USAlocal01 | 2014

New programming freedom with Open Core Engineering

06

Restoring WWII submarine with a RexPak hydraulic power unit

08

IndraMotion MTX micro CNC chosen for next-generation

gantry router10

Dear Readers:

“There’s a way to do it better— find it.”

The words of Thomas Edison remind us that innovation is fundamentally about continuous improvement— a better way, a better process, a better tool. His words also carry a simple, yet urgent, call to action: “Find it.”

We feel the same sense of urgency from our customers every day, in every industry, when they ask us to help them “find it.” Sometimes, they’ve already designed the better way and simply need the right products to help them maximize the return on their idea. In other cases, we work together to find the right solution. Our customers amaze me in their relentless drive to improve, and their inspiration is what drives us to keep pushing forward, too…to “find it.” It is this spirit that helped us develop our GoTo focused delivery program, for example, which has now expanded to include programs in Central Europe and throughout the Americas as GoTo enters its 5th year. It’s also the spirit behind our regional Technology and Service Centers, with the newest opening in Houston just last year: We need to offer the services that you need —when and where you need them.

You’ll read several stories in this issue of drive&control local about customers

who are finding a better way, including a woodworking machinery supplier who chose Rexroth’s new IndraMotion MTX micro for their next-generation gantry router. The turnkey CNC package helped them achieve high feed rates and excellent cutting precision; it also helped them save machine assembly time. That’s a better way. In a very different kind of application, a popular Fisherman’s Wharf submarine, the USS Pampanito, used a RexPak hydraulic power unit to make it easier to demonstrate the ship’s systems, such as its 2000-pound periscope. The new system saves energy compared to the boat’s original system, and is much easier to operate, allowing for more frequent demonstrations for submarine visitors. Again, a better way.

We’ve also included information about our exhibit at CONEXPO/IFPE 2014. There, Rexroth will introduce multiple new technologies and services inspired by our customers’ needs — from solutions to improve energy efficiency and reduce emissions in mobile machinery to investments in infrastructure in the Americas to help us support you better. Later in the issue, you’ll find a related technical feature on important choices in selecting and integrating hydraulic pumps for both on-highway and off-highway mobile machines.

I hope that a few of the ideas, applications and helpful tips in the latest issue of drive&control local bring benefit to you as you evaluate new tools and technologies to find your better way. Whether it’s our GoTo program, our new linear motion how-to video series on YouTube or our innovative Open Core Engineering concept, our job is to help you “find it.” And your passion is what drives us to find better ways for Bosch Rexroth to serve you better. Together, we can find many better ways.

Sincerely,

Berend Bracht President & CEO, Bosch Rexroth Americas

drive & control localEDITORIAL

FEATURES

08 Restoring WWII submarine with a RexPak hydraulic power unit

10 Rexroth IndraMotion MTX micro CNC chosen for next-generation gantry router

VIEWPOINT

06 Open Core Engineering adds new freedom to machine automation programming

NEWS

02 Rexroth highlights hydraulics technology at CONEXPO 2014

02 New microsite supports Rexroth at CONEXPO/IFPE 2014

03 Rexroth’s Sytronix earns product innovation award from Green Manufacturer® magazine

03 Mike Bryan named Trainer of the Year by the German American Chambers of Commerce

07 Hydraulics training now offered at new Technology and Service Center in Houston

TECH FEATURES

12 Mobile machines: Options for driving hydraulic pumps

14 Six keys to achieving better precision in linear motion control applications

TECHNOLOGY

04 Integrated safety solutions from Rexroth with CIP Safety on Sercos

04 Upgraded Rexroth MLC Version 13 features Safety PLC & Open Core Interface

05 Educational resource kits covering a variety of technologies now available

05 GoTo Focused Delivery Program expands in North America

15 Combining hydraulics & variable-speed electric drives pays off

16 New Mobile Hydraulics brochures highlight A1VO pump and directional valves

16 Useful linear motion “how to” videos debut on YouTube

8 6

14 10 12

CREDITSdrive&control local is the magazine for Rexroth US customers. Published by: Bosch Rexroth CorporationCorporate Communications, Charlotte, NC Kevin Gingerich (responsible for content)Editor-in-Chief: Susan Strauss 610-694-8352susan.strauss@boschrexroth-us.com

Editing and design: Godfrey, www.godfrey.com Printed by: WorkflowOne All rights reserved. Any reproduction or copying, either in part or whole, requires prior permission of the publisher. drive&control local is mailed using automated data processing.

01 | 2014 USA

1CONTENTS

A specially created microsite will give attendees at CONEXPO/IFPE 2014 a useful and informative resource about the full range of technologies and capabilities Bosch Rexroth is presenting at the show.

