Bri Helping You Develop

Industry-Adapted Innovations

Helping You Develop:The Rexroth Application Centersfor Industrial Hydraulics

Industrial Hydraulics

Electric Drives and Controls

Linear Motion andAssembly Technologies Pneumatics

ServiceAutomation

MobileHydraulics

2vative components with a broad applicational spectrum. At the same time, you can also benefit from application-oriented sol-utions with an existing track record.

With the aid of our expertise, we develop the best possible solution for you by resorting to our inter-nationally unsurpassed standard product range.

Rexroth satisfies the preconditions for international certification and ensures compliance with interna-tionally valid standards. In doing so, we can call on extensive know-ledge and experience.

For customers with international operations, tried-and-tested logis-tics systems and a worldwide after-sales service are available locally.

Rexroth Your Development Partner for Hydraulic Drive and Control Technology

To give you the best possible support in the development of marketable systems right from the start, Rexroth operates Application Centers serving the international market. Join forces with the specialists of industrial hydraulics in industry-adapted applications from the initial idea through to series maturity!

Innovative market-oriented solutions for many industries are available in close contact with the client.

The Application Centers pool the engineering know-how of the technological market leader with its decades of experience in and a deep understanding of the pro-cesses and technologies needed in specific industries.

This is where you will find drive and control specialists using the very latest equipment for design and simulation. Together with the regional sales organizations, they identify the trends in the industry. With the support of the application developers, development partner-ships are established that take ac-count of the latest technologies in the project right from the outset.

Cooperation with Rexroth special-ists thus yields new, customized solutions be they novel complete systems or combinations of inno-

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Application Development

Electrohydraulic Axis

Machine Tools

Automotive

Presses

Plastics Processing Machines

Steelworks and Rolling Mills

Foundry Machines

Wood Processing and Papermaking Machines

General Machinery

Marine Applications

Simulations on CD ROM

Enclosed in this brochure is a CD ROM with examples of animated function simulations from Rexroths Application Centers. The sections of this brochure to which the simu-lations refer are marked with this symbol.

Focusing on Your Needs Application Development

Rexroth is a byword interna-tionally for particularly market-oriented solutions not least in the hydraulics sector. We are not only the worlds leader in proven standard components, but are also much in demand in helping machine builders de-velop systems geared to their industry.

Innovation mobilizes the market The innovations of the market yield growth in the number of products and applicational solutions avail-able. Yet it is essential that this innovatory potential is correctly exploited. Our application deve-lopers, working as a sales-oriented team within the Rexroth Applica-tion Centers for industrial hydrau-lics, devote themselves to this task.

Application Development4

Market

MachineTools

Automotive Presses PlasticsSteel &Rolling

FoundriesWood &Paper

GeneralMachinery

MarineApplics.


Novel Standard Products and Systems

Application Centers

ElectricDrives and Controls

Linear Motion andAssembly Technologies

Industrial Hydraulics Pneumatics Mobile Hydraulics

Develop to product Developing multi-industry components

Market

Presses


Novel Customized Products and Systems

Application Centers

Develop to customer Developing solutionstailored to the customer

Customer




MachineTools

Automotive PlasticsSteel &Rolling


GeneralMachinery

MarineApplics.

From their daily close contact with the customer, the Application Centers report the need for new developments. With market- and customer-related development projects, the staff in application development convert these ideas into marketable products. They create a bridge between the market and the development departments.

Three main tasks have to be performed: Drawing up the specification in

close cooperation with the client and making it transparent in preparation for development.

Creating scaling effects and economies of scale in product development by taking a multi-industry approach.

Accompanying development from the idea through to the pilot run on the customers premises.

From the point of view of applica-tion development, a distinction can be made between two different types of project:

Develop to productThe goal here is to develop an inno-vative product of interest to a broad market encompassing several indus-tries. A product with a broad range of applications can be produced less expensively.

Develop to customerA specialized drive task has to be performed. The emphasis is not on a broad market impact, but on a system that meets the specific needs of a customer or of an industry.

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Market

MachineTools

Automotive Presses PlasticsSteel &Rolling


GeneralMachinery

MarineApplics.


