ADV200 Flying Shear 4.0: User Manual

ADV200 Flying Shear 4.
0English
User manual
Index ver. Date Author Changes description
17th November Add section 1.1 Drive Firmware /Application version Cross compatibility
14
SW V4.0 30th October 14

Doc V4.0 ID 562 (rimosse word bus di campo non usate)
ID 552 (LT e tempo Taglio valori massimi aumentati)
ID 540 (11140 Check MW default off,
11464 VelMaxMW default 60)
modificata scalatura pErrCorrLimit
V3.xx 2nd July 14 Corrections:
Corrected return after changed cutting length
Revised ramp at removal of run cmd
Corrected ClearAlarm
Corrected negative mechanical ratios
Additions/Changes:
Selection of motor encoder and measurement wheel based on IPA 5310 (Enc
src sel)
Configuration of drive functions and I/O at boot and load default
Addition of ErrPosSpeed (11358) limit parameter in Gains
EnableCut initial default On Remove zero cycle with cam plus encoder index
Addition of MaxMotorSpeed (11270) parameter in MechRatios
Eliminated GetCutTimeCmd
Changed fieldbus mapping
V1.00 4th March 2014
------------------------------------------------------------------------------------------------------------------------------
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ADV200 Flying Shear 4.0 APPLICATION Manual Page 2 of 42

Table of contents
1 Information about this manual ................................................................................................................ 5

1.1 Drive Firmware /Application version Cross compatibility .................................................................... 5
2 General description .................................................................................................................................. 6
2.1 OverAcc parameter ............................................................................................................................. 7
2.2 Detailed Profile Description ................................................................................................................. 8
2.3 High Blade/Low Blade ......................................................................................................................... 9
3 Controls ................................................................................................................................................... 10
3.1 JogPosCmd / JogNegCmd................................................................................................................ 10
3.2 FastStopCmd .................................................................................................................................... 10
3.3 VirtualMstStartCmd ........................................................................................................................... 10
3.4 ZeroQualifier...................................................................................................................................... 10
3.5 VirtualEnableCmd ............................................................................................................................. 10
3.6 SysClearAlarm .................................................................................................................................. 10
3.7 ResetWarningCmd ............................................................................................................................ 11
3.8 SetCutTimeCmd ................................................................................................................................ 11
3.9 ImmediateCut .................................................................................................................................... 11
3.10 RunCmd ** ..................................................................................................................................... 11
4 Drive status ............................................................................................................................................. 12
4.1 Gains and filters ................................................................................................................................ 13
5 Possible Movements and related commands ..................................................................................... 14
5.1 Start-up of Following, cutting and initial cutting................................................................................. 14
5.2 ImmediateCut .................................................................................................................................... 14
5.3 Initial accompanying .......................................................................................................................... 14
6 Basic sequence for PLC ........................................................................................................................ 15
6.1 Auxiliary motion / Additional motion .................................................................................................. 15
6.1.1 Jog ............................................................................................................................................. 15
6.1.2 Limits (Carriage stops) ............................................................................................................... 16
7 Cutting length ......................................................................................................................................... 17
8 Tests to control the metric wheel ......................................................................................................... 18
8.1 Checking that the motion of the metric wheel is within the correct acceleration and speed ranges
and that the wheel does not move backwards............................................................................................. 18
8.2 Checking that the speed of the metric wheel is close to the line speed read by the PLC ................ 18
9 Machine Data .......................................................................................................................................... 20
10 ADV200 Configuration ........................................................................................................................ 21
10.1 Configuring the drive and I/O functions ......................................................................................... 21
10.1.1 Digital I/Os.................................................................................................................................. 22
10.2 Encoders........................................................................................................................................ 22
10.3 Fieldbus ......................................................................................................................................... 23
11 Application key ................................................................................................................................... 26
12 Application alarms .............................................................................................................................. 27
12.1 Limits (Carriage stops) .................................................................................................................. 27
12.2 Speed request under fixed limits ................................................................................................... 27
12.3 cLENGTH_TOO_SHORT .............................................................................................................. 27
13 Start up ................................................................................................................................................ 29

13.1 Drive setting ................................................................................................................................... 31
13.1.1 Main data setting:....................................................................................................................... 31
13.1.2 Self-setting ................................................................................................................................. 31
13.1.3 Field bus..................................................................................................................................... 31
13.1.4 Encoder data .............................................................................................................................. 31
13.2 Inserting mechanical relationships and testing.............................................................................. 31
13.3 Check-up of basic movements ...................................................................................................... 34
13.3.1 Direction checking...................................................................................................................... 34
13.3.2 Zero cycle positioning ................................................................................................................ 35
13.3.3 Checking the value set for metrical wheel circumference ......................................................... 35
13.4 Checking with the virtual master.................................................................................................... 38
13.5 Menu SpeedGains ......................................................................................................................... 39
13.6 Checking with material .................................................................................................................. 39
14 Typical curves ..................................................................................................................................... 40
15 Appendix A: metric wheel encoder selection ................................................................................. 41
16 Appendix B: FieldBus ........................................................................................................................ 42
16.1 Writing parameters via fieldbus ..................................................................................................... 42

1 Information about this manual
This document describes the Flying Shear software for the ADV200 drive.
The description applies to ADV200S (for brushless motors) and ADV200 (for asynchronous motors).
To make it easier to search for parameters in the various menus, these are shown as follows:
“FLYINGSHEAR \MechRelations\MetricWheelSel”. The name includes the list of the menus in which the
parameter is situated. In this case the menu is FLYINGSHEAR followed by MechRelations and lastly the
parameter name MetricWheelSel.
1.1 Drive Firmware /Application version Cross compatibility

Flying Shear Drive Firmware
V 3.00.22 7.0.0
V 4.00.22 7.0.1

2 General description
The blade or cutting assembly is fixed onto a carriage that can move forwards and backwards, piloted by the
application. The application measures the length of the material to be cut by a metric wheel binding onto the
material.
For each position of the material from zero up to the cutting length and according to other mechanical
parameters, the application produces the carriage position and therefore the blade position.
The speed profile is the relationship between the material speed and the carriage speed, see figura 1.
The speed profile consists of:
 A waiting phase where the material slides under the still carriage;
 A second phase called acceleration forward. During this phase the carriage reaches the speed of the
material;
 The third phase is synchronization. The carriage proceeds synchronized with the material to reduce
as much as possible any positional error between the carriage and the material;
 The cutting phase follows. Once the synchronization zone with the material is reached, the
application supplies the indication of ReadyToCut and CutSignal allowing the start of the cutting
operation. The application proceeds in synchronization with the material up to the end of the cutting
space;
 At this point the application returns the carriage to its start position and immediately starts the waiting
phase.
NB.:
1) The length of each phase is measured in terms of space. The space used for each phase is calculated
according to the maximum speed allowed for the material.
2) Even if the material flows slowly, each phase uses the same space. This means that, at the end of the
cutting phase, the carriage always advances to the same point regardless of the speed.
3) The space used by the carriage and maximum speed vary depending on the set cutting length. These
parameters are found in the FLYINGSHEAR\FlyingShear menu.
The forward Acceleration and backward

Deceleration ramps may have constant
or cyclical accelerations.
The choice is made using the
Application\MechRelations\S_ShapedAcc
parameter
The shape of speed forwad deceleration

and reverse acceleration are stated from
Application\MechRelations\S_ShapedRet
parameter
It is important to underline that for the

same movement in the same time, the
cyclical accelerations need a peak
couple higher than 1.6 when compared to
constant acceleration.
This is advantageous in terms of
smoother movement and reduced stress
on the controller.
Red = acceleration
Yellow = speed
S_ShapedAcc = On

S_ShapedAcc = Off
2.1 OverAcc parameter
To be smoother, acceleration should not be varied stepwise (i.e., linear acceleration), but instead should
reach maximum level on a ramp (also called limited jerk ramp).
By doing this, to keep the same acceleration time, maximum acceleration must be greater than the value
needed with linear acceleration.
Its effect is shown in the above picture:
 la The upper image display the acceleration
 The bottom one shown the speed
 In yellow is the linear acceleration, in magenta the rounding due to OveAcc = 1.2.
The acceleration reach its maximum value which is 1.2 times the linear acceleration. Some time is used to
reach the maximum acceleration smoothly.
N.B. In case of selection of FLYINGSHEAR\MechRelations\S_ShapedAcc or S_ShapedRet this selection

have priority on the OverAcc parameter. i.e. the sine acceleration will be used.