The site has multiple sections so that visitors to the booth can get more details on such topics as:

• Rexroth 4EE — our systemic approach to improving energy efficiency, with a special focus on solutions for mobile hydraulics technology

• News —A regularly updated page with CONEXPO-specific Rexroth news items,

• Fast Delivery—with information and links to our GoTo Focused Delivery Program resources

• Local for Local — how Bosch Rexroth is investing in expanding manufacturing and service resources to better

serve customers across the Americas

• Product Highlights —Details and links to more information about the products on exhibit in the Rexroth booth

Special QR codes throughout the Rexroth booth will let mobile users instantly access the microsite during their visit. For those unable to attend CONEXPO, the site can be accessed by visiting www.boschrexroth.com/conexpo.

New microsite supports Rexroth at CONEXPO/IFPE 2014

Visitors to the Rexroth booth can expect to see a broad range of leading hydraulics technology used in loaders, cranes, telehandlers, excavators and other mobile equipment.

R2 hydromechanical variable transmission (HVT)The R2, the latest powersplit system resulting from the joint venture between Dana and Bosch Rexroth AG, is a modular platform that delivers a full suite of configuration options and software controls, such as direct or remote mounting, flexibility in shift control and drive strategy parameters, and the deployment of up to three PTOs.

The HVT will be a part of an innovative functional model which highlights Rexroth’s ability to integrate technologies from both Bosch and Bosch Rexroth, to engineer innovative mobile machine solutions: cleaner diesel

engines exhaust gas aftertreatment, improved fan drive cooling, and intelligent controls and software.

Hydraulic start-stop for construction machinesRexroth’s start-stop system, the hydraulic fly wheel (HFW), operates in the open circuit and gathers energy to be made available to the machine to use later, applying energy in a very efficient manner. With this concept, electronics assess whether enough pressure is available to restart the diesel engine once it has been switched off. If the internal combustion engine is off, the electronics evaluate the consumer’s potential energy needs. If the travel drive or work hydraulics require energy, the start-stop system immediately restarts the diesel engine with the stored energy.

Other technology on display includes new transmission units, mobile electronics, compact hydraulics, product selection software, control valves, and radial piston motors.

Ò www.boschrexroth.com/conexpo

Rexroth highlights latest advances in hydraulics technology at CONEXPO 2014Company emphasizes technology to boost energy efficiency, improve productivity, and expand capabilities of mobile machinery

�During idle periods of construction machines the hydraulic start-stop function by Bosch Rexroth reduces fuel consumption to zero.

2drive & control localNEWS

Mike Bryan named Trainer of the Year by the German American Chambers of Commerce Mike Bryan, Training Specialist at the Bosch Rexroth Fountain Inn Manufacturing Facility, was named Trainer of the Year by the German American Chambers of Commerce (GACC) on December 16, 2013, in recognition of his involvement with Bosch Rexroth’s apprenticeship program. The GACC award recognizes outstanding German subsidiaries that demonstrate excellence in workforce training by fostering advanced skills and competence development, especially in young people.

As part of Bosch and Bosch Rexroth’s investment in developing the science, technology, engineering and math (STEM) skills of the next generation, the Fountain Inn two-year apprenticeship

program, which Bryan implemented in 2008 and oversees, allows engineering

students to earn valuable on-the-job training and experience. Through a partnership with Greenville Technical College, apprentices work at Rexroth’s Fountain Inn facility and attend classes. Upon completion of the program, students earn an apprenticeship certificate.

“This award is a tribute to Mike’s dedication to help young people develop the skills that they—and Bosch Rexroth—will need for future growth in our rapidly changing economy,” said Mike McCormick, Technical Plant Manager, Bosch Rexroth Fountain Inn facility.

Green Manufacturer® magazine, a leading North American trade publication focusing on sustainability practices in the

manufacturing realm, named Rexroth’s Sytronix intelligent variable-speed hydraulic pump drive as a Silver Award recipient in its 2013 Green Manufacturer Product Innovations competition.

The competiton was open to technology developers and manufacturers that have introduced new products designed to ensure environmental sustainability. Winners were selected by an awards committee consisting of esteemed industry experts from diverse companies, who evaluated the Sytronix product features and capabilities, as well as Rexroth’s manufacturing and sustainability efforts, according to established criteria and verifiable data.

Compared to conventional hydraulic systems, where an electric motor constantly powers the hydraulic unit, Rexroth’s Sytronix variable-speed hydraulic pump drives regulate the speed, and thus the energy consumption of the electric motor, according to the demands of the machine—providing power and hydraulic pressure only when required. Depending on a machine’s cycle characteristics and power rating, the pump drives achieve 30 to 80 percent energy savings.

Bosch Rexroth’s committment to sustainability was also a key factor in the award. The awards committee reviewed the Sytronix cradle-to-grave lifecycle design as well as Rexroth’s manufacturing and sustainability practices.

Ò To learn more about Sytronix watch our YouTube video at

http://ow.ly/sNNKX

Rexroth’s Sytronix earns product innovation award from Green Manufacturer® magazineAward recognizes Rexroth’s Sytronix variable-speed hydraulic pump drive for its ability to lower energy consumption and noise emissions.

