Tough application, ingenious solution. Innovations 2013

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The solution has to be perfect: Innovation from Bosch Rexroth

All over the world, there are completely different ideas about "innovation": In industrial countries, it is mostly technology-driven, and is generally about "faster, higher, further". In other regions, it refers to solving a task with sophisticated technology, the lowest possible amount of resources and a design which is concentrated on pure functionality – only those who understand the local requirements and develop customized solutions on-site with researchers and developers can satisfy individual ideas about innovation in a global world.

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At Rexroth, regional developers work in a network in close collaboration with their international colleagues. This results in innovations in almost all fields of application and in all industries. They set worldwide standards and help customers on-site, every day.

For this to happen, we invest substantial sums of money and the creativity of thousands of engineers in research and development. Our R&D quota has been above the industry average for years. More than 2,100 specialists work at Rexroth on new products, solutions and services. They identify long-term megatrends which serve as indicators for changes in the markets, society and legislation. From this, we can systematically derive short- and medium-term requirements which we fulfill with developments based on known technologies.

At the same time, we continue to develop existing solution principles for the long term, or look for new approaches. For us, innovation is always multi-dimensional, and always means improvements for machine manufacturers and users. Therefore, a Rexroth solution not only reduces climate-dam-aging carbon dioxide emissions, for example, but increases productivity at the same time. This is a requirement for innovation which we, as a worldwide market leader, also have in your industry. Here, you can discover some of the most important innova-tions of the last six and next six months.

04 Hydraulics05 Hägglunds CBM direct drive06 IndraMotion MLC control system07 IAC-R 2X control valve08 DBETA-6X pressure control valve09 Control valve for EMA(G) turbines10 CDL2 cylinder11 Highly dynamic HPC control cylinder12 Duplex filters 63 and 50 FLDK (N)13 A15VLO axial piston pump with impeller14 A1VO axial piston pump

15 Electric Drives and Controls16 EFC 3600 frequency converter17 IndraDrive Mi decentralized servo drives18 IndraControl S67 I/O modules19 IndraControl S20 I/O modules20 IndraControl XM21 control system21 SafeLogic safety technology22 SafeLogic compact safety technology23 EasyWizard commissioning assistant24 Open Core Engineering25 IndraWorks engineering framework

26 Linear Motion Technology27 IMS-I integrated measuring system28 PLSA planetary screw assembly29 EMC-HD electromechanical cylinder30 Online screw drive configurator

31 Assembly Technology31 Workplace layout32 MTpro ManModel configurator

33 Multi-technology33 Variable speed pump drives Sytronix34 Sytronix SvP 700035 Sytronix FcP 5000

This brochure contains partial product advertisements. Accu-rate information about availability can be obtained from your responsible contact person in Sales.

4 Hydraulics | Innovations

Whether it is more torque in a smaller space for direct drives, new benchmarks for control valves, secure plug-and-play for positioning drives, highly dynamic cylinders, one-of-a-kind pumps or integrated engineering tools, Rexroth system expertise can be seen in every detail of the new hydraulic components. Take advantage of it!

Hydraulic innovations: For more availability, better performance and integrated engineering

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Hägglunds CBM: The most powerful direct drive on the market

50 % more torque, 50 % less weightThe newly developed CBM motor is a contemporary answer to the market requirement for increasingly higher power, more compact design and reduced weight. The core of the closed drive system is a slow-turning hydraulic motor which is mounted directly on the drive shaft and enables maxi-mum torque, even at minimum speeds. Direct installation means that gears, belts, chains, etc. are not required. The design principle makes optimum use of the advantages of hydraulics. The power can be controlled precisely and made available across the entire power range. For maximum productivity.

Advantages resulting from special product features f 50 % more torque for higher productivity in a very small

space f 50 % less weight f Compact design f Optimum power-to-weight ratio for high efficiency f All-purpose system for flexible use

The new Hägglunds CBM motor produces 50 % more torque in a smaller space: The robust, lightweight motor is mounted directly on the drive shaft and opens up completely new applications to you thanks to its reduced dimensions and enormous performance. The machine and the housing have become smaller, lighter and simpler.

Drive | Hydraulics

Key technical data f Max. torque: 2,000 kNm f Max. rotational speed: 53 rpm f Displacement range: 75.8 to 380.1 l/rev f Max. pressure: 350 bar f Max. power: 2,200 kW

www.boschrexroth.com/cbm

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Key technical data f Motion control axis: Decentralized up to 64,

centralized up to 32 f 1,000 instructions (combined) 35 to 5 µs f Number of functional modules: 2 to 4 f Min. sercos cycle time: 1 to 0.25 ms f Up to 512 local I/Os

IndraMotion MLC: Motion Logic Control for all drives

Fast programming, planning, and commissioningUsers of the new version of IndraMotion MLC will notice our expertise from many thousands of applications in every detail: From intuitive operation of all drives, the simple Wizard-supported configuration, the open controller inter-faces or the customized scalable product range – with a single tool, you can carry out cross-technology planning for your drives. You can program, plan, commission, and local-ize and rectify faults faster.

Advantages resulting from special product features f High-performance motion logic run-time system f Best-in-class motion control for hydraulics with opti-

mized controllers f Open communication and programming, supports all

common Ethernet bus systems (sercos, EtherNet/IP, PROFINET RT)

f Simplified programming of motion sequences and high transparency through sequential programming

f Automatic code generation thanks to GAT template f Wizard-supported configuration

IndraMotion MLC is a motion logic optimized for hydraulic drive tasks, which can be used to operate electrical, hydraulic and hybrid drives. Open programming and inter-faces, scalable hardware and software, and consistently easy to use, it can reduce your engineering costs by up to 50 %.

