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Rexroth IndraMotion for Metal FormingSystem solutions for forming technology

Simple, scalable and powerful

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Content

Rexroth’s innovative automation systems are user-oriented, leaders in terms of technology and suitable for use any-where in the world. IndraMotion for Metal Forming is the scalable automation system designed specifically for material transport in metal forming.

IndraMotion for Metal Forming

Energy efficiency

Safety on Board

Turn-key single-axis solutions for rollfeeds

Turn-key solution for flying shear

Rotary shear technology function

Multi-axis solutions for blanking lines

New concepts for electronically controlled press transfer

Automation of crossbar transfer and compact crossbar transfer systems

Motion logic integration for tandem press lines and feeder

Optimal process adaptation for servo presses

System solution and hardware

System features in detail

Scalable system components

Scalable hardware architecture

Integrated technology functions

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4 IndraMotion for Metal Forming

Rexroth IndraMotion for Metal Forming –cost-effective material transport for press lines, punches and shears

The customized automation concept is based on the IndraMotion MLD (drive-based) and IndraMotion MLC (control-ler-based) system solutions. The system is built around the conver-gence of highly advanced motion control and a standardized PLC functionality.

Expanded with the integrated application-specific technology functions, it is tailored exactly to the requirements of modern pro-duction facilities. IndraMotion for Metal Forming handles all synchronization and positioning tasks particularly efficiently. We can supply IndraMotion for Metal Forming in the following forms to meet the different requirements of your production systems:

Single-axis applications with IndraMotion MLD-S• Rollfeeds• Feedstraighteners• Flyingshear• Rotaryshear• Unwinders• Straighteners

Multi-axis applications with IndraMotion MLD-M and IndraMotion MLC • Blankinglines• Flyingshearsystem• Profilingsystems• Perforatingpresses

(incl. shear computer)• Zig-zagfeeds• Infeed/outfeed• Stackeranddestacker• Electroniccontrolledpresstransfer• Tandempresslines• (Compact)crossbartransfer

systems• Stackingdevices• Servopresses

IndraMotion for Metal Forming is the highly productive system solution from Rexroth‘s consistent and pioneering modular system for the efficient automation of presses, shears and blanking lines. This unique modular system bundles everything you need to implement your automation designs: drives, controllers, a powerful, standard-ized engineering framework and user-friendly operation.

IndraMotion for Metal Forming is the modular, scalable motion control system for particularly cost-effective single- and multi-axis applications on metal forming systems.Preprogrammed controls, compact operator termi-nals and intelligent drives with a wide range of rotary and linear motors ensure maximum produc-tivity and product quality.

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Rexroth has had 50 years of spe-cialist experience in control and drive technology for metal forming industries. You too can enjoy the benefit of our industry expertise through IndraMotion for Metal Forming, whether it‘s a standard-ized single-axis or a complex multi-axis application you want to realize. IndraMotion for Metal Forming makes uncompromising use of recognized worldwide standards and unlocks the door to consistent, open system solutions which are based on standardized hardware and software architec-tures.

IndraMotion for Metal Forming is characterized by:• Preconfigured controls• Scalabledriveplatformswithhigh-

dynamic motors with a power range from 0.1 kW to 650 kW

• Standardizedprogrammingtoolsconforming to IEC 61131-3 and PLCopen

• Drive-integrated safety technol-ogy, certified as complying with EN 954-1, Cat. 3

• Intuitive engineering using the RexrothIndraWorkssoftwareframework

• Easy implementation of process functions

• Exact synchronization between press and feed unit

• Optional technology and communication interfaces

Our Experience – for your benefit

• Operational technology functions as a basis for application-specific ready-to-apply solutions

• Easy integration of decentral drive solutions into existing or newly designed control concepts

• Low assembly and installation expenditure and rapid commis-sioning thanks to coordinated and configured system compo-nents

Increased plant safety thanks to:• Secondaryencoderscreating

redundancy protection• Safetyincaseofmainsfailure

Increased productivity thanks to:• Programmable online collision

monitoring• “Productivity Agent” for preven-

tative maintenance scheduling

IndraMotion for Metal Forming – modular and scalable system solution for efficient material transport in perfection

SERCOS safetyorPROFIsafe SIL 3 IO

IndraMotionMLC

Redundant motor encoder

Redundant press encoder

IndraLogic

IndraDrive/IndraDyn

Inline SIL 2 IO

Auto Manual

IndraMotionMLC

IndraDrive/IndraDyn

SERCOS

Example topology: Forming application

6 Safety on Board

Certified safety functions in the high-dynamic, intelligent servo drivesfromRexrothprovideareliable means of preventing col-lisions and therefore increase the availability of the overall system. SafeLogicandSafeMotion,thesafetyfunctionsfromRexroth,make it easier to implement safe machine concepts and mini-mize unproductive downtimes. Operators need safe access to the press compartment for tool chang-ing, manual loading, unloading and troubleshooting. When guard doors are open, functions such as „SafeOperatingStop“,or„SafeReducedSpeed“protectperson-nel from uncontrolled axis move-ments. The reliable monitoring of movement ranges (absolute position) prevents hazards caused by unacceptable axis positions of forexamplepressfeeders.Reliablespeed monitoring is also possible in automatic mode in the interest of process optimization.