�Bosch Rexroth’s Sytronix variable-speed hydraulic pump drive won a Silver innovation award from Green Manufacturer magazine for its ability to reduce energy consumption and lower noise emissions.

�Led by Mike Bryan (2nd from right) from Bosch Rexroth’s Fountain Inn, SC, manufacturing facility, the Bosch Rexroth Apprenticeship Program in partnership with Greenville Technical College, provides practical, hands-on training in a variety of skilled trades.

01 | 2014 USA

3NEWS

Upgraded Rexroth MLC Version 13 Motion Logic and Controller features Safety PLC and Open Core interface

Integrated safety solutions from Rexroth with CIP Safety on Sercos

The Rexroth MLC motion logic controller with Version 13 firmware features a robust new set of capabilities and function modules designed to make it faster and easier to implement in-demand automation capabilities such as integrated safety, robotics functions and new mobile apps tools.

The open IndraMotion MLC is Rexroth’s most advanced automation platform, combining motion and logic control with robotics to create a control architecture which is both integrated and powerful. It offers a complete and scalable automation system for all machines and plants, synchronized with servo drives. Its runtime system provides motion and logic control functions in accordance

with the open PLC standard IEC 61131-3.

Several key enhancements are now available with the MLC Version 13 platform:

Integrated CIP Safety with Sercos: Responding to the need for standardized, cost-effective functional safety, Rexroth now offers the integrated CIP Safety on

Sercos protocol and the SafeLogic and SafeLogic compact safety PLCs.

Open Core Engineering: The MLC Version 13 is Rexroth’s first controller platform to fully support the award-winning Open Core Engineering system solution, which combines the previously separate PLC and IT worlds into one comprehensive automation portfolio.

FlexProfile: For a host of applications ranging from form, filling and sealing to carton erection and palletizing, Rexroth FlexProfile on the MLC Version 13 offers the ability to create highly effective motion profiles without costly programming.

Ò To learn more about Rexroth MLCs visit

http://ow.ly/t9uDa

The CIP Safety on Sercos safety protocol ensures safe communication from the control unit to the drive with no additional wiring. The SafeLogic and SafeLogic compact controls cover all complexity levels of safety-based automation in connection with the drive-integrated SafeMotion functions.

The user can simply program standard and safety functions in the same engineering environment.

SafeLogic controls the drives for plants and complex machines, such as those used for printing or packaging. The safety function module enhances standard system solutions in the IndraMotion and IndraLogic product lines, turning them into control solutions with integrated

safety functions. Customer-specific modifications in the standard control’s program sequence have no feedback effects on the safety functions. CIP Safety on Sercos ensures safe communication without additional wiring. Engineers use the uniform IndraWorks framework for

standard and safety control. Thanks to the multi-safety master functionality, SafeLogic also enables the integration of decentralized safety peripherals from various manufacturers, increasing investment security.

SafeLogic compact is used in compact machines and small- to mid-size plants. The decentralized safety control activates the drive-integrated safety feature via CIP Safety on Sercos. Programming is intuitive and uses a graphical editor; users verify the functional safety using the integrated offline simulation tool.

Ò To learn more about SafeLogic and PLC

technology visit http://ow.ly/t93oi

4drive & control localTECHNOLOGY

Rexroth’s GoTo Focused Delivery Program expands in North AmericaGoTo program now includes more than 4200 parts across all drive, motion & control technologies

Bosch Rexroth’s GoTo Focused Delivery Program, originally launched in the United States in 2009, has expanded in North America to a single program, with identical product offerings and lead times for U.S. and Canadian customers. Central Europe and Brazil also offer GoTo programs, with additional expansions planned throughout the Americas and other regions.

The GoTo North America program features an enhanced electric drives and controls offering that includes the MTX micro CNC solution, IndraDrive M inverters and power supplies, as well as Motion Logic Control and IO components

to support hydraulic axes and applications. The hydraulics offering has also grown with nearly 200 new hydraulics products, many of which are directional valves, and increased quantity limits for many popular mobile hydraulics products. Assembly conveyor products have also been added to GoTo for the first time, helping to streamline conveyor system installation and start-up times. Overall, GoTo North America offers more than 4200 products across the entire Drive & Control spectrum — a more than three-fold increase from the program’s original offering in 2009. The latest product offering can be retrieved instantly using Rexroth’s GoTo Products app for iPad, iPhone and Android.

Ò For more information on the new additions to the North American GoTo Focused Delivery Program, visit www.boschrexroth-us.com/GoTo

Educational resource kits covering a variety of technologies now available from RexrothBosch Rexroth now offers educational resource kits to help machine builders, systems integrators and manufacturing end-users address engineering challenges in factory automation, linear motion and mobile engineering.

The kit materials are drawn from Bosch Rexroth’s extensive library of drive and control application case studies, expert technical papers, current product brochures, links to state-of-the-art engineering and design tools and the company’s latest videos —carefully selected and combined in one convenient digital package.

