2013 11 21 Simapress (Presa)

Software package to automate a conventional flywheel press
Simatic Simapress Application description September 2013
Applications & Tools

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Siemens Industry Online Support This article is taken from the Siemens Industry Online Support. The following link takes you directly to the download page of this document: http://support.automation.siemens.com/WW/view/en/82605334 Caution The functions and solutions described in this article confine themselves to the realization of the automation task predominantly. Please take into account furthermore that corresponding protective measures have to be taken up in the context of Industrial Security when connecting your equipment to other parts of the plant, the enterprise network or the Internet. Further information can be found under the ItemID 50203404. http://support.automation.siemens.com/WW/view/en/50203404
Copyright Siemens AG 2013 All rights reserved
Simatic Simapress V2.0, Entry-ID: 82605334
Basic information Components of the standard application Installation and commissioning
1 2 3 4 5 6 7 8
Program environment
SIMATIC Simapress
Software package to automate a conventional flywheel press
Program and function description Description of the graphic interface
Scope of delivery
Contact persons
Simatic Simapress 2.0, Entry-ID: 82605334
Warranty and liability
Warranty and liability

Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These application examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these application examples and other Siemens publications e.g. Catalogs the contents of the other documents have priority.
We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act (Produkthaftungsgesetz), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract (wesentliche Vertragspflichten). The damages for a breach of a substantial contractual oblig ation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of Siemens Industry Sector.
Preface
Preface
Aim of the application This application contains the core functions to automate mechanical presses. The user can integrate these functions into his project with low associated costs. Key contents of this application This application deals with the following key points: Demarcation It is assumed that the reader has a basic knowledge about Simatic, Sinamics Starter and WinCC Flexible in order to understand this application example.
Main drive control of a mechanical universal press Braking angle calculation Stroke counter Cam controller Die protection Tonnage monitoring
1 Basic information
Table of contents
Warranty and liability ................................................................................................... 4 Preface .......................................................................................................................... 5 Table of contents ......................................................................................................... 6 1 Basic information .............................................................................................. 9 1.1 1.1.1 1.1.2 1.1.3 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8
Prerequisites ........................................................................................ 9 Target group ......................................................................................... 9 Previous knowledge ............................................................................. 9 Technical environment ......................................................................... 9 Design of a press solution .................................................................. 10 Mechanical universal press ................................................................ 10 Stroke height adjustment.................................................................... 12 Ram adjustment ................................................................................. 14 Stroke counter .................................................................................... 15 Cam controller .................................................................................... 15 Die protection ..................................................................................... 16 Tonnage monitoring ........................................................................... 16 Tool data management ...................................................................... 17
Components of the standard application...................................................... 18 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.5.9 2.5.10 2.6 2.7 2.8 Controlling the main drive and coupling for mechanical universal presses ............................................................................... 18 Operating modes ................................................................................ 18 Minimum stroke rate ........................................................................... 18 Braking angle calculation ................................................................... 18 Rotation monitoring ............................................................................ 19 Stroke height adjustment.................................................................... 19 Stroke counter .................................................................................... 19 Cam controller .................................................................................... 20 Position-based cam ............................................................................ 20 Time-based cam ................................................................................. 21 Counter output cams .......................................................................... 21 Dynamic offset .................................................................................... 22 Die protection ..................................................................................... 22 Monitoring type 1: Continuous signal from the sensor ....................... 22 Monitoring type 2: Sensor before the output cam .............................. 23 Monitoring type 3: Counting the sensor edges .................................. 24 Monitoring type 4: Sensor before the output cam with counter function ............................................................................................... 25 Monitoring type 5: Sensor above output cam..................................... 26 Monitoring type 6: Sensor above the output cam with counter function ............................................................................................... 27 Monitoring type 7: Counting the sensor pulses .................................. 28 Monitoring type 8: Output cam above sensor .................................... 29 Monitoring type 9: Static 0 sensor signal ........................................... 30 Monitoring type 10: Sensor within a number of strokes ..................... 30 Tonnage monitoring ........................................................................... 31 Envelope monitoring ........................................................................... 33 Tool data management ...................................................................... 33
Installation and commissioning ..................................................................... 34 3.1 3.1.1 3.1.2 For your safety ................................................................................... 34 Markings used for safety notes .......................................................... 34 Responsibilities of the operating personnel ....................................... 35
1 Basic information
3.2 3.3 3.4 3.5 4
Installing the hardware and software ................................................. 36 Additional preparations....................................................................... 39 Testing the application ....................................................................... 44 Application with brake/coupling combination ..................................... 46
Program environment ..................................................................................... 51 4.1 4.2 4.3 4.4 4.5 Main drive control ............................................................................... 51 Counters ............................................................................................. 52 Output cams ....................................................................................... 52 Die protection ..................................................................................... 53 Tonnage monitoring ........................................................................... 53
Program and function description ................................................................. 55 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.1.9 5.1.10 5.1.11 5.1.12 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 5.3.8 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.5 5.5.1 5.5.2 5.5.3 5.5.4 Main drive control ............................................................................... 55 Task / functionality of the main drive control ...................................... 55 Call environment and data flow .......................................................... 55 Data blocks and user-defined data types ........................................... 56 Function elements and integration ..................................................... 59 Function block FB10: FB_clutch_control ............................................ 60 Function block FB11: FB_maindrive_control ..................................... 62 Function block FB12: FB_absolute_justage_s120 ............................. 65 Function block FB13: FB_encoder_values ........................................ 66 Function block FB15: FB_calc_brake_angle ..................................... 67 Function block FB19: FB_data_transfer_drive ................................... 68 Function FC15: FC_maindrive_cmd_values ...................................... 69 Function FC18: FC_maindrive_startup .............................................. 70 Counters ............................................................................................. 71 Task and functionality of the counters ................................................ 71 Call environment and data flow .......................................................... 71 Data blocks and user-defined data types ........................................... 71 Function elements and integration ..................................................... 72 Function block FB20: FB_counter ...................................................... 73 Function block FB29: FB_data_transfer_counter .............................. 74 Output cams ....................................................................................... 75 Task / functionality of the output cams ............................................... 75 Call environment and data flow .......................................................... 75 Data blocks and user-defined data types ........................................... 75 Function elements and integration ..................................................... 76 Function block FB30: FB_cam_FM352 .............................................. 77 Function block FB31: CAM_CTRL ..................................................... 78 Function block FB32: CAM_DIAG ...................................................... 78 Function block FB39: FB_data_transfer_cams .................................. 79 Die protection ..................................................................................... 80 Task / functionality of the die protection ............................................. 80 Call environment and data flow .......................................................... 80 Data blocks and user-defined data types ........................................... 80 Function block FB40: FB_dieprotection ............................................. 84 Function block FB42: FB_dieprotect_trace ........................................ 86 Function block FB49: FB_data_transfer_dieprot ............................... 87 Function elements and integration ..................................................... 88 Function block FB65: FB_dieprotection_Ack ..................................... 89 Function block FB801: FB_dieprotect_simulation .............................. 90 Tonnage monitoring ........................................................................... 91 Task / functionality of the tonnage monitoring.................................... 91 Call environment and data flow .......................................................... 92 Data blocks and user-defined data types ........................................... 93 Function elements and integration ..................................................... 98
1 Basic information
5.5.5 5.5.6 5.5.7 5.5.8 5.5.9 5.5.10 5.5.11 5.6 6
Function block FB50: FB_tonnage_mon ............................................ 99 Function block FB51: FB_tonnage_cyclic ........................................ 101 Function block FB54: FB_tonnage_curve ........................................ 102 Function block FB55: FB_tonnage_envelope .................................. 103 Function block FB56: FB_tonnage_env_mon .................................. 105 Function block FB57: FB_tonnage_sim ........................................... 107 Function block FB59: FB_data_transfer_tonnage ........................... 109 Additional functions and data blocks ................................................ 110
Description of the graphic interface ............................................................ 123 6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9 6.4.10 6.4.11 6.4.12 6.4.13 6.4.14 6.4.15 Description of the operator buttons .................................................. 123 Machine data .................................................................................... 124 Task / functionality of the machine data ........................................... 124 List of screens .................................................................................. 124 Figure 400: 400_mada_general ....................................................... 125 Figure 410: 410_mada_maindrive ................................................... 126 Figure 415: 415_mada_strokeheight ............................................... 127 Figure 450: 450_mada_tonnage ...................................................... 128 Figure 451: 451_mada_tonnage_sensors ....................................... 129 Die data ............................................................................................ 130 Task / functionality of the die data .................................................... 130 List of screens .................................................................................. 130 Figure 300: 300_die_data_general .................................................. 131 Figure 310: 310_die_data_maindrive ............................................... 132 Figure 330: 330_die_data_cams ...................................................... 133 Figure 340: 340_die_data_dieprotection .......................................... 134 Figure 350: 350_die_data_tonnage ................................................. 135 Figure 700: 700_die_change ........................................................... 136 Operation .......................................................................................... 137 Task / functionality in operation ........................................................ 137 List of screens .................................................................................. 137 Figure 210: 210_operate_maindrive ................................................ 138 Figure 220: 220_operate_counter1_5 .............................................. 139 Figure 221: 221_operate_counter6_9 .............................................. 140 Figure 230: 230_operate_cams ....................................................... 141 Figure 240: 240_operate_dieprotection ........................................... 142 Figure 245: 245_operate_dieprotect_trend ...................................... 143 Figure 248: 248_operate_diag_dieprotect ....................................... 144 Figure 250: 250_operate_tonnage_values ...................................... 145 Figure 251: 251_operate_tonnage_envelope .................................. 146 Figure 255: 255_operate_tonnage_trend......................................... 147 Fig. 256-259: 257_operate_tonnage_trend_2 ................................. 148 Figure 260: 260_operate_diag_tonnage .......................................... 149 Screens 810 - 817: 815_operate_dieprotect_trend_6_big ............... 150
7 8 9
Scope of delivery ........................................................................................... 151 Contact persons ............................................................................................ 151 History............................................................................................................. 151
1 Basic information
1
1.1
1.1.1
Basic information
Prerequisites
Target group
The standard application is intended for all programmers and users that wish to implement a mechanical excentric press based on SIMATIC.
1.1.2
Previous knowledge
You should understand how to use Simatic Manager when applying this application. It is assumed that the reader has a basic knowledge about Sinamics Starter and WinCC Flexible. This documentation does not provide any introduction to these topics, and is restricted to the instructions for using this standard application.
1.1.3
Technical environment
These standard applications can only be used unchanged in conjunction with Simatic and SINAMICS demonstration case.
1 Basic information
1.2
1.2.1
Design of a press solution

Mechanical universal press
Mechanical universal press Conventional mechanical universal presses normally operate in the automatic continuous stroke mode. The press main drive (DC or AC motor) is coupled with a flywheel to the excentric using a clutch/brake combination and to the press ram using a connecting rod. To keep the speed reduction as small as possible during the forming process, the required energy is stored as kinetic energy in a flywheel via the main drive.
Fig. 1-1: Mechanical universal press
Ram angular position for actual position/stroke rate
Excentric shaft
Brake/coupling combination
Flywheel
SSI encoder
Belt drive Rotary motion Ram Linear motion Tool Main drive Speed setpoint
Main drive and coupling control
Minimum stroke rate for mechanical universal presses When coupling-in and when forming, for mechanical universal presses, the flywheel and motor speeds drop. This is because the mass of the ram must be accelerated, and when forming, part of the kinetic energy of the flywheel is converted into forming energy. The press comes to a standstill if the flywheel does not have enough kinetic energy. This is the reason that there is a minimum stroke rate. The press can only be coupled-in if the motor has the appropriate speed for the minimum stroke rate.
10
1 Basic information
Fig. 1-2: minimum stroke rate
Motor speed Production stroke rate Ram stroke rate minimum stroke rate Coupling the ram Time
Braking angle calculation for mechanical universal presses If, for mechanical universal presses, the coupling is opened, and therefore the brake closed, the ram continues to move as a result of its kinetic energy. In order to be able to realize a precise stop at TDC, the stopping distance for shutdown must be calculated, i.e. the braking angle. This is possible using the following formula: B=a*H+b*H+c H: Setpoint or actual stroke rate a, b, c: machine-specific values (moments of inertia, friction losses, brake/coupling data, ...)
Fig. 1-3: Braking angle calculation
Ram position
0 Braking angle 0
90
180
270
360
angle
Stop command
90
180
270
360
Brake application point
11
1 Basic information
Rotation monitoring Using the rotation monitoring, the mechanical connection between the main drive and ram is monitored. In this case, a check is made as to whether the ram moves after the press safety valve has been closed, and whether the ram comes to a standstill after the press safety valve has been shut down.
1.2.2
Stroke height adjustment

Different dies require different stroke heights. When the stroke height is adjusted, the press opening angle, the velocity with which the upper die impacts the lower die and the forming velocity change.
Smallest stroke During a press stroke the excentric bushing is rigidly connected with the excentric. There is a loose connection between the excentric and the connecting rod. The excentric rotates around its own axis, and causes the connecting rod to move up and down as a result of the excentric arrangement.
Fig. 1-4: Stroke height adjustment shortest stroke
d) b) c)
a)
a) Connecting rod c) Excentric bushing
b) Excentric d) Excentric
12
1 Basic information
Stroke height adjustment When adjusting the stroke height, the rigid connection between the excentric bushing and the excentric is released. The connecting rod and the excentric are connected with one another. If the excentric is then rotated, the excentric and excentric bushing have a different position with respect to one another. This offset then changes the stroke height.
Fig. 1-5: Stroke height adjustment
Locking mechanism
Fig. 1-6: Stroke height adjustment side view

The stroke height depends on the amount of excentricity between the excentric bushing and the excentric. Longest stroke
Fig. 1-7: Stroke height adjustment longest stroke
13
1 Basic information
TDC correction If the stroke height is adjusted, then as a consequence, the TDC position changes referred to the 0 position of the absolute encoder of the press.
Fig. 1-8: Stroke height adjustment TDC correction
TDC offset Locking mechanism
1.2.3
Ram adjustment
The ram is adjusted to change the insertion depth of the upper die into the lower die. The specified ram length depends on the die height. This allows the effects of temperature and die wear to be compensated. The ram can be adjusted, e.g. using a thread between the ram and connecting rod. To do this, the ram can be moved in and out using motors.
Fig. 1-9: Ram adjustment
Parallel offset
14
1 Basic information
1.2.4
Stroke counter
The different stroke rates are counted. The press is frequently equipped with a machine counter, which counts all of the press strokes since it was commissioned. Further, there are counters for strokes per die and pressed parts. The TDC stop after a certain number of strokes can also be set, for example, if a certain number of parts are to be pressed, or if maintenance work has to be carried out after a certain number of strokes.
Fig. 1-10: Stroke counter
2185 strokes
112 strokes
224 parts
1.2.5
Cam controller
Digital signals are output depending on the crank angle of the press ram. These are used to control various machine functions, for example, feed or lubrication systems.
15
1 Basic information
1.2.6
Die protection
The die protection allows the automated press and its dies to be protected in operation against damage as a result of incorrect operation. To achieve this, signal transmitters, for example mechanical limit switches, inductive proximity switches and light barriers are installed in the dies and at the press. By comparing these input signals with the associated query signals (output cams), press subfunctions can be checked, for example, feed, ejector or end of band.
Fig. 1-11: Die protection
Encoder for ram position
Response, immediate stop or TDC stop
Die protection
Digital input signals from sensors Monitoring signals from sensors and transmitters.
1.2.7
Tonnage monitoring
Protective function The tonnage monitoring is a function that is frequently used to protect expensive press dies. To achieve this, measuring sensors are installed in the press columns or in the press die. These continually determine the forces that occur during a press stroke.
16
1 Basic information
Determining measured quantities Data quantities, such as tonnage in the press columns or pressure in the die, are detected using suitable sensors and conditioned for further processing by the connected tonnage monitoring function. As these sensors generally only supply very low analog measured values, they are predominantly transformed into a measured value range (e.g. 0 10V) using amplifier units provided by the sensor manufacturer. Peak tonnage values are only briefly available for high-speed presses. A charge amplifier with peak value memory should be used to acquire these peak values.
Fig. 1-12: Tonnage monitoring
Response, immediate stop or TDC stop
Tonnage monitoring
Analog input signals from sensors Monitoring analog input signals.
1.2.8
Tool data management

The data are saved in the die data management, which differ depending on the die being used. For example, this can involve maximum stroke rates, data for the cam controller, the die protection function or the tonnage monitoring. The die data management should not be confused with the die protection.
17
2 Components of the standard application
2
2.1
2.1.1
Components of the standard application

Controlling the main drive and coupling for mechanical universal presses
Operating modes
The following operating modes are implemented in the standard application "Simapress":
Setup The jog mode is used when setting up. As long as the input for jogging is available, the coupling is closed; the coupling is opened for a falling signal edge. It is possible to select as to whether the press should be stopped at TDC, or whether it should be operated through TDC in the jog mode. Single stroke
In the single-stroke mode, a complete stroke is executed after the press is started. The press then remains stationary at TDC. Using the immediate stop command, the press can also be stopped outside TDC. Continuous stroke In the continuous stroke operating mode, after starting, the press can be stopped using the TDC stop or immediate stop signals. Positioning In the positioning mode, the ram is brought to the specified setpoint position. This operating mode is especially employed for the stroke height adjustment. The stroke height adjustment process is not implemented in the standard application, and must be manually programmed by the user. The motor encoder of the main drive or an external encoder can be used for positioning. Backward The backward operating mode is also a jog mode. This operating mode is especially selected, if after an error-related stop it is not permissible to pass through BDC or the overload protection has tripped. When selecting this operating mode, the flywheel is first braked before it accelerates in the other direction.
2.1.2
Minimum stroke rate

The minimum stroke rate is saved in the project as die data. If this stroke rate is not reached, the block that controls the coupling prevents the ram from being coupled in.
2.1.3
Braking angle calculation

