Preface

Fundamental safety
instructions 1
Part I - Synchronous
Operation 2
SIMOTION Part II - Distributed
Synchronous Operation 3
Motion Control Part III - Synchronous
Technology Objects Synchronous operation across multiple 4
cycles
Operation, Cam

Function Manual Part IV - Cam 5

Valid as of Version 4.4

04/2014
Legal information
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This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
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indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.

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NOTICE
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If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
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The product/system described in this documentation may be operated only by personnel qualified for the specific
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Preface

Preface
This document is part of the System and Function Descriptions documentation package.

Scope
This manual is valid for the following versions:
● SIMOTION SCOUT V4.4,
● SIMOTION Kernel V4.4, V4.3, V4.2, V4.1, V4.0, V3.2, V3.1 or V3.0
● SIMOTION technology packages Cam, Cam_ext/Path (as of Kernel V3.2) and TControl in
the version for the respective kernel (including technology packages Gear, Position and
Basic MC up to Kernel V3.0).

Chapters in this manual

The following is a list of chapters included in this manual along with a description of the
information presented in each chapter.
● Synchronous Operation (Page 13) (Part I)
Function of the synchronous operation, i.e. the grouping of a master object and a following
axis
● Distributed Synchronous Operation (Page 151) (Part II)
Function of the distributed synchronous operation, i.e. synchronous operation across
different controllers
● Synchronous Operation IPO - IPO_2 (Page 217) (Part III)
Function of the synchronous operation with master object and following axis in different
interpolator cycle clocks (IPO or IPO_2)
● Cam (Page 225) (Part IV)
Function of the Cam technology object
● Index
Keyword index for locating information

SIMOTION Documentation
An overview of the SIMOTION documentation can be found in the SIMOTION Documentation
Overview document.
This documentation is included as electronic documentation in the scope of delivery of
SIMOTION SCOUT. It comprises ten documentation packages.
The following documentation packages are available for SIMOTION V4.4:
● SIMOTION Engineering System Handling
● SIMOTION System and Function Descriptions

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Function Manual, 04/2014 3
Preface

● SIMOTION Service and Diagnostics

● SIMOTION IT
● SIMOTION Programming
● SIMOTION Programming - References
● SIMOTION C
● SIMOTION P
● SIMOTION D
● SIMOTION Supplementary Documentation

Hotline and Internet addresses

Additional information
Click the following link to find information on the the following topics:
● Ordering documentation / overview of documentation
● Additional links to download documents
● Using documentation online (find and search manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
[email protected]

My Documentation Manager
Click the following link for information on how to compile documentation individually on the
basis of Siemens content and how to adapt it for the purpose of your own machine
documentation:
http://www.siemens.com/mdm

Training
Click the following link for information on SITRAIN - Siemens training courses for automation
products, systems and solutions:
http://www.siemens.com/sitrain

FAQs
Frequently Asked Questions can be found in SIMOTION Utilities & Applications, which are
included in the scope of delivery of SIMOTION SCOUT, and in the Service&Support pages
in Product Support:
http://support.automation.siemens.com

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4 Function Manual, 04/2014
 Preface

Technical support
Country-specific telephone numbers for technical support are provided on the Internet under
Contact:
http://www.siemens.com/automation/service&support

Technology Objects Synchronous Operation, Cam

Function Manual, 04/2014 5
Table of contents

Preface.........................................................................................................................................................3
1 Fundamental safety instructions.................................................................................................................11
1.1 General safety instructions..........................................................................................................11
1.2 Industrial security........................................................................................................................12
2 Part I - Synchronous Operation..................................................................................................................13
2.1 Overview of synchronous operation............................................................................................13
2.2 Fundamentals of Synchronous Operation...................................................................................20
2.2.1 Gearing........................................................................................................................................20
2.2.2 Velocity gearing...........................................................................................................................26
2.2.3 Camming.....................................................................................................................................27
2.2.4 Setpoint/actual value coupling.....................................................................................................36
2.2.4.1 Actual value coupling with extrapolation.....................................................................................37
2.2.4.2 Actual value coupling with tolerance window..............................................................................40
2.2.5 Synchronization...........................................................................................................................41
2.2.5.1 Synchronization criterion.............................................................................................................43
2.2.5.2 Synchronization direction............................................................................................................47
2.2.5.3 Position of synchronization range relative to synchronization position.......................................48
2.2.5.4 Synchronization via a specifiable master value distance............................................................49
2.2.5.5 Synchronization profile................................................................................................................50
2.2.5.6 Settings for evaluation of the master value behavior during synchronization.............................55
2.2.5.7 Monitoring the synchronization....................................................................................................59
2.2.5.8 Display of the synchronous position............................................................................................61
2.2.5.9 “Synchronous” status during synchronization.............................................................................63
2.2.6 Desynchronization.......................................................................................................................64
2.2.6.1 Desynchronization - Overview.....................................................................................................64
2.2.6.2 Desynchronization criterion/desynchronization position..............................................................64
2.2.6.3 Desynchronization over a specifiable master value distance......................................................65
2.2.6.4 Desynchronization profile via specifiable dynamic response parameters...................................65
2.2.6.5 Position of synchronization range relative to desynchronization position...................................65
2.2.6.6 Replacement of an active synchronous operation......................................................................65
2.2.7 Dynamic response effect on slave values...................................................................................66
2.2.8 Switching of the master value source..........................................................................................68
2.2.8.1 Switching over the master value source – Overview...................................................................68
2.2.8.2 Master value switchover without dynamic response...................................................................69
2.2.8.3 Master value switchover with dynamic response........................................................................69
2.2.8.4 Master value switchover with next synchronization (V4.1 and higher)........................................70
2.2.9 Superimposed synchronous operation........................................................................................71
2.2.10 Synchronous operation monitoring..............................................................................................75
2.2.11 Simulation mode..........................................................................................................................78
2.2.12 Configuring units.........................................................................................................................79
2.2.13 Examples of synchronization operations as a function of the output position on the slave
value side....................................................................................................................................81
2.2.13.1 Synchronization via a specifiable master value distance............................................................81

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Table of contents

2.2.13.2 Synchronization profile based on specifiable dynamic response parameters.............................83

2.2.14 Examples.....................................................................................................................................87
2.2.14.1 Examples of typical synchronization operations..........................................................................87
2.2.14.2 Example of offset and scale on the synchronous object.............................................................98
2.2.14.3 Example of applying offset as superimposition.........................................................................101
2.2.15 Special actions..........................................................................................................................104
2.2.15.1 Redefining the axis position during active synchronous operation...........................................104
2.2.15.2 Retaining a synchronous connection for _disableAxis..............................................................105
2.2.15.3 Substitution of velocity gearing with absolute synchronous operation......................................106
2.2.15.4 Motion with absolute synchronous operation............................................................................107
2.2.15.5 Canceling active and pending synchronous operations............................................................107
2.2.15.6 Adapt the synchronization velocity to the master value velocity ..............................................107
2.2.15.7 Substitution of synchronous operation through _move, _pos, _stop with reset of an existing
acceleration to zero...................................................................................................................109
2.3 Synchronous Operation Configuration......................................................................................111
2.3.1 Creating an axis with synchronous operation............................................................................112
2.3.2 Assigning master values and cams...........................................................................................113
2.3.3 Assigning parameters/defaults for synchronous operation.......................................................115
2.3.3.1 Gearing......................................................................................................................................117
2.3.3.2 Velocity gearing.........................................................................................................................118
2.3.3.3 Camming...................................................................................................................................119
2.3.3.4 Gearing synchronization............................................................................................................121
2.3.3.5 Synchronizing the gear..............................................................................................................122
2.3.3.6 Position reference during synchronization................................................................................123
2.3.3.7 Desynchronizing the gear..........................................................................................................124
2.3.3.8 Position reference during desynchronization............................................................................124
2.3.3.9 Camming synchronization.........................................................................................................125
2.3.3.10 Cam synchronization.................................................................................................................126
2.3.3.11 Cam desynchronization.............................................................................................................127
2.3.3.12 Dynamic response.....................................................................................................................128
2.3.3.13 Master dynamic response.........................................................................................................130
2.3.4 Set synchronization...................................................................................................................132
2.3.5 Configuring synchronous operation monitoring.........................................................................134
2.4 Synchronous Operation Programming/References...................................................................136
2.4.1 Overview of commands.............................................................................................................136
2.4.1.1 Commands for reading out function values...............................................................................138
2.4.1.2 Commands for command tracking............................................................................................139
2.4.1.3 Commands for resetting states and errors................................................................................141
2.4.2 Command processing...............................................................................................................141
2.4.2.1 Command execution.................................................................................................................141
2.4.2.2 Command transition conditions.................................................................................................144
2.4.3 Error handling............................................................................................................................146
2.4.3.1 Local alarm reaction on the synchronous object.......................................................................146
2.4.3.2 Local alarm reaction of the following axis and its mutual effects with the synchronous object....146
2.4.3.3 Error handling in the user program............................................................................................148
2.4.4 Menus........................................................................................................................................149
2.4.4.1 Synchronous Operation - Menu................................................................................................149
2.4.4.2 Synchronous Operation - Context Menu...................................................................................150
3 Part II - Distributed Synchronous Operation.............................................................................................151
3.1 Overview of distributed synchronous operation........................................................................151

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 Table of contents

3.2 Fundamentals of Distributed Synchronous Operation...............................................................153

3.2.1 Boundary Conditions.................................................................................................................153
3.2.1.1 Rules for the communication/topology for distributed operation using PROFIBUS..................153
3.2.1.2 Rules for the communication/topology for the distribution using PROFINET IO with IRT
(V4.0 or later)............................................................................................................................159
3.2.2 Compensations for distributed synchronous operation.............................................................159
3.2.2.1 Compensation on master value side by means of setpoint output delay..................................162
3.2.2.2 Compensation of the slave value side by means of master value extrapolation.......................164
3.2.2.3 Permissible combinations for cycle clock offset compensation in distributed synchronous
operation...................................................................................................................................165
3.2.2.4 Cycle clock offset calculation using a command.......................................................................166
3.2.3 Operating axes with distributed synchronous operation............................................................166
3.2.3.1 Sign-of-life monitoring...............................................................................................................166
3.2.3.2 Operating states........................................................................................................................168
3.3 Distributed Synchronous Operation Configuration....................................................................170
3.3.1 Creating SIMOTION devices with SCOUT................................................................................170
3.3.2 Creating connections with HW Config.......................................................................................170
3.3.3 Creating synchronous operation connections with SCOUT......................................................172
3.3.4 Generating a synchronous operation configuration...................................................................175
3.3.5 Possible error............................................................................................................................175
3.4 Programming distributed synchronous operation......................................................................177
3.4.1 Synchronizing the interfaces.....................................................................................................177
3.4.2 Synchronous commands...........................................................................................................177
3.5 Configuring distributed synchronous operation across projects................................................179
3.5.1 Overview...................................................................................................................................179
3.5.2 PROFIBUS communication configuration.................................................................................181
3.5.2.1 Communication via PROFIBUS DP..........................................................................................181
3.5.2.2 Creating and configuring a "synchronized axis" project............................................................181
3.5.2.3 Creating and configuring a "master object" project...................................................................189
3.5.3 Communication configuration via PROFINET IO......................................................................193
3.5.3.1 Communication via PROFINET IO............................................................................................193
3.5.3.2 Creating and configuring "Synchronous axis" project on SIMOTION D455-2...........................194
3.5.3.3 Creating and configuring "Master Object" project on SIMOTION D455-2.................................200
3.5.4 Proxy objects.............................................................................................................................206
3.5.4.1 Proxy object types.....................................................................................................................206
3.5.4.2 Creating proxy objects...............................................................................................................206
3.5.4.3 Configuring proxy objects with SIMOTION scripting.................................................................211
3.5.5 Interconnection possibilities......................................................................................................213
3.5.6 Synchronizing the interface.......................................................................................................215
3.5.7 Switching over to an external master value source...................................................................215
4 Part III - Synchronous operation across multiple cycles...........................................................................217
4.1 Overview of multiple cycle synchronous operation...................................................................217
4.2 Boundary conditions..................................................................................................................219
4.3 Running synchronous operation across multiple cycles ...........................................................221
4.4 Creating synchronous operation across multiple cycles in SCOUT.........................................223
5 Part IV - Cam............................................................................................................................................225
5.1 Overview of cam........................................................................................................................225

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Table of contents

5.2 Fundamentals of Cam...............................................................................................................227

5.2.1 Definition...................................................................................................................................227
5.2.2 Normalization............................................................................................................................228
5.2.3 Scaling and offset......................................................................................................................229
5.2.4 Interpolation...............................................................................................................................231
5.2.5 Inversion....................................................................................................................................235
5.2.6 Motion laws in accordance with VDI..........................................................................................236
5.2.6.1 Motion tasks..............................................................................................................................237
5.2.6.2 Defining a cam for a motion task using segments.....................................................................239
5.3 Cam Configuration....................................................................................................................240
5.3.1 Creating a cam..........................................................................................................................240
5.3.2 Exporting/importing cams..........................................................................................................241
5.3.3 Defining and loading cams........................................................................................................241
5.4 Cam Programming/References.................................................................................................243
5.4.1 Commands for definition...........................................................................................................243
5.4.2 Commands for reading out function values...............................................................................245
5.4.3 Commands for resetting the cam and errors.............................................................................246
5.4.4 Commands for command tracking............................................................................................247
5.4.5 Programming and sequence model..........................................................................................248
5.4.6 Local alarm response................................................................................................................248
5.5 Graphic output...........................................................................................................................249
5.5.1 Reading out cams with CamEdit...............................................................................................249
Index.........................................................................................................................................................251

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10 Function Manual, 04/2014
Fundamental safety instructions 1
1.1 General safety instructions

WARNING
Risk of death if the safety instructions and remaining risks are not carefully observed
If the safety instructions and residual risks are not observed in the associated hardware
documentation, accidents involving severe injuries or death can occur.
● Observe the safety instructions given in the hardware documentation.
● Consider the residual risks for the risk evaluation.

WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed
parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in
turn can lead to injuries or death.
● Protect the parameterization (parameter assignments) against unauthorized access.
● Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY
STOP or EMERGENCY OFF).

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Function Manual, 04/2014 11
Fundamental safety instructions
1.2 Industrial security

1.2 Industrial security

Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly
that you regularly check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state-of-the-art industrial security concept. Third-party products that may be in use should
also be considered. For more information about industrial security, visit http://
www.siemens.com/industrialsecurity.
To stay informed about product updates as they occur, sign up for a product-specific
newsletter. For more information, visit http://support.automation.siemens.com

WARNING
Danger as a result of unsafe operating states resulting from software manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can lead to death, severe injuries and/
or material damage.
● Keep the software up to date.
Information and newsletters can be found at:
http://support.automation.siemens.com
● Incorporate the automation and drive components into a state-of-the-art, integrated
industrial security concept for the installation or machine.
For more detailed information, go to:
http://www.siemens.com/industrialsecurity
● Make sure that you include all installed products into the integrated industrial security
concept.

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12 Function Manual, 04/2014
Part I - Synchronous Operation 2
2.1 Overview of synchronous operation

This part describes the function of the synchronous operation technology. It introduces you to
the setting and configuration functions, as well as providing information about the
supplementary conditions and the operating characteristics of synchronous objects.

What is synchronous operation used for?

Synchronous operation functions are taking on an increasingly significant role in automation
engineering. The progress in open-loop and closed-loop control engineering and the
availability of increasingly more powerful systems mean that solely mechanical solutions are
more and more frequently being replaced with "electronic" variants.
The synchronous operation functions of the SIMOTION technology provide the option of
replacing rigid mechanical connections with "control engineering", thus producing more
flexible, maintenance-friendly solutions.

What is synchronous operation in SIMOTION?

The synchronous operation functionality of axes is provided by the synchronous object. A
leading object (master) generates a master value, which is processed by the synchronous
object according to specific criteria (gear ratio, scaling, offset, cam) and assigned to the
following axis (slave) as a reference variable.

Mechanical model
The mechanical model for a synchronous operation relationship is, for example, a gear with a
drive wheel and an output wheel. The model for camming could be a cam gear with a
mechanical cam and sampling mechanism. A coupling used for enabling and disabling the
following motion on-the-fly is also used as a model.

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Function Manual, 04/2014 13
Part I - Synchronous Operation
2.1 Overview of synchronous operation

Synchronous operation functions

The following synchronous operation functions can be implemented:
● With gearing (Page 20), a linear transmission function between a master value and a
following axis can be achieved using control engineering, thus producing the same result
as could be achieved mechanically using a gear. A gear ratio can be specified for use in
linear mapping of the master axis position onto the following axis position.
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● With velocity gearing (Page 26), a constant velocity coupling is implemented.

(V3.1 and higher)
● With camming (Page 27), a non-linear transmission function between a master value and
following axis can be achieved. The slave value is generated from the master value using
the transmission function defined in the cam. The cam is defined using interpolation points
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A synchronous operation sequence

Synchronous operation of a following axis to a master value using the SIMOTION synchronous
operation functions is divided into three phases:
● Synchronization
● Synchronized traversing
● Desynchronization
Within these phases, there are several options for influencing the synchronous operation
functions.

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14 Function Manual, 04/2014
 Part I - Synchronous Operation
2.1 Overview of synchronous operation

Synchronization/Desynchronization
The synchronous operation to the master value during synchronization or desynchronization
can be defined differently depending on the application.
It is determined on the basis of:
● The synchronization criterion/synchronization position
● The synchronization direction
● The position of the synchronization range relative to the synchronization position
● Synchronization profile
See the section titled Synchronization (Page 41).

Objects
A synchronous operation relationship exists between the following objects:
● At least one master object (master)
The master object is a technology object that provides motion information with a position
(the motion slave value). This can be, for example, a positioning axis or an external
encoder.
● At least one synchronized axis, comprising:
– A following axis (slave)
– One or two synchronous objects
– Possibly one or more cams
A synchronous object is automatically created as a separate object in SIMOTION SCOUT
when an axis with synchronous operation technology is created.

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Technology Objects Synchronous Operation, Cam

Function Manual, 04/2014 15
Part I - Synchronous Operation
2.1 Overview of synchronous operation

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Master values
The master value can be specified by the following technology objects:
● Axis
● External Encoder
With restrictions (not for distributed synchronous operation or synchronous operation IPO-
IPO_2), the following technology objects can also specify the master value:
● Fixed Gear
● Addition Object
● Formula Object

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16 Function Manual, 04/2014
 Part I - Synchronous Operation
2.1 Overview of synchronous operation

A following axis can be interconnected with more than one master value by means of the
synchronous object. However, only one of these master values can be activated at any given
time. The process of switching over to a different master value is described in the section titled
Switching over the master value source (Page 68).
When axes serve as the master value source, the setpoint coupling or the actual value coupling
with extrapolation can be selected. When external encoders serve as the master value source,
actual value coupling/actual value coupling with extrapolation (V3.0 and higher) can be
selected. See the section titled Setpoint/actual value coupling (Page 36).

Note
A drive axis cannot be used as the master value source for a gearing.

Processing cycle clock of the synchronous object

The processing cycle clock of the synchronous object and the processing cycle clock of the
synchronized axis must be identical.

Note
If you change the processing cycle clock of the synchronized axis using the configuration
screen form, the processing cycle clock of the synchronous object is changed automatically.
If you change the processing cycle clock of the synchronized axis or of the synchronous
object using the expert list, the processing cycle clock of the synchronous object or
synchronized axis is not changed.

Recursive synchronous operation interconnection

A recursive synchronous operation interconnection is present when, in a single synchronous
operation relationship, a synchronized axis is interconnected directly or indirectly again as a
master value via other technology objects. A synchronized axis cannot act as a following axis
to a master value and as a master value for the same axis simultaneously. Recursive
synchronous operation interconnections can result if, for example, a synchronous operation
relationship is to be switched over in the event of an error. Also refer to the section titled Error
handling in the user program (Page 148).

Units
The master and slave values are coupled without physical conversion in the relevant
parameterized units. If, for example, the master axis is a linear axis and the following axis is
a rotary axis, a length unit corresponds to an angular unit (for a 1:1 conversion ratio).

Modulo behavior
Different modulo ranges on the master value object and the following axis are taken into
account on the synchronous object.

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Function Manual, 04/2014 17
Part I - Synchronous Operation
2.1 Overview of synchronous operation

Camming with several cams

Several cams can be used in one camming operation. You can switch over to another cam
dynamically using the _enableCamming() command in the user program.

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Rules for interconnection

To recap, the following rules apply to synchronous operation:
● The synchronous object and following axis must be on the same runtime system
(SIMOTION device).
● The master object and synchronized axis may be in different SIMOTION devices.
Where this applies, reference is made to distributed synchronous operation (Page 151).
● The master object and synchronized axis may operate in different IPO cycles (see
Overview of synchronous operation IPO - IPO_2 (Page 217)).
● The synchronous object and the following axis are permanently assigned to each other
during configuration.
● Up to two synchronous objects may be interconnected with a following axis.
● The master value object may be interconnected with several synchronous objects.
● The synchronous object may be interconnected with several master values and cams.
● A cam may be interconnected with several synchronous objects.

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18 Function Manual, 04/2014
 Part I - Synchronous Operation
2.1 Overview of synchronous operation

Superimposed synchronous operation

In superimposed synchronous operation, two synchronous objects can be connected to one
following axis. The two synchronous operations superimpose one another (V3.0 and higher).

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For additional information, see the section titled Superimposed synchronous operation
(Page 71).

See also
Synchronous Operation Configuration (Page 111)
Synchronous Operation Programming/References (Page 136)

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Function Manual, 04/2014 19
Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

2.2 Fundamentals of Synchronous Operation

2.2.1 Gearing

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Figure 2-8 Gearing

Gearing is characterized by a linear transmission function between the master value source
and the following axis/axes.
Slave value = Gear ratio x Master value + Offset
This gear ratio can be specified as the ratio of two decimal numbers (numerator/denominator)
or as a rational number. A zero point offset can be included in the calculation. Absolute or
relative gearing can be set using the gearingType parameter of the _enableGearing()
command.

Absolute gearing
With absolute gearing (gearingType=ABSOLUTE), the synchronous operation occurs
absolutely relative to the zero point of the master value and slave value, taking into account
the gear ratio.

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Figure 2-9 Sequence of the absolute gearing synchronization (simplified example)

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20 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

A specified offset of the slave value is included. This offset is equal to zero, except when the
synchronization criterion ON_MASTER_AND_SLAVE_POSITION or
IMMEDIATELY_AND_SLAVE_POSITION is set in the syncPositionSlave parameter, in which
case an offset is specified.

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Figure 2-10 Absolute gearing without specification of the slave value position

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Figure 2-11 Absolute gearing with specification of the slave value position

Position differences on the slave value side are compensated for during synchronization.
Modulo settings are taken into account.

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Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

Relative gearing
With relative gearing (gearingType:=RELATIVE), the synchronous operation occurs relative
to the synchronization position on the master value and slave value sides.

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Figure 2-12 Sequence of the relative gearing synchronization (simplified example)

The offset is determined implicitly in the transmission function:

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22 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

● If programmed without a specified offset: The offset is derived from the current position of
the following axis at the start of synchronization and from an offset derived implicitly during
synchronization if the axis is driven to a velocity (and acceleration) derived from the gear
ratio.
● If programmed with a specified offset: Using the synchronization criterion setting
ON_MASTER_AND_SLAVE_POSITION or IMMEDIATELY_AND_SLAVE_POSITION, the
offset is determined from the current following axis position at the start of synchronization
and the offset programmed in syncPositionSlave.
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Figure 2-13 Relative gearing without offset

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Figure 2-14 Relative gearing with offset

From the point at which the status becomes "synchronous", relative gearing is also in positional
synchronism. In other words, the offset remains constant in the transmission function from this
point onwards.

Gear ratio
The gear ratio is used to define the transmission function of the gearing between the master
value and slave value. The gear ratio corresponds to the slope of the transmission function. It

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Function Manual, 04/2014 23
Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

can entered as either a fraction or a floating-point number using the gearingMode parameter
of the _enableGearing() command.
● As a fraction (gearingMode:=GEARING_WITH_FRACTION)
The gear ratio is specified as a fraction (slave value difference/master value difference)
using the following function parameters:
– gearingRatioType: Type of gear ratio specification (directly or via replacement values)
– gearingNumerator: Value for direct specification of the gear ratio numerator
– gearingDenominator: Value for direct specification of the gear ratio denominator
● As a floating-point number (gearingMode=GEARING_WITH_RATIO)
The gear ratio is specified as a floating-point number using the following function
parameters:
– gearingRatioType: Type of gear ratio specification (directly or via replacement values)
– gearingRatio: Value for direct specification of the gear ratio as a floating-point number
Disadvantage: Gear ratios such as 1/3 ≈ 0.333 are subject to rounding errors.
The long-term effect is to be taken into account with modulo axes. If master and slave axes
are configured as modulo axes, to ensure the long-term stability of the gear, the gear ratio is
preferably to be entered as a nominator/denominator ratio. If this is not possible, a LREAL
value with corresponding decimal places should be used.

Direction of gearing
The gear ratio can be set in the same direction or in the opposite direction (corresponding to
a negative gear ratio) using the direction parameter of the _enableGearing command.
● For POSITIVE, traversal is made in the same direction as the master values, this means
that the axes run in the same direction.
● For NEGATIVE, traversal is made in the opposite to master values, this means that the
axes run in the opposite direction.
● With CURRENT, the direction of the current slave values is retained; along with the direction
of the master value; this results in coupling in the same or opposite direction, which is then
maintained for the entire command execution time (that is, if the master value direction
changes, then the slave direction changes as well).
● REVERSE means movement in the inverse direction of the slave values.
If the slave values are at a standstill at the point at which the command is activated, the
following conversion is performed: CURRENT becomes POSITIVE and REVERSE becomes
NEGATIVE.

Change in the offset

The activationMode parameter of the _setGearingOffset() command specifies when the offset
takes effect. (V3.1 and higher)
The changeover applies as follows:

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24 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

● For the next synchronous operation and all subsequent synchronous operations if
DEFAULT_VALUE is set
● For the current synchronous operation only if ACTUAL_VALUE is set
● For the current synchronous operation and all subsequent synchronous operations if
ACTUAL_AND_DEFAULT_VALUE is set
Note the following:
● If the synchronization operation of the _enableGearing() command is not yet active, the
current offset is carried out without compensation, that is, it is figured in directly.
● If the _setGearingOffset() command is programmed to current values during
synchronization, the offset does not take effect until after synchronization. A compensating
movement takes place.

Apply offset as superimposition

The dynamicReference parameter of the _setGearingOffset command can be used to specify
whether the dynamic parameters refer to the total motion or the motion difference (V3.2 and
higher).
● TOTAL_MOVE: Dynamic response parameters refer to the total motion. (Default setting)
The transition process is determined entirely on the basis of the offset values and the
dynamic response parameters.
● OFFSET_MOVE: Dynamic response parameters refer to the motion difference.
The transition process is determined on the basis of the current synchronous operation
definition as superimposed motion with the specified dynamic values.

Note
With a constant master value velocity, the dynamic transitions have a similar form and
differ as a result of the dynamic response parameters that act differently.

See also
Example of applying offset as superimposition (Page 101)

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Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

2.2.2 Velocity gearing

Slave value velocity

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Figure 2-15 Velocity gearing

In contrast to gearing or camming, which relate to the position of an axis, synchronous velocity
operation (V3.1 and higher) relates to the velocity of an axis. A velocity setpoint is calculated
for the following axis. After activation, the axis travels immediately at the specified acceleration
to the synchronous operation velocity. A linear transmission function is implemented.
The gear ratio can be specified as a positive floating-point number.
The gear ratio can be set in the same direction or in the opposite direction (corresponding to
a negative gear ratio) using the direction parameter of the _enableVelocityGearing()
command.
● POSITIVE means that the axes are running in the same direction.
● NEGATIVE means that the axes are running in opposite directions.

See also
Substitution of velocity gearing with absolute synchronous operation (Page 106)

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26 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

2.2.3 Camming

Description

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Figure 2-16 Camming

With camming, a non-linear transmission function between the master value position and
following axis position is implemented using a cam .
See Cam, Definition (Page 227)

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Figure 2-17 Example of transmission function for camming

The cam can be applied as an absolute cam or as a relative cam in both the definition range
(master values) and the value range (slave values). The setting is made for the master values
in the masterMode parameter and for the slave values in the slaveMode parameter of the
_enableCamming() command.
The figure below compares the relationship between the master value and slave value with
the following supplementary conditions:

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Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

● Same cam: here, with definition range {0.0, 300.0}

and value range {0.0, 100.0}
● Same initial value of following axis: here, 150 mm
● Same initial value of master value: here, 450 mm
(master value is modulo value 0 to 1000 mm)

 

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Figure 2-18 Possible combinations of absolute/relative camming on the master/slave value side

Absolute camming on the slave value side

Absolute camming on the slave value side is set in slave Mode:=ABSOLUTE. With absolute
camming on the slave value side, the slave values are taken directly from the value range of
the cam. The offset on the slave value side is equal to zero, except when the synchronization
criterion ON_MASTER_AND_SLAVE_POSITION or
IMMEDIATELY_AND_SLAVE_POSITION is set in the syncPositionSlave parameter, in which
case an offset is specified. (Case 3 and 4 in Figure Possible combinations of absolute/relative
camming on the master/slave value side).

Relative camming on the slave value side

Relative camming on the slave value side is set in slaveMode:=RELATIVE. With relative
camming in slave mode, the initial value of the cam is offset to the slave value position at the
start of synchronization (case 1 and 2 in Figure Possible combinations of absolute/relative
camming on the master/slave value side).
The offset on the slave value side is determined as follows:

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28 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

● If programming is performed without a specified offset, the offset is determined from the
offset of the cam initial value to the slave value position at the start of synchronization
● If programming is performed with a specified offset in the synchronization criterion setting
ON_MASTER_AND_SLAVE_POSITION or IMMEDIATELY_AND_SLAVE_POSITION, the
offset is determined from the offset of the cam initial value to the slave value position at the
start of synchronization plus the offset programmed in the syncPositionSlave parameter.
From the point at which the status becomes "synchronous", the offset on the slave value side
remains constant in the transmission function.
In V4.2 and higher, there is new configuration data element
syncingMotion.camReferenceBySlaveModeRelative with the following settings:
● Effectiveness in the case of relative camming on the slave value side and
– on the absolute master value side with and without master value offset or
– relative master value side with master value offset
● BEGIN_OF_CAM is based on the current following axis position to the initial cam value.
During the synchronization, the following axis also covers the path differential between the
start of the cam and the cam start value if this is not offset by a following value offset.


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● POSITION_AT_START_OF_CAMMING is based on the current following axis position to

the starting point of the synchronization within the cam. The difference between the slave-
side starting point and the initial cam value does not have to be specified in the slave-value
offset.
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Function Manual, 04/2014 29
Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

● In projects upgraded from < V4.2 to >= V4.2, the configuration data is set to
COMPATIBILITY_MODE. This corresponds to
SYNCPOSITION_AT_START_OF_CAMMING for synchronization at a standstill and
BEGIN_OF_CAM with moving following axis or moving master value.
● When creating a new project as of V4.2,
syncingMotion.camReferenceBySlaveModeRelative:=BEGIN_OF_CAM is set.

Absolute camming on the master value side

Absolute camming on the master value side is set in masterMode:=ABSOLUTE. With
ABSOLUTE, the master values are used as absolute values in the definition range of the cam.

Relative camming on the master value side

Relative camming on the master value side is set in masterMode:=RELATIVE. With relative
camming on the master value side, the synchronization position on the master value side is
assigned to the position within the cam definition range specified in the
camStartPositionMaster parameter. The offset on the master value side is determined from
the difference between the synchronization position on the master value side and the value
specified in the camStartPositionMaster parameter.
If the position specified in camStartPositionMaster is not within the definition range of the cam,
alarm "40017 Cam starting point is outside the definition range" is generated. From the point
at which the status becomes "synchronous", the offset on the master value side remains
constant in the transmission function.

Loading a new camming

A new cam is loaded by a recalling an _enableCamming command. Using the
synchronizingMode parameter, the synchronization criterion is specified (e.g. at the end of the
current camming with AT_THE_END_OF_CAM_CYCLE).
If the transition from the old cam to the new cam is already smooth, the synchronization
parameters should be selected in such a way that either the synchronization length is very
small for master value reference or the dynamics are very high for the forward time reference
or, alternatively, use the synchronization profile with backward time reference.

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30 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

Non-cyclic/cyclic cam application

The cammingMode parameter of the _enableCamming() command can be used to set the cam
for either a non-cyclic application or a cyclic application.

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Figure 2-19 Non-cyclic cam application

● Non-cyclic (NOCYCLIC) means that the cam is applied exactly once in the defined master
value range. When the end point or starting point of the cam is reached, the cam terminates
itself.
If the master value range is run through again either in the same direction or, after reversing,
in the opposite direction, the cam is not applied again.
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Figure 2-20 Cyclic cam application

● With the cyclic (CYCLIC) application of a cam, the definition range of the cam is mapped
cyclically onto the master values.
If the master values reverse, the cam is also continued cyclically beyond the original starting
point.

Cyclic application of a cam with absolute synchronous operation on the slave value side

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Figure 2-21 Cyclic absolute cam application with equal initial and end values on the slave value side

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Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

● If the function values of the cam are equal at the start and end of the definition range of the
cam, the motion can be continued smoothly.
This produces a periodic motion.
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● If the function values of the cam are not equal at the start and end of its definition range,
this results in a discontinuity in the position.
This is limited on the following axis to the maximum dynamic values.
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Figure 2-23 Example of cyclic cam application with identical start and end values

● If the function value of the cam is not identical, or equal in terms of a modulo relationship,
at the start and end of its definition range, the new starting point of the cam is the end point
of the executed cam.
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Figure 2-24 Example of cyclic cam application with different start and end values - relative

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32 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

Cam direction
The direction parameter of the _enableCamming command can be used to set the cam in a
positive or negative direction.
● POSITIVE means in the same direction. Increasing master values correspond to increasing
values in the definition range of the cam, and vice versa.
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Figure 2-25 Positive cam application (POSITIVE)

● NEGATIVE means in the opposite direction. Decreasing master values correspond to

increasing values in the cam definition range, and vice versa.
The cam is mirrored at the center of its definition range.
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Figure 2-26 Negative cam application (NEGATIVE)

Example application:
The aim is to use the same cam for deceleration as for acceleration, but in the opposite
direction.