Packaged on convenient USB drives, each kit provides technical information and content relevant to its core topic. The resource kits currently available include:

• Hydraulics Performance Kit, including a free copy of the 40-page Oil Cleanliness Booklet

• Linear Motion and Mechatronics @ Work Kit to help design more effective and productive linear motion and mechatronics systems

• Advancing Factory Automation Kit with special emphasis on the latest developments in electric drive and control platforms

• Mobile Hydraulics Solutions Kit to help mobile machine builders reduce emissions and improve performance

• Packaging and Printing Kit designed to help enable faster changeovers, more flexibility and reduced waste

Ò Resource kits are available for free by request at

www.boschrexroth-us.com/resourcekits

01 | 2014 USA

5TECHNOLOGY

Open Core Engineering adds new freedom to machine automation programmingOpen Core Engineering combines the previously separate PLC and modern IT technology such as smart devices and apps to enable new degrees of freedom, flexibility and efficiency in automation processes.

Many of today’s programmers —including those fresh out of school, or with backgrounds in computers, networking and Web applications — are well-versed in standard programming languages like C++, Visual Basic for Applications (VBA) and Java, or mobile platforms such as Android and Apple iOS. When they start working in an industrial environment, they must learn to program using languages that are very specific to industrial controls.

These programmers may have innovative ideas for new applications that can be created with higher-level

languages commonly used in the IT world. But translating those ideas into applications using traditional PLC programming tools can be difficult and time consuming. If a machine builder wants to offer a data-gathering application that automatically captures and generates Excel reports on machine sensor data, a programmer would typically use Microsoft’s VBA to write some simple code to capture that data.

However, it can be challenging to have that application communicate with PLC platforms using the VBA language — and if you want that application to have a

mobile app interface that runs on both iOS and Android devices, it can be done, but requires multiple software steps.

It’s time to bridge the gap with common languages and a platform that more easily “opens up” industrial controls programming to the wider world of higher level languages. Open Core Engineering is a new approach that combines the previously separate environments of PLC platforms and IT programming into one comprehensive software portfolio.

With Open Core Engineering, the PLC “core” kernel is opened to enable

6drive & control localVIEWPOINT

programmers who use IT industry standard development tools such as C++, VBA and Java to create automation functions and applications.

Open Core Engineering is based on a portfolio of software tools, function packages and support for higher-level languages. It helps streamline the automation engineering workflow: Detailed and time-consuming machine process programming can now be replaced by a simple assignment of parameters.

If a machine builder wanted to include a new type of remote diagnostic capability, building that capability using standard PLC programming languages might not

be easy; integrating it into the PLC may require added resources such as the purchase of a specialized translation module, revisions to PLC firmware or support from an outside PLC programming consultant.

Open Core Engineering changes this. It utilizes a programming interface (Open Core Interface) to create high-level language-based applications that communicate directly to the core of the PLC. Up to this point, PLC authoring platforms have typically been standards-based proprietary systems, custom-designed by PLC controls providers.

Open Core Engineering will “open” up a new range of possibilities for flexibility

and functionality. It means more innovation, as software professionals and programmers who are experienced with technologies like mobile platforms and smartphones will not necessarily need to become experts in IEC 61131 PLC programming languages. The end result is that OEMs and end-users will have a wider range of programming ability to improve machine automation performance.

Ò To learn more about Open Core Engineering

visit www.boschrexroth.com/oce

Contact: Scott Hibbard Email: Scott.Hibbard@boschrexroth-us.com

Hydraulics training now offered at new Houston Technology and Service CenterComprehensive classroom courses cover principles of hydraulic technology, with custom topics and on-site training available for marine, offshore and industrial applications.

Training for hydraulics and controls technologies used in marine, offshore and industrial applications is now available through the newly opened Rexroth Technology and Service Center in Houston, TX.

Comprehensive, five-day classroom courses will be offered by qualified Rexroth experts on the Principles of Hydraulics (POH) covering fluid flow dynamics, controls, pumps, valves, motors schematics, maintenance and more. Customized training courses and on-site training are also available depending on customer needs.

POH classroom courses are designed for new or untrained personnel responsible for hydraulic system operation and design where a thorough understanding of hydraulics physics and devices is critical.

Courses include principles and technologies related to fluid flow and

pressure, controls, valves and actuators, as well as set-up, maintenance and circuit design and function.

The classroom setting is designed to provide a focused, distraction-free environment with class size limited to 12 students to ensure individualized

attention. A Rexroth DS4 Hydraulic Training System is employed to give a hands-on demonstration of concepts using working components and circuits.

Contact: Lois Maura Email: Lois.Maura@boschrexroth-us.com

�The DS4 Hydraulic Training System offers a complete solution for teaching the operation of modern hydraulic circuits and prepares the trainees for their work in the industry.

