Workshop Motion Control With Siemens PLC (En)

Automation Days 2015
Workshop Technology/Drives
Restricted / © Siemens AG 2015. All Rights Reserved.

Challenges for machine builders
Increasing production speeds
Increasing production accuracy
More monitoring and extensive control options inclusive

more sensor systems
Flexible production:
e.g. easy & individual format change
Replacement of mechanical solutions thru electronic
Increased complexity and efforts

Program
Time-Based IO
dience
ence
- Input
stions to audie
Questions from aud
- Output
Control of Motion in PLC

- Different types of motion
- Possible Sol
Solutions
tions
Ques
- EPOS vs TO
- TIA Selection Tool

Challenges for machine builders
SIMATIC Technology
The smart solution for

demandingg tasks!
Live-Demo
Time-based IO
Example for „precise switching“
START!
Switch ON!
Goal:
Switch ON all
4 latern exactly
at 19:00
„Switch ON
at 19:00“
Transmit
message!

Time-based IO
Example for “precise detecting”
Now it is your turn:
Observe the light in the rack and press your button as

fast as y
you can!

Basic principle: “Precise detecting”
Goal: Calculation of the speed of

moving objects Light barrier
t
Signal of
light barrier
t
Refresh state
Program of inputs
cycle OB1
t
Detected
signal
t

“Precise detecting” based on Time-based IO
Now with Time-based IO Light barrier

 Detection of signal changes with
ti
time stamps
t
 Information available in the next
program cycle
t
Signal of
Light barrier
t
Result:
Program
cycle OB1
t
High-precision results t Evaluation in the
Detected next program cycle
… application examples:
signal
t
 Product detection
 Measuring input

Accurate reaction based on Time-based IO
Goal: accurate control of the ejector

Light barrier Ejector
v
s
Signal
Si l off t
Light
light barrier
t
µs-precise
µ p reaction Ejector
t
… application examples:
t3 t4
 Ejecting
t1 t2
 Dosing Program
execution
 Output cam t

Time-based IO in distributed I/Os
ET 200SP CM 4 x IO link
 Up to 4 IO link signals with time stamps
ET 200SP TM Timer
Ti DIDQ 10
10x24V
24V
 4 inputs
 6 outputs
ET 200MP TM Timer DIDQ 16x24V

 8 inputs and 16 outputs
 Up to 16 channels configurable with time
stamps
Requirement: isochronous real time communication (IRT)

Restricted / © Siemens AG 2015. All Rights Reserved. actually usable in distributed I/O stations (ET 200) only!
Use in central structure planned for the future.
Question to the audience
Which SIMATIC CPU supports Time based IO
1510 SP
1511 1515 1517
?
!
1512 SP 1513 1516 1518
ET 200SP
Open Controller
EACH SIMATIC S7-1500

Time-based IO summary
Added values by Time-based IO
High-precision
Hi h i i
… independent of transfer times and the cycle
time of the user program
Load reduction for PLC and bus system

… for increased performance and bigger quantity
structures of I/Os
Reduction of module variety

… for different applications instead of specific
function modules (FMs)
Scalability
y
… fitting to the size of the application
Why Motion Control within the PLC?
Mechanical Solution Motion Integrated

Main drive Coupling Gearbox Gearbox
Output
Camming & drive systems
cam are replacing
p g mechanical
components
Modular machine
concepts
Higher flexibility
Less wear
ON /
Better dynamic
OFF
Easy maintenance
Motion Controller
What is Motion?
Speed Control
2)Interpolation
Handling
2) Distributed
otion Control Functionality
Motion • Pumps, fans, mixers

1)
Camming
ab 1) Gearing
s.
(absolut)
rel.
 Gearing
(relative)
1)Output cams
Mo
Measuring
input
Positioning • Conveyors
 S
Speed
d

What is Motion?
Position Control
2)Interpolation
Handling
• Hoists, Lifts
2) Distributed
Motion
1)
Camming
ab 1) Gearing
s.
(absolut)
• Linear motions
rel.
 Gearing
(relative)
1)Output cams
Mo
Measuring
input
Positioning
 S
Speed
d • Feeders,
Feeders palletizers

What is Motion?
Output cams & Measuring Inputs
2)Interpolation
Handling
2) Distributed
Motion
1)
Camming
ab 1) Gearing
s.
(absolut)
rel.
 Gearing
(relative)
1) Measuringg
Mo
input
Output cams
Positioning S3 S4
 S1 S2
S
Speed
d

