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Controlled Positioning with Asynchronous Motor including HMI Configuration (S7-200, MICROMASTER 420 via USS-Protocol and TP070)
V1.0 (Edition 03/2003)
Micro Application Example 1Structure of the document
Part A1 Automation Description (incl. Component list/Basic performance data)
Part A2 Function Mechanisms in Detail
Part B Step by Step Commissioning and Setup
Part C Program Description
Micro Application Examples The Fast Track to an Optimized Solution
Mic
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Liability Siemens AG do not accept liability of any kind for damages arising from the use of this application, except where they are obliged to by law in the event of damages to items used for personal purposes, personal injury or due to willful damage or gross negligence.
Warranty The program examples given are specific solutions to complex problems which were worked on by Customer Support. We must also point out that it is not possible in the current state of the technology to exclude all errors in software programs under all conditions of use. The program examples were prepared according to the best of our knowledge. However, we cannot accept any liability beyond the standard guarantee for Class C software in accordance with our “General Terms of Sale for Software Products for Automation and Drive Technology". The program examples can be purchased on the Internet as single licenses. They may not be transferred to a third party.
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Table of Contents
Part A1: Application Description................................................................................. 8 1 Automation task ......................................................................................... 9 2 The Automation Solution ........................................................................ 11 2.1 Overview .................................................................................................... 11 2.2 Required Standard, Hardware and Software Components as well
as Application Software Components (“Shopping list”) .............................. 13 2.2.1 Hardware components ............................................................................... 13 2.2.2 Software components ................................................................................ 14 2.2.3 Application software components .............................................................. 15 3 Basic performance data .......................................................................... 16 3.1 General ...................................................................................................... 16 3.2 Measurements taken.................................................................................. 17 3.3 Measured data ........................................................................................... 18 3.3.1 Explanation on evaluating the measured data ........................................... 18 3.3.2 Example diagrams ..................................................................................... 19 3.3.3 Data............................................................................................................ 22 Part A2: Function Mechanisms ................................................................................. 25 4 Function Mechanisms ............................................................................. 26 4.1 Structural description of the complete solution .......................................... 26 4.1.1 Detection and evaluation of encoder impulses (actual value of the
position):..................................................................................................... 27 4.1.2 Control unit (S7-200 CPU) ......................................................................... 31 4.1.3 Controlling and diagnosis of frequency converter MM420 and
asynchronous motor................................................................................... 33 4.1.4 Using and monitoring of the application via TP070.................................... 35 4.2 Program and data structure ....................................................................... 37 4.2.1 Organization block OB 1 ............................................................................ 37 4.2.2 Subprogram for initializing the communication and the positioning
block........................................................................................................... 38 4.2.3 Subprogram for communication with the MICROMASTER and the
evaluation of the end-position switch, as well as the diagnosis communication ........................................................................................... 39
4.2.4 The subprogram “Pos” (positioning block) ................................................. 40 4.2.5 Subprogram for the communication with the MICROMASTER 420
frequency converter via USS protocol........................................................ 43 4.2.6 Used variable (data block, DB) .................................................................. 44
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Part B: Installation of the Sample Application......................................................... 53 5 Installation of Hardware and Software................................................... 54 5.1 Hardware configuration .............................................................................. 54 5.2 Installing the software ................................................................................ 58 5.2.1 Transferring of the application code to the S7-200 CPU............................ 58 5.2.2 Transferring the application code to the Touch Panel TP070 .................... 58 5.2.3 Parameterization of the MICROMASTER 420 ........................................... 59 6 Operation of the application TP 070....................................................... 62 6.1 Providing the S7-200 CPU program with parameters ................................ 62 6.1.1 Parameter movement................................................................................. 63 6.1.2 Parameter mechanics/encoder .................................................................. 64 6.1.3 Parameter P- I- Controller .......................................................................... 65 6.2 Automatic mode and jog mode .................................................................. 66 6.2.1 Automatic ................................................................................................... 66 6.2.2 Jog mode ................................................................................................... 67 6.3 Diagnosis values of the MICROMASTER 420 frequency converter .......... 68 6.3.1 Status values of the MICROMASTER frequency converter and
errors in the USS communication .............................................................. 68 6.3.2 Reading the process values from the MICROMASTER............................. 70 6.4 Modification of the system settings at the TP070....................................... 71 Part C: Program Description ..................................................................................... 72 7 Explanations on the STEP7 Program..................................................... 73 7.1 OB1 (description of the block).................................................................... 73 7.2 INIT (SBR0), (description of the block) ...................................................... 74 7.3 Comm_Diag (SBR9), (description of the block) ......................................... 76 7.4 POS (positioning block, parameter) ........................................................... 82 7.5 Blocks for USS communication (parameter) .............................................. 82 7.6 Data block .................................................................................................. 82 8 Changes in the STEP7 program ............................................................. 83 8.1 Using a linear or round axis as well as modifying units//scales ................. 83 8.2 Using other inputs for the encoder (fast counter)....................................... 84 8.3 Transferring analogously the setpoint for the MICROMASTER
frequency converter ................................................................................... 86 8.4 Using other frequency converter of the MICROMASTER 3XX or
4XX family .................................................................................................. 87 8.5 Moving to freely selectable or relative positions......................................... 87 8.6 S7-Application code for own project use.................................................... 90
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Preamble
This application deals with the topic “Controlled positioning with Asynchronous Motors” which will be briefly incorporated in a survey of the most common positioning procedures. The positioning is mainly differentiated between the “controlled“ positioning and the “regulated“ positioning. The differences of both procedures are shown in Table 1-1. Generally, it can be said that the control unit of a regulated positioning must always know the information about the current position, this does not apply in case of a controlled positioning. Table 0-1 Controlled and regulated positioning
Figure 0-1 Controlled positioning with less weight
The controlled positioning is exactly configured for a weight (e.g. 2kg) In the configuration it has been determined that the motor shall slow down 1m in front of the finishing post. The carriage will stop exactly at the defined place.
Figure 0-2 Controlled positioning with higher weight
Due to the fact that the carriage is loaded with a higher weight the inertia of the weight increases enormously. When the motor slows down 1 m in front of the finishing post, the “slow-down way“ will be longer than in case of a positioning with a less weight. This will result in a deviation if configured as shown in Figure 0-1.
Figure 0-3 Regulated positioning with less weight
The positioning always ”knows“ the current position and the positioning way. The motor speed of the carrier will be regulated in dependence on the remaining distance, hence exactly adjusted.
Figure 0-4 Regulated positioning with higher weight
Due to the “knowledge“ of the current position, it is possible to make corrections if the finishing post has not been passed, i.e. the motors returns shortly and corrects the position.
In this application the cases 3 and 4 of Table 1-1 are considered. They can certainly be realized with different inverters and asynchronous motor.
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However, in this application the following component types are considered as set
• S7-200 CPU
• MICROMASTER
• Asynchronous motor Consequently the application is destined for solving simple point-to-point positioning tasks. Due to the fact that a number of products of different performances are available for the aforementioned components types, we have concretely chosen those with a very high market relevance. S7-226 CPU, MICROMASTER 420, asynchronous motor type 1LA7 (please cf. chapter 1).
In case you use exactly these components, this application on hand offers you a Plug&Play solution for linear axes which even contains performance data measured under load. But even in case you use other products of the aforementioned product types (e.g. MICROMASTER 410 or 440 instead of MM 420, etc.) you will highly profit from this application. Both, a detailed description of the function mechanisms as well as the user program offer you the possibility simply to adjust the delivered functionality to your specific requirements (e.g. to the HW components used by you).. With respect to a number of often asked questions we additionally offer answers leading you step by step to the intended purpose (please cf. chapter 8), for example:
• How will you use the application, if you want to automate a round axis instead of linear axis?
• What will you have to do, if you want to employ an older MM3XX instead of the MM420 in the application?
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The basic solution principle of the application works as follows. In order to realize the positioning forming the basis of the application, different standard components (hardware and software) are required. You have to make this available (please cf. figure 1-5). The application software delivered by us saves you extensive parameterizing and programming of the standard components, thus offering you a comfortable possibility for a fast implementation of the regulated positioning.
Figure 0-5 Basic solution principle of the application on hand.
Possible employment areas for this application are • Palettizing facilities
• Allocation facilities
• Material transport • Paper processing machines
• Cardboard processing machines
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Part A1: Application Description
Objectives of Part A1 Part A1 of this document provides the reader with information on the following topics:
• description of the automation problem
• showing a possible solution
• the performance capacity of the overall application.
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1 Automation task
A typical industrial case The following example shows one possible application case where the provided application can be used. The following is an example as to how each car seat is transported one by one to a defined position by means of conveyor belt. However, this procedure is not dealt with in this application (please see green conveyor belt in Figure 0-1 ). Every time a car seat is at the defined position a gripper operates between two positions “A” and “B”. The (low air pressure) gripper rests in position “A” above a reservoir for seat covers. In case a car seat (as mentioned above) is at the defined position on the conveyor belt, the gripper will suck up a seat cover and turn to position “B” above the car seat where it will then deposit the seat cover. The gripper turns back to the starting position and the car seats are moved on the conveyor belt to the next processing station.
The axis with the two positions “A” and “B” is the positioning task which is dealt with in the application.
Figure 1-1 Example of a positioning
“Abstracted” requirements on the application on hand The application should place upon the “given” HW components (S7-CPU 226, MICROMASTER 420, asynchronous motor type 1LA7, please cf. also list of components in chapter 2.2.1).
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In connection with the “application software“ (see chapter 2.2.3) a certain performance attitude is caused fixing the solution presented here according to its usage range. As a Plug&Play solution (i.e. under employment of the HW components given by us, please see above) it is possible to employ the application in the following basic data areas.
Table 1-1 Basic data areas of the application
Technical date from until
Motor moment -0,8Nm 0,8Nm Position A bei 0mm Position B bei 1000mm Accuracy 3mm Positioning speed (per motion length)
150
Possible encoder 20kHz In general, the “application software” can be operated in connection with other performance classes of frequency converters (series MM420) and asynchronous motors resulting in an appropriate expansion of the employment with respect to the drive performance. The positioning accuracy usually remains unaffected by this. Apart from the technological functionality, the application shall offer both a comfortable and inexpensive HMI connection. Inter alia the following will have to be monitored: The actual value of the position, the setting for the MICROMASTER 420 as well as its diagnosis values being available. Inter alia the following will have to be operable Desired value of the position, jog operation and the possibility of searching for reference. In addition the entire parameterization of the positioning should be possible via the HMI unit.
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2 The Automation Solution
In this chapter you will learn in detail as to how the automation task explained in Chapter 2 is solved by the application described in this document. It demonstrates what the application can do and how it works. The description is deliberately made in universally applicable terms. Part A2 of this documentation includes in-depth information, which you will only need, if you are interested in the detailed processes and the interactions between the individual solution components.
2.1 Overview
The depicted hardware setup gives an overview of the configuration.
Fig 2-1 Please c
! Note The functiohowever, t(e.g. via ththe applica Each haThis provindividua
Limit switch, reference point switch.05.2003 11/91
Hardware components of the automation solution
onsider the following note on visualization:
nality “Controlled Positioning” functions even without the HMI connection, he command interface in the DB (data block) must be operated by other means e digital inputs of the CPU). (Nevertheless, this has not been prepared explicitly in tion project.
rdware element shown in Fig 2-1 is explained in the following table. ides you with an overview of all hardware elements and their l functions for the complete solution of the automation problem:
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No.