01 | 2014 USA

7TECHNOLOGY

Historic hydraulics: Restoring WWII submarine with a RexPak hydraulic power unitThe World War II era submarine USS Pampanito, docked at Fisherman’s Wharf, San Francisco, installed the RexPak power unit to make it easier to demonstrate the ship’s systems such as the periscope and bow planes.

8drive & control localFEATURE

One of the most popular attractions at San Francisco’s historic Fisherman’s Wharf is the World War II submarine the USS Pampanito, which had six combat patrols in the Pacific War.

Operated by the nonprofit San Francisco Maritime National Park Association, the Pampanito has undergone multiple restoration projects, including hydraulically driven equipment such as the periscope and torpedo doors.

To run these systems, the Pampanito needs fully operational hydraulics — and Bosch Rexroth contributed a custom-configured RexPak hydraulic power unit to help bring the ship’s systems to life.

“As much as possible, we try to utilize 1940s era technology for the restorations,” said Richard Pekelney, secretary on the association’s board of trustees. “However, for some systems, we find it’s more effective for us to utilize modern equipment, like the Rexroth RexPak hydraulic unit.”

Until recently, power was supplied by the boat’s original “air over hydraulics” unit. This older system was difficult to operate, and safety considerations required proper training, limiting the times the boat’s hydraulically driven systems could be demonstrated.

Charlie Butcher, Equipment Manager for Northern California at Manson Construction Co. (Seattle, WA), is a former Navy submariner who regularly volunteers on the sub. He contacted Bill McDaniel, Account Manager at Hydraulic Controls, Inc. (Emeryville, CA), a Bosch Rexroth distributor partner, to see if a better hydraulic power solution could be found.

“We decided that the RexPak hydraulic unit was the best choice,” McDaniel said. “We could supply a complete package, test it, make sure everything was good to go and ship them the whole system.”

The RexPak hydraulic power unit supports applications requiring hydraulic power up to 75 horsepower (HP) and operating pressures up to 3200 pounds per square inch (psi). Each RexPak system is custom-configured from a core set of components: motor, pump, fluid reservoir and associated control valves.

For the Pampanito, the RexPak has a 71 cc Rexroth A10VSO axial piston pump driven by a 15 HP motor, supplying a maximum working pressure of 750 psi. The unit provides sufficient hydraulic power to demonstrate the different pieces of equipment on the boat, and allows the 2,000-pound periscope to be raised and lowered at its original speed.

The RexPak unit was provided at cost by Bosch Rexroth and by Hydraulic Controls, Inc.

Using the RexPak unit will help the Pampanito save energy, because it takes much less power; it’s also much easier to operate, allowing more volunteers to be trained on it and more frequent demonstrations of the periscope and other systems.

“Everyone wants to look out the periscope,” said Butcher. “From the young people to the World War II submarine vets and their wives, they all like to see things in operation, so we know the visitors will really appreciate it.”

Ò www.boschrexroth-us.com/success_stories

Ò www.boschrexroth-us.com/rexpak

Contact: Joe Kane Email: Joseph.Kane@boschrexroth-us.com

�Charlie Butcher (right) of Manson Construction Co. and Bill McDaniel of Hydraulic Controls Inc. pose with the complete RexPak hydraulic power unit dockside.

01 | 2014 USA

9FEATURE

KOMO Machine Inc. (www.komo.com) of Lakewood, NJ, designs and builds high-quality precision computer numerically controlled (CNC) routers and machining centers for major market segments, including woodworking, plastics/

composites and sheet metal applications.

The company recently developed a new version of its successful Mach One GT series of routers, offering the same precision and milling quality as the existing routers, but utilizing a new CNC system that delivers excellent

performance in a more affordable platform. KOMO’s new router, called the Mach One GT MTX, features the IndraMotion MTX micro CNC system.

The Mach One GT MTX Series is an open-bed, gantry-style router with a traveling gantry and stationary table

CNC Confidence: Rexroth IndraMotion MTX micro CNC chosen for next-generation gantry routerRexroth’s IndraMotion MTX micro CNC platform key to creating high-capacity CNC wood router that delivers excellent performance in a more affordable platform.

�KOMO’s new Mach One GT MTX features Rexroth’s IndraMotion MTX micro CNC system, a compact, powerful and low-cost CNC solution with high-performance turning and milling capabilities.

10drive & control localFEATURE

design. Created to serve the needs of medium to large wood milling operations, as well as plastics and light sheet metal machining operations, it will support high-output production for a wide range of products, from medium density fiber board and solid wood entry doors, to engineered furniture and detailed decorative engravings for high-end cabinetry.

“We’re known for offering high-end, fast, responsive machines that deliver profitable performance,” said Jeff Erickson, executive vice president at KOMO. “Our goal with the Mach One GT MTX is to maintain that quality and performance, but with a machine that is more affordable for a broader range of shops.”

