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IN
Mechatronics and motion control – Modern machine construction .......................................................
Tasks of a motion control system ..........................................................................................................
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3
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Motion control – Possibilities in automation .......................................................................................... 4
What is SIMOTION? .............................................................................................................................. 5
SIMOTION components ........................................................................................................................ 6
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System architecture of the runtime system ........................................................................................... 7

Technology packages in SIMOTION .................................................................................................... 8
Integration of SIMOTION SCOUT V4.5 ............................................................................................... 9
Installation variants for SIMOTION SCOUT V4.5 ................................................................................. 10
SIMOTION connection to TIA Portal Panels ......................................................................................... 11
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Engineering tools of SIMOTION SCOUT (Classic + TIA) ..................................................................... 12

Programming languages in SIMOTION ................................................................................................ 13
MCC – Programming motion sequences .............................................................................................. 14
LAD/FBD – Programming languages for PLC tasks ............................................................................ 15
ST – High-level language for programming complex algorithms .......................................................... 16
DCC – Graphical tool for generating charts .......................................................................................... 17
The various hardware platforms (1) ..................................................................................................... 18
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The various hardware platforms (2) ..................................................................................................... 19

Integration into the TIA environment ..................................................................................................... 20
SIMOTION documentation .................................................................................................................... 21

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Training documentation 1-1 SIMOTION – An overview
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Previous machine
concepts
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In previous machines, mechanical components, such as cams, gearboxes,
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couplings, line shafts, etc., were still generally used. This meant it was often
costly and time-consuming to make mechanical changes. It was difficult to
create flexible solutions. Now the obstacles imposed by mechanical
components are being eliminated by the use of intelligent automation and drive
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technology.

Intelligent concepts Intelligent software solutions are increasingly replacing mechanical components
with central drive technology. Machine functions are implemented by means of
distributed drive technology. Individual movements are coordinated and
synchronized by the higher-level control.
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Functions that were previously implemented with hardware are now integrated
into the software. Changing machine requirements such as format changes can
be responded to almost at the touch of a button.
Advent of
mechatronics Nowadays "intelligent components" play a key role in modern machine and
production plant construction. These "mechatronic components" are made of
mechanical components, sensors, actuators, electronic components and
software. Today, mechatronic solutions are indispensable for many industries.
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The economic success is not in optimizing subsystems, but in a holistic system

approach. In mechatronics, a machine or production plant is regarded not only
in mechanical terms but as a complete system integrating mechanical
components, electronics, control engineering, and software technology.
SIMATIC and
SIMOTION As the technology leader, Siemens offers manufacturers of machines and
production plants a system platform that provides automation without disruption
between different systems. The wide-ranging services portfolio that this involves
extends from application consulting by competent specialists with sound sector
experience to commissioning and maintenance by our service specialists.

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Training documentation 1-2 SIMOTION – An overview
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MC control
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In SIEMENS control systems, the overall motion functionality is split up into the
actual motion control system and the drive system.
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The MC control has the task of processing the specified (motion) program. In
the motion program, positioning commands can be output to individual axes and
commands and be output to synchronize and coordinate multiple axes
(synchronous operation commands).
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The set positions (interpolation) resulting from the motion commands are fed
into the closed-position control, where they are compared with the actual
positions supplied from the drive system (closed-loop position control). From the
resulting following error, by multiplying with the Kv factor, a new speed setpoint
(axis velocity) is calculated and transferred to the drive. The speed setpoint can
be transferred to the drive system either digitally via PROFIBUS or PROFINET
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– or as an analog signal (+/- 10 V). In addition to the actual motion control

functionality, typical PLC functionality can also be integrated into the MC
system. Like in a SIMATIC PLC, digital or analog I/O signals can be read in,
processed, and the results output again to the I/O devices.

Drive system The task of the drive system is to convert the speed information that is received
into an actual motor speed value. A speed and current controller are integrated
in the drive system for this purpose. The axis is moved to the required target
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position with the set speed defined by the motion control system.
The drive system consists of an inverter, motor, and encoder. When it is
coupled to a SIEMENS motion control system, the drive system runs exclusively
in what is known as speed mode. Motion control functionality (basic positioner,
etc.) that may be integrated in the drive system cannot be used in this case.
Drive systems can also be run without a higher-level motion control system. The
speed can be entered, for instance, via an analog potentiometer.

