Linear Motion and. Electric Drives. Rexroth IndraMotion MLC 04VRS. R Edition 01. Library Description. ML_Technology. Library Description

Transcription

1 Electric Drives Linear Motion and Hydraulics Assembly Technologies Pneumatics Service Rexroth IndraMotion MLC 04VRS Library Description ML_Technology R Edition 01 Library Description

2 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Title Type of Documentation Document Typecode Internal File Reference Purpose of Documentation Record of Revision Rexroth IndraMotion MLC 04VRS Library Description ML_Technology Library Description DOK-IM*MLC-TFB*****V04-AW01-EN-P RS-e3bf7a2813a5fbe60a6846a en-US-7 This documentation describes the function blocks, the functionalities and the data types of the "ML_Technology" library in its version for IndraMotion MLC 04VRS. Furthermore, it contains information with regard to the error responses of the function block. Edition Release Date Notes B331-01/EN First version, MLC04VRS Copyright Validity Published by: Note 2007 Bosch Rexroth AG 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. 2 D Lohr a. Main Phone +49 (0)93 52/ 40-0 Fax +49 (0)93 52/ BRC/EAM AK (BaWe/MePe) This document has been printed on chlorine-free bleached paper.

3 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Table of Contents Bosch Rexroth AG I/III Table of Contents 1 Introduction and Overview Further Documentations... 3 Page 3 Important Instructions on Use Intended Use Introduction Scope of Use and Application Improper 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 General Definitions Function Block for Application "Flying Shear" Introduction and Overview MX(L)_FlyingShear ML_FlyingShear - Special Features of IndraMotion MLC Function Blocks for Application "Touch Probe" Introduction and Overview MC_TouchProbe MC_TouchProbe - Special Features of IndraMotion MLC MC_AbortTrigger MC_AbortTrigger - Special Features of IndraMotion MLC Function Blocks for Application "Cross Cutter" Introduction and Overview... 33

4 II/III Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Table of Contents Page 8.2 MB_CrossCutterCalcType General Special Features of IndraMotion MLC MB_CAM_TABLE_DATA MB_CORR_PROFILE MB_PUSH_OUT_CONFIG MB_RESOLUTION MB_CrossCutSealType MX(L)_CrossCutter ML_Crosscutter - Special Features of IndraMotion MLC Function Block for Application "Register Controller" Register Controller - Overview and Application Introduction and Overview Register Controller Examples for Applications Die Cutting in Label Printing Insetter Control Flow Wrapper MB_RegisterControllerType MB_RegisterControlleType01 - Special Features of the IndraMotion MLC Function Block for Application "Tension Controller" Introduction and Overview ML_TensionControlLoadCellType ML_TensionControlLoadCellType01 - Special Features of IndraMotion MLC Function Blocks for Application "Sag Control" Introduction and Overview ML_SagControlC ML_SagControlA Function Blocks for Application "Adjusting Variables" Introduction and Overview MX(L)_ContinuousAdjustType MX(L)_ContinuousAdjustType MX(L)_IncrementalAdjustType Parameterization of the Function Blocks for Adjusting Variables Function Block for Application "Sensorless Winder" Introduction and Overview ML_COMP_DATA ML_WinderSensorless

5 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG III/III Table of Contents Page 14 Function Block Temperature Controller "IL_TempControlType01" Introduction and Overview Controller Using the Function Block Description of the Individual Functions, Examples Function Blocks and Functions for Maintaining "Cyclical Data Channels" Introduction and Overview MB_CYCLIC_PARAM_REF MB_CYCLIC_TYPES MB_CYCLIC_CHANNELS MB_AllocCyclicParameter MB_FreeCyclicParameter MB_GetCyclicParameterHandle MB_ReadCyclicParameter MB_ReadCyclicRealParameter MB_WriteCyclicParameter MB_WriteCyclicRealParameter MB_GetLastCyclicParameterError Auxiliary Function Blocks MB_Command ML_Group MonitorType ML_GroupMonitorType MB_GetSystemInfo Service and Support Helpdesk Service Hotline Internet Helpful Information Index

6 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description

7 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 1/179 Introduction and Overview 1 Introduction and Overview Technology Function Blocks (Tech-FB's) extend the basic functionality of the target systems (like e.g. MLD / MLC) and provide application-specific functionalities like e.g. Flying Shear, Cross Cutter, Register Controller etc. The function blocks described here are provided via an internal IEC library (as for example MX_Technology0x.lib for MLD or ML_Technology0x.lib for MLC). These documentation describes the functionality as well as the in- and outputs of the Technology Function Blocks. Technology Function blocks of library ML_Technology0x.lib require the firmware support of the target system MLC0x. Specific preconditions of the Technology Function Blocks are documented in the chapter of the corresponding function blocks. The library ML_Technology0x.lib uses functions of library RIL_Utilities.lib and ML_TechCommon. Therefore, in addition, the libaries RIL_Utilities.lib and ML_TechCommon must be included in the PLC-Project.

8 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description

9 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 3/179 Further Documentations 2 Further Documentations The following table provides an overview of the available IndraDrive hardware and firmware as well as of MLC documentations. Title Rexroth IndraDrive, Firmware for Drive Controllers, MPH-04, MPB-04, MPD-04, Functional Description Rexroth IndraDrive, Drive Controllers, MPx-02; MPx-03; MPx-04, Parameter Description Rexroth IndraDrive, Firmware for Drive Controllers, Instructions for Troubleshooting (MPx02, MPx03, MPx04 and HMV) Rexroth IndraMotion MLC; Functional Description Rexroth IndraMotion MLC04VRS; Axis and Control Parameters Rexroth IndraMotion MLC04VRS; Analyses Rexroth IndraMotion MLC04VRS, PLCopen Function Blocks and Data Types Rexroth IndraMotion MLC04VRS; Functional Modules Rexroth IndraMotion MLC04VRS, Getting Started Rexroth IndraMotion MLC04VRS, ML_TechCommon, ML_TechCam and ML_TechCamIEC libraries Rexroth IndraMotion MLC04VRS, ML_Technology Library Rexroth IndraMotion MLC04VRS, ML_Packaging Library Labeling DOK-INDRV*-MP*-04VRS**-FK01-EN-P DOK-INDRV*-GEN-**VRS**-PA03-EN-P DOK-INDRV*-GEN-**VRS-WA03-EN-P DOK-IM*MLC-SYSTEM**V04-FK01-EN-P DOK-IM*MLC-A*C*PAR*V04-PA01-EN-P DOK-IM*MLC-DIAGN***V04-WA01-EN-P DOK-IM*MLC-PLCOPEN*V04-FK01-EN-P DOK-IM*MLC-FM******V04-FK01-EN-P DOK-IM*MLC-F*STEP**V04-KB01-EN-P DOK-IM*MLC-TFB-COM*V04-AW01-EN-P DOK-IM*MLC*TFB*****V04-AW01-EN-P DOK-IM*MLC*TFB-IMPAV04-AW01-EN-P Fig.2-1: Further documentations

10 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description

11 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 5/179 Important Instructions on Use 3 Important Instructions on Use 3.1 Intended Use Introduction Scope of Use and Application All Bosch Rexroth controls and drives are developed and tested in accordance with the state of the art technology. It is not possible to track the continuous further improvement of all materials our controls and drives may come into contact with (e.g. lubricants at machine tools). Reactions with the materials used in the Bosch systems cannot generally be excluded. Therefore, before using new lubricants, cleaning agents etc., must be checked for compatibility with the Bosch housing and device materials. The products may only be used for the intended purpose. When they are not used as intended, situations may arise resulting in damage to person or material. Bosch Rexroth, as the manufacturer of the products, shall not assume any warranty, liability or payment of damages in case of damage resulting from a non-intended use of the products. If the user fails to use the products as intended, the user shall assume sole responsibility for any resulting risks. Before using Bosch Rexroth products, the following prerequisites must be fulfilled to ensure their proper use: Anyone using our products must read and understand the corresponding safety notes and intended use of the product. If the products are hardware, they must be kept in their original state, i.e. no constructional modifications should be made. Software products may not be decompiled; their source codes may not be modified. Damaged or defective products must not be installed or put into operation. It must be ensured that the products are installed according to the regulations specified in the documentation. Bosch Rexroth drive controllers are intended to control electrical motors and monitor their operation. To control and monitor the motor, it may be necessary to connect additional sensors and actuators. The drive controllers must only be used with the accessories and mounting parts listed in this documentation. Do not install or connect components not expressly specified in this documentation. This also applies to cables and lines. The unit may be operated only with the explicitly specified component configurations and combinations and only with the software and firmware specified in the appropriate functional description. Before commissioning, every drive controller must be programmed to ensure that the motor executes the appropriate functions for the application.

12 6/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Important Instructions on Use 3.2 Improper Use The drive controllers have been developed for use in single and multi-axes drive and control tasks. To allow for application-specific requirements in the drive controllers, our product range comprises various device types with different drive powers and interfaces. The drive controller must only be operated under the mounting and installation conditions, the position, and the ambient conditions (temperature, type of protection, moisture, EMC, etc.) specified in this documentation. The use of the drive controllers in applications other than those specified or described in the documentation and the technical data is considered as "improper". Drive controllers must not be used if they are subjected to operating conditions not corresponding to the specified ambient conditions. They must not be operated under water, under extreme temperature fluctuations, or within extreme maximum temperatures. Furthermore, the drive controllers can only be used in applications approved by Bosch Rexroth. Please note the specifications outlined in the general safety instructions!

13 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 7/179 Safety Instructions for Electric Drives 4 Safety Instructions for Electric Drives 4.1 Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others 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. WARNING 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 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.

14 8/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library 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:

15 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 9/179 Safety Instructions for Electric Drives Warning symbol Signal word Danger Degree of hazard seriousness acc. to ANSI Z Death or severe bodily harm will occur. Warning Caution Death or severe bodily harm may occur. Minor or moderate bodily harm or material damage may occur. Fig.4-1: Hazard classification (according to ANSI Z 535) Hazards by Improper Use DANGER High electric voltage and high working current! Risk of death or severe bodily injury by electric shock! Observe the safety instructions! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! Observe the safety instructions! WARNING High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock! Observe the safety instructions! WARNING 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! CAUTION CAUTION 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!

16 10/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of batteries! Observe the safety instructions! 4.2 Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings 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. DANGER 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.

17 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 11/179 Safety Instructions for Electric Drives For electrical drive and filter components with voltages of more than 50 volts, observe the following additional safety instructions. DANGER 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 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. WARNING 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"

18 12/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library 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.

19 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 13/179 Safety Instructions for Electric Drives 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 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.

20 14/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Safety Instructions for Electric Drives Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting 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. WARNING 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.

21 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 15/179 Safety Instructions for Electric Drives 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 Battery Safety Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or material damage. CAUTION 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. 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 Protection Against Pressurized Systems 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.

22 16/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library 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.

23 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 17/179 General Definitions 5 General Definitions Each function block contains a continuous "Error"-Structure, as well as general defined in- and outputs with defined behavior. All function blocks with "Execute"-Input and "Done"-Output have the same edge-oriented runtime behavior. With the rising edge at the "Execute"-Input of a function block the processing is activated. Fig.5-1: Signal-Time-Diagram of Execute, Active, Done and Error When the result is available, "Done" is set to TRUE. When, however, an error case is present, "Error" is set to TRUE and "ErrorID" is set to an error identification. While "Execute" is not canceled, "Done" or "Error" remain on their values. With canceling "Execute", "Done", "Error" and "ErrorID" are reset. If "Execute" is already FALSE when the command is completed, then the information "Done" or "Error" and "ErrorID" remain active for exactly one cycle. Function blocks with an "Enable"-Input are working in a level-oriented way. Normally the input "Enable" is passed on to the appropriate functionality (example: "MC_Power"). Fig.5-2: Signal-Time-Diagram of Enable, Active, Done and Error

24 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description

25 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 19/179 Function Block for Application "Flying Shear" 6 Function Block for Application "Flying Shear" 6.1 Introduction and Overview 6.2 MX(L)_FlyingShear Brief Description Interface Description With the application "Flying shear", a machining station will be synchronized with regard to a continuously passing material (like, for example, metal, plastic, etc.), and the machining is executed in the synchronous run of the machining station. The material position is usually detected via a measuring wheel and transferred via an optional encoder input to the drive controller. Then, the drive controller synchronizes the connected servo motor on the continuously passing through material when the specified cut length was passed through. The function block chapter 6.2 "MX(L)_FlyingShear" on page 19 or chapter 6.3 "ML_Flying Shear - Special Features of IndraMotion MLC" on page 24 is responsible for the synchronization and sets the output "InSync" once the machining station is running synchronously. In this state, the material can be machined since now the machining station runs synchronously to the material. After having finished the machining process, the synchronous run can be interrupted with the input "MoveReturn", and the machining station returns to its specified starting position. For test purposes, a virtual axis can be used instead of the measuring wheel. With this virtual axis, it is then possible to simulate the measuring wheel. The function block MX(L)_FlyingShear contains the typical procedure of a flying shear and performs the following steps once the input "Start" has been set to TRUE: Moves the slave axis to the starting position ReturnPos and wait until the axis has reached its position. Synchronizes the slave axis on the master axis over a Lock On cam profile. Sets the output "InSync" once the slave axis (machining station) has been synchronized on the material. Returns the slave axis to its starting position if the corresponding signal is set at the input "MoveReturn". Fig.6-1: Function block MX(L)_FlyingShear

26 20/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Flying Shear" I/O type Name Data type Comment VAR_IN_OUT Master AXIS_REF Reference to the master axis Slave AXIS_REF Reference to the slave axis (machining station) FSRetain MB_FS_RETAIN_DATA* 1 Reference to the required retain data of this function block VAR_INPUT Start BOOL Start=TRUE: Starts the FlyingShear function block. Depending on the states of the inputs "ImmediateCut" and "CropCut", the function block performs the following functions: Start=TRUE and positive edge at the input "Immediate Cut": The machining station will be synchronized immediately and performs the cutting length (Cutlength) once the immediate cut (ImmediateCut) has been performed. Start=TRUE and positive edge at the input "CropCut": The machining station will be synchronized after the cutting length (Cutlength) has passed the machine and performs the cutting length (Cutlength) once the crop cut (CropCut) has been performed. Start=TRUE and no signal "ImmediateCut" and "Crop Cut": The machining station will be synchronized after the cutting length (Cutlength) has passed the machine (measured from the last cut). CropCut BOOL In the case of a rising edge, the slave axis starts the synchronization process after the cutting length has passed the machine. If a cut cycle is currently performed (InCycle=TRUE), the crop cut will be performed in the next cut cycle. ImmediateCut BOOL (Start = TRUE): This case is intended for an immediate cut on the running material. The immediate cut (ImmediateCut) will be activated by a positive edge. The slave axis will be synchronized immediately. If a cut is currently performed (InCycle = TRUE), the immediate cut will be performed in the next cut cycle. If (Start = FALSE) and (V measuring_wheel < 5 rpm): This case is intended for an immediate cut on stopped material. The immediate cut (ImmediateCut) will be activated by a positive edge. The slave axis remains in its standstill position and will not be synchronized. The output "In Sync" will be set immediately, and the function block expects the input signal "MoveReturn" for finishing the process. After having finished this process, the flying shear is referenced to the material. MoveReturn BOOL Finishes the synchronous run of the slave axis with the material and returns the slave axis to its starting position "ReturnPos". ResetCut Counter BOOL The positive edge resets the cut counter.

27 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives I/O type Name Data type Comment Cutlength REAL Specified material cutting length *2*3 MWFeedconst REAL Feed constant of the measuring wheel per revolution * 2 * 3 SyncDist REAL Synchronization distance required by the slave axis for synchronizing on the master axis* 2 * 3. The shorter the synchronization distance, the higher is the synchronization acceleration. ReturnPos REAL The slave axis moves to this starting position at the beginning and after having been synchronized and once the input MoveReturn is set to TRUE * 2 * 3. ReturnVel REAL The slave axis returns to the starting position "Return Pos" with the velocity ReturnVel * 2 * 3. ReturnAcc REAL The slave axis returns to the starting position "Return Pos" with the acceleration ReturnAcc * 2 * 3. PreSyncPos REAL The output signal "PreSyncSignal" is set before the synchronous position "PreSyncPos" with the distance given here to make preparations before the synchronous run* 2. PreSyncTime TIME Duration of "PreSyncSignal" VAR_OUTPUT InSync BOOL The slave axis runs synchronously with the material. It is in its synchronization window (see drive parameter S ). InCycle BOOL The slave axis currently performs a cut cycle. An immediate or crop cut will be performed in the next cycle (CutCycle = 0). CropCutDone BOOL The crop cut has been performed ImmediateCut Done BOOL The immediate cut has been performed PreSyncSignal BOOL Presignal before the synchronous position "PreSyncPos" ShortPrdWarning BOOL The slave axis does not have enough time to reach the starting position "ReturnPos" for the next cut. The return is interrupted and the synchronization ramp starts again. This case should be prevented since the drive might be overloaded and the machining station might move to the carriage bed end. Countermeasures: Increase return velocity (function block input "ReturnVel") Increase return acceleration (function block input "ReturnAccl") Reduce synchronization distance (function block input "SyncDist") Reduce material feed velocity Bosch Rexroth AG 21/179 Function Block for Application "Flying Shear" MaterialMoving BOOL The speed of the material encoder is higher than 5 rpm. An immediate cut in the case of a material standstill is only possible if MaterialMoving=FALSE. Reserve DINT Reserved increments of the synchronization procedure for analysis purposes. A synchronization is not possible if Reserve 0 -> In this case, the function block returns an error message.

28 22/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Flying Shear" I/O type Name Data type Comment CycleState UINT Current status of the cut cycle: 0: Standstill and waiting phase; 1: Acceleration phase; 2: Synchronous run phase; 3: Return phase. CutCounter UINT With each cut, the cut counter "CutCounter" will be increased. With (Start = FALSE) or a positive edge at the input "ResetCutCounter", the counter will be reset. Error BOOL Indicates an error. Will be deleted if Start=FALSE ErrorID INT (Enum) ERROR_CODE: Brief error description ErrorIdent ERROR_STRUCT Detailed error description Signal/Time Diagram * 1 : MB_FS_RET AIN_DATA* 1 : STRUCT (bcutnotcompleted: BOOL, dimastersyncposition: DINT, irevcounter:int) * 2 : Measuring units according to drive weighting, e. g. mm * 3 : New input values will be taken over with the transition from the synchronous run phase to the return phase. Due to this reason, a new cutting length which is to be activated in the next cycle has to be copied to the function block input before the axis is moved to its return position. Fig.6-2: I/O interface of MX(L)_FlyingShear The following diagram shows the signal flow with immediate cut and stopped material (Start = FALSE): Fig.6-3: Signal/time diagram: Immediate cut with stopped material The following diagram shows the complete signal flow of the function block "Flying shear" with continuously passing material and immediate cut:

29 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 23/179 Function Block for Application "Flying Shear" Troubleshooting Fig.6-4: Complete signal flow of the function block Flying shear with immediate cut The function block "Flying shear" generates the following error messages in Additional1/Additional2 for the table "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR (16#0003) 16# #0000 Drive not enabled or drive error ACCESS_ERROR (16#0004) 16# #0000 Function block was interrupted by another function block ACCESS_ERROR (16#0004) 16# #0000 Unsupported drive firmware RESOURCE_ERROR (16#0003) 16# #0000 Selected axis (Axis_Ref) was changed during the processing of the function block INPUT_RANGE_ERROR (16#0006) 16# #0001 CutLength <= 0

30 24/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Flying Shear" ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR (16#0006) 16# #0002 MWFeedconst <= 0 INPUT_RANGE_ERROR (16#0006) 16# #0003 SyncDist <= 0 INPUT_RANGE_ERROR (16#0006) 16# #0004 ReturnAcc <= 0 INPUT_RANGE_ERROR (16#0006) 16# #0005 ReturnVel <= 0 SYSTEM_ERROR (16#7FFF) 16# #0000 Synchronization position is too far away. Therefore, synchronization is not possible. Reset error and initiate immediate cut. ACCESS_ERROR (16#0004) 16# #0001 S is not configured in the optional cyclical MDT channel of the slave axis. ACCESS_ERROR (16#0004) 16# #0002 P is not configured in the optional cyclical MDT channel of the slave axis. ACCESS_ERROR (16#0004) 16# #0003 P is not configured in the optional cyclical MDT channel of the slave axis. ACCESS_ERROR (16#0004) 16# #0004 P is not configured in the optional cyclical MDT channel of the slave axis. ACCESS_ERROR (16#0004) 16# #0005 P is not configured in the optional cyclical AT channel of the slave axis. ACCESS_ERROR (16#0004) 16# #0006 P is not configured in the optional cyclical AT channel of the slave axis. ACCESS_ERROR (16#0004) 16# #0007 P is not configured in the optional cyclical AT channel of the slave axis. ACCESS_ERROR (16#0004) 16# #0008 P bit 6 is not TRUE (the structure AxisData is not updated). OTHER_ERROR (16#00FE) 16# #0001 The ELS configuration word (P ) of the slave axis has been incorrectly configured. The configuration must be as follows: P = 2#xxxx OTHER_ERROR (16#00FE) 16# #0002 The parameter P of the slave axis has been incorrectly configured. The value must be: P =0. OTHER_ERROR (16#00FE) 16# #0003 The parameter P of the slave axis has been incorrectly configured. The value must be: P =0. OTHER_ERROR (16#00FE) 16# #0004 The parameter P of the slave axis has been incorrectly configured. The value must be: P =0. OTHER_ERROR (16#00FE) 16# #0005 The parameter P of the slave axis has been incorrectly configured. Bit 2 of P must be FALSE. SYSTEM_ERROR (16#7FFF) 16# #0000 Immediate cut (in standstill) has been requested although the material was moving. Fig.6-5: Error codes of MX(L)_FlyingShear 6.3 ML_FlyingShear - Special Features of IndraMotion MLC Required Hardware MLC Hardware IndraDrive C or M

31 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 25/179 Function Block for Application "Flying Shear" Additional encoder interface card to read in the measuring wheel position if a measuring encoder is to be used (can be omitted if a virtual or real axis is used) Additional encoder to read in the measuring wheel position (according to IndraDrive planning) if a measuring encoder is to be used (can be omitted if a virtual or real axis is used) Required Firmware Required Software Required Parameterization MLC Firmware It is recommended to use a high-resolution measuring encoder with a resolution of at least 4096 increments / revolution (possibly sinus encoder). Roughly resolved encoder signals cause low cut accuracies as well as running noises in the synchronous run. MPX drive firmware The following functional packages have to be enabled in the drive: Closed Loop Synchronization IndraWorks MLC The following parameterization has to be accomplished in the drive to ensure a proper functionality of the function block "MX(L)_FlyingShear". 1. Loading the parameter file "FlyingShearSettings.par" By loading the parameter file "FlyingShearSettings.par", important configurations as well as the cams will automatically be loaded on the flying shear axis. The parameter file will be provided on the IndraWorks MLC 0x installation CD 3 over the path "Add ons\ Tech FB_Parameterfile". The parameter file contains the following information: P-72 Lock On Cam Poly 5 P-92 Run Cam P-750=1 P-693=0 P-60=0 P-86=0x P-90=0x A-500=P-691 A-502=P Parameterization of the flying shear axis Parameterization of the flying shear axis according to the application. Weighting should be linear and absolute. 3. Parameterization of the optional encoder IndraWorks Add an encoder axis to the project Weighting should be set to rotary modulo 360. Setting the encoder parameters according to encoder data 4. Ensuring the encoder motion direction In normal operation, the optional encoder (measuring wheel) has to move in positive direction. The motion direction can be observed via the Indra Works dialog of the encoder axis. The motion sense must be inverted if the encoder moves in the negative direction.

32 26/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Flying Shear" Required IndraLogic Steps 5. Parameterize the synchronization acceleration (P ) and synchronization velocity (P ) with preferably high values to ensure a dynamic synchronization process IndraWorks Parameter Editor 6. Parameterize the synchronous run window (S ) preferably small to obtain a possibly high cut accuracy IndraWorks Parameter Editor The function block "MX(L)_FlyingShear" contains high-prior motion commands and should therefore be cyclically called in a high-prior, cyclical PLC task with a cycle time 4ms (MotionTask). Before starting the function block, "MC_Power" must be processed without errors.