Correction of camming motions

Synchronous motions can be corrected by changing the scaling and offset of the master value
and the slave value.
Other options include:
● Offset and scaling on the cam itself
● Superimposed motions on the following axis
● On-the-fly setting of the reference point on the leading value source and the following axis

Scaling and offset

The scaling and offset can be specified on the synchronous object for camming on both the
master value side and slave value side.
The slave value is determined from the master value using the following equation:

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Function Manual, 04/2014 33
Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

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Figure 2-27 Equation for scale and offset on the camming

See also Example of offset and scaling on the synchronous object (Page 98)

Scaling/offset on the cam

In addition to the option of the scaling/offset on the synchronous object, a scaling/offset is also
possible on the cam. This enables a cam to be custom-adjusted in its definition range and
value range.
See Scaling and offset (Page 229)

Changing the scaling and offset

The _setCammingScale() and _setCammingOffset() commands can be used to switch the
scaling and offset within active, cyclic camming. The activationMode parameter determines
when these take effect:
● For the next camming operation and all subsequent operations if DEFAULT_VALUE is set
● For the current camming operation only, if ACTUAL_VALUE is set
● For the current camming operation and all subsequent operations if
ACTUAL_AND_DEFAULT_VALUE is set
Note the following:
● If synchronization of the _enableCamming() command is not yet active, the current scaling/
offset is carried out without compensation; that is, it is included directly.
● If the _setCammingScale()/_setCammingOffset() command is programmed with new
values during synchronization (using the ACTUAL_VALUE setting), the scaling/offset only
becomes active after synchronization. A compensating movement takes place.

Effectiveness of scaling and offset

The scaleSpecification/offsetSpecification parameter of the _setCammingScale() or
_setCammingOffset() command is used to program the effectiveness of a new scaling or offset
procedure.
● With immediate effect (IMMEDIATELY)
● At the start of a new cycle for a cyclic cam application (NEXT_CAM_CYCLE)
Comment: If a _setCammingScale()/_setCammingOffset() command is canceled during the
compensating movement due to another _setCammingScale()/_setCammingOffset()
command with NEXT_CAM_CYCLE, compensation is canceled and a jump in the setpoints
can occur. The new command is enabled at the beginning of the new cam cycle.

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34 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

Examples

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activationMode:=DEFAULT_VALUE; effective: scaleSpecification:=NEXT_CAM_CYCLE

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activationMode:=ACTUAL_VALUE; effective: scaleSpecification:=IMMEDIATELY

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ACTUAL_AND_DEFAULT_VALUE setting with effectiveness IMMEDIATELY

Applying scaling/offset as superimposition

The dynamicReference parameter of the _setCammingScale() or _setCammingOffset()
command can be used to specify whether the dynamic parameters refer to the total motion or
the motion difference (V3.2 and higher).
See Apply offset as superimposition at Gearing (Page 20).

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Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

See also
Display of the synchronous position (Page 61)

2.2.4 Setpoint/actual value coupling

Overview
When an axis is used as a master value object, the following can be configured for the
synchronous operation:
● Setpoint coupling: The setpoint of the axis is used as the master value for the following axis.
This is advantageous if the control specifies the setpoints for both the master axis and
following axis, and the axes are to behave synchronously in relation to one another. In
general, setpoint coupling is recommended for purposes of signal quality.
● Actual value coupling with extrapolation (V3.0 and higher): The actual value of an axis is
used as the master value for the following axis.
The actual value can be extrapolated in order to compensate for delays caused by actual
value acquisition, actual/master value processing in the control, and the dynamic follow-up
response of the following axis. Since the actual values are equal to the setpoints for the
virtual axis, an extrapolated setpoint can be set.
When an external encoder is used as a master value object, the following can be configured
for the synchronous operation:
● Actual value coupling: The actual value of an external encoder is used as the master value
for the following axis.
● Actual value coupling with extrapolation (V3.0 and higher): The actual value can be
extrapolated in order to compensate for delay times caused by actual value acquisition,
actual/master value processing in the control, and the dynamic follow-up response of the
following axis.
A tolerance window with respect to the actual value behavior can be specified for the actual
value coupling.

Note
If the actual values/setpoints are required to be equal during a synchronous operation, the
same Ti (actual value acquisition)/To (setpoint acceptance) times must be adopted for all
drive units used (e.g. SINAMICS_Integrated, CU320).

See also
Actual value coupling with tolerance window (Page 40)

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36 Function Manual, 04/2014
 Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

2.2.4.1 Actual value coupling with extrapolation

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For a synchronized group with actual value coupling (e.g. master value is the actual encoder
value of an axis or an external encoder), the associated principle means delay times result
because of bus communication, system cycle clocks and clock-pulse scaling, fine interpolation,
position setpoint filters, and controller settings. These times can be compensated for using an
extrapolation.
Extrapolation means you know the history and are looking into the future (extrapolation time).
The extrapolation time should be as short as possible for dynamic master value changes. An
IPO : Servo pulse duty factor of 1:1 is good.
If an actual encoder value is assumed as the master value, it is useful to extrapolate the
measured actual value for the synchronous operation in order to compensate for dead times
that result within the system when acquiring actual values, e.g. due to bus communication and
system processing times.
The extrapolation is set on the leading axis or on the external encoder.
Noisy sensor signals result in large velocity jumps which affect the extrapolation. These can
be reduced or compensated for using appropriate filter settings

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Function Manual, 04/2014 37
Part I - Synchronous Operation
2.2 Fundamentals of Synchronous Operation

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Figure 2-32 Actual value coupling with extrapolation for the Axis TO or External Encoder TO

You can find an overview of the actual value coupling with and without extrapolation in the axis
configuration in the SCOUT signal flow dialog (project navigator, select Axis TO > Signal flow
> Extrapolation).

Filtering of actual position

The actual position value for the synchronous operation can be filtered separately for the
extrapolation using a PT2 filter. (V4.1 and higher) The filter for the actual position value of the
axis is set using the typeOfAxis.extrapolation.positionFilter.T1 and
typeOfAxis.extrapolation.positionFilter.T2 configuration data. The filter acts on the actual
position for the extrapolation. The velocity for the extrapolation is taken over from the actual
values of the axis or External Encoder before application of the smoothing filter
(typeOfAxis.smoothingFilter).

Filtering of actual velocity

The position is extrapolated based on the filtered or averaged velocity value.
We would recommend setting the velocity filter (Extrapolation.Filter) first and then also using
the position filter if the result is not sufficient.
The position filter times should also be taken into account in the extrapolation time.
The velocity filter (Extrapolation.Filter) does not affect the extrapolation time, but does have
influence during dynamic changes to master values (due to delayed values). See also the TO
axis, Electric/hydraulic, External encoder Manual.

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● TypeofAxis.Extrapolation.filter.timeConstant: Time used for averaging or time constant for

filtering

Extrapolation of actual velocity and actual position

These delay times can be compensated using an extrapolation.
● TypeofAxis.Extrapolation.extrapolationTime: Time specification for extrapolation
Extrapolation is not performed if 0.0 is specified. The extrapolated values (position and velocity)
can be monitored (extrapolationData system variable). The extrapolation compensates for the
local delays that result from use of the actual value instead of the setpoint.

Note
Extreme care must be taken when changing the extrapolation time to the runtime; otherwise
knocking could result in the machine.

Note
SIMOTION contains utilities & applications which are included in the scope of delivery of
SIMOTION SCOUT, a tool to assist in calculating the extrapolation times.

Switch for the velocity master value during master value extrapolation
The TypeofAxis.Extrapolation.extrapolatedVelocitySwitch configuration data element can be
used to generate the velocity master value from the extrapolated position master value using
differentiation; alternatively, the extrapolated velocity master value for the synchronous
operation can be used.

Display
The extrapolated and filtered values are indicated in the following system variables:
● sensorData[n].position
● sensorData[n].velocity
● sensorData[n].acceleration
The system variables for sensorData are calculated in the position control cycle clock.
The actual axis value that is active for closed-loop control, the IPO cycle, and master value
coupling
is displayed in the following variables:
● positioningState.actualPosition
● motionStateData.actualVelocity
● motionStateData.actualAcceleration
The system variables for positioningState and motionState are calculated in the IPO cycle.
These actual values are the reference for the output cam calculation in the IPO cycle, for the

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actual value connection with external encoders without extrapolation, for the actual value
reference in the IPO cycle,
e.g. for profiles relating to actual position.

Reduction in reaction times/dead times

The Execution.executionLevel:=SERVO setting on the master value object, e.g. External
Encoder technology object, can be configured in the Synchronous Object technology object
and Following Axis technology object to enable execution of the IPO system component of the
master value, synchronous operation, and axis in the Servo following actual value acquisition.
For further information, refer to the Motion Control Technology Objects Axis Electric/Hydraulic,
External Encoder Function Manual, "Motion execution/interpolator".

Transferring the actual velocity from the drive (V4.2 and higher)
With the setting
typeOfAxis.numberOfEncoders.encoder_n.encoderValueType:=POSITION_AND_PROFIDRI
VE_NIST_B, you have the option of converting the speed of rotation transferred in PROFIdrive
NIST_B to a velocity and applying this value as the actual velocity of the encoder/sensor. In
this case, the actual position of the sensor does not need to be differentiated to derive the
actual velocity.
With the setting typeofAxis.numberOfEncoders.encoder_n.encoderValueType:=
POSITION_AND_DIRECT_NIST, a speed of rotation transferred in the I/O area and
normalized as NIST_B is taken as the actual value and converted to an actual velocity. In this
case, 4000H corresponds to 100%. The address is set in
typeofAxis.numberOfEncoders.encoder_n.sensorNist.logAddress, and the reference value is
set in typeofAxis.numberOfEncoders.encoder_n.sensorNist.referenceValue. With encoders
with nact evaluation, the speed determined by the encoder and the resulting velocity can be
accepted by the encoder. In this case, the actual position of the sensor does not need to be
differentiated to derive the actual velocity. Two methods of transmission are available:
● Transmission in the PROFIdrive message frame
● Transmission in the I/O area
See also section Actual value acquisition / Actual value system in the Manual TO Axis electric/
hydraulic, External Encoder.

2.2.4.2 Actual value coupling with tolerance window

If the master value is superimposed with high-frequency noise signals that cannot be followed
by the synchronous operation, this can cause the dynamic response boundaries to be
exceeded or the master value to briefly change directions during synchronization.
In the typeOfAxis.extrapolation.toleranceRange configuration data element on the master
axis or external encoder, a tolerance window can be set around the actual position
(V3.1 and higher), to prevent, for example, the dynamic limits from being exceeded on the
following axis in the case of a master value with high-frequency disturbances, or direction
changes during synchronization.

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2.2.5 Synchronization

In order for the following axis to follow the master value according to the transmission function,
the following axis must first be synchronized to the master value.
The type of synchronization is determined from several assignable parameters/settings:
● The synchronization criterion/synchronization position, which corresponds to the setting
specified in the synchronizingMode parameter; the synchronization position on the master
value side and/or the synchronization position on the slave value side are directly specified
here or are derived from the synchronization criterion and, if necessary, the transmission
function
● The synchronization direction, the motion direction of the slave values during
synchronization; can be set in the synchronizingDirection parameter
● Position of synchronization range relative to synchronization position: Leading, trailing, or
symmetrical synchronization; can be set in the syncPositionReference parameter
● the reference of the synchronization profile; can be set in the syncProfileReference
– Synchronization over a specifiable master value distance
The synchronization length over the master value is specified in the synchronization
command.
– Synchronization profile via specifiable dynamic response parameters (time reference)
The dynamic response parameters are specified in the synchronization command.
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Figure 2-33 Parameters for synchronization

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Properties Synchronization via a Synchronization profile Synchronization profile

specifiable master based on specifiable based on specifiable
value distance dynamic response dynamic response
parameters, leading parameters, trailing
synchronization synchronization
Dynamic response properties
● Constant velocity Yes Yes Yes
synchronization
profile
● Constant No With SMOOTH velocity With SMOOTH velocity
acceleration profile setting profile setting
synchronization
profile
Adherence to dynamic No With master value and Yes
response parameters User can influence the constant velocity,
(without limiting dynamic response via otherwise master value
functions on the the synchronization dynamic response is
following axis side) length superimposed
Dynamic response can Indirectly With dynamicAdaption With dynamicAdaption
be adapted to the setting setting
master value dynamic
response
Applicability to stationary master value
● If following axis is at Conditional Conditional Yes
a standstill Following axis must Following axis must
already be at the already be at the
synchronous position, synchronous position,
e.g., with relative e.g., with relative
gearing gearing
● With moved No No Yes
following axis
Applicability to master value with constant velocity
● If following axis is at Yes Yes Yes
a standstill
● With moved Yes Yes Yes
following axis
Applicability to master value with non-constant velocity
● Master value with Yes Yes Conditional
constant Superimposition of Superimposition of With extended look-
acceleration / master value dynamic master value dynamic ahead or dynamic
deceleration response response response of
synchronization >>
master value dynamic
response
● Modified master Yes Yes No
value dynamic Superimposition of Superimposition of Exception: Dynamic
response or faulty/ master value dynamic master value dynamic response of
noisy master value response response synchronization >>
signal master value dynamic
response
Synchronization properties

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Properties Synchronization via a Synchronization profile Synchronization profile

specifiable master based on specifiable based on specifiable
value distance dynamic response dynamic response
parameters, leading parameters, trailing
synchronization synchronization
● Synchronism Yes Yes Conditional
reached after Exception: master Exception: master No, if master value
starting the value changes motion value changes motion dynamic response >
synchronization direction direction resulting dynamic
response of
synchronization or
varying master value
dynamic response; see
above
● Specification of Supported Supported No
synchronous
position after
starting the
synchronization

Properties of different synchronization options

2.2.5.1 Synchronization criterion

Synchronization criterion/synchronization position

The synchronization criterion can be set for synchronization using the synchronizingMode
parameter of the _enableGearing()/_enableCamming() or _disableGearing()/
_disableCamming() command as outlined below. Synchronization can take place over several
modulo ranges of the master value or slave value.

Synchronization on current master value position without specification of an offset on the slave value
side
The current master value position is the synchronization criterion and the synchronization
position on the master value side. The synchronization criterion is set with
synchronizingMode:=IMMEDIATELY. The syncPositionMaster parameter is not active. An
offset on the slave value side is not specified, and the syncPositionSlave parameter is not
active. With relative camming on the master value side, the camStartPosition parameter is

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active. Synchronization starts immediately. Synchronization occurs subsequently. The

syncPositionReference parameter is not active.

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Figure 2-34 Example of synchronization - immediately active, trailing synchronization, absolute without
offset, ratio 1:1

Synchronization on current master value position with specification of an offset on the slave value side
The current master value position is the synchronization criterion, and an offset on the slave
value side is specified. The synchronization criterion is set with
synchronizingMode:=IMMEDIATELY_AND_SLAVE_POSITION. The synchronization position
on the master value side is the current master value position. The syncPositionMaster
parameter is not active. The offset on the slave value side is specified in the
syncPositionSlave parameter. With relative camming on the master value side, the
camStartPosition parameter is active. Synchronization starts immediately. Synchronization
occurs subsequently. The syncPositionReference parameter is not active.

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Figure 2-35 Example of synchronization - immediately active, trailing synchronization, absolute and
offset on following axis position, ratio 1:1

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Synchronization on specified master value position without specification of an offset on the slave value
side
The specified master value position is the synchronization criterion. The synchronization
criterion is set with synchronizingMode:=ON_MASTER_POSITION. The synchronization
position on the master value side is set in the syncPositionMaster parameter. An offset on the
slave value side is not specified, and the syncPositionSlave parameter is not active. With
relative camming on the master value side, the camStartPosition parameter is active. The
syncPositionReference parameter specifies whether to activate leading, symmetrical (only for
synchronization via a specifiable master value distance), or trailing synchronization.
Regarding the start of synchronization, see Position of synchronization range relative to
synchronization position (Page 48).

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Figure 2-36 Example of synchronization - specification of master value synchronization position, trailing
synchronization, absolute, ratio 1:1

Synchronization on specified master value position with specification of an offset on the slave value side
The specified master value position is the synchronization criterion. The synchronization
criterion is set with synchronizingMode:=ON_MASTER_AND_SLAVE_POSITION. The
synchronization position on the master value side is set in the syncPositionMaster parameter.
With relative camming on the master value side, the camStartPosition parameter is active. The
offset on the slave value side is specified in the syncPositionSlave parameter. The
syncPositionReference parameter specifies whether to activate leading, symmetrical (only for
synchronization via a specifiable master value distance), or trailing synchronization.
Regarding the start of synchronization, see Position of synchronization range relative to
synchronization position (Page 48).

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Figure 2-37 Example of synchronization - specification of master value synchronization position and
following axis offset, trailing synchronization, absolute, ratio 1:1

Synchronization on the specified following axis position

The specified following axis position is the synchronization criterion. The synchronization
criterion is set with synchronizingMode:=ON_SLAVE_POSITION. The synchronization
position on the slave value side is specified in the syncPositionSlave parameter. An offset on
the slave value side cannot be specified. The synchronization position on the master value
side is determined from the application of the inverse transmission function to the
synchronization position on the slave value side. With relative camming on the master value
side, the camStartPosition parameter is active. The syncPositionMaster parameter is not
active. Synchronization starts if the synchronization position specified in the
syncPositionSlave parameter is reached on the following axis as a result of a motion initiated
elsewhere.

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Figure 2-38 Example of synchronization - specification of following axis synchronization position,

trailing synchronization, absolute, ratio 1:1

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Synchronization at the end of the current camming cycle

The master value position at the end of the current camming cycle is the synchronization
criterion. This setting can only be assigned in conjunction with relative camming on the master
value side and already active camming. The synchronization criterion is set with
synchronizingMode:=AT_THE_END_OF_CAM_CYCLE. The synchronization position on the
master value side is the master value position at the end of the current camming cycle. The
syncPositionMaster parameter is not active. With relative camming on the master value side,
the camStartPosition parameter is active. An offset on the slave value side cannot be specified,
and the syncPositionSlave parameter is not active. The syncPositionReference parameter
specifies whether to activate leading, symmetrical (only for synchronization via a specifiable
master value distance), or trailing synchronization.

2.2.5.2 Synchronization direction

The synchronizingDirection parameter of the synchronous operation commands can be used
to specify the direction of the motion for synchronization. If a specific synchronization direction
is specified, the synchronization motion is in this direction only.
The synchronization direction of the following axis in the synchronization phase can be
specified with the synchronizingDirection parameter in the _enableGearing(),
_disableGearing(), _enableCamming(), and _disableCamming() commands (V3.1 and higher).
This function is relevant, for example, for axes, for which synchronization is possible in both
directions.
For information on axes with backstop, refer to the Motion Control Technology Objects Axis
Electric/Hydraulic, External Encoder Function Manual, "Manipulated variable limitation
(backstop)"
Synchronization with direction of specification can be set as follows:
● Maintain present system behavior (SYSTEM_DEFINED):
This corresponds to the shortest path setting, however the direction of motion is maintained
for the axis motion.
● Maintain direction of the following axis (SAME_DIRECTION):
The current direction of following axis motion is maintained during the synchronization
phase.
– The direction of following axis motion is maintained during synchronization when the
master value is at a standstill.
– The synchronization occurs in the positive direction during synchronization at both the
master value standstill and the following axis standstill.
● POSITIVE_DIRECTION setting: A positive synchronization direction is defined.
● NEGATIVE_DIRECTION setting: A negative synchronization direction is defined.
● SHORTEST_WAY setting: Synchronize to the shortest way, regardless of which direction
of motion ensues in the synchronization phase.
With this setting, however, a direction reversal could occur during synchronization.

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2.2.5.3 Position of synchronization range relative to synchronization position

The position of the synchronization range relative to the synchronization position can be set
with the syncPositionReference parameter of the _enableGearing() or _enableCamming()
command:
● Synchronize before the specified synchronization position: Leading synchronization
(syncPositionReference:=BE_SYNCHRONOUS_AT_POSITION)
– The end point of the synchronization is specified via the synchronization criterion.
– The starting point of synchronization is determined for synchronization via a specifiable
master value distance, on the basis of the specified synchronization length, and is
calculated with reference to the dynamic response parameters of the system in
accordance with the specified dynamic values and the master value behavior.
● Synchronize starting from the specified synchronization position: Trailing synchronization
(syncPositionReference:=SYNCHRONIZE_WHEN_POSITION_REACHED)
– The starting point of synchronization is specified directly or implicitly (by means of the
following axis position).
– The end point of the synchronization is calculated for synchronization via a specifiable
master value distance from the specified synchronization length and is calculated with
reference to the dynamic response parameters of the system according to the dynamic
response parameters and the master value behavior.
● Symmetrically relative to the specified synchronization position
(syncPositionReference:=SYNCHRONIZE_SYMMETRIC)
– With synchronization via a specifiable master value distance, the starting point and end
point of synchronization are determined on the basis of the master value positions, in
accordance with the specified synchronization length.
– Synchronization with the SYNCHRONIZE_SYMMETRIC specification is not possible
with a synchronization profile using specifiable dynamic response parameters
(RELATE_SYNC_PROFILE_TO_TIME). This command is rejected with TO alarm
"30001: illegal parameter".
Synchronization starts under the following conditions:
● With trailing synchronization: When the synchronization position on the master value side
or slave value side is reached
● With symmetrical synchronization: When the master value has reached the synchronization
position, reduced by half the synchronization length in the master value direction of motion
Master value>= synchronization position (synchronization length in direction of motion of
master value/2).
● With leading synchronization: When the synchronization position on the master value side
is reached, reduced by the synchronization length in the direction of motion
Note the following:
● With trailing synchronization and absolute synchronous operation, the following axis
distance to be traveled according to the transmission function based on the progress of the
master value must be applied too. For this reason, leading synchronization should be used
whenever possible.
● With synchronization criterion synchronizingMode:=IMMEDIATELY or
IMMEDIATELY_AND_SLAVE_POSITION, trailing synchronization is implicitly present.

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2.2.5.4 Synchronization via a specifiable master value distance

With synchronization via a specifiable master value distance, a synchronization profile is
calculated from a specifiable path length of the master value and is applied relative to the
master value.
The setting is made with the syncProfileReference:=
RELATE_SYNC_PROFILE_TO_LEADING_VALUE parameter.
The path length of the master value is specified in the syncLength parameter.As a result,
synchronism is always achieved in the setpoint specification. The dynamic response during
synchronization is dependent on the calculated profile via the master value and on the change
in the master value. The dynamic response values specified in the command are not active.

Synchronization length
The synchronization operation takes place as long as the master value is within this defined
length. No dynamic response values are taken into account. The profile is calculated as a
function of the master value velocity. (See Synchronization profile type)
The synchronization range is specified using the synchronization length of the master value
defined in the syncLength parameter of the _enableGearing() or _enableCamming()
commands.

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Figure 2-39 Synchronization length for synchronization via a specifiable master value distance

The "synchronous" status is set immediately if the master value source and following axis are
at a standstill and the synchronization criterion has already been fulfilled. In this case, the
message "50006 Activation/deactivation of synchronous operation executed directly" is
output.

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Synchronization profile type

The synchronization profile type for synchronization with master value reference is set using
the syncingMotion.velocityMode configuration data element:
● In the CONTINUOUS setting (default), the synchronization profile is calculated with a
constant position and constant velocity, but not with constant acceleration.
The slave value is synchronized using a polynomial profile and the master value. Therefore,
the resulting velocity and acceleration of the following axis for synchronization are
dependent on the synchronization length and the dynamic response of the master value
during synchronization.
● In the NON_CONTINUOUS setting, the synchronization profile is calculated using the
specified master value length with a constant position only in the slave value behavior.
The slave value is synchronized using a linear profile and the master value.

2.2.5.5 Synchronization profile

Synchronization profile based on specifiable dynamic response parameters (time reference)

When this synchronization profile is used, a synchronization profile is calculated according to
the specified dynamic response parameters and the master value dynamic response that
exists at the start of the profile. The profile is applied according to the master value for leading
synchronization and according to time for trailing synchronization.
The setting is made with the syncProfileReference:= RELATE_SYNC_PROFILE_TO_TIME
parameter.
The dynamic response for the synchronization is specified in the dynamic response
parameters for the synchronous operation commands. A velocity profile with constant velocity
(TRAPEZOIDAL) or constant acceleration (SMOOTH) can be specified using the
velocityProfile parameter. For synchronization with a synchronization profile based on dynamic
response parameters and with constant acceleration, any reversing that takes place during
synchronization is at zero acceleration in the reversing point.
The synchronization profile based on dynamic response parameters can be applied:
● For leading synchronization
● For trailing synchronization
Symmetrical synchronization is not possible.
See also Position of synchronization range relative to synchronization position (Page 48), as
well as the section titled Adapt the synchronization velocity to the master value velocity
(Page 107).

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Application
A synchronization profile based on dynamic response parameters is especially suited for:
● Time-optimized synchronization, according to dynamic response specifications

Adaptation to the dynamic response of the master value (leading and trailing synchronization)
If the current dynamic response variables of the master value are larger than the dynamic
response parameters of the synchronization command, the parameters can be automatically
adapted to the dynamic response parameters. (V3.1 and higher)
Parameters for adapting the synchronization dynamic response to the target dynamic response
can be assigned on the synchronous object under Settings (syncingMotion.synchronizing-
Adaption).
If dynamic response adaptation is disabled, the synchronization dynamic response is no longer
adapted to the required target dynamic response. This can lead to the situation where during
trailing synchronization, the synchronized axis can no longer synchronize with the leading axis.
During leading synchronization, the synchronization motion may not be started under certain
circumstances.

Overdrive factor
The permissible magnification of the specified dynamic response values for making up a
constant path difference is specified using the magnification factor
(syncingMotion.overdriveFactor) under Settings. The magnification factor relates to the
dynamic response of the master value. At 100% magnification, the dynamic response of the
synchronization is adapted to the current dynamic response of the master value, taking into
account the transmission. When overDriveFactor > 100% is set and has taken effect, the
"synchronous" status can also be established if the master value is in the acceleration or
deceleration phase during synchronization.
If an overshoot occurs, alarm 40012 "Dynamic limitations (type: ...) are violated" is output at
the synchronous object.

Application
If a low synchronization velocity is selected on the command, the adaptation is set, and a
corresponding overshoot factor is selected, the synchronization velocity of the following axis
is adapted to the master value velocity.

Direction-dependent dynamic response

Direction-dependent or direction-independent effectiveness of the programmed dynamic
response values can be set with syncingMotion.directionDynamic. (Default: NO)
See Motion Control Technology Objects Axis Electric/Hydraulic, External Encoder Function
Manual, "Dynamic limits"

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2.2 Fundamentals of Synchronous Operation

Leading synchronization with synchronization profile based on dynamic response parameters

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Figure 2-40 Example of leading synchronization (gearing with 2:1 gear ratio, synchronize following axis
from standstill)

Only with a synchronization profile based on specifiable dynamic response parameters is a

synchronization profile calculated for leading synchronization, taking into account the current
master value velocity, the current position, and the dynamic response of the following axis, as
well as the dynamic values for synchronization specified in the command. The synchronization
profile is then traversed relative to the master value. In addition, if the master value dynamic
response changes, the synchronization profile is not recalculated. For this reason, a change
in the master value velocity can be seen superimposed in the synchronization operation.
In addition, with the Extended Look ahead setting, the acceleration of the master value in the
synchronization profile is not taken into account.

Start of synchronization
The synchronization operation starts:
● At the time calculated by the system from which the specified dynamic response parameters
can be optimally synchronized with respect to time at a constant master value velocity
● Immediately, if it is not possible to calculate an optimum synchronization time and the
synchronization position can be reached (with static master value, for example)

Application
Leading synchronization is appropriate in the following cases:
● If there is to be synchronism at the specified synchronous position and the synchronous
position can be easily specified from the application, taking into account the required
synchronization operation.
● If dynamic response changes for the master value can be expected during synchronization
and are taken into account in the synchronization profile but are not to be reinforced through
extrapolation.

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Comments
● The programmed velocity profile (SMOOTH, TRAPEZOID) is applied.
● The syncingMotion.smoothAbsoluteSynchronization configuration data element is not
relevant for leading synchronization.
● Synchronization with extended look-ahead is not active with leading synchronization.
● With leading synchronization, the current master value velocity, and the resulting
synchronization profile, if there is insufficient time for synchronization before the master
value reaches the synchronization position, synchronization does not take place. The status
can be read out via system variables.
Exception: Modulo master value; in this case, the next possible synchronization position is
awaited.

Trailing synchronization with synchronization profile based on dynamic response parameters

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Figure 2-41 Example of trailing synchronization (gearing with 2:1 gear ratio, synchronize following axis
from standstill)

With trailing synchronization, the synchronization operation starts when the synchronization
criterion is reached. Taking into account the current master value velocity and the specified
dynamic response values, the system calculates and executes a time-related synchronization
profile such that synchronization is achieved as fast as possible. When calculating the
synchronization profile, the current master value acceleration is only taken into account in
cases where extended look-ahead is specified.
Changes of the master value for the synchronization are directly taken into account.

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Application
Trailing synchronization is appropriate in the following cases:
● When the current master value position must be used directly as the synchronization
position.
● When no dynamic response changes of the master value during synchronization are
expected.
● When other reasons dictate that synchronization can take place only after the
synchronization position.
Depending on the position of the slave value at the synchronous position, large dynamic
movements of the slave value may occur since, in order to comply with the dynamic limits
and taking into account the master value dynamic response, the following must occur:
– Synchronism must be achieved
– If there are dynamic response changes to the master value, the (anticipated) position
changes to the master value must be made up for.

Comments
Trailing synchronization is not suitable for non-constant velocity and acceleration of the master
value (i.e. if the acceleration/deceleration changes continually).

Smooth synchronization
Absolute trailing synchronization with consideration of jerk
The syncingMotion.smoothAbsoluteSynchronization configuration data element can be used
to specify whether a smooth velocity profile is supported during the succeeding synchronization
(V3.2 and higher).
Synchronization is not calculated subject to changes in the master value velocity.
● Provision for jerk during absolute synchronization can be made by setting
syncingMotion.smoothAbsoluteSynchronization:= YES .
● A setting of NO (default) means that jerk will not be taken into account during absolute
synchronization, even with velocity profile SMOOTH.

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Trailing synchronization with extended look ahead

The synchronization with extended look-ahead allows a constant acceleration/deceleration of
the master value to be used during the synchronization.
● With synchronization with standard look ahead, the position and the velocity are included
in the synchronization calculation.
● For synchronization with extended look-ahead, the current values of the master axis for
position, velocity and acceleration/deceleration are used to calculate the synchronization
distance of the following axis (V3.2 and higher).
Any changes to the acceleration of the master axis during the synchronization action are
ignored and can cause a longer synchronization distance than for synchronization with
standard look-ahead.
● During the braking phase of the master synchronization, it can occur that the
synchronization process is terminated only after the braking phase of the master. In this
case, synchronization without extended look-ahead ,i.e., in Standard mode can be
executed. It can nevertheless occur that the following axis becomes synchronous only after
the braking phase.
The function can be activated via the synchronizingWithLookAhead parameter of the
_enableGearing() command.
Extended look-ahead can be preset on the synchronous object via system variable .gearing‐
Settings.synchronizingWithLookAhead (V4.0 and higher).

See also
Position of synchronization range relative to synchronization position (Page 48)

2.2.5.6 Settings for evaluation of the master value behavior during synchronization

Toleration of a master value reversal during synchronization:

During synchronization, when the direction of the master value is reversed, the synchronization
process is canceled with error message 50007 output at the synchronous object.
If the direction reversal is based on tolerable and predominantly non-influenceable master
value fluctuations during downtime, as they occur in the case of an actual value coupling (so-
called actual value "noise") or primary extrapolation of the master value, cancelation of
synchronization can be prevented by specifying a tolerance band for the master value reversal
(master value hysteresis) (as of V4.0).
The maximum master value fluctuation to be tolerated by the system is to be parameterized
in the configuration data syncingMotion.masterReversionTolerance in the master value
positioning unit. An effective hysteresis at a value greater than 0 freezes the master value in
the reversal point during direction reversal and thus simulates a still-standing master value for
synchronization.

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The master value tolerance continuously acts on the active or soon-to-be active master value
(see master value switching), beginning with activation of the master value and the hysteresis.

Note
When a master value tolerance > 0 is specified, the system is permitted to immediately offset
the following axis change corresponding to one of these master value variables, with
maximum dynamics on the following axis, e.g. during use in connection with time-related
synchronization. During this process, the current effective coupling factor must also be taken
into account.

The variable of the master value tolerance should therefore be selected at as low a level as
possible and should be immediately oriented toward the measured fluctuations of the actual
value or the extrapolation error.
The effective hysteresis, and thus also an existing reversal point, can be reset by setting the
master value tolerance to the value 0. The change, in the same way as setting the tolerance
to a value greater than 0, immediately becomes active.

Effective direction of the hysteresis

The effective direction of the hysteresis is automatically determined by the system and is
maintained by the permanent functionality that is also outside of synchronization.
As of V4.4, you can specify the effective direction of the master value via the configuration
data item syncingMotion.toleranceDirection.
● BOTH_DIRECTIONS (default)
● POSITIVE. The effective direction of the tolerance band is positive. The tolerance band is
effective in the positive direction for a master motion, i.e. the hysteresis function takes effect
when the master moves from a positive to a negative direction, but not vice versa.
● NEGATIVE. The effective direction of the tolerance band is negative. The tolerance band
is effective in the negative direction for a master motion, i.e. the hysteresis function takes
effect when the master moves from a negative to a positive direction, but not vice versa.

No synchronized status while master value in the hysteresis

As of V4.4 there is a configuration data item syncingMotion.enableSyncWithinTolerance with
which the reaching of the synchronized status is retained within the hysteresis of the master
value, or the new response that the synchronized status is only reached by the master value
when it has left the hysteresis range.
You can set that synchronous operation does not go into synchronized status and therefore
refers to the current position of the master value using the synchronous operation rule as long
as the master value is in the hysteresis as a result of a change of direction. In this way, the
difference that results from the synchronous operation rule and the position of the master value
at the start of the hysteresis and the current position, is no longer traversed with the maximum
dynamic response of the following axis.
If a master value reversal tolerance greater than zero is set for the synchronization, then with

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● synchronization with master value reference: relative synchronization at rest

● synchronization trailing with time reference: synchronization ends within the tolerance
an unexpected traversing motion can occur when the synchronized status is reached, because
the difference resulting from the synchronous operation slave value at the start of the hysteresis
and from the synchronous operation slave value for the current master value position is
traversed immediately with the maximum dynamic response of the following axis when the
synchronized status is reached.

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Figure 2-42 Switchover in the hysteresis

To prevent that, as of V4.4 there is a configuration data item

syncingMotion.enableSyncWithinTolerance.
● Synchronized status also in hysteresis
With the setting syncingMotion.enableSyncWithinTolerance = YES (system default setting,
compatibility setting), the synchronized status can also be reached by the master value
within the hysteresis.
● No synchronized status in hysteresis
With the setting syncingMotion.enableSyncWithinTolerance = NO (system setting when
creating a new synchronous axis), the synchronized status is not set for the master value
in the hysteresis range.