Classification according to Figure 2-1
Type (Main) Function
1 Visualization Touch Panel TP070
A total of 8 figures are available whose interactions and functions are described in Part A2 and B. The main functions are: Operating:
• Jog operation • Search for reference • Positioning to an entered mark
Monitoring:
• Position derived from counter content • Setting • Diagnosis
2 Super-ordinate intelligence with E/A modules
S7-CPU 226 • Counting of encoder impulses • Determining the difference between setpoint
and the actual value of the position. • Calculation of setting • Providing of the command interface (e.g. for
TP070) (in the DB) • USS communication to the frequency
inverter • Diagnosis of the frequency inverter (reading
of process values and states) 3 Drive Frequency
converter MM420 • Generating of a three-phase current grid
with variable frequency 4 Motor Asynchronous
motor type 1LA7
• Conversion of the electrical energy in mechanical energy
5 Shaft angle encoder
Optically incremental with HTL level
• Electrical square wave impulses are generated out of the mechanical position information (in the Aplication Example 100Inc/Rev used)
Table 2-1 Functions of the individual hardware components for the complete solution
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2.2 Required Standard, Hardware and Software Components as well as Application Software Components (“Shopping list”)
2.2.1 Hardware components
Products Component Type MLFB/Order informaton No. Remarks
Single-phase converter MICROMASTER 420 6SE6420-2UC11-2AA0 1
S7-200 CPU SIMATIC S7-CPU 226 XM 6ES7216-2BD22-0XB0 1
Motor 3-phase NS asynchronous motor 1LA7 060-4AB10 1
Touch Panel TP 070 6AV6545-0AA15-2AX0 1
Encoder Incremental encoder 6FX2001-4NA10 1
Operation Panel for MICROMASTER BOP (Basic Operator Panel)
6SE400-0BP00-0AA0 1
Note The here chosen encoder has a resolution of 100 increments per revolution, this is sufficient for a solution of the automation problem. In case an encoder with a higher resolution proves to be necessary for other requirements it will have to be considered that the highest possible number of motor revolutions is limited by the sensing frequency of the counter (in the CPU). Maximally impulses with a frequency by 20kHz the counter sensing. If, for example, an encoder with a resolution of 1000 increments per revolution is employed, then the maximal number of motor revolutions will be 1200 revolutions per minute.
! CAUTION This note describes the deceleration of large loads. When braking loads of more than approx 10% of the MICROMASTER rated output power, you must use one the following alternatives.
1. Use a MICROMASTER 440 (with brake resistors) instead of the MM420. 2. For low requirement in terms of positioning dynamics increase the
deceleration time: The braking power of the MICROMASTERs which can be applied decreases (thus the duration of the positioning becomes larger; only applicable by braking power few more of 10% of the MICROMASTER rated output).
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Accessories Component Type MLFB/Order informaton No. Remarks
Connection cable (S7-200 CPU and MICROMASTER 420) PROFIBUS cable 6XV1830-0EH10 1
Yard ware, minimum order quantity 20m, maximum 1000m suitable for quick mounting.
Bus connector Connector for PROFIBUS cable
6ES7 972-0BA12-0XA0 1 With terminating resistance (deactivatable)
Connection cable (S7-200 CPU and TPO70
MPI cable (5m) 6ES7901-0BF00-0AA0 1
Network filter Low leakage EMC filter (for operation at the FI protective switch)
6SE6400-2FL01-0AB0 1 In case of other requirements other filters can be employed.
Note: Instead of the BOP (Basic Operator Panel), the AOP (Advanced Operator Panel) or the PC inverter connection block can alternatively be employed for the parameterization of the MICROMASTER 420. AOP (Advanced Operator Panel): • MLFB 6SE6400-0AP00-0AA1
PC converter connection block
The PC inverter connection block contains the following components: • Serial interface for the MICROMASTER frequency converter
• Serial connection cable between PC and the MICROMASTER frequency converter
• PC startup software STARTER for Windows NT4 SP5/SP6 and Win 2000 SP1 (is included in the delivery on the Docu CD of the MICROMASTER)
• MLFB 6SE6400-1PC00-0AA0
! Important For the operation in an network with an FI protective switch, the network filter for low leakage currents is required! (please see accessories)
! Important Please bear in mind that an output inductor will have to be employed between the MICROMASTER frequency converter and the motor, in the event of a wire length longer than 50m shielded or 100m unshielded. (The output inductor reduces the capacitive equalizing currents occurring in case of long wire lengths.)
2.2.2 Software components
Configuration software/tools Component Type MLFB/Order informaton No. Comment
STEP 7Micro/WIN 32 V3.2 6ES7810-2BC02-0YX0 1
STEP 7Micro/WIN 32 TP-Designer V1.0 6ES7850-2BC00-0YX0 1
Connection cable 2 PC/PPI cable 6ES7 901-3BF20-0XA0 1 For the configuration of S7-200 CPU and TP070
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2.2.3 Application software components
Table 2-2 Application software components
No.
Name
Function description
Technical data
System environment
1 MAIN [OB1] - Calling the INIT (SBR0) block, only in the first cycle - Calling the Comm_Diag (SBR9) block
S7-226 CPU
2 POS (SBR1) - Evaluating quick counters and determining the actual position
- Calculating the setting for setpoint velocity of the motor - Manual procedure - Referencing - Setting a new zero point
S7-226 CPU
3 INIT (SBR0) - Calling the block for initializing the positioning block (USS_INIT)
- Calling the block for initializing the USS protocol (USS_INIT)
- initializing a quick counter - initializing a time interrupt
S7-226 CPU
4 Comm_Diag (SBR9) - Calling the MICROMASTER control block, communication block
- five-time calling of the block ‘read process values’
S7-226 CPU
5 USS3 (SBR2) - Block for communication via USS protocol S7-226 CPU
6 USS_INIT (SBR3) - Initializing USS protocol S7-226 CPU
7 USS1 (SBR4) - Block for communication via USS protocol S7-226 CPU
8 USS2 (SBR5) - Block for communication via USS protocol S7-226 CPU
9 USS_CTRL (SBR6) - Controlling of MICROMASTER via USS protocol - Recording the status of the MICROMASTER
S7-226 CPU
10 USS4 (SBR7) - Block for communication via USS protocol S7-226 CPU
11 USS_RPM_R (SBR8) - Reading process values for diagnosis S7-226 CPU
12 USS6 (SBR9) - Block for communication via USS protocol S7-226 CPU
13 USS7 (INT1) - Block for communication via USS protocol (Interrupt program)
S7-226 CPU
14 USS8 (INT2) - Block for communication via USS protocol (Interrupt program)
S7-226 CPU
15 USS9 (INT3) - Block for communication via USS protocol (Interrupt program)
S7-226 CPU
16 Data block - Provides command interface - First initializing of the block parameter
S7-226 CPU
17 TP-Designer Project - Contains the pictures for operating and monitoring TP070
18 Parameter list of MM420 - Contains the parameter for the MICROMASTER MM420
(19) (STARTER Project) (- Contains the parameter for the MICROMASTER)
Motor-specific parameter are to adjusted to their own motor! (PC/MM420)
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3 Basic performance data
3.1 General
This chapter gives you a summary of the performance criteria of this application. Measurements of the applications were performed on a test model using the given components (see figure 3-1 test setup). The test model is in principle a mechanical setup, which is driven by the motor of the application on hand (tested motor). For simulating a real load, a second motor was added. The effect of the added motor is in direction or counter-direction of the tested motor. Furthermore, the model provides the reference point and the position-end-switch to the test application. For enabling taking up the traveled rotations (or the imagined travel distance), the test model has a separate shaft angle encoder with corresponding evaluation. The test setup is schematically outlined and labeled in the figure below.
Fig. 3-1 Test setup
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3.2 Measurements taken
A measurement is always taken over a defined period of time (e.g. approx. 20s), position setpoint or speed setpoint of the application were always recorded (every 25 ms). From the measured data a diagram was generated from which the data in chapter 3.3.3 were read. The taken measurements can be divided into three categories:
• The load momentum is effective in positioning direction of the motor (tested motor)
• Load momentum is effective against positioning direction of the motor (tested motor)
• An impact of constant momentum is applied to the position control in standstill (constancy)
The simulated load, a constant momentum which is effective against or in positioning direction, was varied in steps of 0.1Nm in the range from 0.0Nm to 0.5 Nm. Additionally, for each measurement there are different variations of the moment of inertia by adding or removing disk flywheels. The moment of inertia was varied by the steps below:
• Without additional disk flywheel (J= ca. 0,005276 Kg m²; measured, calculated)
• With one additional disk flywheel (J= ca. 0.00077 Kg m²; calculated)
• With two additional disk flywheels (J= ca. 0.00077 Kg m²; calculated)
• With three additional disk flywheels (J= ca. 0.00231 Kg m²; calculated)
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3.3 Measured data
This section gives you an explanation on evaluating the measured data, additionally, example diagrams of four measurements are shown. In the last chapter of the basic performance data the detailed tables have been printed with the measured values. Generally it can be summarized, that the position control at load shows better control properties in position direction than at loads against the position direction.
3.3.1 Explanation on evaluating the measured data
For each variation of the measurement, measured values were recorded and a diagram produced. The measured values could be taken from the generated diagrams as illustrated in the figure below.
Figure 3-2 Terminology at the example diagram of a positioning to 1000mm, with an additional moment of inertia of J=0.00077 Kg m² and a constant load of 5Nm.
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3.3.2 Example diagrams
This chapter gives two each examples for measurements with the properties:
• Load momentum is effective in (or against) positioning direction of the motor (tested motor)
• An impact of constant momentum is applied to the position control in standstill (constancy)
constant speedndgültig 13.05.2003 19/91
Fig. 3-3 Travel from position 0mm to 1000mm and back. (At this measurement no load momentum was effective, only the friction of the model had to be overcome. The additional moment of inertia was J=0,00077 Kg m²)
acceleration
deceleration
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Fig. 3-4 Travel from position 0mm to 1000mm and back (One additional moment of inertia of J=0.00231 Kg m² was mounted and the constant load momentum was 0.5Nm.)
