Rexroth VISUALMOTIONOpen system solution for packagingand food processing machines

Systematic packing with flexibility and high productivity

VISUALMOTION ensures shortercycle times for your machinery andfaster format changes with higheraccuracy. Rigid mechanical trans-mission elements, such as gears,shafts and cams, are replaced byprecision servo drives, thus simpli-fying machine design.This convincing concept with itsopen architecture earmarks thisautomation system for all areas ofyour production – from the indivi-

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dual machine right up to the inter-linked production plant:

• forming, filling and closing machines

• board-making machines• thermo-forming machines• blister packaging machines• winding applications• filling machines• pick & place robots• foodstuffs processing machines

VISUALMOTION – for improvedcompetitiveness in world markets

The unique modularsystem of VISUAL-MOTION comprisesMotion Control, PLC,and digital drives, aswell as numerouspossibilities for net-working

How can you make packaging and food-stuffs proces-sing machines more flexible and therefore more produc-tive when product life cycles are always getting shorter?With VISUALMOTION, the open control and intelligentdrive system from Rexroth.

As machine manufacturer ormachine operator, utilise the ad-vantages of VISUALMOTION for:

• faster format changes• improved product quality• improved cycle rates• simplified machine design• increased reliability• faster commissioning• simple programming• reduced maintenance

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Open architecture, scalable power

The open system architectureallows machines to be exportedworldwide with the predominantcountry-specific bus systems. Withthis concept, VISUALMOTIONsafeguards investments, standardi-ses production plant and makesproduction processes more trans-parent.This openness promotes problem-free dialogue between hardwareand software solutions from diffe-rent manufacturers.

The control therefore communica-tes via standards that have beenintroduced worldwide. For example:

• SERCOS interface*• PROFIBUS-DP• DeviceNet• INTERBUS• ControlNet• Ethernet• RS232/RS485

Precise, fast-response servo move-ments, as demanded in the packa-ging and food-stuffs industries,can only be provided via the SER-COS interface* – the digital inter-face between control and drive.

With VISUALMOTION’s modularcontrol software you control up to40 axes. At the same time you stand-ardise your specific functions andtransfer these rapidly and easily toother machine units. Field bussystems can be easily adapted bysimply replacing the interface cardsand adjusting the configuration bymeans of a few parameter changes.

Our intelligent drives are alsomodular and have scalable functio-nality. They also cover all typicalpackaging and food industry re-quirements with a power rangefrom 0.1 kW to 75 kW.

*SERCOS interface, the internationalstandardised drive interface (IEC61491/EN 61491) allows trouble-freeoperation between digital drives andcontrollers from different manufactu-rers, while utilising the best possiblecharacteristics of the respective pro-ducts.

Beverage cartoning

Horizontal form,fill and seal

Vertical form,fill and seal

Cartoning

Case packaging

Palettizing

Filling, seamingand capping

Improved transparency throughgraphical programmingThe system can be programmedusing graphics or text. Graphicalprogramming with defined iconsshortens the training time, accele-rates program development andalso makes the production se-quence transparent in the longterm.

Flexible electronics instead ofrigid mechanical systemIn packaging and foodstuffs pro-cessing machines, VISUALMO-TION from Rexroth replacesmechanical transmission elements,such as gears, line shafts and cams,with high-precision, electric servodrive technology.

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All the advantages at a glance

Graphical programming: simple, fastand straightforward

High-resolution electronic cams re-place expensive mechanical ones

Switch cams that can be modified on-line save additional costs of separatecam controllers

Mechanical drive solution: Traditionaldrive systems are very complex, expen-sive and rapidly wear out. Format chan-ges are both time-consuming andlabour-intensive and therefore reduceproduction output.

Rexroth’s electronic system solution:The innovative VISUALMOTION controland drive system synchronises up to 40servo axes with great precision. Productchanges are made virtually at the touchof a button.