The braking angle calculation is implemented in the standard application. In this case, when commissioning the press, three test strokes must be executed with different stroke rates. The parameters for the braking angle calculation are calculated
18
with the values for the strokes (stroke rate and braking angle). After this, cyclic calculation is possible, depending on the stroke rates.
2.1.4
Rotation monitoring
Rotation monitoring is implemented using timers. You can set the time after which the ram angle should change after starting the press, and the time after which a change is no longer permitted after the press has stopped.
2.2
Stroke height adjustment

The stroke height adjustment is taken into account in "Simapress" in so much that for the appropriate functions, the TDC correction is calculated in. To achieve this, a stroke height table is saved for the particular press as machine data; this stroke height table has the following data: Adjustment position for positioning for the stroke height adjustment TDC correction Maximum stroke rate for the particular stroke height
The stroke height adjustment is implemented using positioning commands. The user should program a sequence chain for this purpose.
2.3
Stroke counter
A maximum of 10 counters can be configured. The counters can count up or count down. The actual count values are kept even after the control system has been switched-off and switched-on again. If the counter is set to count up, and if the setting value for the counter is 0, then the counter can count up to a maximum value of 2147483647.
19
2.4
Cam controller
The following output cam types are available for "Simapress":
2.4.1
Position-based cam
The switch-on area of the output cam is defined from the start position to the end position in a positive counting direction, i.e. within a range between the start position and the end position.
Fig. 2-1: Cam controller position-based output cam
Ram position 0 Output cam 1 phistart phiend 180 360 180 360 180 angle
Output cam 2 phistart phiend
20
2.4.2
Time-based cam
A starting angle is defined for the output cam and a time as to how long the output cams should remain activated. If the starting position is overrun again while switched on, the time-based cam is not switched on again.
Fig. 2-2: Cam controller time-based output cam
Ram position 0 Output cam 1 phistart ton 180 360 180 360 180 angle
Output cam 2 phistart 2.4.3 Counter output cams

For a counter output cam, it can be specified whether the output cam is to be output every time it switches or every nth time it switches. Counter cams can be configured for position-based and time-based output cams. It is possible to define up to two counter output cams on the FM352.
Fig. 2-3: Cam controller counter output cam
ton
Ram position 0 Output cam 1 phistart phiend suppressed 180 360 180 360 180 angle
Output cam 2 phistart ton suppressed
21
2.4.4
Dynamic offset
Both position-based as well as time-based output cams can be offset by a definable time.
2.5
Die protection
The monitoring types that are implemented in "Simapress" are subsequently explained.
2.5.1
Monitoring type 1: Continuous signal from the sensor

The sensor signal must always be available for disturbance-free operation. This monitoring is not dependent on an output cam.
Signal trend with fault examples

Fig. 2-4: Die protection function monitoring type 1 fault
1 0
Sensor
Output cams
1 0
Output cam status irrelevant
Error
1 0
a)
a) The fault is set for a falling edge of the sensor signal. Fault-free signal trend
Fig. 2-5: Die protection function monitoring type 1 fault-free
1 0
Sensor Output cams
1 0
22
2.5.2
Monitoring type 2: Sensor before the output cam

For a rising edge of the output cam, the sensor signal must have been registered at least once. It is permissible that the sensor signal is still available at the start of the interrogation. Between the output cam signals (falling edge to rising edge), the sensor signal must have made at least one signal transition from LOW to HIGH. While the output cam is being interrogated, it is not permissible that the sensor signal has a rising edge; for a falling edge of the output cam signal, the sensor signal must be LOW.

Sensor Output cams
1 0
1 0
Error
1 0
a)
1 0
b)
Sensor Output cams
1 0
Error
1 0
c)
d)
a) Rising edge of the output cam without saved sensor edge b) No rising sensor edge between the falling and rising edge of the output cam c) Rising sensor edge while the output cam has a high signal d) Sensor still available for a falling edge of the output cam Fault-free signal trend
1 0
Sensor Output cams
1 0
23
2.5.3
Monitoring type 3: Counting the sensor edges

The sensor signal changes are counted with the falling output cam edge; this means the rising edges of a sensor pulse with a minimum duration of twice the sampling time. When the output cam signal rises, the number of sensor pulses counted in a period are compared with the appropriate setpoint input (value range: 1 to 255). An error message is output if there is no match, or if the sensor signal is still available when the output cam edge changes. The counted pulses are already detected before the enable; however, the monitoring is only active with the enable. When the output cam signal edge falls, the counter memory is always cleared and the counter started.

1 0
Sensor Output cams

1 0
Error
1 0
a)
b)
c)
a) Sensor signal still available for a positive edge of the output cam b) Too few sensor edges counted between the negative and positive edges of the output cam c) Positive sensor edge while the output cam has a high signal Fault-free signal trend
1 0
Sensor Output cams
1 0
24
2.5.4
Monitoring type 4: Sensor before the output cam with counter function
The sensor signal changes are counted with the falling output cam edge; this means the rising edges of a sensor pulse with a minimum duration of twice the sampling time. When the output cam signal rises, the number of sensor pulses is compared with the appropriate setpoint input (value range: 1 to 255). An error message is output if there is no match. When the output cam signal transitions from LOW to HIGH, the sensor signal must still be available; at the start of a new period, for a falling output cam edge, the sensor must have a LOW signal so that an error message is not output. The counted pulses are already detected before the enable; however, the monitoring is only active with the enable. When the output cam signal edge falls, the counter memory is always cleared and the counter started.

Sensor
1 0
Output cams
1 0
Error
1 0
a)
1 0
b)
Sensor Output cams
1 0
Error
1 0
c)
a) Sensor signal 0 for a rising edge of the output cam b) Too few edges since the falling edge of the output cam c) Rising sensor edge while the output cam has a high signal d) Sensor signal still 1 for a falling edge of the output cam Fault-free signal trend
1 0
d)
Sensor Output cams
1 0
25
2.5.5
Monitoring type 5: Sensor above output cam

As long as an output cam signal is registered, then also the sensor signal must be available; essentially, the output cam must be located below the sensor. Between the output cam end (LOW signal) and a new output cam start (HIGH signal), the sensor signal must have assumed the LOW state at least once. However, before the interrogation, it is permissible that the sensor signal changes several times.

Sensor Output cams
1 0
1 0
Error
1 0
a)
b)
c)
a) Sensor signal 0 for a rising edge of the output cam b) No sensor signal change between the falling and rising edge of the output cam c) Falling sensor signal edge while the output cam has a high signal Fault-free signal trend
1 0
Sensor Output cams
1 0
26
2.5.6
Monitoring type 6: Sensor above the output cam with counter function
The sensor signal changes are counted with the falling output cam edge; this means the rising edges of a sensor pulse with a minimum duration of twice the sampling time. When the output cam signal rises, the number of sensor pulses is compared with the appropriate setpoint input (value range: 1 to 255). An error message is output if there is no match. When the output cam signal transitions from LOW to HIGH, the sensor signal must still be available; at the start of a new period, for a falling output cam edge, the sensor must still have a HIGH signal so that an error message is not output. The counted pulses are already detected before the enable; however, the monitoring is only active with the enable. When the output cam signal edge falls, the counter memory is always cleared and the counter started.

1 0
Sensor Output cams
1 0
Error
1 0
a)
b)
c)
a) Sensor signal 0 for a rising edge of the output cam b) No sensor signal change or too few sensor edges between the falling and rising edge of the output cam c) Falling sensor signal edge while the output cam has a high signal Fault-free signal trend
1 0
Sensor Output cams
1 0
27
2.5.7
Monitoring type 7: Counting the sensor pulses

The sensor signal changes are counted with a falling output cam edge; this means the rising edges at the sensor input. When the next output cam signal rises, the number of counted sensor pulses is compared with the appropriate setpoint input (value range: 1 to 255). As a minimum, the number of counted sensor pulses must correspond to the setpoint input, otherwise an error message is output. The counted pulses are already detected before the enable; however, the monitoring is only active with the enable. When the output cam signal edge falls, the counter memory is always cleared and the counter started.

1 0
Sensor Output cams
Status irrelevant
1 0
Error
1 0
a)
a) Too few sensor edges Fault-free signal trend
1 0
Sensor Output cams
1 0
28
2.5.8
Monitoring type 8: Output cam above sensor

When the sensor has a high signal, then the output cam must also have a high signal. The sensor must have had at least one high signal between rising and falling edges of the output cam.

1 0
Sensor Output cams
1 0
Error
1 0
a)
a) Falling edge of the output cam if sensor 1
b)
c)
b) Falling edge of the output cam and sensor was not 1 between rising and falling edge c) Rising edge sensor and output 0 Fault-free signal trend
1 0
Sensor Output cams
1 0
29
2.5.9
Monitoring type 9: Static 0 sensor signal

For disturbance-free operation it is not permissible that the sensor signal is available. This monitoring is not dependent on an output cam.

1 0
Sensor Output cams
1 0
Error
1 0
a)
b) The fault is set for a rising edge of the sensor signal. Fault-free signal trend

1 0
Sensor Output cams
1 0
2.5.10
Monitoring type 10: Sensor within a number of strokes

Within a specific number of strokes, the sensor signal must have occurred at least once. Stroke counting is restarted with each falling sensor edge.
30
2.6
Evaluating
Tonnage monitoring
The tonnages that occur are monitored in a defined measuring window. The monitoring responds when defined limit values are violated. The limit values are defined using the machine and/or die data. Frequently, dies are not designed for the maximum possible tonnages. In order to facilitate optimum die protection, the setup technician must determine the monitoring limits valid for the particular die; these limits are then saved as die data. Generally, when a limit value is violated, an immediate stop or TDC stop is initiated (for "Minimum force not reached" only TDC stop).
Calibrating measured value sensors Generally, the relationship between the measured analog value in mV or mA and the corresponding tonnage value in kN is not linear. The values are either defined by a specified characteristic from the sensor manufacturer, or are determined directly at the press. The sensor characteristics are saved, linearized in the control. This means that voltage-orientated evaluation electronics can operate with units generally used in practice. For this purpose, the characteristic is defined by the coordinate zero point together with 2 interpolation points via machine data, and therefore approximately simulated.
Fig. 2-22: Tonnage monitoring - sensor characteristics
V
10 V voltage_2
voltage_1
F
force_1 force_2 max_force
31
Monitoring functions A maximum of 4 sensors can be monitored in the following fashion: Monitoring the maximum die force up to an alarm for each sensor Monitoring the maximum die force up to an error reaction for each sensor Monitoring the minimum die force for each sensor Monitoring the maximum die force up to an alarm of the sensor sums Monitoring the summed forces between the sensors Monitoring the differential forces between the sensors Dynamically determining the monitoring window using mean (average) and percentage values Recording the tonnage data and determining the mean values over several strokes Recording the tonnage trend
32
2.7
Envelope monitoring
The tonnages that occur can be monitored using envelope curves. To do this, an average tonnage trend is calculated from a number of freely selectable strokes. By specifying offset values for the press force and the angle, an upper and a lower envelope curve are generated. An envelope curve can be individually calculated for each of the four possible tonnage sensors. In the die data, you can select the number of envelope curve violations that can be tolerated until an alarm or an error reaction is output. This number can be individually configured for each of the 4 selectable sensors. For the parameterizable error reaction, either an TDC stop or immediate stop can be selected.
Fig. 2-23: HMI view envelope curves
2.8
Tool data management

In the standard application "Simapress", die data management is realized via the HMI. There is a recipe data management function in WinCC flexible; data for the individual dies can be saved here. If a die is called, then the appropriate data is checked and the data is transferred in the Simatic data blocks.
33
3 Installation and commissioning
3
3.1
3.1.1
Installation and commissioning

For your safety
Markings used for safety notes
Pictogram, signal word and text All safety information contained in this documentation is identified by a text graphic - comprising a pictogram and a signal word with an explanatory text. The combination of pictogram and signal word permits clearly differentiated information levels based on the degree of danger. Safety information precedes the information about activities to be carried out. Levels For the safety notes, there are five levels. They are marked using the same pictogram. They differ by the signal word used.
DANGER indicates that death or severe personal injury will result if proper precautions are not taken. DANGER
WARNING indicates that death or severe personal injury may result if proper precautions are not taken.
WARNING
CAUTION with a warning triangle indicates that minor injuries may result if proper precautions are not taken.
CAUTION
CAUTION
CAUTION without a safety alert symbol, indicates that property damage could result if proper precautions are not taken.
NOTICE
NOTICE indicates that an undesirable result or state may occur if the corresponding instructions are not observed.
34
3.1.2
Responsibilities of the operating personnel
Correct usage The correct use of the application components exclusively comprises the open-loop and closed-loop control of test set-ups that were adapted to the performance of the application components. In order that the application functions perfectly, the required SIMOTION standard components as well as the necessary hardware and software components must have been installed. The operator may only make changes to the application components after prior written agreement from the suppliers.
Improper use The following are considered to constitute improper use (misuse):
Inadmissible loading of the application components All forms of use which deviate from or exceed the above-mentioned proper use Failure to observe safety information Failure to immediately rectify malfunctions that could impair safety All forms of manipulation of devices which serve to ensure the proper functioning, unrestricted use, or active or passive safety of the equipment The recommended hardware and software components are not used Operation of the application components if they are not in perfect technical condition as well as failure to operate them safely while bearing the inherent risks in mind and complying with all instructions contained in this document
The manufacturer disclaims liability of any kind in the event of improper use.
Obligation to monitor Operating personnel have a duty to continuously monitor the overall technical condition of the application components (obvious defects or damage as well as changes in operating behavior). The operating personnel are obliged to only operate the application if it is in perfect condition. They must check the condition of the application components each time they are used and any defects must be rectified before commissioning starts.
Qualification of personnel The operating company must always deploy trained, authorized and reliable personnel. In so doing, all safety regulations must be observed. The personnel must have received special, in-depth training and instructions about possible hazards and dangers.
35
3.2
Installing the hardware and software

This chapter describes which hardware and software components must be installed. The descriptions and manuals as well as the information that is supplied with the corresponding products, must always be carefully observed.
Hardware components
Table 3-1 Hardware components Hardware components SINAMICS S120 Demonstration and training case Fig. Functions The SINAMICS S120 training case comprises Standard components (CU320-2 PN, two-axis motor module booksize with motors) and contains two axes. These are used to demonstrate the application. The case is already completely assembled and wired up. It only has to be connected to the HMI system and the Simatic control via ETHERNET. Control on which the user program is executed
SIMATIC CPU 317F-2 PN/DP
SIMATIC function module FM352 CAM MODULE Cam controller
Cam controller to generate output cam signals and provide the absolute position at a real machine with brake/coupling combination
SSI encoder Siemens 6FX2001-5QS12
Absolute encoder to provide the cam controller with the ram position.
Motion Connect encoder cable 2 Ethernet cable
This cable is used to establish the connection between the encoder and the cam controller module The cable is used to establish the connection between the HMI system (PG/PC), the SINAMICS S120 training case and the Simatic control The PG/PC is used for display on the HMI user interface.
PG/PC with Ethernet Interface
36
Standard software components Note

If the application is only intended for demonstration and testing, then it is only necessary to install WinCC flexible RT with 512 power tags and recipe. The note regarding missing authorization can be acknowledged.
Table 3-2 Software components Components Step 7 Functions STEP 7 is the basis package for the other software packages, and is used to program SIMATIC S7 Step 7 tool to parameterize the cam controller Tool to parameterize the SINAMICS drive Versions V5.5 SP2 or higher
FM 352 / 452 cam Sinamics Starter or alternatively Simotion Scout WinCC flexible 2008
V6.0 SP2 or higher V4.3.1.0 or higher
WinCC flexible is used to program the HMI user interface. Without this software, you cannot modify the HMI user interface. WinCC flexible RT allows a PG/PC to be used as operator panel.
2008 SP3 Update 3 or higher
WinCC flexible 2008 RT
2008 SP3 Update 3 or higher
Installing the standard software

Table 3-3 Installing the software No. 1. 2. 3. 4. Step 7 V 5.5 SP2 Sinamics Starter or alternatively Simotion Scout WinCC flexible 2008 SP3 Upd3 (with the option: Integration in Step 7) WinCC flexible RT 2008 SP3 Upd3 Action Note
Installing the hardware

Table 3-4 Hardware structure and installation No. 5. Action Carefully ensure that the Drive-CliQ interfaces between CU320-2 (X101) and the Motor Module (X200) have been correctly connected! Note
37
No. 6.
Action Connect the FM 352 function module with the CPU via the backplane bus. Connect the 24 V power supply to the CPU and to the FM. Connect the encoder to the FM 352. Connect the Ethernet interface of your PG/PC with the Ethernet interface of the CPU (X2), and connect the second port of the Ethernet interface with the CU320-2 (contact X150 P1) using two Ethernet cables. Connect the SINAMICS S120 training case to the power supply. Switch on all of the devices.
Note
7. 8.
9. 10.
38
3.3
Additional preparations
Table 3-5: Additional preparations No. 1. Action Setting the PG/PC interface: The CPU has IP address 192.168.0.50 under the subnet mask 255.255.255.0 The Control Unit has IP address 192.168.0.32 under subnet mask 255.255.255.0 Set your interface so that it is compatible.
2. Assigning IP addresses and device names:
39
No.
Action
Assign the CPU IP address "192.168.0.50" under subnet mask"255.255.255.0"and the device named "pn-io".
40
No.
Action Assign the Control Unit IP address "192.168.0.32" under subnet mask"255.255.255.0"and the device name "CU320".
3. 4.
Dearchive the sample project Open the project in Starter, by right clicking on S120_CU320_2_PN in the project tree, and selecting Open Object:
5.
Go online with Starter:
6.
This application example is configured as standard using a 3A/3A Motor Module. Demonstration cases that are equipped with a 5A/5A Motor Module are in circulation. The hardware must be checked before downloading the project. If a 3A/3A Motor Module is not being used in the case, then the project can be reconfigured by fol-
41
No.
Action
lowing the subsequent instructions:
Go offline Open the "Drive navigator" in the project tree A selection window opens by pressing the "Device configuration" button Open the configurator by pressing the "Configure drive" Scroll through the selection menu for the power unit by pressing the "Next" button Select the power unit being used from the list, refer to the serial number on the front of the Double Motor Module, e.g. 6SL31202TE15-0AA3 (5A/5A) Press "Next" and acknowledge any alarm messages Press the "Next" button, without making any other changes, until the "Finish" button is displayed Close the device configurator In the expert list of the drive SERVO_02 (select drive -> right-hand mouse key -> Experts -> Expert list) reduce parameter p210 to 345V and parameter p1248 to 240V Compile and save the project, go online and load the project to the target system
42
No. 7. Download the project to the target system: 8.
Action
Change back into the SIMATIC Manager. Open the hardware configuration and load it into the control system:
9.
Select all blocks and load these into the CPU:
10.
Perform a restart of the CPU:
43
No. 11.
Action Open the WinCC Flexible project by right clicking on "WinCC flexible RT" in the project tree, and select Open Object:
3.4
Table 3-6 No. 1.
Testing the application