What is Motion?
Gearing
2)Interpolation
Handling
2) Distributed
Motion
1)
Camming
ab 1) Gearing
s.
(absolut)
rel.
 Gearing
(relative)
1)Output cams
Mo
Measuring
input
Positioning
 S
Speed
d

What is Motion?
Relative Gearing
Scope 1 Scope 2 Scope 3

No absolute position relation Gear in during standstill Flying coupling of axis
with non time
time-critical
critical gear in
Application example: Application example: Application example:

• Longitudinal cutter • Hoists, lifts • Superimposed operations
• Conveyors • Handling based on several axis • Simple “flying saw” applications
• Portals without external encoder
What is Motion?
Absolute gearing
2)Interpolation
Handling Paper
2) Distributed
Motion
1)
Camming
ab 1) Gearing
s.
(absolut)
rel.
 Gearing
(relative)
1)Output cams
Mo
Measuring
input Print mark
Positioning correction
 S
Speed
d

What is Motion?
Camming
2)Interpolation
Handling
2) Distributed
Motion
1)
Camming
ab 1) Gearing
s.
(absolut) • Rotary knife
rel.
 Gearing
(relative)
1)Output cams
Mo
Measuring
input
Positioning
 S
Speed
d

What is Motion?
Interpolation
2)Interpolation
Handling
2) Distributed
Motion
1)
• Deltapickers
Camming
ab 1) Gearing
s.
(absolut)
rel.
 Gearing
(relative)
1)Output cams
Mo
Measuring
input
Positioning • Milling, CNC Machining
 S
Speed
d

When use the different motion solutions?
Dedicated

Motion technology for multiple drives

in a separate controller.
Stand alone or with a PLC as “Higher

Stand-alone Higher
Level Control”
Simotion
Sinumerik
Dedicated FM
Motion C
Control in extra C
Controller

Motion Control in intelligent drives
Dedicated
Motion technology in the drive
Control from PLC
EPOS
Masterdrive technology cards
Sinamics S DCB library
Motion Control with PLC
Dedicated
Motion Technology in PLC

Control from PLC
S7 1200 / S7
S7-1200 S7-1500
1500 Technology
T h l objects
bj t

Motion Control with S7-1500 /

Motion Control in intelligent drives S7-1200
Dedicated
Motion C
Control in extra C
Controller

Motion solution vs Motion Technology
Siemens Solution
2) Interpolation
Handling
2)
2) Distributed
Motion
1)
Camming
arious
Va
abs. 1) Gearing
SINUMERIK
SIMOTION
(absolut) 1)
rel.
 Gearing
(relative)
CPU
DCB
CPU
1) Output cams
1500T-C
Mo
D
300T-C
Measuring input 1)
S7-1500
 EPOS
TO S7-1200
TO S7-1500
Positioning
 S
Speed
d
Legend: 1) Planned for V14
2) Planned for higher V14 Centralized Decentralized Dedicated
When to think of a dedicated solution.
Siemens
Is the customer in a specific industry like Solution
Interpolation CNC or printing. Does the machine match an
Handling available 80% solution like Vertical Filler?
2)
Distributed
Motion
Camming
arious
Does the application need interpolation, camming
or absolute g g Are there high
gearing? g demands on
Va
abs. Gearing
SINUMERIK
the
1) motion ?
SIMOTION
(absolut)
rel.
 Gearing
(relative)
CPU
DCB
CPU
1500T-C
Output cams Does the customer already have experience with

Mo
D
300T-C
Measuring input 1) Simotion or Sinumerik?

S7-1500
 EPOS
TO S7-1200
TO S7-1500
Positioning
 S
Speed
d
Contact the APC for more information or assistance.
When think of decentralized solutions (not including EPOS)
Siemens Solution Application with a lot of basic motion

2) Interpolation solutions and a few advanced motion
Handling solution
2)
2) Distributed
Motion
1)
Camming
arious
Machine in series production
Va
abs. 1) Gearing
SINUMERIK
SIMOTION
(absolut) 1)
rel.
 Gearing
(relative)
CPU
DCB
CPU
Solution to a specific control-based

1) Output cams
1500T-C
Mo
D
300T-C
1) problem e.g. Winders, distributed load

Measuring input
S7-1500
 EPOS
TO S7-1200
TO S7-1500
Positioning
 S
Speed
d
Contact the APC for more information or assistance. Contact the APC for more information or assistance.
S7-technology or EPOS
Siemens Solution
Interpolation
Handling
Distributed
Motion
Camming
abs. Gearing
(absolut)
rel.
 Gearing
(relative)
Output cams
Mo
Measuring input 1)
S7-1500
 EPOS
TO S7-1200
TO S7-1500
Positioning
 S
Speed
d
Decentralized solution
Drive Library + EPOS