Novel Standard Products and Systems

Application Centers




Develop to product Developing multi-industry components

Market

Presses


Novel Customized Products and Systems

Application Centers

Develop to customer Developing solutionstailored to the customer

Customer




MachineTools

Automotive PlasticsSteel &Rolling


GeneralMachinery

MarineApplics.

6 Electrohydraulic Axis

Individually Controlled:the Electrohydraulic Axis

Develop to product:multi-industry standard products and systems, e. g.:

IAC-R

HACD freely configurable control electronics

HNC100 series 2X digital control electronics with NC functionality

IAC high-response valveThe high-response valve unit with an Integrated Axis Controller for decentralized and centralized con-trol strategies either as a compact unit for pressure and flow control with an integrated sensor or as an axis controller with flexible appli-cations for a variety of controls with external sensors. A field bus interface permits communication with the higher-level control with significantly extended scope for diagnosis.

HACD control electronicsDigital, bus-compatible and freely configurable closed-loop control electronics with Euro-card format. Position, speed, pressure and alter-nating controls are easy to control. Control algorithms specially attuned to hydraulics result in optimum behavior of the particular drive.

Further properties: Field bus (CANopen), analog and digital ac-tual value acquisition, various forms of logic operations, predefined function blocks, ramp generator and much more.

Rexroth HNC100 series 2XThis digital axis control is a freely programmable NC for both electro-mechanical and electrohydraulic drives. It handles communication with the higher-level control as well as process control and the control of up to two independent drives. For this various field bus systems can be employed. Control algo-rithms specially attuned to hydrau-lics achieve optimum behavior from the particular drive. Parameter assignment and programming by the customer ensure maximum flexibility and protection of the users own know-how.

In the design and testing of the innovations, advanced simulation techniques are utilized, e. g. the Hyvos and Moshis simulation pro-grams developed by Rexroth. This way application solutions can be checked and optimized in advance.

7Innovative electrohydraulic systems are the outcome of successful cooperation between the customer, Application Centers and application development. They are integrated in mo-dern drive solutions at the Application Centers.

Develop to customer:customer-driven deve-lopment of products and systems, e. g.:

KBK system

Pitch control in wind turbines

Wall thickness control cylinder with built-on IAC-R

KBK system solutionA certified, reliable electrohydraulic control for coupling-brake combi-nations on mechanical presses. The flow and pressure control yields soft coupling and braking processes with reaction times of less than 0.1 s.

Pitch control in wind turbinesHydraulic drives for adjusting indi-vidual rotor blades in wind turbines are designed for operation in ex-treme climatic conditions. They operate with special fluids and have improved corrosion protection. The design is adapted to customer requirements and offers optimum accessibility even in confined in-stallation spaces.

Automation technology for blow-molding machinesThe modular wall thickness (MWT) system consists of a cylinder with an IAC high-response valve to control the wall thickness of plastic products. The wall thickness profile is defined via the analogue or CAN bus interface. If the CAN bus in-terface is used, the profile can be stored internally and processed independently, thus relieving the machine control.

Higher-level controlPLC or PC

HACD command value and controller card

Drive axis: Hydraulic cylinder with built-on IAC-R

Machine Tools

Power, Dynamics and Precision Hydraulics in Cutting Machine Tools

Along with electric and pneumatic solutions, hydraulic drive techno-logy traditionally has a permanent place in cutting machine tools. The rapid advance of microelectronics now means that electrohydraulic systems operate not only power-fully and dynamically but also with great sensitivity and precision.

These properties come together in position- and pressure-controlled feed drives. Digital control tech-nology additionally facilitates direct integration in modern con-trol architectures and hence flex-ible data transfer and a variety of opportunities for diagnosis.

In the construction of jigs & fix-tures, hydraulic clamping has become indispensable, as its high power density is surpassed by no other drive form. This creates ideal conditions for solving design-related space problems. If masses have to be moved vertically or obliquely, hydraulics is used for compensating for the weight. Con-sequently, electric drives can be given more compact and energy-conserving designs.

Position-controlled hydraulic axes in an indexing rotary machine

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System solutions for the following machines:

Machining centers Transfer machines Turning centers Drills Milling machines Sawing machines Grinders Honing machines Gear cutting machines

The advantages for the customerThe Application Center endeavors to develop recurrent machine functions into standard features so you have a full range of proven functions at your disposal.