Safety on Board – certified safety in metal forming technology

C Standard Machine type Safety-related control functions according to EN 954-1:1996, Cat. 3

Set-up and test strokes Separating guards (fixed, mobile or locked)

EN 692: Feb 08 Mechanical presses (and servo presses)

Safe Operation Stop (SS2, SOS), Safely Limited Speed (SLS) < 10 mm/s,Safe Monitored Direction (SDI),Safely Limited Position (SLP), Safely Limited Increment (SLI)

Safe Maximum Speed (SMS) against parts be-ing catapulted out,Safe Door Locking (SDL), Safe Torque Off (STO),Safely Monitored Deceleration (SMD), Safe I/O (SIO)

EN 693: Apr 01 Electrical transfer in hydraulic presses, variable-speed pump drives

EN 13675: Sept 04 Tube forming and rolling mills If access to a hazard zoneSS2, SOS, SLS, SDI, SLP, SLI

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7Energy efficiency

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Energy efficiency from Rexroth –benchmark for energy savings

Rexrothprovidessupportforyourmechatronic system optimization with its energy-efficient drive technology. This means not just the electric drive technology embracing servo drive controllers, motors and frequency converters, but software tools and services geared towards the optimization of energy consumption. The IndraSizesoftwaretoolsystem-izes the drive design for every application process and therefore minimizes energy consumption. Furthermore,Rexrothoffersacomprehensive mechatronics support service to ensure that your production process is optimally organized and designed to be energy-efficient.

Energy saving controller

• CommonDCbus• Powersupplyunitswithenergy

recovery capability• Efficiencyof97%

Highly efficient motors

• Optimizedwindingtechnology• Efficiency>95%

Decentral and integrated drive technology

• Onehybridcable–upto85%reduction in cabling

• Upto70%reductionin required control

IndraSize software tool for design optimization

• Selectionofthemechanical components

• Predefinedmotionprofiles• Databasewithoptimizedmotor

and controller combinations

Software tools for machine optimization

• Controller-integratedsoftwaretool for cycle and energy efficiency analysis

• Integratedenergyconsumptionmeter in drive controllers (kWh metering)

Mechatronic support service

•Holisticanalysisofthemecha-tronic behaviour of the system to achieve optimum process and energy efficiency

•Useofarangeofsimulationtoolsand models

8 Scalable hardware architecture

Scalable hardware architecturefor maximum efficiency

Consistent automation system for drive and controller-based applications

Open communications standards and standardized IEC 61131-3 compliant PLC platform

End-to-end SERCOS III system bus for controllers, drives, I/O and safety devices

Standardized IndraWorks engineering framework for motion, logic, HMI and drives

Plug-and-play system solutions and application-specific technology functions

Single-axisDrive-based

Ethernet

PROFIBUS

Ethernet

MLD

HMI

I/O

Drives

IndraMotion MLD-S

Multi-axisDrive-based

Ethernet

PROFIBUS

Ethernet

MLD

HMI

I/O

Drives

IndraMotion MLD-M

Multi-axisController-based

Cross Communication

PROFIBUS

MLC MLC

Ethernet

HMI

I/O

Drives

Hydraulics Pneumatics

HMI

DDL

IndraMotion MLC

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BenefitsThe integrated firmware functions of the IndraDrive drive system allow you to realize common forming tasks particularly quickly, e.g.:• Electronicmotionprofile• Camtables• Positivestopdriveprocedure• Measuringwheelmode• Redundantmotorencoder• Redundantpressencoder• Virtualmasteraxisgenerator• Parametersetswitching• Positioningblockmode

(up to 64 position sets)

Integrated technology functions

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Large-scale and sophisticated applications can be handled with particular ease with our ready-to-use function libraries and pre-defined technology functions.You then use the IndraWorks engi-neering framework to add these functions to your applications pro-gram and speed up configuration and parameterization of the entire system.

Integrated technology functions –easy engineering

PortfolioThe rapid implementation of complex automation tasks is enabled by a large portfolio of tailored technology functions:• Perforationfeeder• Flyingshear• Crankkinematics• Programmablelimitswitches• Preventivediagnosis• Crosscommunication• Crosscutter/rotaryshear• Loopcontrol• Winder/unwinder• Tensioncontrol• Gantryaxes• Master/slave• Feeder• FlexProfile• Realmasterencoder• Robotickinematics

10 Turn-key single-axis solutions for rollfeeds

BasedontheIndraDrive,theintelligent drive platform, and the drive-integrated single-axis automationsystemMLD-S,IndraMotion for Metal Forming offers plug-and-play solutions for rollfeeder applications. The predefined rollfeed solutions are available in two variations to ensure rapid implementation and com-missioning of your application:• RollfeedStandard(RFS)• RollfeedExtended(RFE)

Rollfeed Standard (RFS)This is the complete single-axis controller for standard rollfeeder systems and includes the operator controlunitsandHMIs.Noneedtoprogram–justenterthe production data and production can begin!