Centralized Solution
Technology Objects

Compare Solutions
Decentral Central
Motion Control with SINAMICS G/S (FB) Motion Control with SIMATIC S7-1500 (TO)
FB SINA_SPEED
SINA SPEED PLCopen Bl
PLC Blocksk
Motion instructions
FB SINA_POS (EPos)
Technology object (TO)
Axis behaviour
Axis behaviour OB MC-Interpolator (OB92)

Interpolator
Interpolation
OB MC-Servo ((OB91))
Position controller Position controller
Speed / Positioning axis Speed / Positioning axis
Ready to use programm blocks (FB/PLCopen) for both solutions

Advantages of both solutions
Decentral Low PLC load and very high numbers of axis feasible Central
Extensive drive diagnostics and messages
Harmonized Standard-FBs with intuitive interface
Additional drive integrated functions feasible
(monitoring and compensation functions)
Axis behavior and dynamics instantaneously NOT changeable
Highest usability and engineering efficiency without special drive

technology knowledge
Extensive drive & technology diagnostics and messages
Axis behavior and dynamics instantaneously changeable
Motion programming with PLC-Open Standard
Higher PLC load

System Load
Number of Axes
Decentral Central
Motion Control with SINAMICS G/S (FB) Motion Control with SIMATIC S7-1500 (TO)
How many EPos axis can be controlled How many TO axis can be calculated
in maximum by S7-1500? in maximum by S7-1500 (FW1.6)?
Number of I/O Devices depending on
PROFINET RT-Communication:
S7-1511/13: 128 Drive CUs *)
S7-1515/16:
S7 1515/16: 256 Drive CUs *))
S7-1517/18: 512 Drive CUs *)
1510 1512 15111513 1515 1516

SP SP 1517
1518
Whi h PLCs
Which PLC are suitable?
it bl ? Whi h drives
Which di are suitable?
it bl ?
Every PLC including PROFINET– Every drive with PROFIdrive or
Controller or PROFIBUS-Master analog interface, especially
interface, especially SIMATIC PLCs. SINAMICS G/S.
((S7-300, S7-400, S7-1200, S7-1500).
)
The number of axis is the elementary factor

Restricted / © Siemens AG 2015. All Rights Reserved. *) Note: Each SINAMICS S120 CU320-2 operates with up to 6 axis (Multiaxissystem)
Cost of components
Application example for 6 positioning axis:
Decentral Central
Number of axis
Decentral CPU Type CPU Type Central
S7-1511 1 up to 6 S7-1511/13
EPos S7 1511
S7-1511 7 up to 30 S7 1515/16
S7-1515/16 TO
S7-1511 31 up to 96 S7-1517
S7-1511 97 up to 128 S7-1518

SIMATIC S7-1515 129 up to 256 --- SIMATIC
S7-15xx S7-15xx
Decentral Central
SINAMICS L-Price/ L-Price/ SINAMICS

G120 Pcs. Hardware Piece Piece Hardware Pcs.. G120
CU250S-2 PN [EUR] [EUR] CU250S-2 PN
& &
Extended S7-1511 S7-1511 Extended
Functions
1x 1PN   1PN 1x
Functions
6ES7510-1AK00-0AB0 6ES7510-1AK00-0AB0
SAFETY SAFETY
& EPOS 6x PM240-2
0
6SL3210-1PB13-8AL0   PM240-2
0
6SL3210-1PB13-8AL0
6x
CU250S-2
6x PN   CU250S-2 PN
6SL3246-0BA22-1FA0
6x
6SL3246-0BA22-1FA0
EPos position controller: 8ms EPOS & Safety Lizenz

Safety
TO position controller: 8ms
6x 6SL3054-4AG00-2AA0-Z E01 +
F01
  Lizenz
6SL3054-4AG00-2AA0-Z
6x
F01
Ʃ 6- Axis   Ʃ 6- Axis
The customer and the application determine the best applicable configuration
Cost of components
Application example for 8 positioning axis:
Decentral Central
Number of axis
Decentral CPU Type CPU Type Central
S7-1511 1 up to 6 S7-1511/13
EPos S7 1511
S7-1511 7 up to 30 S7 1515/16
S7-1515/16 TO
S7-1511 31 up to 96 S7-1517
S7-1511 97 up to128 S7-1518