2.2 Detailed Profile Description
The figure below illustrates the motion profile of the shear. The numbers indicate the sections of motion
through which it passes.
The movement starts while the material is stopped and the carriage is stopped on point 0 (Home). The butt
cut is carried out and the bar length, FLYINGSHEAR \DriveStatus\BarLength, is reset. This input point is
marked Init.
The motion of the carriage waits for the material to flow under the blade for all of section 12. It then
accelerates until synchronized with the material in section 1. Section 2 is used to stabilise the motion and
reduce the cutting error. Then the ReadyTocut and CutSignal signals are set to high. The CutSIgnal is
different from ReadyToCut signal because it last a time defined in Miscellaneous\TimeCutLength. At the
same time the FLYINGSHEAR \DriveStatus\BarLength is frozen in FLYINGSHEAR
\DriveStatus\RealCutLength indicating the measured cutting length.
Spazio Gap
In i t
4
2 3
0 1 5 6 7 8 12 13
TSincro Ttaglio
Ready To Cut
Cut Completed
(Ok, No Fault)
Lama Bassa
Cesoia Volante - Profilo di Velocità

Lama Alta
Cut Completed Rnc 29 Set 05 Prima versione
(Not Ok, Fault)
Figura 1: Speed profile
The cutting sequence starts. The blade can start its motion. If a gap is foreseen (an increase in speed of the
carriage to distance the blade from the material), this starts when a Low Blade signal is given. No indication
is given if this signal is not present, however if Gap is enabled, an error signal is present with a positional
skip at the end of the cycle.
The High Blade signal is controlled at the end of the synchronization speed section. Before deceleration
takes place, a check is made to make sure that the blade has left the material. If this has not happened, the
system passes into an application alarm situation, giving code CUT_NOTCOMPLETED_ALARM (on
FLYINGSHEAR \DriveStatus\ApplAlarmCause menu ) and stops on FLYINGSHEAR \Ramp\FastStop menu.
If the blade up position has been reached correctly the carriage returns to the home position. The time it
waits in this position depends on the set cutting length. For short cuts the waiting time is practically zero. It
increases for longer cutting lengths.

2.3 High Blade/Low Blade
These inputs are used to indicate the blade position. They are connected to sensors on the blade as
indicated below.
Sensor On
Lama
Blade
Sensor Off
Lama Alta
Blade in Up
position
Lama Bassa
Blade in Low
position
ReadyToCut
Lama Alta
Blade in Up position
Lama Bassa
Blade in Low position
Flying Shear / Cesoia Volante - Cut Sequence

Rnc 29 Set 05 Prima versione
Figura 2: Cutting assembly
In case is necessary to have a cut command with a defined duration use CutSignal. It last according to the
TimeCutSignal value.
CutSignal may work in two different ways:
 with TimeCutSignal different from zero at cutting time it goes high for TimeCutSignal then back to low
state
 with TimeCutSignal set to zero at cutting time it goes high. It return to low after detection of BladeUp
equal zero and following transition of BladeUp to high state.

3 Controls
This section describes the basic flying shear commands. The advanced commands, not necessary for
ordinary use, are listed in the appendix.
3.1 JogPosCmd / JogNegCmd

Carries out jogging (jog). The parameters are Jog Speed and JogRamp on FLYINGSHEAR \Ramp menu.
When the zero cycle has not been carried out, the software limit-switches are ignored and do not operate.
In the case of the hardware limit switches are reached these command a FastStop. No carriage movement is
thus possible. Use the PLC to remove the FastStop and bring the carriage back to the usable space.
3.2 FastStopCmd
When the command turns to ON, the drive passes into speed control mode with reference speed 0. The
ramp used is FLYINGSHEAR \Ramp FastStop Ramp.
When the FastStop command is ON, a message in ApplicationAlarmCause is generated. To restart, the drive
must be disabled. We advise using the ClearAlarm command to reset the ApplicationAlarmCause value.
Note: This command is logical OR for FastStopDig (from digital input not allowed), FastStopBus (from field
bus) and FastStopSer (from serial).
When EnableSerCmd is set to OFF FastStopSer is set to FALSE.
When the Bus control is disabled FastStopBus is set to FALSE.
3.3 VirtualMstStartCmd
Start/Stop of the Virtual Master.
It is used to test the machine without material. The material measurement signal is generated by the
application itself.
Set FLYINGSHEAR \MechRelations\MetricWheelSel to VirtualMaster.

FLYINGSHEAR \Ramp\MstStep and FLYINGSHEAR \Ramp\VirtualMstRamp set the master speed and
ramp time.
3.4 ZeroQualifier
Zero qualifier input. Only from digital input. The zero qualifier indicates when the system has reached the
home position. Depending on the zero cycle setting, once the qualifier has been reached, the carriage is
moved to find the first zero index of the encoder or stopped and the position that is reached is the zero
position.
3.5 VirtualEnableCmd
Drive enable from field bus (VirtualEnableCmdBus) or serial (VirtualEnableCmdSer).
The command is active on the edge.
The drive enable is given by an AND between VirtualEnableCmdBus, VirtualEnableCmdSer and the DI0
digital input.
When the Bus control is disabled, VirtualEnableCmdBus is set to TRUE.
3.6 SysClearAlarm
Zeros the drive alarms. Active to 1. The command is only effective if RunCmd is set to zero and the drive is
disabled.

3.7 ResetWarningCmd
Zeros the code ApplicationAlarmCause. Active to 1. Must be sent with RuncCmd equal to zero and the drive
disabled. The SysClearAlarm can be used for the same purpose.
3.8 SetCutTimeCmd
If field bus is being used, it is possible to program the cutting time value through processing channels.
The new value can be accepted when:
 The drive is disabled (DriveStatus = Disabled);
 On the climbing front of SetCutTimeCmd;
If setting is refused due to a drive state not equal to disable or because the value is too low, the
CutTimeRefused flag becomes high. CutTimeRefused remains high until a value is accepted.
The parameter FLYINGSHEAR \Miscellaneous\ImageFromBus\CuTimeViaBus shows the time value sent via
the bus.
3.9 ImmediateCut
Works in the Camming state. Activates immediate cutting regardless of the length that has been
reached. The carriage is synchronized and the cut is performed.
Note: if the command is sent during the wait phase or during the tracking phase (before the cut), the
system makes the shortest possible cut and returns rapidly to zero.
If the command is sent after the cut, the machine goes rapidly to zero. Give the command again to
start an immediate cut.
3.10 RunCmd **
It is the command that automates the use of the drive. When it passes from 0 to 1, a series of operations are
carried out.
1. Checks to see if the zero sequence has been done. If negative, the zero sequence is carried out;
otherwise it passes to point 3.
2. Zero sequence
3. A Move is done to position 0. The zero position is the found Index position added of ZeroOffset value.
This is the zero reference for the system.
4. Wait of 0.5 sec
5. Cutting command.
6. Wait of 0.5 sec.
7. Starts to follow the material.
Removing the RunCmd command, the carriage stops with StopRamp slope. If the carriage stops (limits) are
exceeded an OverLimitPosition error is issued stopping with the FastStop ramp.
The operation state corresponds to FLYINGSHEAR \DriveStatus\RunCmdState
Camming is the state in which it terminates, when initialization is OK. At this stage the line can be started.
Code RunCmdState
0 DriveStatus not equal to Stop
1 Stop
2 Move to
3 Zero + Move
4 Wait
5 Cut
6 Waiting end of cutting
7 Camming
8 Alarm
10 Waiting steps 4 or 6