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Economic machine designVISUALMOTION controls up to40 axes simultaneously via theSERCOS digital interface. For this,all drives are integrated in a fibre-optic ring. You therefore reducethe amount of cabling, simplify theinstallation and improve the dia-gnostic capability at the same time.If the requirements change, indivi-dual drives can be easily deactiva-ted, replaced or added withouthaving to revise all the controlsoftware.

Simple commissioning

As when programming the control,the drives are also rapidly and con-veniently commissioned via the PCwith graphics support. You adaptand optimise VISUALMOTION toyour machine by simply enteringparameters.The drive is permanently moni-tored to ensure maximum opera-tional reliability and machineavailability.

Plain language diagnostics

The built-in diagnosis tools dis-plays your parameters, variablesand registers and therefore assistsyou during system optimisation.Plain language diagnostics helpyou in rapid troubleshooting. Thediagnostic messages are recordedin a logbook.An integrated oscilloscope keepsyou in the picture about the drivespeed and capacity utilization.

Comprehensive functionality andalways the correct operatingmodeWhatever the requirements youplace on your machine, the variousoperating modes meet them:• electronic synchronisation with

virtual or real master for:- speed synchronisation mode- angular synchronisation mode- electronic cam

• path interpolation for up to 3 axes

• single axis operation for event-controlled positioning of single axes

Improved productivity,fewer bottlenecksThe sequential arrangement ofpackaging lines often means thatfaster machines are not fully utieli-sed because product jams occur onslower machines. Eliminate thesebottlenecks with VISUALMOTIONby increasing the cycle rates ofupstream machines, thus increa-sing the throughput of the pack-aging line.

Improved machine availabilityThe intelligent drive technologyuses absolute position measure-ment and automatically recognisesall current axis positions. Thisallows the machine to be restartedat any time without further refe-rencing and synchronisation.

Format change at the touchof a buttonWith VISUALMOTION changeyour production for reformulationor a packaging change – withouttools and in minutes instead ofhours. All transmission gear ratios,cam settings and motion profilescan be changed electronically –virtually at the touch of a button.

With Rexroth servo performance,mechanical packaging line bottle-necks are readily overcome. You canachieve a better balance betweenmachine speeds. And you can in-crease line throughputs withoutjamming or registration problems.Our open architecture approachhelps you reduce training, com-missioning and manufacturing

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One control strategy, from start to finish

Perfect synchronization between filler and seamer eliminates all mechanical linkages and associated maintenance

SEAMER FILLER

Make programmable velocityand position adjustmentsbetween filler and seamer

Make coarse andfine adjustments on the fly

costs. Our connectivity givesyou timely access to productionmanagement information.

Synchronizing the filler and seamer/capperFillers, seamers and cappers arehigh throughput machines withlarge inertial loads. The motor,gearbox and lineshaft connectingthem are maintenance intensive.

Can seamers in high volume plantsrequire rebuilds as often as every 3years. Electronic line shafting (seedefinition, page 4) can double ortriple the service life – paying foritself in the first year of operationthrough reductions in spares andmechanical maintenance.

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Increasing throughput with conti-nuous motion beverage cartonersFast servo position loop updatesand high resolution feedback ena-ble you to increase top speeds bytightly performing electronic gea-ring.

Our virtual master feature isolatesmechanical disturbances in mecha-nical lineshafts, assuring tightercontrol over the electronicallygeared servo drives.When changing carton size, youcan configure new geared positionsfor each servo drive at the push ofa button.

One motion controller can synchronize up to 40 axes

GLUE GUNS

Built-in programmable limitswitch function fires glueguns

PRODUCT INSERTER

CARTON FEEDERCARTON CONVEYOR

FLAP TUCKERS

Servo-driven flaptuckers assure qualitysealing and gluing

The flap tuckers canrun different motionprofiles for differentsize cartons withoutmechanical changeo-vers

1,024 point cam soft-ware tables eliminatecostly cam followersand mechanical cams

INFEED CONVEYOR

Fast, jam-free operation forvf/f/s machines

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To manage costs, form/fill/sealmachines must adapt to changingmaterial characteristics withoutgenerating scrap.Rexroth’s controllability accommo-dates different wall thicknesses,surface finishes and resistance tosealing.