Toleration of master value velocity changes during synchronization:

The tolerance of master value velocity changes can be set in the
syncingMotion.maximumOfMasterChange configuration data element (default setting: 20%).
If, during synchronization with a synchronization profile based on the master value distance,
there is a change to the master value velocity in excess of what has been parameterized in
the configuration data element, an error message is output and the synchronization profile is
recalculated.
If, during synchronization with a synchronization profile based on dynamic response
parameters and with leading synchronization, there is a change to the master value velocity
in excess of what has been set in the configuration data element, an error message is
generated but the profile is not recalculated.

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During synchronization with a synchronization profile based on dynamic response parameters

and with trailing synchronization, the configuration data element is not active. A change to the
master value velocity produces an immediate response.

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Figure 2-43 Example of syncingMotion.maximumOfMasterChange for leading synchronization with

synchronization profile based on specifiable dynamic response parameters

The values of customizable dynamic parameters for synchronization profiles are initially
reduced by the values defined in the syncingMotion.maximumOfMasterChange configuration
data element. The following axis is then accelerated at reduced acceleration to the reduced
velocity, in order to maintain reserves and to terminate synchronization safely at the specified
synchronization position.
If the master value velocity changes, then the same changes are made to the dynamic
response values of the synchronization procedure. Error message "50009 Changing the
dynamic response of the master leads to a dynamic violation when synchronizing/
desynchronizing" is issued if the parameterized tolerance is exceeded.
If the direction of the master value reverses during synchronization, the synchronization
procedure is aborted with the "50007 Error occurred while activating/deactivating the
synchronous operation" error. This does not apply for immediate synchronization or
synchronization starting at a defined reference point when
syncProfileReference:=RELATE_SYNC_PROFILE_TO_TIME with
synchronizingMode:=IMMEDIATELY or
syncProfileReference:=RELATE_SYNC_PROFILE_TO_TIME with
synchronizingMode:=SYNCHRONIZE_WHEN_POSITION_REACHED.
With trailing synchronization, the syncingMotion.maximumOfMasterChange configuration data
element is not active, i.e. responses are issued continuously.

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2.2 Fundamentals of Synchronous Operation

2.2.5.7 Monitoring the synchronization

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2.2 Fundamentals of Synchronous Operation

Synchronization state on synchronous object

● The state system variable on the synchronous object indicates whether a synchronous
operation is active:
– With state:=CAMMING a camming is active.
– With state:=GEARING a gearing is active.
– With state:=VELOCITY_GEARING a velocity gearing is active.
– With state:=INACTIVE, no function is active on the synchronous object.
When synchronization starts, the system variable is set to the appropriate value and
reset again once synchronization is complete.
● The syncState system variable on the synchronous object indicates whether the slave value
calculated on the synchronous object is synchronous with the master value.
– If both the master value and slave value are synchronous, this variable will be set to the
YES state.
The master value pending on the synchronous object (currentMasterData.value) and
the slave value output to the following axis (currentSlaveData.value) will then be
synchronous.
– The start of desynchronization or any other loss of synchronism causes the variable to
be reset to the NO value.
Any restrictions imposed on the slave value transferred by the following axis as a result
of the limitation to the maximum dynamic values and the associated non-synchronization
of the master and following axis are not reflected in the state of the syncState variable.
With regard to the dynamic response limits on the following axis, see Motion Control
Technology Objects Axis Electric/Hydraulic, External Encoder Function Manual,
"Dynamic limits".
● The master value information on the synchronous operation object does not match the input
values from the master value object 1:1, but is instead influenced by:
– Extrapolation/interpolation for distributed synchronous operation
– Extrapolation/interpolation through task-wide synchronous operation
– Extrapolation/interpolation through setpoint output delays
– Plausibility check at standstill of the master value
Example:
If the actual velocity adopts the value zero (because two position values are the same in
succession), the filtered value is no longer taken for the actual velocity, but is instead set
directly to zero. In the active synchronous operation object therefore 0 is taken for a cycle
in currentMasterData.derivedValue. If the (position) setpoint change = 0, the dynamics for
preventing reverse procedures are already adjusted to the position change with the setpoint
calculation.
● The associated synchronization position of the master and the slave value, i.e. the position
from where the master and the slave axis run synchronous are contained in the
currentSyncPosition system variables on the synchronous object.
See Display of the synchronization position (Page 61).

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● The state of the synchronization can be queried using the synchronizingState system
variable on the synchronous object (as of V3.2).
– WAITING_FOR_SYNC_POSITION: Waiting for master value synchronization position
– WAITING_FOR_CHANGE_OF_MASTER_DIRECTION: Waiting for master value
direction reversal
– SYNCHRONIZING_NOT_POSSIBLE: Synchronization is not possible
– SYNCHRONIZING: Synchronization in progress
– INACTIVE: Synchronization phase is not active
– WAITING_FOR_MERGE: Synchronization command issued, but not yet active
● The execution state of the active command for activation/deactivation is described in the
enableCommand and disableCommand system variables.
– INACTIVE means that no command is configured.
– WAITING_FOR_START means that the command is executed during slave value
generation, and that it is waiting for the start criterion for synchronization to be reached.
– ACTIVE means that synchronization is active and that the operation is synchronous.
– If there are two commands during slave value generation, both system variables can
assume a value not equal to INACTIVE. If both are enable commands, the state of the
current command is displayed (the state of the next command is always
WAITING_FOR_START).
● The relevant active command parameter and the parameter for synchronization are
grouped together and can be read out in the effectiveData system variable structure.

Synchronization state on following axis

● The syncMonitoring.syncState variable on the following axis indicates the synchronous
operation state on the setpoint side.
During synchronization and desynchronization, syncState:=NO.
● The syncMonitoring.followingMotionState variable on the following axis indicates the state
of the synchronous motions:
– INACTIVE: Synchronous motion is not active
– BASIC_MOTION_ACTIVE: Synchronous operation is active as main motion
– SUPERIMPOSED_MOTION_ACTIVE: Synchronous operation is active as
superimposed motion
– BASIC_AND_SUPERIMPOSED_MOTION_ACTIVE: Synchronous operation is active
as main and superimposed motion

2.2.5.8 Display of the synchronous position

The currentSyncPosition system variables on the synchronous object indicate the last
calculated synchronous position of a synchronous operation.
● currentSyncPosition.master: Synchronous position of the master value
● currentSyncPosition.slave: Synchronous position of the following axis

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These value are valid only when 'syncState = YES'.

Start position of the cam on the axis

The master value and slave value at the cam start of the current camming operation are shown
in system variables (V4.0 and higher). The values can also be shown when the starting point
of the synchronous operation lies within the cam.
● currentSyncPosition.camMasterMatchPosition:
Master value at the cam start
● currentSyncPosition.camSlaveMatchPosition:
Slave value at the cam start
● currentSyncPosition.distanceCamMasterMatchPostion:
Current relative position in the cam (distance to the cam start)
Application: Calculation of the corresponding axis positions, also for camming, e.g. a
desynchronization position. The axis position must be specified absolute in relation to the
axis, even for relative synchronous operation.
These system variables, can be used, for example, to determine the exact position of the
cam for the axis, even for relative camming, and to specify the desynchronization position
relative to the axis.
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Figure 2-45 Display of the master value and slave value positions in the currentSyncPosition
system variable

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Position reproduction for modulo axes with gearing

The currentSyncPosition.slavePositionAtMasterModuloStart system variable can be used to
read out the slave value position at the modulo starting point of the master value
(V4.0 and higher).
● currentSyncPosition.slavePositionAtMasterModuloStart:
Slave value position at the modulo starting point of the master value
currentSyncPosition.slave will be indicated if no modulo is active at the master value.
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Figure 2-46 Position difference caused by a different modulo starting point

Application
For known gear ratio and known modulo lengths, the assignment of master value and slave
value can be closed, even when the slave value modulo length does not correspond to the
master value modulo length.

2.2.5.9 “Synchronous” status during synchronization

● With synchronization via a specifiable master value distance, the "synchronous" status is
achieved at the end of the synchronization distance.
● The "synchronous" state of synchronization with a synchronization profile based on
customizable dynamic response parameters and leading synchronization is achieved when
the synchronization position is reached (in this case, this is the same as the synchronous
position).
At the synchronous point, synchronism is present in the position, velocity, and acceleration
(only with SMOOTH velocity profile).
● With synchronization using a synchronization profile based on specifiable dynamic
response parameters and with trailing synchronization, the "synchronous" status is
achieved when synchronism exists in the position, velocity, and acceleration (only with
profile SMOOTH and syncingMotion.smoothAbsoluteSynchronization:=YES) in
accordance with the transmission function.
With relative gearing without offset, the position is not evaluated during synchronization.

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2.2 Fundamentals of Synchronous Operation

2.2.6 Desynchronization

2.2.6.1 Desynchronization - Overview

Desynchronization refers to the termination of the synchronous operation.
The desynchronization is defined by several parameters/settings:
● Desynchronization criterion/desynchronization position
● Position of synchronization range relative to desynchronization position
● the desynchronization profile
– Desynchronization over a specifiable master value distance
The desynchronization length is specified in the desynchronization command.
– Desynchronization profile via specifiable dynamic response parameters
The dynamic response parameters are specified in the desynchronization command.

2.2.6.2 Desynchronization criterion/desynchronization position

The desynchronization criterion/desynchronization position is specified in syncOffMode.
● Desynchronization at the current master value position; immediate desynchronization
Desynchronization at the current master value position is set in
syncOffMode:=IMMEDIATELY. Only trailing desynchronization can occur. The setting in
the syncOffPositionReference parameter is not active. The syncOffPositionMaster
parameter is not active. The syncOffPositionSlave parameter is not active.
● Desynchronization at a specified master value position
Desynchronization at a specifiable master value position is set in
syncOffMode:=ON_MASTER_POSITION. The syncOffPositionReference parameter can
be used to set leading, symmetrical (only with desynchronization via master value distance),
and trailing desynchronization. The desynchronization position on the master value side is
set in the syncOffPositionMaster parameter. The syncOffPositionSlave parameter is not
active.
● Desynchronization at a specified slave value position
Desynchronization at a specifiable slave value position is set in
syncOffMode:=ON_SLAVE_POSITION. The syncOffPositionReference parameter can be
used to set leading, symmetrical (only with desynchronization via master value distance),
and trailing desynchronization. The desynchronization position on the slave value side is
specified in the syncOffPositionSlave parameter. The syncOffPositionMaster parameter is
not active.
● Desynchronization at the end of cam cycle
Desynchronization at the end of the cam cycle is set in
syncOffMode:=AT_THE_END_OF_CAM_CYCLE. The syncOffPositionMaster parameter
is not active. The syncOffPositionSlave parameter is not active.

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2.2.6.3 Desynchronization over a specifiable master value distance

Desynchronization via a specifiable master value distance is set in the
syncProfileReference:=RELATE_SYNC_PROFILE_TO_LEADING_VALUE parameter. The
slave values travel to zero velocity while the master value travels through the
desynchronization length. The desynchronization length is specified in the syncOffLength
parameter.
See also Synchronization over a specifiable master value distance (Page 49).

2.2.6.4 Desynchronization profile via specifiable dynamic response parameters

Desynchronization based on specifiable dynamic response parameters is set in the
syncProfileReference:=RELATE_SYNC_PROFILE_TO_TIME parameter. The slave values
travel to zero velocity with the dynamic response values specified in the desynchronization
command according to the specified desynchronization criterion.
See also Synchronization profile based on specifiable dynamic response parameters (time
reference) (Page 52).

2.2.6.5 Position of synchronization range relative to desynchronization position

The position of the synchronization range relative to the desynchronization position can be
specified more precisely with the syncPositionReference parameter of the _disableGearing()
or _disableCamming() command:
● Desynchronization before the specified desynchronization position
Desynchronization before the specified desynchronization position is set using the
syncOffPositionReference:=AXIS_STOPPED_AT_POSITION parameter. The slave value
travels to zero velocity to the specified desynchronization position.
● Desynchronization starting from the specified desynchronization position
Desynchronization starting from the specified desynchronization position is set using the
syncOffPositionReference:=BEGIN_TO_STOP_WHEN_POSITION_REACHED
parameter. The slave value travels to zero velocity starting from the specified
desynchronization position.
● Symmetrical desynchronization relative to the specified desynchronization position
Symmetrical desynchronization relative to the specified desynchronization position is set
with the syncOffPositionreference:= STOP_SYMMETRIC_WITH_POSITION parameter.
The slave value travels to zero velocity symmetrically relative to the specified
desynchronization position. The setting is not possible for the desynchronization profile
based on dynamic response parameters.

2.2.6.6 Replacement of an active synchronous operation

If a synchronous operation is active, it can be replaced by another synchronous operation only
when the synchronization criterion of the following synchronous operation can be maintained.
Example:

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● For an active camming, the following axis travels only in the negative direction.
● A _enableCamming() command with synchronizingDirection:=POSITIVE_DIRECTION is
issued at the end of the cam cycle (or the criterion, for example, the specified master
distance ensures this).
In this case, the first active camming is not ended: the system waits until the following axis
travels in the positive direction, which, because of the active synchronous operation, never
occurs. To prevent the described behavior, change the synchronization criterion appropriately
or end the active synchronous operation first (using a _disable command) and then activate
the new synchronous operation.

Replacement of a synchronous operation with small synchronization length

If a synchronous operation group is ended using a _disable command with a very short
desynchronization length, high dynamic response values result that must be replaced using
discontinuous acceleration. If the _disable command is replaced before its ending by a new
motion command with continuous velocity profile, the still-present high acceleration values are
replaced prior to processing the added command. This results in a longer traversal distance
of the axis that can also cause the reversing of the axis.
In cases in which an immediate replacement of the synchronous operation is necessary, for
the described reason, no _disable command should be used, but rather an immediate switch
made to the replacing motion command. In this case, the jerk for the following command may
need to be increased.
If no _disable command is necessary, the subsequent move/pos command for a continuous
velocity command should possess high dynamic response values or traverse using a
"trapezoidal profile".

Substituting motions
A motion that is in an acceleration or deceleration phase is replaced by a motion with jerk
limitation (smooth). Correspondingly long times can result from the reduced jerk until the
current acceleration is reduced.
For an actual value coupling, the result is essentially a noisy signal, depending on the encoder
quality. In the case of substitution with jerk limiting (smooth), the slave movement is continued
relative to this noise-prone signal (acceleration). The system interprets the signal as if the
default value is in an acceleration or braking phase and reduces it via the jerk limitation.
Via the optional abortAcceleration parameter, the functions _stop and _stopEmergency can
be set, so that a potential acceleration does not exceed the jerk limitation but is immediately
terminated.

2.2.7 Dynamic response effect on slave values

The dynamic response of the slave values is determined from:
● The dynamic response of the master value
● The dynamic response of any master value switchover occurring during the motion
● The dynamic response of the synchronization

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● The dynamic response resulting from the transmission function

● If necessary, the dynamic response resulting from the application of offsets and scaling
changes
● The limitation of the slave value dynamic response to the maximum values of the following
axis
The dynamic response specifications on the synchronous object refer to the slave values
calculated on the synchronous object during synchronization. The dynamic limits of the
following axis are not taken into account by the synchronous object.
To avoid excessive dynamic response specifications on the slave values,
● The slave values calculated from the the master value based on the transmission function
should not exceed the dynamic limits
● The dynamic response specifications for synchronization and master value switchover
should not exceed the dynamic limits
The resulting dynamic values are limited to the maximum values on the following axis based
on the axis configuration.
The individual dynamic response parameters that are active during synchronous operation are
illustrated in the figure below.

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Figure 2-47 Dynamic response during synchronous operation

Legend:
1. The dynamic response of the master value is determined by the motion.
2. The dynamic response of the master value switchover can be specified using the
_setMaster() command.

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2.2 Fundamentals of Synchronous Operation

3. Synchronization/desynchronization and compensation:

– Without dynamic specification during synchronization via a specifiable master value
distance (RELATE_SYNC_PROFILE_TO_LEADING_VALUE)
– Synchronization profile based on specifiable dynamic response parameters (time
reference) (RELATE_SYNC_PROFILE_TO_TIME)
The dynamic values set on the synchronous object are only valid for camming or gearing
during synchronization/desynchronization and when applying corrections, but not in the
"synchronous" status. See Synchronization (Page 41), Desynchronization (Page 64).
4. The dynamic response specification for the following axis is determined by the synchronous
object and the gear ratio. The synchronous object is not subject to any dynamic limitation
in the 'synchronous' status.
5. The slave setpoints on the following axis are limited to the maximum axial dynamic
response. Configuration data: TypeOfAxis.MaxAcceleration/MaxVelocity/MaxJerk
System variables: plusLimitsOfDynamics/minusLimitsOfDynamics The lowest limit is taken
into account in each case.
See the Motion Control Technology Objects Axis Electric/Hydraulic, External Encoder
Function Manual, "Dynamic limits".
The maximum axial jerk is only used for monitoring and, if necessary, limiting the
synchronous operation setpoints if synchronous operation monitoring has been activated
with provision made for jerk. The setting for synchronous operation monitoring has no effect
on the synchronous operation setpoints generated. This even applies for the
synchronization procedure, for example.
The alarm "40202 Dynamic response of the synchronous operation setpoint cannot be
achieved" is output if the slave setpoints calculated by the synchronous operation are higher
than the active axial limits for velocity and acceleration. If the slave values are limited as a
result of this or due to dynamic discontinuity of slave values for synchronous operation
(caused by master value jumps, for example), a setpoint error is generated in the slave
values. See Synchronous operation monitoring (Page 75).
The maximum jerk on the axis can be exceeded during synchronization and
desynchronization if the jerk setting in the synchronization parameters on the synchronous
object is greater than the maximum jerk on the axis. To prevent this, an alarm response
can be configured, for example.
6. If desynchronization occurs within a system cycle clock and the target dynamics are thereby
at zero with regard to velocity and acceleration at the next cycle clock limit, no alarm is
output.

2.2.8 Switching of the master value source

2.2.8.1 Switching over the master value source – Overview

If more than one master value is assigned to a synchronized axis, the master value source
can be selected and switched over on the synchronous object using the _setMaster
command.
If a synchronous object is assigned to multiple master values, a random master value source
is selected internally following system startup. The correct master value source must be
specified in the user program. The master value source can be switched "on-the-fly". When it

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is enabled, the master values are referenced to the units system of the current master value
source. A relative or absolute coupling influences the transition process.
The master value transition can be set with and without dynamic response using the
transientBehavior parameter of the _setMaster command (V3.2 and higher):
● DIRECT: Without dynamic response (default)
● WITH_DYNAMICS: With dynamic response
● WITH_NEXT_SYNCHRONIZING: With next synchronization (as of V4.1)

See also
Master value switchover without dynamic response (Page 69)
Master value switchover with dynamic response (Page 69)
Master value switchover with next synchronization (V4.1 and higher) (Page 70)

2.2.8.2 Master value switchover without dynamic response

The transition behavior when the master value source is changed is different for absolute
synchronous operation and relative synchronous operation.
● With relative synchronous operation, an additional slave value difference occurs only if the
dynamic master values are different with regard to velocity and acceleration.
● With absolute synchronous operation, a non-continuous master value transition can occur.
Discontinuities in the slave values are limited to the maximum dynamic axis parameters on
the following axis. A compensation movement is generated in certain circumstances.
Different modulo settings of the master value sources are taken into account.

2.2.8.3 Master value switchover with dynamic response

The dynamic response parameters: The velocity profile, velocity, acceleration, and, if
necessary, jerk can be specified directly in the _setMaster() command. These parameters refer
to the dynamic response of the transition of the master value source. The
setMasterCommand system variable indicates the status of the _setMaster() motion on the
synchronous object.

Note
If the _setMaster command switches over the master value, the output of the synchronous
object remains asynchronous to the new master value during the transition. The system
variables for the synchronization remain unaffected. The transition behavior of the master
value does not have any effect on the active gearing/camming.
Please note that a master value switchover does not constitute a new synchronization
procedure, i.e. the syncState system variable (on the synchronous object) indicates YES.

To ensure setpoint synchronism, the setMasterCommand and syncState system variables

must be monitored.

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2.2 Fundamentals of Synchronous Operation

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Figure 2-48 Transition behavior and master value for the master value switching with dynamic response

The transition behavior for the new master value is calculated separately from the
synchronization and desynchronization, and until the end of the compensation is used as
master value for the setpoint monitoring and the evaluation of the syncState,
synchronizingState synchronization status.
The comparison of this value with the output value of the synchronous object sets the
syncState and synchronizingState variables: syncState=YES and
synchronizingState=INACTIVE. Despite the switching, the differenceCommandValue setpoint
difference is zero.

2.2.8.4 Master value switchover with next synchronization (V4.1 and higher)
The master value switchover is active together with the next _enableCamming()/
_enableGearing() synchronization command, whereby all specifications refer to the new
master value. The dynamic response values in the setMaster() command are not active
because the dynamic response values of the synchronization command are active during
synchronization.
System variable stateSetMasterCommand indicates the current status. Parameter
transientBehaviour sets the master value switchover:
● Master value switchover: is not active: system variable stateSetMasterCommand =
INACTIVE , parameter transientBehaviour = INACTIVE
● Master value switchover is active, switchover occurs directly: system variable
stateSetMasterCommand = TRANSIENT_BAHAVIOR_DIRECT, parameter
transientBehaviour = DIRECT
● Master value switchover is active, switchover occurs with dynamic response values: system
variable stateSetMasterCommand = TRANSIENT_BAHAVIOR_WITH_DYNAMICS ,
parameter transientBehaviour = WITH_DYNAMICS
● Master value switchover is active; switchover occurs with next synchronization: system
variable stateSetMasterCommand = TRANSIENT_BAHAVIOR_WITH_NEXT_SYNC,
parameter transientBehaviour = WITH_NEXT_SYNCRONIZING)

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2.2.9 Superimposed synchronous operation

Two synchronous operations can be superimposed by creating another synchronous object
on an axis. (V3.0 and higher)

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Figure 2-49 Schematic of a superimposed synchronous operation

To differentiate from the simple synchronous operation, the first synchronous operation is
called a basic synchronous operation and the second is called a superimposing synchronous
operation. The synchronous objects are called accordingly basic synchronous object and
superimposing synchronous object.
The synchronous operation can be set on the synchronous object to act as the basic motion,
main motion (has the same effect as non-superimposed synchronous operation), or
superimposed (or secondary) motion (syncingMotion.motionImpact:=STANDARD/
SUPERIMPOSED_MOTION configuration data element).
A maximum of one basic synchronous object can be interconnected to an axis, plus one
superimposed synchronous object on the same axis.

Creating an axis with superimposed synchronous operation

In the project navigator under <Axis_n>, it is possible to insert a (maximum) of one further
synchronous object <Axis_n_SYNCHRONOUS_OPERATION_1>, which is then

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2.2 Fundamentals of Synchronous Operation

superimposed, i.e. configuration data motionImpact is initialized to

SUPERIMPOSED_MOTION.
1. Select the axis in the project navigator.
2. Select Expert > Superimposed synchronous object from the shortcut menu.

Figure 2-50 Representation of superimposed synchronous operation in the project navigator

The configuration and settings for superimposed synchronous operation are made in the same
way as for the basic synchronous object.

Programming
All functions of the basic synchronous object (e.g. _enableGearing, _disableGearing, etc.) can
be applied on the superimposed synchronous object. Cross-references between synchronous
objects are not possible.

Absolute or relative superimposed synchronous operation

With superimposed synchronous operation, the properties for absolute or relative are the same
as for basic synchronous operation, with the exception that the coordinates refer to the
superimposed coordinate system on the slave axis.

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Coordinates
For the basic synchronous object, the synchronization parameters specified for the slave value
position refer to:
● The total coordinate system with mergeMode:=IMMEDIATELY and
decodingConfig.transferSuperimposedPosition <> TRANSFER_RESET
● the basic coordinate system in all other cases
The superimposed synchronous object refers to the superimposed coordinates where slave
value position specifications have been given.

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Figure 2-51 Coordinates for superimposed synchronous operation

Just as with a superimposed motion, each synchronous object has its own coordinate system.
The "outputs" of the synchronous objects are added in the Slave Axis technology object. If,
for example, the basic synchronous operation and superimposed synchronous operation have
the same master value, and motion takes place in absolute gearing with a ratio of 1:1, the
position value of the following axis will be twice that of the master axis after both synchronous
objects have been synchronized.

Behavior of superimposed synchronous operation in relation to basic motion

Superimposed synchronous operation behaves like a superimposed positioning motion with
regard to the basic motion on the axis (motion or synchronous operation).
decodingConfig.transferSuperimposedPosition configuration data on the synchronous axis
specifies when superimposed motions are to be applied to the basic motion, and when they
are to be substituted. This setting determines, for example, when mergeMode=
IMMEDIATELY that the superimposed motion is to be substituted on the basic motion. These
configuration data settings also apply to superimposed synchronous operations (see also
here (Page 141)).
There can be only one superimposed motion on the axis at one time, for example, a
superimposed positioning motion orsuperimposed synchronous operation. A superimposed
synchronous operation can be active without a basic motion being active at the same time.
See also superimposed motion for axis, Motion Control Technology Objects Axis Electric/
Hydraulic, External Encoder Function Manual.

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Monitoring
The output values of a synchronous object (and thus also the motion component of the
superimposed synchronous operation for the axis) can be read out in the currentSlaveData
system variable on the synchronous object.

Table 2-1 Table of coordinates on the slave axis for the superimposed synchronous operation

System variable Description

All coordinates:
positioningState. commandPosition Target position (total)
motionStateData. commandVelocity Target velocity (total)
commandAcceleration Target acceleration (total)
Basic coordinates:
basicMotion. position Position in the basic coordinate system
velocity Velocity in the basic coordinate system
acceleration Acceleration in the basic coordinate system
Superimposed coordinates:
superimposedMotion. position Position in the superimposed coordinate system
velocity Velocity in the superimposed coordinate system
acceleration Acceleration in the superimposed coordinate system

The syncMonitoring system variable on the following axis also displays the status of the
synchronous operation motion (V3.0 and higher):
● followingMotionState =
– INACTIVE: Synchronous motion is not active
– BASIC_MOTION_ACTIVE: Standard synchronous operation is active
– SUPERIMPOSED_MOTION_ACTIVE: Superimposed synchronous operation is active
– BASIC_AND_SUPERIMPOSED_MOTION_ACTIVE: Standard synchronous operation
and superimposed synchronous operation are active

Compensations during distributed synchronous operation

Compensation during distributed synchronous operation is also useful/effective during
superimposed synchronous operation.
See Compensations for distributed synchronous operation (Page 159).

Synchronous operation monitoring/statuses

If basic synchronous operation and superimposed synchronous operation are active, the
synchronized status (syncMonitoring.syncState) is only set if both synchronous operations are
synchronized.
Example:
A synchronous operation is started. After synchronization, the synchronous operation is
assigned 'synchronized status. Now another synchronous operation is started. The

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'synchronized' status disappears for the duration of the synchronization and is not reset until
the synchronization of the second synchronous operation is complete.
The variables and monitoring on the axis refer to the total synchronous operation. Error
messages (synchronous operation errors on the synchronized axis) are issued on all
interconnected synchronous objects.

2.2.10 Synchronous operation monitoring

The slave values calculated by the synchronous object (currentSlaveData) and any additional
setpoints on the axis are limited on the following axis to the maximum dynamic response
values. The deviation in the slave values resulting from this limitation is monitored. The current
maximum limits for velocity and acceleration (and jerk) on the axis influence this monitoring
process.
See the Motion Control Technology Objects Axis Electric/Hydraulic, External Encoder Function
Manual, "Dynamic limits".
The syncMonitoring system variables on the following axis indicate setpoint and actual value
differences:
● Setpoint monitoring
differenceCommandValue shows the difference between the setpoint generated at the
synchronous object and the executable setpoint at the axis, with dynamic limits taken into
account. limitCommandValue shows that the difference between the calculated slave value
and executable setpoint is above the permissible tolerance.
● Actual value monitoring
differenceActualValue shows the difference between the synchronous operation setpoint
and current actual value. With V4.2 and higher, the communication times in the system are
taken into account when determining the difference between setpoint and actual value.

Setpoint monitoring
On the axis, the slave values calculated by the synchronous operation are limited to the
maximum dynamic response values of the axes. This can cause the setpoints on the axis to
change.
Any resulting difference between the calculated slave value of the synchronous object
(currentSlaveData) and the executable setpoint is indicated in
syncMonitoring.differenceCommandValue at the following axis.
The syncMonitoring.syncState synchronization status on the following axis is set according to
the syncState on the synchronous object.
Exception: Superimposed synchronous operation (Page 71).
The following comparison must be performed to determine whether the following axis is
synchronized on the setpoint value side:
(<Following axis>.syncMonitoring.syncState:=YES) AND
(<Following axis.syncMonitoring.differenceCommandValue = 0)

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Actual value monitoring

On the following axis, the difference between the slave value calculated from the synchronous
operation (currentSlaveData) and the actual value on the axis can be queried using the
syncMonitoring.differenceActualValue system variable, provided no superimposed motion is
present (see Superimposed synchronous operation (Page 71)).

Note
With V4.2 and higher, the communication times are taken into account in the system during
synchronous operation monitoring.

Velocity gearing monitoring

The syncMonitoring system variable on the slave axis also displays the status of the velocity
gearing (V3.1 and higher):
● differenceCommandVelocity: velocity difference on the setpoint side between the velocity
setpoint calculated on the synchronous object (currentSlaveData) and the executable
velocity on the following axis (only applies to synchronous velocity operation).
● differenceActualVelocity: velocity difference on the actual value side between the velocity
setpoint calculated on the synchronous object (currentSlaveData) and the executable
velocity on the following axis (only applies to synchronous velocity operation).

Configuration
The synchronous operation monitoring is set on the following axis under Monitoring -
Synchronous operation monitoring (GearingPosTolerance configuration data element).
Limiting and monitoring the setpoint error:
● With setting enableCommandValue := NO_ACTIVATE:
– setpoints tolerance monitoring is not activated
● With setting enableCommandValue := WITHOUT_JERK:
– the tolerance monitoring of the setpoints is activated without inclusion of the jerk. Alarm
40201 is output if the setpoint tolerance is exceeded.
● With setting enableCommandValue := WITH_JERK:
– the tolerance monitoring of the setpoints is activated with inclusion of the jerk. Alarm
40201 is output if the setpoint tolerance is exceeded. The jerk on the axis is also
monitored.

Note
In the case of distributed synchronous operation with extrapolation on the following
axis, the setpoint monitoring with jerk setting is not appropriate.

The actual value deviation monitoring is set via GearingPosTolerance.enableActualValue. The

synchronous operation monitoring setting only becomes active after synchronization is
complete (syncState = YES).

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In terms of dynamic limits on the following axis, see Motion Control Technology Objects Axis
Electric/Hydraulic, External Encoder Function Manual, "Dynamic limits".

Error handling
When the synchronous operation tolerance is exceeded, the following axis issues the
technological alarm "40201 Synchronous operation tolerance exceeded on the following axis".
An alarm message can also be sent to the master value source; this setting is made in the
TypeOfAxis.GearingPosTolerance.enableErrorReporting configuration data element. Here, a
distinction can be made between deviation tolerance violations of the calculated slave value
setpoint and of the calculated slave value actual axis value. The leading axis then issues the
error "40110 Error triggered on slave during synchronous operation (error number:
With V4.2 and higher, an error message is also output on the master object when the following
axis disconnects the synchronous coupling for any reason in the event of an error.

Note
If the ALL_ERRORS_WITH_ABORT_SYNCHRONIZATION parameter is set, error message
40110 is triggered on the relevant master object (e.g. also with following error on following
axis).
If the synchronous motion is interrupted by a substitutional motion, no error message is
generated.
Only following axis errors are reported to the master object. Errors on the synchronous object
occurring when issuing the command and/or synchronizing are not taken into account.

The troubleshooting can be set using the following configuration data element:

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2.2 Fundamentals of Synchronous Operation

● <Following axis>.TypeOfAxis.GearingPosTolerance.enableErrorReporting
– NO_REPORTING- (default) no message, present
– COMMAND_VALUE_TOLERANCE- setpoint monitoring, present
– ACTUAL_VALUE_TOLERANCE- actual value monitoring, present
– ALL_ERRORS_WITH_ABORT_SYNCHRONIZATION- all errors that occurred
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Figure 2-52 Interrelationship between synchronous operation monitoring functions

See Error handling in the user program (Page 148).

See also
Monitoring the synchronization (Page 59)

2.2.11 Simulation mode

A synchronous operation can be switched to simulation, i.e. the values on the synchronous
object will be calculated but not output to the slave axis. The synchronous operation simulation
can be activated and deactivated at any time provided there are no faults present. The
simulation [ACTIVE/INACTIVE] system variable provides information about the simulation
status of the axis.
Application: Retaining a synchronous operation connection with _disableAxis() (Page 105).

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Commands for the simulation operation

● The _enableFollowingObjectSimulation() command sets a synchronous operation into
simulation mode. The synchronous values are calculated, but are not output to the following
axis. This can be done at any time. However, the axis states are taken into account when
the slave values are generated.
● The _disableFollowingObjectSimulation() command resets the synchronous operation
relationship out of simulation mode. The synchronous values are output to the following
axis again.
If there is a difference between the setpoint calculated at the synchronous operation and
the setpoint present on the axis, or a superimposed motion has occurred, only dynamic
limitation caused by the maximum values of the following axis occurs.

Configuration data for the simulation operation

The disableSynchronousOperation configuration data can be used to set whether master
values are to be forwarded to the slave axis.
● If NO (default), the synchronous operation is also canceled in simulation mode, provided
that the enables on the following axis have been canceled.
● If YES, the synchronous operation is not canceled in simulation mode if the enables on the
following axis have been canceled while synchronous operation is in simulation mode. Any
synchronous operation commands that are undergoing execution are retained.

2.2.12 Configuring units

You can define the basic units for each technology object. The same physical variables can
have different units in different technology objects. These are converted:
How to configure the units:
1. In the project navigator, open the context menu under the TO.
2. In the context menu, select Expert > Configure units. The Configure Units window appears
in the working area.
3. Select the unit for the physical variables. These units are used for the technology object,
e.g. s for time units.
or

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2.2 Fundamentals of Synchronous Operation

1. In the project navigator, open the Configuration under the TO.

2. Select the units tab.

Figure 2-53 Synchronous operation units

You can set the following parameters:

Field/Button Meaning/Instruction
Table with units
Physical variable column Shows the physical variable. The physical variables which are used by the TO are
available for the configuration.
Unit column Displays and configures the unit. Clicking on the cell opens up a combo box for selecting
the unit.
Toolbar
● Displays whether offline data or online data is shown
● Blue field = offline display
● Yellow field = online display
Close Button for closing the dialog.
Help Button for opening the online help for the dialog.