4 Drive status
In the cam system several status are possible. In the following table, the working mode of the various status
is represented.
State Code Control mode Note
Disable 0 Speed, reference = 0, drive disabled Input state

Stop 1 Speed, reference = 0, drive enabled
Jog 2 Speed, reference = JogRef, Ramp = JogRamp, drive
enabled
Camming 3 Position, Cutting Cam in execution, drive enabled
Ciclo 0 4
Alarm 5
MovePos 6 Position, drive enabled Goes to Home position
OverLimitPosition 7 Speed, reference = 0, Ramp=FastStopRamp, drive Software limits exceeded
enabled
SysEnableStatus = False
Stato_Alarm
AND Stato <> Disabled
INIT (5)
SysSystemAlarm = 0 Reg_v e
RifV=0
Stato_Disabled
(0) EnableCmd AND MovePosCmd=1 SysSystemAlarm = 1
Reg_v e RifV=0 sysEnableStatus AND
ZeroCycleStatus =1
Stato_AllarmeParac
arro (7)
Reg_v e RifV=0
Disabled Stato_Stop
(1) Stato_MovPos
JogCmd+ OR (6)
JogCmd- = 0 Reg_v e
RifV=0 Reg_pos
Stato_Jog
(2)
Reg_v e RampTime =
RifV=JogRef JogCmd+ OR FastStopRamp
JogRamp JogCmd - = 1 Reg_V, RifV=0
CammaCmd =1
RampTime = AND
RampTime =
StopRamp ZeroCycleStatus =1
FastStopRamp
Reg_V
Reg_V, RifV=0
RifV=0
FastStopCmd=0
MovePosCmd=0
OR
ZeroCycleStatus =0
FastStopCmd=0 EnableCmd, CammaCmd,

JogCmd+ e -, FastStop,
CammaCmd=0 MovePosCmd e
OR CammaCmd sono comandi
ZeroCycleStatus =0 da Bus o morsettiera.
FastStopCmd=0 I numeri tra parentesi e

Stato_Camma
il valore di DriveStatus in
(3)
quello stato
Reg_pos e
Camma
Reg_v è Contollo il
velocità
Reg_pos è in Posizione
JogRamp, StopRamp e
Macchina Stati Camma
FastStop Ramp sono
Rnc 30 Ott 08 Stop Ramp tempi di rampa
Rnc 09 Ago 05 Rev PlastiBlow
Rnc 08 Lug 05 Prima versione
Figura 3: Drive status

4.1 Gains and filters
FLYINGSHEAR\Gains\PosPropGain
Proportional gain of system position loop.
FLYINGSHEAR\Gains\PosFFWDGain
FeedForward gain of system position loop.
FLYINGSHEAR\Gains\MeasureWheelFilter
Low pass filter on the measurement wheel. If the value is too high it may cause an error during cutting
when starting-up and stopping the line. Approximate value up to around 4 msec.
During the cutting phase it may be necessary to increase the time constant of the filter on the metric wheel.
This prevents vibrations due to blade/sheet metal interference from affecting carriage movements. The two
parameters shown below can be used for this purpose:
FLYINGSHEAR\Speed Gains\EncFiltTauInCut
Filter constant applied during cutting.
FLYINGSHEAR\Speed Gains\TauInCutDuration
The time for which the filter is applied starting from the ready to cut signal. It must be long enough to
allow the blade to leave the sheet metal.
The direct speed of the metric wheel encoder is shown in blue; The filter eliminates the disturbance on the filtered measurement
Green: filtered metric wheel and thus on the movement of the carriage
Yellow carriage speed
Disturbance due to cutting is seen on the metric wheel and affects
the carriage
When using the additional filter, working with a constant line speed during cutting is recommended to avoid
measurement and movement errors. To guarantee this condition, stop the line acceleration ramp at the start of the
forward movement, indicated by the StartCycle bit (see StatusWord), until the blade down signal is raised.
Warning
CutPGain
Cutting length control gain. This value is used in the cutting length control system. It moves the
carriage forward or back with respect to the material to obtain a correct cut. Values range from 0.5 to
2%.

5 Possible Movements and related commands
5.1 Start-up of Following, cutting and initial cutting

Start-up of following and cutting is conditioned by the execution of the zero cycle and the first butt cut.
To carry out the following and cutting profiles, the state must correspond to Camming. The cycle is started
with the command RunCmd.
FastStop or Jog commands must not be present.

The Drive must be enabled. The enable terminal and VirtualEnableCmd must be set to ON.
RunCmd must be set to zero.
When RunCmd switches from 0 to 1 the following operations are performed
1. Checks to see if the zero sequence has been done. If negative, the zero sequence is carried out;
otherwise it passes to point 3.
2. Zero sequence
3. A Move is done at position 0. The zero position is the found Index position added of ZeroOffset value.
This is the zero reference for the system.
4. Wait of 0.5 sec.
5. If the “InitialCutting” parameter equals one, a cut is commanded each time RunCmd passes from 0 to
1. If this parameter equals zero, the initial cut is made only at the first butt cut.
6. Wait of 0.5 sec.
7. Starts to follow the material. At this stage the line can be started.
The working cycle can be ended by:
RunCmd set to 0. The motor runs at zero speed with the JogRamp time. This is the condition that is normally used.
Activate RunCmd again to repeat the above sequence.
FastStop command. The system stops with the FastStop ramp. the commands RunCmd must be removed.
Otherwise the system could restart incorrectly to follow the material.
Warning
If an alarm occurs, the commands RunCmd must be removed.
Otherwise the system could restart incorrectly to follow the material.
Nota: When starting and the RunCmd procedure is not used, the zero position must be checked by reading
the MotorPosition parameter. If the carriage position is not the same as the zero position, the carriage
will move towards the zero position quickly.
5.2 ImmediateCut
Available in the Camming state. Activates immediate cutting regardless of the length that has been reached.
The carriage is synchronized and the cut is performed.
Note: for more information, see 3.8
5.3 Initial accompanying

If the parameter “InitialEnAccomp” equals 1 at the first butt cut an accompanying cam is run to bring the
carriage to end of travel. When accompanying is done, the cycle restarts from the normal cam.

6 Basic sequence for PLC
Below is an example of how to manage the Flying Shear commands.
Note: In order to enable the drive the terminal must also be connected.
Initially VirtualEnableCmd and RunCmd are both set to zero. First VirtualEnableCmd is set to high, and the
drive is enabled. Next RunCmd is sent. The system executes the zero cycle if necessary. This only happens
when the machine is switched on.
The butt cut is performed. When that has been done RunCmdState turns to 7 and the line can start.
The line can change speed, even to zero, and restart with no problem.
RunCmd and Enable must only be set to zero if operations are to be performed on the material.
When RunCmd is removed the carriage stops with the Jog ramp.
Alarm
StatusBit Word AND 0002 = 0002
OR
ApplicationAlarmCause <> 0
Init
VirtualEnableCmd = 0
RunCmd =0
Init
SysClearAlarm =0
RunCmd =0
Wait until line

StatusBit Word AND 0002 = 0000 Wait speed is zero
Wait 100
100 msec
msec
VirtualEnableCmd = 0 VirtualEnableCmd = 1
RunCmd =0
RunCmd =0 RunCmd =0
SysClearAlarm =1
Wait
Wait
100
100
Wait msec
msec
RunCmd =1
RunCmd =0
Stop Line and Disable
Here the Init Cut is

executed
Wait Wait
TimeOut 100 msec
TimeOut
StatusBit Word AND 003C = 001C
TimeOut. Start Line Stop Line

Check what was wrong
Start the line in Stop the line in
ramp ramp
RunCmd =0
6.1 Auxiliary motion / Additional motion

Other than the motion depending on the profile programmed (following and cutting Camming state) other
states and motions are possible for the drive. These are::
6.1.1 Jog
The Jog state can be reached by using the commands JogCmd+ and JogCmd- when in the Stop state. The
motion is at the speed JogSpeed and ramp JogRamp.
See paragraph 4.