Hydraulics | Control

www.boschrexroth.com/indramotion_mlc

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IAC Multi-Ethernet control valve: Open, scalable and consistently easy

Robust, best-in-class hydraulic controllersDue to the different communication and sensor interfaces, this new generation of control valves can be integrated flexibly into higher-level control networks. Complex engi-neering and hardware adaptations are no longer required – this saves time and money. The combination of tried and tested control valve technology and intelligent electronics enables customized solutions for hydraulic drives which are precise and functional with minimal cost. Together with the IndraWorks engineering framework, more integrated engi-neering is possible – and you can react quickly and eco-nomically to requirements.

Advantages resulting from special product features f Hydraulically optimized, scalable controller structure for

highly dynamic control systems f Open communication: Supports all common Ethernet

bus systems f Integrated engineering with the IndraWorks engineering

framework: Simple and fast commissioning of all com-ponents

f Flexibly scalable: Large selection of valve types for more flexibility for use with minimal cost

f Robust and reliable: Extended temperature and vibra-tion range

f The integrated control electronics of the valve allow the deactivation of a channel in accordance with EN 13849-1

The new generation of 4WRPDH-2X valves with integrated axis controller (IAC) benefits from many years of application experience at Rexroth: The valve is now even more robust and user-friendly. It supports all important bus systems in the field of industry automation, is individually scalable and impresses with hydraulically optimized control-ler structures. It offers intuitive operation for fast project planning, commissioning and diagnostics with IndraWorks software.

Control valve | Hydraulics

Key technical data f Bus connection/service interface

(sercos, EtherCAT, EtherNet/IP, PROFINET RT) f Max. operating pressure: 315 bar, flow: 100 l/min f Sampling time: 0.5 ms for force controller,

1 ms for positioning controller f Directly actuated control valve in servo quality f Integrated digital axis control functionality f 2 x configurable analog sensors (current/voltage) f 1 x linear positioning sensor (SSI, EnDat 2.2 or 1 Vss)

www.boschrexroth.com/iac

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Key technical data f Operating pressure up to 500 bar, flow up to 5 l/min f Low hysteresis and pressure control which is almost indepen-

dent of the volume flow f Integrated pressure sensor f Pressure control can be adapted to the system volumes

(simple adjustment via the DIL switch) f Linear setpoint value/pressure characteristic curve

DBETA-6X pressure control valve with sensor: The new benchmark for operation and performance

Maximum performance in a new designWe have packed the electronics and the pressure sensor into the pressure relief valve in a smaller space and in a new housing. Added value for you due to the integrated pressure sensor: Linear setpoint value characteristic curve, almost no hysteresis, the pressure control is almost independent of the volume flow and can be easily adjusted via the DIL switch. Linear, reproducible and precise results. This inte-gration opens up cost potentials for the drive and machine design due to the fact that external amplifier electronics and additional sensors are no longer required. The commis-sioning costs, and the associated risk of error, are therefore reduced. 500 bar operating pressure makes a wide range of uses possible.

Advantages resulting from special product features f Easy to use: On-board electronics with integrated pres-

sure control and sensors f Fast commissioning without additional parameterization

software f An additional pressure sensor is no longer required in

the application, saving costs and programming f Excellent price-performance ratio f High-pressure applications up to 500 bar

There is no better way to control pressure: The DBETA is the first pressure valve with an integrated pressure sensor. In addition to the first-class technical performance, the demand for professional industrial design has also been met. It enables high-pressure applications of up 500 bar.

Hydraulics | Control valve

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EMA(G): Electromechanical drive with hydrostatic transmission

The secure plug-and-play solutionThe compact positioning drive for direct assembly onto valves replaces hydraulic solutions. At the same time, it is a wear-free alternative to electromechanical drives with a ball screw assembly. The drive is particularly suitable for assem-bly on valves which are used to control the flow of fluids, gases and steams with a safety integrity level of SIL 3. EMA(G) is a pre-configured system of tried and tested com-ponents which only have external electrical and mechanical interfaces. Parameterization is therefore simple and the control system is clear, which minimizes the costs of com-missioning. The resistance to vibrations and high perfor-mance make the drive ideal for use in power plants with large forces and strokes, and which require minimal mainte-nance, long service life and maximum safety.

Advantages resulting from special product features f Stand-alone solution without installing a hydraulic system f Compact design makes more compact machines possible f Pre-configured system for easy parameterization, low

commissioning costs f Tried and tested components with excellent performance f Robust and safe: Minimal maintenance costs and long

service life, SIL 3 compliance

The electromechanical drive supplements the hydraulic valve operating mechanisms for the control and fast-acting shut-down function in valve fittings. With the hydrostatic transmission and the spring-supported fast-acting shut-down function, it works wear-free and is especially easy to handle. This significantly reduces commissioning and maintenance costs and increases efficiency in the power plant.

Control valve | Hydraulics

Key technical data f Electrical interface for power and signal transmission f Positioning using a controlled synchronous motor and hydro-

static transmission f Combined fast-acting shut-down thanks to spring-supported

closed function f Limitation of the max. closing speed during the fast-acting

shut-down f SIL 3 compliant configuration f Integrated damping function

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Key technical data f Nominal pressure: 160/250 bar in one series f Piston: Diameter 25 to 200 mm f Piston rod: Diameter 14 to 140 mm f Stroke length: Up to 3,000 mm f 4 types of mounting, 2 seal designs

CDL2 hydraulic cylinder: The compact design for 2 million load cycles at 160/250 bar

Cost-optimized and customized for industryThe CDL2 series features a round hydraulic cylinder in a welded design, which has been developed and tested spe-cifically for use in industrial systems.

