MCD/SIMIT model for

cylinder positioning

SIMATIC S7-1500 / PLCSIM Advanced V2.0 SP1 /

Siemens
SIMIT 10.1 NX MCD 1872 Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/109775424 Support
 Legal information

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MCD/SIMIT model for cylinder positioning

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 Table of contents

Table of contents
Legal information ......................................................................................................... 2
1 Introduction ........................................................................................................ 4
1.1 Overview............................................................................................... 4
1.2 SIMATIC Print Standard Add-On Cylinder Positioning ........................ 4
1.3 Components used ................................................................................ 5
2 Software setup ................................................................................................... 6
2.1 TIA Portal ............................................................................................. 6
2.2 SIMIT .................................................................................................... 6
2.2.1 Structure of the SIMIT project .............................................................. 6
2.2.2 Updating MCD coupling ....................................................................... 8
2.3 Mechatronics Concept Designer (MCD) .............................................. 9
2.3.1 Overview............................................................................................... 9
2.3.2 Physic elements for printing and anilox cylinder ................................ 10
2.3.3 Changing mechanical properties of the printing unit .......................... 11
3 Operating the digital twin................................................................................ 13
3.1 Starting the simulation ........................................................................ 13
3.2 Controlling the simulation ................................................................... 13
3.2.1 Homing ............................................................................................... 13
3.2.2 Controlling printing positions .............................................................. 16
3.2.3 Contact pressure simulation ............................................................... 17
© Siemens AG 2020 All rights reserved

4 Appendix .......................................................................................................... 19
4.1 Service and support ........................................................................... 19
4.2 Application support ............................................................................. 20
4.3 Links and literature ............................................................................. 20
4.4 Change documentation ...................................................................... 20

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 1 Introduction

1 Introduction
This application example allows you to simulate SIMATIC Print Standard Add-On
Cylinder Positioning using PLCSIM Advanced, SIMIT and NX Mechatronics
Concept Designer (MCD). Therefore, the MCD Model consists of one flexographic
printing unit and simulates it's kinematics. Furthermore, a SIMIT Model is provided
to simulate the behavior model for this machine setup and PLCSIM Advanced is
used to emulate a SIMATIC S7-1500 controller. The PLCSIM Advanced instance
runs the corresponding example project for SIMATIC Print Standard Add-On
Cylinder Positioning. This setup allows a virtual commissioning on the digital twin.

1.1 Overview
The purpose of the simulation is the test and validation of the TIA application.
Therefore, following topics are implemented and will be explained in this document:
• Axis simulation for cylinder positioning axes
• Speed control for rotatory movement of printing cylinders
• Simulation of disturbance force to enforce an alignment error
• Simplified simulation of contact pressure
• Remove and install printing and anilox cylinders during simulation (e.g. for
homing)
• Flexible mechanic: adjustable geometry of printing unit
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With this functionality it is possible to test the application with an adjustable

mechanical model in order to get an optimized TIA code.

1.2 SIMATIC Print Standard Add-On Cylinder Positioning

The application Add-On, Cylinder Positioning, is an addition to the standard
application SIMATIC Print Standard.
https://support.industry.siemens.com/cs/de/de/view/109762435.
The main purpose of this application is to provide the functions for a motorized
positioning of the printing and anilox cylinders in flexographic presses. Each
cylinder is positioned by two motors, one on the operator side and one on the drive
side of the machine. It is also possible to use this application if the cylinder
positioning movement is done by one motor. The application can be used also for
similar application cases. The library LSyncPos has implemented all the
functionalities for the synchronous positioning, which is the basic technology for the
cylinder positioning.
Figure 1-1 Principle of flexography process

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 1 Introduction

1.3 Components used

This application example has been created with the following hardware and
software components:
Table 1-1 Software components
Component Article number
STEP 7 Professional V15.0 Upd3 incl. 6ES7822-1..05-..
Startdrive V15.0 Upd3
PLCSIM Advanced 2.0 SP1 6ES7823-1FA01-0YA5
SIMIT S V10.1 6DL8913-0AK10-0AB5
NX MCD 1872 -