Rollfeed Extended (RFE)RFEoffersallthefunctionsof RFSaswellasthefollowing:• 8toolsincludinginput

or time acknowledgment• Integratedprogrammablelimit

switches(PLS)(8PLSin250µs)• Pressencoder• Partandproductdatalinking

(batching)

Rollfeeders – turn-key single-axis solutions

Single-axis Drive-based

IndraMotion MLD-S

Ethernet

PROFIBUS

Ethernet

MLD

HMI

I/O

Drives

Rollfeed

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BenefitsCut your engineering and training costs:• Lessinstallationexpensethanks

to configured versions• Rapidcommissioningandshort

initiation periods due to menu-driven navigation

• Scalableinpowerandfunctionality• Integratedsafetytechnology

conforming to EN 954-1, Cat. 3• Widerangeofhigh-dynamic

rotary and linear motors

Minimize your maintenance and operating costs:• Easydeviceexchangethanksto

central data storage on flash card (MMC)

• Useofflashmemoryremovesthe need for batteries for data buffering

• Unifiedcontrolplatformreducesvariants and number of spare parts

• Energysavingsandreductioninmechanical wear due to auto-matic feed angle adjustment and higher-order motion profiles

l Standard m Option t In preparation1) Advanced control unit 2) With basic „Starting lockout“ control unit

Roll feed solutions RFS RFE1)

Operating modes (Parameter, Manual, Automatic, Setup) l l

Feed before press (single stroke, continuous)

Press before feed (single stroke, continuous)

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Product counter l l

Clear text diagnosis

Multilingual operator terminal

I/O status

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Production data

• Feed angle utilization as %

• Strokes per minute

• Average web speed

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Measuring wheel m m

Analog speed override l1) l

Micro-adjust l l

Roll lifting (Manual/Auto) l l

Data management for 99 products

• Feed length

• Speed

• Acceleration

• Jerk

• Piece counter

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Flash card (MMC) for central data storage l l

Preconfigured HMI screens l l

PC-less commissioning l l

Serial pass-through mode (2 x Com-Port)

e.g. for communication with the press controll l

Control communication

• Parallel/PROFIBUS

• DeviceNet/SERCOS III

m/mt/t

m/mt/t

Start/Stop/Cycle Stop l l

Reset product counter, piece counter l l

Flexible I/O-Logic l t

Integrated safety technology certified to EN 954-1, Cat. 3 m2) m

Master axis coupling (motion profiles) via virtual or real encoders l l

Press encoder interface – l

Up to 6 feed lengths per product – l

Batching (linking of products), up to 594 feeds – l

Tools before and after the feeder – 8

Automatic feed angle optimization – l

Number of PLS (integrated, dynamic programmable limit switch) – 8

12 Turn-key solution for flying shear

Rollerprofiles,weldedpipes,par-ticleboards and press profiles place high demands on production and storage.Uninterruptedproductionis the most cost-effective option for these products and sometimes it is even essential. The products cannot be coiled up and must therefore be cut to length immediately after pro-duction.Designed to meet exactly these requirementsisRexroth’splug-and-play IndraMotion for Metal Forming SPFsolution(SynchronousProcessFlyingShear).

The complete package is com-prised of an IndraDrive drive con-troller with integrated motion logic (IndraMotionMLD),aHMI,a wide range of rotary and linear motors and preassembled cables. The intuitively serviced Indra-Works engineering framework makes the job of commissioning much simpler. The system can optionally be expanded to meet your specific requirements by addingadditionalI/Omodulesor external encoders.

Flying shear – turn-key solution for continuous production

Single-axis Drive-based

IndraMotion MLD-S

Ethernet

PROFIBUS

Ethernet

MLD

HMI

I/O

Drives

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Features• Optionof3differentmodule

system modes• Toolandproductdataadminis-

trator included• Advancesignaltoprestart

hydraulic and pneumatic system valves

• Integratedcropcut,immediatecut and test cut

• Integratedsafetytechnologycon-forming to EN 954-1, Cat. 3, plus auxiliary monitoring sys-tems for maximum part lengths, traversing ranges, etc.

• OpenPLCinterfacesforversa-tile, specific optimization alter-natives

Additional axesThe integrated cross communi-cation module (CCD) enables additional axes such as tool axes to be controlled. The cross commu-nication is based on the powerful,

service-provenSERCOSIIIproto-col and therefore offers the highest possible precision and speed based on Ethernet.

Benefits • Easyimplementationofcomplex

processes thanks to plug-and-play solutions

• Highdegreeofflexibilitythanksto the open PLC interface

• Simplifiedimplementationofmodular control concepts

• Eliminationofexternalcontrol-lers offers potential for savings

• Increasedproductivitythankstoelectronic cams and high-perfor-mance drive technology

• SafetyonBoardtominimizeidletime

• Absoluteprecisionthankstofastest possible probe processing

• Scalabledrivetechnologyreducesplurality of models

l Default m Optional t In preparation1) Advanced control unit CSH01.2 incl. CCD

Flying shear SPF 1)

Operating modes

• Parameter, manual, automatic l

• Test mode (Simulation mode) l

Various cutting modes, like crop cut, immediate cut, test cut and inhibit cut

l

Preconfigured HMI screens l

Clear text diagnosis l

Multilingual operator terminal l

I/O status l

Simple start-up

• Direct access to all parameters via HMI and PC l

• Preconfigured screen masks on HMI and PC l

Second encoder (measuring wheel) l

Safety technology conforming to EN 954-1, Cat. 3

m

Tool management l

• User-defined tool programs 20

Product management l

• User-defined parts 100

Presignal l

Monitors maximum part length and material length pulse

l

Control communication system via parallel interface and field buses (e.g. PROFIBUS)

l

Flash card (MMC) for central data storage l

Optimized return l

Registration mode (3 modes)

