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• Page 1
  Manual | EN TS5055 TwinCAT 2 | NC Flying Saw 2022-11-22 | Version: 1.3…

• Page 3: Table Of Contents

  Table of contents Table of contents 1 Foreword ………………………… 5 Notes on the documentation …………………. 5 Safety instructions …………………….. 6 Notes on information security…………………. 7 2 General …………………………. 8 3 Synchronisation to velocity …………………… 11 4 Synchronisation to position…………………… 15 5 Parameterisable boundary conditions, specifying the mode of operation …….. 18 6 Characteristic values ……………………..

• Page 4
  Table of contents Version: 1.3 TS5055…

• Page 5: Foreword

  EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding applications or registrations in various other countries. ® EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany Copyright © Beckhoff Automation GmbH & Co. KG, Germany. The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited.

• Page 6: Safety Instructions

  All the components are supplied in particular hardware and software configurations appropriate for the application. Modifications to hardware or software configurations other than those described in the documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG. Personnel qualification This description is only intended for trained specialists in control, automation and drive engineering who are familiar with the applicable national standards.

• Page 7: Notes On Information Security

  Foreword Notes on information security The products of Beckhoff Automation GmbH & Co. KG (Beckhoff), insofar as they can be accessed online, are equipped with security functions that support the secure operation of plants, systems, machines and networks. Despite the security functions, the creation, implementation and constant updating of a holistic security concept for the operation are necessary to protect the respective plant, system, machine and networks against cyber threats.

• Page 8: General

  General General The Flying Saw is a slave axis that can be synchronized to a moving master axis. The slave axis moves in synchronism with the master axis to perform machining processes. This kind of movement, synchronized to the master axis, means that a workpiece can be machined even while it is being transported. An important difference between the «Flying Saw»…

• Page 9
  General Synchronisation to velocity In Synchronisation to velocity [} 11] the slave axis is synchronised to the master axis using the specified dynamic parameters as rapidly as possible. In the synchronous phase, the slave velocity is proportional to the master velocity, so that: The synchronisation procedure Synchronisation of the slave axis to the master axis proceeds according to the following scheme: 1.
• Page 10
  General Parameterisable boundary conditions governing synchronisation In principle, any initial conditions may apply to the calculation of the synchronisation profile for the master and slave axes. The transition of the slave’s movement from its initial state to the synchronous state is calculated in such a way that boundary conditions [} 18] that can be specified by the user and that govern the slave’s movement are maintained.

• Page 11: Synchronisation To Velocity

  Synchronisation to velocity Synchronisation to velocity Under synchronization to velocity, a slave axis, starting in any state, is synchronized as quickly as possible to a moving master axis. The synchronous velocity of the slave here is given by the master velocity multiplied by the coupling factor.

• Page 12
  Synchronisation to velocity Example 2: As example 1, but with coupling factor 1.5. (* Start parameters *) fMasterVelo     :=  500; fSlaveVelo      := -250; (* Coupling parameters *) fGearRatio      :=  1.5; fSlaveAcc       := 2500; fSlaveDec       := 2500; fSlaveJerk      := 5000; Version: 1.3 TS5055…
• Page 13
  Synchronisation to velocity Example 3: The start of the coupling in the acceleration phase of the future slave. (* Start parameters *) fMasterVelo     :=  -500; fSlaveVelo      := 400; (* Coupling parameters *) fGearRatio      :=  1; fSlaveAcc       := 2500; fSlaveDec       := 2500; fSlaveJerk      := 5000; TS5055 Version: 1.3…
• Page 14
  Synchronisation to velocity PLC function blocks The function block MC_GearInVelo is used for the coupling. To end the synchronous phase by uncoupling (online change) the function block MC_GearOut is used. Version: 1.3 TS5055…

• Page 15: Synchronisation To Position

  Synchronisation to position Synchronisation to position In the case of synchronisation to position, the slave axis, starting from its initial state, is synchronised to the master axis in such a way that the required synchronous velocity (v ·= coupling factor) and master synchronisation position are achieved precisely at the master’s synchronisation position.

• Page 16
  Synchronisation to position Example 2: (* Start parameters *) fMasterVelo            :=  500; fSlaveVelo             := -250; fMasterStartPos        := -500; fSlaveStartPos         := -500; (* Coupling parameters *) fGearRatio             := 1.5; fMasterSynchronPos     := 1000; fSlaveSynchronPos      := 500; fSlaveAcc              := 10000; fSlaveDec              := 10000; fSlaveJerk             := 50000; Version: 1.3 TS5055…
• Page 17
  Synchronisation to position PLC function blocks The function block MC_GearInPos is used for coupling. To end the synchronous phase, i.e. for uncoupling (online change of the slave into an independent master), the function block MC_GearOut is used. TS5055 Version: 1.3…

• Page 18: Parameterisable Boundary Conditions, Specifying The Mode Of Operation

  Parameterisable boundary conditions, specifying the mode of operation Parameterisable boundary conditions, specifying the mode of operation It is possible to specify a wide variety of boundary conditions for the slave movement in the synchronization phase of the Universal Flying Saw. These boundary conditions make it possible to specify limit values for the slave magnitudes listed in the table below.