Advantages resulting from special product features f Clear limits of use: For max. 2 million load cycles at

160/250 bar f User-friendly online configuration for easy and fast

design and project planning (online tool incl. CAD draw-ings, documentation, accessories and spare parts)

f Flexible scalability: 2 nominal pressure stages in one series as a cost-effective, customized solution

f Compact design: Small installation space and area

A new series, cost-optimized and, for the first time, with clearly defined limits of use: The CDL2 hydraulic cylinders are designed specifically for industrial use at a nominal pressure range of 160/250 bar and for up to 2 million load cycles. You can configure the compact cylinders online according to your specific needs.

Hydraulics | Cylinder

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HPC: The highly dynamic control cylinder for testing technology

Control axis as a predefined modular system with fast deliveryThe high-performance cylinder (HPC) is an additional mod-ule of Rexroth testing technology, which offers you every-thing from a single source, from the open-loop control system through to the actuator: A practical modular system, whereby the basic design and construction have already been carried out – and you can benefit from shortened delivery times. The non-pressure-dependent, constant friction ensures defined friction values and therefore makes the testing system easier to control.

Advantages resulting from special product features f Perfect for highly dynamic systems: Control axis with an

integrated positioning sensor for frequencies up to 50 Hz f Shortened delivery times: Predefined modular system

with five power levels and two types of mounting f Ensures that the testing system is easier to control:

Non-pressure-dependent, constant friction

The new round hydraulic cylinder has been designed specifically as a control axis for testing technology, with an integrated positioning sensor for frequencies up to 50 Hz. A modular system predefined perfectly for you with five power levels and two types of mounting.

Cylinder | Hydraulics

Key technical data f Power levels: 16, 40, 63, 100, 250 kN f Types of mounting: MF3, MP5 f Frequency: Up to max. 50 Hz f Non-pressure-dependent friction f Application without radial force

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Key technical data f Pmax = 63 bar f Qmax = 250 l/min f Port types from 1" SAE 3000 PSI to 4" SAE 3000 PSI f Either pedestal- or wall-installation f Cyclone effect

63 FLDK (N) duplex filter: Filter better in a smaller space

Minimum pressure loss, high flow ratesFilters are essential for the correct functioning of a hydrau-lic system, but should also be as simple and, in particular, as service-friendly and user-friendly as possible. The new duplex filters are designed exactly for this: A few high-qual-ity components which can be combined ensure high flow rates with minimum pressure loss and also withstand high pressure spikes. In addition, they are easy to handle, and adjustments can also be carried out subsequently without any problems. The aerodynamic design generates a cyclone effect and allows smaller filters to be selected. This results in a better filtering effect and extremely compact outside measurements, which helps to simplify the hydraulic system.

Advantages resulting from special product features f Compact design: Makes a slimline construction of the

hydraulic system possible f Aerodynamic design: Generates an effective cyclone

effect, allows small filters and requires less space f Modular installation: A few parts which can be combined

enable subsequent adaptations to be easily made f Well-thought-out details: Ensure service- and user-friend-

liness, e.g. gas-tight ball valve changeover switch, mag-netic drain screw as standard

Duplex filters can be integrated directly into pressure lines. Thanks to their low cubic capacity, aerodynamic design (cyclone effect) and modular installation, your hydraulic systems remain simple and easy to service. Even ideal for subsequent adaptations.

Hydraulics | Filter

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Key technical data f Nominal pressure: 350 bar f Peak pressure: 420 bar f Open circuit

A15VLO210 axial piston pump with impeller: 20 % more power without higher costs

From 2,100 rpm to 2,500 rpmThe tried and tested Rexroth axial piston pumps have a turbocharger with an integrated impeller: With the same nominal size of 210, the maximum speed can be increased by the infeed via the impeller and the pump output can therefore be increased by approx. 20 %. At an additional price of just 5 % and no additional installation costs at all, this pays off. This is an extremely economical option for increasing output or installing a smaller pump. The impeller is integrated directly into the port plate. No additional instal-lation space is required, and it is possible to operate the pump with a frequency converter.

Advantages resulting from special product features f Infeed via the impeller enables a higher maximum speed f Cost-effective increase of pump output by approx. 20 % f No additional installation costs f No additional installation space required f Possible to operate with a frequency converter

Unrivaled on the market: The A15VLO210 is the only axial piston pump with an inte-grated impeller. The pump rate can therefore be economically increased by approxi-mately 20 % – with the same nominal pump size and without additional installation costs.

Pump | Hydraulics

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Key technical data f 35 cm3 displacement (11/18/28 cm3 in preparation) f Pressure control (hydraulic/electro-hydraulic)/flow and

pressure compensator f Operating pressure: Up to 250 bar f Permissible drive speed: Up to min. 3,000 rpm

Axial piston pump A1VO, series 10: High control quality even for low budgets

Excellent price-performance ratioAs it was developed specifically for price-sensitive applica-tions and markets, the new A1VO requires no compromises regarding efficiency and power density. The cost-optimized design not only provides an especially compact design, but is also impressive due to its high energy-efficiency despite the constant drive speed. The pressure is controlled without bypass losses, so that cooling capacity is greatly reduced or is not needed at all. The series is designed for displace-ment from 11 to 35 cm3 and an operating pressure of up to 250 bar.

