Bosch Rexroth SERCOS III Automation Solutions & Applications

unclesamnorweiganAI and Robotics

Oct 18, 2013 (3 years and 8 months ago)

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Chris Cooper

Regional Sales Manager

Southeast & Southwest Territories

Bosch Rexroth SERCOS III

Automation Solutions & Applications





©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

2

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

3

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Bosch Rexroth in the Americas

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

4

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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



Hydraulics


Electric drives
and controls



Service

Linear and

assembly
technologies



Pneumatics

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

5

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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!

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

6

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Rexroth Automation House

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

7

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

IndraDrive
TM

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


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

Drives and motors

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

8

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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


IndraDyn H

Synchronous high
-
speed motors

up to 30.000 min
-
1


Planetary gearboxes

Drives and motors

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

9

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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

terminals

Visualization and PLC control in one device


Visualization software

Useable on different platforms

(Win XP, CE, Web
)


Accessories

Machine operator panels, keyboards, …

Controls and HMI

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

10

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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


Scalable

in power and functionality


Modular and flexible

with many

open communication standards


Fast and tool
-
less installation

Controls and HMI

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

11

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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



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

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

14

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Architectures

Economic solution for

low to medium demands



up to 8 axes


MLD

M
otion
L
ogic
D
rive
-
based

MLC

M
otion
L
ogic
C
ontroller
-
based

MLP

M
otion
L
ogic
P
C
-
based

Uniform engineering for motion, logic, HMI and drives with IndraWorks

Open standards and uniform PLC platform acc. to IEC 61131
-
3

Uniform system bus for motion, drives, safety and I/O‘s: SERCOS III

MLD

Drives

I
/
O

HMI

MLC

Drives

I
/
O

HMI

Drives

I
/
O

HMI

MLP

Motion Logic

Motion Logic

Motion Logic

WEB, MES, ERP

Uniform general technology functions and program templates

Standard solution for
medium to high demands



up to 64 axes

High integrated solution for
medium demands



up to 32 axes


Drives

I
/
O

HMI

HMI

Motion Logic

Motion Logic

WEB, MES, ERP

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

15

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Architectures

Economic solution for

low to medium demands



up to 8 axes


MLD

M
otion
L
ogic
D
rive
-
based

MLC

M
otion
L
ogic
C
ontroller
-
based

MLP

M
otion
L
ogic
P
C
-
based

Uniform engineering for motion, logic, HMI and drives with IndraWorks

Open standards and uniform PLC platform acc. to IEC 61131
-
3

Uniform system bus for motion, drives, safety and I/O‘s: SERCOS III

MLD

Drives

I
/
O

HMI

MLC

Drives

I
/
O

HMI

Drives

I
/
O

HMI

MLP

Motion Logic

Motion Logic

Motion Logic

WEB, MES, ERP

Uniform general technology functions and program templates

Standard solution for
medium to high demands



up to 64 axes

High integrated solution for
medium demands



up to 32 axes


Drives

I
/
O

HMI

HMI

Motion Logic

Motion Logic

WEB, MES, ERP

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

16

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Line
-
Controller

with fieldbus

(optional)

Sercos
-
III
CCD Master

MASTER

Programming
and
Parametrizing
of all drives
and I/O
´
s with
IndraWorks
w/o changing
the socket

Ethernet TCP/IP

SLAVE 1

SLAVE N

FKM
-

Sercos
-
III

Sercos III

Ethernet based

MLD Systems
-

M
otion
L
ogic
D
rive
-
based


Sercos
-
III Ethernet Master with Sercos
-
III Slave
´
s

HMI

PLC in
Drive

Sercos
-
III I/O
´
s

Switch

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

17

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Application Example #1

BVK1300 HFFS Machine

Cross seal

3


1


5


4


2


Foil Feed

Lug Chain

Rotary knife

Transport

Fin Seal

6


©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

18

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

A3

Cross Seal

A4

Rotary knife

A5

Transport

A6

Fin seal

A1

Lug Chain

PLC

Basic

Advanced

MLD
-
Master

Basic

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

Linear profile

SIII

WinCE

-

Visualisation

PLC Network
variables

A2

Foil feed

Application Example #1

BVK1300 HFFS Machine

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

19

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF


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

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

20

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Architectures

Economic solution for

low to medium demands



up to 8 axes


MLD

M
otion
L
ogic
D
rive
-
based

MLC

M
otion
L
ogic
C
ontroller
-
based

MLP

M
otion
L
ogic
P
C
-
based

Uniform engineering for motion, logic, HMI and drives with IndraWorks

Open standards and uniform PLC platform acc. to IEC 61131
-
3

Uniform system bus for motion, drives, safety and I/O‘s: SERCOS III

MLD

Drives

I
/
O

HMI

MLC

Drives

I
/
O

HMI

Drives

I
/
O

HMI

MLP

Motion Logic

Motion Logic

Motion Logic

WEB, MES, ERP

Uniform general technology functions and program templates

Standard solution for
medium to high demands



up to 64 axes

High integrated solution for
medium demands



up to 32 axes


Drives

I
/
O

HMI

HMI

Motion Logic

Motion Logic

WEB, MES, ERP

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

21

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF


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

Application Example #2

Robotics

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

22

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Axis

Axis

Application Example #2

Robotics

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

23

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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


©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

24

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

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


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

Engineering

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

25

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

SERCOS III


The Next Generation

Rexroth System Products with SERCOS III

IndraMotion
MLC

Inline

Block I/O

Inline

Bus coupler

IndraMotion
MLD

IndraControl L
Option module

(Master)

IndraControl
L15

(Slave)

IndraDrive

IndraMotion
MLP

BDC

Pneumatic

Valve Manifold

IAC
-
R

Control Valve with
integrated hydraulic
axis control

IndraControl L45

IndraControl L65

IndraControl VEP

HNC100

Hydraulic

Axis control

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

27

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Partial list of Rexroth SERCOS III Customers

Robot control, Germany

More than 100 customers

in more than 20 countries

Packaging machine, Italy

Injection molding machine, Canada

Press systems, Canada

Board turner in saw mill, Canada

System integrator, Canada

Automation systems, Canada

Pull nose box loader, Norway

Conversion presses, Germany

Tubular bag machine, USA/Germany

Tea bag machines, Germany

Grinding machine, Japan

Packaging machine

Packaging machine, Germany

Pipe production machine, Germany

Roll forming machines, Belgium

Packaging machine

Production of wheel hub motor „Active Wheel“

Switzerland

Distributor, Automation

Switzerland

Die and device bonding

France/Sweden

Packaging machine, USA

Engineering, USA

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

28

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

SERCOS III and Industrial Ethernet

Reference 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


©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

29

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

SERCOS III and Industrial Ethernet

Reference customers (JTEKT)





Standard Grinding Machine


SERCANS III PCI card



IndraDrive Cs


IndraDyn Motors


IMTS, Chicago, 08
-
13 September
2008



New Generation of

High
-
End Grinding Machine


SERCANS III PCI board



IndraDrive M


Cross Communication & I/Os


IndraDyn Motors


©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

30

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

Examples of SERCOS III Applications

Printing Machines

Packaging Machines

Plastic Injection Molding

High Speed Milling

Crank Shaft Grinding

Test Stands

Profilers

Roll Feeds

Presses

©
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.

W
e also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

31

Electric Drives and Controls
l Bosch Rexroth
-

Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF

For More Information, Contact:


Dan Throne, National Sales Manager


Hoffman Estates



847
-
645
-
3749


Scott Hibbard, VP of Technology


Hoffman Estates


847
-
645
-
3670