This application example consists of the following components:

Table 1-2 Components
Component File name Note
Documentation Manual_MCD_SIMIT_Model_For_
CylinderPositioning_V1_0_0.pdf
STEP 7 project S7LPrintAddOnCylPosExampleM In ZIP file CylPosExample_MCD_
CDSimit_V100.zap15 SIMIT_V100.zip
SIMIT project CylPosExample_V100.simarc In ZIP file CylPosExample_MCD_
SIMIT_V100.zip
© Siemens AG 2020 All rights reserved

MCD project MCD_CylPosExample_V100.zip In ZIP file CylPosExample_MCD_

SIMIT_V100.zip
Main assembly: _PrintingUnit1.prt

Limitations
This application example does not provide information on the following topics:

• Description of the SIMATIC Print Standard functionality:

https://support.industry.siemens.com/cs/de/de/view/109762435.

• Description of the SIMATIC Print Standard Add-On Cylinder Positioning:

https://support.industry.siemens.com/cs/ww/en/view/109775424

• Basics of TIA Portal configuration:

https://support.industry.siemens.com/cs/ww/en/view/109764516

• Basics of SIMIT:
https://support.industry.siemens.com/cs/ww/en/view/109772278

• Basics of NX MCD:
https://www.plm.automation.siemens.com/global/en/support/docs.html

• Basics of Virtual Commissioning

https://support.industry.siemens.com/cs/ww/en/view/109758943

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 2 Software setup

2 Software setup
2.1 TIA Portal
The example application is made for one realistic printing unit. Four Axis TOs are
implemented and connected to drives from the hardware configuration:
• Printing Cylinder OS and DS
• Anilox Cylinder OS and DS
None of the TOs are put to simulation mode. Therefore, this TOs require correct
feedback from real drives or an external simulation model.
The mechanic properties of the simulated printing unit like radius of cylinders and
rectangular distance between the cylinders are applied in the TIA project in FC
"CylPos_CylHandlerSetting" and OB "PrintStd_StartUp". If the mechanic in MCD is
changed, those FC and OB need to be adopted, too!
The application can be controlled by using the watch table "CylPos_Control".
Additional information about the TIA application can be found in the manual for
SIMATIC Print Standard Add-On Cylinder Positioning.

2.2 SIMIT
The SIMIT simulation software maps the behavior of active components (e.g. of
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drives or valves). In SIMIT, you can simulate error scenarios to analyze the
behavior of the machine in a virtual space.

2.2.1 Structure of the SIMIT project

The required components are organized in individual charts. Furthermore, the

SIMIT project contains couplings to the MCD simulation and to the PLCSIM
Advanced instance. Following the individual charts will be explained.
Figure 2-1 SIMIT structure

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 2 Software setup

Mechanics
From SIMIT you can remove and install the cylinders in the MCD simulation. This is
necessary whenever the OS and DS side needs to be moved separately, e.g. for
homing. Furthermore, a rotatory movement for the printing cylinders is calculated in
SIMIT and can be adjusted using a slider. In order to test the alignment observation
of the cylinder positioning application, you can apply a disturbance force to the four
positioning axes.

Figure 2-2 Mechanics chart:

(1) Remove and install printing and anilox cylinder
(2) Speed control for rotatory movement of printing cylinders
(3) Apply a disturbance force to the positioning axes

1
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2 3

SimulateContactPressure
In the cylinder positioning application, the contact pressure between IC and PC
and between AX and PC can be adjusted by moving the cylinders into the elastic
printing plate. To recognize these effects also in the simulation, a linear torque
depending on the distance of those cylinders is added to the actual torque of the
positioning axes. This is a simplified simulation of the contact pressure and does
not provide any predictions regarding the printing process!

Figure 2-3 Contact pressure simulation for one positioning axis

PROFIdrive
For all four positioning axes, the corresponding PROFIdrive telegrams are
simulated in SIMIT. This includes the PROFIdrive Telegram 105 and 750. For the

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 2 Software setup

homing process, a logic for driving on fixed end stop is implemented in these SIMIT
charts.

