Drives and Controls

Economical and intelligent: Handling solutions re-conceived

Guest contributor: Andreas Gryglewski, Bosch Rexroth

The market for handling and robotic solutions is highly price-driven, yet still leaves room for disruptive ideas. Bosch Rexroth provides proof of this with an advanced solution package for Cartesian kinematics. It combines an economical industrial controller with state-of-the-art web technology and assured instruction via a standard tablet. The result: minimum investment costs and maximum efficiency – before and during operation.

Manufacturers of handling solutions for loading and unloading face fierce competition. The volume market demands cost-optimized, rugged and user-friendly solutions that optimally fulfill all requirements in terms of accuracy and cycle times. In addition, users expect quick commissioning with as little programming, instruction and training expenditures as possible. A high degree of productivity and flexibility is also required for the operational phase in order to reduce downtime and so that format or process changes can be more quickly implemented.

All of these requirements are addressed by Bosch Rexroth with a particularly economical solution package for Cartesian kinematics that combines a high-performance motion controller with state-of-the-art web technologies and innovative value-added features. The automation experts make the solution package even more economical with an especially clever idea: users can perform the setup and assured teaching-in on any standard commercially available tablet.

Industrial control, web technology, consumer tablets

In its solution package for Cartesian kinematics, Bosch Rexroth combines a powerful motion controller with modern web technologies and innovative value-added features.

The disruptive solution approach for Cartesian handling from Bosch Rexroth is particularly suitable for machinery manufacturers and end users who want to implement flexibly and reliably adaptable pick-and-place tasks in a short time and at a low cost. Examples include the loading and unloading of injection-molded parts, the sorting of workpieces, or a wide range of intralogistics applications. Bosch Rexroth combines its proven industrial controller with a webserver and a bracket for a typical standard tablet, by means of which the user can visualize the connected handling solution and – graphically-supported – program, teach-in and adjust it as needed. The solution package is comprised of other basic components such as compact servo motors and drives for the kinematics movement, as well as a safety controller for connecting to the tablet bracket for safe teaching-in. From a single source, Bosch Rexroth also optionally offers the mechanical equipment, includinglinear axes with a belt or ball-screw drive and grabbers.

The utmost in connectivity and IT security

In its new handling solution, Bosch Rexroth placed special emphasis on the two key properties of i4.0 –connectivity and IT security. While the optional IoT Gateway ensures the horizontal and vertical networking, the security router with a newly developed IoT firewall, which is also optional, guarantees secure communication between the tablet and controller. Consequently, unauthorized persons can neither log into the controller nor can a virus attack the controller or spread throughout a company’s IT network.

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Thanks to the newly developed solution packages, handling systems from Bosch Rexroth can be more quickly commissioned, easily programmed, and taught most economically using standard tablets.

Easy commissioning without parameterization

One of the numerous unique features is the operating concept for the handling solution: Immediately after a servo motor is connected with a drive, the latter reads out the stored parameter set from the feedback memory and thus already has all the characteristic data of the mechanical equipment. The result: a considerable time savings and prevention of errors during commissioning, because the user no longer has to manually enter up to 70 parameters. When Rexroth mechanical equipment is ordered in the future, the parameters will be stored in the feedback memory of the motor while still in the plant. If the user puts his own mechanical equipment into operation; the associated parameter file can also be stored in the feedback memory and is efficiently read into the drive upon connecting.

Safe teaching-in using a standard tablet

The disruptive character of the new handling solution becomes clear during setup, which can be performed wirelessly with almost any consumer tablet. It is expeditiously fastened in a bracket especially developed by Bosch Rexroth for teaching-in, which can be adjusted to the respective size and securely encloses the mobile device. On the top left is a combination emergency stop and enabling button that makes reliable and comfortable teaching-in possible for the user. While the left hand holds the tablet and can press the red button, the right hand is free for other operational tasks. The visualization and operation of the handling system is web-based and applies the HTML5 standard, hence is independent of the tablet OS. An optional security router with an integrated firewall provides for IT security.

Programming without programming knowledge

Bosch Rexroth also made the process programming, which precedes the teaching-in sequence, as uncomplicated as possible. Because it uses the graphical programming language Google Blockly, as is the case with the tablet, no programming skills in conventional terms are required. In order to move an axis from point A to point B, for example, only the start and end positions need to be specified, and a line to connect them with each other. The grabbers are also opened or closed by means of graphical elements. Thanks to variables, logical expressions and loops, it is possible to easily specify and clearly represent various processes, also complex ones if necessary.

Features for increasing productivity and quality

Positively contributing to the performance of an especially economical operating phase of the new handling solution are its versatile functions and expansion options. These ultimately also afford the user a high degree of flexibility for changes in process or format. For example, the Active vibration damping function, which provides greater product quality in combination with a sensor, or initiates the exact countermovements in the open-loop process in the linear module in order to prevent undesirable vibrations or to move sensitive products. Thus, for instance, the utmost in accuracy can be achieved when loading and unloading using the grabber sparing the mechanical equipment for a longer service life.

Preventive maintenance and IoT integration

Preventive maintenance can also be cost-efficiently realized in combined usage with the optional IoT Gateway. In order to collect data for analysis and evaluation of the service life, the motor decoder can also be used as an intelligent sensor. If the motor revolutions are converted into linear movements, the timing for lubrication intervals or the replacement of components can be derived, for example. Communication standards such as OPC UA can provide for easy integration into customer-specific IoT systems as needed.

Economical in every way

The solution package is especially suited for pick-and-place tasks that must be quickly and flexibly adaptable – such as for the loading and unloading of injection-molded parts, the sorting of workpieces, or for various intralogistics applications.