positioning in load-direction
Positioning oposite load-direction
momentum starts
Position without overshoot reached
Setpoint in limitation
Position Controller in stand
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Fig. 3-5 Impact of 0.5 Nm, without additional flywheel mass
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Position with overshoot reached
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Fig. 3-6 Impact of 0.3 Nm, with additional flywheel mass of 0.00231Kgm²
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3.3.3 Data
Table 3-1 Accuracy load momentum in travel direction
Test condition Accuracy load momentum in travel direction Remarks
Add
ition
al
mom
ent o
f in
ertia
(by
disk
s)
[kg
m²]
Con
st. l
oad
in
Nm
Max
. dev
iatio
n [m
m]
Ris
e tim
e [s
]
Settling time [s] ± 2,5 mm position window
Settling time [s] ± 0.5 mm position window
Rem
aini
ng
devi
atio
n af
ter
20 s
0 0,62 8,38 10,85 0,04
0.1 0.78 8.60 13.85 -0.02
0.2 0.51 8.48 9.13 -0.02
0.3 2.53 8.50 9.25 14.43 -0.08
0.4 4.69 8.50 11.95 15.15 -0.11
0
0.5 14.77 8.43 10.98 17.03 -0.07
kp=120 I=0,02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0,015
0 0.58 8.45 11.53 0.04
0.1 1.20 8.58 12.90 0.04
0.2 1.71 8.58 13.63 -0.04
0.3 2.80 8.53 11.00 14.63 -0.13
0.4 5.10 8.50 10.43 14.73 -0.11
0.0077
0.5 15.07 8.50 11.08 22.48 0.11
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
0 0.74 8.63 14.85 -0.07
0.1 1.53 8.75 14.13 -0.09
0.2 2.33 8.75 14.63 -0.14
0.3 3.75 8.65 13.03 15.98 0.05
0.4 9.73 8.60 13.23 18.28 0.09
0.0154
0.5 19.52 8.58 11.85 12.65 0.17
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
0 0.16 9.15 0.16
0.1 1.40 9.08 24.55 0.50
0.2 2.60 8.93 11.23 23.85 -0.27
0.3 4.37 8.83 20.40 29.03 -0.58
0.4 10.10 8.80 18.68 46.20 -0.11
0.0231
0.5 26.00 8.73 18.83 -0.56
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
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Table 3-2 Accuracy load momentum against travel direction
Test conditions Accuracy load momentum against travel direction Remarks
Add
ition
al
mom
ent o
f in
ertia
(by
disk
s) [k
g m
²]
Con
st. l
oad
in
Nm
Max
. dev
iatio
n [m
m]
Ris
e tim
e [s
]
Settling time [s] ± 2.5 mm position window
Settling time [s] ± 0.5 mm position window
Rem
aini
ng
devi
atio
n af
ter
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0 0.41 8.30 0.01
0.1 0.01 19.05 0.00
0.2 -0.40 16.45 -0.04
0.3 -0.12 18.48 -0.11
0.4 -1.15 11.65 22.63 0.13
0
0.5 -0.29 10.69 11.20 -0.17
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
0 -1.02 8.40 0.03
0.1 -0.07 15.65 -0.03
0.2 -0.11 15.30 -0.09
0.3 -0.14 18.70 -0.13
0.4 -1.60 11.55 23.53 0.08
0.0077
0.5 -2.50 11.05 11.45 11.45 21.28
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
0 -0.78 8.58 15.10 0.04
0.1 -0.09 15.15 -0.06
0.2 -0.44 13.98 0.04
0.3 -1.41 15.65 29.10 0.05
0.4 -1.54 15.80 33.93 0.07
0.0154
0.5 -3.79 12.35 20.33 24.45 0.14
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
0 -0.38 9.13 -0.37
0.1 -0.14 17.43 -0.14
0.2 -0.28 19.83 -0.28
0.3 -3.01 16.33 30.88 36.25 0.01
0.4 -4.29 17.25 34.58 38.80 0.00
0.0231
0.5 -0.84 19.18 18.58 -0.83
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
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Table 3-3 Measurement of constancy (impact on position controller at rest)
Test conditions Constancy Remarks
Add
ition
al
mom
ent o
f in
ertia
(by
disk
s) [k
g m
²]
Con
s. lo
ad in
N
m
Max
. dev
iatio
n [m
m]
Ris
e tim
e [s
]
Settling time [s] ± 2.5 mm position window
Settling time [s] ± 0.5 mm position window
Rem
aini
ng
devi
atio
n af
ter
20 s
0
0.1 0.82 12.65 6.63 -0.01
0.2 1.95 12.25 6.48 -0.01
0.3 3.39 23.50 3.65 8.30 -0.08
0.4 7.67 3.10 3.35 3.60 -0.01
0
0.5 15.83 20.75 2.53 11.88 0.00
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
0
0.1 0.83 15.40 6.70 -0.04
0.2 1.57 29.05 6.58 -0.04
0.3 3.38 15.00 3.78 7.93 -0.09
0.4 3.03 13.58 4.68 7.28 0.03
0.0077
0.5 11.18 3.60 3.38 3.55 0.10
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
0
0.1 0.16 0.08
0.2 1.83 13.08 6.93 -0.01
0.3 3.55 15.23 4.45 7.80 -0.03
0.4 8.18 5.23 10.48 12.73 0.09
0.0154
0.5 18.09 3.63 8.63 9.10 0.00
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
0
0.1 1.89 18.93 14.45 -0.11
0.2 1.06 32.93 25.33 -0.08
0.3 6.64 11.25 10.88 40.70 -0.05
0.4 6.97 14.38 13.25 14.18 -0.10
0.0231
0.5 32.24 11.08 10.55 -1.43
kp=120 I=0.02
Vmax=150mm/s a=75mm/s²
10mm/U corr=0.015
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Part A2: Function Mechanisms
Objectives of Part A2: Part A2 of this document provides the reader with information on the following topics.
• Explanation of all integrated function elements
• Representation of the data flow between the function units
• Providing the necessary background information required for the understanding of the solution.
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4 Function Mechanisms
In principle this application can immediately be used. The installation instructions of part B tell you how to start the application without having read this chapter. But if you want to modify specific parts of the application, you will need certain information, for example to convert your program sequences correctly and without too much effort into the STEP7-Micro/Win Code, TP-Designer Project for TP070 and STARTER-Project for the MICROMASTER. The said information will be given in the following sections.
4.1 Structural description of the complete solution
The structure of the complete solution of the application is shown in Fig. 4-1 .
Fig. 4-1 Fu
Limit switch; reference switch
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nction principle of the application
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From a structural point of view the functions of the applications can be divided in four different parts:
• Detection and evaluation of encoder impulses to determine the actual value of the position (see chapter 4.1.1)
• Controlling of the application (calculation of the manipulated variable for the MM420, command interface (see chapter 4.1.2)
• Controlling of the frequency converter MM420 and asynchronous motor (see chapter 4.1.3)
• Operating and monitoring of the application via TP070 (see chapter 4.1.4)
The mechanics consist, for example, of a threaded spindle with a slide on its top. (Its position is changed by rotation of the spindle. In this connection a rotation of the shaft by X degree corresponds to a movement of the nut by Z millimeters.
Bild 4-2 Example for mechanics, here threaded spindle
4.1.1 Detection and evaluation of encoder impulses (actual value of the position):
The actual value of the position is formed in this application via an evaluation electricity consisting of an incremental encoder (here HTL shaft angle encoder) and a counter (here the HW counter of the S7-200 CPU). The incremental encoder generates a fixed number of impulses per each shaft twist.
Slide with carriage
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Figure 4-3 Function principle of the HTL shaft angle encoder
A luminescent source transilluminates a disc with slits stripes being fixed on the shaft. If the disc rotates it will generate intermittently contrasts which will then be detected by a photo element. These impulses are changed into square wave impulses and are displayed. The incremental encoder owns two channels (A and B), i.e. theoretically there are two encoders. The channels are phase-shifted towards each other by 90°, thus allowing to determine the rotational direction of the shaft (see figure 1-1)
Figure 4-4 Pulse train of the incremental encoder in case of different rotational
directions. In order to increase the resolution all edges of the counter are evaluated resulting in quadruplicating the impulses.
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Figure 4-5 Counter content in dependency of the encoder impulses (with impulse quadruplicating)
The evaluation of the encoder impulses is made via the hardware counter integrated in the S7-226 CPU. The number of the impulses is a measure for the travelled distance. By using the HW counter it is possible to evaluate the encoder impulses indenpendently of the cycle time of the user program. The advantage is the fact that the user program is independent of the counter and does not use up any data processing time. Here it is not possible to use a software counter which can be seen in the following small arithmetic example: An encoder with a resolution of, for example, only 100 impulses per rotation at a motor with e.g. 1350 rotations per minute already generates 2250 impulses/sec.
SecondImpulses2250
Seconds 60Minute
Rotation1350RotationImpulses100
=×
Figure 4-6 Calculation of impulses arising per second This value corresponds 2250° Hertz. In order to record a frequency like this successfully, it will have to be scanned with at least its double frequency. This theoretically corresponds to 4500 callings of a counter block which
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would correspond to a cycle time of 0.22 milliseconds. This cycle time cannot be obtained with S7-200.
dsMillisecon 0,22Seconds 0,000224500Hertz
14500Hertz2250Hertz2
:nCalculatio
Frequency2Frequency: theoremsShannon'
scanned be tomeasure
==
=×
×≥
Figure 4-7 Calculation of the theoretically required cycle time in order to scan the impulses of the shaft angle encoder
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4.1.2 Control unit (S7-200 CPU)
4.1.2.1 Calculation of the manipulated variable for the frequency converter MM420 In the following picture the actual position control is displayed.
Fig. 4-8 Procedure of a position control (determining the difference between setpoint and the actual value of the position and calculating the setting for the motor speed)
The S7-200 CPU determines the actual value of the position via the counter contents. The setting for the setpoint velocity of the motor (P- controller) is constantly determined by the deviation between the setpoint of the position (in the application of the HMI system) and the actual value of the position. Shortly before the actual value reaches the setpoint of the position the motor may come to a stillstand as the setpoint velocity of the motor and thus the motor power are to low to move the motor. This connection is illustrated in the following picture.
Setpoint value Actual value
high deviation between setpoint and actual value, high setting
small deviation between setpoint and actual value, small setting
Figure 4-9 Dependency of the setting from the deviation between setpoint and actual value
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In this way the setpoint position would only be reached approximately. It is possible that a permanent deviation will remain. As a consequence, it will additionally be ascertained during the positioning how long a deviation is remaining thus increasing the setpoint velocity of the motor per time increment (I-controller).
Jerky movements In order to avoid jerky movements at the motor and the connected mechanics, acceleration limitations are put on the setpoint value at the beginning and the end of the positioning.
Figure 4-10 Illustration of the acceleration, the constant and the delay phases in a way-time and speed-time diagram
4.1.2.2 Command interface The command interface is an area in the data block. Here are several bits which display global status information (e.g. in the positioning window) or by means of which global functions of the application (jog operation forward/back) can be controlled Further information and a detailed description of the command interface can be found in chapter 4.2.3 “data block”.
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4.1.3 Controlling and diagnosis of frequency converter MM420 and asynchronous motor
The asynchronous motor is controlled via the frequency inverter MICROMASTER 420. If an asynchronous motor is directly connected to the three-phase current network an exact positioning (for this low speeds are required in case of creep feed) will be nearly impossible. This is due to the fact that, in this case, the speed is in a fixed proportion to the speed of the current network. This means that the speed is largely constant. From the current network with a constant frequency, the frequency inverter generates speed with a variable frequency. (please cf. Fig. 4-2). Consequently the speed of the motor is no longer constant. And consequently, the configuration can be employed for positioning tasks.
Fig. 4-2 Frequency conversion
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The S7-200 CPU and the MICROMASTER frequency converter own a serial RS485 interface and are connected with each other via a PROFIBUS cable. The devices communicate via the USS protocol (see chapter 4.1.2). The converter gets the following parameters from the S7-200 CPU:
• Motor On/Off • Setting (in percent of the converter parameterized maximum speed with
a sign for the direction; -100% 100%) The output variables of the MM420 to the asynchronous motor are:
• Voltage
• Frequency of voltage The following speed areas can be covered by means of the MM420 and a connected norm asynchronous motor
Frequency\pair of poles
2 4 6 8
50Hz 3000min-1 1500min-1 1000min-1 750min-1
60Hz 3600min-1 1800min-1 1200min-1
Apart from realizing the “variable motor speed” the frequency converter assumes further functions, for example the limitation of the motor current or heat protection functions (calculated) of the motor. The diagnosis is made – in the same way as the control of the MM420 – via the USS protocol. Every time the appropriate communication block is called, the latest status of the frequency converter is transmitted. In addition some process values (some of them chosen) are deliberately read. Status and process values are evaluated by the S7-200 CPU and provided in the visualization.