• Expectation window for corrections l

• Cut on registration signal (incl. mask out section and offset dimension)

l

• Counter mode (incl. offset) l

Probe input for maximum precision 4 µs

Handling of short parts l

Bad material detection l

Ethernet communication to PC and HMI l

SERCOS III Ethernet interface l

SERCOS III BLOCk I/O (16DI/16DIO)m

(up to 4)

Control of additional axes via CCD m

Flying shear systems

14 Rotary shear technology function

A rotary shear is generally based on a rotating cylinder with one or more knives attached to it. During rotation the knives swing into the path of the material as it is mov-ing along and cuts it at a precisely defined position. In most cases the cutter unit has to be moving in perfect synchrony with the speed of the material. In some applica-tions, however, the knife is moved fractionally faster than the material (overspeed factor). It may also be necessary, because of the geometry of the knife, for the speed to be adjusted to a position-dependent characteristic during cutting in order to keep the parts of the knife exactly in synchrony with the speed of the material.

Features• Largeformatrangefromfactor

0.2to30• Overspeedinthecuttingrange• cosine-betacompensationfor

thicker materials• Push-outfunctionforselective

separation of cut products• Slippageandoffsetcompensa-

tion • Measuringwheel• Exampleapplicationsprogram

contains machine functions, suchascrop/endcut,cuttingprogram,lockon/off,cuttingcounter, etc.

• Auto-tuningassistant• Commissioningassistanceusing

a graphic operator interface

BenefitsIncreased productivity:• On-the-flyformatchangeover

using electronic synchronization• High-precisiondrivesynchroni-

zationusingaSERCOSIII• Preventivediagnosticsandmain-

tenance• Drive-integratedsafetytechnol-

ogy to minimize idle time

More flexibility:• Standardizedcommunication

interfacessuchasPROFIBUS,DeviceNet, Ethernet

• Openprogrammingstandards(IEC 61131-3, PLCopen)

• Scalablemotioncontrolsolution,from 1-axis rotary shear to auto-mation of a complete strip line

• Suitableforrotarycuttersandguillotines

Highreductioncosts:• Process-specificfunctionlibrar-

ies and technology functions• Consistentsystemsoftware

boosts engineering efficiency• Fewerrejectsthankstohighest

possible cutting precision• Optimizedcamsforminimal

energy consumption

Rotary shear – technology function for rotary cutters and shears

Single-axisDrive-based

IndraMotion MLD-S

Ethernet

PROFIBUS

Ethernet

MLD

HMI

I/O

Drives

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Rotary shear (guillotine)

Typical profile for short format lengths

l Part of the technology functionm Part of the example applications program or an option

Rotary shearTechnology

function

System platformIndraMotion MLD, MLC

Operating modes

• Parameters (entry of plant data) m

• Manual (jog) m

• Automatic m

• Test mode (Simulation mode) m

Format lengths (x-times synchronous format) 0.2 to 30

“On-the-fly” format changeover l

One or more (equidistant) knives l

User selectable cutting range l

Various compensation profiles

• Overspeed in the cutting range l

• Cosine compensation in the cutting range l

• Push-out function l

Combination of cosine compensation and push-out l

Oscillation, incl. oscillation limitation l

Energy-optimized operation (acceleration-optimized, torque-optimized, etc.)

l

Real and virtual master axis encoders l

Measuring wheel l

Slippage and offset compensation m

Correction factor for measuring wheel feed constant m

Automatic cutting profile creation l

Option of 3 cam resolution levels l

Cutting counter l

Control communication via parallel interface or field bus

l

Production data display

• Actual cut length of product m

• Next product length m

Graphical programming and commissioning support

m

Safety on Board compliant with EN 954-1, Cat. 3 m

Ethernet communication to PC and HMI m

SERCOS III Ethernet interface m

SERCOS III Block I/O (16DI/16DIO) m (up to 4)

Control of additional positioning axes via drive cross communication (CCD)

m

A graphic operator interface supports commissioning

16 Multi-axis solutions for blanking lines

IndraMotion for Metal Forming is the scalable automation solution for complex applications such as blanking lines, flying shear systems and profiling systems. IndraMotion MLD-M, the drive-based control system, and IndraMotion MLC, the controller-based multi-axis control, are the ideal foundation.Extensive firmware and technol-ogy functions are available end to end for both platforms. Equipping individual stations or automating a complete system from the uncoiler via the straightener to the feeder –whateveryouwanttodo,themodular system will meet all the requirements of your business.

Bothsystemsofferthefollowing:• Communicationwithhigher-

level control systems• ModularI/Ocomponents• Internationallyrecognized

interfacessuchasSERCOS,PROFIBUS,DeviceNet,parallelinterface and multi Ethernet

• Standardizedengineeringframe-work

• IEC61131-3andPLCopen-compliant programming

• Virtualandrealmasteraxes

IndraMotion MLD-M is designed forapplicationswithupto8axesandlowrequirementsonI/Operipherals and sensors. Fully integrated into the drive unit,it allows the performance capabil-ity of this modular and flexible drive system to be utilized to the maximum.