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Training documentation 1-3 SIMOTION – An overview
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Overview
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The demands placed on a control system largely depend on the application.
SIEMENS therefore offers different systems that have been devised for different
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applications:

SIMATIC SIMATIC is the proven core automation system for solutions in all sectors of
industrial automation. It consists of standard hardware and software compo-
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nents and offers varied options for customized expansions. For SIMATIC S7,
motion control functionality can be integrated using function modules, such as
FM 458, and TDC, …

Technology CPU In addition to the SIMATIC FM modules, the older technology CPUs 315/317T-3
PN/DP and 317TF-3 PN/DP (fail-safe control) fall somewhere between
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SIMATIC and SIMOTION when it comes to demanding motion control tasks.

The CPUs 315/317 can only be configured and programmed under STEP 7
Classic (SIMATIC Manager).
For configuration and programming in the TIA Portal, the technology CPUs of
the S7 1500 series are available. The range comprises the versions:
CPU 1511T-1 PN, CPU 1515T-2 PN, CPU 1517T-3 PN/DP, and the fail-safe
version: CPU 1517TF-3 PN/DP
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SINUMERIK SINUMERIK control systems are specially designed for machine tools, handling
systems and special-purpose machines. SINUMERIK offers the suitable
solution for every task in the machine tool sector using CNC control and drives.

SIMOTION In addition to SIMATIC and SINUMERIK, the Siemens automation range also
encompasses SIMOTION, the motion control system for applications with
complex motion control which integrates motion control and simple control
functionality in one unit. SIMOTION combines the complex handling of motion
functions in a scalable motion control system.

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Training documentation 1-4 SIMOTION – An overview
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SIMOTION
IN
SIMOTION provides an optimized system platform for the automation and drive
solutions in which the focus is on motion control applications and technology
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tasks. This is achieved with the new integrated Motion Control System.
SIMOTION is an integrated motion control system that focuses on the
automation of production machines. Uniformity and integration is achieved in
engineering, programming, communication, data management, the human-
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machine interface (HMI) and thus covers all system components, and of course,
the various hardware platforms.
The merging of
PLC and motion
control The innovative concept of SIMOTION involves eliminating the separation
between pure automation functions (typically PLC controllers) and motion
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functions (motion control). This merging of functionality is implemented in both

the hardware and software.
In the hardware, this new approach means that the controller must be capable
of processing motion functions. On the other hand, a drive system must be able
to perform automation tasks.
In the software, the merging of automation functions and motion functions
engineering simpler. This starts with the configuration and continues through
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parameter assignment and programming.

The integration with SIMATIC brings additional advantages as both systems are
often operated in one installation. The two systems can be configured and
programmed on a standard engineering interface.

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Training documentation 1-5 SIMOTION – An overview
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Overview
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SIMOTION offers an optimized system platform for automation solutions for
machines where the focus is on motion control applications and technology
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tasks. The motion control system consists of the SCOUT engineering system,
the motion control technology packages, and a common runtime system for the
various SIMOTION platforms.
SCOUT
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engineering system The SCOUT engineering system is used for configuring, parameterization, and
programming, irrespective of the hardware platform. Configuring, programming
and setting parameters is either performed by means of graphics or text.

Technology packages Technology packages contain the software functions that are required for
automation in a wide range of different sectors. They expand the basic
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functionality of the SIMOTION devices to suit individual requirements.

Technology packages can be added according to the machine requirements
(e.g. synchronous operation, cam).

Hardware platforms SIMOTION offers flexible solutions – for all requirements – by running on a
range of different hardware platforms. With SIMOTION you can freely select
between three different platforms:
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• SIMOTION C – controller-based
• SIMOTION P – PC-based
• SIMOTION D – drive-based

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Training documentation 1-6 SIMOTION – An overview
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System architecture
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The most outstanding feature of the new automation approach is its system
architecture. This forms the basis for further development of the system in the
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future. The system architecture of SIMOTION supports, in particular, concepts
such as decentralization, different target platforms, and distributed intelligence.
The software is modular and can be flexibly adapted to different requirements.
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Basic functionality The basic functionality of the device (SIMOTION Kernel) includes functions for
open-loop and closed-loop control as well as logic and arithmetic. Program
execution can be cyclical, time-controlled, or interrupt-controlled. As a result, the
SIMOTION Kernel contains the functions needed for virtually all applications
and corresponds in essence to a PLC with the IEC 1131-3 command set plus
system functions for controlling various components, such as inputs/outputs.
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Technology packages The SIMOTION Kernel can be expanded by loading technology packages.
Using additional language commands, the technology packages can be
accessed from the user program in the same way as the SIMOTION Kernel.