6.1.2 Limits (Carriage stops)
Two limit options exist. MaxPosition and MinPosition.

EnablePosLimit enables or disables the test.
All motion, except for jog before the zero cycle execution, must occur between these limits.
If these limits are exceeded, the drive stops in speed control with the FastStop ramp. An ALLARM status is
issued by FLYINGSHEARCauseAlarm = OVER_LIMIT_POSITION.

7 Cutting length
The CutLength parameter must be set. The new dimension is active from the next possible cycle.
When the new length is received, the carriage returns with maximum acceleration
(FLYINGSHEAR\FlyingShear\MaxAcceleration) and speed FLYINGSHEAR\MechRelations\MaxRetSpd at
zero position. It then waits for the new cut at the new length.
If the carriage is accelerating to go to cutting phase, these operations are postponed until the cut is finished.
Two signals are available to help synchronization, StartCycle and CutLengthAccepted.

The two signals have the following meanings.
StartCycle goes high for about 180 msec at the start of every cutting cycle.
CutLengthAccepted goes to zero when a new cutting dimension is given. Goes to 1 when the dimension is
confirmed active. The next cut will be carried out with the new dimension. NB. If the dimension is not
accepted, the signal remains equal to zero and the word ApplicationAlarmCause indicates an error.
To be sure that cutting is active for the next cycle, it is recommended to send a new dimension when
StartCycle = 1. This gives more time for the processor to make the calculation.
The CutLengthAcqDly parameter can be used to delay reading of the CutLength value sent by the field bus.
If the CutLength value changes, the value on the bus is considered valid after this delay time. This can be
useful if the value is set using a combination of relays. Any instability of the contacts can be ignored.
In case a new length is sent with the machine in Camming condition the return to home is executed also if
the line speed is zero.
This movement can occour also also with line stopped (line speed equal zero). Pay attention. No operator
Warning must be close to machine also at line speed zero.
If, when back to zero position, the cutting dimension has already been exceeded
an FLYINGSHEARAlarm CutLengthTooShort error is issued and the machine stops.
The line speed should be decreased beforehand if necessary.
If the dimension is not accepted, the signal rests at zero and the word ApplicationAlarmCause indicates the
Warning error. cCALCOLICARRO_ALARM
Yellow: Speed
Cyan: Start Cycle
CutLengthAccepted
Figura 4: Cutting length change

8 Tests to control the metric wheel
The material may, at times, move suddenly and uncontrollably, when it sticks, puckers and is then released
again, causing the wheel to come away from the material.
Such movements, seen by the metric wheel, are followed by the saw carriage.
In these conditions it may be desirable to recognise the presence of irregular movements and set the
machine to the safety condition.
For this reason a series of metric wheel motion controls have been implemented. These can be divided into
two types:
 Checking that the motion of the metric wheel is within the correct acceleration and speed ranges and
that the wheel does not move backwards;
 Checking that the speed of the metric wheel is close to the line speed read by the PLC.
8.1 Checking that the motion of the metric wheel is within the correct acceleration
and speed ranges and that the wheel does not move backwards
The parameters are in the FLYINGSHEAR \MWControl\MWLimitTest menu.
The following limits can be set:

 maximum acceleration, AccMaxPLim, and deceleration, AccMaxNLim; of the metric wheel
 maximum speed of the metric wheel, VelMaxWP;
 maximum backing of the wheel, MaxBack. If the metric wheel travels in a negative direction for a
distance greater than MaxBack this event is signalled.
To facilitate evaluation of acceleration values and of the limits to be set, two parameters indicate the
maximum value of accelerations measured during movements. The operator must reset these and write their
value as zero. During the movement these store the maximum measured value.
Another variable displays the current acceleration value. The acceleration value used for all the tests is
mediated to 200 msec.
Monitor maximum wheel acceleration AccMaxPosMonitor reset by writing zero

Monitor maximum wheel deceleration AAccMaxNegMonitor reset by writing zero
Acceleration of metric wheel MWAceAcc
When the speed of the wheel exceeds the limit this is indicated in:
Wheel speed fault VelFault
N.B.:
Exceeding of the limits does not result in any direct action by the drive. The event is indicated in the
ApplicationAlarmCause word. The PLC decides what action is to be taken. See chepter 11.
Messages indicating that limits have been exceeded can be excluded by raising the limits to values that
cannot be reached..
8.2 Checking that the speed of the metric wheel is close to the line speed read by
the PLC
The parameters are in the FLYINGSHEAR\MWControl\MWvsLineSpd menu.
The line speed can be sent to the drive, via fieldbus, to check whether the line speed and metric wheel
speed correspond. The drive verifies that the speed measured by the wheel is within a percentage range
calculated with respect to the LineSpeed value received by the PLC.
When the line speed that is received falls to more than 20% less than the maximum line speed allowed the
range is calculated with respect to 20% of this.

The maximum line speed allowed is defined in the VlineaMax_mtMin parameter as a function of the cutting
length.
The width of the range is defined with LineSpdThr.
If the speed of the metric wheel remains outside the range for more than the time set in MWOutRangeTime,
this is signalled. The out of range time is set to zero each time the speed returns to within the limit.
Exceeding of the limit does not result in any direct action by the drive.
The event is indicated in the ApplicationAlarmCause word. The PLC decides what action is to be taken. See
chapter 11.
The test is enabled with EnbMWLineSpdChk via parameter or with CommandReg via Bus.
Enable compare line speed test EnbMWLineSpdChk

Line speed LineSpeed
Speed threshold LineSpdThr
Delay for out of range alarm MWOutRangeTime

9 Machine Data
The data contained in this table must be known well before starting the Start up operation for the saw. This
table can be used as a reminder and completed before or after installation and start-up.
Unit of
Name Value Note
Measure
MechRelations/MetricWheelDisp
(Metric wheel circumference) [mm]
MechRelations/MetricWheelRev
Metric wheel revolutions to have the
circumference given (usually 1)
MechRelations/CarriageDisp
Carriage displacement [mm]
MechRelations/MotorRev
Motor revolutions to have CarriageDisp
FlyingShear/CarriageLength
Carriage length [m]
FlyingShear/MaxCarriageVelocity
Maximum carriage speed [m/s]
FlyingShear/MaxAcceleration
2
Maximum acceleration [m/s ]
FlyingShear/MaxDeceleration
2
Maximum deceleration [m/s ]
FlyingShear/SyncTime
Synchronization time before cutting [s]
FlyingShear/CutAndGapTime
Time used for cutting and Gap execution [s]
FlyingShear/GapLength
[m]
Gap length
FlyingShear/GapTime
[s]
Gap Time
MechRelations/Max position
[m]
MechRelations/Min position
[m]
FlyingShear/MaxCarriageVelocity
Maximum carriage speed [m/s]
MechRelations/MaximumSpeed
Maximum motor speed [rpm]
MechRelations/MaxRetSpd
Maximum return speed [rpm]
The following table shows the chosen configuration.