Action Start WinCC Flexible runtime:
2.
An error occurs "Tonnage simulation error" that you will not be able to acknowledge. To do this, machine and die data must first be saved. To do this, press the "die data" button and shift the message window slightly upwards, as shown in the screen section, so that you can see all 3 buttons. First press "preallocate machine data", and then "save machine data".
44
No. 3.
Action Change the screen using the "die data" button. In the drop-down window, enter a name for the sample die. Confirm by pressing the "die data" button again. Confirm the message that is output with "Yes". Press the "load preset data" button and then "save dataset".
4.
Change the screen using the "tool change" button. Press the "accept data" button. This means that active faults can now be acknowledged, and you can start to test the application.
45
No.
Action
5.
Please refer to the descriptions of the graphic interface in Chapter 6 for additional notes on operating and testing the application.
3.5
Application with brake/coupling combination

The sample project cannot be used in the delivery state for a design with brake/coupling combination. In order to be able to simulate the supplementary functions, the encoder value of the main drive has been interconnected with this function instead of the encoder of the cam controller. To undo this, network 6 only has to be simply deleted in FC11. In the positioning mode, in order to position to an external encoder, which for a real machine is mounted on the excentric shaft, and not to the motor encoder, several additional settings are required. These are described in the following:
46
Table 3-7 No. 1. Action In the Starter project tree, select the drive SERVO_02. There, double-click on the Configuration and the "Configure DDS" button. Then on click "Next" until you reach the Encoder tab.
Here, set the check mark for "Encoder 2", select "Enter data" and click on "Encoder data". 2. The following settings must now be made here: a. In the drop-down menu, under "Measuring system", select "Absolute SSI protocol" b. Set the supply voltage to 24V c. Remove the checkmark for Remote Sense d. Select "Terminal" as encoder connection e. Set the single-turn resolution to 8192 steps f. Set the multi-turn resolution to 1 revolution g. Set the baud rate to 125 kHz
47
No.
Action
3. 4.
Click on "Next" up to the "Measurement system" tab and select the encoder that you have just created. Under the Mechanics tab the screen must look like this:
Now click on "Next" and "Finish". 5. You must now connect the encoder to the terminal input of the SMC 30 and to the FM352.
48
No.
Action
Connect the SMC30 to the Drive-Cliq port automatically created in the topology.
6.
Several changes still have to be made to the FM352 hardware configuration. To do this, double-click on the FM 352 CAM module. Then double-click on encoder. The following window now opens:
For "SSI", the telegram must be set from 13 bit to "Listen-in". OK, save File, export:
49
No.
Action
In the current project (standard), select DB31, click on OK and confirm overwrite. Close the cam controller. 7.
In the project block container, select DB31 and load into the CPU. The cam controller parameterization becomes active the next time that the CPU starts. The SCM30 is now the master at the encoder, and the FM 352 "listens" to the encoder signal.
8.
50
4 Program environment
4
4.1

Program environment
Main drive control
FB10: FB_clutch_control Coupling control dependent on the operating mode FB11: FB_maindrive_control Main drive control, speed setpoints and positions, communication to Sinamics FB12: FB_absolute_justage_s120 Encoder adjustment block, called in FB11 FB13: FB_encoder_values Determine position and stroke rate from an external encoder FB15: FB_calc_brake_angle Braking angle calculation, dependent on the stroke rate FB19: FB_data_transfer_drive Accept die data FC10: FC_maindrive_OB1 All FBs, which are to be executed in OB1, are called here FC11: FC_maindrive_OB32 All FBs, which are to be executed in OB32, are called here FC15: FC_maindrive_cmd_values Setpoints for the main drive control are generated, depending on the die data, machine data and operating modes FC18: FC_maindrive_startup When the CPU boots, HMI variables are assigned actual values DB12: DB_com_Sinamics Communication DB to Sinamics, is written to by FB11 DB 110: DB_maindrive_data Die and machine data for the main drive control DB111: DB_maindrive_actual_data Actual data of the main drive control DB910: DB_HMI_data_maindrive HMI data of the main drive control UDT10: UDT_config_maindrive UDT for machine data UDT11: UDT_die_data_maindrive UDT for die data UDT16: UDT_config_brake_angle UDT for machine data braking angle control UDT18: UDT_strokeheight_table UDT for stroke height table
51
4.2
Counters
FB20: FB_counter Block to execute counter functions FB29: FB_data_transfer_counter Accept die data FC20: FC_counter Calls the counter block DB 120: DB_counter_data Die data for counters DB121: DB_counter_actual_data Actual data of the counter DB920: DB_HMI_data_counter HMI data of the counter UDT20: UDT_counter_data UDT for die data
4.3
Output cams
FB30: FB_cam_FM352 Cam controller FB31: CAM_CTRL Block to communicate with the FM352-CAM, is used in FB30 FB32: CAM_DIAG Diagnostics block of the FM352-CAM, is used in FB30 FB39: FB_data_transfer_cams Accept die data FC30: FC_output_cams Calls the output cam block DB31: DB_FM352_Parameter Parameter-DB for FM352 DB 130: DB_cam_dat Output cam data DB131: DB_cam_actual_data Actual data of the output cam processing DB930: DB_HMI_data_cams HMI data of the output cam processing UDT30: UDT_cam_data UDT for output cam data
52
4.4
Die protection
FB40: FB_dieprotection Monitoring block for die protection FB42: FB_dieprotect_trace Block for tracing the profile for the die protection FB49: FB_data_transfer_dieprot Accept die data FB65: FB_dieprotection_Ack Acknowledging die protection faults FB801: FB_dieprotect_simulation Simulation of the sensor characteristics of the die protection FC41: FC_dieprotect_OB32 Calls the die protection blocks, which should be executed in the OB32 cycle FC60: FC_dieprotect_OB1 Calls the die protection blocks, which should be executed in the OB1 cycle DB 140: DB_dieprotect_data Die data for die protection DB141: DB_dieprotect_act_data Actual data of the die protection DB940: DB_HMI_data_dieprotect HMI data of the die protection UDT40: UDT_dieprotect_data UDT for die protection data UDT41: UDT_dieprotect_addon UDT for supplementary data of the die protection UDT42: UDT_dieprotect_actual UDT for actual data of the die protection UDT43: UDT_dieprotect_diag UDT for diagnostics data of the die protection UDT2000: UDT_TrendDataDieProtect UDT for 3 profile sets of the die protection UDT2001: UDT_CurveDieProtect UDT for a profile set of the die protection
4.5
Tonnage monitoring
FB50: FB_tonnage_mon Block for tonnage monitoring FB51: FB_tonnage_cyclic Block for cyclically processing tonnage monitoring data
53
FB54: FB_tonnage_curve Block for tracing the tonnage profile FB55: FB_tonnage_envelope Block for calculating the envelope curve FB56: FB_tonnage_env_mon Block for monitoring the envelope curve FB57: FB_tonnage_sim Block for simulating the tonnage trend FB59: FB_data_transfer_tonnage Accept die data FC50: FC_tonnage_OB1 Calls the tonnage blocks, which should be executed in the OB1 cycle FC51: FC_tonnage_OB32 Calls the tonnage blocks, which should be executed in the OB32 cycle DB 150: DB_tonnage_data Die data for tonnage monitoring DB151: DB_tonnage_act_data Actual data of the tonnage monitoring DB950: DB_HMI_data_tonnage HMI data of the tonnage monitoring UDT50: UDT_tonnage_data UDT for tonnage monitoring data UDT51: UDT_tonnage_config UDT for machine data of the tonnage monitoring UDT52: UDT_tonnage_die_data UDT for die data of the tonnage monitoring UDT53: UDT_tonnage_actual UDT for actual data of the tonnage monitoring UDT54: UDT_tonnage_trend UDT for tracing the tonnage trend UDT55: UDT_tonnage_diag UDT for diagnosing the tonnage monitoring UDT56: UDT_tonnage_envelope UDT for envelope curve data UDT57: UDT_DetailDiagTonnageEnv UDT for error data of the envelope monitoring
54
5 Program and function description
5
5.1
5.1.1
Program and function description

Main drive control
Task / functionality of the main drive control
Controlling (open-loop) the main press drive with speed and position setpoint. Controlling the coupling/brake combination with braking angle calculation, depending on the operating mode.
5.1.2
Call environment and data flow
Fig. 5-1: Call environment, main drive control
OB1
Sinamics S120
HMI
DB910 FC15:
FC_cmd_values
FB11:
FB_maindrive_control
DB12
FB100:
FB_HMI_control
DB110: DB_maindrive_data DB111: DB_maindrive_actual_data
FB15:
FB_calc_brake_angle
OB32
Coupling Brake
HMI
DB910
FB100:
FB_HMI_control DB110: DB_maindrive_data DB111: DB_maindrive_actual_data
SSI encoder
FB10:
FB_ clutch_control
FB13:
FB_encoder_values
OB100
FC18:
FC_maindrive_startup
DB110: DB_maindrive_data DB150: DB_tonnage_data
HMI
DB910: DB_HMI_data_maindrive DB950: DB_HMI_data_tonnage
55
5.1.3
Data blocks and user-defined data types
Table 5-1: UDT10, UDT_config_maindrive Element UDT_config_maindrive tDRSRangeTime i16MinStrokerate i16MaxStrokerate i16MaxSetupStrokerate i16DRSRangePos i16DieChangeStrokerate Data type STRUCT S5TIME INT INT INT REAL INT ms Stroke/min Stroke/min Stroke/min Stroke/min Delay time when reaching the position Minimum stroke rate Maximum stroke rate Maximum stroke rate, setup mode Tolerance window for position reached Stroke rate for reequipping/positioning Unit Meaning
Table 5-2: UDT11, UDT_die_data_maindrive

Element UDT_die_data_maindrive i16StartupPunchingSpeed i16MaxOperationSpeed i16MaxSetUpSpeed i16TDCStopPosition i16StrokeHeightNumber boDisableSetupTDCStop
Data type STRUCT INT INT INT INT INT BOOL
Unit
Meaning
Stroke/min Stroke/min Stroke/min 0,1 -
Pressing stroke rate Maximum stroke rate Maximum stroke rate, setup mode Position for TDC stop Stroke height number Stop the press at TDC in the setup mode
Table 5-3: UDT18, UDT_strokeheight_table Element UDT_strokeheight_table ar32AdjustPosition ar32TdcOffset ai16StrokeHeight ai16MaxStrokes Data type STRUCT ARRAY[0..9] INT ARRAY[0..9] INT ARRAY[0..9] INT ARRAY[0..9] INT Stroke/min Maximum stroke rate Stroke height TDC offset Press position for adjustment Unit Meaning
Table 5-4: DB 12, DB_com_Sinamics Element DB_com_Sinamics Com_data_maindrive Data type STRUCT UDT_TVB+MDI_TLG111 Telegram configuration Unit Meaning
56
Table 5-5: DB 110, DB_maindrive_data Element DB_maindrive_data config_data_maindrive config_brake_angle_calc confi_strokeheight_table die_data_maindrive act_maxStrokerate_table Data type STRUCT UDT_config_maindrive UDT_config_brake_angle UDT_strokeheight_table UDT_die_data_maindrive INT Stroke/min Main drive configuration Braking angle data Stroke height table Die data, main drive Actual maximum stroke rate dependent on the stroke height table Unit Meaning
Table 5-6: DB111, DB_maindrive_actual_data Element DB_maindrive_actual_data cmd_data_drive strokerate direction

Data type STRUCT STRUCT INT BOOL BOOL DINT BOOL BOOL STRUCT BOOL BOOL BOOL BOOL BOOL BOOL INT BOOL INT DINT INT BOOL BOOL BOOL BOOL BOOL BOOL INT INT INT INT BOOL -
Unit
Meaning
Stroke/min 0,1 0,1 Stroke/min Nm kW A C -
Stroke rate Direction of rotation Start command Position for positioning command Positioning command Immediate stop, main drive Drive active Positioning mode active Positioning active Position reached Drive at standstill Error Error code Warning Warning number Actual position Actual stroke rate Communication error
start_maindrive position start_positioning drive_immediate_stop actual_data_drive drive_is_on opm_positioning pos_run pos_ok drive_in_standstill error error_no warning warning_no actual_position actual_strokerate com_error no_difference_set_act drive_limit_reached temp_motor_ok temp_motor_module_ok n_positive torque_actual power_actual current_actual act_temperature justage_run
Actual torque Actual power Actual current Actual temperature Encoder being adjusted
57
Element justage_finished justage_error justage_done cmd_data_clutch jog start_stroke tdc_stop immediate_stop die_data_error_id cmd_operation_Mode actual_operation_mode cmd_strokerate actual_strokerate_press cmd_position absolute_pos actual_pos
Data type BOOL BOOL BOOL STRUCT BOOL BOOL BOOL BOOL INT INT INT INT INT INT INT INT INT INT INT BOOL BOOL BOOL INT -
Unit
Meaning Encoder adjustment completed Encoder adjustment error Encoder adjustment completed Jog Start stroke TDC stop Immediate stop Die data error number Command, operating mode Actual operating mode Setpoint stroke rate Actual stroke rate Setpoint position Absolute position Actual position Actual braking angle Start of braking output cam End of braking output cam Coupling (clutch) closed Pressing stroke rate reached Stroke rate limited Error number machine data
Stroke/min Stroke/min -
actual_brake_angle brake_cam_start brake_cam_end clutch_closed startup_speed_reached strokerate_limited i16ErrorNrSaveMaDa
Table 5-7: DB 910, DB_HMI_data_maindrive Element DB_HMI_data_maindrive HMI_config_dat_maindrive HMI_conf_dat_brake_angle HMI_strokeheight_table HMI_recipe_dat_maindrive HMI_i16strokerateSetpoin HMI_r32justagePos HMI_r32PosSetpoint HMI_i16OperationMode Data type STRUCT UDT_config_ maindrive UDT_config_ brake_angle UDT_stroke height_table UDT_die_da ta_maindrive INT INT DINT INT Stroke/min 0.1 0.1 Configuration, main drive in the HMI Braking angle data in the HMI Stroke height table in the HMI Die data, main drive in the HMI Stroke rate, setpoint Adjustment position for external encoder Position setpoint for manual positioning Operating mode (1 = Setup, 2 = Single stroke, 4 = Continuous stroke, 8 = Positioning, 16 = Backward) Actual stroke rate Unit Meaning
HMI_actual_strokerate
INT
I strokes/min
58
Element HMI_actual_pos HMI_absolute_pos HMI_actual_brake_angle HMI_actual_temperature
Data type INT INT INT INT
Unit 0.1 0.1 0.1 C
Meaning Actual position Absolute position Actual braking angle Actual temperature, main drive
5.1.4
Function elements and integration
Table 5-8: Elements and integration Function / function block program FB10: FB_clutch_control FB11: FB_maindrive_control Call Called in a cyclic interrupt OB Called in OB1 Property/function Coupling control dependent on the operating mode Main drive control, speed setpoints and positions, communication to Sinamics Block for encoder adjustment Determine position and stroke rate from an external encoder Braking angle calculation, dependent on the stroke rate Accept die data Setpoints for the main drive control are generated, depending on the die data, machine data and operating modes When the CPU boots, HMI variables are assigned actual values
FB12: FB_absolute_justage_s120
Called in FB11 Called in a cyclic interrupt OB Called in OB1 Called in OB1 Called in OB1
FB13: FB_encoder_values FB15: FB_calc_brake_angle FB19: FB_data_transfer_drive FC15: FC_maindrive_cmd_values
FC18: FC_maindrive_startup
Called in OB100
59
5.1.5
Function block FB10: FB_clutch_control
Functionality Coupling control dependent on the operating mode Schematic LAD representation
Fig. 5-2: Schematic LAD representation FB_clutch_control INT INT BOOL BOOL BOOL BOOL BOOL
tdc_brake_cam_start tdc_brake_cam_end speed_0 disablesetupTDCStop start_stroke immediate_stop tdc_stop jog operation_mode actual_pos StartPunchSpeed_Reached
out_clutch_on
BOOL
BOOL INT INT BOOL
Input parameter
Table 5-9: Input parameter Element tdc_brake_cam_start tdc_brake_cam_end speed_0 disablesetupTDCStop start_stroke immediate_stop tdc_stop jog operation_mode Data type INT INT BOOL BOOL BOOL BOOL BOOL BOOL INT Unit [0.1] [0.1] Meaning Starting angle for brake output cam End angle for brake output cam Main drive stationary Deselect TDC stop in setup Start stroke Immediate stop signal, low active TDC stop signal, low active Jog Operating mode 1: Setup 2: Single stroke 4: Continuous stroke 8: Positioning 16: Backward Actual position of the press minimum stroke rate reached
actual_pos StartPunchSpeed_Reached
INT BOOL
[0.1] -
60
Output parameter
Table 5-10: Output parameter Element out_clutch_on Data type BOOL Unit Close coupling Meaning
61
5.1.6
Function block FB11: FB_maindrive_control
Functionality Speed setpoints and positioning, communication to Sinamics Schematic LAD representation
Fig. 5-3: Schematic LAD representation FB_maindrive_control INT INT INT INT BOOL BOOL BOOL
Peri_IN Peri_OUT DB_COM_Nr axis_ID enable_drive Start_Drive immediate_stop ACK OPM_Positioning start_positioning clutch_is_closed positioning_acceleration positioning_deceleration command_position positioning_strokerate pos_ok_range pos_ok_time strokerate direction reference_strokerate encoder_justage_pos start_encoder_justage torque_limit_positioning torque_limit_pos_ok torque_limit_operation kp_reduction_operation positioning_shifted_pos position_shift timer_abs_justage timer_pos_ok_delay
out_drive_on out_pos_mode_active out_positioning_runs out_target_pos_reached out_speed_0 out_error out_error_ID out_warning out_warning_ID out_actual_position out_strokerate Com_Error out_no_cmd_actual_diff out_m_i_p_limit_reached out_temp_motor_ok out_temp_motor_module_ok out_n_positive out_act_torque out_act_power out_act_current out_act_temperature out_justage_active out_justage_done out_justage_error out_enc_reference_set
BOOL BOOL BOOL BOOL BOOL BOOL INT BOOL INT DINT INT BOOL BOOL BOOL BOOL BOOL BOOL INT INT INT INT BOOL BOOL BOOL BOOL
BOOL BOOL BOOL BOOL INT INT D INT INT REAL S5Time INT BOOL REAL DINT BOOL INT INT INT INT BOOL DINT TIMER TIMER
62
Input parameter
Table 5-11: Input parameter Element Peri_IN Peri_OUT DB_COM_Nr axis_ID enable_drive Start_Drive immediate_stop ACK OPM_Positioning start_positioning clutch_is_closed positioning_acceleration positioning_deceleration command_position positioning_strokerate pos_ok_range pos_ok_time strokerate direction reference_strokerate encoder_justage_pos start_encoder_justage torque_limit_positioning torque_limit_pos_ok torque_limit_operation kp_reduction_operatio n positioning_shifted_pos position_shift timer_abs_justage timer_pos_ok_delay INT INT BOOL DINT TIMER TIMER [%] [%] [0,001] DINT BOOL INT INT [0,001] [%] [%] INT INT INT INT BOOL BOOL BOOL BOOL BOOL BOOL BOOL INT INT DINT INT REAL S5Time INT BOOL REAL [%] [%] [0,001] [s/min] [] [Time] [s/min] [s/min] Data type Unit Meaning Input address of the drive telegram Output address of the drive telegram Number of the DB for communication with the drive Axis ID (in the Sinamics) Set axis enable Start main drive Immediate stop Acknowledge Positioning mode Start positioning Coupling is closed Drive acceleration when positioning Drive deceleration when positioning Setpoint position Velocity when positioning Range, position reached Delay time for position reached Setpoint stroke rate 1 = negative Reference stroke rate (= stroke rate at the reference speed of the main drive) Position encoder adjustment Command, start encoder adjustment Torque limiting when positioning Torque limiting when the position is reached Torque limiting for cyclic operation Kp reduction in cyclic operation Positioning including TDC offset TDC offset Time for absolute encoder adjustment Timer for the "position OK" delay
63
Output parameter
Table 5-12: Output parameter Element out_drive_on out_pos_mode_active out_positioning_runs out_target_pos_reach ed out_speed_0 out_error out_error_ID out_warning out_warning_ID out_actual_position out_strokerate Com_Error out_no_cmd_actual_d iff
Data type BOOL BOOL BOOL BOOL BOOL BOOL INT BOOL INT DINT INT BOOL BOOL BOOL BOOL BOOL BOOL INT INT INT INT BOOL BOOL BOOL BOOL -
Unit Drive is on
Meaning
Positioning operation is active Positioning active Target position reached Drive at standstill Error Error code Warning Warning number Actual position Actual stroke rate Communication error No following error Torque, current or power limit reached Motor temperature OK Motor module temperature OK Positive speed Actual torque Actual power Actual current Actual temperature Encoder adjustment active Encoder has been adjusted Encoder adjustment error Encoder referenced
[0,001] [s/min] [%] [%] [%] [] -
out_m_i_p_limit_reac hed out_temp_motor_ok out_temp_motor_mod ule_ok out_n_positive out_act_torque out_act_power out_act_current out_act_temperature out_justage_active out_justage_done out_justage_error out_enc_reference_s et
64
5.1.7
Function block FB12: FB_absolute_justage_s120
Functionality Block for encoder adjustment Schematic LAD representation