2.2.2 Updating MCD coupling

The MCD coupling is linked to the MCD project using the absolute path of the NX
MCD files. If the model has been moved to another path, the MCD coupling must
be updated manually. In this case please select “Link to external file” and choose
the part file “_PrintingUnit1.prt” from the unzipped download. Make sure that the
checkbox “Bus synchronous” is set for time slice 2.

Figure 2-4 MCD coupling in SIMIT

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Figure 2-5 Link MCD coupling in SIMIT to NX MCD main assembly file

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 2 Software setup

2.3 Mechatronics Concept Designer (MCD)

With MCD, you simulate and test the mechanical components of your machine in a
virtual environment. MCD brings CAD data together with a physical engine: The
CAD data is made kinematic. The specification of the degrees of freedom of the
different mechanical components defines the kinematics of the model.
Among other things, rigid bodies, collision bodies and joint connections are
configured in the physics navigator. To make movements possible in MCD, the
moving parts must first be defined as rigid bodies. Afterwards the rigid bodies can
then be connected with joint connections to form a kinematic chain. To affect the
movements from SIMIT speed, position and force/torque controllers are
implemented.

2.3.1 Overview

In the MCD project, one printing unit is modeled. The mechanics are described in
Figure 2-6. Figure 2-7 shows the implemented physic objects for one printing unit.

NOTE The signal adapter IntSA is prepared to move the gantry if the MCD model is
used without a SIMIT simulation. Take care of deactivating this signal adapter
when you simulate with SIMIT!
© Siemens AG 2020 All rights reserved

Figure 2-6 MCD model overview1

(1) Impression cylinder
(2) Printing cylinder
(3) Anilox cylinder
(4) Motors for cylinder positioning
1 (5) Fixed end stops for printing axes
2 (6) Fixed end stops for anilox axes
3 (7) Printing unit with common sledge
6

5
7

1 Courtesy of Pelican Rotoflex Pvt. Ltd.

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 2 Software setup

Figure 2-7 MCD model overview

(1) Force/torque controller for
the disturbance force
(2) Speed controllers for rotatory
movement of the cylinders
(3) Expression blocks to
calculate the actual torque of
the motors
1 (4) Internal signal adapter for
MCD standalone tests
(5) Signal adapter for additional
signals that need to be
2
exchanged with the SIMIT
simulation
(6) Physic elements for the
cylinders and gantries
3

4
5

6
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2.3.2 Physic elements for printing and anilox cylinder

An overview of the used physical elements for the printing and anilox cylinder can
be seen in Figure 2-9.
In a printing unit, it is necessary to remove the cylinders, e.g. to move the OS and
DS side separately. When the cylinders are installed again in the printing unit, the
linear guiding may have a different position. To model that in the simulation, a
runtime behavior has been created. This runtime behavior is controlled by a signal
in MCD. Depending on that signal, the cylinders are removed or installed. To
remove one cylinder, the runtime behavior disables all rigid and collision bodies as
well as collision sensors of the cylinder. After that, the cylinder will be hidden and
both sides from the guiding can be moved separately. To install the cylinder again,
first the rigid bodies of the cylinder is moved to the new position of the linear
guiding. Then all rigid and collision bodies, as well as collision sensors, are
activated and the cylinder will be shown. On example is shown in Figure 2-8.
Figure 2-8 Disassembly and assembly of the anilox cylinder
(1) Removing anilox cylinder
(2) Moving linear guiding to the left
(3) Installing anilox cylinder at new position
1 2 3

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 2 Software setup

Figure 2-9 Physic elements for one cylinder

(1) Physic elements for gantry
mounted cylinders
(2) Speed controllers for motor
shafts (controlled by the
PLC)
(3) Runtime behavior for
removing and installing the
cylinder

3
© Siemens AG 2020 All rights reserved

2.3.3 Changing mechanical properties of the printing unit

A printing unit can be used with different printing cylinders for different printing
formats. Furthermore, the model should allow a flexible simulation with different
mechanical setups. Therefore, the MCD model can be changed easily using
expressions. Table 2-1 shows the prepared parameters.