33 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 27/179 Function Blocks for Application "Touch Probe" 7 Function Blocks for Application "Touch Probe" 7.1 Introduction and Overview 7.2 MC_TouchProbe Brief Description Interface Description The function blocks chapter 7.2 "MC_TouchProbe" on page 27 and chapter 7.4 "MC_AbortTrigger" on page 31 control and manage the "Touch probe" drive functionality. The function block "MC_TouchProbe" activates the selected touch probe, evaluates the status and provides the measured values once the trigger signal has arrived. The function block "MC_AbortTrigger" cancels a running measurement of "MC_TouchProbe". The function block "MC_TouchProbe" is used to detect an axis position, a master position or the touch probe time when the trigger signal arrives. Before starting the function block "MC_TouchProbe", the "Touch probe cycle" command must be started. The "Touch probe cycle" command will be started by writing the parameter "S = 3". Alternatively, the touch probe function can automatically be activated in phase 4 over P , bit 9 = TRUE (from MPx04). Thus, writing to S is no longer required. Fig.7-1: FB MC_TouchProbe

34 28/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Touch Probe" Name Type Comment VAR_IN_OUT Axis AXIS_REF Reference to the selected axis VAR_INPUT Execute BOOL A positive edge at Execute starts the touch probe recording ProbeType PROBE_DATA_FOR MAT Defines the recorded data format. AXIS_POS = 0: Position values in drive weighting (e. g. S ) PROBE_TIME = 1: Touch probe time in µs MASTER_POS = 2: ProbeSelect PROBE_NUMBER Touch probe selection: Master position in increments (e. g. P ) PROBE1 = 1: Touch probe 1 PROBE2 = 2: Touch probe 2 PosEdge BOOL Positive touch probe edge will be evaluated NegEdge BOOL Negative touch probe edge will be evaluated VAR_OUTPUT Done BOOL The selected edges have been triggered Active BOOL The function block is active, measurement is running PosEdgeDetected NegEdgeDetected RecordedPosition This output is only used if "ProbeType = AXIS_POS" has been selected. RecordedPositionNeg This output is only used if "ProbeType = AXIS_POS" has been selected. Recorded Value RecordedValueNeg CommandAborted BOOL BOOL REAL REAL DINT DINT BOOL Error BOOL Indicates an error ErrorID ERROR_CODE Brief error description The positive edge of the selected touch probe has been triggered The negative edge of the selected touch probe has been triggered Position value of the axis with positive edge of the selected touch probe Position value of the axis with negative edge of the selected touch probe Touch probe time (in us) or master axis position (in increments) in the case of a positive edge of the selected touch probe This output is only used if "ProbeType = MASTER_POS" or "PROBE_TIME" has been selected. Touch probe time (in us) or master axis position (in increments) in the case of a negative edge of the selected touch probe. This output is only used if "ProbeType = MASTER_POS" or "PROBE_TIME" has been selected. Command has been canceled by chapter 7.4 "MC_AbortTrigger" on page 31. ErrorIdent ERROR_STRUCT Detailed error description according to error table Fig.7-2: Interface of the function block MC_TouchProbe

35 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 29/179 Function Blocks for Application "Touch Probe" Signal/Time Diagram Troubleshooting Fig.7-3: Signal/time diagram according to PLCopen The function block generates the following error messages in Additional1/Additional2 for the table F_RELATED_TABLE, 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR, 16# # #0000 Unsupported drive firmware RESOURCE_ERROR, 16# # #0000 Touch probe configuration (S ) does not correspond to the inputs of the function block RESOURCE_ERROR, 16# # #0000 Touch probe command (S ) has not been started RESOURCE_ERROR, 16# # #0001 Required touch probe control bit (S , bit 0) is not configured in the signal control word RESOURCE_ERROR, 16# # #0002 Required touch probe control bit (S , bit 0) is not configured in the signal control word RESOURCE_ERROR, 16# # #0003 Required touch probe status bit (S , bit 0) is not configured in the signal status word RESOURCE_ERROR, 16# # #0004 Required touch probe status bit (S , bit 0) is not configured in the signal status word RESOURCE_ERROR, 16# # #0005 Required touch probe status bit (S , bit 0) is not configured in the signal status word RESOURCE_ERROR, 16# # #0006 Required touch probe status bit (S , bit 0) is not configured in the signal status word RESOURCE_ERROR, 16# # #0007 Required touch probe measured value S is not cyclically configured in AT RESOURCE_ERROR, 16# # #0008 Required touch probe measured value S is not cyclically configured in AT RESOURCE_ERROR, 16# # #0009 Required touch probe measured value S is not cyclically configured in AT

36 30/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Touch Probe" ErrorID Additional1 Additional2 Description RESOURCE_ERROR, 16# # #000A Required touch probe measured value S is not cyclically configured in AT INPUT_RANGE_ERROR, 16# # #0001 The selection of the touch probe at the input "Probe Select" is outside the admissible range INPUT_RANGE_ERROR, 16# # #0002 The input "ProbeType" is outside the admissible range Fig.7-4: Error numbers caused by MC_TouchProbe 7.3 MC_TouchProbe - Special Features of IndraMotion MLC Required Hardware Required Firmware Required Software Required Parameterization MLC Hardware IndraDrive C or M MLC Firmware MPX drive firmware The following functional packages have to be enabled in the drive: Servo or Synchronization IndraWorks MLC To use the function block "MC_TouchProbe", the touch probe must be parameterized with the help of the following dialog: Fig.7-5: Touch probe configuration dialog "Continuous measurement" is not supported by the function block "MC_TouchProbe" and must not be selected in the above dialog. Depending on the use of TouchProbe1 or TouchProbe2, the following additional (cyclical) control bits have to be configured: TouchProbe1: S TouchProbe1 Enable TouchProbe2: S TouchProbe2 Enable IndraWorks Right mouse click on axis Communication Signal control word The above mentioned control bits have to be configured depending on the use of TouchProbe1 or TouchProbe2. The order of the control bits in the

37 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 31/179 Function Blocks for Application "Touch Probe" Required IndraLogic Steps additional data containers is arbitrary since the function block scans all channels. According to the use of TouchProbe1 (positive or negative edge) or TouchProbe2 (positive or negative edge), the following additional (cyclical) status bits have to be configured: TouchProbe1, pos. edge: S TouchProbe1 pos. detected TouchProbe1, neg. edge: S TouchProbe1 neg. detected TouchProbe2, pos. edge: S TouchProbe2 pos. detected TouchProbe2, neg. edge: S TouchProbe2 neg. detected IndraWorks Right mouse click on axis Communication Signal status word According to the use of the selected touch probe, the corresponding additional status bits have to be configured. The order of the status bits in the additional data containers is arbitrary since the function block scans all channels. According to the use of TouchProbe1 (positive or negative edge) or TouchProbe2 (positive or negative edge), the following additional measuring data have to be configured in the cyclical SERCOS channel: TouchProbe1, pos. edge: S Measured value 1 positive edge TouchProbe1, neg. edge: S Measured value 1 negative edge TouchProbe2, pos. edge: S Measured value 2 positive edge TouchProbe2, neg. edge: S Measured value 2 negative edge IndraWorks Right mouse click on axis Communication Cyclical SERCOS data channel According to the use of the selected touch probe, the corresponding additional data have to be configured in the AT data. The order of the data in the additional containers is arbitrary since the function block scans all channels. 1. Integrate "ML_Technology0x.lib" library into the IndraLogic project 2. Set write access to S =3 prior to the execution of "MC_TouchProbe" (over "MB_WriteParameter") or set P-226 bit 9 once 3. Call of "MC_TouchProbe" and positive edge at "Execute" 4. "MC_TouchProbe" should be called until "Done" or "Error" will be returned 7.4 MC_AbortTrigger Brief Description Interface Description The function block MC_AbortTrigger aborts a running measurement controlled by MC_TouchProbe. Fig.7-6: Function block MC_AbortTrigger

38 32/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Touch Probe" I/O type Name Data type Comment VAR_IN_OUT Axis AXIS_REF Reference to the selected axis VAR_INPUT Execute BOOL A positive signal edge aborts the measurement ProbeSelect PROBE_NUMBER Specification of the selected touch probe: PROBE1 = 1: Touch probe 1 is selected. PROBE2 = 2: Touch probe 2 is selected VAR_OUTPUT Done BOOL The selected touch probe events will be aborted Error BOOL Indicates an error ErrorID ERROR_CODE Brief error description ErrorIdent ERROR_STRUCT Detailed error description Signal/Time Diagram Troubleshooting Fig.7-7: I/O interface of MC_AbortTrigger Signal/time diagram according to PLCOpen (details see "Signal/Time Diagram" on page 29). The function block generates the following error messages in Additional1/Additional2 for the table F_RELATED_TABLE, 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR (16#0003) RESOURCE_ERROR (16#0003) RESOURCE_ERROR (16#0003) INPUT_RANGE_ERROR (16#0006) 16# #0000 Drive firmware is not supported 16# #0001 Required touch probe control bit (S , bit 0) is not configured in the signal control word 16# #0002 Required touch probe control bit (S , bit 0) is not configured in the signal control word 16# #0001 The function block input ProbeSelect is outside the admissible range Fig.7-8: Error codes of MC_AbortTrigger 7.5 MC_AbortTrigger - Special Features of IndraMotion MLC Required Hardware MLC Hardware IndraDrive C or M Required Firmware MLC Firmware MPX drive firmware The following functional packages have to be enabled in the drive: Servo or Synchronization Required Software IndraWorks MLC Required Parameterization See "MC_TouchProbe", "Required Parameterization" on page 30. Required IndraLogic Steps Include "ML_Technology0x.lib" library into the IndraLogic project Call of "MC_AbortTrigger" in the PLC user program

39 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 33/179 Function Blocks for Application "Cross Cutter" 8 Function Blocks for Application "Cross Cutter" 8.1 Introduction and Overview The function blocks mentioned here are intended for cross cutter and cross sealer applications. In this application, the knife or the sealing jaw is mounted on a rotating cylinder. In a definable area (if the knife or the sealing jaw is located on the material), the knife or the sealing jaw has to move with production velocity. Outside this area, the axis is to perform a compensating motion to produce a respective format length. Fig.8-1: Cross cutter construction The following function blocks are available: MB_CrossCutterCalcType04 Calculating a motion profile for cross cutter and cross sealer applications MB_CrossCutSealType01 Calculating, loading and activating a motion profile for cross cutter and cross sealer applications MX(L)_CrossCutter 8.2 MB_CrossCutterCalcType General Brief Description Activating a cross cutter and cross sealer point table (function block is only contained due to compatibility reasons; the above MB_ function blocks should be used for new applications) The function block MB_CrossCutterCalcType04 provides all required data at its outputs which have to be loaded into the motion profile of an axis to operate a cross cutter or a cross sealer with the functions selected in the parameters of the function block. All inputs of the function block will be taken over by "Execute" once in the case of a rising edge. In addition, the function block writes directly into the arrays specified by the pointers during its runtime. The written data are only valid if the function block has been processed without any errors and if it returns "Done".

40 34/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Interface Description Fig.8-2: Interface function block: MB_CrossCutterCalcType04 Name Type Comment VAR_IN_OUT MasterAxisInitialPosAdr POINTER TO REAL Pointer to an array with three elements to be created by the user in which the function block stores the starting positions of the master axis of the generated motion profile segments DistanceAdr POINTER TO REAL Pointer to an array with three elements to be created by the user in which the function block stores the distances of the generated motion profile segments SlaveAxisVelocityAdr POINTER TO REAL Pointer to an array with three elements to be created by the user in which the function block stores the velocities of the slave axis at the segment limits of the motion profile 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 function block stores the step modes of the generated motion profile segments Pointer to an array with three elements to be created by the user in which the function block stores cam tables as well as meta data of the cams which are inserted as segments in the motion profile

41 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Name Type Comment VAR_INPUT Execute BOOL Enabling the function block (once, edge-controlled) ModuloValue REAL Modulo value of the cross cutter axis in [ ] FormatRatio REAL Format ratio of the product to be cut (no 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 edges of the cutting area)). CorrectionProfile MB_CORR_PROFILE Selection of a special profile. The inputs "Overspeed" or "PushOut" have to be used for the parameterization of the special profile. Further information with regard to the selection options of the enumeration type MB_CORR_PROFILE can be found in the respective section. Overspeed REAL Constant overspeed or reduction of the master axis speed in the cutting area in [%] PushOut In "CorrectionProfile", the option CORR_PROFILE_OVERSPEED has to be selected. Otherwise, "Overspeed" is deactivated and thus ineffective. MB_PUSH_OUT_CON FIG (0%: No overspeed; 100%: Twice the master axis speed; -50%: Half the master axis speed) Bosch Rexroth AG 35/179 Function Blocks for Application "Cross Cutter" Structure for the definition of a push out motion during the cut In "CorrectionProfile", the option CORR_PROFILE_PUSH_OUT or CORR_PROFILE_COS_COMP_AND_PUSH_OUT has to be selected. Otherwise, "PushOut" is deactivated and thus ineffective. Further detailed information concerning the structure MB_PUSH_OUT_CONFIG can be found in the respective section. Resolution MB_RESOLUTION Specification of the resolution of the cam calculation by determining the number of supporting points in three stages. Further information with regard to the selection options of the enumeration type MB_RESOLUTION can be found in the respective section.

42 36/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Name Type Comment VAR_OUTPUT Done BOOL Processing completed without errors, output data valid Active BOOL Processing active, output data are invalid Error BOOL Processing completed with errors ErrorID ERROR_CODE In the case of a set "Error" output, this output contains a rough classification of the error ErrorIdent ERROR_STRUCT In the case of a set "Error" output, this output contains detailed information concerning this error NumberOfSteps USINT Number of the generated motion profile segments and number of the motion profile 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.8-3:.. Interface description of the function block: MB_CrossCutterCalcType04 Name Type Minimum value Maximum value Default value Acceptance Execute BOOL FALSE Continuous ModuloValue REAL >0.0 Not defined For rising edge at "Execute" FormatRatio REAL For rising edge at "Execute" CutAngle REAL 0.0 < "ModuloValue" 12.0 For rising edge at "Execute" PendelumFactor REAL 0.0% 100.0% 0.0% For rising edge at "Execute" CorrectionProfile MB_CORR_PROFILE CORR_PROFILE_NON E For rising edge at "Execute" Overspeed REAL -50.0% 100.0% 0.0% For rising edge at "Execute" PushOut MB_PUSH_OUT_CONFIG For rising edge at "Execute" Resolution MB_RESOLUTION RESOLUTION_HIGH For rising edge at "Execute" Fig.8-4: Minimum/maximum and default values of the function block: MB_Cross CutterCalcType04

43 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 37/179 Function Blocks for Application "Cross Cutter" Signal/Time Diagram Functional Description Fig.8-5: Signal/time diagram function block: MB_CrossCutterCalcType04 On the basis of the operating mode "electronic motion profile", the function block calculates profiles for the "cross cutter" application. The individual segments either consist of analytical segments or of cam tables. After having enabled the processing with "Execute", an "electronic motion profile" consisting of three segments will be calculated once on the basis of the input variables. The parameters describing the profile will be saved in the respective arrays which have to be created by pointers at the inputs of the function block "MB_CrossCutterCalcType04". The arrays have to be large enough to be able to save the number of calculated motion steps (currently three steps). The handling of the pointers is similar to the function blocks "MB_ChangeProfileStep" / "MB_ChangeProfileSet" since these function blocks have to be called by the user after the calculation to be able to write the calculated profile to the respectively free record of the "electronic motion profile". The following list describes the meaning of the individual inputs of the function block "MB_CrossCutterCalcType04" in more detail: The input "ModuloValue" specifies the modulo value of the cross cutter axis. By standard, are specified here. The input "FormatRatio" 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 in the case of "FormatRatio==1", the length of the cut product corresponds to the circumference of the cross cutter cylinder (synchronous format). In the case of "FormatRatio==5", however, the length of the cut product is five times the circumference of the cross cutter cylinder. The input "CutAngle" specifies the cutting area of the cross cutter. In the cutting area, the cross cutter either rotates with the material feed velocity or with a (selectable) correction motion. The input "PendelumFactor" specifies the maximum pendular motion of the cross cutter axis in percent. This means that in the case of "Pende

44 38/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" lumfactor==0%", the cross cutter axis will never rotate with a negative velocity (backwards); in the case of "PendelumFactor==100%", the cross cutter axis will rotate to the end of the cutting area to minimize the energy loss and the required accelerations. This provides special benefits in the case of higher values for "FormatRatio". In the case of "PendelumFactor==100%", the cross cutter does not generally rotate to the end of the cutting area since this is not always advantageous. The respective optimum utilization of the available area will always be automatically calculated by the function block. The input "CorrectionProfile" allows several correction motions in the cutting area which are required depending on the respective application. The following correction motions can be selected: "CorrectionProfile==CORR_PROFILE_NONE" (no correction: cross cutter axis rotates with the velocity of the master axis), "CorrectionProfile==CORR_PROFILE_OVERSPEED" (constant overspeed of the cross cutter 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" (push out of the material), as well as CorrectionProfile==CORR_PROFILE_COS_COMP_AND_PUSH_O UT (constant velocity vector in material direction as well as parallel push out, e. g. for guillotine cutters). The input "Overspeed" allows the exact setting of the overspeed in [%] in the cutting area with "CorrectionProfile==CORR_PROFILE_OVERSPEED". Thus, entering a value of 10 [%] increases the velocity of the cross cutter axis in the cutting area by 10% compared to the material velocity. The input "PushOut" parameterizes the push out correction. The input will only be processed with "CorrectionProfile==CORR_PROFILE_PUSH_OUT" or "CorrectionProfile==CORR_PROFILE_COS_COMP_AND_PUSH_OUT". The input "Resolution" allows the resolution of the used cam tables in three steps. On the one hand, this saves a lot of calculating time, and on the other hand, the accuracy of the calculation will be increased. The successful calculation of a profile will be signaled by the output "Done". The parameters will be written to the data fields addressed by the created pointers. Subsequently, these have to be written to a free motion profile with the help of "MB_ChangeProfileSet"/"MB_ChangeProfileStep". The same procedure applies for the cams. It must be observed that the table into which the cams have to be loaded will be defined in the structure "MB_CAM_TABLE_DA TA". In the following, the loaded motion profile has to be activated by using "MB_MotionProfile". The exact cutting length will be defined with the electronic drive at "MB_MotionProfile". The gear ratio corresponds to the value of "FormatRatio". This means that a new profile will be calculated for each possible product length; this profile takes into account the exact input parameters (especially "CutAngle" and "PendelumFactor"). fig. 8-6 "Sequence diagram for

45 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 39/179 Function Blocks for Application "Cross Cutter" using MB_CrossCutterCalcType04" on page 39 shows a sequence diagram describing the use of the function block MB_CrossCutterCalcType04. Fig.8-6: Sequence diagram for using MB_CrossCutterCalcType04 To use several equidistantly distributed knives, a mechanical gear has to be planned in IndraWorks with reference to the load side. The number of input revolutions will be set to 1, whereas the number of output revolutions will be set to the number of the used knives n. Since, however, no real mechanical gear is existent, the drive will only perform one n-fold revolution. Thus, the velocity of the slave axis in one revolution is n times identical with the velocity of the master axis. Example: Configuration of the Mechanical Gear When Using a Cross Cutter 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

46 40/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" If, with this parameterization, the cutting cylinder moves mechanically by 90, this corresponds to an electrical movement of 360 ( = modulo value of the slave axis). To adjust the velocity of the master axis and the slave axis in the cutting area to the same value, the feed constant between the measuring wheel and the internal virtual master axis has to be adjusted as well. In this context, the circumference of the internal virtual master axis will be specified with the length between two knives of the real slave axis. With this parameterization, it is possible to cut each product with a different length with a corresponding lead time. Troubleshooting Fig.8-7: Master axis structure when operating a cross cutter 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 INPUT_RANGE_ERROR, 16# # #0001 Invalid value of the input "ModuloValue" INPUT_RANGE_ERROR, 16# # #0002 Invalid value of the input "FormatRatio"

47 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR, 16# # #0003 Invalid value of the input "CutAngle" INPUT_RANGE_ERROR, 16# # #0004 Invalid value of the input "CutAngle" in combination with cosine compensation INPUT_RANGE_ERROR, 16# # #0005 Invalid value of the input "PendulumFactor" INPUT_INVALID_ERROR, 16# # #0006 Invalid value of the input "CorrectionProfile" INPUT_INVALID_ERROR, 16# # #0007 Invalid value of the input "Overspeed" INPUT_INVALID_ERROR, 16# # #0008 Invalid starting point for the push out function INPUT_INVALID_ERROR, 16# # #0009 Invalid value for "Overspeed_At_Cut" in the structure "MB_PUSH_OUT_CONFIG" INPUT_INVALID_ERROR, 16# # #000A Invalid value for "Overspeed_Max" in the structure "MB_PUSH_OUT_CONFIG" INPUT_INVALID_ERROR, 16# # #000B Invalid combination of "Overspeed_At_Cut" and "Overspeed_Max" INPUT_INVALID_ERROR, 16# # #000C Value of the input "CutAngle" too small in combination with PushOut. INPUT_INVALID_ERROR, 16# # #000D Invalid value of the input "Resolution" INPUT_INVALID_ERROR, 16# # #000E Invalid values of the "POINTER" inputs STATE_MACHINE_ERROR, 16# #0006 xxyy Invalid status of the finite state machine Fig.8-8: Special Features of IndraMotion MLC Start-up Instructions xx specifies the invalid step. yy specifies the invalid status. Bosch Rexroth AG 41/179 Function Blocks for Application "Cross Cutter" Error numbers caused by MB_CrossCutterCalcType04 With regard to the system IndraMotion MLC, the following start-up instructions have to be taken into account for operating the technology function block MB_CrossCutterCalcType04, downloading the generated motion profiles and cams as well as for linking the cross cutter axis with the master axis: Modulo weighting with the modulo value 360 has to be activated for the cross cutter axis. The function block MB_MotionProfile always has to be operated with the setting "0: absolute synchronization without resynchronization" for the input "StartMode" to ensure the exact exchange of the profiles. For the electronic gear, the function block MB_MotionProfile only allows integral values from 1 to for the numerator and the denominator of the gear ratio. Thus, a maximum cutting length deviation will result due to the quantization. This can be minimized by multiplication with a big constant to be able to almost completely use the value range. The generated motion profile can be downloaded on the MLC with the function block MB_ChangeProfileSet, and the generated cams can be downloaded with the function blocks MB_ChangeCamData or MB_Write ListParameter. In contrast to MB_WriteListParameter, the function block MB_ChangeCamData is faster; however, the cam will not be saved persistently and has to be reloaded after a reboot of the control. When downloading the cams, it must be observed that the respective cam is loaded at its assigned position (described in the structure MB_CAM_TABLE_DATA, element "CamTableID").

48 42/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" A small format ratio (< 1) should be selected carefully since the cross cutter axis reaches very high velocities in the compensation range (up to eight times the velocity of the master axis). Bit 1 has to be set in the parameter A of the cross cutter axis so that the gear will be exchanged at a switching angle of 0 analog to the motion profile and not when calling the function block MB_MotionProfile. Format ratio Ratio of the slave axis velocity to the velocity of the master axis Fig.8-9: MB_CAM_TABLE_DATA Brief Description Interface Description 1 1 0,8 1,5 0,6 2,2 0,4 3,7 0,2 8 Effects of the format ratio on the maximum velocity of the cross cutter axis in the compensation range The structure MB_CAM_TABLE_DATA is used by the function block chapter 8.2 "MB_CrossCutterCalcType04" on page 33. It contains an array with a cam table as well as meta data which describe the number of supporting points of the array as well as the position at which the table has to be loaded into the control / the drive. Structural element Type Description CamTableID DINT Number of the cam table into which the described cam has to be loaded NumberOfElements UINT Number of supporting points of the described cam CamTable ARRAY[ ] OF DINT Array with the supporting points of the cam Minimum, Maximum and Default Values of the Inputs Fig.8-10: Name Interface description structure MB_CAM_TABLE_DATA Type Minimum value Maximum value Default value CamTableID DINT 0 0 NumberOfElements UINT Functional Description Fig.8-11: Minimum, maximum and default values of the structure MB_CAM_TABLE_DATA In the structural element "CamTableID", the number of the cam table has been saved in the format required by the function blocks MB_ChangeCamData, MB_ChangeProfileStep and MB_ChangeProfileSet. fig "Allocation of CamTableID to parameter numbers" on page 42 shows the mappings between "CamTableID" and the corresponding parameter number in MLC and MLD. CamTableID Parameter number MLC Parameter number MLD 1 C P C P C P

49 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 43/179 CamTableID Parameter number MLC Parameter number MLD 4 C P C P C P C C Not available Fig.8-12: Function Blocks for Application "Cross Cutter" Allocation of CamTableID to parameter numbers The following diagram shows how to use the data of the structure MB_CAM_TABLE_DATA to load the cam into the control or the drive, respectively. Fig.8-13: MB_CORR_PROFILE Brief Description Connection plan structure MB_CAM_TABLE_DATA The enumeration MB_CORR_PROFILE is used by the function block chapter 8.2 "MB_CrossCutterCalcType04" on page 33 to define a correction motion in the cutting area. The possible elements of the enumeration type MB_CORR_PROFILE as well as their meanings are described in the following description.