Note: The process values (which are transmitted to the data block when the communication block is being called) will be constantly updated, when the communication block is called cyclically. The diagnostic values are only be updated as a result of a trigger (command). If a constant updating of the process values took place, the communication would burden the bus too much and the control behavior would deteriorate. Only the most important process values are transmitted to the S7-CPU. The communication will also be burdened too much, if too many process values are read out of the converter. The process values used in the application are only one example and could be modified to the individual requirements, as occasion demands.
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4.1.4 Using and monitoring of the application via TP070
Via the TP 070 the application contains a comfortable using and monitoring possibility. A total of 8 figures are available whose functionalities are illustrated in table 4-1. It is a particular comfort for you that each figure can be selected out of each figure. To enable this, a standard navigation bar is at the bottom of each figure. On this are various “sensors”. By pressing a button you can move into the various figures of the project. The button of the currently chosen figure is always shaded in color. Some operation categories contain several figures. In these cases a second navigation bar appears above the standard menu bar. The following two examples illustrate this:
You are in the operation category “Parameter” and you
have opened figure “P-I controller.
Your are in the operation category “Jog Mode”, no
further figures exist here.
Figure 4-3 Figure navigation
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Table 4-1 HMI figures and their functions
Operation category
Figure Figure No. 1
Function description
Movement B1 Entering of all parameters having direct effect on the fastness of the positioning.
Mechanics/ Encoder
B2 Entering of all parameter for encoders (e.g. increments per revolution) as well as the absolute positions A and B, which are to be approached.
Para
met
ers
P/I controller B3 Entering of controller-specific parameters like reinforcements and compensation values, affecting the controlling behaviour. In addition, the possibility of activating the controlling permanently, or switching it off in a specific positioning window, is given here.
Auto
-m
atic
op
e- e
r-at
ion
Automatic B4 Enabling the controller as well as selection of the target positions A and B by pressing the button. Additional display of current setpoints, settings and the setpoint velocity of the motor.
Jog
ope-
ratio
n
Jog mode B5 Manual procedure (forward run/return slow/fast) as well as setting of zero point, looking for reference point by pressing the button and controller enable on/off. Additional display of current setpoints, settings and the setpoint velocity of the motor.
Status: B6 Display of status information of the frequency converter MM420 as well as displaying the error codes relating to USS communication.
Dia
gnos
is
Process values
B7 Display of a selection of process values from the MM420, e.g. output voltage, output current, etc.
System System B8 Modification of the system settings at the TP070.
You will find a detailed description of the individual HMI pictures in Part B, chapter 6 (Operation of the Application). There each of the parameters used in the figures is explained in detail.
Note If desired, you will of course be able to simply modify the delivered HMI figures !
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4.2 Program and data structure
This chapter explains the program and data structure of the S7 Micro/Win program which is on the S7-CPU 226. With respect to their structures the functions being on, the S7-CPU 226 have already been explained previously. The S7-Micro/Win program has the following structure:
Fig. 4-13 Overview of the STEP7 Micro/Win program structure The individual program blocks are described below:
4.2.1 Organization block OB 1
In the following section you can see how the calls in OB1 are functioning program technically:
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In the following figure it is apparent, that the subprograms INIT (SBR0) and Comm_Diag (SBR9) are called.
Fig. 4-4 Structure of the organization block OB1
The organization block OB 1 contains two main fields.
• Call of the subprogram “INIT” (initializing) (network 1).
• Call of the subprogram “Comm_Diag“ for Comunication and Diagnose of the MICROMASTER (reading the process values) and evaluating the limit values and reference point switches (network 2)
4.2.2 Subprogram for initializing the communication and the positioning block
Fig. 4-5 Structure of the initializing block INIT
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The commands of the initialization block are only executed in the first cycle of the CPU. The functions in detail are:
• Set up hardware counter (for encoder pulses)
• Set up time interrupt for the call of the positioning block
• Initializing the USS communication of the CPU for the MICROMASTER 420, by call-up of the subprogram USS_INIT.
4.2.3 Subprogram for communication with the MICROMASTER and the evaluation of the end-position switch, as well as the diagnosis communication
Fig. 4-6 Structure of the initializing block INIT This block is called cyclically in the OB1, it contains the following functionalities:
• Communication with the MICROMASTER 420
• Reading the (diagnostics) process values from the MICROMASTER 420
• Evaluation of the end-position switch and the reference point switch
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4.2.4 The subprogram “Pos” (positioning block)
Fig. 4-15 Structure of the organization block OB1
The subprogram „Pos“ (positioning block) represents the core module of the S7 Micro/Win program. The MICROMASTER frequency converter is completely “controlled” in the automatic operation from here. In particular the subprogram “Pos“ (positioning block) carries out the following tasks:
• Evaluation of the counter contents and generation of the actual value of the position (network 5) The current counter content of the fast hardware counter is read out and converted by means of the parameters increments per revolution and travel per revolution into the current actual value of the position.
• Calculation of the deviation between setpoint and actual value (networks: 28; 59)
The variable “VD_new_position“ (VD1000 in the data block) contains the value of the setpoint. The difference is formed by the value of the current actual value and the deviation between setpoint and the actual value is calculated therefrom.
• Calculation of the setting for the setpoint velocity of the motor (networks: 15-17; 23-27; 30-44; 46-48; 51-53; 55-58; 64-67; 83) By means of the calculated deviation between setpoint and actual value, a setting for the setpoint velocity of the motor is calculated. Vectra
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The calculation consists of 2 parts: ▪ The P-Part and ▪ The I-Part
P-Part The P-part is a purely proportional factor: In case the deviation between setpoint and actual value is too high, the P-part will also be too high, it will only be limited by the maximum output size (positive and negative). I-Part In the event that prior to reaching the setpoint the deviation between setpoint and actual valued is small, then the calculated P-Part will also be (very) small. This will result in a low (setpoint) velocity of the motor . A burden or high friction can have the effect that due to the low speed requirements the motor stops moving and comes to a standstill. Thus causing a remaining system deviation. In order to counteract this fact, the I-Part will be constantly increased during a certain time in case the setpoint is not reached so that the setpoint velocity of the motor generates enough torque to overcome friction and burden.
Fig 4-7 prevailing formula forming setpoint
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• Performing the search for reference and setting of zero value When restarting the S7-200 CPU the current actual position is unknown. The system has to be informed to this effect. There are two solutions for this:
▪ Manual procedure and setting of the zero point by pressing the button (networks: 11-14; 60) Via the jog operation the mechanics are manually moved to a defined point corresponding to the “zero point” of the system. In addition the command “set zero point” is given. By this procedure the system is “taught” the actual value.
▪ Search of reference (networks: 22; 49) In case the mechanics own a reference point switch, then this can be used to “teach” the system the current position. If the command search for reference is given, the control will “look for” the reference point switch until this has been passed over. There the counter content will be put to “zero”.
Note In case the rest position (or the desired zero position) does not correspond to the physical reference point, then a reference point shift unequal 0 can be defined in the parameters.
• Manual motion (network: 18-21; 54; 70-72; 75-82) In order to operate the mechanics manually, four commands are available:
▪ Forward run with low speed (V1) ▪ Return with low speed (V1) ▪ Forward run with high speed (V2) ▪ Return with high speed (V2)
Note For the manual procedure (and referencing) the speeds (V1, V2) can be parameterized in the data block
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4.2.5 Subprogram for the communication with the MICROMASTER 420 frequency converter via USS protocol
Fig. 4-16 Structure of the communication programs for the USS communication with the frequency converter MICROMASTER 420 (blocks of the Instruction Library)
The subprograms for communication via the USS protocol with the MICROMASTER 420 frequency converter have been taken from the S7-Mirco/Win command library. All relevant block are described in the online documentation. Therefore only a summarized overview about the used functions of the USS communication library exists here. The used functions (block) are: • Initialization of the communication block.
The communication to the MicroMaster drive is initialized and activated or deactivated by means of the operation USS_INIT. Before an other USS operation can be used, the operation USS_INIT will have to be executed correctly.
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• Controlling of MICROMASTER frequency converter By means of the operation USS_CTRL an active MicroMaster drive is controlled The operation USS_CTRL disposes the selected commands in a communication buffer, which is then sent to the addressed drive (Parameter Drive), provided that this drive is set in the Parameter Active of the operation USS_INIT.
• Reading the parameters out of the MICROMASTER There are three reading operations for the USS protocol:
▪ Operation USS_RPM_W reads an unsigned one
▪ Operation USS_RPM_D reads an unsigned one
▪ Operation USS_RPM_R reads a floating point parameter, only this block is used in the application.
4.2.6 Used variable (data block, DB)
This chapter contains a list of the variables used by the program. The data block contains, inter alia, the command interface of the positioning block and the parameters used in the application. The following table illustration of the used variables is divided in four areas:
• Parameters
• Internal variables
• Command/status interface
• The memory area in the data block assigned by the USS communication blocks.
The variables are clearly described by their symbolic names and/or a comment. Furthermore the nature/type of the variable are shown and those blocks which access the variables by reading or writing.
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faul
t va
lue
Type
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DB
IN
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COM
M
DIA
G
POS
USS-
Kom
-m
unik
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B
1 VD
_OP_
Vmax
Sp
eed
max
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[mm
/s]
150.
0 Re
al
VD
1140
R
B1
-RW
2 VD
_OP_
Besc
hleu
nigu
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Acce
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[mm
/s²]
75.0
Re
al
VD
1132
R
B1
-RW
3 VD
_OP_
Verz
öger
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Dela
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m/s
²] 75
.0
Real
VD11
36
R
B1-R
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4 VD
_OP_
V1_M
anue
ll Fi
xed
setp
oint
spe
ed m
anua
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[%]
10.0
Re
al
VD
1016
R
B1
-RW
5 VD
_OP_
V2_M
anue
ll Fi
xed
setp
oint
spe
ed m
anua
l 2
[%]
40.0
Re
al
VD
1020
R
B1
-RW
6 VW
_OP_
Hoc
hlau
f_M
an
Star
tup
time
man
ual a
nd
refe
renc
ing
+500
In
t
VW11
56
R
B1-R
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7 VW
_OP_
Aus
lauf
_Man
Sl
owdo
wn
time
man
ual a
nd
refe
renc
ing
+500
In
t
VW11
58
R
B1-R
W
8
Movement parameters
VD_F
akto
r_A
nzei
ge
Fact
or d
ispl
ay c
ompa
red
with
m
eter
s -1
.0 D
ispl
ay a
nd s
peci
ficat
ion
in m
eter
-0
.01
Disp
lay
and
spec
ifica
tion
in c
entim
eter
-0
.001
Dis
play
and
sp
ecifi
catio
n in
mill
imet
er
-0.0
0000
1 Di
spla
y an
d sp
ecifi
catio
n in
mic
rom
eter
1.0
Real
VD11
08
R
9 VD
_OP_
INK_
Umdr
ehun
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crem
ents
per
revo
lutio
n 10
0.0
Real
VD11
48
R
B2-R
W
10
VD_O
P_S_
Umdr
ehun
g Tr
avel
per
revo
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n 10
.0
Real
VD11
52
R
B2-R
W
11
Mechanics /encoder parameter
VD_O
P_Re
f_Ve
rs
Refe
renc
e po
int s
hift
[mm
] 0.