Fig. 5-4: Schematic LAD representation FB_absolute_justage_s120 INT BOOL DINT INT Timer DINT
IN_LADDR Execute absolute_position axis_ID timer_delay modulo_range
Done Busy Error
BOOL BOOL BOOL
Input parameter
Table 5-13: Input parameter Element IN_LADDR Execute absolute_position axis_ID timer_delay modulo_range INT BOOL DINT INT Timer DINT [0,001] Start encoder adjustment Position encoder adjustment Axis ID (in the Sinamics) Timer wait time after encoder adjustment Modulo range (360000) Data type Unit Meaning Output address of the drive telegram
Output parameter
Table 5-14: Output parameter Element Done Busy Error Data type BOOL BOOL BOOL Unit Meaning Encoder has been adjusted Encoder adjustment active Encoder adjustment error
65
5.1.8
Function block FB13: FB_encoder_values
Functionality Determine position and stroke rate from an external encoder Schematic LAD representation
Fig. 5-5: Schematic LAD representation FB_encoder_values DINT DINT INT INT ENCODER_VALUE INC_REVOLUTION TDC_SHIFT EXC_FREQ POSITION_ABSOLUTE POSITION_ACTUAL STROKERATE INT INT INT
Input parameter
Table 5-15: Input parameter Element ENCODER_VALUE INC_REVOLUTION TDC_SHIFT EXC_FREQ Data type DINT DINT INT INT [0,1] [ms] Unit Meaning Singleturn encoder value Encoder resolution TDC offset Call cycle of the FB
Output parameter
Table 5-16: Output parameter Element POSITION_ABSOLUTE POSITION_ACTUAL STROKERATE Data type INT INT INT Unit [0,1] [0,1] [s/min] Meaning Absolute encoder position Actual position including TDC offset Actual stroke rate
66
5.1.9
Function block FB15: FB_calc_brake_angle
Functionality Braking angle calculation, dependent on the stroke rate Schematic LAD representation
Fig. 5-6: Schematic LAD representation FB_calc_brake_angle INT INT BOOL in_stroke_rate tdc_stop_position direction brake_angle cam_end cam_start INT INT INT
Input parameter
Table 5-17: Input parameter Element in_stroke_rate tdc_stop_position direction Data type INT INT BOOL [0,1] Unit [s/min] Meaning Stroke rate, for which the braking angle should be calculated TDC stop position Direction of press motion
Output parameter
Table 5-18: Output parameter Element brake_angle cam_end cam_start Data type INT INT INT Unit [0,1] [0,1] [0,1] Braking angle End of braking output cam Start of braking output cam Meaning
67
5.1.10
Function block FB19: FB_data_transfer_drive
Functionality Accept die data Schematic LAD representation

Fig. 5-7: Schematic LAD representation FB_data_transfer_drive BOOL BOOL in_transfer_data ack error error_id data_transferred BOOL INT BOOL
Input parameter
Table 5-19: Input parameter Element in_transfer_data ack Data type BOOL BOOL Unit Accept die data Acknowledge error Meaning
Output parameter
Table 5-20: Output parameter Element error error_id data_transferred Data type BOOL INT BOOL Unit Meaning Error in the die data Error code Die data successfully transferred
68
5.1.11
Function FC15: FC_maindrive_cmd_values
Functionality Setpoints for the main drive control are generated, depending on the die data, machine data and operating modes Schematic LAD representation
Fig. 5-8: Schematic LAD representation FC_maindrive_cmd_values INT INT INT INT INT
in_operation_mode in_actual_strokerate in_strokerate_setpoint in_diechange_strokerate in_DBnr_Strokeheight
out_StartPunchSpeed out_direction_negative out_strokerate_limited out_strokerate_setpoint out_operation_mode
BOOL BOOL BOOL INT INT UDT_die_ data_maindrive
UDT_die_ data_maindrive
in_die_data
Input parameter
Table 5-21: Input parameter Element in_operation_mode Data type INT Unit Meaning Target operating mode 1: Setup 2: Single stroke 4: Continuous stroke 8: Positioning 16: Backward Actual stroke rate Stroke rate setpoint DB number of stroke height table
in_actual_strokerate in_strokerate_setpoint in_DBnr_Strokeheight
INT INT INT
[s/min] [s/min] [s/min]
Input/output parameters Table 5-22: Input and output parameters

Element in_die_data Data type UDT_die_data_m aindrive Unit Meaning Die data for the main drive control
69
Output parameter
Table 5-23: Output parameter Element out_StartPunchSpeed out_direction_negative out_strokerate_limited out_strokerate_setpoint out_operation_mode Data type BOOL BOOL BOOL [s/min] Unit Meaning Minimum stroke rate reached Drive should rotate in the negative direction Setpoint stroke rate limited Setpoint stroke rate for the drive Active operating mode 1: Setup 2: Single stroke 4: Continuous stroke 8: Positioning 16: Backward
INT INT
5.1.12
Function FC18: FC_maindrive_startup
Functionality HMI variables are written to when starting with program variables
70
5.2
5.2.1
Counters
Task and functionality of the counters
Counting strokes and total number of strokes for dies or the machine.
5.2.2
Fig. 5-9: Call environment for counters
OB32
DB111:
DB_maindrive_actual_data
HMI
DB920
FB100:
FB_HMI_control
FB20:
FB_counter
DB120: DB_counter_data DB121: DB_counter_actual_data
5.2.3
Table 5-24: UDT20, UDT_counter_data Element UDT_counter_data ai32CounterSetValue aboCountMode aboTDCStopCounter Data type STRUCT ARRAY[0..9] DINT ARRAY[0..9] BOOL ARRAY[0..9] BOOL TDC stop when reaching the count value Count mode Counter setpoint Unit Meaning
Table 5-25: DB120, DB_counter_data Element DB_counter_data die_data_counter Data type STRUCT UDT_counte r_data Die data counter Unit Meaning
71
Table 5-26: DB121, DB_counter_actual_data Element DB_counter_actual_data aboResetCounter aboEnableCounter ai32ActualCountValue aboCountValueReached boCounterTDCStop Data type STRUCT ARRAY[0..9] BOOL ARRAY[0..9] BOOL ARRAY[0..9] DINT ARRAY[0..9] BOOL BOOL TDC stop request from a counter Counter setpoint reached Actual count value Enable counter Command to reset counter Unit Meaning
Table 5-27: DB920, DB_HMI_counter_data Element DB_counter_actual_data HMI_recipe_data_counter

Data type STRUCT UDT_counte r_data ARRAY[0..9] DINT -
Unit
Meaning
Die data counter Actual count value
HMI_Actual_Count_Value -
5.2.4
Table 5-28: Elements and integration Function / function block program FB20: FB_counter FB29: FB_data_transfer_counter Call Called in a cyclic interrupt OB Called in OB1 Property/function Block to execute counter functions Accept die data
72
5.2.5
Function block FB20: FB_counter
Functionality Block to execute counter functions Schematic LAD representation

Fig. 5-10: Schematic LAD representation FB_counter BOOL INT ARRAY[0..9] of BOOL ARRAY[0..9] of BOOL UDT_counter_data
enable in_actual_position in_Reset_Counter in_Enable_Counter in_Counter_Data out_Count_Values_Reached out_Actual_Count_Values
busy tdc_stop
BOOL BOOL
UDT_counter_data ARRAY[0..9] of DINT ARRAY[0..9] of BOOL
ARRAY[0..9] of DINT ARRAY[0..9] of BOOL
Input parameter
Table 5-29: Input parameter Element enable in_actual_position in_Reset_Counter in_Enable_Counter Data type BOOL INT ARRAY[0..9] of BOOL ARRAY[0..9] of BOOL [0,1] Unit Block enable Actual position of the press Reset counter Enable counter Meaning
Input and output parameters

Table 5-30: Input and output parameters Element In_Config_Data_Coun ter Out_Actual_Count_V alues out_Count_Values_R eached Data type UDT_counter_dat a ARRAY[0..9] of DINT ARRAY[0..9] of BOOL Unit Meaning Configuration data Actual count value Count value reached
73
Output parameter
Table 5-31: Output parameter Element busy tdc_stop BOOL BOOL Data type Unit Meaning In preparation Request TDC stop
5.2.6
Function block FB29: FB_data_transfer_counter

Fig. 5-11: Schematic LAD representation FB_data_transfer_counter
BOOL BOOL
in_transfer_data ack
error error_id data_transferred
BOOL INT BOOL
Input parameter
Table 5-32: Input parameter Element in_transfer_data ack Data type BOOL BOOL Unit Accept die data Acknowledge error Meaning
Output parameter
Table 5-33: Output parameter Element error error_id data_transferred Data type BOOL INT BOOL Unit Meaning Error in the die data Error code Die data successfully transferred
74
5.3
5.3.1
Output cams
Task / functionality of the output cams
The output of the cam signals depends on the actual press position. The output cam is processed based on the FM352-CAM
5.3.2
Fig. 5-12: Call environment of the output cams
OB1
HMI
DB930
FB30: FB_cam_FM352
FB31:
CAM_CTRL
FB100:
FB_HMI_control
FB32:
CAM_DIAG
DB130: DB_cam_dat DB131: DB_cam_actual_data
5.3.3
Table 5-34: UDT20, UDT_cam_data Element UDT_cam_data ai16StartValue ai16EndValue Data type STRUCT ARRAY[0..31] INT ARRAY[0..31] or ms Angle end of output cam or output cam duration for time-based output cams Output cam rate time Output cam type (position-based or time-based) Count value for count output cam 1 Count value for count output cam 2 Angle, start of output cam Unit Meaning
ai16DynamicShiftTime ai16Type count_value_1 count_value_2
INT ARRAY[0..31] INT ARRAY[0..31] INT INT INT
75
Table 5-35: DB130, DB_cam_dat Element DB_cam_dat output cam output cam status reserve anfWert endWert Data type STRUCT STRUCT ARRAY[1..32] STRUCT BYTE BYTE DINT DINT or ms Angle, start of output cam Angle end of output cam or output cam duration for time-based output cams Output cam rate time Count value for count output cam 1 Count value for count output cam 2 Output cam status Unit Meaning
vorHZeit zaehl_wert1 zaehl_wert2
INT INT INT
ms -
Table 5-36: DB131, DB_cam_actual_data

Element DB_cam_actual_data take_data_FM352 b16State1_16 b16State17_32 i16actCountValue1 i16actCountValue2
Data type STRUCT BOOL WORD WORD INT INT -
Unit
Meaning
Accept data in FM352 Output cam status 1 - 16 Output cam status 17 - 32 Actual count value for count output cam 1 Actual count value for count output cam 2
Table 5-37: DB930, DB_HMI_data_cams Element DB_HMI_data_cams HMI_recipe_data_cams Data type STRUCT UDT_cam_data Output cam die data in the HMI Unit Meaning
5.3.4
Table 5-38: Elements and integration Function / function block program FB30: FB_cam_FM352 FB31: CAM_CTRL Call Called in OB1 Called in FB30 Property/function Cam controller Block for communication with the FM352-CAM Diagnostics block of the FM352CAM Accept die data
FB32: CAM_DIAG
Called in FB30
FB39: FB_data_transfer_cams
Called in OB1
76
5.3.5
Function block FB30: FB_cam_FM352
Functionality Cam controller Schematic LAD representation

Fig. 5-13: Schematic LAD representation FB_cam_FM352 INT INT INT INT INT INT
FM352_CHANNEL_DBNR START_ADDRESS_FM352 FM352_PARAM_DBNR FM352_DIAG_DBNR DB_CAM_DATA TDC_SHIFT
initializing CAM_STATE_0_15 CAM_STATE_16_31 DATA_TRANSFER_ACTIVE DATA_ERROR DATA_ERROR_NO DATA_ERROR_CAM_NO DIAGNOSTIC_ERROR
BOOL WORD WORD BOOL BOOL WORD INT BOOL BOOL
BOOL
ACCEPT_DATA
Input parameter
Table 5-39: Input parameter Element FM352_CHANNEL_D BNR START_ADDRESS_F M352 FM352_PARAM_DBN R FM352_DIAG_DBNR INT INT INT INT INT INT [0,1] Number of the diagnostics DB Number of the DB with output cam data TDC offset Number of the parameter DB Peripheral start address of the FM352 Data type Unit Meaning Number of the channel DB
DB_CAM_DATA TDC_SHIFT

Element ACCEPT_DATA Data type BOOL Unit Meaning Read in new die data
77
Output parameter
Table 5-41: Input parameter Element initializing CAM_STATE_0_15 CAM_STATE_16_31 DATA_TRANSFER_ACT IVE DATA_ERROR DATA_ERROR_NO DATA_ERROR_CAM_N O DIAGNOSTIC_ERROR Data type BOOL WORD WORD BOOL Unit Meaning Output cam data being initialized Status of the first 16 cams Status of output cams 17 to 32 Data transfer active
BOOL WORD INT
Output cam data error Error number, output cam data Output cam number with incorrect data
BOOL
FM352 data error
5.3.6
Function block FB31: CAM_CTRL
Functionality Block for communication with the FM352-CAM Description in the "SIMATIC S7-300 FM 352 electronic cam controller operating instructions" document
5.3.7
Function block FB32: CAM_DIAG
Functionality Diagnostics block of the FM352-CAM Description in the "SIMATIC S7-300 FM352 electronic cam controller operating instructions" document
78
5.3.8
Function block FB39: FB_data_transfer_cams