50 44/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Elements of the Enumeration Type Element Value CORR_PROFILE_NONE 0 CORR_PROFILE_OVERSPEED 1 CORR_PROFILE_COS_COMP 2 CORR_PROFILE_PUSH_OUT 3 CORR_PROFILE_COS_COMP_ AND_PUSH_OUT 4 Description No correction in the cutting area. The velocity of the cross cutter axis corresponds to the velocity of the master axis. Constant overspeed or reduction of the velocity of the cross cutter axis in the cutting area. The velocity of the cross cutter axis is then faster or slower than the velocity of the master axis by the value parameterized at the input "Overspeed" of the function block MB_CrossCutterCalcType04. Correction of the cross cutter axis velocity The velocity is changed in a way so that the cross cutter axis in the direction of the material (the x component of the velocity vector) rotates with constant speed. The speed of the cross cutter axis has to be adapted depending on the current position in the cut. Performing a push out motion at the end of the cut. Parameterization with the input "PushOut" of the function block MB_Cross CutterCalcType04. The speed of the cross cutter axis has to be adapted depending on the current position in the cut. See also the description of the structure "MB_PUSH_OUT_CONFIG". Combination of the corrections "CORR_PROFILE_COS_COMP" and "CORR_PROFILE_PUSH_OUT". Parameterization with the input "PushOut" of the function block MB_CrossCutterCalcType04. See also the description of the structure "MB_PUSH_OUT_CONFIG". Fig.8-14: MB_PUSH_OUT_CONFIG Brief Description Interface Description Elements of the enumeration type MB_CORR_PROFILE The structure MB_PUSH_OUT_CONFIG is used by the function block chapter 8.2 "MB_CrossCutterCalcType04" on page 33. With this structure, a defined push out can be parameterized at the end of the cut. The elements of the structure MB_PUSH_OUT_CONFIG as well as their minimum, maximum and default values are described in the following interface description. Structural element Type Description PushOutBegin Overspeed_At_Cut REAL REAL Beginning of the push out area (parameter A). The value must not be equal to 0. Unit in [ ]. Overspeed during a cut (parameter B). The value must not be equal to 0. Unit in [%]. Overspeed_Max REAL Maximum overspeed (parameter C). Unit in [%]. Fig.8-15: Interface description structure MB_PUSH_OUT_CONFIG

51 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 45/179 Function Blocks for Application "Cross Cutter" Minimum, Maximum and Default Values of the Inputs Name Type Minimum value Maximum value Default value PushOutBegin REAL -5.0 Overspeed_At_Cut REAL % 100.0% 5.0% Overspeed_Max REAL >0.0% 100.0% 10.0% Functional Description Fig.8-16: Minimum, maximum and default values of the structure MB_PUSH_OUT_CONFIG The following diagrams display the velocity characteristics of the cross cutter cylinder in the cutting area. The individual parameters can be adjusted with the elements of the structure MB_PUSH_OUT_CONFIG. A curve profile with a cut angle of 20 has been assumed for the graphics. The degree of the velocity adjustment will be determined with the help of the two variables "Overspeed_At_Cut" and "Overspeed_Max". The beginning of the velocity increase will be determined with the help of "PushOutBegin". For a clear parameterization, it is required that "PushOutBegin" and "Overspeed_At_Cut" are not equal to zero. Both figures show an example of the parameterization. The green line characterizes the degree of the increase and can be determined by connecting the points A, B and C. Fig.8-17: Definition of PushOut.PushOutBegin < 0

52 46/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" MB_RESOLUTION Brief Description Elements of the Enumeration Type Fig.8-18: Definition of PushOut. PushOutBegin > 0 The enumeration MB_RESOLUTION is used by the function block chapter 8.2 "MB_CrossCutterCalcType04" on page 33. With this enumeration, the number of supporting points of the cam tables and thus the required calculation time can be changed. The elements of the enumeration MB_RESOLUTION as well as their meanings are described in the following description. Element Value Description Number of supporting points (cutting segment + compensating segment + cutting segment) RESOLUTION_LOW 1 Low resolution, short calculation time required (faster by approx. factor 3 in contrast to medium resolution) RESOLUTION_MIDDLE 2 Medium resolution, mean calculation time required (faster by approx. factor 3 in contrast to high resolution) RESOLUTION_HIGH 3 High resolution, much calculation time required Functional Description Fig.8-19: Elements of the enumeration type MB_RESOLUTION With the enumeration MB_RESOLUTION, the number of supporting points of the cam tables and thus the required calculation time can be changed. For short formats and little lead time for a format change, the calculation time of the function block can be reduced by selecting the option "RESOLUTION_LOW". However, it must be taken into account that the resolution of the generated cams is reduced and that the machine might not be running smoothly. In the case of long formats and high lead times for format

53 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives 8.3 MB_CrossCutSealType01 Brief Description Interface Description Bosch Rexroth AG 47/179 Function Blocks for Application "Cross Cutter" changes, the option "RESOLUTION_HIGH" can be selected to generate the created cams with the highest possible resolution. Basically, this setting ("RESOLUTION_HIGH") should be preferred. The option to be selected here strongly depends on the used application and should be determined through tests during the initial start-up. The function block MB_CrossCutSealType01 calculates, loads and activates a motion profile for cross sealer or cross cutter applications. The function block internally uses the function block "MB_CrossCutterCalcType04" for the calculation. With the calculated motion profile, the slave axis moves with product velocity within the sealing or cutting area. Other functions like, for example, 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) will be 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 motion profile in the background. The newly calculated motion profile will then be activated and takes effect at the switching angle. In the case of a negative edge at Enable, the cross sealer or cross cutter will be deactivated. The axis will be immediately stopped over the predefined deceleration ramp. Fig.8-20: Interface function block MB_CrossSealType01

54 48/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Name Type Comment VAR_IN_OUT Master AXIS_REF Reference to master axis Slave AXIS_REF Reference to slave axis ( = cross cutter axis / cross sealer axis) The modulo value is 360 (electrical) and is mechanically defined as the distance between two knives / sealing jaws. VAR_INPUT Enable BOOL Enabling the function block for processing CrossCutter BOOL If CrossCutter = TRUE, the cross cutter application (see the following detailed description) will be selected. StartMotionProfile BOOL In this case of application, the master axis has to be standardized in a way so that the material to be cut covers the distance in one revolution that corresponds to the distance of the knives. In this case, the used electronic gear of the motion profile 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 CrossCutter = FALSE, the cross sealer application (see the following detailed description) will be selected. In this case of application, the master axis has to be standardized in a way so that one revolution corresponds to a foil feed of one product length. In this case, the used electronic gear of the motion profile is set to the gear ratio "1 / ProductsPerCut". Furthermore, the input CutSealArea corresponds to the sealing length and will thus be defined in translatory units (e. g. mm or inch). The inputs ProductsPerCut and StartProduct will be evaluated in this case. The activation of a new motion profile will be blocked as long as this input is set to FALSE. StartMotionProfile = TRUE activates the new motion profile 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 MC_CAM_ID In the case of more than one product per sealing or cutting process (ProductsPerCut > 1), the start product can be defined over 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 an equal distance from each other. Start number of the first cam point table. A block of a maximum of 6 point 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]. FormatLength REAL Predefined cutting length or sealing distance / package length [mm or inch]

55 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Name Type Comment 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 influenced by additional inputs like, for example, OverSpeed, PushOut, cosine correction etc. If the input CrossCutter = FALSE, this input corresponds to the sealing length and will thus be 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 Selection of a special profile. The inputs "OverSpeed" or "Push Out" have to be used for the parameterization of the special profile. Overspeed REAL Constant overspeed or reduction of the master axis speed in the cutting area in [%] 0%: No overspeed; 100%: Double master axis speed; -50%: Half the master axis speed. This input is only effective if the option CORR_PROFILE_OVERSPEED has been selected at the input CorrectionProfile. PushOut MB_PUSH_OUT_CONFIG Structure for the definition of a push out motion during the cut or the sealing process In CorrectionProfile, the option CORR_PROFILE_PUSH_OUT or CORR_PROFILE_COS_COMP_AND_PUSH_OUT has to be selected. Otherwise, PushOut is deactivated and thus ineffective. Resolution MB_RESOLUTION Specification of the resolution of the cam calculation by determining the number of supporting points 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 In the case of a negative edge at Enable, the slave axis will be stopped with the deceleration defined here. Units according to axis weighting in rotatory units. VAR_OUTPUT InOperation BOOL Cross cutter runs without any failures Error BOOL Processing completed with errors ErrorID ERROR_ CODE Description of the analysis in the case of an error ErrorIdent ERROR_ STRUCT Detailed analysis Bosch Rexroth AG 49/179 Function Blocks for Application "Cross Cutter" Shutdown BOOL The cross sealer will be stopped with the deceleration ramp StopDeceleration after a negative edge at Enable. During this time, the output ShutDown is activated to display the defined deceleration process.

56 50/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Name Type Comment ChangeProfile BOOL If input variables like, for example, FormatLength are changed during operation, a new motion profile will be calculated and loaded in the background. Subsequently, the new motion profile will be used. Since this process requires several cycles, this output will be activated for this period. If any other input variables are changed during this process (e g. FormatLength), the current process will be interrupted and performed again with the new data. The output will be reset once the newly calculated motion profile becomes effective and the switching angle has been passed through. ProfileReady BOOL This output will be set once the motion profile has been calculated, loaded and activated. The output will be deleted once the motion profile has become effective (after having passed the switching angle). CutCounter UINT The cut counter will be increased for each modulo overrun (360 0 ) of the slave axis. In the case of a rising edge at Enable, the cut counter will be reset to zero. Minimum, Maximum and Default Values of the Inputs Fig.8-21:.. Interface description function block MB_CrossSealType01 Name Type Minimum value Maximum value Default value Acceptance 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 ActualProduct UINT In the case of more than one product per sealing process (ProductsPerCut > 1), the product which is currently processed will be displayed over this output. In the event of a rising edge at Enable, this output will be reset to the input variable StartProduct. 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 mm/inch Rising edge at Enable FormatLength REAL > 0.2* KnifeDistance 30* KnifeDistance mm/inch Continuous* CutSealArea REAL 0 < Continuous* 0 mm < KnifeDistance 10mm/inch PendelumFactor REAL 0.0% 100% 0.0% Continuous*

57 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Name Type Minimum value Maximum value Default value Acceptance CorrectionProfile MB_CORR_PROFILE Continuous* Overspeed REAL % % 0.0% Continuous* PushOut MB_PUSH_OUT_CONFIG Continuous* Resolution MB_RESOLUTION RESOLUTION_ LOW RESOLUTION_ 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 will be displayed over the output ChangeProfile. Fig.8-22: Minimum/maximum/default values of the function block MB_CrossSeal Type01 After processing has been enabled with the help of Enable, the function block calculates a motion profile as well as point tables for the cross sealer / cross cutter application in accordance with the specified input data. In this context, the function block also supports multiple cross sealers / cross cutters with equally distributed knives or sealing jaws. For multiple cross cutters or cross sealers: 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" on page 58). 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. The following input variables take effect in this area: 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 push out motion during the cutting or sealing process Outside the cutting or sealing area, an optimum compensating motion with regard to jerk and energy will be 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 selectable limits to optimally use the acceleration capacity of the drive in the case of large format lengths. The following input variable take effect in this area: Bosch Rexroth AG 51/179 Function Blocks for Application "Cross Cutter" PendelumFactor specifies the maximum admissible pendulum radius [%].

58 52/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" The motion profile and the point tables will be automatically loaded and activated after having finished the calculation. During this period, the output ChangeProfile is activated. If the motion profile has become effective and if the slave axis has been synchronized, the output InOperation will be activated. In this state, the slave axis moves synchronously to the master axis using the previously calculated motion profile. In this state, the cut or seal counter Cut Counter will be increased with each revolution of the cross cutter or cross sealer axis. If input variables like, for example, FormatLength will be changed during the operation, a new motion profile will be calculated in the background. Since this process requires several cycles, the output ChangeProfile will be activated during this period. The output ProfileReady will be activated if the new motion profile has been activated but if the switching angle has not been passed through. If the switching angle is reached subsequently, the calculated motion profile will become effective and the outputs ChangeProfile and ProfileReady will be reset. If any input data will be changed again during the current change of the motion profile, the changes will be discarded and the calculation with the new input data will be restarted. The supporting points of the used point tables within the motion profile can be influenced with the help of the input Resolution. A high resolution results in a maximum accuracy but requires the most time during the calculation. The amount of time can be reduced by the factor 3 or 9 with the settings Medium and Low. The reduction of the resolution makes sense if different product lengths are continuously processed with high clock rates (> 500 cycles/minute). A negative edge at Enable results in a defined shutdown of the cross cutter / cross sealer. The slave axis will be decelerated until standstill with the definable ramp StopDeceleration. During the defined shutdown, the output Shutdown will be activated. The output Shutdown will be reset if the slave axis has reached its standstill position or if an error has occurred. Fig.8-23: Definition of the input KnifeDistance

59 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives For weighting: 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 observed that all translatory input variables are specified with the same unit (mm or inch). Cross sealer application Over the input CrossCutter, 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 will be assumed. The control of a cross sealer cylinder of flow wrappers is a typical example for this application. Here, the sealing jaw is to move with the product velocity and 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 controlled 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 input CutSealArea corresponds to the length of the sealing seam and will thus be specified in translational 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 will be specified over the input ProductsPerCut. This input has a direct influence on the electronic gear of the used motion profile. The first product will be set over the input StartProduct after a positive edge at Enable. This variable has an internal effect on a position offset of the used motion profile. After a positive edge at Enable, the output ActualProduct will be set to the input StartProduct. Optionally, the synchronous lock on and lock off can be connected upstream over another function block MB_CamLock. For starting the function block: Bosch Rexroth AG 53/179 Function Blocks for Application "Cross Cutter" If the master axis and the slave axis are in an optional position during the start of the function block, the slave axis will perform 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 function block for the cross sealer application with optional, synchronous lock on and lock off.

60 54/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Fig.8-24: 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.

61 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 55/179 Function Blocks for Application "Cross Cutter" Fig.8-25: 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 three products per package. Fig.8-26: Example of a signal/time diagram with three products per sealing process Cross cutter application Over the input CrossCutter, the function block generally differentiates between the cross cutter application and the cross sealer application. If the input CrossCutter is TRUE, a cross cutter application will be assumed. During the cutting process, the knife is to move with the velocity of the product and with an optional correction profile. Outside the cutting area, a compensating

62 56/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" 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, in turn, corresponds to the knife distance KnifeDistance. One cut per product is always assumed here. The inputs ProductsPer Cut and StartProduct are not effective (these inputs will be internally set to 1). The output ActualProduct is always set to "1". The used electronic gear of the motion profile will be set to the gear ratio FormatLength / KnifeDistance. This gear only allows integral values from 1 to for the numerator and the denominator of the gear ratio. Thus, a maximum cutting length deviation will result due to the quantization. If a deviation of the cutting lengths occurs due to the quantization, a respective gear ratio fine adjustment will be calculated and specified. In this case, a drift between the master and the slave axis will be resulting 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:

63 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 57/179 Function Blocks for Application "Cross Cutter" Fig.8-27: 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).

64 58/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Fig.8-28: 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 large format (format length = 2* knife distance). Required Basic Conditions and Requirements Fig.8-29: 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.

65 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Example: 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 ) have to be adjusted. These parameters have to be set in a way so that a 360 electrical movement (modulo value of the slave axis) corresponds to the distance between two knives or sealing jaws. Configuration of the Mechanical Gear When Using a Cross Cutter 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: Bosch Rexroth AG 59/179 Function Blocks for Application "Cross Cutter" S = 10 S = 4 If, with this parameterization, the cutting cylinder moves mechanically by 90, this corresponds to an electrical movement of 360 ( = modulo value of the slave axis). Troubleshooting The function block does not perform an independent, motion-side error response. In the case that an error is detected, no further motion command will be transferred to the axis and the function block is left over the output Error. 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). ErrorID Additional1 Additional2 Description ACCESS_ERROR (16#0004) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) 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.

66 60/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) 16# #0006 The input FormatLength is outside the admissible range. 16# #0007 The input CutSealArea is outside the admissible range. 16# #0008 The input PendulumFactor 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 in connection with the master axis velocity and the SERCOS cycle time. Fig.8-30: Error codes function block MB_CrossCutSealType MX(L)_CrossCutter Brief Description Interface Description The function block MX(L)_Crosscutter provides the basic functionalities for a cross cutter application (without print mark evaluation) and performs the following steps: Synchronization of the slave axis on the master axis over a cam profile followed by a continuous cut Format switching on-the-fly Immediate stop of the slave axis in a defined position Fig.8-31: Function block MX(L)_CrossCutter I/O type Name Data type Comment VAR_IN_OUT Master AXIS_REF Reference to the master axis Slave AXIS_REF Reference to the slave axis

67 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives I/O type Name Data type Comment VAR_INPUT Enable BOOL Activating the cross cutter functions CutExecute BOOL A positive edge activates the synchronization phase followed by the cutting phase StopExecute BOOL A positive edge stops the cutting phase and moves the slave axis to the position "StopPos" FormatLength REAL Cut format, length of sheet NumberOfKnives UINT Number of knives from 1 to 4 *1 Pos REAL The slave axis moves to the position "StopPos" if a positive edge is detected at the input "StopExecute" *2*3 Vel REAL The slave axis moves with the maximum velocity Vel to the position "StopPos", if a positive edge will be detected at the input "StopExecute" *2*3 Acc_Dec REAL The slave axis moves to the position "StopPos" with the maximum acceleration "Acc_Dec" *2*3 CamRelValues MB_CC_CAM_REL_VALUES Cam-related values ResetCutCounter BOOL The cut counter will be reset through a positive edge (or "Enable= FALSE") PosOf1stKnife REAL Position of the first knife. Is required to calculate the positions of all knives. All knives are positioned with the same distance from each other. VAR_OUTPUT InSync BOOL The knife drum runs synchronously with the material State UINT Current status of the cut cycle: 0: Standstill and waiting phase 1: Synchronous run phase 2: Cutting phase 3: Stop phase 4: Error status Error BOOL Displays an error, reset with "Enable = FALSE" ErrorID ERROR_CODE Brief error description ErrorIdent ERROR_STRUCT Error code CutCounter UINT With each cut, the cut counter "CutCounter" will be increased. The counter will be reset by "Enable = FALSE" or a positive edge at the input "ResetCut Counter". Signal/Time Diagram Bosch Rexroth AG 61/179 Function Blocks for Application "Cross Cutter" 1: The number of the knives used has an influence on the admissible format length ranges 2: Measurements in correspondence with the drive weighting (mm) 3: New values become active during the standstill and waiting phase (CycleState = 0) Fig.8-32: I/O interface of ML(X)_CrossCutter The following diagram represents a cross cutter cycle from the start of the cross cutter to the stop of the knife drum. Normally, the knife drum will only be stopped in the case of emergency (by doing so, the synchronization with the master axis will be lost). A regular stop of the cutting process should be caused over the master axis.

68 62/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Functional Description Fig.8-33: Cross cutter timing diagram A measuring wheel running on the material determines the position and velocity of the material. The cross cutter is placed at the end of a production line for paper, corrugated paper or other materials. The end products of such machines are stacked sheets or plates with various lengths. Since a lot of different formats have to be produced, the knife drum has to be operated in the electronic cam mode. Fig.8-34: Process: Cutting individual sheets of the raw material The basic issue in such applications is the format change without stopping the machine. The next figure shows a format change from format A to a shorter format B. Format Length Fig.8-35: Format change on the fly at constant material speed The format length is the cutting length of the material. This value depends on the synchronous format and the number of knives.

69 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 63/179 Function Blocks for Application "Cross Cutter" Synchronous Format Fig.8-36: Format length The synchronous format (synchronous length) is the cutting length resulting from one revolution of the cutting cylinder. The length corresponds to the circumference of the cylinder since both cylinders as well as the material are running at the same velocity. Format Ratio Fig.8-37: Synchronous format The format ratio defines the ratio between the circumference of the knife drum and the format length. Format Ranges Fig.8-38: Format ratio The format range is the value which will be calculated on the basis of the circumference of the cutting cylinder. It defines the minimum and maximum cutting lengths which can be generated by each cam profile. A maximum of 4 cam profiles can be configured to support the complete format range of the application. The number of the supported format ranges for one application depends on the number of used knives. The following table lists the minimum and maximum format length for each cam profile as well as the number of the respectively supported knives: Number of knives Format range Minimum range Maximum range 1 Cam profile x synchronous format 2 x synchronous format Cam profile 2 2 x synchronous format 4 x synchronous format Cam profile 3 4 x synchronous format 6 x synchronous format Cam profile 4 6 x synchronous format 8 x synchronous format

70 64/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Number of knives Format range Minimum range Maximum range 2 or 3 Cam profile x synchronous format 4 Cam profile x synchronous format 1.5 x synchronous format Synchronous format Example of a Format Range for 1 Knife Fig.8-39: Supported format range based on the number of knives The following sample application uses one knife which is mounted on a knife drum with a circumference of 500 mm. As long as only one knife is used, all 4 cam profiles will be supported. The format range for each cam profile is as follows: Format range Min. range Max. range Cam profile x 500 mm = 250 mm 2 x 500 mm = 1,000 mm Cam profile 2 2 x 500 mm = 1,000 mm 4 x 500 mm = 2,000 mm Cam profile 3 4 x 500 mm = 2,000 mm 6 x 500 mm = 3,000 mm Cam profile 4 6 x 500 mm = 3,000 mm 8 x 500 mm = 4,000 mm Fig.8-40: Example for 4 cam profiles available for one knife Cam profiles cannot be selected by the user. The cam profiles are selected by the function block MX(L)_Crosscutter. The user specifies the desired cutting length within the admissible range (e. g. 500 mm to 4,000 mm) over the input FormatLength; then, the function block automatically selects the corresponding cam profile. The following example shows the 4 different cam profiles which are available for one knife: Format Range for 2 or 3 Knives Fig.8-41: Four cam profiles for one knife If 2 or 3 knives are used for the same application, cam profile 1 with the following format range will be supported only: Format range Min. range Max. range Cam profile x 500 mm = 250 mm 1.5 x 500 mm = 750 mm Fig.8-42: Example cam profile 1 for 2 or 3 knives

71 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 65/179 Function Blocks for Application "Cross Cutter" Format Range for 4 Knives If 4 knives are used for the same application, only cam profile 1 with the following format range will be supported again: Format range Min. range Max. range Cam profile 1 Fig.8-43: 0.5 x 500 mm = 250 mm Example cam profile 1 for 4 knives Synchronous format = 500 mm If more than 1 knife is used, the entire overall format range for the application will be strongly reduced. Several knives increase the material production but restrict the cutting length range. Thus, the circumference of the knife drum should be selected in a way to provide an acceptable format range if more than one knife is required. Cut Angle The cut angle represents the area around the cut position in which the velocities have been synchronized. Its size depends on the mechanical construction of the knife. Real Master Axis Fig.8-44: Cut angle The knife drum follows a master axis which corresponds to the web velocity. The velocity of the web is determined with the help of a measuring wheel. The master axis must be configured so that the material length transported during a revolution of the master axis corresponds to the circumference of the knife drum. With a linear cam, the knife would cut the "synchronous format". The cutting cycle has to be reduced or extended for other formats. The cutting cycle (and thus, the cutting length) will be defined by the electronic gear. Fig.8-45: Influence of the master axis on the cutting process

72 66/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Adjusting the Knife Position The cam profile always has a fixed reference to the master axis. The initialization profile generated with the CamBuilder or a PLC function block starts at 0. The cut position in the synchronous part of the profile has been defined as 180. While the knife is in contact with the material, the knife drum has to pass the synchronous part of the profile (the cut angle). Depending on the mechanical 0 position, the drum must be adjusted so that it meets this requirement. Calculation of the Cam Profile Fig.8-46: Adjusting the knife position CamBuilder is an IndraWorks off-line tool to perform cam profile calculations. It can be used to download profiles for testing purposes or to design initialization cam tables for applications which can be covered with fixed profiles. A special wizard is available to provide support during the calculation of cam profiles for cross cutter applications. Based on the input parameters for the format length, the knife drum diameter and the cut angle, the wizard generates a profile similar to the profile of the example shown in fig " Cross cutter wizard: Working area" on page 67.