Advantages resulting from special product features f Cost-optimized design: Extremely energy-efficient, the

ideal alternative to fixed displacement pumps f Compact design f Adjustable displacement with high control quality f No bypass losses: Cooling capacity is greatly reduced or

not needed f High efficiency and power density f Low noise levels

More power for the money was the objective during the development of this compact series of pumps for medium-pressure applications. The result: Without compromising on quality, this small powerhouse produces optimum performance values and excellent control quality – an energy-efficient alternative for fixed displacement pumps.

Hydraulics | Pump

www.boschrexroth.com/A1

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Innovations in electric drives and controls: For maximum flexibility and more efficiency

From new all-purpose frequency converters to complete Open Core Engineering for individual real-time control – with the new drive and control solutions, you can make the crucial points of your systems efficient, easy to handle and future-proof.

Innovations | Electric Drives and Controls

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Key technical data f 1 AC (200 V, 0.4 to 2.2 kW), 3 AC (400 V, 0.4 to 4 kW) f High overload capacity: 200 % for 1 s, 150 % for 60 s f 50 °C (122 °F) ambient temperature without derating f Motor temperature monitoring (NTC/PTC) f Fan can be replaced without tools (device up to 0,75 kW do

not have a fan) f Integrated brake chopper and mains filter (EN 61800-3 C3)

EFC 3600 frequency converter: All-purpose, perfectly integrable

Saves time and space – and adds more qualityEfficient speed control is the basis for energy savings and low CO2 emissions – the new frequency converters have therefore been packed with intelligent features which meet all engineering and usability requirements. Compact, with practical side-by-side installation, pluggable I/O terminals and no external components, making installation and saving space extremely easy. Optimum handling is not only ensured by the removable operating panel with memory function for fast transfer of parameters, but also by harmo-nized parameters across the entire series – this saves you time, improves quality and facilitates series commissioning.

Advantages resulting from special product features f Compact and complete: Space-saving side-by-side instal-

lation, pluggable I/O terminals with brake chopper and mains filter – for easy installation and integration

f Simply practical: Removable operating panel with mem-ory function, simple parameter input, harmonized param-eters across the entire series – to save time and improve quality during series commissioning

With their freely definable V/Hz characteristic curve, compact design and integrated brake chopper and mains filter, the new frequency converters can be used universally in a wide range of applications. They are especially easy to install, without additional peripheral devices.

Electric Drives and Controls | Frequency converter

www.boschrexroth.com/efc3600

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IndraDrive Mi: The most flexible decentralized drive system

An all-around talent with integrated safety technologyWith the many new or advanced features of the new IndraDrive Mi, you can be completely flexible: The multi-protocol capability means that it can be used universally with all products from leading control system manufactur-ers. The integrated motion logic combines drive, motion control and processing logic, so that you can carry out complex motion sequences just on the drive level without higher-level control.

The integrated safety technology provides effective protec-tion for people and machines without additional open-loop control: Certified in accordance with EN ISO 13849-1 for Safe Torque Off and Safe Motion, and saves hardware and reduces wiring effort.

Advantages resulting from special product features f Multi-protocol capability: Compatible with all relevant

Ethernet protocols and also all common control products f Integrated safety technology: For optimum protection

without additional open-loop control (certified in accor-dance with EN ISO 13849-1; Safe Torque Off and Safe Motion)

f Integrated motion logic: For carrying out complex motion sequences without higher-level control

f Energy-efficient power supply

The new generation of the IndraDrive Mi can be adapted to individual general condi-tions unlike any other decentralized drive system. This makes it ideally suited for use in all modular machines – for maximum flexibility in the smallest of spaces.

Key technical data f Up to 20 drives on a hybrid cable up to 200 m long f Multi-Ethernet – sercos, Ethernet/IP, ProfiNet, EtherCat f Safety technology – Safe Torque Off and Safe Motion f Integrated motion logic according to IEC 61131-3 f Integration of machinery by uncoupling the control communi-

cation

Servo drive | Electric Drives and Controls

www.boschrexroth.com/indradrive_mi

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IndraControl S67: The best solution for a wide range of performance requirements

Key technical data f Protection category: IP67 f Fully encapsulated for tough ambient conditions f Fieldbus interface connections for sercos, PROFIBUS,

PROFINET and EtherNet/IP f Up to 64 I/O modules/520 channels per station f Up to 50 m gap between two modules, up to 500 m total

length per station f Extended temperature range from -25 °C to +60 °C

The I/O system with protection category IP67 fulfills technically challenging require-ments from all industries in automation engineering efficiently and with long-term reliability, even in the most extreme environments. Thanks to the modular design and easy handling, you can react quickly and flexibly to a wide range of challenges.

React quickly and flexibly. Anytime and anywhere.The IndraControl S67 provides you with the latest and most powerful I/O system with IP67 on the market: The robust design with high EMC protection enables you to use it in even the most extreme ambient conditions. And the well-thought-out modular design facilitates especially quick and easy installation, short commissioning times and simple integration into your system. This is the best solution for a variety of requirements, both technically and economically.

Advantages resulting from special product features f High-performance and intelligent system bus with opti-

mized data communication for various applications f Robust design with IP67 with high EMC protection for

use even under the most extreme conditions f Modular system design with intelligent fieldbus couplers f Quick and tool-free installation using M8 and M12 con-

nectors and a ready-made cable

Electric Drives and Controls | Control

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Key technical data f Protection category: IP20 f Fieldbus interface connections for sercos and PROFINET f Cycle times of 250 µs f Short module reaction times of 1 µs per module f Extended temperature range from -25 °C to +60 °C

IndraControl S20: The fastest I/O components of all time

Optimum system integrationWith IndraControl S20, the I/O system with protection cat- egory IP20, real-time requirements with short cycle times can be carried out easily. In conjunction with the high-per-formance automation bus sercos, extremely short I/O reac-tion times can be achieved for efficient production cycles. This facilitates the most challenging applications, even under extreme conditions, thanks to the optimized design.