10 ADV200 Configuration
The following configurations are required:
 Drive and I/O functions

 Encoders
 Field bus
10.1 Configuring the drive and I/O functions

The inverter is correctly set at start and at load default.
The following table shows the chosen configuration.
IPA Name Setting Notes

Commands Group
1004 Enable/disable mode OFF
1000 Commands remote sel Digital
1018 Digital Enable src Bit0 decomp
1020 Digital Start src Bit1 decomp
1022 FastStop src Bit2 decomp
1042 FR Forward Source Null
1044 FR Reverse Source Null
Jog
916 Jog cmd + src Bit3 decomp
918 Jog cmd - src Bit4 decomp
Speed Reference
642 Dig speed ref 2 0
650 Speed ref 1 src Pad 2
610 Ramp ref 1 src Dig ramp ref 1
616 Ramp ref inv src NULL
3000 Dig speed ratio 100 %
Digita out
1310 Uscita digitale 1 Pad 5 – drive ok
1312 Uscita digitale 2 Pad 6 – nc
1314 Uscita digitale 3 Pad 7 – Ready to cut
1316 Uscita digitale 4 Pad 8 - CutSignal
Analog Out
1800 Uscita analogica 1 velocità motore
1802 Uscita analogica 2 corrente motore
Work mode is closed loop, which is set automatically at Load Default.

IPA 552= Closed loop.

10.1.1 Digital I/Os
Digital Terminal Function Notes

Inputs
DIE 6 Enable drive
DI1 8 FastStopDig for the forward and backward limit switches Active at 0
and/or physical limit switches
DI2 9 Free
DI3 10 Free
DI4 11 High Blade – carriage return enable See CutCompleted
DI5 12 Low Blade – Over speed See Gap
Blade in Lower position – gives permission for over speed
(gap)
Input Capture Terminal Function Notes

Freeze 1 52 Zero qualifier cam Freeze input double encoder
card
Digital Outputs Terminal Function Notes

DO1 R14 Drive OK Output with relay
DO2 R24 Free Output with relay
DO3 13 Cutting command / ReadyToCut
DO4 14 CutSignal Active with ReadyToCut for
length of TimeCutSignal
With TimeCutSignal different

from zero at cutting time, it
goes to 1 for TimeCutSignal.
With TimeCutSignal set to
zero at cutting time, it goes
to 1. Returns to zero after
detecting BladeUp state
equal to zero and following
return of BladeUp to 1.
10.2 Encoders
You have to define the encoder mounted on the motor via IPA 5310: Encoder Sel Source. The other
mounted encoder is used as a measurement wheel.
The following figure shows the suggested configurations.

If there are three encoders, only numbers one and two will be used (number three remains unused).
Suggested configuration for asynchronous motor.

Digital encoder 1 (yellow) on metric wheel
Digital encoder 2 (green) on motor
EncoderConfig/EncoderSelSrc (IPA 5310) = One
Suggested configuration for synchronous motor.

Synchro encoder 1 (red) 5 track on motor
Digital encoder 2 (yellow) on metric wheel
EncoderConfig/EncoderSelSrc (IPA 5310) = Null
Note: zero cam input always on motor encoder.

10.3 Fieldbus
The fieldbus is configurable. The suggested configuration is set with the load default command.
Setting the fieldbus
IPA Value Significance

4010 0 Field M->S Enable = off
This lets you start testing the machine without sending data from Bus.
Must be set to On for final test.
FieldBus M->S
4020 11284 Cut Length

4022 PAR32
4030 11454 Cut&GapTime
4032 PAR32
4040 11480 BusCmdWord
4042 PAR16
4050 11378 1=Ruota Virtuale/ 3=Encoder
4052 PAR16
4060 11132 MW displacement
4062 PAR32
4070 11356 VirtualMstSpeed
4072 PAR32
4080 0 Fill 32 (per fieldbus CAN)
4082 FILL32
FieldBus S->M
4180 12112 StatusBitWord

4182 PAR16
4190 12010 AppAlarmCause
4192 PAR16
4200 12030 DriveStatus
4202 PAR16
4210 12130 Vlinea Max m/m * 10
4212 PAR16
4220 12068 MW value
4222 PAR16
4230 12018 Carriage Pos mm*10
4232 PAR16
4240 12074 Motor current
4242 PAR16
4250 12072 MW speed m/m * 10
4252 PAR16
4260 12090 Real CutLegnth mm
4262 PAR32
4270 0 Fill 32 (per fieldbus CAN)
4272 FILL32

Mapping command bit word (IPA 12114)
bit Name Hex value

0 VirtualEnableCmdBus 0001
1 VirtualMstStartCmd 0002
2 Reserved 0004
3 FastStopCmdBus 0008
4 sysClearAlarm 0010
5 pActiveEncoder 0020
6 ResetWarningCmd 0040
7 Reserved(ZeroCycleCmd) 0080
8 Reserved 0100
9 pDecimalPointCmd 0200
10 JogPosCmd 0400
11 JogNegCmd 0800
12 Reserved(MovePosCmd) 1000
13 EnbMWvsLineSpdCheck 2000
14 CutImmediatoCmd 4000
15 RunCmd 8000
Mapping Status bit word (IPA 12112)

bit Name Note
0 sysEnableStatus
1 sysSystemAlarms <> 0 If 1 an alarm is present
2 VRunCmdState bit 0
6 CutTimeRefused High if SetCutTimeCmd has been refused.
7 vZeroInExecution
8 ZeroFound
9 sysPosOk End of speed profile. Valid with Move command
It goes to 1 at the end of the move operation. It is meaningful only in a Move
operation.
10 Start
11 SpeedZeroState It is 1 when the speed is below SpeedZeroThr
12 LengthAccepted Set to 0 when a new dimension arrives. Set to 1 when the new dimension is
actuated. NB. If the dimension is refused, remains equal to zero.
13 StartCiclo/CycleStart Indicates, set to 1 for about 190 msec, at the start of a cutting cycle
14 StartAcc Active during forward acceleration

Image of digital outputs
bit Name Note
0 Drive OK
1 Free
2 ReadyToCut
3 CutSignal Active with ReadyToCut for length of TimeCutSignal
4 Speed zero 1 if Speed = 0
5 LtaglioAccepted Indicates cutting length has been accepted
6 StartCycleSignal Indicates start of new cycle
7 Free
8 Free
9 Free
10 Free
11 Free
12 Free
13 Free
14 Free
15 Free

11 Application key
This application must be registered.
Register by entering a code depending on the serial number of the control.
The code is supplied by Gefran.
Enter the code as follows:
1) Change the access level. Click Password on the File menu. Click Level 2 in the window. Insert
password 38472.
2) Open the service / serial numbers menu
Parameter 522 is the Serial Number. Write this number down and contact Gefran to receive the application
key to be entered in parameter 572.
Save and reset the drive. The “Key Expiring” message will no longer appear at power-on.

12 Application alarms
The application carries out a series of checks on itself while it is functioning. The information is stored in the
ApplicationAlarmCause parameter.
The checks are:

 Carriage stops
 Speed requests under the fixed limits
The state is checked and signalled in the ApplicationAlarmCause parameter
12.1 Limits (Carriage stops)

If enabled (EnablePosLimit On) the drive check that carriage position remain inside the Max and min
Position values. If it get out the limits a FastStop is issued and an OverLimit_Alarm occour.
12.2 Speed request under fixed limits

The parameter MaximumSpd is the maximum displacement speed. If the profile requests a faster speed, the
speed will be limited to the value in MaximumSpd and the event will be registered in MaximumSpd.
If the value MaximumSpd is reached, positioning will be in error. The profile and the finale position will not be
those requested.
12.3 cLENGTH_TOO_SHORT
When home position is reached after a change in cutting length, not enough material has advanced to
execute the cut at the requested length.
FLYINGSHEAR FLYINGSHEAR Event Note Action

AlarmCause AlarmCause
bit number Number
0 0x0001 FastLink Not used
1 0x0002 CMWSPD_OUT_THR Compare MW vs Signal
LineSpeed
2 0x0004 SpdRefMax Speed requested above Signal
the maximum
3 0x0008 Anticipo Not used
4 0x0010 Motor Not inserted
5 0x0020 cCALCOLICARRO_ALARM Errors in trip calculation The old cutting
dimension is
maintained
6 0x0040 cCUT_NOTCOMPLETED_ALARM Cutting not finished Stops in FastStop and
rests in the alarm
state
7 0x0080 cOVERLIMIT_ALARM Carriage stop Stops in FastStop and
rests in the Stop state
8 0x0100 cLENGTH_TOO_SHORT The carriage did not Stops in FastStop and
return in time for the rests in the alarm
new cutting length set. state
9 0x0200 cMW_TOO_HIGH MW exceeds limit set in Signal