Servo drives from Rexroth can alsobe more economical than mecha-nical components. Adding twoservo axes with electronic gearingon a film advance can cost lessthan a single servo driving a dualoutput gearbox.

Fast, smooth operation in vertical bagforming, filling and sealing machines

PHOTO EYE

SEAL BAR

Adjustable dwell controls duration of seal bar clamping

Torque control adjusts seal barpressure

Electronic camming coordinates movement of the seal bars

FILM ADVANCE

High speed registration controlachieves accurate film feed, auto-matically compensates for materialslippage

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Precision equals speed incontinuous motion cartoners

Thanks to multi-axis digitalmotion control, cartoners areusing 5, 10, even 15 servo drives toincrease speed and functionality.

CARTON FEEDERLEFT HAND

FLAP TUCKER

BARREL LOADER

FLIGHT CHAINRIGHT HAND FLAP TUCKER

GLUE GUNS

INFEED CONVEYOR

Electronic camming permitsadjustable flap tucking

Controller functionality includes built-in16 channel programmable limit switchcapability for glue guns

PHOTO EYE

Absolute feedback automatically keeps track of all axis positions, eliminating theneed to re-home and resynchronize if a jam does occur

FILM TENSIONER

Servo maintains precise filmtension for proper registra-tion

PHOTOEYES

PRODUCT INFEED

Servos run one or more gapping belts faster than the upstream infeed belt to create a gap between products

Intelligent gapping, metering andinfeed means faster wrappingHigh speed wrapping requiresprecise spacing between productson the infeed chain. Electronicgearing synchronizes a series ofbelts running at different speedsin relation to each other and theflow wrapper.

SPACING CONVEYORS

Maintaining registration as flow wrapper speeds exceed1,000 CPMTo achieve higher speeds, flowwrappers must tightly synchronizeproduct and foil feeds, cutting kni-ves and fin sealers. They must alsomaintain precise registration con-trol.

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Servo drives adjust belt speed to control therate of product delivery from gapping belt

COARSE ADJUST

MEDIUM ADJUST

KNIFE

Matches cut point to registrationmark seen by photo eye. Canadjust on the fly for perfect pro-duct cut-off.

Electronic camming adjusts rotaryknife position for package sizechanges – no cams to replace

To execute non-linear knife pro-files faster, high resolution 1,024point software cam tables areavailable in the drive and in themotion controller

LUG CHAIN

Positively locates product within the lugs on thebelt. This servo drive is the master axis fromwhich all other intelligent drives are electronically geared or line shafted.

PHOTO EYE

FIN SEAL

Provides longitudinal sealsand matches foil speed to lug chain speed

OUTFEED BELT

Runs slightly faster thanupstream belt to keep pro-duct clear at the outfeedsection

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FINE ADJUST

Fine speed adjust-ments are based onthe sensed positionof the product, withreference to the lugchain position forproper product place-ment

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INFEED

TIP OVERPHOTOEYE

PICK & PLACE HORIZONTAL AND VERTICAL AXES

CASE FEEDER

Servo indexing is faster than steppers,minimizing back pressure of productentering the case packer

Absolute feedback lets you removejammed product and continuewithout re-homing the machine,saving downtime

COLLATION CONVEYOR

FINAL CONVEYOR

Reliable product handling,orientation and protection

More accurate collation forproduct insertion

Adding performance to case packersWith our economical new ECO-DRIVE, it now becomes cost-effec-tive to automate lower cost machines.High resolution cam tables let casepackers achieve more accurate caseerection and alignment of unstablepackages within cases.