Thanks to its flexibility, the modular I/O system optimally links together with various different control topologies. In conjunction with the new IndraControl XM21 control sys-tem, the full functionality and efficiency is also available as a high-performance I/O expander.

Advantages resulting from special product features f Real-time properties on sercos f Fast signal processing with short update times on the

system bus f High resistance to EMC interferences f Reduced emissions f Easy station installation and device replacement thanks

to tool-free installation f Long-term reliability thanks to maximum power reserve f Extended diagnostics

The full performance and function of the fastest I/O technology with protection cat-egory IP20 on the market is available to you, for even the most challenging applications, via the Ethernet-based automation bus sercos and using optimum system integration.

Control | Electric Drives and Controls

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IndraControl XM21: Control flexibly in real-time

Easy configuration, high-performance data processingComplete motion logic solutions for various applications are available on the new IndraControl XM platform – in conjunc-tion with the IndraLogic XLC or IndraMotion MLC system software. All functions are contained in the compact and robust housing for easy integration into automation net-works. Modules in the new IndraControl S20 I/O family expand the open-loop control system in a flexible way for high-performance process integration. Decentralized I/Os, drives and additional system machinery are connected via sercos as standard. Optional communication modules expand the integration options. The service-friendly design simply reduces the costs for installation and commissioning.

Advantages resulting from special product features f Easy and flexible system configuration with modular I/O

expansion f Complete control system with high-performance process

data processing f High real-time capability of the complete system f Sercos used as a universal automation bus for system-

wide networking f High availability as wear parts such as fans and batteries

are not required f Scalable system firmware for motion logic applications

(IndraLogic XLC/IndraMotion MLC)

The first control system in the new, IndraControl XM modular device family: They combine the high real-time capability of the sercos automation bus with the new IndraControl S20 I/O component family in one modular and functionally complete control system – for a wide range of applications in factory automation.

Key technical data f Modular and robust embedded control design with protection

category IP20 f Integrated fieldbus interface connection for sercos with

250 µs cycle time f High control performance via Intel ATOM processor architec-

ture with 600 MHz f Gigabyte Ethernet, USB, SD card slot, diagnostics LED f Expansion interfaces for function and I/O modules

Electric Drives and Controls | Control

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SafeLogic: More safety, better engineering

The option for secure machines and systemsIncrease your engineering efficiency and make it consistently secure. With the new SafeLogic safety controller, you can connect a wide safety portfolio via sercos and PROFIsafe using the multi-safety master function. As there is no reac-tion between the standard control system and the safety technology, you can expand the system optionally without any problems. In this way, variants of series machines are significantly easier to create. You can use SafeLogic extremely efficiently as an integrated part of the standard control systems to make your machines and systems safer.

Advantages resulting from special product features f Multi-safety master – CIP Safety Originator and

PROFIsafe host f Modular system design thanks to optional safety function

module f No reaction between standard control system and safety

technology f Secure communication for integrating the decentralized

safety machinery f Integrated engineering of the standard control system

and the safety technology with IndraWorks f Standardized safety programming with PLC open safety

The new SafeLogic safety controller rounds off the portfolio of secure logic processing solutions as an optional expansion of the standard control system. SafeLogic is effi-cient, can be programmed freely and enables integrated engineering – perfect for machines and interlinked, extensive systems with comprehensive safety machinery.

Safety | Electric Drives and Controls

Key technical data f Complete safety PLC as a function module with an overall

width of 20 mm f Safety solutions up to Kat 4 PL e (EN ISO 13849-1) or SIL 3

(IEC 62061) f Integrated system expansion with max. 96 secure participants f Digital input/output modules f Relay modules with internal evaluation of feedback contacts

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Key technical data f Secure logic processing up to Kat 4 PL e (ISO 13849)

or SIL 3 (IEC 62061) f CPU modules with/without EFI interface f Interface modules for system integration f Digital input/output modules f Relay modules with feedback contacts

SafeLogic compact: The decentralized and flexible safety control system

Modular and efficient control with direct integration into sercosSafeLogic compact is the decentralized safety control sys-tem solution which can be used extremely flexibly and easily: Thanks to the modular system design, you can reduce your control cabinet size – and your hardware costs. Your engineering becomes easier and more efficient thanks to the intuitive programming with various modules and functions. And due to the direct integration of the control system into the sercos network, you can implement modular machine concepts with SafeLogic compact more easily.

Advantages resulting from special product features f Comprehensive module libraries for evaluation, diagnos-

tics and logic processing of machinery signals f EFI interface for secure station networking f Comprehensive interface portfolio for flexible integration

into the entire automation application f PC-free hardware replacement using memory plug with

integrated application memory f Fast shut-off function for fast shut-down of outputs f Convenient report function for fast application verifica-

tion and documentation

With the programmable small safety control system SafeLogic compact, secure logic processing can be carried out easily and efficiently in small- to medium-sized machines. The control system expands with the number of machinery signals. Defined function modules and graphic wiring simplify configuration and speed up the commissioning process.

