINT n.def n.def 0 Rising edge on Enable ControlValue REAL n.def n.def 0.0 Continuous ModuloValue REAL 0.0 n.def 0.0 Timing Diagram Fig.4-51: Overview Min/Max Values and Default Values of the Inputs Timing diagram according to PLCopen specification. Fig.4-52: MB_RegiRegulateType01 Timing Diagram Rising edge of Enable

133 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 127/190 The function block is used to write control values to a desired parameter in an axis. Depending of the desired target parameter, ControlledValueIDN, the function block incoporates an integration of the ParameterControlValue input. An integration is done for the following ControlledValueIDN values: P , A P , A P , A P , A The "Pause" input is only evaluated as long as the Enable input is active. The ActStep output is updated even if the Pause input is active. As long as Pause is active, the InPause output is TRUE and the "ParameterControl Value" output is paused. The PresetAck output is active if the value on PresetValue is taken into account. The Preset input has priority over Pause. The value in PresetValue is taken into account on a rising edge of Preset" if the Enable input is active. If successful, the PresetAck output is set TRUE and the value in "PresetValue" is written to the controlled parameter. Disables writing to the "ControlledValueIDN" internally from the FB. Every cycle a new "ParameterControlValue" is calculated. The RegiRegulateType is calculating only a new value if the Input Step is changing. The controlled axis must be modulo axis. In the event that the controlled axis is a real axis, the used "ControlledValueIDN" (P-Parameter must be used) has to be configured in the MDT of the controlled axis. In the event of an virtual axis, the A-Parameter must be used as "ControlledValueIDN". The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR RESOURCE_ERROR STATE_MA CHINE_ERROR (16#0005) RESOURCE_ERROR Functional Description Pause Preset DisableCyclicWrites Normal Operation Necessary Parameterization Error Handling 16# #0000 Drive is not enabled or drive error 16# #0000 Drive firmware not supported 16# #0000 Invalid state of function block 16# #0000 Selected axis (AXIS_REF) was changed while FB is in operation 16#000D 16#0000 AXIS_REF is outside valid range 16# #0004 Value < 0 Input "ModuloValue" 16# #0005 Value < 0 Input "RecordedPosition" 16# #0008 Input "RecordedPosition" > "ModuloValue" ML_TechRegi.library 16# #000A S or A of Controlled Axis out of range

134 128/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library ErrorID Additional1 Additional2 Description INPUT_INVA LID_ERROR(16#0001) INPUT_INVALID_ERROR (16#0001) ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR 16# #000B S or A of Controlled Axis out of range 16# #000C P of Controlled Axis out of range 16# #0001 Selected "ControlledValueIDN" is not supported 16# #0004 Input "ModuloValue" invalid 16# #0002 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0003 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0004 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0005 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0006 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0007 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0008 Controlled axis is an MLD-M slave, but Parameter P , Bit 6 is not TRUE Fig.4-53: MB_RegiRegulateType02 Short Description Interface Description MB_RegiRegulate01 Error Codes The MB_RegiRegulateType02 function block is used to write a control value to the drive. If the correction window is active, the control's deviations are corrected within one parameterized correction window. Fig.4-54: MB_RegiRegulateType02 Function Block

135 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 129/190 I/O Type Name Data Type Comment VAR_IN_OUT MeasuredAxis AXIS_REF Reference to the measured axis ControlledAxis AXIS_REF Reference to the controlled axis VAR_INPUT Enable BOOL Enables the MB_RegiRegulateType02 FB Pause BOOL The "Pause" input will only be evaluated while the "Enable" input is active. Preset BOOL The "Preset" input will only be evaluated while "Enable" is TRUE. A positive edge of this input forces the Parameter ControlValue to PresetValue. Step UINT Edge detection DisableCyclicWrites BOOL Disable writing to the "ControlledValueIDN" internally from the FB. If TRUE, the user has to link to the "ParameterControlValue" output for the control functionality. PresetValue REAL A preset value that "ParameterControlValue" is set to on a rising edge of "Preset". ControlPolarity BOOL The polarity of the control value is inverted while this input is TRUE. ControlledValueIDN MB_IDN Sercos-IDN of the controlled parameter (e.g. P ).The following IDN s are supported: MLD: P , P , P , P , P , P MLC: A , P , A , P , A , P , A , P , A , P , A ControlValue REAL Calculated control parameter from, for example, IL_PIType02 CorrectionMode MB_CORREC TION_MODE CORR_ABS = absolute correction window within [CorrectionStart.. CorrectionEnd]. Modulo value is considered. CORR_REL = correction start relative after measured value detection, end of correction relative. Correction window is [measured value + CorrectionStart.. measured value + CorrectionEnd] CORR_REL_ABS = Correction start relative after measured value detection, end of correction absolute. Correction window is [measured value + CorrectionStart.. CorrectionEnd] CORR_ABS_REL = Correction start absolute value, end of correction relative to measured value detection. Correction window is [CorrectionStart.. measured value + CorrectionEnd] CORR_WIN_DISABLED = Correction window is disabled CorrectionStart REAL Start of the correction window: Is an absolute angle or an offset to the measured value. CorrectionEnd REAL End of the correction window: Is an absolute angle or an offset to the measured value. RecordPosition REAL Axis position where edge occurred ModuloValue REAL ModuloValue from measured probe signal VAR_OUTPUT InOperation BOOL Function block is running ML_TechRegi.library

136 130/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library I/O Type Name Data Type Comment Error BOOL Indicates an error. Clear error with Enable = FALSE ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL Function block is in pause PresetAck BOOL Preset function is finished. ActStep UINT Step Value, counting with every new value on the ParameterControlValue output ParameterControlValue REAL Fig.4-55: This calculated value is written to the drive or control parameter set in input "ControlledValueIDN". MB_RegiMeasuringType02 I/O Interface Min/Max Values and Default Values of the Inputs Name Type Min-value Max-value Default-value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Preset BOOL FALSE Continuous Step UINT DisableCyclic Writes BOOL FALSE PresetValue REAL n.def n.def 0.0 Continuous. Starts on rising edge of Enable and falling edge of Pause Rising edge on Preset ControlPolarity BOOL FALSE Continuous Rising edge of "Enable" ControlledValueIDN DINT n.def n.def 0 ControlValue REAL n.def n.der 0.0 Continuous CorrectionMode Rising edge on Enable MB_CORREC TION_MODE 0 4 CORR_REL Continuous CorrectionStart REAL 0.0 ModuloValue 0.0 Continuous CorrectionEnd REAL 0.0 ModuloValue 0.0 Continuous RecordedPosition REAL 0.0 ModuloValue 0.0 ModuloValue REAL 0.0 n.def 0.0 Timing Diagram Fig.4-56: Change of Input "Step" Overview Min/Max Values and Default Values of the Inputs Timing diagram according to PLCopen specification. Rising edge of Enable

137 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 131/190 Functional Description Pause Preset DisableCyclicWrites Correction Window Fig.4-57: Timing diagram of MB_RegiRegulateType02 The function block is used to write control values to a desired parameter in an axis. Depending of the desired target parameter, ControlledValueIDN, the function block incoporates an integration of the ParameterControlValue input. An integration is done for the following ControlledValueIDN values: P , A P , A P , A P , A ML_TechRegi.library The "Pause" input is only evaluated as long as the Enable input is active. The ActStep output is updated even if the Pause input is active. As long as Pause is active, the InPause output is TRUE and the "ParameterControl Value" output is paused. The PresetAck output is active if the value on PresetValue is taken into account. The Preset input has priority over Pause. The value in PresetValue is taken into account on a rising edge of Preset" if the Enable input is active. If successful, the PresetAck output is set TRUE and the value in "PresetValue" is written to the controlled parameter. Disables writing to the "ControlledValueIDN" internally from the FB. Every cycle a new "ParameterControlValue" is calculated. The correction window is an angular range relating to the measuring axis. The register controller regulates the control deviations within this window. The position and size of the correction window are set with the help of the following inputs: The CorrectionMode input sets the correction window either absolute or relative. If the "CorrectionMode is set to CORR_WIN_DISABLED, the correction window is inactive. The "CorrectionStart input defines the start of the correction window. The CorrectionEnd input defines the end of the correction window. The correction window supports only a positive number of revolutions of the measuring axis.