High resolution feedback lets yourepeatably reach stop positions.For case packing robots, Rexrothcan achieve faster coordinatedmotion with powerful kinematicalgorithms. The robot arm maneu-vers product around case sides,optimizing cycle times.

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S-curves speed up palletizersPalletizers are major capital invest-ments that often become down-stream bottlenecks. To keep pacewith the rest of your line, Rexrothcan perform intelligent accumula-

tion and adjust palletizer infeedrates on the fly, based on actualproduct flow.S-curve acceleration profiles rapid-ly but gently accelerate loads for

maximum throughput withoutproduct slippage or damage.Unlike mechanical cams, S-curvesoftware parameters are easilychanged.

Z-AXIS

HORIZONTAL AXIS

VERTICAL AXIS GENTLE S-CURVE ACCELERATION FOR Z-AXIS

ROTATE AXIS

INFEED

PHOTOEYES

PALLET CONVEYOR

DROP GATE

Teach capability allows operators to enter a 3-dimen-sional point in space to set pickup and drop off points.The complex robotic functions are programmed auto-matically.

Dynamic braking provides fast, con-trolled stops, even with heavy loads

Regenerative drive capability returns power back to the 3-phase line, saving energy cost.Rexroth egenerative drives run coolerand require no external bleeder resis-tors, saving cost and cabinet space.

VISUALMOTION from Rexrothcovers all control and drive requi-rements in the automation ofpackaging and food productsmachinery. The scalable systemconcept allows the automation ofsingle machine up to complex pro-duction line. The open system

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structure of the control PPC andthe use of fieldbusses with worldwide acceptance enable an easyintegration, even in existing plants.Various options allow for advancedfunctionality, like: dynamic pro-grammable limit switches (cam-switches), cross communication,

logic control and communicationvia: SERCOS interface, PROFI-BUS-DP, DeviceNet, INTERBUS,ControlNet and Ethernet.Central or decentral I/O with ana-log or digital periphery completethe system and substitude additio-nal PLCs in many applications.

Application success of VISUALMOTION– the flexible control concept of PPC

SpacingConveyors

SpacingConveyors

Palleting

HMI

Ethernet (TCP/IP)

Fieldbus

Cross communication

SERCOSI/O

Packaging lineProduction process

SERCOSinterface

Central anddistributed I/O

Fieldbus Fieldbus

SERCOSinterface

InternetTeleservicingand diagnosis

With a modular system concept, open controls structure and internationally standardized interfaces VISUALMOTION providessolutions for all automation architectures – from the production and the packaging to the dispatch

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Control software• windows-based programming

interface• programming with graphics and

text• fast commissioning via conve-

nient editing• control with multi-tasking

capability• event-controlled programming• electronic cam function built

into control and drive. Online support for cam calculation and editing functions

• electronic cam switchgroup• oscilloscope function• logic task for inputs and outputs

Modular control hardware

• various versions of plug-incontroller cards:- Modular control hardware on

mounting racks - PC-based control hardware as

PCI plug-in card• various plug-in cards for the I/O

interface• on-site diagnostics facility via

built-in displays• bus system connection: PROFI-

BUS, INTERBUS, DeviceNet

Convenient HMI units

• straightforward visualization and diagnosis of system data

• universal operating philosophy• wide range of simple LCD

operator displays – from handy handheld units to PC-basedcontrol terminals

Powerful DIAX drive system

• modular, intelligent drive system for high continuous power levelsup to 75 kW

• power supply modules with direct AC supply connectivity and energy regeneration

• very slim single-axis andtwin-axis control units

• wide range of rotary and linear motorswith extensive choice of ratings

ECODRIVE economical drivesystem

• compact drive system for conti-nuous power ratings up to 24 kW

• space-saving control units with built-in power supply

• wide choice of ratings with rotary motors up to IP68 and linear motors

• plug-in programming and parameterization modules

• auxiliary functions such as:- general cam switchgroup- fast inputs- analogue inputs and outputs

