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Entry type: Application example Entry ID: 21063595, Entry date: 08/08/2008

Micro Automation: Closed-Loop Positioning Control with Standard Drives (MAS 1)

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Note The SIMATIC S7-200 components used in this application example are currently phased out. ...

The SIMATIC S7-200 components used in this application example are currently phased out.
This application can be realized even more effective and easier with the new SIMATIC S7-1200.
The respective application example with SIMATIC S7-1200 is available under entry-ID: 40157517 
Furthermore, many useful applications with SIMATIC S7-1200 are available under entry-ID: 35923253

Automation task
A wire cutting machine shall produce wire rods of a customer-specific length and quantity. After the machine has been equipped with the desired wire coil the type and available capacity of which shall be managed with regard to voltage protection, the positioning axis unwinds the desired length from the wire coil and cuts the wire. This process is repeated according to the quantity entered together with a production ID. After a production job has been finished, all specific production data are to be buffered with regard to voltage resistance in order to read them from a PC once a day and to archive them within the framework of quality assurance. After inserting the wire into the machine prior to production, the wire shall be located in front of the cutting device.

Automation solution
By means of the Touch Panel TP177 micro, all wire coils available for production including their type and capacity can be stored as a recipe in the voltage-resistant memory module of the S7-200 CPU 224XP.

Prior to production, the wire coil to be used for production has to be selected by means of the Touch Panel TP177 micro.

During insertion of the wire, a block running in the S7-200 CPU 224XP controls the frequency inverter G110 via an analog interface so that the wire will stop after having passed an inductive sensor and that the positioning axis thus is referenced. The distance over which the axis has been moved will be reported to the S7-200 CPU 224XP as pulses by an HTL encoder.

After having entered the production ID, length and quantity of the wire pieces to be produced via the Touch Panel TP177 micro, a block running in the S7-200 CPU 224XP will induce the frequency inverter to move the positioning axis over the desired length of the wire. Via a digital output signal, the S7-200 CPU 224XP then controls a cutting device which will cut the wire.

This process is repeated according to the quantity entered. After production has been completed or after an interruption, all production parameters such as e.g. the setpoint and actual quantity of the produced wire rods will be stored in the voltage-resistant memory module of the S7-200 CPU 224XP.

The thus buffered information can be read via serial coupling by means of a PC/PPI cable and the STEP 7 Micro/WIN tool S7-200 Explorer and can be stored as a CSV file.

After production has been completed, the residual wire coil capacity is stored in the voltage-resistant memory module of the S7-200 CPU 224XP.

If the wire quantity is not sufficient for the planned production, this will be indicated via a corresponding message at the Touch Panel TP177 micro.

Startup Code
For startup, we offer you software examples with test code and test parameters as download. The software examples support you during the first steps and tests with your Micro Automation Sets. They enable quick testing of hardware and software interfaces between the products described in the Micro Automation Sets.


Download contents


Micro Application Example V2.0 Set01_DocTech_2d0_en.pdf ( 1444 KB )
Library description V1.1 MAP_Ind_Product_Information_Manual_V1d1_en.pdf ( 1881 KB )
Wire cutting application  
Software example for startup (STEP 7-Micro/WIN project file for positioning) Set1_s7-200_V1d2_en.zip ( 52 KB )
Visualization station  
Software example for startup (WinCC flexible project) Set1_WinCCflex_Visu_V1d1_en.zip ( 2508 KB )
Library V1.21 (STEP 7-Micro/WIN library for the positioning of linear and rotary axes) Set1_S7-200-Library_1d21.zip ( 75 KB )



Entry ID

System Manual S7-200 1109582
Parameter list for frequency inverter SINAMICS G110 20977026


  • Software example for startup (control program and visualization) was optimized.
  • Software example for startup includes library V1.21.
  • Improvement of the library description

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