In practice this means savings during commissioning and high availability of the machines in production.

Hydraulic clamping device in a machining center

Hydraulic sleeve control in a special-purpose machine tool

Tailstock drive in a grinding machine

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Rexroth technology in vehicle production is re-sponsible for all automated motions of workpieces and tools.

10 Automotive

Hydraulic equipment for the production line:

Foundries Mechanical engineering of drives (engine, transmission, axles)

Press departments Bodymaking (frame, body, doors)

Paintshops Assembly lines (compo-nent and final assembly)

Simulation systems

Hydraulic equipment for basic and further training

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Rexroth is in international demand as a partner to the automotive in-dustry and its machine suppliers.

The Application Centers respon-sibility starts with the planning of production plant. During instal-lation, commissioning and oper-ation, Rexroth cares for the hydrau-lic systems.

In the training and further training of employees of the automotive industry and its machine suppliers, Rexroth bears special responsibility for successful ongoing production.

Be it hydraulics for the production line or for testing and simulation systems, Rexroth often as a single-source supplier ensures a high level of plant availability.

The advantages for the customer Rexroths national and interna-tional service network coordinates supraregional projects. The end user receives information on inno-vations in drive and control tech-nology early on and thus has a major say in the future equipment of his production facilities.

Rexroth helps the customer draw up project and performance speci-fications and supports sales and engineering in the development of hydraulic equipment complying with these specifications.

In its constructive and successful cooperation with car manufac-turers, Rexroths specialists con-tribute all their experience and expertise, day after day.

Responsible and Reliable Rexroth Serves the Automotive and Component Supply Industry

Presses12


Press brakes Construction material presses BMC/SMC presses Hydroforming presses IHF presses Mechanical presses Punching presses Powder metal presses Pipe/tube-bending machines Forming presses Cutting presses Extrusion presses Guillotine shears Try-out presses Angle shears Drawing presses

Forming, Cutting and Bending Getting Metal into Shape

Punching press

In press making, the application specialists from Rexroth have to meet extremely demanding re-quirements in achieving high flow rates and pressures with increasing precision and improved control-lability of position, speed and pressure. At the same time, safety has top priority.

Rexroth pumps with the requisite control technology, compact prefill valves, excellent high-response valves combined with dependable digital controls are instrumental in bringing about a change in techno-logy in press making. The advan-tages are lower production costs, improved flexibility and enhanced output, thanks to extremely high dynamics and performance com-bined with outstanding energy exploitation.

A typical outcome of development work is the active multi-point die cushion control. Preacceleration to the die cushions ram speed of over 500 mm/s is achieved here in just a few millimeters. By operating sev-eral cylinder axes with control of position and subsequently of pres-sure, there is huge scope for boost-ing workpiece quality and press output.

Technically sophisticated processes, like those on an extrusion press or powder metal press, require precise, dynamic control of the process parameters. Electrohydraulics with its high power density and excep-tional controllability has advan-tages over purely mechanically or electrically controlled systems.

Press systems, like highly dynamic position-controlled cylinder axes with well over 2,600 strokes per minute or high-pressure forming with up to 4,000 bar in the stan-dard pressure range, are applica-tions on which Rexroth places its entire applicational knowledge at the customers disposal. Valves with integrated digital axis con-trol, as in pipe/tube-bending machines and presses, are newly developed products that satisfy the needs of the customer and the market with precision.

IHF presses

The aim is to choose the ideal components from the broad standard range or to have them modified by application specialists for opti-mum technical and cost-effective use in the customers application.

Plastics Processing Machines14


Injection molding machines Blow molding machines Rubber injection presses Calenders Rotary table injection molding machines Rotary table soling machines Core casting machines

Hydraulics for Plastics Processing Machines

High productivity, assured quality and, last but not least, outstanding cost-effectiveness this is what the drives of modern plastics pro-cessing technology are expected to achieve.

The drive technology for plastics processing machines, traditionally a domain of hydraulics, has been shaped by Rexroth for what is now the last 30 years. In order to meet the constantly growing requirements in terms of improved product quality with increasingly cost-effective processes, only the

very latest electrohydraulic and digital components are employed.

Ground-breaking drive strategies, such as DFE (pressure-flow con-trolled pumps), control strategies (such as the HNC100 hydraulic-numerical control and HACD digital closed-loop control elec-

tronics) and the highly developed technology of proportional and high-response valves set the stan-dard in the plastics processing machine sector.