73 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 67/179 Function Blocks for Application "Cross Cutter" Fig.8-47: Cross cutter wizard: Working area Always activate the option "Use velocity limit". When using CamBuilder version 01Vxx, the option "Allow reverse movement" has to be deactivated in principle. Troubleshooting The output value "Synchronous area gradient" is the ΔTW parameter for the calculation of the stroke factor. The function block generates the following error messages in Additional1/Additional2 for the table "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR (16#0003) 16# #0000 Function block was interrupted by another function block. RESOURCE_ERROR (16#0003) 16# #0000 Drive firmware version is not supported

74 68/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR (16#0006) 16# #0001 Inputs are outside the valid range: Format length is outside the range - the valid range is the format length < 0.5*SyncFormat or format length > 8.0*SyncFormat. INPUT_RANGE_ERROR (16#0006) 16# #0002 Inputs are outside the valid range: Velocity is outside the valid range INPUT_RANGE_ERROR (16#0006) 16# #0003 Inputs are outside the valid range: Acceleration is outside the valid range INPUT_RANGE_ERROR (16#0006) 16# #0004 Inputs are outside the valid range: Position is outside the valid range INPUT_RANGE_ERROR (16#0006) 16# #0005 Inputs are outside the valid range: Cam-related values are not initialized correctly INPUT_RANGE_ERROR (16#0006) 16# #0006 Slave axis Axis_Ref, the axis number is outside the valid range INPUT_RANGE_ERROR (16#0006) 16# #0007 The number of knives is higher than 4 ACCESS_ERROR (16#0004) 16# #0000 S is not configured in P ACCESS_ERROR (16#0004) 16# #0000 P could not be initialized ACCESS_ERROR (16#0004) 16# #0000 Bit 4 of P is not set ACCESS_ERROR (16#0004) 16# #0000 Bit 0 of P is not set in AT ACCESS_ERROR (16#0004) 16# #0000 Bit 4 of parameter P is not set DEVICE_ERROR INDRV_TABLE 16#XXXX 16#0000 See the respective IndraDrive documentation Fig.8-48: Error codes of MX(L)_Crosscutter 8.5 ML_Crosscutter - Special Features of IndraMotion MLC Required Hardware Required Firmware Required Software Required Parameterization MLC Hardware IndraDrive C or M MLC Firmware MPx drive firmware The following functional packages have to be enabled in the drive: Closed Loop Synchronization IndraWorks MLC The following parameterization has to be performed to ensure a proper functionality of the cross cutter function block. Perform the following steps before starting the cross cutter function block. 1. Pre-reference the drive (absolute encoder recommended) 2. Parameterize modulo weighting in the drive 3. Download all 4 cams of the cross cutter: Either with the help of the CAM Builder: You can create your own cams with the help of the "CamBuilder". Create 4 different cams (see example in the following figure; in order to get more information, see the description of the "CamBuilder")

75 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Format length= 0.5 * synchronous format Format length= 2.0 * synchronous format Format length= 4.0 * synchronous format Format length= 6.0 * synchronous format Bosch Rexroth AG 69/179 Function Blocks for Application "Cross Cutter" Fig.8-49: Entire format range: ( ) x synchronous format = ,000 mm Cross cutter example format range

76 70/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Wizard inputs Values and parameters Format range 1 Min. format length = 0.5 x 75 mm = 37.5 mm PLC constant for stroke factor calculation: rdeltatw_05to20 = Download: Cam table 1 P Format range 2 Min. format length = 2.0 x 75 mm = 150 mm PLC constant for stroke factor calculation: rdeltatw_20to40 = Download: Cam table 2 P

77 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 71/179 Function Blocks for Application "Cross Cutter" Wizard inputs Values and parameters Format range 3 Min. format length = 4.0 x 75 mm = 300 mm PLC constant for stroke factor calculation: rdeltatw_40to60 = Download: Cam table 3 P Format range 4 Min. format length = 6.0 x 75 mm = 450 mm PLC constant for stroke factor calculation: rdeltatw_60to80 = Download: Cam table 4 P Fig.8-50: Example: Cam profile calculation - Or - It is recommended to use four different rdeltatw values in the PLC project; see also "CrossCutter_GlobalConstants" Download already prepared, appropriate cam parameter files Setup of the knife drum axis: Setup of the mechanical settings of the knife drum axis (travel ranges, limits)

78 72/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" In order to switch the format between the cam and the cam distance on-the-fly, the following settings have to be made (see the following figure): Reduction (P ) to 1 P (cam switching angle), normally 180 P (cam distance switching angle), the same as P P , bit 4= 1 (stroke switching at the same time like cam switching) Fig.8-51: Setting the parameters with IndraWorks Parameter Reduction / P Stroke switching at the same time like cam switching / P , bit 4=1 Cam switching angle / P Cam distance switching angle Explanation A knife drum can carry more than one knife. Only 1 knife is currently supported. This value specifies if new gear settings are to be activated with a new stroke factor or when switching the cam. This value indicates that a cam is activated. A new cam will become immediately active once the cam passes the "cam switching angle" (P ). In the case of cross cutter applications, the "cam distance switching angle" must be degrees. This option specifies if a new value for the stroke factor ("cam distance") has been activated. A new stroke factor will become active once the cam passes the "cam distance switching angle" (P ). In the case of cross cutter applications, the "cam distance switching angle" must be degrees. Fig.8-52: Exemplary parameter setting with IndraWorks Set the synchronization acceleration (P ) and the synchronization velocity (P ) of the knife drum axis IndraWorks Slave axis Right mouse click Parameter editor P (and P )

79 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 73/179 Set the synchronization direction P ), the synchronization mode (P ) and the command value mode (S ) of the knife drum axis depending on the master drive polarity (P ) IndraWorks Right mouse click Individual parameter P (and P , and S ) To count the number of cuts, a certain area has to be determined within the cut angle. The function block output "CutCounter" will be increased once this area is passed. This area depends on the paper roll velocity and the task cycle time of the function block "ML_Cross Cutter". The area must be at least 5 degrees (max. v web =400 rpm, T cyc =2 ms of the function block "ML-Crosscutter"). For this purpose, the following parameters have to be set (see the following figure): "Reference signal" to S Function Blocks for Application "Cross Cutter" Drive cam switch, switch-on threshold to 180 degrees Drive cam switch, switch-off threshold to 185 degrees Required IndraLogic Steps Fig.8-53: Setting the cut angle counter The cut position in the synchronous part of the profile has normally been defined as 180. For switching the knife drum into the right position (in relation to the master axis), the parameter S has to be set to the correct value (normally 180 degrees if the zero position of the knife corresponds to the cut position). For that purpose, the "parameter editor" of the "slave axis" can be used. Including the "ML_Technology0x.lib" library into the IndraLogic project: The value for the synchronous format and the corresponding "deltatw" values (resulting from the CAM Builder) have to be specified for the input "CamRelValues" of the function block "ML_CrossCutter" (see next figure).

80 74/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Cross Cutter" Fig.8-54: IndraLogic: Implementation of the cam values for the function block ML_CrossCutter based on the cam calculation These values can be found in the "CAMbuilder" application wizard. Call the provided function block in the IndraLogic project. The function block should run in a high-prior motion task with a cycle time of 4ms. Before starting the function block, the function block "MC_Power" must be processed without errors. Then start the CrossCutter function block when the drive has been enabled.

81 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 75/179 Function Block for Application "Register Controller" 9 Function Block for Application "Register Controller" 9.1 Register Controller - Overview and Application Introduction and Overview The register controller function block will be used for paper, printing, packaging and foil applications using synchronized drives (e. g. angle or cam synchronization) for feeding material through a machine. In these applications, variations in the material characteristics, slipping material and the production process have an influence on the accuracy of the material position. The register controller function block determines the actual position of the registration marks which are placed on the material and is thus able to detect deviations from the command value. Furthermore, it calculates the required correction value with the help of a P or PI controller. This procedure ensures that the registration marks are set precisely to their command value and do not drift away Register Controller Examples for Applications Die Cutting in Label Printing The following example describes a die cutting process on a label printing machine: Fig.9-1: Register control of a die cutter Labels are printed on a composite material including a backing foil and a selfadhesive top layer. The unprinted grid is stamped and re-wound. The task of the register controller is to adjust the die cutting drum on the printed web. The die cutting drum runs in angle-synchronized mode. The adjustment with regard to the printed web is accomplished by adjusting the angular offset. The sensor is connected with the drive of the die cutting drum. The angular position (the actual position value) of the die cutting drum is determined over the sensor signal. The command value for the register controller corresponds to the drum position which is exactly aligned with the product. The correction value will be calculated on the basis of the difference between the command value and the actual value and by adding this value to the current angular offset. The most important settings for the touch probe, the register controller and the drive operation mode of this application are: Measured value (touch probe function) = Position feedback 1 value (S )

82 76/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Register Controller" Insetter Control Control variable (ControlledValueIDN) = additive position command value (P ) Drive operation mode = angular synchronization The following figure shows an insetter control in a material infeed application: Flow Wrapper Fig.9-2: Insetter control of the material infeed The material infeed unit transports pre-printed material to a printing machine. After the pre-printing and drying process, the web has shrunk, i. e. the format length does not exactly correspond to the nominal format. The web has to be elongated again for further processing. The task of the register controller is to control the velocity of the material infeed rollers so that the pre-printed web is elongated to the nominal paper format. This implies that one paper format is transported during each revolution of the master axis. The command value of the register controller is related to the master axis. The material infeed roller runs in the speed synchronization mode. The velocity of the infeed roller is controlled over the gear ratio fine adjust. The elongation of the web is correct if the print mark is always detected in the same master axis position by the mark reader. The master axis position will be detected by the sensor signal. The mark reader is connected with the touch probe input of the material infeed roller drive. The most important settings for the touch probe, the register controller and the drive operation mode of this application are: Measured value (touch probe function) = resulting master axis position (P ) Control variable (ControlledValueIDN) = gear ratio fine adjust (P ) Drive operation mode = speed synchronization The following figure shows a sideseal axis (foil infeed axis) of a flow wrapper application:

83 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 77/179 Function Block for Application "Register Controller" Fig.9-3: Foil infeed axis of a flow wrapper application In this application, the product will be fed into the packaging machine with the help of an infeed belt. The foil infeed axis (sideseal axis) runs synchronously with the infeed belt and pulls in the foil. During this process, the correct alignment of the foil to the product as well as an equal product length has to be ensured. Slippage between the material and the infeed rollers as well as inaccuracies of the material can result in positioning errors between the servo motor and the foil. Thus, registration marks are printed on the material allowing a correction of positioning errors. Prints, pictures and dirt on the product can result in unwanted signals at the print mark sensor input. Thus, an expectation window for the print mark signal is required. The drive touch probe function is only active within the expectation window to measure the print mark position. Furthermore, it is required to detect missing marks within the expectation window as well. The correction motion is proportional to the difference between the measured value and the command value. Due to mechanical limits of the machine, the correction motion has to be limited to a user-defined value. The register controller has to adjust the foil infeed axis to the printed foil to adjust the foil to the product position. The foil infeed axis runs in the angular synchronization mode. The register controller calculates an additive position command value for the foil infeed axis by which the foil will be correctly readjusted.

84 78/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Register Controller" The most important settings for the touch probe, the register controller and the drive operation mode of this application are: Measured value (touch probe function) = resulting master axis position (P ) Control variable (ControlledValueIDN) = additive position command value (P ) Drive operation mode = angular synchronization 9.2 MB_RegisterControllerType01 Brief Description Interface Description The register controller function block MB_RegisterControllerType1 provides the following functionalities: Start and monitoring of the drive touch probe Calculation of a correction value on the basis of the measured values and the command value using a P or PI controller (comparable to the indirect control algorithm of SYNAX). Dead time compensation of the measured signal due to the dead time of the used sensor Preset function Pause function Minimum and maximum limitation of the calculated control value Expectation window of the measured signal Fig.9-4: Function block MB_RegisterControllerType01 I/O type Name Data type Comment VAR_IN_OUT ControlledAxis AXIS_REF Reference to the controlled axis MeasuredAxis AXIS_REF Reference to the measured axis

85 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives I/O type Name Data type Comment VAR_INPUT Enable BOOL Activates the register controller Pause BOOL The input "Pause" is only evaluated as long as the input "Enable" is active. A pause is intended to fix the constant control variable "ControlValue". in this case, the control deviation = command value - actual value will be set to zero; thus, the control variable will be fixed. Touch probe events will still be monitored and the controlled parameter will still be influenced. Preset BOOL The input "Preset" is only evaluated as long as the inputs "Enable" and "Pause" are active. A positive edge at this input results in the I part of the controller being set to PresetVal. Furthermore, this function sets the controlled parameter to the absolute value "PresetVal". Polarity BOOL The polarity of the controlled value is inverse as long as the input is TRUE ProbeSelect PROBE_NUMBER Specification of the touch probe input selected for the signal measurement: PROBE1 = 1: Touch probe 1 is selected, PROBE2 = 2: Touch probe 2 is selected ProbeEdge PROBE_EDGE Specification of the touch probe signal edge selected for the signal measurement: POS_EDGE = 1: A positive edge is used NEG_EDGE = 2: A negative edge is used ControlledValueIDN DINT SERCOS IDN of the controlled parameter The following IDNs will be supported: P , P , P , P Setpoint REAL Desired command value With ControlledValueIDN = S , writing to the parameter will be deactivated. The control value can then be manually copied to a certain drive parameter. PControl REAL Proportional gain of the PI controller If 0, the proportional part of the controller will be deactivated and the proportional gain will be internally set to 0 so that the controller acts as pure I controller. IControl REAL Integral time Tn of the PI controller. If set to 0, the integral part of the PI controller will be deactivated. Units [10-2 ] like syntax parameter A SensorDeadTime REAL Dead time of the sensor in µs This value will be used for the dead time compensation of the measured signal. HighLimit REAL Maximum value for ControlValue LowLimit REAL Minimum value for ControlValue Bosch Rexroth AG 79/179 Function Block for Application "Register Controller" PresetVal REAL The value assigned to the system if the preset function (Preset) becomes active

86 80/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Register Controller" I/O type Name Data type Comment VAR_OUTPUT InOperation BOOL Register controller is active Error BOOL Indicates an error. Set "Enable" = FALSE to reset the error. ErrorID INT (Enum) ERROR_CODE: Brief error description ErrorIdent ERROR_STRUCT Detailed error description PresetDone BOOL Preset function (Preset) has been executed HighLimitAck BOOL Upper limit is active LowLimitAck BOOL Lower limit is active ControlValue is higher but will be limited to HighLimit ControlValue is lower but will be limited to LowLimit Counter UINT The counter will be increased if the touch probe is detected. MissingMarks UINT Counter of the missing marks ControlValue REAL Controller value calculated by the register controller ActualValue REAL Actual value used by the register controller Deviation REAL Difference = command value - actual value of the register controller ParameterControlValue REAL Calculated control parameter transferred to the drive Signal/Time Diagram Fig.9-5: I/O interface of the function block MB_RegisterControllerType1 The following diagram displays the signal timing of the function block MB_RegisterControllerType1 including pause and preset function. Fig.9-6: Signal/time diagram of the function block MB_RegisterControllerType01 with pause and preset function Functional Description A sensor detects marks, perforations, a cut or a laminated joint on the material and transfers this information to the drive as a binary signal. The touch probe function of the drive determines the edge of the sensor signal and saves the position in accordance with the selected touch probe signal. Actual drive position (parameter: S , S ) Master axis position (parameter: P , P , P , P , P , P )

87 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 81/179 Function Block for Application "Register Controller" The touch probe function records position data with a resolution of 0.5 µs. The sensor has to provide a 24 V signal with a ramp response time in the µs range. The sensor-specific dead time can be compensated over the input "Sensor DeadTime" of the function block MB_RegisterControllerType01. The register controller calculates the control deviation between the measured value and the command value position and determines the correction value as soon as a new edge of the sensor signal has been detected. Changes of the correction value will be performed over a trapezoidal profile, a velocity ramp, a PT1 filter or instantaneously depending on the selected controller parameter (input "ControlledValueIDN" of the function block). The following table displays the available controller parameters ("ControlledValueIDN") as well as the resulting motion profile of all available drive operation modes with synchronization. Block Diagram Fig.9-7: Supported controller parameters and their behavior The following figure represents the internal block diagram of the register controller.

88 82/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Register Controller" Fig.9-8: Block diagram of the register controller Troubleshooting Fig.9-9: Block diagram of the internal PI controller The function block generates the following error messages in Additional1/Additional2 for the table F_RELATED_TABLE 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR (16#0003) RESOURCE_ERROR (16#0003) STATE_MACHINE_ERROR (16#0005) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) 16# #0000 The function block has been interrupted by another function block. S <> 3 or touch probe has been deactivated while the input Enable was active. 16# #0000 Drive firmware is not supported 16# #0000 Invalid status of the function block 16# #0001 Function block input "ProbeSelect" or "ProbeEdge" is outside the admissible range 16# #0001 Selected "ControlledValueIDN" is not supported 16# #0002 Upper limit < lower limit

89 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) RESOURCE_ERROR (16#0003) RESOURCE_ERROR (16#0003) RESOURCE_ERROR (16#0003) 16# #0003 Input variable PControl < 0 16# #0004 Input variable IControl < 0 16# #0005 Sensor dead time < 0 Bosch Rexroth AG 83/179 Function Block for Application "Register Controller" 16# #0000 Selected touch probe number and edge do not correspond to the touch probe configuration (S ) 16# #0000 Continuous measurement is not active (S ) 16# #0000 Touch probe signal is not configured or the selected touch probe signal is not supported ACCESS_ERROR (16#0003) 16# #0001 The required touch probe value S is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0002 The required touch probe value S is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0003 The required touch probe value S is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0004 The required touch probe value S is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0005 The required touch probe value S is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0006 The required touch probe value S is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0007 The required touch probe value S is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0008 The required touch probe value S is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0009 The required touch probe value S , bit 0 is not configured in the signal control word of the measured axis. ACCESS_ERROR (16#0003) 16# #000A The required touch probe value S , bit 0 is not configured in the signal control word of the measured axis. ACCESS_ERROR (16#0003) 16# #000C The required parameter P is not configured in the optional cyclical MDT channel of the controlled axis. ACCESS_ERROR (16#0003) 16# #000D The required parameter P is not configured in the optional cyclical MDT channel of the controlled axis. ACCESS_ERROR (16#0003) 16# #000E The required parameter P is not configured in the optional cyclical MDT channel of the controlled axis. ACCESS_ERROR (16#0003) 16# #000F The required parameter P is not configured in the optional cyclical MDT channel of the controlled axis. ACCESS_ERROR (16#0003) 16# #0010 The required parameter P is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0011 The required parameter P is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0012 The required parameter P is not configured in the optional cyclical AT channel of the measured axis.

90 84/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Register Controller" ErrorID Additional1 Additional2 Description ACCESS_ERROR (16#0003) 16# #0013 The required parameter P is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0014 The required parameter P is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0015 The required parameter P is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0016 The required parameter P is not configured in the optional cyclical AT channel of the measured axis. ACCESS_ERROR (16#0003) 16# #0017 The measured or controlled axis is an MLD M slave axis but parameter P , bit 6 is not TRUE. ACCESS_ERROR (16#0003) 16# #0000 The input / the inputs "ProbeSelect" or "ProbeEdge" or "ControlledValueIDN" has / have been changed while Enable was TRUE. Fig.9-10: Error codes of the function block MB_RegisterControllerType MB_RegisterControlleType01 - Special Features of the Indra Motion MLC Required Hardware Required Firmware Required Software Required Parameterization MLC Hardware IndraDrive C or M MLC Firmware MPx Drive Firmware MPH03V14 or higher IndraWorks MLC The following axis name definitions are used in the text below: Measured-Axis: Axis which is connected to the touch probe sensor Controlled axis: The axis which is controlled by the Register Controller. Here the control variable has an effect. The following parameterization is required: Parameterization of the touch probe function of the measured axis: IndraWorks Project tree Real Axes Touch probe dialog of the "Measured Axis". The RegisterController1 function block expects the setting "Continuous Measurement" of the touch probe function. In addition, "Marker Failure Monitoring" is required in case the expectation window of the touch probe is used. Inclusion of the following parameters into the optional cyclical AT data of the "Measured Axis" IndraWorks Project tree Real Axes Right mouse click on Measured Axis Communication Cyclical SERCOS data channel, insert the parameters from the following table into the "Cyclical read access (AT)" area. Used touch probe Signal TouchProbe1, pos. edge TouchProbe1, neg. edge Required cyclical AT data S , S and P S , S and P

91 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 85/179 Function Block for Application "Register Controller" Used touch probe Signal TouchProbe2, pos. edge TouchProbe2, neg. edge Required cyclical AT data S , S and P S , S and P Fig.9-11: Required optional cyclical AT data of the measured axis depending on the used touch probe number and edge Configured touch probe signal S , Position feedback 1 value S , Position feedback 2 value P , Actual position of the measuring encoder P , Cam profile, access angle P , Position actual value in actual value cycle P , Resulting master axis position P , Effective master axis position P , Synchronous position command value Required cyclical AT data No data required No data required P P No data required P P P Fig.9-12: Required optional cyclical AT data of the measured axis depending on the used touch probe signal Inclusion of the following bits into the signal control word of the "Measured Axis" IndraWorks Project tree Real Axes Right mouse click on Measured Axis Communication Signal control word, insert the bits from the following table into the signal control word. Used touch probe Signal Required optional Control bit TouchProbe1 S Bit 0 TouchProbe2 S Bit 0 Required IndraLogic Steps Fig.9-13: Required optional signal control bits of the measured axis Inclusion of the controlled parameters into the optional cyclical MDT data of the "Controlled Axis" IndraWorks Project tree Real Axes Right mouse click on Controlled Axis Communication Cyclical SERCOS data channel, insertion of the controlled parameters (like P , P , P , P ) into the "Cyclical write access (MDT)" area. Including library ML_Technology0x.lib in the IndraLogic-Project. This library is provided with the installation of the MLC target Call the provided FB in your IndraLogic project. The FB s should run in a high-prior cyclical task with a cycle time of 8ms because the response time of the function block depends on the cycle time

92 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description

93 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 87/179 Function Block for Application "Tension Controller" 10 Function Block for Application "Tension Controller" 10.1 Introduction and Overview Depending on the measured value of a load cell, the tension controller (chapter 10.2 " ML_TensionControlLoadCellType01" on page 87) controls the tension to the desired command value. The actual value must be provided to the controller and is normally measured over an analog input. Fig.10-1: Schematic diagram of a tension control The tension controller is designed as a PI controller (alternatively as an adaptive PI controller). The controller output affects the gear fine adjust of the slave axis (pull roll). In addition, the controller can hold the tension at standstill by writing to the additive master axis position. The slave axis can either be operated in the velocity-synchronous or in the angle-synchronous operation mode ML_TensionControlLoadCellType01 Brief Description The Tension Controller controls, dependent on the measurement of a load cell, the tension to the desired setpoint value.

94 88/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Tension Controller" Interface Description Fig.10-2: Interface of block ML_TensionControlLoadCellType01 Name Type Comment VAR_IN_OUT Master AXIS_REF Reference to the master axis Slave AXIS_REF Reference to the slave axis Setpoint REAL Setpoint value of the tension. This is normally set by the user, but can also even be changed by the function block (see "SetpointLock"). VAR_INPUT Enable BOOL If this input is set, the FB works. Preset BOOL With the rising edge of this input the controller output is set to the value parameterized in PresetValue and with success the output "Preset Valid" is set. DisableCyclicWrites BOOL With set input the cyclic data are not written directly in the optional cyclical data container, but is issued only at the output. Adaptive BOOL With set input an adaptive P-Gain is used for the control. SetpointLock BOOL With rising edge at the input, the current tension actual value is taken over as the new setpoint for the Tension Controller. Pause BOOL With set input the Tension Controller is stopped and the I-Part of the output value is frozen. NegPolarity BOOL With set input a negative sign is provided to the control variable "CorrectionValue" and "AdditiveVelInc". Feedback REAL Current actual value of the tension. PresetValue REAL Value to which the controller output is set if input "Preset" is set. HighLimit REAL Possible maximal value of the controller output. If the control variable calculated by the controller exceeds this value, the control variable is limited and the I-Part of the controller is no longer added up.