Table 2-1 Mechanical parameters in expressions

Name Default Comment
CircumferencePrintingCylinder 1200 mm Circumference of PC incl. printing plate
RectDistanceAXPC 0 mm Rectangular distance from center AX to
center PC
RectDistanceICPC 0 mm Rectangular distance from center IC to
center PC
ThicknessPrintingPlate 5 mm Thickness of the printing plate

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 2 Software setup

In order to change those parameters, open “Expressions” in the “Tools” tab:

Figure 2-10 Open Expressions

Choose to just view named expressions:

Figure 2-11 Visibility of expressions

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To change the expressions, put in new values and click “Apply”:

Figure 2-12 Changing mechanics using expressions

2
3

3 1 2

NOTE Changing the mechanics in NX MCD is not possible during simulation! If you are
running your simulation via SIMIT and you want to change the mechanical
properties of the MCD model, you need to stop the simulation in SIMIT. After
that, open the NX MCD files in NX, change the mechanics, save the data and
start the simulation again!

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 3 Operating the digital twin

3 Operating the digital twin

3.1 Starting the simulation
After download of the project files the MCD coupling needs to be adjusted (chapter
2.2.2).
The simulation will be started by clicking on the "Start/Play" button. An orange
background indicates that the simulation is active. The PLCSIM Advanced
instance2 (in the background) and NX MCD3 are started automatically. After the
simulation is started, it is possible to download the TIA project. This is not inevitably
necessary since the memory card of the PLCSIM Advanced instance will be saved
within the SIMIT project.

Figure 3-1 Starting the simulation in SIMIT

3.2 Controlling the simulation

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The example application will be controlled using the watchtable “CylPos_Control”.

Therefore, go online in TIA Portal and activate monitoring in this watchtable.
A table with the necessary enumerators can be found in the manual for SIMATIC
Print Standard Add-On “Cylinder Positioning”.

3.2.1 Homing

SIMIT is simulating absolute encoders. Therefore, homing is just necessary once

and not after each simulation start. Table 3-1 shows the sequence for homing:
seq

2 If you want to see the instance of your virtual PLC, please additionally start PLCSIM Advanced
3 The simulation in NX MCD is automatically activated

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 3 Operating the digital twin

Table 3-1 Homing sequence

Screenshots Description
1. Remove both cylinders
via the SIMIT chart
“Mechanics”

2. If the absolute
encoders are not
homed yet, crash
errors may be active
(1) and error messages
for the axes indicate
that the axes are not
referenced (2).

1
© Siemens AG 2020 All rights reserved

3. Start the homing

process for all four
axes (one by one!):
Modify “In.Mode” with
values
• 13: Homing AXOS
• 14: Homing AXDS
• 15: Homing PCOS
• 16: Homing PCDS
A mode change can be
done, if
Out.ModeAct = 0 or
output Out.Mode.
HomingDoneXXYY got
TRUE.

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 3 Operating the digital twin

Screenshots Description
4. The axis will first move
to the fixed end stop
and will return to the
final position after
homing.
After homing, all
CrashErrors are gone.
The error message of
all axes is still
alignment error (1).
This message must be
quit by using the
modes for alignment
1
correction. Modify
In.Mode with the
values 17 and 18 for
alignment correction
(2).
5. The error messages for
all axes indicate
MotionIn is not active
(1) and the collective
error bit is false (2).
© Siemens AG 2020 All rights reserved

6. Install both cylinders

via the SIMIT chart
“Mechanics”

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 3 Operating the digital twin

3.2.2 Controlling printing positions

Table 3-2 shows the sequence for going through the different printing positions.

Table 3-2 Printing positions sequence

Screenshots Description
1. In order to move
through the different
printing positions, the
global error bit needs
to be FALSE (1) and
the error messages of
the axes should show
either 0 (No error), or
102 (MotionIn is not
1 active) (2).