Function libraries The libraries contain standard blocks for frequently performed tasks. In addition
to the standard functions supplied, users can also create their own blocks and
store them in a library.
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From Version 4.0, the following libraries have also been integrated as function
blocks in the system (TP "Cam"), and can now be directly inserted into the user
program from the command library:
• Standard functions, for instance PID controllers, driver blocks for special
I/O modules
• Blocks conforming to PLCopen to control axes (single and multi-axis blocks)

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Training documentation 1-7 SIMOTION – An overview
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IN
Technology packages Technology packages can be loaded in the runtime system to expand the basic
functionality of the SIMOTION Kernel. In addition to the object types, technology
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packages provide a wide range of powerful motion control commands that are
required to solve applications flexibly.
TP "CAM" The "Cam" technology package provides all object types and system
commands to control the speed, and positioning and synchronous axes. In
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addition to the functionality for each of the axis types, TP "Cam" contains the
"Measuring input", "Output cam" and "Cam track" functions (as of V3.2) as well
as the function blocks conforming to PLCOpen.
TP "PATH" The "PATH" technology package provides path functionality. The following are
supported: 2D/3D linear, circular, and polynomial interpolation. In addition,
various kinematics, such as 2D/3D gantry, roll, Delta-2D, Delta-3D-Picker, as
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well as SCARA and articulated arm kinematics

TP "CAM_EXT" Supplementary technology functions are available as of Version 3.2.
• Adder: With adder objects, up to four input vectors can be
added to one output vector.
• Formula: With formula objects, you can apply mathematical operations to
scalar (LREAL, DINT) and motion vectors.
• Controller: Using the controller object, according to a PID algorithm, scalar
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variables can be processed and logically combined.

• Sensor: The sensor technology object can be used to detect and process,
i.e. monitor and smooth, scalar measured values accordingly.
• Fixed gearing: For "fixed" synchronous relationships between axes with an
adjustable gear ratio, however, without specific synchronizing/
desynchronizing strategy.
TP "TControl" The basis of the temperature controller is a DPID controller which has special
functions (threshold monitoring, adaptation of controller parameters, etc.) for
easy adaptation to applications (plastics machines).

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Training documentation 1-8 SIMOTION – An overview
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TIA Portal
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The Totally Integrated Automation Portal (TIA Portal) is an integrated
engineering framework for all controllers, HMI devices, and drive systems in
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production and process automation. Cost savings of up to 30% are possible with
the TIA Portal thanks to simplified engineering, quicker machine commissioning,
and reduced machine downtimes.
The TIA Portal includes:
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• STEP7 (TIA Portal) is the engineering software for configuration and

programming of the SIMATIC S7-1200, S7-1500, S7-300/400 controller
families.
• WinCC (TIA Portal) is an engineering tool for configuration of SIMATIC HMI
operating devices as well as SIMATIC industry PCs and standard PCs with
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WinCC Runtime Advanced and WinCC Runtime Professional.

• STEP7 Safety Advanced enables the implementation of safety-related
automation applications in the TIA Portal. LAD and FBD languages, as well
as pre-configured, certified application blocks are used for programming the
safety program.
• SINAMICS Startdrive is a tool integrated in the TIA Portal for configuration,
commissioning, and diagnostics of the SINAMICS drive family.
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SIMOTION SCOUT SIMOTION SCOUT is the engineering system for SIMOTION and provides all
the required tools for the following functionalities:
• Configuration
• Parameterization
• Programming
• Testing
• Diagnostics

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Training documentation 1-9 SIMOTION – An overview
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SIMOTION SCOUT
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SIMOTION SCOUT is the basis for automation of machines with SIMOTION
and integrates into an existing SIMATIC environment in line with the concept of
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TIA (Totally Integrated Automation).
With the SIMOTION SCOUT V5.1 version, 2 way of integrating into existing
SIMATIC environments are provided. The SIMOTION SCOUT installation
software includes both of the following "setups":
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• SIMOTION SCOUT (Classic) for integration into an existing STEP 7

environment with the SIMATIC Manager. In this case, configuration and
parameter assignment for the SIMOTION Motion Control System's hardware
and incorporation into the network environment is achieved via the "HW
Config" and "NetPro" tools integrated in STEP 7.
Configuration and programming as well as commissioning and testing of the
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motion control function are performed in separate SIMOTION SCOUT