Electric Drives and Controls | Safety

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Key technical data f Input of the linear motion system mechanical data f Optional input of the maintenance period for the linear

motion system f Setting the absolute values f Setting the limit values f Call up the Easy Startup Mode

EasyWizard software engineering: Ready to start in three minutes

Fast, easy and reliable commissioningCommissioning the IndraDrive Cs compact drive has never been faster, but is still safe. The commissioning time has been reduced from the previous time of 90 minutes to around three minutes. The linear motion system data can now be entered easily and intuitively; it is even possible to read in the mechanical data using QR codes. A type plate adapted for the assistant on the linear motion system makes commissioning easier than ever before.

Advantages resulting from special product features f Simple, fast and intuitive commissioning of drives f Extremely short commissioning time of around three

minutes possible f Reading in of mechanical data also using QR codes f Text-based and graphical online help for individual input

fields f Incorrect parameterization is minimized by homogeneous

arrangement of data on the type plate and the Wizard input screen

f Plausibility check during free data input f Suitable for all linear motion systems from Rexroth f For system optimization, the axes can be run in test

mode after parameterization has been completed

EasyWizard is a new, extremely fast commissioning assistant within the IndraWorks DS engineering framework. It guarantees easy and error-free commissioning of the drive controllers in conjunction with linear motion systems in the EasyHandling modular system.

Engineering | Electric Drives and Controls

www.boschrexroth.com/easywizard

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Unique flexibility in programmingOpen Core Engineering combines the previously separate SPS and IT worlds in one integrated range of solutions based on open standards, software tools, function packages and the Open Core Interface to enable new freedom. This bridging combines classic IEC engineering with the new possibilities of standard language programming. Further-more, from enhanced access to the control core, individual real-time control functions can be implemented quickly and independently. The result: More flexibility, individuality and long-term reliability for machine manufacturers and end-users.

Advantages resulting from special product features f Flexible: Standard-language programming in parallel with

classic engineering in IEC 61131-3 f Innovative: Integration of smart devices and IT technolo-

gies in the automation application f Individual: Fast and economical implementation of indi-

vidual real-time control functions f Efficient: Simplified engineering using preprogrammed

function packages and efficient software tools f Reliable long-term: Reliable operation using tried and

tested solutions based on open standards

Key technical data f Standard-language programming: C/C++, C# (.NET), Visual

Basic, VBA (Office), LabVIEW G, Objective-C, Java f Development environment: MS Visual Studio, LabVIEW,

Eclipse, Xcode, Wind River Workbench f Smart devices: Supports the Google Android and Apple iOS

operating systems

Open Core Engineering: Redefining freedom and efficiency

Open Core Engineering not only speeds up and simplifies your software engineering, but also gives you more freedom and flexibility. Now you can choose between various standard languages for programming, integrate smart devices into your automation solution and carry out individual software functions in real time.

Electric Drives and Controls | Engineering

www.boschrexroth.com/oce

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Key technical data f PLC and motion logic programming based on CoDeSys V3

with object-orientated language extensions f Function packages such as Generic Application Template,

CamBuilder and technologies f Integrated Safety Manager for programming secure logic

functions up to Kat 4. PL e or SIL 3 f Standardized integration interfaces such as FDT/DTM, team

engineering and Automation Interface

IndraWorks: The universal tool for efficient software engineering

The integrated engineering tool for motion logicAs part of the range of Open Core Engineering solutions, IndraWorks is the universal engineering framework for auto- mation systems from Rexroth. It offers centralized project management as well as all tools for project planning, pro-gramming, commissioning, visualization and diagnostics. Complete basic functions for all tasks and powerful toolkits ensure fast and efficient implementation of your automation tasks.

Advantages resulting from special product features f Uniform software framework: Uniform engineering of all

control systems, from the small control system to highly complex motion applications

f Complete basic functions: Project planning, parameter-ization, programming, diagnostics, visualization

f Consistent operation: Intuitive interface based on cur-rent Windows technology with centralized project man-agement and wizard support

f Generic Application Template: Predefined modular pro-gram and project structure for developing reusable applications

f Application-orientated functions: Technology libraries, control of hydraulic axes

f Comprehensive diagnostics: Trace, oscilloscope, pre-compile, tooltips, context-sensitive help

IndraWorks is the first engineering framework which has CoDeSys V3 integrated, ready for the market and ready for use. With IndraWorks, Rexroth is a market leader in engi-neering motion logic applications with comprehensive wizards and powerful toolboxes. Therefore, you save a significant amount of time, money and programming effort, with increased quality.

Engineering | Electric Drives and Controls

www.boschrexroth.com/indraworks

26 Linear Motion and Assembly Technology | Innovations

Innovations in linear motion and assembly technology: Work more precisely, efficiently and ergonomically

Contact-free position measuring, moving heavy loads accurately at high speeds and cost-effectively, or especially cost-effective movement of heavy weights – Rexroth is equally innovative in linear motion technology as in assembly technology, with work-place optimization or intuitive simulation and planning software. Take advantage of our process expertise, and the attention to detail in our solutions.

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Key technical data f Signal period: 40 µm (1 Vss) f Pitch accuracy: ± 3 µm/m f Ball rail system: Gr. 20/25/30/35/45 f Roller rail system: Gr. 35/45/55/65 f Rail lengths: up to 4,500 mm in one piece

IMS-I integrated measuring system: Guide and measure with maximum precision

Inductive measuring with a 40 µm signal periodThe IMS-I provides you with a precision instrument that guarantees excellent workpiece quality due to accurate position measuring. Thanks to the inductive, contact-free measuring principle, the system works wear-free, which reduces your downtime. In addition, it is particularly com-pact thanks to the integration of the systems, which saves installation space.