138 132/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library a: Start correction window b: End correction window c: Correction window d: Expectation window Fig.4-58: Correction Window Absolute

139 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 133/190 a: Start correction window = measuring end b: Relative end of correction window to measuring end c: Correction window d: Expectation window Fig.4-59: Correction Window Relative ML_TechRegi.library

140 134/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Normal Operation Necessary Parameterization Data Type MB_CORRECTION_MODE Error Handling a: Start correction window = measuring end b: End of correction window = perm. angle c: Correction window d: Expectation window Fig.4-60: Correction Window Relative Start Absolute End The RegiRegulateType function block only calculates a new value if the Step Input changes. The controlled and measured axis must be modulo axes. In the event that the controlled axis is a real axis, the used "ControlledValueIDN" (P-Parameter must be used) has to be configured in the MDT of the controlled axis. In the event of an virtual axis, the A-Parameter must be used as "ControlledValueIDN". Modes of the correction window. Program: TYPE MB_CORRECTION_MODE: (CORR_WIN_DISABLED :=0, (*Correction window is disabled *) CORR_ABS :=1, (*Correction window is absolute *) CORR_REL :=2, (*Correction window is relative *) CORR_REL_ABS :=3, (*Correction window is relative *) (* start and absolute end *) CORR_ABS_REL :=4);(*Correction window is absolute *) (* start and relative end *) END_TYPE The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170:

141 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 135/190 ErrorID Additional1 Additional2 Description RESOURCE_ERROR RESOURCE_ERROR STATE_MA CHINE_ERROR (16#0005) RESOURCE_ERROR 16# #0000 Selected axis (AXIS_REF) was changed while FB is in operation INPUT_INVA LID_ERROR(16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) ACCESS_ERROR ACCESS_ERROR 16# #0000 Drive is not enabled or drive error 16# #0000 Drive firmware not supported 16# #0000 Invalid state of function block 16#000D 16#0000 AXIS_REF is outside valid range 16# #0001 "CorrectionEnd" < "Correction Start" 16# #0002 Input "CorrectionStart" < 0 16# #0003 Input "CorrectionEnd" < 0 16# #0004 Value < 0 Input "ModuloValue" 16# #0005 Value < 0 Input "RecordedPosition" 16# #0006 Input "CorrectionStart" > ModuloValue 16# #0007 Input "CorrectionEnd" > "ModuloValue" 16# #0008 Input "RecordedPosition" > "ModuloValue" 16# #0009 Correction path > "ModuloValue" 16# #000A S or A of Controlled Axis out of range 16# #000B S or A of Controlled Axis out of range 16# #000C P of Controlled Axis out of range 16# #0001 Selected "ControlledValueIDN" is not supported 16# #0002 Input invalid "CorrectionMode" 16# #0003 "CorrectionStart" = "CorrectionEnd" 16# #0004 Input "ModuloValue" invalid ML_TechRegi.library 16# #0002 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0003 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis

142 136/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library ErrorID Additional1 Additional2 Description ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR 16# #0004 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0005 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0006 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0007 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis 16# #0008 Measured or Controlled axis is an MLD-M slave, but Parameter P , Bit 6 is not TRUE Fig.4-61: MB_RegiRegulateType04 Short Description Interface Description MB_RegiRegulate02 Error Codes The MB_RegiRegulateType04 function block is used to write a control value to up to eight drives. If the correction window is active, the control deviations are corrected within one parameterized correction window. Fig.4-62: I/O Type Name Data Type Comment VAR_IN_OUT MeasuredAxis ARRAY [1..8] OF AXIS_REF MB_RegiRegulateType04 Function Block Reference to the measured axis ControlledAxis AXIS_REF Reference to the controlled axis VAR_INPUT Enable BOOL Enables the MB_RegiRegulateType04 Pause BOOL The "Pause" input will only be evaluated while the "Enable" input is active. Preset BOOL The "Preset" input will only be evaluated while "Enable" is TRUE. A positive edge of this input forces the Parameter ControlValue to PresetValue. Step UINT Edge detection DisableCyclicWrites BOOL Disable writing to the "ControlledValueIDN" internally from the FB. If TRUE, the user has to link to the "ParameterControlValue" output for the control functionality.

143 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 137/190 I/O Type Name Data Type Comment PresetValue REAL A preset value that "ParameterControlValue" is set to on a rising edge of "Preset". ControlPolarity BOOL The polarity of the control value is inverted while this input is TRUE. ControlledValueIDN ARRAY [1..8] OF MB_IDN Sercos-IDN of the controlled parameter (e.g. P ).The following IDN s are supported: MLD: P , P , P , P , P , P MLC: A , P , A , P , A , P , A , P , A , P , A ControlValue REAL Calculated control parameter from, for example, IL_PIType02 CorrectionMode MB_CORREC TION_MODE CORR_ABS = absolute correction window within [CorrectionStart.. CorrectionEnd]. A modulo value is considered. CORR_REL = correction start relative after measured value detection, end of correction relative. Correction window is [measured value + CorrectionStart.. measured value + CorrectionEnd] CORR_REL_ABS = Correction start relative after measured value detection, end of correction absolute. Correction window is [measured value + CorrectionStart.. CorrectionEnd] CORR_ABS_REL = Correction start absolute value, end of correction relative to measured value detection. Correction window is [CorrectionStart.. measured value + CorrectionEnd] CORR_WIN_DISABLED = Correction window is disabled CorrectionStart REAL Start of the correction window: Is an absolute angle or an offset to the measured value. CorrectionEnd REAL End of the correction window: Is an absolute angle or an offset to the measured value. RecordedPosition REAL Axis position where edge occurred ModuloValue REAL ModuloValue from measured probe signal AxisFactor ARRAY [1..8] OF REAL VAR_OUTPUT InOperation BOOL Function block is running Error BOOL Indicates an error. Factor to archive an axis dependent weighting. The value of ParameterControlValue is multiplied with this axis dependent factor (ARRAY) and is distributed to every controlled axis Clear error with Enable = FALSE ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed error description InPause BOOL Function block is in pause PresetAck BOOL Preset function is finished. ML_TechRegi.library ActStep UINT Step Value, counting with every new value on the output "ParameterControlValue"

144 138/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library I/O Type Name Data Type Comment ParameterControlValue AxisControlValue REAL ARRAY [1..8] OF REAL Fig.4-63: This calculated value is written to the drive or control parameter set in input "ControlledValueIDN". Calculated control parameter which is written to the "ControlledValueIDN" input. The "AxisControlValue" is the weighted "ControlValue". Used for diagnostic purposes or if "DisableCyclicWrites = TRUE for further operation. MB_RegiMeasuringType04 I/O Interface Min/Max Values and Default Values of the Inputs Name Type Min-value Max-value Default-value Effective Enable BOOL FALSE Continuous Pause BOOL FALSE Continuous Preset BOOL FALSE Continuous Step UINT DisableCyclic Writes BOOL FALSE PresetValue REAL n.def n.def 0.0 Continuous. Starts on rising edge of Enable and falling edge of Pause Rising edge on Preset ControlPolarity BOOL FALSE Continuous Rising edge of "Enable" ControlledValueIDN ARRAY [1..8] OF DINT n.def n.def 0 ControlValue REAL n.def n.def 0.0 Continuous CorrectionMode Rising edge on Enable MB_CORREC TION_MODE 0 4 CORR_REL Continuous CorrectionStart REAL 0.0 ModuloValue 0.0 Continuous CorrectionEnd REAL 0.0 ModuloValue 0.0 Continuous RecordedPosition REAL 0.0 ModuloValue 0.0 ModuloValue REAL 0.0 n.def 0.0 AxisFactor ARRAY [1..8] OF REAL Timing Diagram Change of Input "Step" Rising edge of Enable n.def n.def 1.0 Continuous Fig.4-64: Overview Min/Max Values and Default Values of the Inputs Timing diagram according to PLCopen specification.

145 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 139/190 Functional Description Pause Preset DisableCyclicWrites Correction Window Fig.4-65: Timing diagram of MB_RegiRegulateType04 The function block is used to write control values to a desired parameter in an axis. Depending of the desired target parameter, ControlledValueIDN, the function block incorporates an integration of the ParameterControlValue input. An integration is done for the following ControlledValueIDN values: P , A P , A P , A P , A ML_TechRegi.library The "Pause" input is only evaluated as long as the Enable input is active. The ActStep output is updated even if the Pause input is active. As long as Pause is active, the InPause output is TRUE and the "ParameterControl Value" output is paused. The PresetAck output is active if the value on PresetValue is taken into account. The Preset input has priority over Pause. The value in PresetValue is taken into account on a rising edge of Preset" if the Enable input is active. If successful, the PresetAck output is set TRUE and the value in "PresetValue" is written to the controlled parameter. Disables writing to the "ControlledValueIDN" internally from the FB. Every cycle a new "ParameterControlValue" is calculated. The correction window is an angular range relating to the measuring axis. The register controller regulates the control deviations within this window. The position and size of the correction window are set with the help of the following inputs: The CorrectionMode input sets the correction window either absolute or relative. If the "CorrectionMode is set to CORR_WIN_DISABLED, the correction window is inactive. The "CorrectionStart input defines the start of the correction window. The CorrectionEnd input defines the end of the correction window. The correction window supports only a positive number of revolutions of the measuring axis.