Fig. 5-14: Schematic LAD representation FB_data_transfer_cams BOOL BOOL in_transfer_data ack error error_id data_transferred BOOL INT BOOL
Input parameter
Table 5-42: Input parameter Element in_transfer_data ack Data type BOOL BOOL Unit Accept die data Acknowledgement of errors Meaning
Output parameter
Table 5-43: Input parameter Element error error_id data_transferred Data type BOOL INT BOOL Unit Error Error code Die data successfully transferred Meaning
79
5.4
5.4.1
Die protection
Task / functionality of the die protection
Comparison of input signals and output cams
5.4.2
Fig. 5-15: Call environment of the die protection
OB1
DB100:
DB_global_data
FB65:
FB_dieprotection_ACK
DB141:
DB_dieprotect_act_data
OB32
HMI
DB940
FB100:
FB_HMI_control DB111: DB_maindrive_actual_data DB140: DB_dieprotect_data DB141: DB_dieprotect_act_data
FB801:
FB_dieprotect_simulation
FB40:
FB_ dieprotection
FB42:
FB_dieprotect_trace
5.4.3
Table 5-44: UDT40, UDT_dieprotect_data Element UDT_dieprotect_data ar32CamStart ar32CamEnd ai16NumberOfEdges Data type STRUCT ARRAY[0..15] INT ARRAY[0..15] INT ARRAY[0..15] INT Number of edges Angle, end of output cam Angle, start of output cam Unit Meaning
80
Element ai16MonitoringType ai16ErrorReaction ai16NumberOfStrokes i16startDisableStrokes
Data type ARRAY[0..15] INT ARRAY[0..15] INT ARRAY[0..15] INT INT -
Unit
Meaning Monitoring type Error reaction Number of strokes Number of strokes for the die protection is been passivated after the start.
Table 5-45: UDT41, UDT_dieprotect_addon Element UDT_dieprotect_ addon b16type0 b16type1 b16type3 b16type8
Data type STRUCT WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD ARRAY[0..15] BOOL -
Unit
Meaning
Additional data Additional data Additional data Additional data Additional data Additional data Additional data Additional data Additional data Additional data Additional data Additional data Additional data Additional data Additional data Output cam type
b16type9 b16type2_5 b16type3_8 b16type5_6 b16type3_4_6 b16type3_5_6 b16type4_5_6 b16type2_3_4_8 b16type3_4_6_7 b16type2_3_4_5_6 b16type10 aboCamType -
Table 5-46: UDT42, UDT_dieprotect_actual Element UDT_dieprotect_ actual ai16CountValue b16CamState b16SensorState b16CounterEqual b16CounterBigger b16StrokesReached Data type STRUCT ARRAY[0..15] INT WORD WORD WORD WORD WORD Output cam status Sensor status Count value equal Count value higher Strokes reached Edge count value Unit Meaning
81
Table 5-47: UDT43, UDT_dieprotect_diag Element UDT_dieprotect_ actual ar32ErrorPos ai16ErrorCount ai16ErrorId b16ChannelFault b16sensor1cam1 b16sensor0cam1 b16SensorChangeMissingRi b16Sensor1FallingEdgeCam b16RisingEdgeSensorCam1 b16LessEdgesSensorRising b16Sensor1RisingEdgeCam
Data type STRUCT ARRAY[0..15] INT ARRAY[0..15] INT ARRAY[0..15] INT WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD WORD -
Unit
Meaning
Position when the error occurs Count value when the error occurs Error code Status Status Status Status Status Status Status Status Status Status Status Status Status Status Status Status Status Status Status
b16Sensor0RisingEdgeCam b16FallingEdgeSensorCam1 b16RisingEdgeSensorMissi b16FallingEdgeSensor b16Sensor0 b16RisingEdgeSensor b16Sensor1 b16MuchEdgesSensor b16SensorMissingWithinSt b16RisingEdgeSensorCam0 b16Sensor1cam0
Table 5-48: UDT2001, UDT_CurveDieProtect Element UDT_CurveDieProtect au16Value Data type STRUCT ARRAY[0..360] INT Profile set for die protection Unit Meaning
Table 5-49: UDT2000, UDT_TrendDataDieProtect Element UDT_TrendDataDieProtect asCamTrace asSensorTraceNew asSensorTraceOld Data type STRUCT ARRAY[0..15] UDT_CurveDieProtect ARRAY[0..15] UDT_CurveDieProtect ARRAY[0..15] Sensor traces old Sensor traces new Output cam traces Unit Meaning
82
Element -
Data type UDT_CurveDieProtect -
Unit
Meaning
Table 5-50: DB140, DB_dieprotect_data Element DB_dieprotect_data die_data_dieprotect die_data_diepr_addon Data type STRUCT UDT_dieprotect_data UDT_dieprotect_addon Die data Supplementary die data Unit Meaning
Table 5-51: DB141, DB_dieprotect_act_data Element DB_dieprotect_act_data dieprotect_trend dieprotect_diag boTDCStopDieProtect

Data type STRUCT UDT_TrendDataDiePro tect UDT_dieprotect_diag BOOL BOOL WORD WORD BOOL UDT_dieprotect_actual BOOL -
Unit
Meaning
Trends Diagnostic data Request TDC stop Request immediate stop Enabling the monitoring channels Sensor signals Trend request Actual data Enables die protection
boImStopDieProtect b16EnableChannels b16SensorSignals boTrendRequest dieprotect_act_data boEnableDieProtect
Table 5-52: DB940, DB_HMI_data_dieprotect Element DB_HMI_data_dieprotect HMI_recipe_data_diepr HMI_diag_data_diepr HMI_trend_data_diepr HMI_ab16trendrequest HMI_ab16trendtransfer HMI_aboenablechannel hmi_aboenableTrace HMI_actual_data boEnableDieProtect Data type STRUCT UDT_dieprotect_data UDT_dieprotect_diag UDT_TrendDataDiePro tect ARRAY[0..1] WORD ARRAY[0..1] WORD ARRAY[0..15] BOOL ARRAY[0..15] BOOL UDT_dieprotect_actual BOOL Actual data Enables die protection Enables the trace Channel enable Trend transfer Die data Diagnostic data Trends Trend request Unit Meaning
83
5.4.4
Function block FB40: FB_dieprotection
Functionality Monitoring block for die protection Schematic LAD representation

Fig. 5-16: Schematic LAD representation FB_dieprotection BOOL INT BOOL enable actual_position in_enable_monitoring tdc_stop immediate_stop error busy WORD WORD UDT_dieprotect_data
BOOL BOOL BOOL BOOL WORD WORD UDT_dieprotect_data UDT_dieprotect_addon UDT_dieprotect_actual UDT_dieprotect_diag
In_enable_channel in_sensor_signals dieprotect_data dieprotect_data_addon actual_dieprotect diag_data
UDT_dieprotect_addon UDT_dieprotect_actual UDT_dieprotect_diag
Input parameter
Table 5-53: Input parameter Element enable in_actual_position in_enable_monitoring Data type BOOL INT WORD [0,1] Unit Block enable Actual position of the press Enables die protection Meaning

Table 5-54: Input and output parameters Element in_enable_channel Data type WORD Unit Meaning Enables the monitoring channels (each bit of the word for one particular monitoring channel) Sensor signals (each bit of the word for one particular monitoring channel) Die protection data Supplementary information for die protection
in_sensor_signals dieprotect_data dieprotect_data_addon
WORD UDT_dieprotect_d ata UDT_dieprotect_a ddon
84
Element actual_dieprotect diag_data
Data type UDT_dieprotect_a ctual UDT_dieprotect_d iag -
Unit
Meaning Actual data of the die protection Diagnostic data
Output parameter
Table 5-55: Output parameter Element tdc_stop immediate_stop error busy Data type BOOL BOOL BOOL BOOL Unit Meaning Request TDC stop Request immediate stop Error Block is active
85
5.4.5
Function block FB42: FB_dieprotect_trace
Functionality Block for tracing the profile for the die protection Schematic LAD representation
Fig. 5-17: Schematic LAD representation FB_dieprotect_trace BOOL INT WORD UDT_TrendDataDieProtect BOOL enable in_actual_position in_sensor_signals out_Trend_Data_DieProtec in_out_trend_request busy BOOL INT WORD UDT_TrendDataDieProtect BOOL
Input parameter
Table 5-56: Input parameter Element enable Data type BOOL Unit Block enable Meaning

Element in_actual_position in_sensor_signals out_Trend_Data_Die Protec in_out_trend_request INT WORD UDT_TrendDataD ieProtect BOOL Data type Unit [0,1] Meaning Actual position of the press Sensor signals (each bit of the word for one particular monitoring channel) trace data trace data can be updated on the HMI
Output parameter
Table 5-58: Output parameter Element busy Data type BOOL Unit Block is active Meaning
86
5.4.6
Function block FB49: FB_data_transfer_dieprot

Fig. 5-18: Schematic LAD representation
FB_data_transfer_dieprot
BOOL BOOL UDT_dieprotect_data UDT_dieprotect_addon UDT_dieprotect_data
Take_die_data ack recipe_data_ dieprotect out_diepr_data_ addon out_diepr_data out_trend_data
error_id error die_data_active
INT BOOL BOOL UDT_dieprotect_addon UDT_dieprotect_data UDT_TrendDataDieProtect
UDT_TrendDataDieProtect
Input parameter
Table 5-59: Input parameter Element Take_die_data ack recipe_data_dieprotect Data type BOOL BOOL UDT_dieprot ect_data Unit Accept die data Acknowledge Die data for die protection Meaning

Table 5-60: Input and output parameters Element out_diepr_data_addon out_diepr_data out_trend_data Data type UDT_dieprot ect_addon UDT_dieprot ect_data UDT_TrendD ataDieProtect Unit Meaning Supplementary data die protection Die data Profile data
Output parameter
Table 5-61: Output parameter Element error error_id data_transferred Data type BOOL INT BOOL Unit Error Error code Die data successfully transferred Meaning
87
5.4.7
Table 5-62: Elements and integration Function / function block program FB40: FB_dieprotection FB42: FB_dieprotect_trace FB49: FB_data_transfer_dieprot FB65: FB_dieprotection_Ack FB801: FB_dieprotect_simulation Call Called in a cyclic interrupt OB Called in a cyclic interrupt OB Called in OB1 Called in OB1 Called in a cyclic interrupt OB Property/function Monitoring block for die protection Block for tracing the profile for the die protection Accept die data Acknowledges die protection Simulation of the sensor traces
88
5.4.8
Function block FB65: FB_dieprotection_Ack
Functionality Diagnostics and acknowledgment of the die protection Schematic LAD representation
Fig. 5-19: Schematic LAD representation FB_dieprotection_Ack BOOL enable busy error BOOL UDT_dieprotect_diag in_reset_error i_o_Diag_Data_DieProtect BOOL BOOL BOOL UDT_dieprotect_diag
Input parameter
Table 5-63: Input parameter Element enable Data type BOOL Unit Block enable Meaning

Table 5-64: Input and output parameters Element in_reset_error i_o_Diag_Data_DieProtect Data type UDT_dieprot ect_addon UDT_dieprot ect_data Unit Meaning Fault acknowledgment Diagnostic data
Output parameter
Table 5-65: Output parameter Element Busy error Data type BOOL INT Unit Block is active Error Meaning
89
5.4.9
Function block FB801: FB_dieprotect_simulation
Functionality Simulation of the die protection sensors Schematic LAD representation

Fig. 5-20: Schematic LAD representation FB_dieprotect_simulation BOOL INT enable actual_position out_simulated_sensors WORD
Input parameter
Table 5-66: Input parameter
Element enable actual_position
Data type BOOL BOOL -
Unit Block enable
Meaning
[0,1]
Actual position of the press
Output parameter
Table 5-67: Output parameter Element Out_simulated_sensors Data type WORD Unit Meaning Simulated sensor signals
90
5.5
5.5.1
Tonnage monitoring
Task / functionality of the tonnage monitoring
Monitoring tonnages against a minimum and maximum value. Monitoring sums and differences, envelope monitoring.
91
5.5.2
Fig. 5-21: Call environment, main drive control
OB1
HMI
DB950
FB100:
FB_HMI_control DB150: DB_tonnage_data
FB51: FB55:
FB_tonnage_envelope
FB_tonnage_cyclic DB151: DB_tonnage_act_data
OB32
HMI
DB950
FB100:
FB_HMI_control DB990: DB_Diagnose
FB57:
FB_tonnage_sim
FB50:
FB_tonnage_mon
DB150: DB_tonnage_data
DB151: DB_tonnage_act_data
FB54:
FB_tonnage_curve DB111: DB_maindrive_actual_data
FB56:
FB_tonnage_env_mon
92
5.5.3
Table 5-68: UDT50, UDT_tonnage_data Element UDT_tonnage_data ar32Coefficient1 ar32Coefficient2 ai16Tonnage1 ai16Tonnage2 ai16Voltage1 ai16Voltage2 Copyright Siemens AG 2013 All rights reserved
Data type STRUCT ARRAY[0..3] REAL ARRAY[0..3] REAL ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT INT INT INT INT INT INT INT INT INT INT INT -
Unit
Meaning
Calculation coefficient tonnage 1 Calculation coefficient tonnage 2 Tonnage 1 Tonnage 2 Voltage as raw value 1 Voltage as raw value 2 Maximum tonnage Minimum tonnage Measuring range, start Measuring range, end Error reaction Maximum value, sum of all sensors Maximum value, difference sensors 1 & 2 Maximum value, sum sensors 1 & 2 Maximum value, sum sensors 1 & 3 Maximum value, sum sensors 2 & 4 Maximum value, sum sensors 3 & 4 Maximum value, difference sensors 3 & 4 Maximum value, difference sensors 1,2,3,4
kN kN Raw Raw kN kN kN kN kN kN kN kN kN kN
ai16MaxTonnage ai16MinTonnage i16MeasuringRangeBeg i16MeasuringRangeEnd i16ErrorReaction i16MaxSumTot i16MaxDifference1_2 i16MaxSum1_2 i16MaxSum1_3 i16MaxSum2_4 i16MaxSum3_4 i16MaxDifference3_4 i16MaxDifference1_2_3_4
Table 5-69: UDT51, UDT_tonnage_config Element UDT_tonnage_config ar32Coefficient1 ar32Coefficient2 ai16Tonnage1 Data type STRUCT ARRAY[0..3] REAL ARRAY[0..3] REAL ARRAY[0..3] INT kN Tonnage 1 Calculation coefficient tonnage 2 Calculation coefficient tonnage 1 Unit Meaning
93
Element ai16Tonnage2 ai16Voltage1 ai16Voltage2 ai16MaxTonnage i16MaxSumTot i16MaxDifference1_2 i16MaxSum1_2 i16MaxSum1_3 i16MaxSum2_4 i16MaxSum3_4 i16MaxDifference3_4 i16MaxDifference1_2_3_4
Data type ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT INT INT INT INT INT INT INT INT
Unit kN Raw Raw kN kN kN kN kN kN kN kN kN Tonnage 2
Meaning
Voltage as raw value 1 Voltage as raw value 2 Maximum tonnage Maximum value, sum of all sensors Maximum value, difference sensors 1 & 2 Maximum value, sum sensors 1 & 2 Maximum value, sum sensors 1 & 3 Maximum value, sum sensors 2 & 4 Maximum value, sum sensors 3 & 4 Maximum value, difference sensors 3 & 4 Maximum value, difference sensors 1,2,3,4
Table 5-70: UDT52, UDT_tonnage_die_data Element UDT_tonnage_die_data ai16MaxTonnage ai16MinTonnage ai16WarningTonnage i16MinSumTonnage i16WarningSumTonnage i16MaxSumTonnage i16EmptySpace i16MeasuringRangeBeg i16MeasuringRangeEnd i16CalcRangeStrokes i16ErrorReaction Data type STRUCT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT INT INT INT INT INT INT INT INT kN kN kN kN kN kN Error reaction Measuring range, start Measuring range, end Minimum value, sum of all sensors Warning value, sum of all sensors Maximum value, sum of all sensors Alarm value Minimum value Maximum value Unit Meaning
Table 5-71: UDT53, UDT_tonnage_actual Element UDT_tonnage_actual ai16ActualTonnage ai16MaxTonnage Data type STRUCT ARRAY[0..3] INT ARRAY[0..3] kN kN Maximum tonnage Actual force Unit Meaning
94
Element i16ActualSumTot i16MaxSumTot i16ActualDifference1_2 i16MaxDifference1_2 i16ActualSum1_2 i16ActualSum1_3 i16MaxSum1_2 i16MaxSum1_3 i16ActualSum2_4 i16ActualSum3_4 i16MaxSum2_4 i16MaxSum3_4 i16ActualDifference3_4 i16ActualDiff1_2_3_4 i16MaxDifference3_4
Data type INT INT INT INT INT INT INT INT INT INT INT INT INT INT INT INT INT -
Unit
Meaning
kN kN kN kN kN kN kN kN kN kN kN kN kN kN kN kN
Actual sum of all sensors Maximum sum of all sensors Actual difference, sensors 1 & 2 Maximum difference, sensors 1 & 2 Actual sum sensors 1 & 2 Actual sum sensors 1 & 3 Maximum sum, sensors 1 & 2 Maximum sum, sensors 1 & 3 Actual sum sensors 2 & 4 Actual sum sensors 3 & 4 Maximum sum, sensors 2 & 4 Maximum sum, sensors 3 & 4 Actual difference, sensors 3 & 4 Actual difference of all sensors Maximum difference, sensors 3 & 4 Maximum difference of all sensors
i16MaxDifference1_2_3_4
Table 5-72: UDT54, UDT_tonnage_trend Element UDT_tonnage_ trend trend_1 trend_2 trend_3 trend_4 Data type STRUCT ARRAY[0..359] INT ARRAY[0..359] INT ARRAY[0..359] INT ARRAY[0..359] INT kN kN kN kN Tonnage trend, sensor 4 Tonnage trend, sensor 3 Tonnage trend, sensor 2 Tonnage trend, sensor 1 Unit Meaning
Table 5-73: UDT55, UDT_tonnage_diag Element UDT_tonnage_ trend ar32ErrorPos ai16ErrorId ai16ErrorTonnage Data type STRUCT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT kN Tonnage when the error occurs Error code Position when the error occurs Unit Meaning
95
Table 5-74: UDT56, UDT_tonnage_envelope Element UDT_tonnage_ envelope ai16envCalcStrokes ai16ActEnvCalcStrokes ai16envPosOffset ai16envTonnageOffset aboStartNewEnvelopeCalc boSaveEnvelopeData_Die boReadEnvelopeData_Die aboEnvelopeFault Copyright Siemens AG 2013 All rights reserved
Data type STRUCT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] BOOL BOOL BOOL ARRAY[0..3] BOOL ARRAY[0..3] BOOL ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] INT ARRAY[0..3] UDT_DetailDia gTonnageEnv BOOL BOOL BOOL INT
On
Meaning
kN -
Number of strokes for calculation Strokes executed for calculation Offset position Tonnage offset Initiate new envelope calculation Save envelope curve data in the die Load envelope curve data from the die Envelope curve error Envelope curve warning Number of permitted errors until a response is issued Number of permitted warnings until a response is issued Number of errors that have occurred Diagnostics, envelope curve
aboEnvelopeWarning ai16NoOfFaultsPossible ai16NoOfWarningsPossible ai16NoOfFaults audtdiagdetail boEnvelopeImmediateStop boEnvelopeOTStop boEnableEnvelopeMonito i16EnvelopeErrorReaction
Immediate stop request Request TDC stop Enable envelope, monitoring Error response envelope monitoring
Table 5-75: UDT57, UDT_DetailDiagTonnageEnv Element UDT_ DetailDiagTonnageEnv ai16FaultTonnage ai16FaultPos aboFaultHighLow Data type STRUCT ARRAY[0..9] INT ARRAY[0..9] INT ARRAY[0..9] BOOL kN Violation of the upper or lower envelope curve Position for envelope curve violation Tonnage for envelope curve violation Unit Meaning
96
Table 5-76: DB150, DB_tonnage_data Element DB_tonnage_data tonnage_monitoring_data tonnage_config_data tonnage_die_data envelope_data envelope_above envelope_below Data type STRUCT UDT_tonnage_data UDT_tonnage_config UDT_tonnage_die_data UDT_tonnage_envelope UDT_tonnage_trend UDT_tonnage_trend General tonnage data Tonnage configuration Die data, tonnage Data for envelope curves Envelope curve trend, above Envelope curve trend, below Unit Meaning
Table 5-77: DB151, DB_tonnage_act_data Element DB_tonnage_act_data tonnage_actual_data sensor_value_1 sensor_value_2 sensor_value_3
Data type STRUCT UDT_tonnage_actual INT INT INT INT BOOL BOOL BOOL UDT_tonnage_diag BOOL UDT_tonnage_trend UDT_tonnage_trend UDT_tonnage_trend UDT_tonnage_trend UDT_tonnage_envelope ARRAY[0..3] BOOL INT -
Unit
Meaning
Tonnage actual data Value, sensor 1 Value, sensor 2 Value, sensor 3 Value, sensor 4 Enables tonnage monitoring Request immediate stop Request TDC stop Diagnostics data, tonnage New trends available New, however incomplete trends Old and complete trends Envelope curve, below Envelope curve, above Envelope curve data Envelope calculation active Error code
kN kN kN kN -
sensor_value_4 enable_monitoring tonnage_im_stop tonnage_tdc_stop tonnage_diag_data boNewTrendData sTonnageTrendNew sTonnageTrendOld sEnvelopeBelow sEnvelopeAbove sEnvelopeData HMI_CalculationRunning i16tonnageTransferErroId
Table 5-78: DB950, DB_HMI_data_tonnage Element DB_HMI_data_tonnage HMI_sRecipeDataTonnage HMI_sConfigDataTonnage HMI_sActualValuesTonnage HMI_sDiagnosticsTonnage HMI_b16TonnageTrendReque HMI_b16TonnageTrendTrans HMI_aboEnableTonnageTrac HMI_tonnage_trend Data type STRUCT UDT_tonnage_die_data UDT_tonnage_config UDT_tonnage_actual UDT_tonnage_diag WORD WORD ARRAY[0..3] BOOL UDT_tonnage_trend Tonnage trend Die data Tonnage configuration Actual data Diagnostic data Trend request Trend transfer Enables trend display On Meaning
97
Element HMI_tonnage_below HMI_tonnage_above HMI_envelope_data HMI_CalculationRunning HMI_enableTonnageMonitor
Data type UDT_tonnage_trend UDT_tonnage_trend UDT_tonnage_envelope ARRAY[0..3] BOOL BOOL
On -
Meaning Envelope curve, below Envelope curve, above Envelope curve data Envelope calculation active Enables tonnage display
5.5.4
Table 5-79: Elements and integration Function / function block program FB50: FB_tonnage_mon FB51: FB_tonnage_cyclic
Call Called in a cyclic interrupt OB Called in OB1
Property/function Block for tonnage monitoring Block for cyclically processing tonnage monitoring data Block for tracing the tonnage profile
FB54: FB_tonnage_curve
Called in a cyclic interrupt OB Called in OB1 Called in a cyclic interrupt OB Called in a cyclic interrupt OB Called in OB1
FB55: FB_tonnage_envelope FB56: FB_tonnage_env_mon FB57: FB_tonnage_sim FB59: FB_data_transfer_tonnage
Block for calculating the envelope curve Block for monitoring the envelope curve Block for simulating the tonnage characteristic Accept die data
98
5.5.5
Function block FB50: FB_tonnage_mon
Functionality Block for tonnage monitoring Schematic LAD representation