Bosch Rexroth has an established relationship with KOMO supplying linear motion components for their routers and machining systems. Building on this relationship, two factors convinced KOMO that Rexroth’s MTX micro was the right CNC for the new machine: The MTX micro’s technology and Bosch Rexroth’s reputation as a top-quality supplier.

“We were familiar with Rexroth from our work with them. We also know they have an excellent reputation in the controls marketplace, and that gave us confidence,” said Mike Kolibas, KOMO president. “We had opportunities to work with smaller controls suppliers,

but we chose Bosch Rexroth because we knew they would be there for the long haul.”

The Rexroth IndraMotion MTX micro is a compact, simple, powerful and low-cost CNC solution for standard turning and milling machines. It provides a

turnkey CNC package that features a high-capacity CNC control, an integrated PLC compliant with IEC 61131-C programming standards and a fully integrated human machine interface (HMI).

KOMO’s machine has three axes of interpolated motion: The X and Y gantry

axes and the Z spindle axis are all controlled by the Rexroth MTX micro CNC. Robust CNC performance supported KOMO’s selection of the MTX micro: “We believe it has good look-ahead capabilities, which will allow shops to run the machine faster, yet

maintain accurate control of the axes,” Erickson said.

For example, when cutting a wood panel, the Mach One GT MTX will support a high feed rate of 1,500 inches per minute.

“As it comes to a corner, it will ramp down to precisely cut a sharp corner without rounding it, and then quickly ramp back up to 1,500 inches per minute, while maintaining control of all the axes,” he said. This will enable the Mach One GT MTX to sustain a higher rate of throughput without sacrificing milling quality.

As part of the complete MTX micro package, the X and Y gantry axes and the Z spindle axis use Rexroth IndraDyn S MSK 60 servo motors. They feature a wide power spectrum, high torque density and compact design to enable easier integration into KOMO’s existing Mach One series machine design.

Modularity and ease of integration were also instrumental to KOMO’s decision to choose the MTX micro. “The package is well-integrated, which allows us to shave time off our assembly of the machine,” said Steve Ostermann, KOMO engineering manager.

According to Mike Kolibas, working with Bosch Rexroth has validated his company’s strategic decision to select the MTX— and Rexroth — for the new Mach One router. “Our comfort level is much higher, working with a global company that stands behind the controller and the support around it,” he said. Since the MTX Micro success, 2014 looks to be a year of product expansion into KOMO. KOMO has expressed interest in the MTX Performance Platform (L65) for their higher end machines. This should all begin early 2014.

Ò www.boschrexroth-us.com/success_stories

Contact: Brian Van Laar Email: Brian.VanLaar@boschrexroth-us.com

�The machine’s X and Y gantry axes and the Z spindle axis use Rexroth IndraDyn S MSK 60 servo motors featuring a wide power spectrum, high torque density and compact design.

01 | 2014 USA

11FEATURE

“ We chose Bosch Rexroth because we knew they would be there for the long haul.”

— Mike Kolibas, KOMO president

Today’s mobile machine designers have multiple options to choose from when selecting the hydraulic pump technology used to supply hydraulic power for machine functions such as drills, transit drives, swing functions, boom operation and conveyor drives — all of the work functions carried out by both on-highway and off-highway machines.

Many of today’s on- and off-highway applications utilize hydraulics as a way to provide working energy that is more compact and precise than traditional mechanical methods. There are many components that comprise these systems such

as valves, cylinders, motors and of course a hydraulic power source, the pump.

There are two separate base type applications, on- and off-highway, that provide opportunities and distinct ways for pump mounting locations and drive inputs.

The prime purpose of the pump is to convert the input of mechanical, rotational power into hydraulic power, meaning flow for the required functions on the machine. Hydraulics are used for many different mobile machine functions such as

Mobile machines: Options for driving hydraulic pumps Selecting and integrating hydraulic pumps for both on-highway and off-highway mobile machines is a key decision in the layout of the machine and its overall performance capabilities.

�Electronically controlled hydrostatic fan drive systems reliably keep combustion engines at their optimum operating temperature, even under the most difficult of application conditions.

Article originally appeared in Hydraulics & Pneumatics Magazine

12drive & control localTECH FEATURE

systems for transit drives, swing functions, boom operation, conveyor drives, etc.

In all of these functions, there must be a pump located somewhere in the system that provides the flow to accomplish the intended work. Where that pump is placed in the system is dependent upon the availability of a mechanical rotational power source to drive the input shaft of the pump.

On-highway equipmentOn-highway applications such as concrete mixer trucks, truck mounted cranes and dump beds rely on traditional mechanical transmissions to move the vehicle. For these vehicles, there are a few options for providing the rotational power for on-board hydraulic pumps. The hydraulic pump is generally mounted on the side of the vehicle’s gearbox integrated power take-off units.

A power take-off (PTO) is any of several methods for taking power from a power source, such as a running engine, and transmitting it to an application, such as an attached implement. Most commonly, it is a system comprising of a splined output shaft designed so that a pump drive shaft can be easily connected and disconnected. The PTOs are engaged and disengaged by means of the truck’s pneumatic system.