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2.2.13 Examples of synchronization operations as a function of the output position on the

slave value side

2.2.13.1 Synchronization via a specifiable master value distance

Together with the master value behavior, the starting position of the following axis relative to
the synchronous position on the following axis side largely determines the characteristic of the
synchronization profile.

Influence of starting position of the following axis

Example:
● Absolute 1:1 gear without offset
● Constant master value velocity
● Slave value at start of synchronization at standstill

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2.2 Fundamentals of Synchronous Operation

● Synchronization over a master value distance

● Velocity profile type CONTINUOUS for synchronization
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Figure 2-54 Synchronization via a specifiable master value distance

While the position characteristics of the individual synchronization operations do not differ very
much, the velocity characteristics differ significantly:
● In order to accelerate to the synchronous velocity in the synchronous position, a motion in
the opposite direction following by a reversal is required (2).
● It is possible to accelerate directly to the synchronous velocity and synchronous position;
the position difference to be applied is minor (3).
● The acceleration to the synchronous velocity in the synchronous position is even (4).

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● Direct acceleration to the synchronous velocity in the synchronous position is possible.

While the position difference to be applied is greater, a velocity greater than the
synchronous velocity and, thus, a velocity reversal is not required for synchronization (5).
● To apply the position difference, a velocity greater than the synchronous velocity and, thus,
a velocity reversal is required for synchronization (6).

Recommendation for master value-related synchronization

Recommendation for synchronization via master value distance with 1:1 gear and
synchronization from standstill:
● Starting position of the following axis removed from the synchronous position by half the
synchronization length.
● Synchronization range symmetrical relative to the synchronous position.

2.2.13.2 Synchronization profile based on specifiable dynamic response parameters

Together with the master value behavior, the starting position of the following axis relative to
the synchronous position on the following axis side largely determines the characteristic of the
synchronization profile.

Influence of starting position of the following axis with leading synchronization

Example:
● Absolute 1:1 gear without offset
● Constant master value velocity
● Following axis at start of synchronization at standstill

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● Synchronization profile based on dynamic response parameters

● Velocity profile type TRAPEZOID for synchronization
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Figure 2-55 Synchronization profile based on specifiable dynamic response parameters and
leading synchronization

In the case of leading synchronization based on dynamic response parameters,

synchronization starts differently depending on the starting position of the following axis:

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● If necessary, the following axis can be accelerated directly to the synchronous velocity and
synchronous position (2).
● If the starting position of the following axis is below this point, a position difference must
also be applied with the specified dynamic values (3).
● If the starting position is above this point, reversing (i.e. traveling in the opposite direction)
is required in order to traverse to the synchronous point at the required synchronous velocity
(4).
Influence of starting position of the following axis with trailing synchronization
Together with the master value behavior, the starting position of the following axis relative to
the synchronous position on the following axis side largely determines the characteristic of the
trailing synchronization profile.
Example:
● Absolute 1:1 gear without offset
● Constant master value velocity
● Following axis at start of synchronization at standstill
● Synchronization profile based on dynamic response parameters
● Velocity profile type TRAPEZOID for synchronization
With this type of dynamic response-related synchronization, a master value position is defined
from which the synchronization procedure between the master value and following axis is
initiated. Here, the desynchronization operation itself is performed based on the dynamic
response value settings.

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Figure 2-56 Synchronization profile based on specifiable dynamic response parameters and trailing
synchronization

With trailing synchronization via dynamic response parameters, the "synchronous" status is
achieved at different times, depending on the starting position of the following axis.
Depending on the starting position of the following axis:
● If necessary, the following axis can be accelerated directly to the synchronous velocity and
synchronous position (2).
● If the starting position of the following axis is below this point, a position difference must
also be applied with the specified dynamic values (3).
● If the starting position of the following axis is above this point, reversing (i.e. traveling in the
opposite direction) is required in order to traverse to the synchronous point at the required
synchronous velocity (4).

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2.2.14 Examples

2.2.14.1 Examples of typical synchronization operations

Several examples for synchronization operations of the gearing and their parameterization in
MCC and ST commands are listed here.

Note
The function parameters that are not important to function calls are omitted from the
examples. The required parameters are entered directly.

Relative synchronization with master value reference

The master axis moves at a velocity of 100 mm/s. The following axis is stationary at position
0 mm. The synchronization is started immediately; after 20 mm, this should result in relative
synchronism between the master axis and following axis.

Table 2-2 ST programming

retval:=_enablegearing (
followingObject:= <SYNCHRONOUSOBJECT>,
direction:=POSITIVE,
direction:=POSITIVE,
gearingType:=RELATIVE,
gearingMode:=GEARING_WITH_FRACTION,
gearingNumerator:=1,
gearingDenominator:=1,
synchronizingMode:=IMMEDIATELY,
syncProfileReference:=RELATE_SYNC_PROFILE_TO_LEADING_VALUE,
syncLengthType:=DIRECT,
syncLength:=20.0);

Table 2-3 MCC programming

Parameters:
Gear ratio: 1:1
Reference point: Gearing relative to start position
Synchronization:
Synchronization reference: Leading axis
Start of synchronization: Synchronize immediately
Synchronization length: 20 mm

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1) Start of synchronization
2) Master axis position
3) Following axis position
4) Synchronization status

Figure 2-57 Master and following axis position

1) Start of synchronization
2) Master axis velocity
3) Following axis velocity
4) Synchronization status

Figure 2-58 Master and following axis velocity

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Absolute synchronization with master value reference

The master axis moves at a velocity of 100 mm/s. The following axis is stationary at position
50 mm. Synchronization is performed within 20 mm; this means that for a master axis position
of 80 mm, absolute synchronism between the master and following axis occurs.

Table 2-4 ST programming

retval:=_enablegearing (
followingObject:= <SYNCHRONOUSOBJECT>,
direction:=POSITIVE,
gearingType:=ABSOLUTE,
gearingMode:=GEARING_WITH_FRACTION,
gearingRatioType:=DIRECT,
gearingNumerator:=1,
gearingdenominator:=1,
synchronizingMode:=ON_MASTER_POSITION,
syncPositionReference:=BE_SYNCHRONOUS_AT_POSITION,
syncProfileReference:=RELATE_SYNC_PROFILE_TO_LEADING_VALUE,
syncLengthType:=DIRECT,
synclength:=20.0,
syncPositionMasterType:=DIRECT,
syncPositionMaster:=80.0);

Table 2-5 MCC programming

Parameters:
Gear ratio: 1:1
Reference point: gearing is made based on the axis zero point
Synchronization:
Synchronization reference: Leading axis
Start of synchronization: at leading axis position
Reference point of the leading axis position: Synchronize before synchronization position
Synchronization length: 20 mm
Leading axis position: 80 mm

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1) Start of synchronization
2) Master axis position
3) Following axis position
4) Synchronization status

Figure 2-59 Master and following axis position

1) Start of synchronization
2) Master axis velocity
3) Following axis velocity
4) Synchronization status

Figure 2-60 Master and following axis velocity

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Relative synchronization with master value reference and offset

The master axis moves at a velocity of 100 mm/s. The following axis is stationary at position
0 mm. Starting with a master axis position of 100 mm, the following axis will be synchronized
relative to the master axis within 40 mm. When synchronism is achieved, this results in a
following axis position based on the position at the start of synchronization and the offset of
30 mm.

Table 2-6 ST programming

retval:= _enablegearing(
followingObject:= <SYNCHRONOUSOBJECT>,
direction:=POSITIVE,
gearingType:=RELATIVE,
gearingMode:=GEARING_WITH_FRACTION,
gearingNumerator:=1,
gearingdenominator:=1,
synchronizingMode:=ON_MASTER_AND_SLAVE_POSITION,
syncPositionReference:=SYNCHRONIZE_WHEN_POSITION_REACHED,
syncProfileReference:=RELATE_SYNC_PROFILE_TO_LEADING_VALUE,
syncLengthType:=DIRECT,
synclength:=40.0,
syncPositionMasterType:=DIRECT,
syncPositionMaster:=100.0,
syncPositionSlaveType:=DIRECT,
syncPositionSlave:=30.0);

Table 2-7 MCC programming

Parameters:
Gear ratio: 1:1
Reference point: Gearing relative to start position
Synchronization:
Synchronization reference: Leading axis
Start of synchronization: at leading axis position with offset
Offset: 30 mm
Reference point of the leading axis position: Synchronize from synchronization position
Synchronization length: 40 mm
Leading axis position: 100 mm

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1) Start of synchronization
2) Master axis position
3) Following axis position
4) Synchronization status

Figure 2-61 Master and following axis position

1) Start of synchronization
2) Master axis velocity
3) Following axis velocity
4) Synchronization status

Figure 2-62 Master and following axis velocity

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Absolute synchronization with time reference, trailing synchronization

The master axis moves at a velocity of 100 mm/s. The following axis is stationary at position
50 mm. The specified dynamic response parameters (velocity = 300 mm/s and acceleration =
1,000 mm/s2) are used for synchronization starting from the master axis position 300 mm, in
order to achieve absolute synchronism between the master and the following axis.

Note
Depending on the specified offset, the following axis may need to perform a reversing motion.

Table 2-8 ST programming

retval:=_enablegearing(
followingObject:= <SYNCHRONOUSOBJECT>,
direction:=POSITIVE,
gearingType:=ABSOLUTE,
gearingMode:=GEARING_WITH_FRACTION,
gearingNumerator:=1,
gearingdenominator:=1,
synchronizingMode:=ON_MASTER_POSITION,
syncPositionReference:=SYNCHRONIZE_WHEN_POSITION_REACHED,
syncProfileReference:=RELATE_SYNC_PROFILE_TO_TIME,
syncPositionMasterType:=DIRECT,
syncPositionMaster:=300.0,
velocityType:=DIRECT,
velocity:=300.0,
positiveAccelType:=DIRECT,
positiveAccel:=1000.0,
negativeAccelType:=DIRECT,
negativeAccel:=1000.0,
positiveAccelStartJerkType:=DIRECT,
positiveAccelStartJerk:=10000.0,
positiveAccelEndJerkType:=DIRECT,
positiveAccelEndJerk:=10000.0,
negativeAccelStartJerkType:=DIRECT,
negativeAccelStartJerk:=10000.0,
negativeAccelEndJerkType:=DIRECT,
negativeAccelEndJerk:=10000.0,
velocityprofile:=SMOOTH);

Table 2-9 MCC programming

Parameters:
Gear ratio: 1:1
Reference point: gearing is made based on the axis zero point

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Synchronization:
Synchronization reference: Timer
Start of synchronization: at leading axis position
Reference point of the leading axis position: Synchronize from synchronization position
Leading axis position: 300 mm
Dynamic response:
Velocity: 300 mm/s
Deceleration: 1000 mm/s²
Jerk: 10000 mm/ s³
Velocity profile: Constant

Note
For a motion with a continuous velocity profile, the enable of the jerk-limited synchronization
syncingMotion.smoothAbsoluteSynchronization:=YES with absolute synchronous operation
relationships should be set on the synchronous object.

1) Start of synchronization
2) Master axis position
3) Following axis position
4) Synchronization status

Figure 2-63 Master and following axis position

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1) Start of synchronization
2) Master axis velocity
3) Following axis velocity
4) Synchronization status

Figure 2-64 Master and following axis velocity

1) Start of synchronization
2) Master axis acceleration
3) Following axis acceleration
4) Synchronization status

Figure 2-65 Master and following axis acceleration

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Absolute synchronization with time reference, leading synchronization

The master axis moves at a velocity of 100 mm/s. The following axis is stationary at position
50 mm. The specified dynamic response parameters (velocity = 300 mm/s and acceleration =
1,000 mm/s2) are used for synchronization so that, with a master axis position of 300 mm,
absolute synchronism exists between the master and following axes. For the synchronization
procedure, a maximum change in the master value velocity of 20% is permitted on the
synchronous object (syncingMotion.maximumOfMasterChange).

Table 2-10 ST programming

retval:=_enablegearing(
followingObject:= <SYNCHRONOUSOBJECT>,
direction:=POSITIVE,
gearingType:=ABSOLUTE,
gearingMode:=GEARING_WITH_FRACTION,
gearingNumerator:=1,
gearingDenominator:=1,
synchronizingMode:=ON_MASTER_POSITION,
syncPositionReference:=BE_SYNCHRONOUS_AT_POSITION,
syncProfileReference:=RELATE_SYNC_PROFILE_TO_TIME,
syncPositionMasterType:=DIRECT,
syncPositionMaster:=300.0,
velocityType:=DIRECT,
velocity:=300.0,
positiveAccelType:=DIRECT,
positiveAccel:=1000.0,
negativeAccelType:=DIRECT,
negativeAccel:=1000.0,
velocityProfile:=TRAPEZOIDAL);

Table 2-11 MCC programming

Parameters:
Gear ratio: 1:1
Reference point: gearing is made based on the axis zero point
Synchronization:
Synchronization reference: Timer
Start of synchronization: at leading axis position
Reference point of the leading axis position: Synchronize before synchronization position
Leading axis position: 300 mm
Dynamic response:
Velocity: 300 mm/s
Deceleration: 1000 mm/s²
Velocity profile: Trapezoidal

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1) Start of synchronization
2) Master axis position
3) Following axis position
4) Synchronization status

Figure 2-66 Master and following axis position

1) Start of synchronization
2) Master axis velocity
3) Following axis velocity
4) Synchronization status

Figure 2-67 Master and following axis velocity

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1) Start of synchronization
2) Master axis acceleration
3) Following axis acceleration
4) Synchronization status

Figure 2-68 Master and following axis acceleration

2.2.14.2 Example of offset and scale on the synchronous object

A leading axis provides position values over a range of 360° and 60° phase offset, i.e. from
60...420°. The following axis should move in the range 40...220°.
Definition range of cam: 0 to 100
Range of cam: 0 to 100
The definition and value range of the cam can be adapted to the required representation range
for the camming using scaling and offset as follows (See also Figure Equation for scale and
offset on the camming in Chapter Camming):

Scaling Offset
Master value 360 / 100 = 3.6 60
Slave value (220 - 40) / 100 = 1.8 40

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1) unscaled, non-offset function

2) scaled, offset function

Figure 2-69 Example of the scaling and the offset of a cam

In the following programming example, the offset and scale commands for the synchronous
object take effect at the subsequent activation of the camming:

Table 2-12 ST programming

(*scaling of the master value*)

retval:= _setCammingScale(
followingObject:= <SYNCHRONOUSOBJECT>,
scalingRange:= MASTER_RANGE,
scaleValue:= 3.6,
activationMode:= DEFAULT_VALUE
);
(*scaling of the slave value*)
retval:= _setCammingScale(
followingObject:= <SYNCHRONOUSOBJECT>,
scalingRange:= SLAVE_RANGE,
scaleValue:= 1.8,
activationMode:= DEFAULT_VALUE
);
(*offset of the master value*)
retval:= _setCammingOffset(
followingObject:= <SYNCHRONOUSOBJECT>,
offsetRange:= MASTER_RANGE,
offsetMode:= ABSOLUTE,

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offsetValue:= 60.0,
activationMode:= DEFAULT_VALUE
);
(*offset of the slave value*)
retval:= _setCammingOffset(
followingObject:= <SYNCHRONOUSOBJECT>,
offsetRange:= SLAVE_RANGE,
offsetMode:= ABSOLUTE,
offsetValue:= 40.0,
activationMode:= DEFAULT_VALUE
);

MCC programming

Table 2-13 <Set scaling on camming>:master value side

Parameters:
Range: Master Range
Offset: 3.6
Effect: on following commands

Table 2-14 <Set scaling on camming>:slave value side

Parameters:
Range: slave range
Offset: 1.8
Effect: on following commands

Table 2-15 <Set offset on camming>:master value side

Parameters:
Range: Master Range
Offset: 60.0
Mode: Absolute
Effect: on following commands

Table 2-16 <Set offset on camming>:slave value side

Parameters:
Range: slave range
Offset: 40.0
Mode: Absolute
Effect: on following commands

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See also
Camming (Page 27)

2.2.14.3 Example of applying offset as superimposition

The following example shows the two dynamic corrections of the dynamicReference parameter
in their different effects using an accelerating master value.
Example: Master and following axis for a synchronous operation of 1:1 are absolutely
synchronous, accelerate at 100 mm/s². The offset of -50 mm on the master value side is
implemented using _setGearingOffset for a programmed correction velocity of 300 mm/s and
a correction acceleration of 3,000 mm/s², by means of a non-continuous-acceleration velocity
profile.

Table 2-17 ST programming

retval := _setGearingOffset (
followingObject:= <SYNCHRONOUSOBJECT>,
offsetRange := MASTER_RANGE,
offsetMode := RELATIVE,
offsetValue := -50.0,
velocityType := DIRECT,
velocity := 300.0,
positiveAccelType := DIRECT,
positiveAccel := 3000.0,
negativeAccelType := DIRECT,
negativeAccel := 3000.0,
velocityProfile := TRAPEZOIDAL,
activationMode := ACTUAL_VALUE,
dynamicReference := TOTAL_MOVE / OFFSET_MOVE
);

Note
When the master value velocity is constant, the dynamic transitions have a generally identical
form and differ only as a result of the dynamic response parameters that act differently.

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1) Master axis position

2) Following axis position

Figure 2-70 Leading and following axis position for dynamicReference:= TOTAL_MOVE

1) Master axis velocity

2) Following axis velocity

Figure 2-71 Leading and following axis velocity for dynamicReference:= TOTAL_MOVE

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1) Master axis position

2) Following axis position

Figure 2-72 Leading and following axis position for dynamicReference:= OFFSET_MOVE

1) Master axis position

2) Following axis position

Figure 2-73 Leading and following axis velocity for dynamicReference:= OFFSET_MOVE

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2.2.15 Special actions

2.2.15.1 Redefining the axis position during active synchronous operation

The following options are available for resetting an axis position, e.g. by means of
_redefinePosition() or _homing():
● Redefining the master axis position causes a jump in the master value.
The following axis then performs a compensating movement and finally moves again in
synchronism with the master axis. If the position tolerance > the synchronous operation
tolerance, the error 40201 "Synchronous operation tolerance on gearing axis exceeded"
will be output.
● Redefining the following axis position does not cause a jump on the master value.
– For the absolute synchronous operation, the slave axis is no longer position-
synchronous and so performs a compensating movement.
– For the relative synchronous operation, the following axis does not perform a
compensation motion, because position synchronization is not necessary.
Examples:

1) Master axis position

2) Following axis position
3) Synchronization status

Figure 2-74 Redefining the leading axis position (absolute or relative gearing) -> The following axis
performs a compensation motion

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1) Master axis position

2) Following axis position
3) Synchronization status

Figure 2-75 Redefining the following axis position for the absolute gearing -> The following axis
performs a compensation motion

1) Master axis position

2) Following axis position
3) Synchronization status

Figure 2-76 Redefining the following axis position for the relative gearing -> The following axis does
not perform a compensation motion

2.2.15.2 Retaining a synchronous connection for _disableAxis

If the slave axis is no longer able to apply the generated synchronous operation setpoints, e.g.
due to the removal of enables or an error response, an active synchronous operation
connection is closed. It is possible to retain the synchronous operation connection by using
synchronous operation in simulation mode and setting the
DecodingConfig.disableSynchronousOperation=YES configuration data element on the
synchronous object.
See Simulation mode (Page 78).

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The existing synchronous connection remains active except in the following situations:
● Restart of following axis (_restartAxis())
● Invalid actual values on the following axis
When simulation mode is terminated, the current synchronous operation setpoints are applied
immediately as axis setpoints.

Remove the axis from the synchronous operation interconnection, and return it
Example:
Opening and closing protective doors

Removing an axis from the synchronized group

1. Stop the leading axis.
2. Switch the synchronous operation to simulation mode.
3. DecodingConfig.disableSynchronousOperation on the synchronous object must be set to
YES. As a result, the synchronous operation connection is not disconnected on
_disableAxis.
4. If a superimposed motion had been performed (e.g. for correcting):
– Save the position of the superimposed coordinate system in a user variable.
– Perform _redefinePosition in the coordinate system 2 to absolute position 0.
5. Cancel the controller enables (_disableAxis()). This will clear the drives. The axis goes into
follow-up mode / "control" on the axes is deleted.

Returning the axis to the synchronized group

1. Reconnect the controller enables.
2. If necessary, use _redefinePosition to pass the save actual position as absolute position
to the coordinate system 2.
3. Reactivate axis/drive with _enableAxis().
4. Switch synchronous operation back from simulation mode.
A compensation motion will be performed if the setpoints for the synchronous object and the
setpoints on the axis do not match.

2.2.15.3 Substitution of velocity gearing with absolute synchronous operation

A synchronous velocity operation cannot be substituted directly with an absolute synchronous
operation. Immediately afterwards, only a relative synchronous operation can be executed.

If an attempt is made to execute an absolute synchronous operation immediately after a

velocity gearing, the following technological alarm is output:
50110 "Call-up of an absolute synchronous position operation after a synchronous velocity
operation not permitted" (as of V3.2)

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Procedure:
● Switch a relative position-controlled synchronous operation in between for one IPO cycle.
(mergeMode = IMMEDIATELY and then a waitTime with Time = 0 sec)

2.2.15.4 Motion with absolute synchronous operation

Substitution of a position axis by an absolute synchronous operation (as of V4.4)

A position axis traversing in speed-controlled mode (_move(movingMode =
SPEED_CONTROLLED)) can be substituted directly by an absolute synchronous operation.
As a consequence of this, for example, with a stationary master value, the following axis
positions itself at the absolute position of the master value.

2.2.15.5 Canceling active and pending synchronous operations

If gearing or camming is active and another gearing or camming operation is started, the first
_disableCamming()/_disableGearing() command ends the synchronous operation to be
synchronized, and the second _disableCamming()/_disableGearing() command ends the
active synchronous operation.
Alternatively, in V4.1 and higher the synchronous operation commands can be canceled using
the commandId associated with the command. The _cancelFollowingObjectCommand()
command can be used to cancel the synchronous operation command by specifying the
commandId in the commandToBeCancelled parameter. This removes the synchronous
operation command from the command buffer. This means that a pending command for
synchronization can be canceled (for example, if the application recognizes that
resynchronization is not intended to take place).

2.2.15.6 Adapt the synchronization velocity to the master value velocity

The following axis cannot be synchronous with the master object if the velocity of the following
axis for the synchronization process is lower than that of the master value during the
synchronization process.
Example: The master axis is, for example, currently travelling at 200 mm/s. A gearing is started
for which the synchronization velocity is limited by the default value of 100 mm/s. The following
axis cannot overtake the master object.
To adapt the synchronization velocity of the following axis to the master value velocity, proceed
as follows:

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1. Create a master axis.

2. Create a following axis (synchronized axis). A
Following_Axis_SYNCHRONOUS_OPERATION object is automatically created below the
following axis.
The project navigator should look like this:

Figure 2-77 Axes for example

3. Make the following settings for FollowingAxis_SYNCHRONOUSOPERATION -> Settings:

– Overdrive factor for dynamic values: 150 %
– Adapting the dynamic values for synchronization: activated

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Figure 2-78 Settings for FollowingAxis_SYNCHRONOUSOPERATION

For the synchronization, the following axis uses the dynamic response values of the master
axis (increased by the overdrive factor) and travels with the maximum velocity of 300 mm/s.

Another application scenario

The master object travels with the constant velocity of 80 mm/s. The dynamic response setting
of the following axis allows a synchronization velocity of 100 mm/s. Under these conditions,
the following axis can synchronize itself without adaptation of the dynamic response values.
If the master object accelerates to 150 mm/s, but the synchronous status is not yet attained,
the following axis can synchronize itself only with adaptation of the dynamic response values.
During the synchronization action, the maximum velocity of the following axis is calculated
using the current set velocity of the master object (150% of the current value).

2.2.15.7 Substitution of synchronous operation through _move, _pos, _stop with reset of an existing
acceleration to zero

Description
When a motion is replaced with the _stop(), _pos() and _move() functions and a smooth velocity
profile with jerk specification is applied during the axis acceleration phase, the velocity can
continue to increase until the acceleration is reduced by means of the jerk that has been set.
In extreme cases, the velocity can rise still further until it reaches the configured maximum
velocity. The axis is only decelerated once acceleration has been reduced by the jerk.
With the abortAcceleration parameter, you can set that a possible acceleration does not
exceed the jerk limitation, but is immediately cleared.

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The abortAcceleration parameter is available for _stop() as of V4.2.1 and for _pos and
_move as of V4.4.
You will find more information in the TO Axis Electric/Hydraulic, External Encoder Function
Manual.

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2.3 Synchronous Operation Configuration

This section shows you how to create and configure axes with synchronous operation in
SIMOTION SCOUT.
It is assumed that you have already created cams, master axes, or external encoders.

Note
If the actual values/setpoints are required to be equal during a synchronous operation, the
same Ti (actual value acquisition) and To (setpoint acceptance) times must be adopted for
all drive units used (e.g. SINAMICS Integrated, CU320).

When configuring a synchronous operation, you must follow the steps below:
● Create an axis with synchronous operation functionality (Page 112).
● Assign master values and cams to the synchronized axis (Page 113).
● Assign synchronous operation parameters (Page 115).
● Define the settings for the synchronization procedure (Page 132).
● Define synchronous operation monitoring (Page 134).

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2.3.1 Creating an axis with synchronous operation

Create a synchronous axis as follows:
1. To create an Axis TO with the Synchronous operation technology in SCOUT, double-click
Insert axis under AXES in the project navigator. You can also copy an existing
Axis technology object using the clipboard and insert it with another name.
2. Activate for creating the axis the Synchronous operation technology. A synchronous object
will automatically be created.

Figure 2-79 Inserting an axis with synchronous operation

Note
If synchronous operation technology is specified for an Axis technology object, the
synchronous object will be inserted together with the Axis technology object. The
synchronous object is permanently assigned to the Axis technology object. The name of
the synchronous object is automatically defined and cannot be changed.
It is not possible to subsequently convert a positioning or speed axis to a synchronous
axis.
It is not possible to add a synchronous object. Only a superimposed synchronous
operation can be added to the synchronous axis using expert (see Superimposed
synchronous operation (Page 71)).

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Representation in the project navigator

The synchronous object is generated automatically when a synchronous axis is created and
is displayed below this synchronous axis in the project navigator. The object is automatically
given the name of the axis, followed by _SYNCHRONOUS_OPERATION. There the permitted
synchronous operation relationships of the synchronous axis can be defined and the
preassignments for the synchronous operation coupling to a leading axis assigned.
The assignment of the master values and cams is indicated in the project navigator using links:
● For the Synchronous object:
Links to the master values (axes, external encoders, addition objects, formula objects, and
fixed gears) as well as cams
● For the technology objects used:
Link to the synchronous object
● Below the master values (axes, external encoders, addition objects, formula objects, and
fixed gears): Link to the synchronous object

Superimposed synchronous operation

If a superimposed synchronous operation relationship to another master value is also to be
established, an additional synchronous object can be placed below the following axis via the
context menu for the following axis (Expert > Insert superimposed synchronous object) (see
Superimposed synchronous operation (Page 71)).
The standard and superimposed synchronous operation relationships then affect the following
axis additively by means of the two master values.

2.3.2 Assigning master values and cams

When an axis with synchronous operation is created, the synchronous operation configuration
still has to be specified, i.e., the master values to be used must be selected and, if required,
a cam must be assigned.

Note
Synchronous operation is not possible if a master value is not assigned. Camming is not
possible if a cam is not assigned.

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Defining the synchronous operation configuration

● In the project navigator, double-click on Interconnections under the object <Axis
name>_SYNCHRONOUS OPERATION. The window below opens.

Figure 2-80 Selection of master values and cams

Assign the master values and cams to the following axis in this window.
You can set the following parameters:

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Table 2-18 Parameters for configuring synchronous operation

Field/Button Explanation/instructions
Following axis The name of the following axis is displayed here.
Possible master The master values available in the project, which you can assign to the following
values (leading axis) axis, are listed here.
The master value can be specified by the following technology objects:
● Axis (real or virtual axis)
● External encoder
● Fixed gear
● Addition object
● Formula object
In accordance with the specified synchronous operation condition (e.g.
camming), the slave value is calculated on the basis of the master value and
assigned to the following axis as a leading value.
When more than one master value is assigned, you must specify which master
value is to be used by means of programming in SIMOTION SCOUT (e.g. with
MCC).
Possible cams Cams created in the project are listed here. You can assign cams to the
synchronous object for camming.
When more than one cam is assigned, you must specify which cam is to be
used by means of programming in SIMOTION SCOUT (e.g. with MCC).

1. Assign the desired master values to the axis with synchronous operation. You select the
current master value to be used in the user program (_setMaster).
2. Assign the desired cams to the axis with synchronous operation. You select the cam to be
used in the user program (_enableCamming).
3. For real axes or external encoders, select setpoint coupling or actual value coupling for
axes, or select actual value coupling or actual value coupling with extrapolation for external
encoders.
See Setpoint/actual value coupling (Page 36).

Figure 2-81 Selection of the coupling type

When the window is closed, the configuration is accepted and saved automatically.

2.3.3 Assigning parameters/defaults for synchronous operation

In the project navigator, double-click Default under the object <Axis name>_SYNCHRONOUS
OPERATION to change the default settings.

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Synchronous operation - Default

In this window, you define the replacement values (default) for calling the synchronous
operation functions (_enableGearing, _enableVelocityGearing, and _enableCamming or
_disableGearing, _disableVelocityGearing, and _disableCamming).
These replacement values are only evaluated if no special settings are made in the associated
function calls for synchronization/desynchronization (ST and LAD or MCC).

You can set parameters for the following functionality:

● Gearing (Page 117)
● Velocity gearing (Page 118)
● Camming (Page 119)
● Gearing synchronization (Page 121)
● Camming synchronization (Page 125)
● Dynamic response (Page 128)
● Master dynamic response (Page 130)

Note
All tabs are always available for default settings. Only parameters used for the relevant
functionality are evaluated.

Further information
● For information about this function, refer to Overview of synchronous operation and
Fundamentals of synchronous operation.
● For information about programming, refer to Synchronous operation programming/
references (Page 136).
● The meaning of the dialog window parameters and their permissible value ranges can be
found in the SIMOTION reference lists.

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2.3.3.1 Gearing
Gearing is characterized by a constant coupling between the master value source and following
axis. This coupling (via the gear ratio) can be specified as the ratio of two decimal numbers
(numerator/denominator) or as a floating-point number.

Figure 2-82 Synchronous object: Default setting for gearing

Gearing - default
In the Gearing tab, select the direction, absolute or relative synchronous operation and the
gear ratio. These settings are only relevant when gearing mode is used.

You can set the following parameters:

Table 2-19 Parameters for gearing

Field/Button Explanation/instructions
direction Here, you specify the direction of the gearing.
Gear type Here, you select the gear type (absolute or relative).
Gear ratio mode Specify the gear ratio mode here. Further parameters are displayed
depending on the selected mode (gear ratio as floating-point number or
gear ratio as numerator/denominator ratio).
Gear ratio You can enter the gear ratio as a floating-point number here.
Counter instructions Here, you can enter the numerator of the gear ratio in the form of a
numerator/denominator ratio.

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Field/Button Explanation/instructions
Denominator Here, you can enter the denominator of the gear ratio in the form of a
numerator/denominator ratio.
Synchronization with look- You can set here whether a constant acceleration/deceleration of the
ahead master value is to be used for the synchronization.

See also
Gearing (Page 20)

2.3.3.2 Velocity gearing

In contrast to gearing or camming, which relate to the position of an axis, velocity gearing
relates to the velocity of an axis with a constant coupling between the master value source
and the following axis. With velocity gearing, a non-position-controlled, i.e. speed-controlled
synchronous operation with the velocity of a master axis, is activated on an axis that is set as
a position-controlled axis (synchronized axis).
Possible master values are:
● Velocity of a master axis configured as a position-controlled axis
● Velocity of an external encoder

Figure 2-83 Synchronous object: Default setting for synchronous velocity operation

Velocity gearing - default

On the Velocity gearing tab, you set the direction and the gear ratio. These settings are only
relevant when velocity gearing mode is used.

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You can set the following parameters:

Table 2-20 Parameters for velocity gearing

Field/Button Meaning/Instruction
direction Specify the direction of the synchronous velocity operation here.
Gear ratio Enter here a coupling ratio for the synchronous velocity operation as
floating-point number.

See also
Velocity gearing (Page 26)

2.3.3.3 Camming
Camming is characterized by variable coupling between the master value source and the
following axis. The coupling is described by a cam (transmission function). Camming can be
scaled and offset on both the master value source side and on the following axis side. This
enables a cam to be custom-adjusted in its definition range and value range.

Figure 2-84 Synchronous object: Default setting for camming

Camming - Default
On the Camming tab, the scaling and offset for each master axis and following axis are shown.
The Scaling and Offset setting can be made on the cam or via _setCammingScale or
_setCammingOffset. You select the direction, absolute or relative synchronous operation for
the master value and the slave value, as well as the cam mode. These settings are only relevant
when camming mode is used.

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You can set the following parameters:

Table 2-21 Parameters for camming

Field/Button Explanation/instructions
Leading axis
Scaling The scaling of the master value is displayed here.
Offset The offset of the master value is displayed here.
Following axis
Scaling The scaling of the following axis is displayed here.
Offset The offset of the slave axis is displayed here.
Camming direction Specify the direction in which the cam is run.
Master mode Specify the mode in which the master value runs through the cam (absolute or
relative).
Slave mode Specify the mode in which the following axis runs through the cam (absolute or
relative).
Cam mode Specify the execution type for the cam here (cyclic or non-cyclic).
Starting point in the Specify here for relative master value reference the reference of the master
cam for relative values by specifying a starting position (camStartPositionMaster) in the cam.
camming The position is always an absolute reference in relation to the definition range
of the cam.

See also
Camming (Page 27)

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2.3.3.4 Gearing synchronization

Figure 2-85 Synchronous object: Default setting for gear synchronization

Gear Synchronization - Default

You use the Gear synchronization tab to set the parameters for synchronization and
desynchronization. These settings are only relevant when gearing mode is used.