SIMATIC S7-1515 129 up to256 --- SIMATIC
S7-15xx S7-15xx
Decentral Central
SINAMICS L-Price L-Price/ SINAMICS

G120 Pcs. Hardware Piece Piece Hardware Pcs.. G120
CU250S-2 PN [EUR] [EUR] CU250S-2 PN
& &
Extended S7-1511 S7-1515 Extended
Functions
1x 1PN   2PN 1x
Functions
6ES7510-1AK00-0AB0 6ES7515-2AM00-0AB0
SAFETY SAFETY
& EPOS 8x PM240-2
0
6SL3210-1PB13-8AL0   PM240-2
0
6SL3210-1PB13-8AL0
8x
CU250S-2
8x PN   CU250S-2 PN
6SL3246-0BA22-1FA0
8x
6SL3246-0BA22-1FA0
EPos position controller: 8ms EPOS & Safety Lizenz

Safety
TO position controller: 8ms
8x 6SL3054-4AG00-2AA0-Z E01 +
F01
  Lizenz
6SL3054-4AG00-2AA0-Z
8x
F01
Ʃ 8- Axis   Ʃ 8- Axis
The customer and the application determine the best applicable configuration
Performance
Accuracy and Dynamics
Positioning Positioning Positioning Positioning Positioning

accuracy accuracy dynamic dynamic dynamic
> 1° < 1° low medium high
(Movement cycle > 1s) (Movement cycle < 1s) (Movement cycle < 100ms)
G110M G120C
G110M,
entral (TO)
G120 CU240B/E-2
G120D CU240D-2
G120 CU250S-2
Ce
S110
S120
EPos)
G110M, G120C
G120 CU240B/D/E-2
Decentral (E
G120 CU250D-2
G120D CU250S-2
S110
S120
Technology Objects offer new possibilities for price sensitive positioning applications
Restricted / © Siemens AG 2015. All Rights Reserved. Isochronous communication Technically feasible / recommended Restricted recommended, because of
Legend: range limitations or overdimension
NON isochronous communication Technically NOT feasible / recommended
Optimal Solution
What to consider
Customer has experience

with PLC or Drives?
Possible configuration
suitable for application?
Price of components?
For further information: contact APC/SSS

Motion Control with SIMATIC S7-1500
Realization of gearing based on
• Technology Object Positioning

• Basic Positioner with
SINA_POS
Live Demo
Live-Demo
Identical Motion Control functionality in each PLC
Scalability in amount of axis
1510 SP 1512 SP
1511 1513 1515 1516

1517
ET 200SP Open Controller 1518
TIA Selection Tool
1. Click: New device

11 2. Click: SIMATIC S7
3. Click: SIMATIC S7-1500
7 4. Click: Setup device
9 8
2 5. Activate:
Motion Integrated
3
6 S
6. Select:
l t
1
- Type of axis
- Number of axis
Application specific
PLC load due to - Motion cycle time
4
Motion Integrated 7 Click:
7. Cli k Configure
C fi
Attention: This is a mistake
in the pre-version! 8. Select: Type of CPU
5
This should be 188,8 s 9. Drag&Drop the chosen
6 CPU onto the rack
NEW Version available in April 2015! 10. Click: Project view
10
11. Click: Limits
Dimensioning of a PLC with

TIA Selection Tool
Live Demo
Live-Demo
Technology Object Interfaces for the control of drives
S7-1200 S7-1500
U/I U/I
Puls Train Analog Puls Train Output Analog

Output Signal PTO Signal
PTO (in the future)
Usable drive types

yp SINAMICS
Standard frequency converter,
SINAMICS G/S
servo converter
Standard frequency converter,
Analog Signal U/I servo converter
Every SINAMICS
Step drives,
Puls Train Output SINAMICS V60, V90, S110
servo converter
Unique Selling Point (USP):
S7-1500 Motion Control & Safety
Principle within S7-1500
MC-
Programm Safety
Programm What happens, if the safety program controls the drive
Technology with an operation that conflicts with the TO?
Object
Safety OB  TO always reacts in the right way!
MC OBs
Standard Telegramm Safety Telegramm Motion Control and Safety in parallel

… across the complete system
from the PLC down to the drive

Outlook: Motion Integrated within the S7-1500/1500T Portfolio
S7-1511 S7-1513 S7-1515 S7-1516 S7-1517 S7-1518

2) Interpolation
Handling
2) Distributed Technology
Motion PLC 1) 1) 1) 1) 1) 1)
1)
Camming S7-15xxT,
S7-15xxTF
abs. 1) Gearing
(absolut)
rel.
 Gearing
(relative)
1) Output cams Standard
           