Many pump manufacturers, such as Bosch Rexroth, offer pump mounting flange options that are compact in space or bent-axis pumps that would offer better clearance around the axle. Bent-axis pumps are similar to bent-axis motors in that the piston pump contains pistons mounted at an angle to a drive shaft, which rotates the pistons.

Off-highway equipmentOff-Highway equipment typically does not follow a pre-existing drive chassis and is designed for a specific machine purpose or activity. This allows the designers to work with a blank canvas for providing rotational power for pumps. Options that are typically used in these applications are: engine flywheel case coupling, engine crankshaft, belt/pulley, single or multi-pad PTOs and pumps with built-in through drives.

Some pump manufacturers offer engine flywheel mounts for their pumps which allow a direct coupling to the diesel engine. Most of these purposed pumps are in the high-pressure category, such as the Bosch Rexroth A11VO and A8VO, and offer installation space savings for applications.

These are usually found in machines that use the hydraulics system as their only means to perform work, like excavators and feller bunchers. In these applications the engine power does not have to drive an axle, mechanical transmission or cardan shaft, allowing the space-saving installations.

The pump drive is a key decision in the layout of the machine and overall performance for the OEM. Depending on where the

hydraulic work is performed, e.g. at the cylinders on a boom or the wheel drives of a loader, the freedom that hydraulics provide allow the designer to place his components in multiple locations on a machine which cannot be surpassed by any mechanical drive.

Contact: Jay Edwards Email: Jay.Edwards@boschrexroth-us.com

�Off-Highway equipment is typically designed for a specific machine purpose or activity and does not follow a pre-existing drive chassis, allowing for several available options to provide rotational power for pumps.

�Hydraulics are used for many different mobile machine functions, all of which require a pump that provides the flow to accomplish the intended work.

01 | 2014 USA

13TECH FEATURE

Even when equipped with the most sophisticated motion controller, machine designers may find it difficult to achieve exact linear motion precision unless their mechanical components are accurately specified for the application. That’s why it’s important to recognize that the best results are achieved when engineers account for mechanical factors and machine structure. To achieve the required degree of precision, focus on the following parameters:

1. Travel accuracyTravel accuracy measures pitching (up and down), yawing (side to side) or rolling (around the axis). Minimizing these motions depends on the quality of the travel guidance system and the surface to which it is mounted.

2. Positioning accuracyPositioning accuracy depends on the tolerances of a drive element, such as an electromechanical ball screw, hydraulic or pneumatic cylinder, electric linear motor or rack and pinion, among others.

3. System stiffnessSystem stiffness is critical because any force or load applied to the motion components — downward, upward or sideways — can cause system deflection, an enemy of repeatability. The greater the force, the more deflection will be experienced.

4. Speed Short cycle times sometimes have speed requirements that push the limits of linear guide and ball screw speed/

acceleration capabilities. The first limit is the ball screw shaft’s critical speed —the speed at which the screw will vibrate or oscillate excessively (known as screw whip). The second limitation is the bearing system’s characteristic speed, based on the circulation of anti-friction elements through the system.

5. Thermal considerations All linear motion components (motor, bearings, nut) will generate heat that must be accounted for; proper management of these thermal influences can help improve the performance and the precision of a system. Different axis parts can have different temperatures

based on running time, dynamic cycle and process force on each part.

6. Machine resonance The above factors can cause machine resonance or vibration, which compromises precision and quality of surface finish (for example, on a machined work piece). Extreme vibration (such as that produced by exceeding critical speed) can cause “whipping” of the screw and machine damage.

Ò www.boschrexroth-us.com/success_stories

Contact: Clint Hayes Email: Clint.Hayes@boschrexroth-us.com

Six keys to achieving better precision in linear motion control applications To achieve the required degree of precision in linear motion control applications, it is important to understand these key parameters and their impact on motion control.

�Equipped with even the most sophisticated motion controller, machine designers may find it difficult to achieve exact precision unless their mechanical components are accurately specified for the application.

14drive & control localTECH FEATURE

With conventional hydraulic systems used on many industrial machines, the hydraulic power unit is typically powered by an electric motor running at constant speed, regardless of what flow/pressure is needed at that moment. Even when the machine is idle, the motor is always running and consuming energy -- which is a major concern as electricity becomes more costly. Fortunately, in recent years, the cost of

variable-speed drive technology has become more economical, making it effective to apply variable-speed electric drives in many hydraulic applications to provide an energy saving, high-

performance alternative.

In constant-speed pump drives, the electric motor always runs at the same rotational speed. If the system does not need the maximum installed output, system pressure is controlled either by the hydraulic pump pressure compensator control, or by additional hydraulic pressure control valves mounted downstream of the pump. Consequently, some motor horsepower is wasted. At the same time, the hydraulic pump leakage and/or valve leakage is heating the hydraulic oil, requiring more energy for cooling.

