⚡ PORTFOLIO — SIMULATION
Flying Saw Flying Saw Synchronization
Industrial cutting system that cuts pipe or profile moving continuously on a conveyor belt to a set length by synchronizing a servo axis with the belt speed. CAM-based motion profile with 5-phase cycle logic.
CODESYS Servo CAM EtherCAT Sync Motion Lenze i950 Motion Control Flying Saw Uçar Makas
FLYING SAW / SYNC v1.0 | Servo Sync Controller
● RUNNING
▸ BELT
V80mm/s
▸ SAW AXIS
X0mm
V0mm/s
PHASEIDLE
▸ SYSTEM
CUTS0
LEN160mm
STATUSRUN
▸ AXES
SAW-X OK
BELT OK
MOD:
BELT SPD 80 mm/s
PIPE LEN 160 mm
CAM: Flying Saw · Servo Sync What Does It Do?
📏 LENGTH CUT
- ▸ Cuts to a fixed length set via slider (100–400 mm)
- ▸ Encoder distance counted each cycle; SYNC starts at target position
- ▸ Continuous equal-length output without stopping the belt
📡 SENSOR CUT
- ▸ Optical sensor detects mark positions (dot/barcode/hole) on the belt
- ▸ Each trigger stamps an encoder position into a FIFO queue
- ▸ Saw tracks the next queue position and cuts exactly at that point
How Does It Work?
5-Phase State Machine
- ▸ IDLE: Saw waits at HOME until cut point approaches
- ▸ SYNC: PD controller syncs velocity and position to the belt
- ▸ CUT: Blade descends when speed & position match; cut completes
- ▸ RETRACT → RETURN: Blade retracts, saw returns to HOME position
Mode Difference
- 📏 Length mode target: pipe head − set length
- 📡 Sensor mode target: front encoder stamp in the FIFO queue
- ▸ Real-world: EtherCAT + CAM table + master encoder, sub-1 ms cycle
Industrial Use Cases
📏 Fixed-Length Cut
- ⚙ Steel & aluminum pipe / profile mills
- ⚙ HDPE / PP plastic pipe extrusion lines
- ⚙ Cable & wire cutting machines
📡 Sensor-Based Cut
- ⚙ Printed packaging & label cutting systems
- ⚙ Rolled products with punch marks / print marks
- ⚙ Pattern-aligned cutting in wood & composite panels
// Without Flying Saw vs. With Flying Saw
| Criterion | ❌ Traditional (Stop-Cut) | ✅ Flying Saw |
|---|---|---|
| Line stops | 2–5 sec / cut | ⚡ Zero stops |
| Cut tolerance | ±3–10 mm | ±0.1–0.5 mm |
| Throughput | 10–60 m/min | 60–300 m/min |
| End quality | Vibration marks / burr risk | Clean, vibration-free cut |
| Mechanical wear | High (start/stop shock) | Low (smooth motion) |
| Energy consumption | High (line stopping loss) | Low (line runs continuous) |
// Typical Application Parameters
| Parameter | Value | Unit / Note |
|---|---|---|
| Belt speed (max) | 30 – 200 | m/min (pipe/profile line) |
| Cut length | 100 – 3.000 | mm |
| Cut tolerance | ±0.1 – 0.5 | mm |
| Sync window | ±2 – 5 | mm/s (CUT trigger) |
| EtherCAT döngüsü | 250 µs – 1 | ms |
| Return speed | 3–5× belt speed | (depends on stroke) |
| Safety function | STO / SS1 / SLS | PLCopen Part 4 / IEC 62061 |
| Servo drive | Lenze i950 | Premium Servo Driver |
| Software platform | CODESYS v3.5 / Lenze | L_TS2P_FlyingSawState |
// Cycle Phases
IDLE
Saw waits at HOME, cut point approaching
SYNC
PD controller syncing saw velocity to belt speed
CUT
Blade descends, cuts while moving with pipe
RETRACT
Blade retracts, saw still at belt speed
RETURN
Saw returns to HOME rapidly (5× belt speed)