• Page 19
  Parameterisable boundary conditions, specifying the mode of operation MAXJERK 32 0x0000 0020 Checks whether ≤ j Slave SlaveMax the maximum slave jerk (machine data) has been exceeded. OVERSHOOTPOS 256 0x0000 0100 Checks for overshooting of slave position. UNDERSHOOTPO 512 0x0000 0200 Checks for undershooting of slave position.´…
• Page 20
  Parameterisable boundary conditions, specifying the mode of operation PREFERCONSTV 1048576 0x0010 0000 Bit = 0: (default) Default setting Bit = 1: The system will try to use a phase with constant velocity, instead of just one 5th order polynomial. This can result in a combination of a 5th-order polynomial, a synchronous phase and another 5th- order polynomial (P5-P1-P5), (see…

• Page 21: Characteristic Values

  Characteristic values Characteristic values Once the Universal Flying Saw has been started, the MC_ReadFlyingSawCharacteristics PLC function block can be used to read the characteristic values associated with the slave set value profile that has been calculated for the synchronisation phase. These characteristic values therefore refer neither to the synchronous phase nor to the preliminary phase, but only apply to the synchronisation phase! The individual characteristic values are described in the table below.

• Page 22
  Characteristic values Denomination Description Independent of master accelera- tion fSlavePosMin Minimum slave position   fMPosAtSVeloMin Master position at the time of the minimum slave velocity fSlaveVeloMin Minimum slave velocity   fMPosAtSAccMin Master position at the time of the minimum slave acceleration fSlaveAccMin Minimum slave acceleration fSVeloAtSAccMin…

• Page 23: Calculating The Synchronisation Phase

  Calculating the synchronisation phase Calculating the synchronisation phase An attempt is made when calculating the synchronisation phase to find an optimum solution while observing the boundary conditions specified by the user. If it is not possible to observe the specified boundary conditions, the coupling is declined and an appropriate error message is issued.

• Page 24
  Calculating the synchronisation phase Optimisation flow diagram: The optimizations carried out internally are illustrated in the following flow diagram. Essentially, the slave set value profile is calculated as a 5th order polynomial. This 5th order polynomial can be combined with a first order polynomial in order to maintain the parameterized boundary conditions.

• Page 25: Reversal Of The Master Axis Movement / Reverse Motion Stop

  Reversal of the master axis movement / reverse motion stop Reversal of the master axis movement / reverse motion stop The behavior of the Universal Flying Saw in case of a motion reversal of the master can be defined via 2 bits of the SyncMode.

• Page 26
  Reversal of the master axis movement / reverse motion stop ROLL INSTANT Synchro- Description BACK STOP nous LOCK phase ROLLBACK  reached?   Case 3: As in case 2, except that the velocity of the slave axis is reduced to zero within one tick after reaching the coupling position.
• Page 27
  Reversal of the master axis movement / reverse motion stop ROLL INSTANT Synchro- Description BACK STOP nous LOCK phase ROLLBACK  reached? The bit combination indicated on the left is used to activate the backstop of the Universal Flying Saw.  In the figure below, a motion reversal of the master axis occurs in the synchronous phase, so that it moves backwards beyond the coupling position.
• Page 28
  Reversal of the master axis movement / reverse motion stop ROLL INSTANT Synchro- Description BACK STOP nous LOCK phase ROLLBACK  reached?   Version: 1.3 TS5055…

• Page 29: Diagonal Saw

  Diagonal saw Diagonal saw The simplest case of the diagonal saw involves synchronization to velocity. In contrast to the Flying Saw, where the angle between the directions of the master and the slave movements is given, the coupling factor is given for the Universal Flying Saw. This coupling factor must be calculated in such a way that in the synchronized phase the component of the velocity of the slave axis in the direction of the master axis is the same as the master velocity.

• Page 30: Interfaces

  Interfaces Interfaces Cyclic axis interface The variable nAxisState in the cyclic axis interface indicates the state of movement of the slave or master axis. The movement states of the slave axis are described in the table. All those states that are not listed are master states, and these are explained elsewhere.

• Page 31
  Interfaces ADS interface Documentation of the ADS interface. TS5055 Version: 1.3…

• Page 32: Operation From The System Manager

  Operation from the System Manager Operation from the System Manager For commissioning purposes the Universal Flying Saw can also be started directly from the System Manager. Version: 1.3 TS5055…

• Page 33: Plc Api

  PLC API PLC API In many plants workpieces undergo machining operations while being transported. For this purpose it is necessary to synchronise the position and the speed of tool and workpiece, so that the tool can then be applied as if to a stationary workpiece. One example of such an application is a saw that during the transport process cuts through the material that is being transported (flying saw).