A properly integrated variable-speed drive for a hydraulic system can deliver dramatic energy savings. Depending on the application and cycle characteristics, energy consumption can be reduced by 30 to 80 percent. Delivered flow is matched to the requirements of the machine cycle. Moreover, heat input into the oil is reduced, which further reduces the energy needed for cooling.

Additional benefit: the reduction in average drive speed can reduce noise emission of the hydraulic power unit by up to 20 dB(A).

Variable-speed drives can provide additional benefits, such as providing precise clamping and tensioning functions for machine tools; enabling fast acceleration for high dynamics in plastic processing machines; offering high power density and load-holding capabilities on die-casting machines; and improving winding and pressure-holding functions on woodworking and papermaking machines.

Combining variable-speed drives with hydraulic systems significantly advances efficiency and performance -- giving many new and retrofit industrial hydraulic applications a boost in productivity and energy savings.

Contact: Jan Komsta Email: Jan.Komsta2@boschrexroth-us.com

Combining hydraulics with variable-speed electric drives pays off in energy savings and performance Variable-speed pump drives change the framework conditions of hydraulic systems and open new design possibilities for efficient solutions.

01 | 2014 USA

15TECHNOLOGY

Just in time to help you prepare for CONEXPO/IFPE 2014, Bosch Rexroth has released three new Mobile Hydraulics brochures covering a variety of products, some of which will be exhibited at the Bosch Rexroth booth in Las Vegas March 4-8.

The new brochure for the A1VO Axial Piston Pump describes how this

award-winning pump provides a highly economical load-sensing alternative to fixed gear pumps. This brochure describes the advantages of a load-sensing system over an open center system, and provides complete details for pump options such as control selection, mounting interface and auxiliary, as well as envelope dimensions of the unit.

There are two new Modular Directional Control Valve brochures: the Control Block EDD Modular Directional Valve brochure provides details on the new EDD size 08 directional control valve

with up to 80 l/min to the Bankable product line. The new valve allows electrohydraulic control of actuators (motor or cylinders) in open circuit applications.

The Control Block EDC Modular Directional Valve Flow Sharing System introduces the EDC size 06 directional control valve with flow sharing to the Bankable product line. It is ideal for applications that require simultaneous movement on more than one actuator in small to medium size mobile machinery.

Ò To download these brochures visit

http://ow.ly/t93Z1

An informative series of “How To” instructional videos, presented by experienced Rexroth linear motion and mechatronics experts, have been posted to the Bosch Rexroth U.S. YouTube channel.

The videos cover several Linear Motion-related topics, and offer step-by-step direction on the use of multiple Rexroth online product configuration tools, as well as useful insight into ways to improve the performance of linear systems such as ball rail assemblies and ball screw tuning.

For those interested in developing a custom-configured handling system using Rexroth’s EasyHandling system platform, there is a three-part, step-by-step presentation on the use of the online Easy Select tool. Viewers will learn how to optimize the selection of components, compile a Bill of Materials and generate a CAD model of an EasyHandling system.

Another video, presented by Rexroth project engineer Nathan Davis, demonstrates how certain combinations of drive

stiffness and mounting substrate can cause ball-screw driven linear modules to exhibit oscillation noise if not properly tuned. He gives step-by-step instructions on using the IndraWorks software package auto-tuning feature to set the optimum tuning parameters for ball screw driven linear modules.

Other topics include an overview of how to mount Rexroth’s ball rail system in a typical application and a demonstration of Rexroth’s online ball screw configuration tool. New “How To” videos drawing on the expertise of multiple Rexroth engineers will be produced and posted online to YouTube — check back often!

Ò To view these videos visit http://ow.ly/t94jK

New mobile hydraulics brochures highlight A1VO pump and directional valves

Useful linear motion “how to” videos debut on YouTube

16drive & control localTECHNOLOGY

Bosch Rexroth Corporationwww.boschrexroth.com/conexpo

Mobile hydraulics technology delivers effi cient solutions for your successCranes, backhoe loaders, dozers, or road rollers – today’s mobile working machines must combine maximum productivity and on-the-job fl exibility with improved energy effi ciency. Operators need versatile machines engineered to deliver rugged, reliable performance while complying with stringent emissions regulations. Count on Rexroth to help: As a global leader in mobile hydraulics technology, we work with you to build mobile machines with improved energy effi ciency, reduced noise, and more intelligent control. The result: mobile solutions that move you forward and help sustain your competitive edge.

Ingenious solutionsmove us forward

Exactly

Visit Bosch Rexroth at CONEXPO/IFPE 2014 South Hall 3, Booth 80216

Bosch Rexroth CorporationCorporate Communications14001 South Lakes DriveCharlotte, NC 28273

Telephone (800) 438-5983Facsimile (704) 583-0523E-Mail: info@boschrexroth-us.comwww.boschrexroth-us.com