screen forms and editors. Configuration, commissioning, and testing of the
connected drive are performed in the "Starter" tool integrated in the SCOUT
user interface
• SIMOTION SCOUT TIA for integration into a TIA Portal environment. With
SIMOTION SCOUT TIA, all automation components, e.g. SIMOTION
modules, SIMATIC modules, Startdrive drives, HMI, etc. incorporated in one
project.
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The user uses the fully graphical TIA Portal editors to configure the SIMOTION
hardware and incorporate it into a network environment. Configuration and
programming of the SIMOTION motion control functions, including
parameterization and diagnostics of the connected drive systems, is performed
on the proven SCOUT user interface as it was previously.
Both SCOUT variants are offered by the installation software. Both variants can
also be installed in parallel with STEP 7 and the TIA Portal.

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Training documentation 1 - 10 SIMOTION – An overview
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IPE
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The TIA Portal allows technological and HMI configuration to be introduced in
various projects. For example, one operator creates the HMI configuration and
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the second operator creates the technological configuration. In the TIA Portal,
this working method is called "Inter Project Engineering". Inter Project
Engineering is primarily used with SIMOTION to make HMI Panels available for
SIMOTION SCOUT, SIMATIC STEP 7 V5.6, and WinCC flexible, which can still
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only be configured in the TIA Portal.

Device proxy To this end, a device proxy is configured in the TIA Portal project (as of V13), to
which the Comfort Panel for HMI visualization is then connected. The device
proxy is a proxy object in the TIA Portal project for devices that do not belong to
the TIA Portal project. Configuration of the SIMOTION controller is reproduced
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in the TIA Portal project by initializing the device proxy.

The HMI panel in the TIA Portal project can therefore access the global user
and system variables of the SIMOTION control system. The device proxy also
adopts the message configuration of the SIMOTION control system.
If new variables, TOs, or alarms are created in the SIMOTION SCOUT Classic
project, the device proxy must then be updated in the TIA Portal in order to
make the new variables and alarms available in the TIA Portal project. It is
possible to perform technological and HMI configuration via a device proxy for
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various projects for SIMOTION SCOUT TIA, too.

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Training documentation 1 - 11 SIMOTION – An overview
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Engineering system
SCOUT
IN
The SCOUT project navigator is the common framework for all tools of the
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engineering system. This Workbench is also the navigation center for the
individual engineering steps. It is used to create and manage SIMOTION
projects and provides a uniform view of all data and programs.
The essential new feature is the graphical programming of the motion sequence
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by means of Motion Control Chart (MCC). As of SCOUT V4.1, there is also the
optional DCC programming language (Drive Control Chart), only in "SCOUT
Classic", to create continuous, closed-loop control circuit diagrams for
controlling drives.
The technological tree structure of the project includes
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• all devices (control, drives etc.),

• all technological objects (axes, output cams, cams, etc.) and
• user programs in hierarchic views that can be filtered.
The navigation in the tree structure opens the parameter assignment or
programming tool assigned to the selected object.
The SIMOTION SCOUT engineering system is a powerful tool that acts as the
PC development environment to optimally support the required engineering
steps in a user-friendly way.
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The "SCOUT Classic" engineering tool is integrated as an option package for

STEP 7 in the SIMATIC environment. "SCOUT TIA" is an option package as of
TIA Portal V13.

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Training documentation 1 - 12 SIMOTION – An overview
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Overview
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SIEMENS offers a range of task-oriented programming languages for
SIMOTION that allow the user to focus on the actual task at hand. SIMOTION's
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modular design makes it possible to create blocks in different languages
depending on the requirements of each individual task.

MCC MCC is a graphical language for creating operational sequences. This language
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offers entry-level users, in particular, support with quick and understandable

creation of program sequences in MotionTasks. Any additional ST code can be
integrated in the MCC program with the "ST Zoom" command.

LAD/FBD These programming languages are unparalleled for programming binary signal
logic operations. In addition to the wide range of options in the area of binary
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signal logic operation (edge evaluation, flip-flops, etc.), many other functions
such as IEC-compliant counter and timer blocks are integrated. Almost all
system functions can be directly called and tested in a network.

ST Structured Text is a text-based, high-level language similar to PASCAL.

