Flying Saw PLC Control System: IEC 61131-3 Experimental Setup Guide
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Flying Saw PLC Control System: IEC 61131-3 Experimental Setup Guide
A flying saw PLC control system synchronises a cutting carriage to a continuously moving production line, cutting steel, aluminium, or plastic profiles to length without ever stopping the conveyor. This article walks through the experimental system composition of a modern flying saw PLC setup, updated with
Detail
, register-cam profiles, and PLCopen function blocks that have reshaped how engineers design, commission, and maintain these high-speed cut-to-length stations.
A flying saw PLC system comprises PLC CPU, HMI panel, servo drive and motor, encoder, registration sensor, and safety loop, each playing a specific, non-redundant role in synchronised cut execution.
, to build electronic register-cam profiles that replace legacy mechanical cam switches and reduce changeover time.
Jerk-limited Sin-Lin interpolation and online cam switching now allow product-length changes without stopping the line, cutting downtime by up to 40% versus 2024-vintage fixed-cam approaches.
CODESYS SoftMotion, Beckhoff TwinCAT NC PTP, and Bachmann M-SMC are three widely adopted platforms for flying saw motion control, each offering EtherCAT-based multi-axis synchronisation.
Adding a digital twin simulation step before physical commissioning reduces cut-length rejects by over 60% in recent field data collected through mid-2026.
Hardware composition, register-cam profile design, PLCopen block wiring, and safety interlocking of a flying saw PLC system, practical tips for engineers in 2026.
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