95 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 89/179 Function Block for Application "Tension Controller" Name Type Comment LowLimit REAL Possible minimal value of the controller output. If the control variable calculated by the controller is less than this value, the control variable is limited and the I-Part of the controller is no longer added up. Ki TIME Reset time of the I-Controller KpLowVel REAL P-Gain of the controller if "Adaptive" = FALSE. Otherwise the value is equal to the value of the P-Gain at low master axis velocities. REAL Only effective if "Adaptive" = TRUE. Master axis velocity from that the "KpLowVel" is used. KpHighVel REAL P-Gain of the controller at high master axis velocities. If "Adaptive" = FALSE, this input has no effect. MasterVelocityLow MasterVelocityHigh WindowValue WindowMax Value WindowMin Value REAL REAL REAL REAL Only effective if "Adaptive" = TRUE. Master axis velocity from that the "KpHighVel" is used. Process size window Maximal value of process size Minimal value of process size StandstillVel REAL Additive velocity for the controller at standstill. StandstillVel Deadband StandstillEnable REAL BOOL This value determines the value of the control deviation below that the tension velocity is reduced by the regulation in standstill. At set input the specified additive velocity in "StandstillVel" is effective. VAR_OUTPUT InOperation BOOL The Tension Controller works and the outputs are valid PresetValid BOOL If this output is active, the Preset input is evaluated and output "Setpoint" has accepted the value "PresetValue" HighLimitAck BOOL This output is set, if the control variable calculated by the controller is greater than the specified value in "HighLimit". LowLimitAck BOOL This output is set, if the control variable calculated by the controller is less than the specified value in "LowLimit". WindowIn BOOL If TRUE, the process size is within the parameterized window. WindowMax BOOL If TRUE, the process size is above the parameterized maximal value. WindowMin BOOL If TRUE, the process size is below the parameterized minimal value. Correction Value AdditiveVelInc REAL DINT Control variable of the Tension Control Additive velocity in increments per SERCOS cycle Error BOOL Signals an error. With "Enable" = FALSE the error is cleared ErrorID ERROR_CODE Error short description ErrorIdent ERROR_STRUCT Detailed error description according to error table Fig.10-3: Interface of ML_TensionControlLoadCell

96 90/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Tension Controller" Functional Description In the following the several functions of the inputs of the function block are nearer elucidated. Generally applies for all inputs that they are continued evaluated with set input "Enable". This means, that changes of the inputs become immediately effective without toggling the input "Enable". All input values get assigned the value 0 or FALSE inside if their inputs are not connected. Exception of this rule is the "PresetValue" input that is only accepted with rising edge of input "Preset". Also input "DisableCyclicWrites" that is only evaluated with rising edge of input "Enable". The entire effectiveness of the Tension Controller is shown in the following flow chart. The greyed names are internal variables or parameters. All other names correspond to the in- and outputs of the block. The tension is directly written to the drive via parameter "Gear fine adjust (P )" if input "DisableCyclicWrites" is inactive. Besides, the value is always available via output "CorrectionValue". Fig.10-4: Flow chart of the Tension Controller for the control via gear fine adjust For the control at standstill, additionally another path can be switched ative and in this it is written to the "Additive master axis position (P )" if "Disable CyclicWrites" is inactive. At the same time this value is always available via output "AdditiveVelInc". Preset PresetValid Fig.10-5: Flow chart of the Tension Controller for the control at standstill For reasons of clarity the flow chart contains not the limitations "WindowValue", "WindowMaxValue", "WindowMinValue" as well as whose status displays. By setting of input "Preset" a start value for the control variable is given via variable "PresetValue". At the same time the internal variables of the controller are set in that way, that a start without jerk takes place.

97 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 91/179 Function Block for Application "Tension Controller" The output "PresetValid" is set, if "PresetValue" at the output of the Tension Control is valid. The "Preset" input is only effective with rising edge. DisableCyclicWrites Adaptive/ KpLowVel/ KpHighVel/ MasterVelocityLow/ MasterVelocityHigh The input "DisableCyclicWrites" determines whether the values calculated by the function block are written directly via the cyclical channel (FALSE) or are only available at the block output (TRUE). With it is possibly to cascade several blocks while "DisableCyclicWrites" is set to TRUE. Then only the outputs ("CorrectionValue" and "AdditiveVelInc") can be used and modified. But then it is still necessary that the user self writes the values in the optional cyclical channel. If "DisableCyclicWrites" is set totrue, then the check whether the optional cyclical parameters are also configured, is not executed. The P-Gain may be alternatively forced as constant P-Gain or as adaptive P- Gain. Via input "Adaptive" it is chosen between adaptive or constant P-Gain. By setting of "Adaptive" to TRUE, the adaptive P-Gain is selected. If a constant P-Gain is selected, only the value in "KpLowVel" is effective for the P-Gain. If the adaptive P-Gain is selected, the inputs "KpLowVel", "KpHighVel", "MasterVelocityLow" and "MasterVelocityHigh" must be connected. Then the characteristic looks like as follows: SetpointLock Fig.10-6: Characteristic of adaptive P-Gain The several inputs characterize the characteristic for positive master axis velocities. The characteristic for negative master axis velocities result from mirroring at the axis of the P-Gain. This means that only symmetrical characteristics are possible. The P-Gain between the master axis velocities "MasterVelocityLow" and "MasterVelocityHigh" is linear interpolated. Thus it results in some conditions for the value ranges of the inputs: The values for "MasterVelocityLow" and "MasterVelocityHigh" must be positive. The values for "MasterVelocityLow" and "MasterVelocityHigh" must not be equal. The value of "MasterVelocityLow" must be less than the value of "MasterVelocityHigh". If one of these conditions is violated, an error is generated at the output of the block. By setting of input "SetpointLock" the tension actual value is accepted as the new setpoint value for the Tension Controller. For example, this function allows

98 92/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Tension Controller" Pause NegPolarity Feedback PresetValue HighLimit HighLimitAck LowLimit LowLimitAck KpLowVel WindowValue/ WindowIn to get a meaningful start value for the setpoint value of the tension that reflects the actual state of the machine. The input "Pause" enables the halt of the Tension Controller. If this input is set to TRUE, the controller deviation is set to "0", i.e. the controller output is frozen on the actual I-Part. The input "NegPolarity" affects the regulation sense. Depending on the position of the pull roll, regarding the direction of material flow and the position of the feed roll, the regulation sense must be positive or negative. If this input is FALSE, the regulation sense becomes positive and a positive control deviation leads to a positive actuation. The input also has an effect on the standstill regulation. This inputs represents the actual value of the tension. This input can be read e.g., by an analog input at the drive or via the Inline-I/Os. Thereby the user is responsible for a meaningful scaling. By setting of input "Preset" a start value for the control variable is given via variable "PresetValue". At the same time the internal variables of the controller are set in that way, that a start without jerk takes place. With this input the control variable of the controller is limited to a maximum value. If the limitation occurs, the I-Part of the controller is no longer added up ("Anti-reset-windup"). The maximal value is determined by the defined maximal value for the gear fine adjust in the drive. If a limitation occurs, output "HighLimitAck" is set. With this input the control variable of the controller is limited to a minimum value. If the limitation occurs, the I-Part of the controller is no longer added up ("Antireset-windup"). The minimal value is at 95 independent from possible lower values in the drive. In addition see also section "Gear fine adjust". If a limitation occurs, output "LowLimitAck" is set. This value corresponds to the proportional gain of the Tension Controller if input "Adaptive" is not active. Otherwise it represents the lower gain of an adaptive P-Gain. With this value the user can define a symmetric window where the actual tension value shall be within. The window is defined as follows: WindowMaxValue/ WindowMax If this condition is fulfilled, output "WindowIn" is set. Otherwise the output is not set and also no limitation takes place. With this value the user can define an upper value for the process size. The value is evaluated as follows: WindowMinValue/ WindowMin Fig.10-7: WindowMaxValue/ WindowMax If this condition is fulfilled, output "WindowMax" is set. Otherwise the output is not set and also no limitation takes place. With this value the user can define a lower value for the process size. The value is evaluated as follows:

99 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 93/179 Function Block for Application "Tension Controller" StandstillEnable Fig.10-8: WindowMinValue/ WindowMin If this condition is fulfilled, output "WindowMax" is set. Otherwise the output is not set and also no limitation takes place. With setting of input "StandstillEnable" the velocity, specified in "Standstill Vel", is added up additive on the to be controlled axis. With it a tension control is also possible at standstill. It must be noticed, that the controller for the gear fine adjust continues working independent of the added up velocity. This may result in instabilities. If this input is used it must be ensured, that the Tension Controller is only used in the SERCOS synchronous task. If not it may result in a bumpy run of the motor. StandstillVel This value specifies the additive velocity that is send to the drive if the input "StandstillEnable" is set. The units of the velocity correspond to the adjusted weighting in the drive. Because the velocity must be reached within one SERCOS cycle, no arbitrarily high values can be given. Thereby the maximal value is adapted by the scaling of the velocity as well as the adjusted maximal acceleration and connected mass at the drive. To avoid this, a filter time constant can be defined in drive parameter P by which no more stepwise changes can appear. Gear Fine Adjust Background Information The Tension Controller works normally with velocities greater 0. Thereby the gear fine adjust is an appropriate instrument to keep the tension. But there are also some boundary conditions that shall be explained here. The gear fine adjust is internally limited to a minimum of 95%. If a lower value is entered, the block generates an error. Background of this limitation is the calculated output value that is defined by a given input value as follows: StandstillEnable, StandstillVel, StandstilVelDeadband With the equation you can recognize, that - if the gear fine adjust goes about 100% - the output value goes about 0. With it the control loop would be opened, because a change of the input values has no reaction at the output. Still worse, at a gear fine adjust that would be lower than 100%, the sign of the output value is inverted. In the control loop a positive feedback would be generated, that results in an instability of the system. The control in standstill can take place by use of the inputs "StandstillEnable" and "StandstillVel". Thereby an additive velocity is added up. To get a better performance, it is reduced around the setpoint value. This is done by the help of a modified Signum-Function, that have the following transfer function:

100 94/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Tension Controller" Fig.10-9: Modified Signum-Function for the limitation of the added up StandstillVel Thereby the control deviation is relativized in the range of the "Setpoint". If the "Feedback" comes closer to the "Setpoint" the control becomes "more sensitive" than a pure two-position controller. The value this limitation takes place can be adjusted at input "StandstillVelDeadband". Besides, the values possess the same units like input "Setpoint" or "Feedback". Between the extreme values +"StandstillVel" and "StandstillVel" is interpolated linear, so that above transfer function arises for control deviation and tension velocity. Subsequently the determined factor is multiplied with the given "Standstill Vel". Thereby the velocity is processed as revolution with the adjusted weighting in the drive. If you would like to enter a revolution instead of a path velocity, it must be self-calculated before. To get a reverse motion direction for the regulation at standstill, input "NegPolarity" must be set. In the following it is multiplied by a correction factor. This correction factor consists of the gear transmission ratio. However, the gear fine adjust is not considered. In practice the gear fine adjust is normally very small, so that it doesn't carry weight. The gear transmission ratio is only taken over at a rising edge of input "Enable". In the flow-chart is obvious that the specified velocity is converted in increments. Thereby some rules must be considered: The given velocity cannot be chosen any high because the drive has to reach the velocity within one SERCOS cycle. With it only very small values are permitted. The size depends on the used scaling and the mass at the motor. The calculated increments are preset via parameter P , moreover, this can be smoothed by the available filter in the drive (P ), so that also bigger jumps are possible. The calculated increments are added up before the gear. The gear transmission ratio (A and A ) is included in the calculation. However, the gear fine adjust (P and P ) are not considered, because they are normally very small. This may lead to the behavior, that the axis moves with another velocity than adjusted. A scaling of the units takes place. Also the entered velocity value is not verified on maximum- and minimum values. Thereby very large values for the number of increments per SERCOS cycle may result. If the calculated interim value exceeds the maximal values of +- half modulo value, they

101 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 95/179 Function Block for Application "Tension Controller" Error Handling are automatically limited. The result is a lower additive velocity than given at input "StandstillVel". With very small velocities it also must be noticed, that the actual velocity may differ to the specified velocity. This is explained by the granulation of the increments per SERCOS cycle: matches e.g. 1 increment a velocity of 0,03 r.p.m., only velocities that are a multiple of 0,03 r.p.m. can be adjusted. Otherwise is rounded to the nearest value. The calculated increments are processed with each SERCOS cycle. Thus at use of the control at standstill, the block must be processed in the SER COS synchronous task. Otherwise the drive moves the number of calculated increments for one SERCOS cycle, and stops in the next SERCOS cycle again resulting in a jerky movement. The use of the filter in P can also put things right here. The function block creates in Additional1/Additional2 the following error messages for table F_RELATED_TABLE, 16#0170: ErrorID Additional1 Additional2 Description ACCESS_ERROR, 16# #0A00 16#0001 Parameter P is not parameterized in the optional cyclical telegram of the slave axis. ACCESS_ERROR, 16# #0A00 16#0002 Parameter P is not parameterized in the optional cyclical telegram of the slave axis. INPUT_RANGE_ERROR, 16# #0A01 16#0001 The master axis velocity in the lower operating point ("MasterVelocityLow") is < 0 INPUT_RANGE_ERROR, 16# #0A01 16#0002 The master axis velocity in the upper operating point ("MasterVelocityLow") is < 0 INPUT_RANGE_ERROR, 16# #0A01 16#0003 The master axis velocity in the lower operating point ("MasterVelocityLow") and upper operating point ("MasterVelocityHigh") have the same values. INPUT_RANGE_ERROR, 16# #0A01 16#0004 The value of the master axis velocity in the lower operating point ("MasterVelocityLow") is greater than the value in the upper operating point ("MasterVelocity High"). INPUT_RANGE_ERROR, 16# #0A01 16#0005 The value of input "LowLimit" is lower than the minimal permitted (-95). INPUT_RANGE_ERROR, 16# #0A01 16#0006 The value of inputs "PGainLowVel" or "PGainHigh Vel" is lower or equal 0. DEVICE_ERROR, 16# #0A02 16#0007 No power is switched on at the drive specified in "Slave". Thus a tension control is not possible. DEVICE_ERROR, 16# #0A02 16#0008 The drive specified in "Slave" is not in a synchronous operation mode. Compatible Changes Fig.10-10: Error numbers, caused by ML_TensionControlLoadCell Changes at the function block of MLC version 02 The following changes were made at block "ML_TensionControlLoadCell Type01". The block is not compatible between the version 02 and 03. Add default values for writing the inputs It was not obvious which default values for the inputs of the Tension Controller are applied. Now these are explicitly indicated in the variable declaration in the library. With it the user can determine the values which are applied with missing input allocation.

102 96/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Tension Controller" Incompatible Changes The following changes are incompatible, because they represent either a change of the interface of the function block, or the functionality has changed. Outputs "WindowIn", "WindowMax" and "WindowMin" are evaluated only with active "Enable". Up to now the outputs were always updated in dependence on the functionality in the Synax system, even if the "Enable" input was active. However, this is not allowed as per definition of the "Enable" input and, therefore, was changed. Input "NegPolarity" also has an affect on the standstill regulation Up to now the the input "NegPolarity" had an effect only on the Tension Controller for the gear fine adjust, but not on the Tension Controller for the standstill regulation. This led to confusion and was changed to that effect that the input has an effect now also on the standstill controller. I.e. if input "NegPolarity" is active, the rotation direction is inverted with tension in standstill. Attention: by the regulation in standstill a negative velocity can be also entered. Up to now a an inversion of the direction could be also thereby produced. For user which have used a negative velocity means, that they must specify now a positive velocity and set, in addition, the input "NegPolarity". P instead of P in the optional cyclical channel Because the MLC03VRS puts on P in the cyclical channel, this is not available any more for technology functions. Therefor P is available, that furthermore offers the advantage to specifiy a filter time constant. With it stepwise changes of the tension velocity can be also processed. Therefore, the user must configure the parameter P instead of P in the optional cyclical channel. Name of the block changed The block name has changed from ML_TensionControlLoadCell on ML_TensionControlLoadCellType01 to be able to create other types for future variants. Effectiveness of the modified Signum function for the standstill controller changed The previous modified Signum function had the following appearance. The intention of the function is to make "more sensitive" the regulation in standstill near the setpoint value. I.e. the tension velocity is automatically reduced. But the area in that the reduction of the velocity takes place is fixed adjusted to 1% of the setpoint value. This had the following disadvantages: - The value is fixed given and cannot be adjusted application-specific - It is a percentage value which refers to the setpoint value. With a setpoint value of zero the reduction is effectively switched off. Besides, the graphics was labeled partly wrong. The abscissa must indicate the values for ("Setpoint" - "Feedback")

103 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 97/179 Function Block for Application "Tension Controller" Fig.10-11: Modified Signum-Function for the limitation of the added up StandstillVel The changed Signum function gets an own input at the block with which can be determined individually from which value the reduction of the standstill velocity should take place. This value is also not weighted any more percental, but as an absolute value. I.e. the units of the input "StandstillVelDeadbead" are in the same units like the inputs "Setpoint" and "Feedback". Fig.10-12: Modified Signum-Function for the limitation of the added up StandstillVel 10.3 ML_TensionControlLoadCellType01 - Special Features of IndraMotion MLC Required Hardware Required Firmware MLC Hardware IndraDrive C or IndraDrive M with advanced or basic performance Additional IO interface card to read in the tension (can be omitted if the tension is read in directly over the drive) MLC Firmware MPx drive firmware

104 98/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Tension Controller" Required Software Required Parameterization Required IndraLogic Steps The following functional packages have to be enabled in the drive: Closed Loop Synchronization IndraWorks MLC The following parameterization has to be accomplished in the drive to ensure a proper functionality of the function block "ML_TensionControlLoadCell". Configuration of the drive parameters P and P in the optional cyclical SERCOS MDT data IndraWorks Right mouse click on the axis assigned to the tension controller Communication Cyclical SER COS data channel Configuration of P and P in the MDT data (it is not important which data container is used since the function block scans all channels). Parameterization of the axis assigned to the tension controller according to the application The function block "ML_TensionControlLoadCellType01" contains motion commands and thus has to be called in a cyclical PLC. If the input "StandstillEnable" is used, the function block may only be executed in the SERCOS-synchronous tasks (motion task). Before starting the function block, "MC_Power" has to be executed without errors and the axis must run in a synchronous operating mode with the help of "MC_GearIn" or "MB_GearInPos". The gear fine adjust (input "MasterFineadjust" of the function blocks "MC_GearIn" or "MB_GearIn Pos") should be set to "0".

105 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 99/179 Function Blocks for Application "Sag Control" 11 Function Blocks for Application "Sag Control" 11.1 Introduction and Overview Sag Controls are used for decoupling machine parts. A typical application is the following production line. Fig.11-1: 11.2 ML_SagControlC Brief Description Production line, schematic diagram The sag is between the feed roll of the punch and the upstreamed material feeding system. It should uncouple both motion systems (Start/Stop or Continuous). The sag contents depends on the feed roll data. In normal operation the range of the production line runs continuous with an averaged velocity "v" given by the user. The other part of the machine runs in Start-Stop-Operation. During the sheet metal forming this part of the machine goes to Stop and the sag contents increases. If the material for the next processing is load, the sag content is reduced. In one work cycle the sag moves always between the Min/Max-Contacts. Pre-condition for use of the Sag Control FB: When installing the production line, the new sheet strip is carried through the straightener to the punch by the Coil in that way, that already a sag between the Min/Max-Contacts (or Min/Max-Analog values) exists. ML_SagControlC, page 99, controls the sag by Min/Max-Contacts. ML_SagControlA, page 103, controls the sag by analog switching signals. The function block "ML_SagControlC" contains a Sag Controller with binary Min/Max- Contacts.

106 100/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Sag Control" Interface Description Fig.11-2: FB ML_SagControlC Name Type Comment VAR_IN_OUT Slave AXIS_REF Slave Axis VAR_INPUT Enable BOOL Activates / deactivates the velocity control VelocityAv REAL Averaged velocity of the production line Acceleration REAL Acceleration for velocity changes Deceleration REAL Deceleration for velocity changes MaxContact BOOL Max-Contact of the sag MinContact BOOL Min-Contact of the sag MaxVelocity INT Maximum velocity in % related to the averaged velocity of the production line MinVelocity INT Minimum velocity in % related to the averaged velocity of the production line AdaptTime TIME Adaption time (Ta) ErrorTime TIME Error time (Te) CoilDiameter REAL Coil diameter Weighting of the velocity in %. If the input is not connected, the default value is set to 100%. VAR_OUTPUT Active BOOL Sag Control works Error BOOL Signals an error. With "Execute" = FALSE the error is cleared. ErrorID ERROR_CODE INT (Enum): Error short description ErrorIdent ERROR_STRUCT Detailed error description depending on the error table Functional Description Fig.11-3: Interface of ML_SagControlC The "Enable" input activates / deactivates the velocity control. The first active velocity is the average velocity given by the operator of the system. If the "Enable" input is reset, the drive to be controlled goes to stop. The function block for the sag control affects only the drive of the material supply. For this it is tried to hold the sag in a defined window (Min/Max-Value) by adjusting the actual velocity of the production line, depending on the deviation, optionally measured by a sensor that detects the coil diameter.

107 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 101/179 Function Blocks for Application "Sag Control" When reaching the Min-Contact, the velocity of the material supply system is increased to the maximal velocity applied at the block to build-up a greater sag. If the Min-Contact is left within the error reaction time "Te" in Max-Contact direction again, so for the retain time "Ta" is still moved with the increased velocity; then is continued with the given averaged velocity again. If the sag increases so that the Max-Contact is activated, the velocity is reduced to the minimal value applied at the block. If the Max-Contact is left within the error reaction time "Te", so for the time "Ta" the drive keeps on moving with the reduced velocity. Then is continued with the given averaged velocity again (see v-t diagram). Error Handling Fig.11-4: Block behavior, error-free If the Min-Contact is still active for a time greater than "Te", an error is generated and continued with the same velocity. This state is kept until the contact will be left again. After this the drive still moves for the retain time "Ta" with the increased velocity and then with the given averaged velocity. If, however, the Max-Contact remains active for the time "Te", the velocity is reduced to zero. If the Max-Contact switches again, the drive will farther remain in stop for the time "Ta", then is accelerated again to the given averaged velocity "Vm" and continued with this velocity. Fig.11-5: Block behavior, incorrect The function block creates in Additional1/Additional2 the following error messages for table F_RELATED_TABLE, 16#0170:

108 102/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Sag Control" ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR, 16# # #0000 Inputs outside valid range: Velocity <= 0 Acceleration <= 0 Deceleration <= 0 Max. velocity <= Min. velocity Adaption time <= 0 Error reaction time <= 0 Coil diameter <= 0 SYSTEM_ERROR,16#7FFF 16# #0000 Velocity adaption unsuccessful, adaption time and error reaction time expired, Max-Contact is still present. SYSTEM_ERROR, 16#7FFF 16# #0000 Velocity adaption unsuccessful, adaption time and error reaction time expired, Min-Contact is still present. SYSTEM_ERROR, 16#7FFF 16# #0000 Max/Min-Contact are present at the same time. Contact problem? SYSTEM_ERROR,16#7FFF 16# #0000 The given velocity couldn't be reached. Check velocity presettings. Firm-, Soft- and Hardware Requirements Application Example 1 Fig.11-6: Error numbers, caused by ML_SagControlC The following Firm-, Soft- and Hardware is required: Hardware - IndraDrive C or M Firmware - Drive firmware MPH03V08 or higher Function package - Closed Loop Software - IndraWorks 03V17 / IndraWorks MLC 01V07 or higher PLC-Software - IndraLogic 1.26 or higher In the general form there are 2 contacts, a Min- and a Max-Contact, that are available as control parameter. Fig.11-7: Application 1, ML_SagControlC In normal operation the production line runs with an averaged velocity "Vm" given by the operator. The FB for the sag control tries now to keep the sag in a defined window (Min/Max-Contact) by adjusting the actual velocity depending on the deviation of the production line.