ST contains all typical elements of a high-level language, such as operators,
expressions, control statements, etc. ST supports, in particular, programming of
mathematical algorithms and data administration tasks.
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Due to the many control structures it offers, ST is also suitable for programming
process sequences.

DCC The Drive Control Chart (DCC) option is a modular, scalable programming
language based on the STEP 7 package CFC (Continuous Function Chart) for
developing continuous open-loop or closed-loop control solutions for controlling
drives.

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Training documentation 1 - 13 SIMOTION – An overview
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SIMOTION C
IN
The C2xx is a motion control module for controlling servo drives via PROFIBUS
DP (PROFINET on C240 PN) and four onboard drive interfaces (C240 only).
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SIMOTION C is a powerful module for independent single-axis positioning or for
axis grouping motion. It supports operation of both rotary and linear axes. The
engineering system is used for configuration, parameterization, commissioning,
programming and diagnostics of the SIMOTION C.
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SIMOTION P SIMOTION P is a PC-based motion control system. Control, motion control, and
HMI functions run concurrently on this PC.
SIMOTION P combines PC technology with the advantages of a maintenance-
free an PC solution without any rotating parts. It can be operated without any
display or monitor, or with a monitor. The drive is connected through
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3 integrated PROFINET interfaces In addition, a so-called IsoProfibusBoard can

be plugged in for option connection of drives via PROFIBUS. A wide range of
SIMATIC Panels is available for implementing visualization tasks.
The P320-4 Embedded has two memory cards (CFAST: successor to the CF
card). One card can be accessed externally. The P320-4 Standard has a Solid
State Disk (SSD) as internal memory. This significantly improves the
performance of the box with the Intel i7 processor.
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Unlike the SIMOTION C system, the controller-based solution, the SIMOTION P

has the advantage of a PC solution with standard PC applications running
parallel to the motion control program, large data storage, and rapid high-
volume data processing. The P320 has been specially optimized for hydraulic
applications. Together with the ET 200 HS PN (High-Speed PROFINET) I/O
system, cycle times as fast as 125 µs, and consequently response times far
below 1 ms, can be achieved.

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Training documentation 1 - 18 SIMOTION – An overview
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SIMOTION D
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SIMOTION D merges SIMOTION functionality and drive functionality of a drive
system on the drive hardware. This results in a system which is both highly
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compact and with fast response times.
SIMOTION D is used when a compact machine concept and high performance
for motion control tasks are required in conjunction with high-speed I/Os.
SIMOTION D is offered in the versions D425-2 (low-end performance range),
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D435-2 (medium performance range), D445-2 (high-end performance range)

and D455-2 (highest performance range).
These modules of the SIMOTION D range are available as pure PROFIBUS
versions (D4x5-2 DP) for connecting distributed I/O or as PROFIBUS/
PROFINET systems (D4x5-2 DP/PN) permitting connection of distributed I/O
via PROFIBUS and/or PROFINET.
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The single-axis system can be used to expand SIMOTION D systems one axis
at a time. The D410-2 DP and D410-2 DP/PN systems are available with the
option of multi-axis application.
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Training documentation 1 - 19 SIMOTION – An overview
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Notes
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Training documentation 1 - 20 SIMOTION – An overview
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Totally Integrated
Automation
IN
TIA with SIMATIC includes all of the technologies required in an automation
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landscape, including programmable logic controllers, PC-based control,
automation computers, distributed I/Os, HMI systems, communication networks,
or process control systems.
TIA enable implementation of the solution that is technically required and makes
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economic sense from a complete and integrated modular system. SIMOTION is

completely integrated in the TIA concept.

PROFIBUS DP Standard PROFIBUS DP with DP/V1 functionality:

• for the connection of distributed I/Os
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• for the connection to a higher-level automation system

• for the connection of HMI devices
• for the connection to the SCOUT engineering system
All standard DP slaves (e.g. distributed I/Os, drives) can be connected to
PROFIBUS.

Industrial Ethernet Fast Industrial Ethernet that can be used for the following purposes:
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• Connecting HMI devices

• Connecting to the SCOUT engineering system
• Communication with TCP/IP and UDP (User Datagram Protocol)

PROFINET PROFINET is the innovative and open Industrial Ethernet standard (IEC 61158)
for industrial automation. With PROFINET, devices can be linked up from the
field level through to the management level.
With PROFINET, drives can be controlled isochronously via a network and
communication that is not time-critical (e.g. TCP/IP) can be established between
automation components.

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Training documentation 1 - 21 SIMOTION – An overview
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