Mo
Measuring input PLC
 Positioning S7-15xx,
S7-15xxF
 S
Speed
d
Legend: 1) Planned for V14 2) Planned for higher V14 Price / Performance / Number of axis

Integration of SINAMICS in TIA Portal
SINAMICS G110M, G120x SINAMICS S120

via Startdrive via Starter and GSD-File
Fast & Easy network and S7 1500 Motion Control with
S7-1500
HW configuration SINAMICS S120 usable
PROFINET IRT
Commisioning wizards
communication & DSC*)
System diagnosis for drives System diagnosis for drives
Automatic generation
Libraryy concept
p for drives
of GSD-Files
GSD Files in Starter
*) Dynamic Servo Control
Identical Look & Feel for
SIMATIC & SINAMICS 1. Configure drive
2. Generate GSD-File
HMI direct access
3. Import GSD-File in TIA Portal

Overview of the drive types
Drive type Example Benefit Disadvantage
• P
Precise
i positioning
iti i
Servo drives +
• High dynamic • High motor price
servomotors • Precise even at low speed
• Turbulent behavior
Frequency at low speeds
• Low motor price
converters + • Separate fan necessary
• Robust
for low speeds
induction motors
• Big motor size

Thank you for your attention!
Team Technology
Automation Days 2015
Application Center / Simatic System Support

simatic.systems.support.nl@siemens.com
y @

Workshop Motion Control With Siemens PLC (En)

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Workshop Motion Control With Siemens PLC (En)

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Automation Days 2015

Restricted / © Siemens AG 2015. All Rights Reserved.

Increasing production speeds

Increasing production accuracy

More monitoring and extensive control options inclusive

Replacement of mechanical solutions thru electronic

Increased complexity and efforts

Restricted / © Siemens AG 2015. All Rights Reserved.

Control of Motion in PLC

Restricted / © Siemens AG 2015. All Rights Reserved.

The smart solution for

Restricted / © Siemens AG 2015. All Rights Reserved.

Now it is your turn:

Observe the light in the rack and press your button as

Restricted / © Siemens AG 2015. All Rights Reserved.

Goal: Calculation of the speed of

Restricted / © Siemens AG 2015. All Rights Reserved.

Now with Time-based IO Light barrier

Restricted / © Siemens AG 2015. All Rights Reserved.

Goal: accurate control of the ejector

Restricted / © Siemens AG 2015. All Rights Reserved.

ET 200MP TM Timer DIDQ 16x24V

Requirement: isochronous real time communication (IRT)

Which SIMATIC CPU supports Time based IO

Restricted / © Siemens AG 2015. All Rights Reserved.

Added values by Time-based IO

Load reduction for PLC and bus system

Reduction of module variety

Mechanical Solution Motion Integrated

Motion • Pumps, fans, mixers

Restricted / © Siemens AG 2015. All Rights Reserved.

Restricted / © Siemens AG 2015. All Rights Reserved.

Restricted / © Siemens AG 2015. All Rights Reserved.

Restricted / © Siemens AG 2015. All Rights Reserved.

Scope 1 Scope 2 Scope 3

Application example: Application example: Application example:

Restricted / © Siemens AG 2015. All Rights Reserved.

Restricted / © Siemens AG 2015. All Rights Reserved.

Restricted / © Siemens AG 2015. All Rights Reserved.

Restricted / © Siemens AG 2015. All Rights Reserved.

Motion technology for multiple drives

Stand alone or with a PLC as “Higher

Restricted / © Siemens AG 2015. All Rights Reserved.

Motion Control in intelligent drives

Motion Control with PLC

Motion Technology in PLC

Restricted / © Siemens AG 2015. All Rights Reserved.

Motion Control with S7-1500 /

Restricted / © Siemens AG 2015. All Rights Reserved.

Output cams Does the customer already have experience with

Measuring input 1) Simotion or Sinumerik?

Siemens Solution Application with a lot of basic motion

Solution to a specific control-based

1) problem e.g. Winders, distributed load

Restricted / © Siemens AG 2015. All Rights Reserved.

Restricted / © Siemens AG 2015. All Rights Reserved.

Axis behaviour OB MC-Interpolator (OB92)

Speed / Positioning axis Speed / Positioning axis

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

Highest usability and engineering efficiency without special drive

Restricted / © Siemens AG 2015. All Rights Reserved.

1510 1512 15111513 1515 1516

The number of axis is the elementary factor