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
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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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Bosch Rexroth in the Americas
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
3
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
Electric drives
and controls
Electric Drives and Controls
Hydraulics
Linear and
assembly
technologies
Pneumatics
Service
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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The Company – The Markets
Rexroth services are used worldwide
in nearly all industries ...
 Food and Packaging
 Cutting and forming
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500,000 Customers worldwide!
Electric Drives and Controls
machine tools
Automotive industry
Printing and converting
Assembly/handling
Logging industry
Rubber and injectionmolding machines
Tunnel and mining
industry
Civil engineering
Entertainment
Offshore technology
Shipbuilding
Maritime applications
... and much more
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Rexroth Automation House
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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IndraDriveTM
The new drive generation for all applications
 Worldwide first provider of servo- and frequency converter on one
platform
 SERCOS II & III Interfaces
Open architecture connectivity
 Drive-integrated safety technology
for safe stop and safe motion
(certified acc. to EN 954-1, safety category 3)
 Single- and multi-axes Motion Logic
Drives and motors
acc. to IEC 61131-3 and PLCopen
 Scalable power, functionality and
performance for best application fit
 Fast and easy start-up assistant incl.
automatic motor identification and
auto-tuning
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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IndraDyn
Next generation of motors
 IndraDyn S
Synchronous servo motors up to 240 Nm
 IndraDyn A
Asynchronous servo motors up to 100 kW
 IndraDyn L
Synchronous linear motors up to 22.000 N
 IndraDyn T
Synchronous torque motors
up to 13.800 Nm
Drives and motors
 IndraDyn H
Synchronous high-speed motors
up to 30.000 min-1
 Planetary gearboxes
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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IndraControl V
Controls and HMI
 Controller based terminals
From text displays up to graphical touch screen
 Windows CE Embedded based terminals
Visualization and PLC runtime in one device
 Standard industrial PC’s
Cost-effective solutions by standardised PC hardware
 High-end industrial PC’s
For highest demands in industrial environment
 Complete PC-based operator
Controls and HMI
terminals
Visualization and PLC control in one device
 Visualization software
Useable on different platforms
(Win XP, CE, Web)
 Accessories
Machine operator panels, keyboards, …
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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IndraControl L
Controls and HMI
 IndraControl L
The 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 Fieldline
The rugged I/O technique for
field installation with degree of
protection IP67
Controls and HMI
 Scalable in power and functionality
 Modular and flexible with many
open communication standards
 Fast and tool-less installation
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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IndraLogic
The 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
PLC
 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
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Architectures
MLD
MLC
MLP
Motion Logic Drive-based
Motion Logic Controller-based
Motion Logic PC-based
WEB, MES, ERP
MLD
Motion Logic
MLC
Motion Logic
MLP
Motion Logic
HMI
HMI
HMI
I/O
I/O
I/O
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
14
Architectures
MLD
MLC
MLP
Motion Logic Drive-based
Motion Logic Controller-based
Motion Logic PC-based
WEB, MES, ERP
MLD
Motion Logic
MLC
Motion Logic
MLP
Motion Logic
HMI
HMI
HMI
I/O
I/O
I/O
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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MLD Systems - Motion Logic Drive-based
Sercos-III Ethernet Master with Sercos-III Slave´s
HMI
Line-Controller
with fieldbus
(optional)
FKMSercos-III
Sercos-III
CCD Master
Ethernet TCP/IP
Programming
and
Parametrizing
of all drives
and I/O´s with
IndraWorks
w/o changing
the socket
Switch
Electric Drives and Controls
Sercos III
Ethernet based
PLC in
Drive
Sercos-III I/O´s
MASTER
SLAVE 1
SLAVE N
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Application Example #1
BVK1300 HFFS Machine
Foil Feed
Cross seal
2
Transport
3
1
Lug Chain
5
6
Fin Seal
4
Rotary knife
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Application Example #1
BVK1300 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
PLC
Basic
Advanced
MLD-Master
Basic
Basic
Basic
I/Os
Reference
switch
1 Probe Input
2 Inputs
1 PLS Output
3 Outputs
Reference
switch
Reference
switch
Reference
switch
Operating mode
electronic motion
profile
Linear
profile
Linear profile
Cross seal
profile
Non linear
profile
Linear profile
Electric Drives and Controls
Basic
Linear profile
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Servo Requirements for a HFFS machine
 High Speed handling of many Products per minute
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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= Nowrap” functionality
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Architectures
MLD
MLC
MLP
Motion Logic Drive-based
Motion Logic Controller-based
Motion Logic PC-based
WEB, MES, ERP
MLD
Motion Logic
MLC
Motion Logic
MLP
Motion Logic
HMI
HMI
HMI
I/O
I/O
I/O
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Application Example #2
Robotics
 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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Application Example #2
Robotics
Axis
Axis
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Application Example #2
Robotics
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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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IndraWorks
Framework 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
Engineering
 Comfortable programming editors
according to IEC 61131-3 and
DIN 66025/RS247
 Guaranteed future by the latest
.net based system architecture
 Openness by support of
standardized software interfaces
Electric Drives and Controls
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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SERCOS III – The Next Generation
Rexroth System Products with SERCOS III
IndraMotion
MLD
IndraControl L
Option module
(Master)
IndraControl
L15
(Slave)
BDC
Pneumatic
Valve Manifold
Electric Drives and Controls
Inline
Bus coupler
Inline
Block I/O
IAC-R
Control Valve with
integrated hydraulic
axis control
IndraMotion
MLC
IndraMotion
MLP
IndraControl VEP
IndraControl L45
IndraControl L65
IndraDrive
HNC100
Hydraulic
Axis control
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Partial list of Rexroth SERCOS III Customers
Roll forming machines, Belgium
Conversion presses, Germany
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
Electric Drives and Controls
Distributor, Automation
Switzerland
Packaging machine, Italy
More than 100 customers
in more than 20 countries
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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SERCOS III and Industrial Ethernet
Reference customers (Rovema)
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 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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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SERCOS III and Industrial Ethernet
Reference customers (JTEKT)
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Standard Grinding Machine
SERCANS III PCI card
IndraDrive Cs
IndraDyn Motors
IMTS, Chicago, 08-13 September
2008
 New Generation of
High-End Grinding Machine
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Electric Drives and Controls
SERCANS III PCI board
IndraDrive M
Cross Communication & I/Os
IndraDyn Motors
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Examples of SERCOS III Applications
Crank Shaft Grinding
Test Stands
Plastic Injection Molding
Profilers
Electric Drives and Controls
Packaging Machines
Roll Feeds
High Speed Milling
Printing Machines
Presses
l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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For More Information, Contact:
 Dan Throne, National Sales Manager – Hoffman Estates
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 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
© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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