Leading manufacturers of plastics processing machines place their faith in Rexroths unparalleled know-how and in-depth knowledge of the industry.

Injection process controlThe technically exacting process of injection control demands both the sensitive and, at the same time, dynamic compliance with the pa-rameters of pressure, position and speed. The greater the reproduc-ibility of this process, the better the product quality.

The task involves filling in some cases complex, thin-walled molds with plastic material at pressures up to 2,000 bar, with immaculate surface quality and without inner tension.

Blow molding technologyThe production of hollow bodies is the speciality of blow molding machines. Blow moldings are widely encountered in everyday life like the frequently used PET bottles, simple containers for shampoo and cleaners, or the complex structures of a vehicle fuel tank. The required sequence of motions, such as mold closure, ejection or carriage mo-tions are taken care of by Rexroth.

Rexroth offers customers a complete range of perfectly matched components.

Steelworks & Rolling Mills16

System solutions for the following applications:

Blast furnaces Electric furnaces Secondary metallurgy Walking beam /continuous type furnace

Continuous casting plant Hot rolling mills Cold rolling mills Strip finishing lines Materials handling systems

Steel is made from iron ore and scrap in blast furnaces and electric furnaces. Molten steel usually undergoes continuous casting. After solidification, the casting is cut with travelling flame cutters or shears. Further processing into finished products (forming) is mainly carried out by hot or cold rolling. To produce thin sheet, for instance, several rolling cycles are necessary.

Because of the ever-higher quality demanded of continuously cast and rolled products, the number of hy-draulic drives in modern steelworks is growing.

Your benefit:Maximum reliabilityThe advantages of hydraulic actua-tor drives include their immense power density combined with good controllability even in challeng-ing environments.

Hydraulic cylinder drives handle crucial control processes and are largely responsible for the high quality of the end products par-ticularly in the controlled drives of continuous casting plants for mold oscillation and segment ad-justment and in rolling mills for roll gap adjustment, roll bending and roll shift.

High reliability ensures high con-tinuity during the production pro-cess. Over and above this, Rexroth customers appreciate the stability, functionality and maintenance-friendliness of the components and systems.

Continuous casting plant

From Ore to Steel System Solutions from Rexroth

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Continuous casting line with downstream rolling mill

Hydraulic equipment for an aluminum rolling mill

18 Foundry Machines


Green sand molding plant, boxless or with boxes Molding machines Pushing devices Synchronized table

lifting/lowering Core shooters Die-casting machines Shot control Intensification

in the 3rd phase Core pullers Centrifugal casting machines Ladle cars

Foundry machines operating with system solutions from Rexroth per-form their tasks around the clock reliably, safely and in extreme con-ditions such as heat, dust, sand and vibrations.

The cycle times are becoming shor-ter and motion sequences faster while drives are expected at the same time to give machines gentle treatment.

In close cooperation with leading machine and plant engineers, Rexroth meets these requirements reliably and with complete mastery.

Reliable System Solutions for Foundry Machines

Control of the closing cylinder in a die-casting machine

Molding line with molding machine

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Thanks to many years of cooper-ation with leading machine builders, Rexroth has had a major hand in the industrys development. With hydraulic drives and their control and their interaction with other drive technologies, Rexroth as a long-standing co-developer has all the requisite knowledge of the pros and cons of the respective processes.

The Application Center coordinates the handling of whole projects and in doing so resorts to case-related computation models for the simu-lation of results.

Clients rely heavily on Rexroth as a problem solver for instance, in the optimization of drives in terms of cycle time, precision and oper-ational reliability for molding table and pushing movements of the molding boxes with the aid of con-trolled travel motions.

20 Wood Processing and Papermaking Machines

System solutions for the following installations:

Pulp production: Chippers Digesters Pressure washers Dewatering presses Refiners

Papermaking: Wet presses Calenders Winders Slitters Coaters Supercalandering machines

With Rexroth from Pulp to Paper

The production of pulp and paper is a long process involving the use of a variety of machine and plant types with hydraulic drive techno-logy.