VelMaxWP
10 0x0400 cACC_TOO_HIGH MW exceeds limit set in Signal
AccMaxPLimit or
AccMaxNLimit
11 0x0800 cMW_BACK Metric wheel has moved Signal
back
12 0x1000 cFAST_STOP FastStop command Stops in FastStop and
received stays in this state until
ClearAlarm

FLYINGSHEAR FLYINGSHEAR Event Note Action
AlarmCause AlarmCause
bit number Number
13
14
15 0x8000 No FLYINGSHEARCauseAlarm If 1 there are no
AlarmCause active

13 Start up
Start up is performed after machine development. If development was done with Gefran’s ShearTool, most
of the required data are already in the sizing report.
To illustrate Start up, we will use the following machine data.
Carriage length 1000 mm

Maximum cutting time 500 mSec
Rated motor speed 1500 rpm
Reduction gear unit 28.28 Number of turns on the high-speed shaft for one turn on the slow
shaft.
Primitive length development 580.616 Saw carriage linear advancement for one turn of the slow shaft
mm
Material advancement after cutting 5 mm
(Gap)
Metric wheel circumference 400 mm
The procedure describes Start up with a single metric wheel connected to the XER input.
If you want to use two metric wheels, see paragraph 12.3.3 “Checking the value set for metric wheel
circumference.”
See the connection diagrams proposed for asynchronous or synchronous motors:
Figura 5: Connection diagram (Asynchronous motor)

Figura 6: Connection diagram (Synchronous motor)
If necessary the commands can be made to pass via the PLC (e.g. to allow manual control of the cutting
unit).
The physical limit switches must be managed by external control units. This is because when engaged they activate
the Stop state and the carriage cannot be moved.
The FastStop command must be removed by means of an appropriate sequence controlled by the operator.
Caution

13.1 Drive setting
13.1.1 Main data setting:
13.1.2 Self-setting
For setting-up, refer to the chapter 3 of ADV200 QS manual.

For initial test, we recommend that the motor shaft be disconnected from the machine
Caution
13.1.3 Field bus
By means of two parametrs the source of some parametrs is set. The source may be Serial port or Field Bus
Setting Bus_enable OFF and EnableSerialCmd ON data are set trough serial port.
Setting Bus_enable ON and EnableSerialCmd Off the CutLength, CutTime and CmdRegister(sysFBRxw7)
came via field bus.
13.1.4 Encoder data
Insert the encoder data in the ENCODER CONFIG menu. With the configuration shown leave
Encoder sel src = Null.
Encoder 1 corresponds to the slave, i.e., to the carriage.
Encoder 2 corresponds to the metric wheel.
Set ppr (pulses per revolution).
13.2 Inserting mechanical relationships and testing

The drive is disabled.
Start by inserting the mechanical data. These can be found in the FLYINGSHEAR\5-MechanicalRelations
menu. The Master (Mst) is the metric wheel. The Slave (Slv) is the carriage.
The measurements units are in mm or meters depending on the parameter.
Pay attention.
FLYINGSHEAR\5-MechanicalRelations
Name Meaning Note
ActiveWheelSel Select size of wheel in question Off MetricWheelDisp
On MetricWheelDisp2nd
MetricWheelDisp Material advancement in MetricWheelRev If MetricWheelRev = 1 then DeltaDispMst is the
revolutions of the measurement wheel. material advancement per revolution of the
measurement wheel.
MetricWheelRev Number of measurement wheel revolutions with
which the material advances by
MetricWheelDisp
MetricWheelDisp2nd Material advancement in one revolutions of the
second measurement wheel
CarriageDisp Carriage advancement in MotorRev revolutions If MotorRev = 1 then CarriageDisp is the
of the motor shaft. carriage advancement per revolution of the
motor shaft.
MotorRev Number of motor shaft revolutions with which
the carriage advances by CarriageDisp
MaxMotorSpeed Maximum motor speed If this level is exceeded the speed is limited. An
appropriate ApplicationAlarmCause value
signals this condition

FLYINGSHEAR\5-MechanicalRelations
Name Meaning Note
ReverseMasterDirectio Master direction inversion (measurement wheel) The master must always increase. If the wheel
n measurement decreases, set
ReverseMasterDirection to On
MaxRetSpd Motor return speed during the cutting length
change phase.
MaxPosition Maximum Carriage Position Limit switch
MinPosition Minimum Carriage Position Limit switch
EnablePosLimit Enable the limit switch control Set it on
With reference to our data, we will insert:
Name Assigned to Note
MasterSelection VirtualMaster This configuration is used to test the machine without material. The material
advancement is simulated internally
CarriageDisp 580.616 Saw carriage advancement
MotorRev 28.28 Number of motor revolutions for one revolution of the slow shaft
MetricWheelDisp 400 Metric wheel circumference
MetricWheelRev 1
MetricWheelDisp2nd
MaximumSpd 1800 rpm This speed is set to about 20% above the maximum motor speed reached.
This speed must keep in mind the Gap and the return speed. If this level is
exceeded, the ApplicationAlarmCause value signals an error.
MaxRetSpd 1500 rpm Motor return speed during the cutting length change phase.
ReverseMasterDirection See below
MaxPosition Off
MinPosition Off
EnablePosLimit 1010 (to verify with carriage movement)
ActiveMetricWheel On
Now go to the FLYINGSHEAR\2-Ramp..
JogRamp is the ramp used in Jog mode. (See Figure 3: Drive states).
A reasonable value is 1 s (1 seconds to pass from 0 to Motor max Speed).
JogSpeed is the Jog speed e.g. 100 rpm.

StopRamp is the ramp used when Camming passes to Stop. (See Figure 3: Drive states).
A reasonable value is 1 s. (1 second to pass from 0 to Motor max Speed).
SpazioArresto is the stopping space in meters, (the unit of measure is between []):
( MaximumSpd [ rpm]  DeltaDispS lv[ mm])

V max Carro  Maximum carriage speed in m/s
60'000  Re vSlv
2  SpazioDiArresto[m]
TempoDiArresto  Stopping time in seconds
VMaxCarro[m / s]
In our example, if we had a stopping space of 10 cm (0.1 mt), therefore:
VmaxCarro = (1600*580.616)/(60’000*28.28) = 0.568 m/s
TempoDiArresto = 2*0.1/0.568 = 0.352 s
To have a stopping space of 10 cm, we would set FastStopRamp to 0.352
MstStep is the speed of the virtual master. This simulates the metric wheel during the test without material.
The virtual material speed is expressed in mt/s.

VirtualMstRamp is the ramp applied to the variations of MstStep inside the cycle. Suggested value 1 s.
-------------- Leave MstStep at zero for the moment.---------------
Note:
If the value of MstStep is modified, the internal cycle ramp is changed. The new cycle starts immediately with
the final value. Change MstStep gradually.
MoveToSpeed. Using the command RunCmd, the saw proceeds to the zero position before cutting the butt
and starting to follow the material. The speed at which it travels to the zero position is MoveToSpeed, the
ramp is JogRamp. See Figure 3: Drive states

13.3 Check-up of basic movements
Select MetricWheelSel = VirtualMaster
We now continue with the Start up phase by checking the data inserted and machine movements. The mode
now described uses the GF_Express and serial connections. A straight cable (not cross-over) and a
RS_485 adapter are necessary. The operations could be carried out by the PLC as well, however, they
would be more complex. The operations cannot be done by using digital commands only.
The controls will be passed integrally to the serial line. To enable this set Bus_enable to OFF and
EnableSerialCmd to ON. These are found in the Miscellaneous menu.
On the command page of the configurator, all useful measurements are shown.
Have an emergency push button available to disarm the system if necessary. This push button must be easily
reached.
The following operations require the machine in motion.