109 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 103/179 Function Blocks for Application "Sag Control" Application Example 2 With this variant the to be controlled drive is the Coil itself. In addition to the Min/Max-Contacts the decreasing Coil diameter is added as control variable. Fig.11-8: Application 2, ML_SagControlC 11.3 ML_SagControlA Functional Description Interface Description The function block "ML_SagControlA" contains a Sag Controller with an analog measuring of actual value of the sag. Fig.11-9: FB ML_SagControlA Name Type Comment VAR_IN_OUT Slave AXIS_REF Slave Axis VAR_INPUT Enable BOOL Activates / deactivates the velocity control AnalogIn REAL Analog value of the sag (0..10) VelocityAv REAL Averaged velocity of the production line Acceleration REAL Acceleration for velocity changes Deceleration REAL Deceleration for velocity changes MaxContact BOOL Max-Contact of the sag

110 104/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Sag Control" Name Type Comment MinContact BOOL Min-Contact of the sag MaxVelocity INT Maximum velocity in % related to the averaged velocity of the production line MinVelocity INT Minimum velocity in % related to the averaged velocity of the production line AdaptTime TIME Adaption time (Ta) ErrorTime TIME Error time (Te) CoilDiameter REAL Coil diameter Weighting of the velocity in %. If the input is not connected, the default value is set to 100%. VAR_OUTPUT Active BOOL Sag Control works Error BOOL Signals an error. With "Execute" = FALSE the error is cleared. ErrorID ERROR_CODE Error short description ErrorIdent ERROR_STRUCT Detailed error description depending on the error table Functional Description Fig.11-10: Interface of ML_SagControlA The Enable input activates / deactivates the velocity control. The first active velocity is the average velocity given by the operator of the system. If the Enable input is reset, the drive to be controlled goes to stop. The function block for the sag control affects only the drive of the material supply. For this it is tried to hold the sag in a defined window (analog value sensor) by adjusting the actual velocity of the production line, depending on the deviation, optionally measured by a sensor that detects the coil diameter. When reaching the Min-Contact, the velocity of the material supply system is increased to the maximal velocity applied at the block to build-up a greater sag. If the Min-Contact is left within the error reaction time "Te" in Max-Contact direction again, so for the retain time "Ta" it is still moved with the increased velocity; then it is continued with the given averaged velocity again. If the sag increases so that the Max-Contact is activated, the velocity is reduced to the minimal value applied at the block. If the Max-Contact is left within the error reaction time "Te", so for the time "Ta" the drive keeps on moving with the reduced velocity. Then is continued with the given averaged velocity again (see v-t diagram). Error Handling Fig.11-11: Block behavior, error-free If the Min-Contact is still active for a time greater than "Te", an error is generated and continued with the same velocity. This state is kept until the contact will be left again. After this the drive still moves for the retain time "Ta" with the in

111 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 105/179 Function Blocks for Application "Sag Control" creased velocity and then with the given averaged velocity. If, however, the Max-Contact remains active for the time "Te", the velocity is reduced to zero. If the Max-Contact switches again, the drive will farther remain in stop for the time "Ta", then is accelerated again to the given averaged velocity "Vm" and continued with this velocity. Fig.11-12: Block behavior, incorrect ErrorID Additional1 Additional2 Description The function block creates in Additional1/Additional2 the following error messages for table F_RELATED_TABLE, 16#0170: INPUT_RANGE_ER ROR, 16#0006 SYSTEM_ERROR, 16#7FFF SYSTEM_ERROR, 16#7FFF SYSTEM_ERROR, 16#7FFF 16# #0000 Inputs outside valid range: Velocity <= 0 Acceleration <= 0 Deceleration <= 0 Max. velocity <= Min. velocity Adaption time <= 0 Error reaction time <= 0 Coil diameter <= 0 16# #0000 Velocity adaption unsuccessful, adaption time and error reaction time expired, Max-Contact is still present. 16# #0000 Velocity adaption unsuccessful, adaption time and error reaction time expired, Min-Contact is still present. 16# #0000 The given velocity couldn't be reached. Check velocity presettings. Firm-, Soft- and Hardware Requirements Application Example 1 Fig.11-13: Error numbers, caused by ML_SagControlA The following Firm-, Soft- and Hardware is required: Hardware - IndraDrive C or IndraDrive M Firmware - Drive firmware MPH03V08 or higher Function package - Closed Loop Software - IndraWorks 03V17 / IndraWorks MLC 01V07 or higher PLC-Software - IndraLogic 1.26 or higher In this variant a sensor represents the sag position as an analog input (0-10V) that is used for velocity control.

112 106/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Sag Control" Application Example 2 Fig.11-14: Application 1, ML_SagControlA In normal operation the production line runs with an averaged velocity Vm given by the operator. The FB for the sag control tries now to keep the sag in a defined window (Min/Max-Position) by adjusting the actual velocity depending on the deviation of the production line. With this variant the to be controlled drive is the Coil itself. In addition to the analog value input the decreasing coil diameter is also added as control variable. Fig.11-15: Application 2, ML_SagControlA

113 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 107/179 Function Blocks for Application "Adjusting Variables" 12 Function Blocks for Application "Adjusting Variables" 12.1 Introduction and Overview General Fundamentals With the following function blocks, PLC variables can be continuously or incrementally adjusted (jogged) over binary inputs: chapter 12.2 "MX(L)_ContinuousAdjustType01" on page 110 chapter 12.3 "MX(L)_ContinuousAdjustType02" on page 113 chapter 12.4 "MX(L)_IncrementalAdjustType01" on page 116 When using the above mentioned function blocks for adjusting PLC variables, the following requirements have to be taken into account: The operation must be stopped over a binary input ("Enable"). The variable to be influenced can be continuously adjusted with the function blocks MX(L)_ContinuousAdjustType01 and MX(L)_ContinuousAdjustType02 (similar to the long jog for SYNAX). The variable to be influenced can be incrementally adjusted with the function block MX(L)_IncrementalAdjustType01 (similar to the short jog for SYNAX). The selected variable can be incremented or decremented within the limit values. When reaching a limit value "HighLimitAck" = TRUE or "LowLimitAck" = TRUE), the continuous adjustment will be deactivated, i. e. the function block will no longer influence the variable. In this case, the respective limit value will be displayed at the input "HighLimit" or "LowLimit". If the limits "HighLimit" and "LowLimit" have the same value at a specified modulo value, "LowLimit" is set equal to zero and "HighLimit" is set equal to the modulo value. Thus, it is possible to adjust the limit values over the entire modulo value range. The alteration velocity describes the gradient by which the influenced variable is adjusted during the adjustment procedure. This gradient depends on the step width and the number of steps per second. The alteration velocity is calculated as follows, for example, when adjusting a position: Fig.12-1: Velocity adjustment when adjusting a position If, for example, the speed of the virtual master axis is changed, the alteration velocity is calculated as follows: Adjustment Limits Fig.12-2: Velocity adjustment when adjusting the speed of an axis As long as the input signal is present, the influenced variable will be changed with the defined velocity. The variable can only be adjusted over the corresponding inputs within the determined limit values. Exception:

114 108/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Adjusting Variables" Basic Rules If the initial value of the variable to be adjusted is outside the specified limits, the influenced variable can only be adjusted in the direction of the target range. In the case of a specified modulo value, the influenced variable can be adjusted in both directions. After having reached the target range, it is no longer possible to leave this range. If both adjustment signals ("Inc"/"Dec") are TRUE at the same time, they will be evaluated as FALSE. An adjustment signal changes the polarity and causes an immediate shift in direction. Furthermore, the current adjustment will not be finished. If the alteration velocity is changed during a motion, the behavior of the function blocks MX(L)_ContinuousAdjustType01/MX(L)_ContinuousAdjustType02 and MX(L)_IncrementalAdjustType01 will be different. For MX(L)_ContinuousAdjustType01 and MX(L)_ContinuousAdjust Type02, the adjustment will become effective immediately. In contrast, the motion for MX(L)_IncrementalAdjustType01 is finished before the new step velocity will be accepted. A subsequent adjustment procedure will then be performed with the adjusted variables. Furthermore, the following rules apply for the function block MX(L)_IncrementalAdjustType01: The inputs "Inc" and "Dec" will be evaluated in relation to the edge. A rising edge causes an adjustment by the specified step width ("StepWidth"). A new adjustment signal detected during a running motion (positive edge) with the same polarity causes another motion following the current motion.

115 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 109/179 Function Blocks for Application "Adjusting Variables" Fig.12-3: Comparison of the behavior of a continuous and an incremental adjustment During the first activation ("Enable" = TRUE), the function blocks MX(L)_ContinuousAdjustType01, MX(L)_ContinuousAdjustType02 and MB_Incremental- Adjust initialize the variables required for the determination of the cycle time (independent from the present inputs). In the second cycle, a calculated cycle time will be available which is required for calculating the correct adjustment velocity. Subsequently, the cycle time will be updated continuously. By specifying a modulo value, the function block provides an output variable between zero and the specified modulo value. When exceeding the modulo value, the output variable will be reset to zero; however, the adjustment procedure will continue. The specified valid range can thus be between zero and the modulo value. It should be possible to adjust the range by the zero value. In addition, the function block MX(L)_ContinuousAdjustType01 or MX(L)_ContinuousAdjustType02 provides the possibility to adjust the alteration velocity dependent on time by specifying weighting factors and time intervals.

116 110/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Adjusting Variables" Fig.12-4: Possible allocation of a valid range when specifying a modulo value of MX(L)_ContinuousAdjustType01 Short Description Interface Description The MX(L)_ContinuousAdjustType01 function block allows the continuous adjustment of an adjustable REAL variable via binary inputs. Fig.12-5: MX(L)_ContiniuousAdjustType01 Function Block I/O Type Name Data Type Comment VAR_INPUT Enable BOOL Enable the function block (cyclical, state-triggered) Inc BOOL Increment the adjustable variable Dec BOOL Decrement the adjustable variable Preset BOOL Set the Preset-Value (PresetValue) PresetValue REAL Specified value for Preset ModuloValue REAL Modulo value (if 0, then absolute processing) HighLimit REAL Maximum output value of the adjustable variable

117 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 111/179 Function Blocks for Application "Adjusting Variables" I/O Type Name Data Type Comment LowLimit REAL Minimum output value of the adjustable variable StepWidth REAL Increments StepsPerSecond REAL Number of increments per second AdjTimeIntervals AdjWeightFactors ARRAY [1..4] OF REAL ARRAY [1..5] OF REAL Time intervals (in seconds) for scaling of the alteration velocity Scaling factors of the alteration velocity VAR_OUTPUT InOperation BOOL No calculations active. Outputs HighLimitAck and LowLimitAck are valid. Error BOOL Calculation of the adjustable variable "Value" completed with error, output variable ErrorIdent is valid ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed description of the diagnostics in case of an error Changing BOOL Calculation of the adjustable variable takes place. Adjustable variable "Value" is valid HighLimitAck BOOL Maximum output value of the adjustable variable reached LowLimitAck BOOL Minimum output value of the adjustable variable reached VAR_IN_OUT Value REAL Adjustable variable Timing Diagram Fig.12-6: MX(L)_ContinuousAdjustType01 I/O Interface Functional Description Fig.12-7: Continuous Parameter Adjustment The adjustment of the adjustable variable "Value" may take place in positive or negative direction. The limits set a valid range for adjusting the variable. Specifying a modulo value allows the adjustment to be within an axis frame of reference. Predefining increments and increments per second determines the alteration velocity of the adjustable variable. It is possible to write a given value ("PresetValue"), inside the valid operating range, directly to the adjustable variable. After activation, with "Enable", the adjustable variable can be changed via inputs "Inc" (positive direction) and "Dec" (negative direction). While input "Inc" or "Dec" is set, the adjustable variable is continuously increased (or decreased) with the given velocity. ("StepsPerSecond" * "StepWidth"). At initialization, ensure the inputs "ModuloValue", "HighLimit" and "LowLimit", contain valid values.

118 112/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Adjusting Variables" By determining scaling factors ("AdjWeightFactors[ ]") and the corresponding time intervals ("AdjTimeIntervals[ ]") it is possible to make time-dependent velocity modifications. The scaling factors and time intervals must also be set on the inputs "StepsPerSecond" and "StepWidth". Depending on the actual time interval, the alteration velocity is then multiplied with the appropriate scaling factor. The figure below shows the behavior of the block with an example configuration: The input factors of "AdjTimeIntervals" ([T1; T2; T3; T4]) are specified in seconds. T5 specifies the period after completion of time interval T4 when the adjustment procedure aborts. The input factors of "AdjWeightFactors" ([0,5; 1; 1,5; 2; 4]) determine the scaling of the alteration velocity. The last value of "AdjWeightFactors [5"] is assigned to time interval T5. Fig.12-8: Scaling Adjustment When a time interval = 0, the next scaling factor is used until the adjustment process aborts. Example: If AdjTimeIntervals[2] = 0, then the scaling factor of AdjWeightFactors[3] is used until terminated. To determine the correct time interval of the scaling factors, the expired time is reset with each new starting adjustment process. If inputs "AdjWeightFactors" and "AdjTimeIntervals" are not set, a continuous adjustment with the given alteration velocity specified with "StepsPerSecond" and "StepWidth" occurs. Values in "AdjTimeIntervals" must only contain positive values. scaling factors can be positive or negative. The adjustable variable can only be set to the specified preset value if it is within the valid range between "HighLimit" and "LowLimit". Error Handling Output "InOperation" signals that the block is in use, but an adjustment is not active. "Changing" indicates an error-free adjustment and the value of the adjusted variable "Value" is valid. "Error" indicates that an error occurred during the adjustment process. Details are indicated in the "ErrorIdent" structure. The function block generates the following error messages in Additional1/Additional2 of the table "F_RELATED_TABLE", 16#0170:

119 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 113/179 Function Blocks for Application "Adjusting Variables" ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR (16#0006) 16# #0000 Inputs are outside permitted range RESOURCE_ERROR (16#0003) 16# #0000 Drive firmware not supported. STATE_MACHINE_ERROR (16#0005) 16# #0000 Invalid status of the function block Fig.12-9: MX(L)_ContinuousAdjustType01 Error Codes 12.3 MX(L)_ContinuousAdjustType02 Short Description Interface Description The MX(L)_ContinuousAdjustType02 function block enables the continuous adjustment of an adjustable DINT variable using binary inputs. Fig.12-10: MX(L)_ContinuousAdjustType02 Function Block I/O Type Name Data Type Comment VAR_INPUT Enable BOOL Enables the function block (cyclical, state-controlled) Inc BOOL Increment the adjustable variable Dec BOOL Decrement the adjustable variable Preset BOOL Set the Preset-Value (PresetValue) PresetValue DINT Specified value for Preset ModuloValue DINT Modulo value (if 0, then absolute processing) HighLimit DINT Maximum output value of the adjustable variable LowLimit DINT Minimum output value of the adjustable variable StepWidth REAL Increments StepsPerSecond AdjTimeIntervals AdjWeight Factors REAL ARRAY [1..4] OF REAL ARRAY [1..5] OF REAL Increments per second Time intervals in seconds for scaling the alteration velocity scaling factors of the alteration velocity VAR_OUTPUT InOperation BOOL No calculation active. Ouputs HighLimitAck and LowLimitAck are valid.

120 114/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Adjusting Variables" I/O Type Name Data Type Comment Error BOOL Calculation of the adjustable variable "Value" completed with error, output variable ErrorIdent is valid ErrorID ERROR_CODE Error short description ErrorIdent ERROR_STRUCT Detailed description of the diagnostics in case of an error Changing BOOL Calculation of the adjustable variable takes place. adjustable variable "Value" is valid HighLimitAck BOOL Maximum output value of the adjustable variable reached LowLimitAck BOOL Minimum output value of the adjustable variable reached VAR_IN_OUT Value DINT Adjustable variable Timing Diagram Fig.12-11: MX_ContinuousAdjustType02 I/O Interface Functional Description Fig.12-12: Continuous Parameter Adjustment The adjustment of the adjustable variable "Value" may take place in positive or negative direction. The limits set a valid range for adjusting the variable. Specifying a modulo value allows the adjustment to be within an axis frame of reference. Predefining increments and increments per second determines the alteration velocity of the adjustable variable. It is possible to write a given value ("PresetValue"), inside the valid operating range, directly to the adjustable variable. After activation, with "Enable", the adjustable variable can be changed via inputs "Inc" (positive direction) and "Dec" (negative direction). While input "Inc" or "Dec" is set, the adjustable variable is continuously increased (or decreased) with the given velocity. ("StepsPerSecond" * "StepWidth"). At initialization, ensure the inputs "ModuloValue", "HighLimit" and "LowLimit", contain valid values. By determining scaling factors ("AdjWeightFactors[ ]") and the corresponding time intervals ("AdjTimeIntervals[ ]") it is possible to make time-dependent velocity modifications. The scaling factors and time intervals must also be set on the inputs "StepsPerSecond" and "StepWidth". Depending on the actual time interval, the alteration velocity is then multilpied with the appropriate scaling factor. The figure below shows the behavior of the block with an example configuration: The input factors of "AdjTimeIntervals" ([T1; T2; T3; T4]) are specified in seconds. T5 specifies the period after completion of time interval T4 when the adjustment procedure aborts. The input factors of "AdjWeightFactors" ([0,5; 1; 1,5; 2; 4]) determine the scaling of the alteration velocity. The last value of "AdjWeightFactors [5]" is assigned to time interval T5.

121 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 115/179 Function Blocks for Application "Adjusting Variables" Fig.12-13: Scaling Adjustment When a time interval = 0, the next scaling factor is used until the adjustment process aborts. Example: If AdjTimeIntervals[2] = 0, then the scaling factor of AdjWeightFactors[3] is used until terminated. To determine the correct time interval of the scaling factors, the expired time is reset with each new starting adjustment process. If inputs "AdjWeightFactors" and "AdjTimeIntervals" are not set, a continuous adjustment with the given alteration velocity specified with "StepsPerSecond" and "StepWidth" occurs. Values in "AdjTimeIntervals" must only contain positive values. scaling factors can be positive or negative. The adjustable variable can only be set to the specified preset value if it is within the valid range between "HighLimit" and "LowLimit". Error Handling Output "InOperation" signals that the block is in use, but an adjustment is not active. "Changing" indicates an error-free adjustment and the value of the adjusted variable "Value" is valid. "Error" indicates that an error occurred during the adjustment process. Details are indicated in the "ErrorIdent" structure. The function block generates the following error messages in Additional1/Additional2 of the table "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR (16#0006) 16# #0000 Inputs are outside permitted range RESOURCE_ERROR (16#0003) 16# #0000 Drive firmware not supported STATE_MACHINE_ERROR (16#0005) 16# #0000 Invalid status of the function block Fig.12-14: MX(L)_ContinuousAdjustType02 Error Codes

122 116/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Adjusting Variables" 12.4 MX(L)_IncrementalAdjustType01 Short Description Interface Description The MX(L)_IncrementalAdjustType01 function block enables incremental adjustment of an adjustable REAL variable using binary inputs. Fig.12-15: MX(L)_IncrementalAdjustType01 Function Block I/O Type Name Data Type Comment VAR_INPUT Enable BOOL Enable the function block (cyclical, state-controlled) Inc BOOL Increment the adjustable variable Dec BOOL Decrement the adjustable variable Preset BOOL Set the Preset-Value (PresetValue) PresetValue REAL Specified value for Preset ModuloValue REAL Modulo value for rotatory calculation HighLimit REAL Maximum output value of the adjustable variable LowLimit REAL Minimum output value of the adjustable variable StepWidth REAL Step Width StepsPerSecond REAL Increments per second VAR_OUTPUT Done BOOL Calculation of the adjustable variable completed. The output variables "Value", "HighLimitAck" and "LowLimitAck" are valid. Active BOOL Calculation of the adjustable variable not yet completed. The adjustable variable "Value" is still in process. The outputs "HighLimitAck" and "LowLimitAck" are valid. Error BOOL Calculation of the adjustable variable "Value" completed with error, output variable "ErrorIdent" is valid ErrorID ERROR_CODE Short error description ErrorIdent ERROR_STRUCT Detailed description of the diagnostics in case of an error HighLimitAck BOOL Maximum output value of the adjustable variable reached

123 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 117/179 Function Blocks for Application "Adjusting Variables" I/O Type Name Data Type Comment LowLimitAck BOOL Minimum output value of the adjustable variable reached VAR_IN_OUT Value REAL adjustable variable Timing Diagram Fig.12-16: MX(L)_IncrementalAdjustType01 I/O Interface Functional Description Fig.12-17: Incremental Parameter Adjust The adjustment of the adjustable variable "Value" may take place in positive or negative direction. The limits set a valid range for adjusting the variable. Specifying a modulo value allows the adjustment to be within an axis frame of reference. Predefining increments and increments per second determines the alteration velocity of the adjustable variable. It is possible to write a given value ("PresetValue"), inside the valid operating range, directly to the adjustable variable. After activation, with "Enable", the adjustable variable can be changed via inputs "Inc "(positive direction) and "Dec" (negative direction). While input "Inc" or "Dec" is set, the adjustable variable is continuously increased (or decreased) with the given velocity. ("StepsPerSecond" * "StepWidth"). The adjustable variable can only be set to the specified preset value when it is within the valid range between "HighLimit" and "LowLimit". Error Handling "Active" signals that the adjustment procedure is not yet completed. "Done" = TRUE signals the adjustment completed without error. If an error occurs during processing of the function block, it is indicated with "Error" = TRUE, with the details in the output structure "ErrorIdent". The function block generates the following error messages in Additional1/Additional2 of the table "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description INPUT_RANGE_ERROR (16#0006) 16# #0000 Inputs are outside permitted range RESOURCE_ERROR (16#0003) 16# #0000 Drive firmware not supported STATE_MACHINE_ERROR (16#0005) 16# #0000 Invalid status of the function block Fig.12-18: MX(L)_IncrementalAdjustType01 Error Codes

124 118/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks for Application "Adjusting Variables" 12.5 Parameterization of the Function Blocks for Adjusting Variables Required Hardware Required Firmware Required Software Parameterization of the Function Blocks for Adjusting Variables The following Rexroth hardware components are required: MLC Hardware The following drive firmware has to be used together with the above mentioned Rexroth hardware components: MLC Firmware The following PC software has to be used: IndraWorks MLC No special parameterization is required.

125 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 119/179 Function Block for Application "Sensorless Winder" 13 Function Block for Application "Sensorless Winder" 13.1 Introduction and Overview The sensorless winding calculator will be used for center winders. The drive of the winding axis operates with a user-specific torque limit. The torque limit depends on the current winder diameter and the set tension. The tensile force will be generated by setting the torque of the winding axis. Additional measuring units are not required. Fig.13-1: 13.2 ML_COMP_DATA Principle of the winder The data structure chapter 13.2 "ML_COMP_DATA" on page 119 contains the design parameters for the friction compensation and the winding tightness characteristic curves. The function block chapter 13.3 "ML_WinderSensorless" on page 120 is responsible for the control of the winder. The data structure ML_COMP_DATA contains the design parameters for the friction compensation and the winding tightness characteristic curves. Function Name Type Comment Friction compensation RStandStillFriction REAL Standstill friction torque [%] RMaxFrictTorque REAL Maximum friction torque [%] RToppleFrictTorque REAL Pull-out / friction torque [%] RToppleRev REAL Pull-out speed Winding tightness characteristic curves BCurveType BOOL Curve type: 0 = linear; 1 = hyperbolic RrefDiameter REAL Beginning of the characteristic curve Rtaper REAL Characteristic curve progression: 0 to 100% => rising, 0 to -100% => falling Fig.13-2: Content of the data structure ML_Comp_Data

126 120/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Sensorless Winder" 13.3 ML_WinderSensorless Brief Description Interface Description The function block ML_WinderSensorless realizes the control of a center winder with a user-defined torque limit depending on the current winder diameter and the set tension. The functionality of the function block will be described in the following. * Variable adjustments are immediately effective in the case of an active function block! ** Takeover with Preset Fig.13-3: ML_WinderSensorless Name Type Comment VAR_IN_OUT RefAxis AXIS_REF Reference axis Encoder axes, real axes and virtual axes with a modulo weighting of 360 can be used. WindingAxis AXIS_REF Reference to the winding axis FSCompData ML_COMP_DATA Contains design parameters for friction compensation and winding tightness characteristic curves.

127 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Name Type Comment VAR_INPUT Enable BOOL Activates the winding calculator Preset BOOL Initializes the function block with Preset WinderType BOOL Winder type: 0=> unwinder, 1 => rewinder TightMethod BOOL Tensioning method: 0 => tensioning with constant speed, 1 => tensioning with constant web velocity SetVal1 REAL Tensile force command value [N] CoreDiameter REAL Diameter of the empty winder [mm] CoilDiameterPreset REAL Preset diameter Initial value for the diameter calculation, e. g. after a coil change. In the case of a preset, the parameterized value will be accepted as current winder diameter. TractionLimitWindow REAL Monitoring window for the tension [%] Also effective in the case of a deactivated winding calculator TightRev REAL The winding material will be tensioned with the speed set here [rpm] VAR_OUTPUT InOperation BOOL In operation after having finished preprocessing PresetDone BOOL Preset has been accomplished CalcDiamDone BOOL After having activated the winding calculator, "CalcDiameterDone" will be set once the first diameter calculation has been finished. The signal will be reset in the following cases: 1. Deactivation of the winding calculator 2. Transition to the untensioned status CurrentTrackingForce REAL Actual tension value [N] TractionInLimits BOOL Tensile force in the monitoring window ActCoilDiameter REAL Currently calculated winder diameter [mm] CoilTightened BOOL Winding material tensioned Warning BOOL Indicates a warning Error BOOL Indicates an error ErrorID ERROR_CODE Brief error description Bosch Rexroth AG 121/179 Function Block for Application "Sensorless Winder" ErrorIdent ERROR_STRUCT Detailed error description according to error table Fig.13-4: Interface of ML_WinderSensorless

128 122/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Sensorless Winder" Signal/Time Diagram Fig.13-5: Signal/time diagram of the winder Functional Description In the case of an active function block, an error message does not result in an interruption of the winding procedure in any case. The user has to decide upon the further procedure on the basis of the error codes. The input "Enable" activates / deactivates the winding calculator. With "Enable", the winding material will initially be tensioned with the set tensioning speed. To avoid the formation of loops, the master axis should be in standstill during this procedure. The winding material is considered as being tensioned if the relative deviation between the torque limit (S ) and the actual torque value (S ) is lower than 25%. "Winding material tensioned" will be indicated with "CoilTightened". The following two methods Tensioning with constant speed and Tensioning with constant web velocity can be used for tensioning the winding material. Calculation of the winder diameter: The torque for the winder drive results from the product "tensile force x radius" of the winder. The radius or the diameter of the winder will thus be determined on a continuous basis. After having activated the winding calculator and after having successfully completed the tensioning process, the diameter calculation will be performed for the first time after half a revolution and subsequently every 180 in the tensioned condition. The current winder diameter is available at "ActCoilDiameter".