146 140/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library a: Start correction window b: End correction window c: Correction window d: Expectation window Fig.4-66: Correction Window Absolute

147 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 141/190 a: Start correction window = measuring end b: Relative end of correction window to measuring end c: Correction window d: Expectation window Fig.4-67: Correction Window Relative ML_TechRegi.library

148 142/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library a: Start correction window = measuring end b: End of correction window = perm. angle c: Correction window d: Expectation window Fig.4-68: Correction Window Relative Start Absolute End The function block distributes the control value to up to 8 controlled axes. These axes are referenced by the ControlledAxis[ ] input array. The control value can be weighted with a different weighting factor AxisFactor[ ] for every controlled axis. The RegiRegulateType function block only calculates a new value if the Step Input changes. The controlled and measured axis must be modulo axes. In the event that the controlled axis is a real axis, the used "ControlledValueIDN" (P-Parameter must be used) has to be configured in the MDT of the controlled axis. In the event of an virtual axis, the A-Parameter must be used as "ControlledValueIDN". The function block generates the following error messages in Additional1/Additional2 using the "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR RESOURCE_ERROR Multiple axes Different Control Weighting Normal Operation Necessary Parameterization Error Handling STATE_MA CHINE_ERROR (16#0005) 16# #0000 Drive is not enabled or drive error 16# #0000 Drive firmware not supported 16# #0000 Invalid state of function block

149 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 143/190 ErrorID Additional1 Additional2 Description RESOURCE_ERROR 16# #0000 Selected Axis (AXIS_REF) was changed while FB is in operation 16#000D 16#0000 AXIS_REF is outside valid range 16# #0001 "CorrectionEnd" < "Correction Start" 16# #0002 Input "CorrectionStart" < 0 16# #0003 Input "CorrectionEnd" < 0 16# #0004 Value < 0 Input "ModuloValue" 16# #0005 Value < 0 Input "RecordedPosition" 16# #0006 Input "CorrectionStart" > ModuloValue 16# #0007 Input "CorrectionEnd" > "ModuloValue" 16# #0008 Input "RecordedPosition" > "ModuloValue" 16# #0009 Correction path > "ModuloValue" ML_TechRegi.library 16# #0010 S or A of Controlled Axis[1] out of range 16# #0011 S or A of Controlled Axis[2] out of range 16# #0012 S or A of Controlled Axis[3] out of range 16# #0013 S or A of Controlled Axis[4] out of range 16# #0014 S or A of Controlled Axis[5] out of range 16# #0015 S or A of Controlled Axis[6] out of range 16# #0016 S or A of Controlled Axis[7] out of range 16# #0017 S or A of Controlled Axis[8] out of range 16# #0020 S or A of Controlled Axis[1] out of range 16# #0021 S or A of Controlled Axis[2] out of range 16# #0022 S or A of Controlled Axis[3] out of range 16# #0023 S or A of Controlled Axis[4] out of range

150 144/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library ErrorID Additional1 Additional2 Description INPUT_INVA LID_ERROR(16#0001) INPUT_INVA LID_ERROR(16#0001) INPUT_INVA LID_ERROR(16#0001) INPUT_INVA LID_ERROR(16#0001) INPUT_INVA LID_ERROR(16#0001) INPUT_INVA LID_ERROR(16#0001) INPUT_INVA LID_ERROR(16#0001) INPUT_INVA LID_ERROR(16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) INPUT_INVALID_ERROR (16#0001) 16# #0024 S or A of Controlled Axis[5] out of range 16# #0025 S or A of Controlled Axis[6] out of range 16# #0026 S or A of Controlled Axis[7] out of range 16# #0027 S or A of Controlled Axis[8] out of range 16# #0030 P of Controlled Axis[1] out of range 16# #0031 P of Controlled Axis[2] out of range 16# #0032 P of Controlled Axis[3] out of range 16# #0033 P of Controlled Axis[4] out of range 16# #0034 P of Controlled Axis[5] out of range 16# #0035 P of Controlled Axis[6] out of range 16# #0036 P of Controlled Axis[7] out of range 16# #0037 P of Controlled Axis[8] out of range 16# #0001 Selected "ControlledValueIDN[1]" is not supported 16# #0005 Selected "ControlledValueIDN[2]" is not supported 16# #0006 Selected "ControlledValueIDN[3]" is not supported 16# #0007 Selected "ControlledValueIDN[4]" is not supported 16# #0008 Selected "ControlledValueIDN[5]" is not supported 16# #0009 Selected "ControlledValueIDN[6]" is not supported 16# #000A Selected "ControlledValueIDN[7]" is not supported 16# #000B Selected "ControlledValueIDN[8]" is not supported 16# #0002 Input invalid "CorrectionMode" 16# #0003 "CorrectionStart" = "CorrectionEnd" 16# #0004 Input "ModuloValue" invalid

151 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 145/190 ErrorID Additional1 Additional2 Description ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ML_TechRegi.library 16# #0002 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[1] 16# #0021 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[2] 16# #0022 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[3] 16# #0023 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[4] 16# #0024 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[5] 16# #0025 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[6] 16# #0026 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[7] 16# #0027 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[8] 16# #0003 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[1] 16# #0031 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[2] 16# #0032 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[3] 16# #0033 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[4] 16# #0034 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[5] 16# #0035 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[6] 16# #0036 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[7] 16# #0037 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[8] 16# #0004 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[1] 16# #0041 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[2] 16# #0042 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[3] 16# #0043 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[4] 16# #0044 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[5] 16# #0045 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[6] 16# #0046 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[7]

152 146/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library ErrorID Additional1 Additional2 Description ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR 16# #0047 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[8] 16# #0005 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[1] 16# #0051 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[2] 16# #0052 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[3] 16# #0053 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[4] 16# #0054 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[5] 16# #0055 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[6] 16# #0056 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[7] 16# #0057 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[8] 16# #0006 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[1] 16# #0061 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[2] 16# #0062 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[3] 16# #0063 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[4] 16# #0064 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[5] 16# #0065 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[6] 16# #0066 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[7] 16# #0067 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[8] 16# #0007 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[1] 16# #0071 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[2] 16# #0072 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[3] 16# #0073 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[4] 16# #0074 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[5] 16# #0075 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[6]

153 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 147/190 ErrorID Additional1 Additional2 Description ACCESS_ERROR ACCESS_ERROR ACCESS_ERROR 16# #0076 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[7] 16# #0077 Required parameter P is not configured in the optional cyclic MDT data of the controlled axis[8] 16# #0008 Measured or Controlled axis is an MLD-M slave, but Parameter P , Bit 6 is not TRUE Fig.4-69: MB_RegiRegulate04 Error Codes 4.5 Functions Blocks for the Q.I. Camera Sensor Actuation Overview Registration marks The Q.I. Press Control camera sensor identifies up to 6 defined quadratic registration marks and outputs the deviations via the integrated Ethernet interface. A camera is used for the mark identification. The sensor is to be configured for the pressure mark before measuring. The registrations marks are applied as small squares in a specified arrangement by each printing unit. Each printing unit applies color. The offset of the printing units can be determined using the deviations of the points from the command position. The following registration mark sizes are available: "SMALL" - 0.4mm marks in a 3.5x3.5mm arrangement ML_TechRegi.library

154 148/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Fig.4-70: Registration mark SMALL "TINY" - 0.2mm marks in a 1.8x1.8mm arrangement

155 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 149/190 Fig.4-71: Registration mark TINY "IRIS" - 0.2mm marks in a 4x3.8mm arrangement ML_TechRegi.library

156 150/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Communication Encoder Fig.4-72: Registration mark IRIS Registration mark 1 = Magenta Registration mark 2 = Black Registration mark 3 = Cyan Registration mark 4 = Yellow Registration mark 5 = PMS 1 Registration mark 6 = PMS 2 The sensor is actuated via an Ethernet 100baseTX interface. The sensor just supports a transmission rate of 100MBit/s. The IP address of the sensor is between and and results from the serial number. The data exchange is carried out with UDP packages on the UDP port of the sensor. The sensor sends its data always to the address of the data package received last. Therefore, it is not possible to connect with two controls on the sensor at the same time. There is no password protection. The sensor requires an encoder signal to identify the registration marks. It has to contain the zero pulse and from 100 to 4096 pulses between the zero pulses. Generally, the encoder signal is tapped by the motor encoder. It is also possible to generate it via an encoder simulation.