IndraMotion MLC is the right choice if you want to automate a systemwithmorethan8axesand/or have enhanced requirements on your peripherals. IndraMotion MLC also permits cross commu-nication with additional control systemsthroughSERCOS.

Blanking lines – automated intelligently with multi-axis solutions

Multi-axisController-based

Cross Communication

PROFIBUS

MLC

Ethernet

HMI

I/O

Drives

Hydraulics Pneumatics

DDL

IndraMotion MLC

Multi-axisDrive-based

Ethernet

PROFIBUS

Ethernet

MLD

HMI

I/O

Drives

IndraMotion MLD-M

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Features• Opensystemarchitecturethanks

to support of all common field bus systems, Ethernet, OPC and SERCOS

• Flexible,high-performancemotion logic integration

• Systemsolutionwithcontinuityfor all applications in the press shop

• Fullrangeofhighdynamic,robust servo drives

Benefits• Greatermachineavailability

because of the reliable drive and control equipment and global support

• Higherstrokenumbersduetothe high dynamic servo axes and short system cycle times

• Protectionofthemechanicalsys-tem through selectable sequences ofmotion–highdynamicorsoft motions depending on the respective part and material

• Fastproductchangethanksto

shorter tool set up times• Lowenergyconsumption

through DC links of all axes

Handling and transport systems with Rexroth servo drives remove, transport and stack the finished parts. Fast unloading of parts makes it possible to realize high production rates.

The frequency converter is capable of energy recovery from the main press drive, so reactive power compensation equipment is no longer required

A high dynamic servo drive system feeds the material into the press precisely and reliably. The synchronization with the press is effected through cam switches or alternatively through electronic cams via a press encoder.

Straightening unit driven by a Rexroth drive

Drives by Rexroth for precise tension control and hydraulic coil changing system

18 New concepts for electronically controlled press transfer

IndraMotion for Metal Forming replaces expensive, high mainte-nance mechanical elements in your press transfer system: for example, high-precision servo drives are used instead of cams or program-mable limit switches. Furthermore, the highly valuable flexibility of the motion control system, which is achieved through the program-mable motional sequences, enables new machine concepts to be real-ized which ensure high precision synchronizationofallprocesses–also between the electronically controlled press transfer and hydraulically controlled press.

Features• Opensystemsolutionwith

standardized interfaces to any PLC, PC or field bus

• Expensive,inflexiblemechanicalcams are replaced by electronic cams

• Exactelectronicsynchronizationof the press transfer for maxi-mum press strokes

• Settinguptransferandtoolingthrough a virtual master axis and checking for existence of obsta-cles

• Dynamicswitchingofpressencoder and virtual master axis with cycle end and block restart

• Adaptablefilteringofpressencoder

• Integratedprotectivefunctions,e.g. redundant motor and press encoders

• Strategicavoidanceofcollisionsin the event of power failure, including programmable error reaction

Benefits• Higherstrokenumbersdueto

the high dynamic servo axes and short system cycle times

• Shortertoolsetuptimesduetothe fast adjustment of all motion functions for the current part being manufactured

• Optimized,faultlessparthan-dling in all operating modes

Electronically controlled press transfer – new concepts for absolute precision

• Protectionofthemechanicalsys-tem through selectable sequences ofmotion–highdynamicorsoftmotion depending on the respec-tive part and material

• Avoidanceofcollisions,down-times and repair costs

Multi-axisController-based

Cross Communication

PROFIBUS

MLC

Ethernet

HMI

I/O

Drives

Hydraulics Pneumatics

DDL

IndraMotion MLC

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The Rexroth motion control solution coor-dinates the movements of all axes and the addressing of the I/O logic in all operating modes, thus ensuring precise synchroni-zation between transfer and press

Regenerating and maintenance free frequency converter as main press drive

Intelligent servo drives for high dynamic gripping, lifting, and transport of the parts between the press sections. Synchronization with power failure pro-tection due to DC bus coupling to the main drive. Collisions between tool and transfer are avoided by using redundant motor encoders.

Finished parts of the highest quality, produced with maxi-mum stroke rates and minimum scrap

Hydraulically controlled Rexroth coupling and brake combination

Use of a redundant press encoder enhances machine safety

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20 Automation of crossbar transfer and compact crossbar transfer systems

IndraMotion for Metal Forming byRexrotheconomicallyandaccu-rately synchronizes all axes of the (compact) crossbar transfer system –fromtheunstackingdeviceviatool cars and transfer axes to the stacking device and conveyor belts.Thus, up to 64 controls synchro-nize with a maximum of 64 servo drives on each control. Faster start up, easier servicing and enhanced reliability thanks to the decentral-ized, modular system architecture.