129 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 123/179 Function Block for Application "Sensorless Winder" Winder Types Winding Tightness Characteristic Curves: Data Structure ML_COMP_DATA Linear Winding Tightness Characteristic Curve Fig.13-6: Winder Types The four different applications will be configured with the help of two variables. The function of an unwinder or rewinder will be set with the variable "Winder Type". The rotating direction of the winder drive in relation to the master axis will be determined with the drive parameter "Master drive polarity" (P ). A selectable winding tightness characteristic curve can be set for a rewinder. In principle, the winding tightness characteristic curve will be used to wind up the initial layers of the winder with a higher tension and to reduce the tension with an increasing winder diameter. The variable "rrefdiameter" (initial winder diameter) can be used to set the diameter from which the winding tightness characteristic curve becomes effective. The variable "rtaper" is used to specify the tension change (in %) in relation to an increasing diameter. If the value for the winding tightness is between 0% and 100%, the tension decreases with an increasing diameter; if the value is between 0% and -100%, the tension increases with an increasing diameter. The higher the absolute value for the winding tightness, the higher is the increase or decrease of the tension. With the help of the variable "bcurvetype", two different winding tightness characteristic curves can be selected. Depending on the parameter "rtaper", the tension will be changed linear to an increasing diameter.

130 124/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Sensorless Winder" Hyperbolic Winding Tightness Characteristic Curve Fig.13-7: Linear winding tightness characteristic curve Depending on the parameter "rtaper", the tension will be changed hyperbolically (1/diameter). Friction compensation Fig.13-8: Hyperbolic winding tightness characteristic curve A speed-dependent compensation of the friction torque can be set with the help of the parameters "friction torque at standstill" "rstandstillfriction", "friction torque at maximum speed" "rmaxfricttorque", "minimum winder friction torque" "rtopplefricttorque", "winder - speed - minimum friction torque" "rtopplerev". The friction torque will be specified in percent in relation to the standstill permanent torque of the motor. (S , P ).

131 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 125/179 Function Block for Application "Sensorless Winder" Coil Change Fig.13-9: Friction compensation After a coil change, the winder diameter normally changes immediately. The last calculated internal value does no longer correspond to the current diameter. A preset has to be performed to ensure a correct diameter calculation during a restart. The parameter "winder diameter preset" "CoilDiameterPreset" has to be provided with the current winder diameter as initial value. If no preset is performed, this may result in certain malfunctions. The preset has to be completed before connecting the winding calculator. Setting the Preset Value in the Case of a Coil Change On-The-Fly Block Diagram In the case of a coil change on-the-fly (several winding axes), the "winder diameter preset" "CoilDiameterPreset" should be set to a slightly smaller diameter for a rewinder and to a slightly larger diameter for an unwinder than the actual value. In the case of a rewinder, a higher speed will be set; in the case of an unwinder, a lower speed will be set. This accelerates the tensioning process correspondingly..

132 126/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Sensorless Winder" Troubleshooting Fig.13-10: Block diagram / functional overview The function block generates the following error messages in Additional1/Additional2 for the table "F_RELATED_TABLE", 16#0170: ErrorID Additional1 Additional2 Description RESOURCE_ERROR (16#0003) ACCESS_ERROR (16#0004) 16# #0000 Drive power or controller enable is not connected. 16#0B01 16#0001 Drive parameter S is not cyclically configured in MDT.

133 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 127/179 ErrorID Additional1 Additional2 Description Function Block for Application "Sensorless Winder" ACCESS_ERROR (16#0004) ACCESS_ERROR (16#0004) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) INPUT_RANGE_ERROR (16#0006) RESOURCE_ERROR (16#0003) 16#0B01 16#0002 Drive parameter S is not cyclically configured in MDT. 16#0B01 16#0003 Drive parameter S is not cyclically configured in MDT. 16#0B02 16#0001 Input parameter outside the value range: Process variable command value (tensile force [N]) 16#0B02 16#0002 Input parameter outside the value range: Process variable window (%) 16#0B02 16#0003 Input parameter outside the value range: Specification tensioning speed [rpm] 16#0B02 16#0004 Input parameter outside the value range: Winder diameter preset [mm] 16#0B02 16#0005 Input parameter outside the value range: Minimum winder diameter [mm] 16#0B03 16#0001 Input parameter outside the value range: Data Structure ML_COMP_DATA (Winding tightness characteristic curves: Reference diameter [mm]) 16#0B03 16#0002 Input parameter outside the value range: Data Structure ML_COMP_DATA (Winding tightness characteristic curves: Taper [%] ) 16#0B03 16#0003 Input parameter outside the value range: Data Structure ML_COMP_DATA (Standstill friction torque [%]) 16#0B03 16#0004 Input parameter outside the value range: Data Structure ML_COMP_DATA (Maximum friction torque [%]) 16#0B03 16#0005 Input parameter outside the value range: Data Structure ML_COMP_DATA (Pull-out / friction torque [%]) 16#0B03 16#0006 Input parameter outside the value range: Data Structure ML_COMP_DATA (Pull-out speed [rpm] ) 16#0B04 16#0001 Winding axis not in synchronous operation: GearIn not active or not processed without errors. If required, adjust S "Velocity synchronization window". Required Hardware Required Firmware Fig.13-11: Error codes caused by ML_WinderSensorless MLC Hardware CML40.1 or CML40.2 IndraDrive C or IndraDrive M with advanced or basic control part MLC firmware CML40s-MLs-02V or higher Drive firmware MPH03V10 or higher with the following functional packages:

134 128/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Sensorless Winder" Required Software Required Parameterizations Closed Loop Synchronization IndraWorks MLC 01VRS The parameterization over IndraWorks is accomplished as follows: Fig.13-12: Cyclical SERCOS channel (MDT) The position of the parameter inputs is free. In the case of incorrect or missing inputs, an error message will be displayed. Parameterization Winder Drive Rotating Direction of the Winder Drive Filtering Actual Values Disabling the Warning Message E8260 The following parameterization has to be accomplished in the drive to ensure a proper functionality of the function block. The rotating direction of the winder drive in relation to the master axis will be determined with the drive parameter "Master drive polarity" (P ). Filtering the torque/force feedback value S : In the case of a low tensioning speed, an unfiltered actual torque value can result in a malfunction of the winding calculator. Since the engagement condition of the winding calculator requires a relative deviation between the torque limit value and the actual torque value of < 25%, a diameter calculation will possibly not be performed. Filtering the velocity feedback value S : In the case of a low speed, an unfiltered velocity feedback value can, among other consequences, result in incorrect values for the friction compensation. With the help of the parameters P , average value filter for display: signal selection P , average value filter for display: signal selection list P , average value filter for display: time constant the actual velocity or torque value can be smoothed with the help of average value filters. In the case of an active winding calculator, the warning E8260 "Torque/force command value limitation active" will be displayed at the winder drive. In the case of an active torque/force limitation, the warning display can be deactivated in "P , Config word of axis controller", if required: Bit 4 0: E8260 will be displayed 1: E8260 will not be displayed See also Rexroth IndraDrive MPx03 parameter description

135 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 129/179 Function Block for Application "Sensorless Winder" Required IndraLogic Steps Settings for the Diameter Calculation Example The function block ML_WinderSensorless records drive data which have to be provided on a cyclical basis. Thus, the function block has to be called in a highprior, cyclical PLC task with a cycle time 4ms (motion task). Prior to the start of the winder function block, the winder must be connected to the master axis over the function block MC_GearIn. The function block realizes an electronic gear function with fine adjustment (speedsynchronous). MC_GearInPos may not be used for connection purposes. Prior to the start of the function block, the power of the winder drive must be connected with MC_Power. The winder diameter will be calculated from the "minimum winder diameter" and the related gear ratio between the master axis and the winding axis. The gear ratio between the master axis and the winding axis will be calculated with the help of RatioNumerator (master axis gear output revolutions) RatioDenominator (master axis gear input revolutions) (MC_GearIn input variables). They must be set in a way so that the web velocity of the winding material is equal to the circumferential velocity of the empty winder. One master axis revolution corresponds to a format of 420 mm, and the empty winder has a diameter of 100 mm. Master axis gear input revolutions = 100 * pi = 314 Master axis gear output revolutions = 420 Instructions for Initial Start-up Determination of the Friction Torque in Standstill Determination of the Friction Torque With Maximum Speed Fig.13-13: Formula for the diameter calculation The compensation data have been summarized in the data structure "ML_COMP_DATA", see fig "Content of the data structure ML_Comp_Data" on page 119. It contains the design parameters for the friction compensation and the winding tightness characteristic curves. The "standstill friction torque" "rstandstillfriction", see fig "Content of the data structure ML_Comp_Data" on page 119, will be determined with a stopped master axis and an empty winder: The inputs Enable and Preset are initially inactive ("0"). The variable "TightRev", see fig "Interface of ML_WinderSensorless" on page 120, will be set to a low speed (e. g. 10 rpm). Connect the winding axis with the reference axis with the help of GearIn. Enable the winding calculator with "Enable". The value of the variable "rstandstillfriction", see fig "Content of the data structure ML_Comp_Data" on page 119, will be incrementally increased until the drive starts to rotate. The enabling of the process controller will be reset. Thus, setting the parameter "Standstill friction torque" is completed. The "friction torque at maximum speed" "rmaxfricttorque", see fig "Content of the data structure ML_Comp_Data" on page 119, will be determined as follows with a stopped master axis and an empty winder: The inputs "Enable" and "Preset" are inactive ("0").

136 130/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block for Application "Sensorless Winder" Determination of the Minimum Friction Torque (Pull-out Torque, Pullout Speed) Final Settings Preset Fine Adjustment Winder - Tensioning Speed Initial Start-up of the Winding Axis The variable "tensioning torque" "TightRev", see fig "Interface of ML_WinderSensorless" on page 120, will be set to the maximum speed of the winder (see also "Bipolar velocity limit value" (S )). The "friction torque at maximum speed" "rmaxfricttorque", see fig "Content of the data structure ML_Comp_Data" on page 119, will be set to 100 %. Connect the winding axis with the reference axis with the help of GearIn. Enable the winding calculator over the input "Enable". Now, the winder drive is accelerated up to the maximum speed. The parameter "friction torque at maximum speed" "rmaxfricttorque", see fig "Content of the data structure ML_Comp_Data" on page 119, will be incrementally decreased until the drive starts to decelerate. The speed can be controlled with the drive parameter "velocity feedback value" (S ). The enabling of the process controller will be reset. Thus, setting the parameter "friction torque at maximum speed" is completed. The minimum friction torque will be determined with the help of a brake test with empty winder. The winder drive will be decelerated until standstill with a constant velocity (e. g. 50 rpm). At the same time, the drive parameters "torque/ force command value" (S ) and "velocity feedback value" (S ) will be recorded with an oscilloscope or with the IndraWorks oscilloscope function. The minimum value for the torque curve will be entered into the data structure "ML_COMP_DATA.RtoppleFrictTorque", see fig "Content of the data structure ML_Comp_Data" on page 119; the corresponding speed will be entered into "ML_COMP_DATA.RtoppleRev", see fig "Content of the data structure ML_Comp_Data" on page 119. Operating tension: The desired operating tension will be set with the parameter "tensile force command value [N]" "TractionForce", see fig "Interface of ML_WinderSensorless" on page 120. To ensure the required lead and lag of the winding axis, the MC_GearIn variable "MasterFineAdjust" has to be set as follows. Rewinder: "MasterFineAdjust" will be set to a value of 2.00 %. Unwinder: "MasterFineAdjust" will be set to a value of %. Winding with constant speed: The "tensioning speed" "TightRev", see fig "Interface of ML_WinderSensorless" on page 120, will be set to the desired value. Winding with constant web velocity: The tensioning speed for an empty winder will be entered into the "tensioning speed" "TightRev", see fig "Interface of ML_WinderSensorless" on page 120. The winding material will be applied in untensioned condition (slightly sagging). Connect the reference axis and the winding axis with MC_GearIn. Initialize the function block with "Preset", see fig "Interface of ML_WinderSensorless" on page 120.

137 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 131/179 Function Block for Application "Sensorless Winder" Activate the winding calculator with "Enable". The winding material now has to be tensioned with the "tensioning speed" "TightRev", see fig "Interface of ML_WinderSensorless" on page 120. The output "tensile force in monitoring window" "TractionInLimits", see fig "Interface of ML_WinderSensorless" on page 120, must be set now. If this message is not displayed, the "tension monitoring window" "TractionLimitWindow", see fig "Interface of ML_WinderSensorless" on page 120, has to be corrected. The master axis will be enabled with a low speed (e. g. 10 rpm). After some revolutions of the winding axis, the output "CalcDiamDone", see fig "Interface of ML_WinderSensorless" on page 120, must have become active and thus the winding calculator must have become engaged. With the winding calculator being engaged, the standstill tension and the operating tension can be checked. The output variable "currently calculated winder diameter" "ActCoilDiameter", see fig "Interface of ML_WinderSensorless" on page 120, displays the result of the diameter calculation. The calculated value has to correspond approximately to the actual diameter of the winder. Since the diameter of the winder is calculated every 180, the speed of the winder should not exceed 3,500 rpm due to the modulo calculation. Higher speeds can result in a modulo overrun and thus to incorrect diameter calculations.

138 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description

139 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives 14 Function Block Temperature Controller "IL_TempControlType01" 14.1 Introduction and Overview Brief Description Interface Description Bosch Rexroth AG 133/179 Function Block Temperature Controller "IL_TempControlType01" The function block "IL_TempControlType01" serves for the control of temperatures. It can determine the controller parameters either independently or with the help of certain specifications. Special functions like monitoring, pause and manual operation can be activated in addition. Fig.14-1: Interface Description Name Type Description VAR_INPUT Enable BOOL The function block is active if this input is "TRUE". The function block will be reset to its initial values with a falling edge. The parameter will be read in each cycle. SetPoint REAL Command temperature Unit in [u] The parameter will be read in each cycle. SetPointGradient REAL Maximum adjustment of the parameter "SetPoint" in [u/ s] The parameter will be read in each cycle. The preset value is "0 [u/s]" (not active). Feedback REAL Input for the actual temperature Unit in [u] The parameter will be read in each cycle.

140 134/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" Name Type Description Pause BOOL This input "freezes" the control variable and the controller calculation. The parameter will be read in each cycle. The preset value is "FALSE" (not active). OperatingMode BOOL Changes the controller mode from automatic to manual operation: AUTO:=FALSE, MANUAL:=TRUE. The preset value is "FALSE" (AUTO). The parameter will be read in each cycle. ManContrValue REAL Specifies the control variable in [%] for the manual operation but will only be actively read if "OperatingMode:=1". The parameter will be read in each cycle. The preset value is "0%" (no control variable). StartAutoTune BOOL A rising edge starts the identification process. The PID controller parameters will be calculated subsequently but not actively until a falling edge is present. The parameter will be read in each cycle. The preset value is "FALSE" (not active). AutoTuneTimeOut TIME Watchdog responsible for monitoring the time during the identification process The preset value is "10000 T A ". The parameter will be read by "StartAutoTune" in the case of a rising edge. AutoTuneStartPower REAL Control variable in [%] representing the lower limit of the identification process The preset value is "0%". The parameter will be read by "StartAutoTune" in the case of a rising edge. AutoTuneFinishPower REAL Control variable in [%] representing the upper limit of the identification process The preset value is "50%". The parameter will be read by "StartAutoTune" in the case of a rising edge. OutputPowerMax REAL Maximum output control variable in [%] The preset value is "100%". The parameter will be read in each cycle. Quickness USINT Quickness of the controller The preset value is "3" (very slight overshoot). The parameter can be selected in the range from "1" (quick control, strong overshoot) to "5" (slow control, no overshoot). The parameter will be read by "StartAutoTune" in the case of a rising edge.

141 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Name Type Description Preset BOOL A rising edge takes over the control parameters of the "ContrParam" structure. The preset value is "FALSE" (not active). The parameter will be read in each cycle. StartUpTemp REAL Start-up temperature in [u] The parameter will be read by "Enable" in the case of a rising edge. The preset value is "0u" (not active). Only becomes active if the parameter "StartUpTime" is parameterized with a value which is not equal to "0". StartUpTime TIME Start-up time, i. e. the period during which the start-up temperature ("StartUpTemp") is hold until the "normal" control process is started. The preset value is "T#0s" (not active). The parameter will be read by "Enable" in the case of a rising edge. ControlUpdateRate DINT This factor specifies how much slower the controller works compared to the task of the function block. Limits IL_TEMPCONTROL_LI MITS The sampling time results from multiplying the cycle time (= task interval time) with "ControlUpdateRate". Structure containing the alarm limits in [u] The preset value is "0u" (not active). The parameter will be read in each cycle. If the structure is filled with values, Limits.UpperAlarm has to be > Limits.LowerAlarm and (Setpoint + Limits.UpperAtSetpoint) has to be > (Setpoint - Limits.LowerAtSetpoint); otherwise, an error will be generated. VAR_OUTPUT InOperation BOOL The temperature control is active for a set output. Active BOOL This output will be set if "Enable" is set and if the controller is active. Error BOOL An error has occurred during operation. The control variable will be set to "0%". ErrorID ERROR_CODE In the case of a set "Error" output, this output contains a rough classification of the error. ErrorIdent ERROR_STRUCT In the case of a set "Error" output, this output contains detailed information concerning this error. AutoTuneActive BOOL The identification process is active. Bosch Rexroth AG 135/179 Function Block Temperature Controller "IL_TempControlType01" AutoTuneDone BOOL The identification process has been successfully completed. ControlValueAnalog REAL Analog value of the control variable in %. ControlValuePWM BOOL Digital, pulse-width modulated control variable value, either "0" or "1".

142 136/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" Name Type Description SetPointReached BOOL Status output displaying if the actual value is within the limits ("Setpoint" + "Limits.UpperAtSetpoint") >= actual value >= (Setpoint - "Limits.LowerAtSetpoint") VAR_IN_OUT ContrParam IL_TEMPCONTROL_C ONTR_PARAM This structure contains the current parameters K P, K I and K D of the controller as well as the dead time T t. Data Structures Fig.14-2: Inputs/outputs for IL_TempControlType01 Name of the structure Elements Data type IL_TEMPCONTROL_LIMITS UpperAlarm REAL LowerAlarm UpperAtSetpoint LowerAtSetpoint REAL REAL REAL IL_TEMPCONTROL_CONTR_PARAM KP REAL KI KD Tt REAL REAL TIME Timing Diagram Fig.14-3: Data structures Error Description Fig.14-4:. Timing diagram

143 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives ErrorID Table Add1 Add2 Description STATE_MACHINE_ER ROR F_RELATED_TABLE 16#1600 Current status Error of the state machine, invalid status INPUT_RANGE_ERROR F_RELATED_TABLE 16# #0001 Input values for a maximum output value SYSTEM_ERROR F_RELATED_TABLE 16#1602 Sampling time ("OutputPowerMax") is outside the valid range The value must be higher than 0 [%] up to max. 100 [%]. 16#1602 Input values invalid for alarm limits (condition: Limits.UpperAlarm > LowerAlarm) 16#1603 Input values invalid for manual control variable The value must be in the range from 0 [%] to 100 [%]. 16#0004 Controller parameter invalid 16#000A The start and end value for identification are too close to each other. The minimum difference is 5 [%]. 16#000B The input SetpointGradient is invalid. The value must be higher than 0. 16#000C Input values invalid for status limits (condition: (Setpoint + Limits.UpperAtSetPoint) > (Setpoint - Limits.LowerAtSetPoint) 16#000D Time for identification is too long ("AutoTuneTimeOut"). 16#000E Value for "Quickness" is not within the valid limits (1..5) 16#000F Value for "ControlUpdateRate" is not within the valid limits ( ) Jitter of the sampling time > 20 [%] Error only becomes active if the cycle time is exceeded two times in a row 16#0005 Gradient of the actual value is too high, possibly due to a sensor error (analysis) 16#0006 Error of the control loop, sensor has possibly been shifted or destroyed CALCULATION_ERROR F_RELATED_TABLE 16# #0007 Identified controlled system parameters are invalid, self-identification of the controlled system failed ACCESS_ERROR F_RELATED_TABLE 16#1604 Field number of the array Bosch Rexroth AG 137/179 Function Block Temperature Controller "IL_TempControlType01" 16#0008 The identified process model is not appropriate / invalid. Incorrect access to internal variable

144 138/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" ErrorID Table Add1 Add2 Description OTHER_ERROR F_RELATED_TABLE 16# #0009 Time elapsed during identification (watchdog) DEVICE_ERROR F_RELATED_TABLE 16#1606 Temperature Temperature error limit exceeded, temperature outside the error limits Comments on Certain Errors Fig.14-5: Error Error description "Gradient of the actual value is too high" (Additional1 = 16#1602; Additional2 = 16#0005): The gradient of the actual value will be monitored. If the difference between two consecutive actual values is higher than 10u/ms, this error will be generated. This may be the case when using an in-line temperature model since error analyses will be displayed as measured values with values higher than (bit 15 set). If this analysis is not evaluated by the user, this error message may be generated. Error "Error of the control loop, sensor has possibly been shifted or destroyed" (Additional1 = 16#1602; Additional2 = 16#0006): It will be monitored if the actual value approaches the command value in the case of a maximum output power. For this purpose, a time monitoring process will be started which is 2000 / Ki + Tt in the case of an active I part and 2000 * sampling time + Tt without I part. If the actual value does not approach the command value during this period, the error will be generated. It is possible that the sensor is defect / has been shifted or that the heating / cooling system does not work. The error may also occur if not dead time (Tt) is specified when specifying the controller parameters over the structure "IL_TEMPCONTROL_CONTR_PARAM". In this case, the value of the dead time should be estimated and the controller parameters should be set again. This will be accomplished automatically when identifying the controlled system. Error "Identified controlled system parameters are invalid, self-identification of the controlled system failed" (Additional1 = 16#1603; Additional2 = 16#0007): The values of the controlled system parameters were invalid. This may be due to an incorrect sampling time or due to incorrect actual values (sensor not connected). See also "Recommendations for Selecting the Sampling Time" on page 143. Error "The identified process model is not appropriate / invalid" (Additional1 = 16#1603; Additional2 = 16#0008): When identifying the controlled system, the calculated model will be compared with the measured values. The comparison did not show any satisfying results. The model shows a deviation of more than 20 % from the measured values. Maybe the sampling time has not been chosen correctly, or the controlled system does not show an aperiodic behavior. Disturbance variables occurring during the identification process can also lead to this effect. Error

145 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives "Time elapsed during identification (watchdog)" (Additional1 = 16#1605; Additional2 = 16#0009): When identifying the controlled system, the system waits until the actual value is in steady state; then, a command value step change is performed and the system waits again until the actual value is in steady state. If this requires too much time, the error will be generated. The reason for this is either a strongly varying actual value or an incorrectly selected sampling time (see also next section). Error "Time for identification is too long ('AutoTuneTimeOut')" (Additional1 = 16#1601; Additional2 = 16#000D): Bosch Rexroth AG 139/179 Function Block Temperature Controller "IL_TempControlType01" When identifying the controlled system, the time monitoring value can be set. This value can have a maximum of * sampling time. In this case, the time monitoring value has to be set to 0 (maximum possible time for identification in the case of a given sampling time) or the sampling time must be increased correspondingly. Application Identification The function block can be used for IndraLogic and IndraMotion MLC with the help of in-line temperature modules (IL TEMP 2 RTD). At the moment, the inline modules are not yet available for IndraMotion MLD. In general, however, each value can be used as a temperature value since the temperature controller does not directly access the hardware. Thus, it is also possible to obtain temperature values, for example, over field bus connections. The automatic identification, also known as "AutoTune", serves to identify the parameters of the controlled system to determine the parameters of the controller. First, certain model parameters will be calculated; subsequently, the model will be compared with the real controlled system to avoid incorrect parameterizations of the controller parameters. Before the jump will be activated, it must be ensured that the controlled system is in passive state. A time monitoring process will be started for this purpose. The preset value for this time monitoring process is 5000 multiplied with the root of the sampling time in [ms]. The actual value must not exceed the tolerance limits of the defined tolerances prior to the end of the time monitoring process; otherwise, the time monitoring process will be restarted and the system will wait until the specified time has elapsed. The limit for the temperature window containing the actual value for the time of the time monitoring process will be calculated as follows: The variable "IdentTemp" is the value for which the tolerance window of the actual temperature will be created. Waiting for the stationary final value is performed in the same way. The quality of the determined model will be estimated. If the deviation is too big, the function block displays the error "16#1603" (CALCULATION_ERROR) with the identifier "16#0008" (invalid process model) Controller Setting the Controller Parameters Equation of the controlled system:

146 140/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" Equation of the controller: Setting to optimum value: or Quickness = 1...5; 1 = very fast with large overshoot, 5 = very slow without overshoot; the preset value is Quickness = 3. Setting the filter time for the difference: Control Algorithm This value will be fixed and cannot be changed. The calculated controller parameters will be entered into the provided structure "IL_TEMPCONTROL_CONTR_PARAM". The entry KP KI KD Tt corresponds to the proportional gain factor, corresponds to the integration constant, corresponds to the differentiation constant and corresponds to the dead time. If these parameters are specified by the user, an estimated value should at least be entered for the dead time to avoid the error "Error of the control loop, sensor has possibly been shifted or destroyed" (Additional1 = 16#1602; Additional2 = 16#0006), if possible. An additive PIDT 1 algorithm with anti-wind-up of the I part and PT 1 filtering of the D part has been implemented. The additive form allows to deactivate certain parts of the controller so that, for example, the structure of a PI controller can be used by parameterizing the D part to "zero". The I part will be limited with the help of an anti-wind-up limiter which has been internally preset to a value of 90% of the control variable.