157 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 151/ MB_RegiSensor02ConfigType01 Brief description Interface description The MB_RegiSensor02ConfigType01 FB configures a Q.I. Press Control camera sensor to use is as measurement source in the register controller chain. Fig.4-73: Name Type Comment The MB_RegiSensor02ConfigType01 function block VAR_INPUT Execute BOOL Starts the Q.I. Press Control sensor configuration Format length REAL Format length in mm MarkStructure EncoderConfig MB_RE GI_MARK02_STRUC TURE MB_REGI_ENCOD ER_CONFIG Defines the mark size and the active marks Defines the measuring encoder settings. InverseDirection BOOL Camera position lengthways and in inverse direction Communication Config MB_REGI_COMMUNI CATION_CONFIG Contains the IP address of the camera. BarPosition REAL Camera position on the scanner bar VAR_OUTPUT Done BOOL The sensor configuration was completed successfully Active BOOL The FB is operating Error BOOL Indicates that an error occurred within the function block ErrorID ERROR_CODE Error identification ErrorIdent ERROR_STRUCT For the error structure with further error division, see Error codes, page 153. CameraVersion STRING Version identification of the camera VAR_INOUT RegiSensorCfg MB_REGI_SEN SOR02_CFG Note: The different inputs and outputs are described later in detail. Fig.4-74: Camera sensor settings. The MB_RegiSensor02ConfigType01 function block Name Type Min. value Max. value Default value Transfer Execute BOOL FALSE Continuous Format length REAL Rising edge at "Execute" Inverse direction BOOL FALSE Rising edge at "Execute" BarPosition REAL 0.0 n. def. 0.0 Rising edge at "Execute" Fig.4-75: Input behavior of the MB_RegiSensor02ConfigType01 FB ML_TechRegi.library

158 152/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Functional Description In case of a rising edge at "Execute", an UDP socket is opened and communication is tried. Therefore, the camera sensor specified in "CommunicationConfig" is used. The following parameters are written after the communication has been successfully established: Parameters Command Source Possible values Mark size RMT, RMS, RMI MarkStructure.MarkSize SMALL, TINY, IRIS Mark 1 active 1ON, 1OF MarkStructure.SelectMarks[1] TRUE, FALSE Mark 2 active 2ON, 2OF MarkStructure.SelectMarks[2] TRUE, FALSE Mark 3 active 3ON, 3OF MarkStructure.SelectMarks[3] TRUE, FALSE Mark 4 active 4ON, 4OF MarkStructure.SelectMarks[4] TRUE, FALSE Mark 5 active 5ON, 5OF MarkStructure.SelectMarks[5] TRUE, FALSE Mark 6 active 6ON, 6OF MarkStructure.SelectMarks[6] TRUE, FALSE Reference mark RFM, RFA, RFB MarkStructure.ReferenceMark MARK_1, MARK_2, MARK_BOTH Lengthways WDS, WDO InverseDirection TRUE, FALSE Format length RLxxxxx Format length 0, ,0 Encoder selection ENA, ENB EncoderConfig.EncoderSelect ENC_A, ENC_B Encoder resolution ENCxxxx EncoderConfig.EncoderSize Bar calibration CAL Bar target position SLxxxx BarPosition >0.0 Actual bar position APxxxx Communication Mark selection Encoder Camera positioning Camera bar Fig.4-76: Parameters used to configure the Q.I. camera sensor In the communication settings of the CommunicationConfig input, the IP address of the camera sensor has to be entered in the "IP" field. The other fields remain empty. The "MB_REGI_COMMUNICATION_CONFIG" data structure is described in MB_REGI_SENSOR02_CFG on page 155. The mark selection allows the setting of the mark size, the marks to be evaluated and the reference mark. The registration mark configuration can be set via the "MB_REGI_MARK02_STRUCTURE" data structure. The "MB_REGI_MARK02_STRUCTURE" data structure is described in MB_REGI_SENSOR02_CFG on page 155. The "MB_REGI_ENCODER_CONFIG" data structure contains the encoder interfaces configuration. It can be selected between the encoder inputs A and B and the encoder resolution can be set. The "MB_REGI_ENCODER_CONFIG" data structure is described in MB_REGI_SENSOR02_CFG on page 155. The camera can either be positioned in web direction or opposite web direction. The camera positioning can be specified via the "InverseDirection" input. The camera sensor does not find any marks due to an incorrect setting at the "InverseDirection" input. The MB_RegiSensor02ConfigType01 FB contains an optional camera bar actuation. The camera can be positioned on the bar via the "BarPosition" input. If the "BarPosition" is 0.0, the camera is not positioned.

159 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 153/190 RegiSensorCfg Signal-time diagram This data structure is filled by the FB. It contains all the settings that were also set to the camera. The data structure is to be created at the MB_RegiSensor02CycComType01 FB. The "MB_REGI_SENSOR02_CFG" data structure is described in MB_REGI_SENSOR02_CFG on page 155. The configuration starts when there is a rising edge at "Enable". An UDP socket is opened on the control. The socket is used for the UPD data package exchange with the sensor. "Active" is set to TRUE during the configuration. The socket is closed, "Active" is reset and "Done" is set after a successful configuration. If an error occurs, "Error" is TRUE and "ErrorID" as well as "ErrorIdent" contain valid error codes (also refer to Error codes, page 153.). The FB uses the error table F_RELATED_TABLE, 16#0170. It can generate the following error messages in Additional1/Additional2. ErrorID Additional1 Additional2 Description STATE_MACHINE_ERROR (16#0005) Error codes COMMUNICATION_ERROR (16#0002) 16# # Runtime error in the function block: Invalid state of the state machine 16# # Camera sensor not found INPUT_INVALID_ERROR, 16# # # Invalid mark size INPUT_INVALID_ERROR, 16# # # Invalid mark selection INPUT_INVALID_ERROR, 16# # # Invalid reference mark selection INPUT_INVALID_ERROR, 16# # # Invalid format length INPUT_INVALID_ERROR, 16# # # Invalid encoder INPUT_INVALID_ERROR, 16# # # Invalid encoder size Fig.4-77: MB_RegiSensor02CycComType01 Brief description Interface description Generated error numbers of the MB_RegiSensor02ConfigType01 FB The MB_RegiSensor02CycComType01 FB evaluates the measured values of the Q.I. Press Control camera sensor and provides the deviations in the registration mark for the controller chain. Fig.4-78: Name Type Comment The MB_RegiSensor02CycComType01 FB ML_TechRegi.library VAR_INPUT Enable BOOL Starts the measured value acquisition of the Q.I. Press Control sensor Pause BOOL The measured value acquisition is temporarily paused

160 154/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library Name Type Comment VAR_OUTPUT InOperation BOOL The measured value acquisition is active and the measured value outputs are valid. Error BOOL Indicates that an error occurred within the function block ErrorID ERROR_CODE Error identification ErrorIdent ERROR_STRUCT For the error structure with further error division, see Error codes, page 155. InPause BOOL Pause is set VAR_INOUT RegiSensorData MB_REGI_SEN SOR_DATA RegiSensorCfg MB_REGI_SEN SOR02_CFG Note: The different inputs and outputs are described later in detail. Fig.4-79: The measurement was paused. No new measured values are output Measured values of the registration mark Camera sensor settings The MB_RegiSensor02CycComType01 FB Name Type Min. value Max. value Default value Transfer Enable BOOL FALSE Continuous Pause BOOL FALSE Functional Description Sensor state Measured values Configuration Fig.4-80: Continuously if "InOperation" is TRUE Input behavior of the MB_RegiSensor02CycComType01 FB In case of a rising edge at "Enable", an UDP socket is opened and communication is tried with the camera sensor. Subsequently. the measured value transmission is started and set to "InOperation". If the sensor sends values, the deviations are output in longitudinal and lateral direction. The "ActStep" output is increased for each registration mark found. The outputs are not modified for non-configured registration marks. The sensor state is output in the "SensorState" array of the "RegiSensorData" output. It contains the sensor state. The "MB_REGI_SENSOR_STATE" data type is explained in MB_REGI_SENSOR_DATA on page 156. There is a new set of measured values whenever the "ActStep" array changes in the "RegiSensorData". The deviations of the marks are stored in the "RegiSensorData". For non-configurable marks, the respective entry is set on "NOT_CONFIGURED" in the "MarkState" array. Marks that are temporarily not found, get the "MISSING" entry in the "MarkState". The "LengthFeedback" array contains longitudinal deviations of the individual marks. The "SideFeedback" array contains lateral deviations of the individual marks. The values in "LengthFeedback" and "Side Feedback" are only valid if the respective entry in "MarkState" is set to "FOUND". The MB_REGI_SENSOR_DATA data structure is described in MB_RE GI_SENSOR_DATA on page 156. The "MB_REGI_SENSOR02_CFG" contains the configuration created by the MB_RegiSensor02ConfigType01 FB. The same data structure used when calling the configuration FB is to be created. The "MB_REGI_SENSOR02_CFG" data structure is explained in MB_REGI_SENSOR02_CFG on page 155.