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You can set the following parameters:

Table 2-22 Parameters for gear synchronization

Field/Button Explanation/instructions
Synchronization Specify when synchronization of the following axis with the master value is
performed.
For more information, see Synchronizing the gear (Page 41)
Position reference Here, you specify the position of the synchronization profile relative to the
position of the synchronization point.
For more information, see Position reference during synchronization
(Page 123)
Synchronization Specify the synchronization direction here. See Synchronization direction
direction (Page 47).
Master value SyncPos Here, you enter the position of the synchronization point of the master value.
SyncPos slave axis Here, you enter the position of the synchronization point of the slave axis
Desynchronization Specify when desynchronization of the following axis with the master value
is performed.
For more information, see Desynchronizing the gear (Page 124).
Position reference Here, you specify the position of the desynchronization profile relative to the
position of the desynchronization point
For more information, see Position reference during desynchronization
(Page 124).
Desync. Master value Here, you enter the position of the desynchronization point of the master
value.
Desync. Following axis Here, you enter the position of the desynchronization point for the following
axis

2.3.3.5 Synchronizing the gear

You can set the synchronization condition using the Synchronization drop-down list box on the
Gear synchronization tab:

Table 2-23 Parameters for gear synchronization

Setting Meaning
Effective immediately Synchronization takes immediate effect.
The start point is derived from the position of the current master value.
The settings in Master value SyncPos and Following axis SyncPos are
not evaluated.
Default synchronization This setting is only appropriate for an absolute master value coupling.
position of the leading axis The synchronization depends on the position of the master value.
The synchronization position is specified in Master value SyncPos. The
setting in Following axis SyncPos is not evaluated.

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Setting Meaning
Specified by the This setting is only appropriate for an absolute following axis.
synchronization position of The synchronization criterion depends on the position of the following
the following axis axis.
The synchronization position is specified in Following axis SyncPos. The
setting in Master value SyncPos is not evaluated.
Default synchronization This setting is only appropriate for an absolute master and an absolute
position of the leading axis following axis.
and following axis The synchronization depends on the position of the master value.
The synchronization position is specified in Master value SyncPos. In
addition, an offset is generated on the following axis via the setting in
Following axis SyncPos, i.e. the following axis does not synchronize to
the programmed slave position but to the Following axis SyncPos
position plus absolute position value of the following axis.
Last programmed setting Setting of the last active command

See also
Synchronization criterion/synchronization position (Page 43)

2.3.3.6 Position reference during synchronization

How synchronization is to performed is set via the Position reference picklist:

Table 2-24 Position reference parameters for synchronization

Setting Meaning
Synchronize from Synchronization starts at the synchronization position. The following axis
synchronization position runs synchronously after the synchronization length resulting from the
dynamic response data.
Synchronize before The synchronization is performed so that the following axis runs
synchronization position synchronously to the master value at the synchronization position. If the
following axis is stopped, it is accelerated before the synchronization
position so that it runs synchronously to the master value at the
synchronization position. The position at which the axis is accelerated is
the synchronization position minus the synchronization length.
Synchronize The synchronization is performed so that the synchronization position is
symmetrically to exactly in the middle of the synchronization length. Therefore, a stopped
synchronization position following axis is already accelerated before the synchronization position
and only runs synchronously to the master value after half the
synchronization length.
Last programmed setting Setting of the last active command

You will find further information in the section Position of synchronization range relative to
synchronization position (Page 48).

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2.3.3.7 Desynchronizing the gear

You can set the position at which desynchronization is to start using the Desynchronization
drop-down list box on the Gear synchronization tab:

Table 2-25 Parameters for desynchronization

Setting Meaning
Effective immediately Desynchronization takes immediate effect.
Specified by the The desynchronization is performed as of the Master value desync value.
desynchronization The setting in Following axis desync is not evaluated.
position of the leading axis
Default The desynchronization is performed as of the Following axis desync value
desynchronization of the following axis.
position of the following The setting in Master value desync is not evaluated.
axis
Last programmed setting Setting of the last active command

See also
Desynchronization criterion/desynchronization position (Page 64)

2.3.3.8 Position reference during desynchronization

How desynchronization is to performed is set via the Position reference picklist:

Table 2-26 Parameters for the position reference

Setting Meaning
Stop after The desynchronization is started at the desynchronization position.
desynchronization The desynchronization is completed after the synchronization length
position resulting from the dynamic response data.
Stop before The desynchronization is performed so that the desynchronization is
desynchronization completed at the desynchronization position.
position The position at which the desynchronization is started is the
desynchronization position minus the desynchronization length.
Stop symmetrically to The desynchronization is performed so that the desynchronization position
desynchronization is exactly in the middle of the desynchronization length.
position

See also
Position of synchronization range relative to desynchronization position (Page 65)

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2.3.3.9 Camming synchronization

Figure 2-86 Synchronous object: Default setting for cam synchronization

Cam Synchronization - Default

You use the Cam synchronization tab to set the parameters for synchronization and
desynchronization. These settings are only relevant when camming mode is used.

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You can set the following parameters:

Table 2-27 Parameters for camming synchronization

Field/Button Explanation/instructions
Synchronization Specify when synchronization of the following axis with the master value is
performed.
For more information, see Synchronizing the curve (Page 126).
Position reference Here, you specify the position of the synchronization profile relative to the
position of the synchronization point.
For more information, see Position reference during synchronization
(Page 123)
Synchronization Specify the synchronization direction (Page 47) here.
direction
Master value SyncPos Here, you enter the position of the synchronization point of the master value.
SyncPos slave axis Here, you enter the position of the synchronization point of the slave axis
Desynchronization Specify when desynchronization of the following axis with the master value
is performed.
For more information, see Desynchronizing the curve (Page 127).
Position reference Here, you specify the position of the desynchronization profile relative to the
position of the desynchronization point
For more information, see Position reference during desynchronization
(Page 124).
Desync. Master value Here, you enter the position of the desynchronization point of the master
value.
Desync. Following axis Here, you enter the position of the desynchronization point for the following
axis

See also
Synchronization (Page 41)

2.3.3.10 Cam synchronization

You can set the synchronization condition using the Synchronization drop-down list box on the
Cam synchronization tab:

Table 2-28 Parameters for synchronization

Setting Meaning
Effective immediately Synchronization takes immediate effect. The start point is derived from
the position of the current master value. The settings in Master value
SyncPos and Following axis SyncPos are not evaluated.
Default synchronization This setting is only appropriate for an absolute master value coupling.
position of the leading axis The synchronization depends on the position of the master value. The
synchronization position is specified in Master value SyncPos. The
setting in Following axis SyncPos is not evaluated.

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Setting Meaning
Transition at the end of the This setting is only possible for a relative master value coupling. The
active cam synchronization criterion is the master setpoint position at the end of the
current cam disk cycle. The setting in Following axis SyncPos is not
evaluated.
Default synchronization This setting is only appropriate for an absolute master and an absolute
position of the leading axis following axis. Synchronization depends on the position of the master
and following axis value. The synchronization position is specified in Master value
SyncPos. In addition, an offset is generated on the slave axis via the
setting in SyncPos slave axis, i.e. the slave axis does not synchronize
to the programmed (e.g. via cam) slave position but to the position
SyncPos slave axis plus absolute position value of the slave axis in
relation to the cam.
Last programmed setting Setting of the last active command

See also
Synchronization criterion/synchronization position (Page 43)

2.3.3.11 Cam desynchronization

You can set the position at which desynchronization is to start using the Desynchronization
drop-down list box on the Cam synchronization tab:

Table 2-29 Parameters for desynchronization

Setting Meaning
Effective immediately Desynchronization takes immediate effect.
At position of the leading The desynchronization is performed as of the Master value desync value.
axis The setting in Following axis desync is not evaluated.
At position of the following The desynchronization is performed as of the Following axis desync value
axis of the following axis. The setting in Master value desync is not evaluated.
End of cam cycle The desynchronization is performed at the end of the current cam cycle.
Last programmed setting Setting of the last active command

See also
Desynchronization criterion/desynchronization position (Page 64)

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2.3.3.12 Dynamic response

Figure 2-87 Synchronous object: Default setting for dynamic response

Dynamic response - Default

In the Dynamics tab, you make the basic settings for synchronization and
desynchronization.
You can enter the following profile settings:
● Length-related synchronization; see Synchronization via a specifiable master value
distance (Page 81).
● Time-related synchronization; see Synchronization profile based on specifiable dynamic
response parameters (Page 83).
Dynamic response parameters are used for:

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● Time-related synchronization
● Compensatory motions on the synchronous object
You can set the following parameters:

Table 2-30 Dynamic response parameters

Field/Button Explanation/instructions
Profile specification Specify the reference for the synchronization profile here.
Leading axis-related synchronization
Sync. Length Here, you enter the path length for synchronization.
Desync. Length Here, you enter the path length for desynchronization.
Time-related synchronization
Velocity profile Select the velocity profile here.
Velocity Enter the maximum velocity here.
Acceleration Enter the maximum acceleration here.
Deceleration Enter the maximum deceleration here.
Jerk Enter the maximum jerk here.

The synchronization length and desynchronization length are only evaluated for master-axis-
related synchronization profiles. Velocity profile, velocity, acceleration, deceleration and jerk
are only evaluated for time-related synchronization profiles.

See also
Synchronization (Page 41)

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2.3.3.13 Master dynamic response

Figure 2-88 Synchronous object: Default setting for master dynamic response

Master dynamic response - default

In the Master dynamic response tab, you make the settings for the dynamic response for the
master value switchover.
You can set the following parameters:

Table 2-31 Dynamic response parameters - Master

Field/Button Explanation/instructions
Master switchover with dynamic response values
Velocity profile Select the velocity profile here.

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Field/Button Explanation/instructions
Velocity Enter the maximum velocity here.
Acceleration Enter the maximum acceleration here.
Deceleration Enter the maximum deceleration here.
Jerk Enter the maximum jerk here.

See also
Switching over the master value source – Overview (Page 68)

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2.3.4 Set synchronization

Certain settings for synchronization can be defined on the synchronous object.
● In the project navigator, double-click Settings under the synchronous object.

Figure 2-89 Settings on the synchronous object

Synchronous object - Settings

In this window, define the parameters for the synchronization.

Table 2-32 Synchronization parameters

Field/Button Explanation/instructions
Permit absolute synchronization with For absolute synchronization, the "Yes" setting of the jerk
provision for jerk is used.
If "No" is set, the set jerk will not be used in spite of velocity
profile = SMOOTH being selected. Travel follows a
trapezoidal path.
(syncingMotion.smoothAbsoluteSynchronization)
See also the section titled Trailing synchronization with
synchronization profile based on dynamic response
parameters (Page 53).
Adapt the dynamic response values for the Adaptation to the dynamic response in the synchronous
synchronization position (syncingMotion.synchronizingAdaption)
If "Yes" is set, the following parameter is available:
See also the section titled Synchronization profile based
on specifiable dynamic response parameters (time
reference) (Page 50).

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Field/Button Explanation/instructions
Magnification factor for the dynamic Overdrive factor for the adapted dynamic response values
response values to compensate for a remaining path difference
(syncingMotion.overdriveFactor)
Value as percentage (%)
Reference to the current master value velocity for the
synchronization start.
See also the section titled Synchronization profile based
on specifiable dynamic response parameters (time
reference) (Page 50) as well as the section titled Adapt
the synchronization velocity to the master value velocity
(Page 107).
Tolerance for master direction reversal Tolerance window for canceling the synchronization for
direction reversal of the master values
(syncingMotion.masterReversionTolerance)
Position value in the user unit of the master values.
See also the section titled Settings for evaluation of the
master value behavior during synchronization (Page 55).
Permitted velocity change of the master Maximum permitted change of the master value velocity
without restarting for synchronization (syncingMotion.maximumOfMasterChange)
Refers to the current master value velocity for the
synchronization start.
Value as percentage (%).
See also the section titled Settings for evaluation of the
master value behavior during synchronization (Page 55).

See also
Dynamic response effect on slave values (Page 66)
Synchronization (Page 41)

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2.3.5 Configuring synchronous operation monitoring

Synchronous operation monitoring between the master value/following object and the following
axis can be configured on the synchronized axis.
1. In the project navigator, double-click Monitoring under the axis object.
2. Set the required parameters on the Synchronous operation tab.

Figure 2-90 Monitoring of a following axis

Here, you specify the synchronous operation monitoring of the axis.

Table 2-33 Monitoring parameters

Field/Button Explanation/instructions
Activate setpoint monitoring Activate the setpoint monitoring of the following axis here.
(TypeOfAxis.GearingPosTolerance. enableCommandValue)
Setpoint tolerance Specify the setpoint tolerance with activated setpoint monitoring.
(TypeOfAxis.GearingPosTolerance .commandValueTolerance)
Activate actual value monitoring Activate the actual value monitoring of the following axis here.
(TypeOfAxis.GearingPosTolerance. enableActualValue)
Actual value tolerance Specify the actual value tolerance with activated actual value
monitoring.
(TypeOfAxis.GearingPosTolerance. actualValueTolerance)
Signal error of the leading axis Specify here which tolerance-exceeded messages (actual values /
setpoints) are signaled to the leading axis.
Take into account that the tolerance-exceeded messages are signaled
to all higher-level leading axes (if, for example, the leading axis is also
a following axis in a synchronous operation configuration).
(TypeOfAxis.GearingPosTolerance. enableErrorReporting)

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See also
Synchronous operation monitoring (Page 75)
Error handling (Page 146)

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2.4 Synchronous Operation Programming/References

This chapter contains an overview of the Synchronous Operation technology object commands
and information on the local alarm response. For a complete list of all commands and their
syntax, the system variables and error messages, please see the SIMOTION Reference Lists.

See also
Overview of commands (Page 136)
Command processing (Page 141)
Error handling (Page 146)
Menus (Page 149)

2.4.1 Overview of commands

ST commands

Table 2-34 Commands on the synchronous object

Command type / command Description

Information and conversion See Commands for reading out function values (Page 138).
_getMasterValue The _getMasterValue command supplies the master value at a specified
slave value position.
_getSlaveValue The _getSlaveValue command supplies the slave value on a specified
master value position.
_setMaster The _setMaster command is used to assign a new master value source
to a synchronous object.
See Switching of the master value source (Page 68).
Command tracking See Commands for command tracking (Page 139).
_getStateOfFollowingObjectCommand The _getStateOfFollowingObjectCommand command returns the
execution status of a synchronous operation command:
_getMotionStateOfFollowingObjectCommand The _getMotionStateOfFollowingObjectCommand command returns a
structure with the state of a synchronous operation command.
The state of a synchronous operation command must then also be read
out.
_bufferFollowingObjectCommandId The _bufferFollowingObjectCommandId command enables the
commandId and the associated command status to be saved beyond the
processing time of the command.
The commandId parameter is used to define the command for which the
respective status is to be saved.
The maximum number of savable command states is specified in the
decodingConfig.numberOfMaxBufferedCommandId configuration data
element.

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Command type / command Description

_removeBufferedFollowingObjectCommandId The _removeBufferedFollowingObjectCommandId command
discontinues saving of the commandId and the associated command
status beyond the processing time of the command.
Motion
_enableGearing The _enableGearing command produces gearing with a constant
transfer ratio.
See Gearing (Page 20).
_disableGearing The _disableGearing command terminates gearing with a constant
transfer ratio.
_enableVelocityGearing The _enableVelocityGearing command produces velocity gearing with a
constant coupling.
See Velocity synchronous operation (Page 26).
_disableVelocityGearing The _disableVelocityGearing command terminates velocity gearing with
a constant coupling.
_enableCamming The _enableCamming command produces camming with a variable
transfer ratio.
See Camming (Page 27).
_disableCamming The _disableCamming command terminates camming with a variable
transfer ratio.
Correction and superimposition
_setGearingOffset The _setGearingOffset command offsets the gearing with reference to
the master value or the slave value (V3.1 and higher).
See Changing the offset in chapter Gearing (Page 20)
_setCammingScale The _setCammingScale command scales the camming relative to the
master value or the slave value.
See Scaling and offset in Camming (Page 27).
_setCammingOffset The _setCammingOffset command offsets the camming with reference
to the master values or the slave values.
See Scaling and offset in Camming (Page 27).
Object and Alarm Handling See Commands for resetting of states and errors (Page 141).
_resetFollowingObject The _resetFollowingObject command resets the synchronous object, i.e.
an active synchronous grouping will be cancelled, any pending errors
will be cleared.
_resetFollowingObjectError The _resetFollowingObjectError command acknowledges and resets
errors on the synchronous object.
_resetFollowingObjectErrorState The _resetFollowingObjectErrorState command acknowledges and
resets the error status on the synchronous object.
_getFollowingObjectErrorNumberState The _getFollowingObjectErrorNumberState command is used to fetch
the status of a specific error
Simulation See Simulation mode (Page 78).
_enableFollowingObjectSimulation The _enableFollowingObjectSimulation command sets a synchronous
operation into simulation mode.
_disableFollowingObjectSimulation The _disableFollowingObjectSimulation command disables simulation
mode of the synchronous grouping.

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PLCopen commands
MultiAxis commands of PLCopen are relevant for synchronous operation. These commands
are provided for use in cyclic programs/tasks and enable motion control programming in a view
shaped by a PLC. They are used primarily in the LAD/FBD programming language. The
commands are certified in accordance with "PLCopen Compliance Procedure for Motion
Control Library V1.1".

Table 2-35 PLCopen commands for synchronous operation

Command Description
_MC_CamIn Synchronize and engage cam; included implicitly:
_MC_CamOut Desynchronize and disengage cam
_MC_GearIn Synchronize synchronous operation
_MC_GearOut Desynchronize synchronous operation
_MC_Phasing Phase offset

For further information, refer to the PLCopen Blocks Function Manual.

MCC commands
MCC commands are available for synchronous operation. For information on this see the
Programming and Operating Manual for the SIMOTION MCC Motion Control Chart.

2.4.1.1 Commands for reading out function values

Commands that calculate values and supply them as return values are available for reading
out master value positions and slave value positions in pairs:
● The _getSlaveValue command supplies the slave value at a specified master value position.
If several master values may have the same slave value, an approximate value can be
specified for the master value.
– slavePositionType:=CURRENT returns the current value.
– slavePositionType:=DIRECT returns in slavePosition the specified approximation value.
● The _getMasterValue command supplies the master value at a specified slave value
position.
If several slave values may have the same master value, an approximate value can be
specified for the slave value.
– masterPositionType:=CURRENT returns the current value.
– masterPositionType:=DIRECT returns the approximate value specified in
masterPosition.
The commands only supply the correct position if a synchronous relationship is active and
synchronized.

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2.4.1.2 Commands for command tracking

The following commands are available for command tracking:
● The _getStateOfFollowingObjectCommand command returns the execution state of a
synchronous operation command:
– ACTIVE: The command is being executed.
– NON_EXISTENT: The command is complete or the commandID is unknown.
– WAITING: The command is decoded, but execution not yet started.
– WAITING_FOR_SYNC_START: The command is waiting for synchronous start.
● The _getMotionStateOfFollowingObjectCommand command returns a structure with the
processing status of a command.
– functionResult specifies the error code.
– motionCommandIdState returns the current phase of the motion of the queried
command.
– abortId specifies the reason for aborting the command.
The reason for aborting is specified with alarm 30002 "Command aborted (reason:
<abortId>, command type: ...)".
● With _bufferFollowingObjectCommandId, the command status can be queried after
completion or an abort of the command.
● With _removeBufferedFollowingObjectCommandId, the command should be explicitly
removed from the command management of the technology object after evaluation is
complete.
The number of motion commands that the MotionBuffer can accept can be specified using the
followingObjectType.DecodingConfigInfo.numberOfMaxbufferedCommandId configuration
data.

System variables
The sequence of programmed commands can be read out by means of system variables; see
Monitoring the synchronization (Page 59).

System variable syncMonitoring:

The structure elements belonging to syncMonitoring indicate the monitoring functions and
status information for synchronization.
The variable is used for the actual value monitoring of the synchronous operation relationship
to the synchronous operation setpoint.
● The limitCommandValue variable indicates whether the setpoint differences have
exceeded the maximum limit for synchronous operation errors.
● The differenceCommandValue variable shows the difference between the setpoint
generated at the synchronous object and the executable setpoint at the axis, with dynamic
limits taken into account.
● The syncErrorReported variable indicates whether an alarm has already been issued to
the master axis.

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● The limitActualValue variable indicates whether the actual value differences have exceeded
the maximum limit for synchronous operation errors.
● The differenceActualValue variable indicates the difference between the setpoint calculated
on the synchronous object and the actual value present in the interpolator. If a
superimposed motion is started on the following axis, it is not identical to the sum of
syncMonitoring.differenceCommandValue and
positioningState.differenceCommandToActual. This superimposed motion is fully
incorporated in the differenceActualValue variable and triggers monitoring on the actual
value side.
● The syncState variable indicates the synchronous operation state on the setpoint side.
During synchronizing and desynchronizing, syncState:=N/umc/interf/dsc/tech/to/gea/
sysvar.txt. The synchronous operation error on the setpoint side is the error resulting from
the setpoint limit on the maximum dynamic values of the following axis for the
synchronization component. The followingMotionState indicates the status of the
synchronous operation motions. The differenceCommandVelocity variable shows the
difference, during velocity synchronous operation, between the set velocity calculated on
the synchronous object and the set velocity that is executable on the axis taking into account
the dynamic limits.
● The differenceActualVelocity variable indicates the difference, during velocity synchronous
operation, between the set velocity calculated on the synchronous object and the actual
velocity present in the interpolator.

Canceling/deleting a synchronous operation command

The _cancelFollowingObjectCommand command can be used to cancel a synchronous
operation command by specifying the commandId in the commandToBeCancelled parameter
(V4.1 and higher). This removes the synchronous operation command from the command
buffer and, if necessary, also from the IPO.
The synchronous motion is canceled with the local response
FOLLOWING_OBJECT_DISABLE; see also _cancelAxisCommand/
_cancelExternalEncoderCommand for the Axis/External Encoder technology object.

Additional references
You can find detailed information in both the Motion Control Technology Objects Axis Electric/
Hydraulic, External Encoder Function Manual and the SIMOTION reference lists.

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2.4.1.3 Commands for resetting states and errors

The following commands are available for resetting states and errors:
● The _resetFollowingObject command resets the synchronous object, i.e. an active
synchronous operation relationship is canceled and any pending errors cleared.
The command can be executed when an error response (e.g. DECODE_STOP) is pending.
All active commands and commands pending in the buffer are canceled. Changed default
values can be reset using the userDefaultData:=ACTIVATE_CONFIGURATION_DATA
parameter. Canceling commands by resetting the synchronous operation function does not
generate any warnings.
The deleteSynchronizingCommandsOnly parameter (V3.2 and higher) can be used to
remove the waiting and active commands directly, without the need to reset the entire
technology object.
● The _resetFollowingObjectError command acknowledges and resets errors on the
synchronous object.
The command can be executed when an error response (e.g. DECODE_STOP) is pending.
One particular error or all errors can be ordered to be reset. The error response changes
to the response with the highest priority of the still pending errors. It is terminated with a
negative acknowledgment for any errors that cannot be acknowledged at this point. If all
errors can be reset, the error response changes to NONE.
● The _getFollowingObjectErrorNumberState command is used to fetch the status of a
specific error

2.4.2 Command processing

2.4.2.1 Command execution

Command advance
A criterion for the command advance is specified in the commands. If the condition for the
command advance is satisfied, the next command in the user program is executed. Specifying
a command advance condition in a command influences the time at which the next
programmed command will be executed.

Possible step enabling conditions on the synchronous object

The step enabling condition is indicated in the command parameter nextCommand.

Table 2-36 Step enabling conditions on synchronous object commands

Step enabling condition for next Time of advance

command
IMMEDIATELY As soon as the command is issued
WHEN_BUFFER_READY When the command enters the command buffer
AT_MOTION_START When the command changes over to the interpolator
WHEN_ACCELERATION_DONE When the acceleration phase is complete

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Step enabling condition for next Time of advance

command
AT_DECELERATION_START When deceleration starts
WHEN_INTERPOLATION_DONE When setpoint interpolation for this command is complete
WHEN_AXIS_SYNCHRONIZED When axis is synchronized with the master value
WHEN_MOTION_DONE When motion generation is complete

Group classification of commands and command buffers

Each synchronous object has two dedicated command buffers for each command, which can
be fetched for each IPO cycle. These command buffers are the buffer for synchronous
operation commands and the buffer for parallel effective commands. The behavior of the
buffers corresponds to the behavior of the axis.
Commands are classified in groups as follows:
● Group 1: Synchronous operation commands
The following commands belong to this group: _enableGearing, _disableGearing,
_enableVelocityGearing, _disableVelocityGearing, _enableCamming, and
_disableCamming
Depending on the transition behavior, new commands to be entered may behave in the
following ways if the buffer is full:
– Return with an error
(nextCommand = IMMEDIATELY and mergeMode = SEQUENTIAL),
– Wait for the buffer to become available
(nextCommand ≠ IMMEDIATELY and mergeMode = SEQUENTIAL) or
– Supersede the command pending in the buffer
(mergeMode = IMMEDIATELY).
● Group 2: Parallel effective commands:
Commands that supersede each other in the command buffer. These commands are
executed in the IPO. If there are more than one parallel effective command, only the last
one is executed, because these commands overwrite each other. In this case, technology
alarm 30002 "Command aborted (reason: ..., command type: ...)" is output.
The following commands belong to this group: _setGearingOffset, _setCammingScale,
_setCammingOffset, _enableFollowingObjectSimulation,
_disableFollowingObjectSimulation, and _setMaster
● Group 3: Directly executed commands without entry in a command buffer
Commands in this group do not abort each other.
This group includes:
_getSlaveValue, _getMasterValue,
_resetFollowingObjectError,
_getStateOfFollowingObjectCommand,
_getMotionStateOfFollowingObjectCommand,
_bufferFollowingObjectCommandID,
_removeBufferFollowingObjectCommandId,
_resetFollowingObject,
_resetFollowingObjectConfigDataBuffer,
_getFollowingObjectErrorNumberState

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Command execution of sequential commands in the IPO cycle clock

If enabled to this effect, the commands are read out from the command buffer in every
interpolation cycle. Within the slave value generation, up to two synchronous operation
commands (_enableGearing(), _disableGearing(), _enableVelocityGearing(),
_disableVelocityGearing(), _enableCamming(), _disableCamming() ) are active at the same
time and are executed in the IPO.

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Behavior regarding programming of a motion command:

● No motion command is active:
An _enable... command is processed as the current command in the interpolator first as a
waiting command, while a _disable... command is aborted immediately. If the
synchronization criterion is satisfied, the waiting command changes its state to active
(synchronizing/synchronous).
● If a motion command is waiting or active, the new motion command is processed as the
next command in the interpolator first as a waiting command. A new _disable... command
is immediately canceled if the current command is not a complementary _enable...
command. If the next command is active, the current command is canceled. The next
command is thereafter processed as the current command.
● If two motion commands are active or waiting and mergeMode:=SEQUENTIAL or
mergeMode:= NEXT_MOTION, the new command is prevented from being read in until at
least one command has been aborted or completed. With mergeMode:= IMMEDIATELY,
the next command up to that point is aborted and replaced with the new command.
Exception: If the new command is a complementary _disable... command for the next
command, the new command is canceled immediately and only the current command is
waiting/active.
See Command transition conditions (Page 144) for further information.
Behavior regarding programming of a parallel effective command:
● _setCammingScale()/_setCammingOffset()/_setGearingOffset() act on the current
(_enable...) command when activationMode:= ACTUAL_VALUE or activationMode:=
ACTUAL_AND_DEFAULT_VALUE.
If no command is active or the active command does not correspond to the correction being
executed, the parallel effective command is canceled.
● In general, commands for simulation mode and resetting of current master value source
are active.

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2.4.2.2 Command transition conditions

The transition behavior is set in the mergeMode command parameter, on the commands of
the synchronous object. The transition behavior affects the execution of the queued commands
on the synchronous object. An active command can thus affect the execution of a command
of another task.
The mergeMode on the synchronous object commands also determines the behavior of the
following axis commands.
● A command issued with mergeMode = IMMEDIATELY clears the command buffer and
overwrites the IPO (next command). The current command is executed. The next command
is substituted.
● A command issued with mergeMode = NEXT_MOTION will be executed once the active
command is complete and the pending commands have been deleted. It overwrites the
command buffer.
● A command issued with mergeMode = SEQUENTIAL will be executed after the completion
of the active command and the motion. The command will be entered in the command
buffer when it is empty; if the command buffer is not empty, the command waits.

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Influences between axis and synchronous object

Table 2-37 Transition behavior on synchronous object commands

Transition behavior for Effect

synchronous motion
IMMEDIATELY The active command is aborted. The starting point for the slave value in the synchronous operation
is the current axis setpoint.
If the synchronous motion is active, the second synchronous function to be programmed or the
non-active synchronous function is overwritten.
If the synchronous function is already effective, then it remains effective.
An active motion function in the following axis is overridden. It is therefore possible for motion,
positioning, and synchronous operation to override each other another.
If a synchronous operation command is issued with mergeMode:=IMMEDIATELY, the command
waits in the command buffer until the synchronization criterion is fulfilled. Only then will the
command enter the active state.
A synchronous operation command will only be aborted by another motion command if the motion
command is already active. In the same way, motion commands that are already active will only
be aborted once a waiting synchronous operation command is activated.
SEQUENTIAL, If a main motion is active on the following axis, this main motion is first carried out completely. The
NEXT_MOTION starting point is the current axis setpoint for the main motion or, in the case of multiple synchronous
commands, the internally generated slave value.
If a synchronous motion is already active, the synchronous function is set to wait until the active
synchronous function is completed or aborted.
This requires the nextCommand=WHEN_BUFFER_READY setting. When
nextCommand=IMMEDIATELY is set, the command is not executed and is returned with error
information in the return value.
The synchronous function is added to an active motion function in the following axis.
A synchronous function that is in effect but not yet active can be deleted
● With the _disable... command with mergeMode=IMMEDIATELY and Synchronization
criterion=IMMEDIATELY or
● With the _resetFollowingObject command

Table 2-38 Transition behavior on axis commands

Transition behavior for Effect on the synchronous object

axis motion
IMMEDIATELY All active synchronous motions are aborted. None of the synchronous motions that are not active
(i.e. they are neither in the synchronization motion nor in the "synchronous" status, but are instead
waiting for the synchronization criterion) are aborted.
SEQUENTIAL, The synchronous operation commands/synchronous motions are not aborted and the axis motion
NEXT_MOTION only becomes active once the synchronous operation is complete.

The following special feature applies when motion commands are pending on the synchronous
object and on the axis in the same interpolation cycle clock:
● If mergeMode(axis)=SEQUENTIAL, the synchronous command is executed
● If mergeMode(axis)=IMMEDIATELY, the axis command is executed

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2.4.3 Error handling

2.4.3.1 Local alarm reaction on the synchronous object

Local alarm responses are specified by means of the system.
The following responses are possible:
● NONE
No response
● DECODE_STOP
Abort of the command preparation, the current synchronous operation function remains
active.
● FOLLOWING_OBJECT_DISABLE
Abort of the command preparation, abort of the current synchronous operation function.
An error can be reset with _resetFollowingObject or _resetFollowingObjectError

Note
The stop responses are listed in order of increasing priority. Global alarm responses can be
set in the alarm configuration in the technology object; these can also be set to require Power
On. For further information, see the Motion Control Basic Functions Function Manual,
"Configuring technological alarms".

2.4.3.2 Local alarm reaction of the following axis and its mutual effects with the synchronous object
The synchronous object and the Axis TO have a reciprocal effect on each other depending on
their respective operating modes and which commands are in effect. Thus, errors and alarms
in the TO axis have a direct effect on the synchronous object functions. For example, if a
technology alarm triggers a stop response in the following axis, the synchronous motion is also
stopped. If an error is pending on the synchronous object only, the following axis can still
position but can no longer perform synchronous operation.
The following responses by the Axis TO, which can be read in the errorReaction system
variable, affect the synchronous object:
● MOTION_STOP
Controlled motion stop with programmed ramp values.
● MOTION_EMERGENCY_STOP
Controlled motion stop with maximum ramp values/limits for the axis.
● MOTION_EMERGENCY_ABORT
Controlled motion stop with maximum axis dynamic values (starting from the
current setpoint).

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● FEEDBACK_EMERGENCY_STOP
Motion stop with preassigned braking ramp.

Note
Problems with FEEDBACK_EMERGENCY_STOP on the leading axis
Switchover to the actual value of the leading axis is performed. An existing setpoint-actual
value different results in a step response of the speed or position on the synchronous
object and therefore also on the synchronized axis.
● Configure Motion_Emergency_Abort on the master axis

● OPEN_POSITION_CONTROL
Motion stop with speed setpoint zero and abort.
● RELEASE_DISABLE
Motion disable with controller disable and abort of all commands.
Synchronous operation is aborted for all responses indicated.

Note
Errors on the synchronous object do not have any effect on the enables/error response of
the following axis.

Note
If the disableSynchronousOperation configuration data item is set to YES and simulation is
active on the synchronous object, the synchronous operation function is not aborted on the
stop response or when the _disableAxis command is executed.
The synchronous operation function is aborted with alarm "20005 Device type:..., log.
address:... failed" if no valid actual value is present, e.g. if the axis is restarted.

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2.4.3.3 Error handling in the user program

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The starting point is a synchronous operation error in a following axis (synchronous operation
tolerance exceeded). Alarm 40201 "Synchronous operation tolerance of the gearing axis
exceeded" is issued. The following axis changes to STOP mode.
The leading axis/external encoder responds with an error. The alarm 40110 "Error triggered
on slave during synchronous operation (error number: ...) is signaled. The master object enters
the STOP state.
● The local following axes also change to STOP mode.
● However, distributed synchronized axes continue to follow the master setpoint if measures
are not taken in the user program to initiate an appropriate response to this error response.

Note
With V4.2 and higher, an error message is also output on the master object when the
following axis disconnects the synchronous coupling for any reason in the event of an
error.

For additional information, see Synchronous operation monitoring (Page 75).

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2.4.4 Menus

2.4.4.1 Synchronous Operation - Menu

Grayed-out functions cannot be selected.

Table 2-39 You can select the following functions:

Function Meaning/Note
Close Use this function to close the active window in the working area.
Properties Properties displays the properties of the synchronous object selected in the
project navigator. You can enter the object name plus author and version in
this window.
Configuration This function opens the configuration for the synchronous object selected in
the project navigator. Assign the master values and cams to the following axis
in this window.
Expert List This function opens the expert list for the synchronous object selected in the
project navigator. The configuration data and system variables can be
displayed and changed in this list; see Basic functions - Expert list.
Default setting This function opens the default settings for the synchronous object selected
in the project navigator. In this window, you define the replacement values for
calling synchronous operation functions (_enableGearing,
_enableVelocityGearing, and _enableCamming or _disableGearing,
_disableVelocityGearing, and _disableCamming).
Settings This function opens the settings for the synchronous object selected in the
project navigator. You can define some synchronization settings in this
window.
Interconnections This function opens the interconnections for the synchronous object selected
in the project navigator. You can see the inputs of the axis in this window.
Expert This function opens the submenu for the expert settings.
Configure units This function opens the Configure units of the object window in the working
area. You can configure the units used for the selected object here.