147 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 141/179 Function Block Temperature Controller "IL_TempControlType01" Controller Structure The saturation limit of the controller is the maximum output value (VAR_IN OutputPowerMax) of the controller. The preset value is 100%. In the following, the PIDT 1 controller structure with anti-wind-up limitation and limitation of the maximum control variable will be displayed. Due to the additive structure, the parts of the controller can be individually deactivated. Thus, pure P, PI or PDT 1 controller can be parameterized as well. However, the individual parts have to be deactivated by the user. For this purpose, the desired values have to be entered into the structure "contrparam". In the case of a rising edge at the input "Preset", these new parameters will be activated in the controller. By standard, the controller works with the complete PIDT 1 structure. Control Loop Monitoring Fig.14-6: Controller structure The actual temperature value will be smoothed with a PT 1 filter both during the identification and the control process to avoid stochastic failures. The time constant of the filter is fixed to 20 times the cycle time. The function block is provided with a control loop monitoring option. In the case of a control variable output of "100%" (full power), the temperature has to change in the direction of the set sign in K P. Otherwise, a timer will be activated displaying an error when the time has elapsed. The timer will be reset once the temperature moves into the correct direction. The values for the timer will be set as follows: In the case of an existing I part, a value of (2000 / K I ) + dead time will be used. If no I part is used, the value 2000 * sampling time will be preset only. The timer will be reset even if the control variable becomes smaller than "100%". It is important to specify the dead time (Tt) in the structure for the controller parameters as well if the controller parameters are specified by the input "Preset". In the case of a high K I value and a high dead time value, the monitoring process could be started. Due to this monitoring process, sensor errors (e. g. by being shifted) or controlling element errors can be detected. In addition, the function block also monitors the gradient of the actual value; however, this monitoring function becomes active only in the case of large deviations. These deviations can occur, for example, if the sensor displays an error code and if this error code is not recorded / evaluated by the user. The gradient is fixed to a value of 10 u/ms. A single deviation will be tolerated before an error is generated Using the Function Block The function block should be operated in a cyclical task. The function block automatically detects the task interval time (= cycle time) and adjusts the control algorithm accordingly. The controller works with the sampling time resulting from the task interval time multiplied with the input variable "ControlUpdateRate". If "ControlUpdateRate" = 1, the sampling time thus corresponds to the task interval time. The sampling time is used for the identification of the controlled

148 142/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" system as well as in the case of an activated controller. All other functions of the function block (read actual values, PWM output, manual control) use the task interval time. Thus, it is possible to separate the control / identification process from other functions of the function block (with regard to the time). This is especially important to separate the output of the control variable from the control / identification process with the help of PWM. The task interval time forms the basis for the pulse-width modulation (PWM), i. e. the task interval time is the smallest possible time slice which can be set to "ON" or "OFF" in the case of the pulse-width modulation. One period of the PWM is 20 times longer than the task interval time. Thus the control variable can be changed in steps of 5% between 0% and 100%. Example: The task interval time will be parameterized to 20 ms for the cyclical task. This means that a new value for the control variable can be transferred to the PWM every 400 ms. Thus, the possible activation or deactivation times for the PWM are: Fig.14-7: Control variable [%] Activation time [ms] Deactivation time [ms] Example for activation / deactivation times The task interval time and "ControlUpdateRate" always have to be selected depending on the controlling element and the controlled system. If the task interval times are too short, the controlling element will wear too quickly (for example, relay modules); if the task interval times / sampling times are too long, the accuracy of the control will be reduced. Furthermore, the sampling time will be monitored, i. e. if the sampling time exceeds / falls below a value of more than 20%, an error will be generated and the output "Error" is set to TRUE. Recommendations for Selecting the Task Interval Time The task interval time / cycle time should be set in a way so that the PWM does not cause any visible temperature changes within a PWM period of 20*task interval time. If, in the case of a control variable of 20%, the temperature of the controlled system strongly increases during the heating process and if the temperature is reduced during the deactivated state of the heating, this means that the task interval time is too long. This can be seen in the following figure where the upper curve displays the temperature curve and the lower curve displays the heating phases (TRUE). It is clearly visible that the controlled system is heated with every heating process and that the controlled system cools down while the heating is deactivated.

149 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 143/179 Function Block Temperature Controller "IL_TempControlType01" Recommendations for Selecting the Sampling Time Fig.14-8: Task interval time In contrast, it is also not recommended to choose a too short task interval time since the control variable is then subject to higher loads (e. g. the relay module has to perform a lot of switching processes). An appropriate task interval time has to be determined with the help of certain tests. First, the task interval time should be selected as described in the previous section. Then, the sampling time can be set to the desired value by using the input "ControlUpdateRate". The following recommendation applies to the sampling time: 10 ms for quick / dynamic controlled systems (time constant of the controlled system from 200 ms to 2 s), 100 ms for average controlled systems (time constant of the controlled system from 2 s to 20 s) and 1 s to 30 s for slow / static controlled systems (time constant of the controlled system from 20 s to 100 min). The sampling time should be approximately 20 to 200 times faster than the "dominating time constant" of the controlled system. The "dominating time constant" is approximately the time a controlled system requires to pass through 63% of the change of a jump. In principle, however, the sampling time can be freely selected by the user.

150 144/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" If the sampling time has been selected too short, the error "Time elapsed during identification (watchdog)" (Additional1 = 16#1605; Additional2 = 16#0009) may occur during the identification process. In this case, a longer sampling time has to be selected since the controlled system was not in steady state when the time monitoring process had expired. If the sampling time has been selected too long, the error "Identified controlled system parameters are invalid, self-identification of the controlled system failed" (Additional1 = 16#1603; Additional2 = 16#0007) may occur during the identification process. In this case, a shorter sampling time has to be selected since the intervals for measuring the behavior of the controlled system were too long Description of the Individual Functions, Examples With regard to the following application examples, the following variables have to be specified in the declaration part of the user's program for the configuration of the function block. Program: VAR fb_tempcontrol:il_tempcontroltype01; (* Instance of FB *) strcontrparam: IL_TEMPCONTROL_CONTR_PARAM; (* Structure containing control parameters *) strlimits: IL_TEMPCONTROL_LIMITS; (* Alarm limits / status limits *) ractualtemp:real; (* Actual temperature *) ractualpower:real; (* Control variable, analog *) bactualpower:bool; (* Control variable, digital (PWM) *) bautotunedone:bool; (* Identification state *) bsetpointreached:bool; (* Actual value reached setpoint value window *) berror:bool; (* Error output state *) istate:int; (* Value in state intervals *) END_VAR Simple Control With Specification of the Controller Parameters To make the description more simple, no errors will be described in the following examples. In the structure "strcontrparam", the function block will be parameterized with the desired controller parameters. In the case of a rising edge at the input "Preset", new controller parameters can also be parameterized during the control process. The command value ("Setpoint") can be preset and the actual value ("Feedback") has to be returned. The control variable can either be retrieved at the analog output ("ControlValueAnalog") or at the digital output ("ControlValuePWM"). Program: (* Setting the control parameters *) strcontrparam.kp := 1.5; strcontrparam.ki := 2; strcontrparam.kd := 0.6; strcontrparam.tt := T#1s; (* Starting module and applying control parameter at the same time*) fb_tempcontrol( Enable:=TRUE, Setpoint:=50, Feedback:=rActualTemp, Preset:=TRUE, ContrParam:=strContrParam, ControlValueAnalog=>rActualPower, ControlValuePWM=>bActualPower); Thus, the controller parameters will only be transferred once and the controller works with the specified values.

151 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 145/179 Function Block Temperature Controller "IL_TempControlType01" Simple Identification of a Controlled System With Subsequent Transition to a Control Process First, the function block will be set to the identification or AutoTune mode. After having successfully completed the identification, the control process will be started by generating a falling edge at the input "StartAutoTune". The calculated controller parameters are saved in the structure "strcontrparam" and are thus available to the user. Thus, these controller parameters can be saved in the retain area of the control by the user (see also the example "Retaining the controller parameters"). Another identification process is thus no longer required when starting the control process again but the simple control with parameter specification can be started immediately. With the optional input "Quickness", a slightly quicker setting process has been specified for the controller (quicker control but higher disposition for overshoots). The identification will be performed with a jump from 0% ("AutoTuneStartPower") to 10% ("AutoTuneFinishPower") output power. Program: CASE istate OF 1: (* Identification *) fb_tempcontrol ( Enable:=TRUE, StartAutoTune := TRUE Feedback:=rActualTemp, AutoTuneStartPower:= 0, AutoTuneFinishPower:= 10, Quickness:=2, ContrParam:=strContrParam, ControlValueAnalog=>rActualPower, ControlValuePWM=>bActualPower, AutoTuneDone=>bAutoTuneDone); IF (bautotunedone = TRUE) THEN istate := 2; END_IF 2: (* Application in control *) fb_tempcontrol( Enable:=TRUE, StartAutoTune := FALSE, Setpoint:=50, Feedback:=rActualTemp, ContrParam:=strContrParam, ControlValueAnalog=>rActualPower, ControlValuePWM=>bActualPower); Identification of the Controlled System in the Operating Point During a process control, another identification in the operating point may be desired. In the following, the corresponding procedure will be described on the basis of the previous example "Simple identification of a controlled system with subsequent transition to a control". By setting the input "AutoTuneStart", the identification process will be started; the initial and final parameters of the control variable parameters will be transferred to "AutoTuneStartPower" and "AutoTuneFinishPower". After a successful identification, the new controller parameters will be available for the user in the structure "strcontrparam". In the example, the operating range will be calculated on the basis of the actual value of the control variable (in %). The prerequisite is, of course, that the controlled system is in steady (stationary) state. In the example, the operating range has been selected from "control variable -10%" to "control variable +10%". The identification in the operating point starts with changing to state "3". Program: CASE istate OF 2: (* Control *) fb_tempcontrol( Enable:=TRUE, StartAutoTune := FALSE, Setpoint:=50, Feedback:=rActualTemp,

152 146/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" ContrParam:=strContrParam, ControlValueAnalog=>rActualPower); If (bident = TRUE) THEN istate := 3; End_IF; 3: (* Identification in operating point *) fb_tempcontrol( Enable:=TRUE, StartAutoTune := TRUE, AutoTuneStartPower:=rActualPower-10, AutoTuneFinishPower:=rActualPower+10, Feedback:=rActualTemp, ContrParam:=strContrParam, ControlValueAnalog=>rActualPower, AutoTuneDone=>bAutoTuneDone); IF (bautotunedone = TRUE) THEN istate := 2; END_IF Definition of a Start-up Ramp Definition of Alarm and Status Limits If a process prior to the actual temperature control requires the system to wait at a certain temperature for a certain time (start-up ramp), this function is available over the inputs "StartUpTemp" and "StartUpTime". First, the controller controls until the start-up temperature. If this is not achieved, the start-up time "StartUpTime" expires and the controller maintains a constant start-up temperature. After the start-up time "StartUpTime" has elapsed, the start-up ramp is completed and the controller shows its normal behavior. The start-up ramp will be performed once after each change from "Enable" to "TRUE". In the example, the controller controls to a temperature of "100", then it waits for 5 minutes and 30 seconds and finally it controls to the desired temperature of "150" (see fig "Using a command value gradient and a start-up ramp" on page 148). Program: fb_tempcontrol( Enable:=TRUE, Setpoint:=150, Feedback:=rActualTemp, Preset:=TRUE, StartUpTemp:=100, StartUpTime:=t#5m30s, ContrParam:=strContrParam, ControlValueAnalog=>rActualPower); Alarm and status limits can be set for process monitoring purposes. The structure "Limits" contains the values "UpperAlarm" and "LowerAlarm". When exceeding the alarm limits, an error will be generated. The monitoring function only becomes active if the current process temperature ranges between the values of "UpperAlarm" and "LowerAlarm" so that no error is generated during the start-up of the process. The structure "Limits" also contains the values "UpperAtSetPoint" and "Lower AtSetPoint". The output "SetPointReached" will be set once the condition ("Setpoint Limits.LowerAtSetPoint") actual value ("Setpoint + Limits.UpperAtSetPoint") has been fulfilled. Thus, it can be determined if the desired temperature has already been reached. Program: strlimits.upperalarm:=250; strlimits.loweralarm:=70; strlimits.upperatsetpoint:=20; strlimits.loweratsetpoint:=20; fb_tempcontrol( Enable:=TRUE, Setpoint:=150, Feedback:=rActualTemp,

153 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 147/179 Function Block Temperature Controller "IL_TempControlType01" Limits:=strLimits, ContrParam:=strContrParam, ControlValueAnalog=>rActualPower, SetPointReached=>bSetPointReached); Pausing the Control Process (PAUSE mode) Fig.14-9: Operation mode of the alarm and status limits Pausing the control process can be realized over the input "Pause". The control variable remains constant and the controller as well as all its values will be "frozen". After having reset the input "Pause", the control process will continue as usual. In the example, the temperature will be controlled to "150" in state "4". By switching to state 5, the control process will be "frozen" and no new control variables will be output. By returning to state "4", the control process will be continued as usual and new control variables will be output again. A jump may occur if the actual value has strongly changed in the meantime. Program: CASE istate OF 4: fb_tempcontrol( Enable:=TRUE, Pause:=FALSE, Setpoint:=150, Feedback:=rActualTemp, Preset:=TRUE, ContrParam:=strContrParam, Limits:=strLimits, ControlValueAnalog=>rActualPower); 5: fb_tempcontrol( Enable:=TRUE, Pause:=TRUE, Setpoint:=150, Feedback:=rActualTemp, Preset:=TRUE, ContrParam:=strContrParam, Limits:=strLimits, ControlValueAnalog=>rActualPower); Analog / Digital Control Variable Output The function block is provided with two control variable outputs: one analog output ("ControlValueAnalog") which displays REAL values between "0%" (no power) and "100%" (full power), and one digital output ("ControlValuePWM") displaying the BOOL values "FALSE" (no power) or "TRUE" (full power). The digital output can be used for pulsing the power in the case of relay modules. The pulsing process is performed with the help of a pulse-width modulation

154 148/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" whose cycle time is 20 times slower than the time of the cyclical task in which the function block is running. Thus, control variables with a resolution from 0% to 100% can be modulated in steps of 5%. The analog output can be used for an analog output or for monitoring the current control variable. Program: fb_tempcontrol( Enable:=TRUE, Pause:=FALSE, Setpoint:=150, Feedback:=rActualTemp, Preset:=TRUE, ContrParam:=strContrParam, Limits:=strLimits, ControlValueAnalog=>rActualPower ControlValuePWM=>bActualPower); Specification of a Command Value Gradient The function block provides the possibility to limit (to ramp) the increase of the command value. This reduces the overshoot and prevents the unit from damages. For each new specification of the input "SetPoint", the command value will be internally changed in the form of ramps (not jumps) until the desired command value has been reached. "SetPointGradient" will be specified in [u/ s]. In the example, the command temperature will be controlled to "150" with an increase of "0.5 per second". Program: fb_tempcontrol( Enable:=TRUE, Pause:=FALSE, Setpoint:=150, Setpointgradient:=0.5, Feedback:=rActualTemp, Preset:=TRUE, ContrParam:=strContrParam, Limits:=strLimits, ControlValueAnalog=>rActualPower); A ramping process with command value gradient and an additional start-up ramp would show the following development of command value and actual value. Here, a target temperature ("Setpoint:=200") of "200 C" has been controlled with a gradient ("Setpointgradient:=1") of "1 C/s". The start-up temperature ("StartUpTemp:=100") is "100 C" and the start-up time ("StartUpTime:=T#50s") is "50s". Fig.14-10: Using a command value gradient and a start-up ramp

155 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 149/179 Function Block Temperature Controller "IL_TempControlType01" Specification of a Manual Control Variable Retaining the Controller Parameters A manual control variable can be defined to control the temperature manually. At the same time, this variable represents the control variable at the output of the function block. A manual control variable may be required to record manual testing functions or to activate an emergency operating mode in the case of a sensor error. In the example, the function block will be manually controlled with a control variable of "50%". Program: fb_tempcontrol( Enable:=TRUE, Pause:=FALSE, OperatingMode:=TRUE, ManContrValue:=50, ContrParam:=strContrParam, Limits:=strLimits, ControlValueAnalog=>rActualPower); To ensure that the controller parameters are safely stored even in the case of a power failure, they can be saved in the retain area. By doing so, no identification process has to be performed when restarting the controller but the control process can be started immediately. For this purpose, the user has to create the structure "strcontrparam" as retain variables ("VAR RETAIN") which then contains the values of the individual controller parameters. At the same time, the user has to create a mechanism to differentiate at the initial start-up if an identification process has already been performed. Additional retain variables have to be created in the header. Program: VAR RETAIN strcontrparam : STRUCT_CONTR_PARAM; bidentification: BOOL := FALSE; END_VAR If (bidentification = FALSE) THEN fb_tempcontrol( Enable:=TRUE, StartAutoTune := TRUE, Feedback:=rActualTemp, Quickness:=2, ContrParam:=strContrParam, ControlValueAnalog=>rActualPower, ControlValuePWM=>bActualPower, AutoTuneDone=>bAutoTuneDone); IF (bautotunedone = TRUE) THEN bidentification:= TRUE; END_IF ELSE fb_tempcontrol( Enable:=TRUE, StartAutoTune := FALSE Preset:=TRUE, Setpoint:=150, Feedback:=rActualTemp, ContrParam:=strContrParam, Limits:=strLimits, ControlValueAnalog=>rActualPower); END_IF; In the above example, the values of the controller will be stored in the retain variables in each cycle. After a deactivation / power failure, the code checks with the help of the Boolean variable "bidentification" if there has already been an identification. If this is not the case, an identification process will be performed; otherwise, the controller can be restarted with the saved (old) parameters. A rising edge has to be present at the input "Preset".

156 150/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Block Temperature Controller "IL_TempControlType01" Troubleshooting With the Help of the Substitute Value Strategy By standard, the function block displays the control variable "0%" (no power) in the case of an error. This will be done for the safety of the system. If the user wants to use a control with a certain power, for example, to avoid a strong cool down of a system, it is recommended to use the substitute value strategy described in the following example. Errors can be checked in state "6" with "berror". If this condition is "TRUE", the function block will be reset ("Enable:=FALSE") and state "7" will be activated. In state "7", the function block will be restarted with a rising edge at the input "Enable" and operated in the manual mode (see "Specification of a Manual Control Variable" on page 149). In the example, a control variable of "50%" will be output. Further information concerning the error will be displayed at the outputs "ErrorID" and "ErrorIdent" which have, however, not been analyzed in this example. Program: CASE istate OF: 6: fb_tempcontrol( Enable:=TRUE, Setpoint:=50, Feedback:=rActualTemp, Preset:=TRUE, ContrParam:=strContrParam, Limits:=strLimits, ControlValueAnalog=>rActualPower, Error=>bError); IF (berror = TRUE) THEN fb_tempcontrol( Enable:=FALSE, ContrParam:=strContrParam, Limits:=strLimits); istate:=7; END_IF 7: fb_tempcontrol( Enable:=TRUE, Pause:=FALSE, OperatingMode:=TRUE, ManContrValue:=50, ContrParam:=strContrParam, Limits:=strLimits, ControlValueAnalog=>rActualPower); It must be stated in addition that the control variable output in the above example will be set to 0 for one cycle (if the error has been detected and if Enable:=FALSE). In state 7, the manual value will then be used as control variable.

157 Library Description Rexroth IndraMotion MLC 04VRS Electric Drives Bosch Rexroth AG 151/179 Function Blocks and Functions for Maintaining "Cyclical Data Channels" 15 Function Blocks and Functions for Maintaining "Cyclical Data Channels" 15.1 Introduction and Overview With the SERCOS interface, it is possible to apply freely configurable, cyclical data. These data will be cyclically transferred in each SERCOS cycle both by the control to the drives and from the drives to the control. Four parameters are available in read and write direction for each axis. In addition, four bits can be read or written. The cyclical data are configured in the parameterization mode (PM, SERCOS phase 2) and cannot be changed in the operation mode (BB, SERCOS phase 4). In the parameterization mode (PM, SERCOS phase 2), a cyclical data channel for a parameter to be transferred can be requested with the help of the function block MB_AllocCyclicDataParameter. If the parameter has already been applied in the cyclical data channel, the configuration will not be changed. Otherwise, a free data channel will be selected and the respective parameter will be applied. If the configuration is changed, a parameter which has been cyclically applied can also be released with chapter 15.6 "MB_FreeCyclicParameter" on page 155. Thus, this channel is available for a new configuration. The channel must only be explicitly released if the data channels are newly configured during runtime from the PLC. The configuration can also be performed in IndraWorks over AxisData or the cyclical actual and command value dialog. A configuration made with Indra Works will be used automatically. If some parameters are configured over IndraWorks and if other parameters are requested at a later date during runtime with chapter 15.5 "MB_AllocCyclicParameter" on page 154, the new parameters will be distributed to free channels. In the operational mode (BB), the function block chapter 15.7 "MB_GetCyclic ParameterHandle" on page 157 browses for a cyclically applied parameter in the configuration of one axis and writes all required information into a handle. With this handle, the parameter can be read or written to in each SERCOS cycle with chapter 15.8 "MB_ReadCyclicParameter" on page 158 and chapter "MB_WriteCyclicParameter" on page 159. The functions chapter 15.9 "MB_ReadCyclicRealParameter" on page 159 and chapter "MB_Write CyclicRealParameter" on page 160 are available for cyclical parameters with decimal places. Errors occurred during the access to the cyclical data channels can be retrieved over the function chapter "MB_GetLastCyclicParameterError" on page 160. The cyclically applied parameters are also available in the AxisData structure of the respective axis. The actual values are specified in UserActualDataX whereas the command values are described over UserCmdDataX. However, the correct data type has to be described according to the respectively applied parameter. This does not have to be done when using the function blocks MB_ReadCyclicParameter and MB_WriteCyclicParameter.

158 152/179 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC 04VRS Library Description Function Blocks and Functions for Maintaining "Cyclical Data Channels" Fig.15-1: Access to cyclical data with the help of the CyclicParameter function blocks and functions 15.2 MB_CYCLIC_PARAM_REF Type Definitions The following definition describes data types which are used in the function block chapter 15.7 "MB_GetCyclicParameterHandle" on page 157. The type definitions are contained in the library. The structure "MB_CYCLIC_PARAM_REF" may be read but must not be written to. Changing the content can lead to malfunctions. The structure can change in higher versions. The structure should only be read for debugging purposes. The structure "MB_CYCLIC_PARAM_REF" looks as follows: Structural element Type Description ParameterNumber DINT FP number of the parameter AxisNo OBJECTS Logical number of the axis ParamType MB_CYCLIC_TYPES Data type of the parameter Bit INT Internal bit number of the parameter AccessChannel MB_CYCLIC_CHANNELS Data channel in which the parameter was found ParamAdr POINTER TO SM_TYPES Pointer to the cyclical parameter BitParamAdr POINTER TO WORD Pointer to the cyclical bit parameter