161 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 155/190 The acquisition of the measured values starts when there is a rising edge at "Enable". An UDP socket is opened on the control. The socket is used for the UPD data package exchange with the sensor. "InOperation" is set on TRUE as soon as the measurement is started. At a falling edge at "Enable", the measurement is completed and the socket is closed. All Boolean outputs are reset. If an error occurs during the processing, "Error" is TRUE and "ErrorID" as well as "ErrorIdent" contain valid error codes (also refer to Error codes, page 155.). If the "Pause" input is enabled, the measured value acquisition is paused and the "InPause" output is set. No new measured values are generated and the step counter "ActStep" remains in the "RegiSensorData" output. The FB uses the error table F_RELATED_TABLE, 16#0170. It can generate the following error messages in Additional1/Additional2. ErrorID Additional1 Additional2 Description STATE_MACHINE_ERROR (16#0005) COMMUNICATION_ERROR (16#0002) 16# # Runtime error in the function block: Invalid state of the state machine 16# # Camera sensor not found Fig.4-81: MB_REGI_SENSOR02_CFG Generated error numbers of the MB_RegiSensor02CycComType01 FB The MB_REGI_SENSOR02_CFG data structure contains the configuration of a Q.I. camera sensor. It is written by the FB MB_RegiSensor02ConfigType01 on page 151 and evaluated by the FB MB_RegiSensor02CycComType01 on page 153. Name Type Description MarkStructure MB_REGI_MARK02_STRUCTURE Mark structure description EncoderConfig MB_REGI_ENCODER_CONFIG InverseDirection BOOL Camera positioning CommunicationData Signal-time diagram Error codes Brief description MarkStructure MB_REGI_COMMUNICATION_CONFIG Fig.4-82: Description of the measuring encoder configuration Description of the Ethernet communication settings Structural description of the MB_REGI_SENSOR02_CFG FB The mark selection allows the setting of the mark size, the marks to be evaluated as well as the reference mark. The registration mark configuration can be set via the "MB_REGI_MARK02_STRUCTURE" data structure. Name Type Default Description MarkSize MB_REGI_MARK_SIZE TINY Registration mark size SelectMarks ARRAY[1..6] OF BOOL [6(FALSE)] Registration marks to be evaluated ReferenceMark MB_REGI_REFERENCE MARK_BOTH Reference mark selection Fig.4-83: ML_TechRegi.library Structural description of the MB_REGI_MARK02_STRUCTURE FB

162 156/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description ML_TechRegi.library EncoderConfig Name Value Description SMALL 0 "SMALL" - 0.4mm marks in a 4x4mm arrangement TINY 1 "TINY" - 0.2mm marks in a 2x2mm arrangement IRIS 2 "IRIS" - 0.2mm marks in a 4x4mm arrangement Fig.4-84: Enumeration data type MB_REGI_MARK_SIZE Name Value Description MARK_BOTH 0 Registration mark 1 if not found, then registration mark 2 MARK_1 1 Registration mark 1 MARK_2 2 Registration mark 2 Fig.4-85: Enumeration data type MB_REGI_REFERENCE The "MB_REGI_ENCODER_CONFIG" data structure contains the encoder interfaces configuration. It can be selected between the encoder inputs A and B. The encoder resolution can be set as well. Name Type Default Description EncoderSelect MB_REGI_ENCODER_TYPES ENC_A Selecting the encoder input EncoderSize UINT 2500 Encoder resolution ( ) InverseDirection CommunicationData Fig.4-86: Structural description of the MB_REGI_ENCODER_CONFIG FB Name Value Description ENC_A 0 Encoder input A ENC_B 1 Encoder input B Fig.4-87: Enumeration data type MB_REGI_ENCODER_TYPES The camera can either be positioned in web direction or opposite web direction. The camera positioning can be specified via the "InverseDirection" array. The camera sensor does not find any marks due to an incorrect setting at the "InverseDirection" input. This structure contains all the data required to establish a communication with the sensor. Name Type Default Description IP STRING ' ' IP address of the sensor TcpPort UINT 0 Not used UdpPort UINT 0 UDP port Socket UDINT INVALID_SOCKET Not used Fig.4-88: MB_REGI_SENSOR_DATA Brief description Structural description of the MB_REGI_COMMUNICATION_CONFIG FB The MB_REGI_SENSOR_DATA data structure contains all the measured data of a sensor required for the closed loop register control. It is described by the function block MB_RegiSensor02CycComType01 on page 153.

163 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 157/190 Name Type Default Description ActStep UINT 0 Current step LengthFeedback ARRAY[0..16] OF REAL [17(0.0)] SideFeedback ARRAY[1..16] OF REAL [16(0.0)] MarkState ARRAY[0..16] OF MB_RE GI_MARK_STATE SensorState MB_SENSOR_MARK_STATE SENSOR_START ActStep SensorState MarkState LengthFeedback, SideFeedback Fig.4-89: Deviation in longitudinal direction for registration marks. Entry 0 is free, are marks Deviation in lateral direction for registration marks. [17(0.0)] State of the registration marks Sensor state Outputs warnings and diagnostics of the sensor while the measurement is executed. Structural description of the MB_REGI_SENSOR_DATA FB This data structure contains the measured values of a registration mark sensor. There is a new set of measured values if the "ActStep" array changes. This entry contains the complete state of the sensor. New measured values are only implemented in the "SENSOR_INOP" state. Name Value Description SENSOR_START 0 Starting state SENSOR_SEARCHING 1 Mark search SENSOR_INOP 2 Marks found - measured value acquisition running SENSOR_STOP 3 Evaluation stopped SENSOR_LAMP 4 Lamp defective SENSOR_DIRTY 5 Sensor dirty Fig.4-90: Enumeration data type MB_REGI_MARK_STATE This array contains a state for each registration mark. Found marks are in the "FOUND" state. It the mark is not found, the corresponding entry is provided with the value "MISSING". Mark that are not configured or not used are in the "NOT_CONFIGURED" state. Name Value Description FOUND 0 Mark found ROTATED 1 Mark rotated TOO_LARGE 2 Mark too large TOO_SMALL 3 Mark too small MISSING 4 Mark missing NOT_CONFIG URED Fig.4-91: 5 Mark not configured Enumeration data type MB_REGI_SENSOR_STATE ML_TechRegi.library The arrays "LengthFeedback" and "SideFeedback" contain longitudinal or lateral deviations of the individual marks. The values in "LengthFeedback" and "SideFeedback" are only valid if the respective entry in "MarkState" is set to "FOUND".

164 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description

165 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 159/190 5 RMB_TechCrossCutCrossSeal.library 5.1 RMB_TechCrossCutCrossSeal, Overview The library RMB_TechCrossCutCrossSeal contains the function blocks and data types for the cross cutter / cross sealer functionality in the MLC systems. Function blocks The MB_CrossCutSealType01, page 159 FB calculates, loads and activates a MotionProfile for cross sealer or cross cutter applications. MB_CrossCutCalcType04, page 172, data provision for a MotionProfile of an axis. Data types 5.2 MB_CrossCutSealType01 Library Brief description ML_TechCrossCutCrossSeal.library - MB_CAM_TABLE_DATA, page 180, array and meta data of a cam. MB_CORR_PROFILE, page 181, motion correction in the interface area. MB_RESOLUTION, page 182, number of cam table base elements and the required calculation time. MB_PUSH_OUT_CONFIG, page 183, PushOut at the end of the cut. The MB_CrossCutSealType01 FB calculates, loads and activates a Motion Profile for cross sealer or cross cutter applications. The function block uses the MB_CrossCutterCalcType04, page 172, FB internally for the calculation. With the calculated MotionProfile, the slave axis moves with product velocity within the sealing or cutting area. Other functions like OverSpeed, PushOut or cosine correction can be optionally added within this area. Outside the sealing or cutting area, an almost optimum compensating motion (with regard to acceleration and energy loss) is performed if the specified format length does not correspond to the distance of the knife or the sealing jaw. Furthermore, a pendular motion of the cross sealer or cross cutter axis within freely selectable limits can be predefined to optimally use the acceleration capacity of the drive in the case of large format lengths. During operation, input variables like, for example, the format length, can be changed to automatically calculate a new MotionProfile in the background. The newly calculated MotionProfile is then activated and becomes effective at the switching angle. At a negative edge at "Enable", either the cross sealer or the cross cutter are deactivated. The axis is immediately stopped via the predefined deceleration ramp. Fig.5-1: Range Library assignment RMB_TechCrossCutCrossSeal.library

166 160/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library Interface description Fig.5-2: Interface of the MB_CrossSealType01 FB Name Type Comment VAR_IN_OUT Master AXIS_REF Reference to the master axis Slave AXIS_REF Reference to the slave axis ( = cross cutter axis / cross sealer axis) VAR_INPUT Enable BOOL Processing enable of the FB The modulo value is 360 electrical and is mechanically defined as the distance between two knives / sealing jaws. CrossCutter BOOL If CrossCutter = TRUE, the cross cutter application (see the following detailed description) is selected. In this case, the master axis has to be standardized so that the material to be cut covers the distance in one revolution that corresponds to the knive distance. The electronic gear of the MotionProfile used is set to the gear transmission ratio "FormatLength / KnifeDistance". Furthermore, the input CutSealArea functions as the cut angle of the cross cutter whereas the input variables ProductsPerCut and StartProduct are not effective. If the CrossCutter = FALSE, the cross sealer application (see the following detailed description) is selected. In this case, the master axis has to be standardized so that one revolution corresponds to a foil feed of one product length. The electronic gear of the MotionProfile used is set to the gear ratio "1 / ProductsPerCut". Furthermore, the input CutSealArea corresponds to the sealing length and is thus defined in translatory units (e.g. mm or inch). The inputs ProductsPerCut and Start Product are evaluated in this case.