See also
Synchronous Operation Configuration (Page 111)

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2.4.4.2 Synchronous Operation - Context Menu

Grayed-out functions cannot be selected.

Table 2-40 You can select the following functions:

Function Meaning/Note
Open configuration This function opens the configuration for the synchronous object
selected in the project navigator. Assign the master values and cams to
the following axis in this window.
Default setting This function opens the default settings for the synchronous object
selected in the project navigator. In this window, you define the
replacement values for calling synchronous operation functions
(_enableGearing, _enableVelocityGearing, and _enableCamming or
_disableGearing, _disableVelocityGearing, and _disableCamming).
Settings This function opens the settings for the synchronous object selected in
the project navigator. You can define some synchronization settings in
this window.
Interconnections This function opens the interconnections for the synchronous object
selected in the project navigator. You can see the inputs of the axis in
this window.
Expert This function opens the submenu for the expert settings.
Insert script folder Insert script folder enables you to insert a folder for scripts.
Import object Use Import object to open a window for the XML import. You can define
the parameters for the XML import in this window.
Save project and export Use Save project and export object to open a window for the XML export.
object You can define the parameters for the XML export in this window.
Insert external master External master value (ExternalMasterType): Proxy object for an
value external master value.

See also
Synchronous Operation Configuration (Page 111)

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3.1 Overview of distributed synchronous operation

This chapter describes the Distributed Synchronous Operation function (V3.0 and higher). It
introduces you to the operating principle and provides information about the technological
supplementary conditions as well as the operating characteristics of distributed synchronous
operation. You are shown how to create and configure a distributed synchronous operation.

Function overview
The Distributed synchronous operation functionality allows you to create a master value source
and a synchronized axis on different controls. In a project, it is possible to form function groups
and thus a machine structured on a modular basis. Synchronized axes no longer need to be
present in a single control, but can instead be distributed among several controls.

Isochronous (clock-synchronized) bus coupling

The coupling between the master axis (or the external encoder) and the following axis is
performed using an isochronous bus coupling between the controls, via PROFIBUS DP or
PROFINET IO with IRT.

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3.1 Overview of distributed synchronous operation

Synchronizing the bus interfaces

The DP/PN interfaces must be synchronized with each other for distributed applications using
the isochronous PROFIBUS or PROFINET IO with IRT.
Information on this subject is available in the Motion Control Basic Functions for Modular
Machines Function Manual and the Communication Configuration Manual.

Application
You can use distributed synchronous operation to create function groups in your project and
set up a machine on a modular basis. Instead of having to use the same control system to
control synchronously operating axes, you can now distribute the axes across a number of
modules.

Operating principle/Compensation
With distributed synchronous operation, the interpolator cycle clocks of the master object and
the following axis may be offset. As a result of the communication required, there is also an
offset in the calculation of related signals (master value source and remote following axis).
The cycle clock offset can be compensated using the following measures:
● Compensation on the master value side by means of setpoint output delay
● Compensation on the slave value side by means of master value extrapolation
See Compensations for distributed synchronous operation (Page 159).

See also
Fundamentals of Distributed Synchronous Operation (Page 153)
Distributed Synchronous Operation Configuration (Page 170)
Configuring distributed synchronous operation across projects (Page 179)

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3.2 Fundamentals of Distributed Synchronous Operation

3.2.1 Boundary Conditions

3.2.1.1 Rules for the communication/topology for distributed operation using PROFIBUS
The following rules apply for the PROFIBUS topology with distributed synchronous
operation:
● Distributed synchronous operation is only possible via equidistant master/slave
communication.
● The leading axis or external encoder must be located in the PROFIBUS master, and the
distributed following axis must be located in the PROFIBUS slave.
Further local synchronizations with the master control are possible.
● Distributed synchronous operation can only be created on one PROFIBUS level.
Consequently, cascaded distributed synchronous operation is not possible.
● Different IPO cycle clocks and position control cycle clocks can be used in the SIMOTION
devices involved.
● The same DP cycle clock must be used in the SIMOTION devices taking part in the
distributed synchronous operation.
Exception: See Cycle clock scaling for SIMOTION D in this chapter

Data transmission for distributed synchronous operation using PROFIBUS

A total of 24 bytes are transmitted and received via the PROFIBUS interface for each
synchronous operation connection and cycle clock (bi-directional connection for synchronous
operation data). Only a certain amount of data can be transmitted in each DP cycle for each
master-slave connection (a maximum of 244 bytes can be sent and received). This also
enables a maximum of 10 connections with 24 bytes each. In addition, the amount of data in
the PROFIBUS master is limited to 1 Kbyte for inputs and 1 Kbyte for outputs per PROFIBUS
interface, irrespective of the number of devices connected; in other words, 40 connections are
theoretically possible.
In addition to the transmitted data, the following must be noted:
● Drive connection
● I/O connection
● Application Data
This limits the number of possible connections with distributed synchronous operation.
The system can be optimized. Instead of several distributed connections, for example, a virtual
axis on the slave can first be coupled to a (real or virtual) master axis which then serves several
following axes.

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Figure 3-2 Example of optimizing connections using virtual master axes on slave devices

The virtual master axes on each slave allow axis groupings of the individual machine modules
to also be operated "independently" (e.g. for the commissioning of individual modules).

Master-slave relationship

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Connection between axis and synchronous object

The synchronous object and, if appropriate, the cam must be located on the slave controller,
together with the slave axis. The master value source (axis or external encoder) is always
located on the master control.

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Figure 3-4 Following axis and synchronous object on the same control

Cascading
A distributed synchronous operation can be interconnected with a series-connected local
synchronous operation on the slave controller.

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operation

However, it is not possible to cascade two distributed synchronous operations one after the
other, i.e. the following axis in distributed synchronous operation 1 cannot be used as the

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master axis in distributed synchronous operation 2. This is also true if the second PROFIBUS
interface configured as a master is used.

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Figure 3-6 Distribution via one PROFIBUS level only

No feedback
It is not permitted to configure distributed synchronous operation from Device1 to Device2 and
back again. This is true even if two appropriately configured PROFIBUS interfaces are used.

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Example hierarchy with synchronized equidistant PROFIBUS interfaces

The following is an overview of requirements for distributed synchronized operation:
All PROFIBUS connections:

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● Must have the same DP cycle clock settings

Exception: See Cycle clock scaling for SIMOTION D in this chapter
● Must have isochronous cycle clock settings
● Must have master and slave synchronization
if a master and slave are used on the same device
● Distributed synchronous operation is only possible over one shared bus segment.
● Possible number of slaves: See Data transmission for distributed synchronous operation
using PROFIBUS in this chapter

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Cycle clock scaling for SIMOTION D

With SIMOTION SCOUT V3.2 SP1 and higher, a distributed synchronous operation with cycle
clock scaling between the two external DP interfaces (DP1/DP2) and the internal DP interface
for SIMOTION D is possible.
If the master value changes only very slowly or the external DP interface requires a faster cycle
time than the internal DP interface, a decoupling of the fast internal DP cycle from the slower
external DP cycle is desirable.

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3.2 Fundamentals of Distributed Synchronous Operation

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This is possible under the following boundary conditions:

● An external DP interface of SIMOTION D is used as an isochronous slave interface. Only
in this case can an integer cycle clock scaling of isochronous external DP slave interface
to internal interface be specified.
● For SERVO, IPO, and IPO_2, settings can be made for all permissible cycle clocks. The
master axis and following axis can run on different IPO levels.
The IPO cycle clock of the synchronous object, however, must be set equal to the cycle
clock of the isochronous external DP slave interface (otherwise the error message "50205
- Offset cannot be determined" will be issued).
● In addition, the second external DP interface can be operated as isochronous master (the
first is isochronous slave), for example, to operate external drives. In this case, the cycle
clock must be the same as the cycle clock of the internal DP cycle.
● The second external DP interface can also be operated as a "non-isochronous, free-running
interface". In this case, there is no effect on the cycle clock settings.
● The reduced cycle clocks of the external DP interfaces must be set in HW Config.
● For D4xx, DP to Servo reduction ratio is possible
● For D4xx-2, a DP to Servo reduction ratio is possible from V4.3 and higher
● A DP to Servo reduction ratio is generally only permissible if no PROFINET IO with IRT
has been configured.

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3.2.1.2 Rules for the communication/topology for the distribution using PROFINET IO with IRT (V4.0
or later)
Distributed synchronous operation between SIMOTION devices via PROFINET IO with IRT
uses the controller-controller data exchange broadcast for PROFINET IO to exchange the
synchronous operation data.

Differences to PROFIBUS
Regarding distributed synchronous operation with PROFIBUS, see Rules for the
communication/topology for distributed operation using PROFIBUS in this chapter, the
following differences exist:
● Master object and following axis / synchronous object can be located on any controllers.
(PROFINET IO with IRT does not have any communications master and communications
slave as for PROFIBUS.)
● Cascading of distributed synchronous operations is possible over more than one level.
● Recursive interconnection with PROFINET is possible (see Note)
Note:
slave value compensation via master value extrapolation is possible.
Master value compensation by delaying setpoint output is not possible.

Note
For the following Control Units, a second Servo task is optionally available:
- SIMOTION D435-2 DP/PN (V4.3 and higher)
- SIMOTION D445-2 DP/PN (V4.2 and higher)
- SIMOTION D455-2 DP/PN (V4.2 and higher)
For further information see D4x5-2 Commissioning and Hardware Installation Manual and
Basic Functions Function Manual.

3.2.2 Compensations for distributed synchronous operation

In a distributed synchronous coupling, calculation of related signals between the master value
source and the remote following axis is offset due to the distribution and the associated
communication requirements. Compensation of this offset is supported by the system.
The following compensation methods are available in the system:
● Compensation on the master value side by means of setpoint output delay on the
component that provides the master value for the distributed synchronous operation
● Compensation on the slave value side by means of master value extrapolation on the
component containing the remote slave objects

Note
For distributed synchronous operation with extrapolation on the following axis, the setpoint
monitoring with jerk setting is not appropriate.

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The compensations are set and displayed via the system variable distributedMotion.
● The output delay is displayed on the leading axis.
● The master value delay is displayed on the synchronous object.
● The cycle clock offset is displayed on the synchronous object.
Sign-of-life monitoring is required for the compensation using master value extrapolation.

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Applications and results

● It is useful to activate a setpoint output delay on the master value side if, for example,
synchronism of distributed synchronous operation is of primary importance and a rapid
response on the master value side to local events is of lesser importance.
● It is useful to activate compensation on the slave value side by means of master value
extrapolation without a setpoint output delay on the master value side if, on the master side,
the master values and slave values need to be output without a delay due to a short
response time, for example, and if, on the slave side, synchronism or a secondary error
resulting from the larger extrapolation range is permissible.
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side and without compensation on the following axis side

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Figure 3-12 Master value extrapolation on the slave value side without setpoint output delay on the
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Figure 3-13 Setpoint output delay on the leading axis side

Activating
● When output delay on the master value side is activated, the signal output on the master
value side is delayed by the calculated IPO clock cycles and any resulting IPO phase offset
is compensated by means of interpolation on the slave value side.
● When master value extrapolation on the slave value side is activated without output delay
on the master value side, the total cycle clock offset between the master value calculation
and the slave value calculation is compensated for by means of the master value
extrapolation on the slave value side.

Scope
● The setpoint output delay on the master value side is applicable to the following:
– Axis setpoints calculated directly on the leading axis that are delayed on the axis prior
to being passed on to the servo
– Axis setpoints calculated by local synchronous objects; the synchronous object forwards
the calculated setpoints to the axis
● Compensation on the slave value side by means of interpolation/extrapolation takes place
on the master value of the remotely interconnected synchronous object.

See also
Compensation on master value side by means of setpoint output delay (Page 162)
Compensation of the slave value side by means of master value extrapolation (Page 164)
Permissible combinations for cycle clock offset compensation in distributed synchronous
operation (Page 165)
Cycle clock offset calculation using a command (Page 166)

3.2.2.1 Compensation on master value side by means of setpoint output delay

Compensation on the master value side by means of setpoint output delay of the distributed
synchronous operation will be activated for the master object.

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Compensation on the master value side results in the following:

● The output of setpoints calculated for the axis, delayed by "n" IPO cycle clocks, to the servo/
position controller of the axis
● The output of setpoints from a local synchronous object interconnected with the master
axis or external encoder, delayed by "n" IPO cycle clocks, to the interconnected
synchronized axis
The number of IPO cycle clocks is calculated from the maximum cycle clock offset across all
distributed synchronous relationships with the master value source. The number of IPO cycle
clocks (integer), which contains the total delay, is calculated.
When compensation on the master value side by means of setpoint output delay is deactivated,
setpoints are output to the axis and the master value is forwarded to and evaluated on local
synchronous objects without delay.

Activating compensation on the master value side by means of setpoint output delay
Master value compensation by delaying setpoint output is activated using the following
configuration data on the master axis and/or an external encoder:
● (TypeOfAxis.)distributedMotion.enableOffsetCompensation:=YES:Calculation of offset is
activated
● (TypeOfAxis.)distributedMotion.enableDelayOfCommandValueOutput:= YES:
Compensation on master value side is activated Delay to setpoint output on master value
side, simultaneous start and no overshoots. The local following axis also has a delayed start.
Disadvantage of "YES": There is less likely to be a response to an event on the master.
When activated, a setpoint output delay on the axis is always effective.
● enableDelayOfCommandValueOutput:= NO is used to deactivate compensation on the
master side. The master immediately outputs the setpoint value.
When activated, a setpoint output delay on the axis is always effective.

Cycle clock offset calculation

The system automatically calculates the maximum cycle clock offset after a transition from
STOP/STOPU to RUN. Cycle clock offset calculation also runs after one of the axes or external
encoders involved has been restarted, as well as the connection has been canceled/restored.
The status of the cycle clock offset calculation is indicated in the
distributedMotion.stateOfOffsetCalculation system variable on the master axis and on the
remote distributed synchronous object. The cycle clock offset is not yet determined for status
INVALID, the cycle clock offset cannot be determined. The master axis/external encoder
issues the technological alarm "40304 Offset cannot be determined".
Compensation on the master value or slave value side requires that offset calculation be
activated in configuration data element
(TypeOfAxis.)distributedMotion.enableOffsetCompensation, on the master axis or external
encoder.

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setpoint output delay

The absolute value of the setpoint output delay can be read out by means of the
distributedMotion.delayOfCommandValueOutput system variable on the master axis.
The time is indicated in the distributedMotion.timeDelayToCommandValueCalculation system
variable on the synchronous object of the remote following axis.
The status of the setpoint output delay is indicated in the
distributedMotion.stateOfDelayValue system variable on the master axis or external encoder
and on the remote synchronous object.
● If the status is INVALID, the setpoint output delay is not activated.
● If the status is VALID, the setpoint output delay is active.
The maximum permissible delay for setpoint output is 10 interpolation cycle clocks. If the delay
exceeds this, two alarms are output on the master value axis or external encoder: "40124
Offset cannot be compensated" and "40125 Setpoint output delay on the master side is
deactivated".
If a local interconnected synchronized axis is acting as the master value for a distributed
synchronous operation, the same setting in terms of the effective compensations on the master
value side should be made on the first master value and on the local synchronized axis.

3.2.2.2 Compensation of the slave value side by means of master value extrapolation
When compensation on the master value side by means of setpoint output delay is not
activated, the compensation on the slave value side performs a linear extrapolation using the
two most recent master values received in order to compensate for the cycle clock offset.
In the event that master values are lost, the two most recent master values received are used
for the extrapolation.

Activating compensation on the slave value side using master setpoint extrapolation
Slave value compensation (interpolation/extrapolation) is activated using the following
configuration data on the master axis and/or an external encoder:
● (TypeOfAxis.)distributedMotion.enableOffsetCompensation:=YES: Calculation of offset is
activated.
● (TypeOfAxis.)distributedMotion.enableDelayOfCommandValueOutput:= NO:
Compensation on master value side is deactivated.

Display of setpoint output time delay on the master value side

The setpoint output delay time on the master value side is indicated in the
distributedMotion.timeDelayToCommandValueCalculation system variable on the
synchronous object. This delay time is generally greater than the offset calculated across all
remote synchronous relationships.
The distributedMotion.timeDelayToCommandValueCalculation system variable on the remote
synchronous object corresponds to the distributedMotion.delayOfCommandValueOutput
system variable of the associated master value object.

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Status of calculation of compensation on the slave value side

The status of the compensation calculation on the slave value side is indicated by means of
the distributedMotion.stateOfOffsetCalculation system variable on the synchronous object as
well as on the master value source/master axis.

Cycle clock offset calculation

The system automatically calculates the maximum cycle clock offset after a transition from
STOP/STOPU to RUN. Cycle clock offset calculation also runs after one of the axes or external
encoders involved has been restarted, as well as the connection has been canceled/restored.
The status of the cycle clock offset calculation is indicated by means of the
distributedMotion.stateOfDelayValue system variable on the synchronous object as well as on
the master value source.
If a command is transmitted to the synchronous object before completion of the cycle clock
offset calculation, a technological alarm is output ("50204 Offset calculation is active"). If the
cycle clock offset cannot be calculated, the synchronous object outputs a technology alarm
("50205 Offset cannot be calculated").

Cycle clock offset between master value calculation and slave value calculation
The clock cycle offset between the master value calculation and slave value calculation is
indicated on the synchronous object by means of the distributedMotion.offsetValue system
variable. The cycle clock offset displayed does not depend on the output delay on the master
value side.
Comment:
● All system variables on the master value source indicate the status or the respective value
across all interconnected following axes.
● All system variables on the synchronous object indicate the status or the respective value
for the interconnection with the current master value source.

3.2.2.3 Permissible combinations for cycle clock offset compensation in distributed synchronous
operation
The compensation settings are made on the master value side (on the master control) using
configuration data elements (TypeOfAxis.)-
distributedMotion.enableDelayOfCommandValueOutput and
(TypeOfAxis.)distributedMotion.enableOffsetCompensation.
The following combinations are possible:

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Table 3-1 Permitted settings of compensation on the master value side and slave value side (setting
on the leading axis or external encoder)

enableOffset enableDelay
Compensation OfCommand
ValueOutput
NO NO No compensation activated
NO YES Not permitted. An output delay on the master value side
without interpolation on the remote following axis is not
permitted.
YES NO Linear extrapolation in the following axis on the last two
master setpoints using the cycle clock offset
YES YES Leading setpoint output delay in the local following axis,
linear interpolation in the following axis of the master
setpoints transmitted using the cycle clock and phase offset

3.2.2.4 Cycle clock offset calculation using a command

The cycle clock offset calculation can be initiated explicitly (V4.1 and higher), for example,
when adding an axis for modular machine concepts.
The cycle clock offset can be calculated on the leading axis with the
_enableDistributedMotionDelayValueCalculation command. This command acts on the
master value and all cascades below it for which this master value applies in its cascade. Active
synchronous operation commands are aborted when the offset calculation is started. If there
are multiple master values at the top level, the command must be called on each object.

See also
Rules for the communication/topology for the distribution using PROFINET IO with IRT (V4.0
or later) (Page 159)

3.2.3 Operating axes with distributed synchronous operation

3.2.3.1 Sign-of-life monitoring

The master axis/external encoder and the remote synchronous object exchange life-signs in
order for each to confirm that the application is running correctly on the other. For example, a
distributed synchronous operation connection can be adversely affected by a fault on the bus
(such as, message frame repetition).
Life-sign monitoring is implemented in the form of one life-sign counter in the master axis/
external encoder and the synchronous object for each distributed synchronous operation. The
process could be described as a "clock comparison". The life sign is sent from the synchronous
object to the master axis/external encoder and vice-versa (bidirectional life-sign monitoring).
The life-sign counters are incremented on the source side in each IPO cycle clock, and the
current value is transmitted to the relevant partner, where it is compared to an expected value.

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If the life-sign counter values differ from the expected values, an error will be output. Life-sign
monitoring is only active if both SIMOTION devices are in RUN mode.

Note
A life-sign failure is not the same as an interrupted connection. The life-sign failure occurs if
the life-sign is not received by the communication partner. This is the case with IPO overflow,
for example. The connection is interrupted when the two communication partners are
physically separated from one another. Further information can be found under "Connection
interruption" in this chapter.

Failure limit
A parameter can be assigned to permit the life-sign to fail "n" times before an error response
is output. This is set using the (TypeOfAxis.)DistributedMotion.numberOfLifeSignFailures
configuration data (default: 1).
The failure limit can be set on the leading axis or external encoder and on the following axes.

Extrapolation in the event of a failure

In the event of a life-sign failure (and the subsequent failure of the master value) that does not
trigger an error response (n > 0), the last available master setpoint is extrapolated.

Error reaction
An error response is triggered if the number of failures exceeds the parameterized value "n".
The life-sign error is indicated on the following axis and the leading axis/external encoder.
Consequently, the error reaction is applied to both of the following:
● Leading axis/external encoder: 40301 Loss of slave connection to the distributed control in
the distributed synchronous operation
● Following axis: 50201 Loss of connection on the assigned control to the master in the
distributed synchronous operation

Activating/deactivating life-sign monitoring

Life-sign monitoring can be enabled/disabled using the
(TypeOfAxis.)distributedMotion.enableLifeSignMonitoring configuration data element on the
master axis/external encoder and the synchronous object (default: YES).

Status signal
Life-sign monitoring must be activated on all participating objects or deactivated on all
participating objects. If this is not the case, a technological alarm is issued on the master axis/

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external encoder or synchronous object to indicate that life-sign monitoring has been
deactivated:
● Leading axis/external encoder: 40302 Life-sign monitoring for slave deactivated in
distributed synchronous operation
● Following axis: 50202 Life-sign monitoring for master deactivated in distributed
synchronous operation
The distributedMotion.lifeSignError system variable on both the leading axis/external encoder
and synchronous object can be used to check whether life-signs have failed. When life-sign
monitoring is activated, the assigned tolerated life-sign monitoring failures in
(TypeOfAxis.)DistributedMotion.numberOfLifeSignFailures must be identical.

Connection interruption
If there is no axis error as subsequent error of synchronous operation monitoring, the following
steps must be complied with in the event of a connection interruption:
● The connection must be physically restored.
● Wait with the program execution until the offsets have been exchanged and the setpoint
output delay has been calculated (see System variables stateOfOffsetCalculation,
stateOfDelayValue).
● The synchronous operation must be enabled again.

3.2.3.2 Operating states

Please note that in order for distributed synchronous operation to function, the master CPU
and the slave CPU must both be in RUN mode. The connection for distributed synchronous
operation does not occur automatically unless both are in RUN mode.

Association with life-sign monitoring

If life-sign monitoring is deactivated
((TypeOfAxis.)distributedMotion.enableLifeSignMonitoring = No) and a transition occurs from
RUN to STOP/STOPU, the master CPU outputs a technological alarm (life-sign error 50201)
to all connected slave CPUs.

Synchronization status
The following device-related system variables on the slave indicate the status of
synchronization:
● StateOfDpinterfaceSynchonization: only relevant if DP of PROFIBUS is equidistant
● StateOfDpSlaveSynchonization: only relevant if DP of PROFIBUS is not equidistant

Direction reversal of the master value for the synchronization

A maximum master value reversal can be defined in the configuration data
syncingMotion.masterReversionTolerance on the synchronous object (V4.0 and higher).
Specifying a tolerance is particularly useful for a distributed synchronous operation, where

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master value noise for actual value coupling can cause a master value reversal due to
extrapolation.
See Actual value coupling with tolerance window (Page 40).

Error handling
During distributed synchronous operation, the following axis sends the "Synchronous
operation tolerance exceeded" error to the master axis. With V4.2 and higher, an error
message is also output on the master object when the following axis disconnects the
synchronous coupling for any reason in the event of an error. The error transfer must be
configured: By means of the synchronous operation monitoring wizard on the following axis of
the slave or by means of the TypeofAxis.GearingPosTolerance.enableErrorReporting
configuration data.
Other errors (e.g. if the following axis is unable to synchronize) are not communicated to the
master object. It is recommended that the 4xxxx errors be sent by the application to the master
via the bus.
In HW Config of the I-slave, for example, a byte can be added to the configuration created by
the system. This means that the following axis can report every error to the master axis by
means of an application.

Figure 3-14 Configuration of an error byte for signaling the leading axis

See Error handling (Page 146).

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3.3 Distributed Synchronous Operation Configuration

This section describes how to create and configure SIMOTION devices and objects with
distributed synchronous operation, and how to download them to the target system.
It is assumed that you have already created cams, master axes, or external encoders. A sample
project for distributed synchronous operation can be found in the FAQ on the SIMOTION
Utilities & Applications DVD.
To configure a distributed synchronous operation, you must carry out the following tasks:
● Creating SIMOTION devices with SCOUT (Page 170)
● Creating connections with HW Config (Page 170)
● Creating synchronous operation connections with SCOUT (Page 172)
● Synchronizing the interfaces (Page 177)
● Generating a synchronous operation configuration (Page 175)
● Identify Possible error (Page 175)

3.3.1 Creating SIMOTION devices with SCOUT

Creating a slave and master
In SIMOTION SCOUT, create two SIMOTION devices in your project:
● A SIMOTION device configured as a slave
● A SIMOTION device configured as a master
● Both SIMOTION devices must be connected and configured so that the HW Config can be
compiled with no errors.

Note
The SIMOTION devices must always be created with the same kernel version for the
master and all slaves.

Note
Addresses entered by SIMOTION SCOUT for axis communication of distributed
synchronous operations in HW Config may not be changed.

3.3.2 Creating connections with HW Config

Requirement
You have created a SIMOTION project containing two SIMOTION devices.

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Creating connections using PROFIBUS

1. Set the "Operating mode" property for SIMOTION devices in HW Config. To do this, open
the "Properties" window on the appropriate interface, e.g. DP/MPI. On the "Operating
mode" tab, set one SIMOTION device to DP slave and the other device to DP master.
2. Set PROFIBUS addresses for both SIMOTION devices.
3. Set the DP mode to DPV1 for both SIMOTION devices.
4. Insert a subnet master system on the PROFIBUS master.
5. Under Properties, set the transmission rate.
For PROFIBUS communication, a transmission rate of 12 Mbit/s is recommended.
6. Under Options in Properties, select Equidistant bus cycle and set the cycle time.
7. Check that the checkbox for Programming, status/control or other PG functions and non-
configured communication connection possible under Operating mode in PROFIBUS
properties for the slave has not been activated. Deactivate it if necessary.
If the checkbox is activated, isochronous operation is not possible.
8. From the hardware catalog of PROFIBUS DP, already configured stations, add the C23x/
P3xx/D4xx ISlave to the existing master system.
9. The DP slave which has already been configured is offered under Coupling. Use Connect
to connect the slave to the master.

Figure 3-15 Device as PROFIBUS master

10.Establish a connection between the two devices (e.g. one byte for synchronization tasks
between user programs on the devices); alternatively, you can ignore compilation errors in
HW Config resulting from the absence of configured connections.
The connection is configured only once the axes on various devices in SIMOTION SCOUT
have been interconnected.

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Detailed information on cross-project distributed synchronous operation illustrated with an

example configuration can be found in Section PROFIBUS communication configuration
(Page 181). You will find detailed information on communication configuration in SCOUT TIA
in Section Communication between SIMOTION two controllers in the SIMOTION SCOUT TIA
Configuration Manual.

Creating connections using PROFINET IO with IRT

The creation of a distributed synchronous operation connection requires that at least two IO
controllers are connected with each other using IRT; a complete IRT configuration does not
need to have been performed:
1. Set the IP addresses. Recommendation: fixed IP addresses
2. Create the two SIMOTION devices.
3. Configure the IRT operation by setting synchronization type SyncSlave for one of the
devices and SyncMaster for the other device in HW Config.
This creates HW Config for distributed synchronous operation. The configuring of the axes
and the interconnection of the axes is the same as for PROFIBUS.
Detailed information on cross-project distributed synchronous operation illustrated with an
example configuration can be found in Section Communication configuration via PROFINET
IO (Page 193).
Saving and compiling in SIMOTION SCOUT automatically creates the data to be exchanged
between the SIMOTION devices for the distributed synchronous operation.

3.3.3 Creating synchronous operation connections with SCOUT

Master axis/external encoder

1. Create the master axis or the external encoder (in the PROFIBUS master for the distribution
using PROFIBUS).
2. Configure the master object (master axis/external encoder) using the wizard.

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Following axis
1. Create a following axis (in the PROFIBUS slave if distribution is taking place via
PROFIBUS).
Make sure that Synchronous operation is activated as the technology when creating the
following axis.

Figure 3-16 Inserting an axis with synchronous operation

2. Configure the following axis using the wizard.

3. Connect the synchronous object for the following axis to the master object (master axis/
external encoder) by selecting the master object under Interconnections.

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Figure 3-17 Distributed synchronous operation: Connecting a leading axis to a following axis

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3.3.4 Generating a synchronous operation configuration

Compiling the project

Save the project via the menu Project -> Save and compile changes.
The system automatically generates the PROFIBUS IO configuration data in HW Config for
the 24 bytes of send and receive info for the distributed synchronous operation. The
configuration is generated and checked for consistency. Both SIMOTION devices must be
connected and configured so that the HW Config can be compiled with no errors.

Note
Only at this point can it be determined whether the network resources are sufficient. If they
are not, an error message will be generated to this effect. The compilation process must be
free of errors; otherwise, it will not be possible to download the project to the target system.

Downloading the project to the target system

Load the project to both SIMOTION devices, so that these are displayed consistently. The
configuration for the synchronous operation is also transferred to the SIMOTION devices
during loading.

Note
There is no mechanism integrated into the SIMOTION Kernel for checking the consistency
of downloaded projects among multiple devices, e.g. during ramp-up. Consistent
downloading can only be achieved by means of "Download" in SIMOTION SCOUT.

3.3.5 Possible error

I/O resources unavailable (PROFIBUS)
If the system detects that the required resources (number of bytes) are no longer available in
the PROFIBUS I/O data, SCOUT will generate an error message during the compilation
process.
Check resources

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● Call the PROFIBUS DP Properties for the relevant slave in HW Config.

Figure 3-18 View of PROFIBUS resources with automatically generated entries

Note
Do not change or delete the entries in the I/O PROFIBUS configuration generated
automatically by SIMOTION SCOUT. If you do, the distributed synchronous operation
connection can no longer be used.

Faulty/incomplete configuration
If the system detects a fault in the configuration, SIMOTION SCOUT will output an error
message during the compilation process.

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3.4 Programming distributed synchronous operation

3.4.1 Synchronizing the interfaces

The interfaces are synchronized in the StartupTask for the slave by means of the
_enableDpInterfaceSynchronizuationMode function call, either automatically by transferring
the dpInterfaceSyncMode function parameter with the
AUTOMATIC_INTERFACE_SYNCHRONIZATION option, or manually by transferring the
MASTER_SLAVE_ALARMMESSAGES_1 option.
If the _enableDpInterfaceSynchronizationMode function is called with the
MASTER_SLAVE_ALARMMESSAGES_1 option, the _synchronizeDpInterface function must
be called at a later point in time to synchronize the interfaces.
If the "automatic" function is used and the connection is interrupted, the interface synchronizes
itself automatically once the connection is restored.
If the "automatic" function is not used, the interface must be synchronized manually every time
the connection is interrupted.
The stateOfDpInterfaceSynchronization = DP_INTERFACES_SYNCHRONIZED system
variable on the slave indicates whether the two interfaces are synchronized.
Exception for SIMOTION C240:
If drives are connected to a SIMOTION C240 via the analog interface (onboard, e.g. for
hydraulic applications), the synchronization is displayed via the
stateOfDpSlaveSynchronization = DP_INTERFACES_SYNCHRONIZED system variable.
The interfaces must be synchronized in order to ensure error-free distributed synchronous
operation.
Further information is available in the Motion Control Basic Functions for Modular Machines
Function Manual.

3.4.2 Synchronous commands

If your commands include the object name of the master value source that is located on the other
SIMOTION device, you must specify the name of this device as a prefix (e.g. D445.axis_1)
If you require data from technology objects that are located on the other device, you can use
the application as a vehicle for this, by expanding synchronous operation communication
between the devices.
See also the section titled Error handling.

Checking to determine whether the following axis is ready

When the distributed synchronous operation is to be started on the following axis (e.g. through
_enableGearing), he application must ensure that the synchronized axis is ready.

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Compensation on the following value side:

The following conditions must be satisfied on the following axis if the following are activated
on the master axis TypeOfAxis.DistributedMotion.enableOffsetCompensation = YES and
TypeOfAxis.DistributedMotion.enableDelayOfCommandValueOutput = NO:
● The stateOfDpInterfaceSynchronization system variable for the following axis must display
DP_INTERFACES_SYNCHRONIZED.
● The distributedmotion.stateOfOffsetCalculation system variable for the synchronous object
must display valid.

Compensation on the master value side:

The following conditions must be satisfied on the following axis if the following are activated
on the master axis TypeOfAxis.DistributedMotion.enableOffsetCompensation = YES and
TypeOfAxis.DistributedMotion.enableDelayOfCommandValueOutput = YES:
● The stateOfDpInterfaceSynchronization system variable for the following axis must display
DP_INTERFACES_SYNCHRONIZED.
● The distributedmotion.stateOfOffsetCalculation system variable for the synchronous object
must display valid.
● The distributedMotion.stateOfDelayValue system variable for the synchronous object must
display valid.

No compensation:
When TypeOfAxis.DistributedMotion.enableOffsetCompensation = NO and
TypeOfAxis.DistributedMotion.enableDelayOfCommandValueOutput = NO is activated on the
master axis, the function is the same as for compensation on the following value side.
If this is not the case (for example, if _enableGearing() is executed on the following axis even
though the master axis is not ready), the command is aborted with error "50102 Master is not
assigned/configured or is faulty (reason: ..." aborted).

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3.5 Configuring distributed synchronous operation across projects

3.5.1 Overview
With V4.1 and higher, it is possible to configure a distributed synchronous operation across
projects; this is carried out using proxy objects. The SIMOTION devices for the master object
and the following axis are located in separate SIMOTION projects.
In each case, there is a proxy "External Synchronous Operation" technology object, which is
assigned to the master axis, and a proxy "External Master Value" technology object, which is
assigned to the slave axis. The external interface of the proxy technology objects is formed by
means of coupling via I/O addresses. The network configuration must be set in HW Config.
The send and receive data must be interconnected with one another. From the point of view
of the runtime system, distributed synchronous operation and cross-project distributed
synchronous operation using proxy technology objects are identical.