0 Re
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VD
1144
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B2
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12
Controlle
r para
VD_O
P_P_
Fakt
or
P am
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0.0
Real
VD10
72
R
B3-R
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VD_O
P_I_
Fakt
or
I- a
mpl
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0.02
Re
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VD
1008
R
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14
VD_O
P_A
nlag
enbe
iwer
t
Corr
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n fa
ctor
for
P-
Rein
forc
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t (P
-Rei
nfor
cem
ent
x co
rrec
tion
fact
or =
real
P-
Rein
forc
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t
0.01
5 Re
al
VD10
80
R
B3-R
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15
VD_O
P_Gr
enze
n_A
usga
be
Outp
ut li
mit
100.
0 Re
al
VD
1076
R
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16
VD_O
P_Fe
nste
r_Po
s Po
sitio
ning
win
dow
, con
trol
switc
hes
off h
er [m
m]
1.0
Real
VD11
28
R
B3-R
W
17
timin
g Cl
osed
Loo
p Cy
cle
30
byte
VB99
4 R
18
VD_n
eue_
Posi
tion
New
pos
ition
[m]
0.0
Real
VD10
00
RW
19
VD_i
st_P
ositi
on
Cur
rent
pos
ition
[m]
0.0
Real
VD10
04
RW
20
VD_S
ollp
ositi
on_G
en
Setp
oint
pos
ition
of s
et-
poin
t val
ue g
ener
ator
[m]
0.0
Real
VD10
24
RW
21
VD_S
tellw
ert_
int
Setti
ng [m
] 0.
0 Re
al
VD
1028
RW
22
VD_S
treck
e_G
en
Ope
ratio
n di
stan
ce [m
] 0.
0 Re
al
VD
1032
RW
23
VD_a
lte_P
ositi
on
Old
pos
ition
[m]
0.0
Real
VD10
36
RW
24
VD_Z
eitw
ert
Tim
e va
lue
[0,1
sec
unds
] 0.
0 Re
al
VD
1040
RW
25
VD_W
EG_U
mdr
ehun
g Tr
avel
per
revo
lutio
n [m
m]
Re
al
VD
1092
RW
26
VD_V
_Sol
l_Ge
n Se
tpoi
nt s
peed
of t
he
gene
rato
r [m
/s]
0.0
Real
VD10
56
RW
27
Internal variables
VD_H
S1_G
en
Auxi
liary
sto
rage
1
gene
rato
r 0.
0 Re
al
VD
1060
RW
28
VD_H
S2_G
en
Auxi
liary
sto
rage
2
gene
rato
r 0.
0 Re
al
VD
1064
RW
29
Internal variables
VD_H
S3_G
en
Auxi
liary
sto
rage
3
gene
rato
r 0.
0 Re
al
VD
1068
RW
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Type
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DB
IN
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COM
M
DIA
G
POS
USS-
Kom
-m
unik
atio
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VD_R
ampe
_I_A
ntei
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I fra
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VD
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VW_S
peic
her_
Hoch
lauf
St
orag
e st
artu
p m
anua
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0 In
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VW10
88
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32
VW_S
peic
her_
ausl
auf
Stor
age
slow
dow
n m
anua
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0 In
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VW10
90
RW
33
VD_V
_Man
uell
Spee
d ou
tput
man
ually
0.
0 Re
al
VD
1100
RW
34
VD_S
peic
her_
Man
uell
Inte
rmed
iate
sto
rage
m
anua
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ion
0.0
Real
VD11
04
RW
35
Diag
_Poi
nter
VSpe
iche
r6
Poin
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for 1
6 by
tes
stor
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for d
iagn
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co
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unic
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Byte
VB17
18
RW
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Diag
_Poi
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VSpe
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r5
Poin
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for 1
6 by
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stor
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for d
iagn
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Byte
VB16
92
RW
37
Diag
_Poi
nter
VSpe
iche
r4
Poin
ter 4
for 1
6 by
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stor
age
for d
iagn
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Byte
VB16
76
RW
38
Diag
_Poi
nter
VSpe
iche
r3
Poin
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for 1
6 by
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stor
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for d
iagn
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co
mm
unic
atio
n
Byte
VB16
60
RW
39
Diag
_Poi
nter
VSpe
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r2
Poin
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for 1
6 by
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stor
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for d
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co
mm
unic
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Byte
VB16
44
RW
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Diag
_Poi
nter
VSpe
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r1
Poin
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for 1
6 by
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stor
age
for d
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co
mm
unic
atio
n
Byte
VB16
02
RW
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Diag
_Err
or
Erro
r byt
e of
the
diag
nosi
s co
mm
unic
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Byte
VB16
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42
Done
06
Don
e Bi
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di
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com
mun
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Bi
t
V160
0.5
R
W
43
Internal variables
Done
05
Don
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f dia
gnos
is
Bi
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V160
0.4
R
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iabl
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ogra
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s ha
ving
acc
ess
to th
e va
riabl
es (R
=rea
ding
,W=w
ritin
g Serial no.
Category Sy
mbo
lic N
ame
Com
men
t De
faul
t va
lue
Type
Fl
ags
DB
IN
IT
COM
M
DIA
G
POS
USS-
Kom
-m
unik
atio
n B&
B
44
Done
04
Don
e Bi
t 4 o
f the
di
agno
sis
com
mun
icat
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Bi
t
V160
0.3
R
W
45
Done
03
Don
e Bi
t 3 o
f the
di
agno
sis
com
mun
icat
ion
Bi
t
V160
0.2
R
W
46
Done
02
Don
e Bi
t 2 o
f dia
gnos
is
Bi
t
V160
0.1
R
W
47
Done
01
Don
e Bi
t 1 o
f the
di
agno
sis
com
mun
icat
ion
Bi
t
V160
0.0
R
W
48
D
one
USS
_IN
IT
Bi
t
W
49
R
espo
nse_
R U
SS_C
TRL
Bi
t
W
50
Sp
eed
USS
_CTR
L
Real
W
51
R
un_e
nabl
ed U
SS_C
TRL
Bi
t
W
52
D
_Dire
ctio
n U
SS_C
TRL
Bi
t
W
53
In
hibi
t USS
_CTR
L
Bit
W
54
Fa
ult U
SS_C
TRL
Bi
t
W
55
timin
g_w
Cl
osed
Loo
p Co
ntro
l tim
e in
W
ord
Form
at
30
Wor
d
VW99
6 W
R
56
Mer
ker_
low
M
emor
y fo
r low
er li
mit
0 Bi
t
V999
.0
RW
57
Mer
ker_
uppe
r M
emor
y fo
r upp
er li
mit
0 Bi
t
V999
.1
RW
58
VD_O
P_N
eue_
Posi
tion
New
, re
sp. n
ext p
ositi
on
[mm
] 0.
0 Re
al
VD11
20
R
B4-R
W
59
VD_O
P_Ak
tuel
l_Po
sitio
n C
urre
nt p
ositi
on [m
m]
Re
al
VD
1124
RW
B4-R
60
VD_S
tellw
ert
Setti
ng [±
%]
0.0
Real
VD11
60
W
R B4
;5-R
61
Kommando- / Statustabelle
Diag
_Mot
orau
slas
tung
Va
lue
of m
otor
wor
kloa
d (%
, cal
cula
ted)
Real
VD16
40
W
B7
-R
Con
trolle
d Po
sitio
ning
with
Asy
nchr
onou
s M
otor
s in
clud
ing
HM
I Con
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atio
n
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Des
crip
tion
of th
e va
riabl
e N
atur
e an
d ty
pe o
f the
var
iabl
e Pr
ogra
m b
lock
s ha
ving
acc
ess
to th
e va
riabl
es (R
=rea
ding
,W=w
ritin
g Serial no.
Category Sy
mbo
lic N
ame
Com
men
t De
faul
t va
lue
Type
Fl
ags
DB
IN
IT
COM
M
DIA
G
POS
USS-
Kom
-m
unik
atio
n B&
B
62
Diag
_Ant
riebs
tem
p
Valu
e of
the
driv
e te
mpe
ratu
re (°
C)
Real
VD16
36
W
B7
-R
63
Diag
_Ant
riebs
ausl
astu
ng
Valu
e of
the
driv
e w
orkl
oad
(%)
Re
al
VD
1632
W
B7-R
64
Diag
_Aus
gang
s_I
Valu
e of
the
conv
erte
r ou
tput
cur
rent
(A)
Re
al
VD
1628
W
B7-R
65
Diag
_Zw
isch
enkr
_U
Valu
e of
the
conv
erte
r lin
k vo
ltage
(V)
Re
al
VD
1624
W
B7-R
66
Diag
_Aus
gans
_U
Valu
e of
the
conv
erte
r ou
tput
vol
tage
(V)
Re
al
VD
1620
W
B7-R
67
St
atus
bits
of t
he
frequ
ency
con
verte
r
W
B7-R
68
Er
ror b
yte
of th
e co
nver
ter c
omm
unic
atio
n
W
B6-R
69
Acce
lera
tion
Bi
t
V118
0.0
RW
70
Con
stan
t mot
ion
Bi
t
V118
0.1
RW
71
Del
ay
Bi
t
V118
0.2
RW
72
STDW
(Ste
uerd
oppe
lwor
t)
Gen
erat
or in
pos
ition
Bit
V1
180.
3
RW
73
Sign
dis
tanc
e ge
nera
tor
(1=m
inus
)
Bit
V1
180.
4
RW
74
Sign
of s
ettin
g (1
=min
us)
Bi
t
V118
0.5
RW
75
In p
ositi
onin
g w
indo
w
Bi
t
V118
0.6
RW
76
New
pos
ition
ing
Bi
t
V118
0.7
RW
77
Mot
ion
rele
ase
0 Bi
t
V118
1.0
R
B4;5
-RW
78
Kommando- / Statustabelle
STDW
(Steuerdoppelwort)
Set z
ero
poin
t
Bit
V1
181.
1
R
B5
-W
Con
trolle
d Po
sitio
ning
with
Asy
nchr
onou
s M
otor
s in
clud
ing
HM
I Con
figur
atio
n
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Des
crip
tion
of th
e va
riabl
e N
atur
e an
d ty
pe o
f the
var
iabl
e Pr
ogra
m b
lock
s ha
ving
acc
ess
to th
e va
riabl
es (R
=rea
ding
,W=w
ritin
g Serial no.
Category Sy
mbo
lic N
ame
Com
men
t De
faul
t va
lue
Type
Fl
ags
DB
IN
IT
COM
M
DIA
G
POS
USS-
Kom
-m
unik
atio
n B&
B
79
Man
ual m
otio
n V1
fo
rwar
d ru
n
Bit
V1
181.
2
R
B5
-W
80
Man
ual m
otio
n V2
fo
rwar
d ru
n
Bit
V1
181.
3
R
B5
-W
81
Man
ual m
otio
n V1
rtn
run
Bi
t
V118
1.4
R
B5-W
82
Man
ual m
otio
n V2
rtn
run
Bi
t
V118
1.5
R
B5-W
83
Ref
eren
ce p
oint
sea
rch
Bi
t
V118
1.6
R
B5-W
84
Ope
ratio
n m
anua
l or
refe
renc
ing
Bi
t
V118
1.7
RW
85
0=U
nipo
lar 1
=Bip
olar
1
Bit
V1
182.