Advantages resulting from special product features f High system accuracy f Inductive, contact-free measuring principle f Measuring function integrated into the guide rail f Resistant to contamination without additional measures

The integrated measuring system combines Ball Rail® and roller rail systems with an incremental length measuring system in the new IMS-I product. The system accuracy of this inductive measuring system is comparable to high-precision glass scales, and is therefore ideally suited for use in external measuring systems in machine tools.

Ball rail and roller rail systems | Linear Motion Technology

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Key technical data f Numerous large contact surfaces f No feedback and no contact between the planets f Guided planets using synchronization f Compact design f Rolled spindle

PLSA planetary screw assembly: High movement speed, heavy bearing load, low costs

Compact, robust, economicalRexroth uses its experience gained from cost-efficient roller processes when manufacturing spindles, so that they can offer the planetary screw assemblies at a lower price than that of their competitors, with the same performance. A higher load-bearing capacity than that of ball screw assemblies can be achieved in the same amount of installa-tion space. The numerous large contact surfaces also ensure a high level of rigidity, long service life and a high level of efficiency. And because there is no feedback and no contact between the planets, significantly higher movement speeds can be achieved.

Advantages resulting from special product features f High load-bearing capacity and rigidity thanks to numer-

ous large contact surfaces f Small installation space thanks to increased power

density f Quiet operation due to guided planets f Different nut types available f Reduced lubricant consumption due to effective seals f Economic solution thanks to rolled spindle

With the newly developed planetary screw assemblies, Rexroth has expanded the range of uses of electromechanical applications to include the fast movement of heavy loads – with the same performance data and competitive price-performance ratio.

Linear Motion Technology | Screw assembly

www.boschrexroth.com/plsa

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EMC-HD electromechanical cylinder: The energy-efficient alternative to hydraulic cylinders

The robust completely modular systemThe new electromechanical cylinders have been created to provide long service life under tough conditions: With per-fect sealing and without leakage, a high IP protection class and a high level of corrosion protection can be achieved. The precision-rolled screw drives position accurately and powerfully, but at the same time are characterized by a high level of cost effectiveness with low operating costs and high energy-efficiency. The configurable servo drive can be pro-grammed freely, and process parameters can be changed easily – you can therefore also carry out complex processes accurately and adapt them at any time.

Advantages resulting from special product features f Simple, robust assembly for long service life, even in

tough environments f Complete modular system and great variability f With precision-rolled screw drives for high power with

maximum cost-effectiveness f Complete system ready to install and use f Configurable electromechanical servo drive solution for

free programmability and carrying out complex pro-cesses

The robust electromechanical cylinder has been developed for use in heavy load appli-cations. Designed as a completely modular system with integrated planetary or ball screw assemblies, it is designed for cost-efficient work, even under tough conditions.

Cylinders | Linear Motion Technology

Key technical data f Dynamic load rating (Cdyn): 50 to 470 kN f Axial force: Up to 290 kN (tension/pressure) f Max. travel speed: 1 m/s f Stroke: Up to 1,700 mm f Protection category: IP65

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Key technical data f Complete range of sizes shown f End processing customized for customer requirements or

according to the catalog f All configuration options available

Screw assembly configurator: Available online at any time

Configured easily, delivered quicklyOnce again, Rexroth is one step ahead: The new online configurator provides an unbeatable fast and easy way to order screw drives. Integrated practically into the Rexroth eShop, you can order standard components directly or be guided through the configuration process with images to your specific solution, while always being informed about the cost. 2D and 3D data is available to download in all common formats. Go online. At any time. It couldn't be easier.

Advantages resulting from special product features f Easy and fast design using image-guided configuration f Configurator integrated into the eShop f Ordering available 24 hours a day, seven days a week f 2D and 3D data available to download in all common

formats f Available online anytime and anywhere

Rexroth presents the first online configurator for screw assemblies: 24 hours a day, seven days a week, you can now design your specific solution or even order standard products quickly and easily. With practical cost overview and short delivery times.

Linear Motion Technology | Configurator

www.boschrexroth.com/ballscrew-configurator

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Workplace layout: Ergonomics designed in detail

Optimized workRexroth develops optimized workplaces according to the rules of ergonomics or Methods Time Measurement (MTM): A series of chairs for dynamic seating with perfect lumbar support, tactile feedback for predictable grabbing and ergo-nomic tool holders for short and defined movement sequences. In this way, users can guard against medical conditions which can arise due to incorrect posture and static strain. This not only improves ergonomics, but also the processes, and not least the health of employees.

Advantages resulting from special product features f Synchronous technique and weight regulation for swivel

work chairs promotes dynamic sitting, so that employees sit in a healthier way

f Standardized tool holders keep tools available in defined places for fast reaching, grabbing and retrieving actions

f Grab container with dividers can be adapted to the cus-tomer's individual system, and therefore reduces costs according to lean and MTM principles

Whether it is proper seating in the new dynamic swivel work chairs, predictable grasp-ing of parts with grab containers for lean racks, or making it easy to reach and retrieve with standardized tool holders, Rexroth improves the ergonomics in the workplace in every detail and supports you with well-thought-out optimization for an aging society.