Papermaking machines produce kilometer upon kilometer of paper web at speeds of up to 2,000 m/min around the clock. The risk of drive malfunction and the associated downtime is reduced by dynamic, reliable and low-maintenance drive systems.

For the various processes in the production of paper, a variety of hydraulic drive systems are de-signed to customer requirements. For this, Rexroth employs advanced system solutions, such as electro-hydraulic drive technology and integrated axis controllers.

Product developments, e. g. for zone control on calender rolls, are outstanding examples of applica-tion-driven projects from Rexroths engineering specialists on the basis of their in-depth knowledge of the industry.

Papermaking machine

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from Trunk to Wood Product


Log handling yard: Position-controlled cylinder drives for chop saws

Hydrostatic drives for grapplers

Belt, circular and curve saws: Dynamic position-controlled cylinder drives for width of cut adjustment/curve saw function

Veneer lathes: Synchronization controls for hydraulic cylinder drives on the peeling knife

Knife ring flaker: Position-controlled cylinder drives for the knife ring

In the wood processing industry, the market is demanding modern, cost-effective strategies permitting higher throughput, more efficient wood use and narrower processing tolerances.

From a wide range of standard and customized components, Rexroth puts together hydraulic drive sol-utions geared specifically to the industry and to the needs of the customer in question.

Cooperation with the application development department yields special versions of selected products that satisfy the particular demands of the wood processing industry, such as resistance to impact and soiling.

The application specialists give ad-vice in the design of the drive and control systems. In doing so, they take account of current trends, such as that towards decentralized con-trol strategies.

Width of cut adjustment on an edging circular sawing machine in a profiling line

22 General Machinery


Wind turbine generators Transportation systems Materials handling systems Special cranes Test benches Tunnel boring machines Crude oil pumping stations

Whatever your plans, Rexroth is familiar with the requirements of your industry and offers you and your customers tailor-made stra-tegies for driving and controlling your plant. We turn your visions into reality.

Rexroth Brings the Latest Technology to Your Branch of Industry

Pitch control systems, brake systems and auxiliary drives all come from Rexroth.

Tunnel boring machine

The Application Center expertise for your successThe Application Center for general machinery supports you in the design of your drive strategy and in the incorporation of control technology through to the com-missioning of the system. Applica-tion specialists integrate secondary-controlled drives in your drive strategy or drive your application as an independent system. Project planning, project implementation and commissioning from a single source are just as much part of Rexroths services as outstanding project monitoring thereafter.

Wind turbine generators clean energy at competitive pricesPrecise, fast and reliable actuator drives help the manufacturer to steadily improve wind turbines in terms of price and efficiency.

Wind turbines are becoming lighter and slimmer, thus bringing

down the manufacturing, trans-portation and erection cost,

more efficient and hence more profitable,

easier to control and can thus be employed universally as stand-alone turbines, in wind farms and in any location,

more reliable innovative system solutions prevent damage due to overload. Rugged technology, un-surpassed workmanship and long service intervals keep maintenance needs to a minimum.

Trouble-free continuous operation WTG operators are coming ever closer to this goal thanks to Rexroths support.

Highly dynamic loading tests on 12-cylinder internal combustion engines in motor racing are mas-tered with this drive strategy, just as the laying of 16-inch steel pipe-lines at sea at a depth of 2,500 meters.

For the positioning of 60-tonne container transporters with milli-meter precision and the testing of space equipment at 30 times the earths gravity, Rexroth has the answer.

MiningWhatever the task digging a tunnel beneath the river Elbe or extracting heavy crude oil in Ecuadors rainforest; whatever the task drives for cutting heads, stone crushers and erectors of tunnel boring machines, or drive solutions for crude oil pumping stations Rexroth applies its comprehensive knowledge and its broad, technically mature pro-duct range in making your ideas come true. This can extend from lending technical support in the choice of individual components through to the engineering of entire hydraulic drive systems.

Secondary control todays system solutions for tomorrows applicationsThe expectations of system sol-utions are higher today than ever before. High performance, low energy consumption, dynamics and outstanding controllability are just some of the properties a modern drive strategy must exhibit.

Secondary-controlled drives from Rexroth combine high dynamics with control accuracy and energy recovery.

The application fields for secondary-controlled drives are both varied and contrasting. They can be found on test benches in companies and technical colleges and operating in taxing environmental conditions at sea or in foundry machines.