Fig. 5-22: Schematic LAD representation FB_tonnage_mon BOOL INT INT INT INT Enable_monitoring IN1 IN2 IN3 IN4 busy error warning tdc_stop immediate_stop press_in _monitoring_ra
BOOL BOOL BOOL BOOL BOOL BOOL INT UDT_tonnage _data UDT_tonnage _die_data UDT_tonnage _actual UDT_tonnage _diag
INT UDT_tonnage _data UDT_tonnage _die_data UDT_tonnage _actual UDT_tonnage _diag
in_actual_position in_Tonnage_Data in_Tonnage_Die_Data out_Actual_Values_Ton out_Diagnostic_Data_Ton
Input parameter
Table 5-80: Input parameter Element enable_monitoring IN1 IN2 IN3 IN4 Data type BOOL INT INT INT INT Unit Meaning Enables tonnage monitoring Input raw value sensor 1 Input raw value sensor 2 Input raw value sensor 3 Input raw value sensor 4
Input and output parameters Table 5-81: Input and output parameters
Element in_actual_position in_Tonnage_Data INT UDT_tonnage Data type Unit [0,1] Meaning Actual position of the press Tonnage data
99
Element in_Tonnage _Die_Data out_Actual _Values_Ton out_Diagnostic _Data_Ton
Data type _data UDT_tonnage _die_data UDT_tonnage _actual UDT_tonnage _diag -
Unit Die data
Meaning
Actual tonnage data Diagnostic data
Output parameter
Table 5-82: Output parameter Element busy error warning tdc_stop immediate_stop
Data type BOOL BOOL BOOL BOOL BOOL BOOL -
Unit Block is active
Meaning
Tonnage monitoring error Tonnage monitoring warning Request TDC stop Immediate stop request Press in the monitoring range
press_in _monitoring_ra
100
5.5.6
Function block FB51: FB_tonnage_cyclic
Functionality Block for cyclically processing tonnage monitoring data Schematic LAD representation
Fig. 5-23: Schematic LAD representation FB_tonnage_cyclic ARRAY[0..3] OF REAL ARRAY[0..3] OF REAL UDT_tonnage_diag
UDT_tonnage_config BOOL UDT_tonnage_diag
config_data_tonnage ack diag_data
coefficient1 coefficient2
Input parameter
Table 5-83: Input parameter Element config_data_tonnage ack Data type UDT_tonnage_co nfig BOOL Unit Meaning Machine data for tonnage monitoring Acknowledge
Input and output parameters Table 5-84: Input and output parameters
Element diag_data Data type UDT_tonnage _diag Unit Meaning Diagnostics data tonnage monitoring
Output parameter
Table 5-85: Output parameter Element coefficient1 coefficient2 Data type ARRAY[0..3] OF REAL ARRAY[0..3] OF REAL Unit Meaning Coefficient 1 for scaling the tonnage Coefficient 2 for scaling the tonnage
101
5.5.7
Function block FB54: FB_tonnage_curve
Functionality Block for tracing the tonnage profile Schematic LAD representation
Fig. 5-24: Schematic LAD representation FB_tonnage_curve BOOL INT ARRAY[0..3] of INT enable angle tonnage busy new_data trend_data_new trend_data_old BOOL BOOL UDT_tonnage_trend UDT_tonnage_trend
Input parameter
Table 5-86: Input parameter Element enable angle tonnage Data type BOOL INT ARRAY[0..3] of INT [0,1] [kN] or [t] Unit Block enable Actual position of the press Actual press force Meaning
Output parameter
Table 5-87: Output parameter Element busy new_data trend_data_new trend_data_old Data type BOOL BOOL UDT_tonnage_tre nd Unit Block is active New trend data available for HMI and envelope calculation New trend data (is currently being traced) Old trend data (one stroke earlier) Meaning
UDT_tonnage_t rend
102
5.5.8
Function block FB55: FB_tonnage_envelope
Functionality Block for calculating the envelope curve Schematic LAD representation
Fig. 5-25: Schematic LAD representation FB_tonnage_envelope INT INT INT BOOL BOOL BOOL
x_offset y_offset no_of_calc_strokes calc_envelope new_data reset curve envelope_above envelope_below
error error_id calc_running calc_done calc_env_running act_calc_strokes
BOOL WORD BOOL BOOL BOOL INT ARRAY[0..359] of INT ARRAY[0..359] of INT ARRAY[0..359] of INT
ARRAY[0..359] of INT ARRAY[0..359] of INT ARRAY[0..359] of INT
Input parameter
Table 5-88: Input parameter Element x_offset y_offset INT INT INT BOOL BOOL Data type [] [kN] or [t] Unit Meaning Clearance of the envelope curve in the direction of the angle Clearance of the envelope curve in the direction of the tonnage The number of strokes that should be calculated over the envelope curve Calculates the envelope curve Resets the envelope curve
no_of_calc_strokes calc_envelope reset
103

Table 5-89: Input and output parameters Element curve envelope_above envelope_below Data type ARRAY[0..359] of INT ARRAY[0..359] of INT ARRAY[0..359] of INT Unit Meaning Initial curve for calculating the envelope curve Upper envelope curve Lower envelope curve
Output parameter
Table 5-90: Output parameter Element error error_ID calc_running calc_done
Data type BOOL WORD BOOL BOOL BOOL INT -
Unit Error present Error code
Meaning
Curve being calculated Envelope curve has been calculated Envelope curve being calculated Strokes that have been executed for the envelope calculation
calc_envelope _running Act_calc_strokes
104
5.5.9
Function block FB56: FB_tonnage_env_mon
Functionality Block for monitoring the envelope curve Schematic LAD representation
Fig. 5-26: Schematic LAD representation FB_tonnage_env_mon BOOL enable busy out_env_fault out_env_warning TDC_stop Immediate_stop BOOL REAL
BOOL BOOL BOOL BOOL BOOL BOOL REAL INT INT INT INT ARRAY[0..3] OF INT ARRAY[0..3] OF INT UDT_tonnage_trend UDT_tonnage_trend UDT_tonnage _envelope
reset in_actual_position in_Actual_Tonnage_sens_1 in_Actual_Tonnage_sens_2 in_Actual_Tonnage_sens_3 in_Actual_Tonnage_sens_4 in_no_envelope_warn in_no_envelope_fault in_envelope below in_envelope above data_envelope_mon
INT INT INT INT ARRAY[0..3] OF INT ARRAY[0..3] OF INT UDT_tonnage_trend UDT_tonnage_trend UDT_tonnage _envelope
Input parameter
Table 5-91: Input parameter Element enable Data type BOOL Unit Meaning Enable envelope, monitoring
105

Table 5-92: Input and output parameters Element reset In_act_position in_Actual_Tonnage_s ens_1 in_Actual_Tonnage_s ens_2 in_Actual_Tonnage_s ens_3 in_Actual_Tonnage_s ens_4 in_no_of_envelope_w arn in_no_of_envelope_fa ult envelope_below
Data type BOOL REAL INT INT INT INT INT INT UDT_tonnage _trend UDT_tonnage _trend UDT_tonnage _envelope -
Unit Reset error
Meaning
[1,00] [kN] or [t] [kN] or [t] [kN] or [t] [kN] or [t] -
Actual position of the press Actual tonnage sensor 1 Actual tonnage sensor 2 Actual tonnage sensor 3 Actual tonnage sensor 4 Number of violations (exceeded or fallen below) until a warning is initiated Number of violations (exceeded or fallen below) until an error is initiated Envelope curve, below Envelope curve, above Envelope curve data
envelope_above data_envelope _mon
Output parameter
Table 5-93: Output parameter Element busy out_env_fault out_env_warning TDC_stop immediate_stop Data type BOOL BOOL BOOL BOOL Unit Meaning Block being executed Envelope curve error Envelope curve warning Request TDC stop Request immediate stop
BOOL
106
5.5.10
Function block FB57: FB_tonnage_sim
Functionality Block for tonnage simulation Schematic LAD representation

Fig. 5-27: Schematic LAD representation FB_tonnage_sim BOOL BOOL INT INT INT INT INT
in_boReset in_boJumpActive in_i16MaxForce1 in_i16MaxForce2 in_i16MaxForce3 in_i16MaxForce4 in_i16JumpForce in_r32StartForce1 in_r32StartForce2 in_r32StartForce3 in_r32StartForce4 in_r32StartJump in_r32ActualAngle in_sTonnageData
out_i16Voltage1 out_i16Voltage2 out_i16Voltage3 out_i16Voltage4 error error_ID
INT INT INT INT BOOL INT
REAL REAL REAL REAL REAL REAL UDT_tonnage _data
UDT_tonnage _data
Input parameter
Table 5-94: Input parameter Element in_boReset in_boJumpActive in_i16MaxForce1 in_i16MaxForce2 in_i16MaxForce3 in_i16MaxForce4 in_i16JumpForce in_r32StartForce1 Data type BOOL BOOL INT INT INT INT INT REAL [kN] or [t] [kN] or [t] [kN] or [t] [kN] or [t] [kN] or [t] [1,00] Unit Reset error Jump at sensor 1 active Maximum tonnage sensor 1 Maximum tonnage sensor 2 Maximum tonnage sensor 3 Maximum tonnage sensor 4 Maximum tonnage at the jump Starting point tonnage buildup, sensor 1 Meaning
107
Element in_r32StartForce2 in_r32StartForce3 in_r32StartForce4 in_r32StartJump in_r32ActualAngle
Data type REAL REAL REAL REAL REAL
Unit [1,00] [1,00] [1,00] [1,00] [1,00]
Meaning Starting point tonnage buildup, sensor 2 Starting point tonnage buildup, sensor 3 Starting point tonnage buildup, sensor 4 Starting point jump, sensor 1 Actual position of the press

Table 5-95: Input and output parameters Element in_sTonnageData Data type UDT_tonnage _data Unit Tonnage data Meaning
Output parameter
Table 5-96: Output parameter Element
Data type INT INT INT INT BOOL INT
Unit Raw Raw Raw Raw -
Meaning Tonnage raw value, sensor 1 Tonnage raw value, sensor 2 Tonnage raw value, sensor 3 Tonnage raw value, sensor 4 Error present Error code
out_i16Voltage1 out_i16Voltage2 out_i16Voltage3 out_i16Voltage4 error error_ID
108
5.5.11
Function block FB59: FB_data_transfer_tonnage

Fig. 5-28: Schematic LAD representation FB_data_transfer_tonnage BOOL BOOL in_transfer_data ack error error_id data_transferred BOOL INT BOOL
Input parameter
Table 5-97: Input parameter Element in_transfer_data ack Data type BOOL BOOL Unit Accept die data Acknowledge Meaning
Output parameter
Table 5-98: Output parameter Element error error_id data_transferred Data type BOOL INT BOOL Unit Error Error code Die data successfully transferred Meaning
109
5.6
Additional functions and data blocks

Element Data type STRUCT UDT_TVB+MDI_TLG111 Unit Meaning Communication to S120 Communication to S120
Table 5-99: DB12, DB_com_Sinamics
DB_com_Sinamics Com_data_maindrive
Table 5-100: DB100, DB_global_data Element DB_global_data ACK take_die_data error_die_data die_data_transferred Data type STRUCT BOOL BOOL BOOL BOOL Unit Meaning General global data Fault acknowledgment Accept die data Error when transferring the die data Die data accepted
Table 5-101: DB201, DB_WR_PARAM_3100 Element DB_WR_PARAM_3100 Request_reference Request_ID Drive_object_nr Number_of_parameters Attributes Number_of_elements Parameter_number Subindex Format Number_of_values Value_16Bit Data type STRUCT BYTE BYTE BYTE BYTE BYTE BYTE WORD WORD BYTE BYTE WORD Unit Meaning Parameter data 3100(time sync)
Table 5-102: DB202, DB_WR_PARAM_3101_1 Element DB_WR_PARAM_3101_1 Request_reference Request_ID Drive_object_nr Number_of_parameters Attributes Number_of_elements Parameter_number Subindex Data type STRUCT BYTE BYTE BYTE BYTE BYTE BYTE WORD WORD Unit Meaning Parameter data 3101(time sync)
110
Element Format Number_of_values Value_16Bit Value_32Bit BYTE BYTE
Data type -
Unit
Meaning
WORD WORD
Table 5-103: DB203, DB_WR_PARAM_3101_0 Element DB_WR_PARAM_3101_0 Request_reference Request_ID Drive_object_nr Number_of_parameters Attributes Number_of_elements Parameter_number Subindex
Data type STRUCT BYTE BYTE BYTE BYTE BYTE BYTE WORD WORD BYTE BYTE WORD WORD -
Unit
Meaning Parameter data 3101(time sync)
Format Number_of_values Value_16Bit Value_32Bit
Table 5-104: DB204, DB_Comm_OBs Element DB_Comm_OBs syncTime_boExecute syncTime_boDone Data type STRUCT BOOL BOOL Unit Meaning Time synchronization Initiate time of day synchronization Time synchronization carried out
Table 5-105: DB700, DB_preallocation Element DB_preallocation sDieDataMaindrive sDieDataCounter sDieDataCAMS sDieDataDieprotect sDieDataTonnage sDieDataEnvelope sMachineDataMaindrive sMachineDataBrakeangle sMachineDataStrokeheight Data type STRUCT UDT_die_data_maindrive UDT_counter_data UDT_cam_data UDT_dieprotect_data UDT_tonnage_die_data UDT_tonnage_envelope UDT_config_maindrive UDT_config_brake_angle UDT_strokeheight_table Unit Meaning Data for preallocations and simulation Die data, main drive Die data, counter Die data, output cams Die data, die protection Die data, tonnage Die data, envelope curves Machine data, main drive Machine data, braking angle Machine data, stroke height table
111
Element sMachineDataTonnage
Data type UDT_tonnage_config -
Unit
Meaning Machine data, tonnage
Table 5-106: DB800, DB_Simulation Element DB_ Simulation sensor_permanent_ON sensor_permanent_OFF Sensors_simulated Data type STRUCT ARRAY[0..15] BOOL ARRAY[0..15] BOOL INT Signal simulated sensors Sensor permanently OFF Unit Meaning Sensor simulation die protection Sensor permanently ON
Table 5-107: DB901, DB_HMI_control Element DB_HMI_control