• can also be used as independent single-axis positioning drive withfield bus or parallel interface

The right componentsfor every system solution

12.4 Virtual master 2 2

12.5 Real master 3 3

12.6 Link-Ring Master 1 1(Cross communication)

12.7 Number of masters activated simultaneously 6 6(including group masters)

12.8 ELS groups 8 8

12.9 Superimposed cams ● ●

12.10 Electronic cams 40 40(control side)

12.11 Maximum number of axes with 10/32 10/32control cams

12.12 Dynamic synchronisation between real ● ●and virtual masters

12.13 Simultaneous lock-on and lock-off of ● ●synchronised axes

12.14 Slip monitoring for master ● ●

12.15 Online calculation of cams ● ●

12.16 Online calculation of process-dependent ● ●cams (CAM indexer)

13 Kinematic function ● ●

13.1 Kinematic transformations ● ●

13.2 Linear interpolation ● ●

13.3 Circular interpolation ● ●

13.4 Synchronisation of robot ● ●to master axis

13.5 Absolute co-ordinates ● ●

13.6 Relative co-ordinates ● ●

13.7 Protection zones ● ●

13.8 Teach-in function ● ●

14 Programmable limit switches (PLS-control side) 2 x 16 2 x 16

14.1 Online modifications ● ●

14.2 PLS – lead time ● ●

15 Predefined functions

15.1 “Flying Shear” ●

15.2 Registration function ● ●(registration mark control)

16 Diagnostic log file 100 100(number of diagnoses)

17 Oscilloscope ● ●

17.1 Number of channels (control side) 3 3

17.2 Number of channels (per axis) 2 2

18 PC based End-User Tool for ● ●Diagnostic, Archive etc.

19 Remote support with modem ● ●

19.1 TAPI-Interface ● ●(Microsoft-Telephone Application Interface)

19.2 RS232/RS485 ● ●

Control functions VM08 VM09 Control functions VM08 VM09

1 Control Hardware

1.1 PPC-R01 (Rack) ● ●

1.2 PPC-R02 (Rack) ● ●

1.3 PPC-P (PCI) ●

2 Control options

2.1 PROFIBUS-Slave ● ●

2.2 DeviceNet-Slave ● ●

2.3 INTERBUS-Slave ● ●

2.4 ControlNet-Slave ● ●

2.5 Ethernet (TCP/IP) ● ●

2.6 Cross communication ● ●

2.7 Dynamic Hardware-Cam switch 16/32 Bit 16/32 Bit

3 Graphical programming ● ●

4 Textual programming ● ●

5 Debugging-Wizards ● ●

5.1 Program sequence analysis (online) ● ●

5.2 Program structure and write analysis ● ●

5.3 Single step mode (Trace Mode) ● ●

6 User programs (multitasking) 4 4

6.3 Password protection ●

7 Initialisation task (SERCOS phase 2) 1

8 Logic task for I/O 1 1(2 ms or 4 ms equidistant processing)

8.1 Combinatorial and/or ● ●

8.2 Counters ● ●

8.3 Timers ● ●

8.4 One Shots ● ●

8.5 Shift register ● ●

8.6 Latches ● ●

9 Events ● ●

9.1 Time triggered ● ●

9.2 Probe input triggered ● ●(registration input)

9.3 Path triggered ● ●(positioning and path interpolation)

9.4 I/O triggered ● ●

10 Maximum number of axes per control 32 40

11 Single axis operating modes ● ●

11.1 Torque controlled axes ● ●

11.2 Speed controlled axes ● ●

11.3 Positioning axes ● ●

12 Electronic line shaft (ELS) ● ●

12.1 Phase synchronised axes ● ●

12.2 Velocity synchronised axes ● ●

12.3 Electronic cams ● ●

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Functional overview

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Motorola Power PCMicroprocessor