Highly dynamic distorsion test bench with command value feed forward and twisting angle control

Driverless container transport system

Marine Applications24


Winch drives Rudder systems Cargo pumps Bow thrusters Hatch covers Bow and stern gates Bulkhead and shell doors Ramps Lifts Stabilizers Propeller drives Controllable pitch propellers Jet drives Generator drives Subsea applications

At Home on the Ocean Rexroth in Marine Engineering

Modern shipping is inconceivable without hydraulics key functional units on ships are hydraulically powered. Because of the harsh, aggressive environment, the techno-logy has to satisfy high standards of stability, reliability and durability. No principle is better at meeting these expectations than hydraulics.

For maritime applications, Rexroth resorts to know-how stretching back decades. The Application Center for marine applications also has extensive knowledge of the strict test criteria of the classifica-tion societies, the procedures and their application and ensures there are no problems obtaining appro-vals for and the certification of hydraulic equipment.

Leading shipyards and shipping lines all over the world trust in the high availability and reliability of Rexroth systems.

Branches in over 70 countries pro-vide expert advice and high-speed service locally as well as quick re-pairs and a reliable supply of parts.

Hydraulic rudder systems keep even the biggest container ships and super-tankers on course. Pumps, valves and cylinders from Rexroth generate the ne-cessary force for moving huge masses.

Rexroth designs and supplies reliable hydraulic drive systems including drives for anchor and mooring winches.

Ships equipped with hydraulics from Rexroth are in operation all over the world.

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This CD ROM shows the following function simulations from the Rexroth Application Centers: Electrohydraulic axes Machine tools Presses Plastics processing machines Steelworks and rolling mills Papermaking machines Wood processing machines Wind turbines Winches

Simulation as a Cost-effective Development Tool

With the aid of the very latest design processes and simulation software, the innovations from the Application Centers are tested for functionality, performance and durability. Any deficiencies can thus be identified early on and the system consistently improved through to production maturity.

Development work takes account of the latest technological advances and the requirements of specific applications.

Elaborate prototype engineering and intensive test series are scaled down to reduce development costs.

The Application Centers

Examplesof functionsimulations

Bosch Rexroth AGIndustrial HydraulicsZum Eisengieer 197816 Lohr, GermanyPhone: +49(0)93 52/18-12 37

RDE 00073-CD/02.04

IndustrialHydraulics

Electric Drives and Controls

LinearMotion andAssemblyTechnologies

Pneumatics

ServiceAutomation

Mobile Hydraulics

The Drive & Control CompanyRexroth offers an unique and comprehensive range of pro-ducts and services across technologies in its six fields of technology and service areas strong in high-quality individual technologies, combined with highest application-specific com-petence in system packages with integrated complete solutions.

Rely on service across technologiesRexroth integrates all services for the entire product spectrum in the field of factory and industrial automation into a single organiz-ation: from immediate support, spare parts service, field and repair service, retrofit/modern-ization through to training.

Wherever forces need to be utilized economically, the advantages of in-dustrial hydraulics are obvious whether it is required to lift and lo-wer loads smoothly, perform linear or rotary movements, achieve con-stant acceleration, maintain given speeds, approach positions exactly, transmit powers or interlink se-quences.

Rexroth is the technology and market leader in industrial hydrau-lics with a comprehensive product range and distinct application expertise.

At Rexroth you can select from the worlds largest standard product range in the field of hydraulics, application and customer-specific

system solutions of high quality. With advanced micro-electronics Rexroth has made hydraulics even more powerful.

For you, Rexroth is the ideal partner for developing highly efficient machines and production facilities from the first point of contact to commissioning and throughout the entire life cycle. Teams that operate worldwide carry out the complete engineering of your systems and, if requested, up to the hand-over of turnkey systems and beyond service included.

Thanks to the use of hydraulic drive and control technology from Rexroth you will be more competi-tive than ever.

Intelligent Hydraulics in New Dimensions

Printed in GermanyRE 00073/02.04

Bosch Rexroth AGIndustrial HydraulicsZum Eisengieer 197816 Lohr, GermanyPhone: +49(0)9352/18-1237Fax: +49(0)9352/18-1222application-centre @boschrexroth.dewww.boschrexroth.com/awz

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