Features• Opensystemsolutionwithstan-

dardized interfaces to any PLC, PC or field bus

• Expansionofthehighprecisionsynchronization up to 64 con-trols

• Exactelectronicsynchronizationof the transfer to the press and between each individual modular transfer system for maximum press stroke rates

• Settingupofthepresstransferand tooling through a virtual master axis and checking for existence of obstacles

• Dynamicswitchingofpressencoder and virtual master axis with cycle end and block restart

• Adaptablefilteringofpressencoder

• Integratedprotectivefunctionse.g. redundant motor and press encoders

• Expensive,inflexiblemechanicalcams are replaced by electronic cams

• Strategicavoidanceofcollisionsin event of power failure, includ-ing programmable error reaction

Benefits• Higherstrokenumbersdueto

the high dynamic servo axes and short system cycle times

• Shortertoolsetuptimesduetothe fast adjustment of all motion functions for the current part being manufactured

• Optimized,faultlessparthan-dling in all operating modes

• Protectionofthemechanicalsys-tem through selectable sequences ofmotion–highdynamicorsoftmotion depending on the respec-tive part and material

• Partsorientation,includingparts with complex geometries, between the tools thanks to high dynamic servo axes

• Fasterstartup,easierservicingand high reliability thanks to the modular system structure

• Avoidanceofcollisions,down-times and repair costs

Crossbar transfer and compact crossbar transfer systems – modular and flexible automation

Multi-axisController-based

Cross Communication

PROFIBUS

MLC

Ethernet

HMI

I/O

Drives

Hydraulics Pneumatics

DDL

IndraMotion MLC

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All movements of the servo axes are referenced to the press motion through electronic cams via redundant press encoders or a virtual master axis

Efficient production at increased rates thanks to the system solution with motion control and servo drives

Protective functions such as redundant motor and press encoders ensure that the production system is safe

Optimization of transfer motion of every modular transfer module using freely programmable motion profiles

Compact crossbar transfer systems

Crossbar transfer systems

Maximum availability and production output performance with motion control and servo drives

Reliable production due to well established strategies for collision avoidance

22 Motion logic integration for tandem press lines and feeder

Features• Precisecoordinatedmovements

from setting stations to the com-plex kinematics of part loading robots

• Electroniccamsforprogram-ming smooth motion processes

• High-performance,flexibleprogramming system for online warning and collision avoidance

• “ProductivityAgent”forpreven-tative maintenance scheduling

• Fastrestartswithoutresettingofzero or reference points is made possible by absolute encoders

• Crosscommunicationbetweenthe control systems ensures press synchronization

Benefits• Higherstrokenumbersdueto

the high dynamic servo axes and short system cycle times

• Configurablestrategiesforavoid-ing collisions between the press tool and feeder and between the feeders

• Greatermachineavailability• Modularsystemstructurefor

faster start up, easier servicing and high reliability

Tandem press lines and press feeder –innovative motion logic integration

IndraMotion for Metal Forming ensures smooth transfer of parts between presses at high rates and with state of the art safety charac-teristics. This includes control of unstacking and conveying devices, setting stations, orientation sta-tions, part turning devices, tool changing devices, shuttles and the main press drives. Faster start up, easier servicing and enhanced reli-ability thanks to the decentralized, modular system architecture.

Multi-axisController-based

Cross Communication

PROFIBUS

MLC

Ethernet

HMI

I/O

Drives

Hydraulics Pneumatics

DDL

IndraMotion MLC

22

23

Mot

ion

logi

c in

tegr

atio

n fo

r ta

ndem

pre

ss li

nes

and

feed

er

Expensive collisions and ensuing downtime are avoided thanks to the integrated safety functions

High dynamic servo drives on the press feeders improve parts flow to the tandem press line

Rexroth linear modules with intelligent drives ensure reliable production

The Rexroth motion control solution providing high precision control of complex kinematics for feeder systems

Complex part positioning with a multi-axis orientation station – perfectly coordinated

Regenerating and maintenance free frequency converter as main press drive

24

IndraMotion for Metal Forming opens up a whole new range of possibilities for your servo presses. The FlexProfile technology func-tion makes it possible to adapt the motion profiles to the metal forming process, the tool and the automation system to optimum effect. This means a significant increase in strokes per minute for the same or even reduced drawing speed.Regardlessofwhethertheservo press is used as an automatic punching and forming unit, a transfer system or cutter press, or integrated in fully automated press lines.

Optimal process adaption for servo presses

Multi-axisController-based

Cross Communication

PROFIBUS

MLC

Ethernet

HMI

I/O

Drives

Hydraulics Pneumatics

DDL

IndraMotion MLC

Servo press – optimal process adaptation and increased productivity

Motion profile of the servo press in normal operating mode compared to an eccentric press

Servo press Excentric press

Motion profile of the servo press in oscillating mode compared to a mechanical press

Features• Opensystemsolutionwith

standardized interfaces to any PLC, PC or field bus

• Electroniccams(RexrothFlexProfile) for optimum adap-tation of the motion kinematics to the tool and automation process parameters

• Directpowerinputfromhighdynamic servo drives for main drive

• Fulltorqueavailabilitystartsat strokerateof1stroke/min• Energyrecoverythanksto

regenerating servo drives• Kineticbufferingandcapacities

as backup during power failure and to minimize energy peaks

• Integratedprotectivefunctionse.g. redundant motor and press encoders

• Strategicavoidanceofcollisionsin the event of power failure, including programmable error reaction

• Highprecisionpositioningofthemain drive (press ram) for tool adjustment in tryout mode

Servo press Mechanical press

24

25

Opt

imal

pro

cess

ada

ptio

n fo

r se

rvo

pres

ses

High dynamic regenerating and mainte-nance free servo motors as main press drives. Use of a redundant press encod-er enhances machine safety.