Key technical data f Swivel work chair: Four design versions – textile, PU, artificial

leather, ESD f Chair with synchronous technology, weight regulation and

perfect lumbar support f Ergonomic tool holders with space for lettering f Standardized components in accordance with MTM f All components are conductive for safe use in EPAs (Electro-

static Protected Area)

Ergonomics | Assembly Technology

www.boschrexroth.com/workchairs

32 Assembly Technology | Project planning software

Key technical data f Electronic product catalog for assembly technology f Product configuration and calculation of order lists f CAD library with direct interfaces to all common CAD systems f Layout Designer for planning frames, work systems and

assembly systems f Man models for simulating reaching distances and visual fields

in CAD systems and the Layout Designer

MTpro with ManModel function: Assembly system with ergonomically optimized design

MTpro is the intuitive software for planning assembly systems. It assists you at every step, from selection, to configuration, through to ordering products from Rexroth. A ManModel function enables you to adapt designs so that they are ergonomically opti-mized for people – with the correct reaching distance, the correct distance to working equipment and the correct angle.

Perfect simulation as early as the planning phaseUsing simulation, MTpro facilitates the ergonomic design of work systems as early as the planning phase, complete with calculation of bill of material. Using the intuitive operating concept of the Layout Designer, you can create complex designs and system layouts yourself in a short period of time. The ManModel function significantly facilitates the design of ergonomic workplaces, even with a wide range of user groups: The man models are displayed with clear simulation of reaching distances and visual fields and can be used in both the Layout Designer and in any CAD systems.

Advantages resulting from special product features f ManModel: Standardized models of human forms for

men and women in three sizes – small, medium and large f Standardized positions: Sitting, standing, walking f Automatic placement of work chairs f Angles of all joints in the body are individually adjustable f Display of different reaching distances and visual fields f Possible to use in Layout Designer, and to export to CAD

systems

www.boschrexroth.com/mtpro

33Energy-efficiency | Multi-technology

Variable speed pump drives Sytronix save up to 80 % of energy and 20 dB (A) in noise emissions

Sytronix, the combination of robust hydraulics and efficient electronics is the intelligent answer to increasing energy prices, cost pressure and strict environmental require-ments. You can control the variable speed pump drives in line with demand using the intelligent electronic drive unit with the latest firmware and software. The Sytronix port-folio offers you a finely scaled range of pre-configured, individual sets of inverters, motors and pumps, together with accessories.

www.boschrexroth.com/sytronix

34 Multi-technology | Energy-efficiency

Key technical data f System performance of pre-configured sets extended from

60 l/min to 480 l/min f Finely scalable performance levels – economy, standard and

advanced f Up to 150 mm shorter installation length: 25 % more compact

in the upper power range f Various combination possibilities for optimum scaling f Nine motor installation lengths, eleven nominal pump sizes

Sytronix SvP 7000: Dynamic, compact, energy-efficient

High-performance – finely scalable, highly efficientThe SvP 7000 system consists of a pump which is optimized for variable speed operation, a highly dynamic synchronous servo motor and a compatible servo inverter, along with accessories. A completely modular system with finely scal-able performance levels, which have been extended to a maximum of 480 l/min and can be optimally adapted to a wide range of requirements. SvP 7000 drives work in an open circuit or can provide 4-quadrant operation in a closed circuit. When interconnected in cascade systems, they are suited even for extremely high performance in plant manu-facturing. For maximum performance with optimum effi-ciency.

Advantages resulting from special product features f Lower noise levels and lower weight f Compact, as additional couplings, bell housings and

pump supports are not needed f Improved motor cooling thanks to optimized heat trans-

fer from the motor to the pump f Improved energy efficiency and dynamics due to reduced

moment of inertia f Practical: Ready-to-install pre-assembled motor-pump

assembly group f All-purpose: Liquid-cooled motor also available in stain-

less steel

The comprehensive portfolio of pre-configured Sytronix SvP 7000 complete sets has been expanded with direct-coupled MPA01 motor-pump assembly groups. Take advan-tage of the benefits offered by these customized, compact solutions which can be easily installed: In small spaces, you can not only be sure of less noise, but above all of greater dynamics with an energy saving of up to 80 %.

www.boschrexroth.com/sytronix

35Energy-efficiency | Multi-technology

Key technical data f System performance extended to 90 kW f 15 power levels f 5 sizes for optimum use of space in the control cabinet f New Rexroth Fv frequency converter

Sytronix FcP 5000: Complete set for power ranges of up to 90 kW

Basic performance, full efficiency – ideal for machine toolsThe variable speed FcP 5000 drive sets are designed for open hydraulic circuits, for highly efficient, and on demand pressure and flow control. With their asynchronous stan-dard motors, they are suitable for use as a constant pres-sure system for numerous standard power units, for exam-ple, in machines tools. The new frequency converter now makes operation even easier and extends the power range to up to 90 kW, as a result of which the complete sets can be used even more flexibly in a wide variety of different industries.

Advantages resulting from special product features f No commissioning efforts required due to

pre-configured sets f Simple operation due to manual parameterization f Operating panel with copy function f Low commissioning costs

The Sytronix FcP 5000 system has been expanded with FcP 5010 sets for power ranges from 1.5 to 90 kW. As a result, it is an ideal constant pressure system in machine tools, for example, especially for systems with low dynamic requirements: Easy to operate, parameterize and install, including all the efficiency advantages of the Sytronix principle.

Return on investment of speed-controlled drives

Operating costs

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Classic hydraulic system

Sytronix

Years1 2 3 4 5 6

Return on Investment

Time Frame

www.boschrexroth.com/sytronix

Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 297816 Lohr, Germanywww.boschrexroth.com

R999000265 (2013-06)© Bosch Rexroth AG 2013Subject to revisions!

Find your local contact person here: www.boschrexroth.com/contact

The data specified above only serve to describe the product. As our products are constantly being further developed, no statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.