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Bosch Rexroth SERCOS III Automation Solutions & Applications

Bosch Rexroth SERCOS III Automation Solutions & Applications. Chris Cooper Regional Sales Manager Southeast & Southwest Territories. Agenda- Automation Solutions & Applications. Introduction to Bosch Rexroth Automation Solutions De-centralized Drives High Performance Controls

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Bosch Rexroth SERCOS III Automation Solutions & Applications

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  1. Bosch Rexroth SERCOS III Automation Solutions & Applications Chris Cooper Regional Sales Manager Southeast & Southwest Territories

  2. Agenda- Automation Solutions & Applications • Introduction to Bosch Rexroth • Automation Solutions • De-centralized Drives • High Performance Controls • SERCOS III Ethernet Based System Architectures • SERCOS III Application Examples Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  3. Bosch Rexroth in the Americas Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  4. The Company – The Technology Areas Everything from one source – specialized and integrated Components, modules, systems, as well as services and engineering services in the areas Service Electric drives and controls Hydraulics Linear andassembly technologies Pneumatics Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  5. The Company – The Markets • Food and Packaging • Cutting and forming machine tools • Automotive industry • Printing and converting • Assembly/handling • Logging industry • Rubber and injection-molding machines • Tunnel and mining industry • Civil engineering • Entertainment • Offshore technology • Shipbuilding • Maritime applications ... and much more Rexroth services are used worldwide in nearly all industries ... 500,000 Customers worldwide! Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  6. Rexroth Automation House Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  7. IndraDriveTMThe new drive generation for all applications • Worldwide first provider of servo- and frequency converter on one platform • SERCOS II & III InterfacesOpen architecture connectivity • Drive-integrated safety technologyfor safe stop and safe motion (certified acc. to EN 954-1, safety category 3) • Single- and multi-axes Motion Logicacc. to IEC 61131-3 and PLCopen • Scalable power, functionality and performancefor best application fit • Fast and easy start-up assistant incl. automatic motor identification and auto-tuning Drives and motors Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  8. IndraDynNext generation of motors • IndraDyn S Synchronous servo motors up to 240 Nm • IndraDyn A Asynchronous servo motors up to 100 kW • IndraDyn LSynchronous linear motors up to 22.000 N • IndraDyn TSynchronous torque motors up to 13.800 Nm • IndraDyn HSynchronous high-speed motors up to 30.000 min-1 • Planetary gearboxes Drives and motors Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  9. IndraControl VControls and HMI • Controller based terminalsFrom text displays up to graphical touch screen • Windows CE Embedded based terminalsVisualization and PLC runtime in one device • Standard industrial PC’sCost-effective solutions by standardised PC hardware • High-end industrial PC’sFor highest demands in industrial environment • Complete PC-based operator terminalsVisualization and PLC control in one device • Visualization softwareUseable on different platforms (Win XP, CE, Web) • AccessoriesMachine operator panels, keyboards, … Controls and HMI Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  10. IndraControl LControls and HMI • IndraControl LThe most compact embedded control with Ethernet, SERCOS II, III and PROFIBUS interfaces in their class • Rexroth Inline The flexible I/O portfolio for cabinet installation with degree of protection IP20 • Rexroth FieldlineThe rugged I/O technique for field installation with degree of protection IP67 • Scalable in power and functionality • Modular and flexible with many open communication standards • Fast and tool-less installation Controls and HMI Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  11. IndraLogicThe uniform and open PLC solution • Uniform PLC runtime for all Rexroth systems:Motion Control, CNC and PLC system solutions • Scalable in performance and control platform: • Drive-based for drive-based applications with integrated motion-logic • Controller-based based on IndraControl L and direct connection of the I/O portfolio Rexroth Inline • PC-based combined with integrated Visualization based on IndraControl V • Programming according to IEC 61131-3 • Common PLCopen library with standardised motion functions • Complete engineering with IndraWorks PLC Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  12. Architectures MLD Motion Logic Drive-based MLC Motion Logic Controller-based MLP Motion Logic PC-based WEB, MES, ERP WEB, MES, ERP Motion Logic Motion Logic Motion Logic MLD Motion Logic Motion Logic MLC MLP HMI HMI HMI HMI HMI I/O I/O I/O I/O Drives Drives Drives Drives Economic solution for low to medium demands • up to 8 axes Standard solution for medium to high demands • up to 64 axes High integrated solution for medium demands • up to 32 axes Uniform general technology functions and program templates Uniform system bus for motion, drives, safety and I/O‘s: SERCOS III Open standards and uniform PLC platform acc. to IEC 61131-3 Uniform engineering for motion, logic, HMI and drives with IndraWorks Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  13. Architectures MLD Motion Logic Drive-based MLC Motion Logic Controller-based MLP Motion Logic PC-based WEB, MES, ERP WEB, MES, ERP Motion Logic Motion Logic Motion Logic MLD Motion Logic Motion Logic MLC MLP HMI HMI HMI HMI HMI I/O I/O I/O I/O Drives Drives Drives Drives Economic solution for low to medium demands • up to 8 axes Standard solution for medium to high demands • up to 64 axes High integrated solution for medium demands • up to 32 axes Uniform general technology functions and program templates Uniform system bus for motion, drives, safety and I/O‘s: SERCOS III Open standards and uniform PLC platform acc. to IEC 61131-3 Uniform engineering for motion, logic, HMI and drives with IndraWorks Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  14. MLD Systems - Motion Logic Drive-basedSercos-III Ethernet Master with Sercos-III Slave´s HMI Line-Controller with fieldbus(optional) FKM- Sercos-III Sercos-III CCD Master Ethernet TCP/IP Switch Programming and Parametrizing of all drives and I/O´s with IndraWorks w/o changing the socket Sercos III Ethernet based PLC in Drive Sercos-III I/O´s MASTER SLAVE 1 SLAVE N Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  15. 