Collisions between tool and transfer are avoided by using redundant motor encoders

In combination with the servo drives the Rexroth motion control solution offers maximum motion model versatility and minimum downtimes

Benefits• Increasedproductionoutput

performance thanks to individu-al adaptation of the motion pro-files to the forming and transfer process

• Processoptimizationbecauseall sub-processes are freely pro-grammable

• Highdegreeofflexibilitythanksto freely programmable ram kinematics

• Shortertoolsetuptimesduetothe fast adjustment of all motion functions for the current part being manufactured

• Highoutputthankstoprogram-mable ram motion kinematics (oscillating mode)

• Flexibletryoutmodepossiblebecause the ram movement is reversible in every position

26

CrossCommunication

Operation

Ethernet

I/O

Drives

Pneumatics

DDL

IndraControl L 3rd partycontrol

Drives

IndraControl L

Drives

Redundant motorencoder

Redundant pressencoder

Hydraulics

System solution and hardware

IndraMotion for Metal Forming meets all control and drive require-ments for press automation. The scalable system concept allows for automation of all types of presses, from simple independent machines to complex production plants. You can rest assured that system inte-gration even into existing plants is easy thanks to the open structure of the IndraMotion MLC motion

control with standardized PLC platform based on the IEC 61131-3 standard and the use of internationally accepted field bus standards. AndwithSERCOSthereisvirtuallyunlimited capacity for expansion of production plants by extending cross communication between controls. Interpolation between electric and hydraulic axes is

possible for IndraMotion for Metal Forming as it is operating the pneumatics system. The central or distributed logic functionality with analoganddigitalperipheralI/Orounds off the system and often acts as a substitute for an addi-tional PLC.

The appropriate system solution for every application with IndraMotion MLC

Motion-Logic – controller-based

24

27

Open hardware options through IndraControl L

IndraControl L, the space-saving control platform, offers you a whole range of expansion options in different classes of performance. With the use of function modules, IndraControl L can be optimally integrated in heterogeneous control landscapes and adapted to your specific functional requirements.

Sys

tem

sol

utio

n an

d ha

rdw

are

MLC functional modules Description

DeviceNet master • CFL01.1-V1• Master functionality for DeviceNet• Transmission rates 125, 250, 500 kB

PROFIBUS master • CFL01.1-P1• PROFIBUS master functionality• With operation of the on board

interface as slave

Programmable limit switch • CFL01.1-N1• 16 outputs• Scanning frequency 125 µs

SERCOS 2 • CFL01.1-R3• Master axis cross communication• Medium: SERCOS FOC• MLC interface with max. 64 MLC• Axis synchronization with MLC

MLC functional modules Description

SERCOS III • CFL01.1-Q2• Control communication• Master axis cross communication• Medium: Ethernet• Data rate: 100 MB

Encoder interface (in development)

• CFL01.1-G1• 1 x Endat interface• For (redundant) real ref. value encoder

Fast I/O • CFL01.1-E2• Fast digital inputs/outputs• 8 inputs, 8 outputs• 8 freely programmable I/O

SRAM (for robot control) • CFL01.1-Y1• Memory: 8 MB• With battery back-up

DeviceNet-Master

SERCOS III

Programmable limit switch

PROFIBUS-Master

SRAM (for robot control)

Encoder interface

SERCOS 2

Fast I/O

28

Blanking line (rollfeed and straightener)

Blanking line (unwinder with direct pull-off, straightener and rollfeed)

Profiling system inc. flying shear system

Blanking line (unwinder, straightener and rollfeed)

Zig-Zag Feeder

System features in detail

System features in detail

Hardware IndraMotion MLD IndraMotion MLC

Number of axes per controller (real, virtual, encoder, network) 8 64 1)

Number of controllers in cross communication network (Cross Communication)

– 64

Supported drives

IndraDrive M, C, Mi, Cs l l

IndraDrive Fc (via Fieldbus) – l

Generic drives with SERCOS pack profiles – l

Hydraulic drives via HNC100 – l

Communication interfaces on board

SERCOS III l l

PROFIBUS V1 master/slave –/l l/l 2)