167 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 161/190 Name Type Comment StartMotionProfile BOOL The activation of a new MotionProfile is blocked as long as this input is set to FALSE. StartMotionProfile = TRUE activates the new MotionProfile if the output ProfileReady is TRUE. ProductsPerCut UINT Input is only effective if CrossCutter = FALSE. Number of products per sealing process. Corresponds to the number of master revolutions per sealing or cutting process. StartProduct UINT Input is only effective if CrossCutter = FALSE. NumberOfKnives UINT StartCamTableID In the case of more than one product per sealing or cutting process (ProductsPerCut > 1), the start product can be defined via this input when activating the function block. Number of sealing jaws or knives available on the circumference of the sealing or cutting cylinder. The sealing jaws or knives are positioned with same distance from each other. MC_CAM_ID Start number of the first cam table. A block of a maximum of 6 cam tables is required. KnifeDistance REAL Distance of the knives or sealing jaws. Corresponds to the circumference divided by the number of knives or sealing jaws [mm or inch]. Format length REAL Predefined cutting length or sealing distance / package length [mm or inch] CutSealArea REAL Within this area, the knife or the sealing jaw moves with the velocity of the product. The velocity within this window can be affected by additional inputs like, for example, OverSpeed, PushOut, cosine correction etc. If the input CrossCutter = FALSE, this input corresponds to the sealing length and is thus defined in translatory units (e.g. in mm or inch). If the input CrossCutter is TRUE, this input functions rotatorily as angle in [ ]. PendelumFactor REAL Maximum pendulum radius in [%] 0%: No pendular motion (standstill in the case of a large format length); 100%: Maximum pendular motion (pendular motion possible up to the edges of the sealing or cutting area). CorrectionProfile MB_CORR_PROFILE MB_CORR_PROFILE, page 181: Selection of a special profile. The inputs "OverSpeed" or "PushOut" have to be used for the parameterization of the special profile. Overspeed REAL Constant overspeed or reduction of the master axis velocity in the cutting area in [%] 0%: No overspeed RMB_TechCrossCutCrossSeal.library 100%: Double master axis velocity; -50%: Half the master axis velocity This input is only effective if the option CORR_PRO FILE_OVERSPEED was selected at the input CorrectionProfile.

168 162/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library Name Type Comment PushOut MB_PUSH_OUT_CONFIG MB_PUSH_OUT_CONFIG, page 183: Structure for the definition of a PushOut motion during the cut or the sealing process. In the CorrectionProfile, either the option CORR_PRO FILE_PUSH_OUT or CORR_PRO FILE_COS_COMP_AND_PUSH_OUT has to be selected. Otherwise, PushOut is deactivated and thus ineffective. Resolution MB_RESOLUTION MB_RESOLUTION, page 182: Specification of the cam calculation resolution by determining the number of base elements in three stages (details can be found in the data structure MB_RESOLUTION). SyncMode MC_SYNC_DIRECTION Synchronized direction (Shortest_Way, Catch_Up, Slow_Down) StopDeceleration REAL At a negative edge at "Enable", the slave axis is stopped with the deceleration defined here. Units according to axis scaling in rotatory units. VAR_OUTPUT InOperation BOOL Cross cutter runs without any failures Error BOOL Processing completed with error ErrorID ERROR_ CODE Description of the diagnostics in case of error ErrorIdent ERROR_STRUCT Error handling, page 171 Shutdown BOOL The cross sealer is stopped with the deceleration ramp Stop Deceleration after a negative edge at "Enable". During this time, the output ShutDown is activated to display the defined deceleration process. ChangeProfile BOOL If input variables like, for example, FormatLength are changed during operation, a new MotionProfile is calculated and loaded in the background. Subsequently, the new MotionProfile is used. Since this process requires several cycles, this output is activated for this period. If any other input variables are changed during this process (e g. FormatLength), the current process is interrupted and performed again with new data. The output is reset once the newly calculated MotionProfile becomes effective and the switching angle was passed through. ProfileReady BOOL This output is set as soon as the MotionProfile was calculated, loaded and activated. The output is deleted as soon as the MotionProfile has become effective (after having passed the switching angle). ActualProduct UINT In the case of more than one product per sealing process (ProductsPerCut > 1), the currently processed product is displayed via this output. At a rising edge at "Enable", this output is reset to the input variable StartProduct. CutCounter UINT The CutCounter increases with each modulo overrun (360 0 ) of the slave axis. At a rising edge at "Enable", the CutCounter is reset to zero. Minimum, maximum and default values of the inputs Fig.5-3: Interface description of the MB_CrossSealType01 FB

169 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 163/190 Name Type Min. value Max. value Default value Transfer Enable BOOL FALSE Continuous CrossCutter BOOL FALSE Rising edge at "Enable" BOOL TRUE Continuous ProductsPerCut UINT Rising edge at "Enable" StartProduct UINT Rising edge at "Enable" NumberOfKnives UINT Rising edge at "Enable" StartMotionProfile StartCamTableID MC_CAM_ID 1 94 (for MLC) 3 (for MLD) 1 Rising edge at "Enable" KnifeDistance REAL > 0.0 mm/inch Not defined 100.0mm/inch Rising edge at "Enable" Format length REAL > 0.2* KnifeDistance CutSealArea REAL 0 0mm 30* KnifeDistance < 360 < KnifeDistance 100.0mm/inch 10 10mm/inch Continuous* Continuous* PendelumFactor REAL 0.0% 100% 0.0% Continuous* CorrectionProfile MB_CORR_PROFILE Continuous* Overspeed REAL % % 0.0% Continuous* PushOut MB_PUSH_OUT_CONFIG Continuous* Resolution MB_RESOLUTION RESOLU TION_LOW RESOLU TION_HIGH RESOLUTION_MEDI UM Rising edge at "Enable" SyncMode MC_SYNC_DIRECTION 0 2 Catch_Up Rising edge at "Enable" StopDeceleration REAL > 0.0 Not defined Continuous Functional description * The acceptance of the inputs requires several cycles and is displayed via the "ChangeProfile output. Fig.5-4: Minimum, maximum and default values of the MB_CrossSealType01 FB After the processing was enabled via Enable, the function block calculates a MotionProfile as well as cam tables for the cross sealer / cross cutter application according to the specified input data. The function block also supports multiple cross sealers / cross cutters with equally distributed knives or sealing jaws. For multiple cross cutters or cross sealers: RMB_TechCrossCutCrossSeal.library In the case of multiple cross cutter or cross sealer applications, the parameterization of the mechanical gear has to be adjusted (see also Required basic conditions and requirements, page 170). For this purpose, the calculated motion sequence is divided into the following two sections: The cutting or sealing area is defined by the input variable CutSealArea. Within this area, the knife or the sealing jaw moves with the velocity of the product. In addition, other functions like, for example, OverSpeed for overspeed or a reduction of the velocity, PushOut for a push out motion or the cosine correction can be optionally added.

170 164/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library In this area, the following input variables become effective: CorrectionProfile Provides special profiles in the cutting and sealing area (OverSpeed, PushOut, cosine correction, PushOut + cosine correction). OverSpeed Specifies the increase or reduction of the velocity in CutSealArea [%]. PushOut Defines a special PushOut motion during the cutting or sealing process. Outside the cutting or sealing area, an optimum compensating motion with regard to jerk and energy is performed if the specified format length FormatLength does not correspond to the distance of the knives or the sealing jaws KnifeDistance.. Furthermore, a pendular motion of the cross sealer axis or cross cutter axis can be specified within adjustable limits to optimally use the acceleration capacity of the drive in case of large format lengths. The following input variable become effective in this area: PendelumFactor specifies the maximum admissible pendulum radius [%]. The MotionProfile and the cam tables are automatically loaded and activated after the calculation. During this period, the output ChangeProfile is activated. If the MotionProfile is effective and if the slave axis is synchronized, the output InOperation is activated. In this state, the slave axis moves synchronously to the master axis using the previously calculated MotionProfile. In this state, the cut or seal counter CutCounter is increased with each revolution of the cross cutter or cross sealer axis. If input variables like, for example, FormatLength are changed during the operation, a new MotionProfile is calculated in the background. Since this process requires several cycles, the output ChangeProfile is activated during this period. The output ProfileReady is set if the new MotionProfile has been activated but if the switching angle has not yet been passed through. If the switching angle is reached subsequently, the calculated MotionProfile becomes effective and the outputs ChangeProfile and ProfileReady are reset. If any input data is changed again during the current change of the MotionProfile, the changes are discarded and the calculation with the new input data is restarted. The base elements of the cam tables used within the MotionProfile can be affected via the Resolution input. A high resolution results in a maximum accuracy but requires the most time during the calculation. The time effort can be reduced by the factor 3 or 9 using the settings "Medium" and "Low". The reduction of the resolution is useful if different product lengths are continuously processed with high cycle rates (> 500 cycles/minute). A negative edge at Enable results in a defined shutdown of the cross cutter / cross sealer. The slave axis is decelerated until standstill with the adjustable ramp StopDeceleration. During the defined shutdown, the output Shutdown is activated. The output Shutdown is reset if the slave axis has reached its standstill position or if an error occurred.

