Beckhoff TwinCAT 2 User manual
Manual | EN
TS5055
TwinCAT 2 | NC Flying Saw
2022-11-22 | Version: 1.3
Table of contents
TS5055 3Version: 1.3
Table of contents
1 Foreword....................................................................................................................................................5
1.1 Notes on the documentation .............................................................................................................5
1.2 Safety instructions.............................................................................................................................6
1.3 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 ..............................................................................................................................21
7 Calculating the synchronisation phase ................................................................................................23
8 Reversal of the master axis movement / reverse motion stop ...........................................................25
9 Diagonal saw ...........................................................................................................................................29
10 Interfaces .................................................................................................................................................30
11 Operation from the System Manager ....................................................................................................32
12 PLC API ....................................................................................................................................................33
12.1 TcMC2_FlyingSaw ..........................................................................................................................33
12.1.1 MC_GearInVelo ...............................................................................................................33
12.1.2 MC_GearInPos ................................................................................................................36
12.1.3 MC_ReadFlyingSawCharacteristics................................................................................. 39
12.2 TcMC2.............................................................................................................................................40
12.2.1 MC_GearOut.................................................................................................................... 40
12.3 Data types .......................................................................................................................................41
12.3.1 ST_SyncMode.................................................................................................................. 41
12.3.2 MC_FlyingSawCharacValues ..........................................................................................42
12.4 Example program............................................................................................................................44
12.4.1 Flying saw sample program .............................................................................................44
13 Error situations and error codes: ..........................................................................................................45
Table of contents
TS50554 Version: 1.3
Foreword
TS5055 5Version: 1.3
1 Foreword
1.1 Notes on the documentation
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning the components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, TwinCAT/BSD®, TC/BSD®, EtherCAT®, EtherCAT G®, EtherCAT G10®, EtherCAT P®,
Safety over EtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by
Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents:
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.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
Foreword
TS50556 Version: 1.3
1.2 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
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.
Description of symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the life and health of
persons.
WARNING
Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and health of per-
sons.
CAUTION
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to persons.
NOTE
Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the environment or
equipment.
Tip or pointer
This symbol indicates information that contributes to better understanding.
Foreword
TS5055 7Version: 1.3
1.3 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. The products sold by Beckhoff are only part of the overall security concept.
The customer is responsible for preventing unauthorized access by third parties to its equipment, systems,
machines and networks. The latter should be connected to the corporate network or the Internet only if
appropriate protective measures have been set up.
In addition, the recommendations from Beckhoff regarding appropriate protective measures should be
observed. Further information regarding information security and industrial security can be found in our
https://www.beckhoff.com/secguide.
Beckhoff products and solutions undergo continuous further development. This also applies to security
functions. In light of this continuous further development, Beckhoff expressly recommends that the products
are kept up to date at all times and that updates are installed for the products once they have been made
available. Using outdated or unsupported product versions can increase the risk of cyber threats.
To stay informed about information security for Beckhoff products, subscribe to the RSS feed at https://
www.beckhoff.com/secinfo.
General
TS50558 Version: 1.3
2 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" and the "Universal Flying Saw" is associated with the
initial conditions required of the slave axis for the synchronization. The "Universal Flying Saw", unlike the
"Flying Saw", is able to start synchronization of the slave even when the slave has already started, and is
therefore no longer stationary. The "Universal Flying Saw" also calculates improved set value profiles, and
these can be influenced by the user through a wide range of boundary conditions.
The ratio of the master velocity to the slave velocity in the synchronous phase is parameterized via a
variable coupling factor. This coupling factor in the case of a diagonal saw, for instance, is chosen to be
unequal to 1, so that the velocity component of the slave axis in the direction of the master axis movement
(vslave parallel to Vmaster) in the synchronized phase is equal to the master velocity (vmaster). (See diagram.)
The Universal Flying Saw basically provides two different synchronization methods. In the case of
synchronization to velocity the slave is synchronized to the master as quickly as possible, bearing in mind
the coupling factor. The coupling position for the master and slave axes therefore results from having set the
fastest possible synchronization as the target. In contrast to this, the coupling position of the master and
slave axes is parameterized by the user under synchronization to position. The master and slave movements
will in this case therefore be moving in synchronization as from the specified position at the latest.