0
R
86
0=C
ontro
l onl
y ou
tsid
e w
indo
w 1
=Alw
ays
0 Bi
t
V118
2.1
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87
Pow
er o
n re
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Bit
V1
182.
2
RW
B3-R
W
88
Mem
oriz
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sear
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part
2
Bit
V1
182.
3
RW
89
Perfo
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arch
for
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rt 2
Bi
t
V118
2.4
RW
90
Man
ual m
otio
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ange
Bit
V1
182.
5
RW
91
Res
.
Bit
V1
182.
6
RW
92
To 0
.0 a
fter s
earc
h fo
r re
fere
nce
Bi
t
V118
2.7
RW
93
Dig
ital F
U O
n fo
rwar
ds
Bi
t
V118
3.0
RW
95
Dig
ital F
U O
n fo
rwar
ds
Bi
t
V118
3.1
RW
96
Kommando- / Statustabelle
STDW
(Ste
uerd
oppe
lwor
t)
Res
erve
Bit
V1
183.
2 bi
s V1
183.
7
97
Rang
e Ra
nge
in th
e da
ta b
lock
for t
he U
SS
com
mun
icat
ion
VB
1200
bis
VB
1600
RW
Con
trolle
d Po
sitio
ning
with
Asy
nchr
onou
s M
otor
s in
clud
ing
HM
I Con
figur
atio
n
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PrkNN.NN-N/A
N
ote
1 Th
e co
mpl
ete
func
tiona
lity
of th
e po
sitio
ning
can
be
“ser
ved”
and
“mon
itore
d” v
ia th
e sh
own
com
man
d / s
tatu
s in
terfa
ce.
I.e. t
he a
pplic
atio
n co
uld
be s
erve
d an
d co
ntro
lled
by m
eans
of t
he d
igita
l inp
uts.
Th
e po
sitio
ning
func
tiona
lity
coul
d be
con
nect
ed w
ith a
n ex
istin
g pr
oces
s, e
.g. a
sto
p br
ake
coul
d be
con
trolle
d vi
a th
e Bi
t V11
80.6
(in
posi
tioni
ng w
indo
w).
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Part B: Installation of the Sample Application
Part B of this document provides the reader with information on the following topics.
• how to install the sample application with all hardware and software components
• how to operate the application via the TP070
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5 Installation of Hardware and Software
On the basis of the components mentioned under chapter 2.2 the complete application (standard and application componetns) will be able to run immediately upon installation. The actual installation involves installing the SIMATIC hardware (chapter 5.1) and software (chapter 5.2).
Note With respect to the installation it is assumed that the MICROMASTER 420 with BOP (Basic Operator Panel) is used. The AOP (Advanced Operator Panel) and the PC converter connection block are alternatives to the BOP and are not explicitly described.
5.1 Hardware configuration
For hardware components required we refer to chapter „2.2.1 Hardware components“. The hardware configuration consists of four parts:
• S7-CPU 226
• TP070
• MICROMASTER frequency converter MM420 with BOP (Basic Operator Panel)
• Motor type 1LA7 and mechanics with shaft angle encoder
! Note Here it will not be dealt with:
• how the shaft angle encoder is mechanically connected with the motor
• how the motor is mechanically linked to the connected process
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In the following the installation/connection of the HW components is described:
Table 5-1 Hardware configuration Step Focus Instruction
1 Modules on the top hat rail
Attach the MICROMASTER frequency converter and the S7-200 CPU to the top hat rail..
2
Connecting the shaft angle encoder with the integrated hardware counter of the S7 200 CPU
The encoder changing the movement of the mechanics into electrical impulses is connected with the fast counter (e.g. HSC0) of the S7-200 CPU. The counter HSC0 is used in the sample application. This assigns the inputs E0.0 and E0.1. Along with the additional input E0.2 the counter can be set back. Furthermore the shaft angle encoder requires an external supply voltage. The load current supply of the S7-200 CPU can be used for this. Wire the encoder and the CPU according to the following table:
Table 5-2 Assignment plan CPU shaft angle encoder
Serial no. Encoder
(Core color) Inputs/outputs of the CPU
1 Brown E0.0
2 Grey (dark) E0.1
3 Blue Load current supply (+)
4 White Load current supply (-) and weight
! Note
In case you use another counter than the one mentioned in the chapter, it will be possible that the assignment plan deviates. In this connection please read the description of the encoder and the manual of the S7-200 CPU.
Note 2
It is possible, that the count direction deviates (depending on encoder installation position). In this case, please swap both channels of the encoder (brown and gray cable).
3
Connecting the reference point switch and the end-position switch
Connect the end-position switch and the reference point switch according to the following assignment table.
Table 5-2 Assignment plan CPU – Reference point switch, end-position switch
No. Switch Inputs/outputs of the CPU
1 Lower end-position switch E0.3
2 Upper end-position switch
E0.4
3 Reference end-position switch
E0.5
4 Connecting the Touch Panels with the S7-200 CPU
The Touch Panel TP070 is connected with the S7-200 CPU by means of the MPI cable. The power supply of the device can also be made via the load current supply of the S7-200 CPU, provided that the maximum current is not exceeded by that.
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Step Focus Instruction
5 Connecting the S7-200 CPU with the MICROMASTER frequency converter
The MICROMASTER is connected to the S7-200 CPU via a PROFIBUS cable. At the MICROMASTER the cable is connected with the terminals 14 (red) and 15 (green). At the CPU side there is the usual PROFIBUS connector
Fig. 5-1 Connection sample MICROMASTER 420
6 Connecting the
asynchronous motor to the MICROMASTER frequency converter
At the MICROMASTER the motor is connected to the three terminals U, V and W.
Take care that the output inductors will have to be used in the event of longer cables between the MICROMASTER and motor.
Fig. 5-2 Connection motor with MICROMASTER
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7 Connecting the
MICROMASTER and the S7-200 CPU to the power supply
After all the wiring has been carried out properly, the configuration can be connected to the power supply.
MICROMASTER frequency converter: Depending on the features of the connected current network the MICROMASTER may require input filter. This also applys to the operation of the MICORMASTER at a FI protective switch. At the connected current network, the MICROMASTER frequency converter is to be protected correctly .
Fig. 5-3 Connection of the MICROMASTER to the power supply.
Fig. 5-4 Recommended protective network of the MICROMASTER 420 Legend: Sicherung := fuse; einphasig := single-phase; Schutz := protection; Optimaler Filter := optimal filter; Schirmung := shielding
S7-200 CPU
In the application, an AC S7-200 CPU is used for the connection to a usual 230V power supply.
Fig. 5-5 Network connection S7-200 CPU
!
Important Please take care that the protective conductor at the S7-200 CPU (at the terminal strip for the power supply) and at the MICROSMASTER 420 (at the blackplane sheet) has been correctly connected.
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5.2 Installing the software
• The installation of STEP7-Micro/Win, the TP-Designer and the MICROMASTER installation program “Starter“ is not described here. Installation takes place in the familiar Windows environment and is self-explanatory.
• The applications software and projects are to be transferred to the S7-200 CPU, the Touch Panel TP070 and the MICROMASTER 420.
Note It is assumed here that all components have been installed correctly and connected to the power supply.
5.2.1 Transferring of the application code to the S7-200 CPU
Step Focus Instruction
1 Installing the STEP7-Micro/Win software Please install the STEP7-Micro/Win software according to instruction
2 Opening of the project Open STEP7-Micro/Win – application code in the program (open file).
3 Setting the communication connection Set your link path to the S7-200 CPU in STEP7 Micro/Win (in the operation tree under communication).
4 Creating the cable connection Create the cable connection between S7-200 CPU und the PC/PG . Make sure that this corresponds with the features being already set under step 3!
5 Compile and load everything into the CPU Click the button “compile everything” in the task bar and then the button “load in CPU”
5.2.2 Transferring the application code to the Touch Panel TP070
Step Focus Instruction
1 Installing the TP-Designer Please install the TP-Designer software according to instruction.
2 Opening of the project Open the TP configuration file in the program (open file).
3 Setting the communication connection Set your link path to the S7-200 CPU in the TP-Designer (setting communication PC to TP communication).
4 Creating the cable connection Create the cable connection between the Touch Panel TP070 and the PC/PG. Make sure that this corresponds with the features being already set under step 3!
5 Compile and load everything into Touch Panel laden
Click the button “compile” in the task bar and then the button “load in TP”
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5.2.3 Parameterization of the MICROMASTER 420
For the parameterization with the parameter list (list of the system-specific values for the MICROMASTER 420, please cf. the following table) the hardware components shown in the following picture are required at the MICROMASTER.
Fig. 5-6 BOP for the parameterization of the MICROMASTER 420 frequency converter
In the following the variation for parameterizing the MICROMASTER frequency converter is dealt with in detail
Table 5-3 Parameterizing with AOP or BOP Step Focus Instruction
1 Fixing of BOP or AOP Remove the shutter of the MICROMASTER and fix the BOP or the AOP.
2 Parameterizing Enter the parameters one after the other into the following Parameterliste.
The parameter list is stated below. When using a BOP or AOP (Basic Operator Panel oder Advanced Operator Panel) you can enter the parameters one after the other.
Schritt Parameter Index Wert (zu parametrieren)
Kommentar
1. P0003 3 Access step
2. P0010 30
3. P0970 1 Startup parameters on factory defaults
4. P0010 1 Quick Commissioning
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Schritt Parameter Index Wert (zu parametrieren)
Kommentar
5. P0100 0 Europe 50Hz P in kW
6. P0304 Rated Motor Voltage
7. P0305 Rated Motor Current
8. P0307
Typenschild des Motors
Rated Motor Power
9. P0310 Rated Motor Frequency
10. P0311 Typenschild des
Motors Rated Motor Speed in rpm
11. P0700 5 Selection of Command Source
12. P1000 5 Selection of Frequency Setpoint
13. P1080 0,20 Hz Min. Motor Frequency
14. P1082 50Hz Max. Motor Frequency
15. P1120 0,00 Ramp-Up Time
16. P1121 0,00 Ramp-Down Time
17. P3900 1 End Quick Commissioning
18. P0003 3 Access step
19. P2000 50.00 Reference frequency 50 Hz (1 to 650 Hz)
20. P2009 0 0 USS normalizing 0 to 65535 ms
21. P2010 0 7 Speed of data transmission 19200 baud
22. P2011 0 1 Adress (Slave)
23. P2012 0 2 USS PZD-length
24. P2013 0 127 USS PKW-length
25. P2014 0 300
Communication monitoring Value 0 is not being monitored; if you have to modify this value, the SPS will have to start the execution of USS protocol previously, as otherwise error 72 appears. You will also have to modify the value with the arrow downwards, as the arrow up would be the first value 1 ms causing an immediate error message.
26. P0971 1 Protect the data in the E²PROM
! Important The parameter (P0304-P0311) for the motor data must be adjusted to the respectively used motor.
Note After parameterizing the MM it is recommended to check the direction of encoder and MM. To do this, specify a small inching setpoint, e.g. 5 to 10%. Then the drive is moved in one direction in inching mode. The actual value of the position must be changed according to the direction or rotation, i.e. reduce at counterclockwise operation. If this is not the case, either both track signals of the incremental encoder, or two phases (e.g. U and V) of the motor must be exchanged. Clockwise operation is referred to the motor shaft moving to the top right while looking from the load side onto the motor shaft, see below figure.