2. Go to passive position:
Change In.Mode to 7
(1).
© Siemens AG 2020 All rights reserved

2 The axes move to

passive position
immediately.
If the positioning is
ready, the output
Out.Mode.
PassivePosDone =
TRUE and
Out.ModeAct = 0 (2).

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 3 Operating the digital twin

Screenshots Description
3. Go to print position:
Change In.Mode to 8
(1).

2 The axes move to print

position immediately.
If the positioning is
ready, the output
Out.Mode.
PrintPosDone = TRUE
and
Out.ModeAct = 0 (2).

Furthermore, the
output
Out.FastMode.
PrintOffDone = TRUE.

Because Out.Mode.
PrintPosDone = TRUE,
now FastModes can be
chosen!
4. The precondition for
© Siemens AG 2020 All rights reserved

the fast mode is:

In.Mode = 8
and the output
Out.Mode.
PrintPosDone = TRUE
This is accomplished
now!

Now you can choose a

fast mode at
In.FastMode:

e.g. Inking:
In.FastMode = 3.

3.2.3 Contact pressure simulation

A simplified contact pressure simulation is implemented in SIMIT and MCD

(chapter 2.2.1). Depending on the configuration in the cylinder positioning
application, the anilox and impression cylinder move into the printing plate. The
resulting torque profile can be traced in TIA Portal. In Figure 3-2 you may
recognize on trace 1 the small amplitudes of the torque profile caused by the
acceleration and deceleration of the positioning axis. In trace 2, you can see the
rising torque starting at 300 ms. That is mainly caused by the contact pressure
simulation for the increasingly overlapping cylinders.
Additional information for the contact pressure settings can be found in the manual
for SIMATIC Print Standard Add-On “Cylinder Positioning”.

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 3 Operating the digital twin

Figure 3-2 Torque trace with different contact pressure settings

(1) ContactPressure.AXtoPC.Cyl = 0.0
(2) ContactPressure.AXtoPC.Cyl = 2.0

1 2
© Siemens AG 2020 All rights reserved

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 4 Appendix

4 Appendix
4.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks:
support.industry.siemens.com

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts. Please send queries
to Technical Support via Web form:
www.siemens.com/industry/supportrequest
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SITRAIN – Training for Industry

We support you with our globally available training courses for industry with
practical experience, innovative learning methods and a concept that’s tailored to
the customer’s specific needs.
For more information on our offered trainings and courses, as well as their
locations and dates, refer to our web page:
www.siemens.com/sitrain

Service offer
Our range of services includes the following:
• Plant data services
• Spare parts services
• Repair services
• On-site and maintenance services
• Retrofitting and modernization services
• Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
support.industry.siemens.com/cs/sc

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for Apple iOS, Android and Windows
Phone:
support.industry.siemens.com/cs/ww/en/sc/2067

MCD/SIMIT model for cylinder positioning

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 4 Appendix

4.2 Application support

Siemens AG
Digital Industries
Factory Automation
Production Machines
DI FA PMA APC
Frauenauracher Str. 80
91056 Erlangen, Germany
mailto: [email protected]

4.3 Links and literature

Table 4-1
No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Link to this entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/109775424
\3\ Description of the SIMATIC Print Standard functionality
© Siemens AG 2020 All rights reserved

https://support.industry.siemens.com/cs/de/de/view/109762435.
\4\ Basics of TIA Portal configuration
https://support.industry.siemens.com/cs/ww/en/view/109764516
\5\ Basics of SIMIT:
https://support.industry.siemens.com/cs/ww/en/view/109772278
\6\ Basics of NX MCD:
https://www.plm.automation.siemens.com/global/en/support/docs.html
\7\ Basics of Virtual Commissioning
https://support.industry.siemens.com/cs/ww/en/view/109758943

4.4 Change documentation

Table 4-2
Version Date Modifications
V1.0 01/2020 First version

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