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3.5 Configuring distributed synchronous operation across projects

This figure shows the logic view of a synchronous operation interconnection. If the objects are
located in the same project, the master object (master) and the synchronous object (slave)
can be directly interconnected (see left-hand side of figure).
If the master object and synchronous object are in different SIMOTION devices that are not
located in the same project, they must be interconnected using proxy objects. In each case,
these represent the external object (see right-hand side of figure). External synchronous
operation reflects the "transmitter master value", whereas the external master value reflects
the "receiver master value".
This description uses the following terms:

Table 3-2 Terms used

Master/slave PROFINET IO PROFIBUS DP

Master object on IO controller DP master
Synchronous object on I device I slave

The description below uses an example to explain how communication is configured for cross-
project distributed synchronous operation.

Communication configuration for PROFIBUS DP

The following steps need to be carried out for configuration using PROFIBUS DP:
● Create and configure a "synchronized axis" project; see the section titled Creating and
configuring a "synchronized axis" project (Page 181).
● Create and configure a "master object" project; see the section titled Creating and
configuring a "master object" project (Page 189).
● Create proxy objects; see the section titled Creating proxy objects (Page 206).

Communication configuration for PROFINET

The following steps need to be carried out for configuration using PROFINET:
● Create and configure a "synchronized axis" project; see the section titled Creating and
configuring "Synchronous axis" project on SIMOTION D455-2 (Page 194).
● Create and configure a "master object" project; see the section titled Creating and configuring
"Master Object" project on SIMOTION D455-2 (Page 200).
● Create proxy objects; see the section titled Creating proxy objects (Page 206).

See also
PROFIBUS communication configuration (Page 181)
Communication configuration via PROFINET IO (Page 193)
Proxy objects (Page 206)

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3.5.2 PROFIBUS communication configuration

3.5.2.1 Communication via PROFIBUS DP

This section uses an example to describe how cross-project distributed synchronous operation
is configured using PROFIBUS DP. You can adapt the project properties to suit your system
requirements. Please note that you must set the entire PROFIBUS configuration. This example
only refers to configuring cross-project distributed synchronous operation.

Introduction
If the SIMOTION devices are connected via PROFIBUS, data exchange takes place between
a DP master and a DP slave. The SIMOTION device for the "master object" project is
configured as the DP master and the SIMOTION device for the "synchronized axis" project is
configured as the DP slave. In the "master object" project, in order to configure data exchange
with the DP slave in the "synchronized axis" project the DP slave on the PROFIBUS line must
be configured with the "GSD file" of the SIMOTION device.

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3.5.2.2 Creating and configuring a "synchronized axis" project

This description is just an example. You can adapt the project properties to suit your system
requirements. In this example, communication takes place via PROFIBUS.

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Creating a DP slave (project creation in SIMOTION SCOUT)

1. Open SIMOTION SCOUT and create a new project named "synchronous axis".
2. Double-click on "Add SIMOTION device" and add a SIMOTION D455-2 DP/PN V4.3.
3. Click "OK".
4. In the "Interface Selection - D455-2" window, select the "PROFIBUS DP1 (X126)" interface
by clicking "OK" and click "OK" again to confirm.
HW Config opens.

Configuration of the interface in HW Config

1. In the rack, double-click the "DP" interface.
The "Properties - DP - (R0/S2.1)" window opens.
2. Click the "Properties..." button on the "General" tab.
The "Properties - PROFIBUS interface DP - (R0/S2.1)" window opens. Address 2 is
displayed as the default PROFIBUS address. Leave this setting unchanged.
3. Click the "New..." button in the "Subnet" area to create a subnet.
The "Properties - New PROFIBUS subnet" window opens.
4. On the "General" tab, enter the name "Synchronous operation" at "Name".
5. Click the "Network settings" tab and set the recommended value of 12 MBit/s as the
transmission rate.
6. Click "OK" to confirm your settings. You will then be in the "Properties - DP1 - (R0/S2.1)"
window.

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Setting DP slave
1. Click the "Operating Mode" tab and activate "DP Slave".
Ensure that the option button "Programming, status/control or other PG functions and non-
configured communication connection possible" is not activated, deactivate it if necessary.
When the option is activated, no isochronous operation is possible.

Figure 3-21 Setting the properties for the DP slave

2. Click the "Configuration" tab to create input and output addresses for communication.

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3. Click the "New..." button.

The "Properties - DP - (R0/S2.1) - Configuration - Line 1" window opens.
Enter the following settings for the input data:
– Address type: Input
– Address: 256
– Length: 12
– Unit: Word
– Consistency: Unit
, and click "OK" to confirm your settings.

Note
In this example, you enter 256 as the first available address. If you have already
configured other objects in the project, such as a drive, you will need to enter the first
potentially available address.
Please note that you will need the set input and output addresses later when
configuring the external master value in SIMOTION SCOUT.

Figure 3-22 Configuring the input address on the slave

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4. Click "New...".
The "Properties - DP1 - (R0/S2.1) - Configuration - Line 2" window opens.
Enter the following settings for the output data:
– Address type: Output
– Address: 256
– Length: 12
– Unit: Word
– Consistency: Unit
, and click "OK" to confirm your settings.

Figure 3-23 Configured input and output addresses on the DP slave

Note
Please also note that, in addition to the data for the synchronous operation, you may
also want to transfer user data (communication between master and slave, such as
project-specific control and status data for synchronous axes) and will, therefore, need
to configure further lines with additional input and output addresses accordingly.

5. Click "OK" to confirm your settings, followed by the "Save" button.

In order to configure an isochronous PROFIBUS line, you must now use HW Config to create
and configure a new station ("Dummy master") in the same project. This "dummy master" is
only required to act as a proxy and does not have to be physically present.

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Configuring the dummy master

It is recommended that you configure an S7 CPU as the master, so that the slave project
remains clear and the dummy master is not visible in SIMOTION SCOUT.
1. Open or switch to HW Config of the DP slave.
2. In the HW Config menu bar, click "Station > New...".
The "New" window opens. Enter "dummy master" as the object name and select the
SIMATIC 300 station as the object type.

Figure 3-24 Creating a new station ("Dummy master") in HW Config

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3. Click "OK" to confirm your settings. The new "Dummy master" station opens

Figure 3-25 New station in HW Config

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4. In the hardware catalog, open "SIMATIC 300 > RACK 300". Double-click the "Mounting
rail". This is inserted in HW Config.

Figure 3-26 Inserting a mounting rail in HW Config

5. In the hardware catalog, open SIMATIC 300 > CPU 300 > CPU 316-2 DP > 6ES7
316-2AG00-0AB0. Select "V1.2" and move the module to its designated slot (highlighted
in green) using drag-and-drop.
The "Properties - PROFIBUS interface DP - (R0/S2.1)" window opens. It is not necessary
to set the operating mode for the dummy master.
6. Select PROFIBUS address 3 as the address. The PROFIBUS address of the dummy
master must be identical to that of the DP master in the "master object" project. You will
create the "master object" project later.
7. Click "New...". The "New" window opens.
8. Click the "Network settings" tab and set the recommended value of 12 MBit/s as the
transmission rate.
9. Click the "Options..." button. The "Options" window opens.
10.Activate the "Activate equidistant bus cycle" function and enter 3 ms for the "Equidistant
DP cycle". This value must also be set later in the "master object" project.

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11.Click "OK" to confirm your settings in the open window, followed by the "Save" button.
12.Switch to SIMOTION SCOUT and save the "synchronous axis" project.
This concludes configuration of the DP slave communication in HW Config. The next step
involves creating the "master object" project in SIMOTION SCOUT; refer to the section
titled Creating and configuring a "master object" project (Page 189).

3.5.2.3 Creating and configuring a "master object" project

This description is just an example. You can adapt the project properties to suit your system
requirements. In this example, communication takes place via PROFIBUS.

Creating a "Master object" project in SIMOTION SCOUT

1. Open SIMOTION SCOUT and create a new project named "Master Object".
2. Double-click on "Add SIMOTION device" and add a SIMOTION D455-2 DP/PN V4.3.
3. Click "OK".
4. In the "Interface selection - D435" window, select the "PROFIBUS DP1 (X126)" interface
by clicking "OK" and click "OK" again to confirm.
The HW Config opens.

Configuration of the interface in HW Config

1. In the rack, double-click the "DP" interface.
The "Properties - DP - (R0/S2.1)" window opens.
2. Click the "Properties" button on the "General" tab.
The "Properties - PROFIBUS interface DP - (R0/S2.1)" window opens.
3. Select the PROFIBUS address by putting 3 in the "Address" field. The address of the DP
master must be identical to that of the dummy master in the "synchronous axis" project.
4. Click the "New..." button in the "Subnet" area to create a subnet.
The "Properties - New PROFIBUS subnet" window opens.
5. On the "General" tab, enter the name "Synchronous operation" at "Name".
6. Click the "Network settings" tab and set the recommended value of 12 MBit/s as the
transmission rate, then click "Options".
The "Options" window opens.
7. Activate the "Activate equidistant bus cycle" function and enter 3 ms for the "Equidistant
DP cycle".
8. Click "OK" to confirm your settings in the open window.

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Setting DP Slave
1. In the hardware catalog, open "PROFIBUS DP > Additional field devices > PLC >
SIMOTION" and select "SIMOTION D4xx".
2. Using drag-and-drop, move "SIMOTION D4xx" (DP slave) to the "Synchronous operation:
DP master system (2)" subnet. The "Properties – PROFIBUS interface SIMOTION D4xx"
window opens.
3. Select PROFIBUS address 2 as the address and confirm the settings with "OK". This
PROFIBUS address must be identical to that of the DP slave in the "synchronous axis"
project.

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4. Insert a 12-word module from the hardware catalog for the slave outputs first. Under
"SIMOTION D4xx" in the hardware catalog, select the "Master_O Slave_I 12Wo/Unit"
module and move it to its designated slot (highlighted in green) using drag-and-drop.

Note
Please note that the the inputs and outputs must always be configured in the opposite
direction. An input slot must always go to an output slot (and vice-versa). That means that
if the first slot is configured as an input in the "synchronous axis" project, then the first slot
in the "master object" project has to be configured as an output. The length of configured
inputs and outputs must always be identical.
The addresses for the inputs and outputs must lie above the first 64 bytes of the logic
address area. You will need this address again later for configuring the proxy object.

Figure 3-27 Creating an output module on the DP slave in HW Config

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5. Under "SIMOTION D4xx" in the hardware catalog, select the "Master_I Slave_O 12Wo/Unit"
module and move it to its designated slot (highlighted in green) using drag-and-drop.

Figure 3-28 Creating an input module on the DP slave in HW Config

6. Click the "Save" button.

7. Switch to SIMOTION SCOUT and save the "master object" project.
This concludes configuration of the DP master communication in HW Config. The next step
involves creating proxy objects in SIMOTION SCOUT; refer to the section titled Creating
proxy objects (Page 206).

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3.5.3 Communication configuration via PROFINET IO

3.5.3.1 Communication via PROFINET IO

This section uses an example to describe how cross-project distributed synchronous operation
is configured using PROFINET IO. You can adapt the project properties to suit your
requirements.

Introduction
If the devices are connected via PROFINET, data exchange takes place between an
IO controller and an I device. The I device must be taken into account during the configuration
of the IO controller by means of its GSDML file. The GSDML can be generated in HW Config
of the I device.

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Note
The I device can be configured in STEP 7 V5.4 SP2 and higher.

Note
Distributed synchronous operation is also possible via 2 PN interfaces, see chapter Example
configuration for controlled Sync Master in the Communication System Manual.

3.5.3.2 Creating and configuring "Synchronous axis" project on SIMOTION D455-2

This description is just an example. You can adapt the project properties to suit your system
requirements. In this example, configuration using PROFINET V2.2 is described. SIMATIC
STEP 7 V5.5 SP1 must be installed for this.
The creation and configuration of a "synchronous axis" project on SIMOTION D455-2 consists
of the following steps:

Project creation in SIMOTION SCOUT

1. Open SIMOTION SCOUT and create a new project named "synchronous axis".
2. Double-click on "Add SIMOTION device" and add a SIMOTION D455-2 DP/PN V4.3.
3. Click "OK".
4. Click on "New..." in the "Properties - Ethernet interface PNxIO" window.
5. In the following window, add a new Industrial Ethernet subnet with the name "Synchronous
operation".
6. Make the interface selection for PG/PC connection.
7. Click "OK" to confirm your settings. HW Config opens.

Configuration of I device in HW Config

1. In the rack, double-click the PNxIO interface to change the device name for the PROFINET
interface of the I device, and enter the device name "pn1a".
This is necessary because you are working with 2 projects and the default name is the
same for both. retaining these same names would result in consistency problems at a later
point.
2. In this same window, click the "PROFINET" tab and set the required send cycle clock. In
this example, this is set to 2 ms.

Note
You can set the cycle clocks in two ways:
● You can set the send cycle clock so it is equal to the DP cycle clock on the drive.
● You can set the send cycle clock so that it is lower than the DP cycle clock: By opting
for this you will be working with cycle clock scaling. The position control cycle clock
(master application cycle) and the DP cycle on the drive must then be of an equal
length.

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3. In this same window, click the "I device" tab.

Figure 3-30 Settings on the I device

4. Activate the "I device mode", "Parameterization of the PN interface and its ports on the
higher level IO controller" and "Operate complete I device (all submodules) isochronously"
functions.
5. In the lower area of this same tab, click "New...".
The "Properties of virtual submodule" window opens.

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6. Enter the following properties for the send and receive data:
– Address type: Input
– Start: 256
– Length: 24
and click "OK" to confirm your settings.

Figure 3-31 Configuring settings on the I device

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7. Click the "New..." button again to configure the output address as described below:
– Address type: Output
– Start 256
– Length 24
and click "OK" to confirm your settings.
You will need the set input and output addresses later to configure the proxy object in
SIMOTION SCOUT.

Figure 3-32 Configuring output addresses on the I device

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Figure 3-33 Settings on the I device - Addresses

Note
Please note that, in addition to the data for the synchronous operation, you may also
want to transfer user data (communication between master and slave, such as project-
specific control and status data for synchronous axes) and will, therefore, need to
configure additional inputs and outputs accordingly.

8. Confirm your entries with "OK". The I device is created.

Setting DP cycle
1. Double-click on SINAMICS_Integrated.
The "DP slave properties" window opens.
2. Click the "Isochronous operation" tab and set the "DP cycle" to factor 16. This corresponds
to a DP cycle clock of 2 ms.
3. Confirm your entry with "OK".
4. Click the "Save" button.

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Creating the GSD file for the I device

1. In the menu bar, select Options > Create GSD for I Device.
The "Create GSD for I Device" window opens.

Figure 3-34 Creating the GSDML file

2. Click the "Create" button. This creates a GSDML file for the I device. You will need this file
as the proxy for the I device in the "master object" project on the PROFINET IO controller.
The name of the GSDML file is shown.
3. Click the "Install" button.

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4. Click "OK" to confirm the message that appears, followed by the "Close" button. The
GSDML file will now be entered in the HW Config hardware catalog in the PROFINET IO
> Preconfigured Stations/D455 structure.

Figure 3-35 View of HW Config after installation of GSDML file

Note
If the project for the PROFINET IO controller is not to be executed with the same
engineering system, you must export the GSDML file. The GSDML file must then be
imported into HW Config of the other engineering system.

5. Click the "Save" button.

6. Switch to SIMOTION SCOUT and save the "Synchronous axis" project.
This concludes configuration of the I device communication in HW Config. The next step
involves creating the "master object" project in SIMOTION SCOUT; refer to the section
titled Creating and configuring "Master Object" project on SIMOTION D455-2 (Page 200).

3.5.3.3 Creating and configuring "Master Object" project on SIMOTION D455-2

This description is just an example. You can adapt the project properties to suit your system
requirements.
The creation and configuration of a "master object" project for communication via PROFINET
IO consists of the following steps:

Project creation in SIMOTION SCOUT

1. Create a new project in SIMOTION SCOUT and call it "Master object".
2. Double-click on "Add SIMOTION device" and add a SIMOTION D455-2 DP/PN V4.3.
3. Click "OK".

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4. Click on "New..." in the "Properties - Ethernet interface PNxIO" window

5. In the following window, add a new Industrial Ethernet subnet with the name "Synchronous
operation".
6. Make the interface selection for PG/PC connection.
7. Click "OK" to confirm your settings. HW Config opens.

Setting synchronization type

1. In the rack, double-click on the PNxIO interface.
The "Properties - PNxIO (R0/S2.10)" window opens.
2. Click the "Synchronization" tab and set Sync-Master as the synchronization type.

Figure 3-36 Setting Sync-Master on the IO controller

3. Click "OK" to confirm your settings.

4. In the menu bar, select Edit > PROFINET IO > Domain management...
The "Domain management - Synchronous operation" window opens.

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5. Set the required send cycle clock: In our example, this is 2 ms.

Figure 3-37 Setting the sending cycle on the IO controller

6. Click "OK" to confirm your settings.

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Interconnect to PROFINET IO I device

1. Using drag-and-drop, move the I device from the hardware catalog to the "Synchronous
operation: PROFINET IO system (100)" subnet. The proxy for the I device is located in the
hardware catalog in the PROFINET IO > Preconfigured Stations > D455 structure.

Figure 3-38 View of HW Config after insertion of the I device

Note
When you insert the proxy for the I device, the logic addresses for the cyclic input and
output data of HW Config are preassigned. If necessary, correct these addresses before
continuing with the configuration of the proxy objects in SIMOTION SCOUT.

2. Select the I device and double-click "Interface" in the detail view.

The "Properties - Interface (X150)" window opens.
3. Click the "Synchronization" tab and set Sync-Slave as the synchronization type.

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4. In this same window, click the "IO Cycle" tab and select the "Servo" entry in the "IO-Device/
assign isochronous application" drop-down list.

Figure 3-39 Setting isochronous mode

5. Click "OK" to confirm your settings.

Setting DP cycle
1. Double-click the SINAMICS_Integrated.
The "DP slave properties" window opens.
2. Click the "Isochronous operation" tab and set the "DP cycle" to factor 16. This corresponds
to a DP cycle clock of 2 ms.
3. Confirm your entry with "OK".

Interconnecting ports
1. Interconnect the ports by double-clicking on port 1 of the PNxIE net in the rack.
The "Properties - PN-IO - Port 1 (R0/S2/X1400 P1 R)" window opens.
2. Click the "Topology" tab.

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3. At "Partner", select the required port;

In our example, this is "SIMOTION D\(1)pn1a\Port 1 (X1400 P1)".

Figure 3-40 Interconnecting ports

4. Confirm your entry with "OK".

5. Click the "Save" button.
6. Switch to SIMOTION SCOUT and save the "master object" project.
This concludes configuration of the IO controller communication in HW Config. The next
step involves creating proxy objects in SIMOTION SCOUT; refer to the section titled
Creating and configuring "Synchronous axis" project on SIMOTION D455-2 (Page 194).

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3.5.4 Proxy objects

3.5.4.1 Proxy object types

Proxy object types

There are two different types of proxy objects:
● External master value (ExternalMasterType): Proxy object for an external master value
A proxy object for an external master value can only be created under a synchronous object,
i.e. interconnected with it.
● External synchronous operation (ExternalFollowingObjectType): Proxy object for an
external synchronous operation
A proxy object for external synchronous operation can be created under the following
technology object types, i.e. interconnected with them.
– External encoder
– Synchronized axis
– Positioning axis
– Path axis

See also
Creating proxy objects (Page 206)
Configuring proxy objects with SIMOTION scripting (Page 211)

3.5.4.2 Creating proxy objects

In SIMOTION SCOUT, you now need to create the proxy objects. This section uses an example
to describe the process involved in this.

Creating TOs with a master value for external synchronous operation

1. In the "master object" project, create a virtual position axis using the axis wizard and call it
"master_axis_vir".
2. Select the axis in the project navigator, followed by Expert > Insert external synchronous
operation (in the context menu).
An object called "Ext_sync_operation" is created below the selected axis and
interconnected with the "Master_axis_vir".

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3. In the working area, enter the input and output addresses configured in HW Config. 256 is
set for the address in this example.

Figure 3-41 Entering input and output addresses

4. Save and close the project.

This concludes configuration of the "Ext_sync_operation" on the master object. The next step
involves creating the "Ext_master_value" in the "synchronous axis" project.

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Creating the synchronous axis TO with an external master value

1. Open the "synchronous axis" project.
2. Create a synchronous axis and call it "synchronous_axis_slave".

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3. An "Ext_master_value" object is created below the selected synchronous object and

interconnected with the synchronous object. In the project navigator, select the
"synchronous_axis_slave_SYNCHRONOUS_OPERATION" synchronous object below the
synchronous axis, followed by Expert > Insert external master value (in the context menu).
The "Ext_master_value" window opens in the working area.

Figure 3-42 Proxy technology object - Setting the external master value

4. In the "Ext_master_value" window within the working area, enter the input and output
addresses that you set as input and output addresses in HW Config. 256 is set for the
address in this example.

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Figure 3-43 Entering input and output addresses on the external master value

This concludes configuration of the communication for cross-project distributed synchronous

operation. The steps that follow this are the same as those involved in configuring a distributed
synchronous operation; refer to the section titled Distributed Synchronous Operation
Configuration (Page 170).

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3.5.4.3 Configuring proxy objects with SIMOTION scripting

The logical input and output addresses for the proxy object can be accessed with SIMOTION
Scripting. Only the offline data of the object can be accessed. Further information can be found
in the online help and on the Utilities & Applications DVD.

Table 3-3 Configuration data for access via scripting

DriverInfo
logAddressIn Base address of the 12-word input data from HW Config
logAddressOut Base address of the 12-word output data from HW Config

Changing the logical input and output addresses in the SIMOTION project
An example is described below. The logical input address is changed to address 257 and the
output address to address 258.

Note
If the logical input and output addresses are changed with SIMOTION Scripting within the
SIMOTION SCOUT project, the project will no longer be consistent, as there is no automatic
alignment with HW Config. This means that you must automate the changes to the input and
output addresses in HW Config, for example via SIMATIC STEP 7 Scripting.

Proceed as follows to change the logical input and output addresses with SIMOTION Scripting:
1. In SIMOTION SCOUT, create a folder called SCRIPTS below the project. Select the name
of the project, open the context menu and click on Insert script folder.
2. Create a script.
3. Enter the following text:
– PROJ.TOs
("Ext_sync_operation").Symbols("DriverInfo.LogAddressIn") = 257
– PROJ.TOs
("Ext_sync_operation").Symbols("DriverInfo.LogAddressIn") = 258

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4. Save the project.

5. Execute the script by selecting it and clicking on Accept and execute in the context menu.
The logical input and output addresses are then changed.

Figure 3-44 SIMOTION Scripting - example

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3.5.5 Interconnection possibilities

In general, proxy objects can be interconnected with a maximum of one technology object.
The following figure shows the interconnection options.

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In order to interconnect multiple synchronous objects to one external master value, you must
create an additional synchronous operation with a virtual axis, to which the external master
value proxy object will be assigned. In this case, the additional virtual axis acts as a master
value source for multiple synchronous objects.

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Figure 3-46 Interconnection of multiple synchronous objects to an external master value

The same also applies when different master objects can alternatively be the master value for
an external synchronous operation. In this case, an additional synchronous object with a virtual
axis must be provided to be interconnected with the master object. The external synchronous
operation is assigned to the virtual axis.

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3.5.6 Synchronizing the interface

See Synchronizing the interfaces (Page 177).

3.5.7 Switching over to an external master value source

If more than one master value is assigned to a synchronized axis, the master value source
can be selected and switched over on the synchronous object using the _setMaster command
(see Fundamentals of synchronous operation, "Switching over the master value source"). If

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you want to switch to an external master value source, you must specify the name of the
external master value proxy object in the _setMaster command.

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Figure 3-48 Synchronous operation with external and local master value source

This figure shows an example with interconnection to a local and external master value source.
In order to switch to the master value of Axis_1 with the _setMaster command, the name of
the Ext_master_value_1 proxy object must be specified in the command.

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Part III - Synchronous operation across multiple cycles 4
4.1 Overview of multiple cycle synchronous operation
This part describes the function of synchronous operation across multiple cycles. A
synchronous operation can be configured such that high-priority axes are calculated in the
SERVO or IPO processing cycle clock and low-priority axes in the IPO or IPO_2 processing
cycle clock (see under processing cycle clock Real and virtual axes Runtime model and
processing). It introduces you to the operating principle and technological boundary conditions
of synchronous operation with the master object and following axis in different interpolator
cycle clocks (IPO, IPO_2, SERVO). You are shown how to create and configure a synchronous
operation in different interpolator cycle clocks.

Function overview
The synchronous operation across multiple cycles functionality allows you to operate a master
value source and a synchronous axis in different IPO cycle clocks (IPO, IPO_2 and SERVO).
Example:
● Axis_1 is the master axis and is assigned to the IPO task.
● Axis_2 is the following axis and is assigned to the IPO_2 task.

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4.1 Overview of multiple cycle synchronous operation

Application
The synchronous operation across multiple cycles function enables the interpolator to be
placed in a cyclical system task with a greater cycle time for axes that do not require a high
time resolution for calculating the reference value. This reduces the required processor
performance.
In this way, it is possible to:
● Operate coupled axes on one device in different IPO cycle clocks
● Operate coupled axes on different devices in different IPO cycle clocks (synchronous
operation across multiple cycles can be combined with distributed synchronous operation).

Operating principle/Compensations
The phase error, which results from processing in a succession of different cycles, can be
compensated for in the same way as with distributed synchronous operation:
● Compensation on the master value side by means of setpoint output delay
● Compensation on the slave value side by means of master value extrapolation
Please see the section titled Running synchronous operation across multiple cycles
(Page 221).

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4.2 Boundary conditions

4.2 Boundary conditions

Objects with synchronous operation across multiple cycles cannot be created arbitrarily, but
rather must satisfy the following rules:
● In a synchronous operation interconnection of multiple axes, more than one transition of
axes is allowed in different IPO cycle clocks. Several compensations are thus required.
These can be set independently at the transitions. The total compensation is determined
by the system. The effective delay and offset are indicated at each axis and following object.

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Since the calculation of compensation values needs processor resources, it is recommended

to keep the number of transitions low and to form axis groups.

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4.2 Boundary conditions

● Distributed synchronous operation and synchronous operation across multiple cycles can
be combined.
Synchronous operation across multiple cycles is permitted both in the master system as
well as in the slave system.
For further information, see Rules for the communication/topology for distribution using
PROFIBUS. (Page 153)
● A distributed synchronous operation and an IPOx - IPOy transition is only possible between
a leading axis (Axis TO or External Encoder TO) and a synchronous object.
– A Fixed Gear TO, Addition Object TO, Formula Object TO, Closed-loop controller TO
cannot be at a transition, neither on the master value side nor on the slave value side.
– These technology objects may only be located in the action chain where there are no
transitions between distributed synchronous operation or IPO-IPO_2.
● Recursive interconnections which also contain IPOx - IPOy transitions are not prevented.
Please note, however, that:
When switching over during motion, the compensations will lead to a jump or a temporarily
constant position setpoint, and a loss in velocity as a result. (Although the monitoring
functions will remain active.)
Therefore, the IPOx- IPOy transitions in the recursive synchronous operation
interconnection should be switched during standstill only.

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 Part III - Synchronous operation across multiple cycles
4.3 Running synchronous operation across multiple cycles

4.3 Running synchronous operation across multiple cycles

With synchronous operation across multiple cycles, an offset between the master value source
and following axis results from the calculation of the synchronous operation in different
cycles.

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Figure 4-4 Schematic representation of the clock cycle offset due to different interpolator clock cycles

Compensation
The offset can be compensated for in the same way as for distributed synchronous operation:
● Compensation on the master value side by means of setpoint output delay in the IPO cycle
clock that provides the master value for the distributed synchronous operation (master
CPU).
● Compensation on the slave value side by means of master value extrapolation in the IPO
cycle clock containing the slave objects (slave CPU).
The compensations are set and displayed via the system variable distributedMotion.
● The output delay is displayed on the leading axis.
● The master value delay is displayed on the synchronous object.
● The cycle clock offset is displayed on the synchronous object.
The details in Compensations for distributed synchronous operation apply accordingly.

Information on compensations
● Compensations can be set differently on different master objects.
● If "Extrapolation" compensation mode is selected, the output delay on the master is zero.
In this way, there is no effect on other higher-level master values and their compensation
calculation. This allows you to form axis groups.

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4.3 Running synchronous operation across multiple cycles

● It is not possible to specify interpolation on the following axis without master value delay
on the leading axis.
● With the "No compensation" setting, the master values are taken over as the exist.
– Therefore a transition from the slower IPO to the faster IPO is possible but not technically
practical.
– A transition from the faster IPO to the slower IPO is possible, but is associated with a
phase offset.

Life-sign monitoring
The life-sign monitoring is also active for synchronous operation across multiple cycles and
takes effect, for example, with level overflows.
The details in Operating axes with distributed synchronous operation apply accordingly.

Note
If commands for the master value and the slave value are programmed in the same task, it
must be ensured that the commands are effective in the respective processing cycle clock.
If the master value is in a slower execution level than the slave value (e.g. IPO_2 to IPO), it
must be noted, for example, that a _redefinePosition to the master value for the slave value
only becomes effective at the IPO_2 cycle limit. This must be taken into account before issuing
an immediately following synchronize command.

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4.4 Creating synchronous operation across multiple cycles in SCOUT

4.4 Creating synchronous operation across multiple cycles in SCOUT

This section describes how to create and configure devices and objects with synchronous
operation across multiple cycles.

Master object
1. Insert the leading axis or external encoder and configure it.
2. If required, insert cams and configure these.

Following axis
1. Create one or more following axes.
Make sure that Synchronous operation is activated as the technology on the following axes.
2. Configure the synchronous object.
Interconnect the synchronous object with the master object.

Processing cycle clock

The processing cycle clock is defined in the executionConfigInfo.executionLevel configuration
data element of the axis and the synchronous object. The setting can also be made on the
axis via the configuration mask.
● Set the desired IPO cycle clock for each object.
When doing so, select the IPO or IPO2 setting for the Processing cycle clock.

Figure 4-5 Defining the execution cycle in the axis configuration

Configuration
1. In the context menu of the synchronous object, select Expert > Expert list; see Motion
Control Basic Functions, "Expert list".
2. Specify the required configuration (see Operation of synchronous operation across multiple
cycles (Page 221) and Compensations of the distributed synchronous operation
(Page 159)).

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5.1 Overview of cam
This part describes the function of the Cam technology object. It introduces you to the creation
and definition of cams, as well as providing information on supplementary conditions and the
operating characteristics of cams.

Function overview
The Cam technology object can be used to define a transmission function and apply it with
other technology objects. A cam describes the dependency of an output variable on an input
variable.
● An input variable could be the actual position of a master axis, a virtual master value source,
or the time.
● An output variable could be used as the set position of a following axis, the setpoint profile,
or the pressure/force profile.
The TO cam is a stand-alone technology object, which can be interconnected with other
technology objects.

Application
At present, a TO cam can be utilized with the following objects:
● With a synchronous object as a transmission function
● With a TO axis, e.g.
– As a velocity, position, or pressure profile
– As a valve characteristic curve in the hydraulic axis setting

Definition
A TO cam describes a function y = f(x) in sections. The sections can be defined by means of
interpolation points or segments (using polynomials). Cams are dimensionless. No physical
units are used to define them.

Creation and storage

Cams can be created by means of the SIMOTION parameter assignment tool in the
engineering system (CamEdit) or using the CamTool add-on. Cam objects cannot be created
by the user program.
In order to define a cam in the user program, the object must have been created previously in
SIMOTION SCOUT.
Cams are stored by device and can be assigned to each applicable object of this device. Multi-
device cams are not possible.

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Exporting/importing cams
With CamEdit, you can export or import the geometry data of the cam.

Scaling and offset

Cams are scalable either in subranges or overall using commands from the user program,
even if you have defined the cam using the parameter assignment system. For further
information, see "Scaling and offset".

Interpolation
If a cam is defined using segments, gaps in the definition range can be filled by interpolation.
If the cam is defined by interpolation points, the characteristic is interpolated. You can select
from a variety of interpolation methods. For additional information, see "Interpolation".

Reset
Resetting a cam causes the contents of the cam to be reset. The reset command deletes
previously defined interpolation points or segments. The reset command sets the scaling factor
to 1 and the offset to 0. If the cam is interpolated, it must be reset before definitions are made
in the user program.

Access protection
Only one write action can be performed on the cam at any one time. Any number of read
actions can be performed on the cam at any one time. Several write or read actions cannot
be performed at the same time.

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5.2 Fundamentals of Cam

5.2.1 Definition
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A cam is defined by the following:

● Definition range
● Starting point and end point of the function in the definition range
● Transmission function
● The value range, which is generated from the transmission function
SIMOTION provides the following two options for defining cams. As an option, on the cam in
the interpolatorSettings.dataMode configuration data element you can set whether only
interpolation points, only segments, or both are to be used:
● Definition by means of interpolation points and segments (default). Setting
interpolatorSettings.dataMode=SEGMENTS_AND_POINTS
● Definition by means of segments. Setting
interpolatorSettings.dataMode=SEGMENTS_ONLY
● Definition by means of interpolation points. Setting
interpolatorSettings.dataMode=POINTS_ONLY
A cam can be non-normalized or normalized (with a unit interval of 0.0...1.0) (see
Normalization (Page 228)).

Definition based on interpolation points

Interpolation points are represented in the form P = P(x, y) in the interpolation point tables.
The order by which the value pairs are entered is irrelevant. They are automatically sorted in
the definition range in ascending order. SIMOTION interpolates according to the assigned
interpolation type.

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Definition by means of segments

Individual segments are described in accordance with VDI 2143, Motion Laws for Cam
Mechanisms. For additional information, see Motion laws in accordance with VDI (Page 236).
Polynomials with a maximum polynomial degree of 6 and (as an option) a compound
trigonometric function are used for this purpose.

Advantages and disadvantages of the definition modes

Table 5-1 Advantages and disadvantages of defining cams by means of interpolation points or segments

Definition based on interpolation points Definition by means of segments

advantages ● Simple definition ● Fewer data used for definition
● Any algorithms can be mapped by ● Standard transitions in accordance with VDI ...
interpolation points ● Contour is very precise, transitions are continuous
● Curve creation assisted by teach-in
● Simple interface to HMI
Disadvantages ● Large number of interpolation points required ● Complex arithmetic required for calculation of
for the exact representation of the contour coefficients

Definition by means of interpolation points and segments (mixed)

With V4.2 and higher, on the cam in the interpolatorSettings.dataMode configuration data
element you have the option of setting whether only interpolation points, only segments, or a
mixture of both are to be used.