Bild 5-1 Clockwise operation
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Note
Parameterization with PC via a serial interface A further possibility to parameterize the MICROMASTER is provided via a serial connection to a PC/PG.
Step Focus Instruction
1 Fix a serial interface
Remove the shutter of the MICROMASTER and fix new shutter with a serial interface.
2 Parameterizing software „Starter“
Install the parameterizing software “Starter” on the PC/PG according to the instructions.
3 Connecting Create cable connection between the serial interface of the MICROMASTER and the PC/PG.
4 Looking for online drives
Select the menu item “look for online drive” in the welcome wizard
Fig. 5-7 Configuration assistant
In the course of the assistant always follow the instructions.
5 Enter parameter
Navigate into the expert list of all parameter, as shown in the following illustration and enter the parameter mentioned below.
Fig. 5-8 Navigation expert list
Copy the data on the EEPROM after the parameters have been entered. They are then stored safely against voltage drop.
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6 Operation of the application TP 070
Each of the operating and monitoring figures and each of the values and parameters is explained.
Preconditions The conditions described in the chapter “Installing Hardware and Software“ (chapter 6) are to be complied with and all devices have been switched on.
6.1 Providing the S7-200 CPU program with parameters
For operating the application it is essential that it is provided with system-specific parameters (resolution encoder, features of the mechanics). For this reason, the navigation bar at the bottom of the screen contains the item “Parameter”. If this item is selected, you will move into the following figure (Figure 6-1). The category parameter is divided in three figures:
• Movement (chapter: 6.1.1)
• Mechanics/encoder (chapter: 6.1.2)
• P-I-controller (chapter: 6.1.3) Typical default values of the parameters are stored in the data block of the S7-200 CPU. Please see chapter 4.2.3. The parameters of the individual figures are explained in the following:
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6.1.1 Parameter movement
Figure 6-1 TP070 Figure “Parameter – Movement“
The parameter speed max. (mm/s) contains the value being admissible as maximum speed for the materials-handling technology (e.g. low air pressure encoder). Thus the maximum motor drive being limited upwards.
!
Note The value of the speed of the materials-handling technology (e.g. the low air pressure encoder) is subject to the features of the mechanics and the resolution of the encoder. The modification of these values will automatically result in a modification of the actual speed. At worst, the given value for speed max. (mm/s) can be too high. This can cause damages to the mechanics.
Values are entered in both fields acceleration (mm/s²) and deceleration (mm/s²) which should avoid sudden changes in the number of revolutions and speed. The fields with the fixed value contain the speeds for a manual procedure (jog mode) and for the search of reference. The manuel speed value slow (%) corresponds to the slow speed, the manuel speed value fast (%) to the fast speed. A fixed value of 100% corresponds to the speed max. (mm/s), explained in the previous chapter.
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6.1.2 Parameter mechanics/encoder
Fig. 6-2 TP070 figure “parameters – mechanic/encoder” The first field on this figure contains the value for the resolution of the use shaft angle encoder in increments per revolution. For this value the physical resolution is required (without edge evaluation which is carried out in the counter of the S7-200 CPU).
The used mechanics is described by the value of the parameter distance per revolution. In this sample application we proceed from a linear axis.
Note The two parameter increments per revolution and ditance per revolution directly influence the control behavior and the speed of the positioning. Wrong values may damage the mechanics.
The fields with the values of the parameter position A (mm) and position B (mm) contain defined positions which should be approached by the materials-handling technology (e.g. low air pressure encoder). These are absolute specifications starting from the zero point.
The parameter reference offset (mm) indicates the distance the zero point has been shifted from the reference point.
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6.1.3 Parameter P- I- Controller
Fig. 6-3 TP070 Figure “Parameter – P- I- controller“
The parameters P-amplification, I- amplification und correction value are controller-specific parameters. These values are to be adjusted to the respective system. The values and the correction value are factors and are the actual P-factor of the position controller. The correction value provides for the scaling of P-Reinforcing.
P-factor = P-Reinforcing x correction value Further information on the P-I-controller can be found on page 32 under “Setting of the setpoint velocity for the motor”.
In addition, there is a switch “Permanent controlling“ moving between the mode “Always positioning” and “Controlling inside the positioning window off“.
Note
In case the modus “Permanent controlling“ is used, the motor will require a forced air cooling. In the mode “Controlling inside the positioning window”, it is quite possible to use a stop brake.
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6.2 Automatic mode and jog mode
The actual operation of the application is made in the two figures “Automatic“ and “Jog mode“. In the following sections they are explained in detail.
6.2.1 Automatic
Fig. 6-4 TP070 Figure “Automatic operation“
For the operation there are three elements in this figure. The two positions A and B are selected by means of the respective sensors.
For activating the position control, the Closed loop control on is to be given. When this is set and a position is selected the motor immediately starts to accelerate. In addition the following values are shown.
• position (mm)
• Setpoint (%)
• speed (Setpoint velocity of the motor)
DANGER Overloading the MICROMASTERS and/or the motor can cause an inadmissible status of the position controller! This situation is to be avoided and must be considered during dimensioning MICROMASTER and motor!
Note If a position is reached, in which a situation limit switch becomes active, then the automatic controller release is durably closed. The barrier is driven waived into manually over the switch of point of reference back into the permissible range.
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6.2.2 Jog mode
Fig. 6-5 TP070 Figure “Hand Ctrl.“
The operation in the jog mode figure can be roughly divided in two categories.
• The first category contains the manual procedure, i.e. it is possible to operate the position of the materials-handling technology manually. For activating the jog mode the Closed loop control on (functionally identical with the controller enable in the figure Automatic) is to be taken. The operating elements are self-explanatory.
▪ Slow forward run ▪ Slow return ▪ Fast forward run ▪ Fast return
The parameterizing of both speeds for this mode has already been dealt with in chapter “6.1.1 Parameter movement”.
• The second category contains the operating elements dealing with the reference point and the zero point:
▪ Reference point search looks for the reference point switch and puts it here to the zero point (the zero point shift is taken into account).
▪ Setting of zero point, puts the counter at the current position to 0.0. The following details are also illustrated:
• Position (mm)
• Setpoint (%)
• speed (Setpoint velocity of the motor)
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Note If an end-position switch was passed over, the direction of the end-position switch that was passed over is also blocked for manual operation. If for example the lower end-position switch was passed over, the negative direction (backwards) cannot be manually operated.
Note For starting the search for reference it must be ensured, that the current position has a positive distance from the reference point. The search for reference always occurs in negative direction.
6.3 Diagnosis values of the MICROMASTER 420 frequency converter
For greater clarity and for the structure of the diagnosis functions, the figure “Diagnosis is divided in two individual categories.
6.3.1 Status values of the MICROMASTER frequency converter and errors in the USS communication
Fig. 6-6 TP070 Figure “Diagnosis - Status“
The right part of the figure contains selected status information of the frequency converter. An active status is represented as “pressed button” but is not operable.
▪ Ready to operate: The MICROMASTER is switched on and ready.
▪ Ready for start: The MICROMASTER is waiting for the “signal motor on” and a setpoint velocity value of the motor
▪ Operation active: Motor is running.
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▪ Drive warning: There is an error in the drive (MM420).
▪ Overload drive:The motor is not overloaded.
▪ Overload MICROMASTER: The MICROMASTER is not overloaded.
▪ Current limitation: The output current is not limited.
The error bytes of the USS communication to MM4 are represented on the left top of the figure. If value “0” is shown, no error has been occurred. For identifying occurred errors the following table contains the error codes:
Error code Error description
0 No error occurred 1 Drive does not react. 2 The response of the drive contains a checksum error
3 The response of the drive contains a parity error
4 Error caused by a failure of the user program
5 Invalid command
6 Invalid drive address
7 The communication interface has not been set up for the USS protocol
8 The communication interface is processing another operation
9 The given speed of the driving motor is outside the range
10 Wrong length of the drive’s response
11 The first sign of the drive’s response is wrong
12 The length sign in the response of the drive is not supported by the USS operation
13 Reaction of the wrong drive
14 Wrong DB_Ptr address
15 Wrong parameter number
16 An invalid protocol has been selected
17 USS is active, modifications are not allowed
18 An inadmissible baud rate has been given
19 No communication: the drive is not active
20 The parameter or the value in the response of the drive is wrong or contains an error code
21 Instead of the required word value a double word value has been output
22 Instead of the required double word value a word value has been output
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6.3.2 Reading the process values from the MICROMASTER
Fig. 6-7 “TP070 Figure Diagnosis – Process values“
The diagnosis figure process values contains a selection of process values from the MICROMASTER. Only the most important have been chosen as example. In order to save cycle time in the user program of the CPU, an updating will only be carried out in case of one changeover into the diagnosis figure process values and each time the button “process values“ is pressed again. The fields only contain “instantaneous exposures” of the read values.
Note A cyclical reading and illustration of the value is possible, provided a low cycle time and high positioning accuracy is not important. The following is a brief comment on the illustrated process values:
▪ Output voltage MICROMASTER (V): Contains the amount of the output voltage of the MICROMASTER In case the motor is in a brakeless stillstand, the value will be 0 V.
▪ intermediate circuit voltage MM (V): The link voltage in the converter is usually about 310 V (on 230V supply voltage).
▪ Output current MICROMASTER (A): In the event that this value is higher than the maximally allowed motor current, than this will be limited. When the MICORMASTER is parameterized, the maximum motor current is fixed as a parameter.
▪ load MICROMASTER (%):
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▪ Temperature MICROMASTER (%): Contains the value of the converter temperature.
▪ Drive load (calculated, I²t) (%): The workload of the converter is calculated by means of the recorded current and time. If this value exceeds 100% the motor will be switched off. The converter displays an error.
6.4 Modification of the system settings at the TP070
Fig. 6-8 TP070 Figure “System settings“
• The display contrast can be modified by means of the buttons contrast + and contrast -.
• The connection status is influenced by the two sensors online and offline.
• If it is necessary to clean the screen, the button Cleaning screen will have to be pressed beforehand. This deactivates the screen which is sensitive to touch.
• A calibration ensures the congruence between the invisible raster of the touch screen and the actually optical display. These are calibrated by pressing the button Calibrate screen.
• By pressing the button Serial upload a new TP070 project can be loaded on to the touch panel.
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Part C: Program Description
Objectives of Part C: The purpose of this section is to
• explain the code details of some core elements in the program
• give instructions where extensions are appropriate
Preconditions This is not an introduction into STEP7 Micro/Win language AWL, KOP or FUP. Readers should be familiar with the basics of these languages. Before reading the description of the code, it may be useful to read the chapters in part A2.
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7 Explanations on the STEP7 Program
7.1 OB1 (description of the block)
In the following section you can see how the calls in OB1 are functioning program technically: In the following figure it is apparent, that the subprograms INIT (SBR0) and Comm_Diag (SBR9) are called.
Fig. 7-1 Network 1 and 2 in the OB1 In network 1, the subprogram INIT (SBR0) is called once in the first cycle. In this subprogram, initializations of the fast counter, the time interrupt and the USS communication are processed. In network 2, the program Comm_Diag is called for each cycle, it performs the communication and the evaluation of the reference and end-position switches.
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7.2 INIT (SBR0), (description of the block)
Fig. 7-2 Network 1 and 2 in INIT (SBR0) In network 1 the fast counter is initialized for the evaluation of the shaft angle encoder. For the temporal call of the interrupt program the time value is passed on in milliseconds (as byte).