• Page 34
  PLC API     Deceleration     : LREAL;     Jerk             : LREAL;     BufferMode       : MC_BufferMode;     Options          : ST_GearInVeloOptions; END_VAR Execute The command is executed with a rising edge at Execute input. RatioNumerator Gear ratio numerator. Alternatively, the gear ratio can be specified as a floating point value, if the denominator is 1. RatioDenominator Gear ratio denominator SyncMode…
• Page 35
  PLC API Active Active indicates that the command is executed (currently Active=Busy, see BufferMode) CommandAborted Becomes TRUE, if the command could not be fully executed. The axis may have become decoupled during the coupling process (simultaneous command execution). Error Becomes TRUE, as soon as an error occurs. ErrorID If the error output is set, this parameter supplies the error number, see Overview of NC errors (TC2).

• Page 36: Mc_Gearinpos

  PLC API 12.1.2 MC_GearInPos MC_GearInPos Execute  BOOL BOOL  StartSync RatioNumerator  LREAL BOOL  InSync RatioDenominator  UINT BOOL  Busy MasterSyncPosition  LREAL BOOL  Active SlaveSyncPosition  LREAL BOOL  CommandAborted SyncMode  ST_SyncMode BOOL  Error MasterStartDistance  LREAL UDINT  ErrorID Velocity  LREAL Acceleration  LREAL Deceleration  LREAL Jerk  LREAL BufferMode  MC_BufferMode Options  ST_GearInPosOptions ↔ Master  Reference To AXIS_REF ↔ Slave  Reference To AXIS_REF The function block MC_GearInPos synchronizes a slave axis precisely with a master axis (flying saw). The synchronization velocity is achieved exactly at the synchronous position of the master and slave.

• Page 37
  PLC API Acceleration Maximum slave acceleration in the synchronization phase. If an acceleration is not specified, the maximum acceleration of the axis from the System Manager data is used. The acceleration given here is only checked if this checking is activated through the SyncMode [} 41] variable.
• Page 38
  PLC API The axis data structure of type AXIS_REF addresses an axis unambiguously within the system. Among other parameters it contains the current axis status, including position, velocity or error state. Version: 1.3 TS5055…

• Page 39: Mc_Readflyingsawcharacteristics

  PLC API 12.1.3 MC_ReadFlyingSawCharacteristics MC_ReadFlyingSawCharacteristics Execute  BOOL BOOL  Done ↔ Slave  Reference To AXIS_REF BOOL  Busy ↔ CamTableCharac  Reference To MC_FlyingSawCharacValues BOOL  Error UDINT  ErrorID The MC_ReadFlyingSawCharacteristics function allows the characteristic figures for the synchronization phase of the Universal Flying Saw to be read. Inputs VAR_INPUT     Execute  : BOOL; END_VAR Execute A rising edge initiates reading the characteristic values from the TwinCAT NC.

• Page 40: Tcmc2

  MC_MoveVelocity command. In TwinCAT 2.10, the setpoint generator type can be selected by the user. From TwinCAT 2.11, the setpoint generator type is set to «7 phases (opti- mized)». The behavior described here is the result of a project update from TwinCAT 2.10 to TwinCAT 2.11.

• Page 41: Data Types

  PLC API The axis data structure of type AXIS_REF addresses an axis uniquely within the system. Among other parameters it contains the current axis status, including position, velocity or error status. 12.3 Data types 12.3.1 ST_SyncMode TYPE ST_SyncMode : STRUCT     (* mode *)     GearInSyncMode                          : E_GearInSyncMode;…

• Page 42: Mc_Flyingsawcharacvalues

  PLC API 12.3.2 MC_FlyingSawCharacValues TYPE MC_FlyingSawCharacValues : STRUCT     (* Master Velocity*)     fMasterVeloNom     : LREAL; (* 1. master nominal velocity (normed:=> 1.0) *)     (* characteristic slave data *)     (*===========================*)     (* Start of cam table *)     fMasterPosStart    : LREAL; (* 2. master start position*)     fSlavePosStart     : LREAL;…

• Page 43
  PLC API Type definition for the characteristic parameters of a flying saw synchronization. TS5055 Version: 1.3…

• Page 44: Example Program

  The example program requires the flying saw library and operates fully in simulation mode. Progress can be monitored in TwinCAT Scope View with the configuration provided. Click here to save the example program: https://infosys.beckhoff.com/content/1033/TS5055_TCNC_FlyingSaw/Resources/437571723/.zip Version: 1.3 TS5055…

• Page 45: Error Situations And Error Codes

  Error situations and error codes: Error situations and error codes: The following situations and/or parameters are not permitted, and result in errors: • The Universal Flying Saw cannot at present be coupled if the master velocity at the coupling time is zero, but the slave velocity is not zero.

• Page 47
  More Information: www.beckhoff.com/ts5055 Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 33415 Verl Germany Phone: +49 5246 9630 info@beckhoff.com www.beckhoff.com…