Unforeseen machine movement is always possible. Take this into account and take the necessary precautions.
The operation described can be (must be) initially carried out with the motor disconnected from the machine.
Once the functions have been tested, the operations can be repeated with the motor connected to the
machine.
Set VirtualEnableCmd to ON (Green

indicator). All other indicators must be Red.
Using the monitor window, display:

DriveStatus, MotorSpd.
Red indicates command set to zero (not

Active)
Green set to one (Active).
Set the enable digital input, terminal 7, to + 24V.
13.3.1 Direction checking
Jog forwards and backwards. Check for movement in the correct direction. With Jog forward the carriage
advances in a positive direction and the MotorPosition increases.
Otherwise, reverse the motor phases and encoder channels A+ and A-.

The MinPosition and MaxPosition limits must be adjusted. The MaxPosition limit must always be greater
than the MinPosition limit. If this is not done the Move command may not function. Sometimes it is
necessary to reset the OverLimit alarm.
Warning
13.3.2 Zero cycle positioning
Zero searching is to be checked out. MechRelations\ZeroCycle menu.
Select ZeroType:
1=CamOnly;
SpeedZero: zero qualifier search speed (e.g. -50 rpm)

SpeedZero1: index search speed (e.g. -5 rpm)
ZeroOffset: zero position with respect to the index. The carriage searches for zero index. At the end
goes to the ZeroOffset position.
Enable the drive.

Disable VirtualMstStartCmd (red)
Place RunCmd to green.
The status must become ZeroCycle. The carriage must move towards the zero position. Otherwise, remove
RunCmd and invert SpeedZero and SpeedZero1. Repeat RunCmd.
As soon as the drive reaches the Camming state, remove RunCmd (set it to red). The drive stops in Enabled
state.
Note:
When passing to camming, an initial butt cut is carried out. If the high blade and low blade sensors are not
connected, the drive will go to an alarm state, with FLYINGSHEARAlarmCasue = Cut not completed (code
64).
To modify the zero position change the ZeroOffset value and repeat the RunCmd. The carriage will move to
the new zero position.
13.3.3 Checking the value set for metrical wheel circumference
Carriage length development:

The Jog command is used. After the zero cycle position measurement is active.
Mark the position on the carriage and register the MotorPosition position. The carriage moves with JogPos or
JogNeg depending on the direction desired. Measure the distance travelled confronting the distance to the
difference of the two MotorPosition positions. Adjust the CarriageDispSlv value if any errors occur.
E.g.:
Difference between the two Motor Positions = 600 mm
Carriage distance travelled = 590 mm
CarriageDisp = 0.580 m
New CarriageDisp = (0.580*590)/600
Repeat the check.
Longitudinal development of the metric wheel:

Check the longitudinal development of the metric wheel. Read MetricWheelPos. This value must increase as
the material advances.
If the direction is in error set ReverseMasterDirection to On.
Check that the measurement is congruent.

The mechanical displacement must be set in FLYINGSHEAR\MechRelations\MetricWheelDisp2nd. It is the
material displacement for one wheel turn of the second metric wheel.
The two wheels must be switched by an appropriate circuit external to the drive.
The active metric wheel is set by FLYINGSHEAR\MechRelations\ActiveMetricWheel. Setting it to Off (zero)

the main wheel. If On (one) the secondary wheel. The change cannot be made when the machine is moving.
N.B.
Both the wheel must count in the same direction. The ReverseMasterDirection flag acts on both.
Inserting cutting data

Referring to the following figures, insert the machine data.
Deve essere uno spazio sufficiente all’arresto

con Fast Stop nel caso intervengano i fine
corsa Software
Fine Corsa
Software
Cesoia
LunghezzaUtileCarro
Posizone di
Zero
Fine Corsa Deve permettere l’arresti in FastStop

Hardware in caso di intervento dei fine corsa
HardWare
Lunghezza limite moto carro

Cesoia Volante - Carro
Rnc 29 Set 05 Prima versione
Parameter/Variable Meaning Note

CarriageLength Useful carriage length. Corresponds to the usable
part of the carriage during motion. Some of the
effective length must be reserved for:
Stopping by using software carriage stops
Stopping by using hardware carriage stops.
MaxAcceleration Maximum acceleration to be obtained by the
machine at the calculated line speed
MaxDeceleration Maximum deceleration to be obtained by the Becouse of the gearbox efficiency it is
machine at the calculated line speed possibile set the deceleration some
percent higher of the acceleration
CutAndGapTime Time necessary to cut the material and to carry out The cutting time must be estimated
the Gap and then add the time that will be used
to do the Gap
MaxCarriageVelocity Maximum carriage speed
Sync Time The time passed at synchronization speed to permit
the carriage to be stabilized before the carriage is
enabled
GapTime Time in which the gap is carried out.
GapLength Space gained by the carriage.
CutStatus
OverallMstTrip Used for testing

Parameter/Variable Meaning Note
OverallSlvTrip Used for testing
UsedCarriage* Carriage space used for cutting at this cutting length
CutLength cutting length
MaxLineSpeed* Maximum allowed line speed
InUseCutLength*
* These vary depending on the cutting length
Spazio Gap
Init
4
2 3
0 1 5 6 7 8 12 13
TSincro Ttaglio
Ready To Cut
Cut Completed
(Ok, No Fault)
Lama Bassa
Cesoia Volante - Profilo di Velocità

Lama Alta
Cut Completed Rnc 29 Set 05 Prima versione
(Not Ok, Fault)
If the required cutting length is not compatible with the other data, it is refused and the last value is
maintained.
Comments on the data:
SyncTime Synchronization time

Gap Time Time needed to move forward in Gap Length space
Gap Length Forward movement of carriage made at end of cut (Low Blade signal given)
CutAndGapTime (Cutting Time): It is the time used for cutting and gap execution. The time starts when the
ReadyToCut signal is given. Keep this in mind when taking into account Plc delays and
various actuators.
GapLength is carried out in GapTime (Sec). GapTime is usually less than blade up time (about half of cutting
time).
N.B.
The cutting system is made up of several elements with times related between each other.
1) A time interval at the end of the ramp to stabilize the system.

2) A delay time between ReadyToCut and the activation of the cutting system.

3) A time interval between blade start-up and the actual start of cutting (Low Blade).
4) Gap starts after the low blade sensor signals and therefore during the cutting period.
It is therefore possible to adjust the various timing intervals and decrease some of them. This must be done
after the following consideration:
a) Phase two time can partially be used as phase one time.
b) This cutting time is the cutting cycle time (from blade start to its return to starting position). Part of
this time runs after movement from Low Blade. When Low Blade is reached, Gap starts.
MaxCarriageVelocity [m/s]:
VelocitàMo tore[ rpm]  CarriageDi spl[ mm]
Is given by the formula: V max Carro[ m / s ] 
60 1'000  Motor Re v
MaxAcceleration: is the acceleration used to calculate the motion profile. This acceleration is obtained
when the system works at the calculated VlineaMax value.
The value can be supplied by the manufacturer or can be found empirically with the drive
connected, as follows:
1. The parameters CarriageLength, CutAndGapTime, MaxCarriageVelocity, SyncTime, GapTime,

GapLength, are set.
2. Starting with an MaxAcceleration value of 2 m/s2.
3. Once the new values are inserted, the variables values of MaxLineSpeed, CarriageSpace,
InUseCutLength are updated.
Check that the InUseCutLength value is equal to the required value and that the MaxLineSpeed value
is sufficient. If not, increase the acceleration to obtain the desired value.
4. Check for the other cutting length values
The following table is for indication purposes only:
acc <= 2.5; slow

acc >2.5 e <5; medium
acc>5; considerable
Cutting state: varies depending on the blade and ready to cut positions. A value of 99 indicates an error
state.
OverallMstTrip, OverallSlvTrip ViaggioTotaleMst and Slv: Are the distance covered by the metric wheel
(equal to the cutting length) and the total distance of the carriage (about zero). They are
present only for checking..
UsedCarriage SpazioAndata*: Space used by the carriage to carry out the cut
MaxLineSpeed VlineaMax*: Maximum line speed possible with respect to the data inserted. The line can
have a higher value. Timing and acceleration will not be respected.
InUseCutLength LtaglioInUso: Cutting length in use. It could be different than the one set, if calculation
errors are present.
13.4 Checking with the virtual master

We can now proceed with the tests by simulating the metric wheel with the virtual master.
Configure MechanicalRelations\MetricWheelSel to VirtualMaster.