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Fig. 7-3 Network 3 to 15.24 cm INIT (SBR0) In the third network, the interrupt program is set up, i.e. an event is assigned. (Event 10 means temporal execution with time configured in SMB34) Network 4 provides the time value of the SMB34 as integer value. In network 5, the communication from CPU to converter is initialized. For error confirmation at the inverter a time is started in network 6 after CPU startup, after it has elapsed an Error – Acknowledge is send to the MICROMASTER.
Note If you configure your MICROMASTER with other address or speed parameters, these parameters will have to correspond to those at the initializing call of the USS communication.
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7.3 Comm_Diag (SBR9), (description of the block)
Fig. 7-4 Network 1 to 3 In the first network, the positioning block is instructed to transfer bipolar set values to the MICROMASTER. The second network switches the inverter on in the various operating phases. In the third network, the Acknowledge is transmitted to the USS communication block after the time has elapsed.
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Fig. 7-5 Network 4 to 6 The USS communication block is called in network 4. Bits transferred in the status word are negated in networks 5, 6, and 7. They hence need not be displayed as negated values.
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Fig. 7-6 Network 7 to 9 The networks 8 to 14 are nearly identical, here a value is respectively read out of the MICROMASTER. This procedure is triggered by a Bit (M0.6) in the (first diagnosis) network 8. After the communication of the first value is completed, all following values are read out of the MICROMASTER in a step sequence. At the end of the step sequence the “start“ bit (M0.6) is set back. The number of the diagnosis values and the repeating speed of the diagnosis can adjusted individually. The diagnosis values in the application are only shown as examples. The following is read:
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No. Net-work Diagnosis value Parameter of the MICROMASTER 420
1 8 Output voltage P0025
2 9 Link voltage P0026
3 10 Output current P0027
4 11 Drive workload P0036
5 12 Drive temperature P0037
6 13 Motor workload P0034
Note A permanent reading of process (diagnosis) values can result in an extreme load of the communication between the MICROMASTER 420 and S7 200 CPU. A constantly fast communication, which is required for a precise position control, does not take place anymore. This “effect” has a decisive influence on the control behavior. Unter Berücksichtigung des „Effektes“ aus dem oben aufgeführten Hinweis wird das Lesen der Diagnosewerte nur bei „Bedarf“ ausgeführt. D.h. explizit, nur wenn das Bild Prozesswerte aufgerufen wird oder wenn der Taster Prozesswerte erneut betätigt wird.
Fig. 7-7 Network 10 to 11
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See text on page 80, networks 8 to 14.
Fig. 7-8 Network 12 to 13 See text on page 80, networks 8 to 14.
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Fig. 7-9 Network 14 to 18 In network 15 the reference point switch is evaluated and only transferred to the positioning switch as long as the search for reference is active. In the last following networks the end-position switches are evaluated. If an end-position switch becomes active (i.e. is passed over) this sets a marker. This marker blocks the controller enable and the manual procedure in the direction in which the end-position switch was passed over. The marker of the end-position switches are set back by the reference point switch.
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Fig. 7-10 Network 19 and 50.80 cm INIT (SBR0)
7.4 POS (positioning block, parameter)
The interrupt program POS is not called cyclically in the OB1, but time controlled (in the application example every 30 ms).
Note You will find the code with detailed comments in the application project „CODE_Lagereglung_e_.mwp“. A description of the command interface is shown in chapter 4.2.4.
7.5 Blocks for USS communication (parameter)
Note Standard blocks have been used for the communication between the MICROMASTER 420 and S7 226 CPU. You will find a documentation of these blocks in the manual of the S7 200 CPU or in the Online help of the S7 Micro/Win 32.
7.6 Data block
You will find a detailed description of all used variables including the data block in chapter 4.2.4.
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8 Changes in the STEP7 program
In the following you are given some tips and instructions how to adjust the program to you specific requirements.
8.1 Using a linear or round axis as well as modifying units//scales
This chapter will answer the question if and how a round axis can be employed instead of a linear axis, and how other “mechanics” can be adjusted in the application project. In case a round axis is employed instead of a linear axis, then this will only apply to:
• The physical units in the TP Designer Project of the Touch Panel TP070 (visualization, only purely optical, no functionality)
• The parameter travel per revolution is to be changed into the relevant degree specification or into the new, desired unit.
Note The modification of the parameter can have decisive influences on the control behavior of the application.
Modifying physical units in the TP-Designer Project Step Focus Instruction
1 Opening the project Open in the TP-Designer the „*.tpf“ project. added to the application. Go to file open to do this..
2 Modifying the units
You can adjust the units in the intended text boxes in the figures ‘automatic’, ‘jog mode’ and ‘parameterizing 1/2/3’. The following units are for the parameters:
• Setpoint (automatic)
• Setpoint position (jog mode)
• Speed maximum (parameter 1)
• Acceleration (parameter 1)
• Delay (parameter 1)
• Travel per revolution (parameter 2)
• Route mark position A (parameter 2)
• Route mark position B (parameter 2)
• Reference point shift (parameter 2) Positioning window (parameter 3)
3 Securing and new transferring
Store the modifications (under file store). Compile the project and transfer it afterwards to the Touch Panel TP070.
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Modifying the parameter “distance per revolution” Step Focus Instruction
1 Opening the project Open the application project in S7 Micro/Win 32
2 Modifying the ratio
Move to the view of the data block. For that purpose you click on the data block in the operation tree. Here you look for the comment heading Mechanics / Encoder. There you will find the entries of the two variable with comments:
• Ttravel per revolution
• Factor of the display compared with metrs. Modify the settings of the default values according to your requirements-
3 Securing and new transferring Restore your project, compile it and load it into the CPU.
8.2 Using other inputs for the encoder (fast counter)
This chapter answers the question:
• How can I use other inputs for the connection of my shaft angle encoder?
Using other inputs for the shaft angle encoder In case the digital inputs of the counter are already assigned to an existing project, another free counter of the CPU may be used, provided that the counting mode 101 is supported. However, the variable for the access to the counter will have to be corrected in the entire S7 Micro/Win project.
Table 8-1 used inputs of the counter Serial no.
Fast counter Assigned inputs
1 HSC0 E0.0, E0.1, E0.2
2 HSC1 E0.6, E0.7, E1.0, E1.1
3 HSC2 E1.2, E1.3, E1.4, E1.5
4 HSC3 E0.1
5 HSC4 E0.3, E0.4, E0.5
6 HSC5 E0.4
The S7-226 CPU owns, e.g., 5 counters, HC0 to HC5, from these only the counters HC0, HC1, HC2 and HC4 support the mode 10.
1 A/B counter with quadruple counting speed, no start input, reset input
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Step Focus Instruction
1 Opening the project Open the application project in S7 Micro/Win 32
2
Move into the positioning block and adjust the variables
Move into the operation tree and select the INIT (SBR0) block. There you go to network 2. Here you modify the variables/values marked in the following figure.
Fig. 8-1 Network 2 in the INIT block
Please modifiy in network 5 (in the positioning) the following variables on the counter used by you.
Fig. 8-2 Network 5 in the positioning block
3 Securing and new transferring Restore your project, compile it and load it into the CPU.
Controlled Positioning with Asynchronous Motors including HMI Configuration
Rev. A - Endgültig 13.05.2003 86/91
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8.3 Transferring analogously the setpoint for the MICROMASTER frequency converter
The setting for the MICROMASTER 420 calculated by the positioning block is directly transferred in the application to the MICROMASTER 420 via the communication block (via USS protocol). If it is necessary to configure a (very) dynamic control it can be advantageous to transfer the setting to the MICROMASTER analogously. Therefore the communication time between the S7-226 CPU and the MICROMASTER 420 is dropped, In this case the S7-226 CPU would additionally require an analog output module. The MICROMASTER has an analog value input as standard. The structure could be as follows:
Fig. 8-3 Possible modification of the application (transfer of the setting via an analog value)
This is only an overview of the necessary modifications in the S7 Micro/Win project and not a detailed description. The USS communication can be neglected, consequently it is not necessary to use the library blocks for this communication. The MICROMASTER 420 is exclusively controlled by the digital outputs and anolog values for the setpoint velocity. The setting being calculated in the positioning block is to be transferred to the analog initial word of the analog expansion module. The following data are to be transferred to the MICROMASTER via a direct wiring.
• Motor ON/OFF (binary)
• Direction (binary)
• Setting (analog)
Controlled Positioning with Asynchronous Motors including HMI Configuration
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8.4 Using other frequency converter of the MICROMASTER 3XX or 4XX family
Generally, only the replacement of the MICROMASTER 420 by a MICROMASTER 3XX results in modifications of the actual S7-Micro/Win application code. When calling the USS communication library it has to be taken care in OB1 (network 7) that the correct value for the parameter “Type“ is transferred. Please see the following picture:
Fig. 8-4 Network 7 in OB1, adjustment of the parameter “Type“ for the communication with a MICROMASTER 3XX or 4XX
The input type (drive type) sets the nature of the drive. In case of a drive MICROMASTER 3XX (or earlier) you set 0 for “Type“. In case of a drive MICROMASTER 4XX you set “Type“ to 1.
8.5 Moving to freely selectable or relative positions
In the following the procedure is described, if you want to move to a freely selectable position instead of the positioning between two defined points A and B.
Moving to freely selectable positions Step Focus Instruction
1 Opening the project Open in the TP Designer the „*.tpf“ project. added to the application Go to file open to do this.
Controlled Positioning with Asynchronous Motors including HMI Configuration
Rev. A - Endgültig 13.05.2003
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Step Focus Instruction
2 Select figure Automatic Select the figure Automatic in the operation tree.
3 Deleting of operating elements
Delete the operating elements shown in the following figure
Fig. 8-1 Deleting of elements Legend: Reglerfreigabe := controller enable; Istposition := actual value; Stellwert := setting; Fahrt := travel;
4 Add input box
Then complete an input box and link this with the variable Neu_Pos (VD1120 in the S7 226 CPU).
Fig. 8-6 Add input box
3 Securing and new transferring
Store the modifications (under file store). Compile the project and transfer it afterwards to the Touch Panel TP070.
1.
2.3.
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Controlled Positioning with Asynchronous Motors including HMI Configuration
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Moving to relative positions This is only an overview of the necessary modifications in the S7 Micro/Win project and not a detailed description. Upon each executed positioning and with a rising edge of the status bit in the “positioning window”, the command “set zero point” can be given. This means that upon each positioning the current position is “0”. Each new positioning is approached from the reference point of the current position, thus resulting in a “simulated” relative positioning.
Controlled Positioning with Asynchronous Motors including HMI Configuration
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8.6 S7-Application code for own project use
Note An S7-Micro/Win library cannot be generated from the application code, as the core module of the application code is located in a time-interrupt program. Here the principle procedure is described, how to still use the core module of the application in your own project. Schritt Fokus Aktion
1 Open the project Open the production master of the application project via ‘File open’ .
2 Copy interrupt program into clipboard
3 Open new/own project
Open the work copy of your own project via “File open“ or create a new one via “File new”.
4 Insert Interruptprogram from clipboard
5 Change to Application project Change to Application project
Controlled Positioning with Asynchronous Motors including HMI Configuration
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Schritt Fokus Aktion
6 Copy symbol table USR1 to clipboard
7 Change to new/own project Change to new/own project
8 insert symbol table USR1 from clipboard
9 copying of USR2 and USR3 Repeat the steps 5-8 for the symbol tables USR2 and USR3
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