Data type STRUCT BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL -
Unit
Meaning Data for and from the HMI Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable
HIM_b32Display24 HIM_b32Display25 HIM_b32Display26 HIM_b32Display27 HIM_b32Display28 HIM_b32Display29 HIM_b32Display30 HIM_b32Display31 HIM_b32Display16 HIM_b32Display17 HIM_b32Display18 HIM_b32Display19 HIM_b32Display20 HIM_b32Display21 HIM_b32Display22 HIM_b32Display23 HIM_b32Display8 HIM_b32Display9 HIM_b32Display10 HIM_b32Display11 HIM_b32Display12 HIM_b32Display13 HIM_b32Display14 HIM_b32Display15 HIM_b32Display HIM_b32Display1 HIM_b32Display2
112
Element HIM_b32Display3 HIM_b32Display4 HIM_b32Display5 HIM_b32Display6 HIM_b32Display7 HMI_b32Button24 HMI_b32Button25 HMI_b32Button26 HMI_b32Button27 HMI_b32Button28 HMI_b32Button29 HMI_b32Button30 HMI_b32Button31 HMI_b32Button16 HMI_b32Button17 HMI_b32Button18
Data type BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL -
Unit
Meaning Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable
HMI_b32Button19 HMI_b32Button20 HMI_b32Button21 HMI_b32Button22 HMI_b32Button23 HMI_b32Button8 HMI_b32Button9 HMI_b32Button10 HMI_b32Button11 HMI_b32Button12 HMI_b32Button13 HMI_b32Button14 HMI_b32Button15 HMI_b32Button0 HMI_b32Button1 HMI_b32Button2 HMI_b32Button3 HMI_b32Button4 HMI_b32Button5 HMI_b32Button6 HMI_b32Button7 HMI_b32ButtonDisp24 HMI_b32ButtonDisp25 HMI_b32ButtonDisp26 HMI_b32ButtonDisp27 HMI_b32ButtonDisp28 HMI_b32ButtonDisp29
113
Element HMI_b32ButtonDisp30 HMI_b32ButtonDisp31 HMI_b32ButtonDisp16 HMI_b32ButtonDisp17 HMI_b32ButtonDisp18 HMI_b32ButtonDisp19 HMI_b32ButtonDisp20 HMI_b32ButtonDisp21 HMI_b32ButtonDisp22 HMI_b32ButtonDisp23 HMI_b32ButtonDisp8 HMI_b32ButtonDisp9 HMI_b32ButtonDisp10 HMI_b32ButtonDisp11 HMI_b32ButtonDisp12 HMI_b32ButtonDisp13
Unit
HMI_b32ButtonDisp14 HMI_b32ButtonDisp15 HMI_b32ButtonDisp HMI_b32ButtonDisp1 HMI_b32ButtonDisp2 HMI_b32ButtonDisp3 HMI_b32ButtonDisp4 HMI_b32ButtonDisp5 HMI_b32ButtonDisp6 HMI_b32ButtonDisp7 HMI_b32ButtonOp24 HMI_b32ButtonOp25 HMI_b32ButtonOp26 HMI_b32ButtonOp27 HMI_b32ButtonOp28 HMI_b32ButtonOp29 HMI_b32ButtonOp30 HMI_b32ButtonOp31 HMI_b32ButtonOp16 HMI_b32ButtonOp17 HMI_b32ButtonOp18 HMI_b32ButtonOp19 HMI_b32ButtonOp20 HMI_b32ButtonOp21 HMI_b32ButtonOp22 HMI_b32ButtonOp23 HMI_b32ButtonOp8
114
Element HMI_b32ButtonOp9 HMI_b32ButtonOp10 HMI_b32ButtonOp11 HMI_b32ButtonOp12 HMI_b32ButtonOp13 HMI_b32ButtonOp14 HMI_b32ButtonOp15 HMI_b32ButtonOp HMI_b32ButtonOp1 HMI_b32ButtonOp2 HMI_b32ButtonOp3 HMI_b32ButtonOp4 HMI_b32ButtonOp5 HMI_b32ButtonOp6 HMI_b32ButtonOp7 HMI_b32ButtonVis24
Unit
HMI_b32ButtonVis25 HMI_b32ButtonVis26 HMI_b32ButtonVis27 HMI_b32ButtonVis28 HMI_b32ButtonVis29 HMI_b32ButtonVis30 HMI_b32ButtonVis31 HMI_b32ButtonVis16 HMI_b32ButtonVis17 HMI_b32ButtonVis18 HMI_b32ButtonVis19 HMI_b32ButtonVis20 HMI_b32ButtonVis21 HMI_b32ButtonVis22 HMI_b32ButtonVis23 HMI_b32ButtonVis8 HMI_b32ButtonVis9 HMI_b32ButtonVis10 HMI_b32ButtonVis11 HMI_b32ButtonVis12 HMI_b32ButtonVis13 HMI_b32ButtonVis14 HMI_b32ButtonVis15 HMI_b32ButtonVis HMI_b32ButtonVis1 HMI_b32ButtonVis2 HMI_b32ButtonVis3
115
Element HMI_b32ButtonVis4 HMI_b32ButtonVis5 HMI_b32ButtonVis6 HMI_b32ButtonVis7 HMI_b32Visible24 HMI_b32Visible25 HMI_b32Visible26 HMI_b32Visible27 HMI_b32Visible28 HMI_b32Visible29 HMI_b32Visible30 HMI_b32Visible31 HMI_b32Visible16 HMI_b32Visible17 HMI_b32Visible18 HMI_b32Visible19
Data type BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL ARRAY[0..4] WORD INT INT INT BOOL BOOL -
Unit
Meaning Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Screen number Die data set number Status die save Transfer die data Graphic-dependent variable Graphic-dependent variable
HMI_b32Visible20 HMI_b32Visible21 HMI_b32Visible22 HMI_b32Visible23 HMI_b32Visible8 HMI_b32Visible9 HMI_b32Visible10 HMI_b32Visible11 HMI_b32Visible12 HMI_b32Visible13 HMI_b32Visible14 HMI_b32Visible15 HMI_b32Visible HMI_b32Visible1 HMI_b32Visible2 HMI_b32Visible3 HMI_b32Visible4 HMI_b32Visible5 HMI_b32Visible6 HMI_b32Visible7 HMI_ab32ScreenNumber HMI_i16recipeNumber HMI_i16statesavedata HMI_i16transferRecipe HMI_b32TemplButton24 HMI_b32TemplButton25
116
Element HMI_b32TemplButton26 HMI_b32TemplButton27 HMI_b32TemplButton28 HMI_b32TemplButton29 HMI_b32TemplButton30 HMI_b32TemplButton31 HMI_b32TemplButton16 HMI_b32TemplButton17 HMI_b32TemplButton18 HMI_b32TemplButton19 HMI_b32TemplButton20 HMI_b32TemplButton21 HMI_b32TemplButton22 HMI_b32TemplButton23 HMI_b32TemplButton8 HMI_b32TemplButton9
Unit
HMI_b32TemplButton10 HMI_b32TemplButton11 HMI_b32TemplButton12 HMI_b32TemplButton13 HMI_b32TemplButton14 HMI_b32TemplButton15 HMI_b32TemplButton HMI_b32TemplButton1 HMI_b32TemplButton2 HMI_b32TemplButton3 HMI_b32TemplButton4 HMI_b32TemplButton5 HMI_b32TemplButton6 HMI_b32TemplButton7 HMI_b32TemplButtonDisp24 HMI_b32TemplButtonDisp25 HMI_b32TemplButtonDisp26 HMI_b32TemplButtonDisp27 HMI_b32TemplButtonDisp28 HMI_b32TemplButtonDisp29 HMI_b32TemplButtonDisp30 HMI_b32TemplButtonDisp31 HMI_b32TemplButtonDisp16 HMI_b32TemplButtonDisp17 HMI_b32TemplButtonDisp18 HMI_b32TemplButtonDisp19 HMI_b32TemplButtonDisp20
117
Element HMI_b32TemplButtonDisp21 HMI_b32TemplButtonDisp22 HMI_b32TemplButtonDisp23 HMI_b32TemplButtonDisp8 HMI_b32TemplButtonDisp9 HMI_b32TemplButtonDisp10 HMI_b32TemplButtonDisp11 HMI_b32TemplButtonDisp12 HMI_b32TemplButtonDisp13 HMI_b32TemplButtonDisp14 HMI_b32TemplButtonDisp15 HMI_b32TemplButtonDisp HMI_b32TemplButtonDisp1 HMI_b32TemplButtonDisp2 HMI_b32TemplButtonDisp3 HMI_b32TemplButtonDisp4
Unit
HMI_b32TemplButtonDisp5 HMI_b32TemplButtonDisp6 HMI_b32TemplButtonDisp7 HMI_b32TemplButtonOp24 HMI_b32TemplButtonOp25 HMI_b32TemplButtonOp26 HMI_b32TemplButtonOp27 HMI_b32TemplButtonOp28 HMI_b32TemplButtonOp29 HMI_b32TemplButtonOp30 HMI_b32TemplButtonOp31 HMI_b32TemplButtonOp16 HMI_b32TemplButtonOp17 HMI_b32TemplButtonOp18 HMI_b32TemplButtonOp19 HMI_b32TemplButtonOp20 HMI_b32TemplButtonOp21 HMI_b32TemplButtonOp22 HMI_b32TemplButtonOp23 HMI_b32TemplButtonOp8 HMI_b32TemplButtonOp9 HMI_b32TemplButtonOp10 HMI_b32TemplButtonOp11 HMI_b32TemplButtonOp12 HMI_b32TemplButtonOp13 HMI_b32TemplButtonOp14 HMI_b32TemplButtonOp15
118
Element HMI_b32TemplButtonOp HMI_b32TemplButtonOp1 HMI_b32TemplButtonOp2 HMI_b32TemplButtonOp3 HMI_b32TemplButtonOp4 HMI_b32TemplButtonOp5 HMI_b32TemplButtonOp6 HMI_b32TemplButtonOp7 HMI_b32TemplRectDisp24 HMI_b32TemplRectDisp25 HMI_b32TemplRectDisp26 HMI_b32TemplRectDisp27 HMI_b32TemplRectDisp28 HMI_b32TemplRectDisp29 HMI_b32TemplRectDisp30 HMI_b32TemplRectDisp31
Data type BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL INT INT ARRAY[0..3] -
Unit
Meaning Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Active screen Active die
HMI_b32TemplRectDisp16 HMI_b32TemplRectDisp17 HMI_b32TemplRectDisp18 HMI_b32TemplRectDisp19 HMI_b32TemplRectDisp20 HMI_b32TemplRectDisp21 HMI_b32TemplRectDisp22 HMI_b32TemplRectDisp23 HMI_b32TemplRectDisp8 HMI_b32TemplRectDisp9 HMI_b32TemplRectDisp10 HMI_b32TemplRectDisp11 HMI_b32TemplRectDisp12 HMI_b32TemplRectDisp13 HMI_b32TemplRectDisp14 HMI_b32TemplRectDisp15 HMI_b32TemplRectDisp HMI_b32TemplRectDisp1 HMI_b32TemplRectDisp2 HMI_b32TemplRectDisp3 HMI_b32TemplRectDisp4 HMI_b32TemplRectDisp5 HMI_b32TemplRectDisp6 HMI_b32TemplRectDisp7 HMI_i16ActiveScreen HMI_i16ActiveRecipe HMI_aboSwitch
119
Element HIM_b16Display8 HIM_b16Display9 HIM_b16Display10 HIM_b16Display11 HIM_b16Display12 HIM_b16Display13 HIM_b16Display14 HIM_b16Display15 HIM_b16Display0 HIM_b16Display1 HIM_b16Display2 HIM_b16Display3 HIM_b16Display4 HIM_b16Display5 HIM_b16Display6
Data type BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL ARRAY[0..33] BYTE BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL -
Unit
Meaning
Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable
HIM_b16Display7 HMI_spare HMI_b32ButtonImpInt24 HMI_b32ButtonImpInt25 HMI_b32ButtonImpInt26 HMI_b32ButtonImpInt27 HMI_b32ButtonImpInt28 HMI_b32ButtonImpInt29 HMI_b32ButtonImpInt30 HMI_b32ButtonImpInt31 HMI_b32ButtonImpInt16 HMI_b32ButtonImpInt17 HMI_b32ButtonImpInt18 HMI_b32ButtonImpInt19 HMI_b32ButtonImpInt20 HMI_b32ButtonImpInt21 HMI_b32ButtonImpInt22 HMI_b32ButtonImpInt23 HMI_b32ButtonImpInt8 HMI_b32ButtonImpInt9 HMI_b32ButtonImpInt10 HMI_b32ButtonImpInt11 HMI_b32ButtonImpInt12 HMI_b32ButtonImpInt13 HMI_b32ButtonImpInt14 HMI_b32ButtonImpInt15
120
Element HMI_b32ButtonImpInt HMI_b32ButtonImpInt1 HMI_b32ButtonImpInt2 HMI_b32ButtonImpInt3 HMI_b32ButtonImpInt4 HMI_b32ButtonImpInt5 HMI_b32ButtonImpInt6 HMI_b32ButtonImpInt7 HMI_b32TemplButtImpInt24 HMI_b32TemplButtImpInt25 HMI_b32TemplButtImpInt26 HMI_b32TemplButtImpInt27 HMI_b32TemplButtImpInt28 HMI_b32TemplButtImpInt29 HMI_b32TemplButtImpInt30 HMI_b32TemplButtImpInt31
Data type BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL -
Unit
Meaning Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable Graphic-dependent variable
HMI_b32TemplButtImpInt16 HMI_b32TemplButtImpInt17 HMI_b32TemplButtImpInt18 HMI_b32TemplButtImpInt19 HMI_b32TemplButtImpInt20 HMI_b32TemplButtImpInt21 HMI_b32TemplButtImpInt22 HMI_b32TemplButtImpInt23 HMI_b32TemplButtImpInt8 HMI_b32TemplButtImpInt9 HMI_b32TemplButtImpInt10 HMI_b32TemplButtImpInt11 HMI_b32TemplButtImpInt12 HMI_b32TemplButtImpInt13 HMI_b32TemplButtImpInt14 HMI_b32TemplButtImpInt HMI_b32TemplButtImpInt HMI_b32TemplButtImpInt1 HMI_b32TemplButtImpInt2 HMI_b32TemplButtImpInt3 HMI_b32TemplButtImpInt4 HMI_b32TemplButtImpInt5 HMI_b32TemplButtImpInt6 HMI_b32TemplButtImpInt7
121
Table 5-108: DB990, DB_Diagnose Element DB_Diagnose diag_die_data diag_maindrive Data type STRUCT ARRAY[0..3] WORD ARRAY[0..1] WORD Diagnostic code Unit Meaning General global data Diagnostic code
Table 5-109: DB2001, DB_trend Element DB_trend trend Data type STRUCT UDT_TrendDataDieProtect Unit Meaning General global data
122
6 Description of the graphic interface
6
6.1
Description of the graphic interface

Description of the operator buttons
The main functions of the graphic interface, which can be operated from every screen, are located at the edge of each screen in the form of gray buttons.
Fig. 6-1: Operator buttons in the screen template
Switching on the main drive Switching off the main drive Jogging when setting up and moving backward Start for single stroke, continuous stroke and positioning
Acknowledge error
TDC stop in the continuous stroke mode Immediate stop for single stroke or continuous stroke
Change to the main operating window (210)
Change to the main machine data window (400)
In the demonstration project without function
Log off user
Toggling between German and English
Change to the main die data window (300)
Change to the tool (die) change window (700)
Change into the main diagnostics window (500)
Change into the user management
Close WinCC flexible runtime
123
6.2
6.2.1
Machine data
Task / functionality of the machine data
All data, which are of significance for operating the press, are saved under machine data. This includes data used as basis for various calculations or machine limits. The machine data are saved in a retentive data block in the control system.
6.2.2
List of screens
Table 6-1: List of screens, machine data Screen number 400 410 Screen name 400_mada_general 410_mada_maindrive Property/function Main screen, machine data; saving, loading, preallocating machine data Main drive data and data to calculate the braking angle Stroke height table Tonnage data Sensor characteristics
415
415_mada_strokeheight 450_mada_tonnage 451_mada_tonnage_sensors
450 451
124
6.2.3
Figure 400: 400_mada_general
Functionality Main screen, machine data; saving, loading, preallocating machine data
Fig. 6-2: Main screen, machine data
This involves the main screen of the machine data management. Active machine data can be loaded into the HMI, the data entered into the HMI saved, and machine data preallocated. Preallocating the machine data makes it simpler to demonstrate the functionality using a test setup.
125
6.2.4
Figure 410: 410_mada_maindrive
Functionality Limiting data for the main drive, measurement results to calculate the braking angle
Fig. 6-3: Limiting data, main drive
The main drive data should be saved in the upper part of the window. Measured values from the 3 braking operations at different stroke rates are saved in the lower section. Factors A, B and C are calculated when the machine data are saved. Based on these factors, in operation, the braking angle is calculated as a function of the stroke rate.
126
6.2.5
Figure 415: 415_mada_strokeheight
Functionality Stroke height table