5.2.2 Normalization
When a cam is defined by means of segments, the individual cam segments can be in normal
form (normalized to 1), i.e. both the definition range and value range are contained within the
interval [0,1].
Alternatively, the segments can also be entered in the real range.

Figure 5-2 Mapping of a real cam segment to the normalized range

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A normalization offers the following advantages:

● Motion is clearly defined for similar tasks
● Independent of the real units and value ranges
In addition to the function, the derivatives can also be normalized (normalized transmission
function, NTF).

5.2.3 Scaling and offset

The definition range and value range of a cam can be adjusted according to the application,
i.e. the function can be offset and stretched/compressed (scaled).
The function value for a scaled and offset cam is generated from the definition using the
following formula:

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Figure 5-3 Formula for scaling and offset of the cam

Scaling
The _setCamScale command scales a cam in the value range or definition range. Scaling is
applied when the command is successfully issued. Scaling takes place over the complete cam
or within a range defined by the starting and end points.
● With basic scaling, the entire cam can be scaled and offset.
● With range scaling, individual segments of a curve can be scaled and offset.
The zero point of the coordinate axes is used as the scaling point ("pivot point") for basic
scaling, whereas the starting point of the specified scaling range is used for range scaling. The
starting point of the range scaling can be greater than the end point. In this case, the larger
value is the pivot point for scaling (thus the starting point).
The following are possible for the x-axis and y-axis, respectively:
● One complete scaling
● Two range scalings
● One offset
The range scalings can overlap.

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y y

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Figure 5-5 Example of two range scalings and a complete scaling in the value range

Scaling can be performed before or after segments and points are inserted or the interpolation
is performed. If scaling is performed after interpolation, however, there will be a discontinuity
in the first derivative of the cam (even if B-spline or C-spline interpolation is used).
Tip: To prevent this, scaling should begin and end in the dwell ranges.

Offset
The _setCamOffset command can be used to separately offset the domain and/or range of a
cam.
An offset can be specified as absolute or relative with respect to the current offset.

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● With ABSOLUTE, the offset value applies instead of the previous offset value.
● With RELATIVE, the offset value is added to the current offset value.

5.2.4 Interpolation
If a curve is defined using segments, gaps in the domain can be filled by interpolation.
When the cam is defined using interpolation, the following checks are performed:
● A plausibility check is performed, i.e. the cam definition is checked.
(e.g. duplicated values in the in the definition range).
● Missing ranges are added (interpolated).
● Continuity and junction conditions in boundary points are checked.

Note
Once interpolation has been performed, new segments or interpolation points can only
be inserted after resetting the cam (see Commands for resetting the cam and errors
(Page 246)).
If an attempt is made to insert new segments or interpolation points without first resetting
the cam, the attempt is rejected and the return value for the function provides error
information. Previously defined interpolation points and segments are deleted when the
cam is reset.

Interpolation types
SIMOTION offers the following interpolation types for the Cam technology object:

Interpolation Description Example

LINEAR Linear interpolation

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B_SPLINE Approximation using Bezier

splines, i.e., curve
characteristic along the
interpolation points

With V4.2 and higher, in the

interpolationSettings.bSplineInterpolation =
WITHOUT_APPROXIMATION configuration data
element you have the option of setting whether the
2nd derivation should run continuously.
C_SPLINE Interpolation using cubic
splines, i.e., curve
characteristic through the
interpolation points

With V4.2 and higher, in the

interpolationSettings.cSplineInterpolation =
ADVANCED configuration data element you have
the option of setting whether the 2nd derivation
should run continuously.

Special interpolation settings

● B spline interpolation: As an option, you may choose not to set approximation of the B
splines in the interpolationSettings.bSplineInterpolation configuration data element. This is
a good idea if the interpolation points are not at the same distances and at least continuity
of the 2nd derivation is required. An accurate display in the ES is not supported in this mode.
● C spline interpolation: As an option, you may choose to set a global interpolation in the
interpolationSettings.cSplineInterpolation configuration data element if problems
sometimes arise in the continuity of the 2nd derivation. This results in additional memory
and performance requirements.

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Continuity check
A function with assigned parameters can be checked for continuity in the definition range and
value range, and possible points of discontinuity can be corrected. During this process, the
points of discontinuity are examined separately for the definition range and value range, and
are rated for one of the following corrective actions:
● If the absolute value of the spacing between segments exceeds a maximum value, a
correction is made by performing an interpolation between the two segments. This results
in insertion of a new segment.
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Figure 5-6 Interpolation by insertion a new segment

● If the absolute value of the spacing between segments is greater than the minimum value
and less than the maximum value, correction is made by joining the segment end points.
The mean value of the spacing of the function is used for the correction. The shape of the
segments is affected as a result.
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● If the absolute value of the spacing between segments or interpolation points is less than
the minimum value, a correction is not made. The discontinuity point is retained. When this
discontinuity point is accessed, the right boundary point is output.
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Figure 5-8 Allowing the discontinuity to remain unchanged

The point of discontinuity is corrected according to the evaluation for the definition range and
value range.

Table 5-2 Boundary conditions for evaluation in the definition range or value range of the point of
discontinuity

Condition Result
Deviation < minimum Discontinuity retained
Minimum < deviation < maximum Join segment end points
Deviation > maximum Interpolation (new segment)

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5.2 Fundamentals of Cam

The correction is controlled (separately for definition range and value range) by specifying the
minimum and maximum shape deviation. This specification can be made on the
_interpolateCam command for interpolation of the cam.
Depending on the combined evaluation in the definition range and value range, the point of
discontinuity is corrected according to the following scheme:

Table 5-3 Combined evaluation for definition range and value range of point of discontinuity

Correction for definition range

Discontinuity retained Join segment end Interpolation
points
Correction for Retain discontinuity Retain discontinuity Join segment end New segment
value range points
Join segment end Join segment end Join segment end New segment
points points points
Interpolation Retain discontinuity Join segment end New segment
points

● Function continuity can be achieved with linear interpolation.

● With spline interpolation, continuity is possible in the derivatives.
If the continuity condition cannot be adhered to because of the selected interpolation method
or the programmed geometry, a message is provided to that effect.
If an interpolation boundary point lies within the programmed geometry, all geometry elements
up to the boundary points are rejected. If an interpolation boundary point lies outside the
programmed geometry, an end point is extrapolated according to the interpolation method
used and taking into account the geometry characteristic.

Continuity at boundary points

When assigning parameters to a cam object, you can make three different settings in the
interpolation tab.
These settings specify how the runtime system should handle discontinuity at the boundaries
of the cam. The appearance of the cam in SIMOTION SCOUT may be different from when it
is used later in the runtime system.
● Non-cyclic: Not constant at the boundary points
The runtime system uses the cam as specified, including all discontinuities at the
boundaries, even if it is applied cyclically. However, the acceleration limits and moment
inertia of the mechanical system / drive are the governing factors.
● Cyclic absolute: Position-continuous in the boundary points
The runtime system converts the cam in such a way that is position-continuous and velocity-
continuous at the boundaries during cyclic operation, which can cause changes to occur
in the characteristic.
● Cyclic relative: Constant velocity in the boundary points
The runtime system calculates the cam in such a way that is has constant velocity at the
boundaries during cyclic operation - within mathematical limits, which can cause changes
to occur in the characteristic.

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Overlapping segments
In the case of overlapping segments, segment validity can be defined using the options listed
below.
● Segments after the segment starting points are valid
● Segments up to the segment end points are valid
● Valid segments are determined by the chronological order of insertion.
This behavior is set using the _resetCam command.

5.2.5 Inversion

Inverse mapping
For some applications, it is necessary to determine the master value for a defined slave value.
The master value can be retrieved using _getCamLeadingValue. This inverse mapping is only
unique in the case of strictly monotone output functions. In order to supply a master value for
output functions that are not strictly monotone, an x-value is specified, and the nearest solution
(in both directions) for a y-value is then sought for the specified x-value. If an x-value is not
specified, the search will begin from the starting point of the function.

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Figure 5-9 Output function

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5.2 Fundamentals of Cam

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Figure 5-10 Inverse mapping

Inversion during interpolation

The option exists to invert a cam during preparation/interpolation and to store the cam in both
the non-inverted and inverted shape (V3.0 and higher). Setting via configuration data
camRepresentation
Advantage:
Data that has already been inverted can be accessed more quickly when the master value
associated with the slave value is read out.
Disadvantage:
More memory is required in the runtime system.

Note
The inverted shape of the cam cannot be represented.

5.2.6 Motion laws in accordance with VDI

The VDI concept of working ranges and motion transitions is used to define a cam by means
of segments. The VDI Wizard can also be used for assistance in the creation of cams.

References
● VDI Guideline 2143, 1: Motion Laws for Cam Mechanisms - Basic Theory Düsseldorf:
published by VDI-Verlag, 1980
● Volmer, J. (edited.): Mechanism Design - Cam Mechanisms, 2. Ed. Berlin: Published by
Technik Verlag, 1989

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See also
Motion tasks (Page 237)
Defining a cam for a motion task using segments (Page 239)

5.2.6.1 Motion tasks

The VDI concept differentiates between working ranges and motion transitions.
● Working ranges correspond to sequences in a process. The VDI (Association of German
Engineers) distinguishes between four different types of working ranges (see below).
● Motion transitions are transitions between working ranges, which are not directly relevant
to the process but must satisfy certain boundary conditions (such as continuity in velocity
and acceleration).

Working ranges in accordance with VDI

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The VDI concept distinguishes between the following working ranges:

● R: Dwell (velocity = 0, acceleration = 0)
● V: Constant velocity (velocity <> 0, acceleration = 0)
● A: Dwell (velocity = 0, acceleration <> 0)
● B: Motion (velocity <> 0, acceleration <> 0)

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5.2 Fundamentals of Cam

Example

Figure 5-12 Example of a cam with three working ranges

Motion transitions in accordance with VDI

The motion transitions shown in the figure can occur between the individual working ranges.

R G U B
v=0 v≠0 v=0 v≠0
a=0 a=0 a≠0 a≠0
v=0 v=0 v=0 v=0
R a=0 a=0 a=0 a=0

v=0 v≠0 v=0 v≠0

a=0 a=0 a≠0 a≠0
v=0 v≠0
v≠0 v≠0 a≠0 a=0
G a≠0 a=0

v=0 v≠0 v=0 v≠0

a=0 a=0 a≠0 a≠0
v=0 v=0 v=0 v=0
a≠0 a≠0 a≠0
U a≠0

v=0 v≠0 v=0 v≠0

a=0 a=0 a≠0 a≠0
v≠0 v≠0 v≠0 v≠0
B a≠0 a≠0 a≠0 a≠0

Figure 5-13 Motion transitions in accordance with VDI 2143

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5.2.6.2 Defining a cam for a motion task using segments

Definition of working ranges

The working ranges of a motion task are usually specified by the process.
Example:
1. A tool waits on a production line for a piece to pass by (dwell).
2. The tool is synchronized to the work piece and performs an action on the work piece
(constant velocity).
3. The tool then returns to the waiting position (reversal).
The process starts over from the beginning.
● In order to implement this sequence, the segments of a cam corresponding to the working
ranges must first be created.

Creating a motion transition

Now the "only" things left to define are the motion transitions that satisfy certain conditions
(e.g., jerk-free motion).
● Start by transforming the motion transition to the normalized range.
For additional information, see Normalization (Page 228).
● The boundary conditions, i.e., positions, velocities, and accelerations, must then be taken
into account on the segment borders.
● In order to apply a polynomial defined in such a way, it must be transformed back into the
real range.

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5.3 Cam Configuration

5.3 Cam Configuration

Cams can be created with SIMOTION SCOUT or the optional SIMOTION CamTool add-on.
In addition, the curve characteristic can also be defined by a user program during runtime.
You must carry out the following tasks if you are configuring cams in SIMOTION SCOUT:
● Create the cam (Page 240).
● Define the cam (Page 241).
● Exporting/importing cams (Page 241)
● Interconnect the cam.
Cams are assigned in the respective application. For related information, refer to the
descriptions for the corresponding technology objects.

5.3.1 Creating a cam

Follow the steps described below to create a cam:
1. To create a Cam TO in SCOUT, double-click Insert cam below CAMS in the project
navigator. You can also copy an existing Cam TO using the clipboard and insert it under
another name.
2. Define the cam.
All cams are saved to the CAMS folder and are valid for the entire device. The cams can be
assigned to all applicable objects of a device (e.g. synchronous objects). This assignment is
symbolized in the project navigator, for example, as follows:

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● A link to the cam is created below the synchronous object.

● A link to the synchronous object is created below the cam.

Figure 5-14 Representation of cams in the project navigator

5.3.2 Exporting/importing cams

Description
With CamEdit, you can export or import the geometry data of the cam. For further information,
refer to the online help of the CamEdit cam editor.

5.3.3 Defining and loading cams

Defining with CamEdit

CamEdit can be used to describe cams by means of either interpolation points or segments.
These two methods cannot be combined. If the cam is to be created from segments using
polynomials, SIMOTION SCOUT provides the VDI Wizard to assist in creation of the cam.

Defining with CamTool

CamTool is an add-on to the SIMOTION SCOUT engineering system providing a graphical
option for creation of cams. The add-on is supplied with its own documentation.

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5.3 Cam Configuration

Defining by means of program

SIMOTION provides various commands for creation of cams from the application. In ST, cams
can be defined by specifying interpolation points, segments, interpolation type, and scaling.
For additional information, see Cam Programming/References (Page 243).

Loading cams
With V4.2 and higher, an active, meshing cam can be loaded with CamEdit or by pressing the
Download button.
Meshing cams can, therefore, be modified in the engineering system and replaced online.
Neither the active camming motions nor active calculation of the valve characteristics are
interrupted.
With versions lower than V4.2, it is not possible to download meshing cams to the device.

A cam is only calculated during runtime in the runtime system.

To facilitate diagnostics, the cam can be uploaded again from the runtime system following
download so that any changes due to dynamic response adaptations can be detected.
If the cam is modified during runtime and the original cam is going to be downloaded to the
runtime system again, the cam must be recompiled in SIMOTION SCOUT (otherwise, no
change will be detected and the download will be skipped).

See also
Commands for definition (Page 243)

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5.4 Cam Programming/References

Table 5-4 Commands for cam programming

Command Description
Message functions Commands for reading out function values (Page 245)
_getCamFollowingValue The _getCamFollowingValue command returns the cam value,
_getCamFollowingDerivative _getCamFollowingDerivative, the nth derivation for a specified value in the
_getCamFollowingMinMax definition range. The _getCamFollowingMinMax command returns (with V4.2 and
higher) the minimums and maximums of the cam or of an area of the cam and
the associated nth derivation in a specified section of the definition range.
_getCamLeadingValue _getCamLeadingValue returns the value in the definition range for the specified
value in the value range
Command tracking Commands for command tracking (Page 247)
_getStateOfCamCommand The _getStateOfCamCommand command returns a structure with the processing
status of a command.
_bufferCamCommandId With _bufferCamCommandId, the command status can be queried after
completion or an abort of the command.
_removeBufferedCamCommandId With _removeBufferedCamCommandId, the command should be explicitly
removed from the command management of the TO after evaluation is completed.
Geometry Commands for definition (Page 243)
_addSegmentToCam The _addSegmentToCam command provides you with the option to define a cam
profile in the user program on the basis of polynomial segments f = f(t).
_addPointToCam The _addPointToCam command provides you with the option to define a cam
profile in the user program on the basis of individual interpolation points.
_addPolynomialSegmentToCam The _addPolynomialSegmentToCam command creates a segment f = f(t),
consisting of a polynomial with a maximum of 6 degrees.
_interpolateCam Before a cam is used, it must first be interpolated with the _interpolateCam cam.
_setCamScale The _setCamScale command scales a cam in the range or domain.
See Scaling and offset (Page 229).
_setCamOffset The _setCamOffset command can be used to separately offset the domain and/
or range of a cam.
See Scaling and offset (Page 229).
See Chapter Scaling and offset
Object and Alarm Handling Commands for resetting the cam and errors (Page 246)
_getCamErrorNumberState The _getCamErrorNumberState command can be used to fetch the status of an
error number.
_resetCam The _resetCam cam resets the cam.
_resetCamError The _resetCamError command provides you with the option of acknowledging a
particular error or all pending errors on the cam.

5.4.1 Commands for definition

Interpolation points, segments, or a combination of the two can be used to describe cams.
Commands for the following actions are available for modifying the definition of a cam:

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● Adding segments (_addSegmentToCam)

● Adding interpolation points (_addPointToCam)
● Adding a polynomial segment (_addPolynomialSegmentToCam)
● Interpolation (_interpolateCam)

Programming a cam
When the cam is created, the order in which the cam is edited plays a role. If the shape of the
cam is dependent on parameters and undergoes a change, the cam must be reset before each
redefinition using the _resetCam command. The cam can also be reset prior to the first
calculation without triggering an error message. This command "erases" the cam. This means
that the interpolation is cleared and the points and segments are removed. The technology
object is retained but is empty.
The interpolation points and/or segments are then placed side by side in the appropriate order.
As with CamEdit, the interpolation points can be in any order and will be sorted automatically.
● This is accomplished using the _addPointToCam command (addition of an interpolation
point), the _addSegmentToCam command (addition of a segment) or
_addPolynomialSegmentToCam (addition of a polynomial segment).
● Use the _resetCam command to define cam behavior for overlapping segments/ranges.
● If the shape of the cam is described completely, interpolation is performed using the
_interpolateCam command.
Subsequent addition of one or more points or segments, or modification of points or segments
is not possible. In this case, the cam must be reset and recreated.

Adding segments (_addSegmentToCam)

The _addSegmentToCam command provides you with the option of defining a cam profile in
the user program on the basis of polynomial segments f = f(t). Individual segments consist of
a polynomial with a maximum of 6 degrees and a trigonometric component.
The polynomial parameters, amplitude, period, and phase of a sine function must be entered
in standard form. The transformation parameters must be specified in the basic cam
representation (without scaling or offset) or in the actual cam representation (with scaling,
offset). The definition range values of the cam must always be increasing, i.e. specified in the
positive direction.

Adding interpolation points (_addPointToCam)

The _addPointToCam command provides you with the option of defining a cam profile in the
user program on the basis of individual interpolation points. This includes the option of
specifying values for either a scaled and offset or non-scaled and offset area. In all cases, the
values in the cam definition range must be ascending; in other words, they must be specified
in a positive direction.

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5.4 Cam Programming/References

Adding a polynomial segment (_addPolynomialSegmentToCam)

The _addPolynomialSegmentToCam command creates a segment f = f(t), consisting of a
polynomial with a maximum of 6 degrees. The polynomial parameters are input in the real
range.

Interpolation (_interpolateCam)
Before a cam is used, it must be interpolated. The interpolation defines the connections
between points, between segments and between a point and a segment.
For additional information, see Interpolation (Page 231).

5.4.2 Commands for reading out function values

The following commands can be used to read out individual function values from cam
characteristics.
● The _getCamLeadingValue command supplies the value in the domain (master value) for
the specified value in the range (slave value).
Since this relationship is not always unique, a reference value can be specified. See
Inversion (Page 235).
● The _getCamFollowingValue command supplies the cam with a specified value in the
domain (master value).
● The _getCamFollowingDerivative command can be used to obtain the n-th derivative of the
function for a specified value in the domain (V4.0 and higher).
The derivativeOrder parameter can be used to select the n-th derivative.
This allows, for example, the application to replace specific cams and so take account of
the velocity, acceleration, etc.
The leadingPositionMode parameter can be selected for the commands to specify whether
the scaling and offset is to be used (ACTUAL) or not (BASIC).

Reading out the minimums/maximums of a cam

The _getCamFollowingMinMax command returns (with V4.2 and higher) the minimums and
maximums of the cam or of an area of the cam and the associated nth derivation in a specified
section of the definition range.
The minimums/maximums are also available (in the case of V4.2 and higher) via the
followingRange system variable.

System variables
The sequence of programmed commands can be read out by means of system variables; see
Monitoring the synchronization (Page 59).
The activeCam variable indicates the active cam on the synchronous object. The variable is
a read-only variable.
The activeMaster variable indicates the active master on the synchronous object. The variable
is a read-only variable.

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5.4 Cam Programming/References

5.4.3 Commands for resetting the cam and errors

● The _resetCam command has the following effect:
– The cam is reset to the initial state.
– Pending errors are deleted.
– Depending on the command parameters, the geometry and corrections are deleted as
applicable (see table below).
– The system variables are reset according to parameters.
With versions lower than V4.2, resetting an active cam that is interconnected with a
synchronous operation function by means of the _enableCamming command always
results in an error message that has to be acknowledged. The _resetCam command
cannot be executed.
– With V4.2 and higher, the camModify =
WITHOUT_INTERPOLATION_AND_HOLD_ACTIVE_CAM parameter can even be
used to reset an active cam. This makes it easy to modify the cam subsequently.
● The _resetCamError command provides you with the option of acknowledging a particular
error or all pending errors on the cam.
The command is terminated with a negative acknowledgment if any errors that must not
be acknowledged at this point are present.
● Parameter of the _resetCam command (for additional information, see TP system functions
reference list)
● insertMode parameter (optional). Specifies the sequence interpretation with respect to
subsequent entry of overlapping segments.
● userDefaultData parameter (optional). This parameter controls whether the user default
values are reset to the configured values.
● activateRestart parameter (optional). Can be used to perform a technology object restart
as well.
● camData parameter (optional). Specifies how the cam is to be reset.
● camModify parameter (optional, V4.2 and higher). This parameter controls the cam status
during and after the _resetCams in relation to the geometry data.

Table 5-5 Modes of operation for the parameters associated with the _resetCam command for modifying a cam via the
user program (UP)

camModify parameter (V4.2 and higher)

WITH_INTERPOLATION WITHOUT_INTERPOLATIO WITHOUT_INTERPOLATIO
N N_AND_HOLD_ACTIVE_CA
M
camData parameter
CAM_DATA_RESET Deletes the currently Deletes the currently The active cam is retained.
effective cam. effective cam. The cam can be
The cam can be The cam can be reprogrammed in the
reprogrammed. *) reprogrammed. *) background in parallel. *)
(Also applies to < V4.2) _interpolateCam() activates
the cam programmed in the
background.

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5.4 Cam Programming/References

LOAD_CONFIGURED_DAT The currently effective cam is The currently effective cam is The active cam is retained.
A loaded and interpolated with loaded without interpolation The cam is reloaded in
the configured interpolation with the data specified by the parallel in the background
with the data specified by the ES. without interpolation with the
ES. It can then be modified via data specified by the ES and
(Also applies to < V4.2) the UP and subsequently can be modified via the UP. *)
interpolated. *) _interpolateCam() activates
the cam programmed in the
background.
MAINTAIN_PROGRAMMED Regardless of whether it is Regardless of whether it is The active cam is retained.
_DATA (V4.2 and higher) loaded from the ES or loaded from the ES or Regardless of whether it is
programmed via the UP, the programmed via the UP, the loaded from the ES or
currently effective cam is currently effective cam is programmed via the UP, the
interpolated with the current loaded without interpolation. cam is loaded in parallel in
interpolation settings. It can then be modified via the background without
the UP and subsequently interpolation. It can then be
interpolated. *) modified via the UP. *)
_interpolateCam() activates
the cam programmed in the
background.

*) Alteration of geometry definition, e.g. with _add...ToCam()

5.4.4 Commands for command tracking

● The _getStateOfCamCommand command returns a structure with the processing state of
a command.
– functionResult specifies the error code.
– commandIdState returns the current state of the cam.
– abortId specifies the command abort reason. The abort reason is specified for the alarm
30002 "Command aborted (reason: <abortId>, command type ...)".
See also _getMotionStateOfAxisCommand for the Axis technology object.
● With _bufferCamCommandId, the command status can be queried after completion or an
abort of the command.
● With _removeBufferedCamCommandId, the command should be explicitly removed from
the command management of the TO after evaluation is completed.
The number of motion commands that the MotionBuffer can accept can be specified using the
camType.DecodingConfigInfo.numberOfMaxbufferedCommandId configuration data.
Further information is available in the SIMOTION reference lists.

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5.4 Cam Programming/References

5.4.5 Programming and sequence model

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The following commands and functions are active in the particular technology object states:
*1 _setCamScale
_setCamOffset
*2 _addPointToCam
_addSegmentToCam
*3 _getCamFollowingValue, _getCamFollowingDerivative
_getCamLeadingValue
*4 Error
In general, illegal parameters and commands do not affect the states of the technology object,
but they must be acknowledged using _resetCamError.

Figure 5-15 Programming and sequence model for a cam technology object

If commands that are not permitted in the technology object state are transmitted to the Cam
technology object, an error message is triggered, which requires an acknowledgment. The
technology object state, such as programmable or cannot be activated, is retained.

5.4.6 Local alarm response

Local alarm responses are set by means of the system.
The following responses are possible:
● NONE
No response
● DECODE_STOP
Command preparation aborted.
Following a _resetCam or _resetCamError, editing of the Cam technology object can be
resumed.

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5.5 Graphic output

5.5 Graphic output

5.5.1 Reading out cams with CamEdit

Cams can be read out from the controller and displayed graphically using CamEdit.
A cam is only calculated during runtime in the runtime system. If it is read out from the controller,
the calculated cam can be displayed graphically in CamEdit. If the cam is modified during
runtime and the original cam is going to be downloaded to the runtime system again, the cam
must be recompiled in SIMOTION SCOUT (otherwise, no change will be detected and the
download will be skipped).
By default, the cam is graphically displayed in the standard form in CamEdit. If scaling and/or
offsetting of the cam is required, display in scaled form must be explicitly enabled.
If the command _resetCam with the parameter camModify =
WITHOUT_INTERPOLATION_AND_HOLD_ACTIVE_CAM has been output in the user
program, the active cam disk will be retained. On read-out, the data of the cam disk loaded in
parallel in the background and modified via user program are fetched.

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Index
Self-terminating, 31
Cam coupling, 18
Cam synchronization
assigning parameters/defaults, 125
Synchronization
Camming, 14, 27
Synchronization profile type, 49
Absolute, 28
assigning parameters/defaults, 119
Cam synchronization, 125
A Cyclic, 31
Absolute camming, 28 Non-cyclic, 31
Absolute gearing, 21 Offset, 33
Actual value, 36 Scaling, 33
Actual value coupling, 36, 38 Cascading
With extrapolation, 36 In distributed synchronous operation, 155
with tolerance window, 40 Combination
Actual value error, 76 Synchronous operation compensation, 165
Adapting the synchronization velocity, 107 Command buffer
Axis Synchronous operation, 142
Removing from the synchronous operation Command execution
interconnection, 106 Synchronous operation, 141
Command processing
In the IPO cycle clock, 143
B Synchronous operation, 146
Command tracking
Basic scaling, 229
Synchronous operation, 139
Basic synchronous operation, 71
Command transition conditions
Bezier splines, 232
Synchronous operation, 144
Boundary conditions
Commands
Synchronous operation IPO - IPO_2, 219
Cam, 243, 245, 246, 247
Resetting errors, 141
Resetting states, 141
C Synchronous operation, 138
Cam, 15 Compensation, 152
Application, 225 Combination, 165
Assigning, 113 Distributed synchronous operation, 159
Configuring, 240 Master value side, 162
Creating, 240 On the slave value side, 164
Cyclic application, 32 Superimposed distributed synchronous operation,
Defining with segments, 239 74
Definition, 225, 227 Synchronous operation IPO - IPO_2, 221
Direction, 33 Compensation on the master value side, 162
Interpolation, 231 Compensation on the slave value side, 164
Inversion, 235 Calculating, 165
Normalization, 228 Configuring
Opposite direction, 33 Cam, 240
Overview, 225 Distributed synchronous operation, 170
Programming model, 248 Synchronous operation, 111
Same direction, 33 Synchronous operation IPO - IPO_2, 223
Scaling and offset, 229 Constant velocity, 237

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Index

Continuity at boundary points DP slave

Cam, 234 Creating, 189
Continuity check, 233 Dummy master
Coupling Creating, 185
Cam, 18 Dwell, 237
Cross-project distributed synchronous operation Dynamic response
Overview, 179 assigning parameters/defaults, 128
Cubic splines, 232 Synchronous operation influence, 67
Cycle clock offset, 152 Dynamic response parameters
Calculating, 163, 165, 166 Desynchronization, 65
Distributed synchronous operation, 159 Synchronization, 52, 53
Cycle clock scaling
Distributed synchronous operation, 157
Cyclic E
Camming, 31
Error message
Cyclic cam application, 32
Synchronous operation, 175
Error reaction
For cam, 248
D Synchronous operation, 146
Default value Example
Cam synchronization, 125 Cross-project distributed synchronous operation,
Camming, 119 189, 194, 200
Dynamic response, 128 Programming, 98, 101
Gear synchronization, 121 External master value
Gearing, 117 Creating, 206
Master dynamic response, 130 External master value source
Velocity gearing, 118 Switching, 216
Definition
Commands for cam, 243
Delay time F
Synchronous operation, 164
Filtering
Desynchronization, 15, 64
for actual value coupling, 38
Desynchronization position, 65
Following axis, 15
Master value distance, 65
Synchronous operation, 64, 124, 127
Via dynamic response parameters, 65
Desynchronization position
G
Synchronous operation, 65 Gear ratio, 20
direction Gearing, 24
Gearing, 24 Velocity gearing, 26
Distributed synchronous operation Gear synchronization
Cascading, 155 assigning parameters/defaults, 121
Compensation, 159 Gearing, 14, 20
Configuring, 170 Absolute, 21
Master-slave relationship, 154 assigning parameters/defaults, 117
Operating states, 168 Direction, 24
Overview, 151, 170 Relative, 23
Rules for topology, 153
Synchronization interfaces, 177
With cycle clock scaling, 157
DP master
Creating, 189

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 Index

Master value distance

Synchronization, 49
I Master value position, 44, 45
Master value source
I device
Switching, 68
Creating, 194, 200
Master value switchover
In the opposite direction
Synchronous operation, 69, 70
Synchronous operation, 33
With dynamic response, 69
In the same direction
Without dynamic response, 69
Synchronous operation, 33
Master-slave relationship
Interconnection, 18
In distributed synchronous operation, 154
Interfaces
Monitoring
Synchronizing, 177
Life-sign, 166
Interpolation
Synchronous operation, 134
Cam, 231
Motion, 237
Interpolation point table, 227
Motion laws in accordance with VDI, 236
Interpolation points, 227
Motion tasks
Interpolation type, 227
In accordance with VDI, 237
Interpolation types, 231
Motion transition
Inverse mapping, 235
Creating, 239
Inversion
Motion transitions
Cam, 235
In accordance with VDI, 237, 238
IO controller
Creating, 194, 200
IPO - IPO_2
Synchronous operation, 217
N
IPO cycle clock Non-cyclic
Command processing, 143 Camming, 31
Normalization
Cam, 228
L Normalized transmission function, 229
Life-sign
Monitoring, 166
Life-sign monitoring
O
Synchronous operation IPO - IPO_2, 221 Offset
Linear interpolation, 234 Cam, 230
Local alarm response Camming, 33
during synchronous operation, 248 Changing, 24, 34
For cam, 248 Distributed synchronous operation, 159
Effectiveness, 34
Superimposing, 25
M Synchronous operation, 21
Operating states
Master, 15
In distributed synchronous operation, 168
Master dynamic response
Overlapping segments
assigning parameters/defaults, 130
Cam, 235
Master object, 15
Overshoot factor
Creating, 206
Synchronization, 51
Master value
Overview
Assigning, 113
Cam, 225
Creating, 206
Switching, 216
Master Value, 16

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Index

Shape deviation, 234

Simulation mode
P Synchronous operation, 78
Slave, 15
Parallel effective commands, 142
Spline interpolation, 234
Polynomials, 225, 228
Standstill
Position reference
of the master value, 49
Synchronizing synchronous operation, 123
Status
Processing cycle clock
of synchronization, 60
Synchronous object, 17
Synchronization, 63
Programming model
Substitute
Cam, 248
Synchronous operation, 66
Protective doors
Superimposed synchronous operation, 19, 71
Opening and closing, 106
Superimposition
Proxy
Offset, 25
Cross-project distributed synchronous operation,
Switching
206
Master value source, 68
Types, 206
To external master value source, 216
Proxy object
Synchronization, 15, 49
Creating, 206
Cam, 126
Interconnecting, 213
Camming cycle, 47
Display, 62
Following axis position, 46
R Interfaces, 177
Range scaling, 229 Master value position, 44, 45
Reading out function values Overshoot, 51
Synchronous operation, 138 Status, 60, 63
Readout of function values Synchronization direction, 47
Commands for cam, 245 Synchronization profile, 50
Recursive synchronous operation interconnection, Synchronization range, 48
17 Synchronous operation, 41, 126
References, 3 via dynamic response parameters, 53
Relative gearing, 23 Via dynamic response parameters, 52
Resetting of states and errors Via master value distance, 49
Commands for cam, 246 Synchronization criterion, 43
Reversal, 237 Synchronization direction, 47
Reversing function, 235 Synchronization profile, 50
Rules Synchronized axis, 15
Synchronous operation interconnection, 18 Synchronized group, 15
Synchronous axis
Creating, 112
S Synchronous commands, 142
Synchronous object, 15
Scaling
Settings, 132
Cam, 229
Synchronous operation, 13
Camming, 33
Adapting the synchronization velocity, 107
Changing, 34
Assigning, 113
Effectiveness, 34
assigning parameters/defaults, 115
Segments, 228
Camming, 27
Setpoint, 36
Command buffer, 142
Setpoint value coupling, 36
Command execution, 141
Settings
Command processing, 146
on the synchronous object, 132

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 Index

Command tracking, 139

Command transition conditions, 144
Commands, 141 W
Configuring, 111
Working ranges
Context menu, 150
In accordance with VDI, 237
Desynchronization, 65
Specifying, 239
Desynchronization position, 65
Desynchronizing, 124, 127
Dynamic response, 128
Dynamic response influence, 67
Master dynamic response, 130
Master value switchover, 69
MCC commands, 138
Menu, 149
Monitoring, 134
Monitoring functions, 75
PLCopen commands, 138
Reading out function values, 138
Recursive, 17
Simulation mode, 78
ST commands, 138
Substituting, 66
Superimposed, 71
Synchronizing the position reference, 123
Synchronous operation across multiple cycles, 217
Synchronous operation configuration
Specifying, 113
Synchronous operation IPO - IPO_2
Boundary conditions, 219
Compensations, 221
Configuring, 223
Life-sign monitoring, 221
Synchronous operation relationship, 15

T
Tolerance window
for actual value coupling, 40
Topology
Distributed synchronous operation via
PROFIBUS, 153

V
VDI
Motion laws, 236
VDI Guideline 2143, 236
Velocity gearing, 14, 26
assigning parameters/defaults, 118

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