Both of these synchronization methods permit a variety of boundary conditions to be specified for the
synchronization phase. These boundary conditions make it possible to adapt the synchronization process to
the needs of the machine.
This manual describes the Universal Flying Saw TcMc2_FlyingSaw.lib, which is available from
TwinCAT Version 2.9, Build 248. If you are using the previous version TcNcFlyingSaw.lib and need
further information, see here.
Interfaces
The Universal Flying Saw is operated and monitored from the PLC using appropriate function blocks. For
commissioning purposes, however, the Universal Flying Saw can also be started directly from the TwinCAT
System Manager [}32]. In this case, the cyclic NC/PLC axis interface and ADS communication are used as
the underlying interface.
General
TS5055 9Version: 1.3
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. Starting the Universal Flying Saw. This corresponds to the logical coupling to the master axis. This
moment is referred to as the coupling time.
2. The synchronisation phase: The slave is accelerated from its initial condition up to the velocity of the
master whilst observing the boundary conditions for slave movement specified by the user. The time
at which the synchronisation phase changes to the synchronous phase is referred to as the synchroni-
sation time.
3. Synchronous phase: The slave moves synchronously with the master.
4. Uncoupling the Universal Flying Saw. This is an online change. The coupled slave once again be-
comes an independent master that continues to move without limit with the velocity resulting from the
online change.
5. This could mean that the former slave restarts or stops. The full functionality of a TwinCAT NC master
axis is once more available.
Synchronisation to position
In Synchronisation to position [}15] the slave axis is synchronised to the master at the specified
synchronisation position using the specified dynamic parameters. This means that the slave axis reaches the
synchronous velocity at exactly the synchronisation position of master and slave, after which it moves in
synchronism with the master. The slave velocity in the synchronous phase is governed by:
The synchronisation procedure
Synchronisation of the slave axis to the master axis proceeds according to the following scheme:
1. The start of the Universal Flying Saw. This is the logical coupling to the master axis. This moment is
referred to as the coupling time.
2. The synchronisation phase: The slave is accelerated from its initial condition to the master's velocity,
reaching the slave synchronisation position and synchronisation velocity precisely at the specified
master synchronisation position. The boundary conditions specified by the user for slave movement
are maintained during this process. The time at which the synchronisation phase changes to the syn-
chronous phase is referred to as the synchronisation time.
3. Synchronous phase: The slave moves synchronously with the master.
4. Uncoupling the Universal Flying Saw. This is an online change. The coupled slave once again be-
comes an independent master that continues to move without limit with the velocity resulting from the
online change.
5. This could mean that the former slave restarts or stops. The full functionality of a TwinCAT NC master
axis is once more available.
General
TS505510 Version: 1.3
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. These boundary conditions can be used, for instance, to limit the maximum slave
velocity, or to prevent an overshoot in its position.
The calculation and checking of the parameterisable boundary conditions proceeds on the basis of the
characteristic values determined for the synchronisation phase. In the determination of the characteristic
values, the idealised assumption is made that the master axis will continue to move at a constant velocity,
i.e. with no acceleration, after the coupling time. Exact calculation and checking of the parameterisable
boundary conditions is only possible if this assumption is made. Any other reasonable assumption about the
future movement of the master is not possible, since the master's future movement is not known at the time
of coupling.
An acceleration of the master that might occur in the future will also affect the slave dynamics as a result of
the coupling. Such acceleration by the master will have the effect that the calculated and checked values
may be overshot or undershot in some cases, depending on the master's acceleration. Characteristic values
that may be affected by master acceleration can be seen in the tabular description of the characteristic values
[}21].
Characteristic values describing slave movement
The characteristic values [}21] governing the movement that the slave will undergo during the
synchronisation phase are available to the user after the Universal Flying Saw has been started. This value
structure contains magnitudes such as the maximum slave acceleration, the minimum and maximum slave
position, and so forth. These values are calculated under the assumption that the master is free from
acceleration, and are therefore in some cases only exactly correct for such a case.
NOTE
The master acceleration at the time that the "Universal Flying Saw" starts has a significant effect on the
profile calculation and its optimization. This means that if an encoder axis is the master, the velocity and the
acceleration must be carefully filtered, or even the calculation of the actual acceleration must be deselected
(see. "Encoder mode").
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