171 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 165/190 Cross sealer application Fig.5-5: Definition of the input "KnifeDistance" For scaling: RMB_TechCrossCutCrossSeal.library The translatory input variables of the function block (e. g. Format Length) can be specified either in "mm" or in "inch". However, it must be taken into consideration that all translatory input variables are specified in the same unit (mm or inch). Via the CrossCutter input, the function block generally differentiates between the cross cutter application and the cross sealer application: If the input CrossCutter is FALSE, a cross sealer application is assumed. The triggering of a cross sealer cylinder of flow wrappers is a typical example for this application. The sealing jaw should move with the product velocity and with an optimum correction profile during the sealing process. Outside the sealing area, a compensating motion is to be performed if the format length Format Length does not correspond to the distance of the sealing jaws KnifeDistance. Furthermore, the cross sealer can be optionally triggered by an upstream, cycle-synchronous lock on and lock off motion to realize the functions "NoGap / NoSeal" and "NoProduct / NoBag". The cross sealer application provides the following characteristics: The CutSealArea input corresponds to the length of the sealing seam and is thus specified in translatory units (mm or inch). One master axis revolution (360 ) corresponds to the foil feed of one product length. One sealing process can include several products. The number of products per sealing process is specified via the ProductsPerCut input. This input directly influences the electronic gear of the MotionProfile used. The first product is set via the StartProduct input after a positive edge at "Enable". This variable internally effects a position offset of the Motion Profile used. After a positive edge at "Enable", the output ActualProduct is set to the input StartProduct.

172 166/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library Optionally, the cycle-synchronous lock on and lock off can be connected upstream via another MB_CamLock FB. To start the FB: If the master axis and the slave axis are in an position at will during the start of the FB, the slave axis performs a dynamic synchronization to synchronize with the master axis. If this is not desired, the master axis and the slave axis have to be set to the position 0 or 180 prior to the start of the function block. The following figure shows the master axis structure and the effects of the FB for the cross sealer application with optional, cycle-synchronous lock on and lock off. Fig.5-6: Master axis structure for cross sealer applications with lock on / lock off The following figure shows an example of a signal-time diagram of the master axis and the cross sealer axis for one product per package.

173 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 167/190 Cross cutter application Fig.5-7: Example of a signal-time diagram with one product per sealing process The following figure shows an example of a signal-time diagram of the master axis and the cross sealer axis for 3 products per package. Fig.5-8: RMB_TechCrossCutCrossSeal.library Example of a signal-time diagram with 3 products per sealing process Via the CrossCutter input, the FB generally differentiates between the cross cutter application and the cross sealer application. If the input CrossCutter is TRUE, a cross cutter application is assumed. During the cutting process, the knife should move with the velocity of the product and with an optional correction profile. Outside the cutting area, a compensating

174 168/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library motion is to be performed if the format length FormatLength does not correspond to the distance of the sealing jaws KnifeDistance. The cross cutter application provides the following characteristics: The input CutSealArea corresponds to the angular range of the cross cutter in which it is moving with the velocity of the product and the optional correction profile. One revolution of the master axis corresponds to the material feed length which corresponds to the knife distance KnifeDistance. One cut per product is assumed. The inputs ProductsPerCut and Start Product are not effective (these inputs is internally set to 1). The output ActualProduct is always set to "1". The electronic gear of the MotionProfile used is set to the gear ratio FormatLength / KnifeDistance. This gear only allows integer values from 1 to for the numerator and the denominator of the gear ratio. Thus, there is a maximum cutting length deviation due to quantization. If a deviation of the cutting lengths occurs due to the quantization, a respective gear ratio fine adjustment is calculated and specified. In this case, a drift between the master and the slave axis results due to the system conditions. The following figure shows the master axis structure and the effects of the function block for the cross cutter application:

175 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 169/190 Fig.5-9: RMB_TechCrossCutCrossSeal.library Master axis structure for the cross cutter application The following figure shows an example of a signal-time diagram of the measuring wheel axis, the master axis and the cross cutter axis for a short format (format length = 0.5* knife distance).

176 170/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library Required basic conditions and requirements Fig.5-10: Example of a signal-time diagram for a format length = 0.5* knife distance The following figure shows an example of a signal-time diagram of the measuring wheel axis, the master axis and the cross cutter axis for a long format (format length = 2* knife distance). Fig.5-11: Example of a signal-time diagram for a format length = 2* knife distance The sealing jaws / knives are symmetrically distributed over the circumference. The 0 position of the slave axis is always exactly in the middle of Cut SealArea.

177 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 171/190 Example of a gear configuration For drive parameterization: In the case of more than one sealing jaw or knife per circumference, the settings for the mechanical gear (drive parameters: S , S ) must be adapted. These parameters have to be set in a way so that a 360 electrical motion (modulo value of the slave axis) corresponds to the distance between two knives or sealing jaws. The configuration of the mechanical gear when using a CrossCutter with four equidistantly distributed knives on the cross cutter axis Input variables: Mechanical gear at the motor, input revolutions n input = 10 Mechanical gear at the motor, output revolutions n output = 1 Number of knives per circumference n knife = 4 Calculation of the required gear setting: S = 10 S = 4 ErrorID Additional1 Additional2 Description ACCESS_ERROR (16#0004) Error handling RMB_TechCrossCutCrossSeal.library If the cutting roll moves mechanically by 90, this corresponds to 360 electrical move (= modulo value of the slave axis). The function block does not perform an independent, motion-side error response. If an error is detected, no further motion command is transferred to the axis and the function block is exited via the Error output. A negative edge at "Enable" deletes the error output and the error state in the function block. The function block uses the error table F_RELATED-TABLE (16#0170). 16# #0000 The function block was interrupted by another function block. 16# #0001 The input "ProductsPerCut" is outside the admissible range (1..32). 16# #0002 The input "StartProduct" is outside the admissible range (1..32). 16# #0003 The input "NumberOfKnives" is outside the admissible range (1..8). 16# #0004 The input "StartCamTableID" is outside the admissible range (1..94). 16# #0005 The input "KnifeDistance" is outside the admissible range. 16# #0006 The input "FormatLength" is outside the admissible range. 16# #0007 The input "CutSealArea" is outside the admissible range.

178 172/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library ErrorID Additional1 Additional2 Description 16# #0008 The input "PendelumFactor" is outside the admissible range. 16# #0009 The input "Overspeed" is outside the admissible range. 16# #000A The input "Resolution" is outside the admissible range. 16# #000A CutSealArea is too small with regard to the master axis velocity and the SERCOS cycle time. Fig.5-12: 5.3 MB_CrossCutterCalcType04 Library ML_TechCrossCutCrossSeal.library - VAR_IN_OUT Short Description Interface Description Error codes of the MB_CrossCutSealType01 FB The MB_CrossCutterCalcType04 FB provides all required data at its outputs which have to be loaded into the MotionProfile of an axis to operate a Cross Cutter or a CrossSealer with the functions selected in the parameters of the function block. Fig.5-13: Fig.5-14: All inputs of the function block will be transferred once for a rising edge at "Execute". In addition, the function block writes directly into the arrays specified by the pointers during its runtime. The written data is only valid if the function block was processed without errors and if it returns "Done". Range Library assignment Name Type Comment MasterAxisInitialPosAdr POINTER TO REAL Interface function block: MB_CrossCutterCalcType04 Pointer to an array with three elements to be created by the user in which the FB stores the starting positions of the master axis of the generated MotionProfile segments. DistanceAdr POINTER TO REAL Pointer to an array with three elements to be created by the user in which the FB stores the distances of the generated MotionProfile segments.

179 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 173/190 Name Type Comment SlaveAxisVelocityAdr POINTER TO REAL Pointer to an array with three elements to be created by the user in which the FB stores the velocities of the slave axis at the segment limits of the MotionProfile segments. StepModeAdr CamTableAdr POINTER TO MC_STEP_MODE POINTER TO MB_CAM_TABLE_DA TA Pointer to an array with three elements to be created by the user in which the FB stores the step modes of the generated MotionProfile segments. MB_CAM_TABLE_DATA, page 180: Pointer to an array with three elements to be created by the user in which the FB stores cam tables as well as meta data of the cams which are inserted as segments into the MotionProfile. VAR_INPUT Execute BOOL Enabling the function block (once, edge-controlled) ModuloValue REAL Modulo value of the CrossCutter axis in [ ] FormatRatio REAL Format ratio of the product to be cut (without unit) CutAngle REAL Length of the cutting area in [ ] PendelumFactor REAL Maximum pendulum radius in [%] (0%: No pendular motion; 100%: Maximum pendular motion (pendular motion up to the cutting area limits). CorrectionProfile MB_CORR_PROFILE MB_CORR_PROFILE, page 181: Special profile selection The inputs "Overspeed" or "PushOut" have to be used for the parameterization of the special profile. Further information on the options of the enumeration type MB_CORR_PROFILE can be found in the respective section. Overspeed REAL Constant overspeed or velocity reduction in the cutting area [%] of the master axis velocity. PushOut MB_PUSH_OUT_CON FIG (0%: No overspeed; RMB_TechCrossCutCrossSeal.library 100%: Twice the master axis velocity; -50%: Half the master axis velocity) In the "CorrectionProfile", the CORR_PROFILE_OVER SPEED option has to be selected. Otherwise, "Overspeed" is deactivated and thus ineffective. MB_PUSH_OUT_CONFIG, page 183: Structure for the definition of a PushOut motion during the cut. In the "CorrectionProfile", either the option CORR_PRO FILE_PUSH_OUT or CORR_PRO FILE_COS_COMP_AND_PUSH_OUT has to be selected. Otherwise, "PushOut" is deactivated and thus ineffective. Further detailed information on the MB_PUSH_OUT_CONFIG structure can be found in the respective section.