3 Foil Feed 2 Cross seal Transport 5 1 6 Fin Seal 4 Lug Chain Rotary knife Application Example #1BVK1300 HFFS Machine Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  16. Application Example #1BVK1300 HFFS Machine PLC Network variables WinCE - Visualisation A1 Lug Chain A2 Foil feed A3 Cross Seal A4 Rotary knife A5 Transport A6 Fin seal SIII Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  17. High Speed handling of many Products per minute Depending on the product size and the machine design, the throughput requirements can be anywhere from 5 to 2000 products per minute (250 to 500 typically) Registration Accurate and high speed registration must be performed in order to align package labeling ELS (Electronic Line Shafting) functionality Reduces mechanical components on the machine and significantly reduces setup and product change-over time Electronic Camming allows for different knife profiles to be executed based on the product length & height Lock-on, Lock-off cam profiles to achieve “No-product= No-wrap” functionality Servo Requirements for a HFFS machine Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  18. Architectures MLD Motion Logic Drive-based MLC Motion Logic Controller-based MLP Motion Logic PC-based WEB, MES, ERP WEB, MES, ERP Motion Logic Motion Logic Motion Logic MLD Motion Logic Motion Logic MLC MLP HMI HMI HMI HMI HMI I/O I/O I/O I/O Drives Drives Drives Drives Economic solution for low to medium demands • up to 8 axes Standard solution for medium to high demands • up to 64 axes High integrated solution for medium demands • up to 32 axes Uniform general technology functions and program templates Uniform system bus for motion, drives, safety and I/O‘s: SERCOS III Open standards and uniform PLC platform acc. to IEC 61131-3 Uniform engineering for motion, logic, HMI and drives with IndraWorks Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  19. Application Example #2Robotics • Multi axis kinematic up to 8 axis • Over 100 kinematic transformations • Easy kinematic configuration • Zero offset, Override, Teach-In, … • Adaptive belt tracking (4 belts) • Easy integration of vision systems • Customer-defined kinematics Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  20. Axis Axis Application Example #2Robotics Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  21. Application Example #2Robotics • Highlights: • Hardware: MLC V03 • 7X SERCOS III Indradrive (2 ms SERCOS time) • Camera interface via Ethernet TCP/IP • HMI interface via Ethernet OPC • Belt synchron (Infeed and Outfeed belt) • Delta kinematics Transformation Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  22. IndraWorksFramework for all Rexroth System Solutions • Software tools for all engineering tasks included • Ergonomic, Windows conform graphical user interface • Wizards for configuration and parameter setup • Transparent project navigation with functional arrangement of device objects • Comfortable programming editors according to IEC 61131-3 andDIN 66025/RS247 • Guaranteed future by the latest .net based system architecture • Openness by support of standardized software interfaces Engineering Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  23. IndraMotion MLD IndraMotion MLC IndraMotion MLP IndraControl L15(Slave) Inline Block I/O IndraControl VEP IndraControl L Option module(Master) Inline Bus coupler IndraControl L45 IndraControl L65 IndraDrive BDC PneumaticValve Manifold IAC-R Control Valve with integrated hydraulic axis control HNC100 HydraulicAxis control SERCOS III – The Next Generation Rexroth System Products with SERCOS III Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  24. Partial list of Rexroth SERCOS III Customers Conversion presses, Germany Roll forming machines, Belgium Pull nose box loader, Norway System integrator, Canada Production of wheel hub motor „Active Wheel“ Switzerland Tubular bag machine, USA/Germany Robot control, Germany Packaging machine, USA Engineering, USA Tea bag machines, Germany Packaging machine Injection molding machine, Canada Press systems, Canada Packaging machine Grinding machine, Japan Automation systems, Canada Pipe production machine, Germany Die and device bonding France/Sweden Board turner in saw mill, Canada Packaging machine, Germany More than 100 customers in more than 20 countries Distributor, Automation Switzerland Packaging machine, Italy Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  25. SERCOS III and Industrial EthernetReference customers (Rovema) • Flow wrapper VPL260 • PC based control architecture • ROVEMA P@ck-Control • with SERCOS III-Master(from AUTOMATA) • IndraDrive drives with SERCOS III • SERCOS III I/Os • presented at Interpack 2008 Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  26. SERCOS III and Industrial EthernetReference customers (JTEKT) • Standard Grinding Machine • SERCANS III PCI card • IndraDrive Cs • IndraDyn Motors • IMTS, Chicago, 08-13 September 2008 • New Generation ofHigh-End Grinding Machine • SERCANS III PCI board • IndraDrive M • Cross Communication & I/Os • IndraDyn Motors Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  27. Examples of SERCOS III Applications Crank Shaft Grinding High Speed Milling Test Stands Plastic Injection Molding Packaging Machines Printing Machines Presses Profilers Roll Feeds Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

  28. For More Information, Contact: • Dan Throne, National Sales Manager – Hoffman Estates • 847-645-3749 • Scott Hibbard, VP of Technology – Hoffman Estates • 847-645-3670 Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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