4 MB FLASH (PSM PC-Card)64 KB nvRAM

Program and data memory

1 for PPC-R01.23 for PPC-R02.2

Optional extension cards

make contact Un = 24 V, Imax = 150 mAWatchdog relay

RS232/RS422/RS485Maximum transmission rate 115.200 Bd(D-SUB, 15-way, female)galvanic separated

Programming interface (PROG)

max. 2 x RS232/RS422/RS485Maximum transmission rate 115.200 Bd(D-SUB, 15-way, female)

Serial interfaces (COM)

IP20, EN 60529, VDE 0470Protection rating

Optional (with additional battery)Real time clock

using RMB02.2 rackson TS 35 x 27 x 15 DIN rail

Mounting

24 VDC (- 15... + 20 % to EN 61131-2)max. current consumption 0,7 A (PPC-R01)

1,2 A (PPC-R02)

Supply voltage

Judgement criterion B to EN 61000-4-2 (ESD)Judgement criterion B to EN 61000-4-4 (Burst)Judgement criterion B to EN 61000-5-5 (Surge)

Electromagnetic compatibility (EMC)

3Digital inputs for software interrupts

Four digit display for status and diagnosisSERCOS interface (for up to 40 axis)

Others

Description

Hardware specifications

PPC-R hardware is available with 1 or 3 expansion slots. Optionally configurable are all standardized fieldbus interfaces“control to control” cross communication, a dynamic CAM-switch card and a network communication interface for Ethernet.

Optional extension cards

PPC-R01 PPC-R02

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6-D

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RM

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2-D

C02

4

RM

E02

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6-A

C11

5

RM

A02

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6-D

C02

4-20

0

RM

A02

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2-D

C02

4-05

0

RM

A02

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6-A

C23

0-20

0

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6-R

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0-20

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RM

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RM

B02

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Flexible I/O-periphery

Declaration Description

with 4 SlotsRMB02.2-04

Decentral SERCOS coupling unit for I/O peripheryRMK02.2-LWL-SER

16 Inputs (24 VDC) arranged in 2 isolated groupsRME02.2-16-DC024

32 Inputs (24 VDC) arranged in 4 isolated groupsRME02.2-32-DC024

16 Inputs (115 VAC/60 Hz) arranged in 2 isolated groupsRME02.2-16-AC115

16 Outputs (24 VDC/2 A) arranged in 2 isolated groupsRMA02.2-16-DC024-200

32 Outputs (24 VDC/0,5 A) arranged in 4 isolated groupsRMA02.2-32-DC024-050

16 Outputs (230 VAC/2 A) arranged in 2 isolated groupsRMA02.2-16-AC230-200

16 Relay (switching capacity 200 W) arranged in 2 isolated groupsRMA02.2-16-RE230-200

2 isolated input channels with separate constant current source (2,5 mA)1 analog output (voltage output ± 10 V or current output (0 - 20 mA))

RMC02.2-2E-1A

Digital inputs

Relais

Analogin- and outputs

Digital outputs

SERCOS coupling unit

Base rack

Up to 4 base racks connectable i.e.:• Up to 15 I/O modules

with PPC-R01• Up to 14 I/O modules

with PPC-R02• Up to 15 I/O modules with

SERCOS-coupling unit RMK02.2-LWL-SER forevery decentral I/O unit

The wide spectrum of I/O cards covers all requirements of industrial automation

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Compact dimensions

189 mm182 mm

217

mm

77 m

m

RME02.2-32-DC024 RME02.2-32-DC024 RMA02.2-16-AC230-200 RMA02.2-16-DC024-200 RMA02.2-32-DC024-050

42 mm PPC-R01

84 mm PPC-R02

194

mm

115

mm

54,5 mm

56 mm

184 mm

RECO

PPC-R02.x

approx. 286 mm

PCMCIAFLASH

Memory card

DIN rail

TS 35 x 27 x 15