180 174/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library Name Type Comment Resolution MB_RESOLUTION MB_RESOLUTION, page 182: The resolution of the cam calculation is specified by determining the number of points in three stages. Further information on the options of the enumeration type MB_RESOLUTION can be found in the respective section. VAR_OUTPUT Done BOOL Processing completed without errors, output data is valid. Active BOOL Processing active, output data is invalid. Error BOOL Processing completed with errors. ErrorID ERROR_ CODE If the "Error" output is set, it contains a broad error classification. ErrorIdent ERROR_STRUCT Error Handling, page 178. If the "Error" output is set, it contains a detailed error information NumberOfSteps USINT Number of the generated MotionProfile segments and number of the MotionProfile segments to be downloaded. NumberOfCams USINT Number of the generated cams and number of the cams to be downloaded. Minimum, maximum and default values of the inputs Fig.5-15: Name Type Min. value.. Interface description: MB_CrossCutterCalcType04 Max. value Default value Transfer Execute BOOL FALSE Continuous ModuloValue REAL >0.0 n.def At a rising edge at "Execute" FormatRatio REAL At a rising edge at "Execute" CutAngle REAL 0.0 < "ModuloValue" 12.0 At a rising edge at "Execute" PendelumFactor REAL 0.0% 100.0% 0.0% At a rising edge at "Execute" CorrectionProfile MB_CORR_PROFILE CORR_PRO FILE_NONE At a rising edge at "Execute" Overspeed REAL -50.0% 100.0% 0.0% At a rising edge at "Execute" PushOut MB_PUSH_OUT_CONFIG At a rising edge at "Execute" Resolution MB_RESOLUTION RESOLUTION_HIGH At a rising edge at "Execute" Fig.5-16: Minimum, maximum and default values of the FB: MB_CrossCutter CalcType04

181 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 175/190 Signal-time diagram Functional Description Fig.5-17: RMB_TechCrossCutCrossSeal.library Signal-time diagram: MB_CrossCutterCalcType04 Based on the operation mode "electronic MotionProfile", the FB calculates profiles for the "CrossCutter" application. The individual segments consist either of analytical segments or cam tables. After having enabled the processing with "Execute", an "electronic MotionProfile" consisting of three segments is calculated once based on the input variables. The parameters describing the profile are saved in the respective arrays which have to be provided by pointers at the inputs of the "MB_CrossCutterCalcType04" FB. The arrays have to be large enough to be able to save the number of calculated motion steps (currently three steps). The pointer handling is similar to the "MB_ChangeProfileStep" / "MB_ChangeProfileSet" FBs since these function blocks have to be called by the user after the calculation to write the calculated profile to the respectively free set of the "electronic MotionProfile". The following list describes the meaning of the individual inputs of the "MB_CrossCutterCalcType04" FB in detail: The "ModuloValue" input specifies the modulo value of the CrossCutter axis are specified by default. The "FormatRatio" input specifies the product length to be cut. It describes the ratio of the desired product length and the circumference of the Cross Cutter cylinder. This means that if "FormatRatio==1", the length of the cut product corresponds to the circumference of the CrossCutter cylinder (synchronous format). If "FormatRatio==5", the length of the product cut is five times the circumference of the CrossCutter cylinder. The "CutAngle" input specifies the cutting area of the CrossCutter. In the cutting area, the CrossCutter either rotates with the material feed velocity or with a (selectable) correction motion. The "PendelumFactor" input specifies the maximum pendular motion of the CrossCutter axis in percent. This means that if "PendelumFactor==0%", the CrossCutter axis never rotates with a negative velocity (backwards). If "PendelumFactor==100%", the CrossCutter axis rotates

182 176/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library to the border of the cutting area to minimize the energy loss and the required acceleration. This provides special benefits in the case of higher values for "FormatRatio". If "PendelumFactor==100%", the CrossCutter does not generally rotate up to the border of the cutting area since this is not always advantageous. The respective optimum utilization of the available area is always automatically calculated by the FB. The "CorrectionProfile" input allows different correction motions in the cutting area required for the respective application. The following can be selected: "CorrectionProfile==CORR_PROFILE_NONE" (no correction: CrossCutter axis rotates with the master axis velocity), "CorrectionProfile==CORR_PROFILE_OVERSPEED" (constant overspeed of the CrossCutter axis in the cutting area), "CorrectionProfile==CORR_PROFILE_COS_COMP" (constant velocity vector in material direction, e. g. for guillotine cutters), "CorrectionProfile==CORR_PROFILE_PUSH_OUT" (PushOut of the material) as well as CorrectionProfile==CORR_PRO FILE_COS_COMP_AND_PUSH_OUT (constant velocity vector in material direction as well as simultaneous PushOut, e. g. for guillotine cutters). The "Overspeed" input allows the exact setting of the overspeed in [%] in the cutting area if "CorrectionProfile==CORR_PROFILE_OVERSPEED". Thus, entering a value of 10 [%] increases the velocity of the CrossCutter axis in the cutting area by 10% compared to the material velocity. The input "PushOut" parameterizes the PushOut correction. The input is only processed if "CorrectionProfile==CORR_PROFILE_PUSH_OUT" or "CorrectionProfile==CORR_PROFILE_COS_COMP_AND_PUSH_OUT". The "Resolution" input allows the selection of the resolution of the cam tables used in 3 stages. Selecting a lower resolution saves calculation time, but reduces accuracy. High resolution increases the calculation time and the accuracy respectively. The successful calculation of a profile is signaled via the "Done" output. The parameters are written to the data arrays addressed by the provided pointers. Subsequently, these have to be written on a free MotionProfile using "MB_ChangeProfileSet"/"MB_ChangeProfileStep". The same procedure applies for the cams. It must be ensured that the table into which the cams have to be loaded is defined in the "MB_CAM_TABLE_DATA" structure. Then, the loaded MotionProfile is to be activated by using the "MB_MotionProfile" FB. The exact cutting length is defined with the electronic gear at the "MB_MotionProfile" FB. The gear ratio corresponds to the "FormatRatio" value. That means that a new profile is calculated for each product length possible. Each profile considers one input parameter only (especially "CutAngle" and "Pendelum Factor". The following sequence diagram describes the use of the MB_Cross CutterCalcType04 FB.

183 Functional Description Rexroth IndraMotion 09VRS Electric Drives Bosch Rexroth AG 177/190 Example of a gear configuration Fig.5-18: Sequence diagram for using MB_CrossCutterCalcType04 To use several equidistantly distributed knives, a mechanical gear is to be configured in IndraWorks with reference to the load side. The number of input revolutions is set to 1 and the number of output revolutions is set to the number of the knives n used. Since no real mechanical gear exists, the drive only performs one n-fold revolution. Thus, the velocity of the slave axis in one revolution is n times identical to the velocity of the master axis. The configuration of the mechanical gear when using a CrossCutter with four equidistantly distributed knives on the cross cutter axis Input variables: Mechanical gear at the motor, input revolutions n input = 10 Mechanical gear at the motor, output revolutions n output = 1 Number of knives per circumference n knife = 4 Calculation of the required gear setting: S = 10 S = 4 RMB_TechCrossCutCrossSeal.library If the cutting roll moves mechanically by 90, this corresponds to 360 electrical move (= modulo value of the slave axis). To adjust the master axis velocity and the slave axis velocity in the cutting area to the same value, the feed constant between the measuring wheel and the

184 178/190 Bosch Rexroth AG Electric Drives Rexroth IndraMotion 09VRS Functional Description RMB_TechCrossCutCrossSeal.library Error Handling internal virtual master axis has to be adjusted. Therefore, the circumference of the internal virtual master axis is specified with the length between two knives of the real slave axis. This parameterization permits the cutting of each product with a different length at a corresponding preparation time. Fig.5-19: Master axis structure when operating a CrossCutter The function block uses the error table F_RELATED_TABLE, 16#061x. It can generate the following error messages in Additional1 and Additional2: ErrorID Additional1 Additional2 Description, 16# # #0001 Invalid value of the "ModuloValue" input, 16# # #0002 Invalid value of the "FormatRatio" input, 16# # #0003 Invalid value of the "CutAngle" input, 16# # #0004 Invalid value of the "CutAngle" input combined with the cosine compensation, 16# # #0005 Invalid value of the "PendulumFactor" input