EtherNet/IP scanner/adapter –/l –/l

Ethernet TCP/IP l l

Master axis interface (Cross Communication) via SERCOS III – l

Inputs/outputs on board

Highspeed digital inputs/digital outputs l 8/8

Drive I/O (depending on configuration) – l

Optional function modules

PROFIBUS V1 master – l

SERCOS 2 master – l

SERCOS III – l

SRAM – l

DeviceNet master – l

Highspeed PLS (125 µs) – l

Fast I/O – highspeed dig. inputs/dig. outputs/configurable – 8/8/8

Master axis encoder – t

Local inputs/outputs

Inline (IP20, digital I/O, analog I/O, temperature, etc.) – l

SERCOS III bus coupler l l

SERCOS III Block I/O (analog/digital) l l

Fieldline (IP67) – l

HMI connectivity

IndraControl VCP (controller-based) Ethernet

IndraControl VEP (embedded PC) Ethernet

IndraControl VSP (industrial PC) Ethernet

l Standard1) IndraControl L40: 32/

IndraControl L65: 643) Technology function in drive

t Available soon 2) IndraControl L40: PROFIBUS-Master/Slave/

IndraControl L65: PROFIBUS-Master

4) Extension pack in drive

28

29

Synchronized rollfeed

(Compact) crossbar transfer

Tandem press line

Servo press

Press transfer

Sys

tem

feat

ures

in d

etai

l

Functions IndraMotion MLD IndraMotion MLC

Motion control

Single axis with torque control l l

Single axis with speed control l l

Single axis positioning l l

Electronic synchronization, phase synchronized l l

Electronic synchronization, velocity synchronized l l

Cams in drive (max. 1024 points) 8 per drive 8 per drive

Cams controller-based – 99

Points table for cam l l

Segmented cam profile (up to 16 segments) l l

Rexroth FlexProfile – l

Virtual master l l

Real master l l

Robot control

Number of kinematics (number of robots) – 16

Maximum number of axes per kinematic – 8

Linear/circular/point-to-point interpolation – l

Movements with blendings – l

Logic control

IndraLogic PLC kernel compliant with IEC 61131-3 l l

Freely configurable tasks (cyclical, free-running, event-controlled)

4 8

Minimal cycle time 1 ms 1 ms

Program memory 2 MB 8 MB

Free memory for retain data 32 kB 256 kB

Technology functions (selection)

Adjusting l l

Rotary shear l l

On-the-fly machining l l

Roll feeder l l 3)

Probe l l

Crank kinematics l l

Loop control – l

Tension control l l

Sensorless winding controller/force transducer/dancers l/–/– l/l/l

Productivity agent l l 4)

Engineering framework IndraMotion MLD IndraMotion MLC

IEC 61131-3 compliant programming languages IL, ST, FBD, LD, SFC, CFC

Cam Editor/CamBuilder l l

Online/offline switching l l

Startup wizards l l

Diagnostics and debugging l l

30 Scalable system components

Scalable system components for flexible automation

IndraControl L – the controller-based control platform

• CentralassemblyforDINrailmounting

• Maximumperformanceinultra-compact terminal format

• 8rapidI/Osonboard• PROFIBUS(master/slave),

RS232andEthernetcommunica-tion interfaces integrated

• IntegratedSERCOSdriveinter-face

• DirectconnectionoflocalinlineI/Os

• Easyexpansionusingfunctionmodules for communication and technologies

IndraControl VCP, VEP and VEH – the convenient HMI terminals

• EconomicHMIsolutionsforallapplications

• WideportfolioofIndraControlVCPcontroller-basedterminals–fromthetext-orientedkeypadunit to the fully graphics-capable touch-screen

• IndraControlVEPembeddedPCterminalswith8.4.”,12.1”or15”touch-screen

• IndraControlVEHembeddedPC-based handheld operator control unit for mobile use

• Interfacesforfieldbus,RS232and Ethernet connection

• Intuitivesoftwaretoolsfortherapid creation of screen masks

IndraControl VPP and VSP – the powerful industrial PCs

• Standardandhigh-endversionswith state-of-the-art processor technology

• WiderangeofpanelPCsandcontrol cabinet PCs with remote displays as well as complete PC HMIs

• Keyortouchscreenversions,withdisplaysrangingfrom12.1“to 15“ in size

• Extensiverangeofaccessoriessuch as terminals, membrane keyboardsandUPS

• IntuitiveconfigurationwithIndraWorksandWinStudio

30

31

Sca

labl

e sy

stem

com

pone

nts

Inline – the flexible I/O system in IP20

• ScalableI/Osystemforcentralordecentral connection

• Maximumselectivityofthedigi-talmoduleswith2,3or4-wiretechnology

• Wideportfoliowithanalog,function, relay and feeder termi-nals

• Toollessassembly• Detaileddiagnosisofallmodules• Space-savingdesign• FieldbuslinkforPROFIBUSand

DeviceNet• I/OsystemsinIP67fortough

operating conditions as well (Fieldline)

IndraDrive and IndraDyn – the scalable drive platform

• Scalableoutputsfrom0.1kWto630 kW

• Highestperformanceandpreci-sion

• SafetyonBoardconformingtoEN 954-1, Cat. 3

• IntegrateddrivePLC(optional)• Powerrecoveryanddirectcon-

nection to mains supply from 380Vto480V

• Infeedingpowersupplyfrom 380Vto690V

• Integratedlinecontactorandbraking resistor

RD 500 SFT – Sinus Fronted Technology

• Sinusoidalfrequencyconverterupto 650 kW with energy recovery

• DCbuslinkwithadditionalaxes• Excellentoperationalreliability

in case of mains power failures• Driveofsynchronousandasyn-

chronous motors, even without transmitters

• Energysavingthrough100%power recovery

• Noharmonicdistortion• Rapidanduniformoperationon

transitions between infeed and recovery

• Noreactivepowercompensationequipment required

• Norequirementforadditionalmains power supply compo-nents, including filter and con-nection technology

Bosch Rexroth AGElectric Drives and ControlsP.O. Box 13 5797803 Lohr, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr, GermanyPhone +49 9352-40-0Fax +49 9352-40-4885www.boschrexroth.com

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 ourinformation. 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.

Presented by:

71 253 AE/2008-11–A1–HWR911326344© Bosch Rexroth AG 2008Subject to revisions!Printed in Germany