Ramp\MstStep is the speed of the virtual master. This simulates the metric wheel during the test without
material.
The value is inserted in mt/s.
Note:
1) Display in the Monitor Window the data MetricWheelPos, BarLength, DriveStatus.
This is done by opening the Monitor Window (Menu View) and dragging the desired parameters
inside.
2) At the first cut the material advances (the Metric Wheel increases) while the carriage is stopped.Menu
SpeedGains.
13.5 Menu SpeedGains

Set
MeasureWheelFilter = 4 msec
CutPGain = 0.1
Set the following parameters in the Monitor Window of GF_Express:
DriveStatus,
MetricWheelPos,
MotorPosition,
BarLength,
RealCutLength.
Set:
RunCmd OFF
Enable Drive
Checking DriveStatus, set RunCmd to On (Red).

Drive Status will pass through several states until it gets to Camming.
If the saw is out-of-position, it will travel to the zero position with a speed of Ramp\MoveToSpeed.
An initial butt cut will be carried out and the bar length will be reset.
After which MetricWheelPosition will start to increase. (Note: during the first cycle, the waiting time at the
zero position will be longer than the following cycles).
Check for any irregular movements, the space used (equal to UsedCarriage) and RealCutLength length
(equal to the required cutting length).
Having done the above, we can proceed to set the drive, by increasing the cycle speed (increasing the
MstStep value).
13.6 Checking with material

Configure MechanicalRelations\MetriWheelSel to DIEncoder. Proceed as above.

14 Typical curves
SpdReference and
ReadyToCut signals
Gap starts immediately

as the High blade signal
was already high..
S_Shaped On
S_ShapedRet Off
S_ShapedRet and
S_Shaped are both On

15 Appendix A: metric wheel encoder selection
The selection of the pulses per revolution of the metric wheel encoder is basic to have a well working
system.
Its selection is depending from both metric wheel and carriage geometry.
The resolution of the metric wheel part must be equal or higher of the one of the carriage part.
In other words the ratio between the carriage displacement for motor revolution and motor encoder ppr must
be similar to the ratio of the metric wheel length and its encoder.
Supposing to have:
 avanza carriage advance 36 mm per revolution;
 motor encoder 1024 ppr;
metric wheel radius 100 mm equal to 314 mm of development.
Number of ppr of metric wheel encoder comes from:
SviluppoRuotaMetrica
pprRuotaMe trica   ImpulsiGiroEncoderMotore
Avanzament oCarroPerG iroMotore
pprRuotaMe trica  314 * 1024/36  8931
in this case a 8192 ppr encoder is adequate.

16 Appendix B: FieldBus
16.1 Writing parameters via fieldbus
Suppose the circumference of the metric wheel is to be written via fieldbus. This is possible using the free
words on the bus. The procedure is shown below.
1) In the MechanicalRel menu, note that MetricWheelDisp is parameter IPA 11132 and float format.
The float format of ADV200 is 32 bit.
2) In the /COMMUNICATION/FIELDBUS M->S menu select Fieldbus M->S4 IPA.
Assign the parameters as shown here:
3) Save and reset the drive.
Note:
For more details, please refer to Profibus card manual (cod.1S5F24_EXP-PDP-ADV_IT/EN) and ADV200 FP
manuals.

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ADV200 Flying Shear 4.0: User Manual

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ADV200 Flying Shear 4.

SW V4.0 30th October 14

Thank you for choosing this Gefran product.

ADV200 Flying Shear 4.0 APPLICATION Manual Page 2 of 42

1 Information about this manual ................................................................................................................ 5

ADV200 Flying Shear 4.0 APPLICATION Manual Page 3 of 42

ADV200 Flying Shear 4.0 APPLICATION Manual Page 4 of 42

1.1 Drive Firmware /Application version Cross compatibility

ADV200 Flying Shear 4.0 APPLICATION Manual Page 5 of 42

The forward Acceleration and backward

The shape of speed forwad deceleration

It is important to underline that for the

ADV200 Flying Shear 4.0 APPLICATION Manual Page 6 of 42

2.1 OverAcc parameter

N.B. In case of selection of FLYINGSHEAR\MechRelations\S_ShapedAcc or S_ShapedRet this selection

ADV200 Flying Shear 4.0 APPLICATION Manual Page 7 of 42

Cesoia Volante - Profilo di Velocità

Figura 1: Speed profile

ADV200 Flying Shear 4.0 APPLICATION Manual Page 8 of 42

Flying Shear / Cesoia Volante - Cut Sequence

Figura 2: Cutting assembly

ADV200 Flying Shear 4.0 APPLICATION Manual Page 9 of 42

3.1 JogPosCmd / JogNegCmd

Set FLYINGSHEAR \MechRelations\MetricWheelSel to VirtualMaster.

ADV200 Flying Shear 4.0 APPLICATION Manual Page 10 of 42

ADV200 Flying Shear 4.0 APPLICATION Manual Page 11 of 42

State Code Control mode Note

Disable 0 Speed, reference = 0, drive disabled Input state

FastStopCmd=0 EnableCmd, CammaCmd,

FastStopCmd=0 I numeri tra parentesi e

Figura 3: Drive status

ADV200 Flying Shear 4.0 APPLICATION Manual Page 12 of 42

ADV200 Flying Shear 4.0 APPLICATION Manual Page 13 of 42

5.1 Start-up of Following, cutting and initial cutting

FastStop or Jog commands must not be present.

When RunCmd switches from 0 to 1 the following operations are performed

The working cycle can be ended by:

5.3 Initial accompanying

ADV200 Flying Shear 4.0 APPLICATION Manual Page 14 of 42

Wait until line

Here the Init Cut is

TimeOut. Start Line Stop Line

6.1 Auxiliary motion / Additional motion

ADV200 Flying Shear 4.0 APPLICATION Manual Page 15 of 42

Two limit options exist. MaxPosition and MinPosition.

ADV200 Flying Shear 4.0 APPLICATION Manual Page 16 of 42

Two signals are available to help synchronization, StartCycle and CutLengthAccepted.

Cyan: Start Cycle

Figura 4: Cutting length change

ADV200 Flying Shear 4.0 APPLICATION Manual Page 17 of 42

The following limits can be set:

Monitor maximum wheel acceleration AccMaxPosMonitor reset by writing zero

Wheel speed fault VelFault

ADV200 Flying Shear 4.0 APPLICATION Manual Page 18 of 42

Enable compare line speed test EnbMWLineSpdChk

ADV200 Flying Shear 4.0 APPLICATION Manual Page 19 of 42

The following table shows the chosen configuration.

ADV200 Flying Shear 4.0 APPLICATION Manual Page 20 of 42

 Drive and I/O functions

10.1 Configuring the drive and I/O functions

IPA Name Setting Notes

Work mode is closed loop, which is set automatically at Load Default.

ADV200 Flying Shear 4.0 APPLICATION Manual Page 21 of 42

VmaxCarro = (1600580.616)/(60’00028.28) = 0.568 m/s