Fig. 6-4: Stroke height table
The stroke height table is saved in this screen. For each stroke height number, the particular stroke height, the TDC offset, the adjustment position when reequipping and the maximum stroke rate are set.
127
6.2.6
Figure 450: 450_mada_tonnage
Functionality Maximum permissible tonnages at the sensors

Fig. 6-5: Maximum permissible tonnages at the sensors
The maximum tonnage, which may be present at each individual sensor, is specified in the upper part of the window. The permissible sums from a combination of 2 sensors and the sum of all sensors are specified in the center part of the window. The amount by which sensors 1 and 2 or 3 and 4 may differ is specified in the lower part of the window. Also the difference between the sums from sensor 1 with 2 and 3 with 4.
128
6.2.7
Figure 451: 451_mada_tonnage_sensors
Functionality Sensor characteristics

Fig. 6-6: Sensor characteristics
The linearized characteristic is saved for each sensor in this screen. Each characteristic is linearized across 2 points.
129
6.3
6.3.1
Die data
Task / functionality of the die data
All data that are dependent on the die and are of significance for operating the press are saved under die data. This includes data used as basis for various calculations or load limits. The machine data are saved in the HMI as recipe. The active die data set is loaded into the control system.
6.3.2
List of screens
Table 6-2: List of screens, die data Screen number 300 310 Screen name 300_die_data_general 310_die_data_maindrive Property/function Main screen, die data; saving, loading, preallocating die data Main drive data and counter parameterization
330 340 350 700
330_die_data_cams 340_die_data_dieprotection 350_die_data_tonnage 700_die_change
Output cam parameterization Parameterizing the die protection Tonnage monitoring limits Changing the die data set
130
6.3.3
Figure 300: 300_die_data_general
Functionality Main screen, die data; saving, loading, preallocating die data
Fig. 6-7: Main screen, die data
This involves the main screen of the die data management. A die data set can be selected using the drop-down window. Using the two small buttons below, a new data set can be created, or an existing data set deleted. The data entered at the HMI is saved in the recipe data set of the HMI by pressing the "Save dataset" button. The preallocation makes it easier to demonstrate the functionality of the test setup without ordering complex machines and die data that match one another.
131
6.3.4
Figure 310: 310_die_data_maindrive
Functionality Main drive data and counter parameterization

Fig. 6-8: Main drive data and counter parameterization
The main drive data of the die are set here. The counters are parameterized in the right-hand section. Count values and count direction can be set. Using the adjacent check mark, you can select as to whether a TDC stop should be executed when reaching the count value (or 0, when counting down).
132
6.3.5
Figure 330: 330_die_data_cams
Functionality Output cam parameterization

Fig. 6-9: Output cam parameterization
The output cams are parameterized here. As explained in more detail in Chapter 2.4, output cams can be parameterized here for up to 16 channels. The start value is set in degrees. The type is the next setting option. Either position-based or timebased can be selected. If, from the output cams, an output cam is not to be used, then in this case "off" should be selected here. If a position-based output cam was parameterized, then the end value can be set in degrees; if a time-based cam was parameterized, then the time can be set in milliseconds. Further, a rate time can be parameterized for each output cam. Exclusively, for the first two output cams, a count value can be specified so that at each nth stroke, the output cam is output.
133
6.3.6
Figure 340: 340_die_data_dieprotection
Functionality Parameterizing the die protection

Fig. 6-10: Parameterizing the die protection
The individual channels (up to 16) are parameterized here. A name for the particular channel can be assigned in the first column. The monitoring type is selected in the second column. You can click on the info symbol to obtain more detailed information about the particular monitoring type. A precise description of the monitoring types is provided in Chapter 2.5. The channel is then parameterized according to the type as described in Chapter 2.5 with count value, start, end and number of strokes. In the last line, you can select as to how the machine should respond when an error occurs in the particular channel. You can select between an immediate stop, TDC stop and no reaction.
134
6.3.7
Figure 350: 350_die_data_tonnage
Functionality Tonnage monitoring limits

Fig. 6-11: Tonnage monitoring limits
The permissible tonnages dependent on the selected die are parameterized here. A measuring range must be specified. Monitoring only takes place in this range. A minimum tonnage, tonnage from which a warning is initiated and maximum tonnage when the error reaction takes effect are parameterized. The error reaction is always a TDC stop when the minimum tonnage is fallen below. The envelope monitoring is parameterized in the lower part of the window. Here, you can select the number of envelope curve violations that can be tolerated, when a warning and when a error reaction is output. For the parameterizable error reaction, either an TDC stop or immediate stop can be selected.
135
6.3.8
Figure 700: 700_die_change
Functionality Changing the die data set

Fig. 6-12: Changing the die data set
A die data set can be selected using the drop-down window. The data set is transferred from the HMI into the control by pressing the "accept data" button. An error message is output if a die that does not match the machine data was parameterized.
136
6.4
6.4.1
Operation
Task / functionality in operation
All screens that are required in operation for monitoring, information and setting purposes.
6.4.2
List of screens
Table 6-3: List of screens for operation Screen number 210 Screen name 210_operate_maindrive Property/function Main screen for operation, operating mode selection, enabling the monitoring functions, main drive information Display counter state (counters 1-5)
220
220_operate_counter1_5
221
221_operate_6_9 230_operate_cams 240_operate_dieprotection 245_operate_dieprotect_trend 248_operate_diag_dieprotect 250_operate_tonnage_values 251_operate_tonnage_envelope 255_operate_tonnage_trend 257_operate_tonnage_trend_2_big 260_operate_diag_tonnage 815_operate_dieprotect_trend_6_big
Display counter state (counters 6-9) Output cam display Die protection display Die protection trend Die protection diagnostics Tonnage monitoring display Envelope calculation Tonnage trend Tonnage trend of a sensor, magnified Diagnostics tonnage monitoring Trend of a channel of the die protection, magnified
230 240 245 248 250 251 255 257 260 815
137
6.4.3
Figure 210: 210_operate_maindrive
Functionality Main screen for operation, operating mode selection, enabling the monitoring functions, main drive information
Fig. 6-13: Main screen for operation
The operation mode is selected using the drop-down menu on the left-hand side. The "Setup", "Single stroke", "Continuous stroke", "Positioning" and backward operating modes are available. Below, you can find information on enabling the main drive, the position of the braking/coupling combination, the punch stroke rate and stroke rate limiting. Below this, the die protection, tonnage monitoring and the envelope monitoring are activated or deactivated. The stroke rate is selected in the lower part of the window. It can be adjusted using the slider or using the input window to the left. The measured stroke rate is displayed at the top right-hand section of the window. Below this, the absolute and actual (absolute+offset) ram position is displayed. The display includes the actual braking angle, which is always calculated for the selected stroke rate. An information field includes the display of the main drive temperature.
138
6.4.4
Figure 220: 220_operate_counter1_5
Functionality Display counter state (counters 1-5)

Fig. 6-14: Counter state (counters 1-5)
The counter states of counters 1 to 5 and the machine counter are shown in this screen. The status of the machine counter is located at the top. This counts each machine stroke. It can be reset using the adjacent button. Additional counters (part counters, maintenance interval counters) are located below. They can be individually activated/deactivated using the left-hand button. The actual count value is located next to it; this can be reset using the reset button. The setpoint of the individual counters is located on the right-hand side. Once the setpoint is reached, the circle next to it turns green, and the TDC stop, possibly parameterized in the die data, is executed.
139
6.4.5
Figure 221: 221_operate_counter6_9
Functionality Display counter state (counters 6-9)

Fig. 6-15: Counter state (counters 6-9)
The counter states of counters 6 to 9 and the machine counter are shown in this screen. The status of the machine counter is located at the top. This counts each machine stroke. It can also be reset using the adjacent button. Additional counters (part counters, maintenance interval counters) are located below. They can be individually activated/deactivated using the left-hand button. The actual count value is located next to it; this can be reset using the reset button. The setpoint of the individual counters is located on the right-hand side. Once the setpoint is reached, the circle next to it turns green, and the TDC stop, possibly parameterized in the die data, is executed.
140
6.4.6
Figure 230: 230_operate_cams
Functionality Output cam display

Fig. 6-16: Output cam display
The states of the output cams are shown in this screen. Only the parameterized output cams are shown. All of the cams not parameterized in the die data are hidden.
141
6.4.7
Figure 240: 240_operate_dieprotection
Functionality Die protection display

Fig. 6-17: Die protection display
The status of the die protection is displayed in this screen. All of the channels not parameterized in the die data are hidden. The first column includes the channel identifier, which was selected in the die data. In the Enable column, each channel can be separately activated/deactivated. The status of the sensor and the associated output cam are shown in the Sensor or Output cam columns. The counter value is shown in the next column. If an error occurs in one of the die protection channels, then this is shown using a green circle in the Error column. An error can be simulated using a sensor that is continuously on or off. These buttons should be hidden for a real machine.
142
6.4.8
Figure 245: 245_operate_dieprotect_trend
Functionality Die protection trend

Fig. 6-18: Die protection trend
If an error occurs in the die protection, then this can be more precisely analyzed in this screen. For channels 1 to 8, the sensor state and the output cam state with respect to the press position can be traced. The sensors are shown using green lines and the output cams with light blue lines. If a channel should be permanently traced, then this can be activated using the "Play" key (arrow to the right). The stroke trend is shown here after each completed stroke. During a stroke, if the diagram should be updated, for example in the case of an error, then it can be selected using the green "Refresh" button. The part of the stroke already executed is shown as above. The part of the stroke that has still not been executed can be identified by the fact that the graph is located on the x axis. The diagram of the selected channel is shown magnified (zoomed in) by pressing the right-hand button (arrow towards the top).
143
6.4.9
Figure 248: 248_operate_diag_dieprotect
Functionality Die protection diagnostics

Fig. 6-19: Die protection diagnostics
If an error occurs in the die protection, then it is shown here and described in words. A message window is displayed with "die protection error". The error number, the error description, the position where the error occurred and the count value when the fault occurred are shown in the actual screen for each monitoring channel.
144
6.4.10
Figure 250: 250_operate_tonnage_values
Functionality Tonnage monitoring display

Fig. 6-20: Tonnage display
All of the values in the screen are maximum values during a press stroke in the trace range. All of the values are updated when the trace range is exited (this is defined in the die data). The maximum values of the individual sensors are shown, graphically and numerically in the upper section of the screen. The maximum summed tonnages can be read off at the center of the screen. The differences between the maximum tonnages of the sensors can be read off at the lower part of the screen.
145
6.4.11
Figure 251: 251_operate_tonnage_envelope
Functionality Envelope calculation

Fig. 6-21: Envelope calculation
Using this window, the envelope curves can be individually calculated for each of the four tonnage sensors. For each sensor, a clearance value is specified for the angle and the tonnage. A number of strokes must be entered. When pressing the "start envelope calculation" button, this is assigned a blue background and the envelope calculation is started. The number of strokes specified above must be executed in order to obtain an average tonnage trend. The upper and lower envelope curves are then placed around this average trend. The number of strokes that have already been executed can be read off from the diagram.
146
6.4.12
Figure 255: 255_operate_tonnage_trend
Functionality Tonnage trend

Fig. 6-22: Tonnage trend
If an error occurs in the tonnage or envelope monitoring, then this can be more precisely analyzed in this screen. For tonnage sensors 1-4, the tonnage can be traced with respect to the press position. The tonnage is shown using green lines and the two envelope curves with purple lines. If a sensor should be permanently traced, then this can be activated using the "Play" key (arrow to the right). The stroke trend is shown here after each completed stroke. During a stroke, if the diagram should be updated, for example in the case of an error, then it can be selected using the green "Refresh" button. The part of the stroke already executed is now shown as above. The diagram of the selected sensor is shown magnified (zoomed in) by pressing the right-hand button (arrow towards the top). More precise values can be read off in the tables below the diagrams.
147
6.4.13
Fig. 256-259: 257_operate_tonnage_trend_2
Functionality Tonnage trend of a sensor, magnified

Fig. 6-23: Tonnage trend of a sensor
This screen is called if one of the zoom buttons is pressed in screen 255. If an error occurs in the tonnage or envelope monitoring, then this can be more precisely analyzed in this screen. The tonnage is shown using green lines and the two envelope curves with purple lines. If a sensor should be permanently traced, then this can be activated using the "Play" key (arrow to the right). The stroke trend is shown here after each completed stroke. During a stroke, if the diagram should be updated, for example in the case of an error, then it can be selected using the green "Refresh" button. The part of the stroke already executed is shown as above. More precise values can be read off in the tables below the diagrams. The diagram of the selected sensor is shown small / screen 255 is selected again by pressing the right-hand button (arrow towards the bottom).
148
6.4.14
Figure 260: 260_operate_diag_tonnage
Functionality Diagnostics, tonnage monitoring and envelope monitoring

Fig. 6-24: Diagnostics, tonnage monitoring and envelope monitoring
If an error occurs in the tonnage monitoring, then it is shown here in the upper section of the window and described in words. A message window is also displayed with "tonnage monitoring error". The error number, the error description, the position where the error occurred and the tonnage when the error occurred are shown in the actual screen for each sensor. If an error occurs in the envelope monitoring, then it is shown here in the lower section of the window and described in words. The error description, the position where the error occurred and the tonnage when the error occurred are shown for each sensor. Using buttons Sensor 1 to Sensor 4, you can call up the error messages and the number of envelope curve violations that have occurred for the other sensors. If the permissible number of envelope curve violations has been exceeded, then the error reaction parameterized in the die data is executed, and a message appears in the message window.
149
6.4.15
Screens 810 - 817: 815_operate_dieprotect_trend_6_big
Functionality Trend of a channel of the die protection, magnified

Fig. 6-25: Trend of a channel of the die protection
This screen is called if one of the zoom buttons is pressed in screen 245. If an error occurs in the die protection, then this can be more precisely analyzed in this screen. The sensors are shown using green lines and the output cams with light blue lines. If a channel should be permanently traced, then this can be activated using the "Play" key (arrow to the right). The stroke trend is shown here after each completed stroke. During a stroke, if the diagram should be updated, for example in the case of an error, then it can be selected using the green "Refresh" button. The part of the stroke already executed is now shown as above. The part of the stroke that has still not been executed can be identified by the fact that the graph is located on the x axis. The diagram of the selected channel is shown small / screen 245 is selected again by pressing the right-hand button (arrow towards the bottom).
150
7 Scope of delivery
Scope of delivery
The "Simapress" package comprises: 1x SIMATIC project with the WinCC flexible HMI program and S120 project Documentation
Contact persons
Siemens AG Industry Sector I DT MC PMA APC Frauenauracher Strasse 80 D - 91056 Erlangen, Germany E-mail: tech.team.motioncontrol@siemens.com
History
Table 9-1: Version V1.0 V2.0 Date 08.2011 09.2013 First edition Change/addition Change
151

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Software package to automate a conventional flywheel press

Simatic Simapress Application description September 2013

Applications & Tools

Copyright Siemens AG 2013 All rights reserved

Simatic Simapress V2.0, Entry-ID: 82605334

Basic information Components of the standard application Installation and commissioning

Program and function description Description of the graphic interface

Simatic Simapress 2.0, Entry-ID: 82605334

Warranty and liability

Warranty and liability

Copyright Siemens AG 2013 All rights reserved

Simatic Simapress V2.0, Entry-ID: 82605334

Simatic Simapress 2.0, Entry-ID: 82605334

Simatic Simapress V2.0, Entry-ID: 82605334

3.2 3.3 3.4 3.5 4

Copyright Siemens AG 2013 All rights reserved

Simatic Simapress 2.0, Entry-ID: 82605334

5.5.5 5.5.6 5.5.7 5.5.8 5.5.9 5.5.10 5.5.11 5.6 6

Copyright Siemens AG 2013 All rights reserved

Simatic Simapress V2.0, Entry-ID: 82605334

Copyright Siemens AG 2013 All rights reserved

Simatic Simapress 2.0, Entry-ID: 82605334

Design of a press solution

Main drive and coupling control

Simatic Simapress V2.0, Entry-ID: 82605334

Fig. 1-2: minimum stroke rate

Copyright Siemens AG 2013 All rights reserved

Fig. 1-3: Braking angle calculation

Brake application point

Simatic Simapress 2.0, Entry-ID: 82605334

Stroke height adjustment

a) Connecting rod c) Excentric bushing

Simatic Simapress V2.0, Entry-ID: 82605334

Fig. 1-6: Stroke height adjustment side view

Simatic Simapress 2.0, Entry-ID: 82605334

TDC offset Locking mechanism

Simatic Simapress V2.0, Entry-ID: 82605334

Copyright Siemens AG 2013 All rights reserved

Simatic Simapress 2.0, Entry-ID: 82605334

Response, immediate stop or TDC stop

Copyright Siemens AG 2013 All rights reserved

Simatic Simapress V2.0, Entry-ID: 82605334

Response, immediate stop or TDC stop

Copyright Siemens AG 2013 All rights reserved

Tool data management

Simatic Simapress 2.0, Entry-ID: 82605334

2 Components of the standard application

Components of the standard application

Minimum stroke rate

Braking angle calculation

Simatic Simapress V2.0, Entry-ID: 82605334

2 Components of the standard application

Stroke height adjustment

Copyright Siemens AG 2013 All rights reserved

Simatic Simapress 2.0, Entry-ID: 82605334

2 Components of the standard application

Copyright Siemens AG 2013 All rights reserved

Output cam 2 phistart phiend

Simatic Simapress V2.0, Entry-ID: 82605334

2 Components of the standard application

Copyright Siemens AG 2013 All rights reserved

Output cam 2 phistart 2.4.3 Counter output cams