 

With the new solution package, Bosch Rexroth introduces a fresh impetus into the competitive market for Cartesian handling. Automation expertise, modern web and IoT technologies, and productivity-enhancing features are combined in a rugged and practical solution concept that takes into account current and future market requirements, and which generates disruptive energy. Consequently, machinery manufacturers and end users find quick and very economical way to implement a reliable, efficient and flexible handling solution that can be commissioned, taught, and adapted to current requirements without any significant knowledge of programming and parameterization.

Innovative approaches of the new handling system:

  • A comprehensive economic package comprising industrial controller, servo motor, drives, security zone module and teaching-in bracket for consumer tablets
  • Maximum security through a router with firewall (optional)
  • Minimal total cost of ownership thanks to:
    • Commissioning without the need for parameterization: Drives automatically read stored mechanical parameters when connected with a motor
    • Device-independent visualization and operation (HTML5)
    • Safe teaching-in bracket for consumer tablets
    • Simplified process flow design without programming knowledge, thanks to Google Blockly
  • Added value functions for productivity and quality – for example vibration absorption
  • Prepared for data tracking for preventive maintenance
  • Easy integration into IoT systems through open interfaces such as OPC UA

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CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Innovative automation solutions for additive manufacturing 2.0

Guest contributor: Peter Berens, Bosch Rexroth

Additive manufacturing is a growth market – sales worth tens of billions of euros are expected by 2020. However, innovative automation solutions are needed if this disruptive technology is to achieve a breakthrough and make the leap from prototype construction and toolmaking to industrial mass production.

If machine manufacturers want to achieve the productivity needed for mass production, they need to reduce the amount of manual work involved, the reject rate and the quality assurance outlay and successfully integrate the machines into the production line. Both challenges can be met through high-performance, intelligent and connective automation.

IoT as a key technology

In the factory of the future, AM machines will be connected horizontally and vertically to higher-level and neighboring IT systems. When it comes to the industrial Internet of things, Bosch Rexroth relies on open i4.0 standards such as OPC UA. With full server/client functionality, processes, cycle times and energy consumption can be evaluated in real time and optimized to achieve better productivity and quality. In conjunction with intelligent algorithms in drive and control technology, Bosch Rexroth also carries out predictive maintenance.

3D printing and the factory of the future

Thanks to decentralized intelligence, drive technology without control cabinets and open standards, the next generation of AM machines is ready for the factory of the future. Wireless communication and modular production lines increase flexibility while reducing set-up times. As a result, the factory layout can be geared to current and future requirements. The next logical step is the decentralization of the control system which will then receive its programs as necessary from the cloud.

What the hardware must be capable of

Whether it be metal, plastic or ceramic: the output in the relevant AM procedure depends very much on the performance of the CNC or motion control system. The shorter the cycle times, the more quickly the NC programs run. The higher the performance, the quicker 3D data can be computed on the CNC and process data collected and processed in real time. The MTX CNC system from Rexroth achieves this with a combination of a high-performance dual core processor and decentralized intelligence allowing fast reaction times. As a result, many additional tasks can be performed by the machine. Planning, programming and the commissioning of all system components take place in a standardized manner via IndraWorks Engineering.

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Software makes all the difference

In order to be able to control the application of additive materials precisely and to influence it easily with process variables, the control software too must be particularly powerful. The MTX system software includes numerous AM-specific CNC functions for this purpose. These include an intelligent temperature control system and a 3D online simulation with collision recognition which automatically visualizes the construction time, positioning and printing head travel. The standardized G code is supported by any slicer software. Integrated NC encoding systems protect manufacturer-specific know-how.

Digitizing the workflow

Another key development area is the digitization of the workflow with typical tasks such as print configuration, job management, machine monitoring including online process modification or controlling intralogistics. Because this is not possible without interfaces to the software programs involved (e.g. CAD/CAM systems or simulation solutions), the MTX CNC system has an open system architecture and the Open Core Interface. As a result, machine operators can easily integrate their workflows. In a pre-production context, there are numerous benefits including material simulations or the certification of quality-related parameters. The CNC system thus fits seamlessly into simulation environments as “hardware in the loop”.

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Efficient, intelligent and connective: the MTX CNC system from Rexroth. (Source: Bosch Rexroth AG)

Industrial 3D printing in practice

Norsk Titanium AS demonstrates just how efficient industrial 3D printing can be. The world’s leading provider of additive manufacturing technologies for aerospace-grade titanium established the first additive production facility on an industrial scale. In its Rapid Plasma Deposition™ machines, an MTX system controls not only plasma burners but also ten servo axes for producing components and conveying or handling the titanium wire. The MTX system also takes care of process optimization in real time by evaluating sensors and calculating correction values. Bosch Rexroth contributed to the partnership through the experience that it gained during more than 100 group AM projects along with various system components such as drive controllers, supply units, motors and linear systems including the IMS high-precision integrated measuring system.

The German machine tool manufacturer Weisser presented its Weisser additive manufacturing exhibit for the first time at the EMO 2017 and the Metav 2018. Equipped with an additive friction welding unit (AFW), it allows fine layers of metal to be deposited on metal materials and then precision-machined using metal-cutting techniques. As a result, the final contour is maintained with minimal material use. This technology too benefits from the MTX CNC system whose user interface can be integrated seamlessly into the multi-touch operating panel thanks to the open architecture.

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The future will be even simpler

With high-performance and high-connectivity automation solutions, industrial 3D printers will be fast and reliable enough for use in mass production. Open interfaces will help to digitize workflows. IoT connectivity is paving the way for the factory of the future. At the same time, experienced system partners such as Bosch Rexroth who provide not only engineering and application support but also complementary technologies such as decentralized drive or linear technology with integrated sensor systems can help manufacturers to acquire the necessary know-how.

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CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

The 5 automation trends in the packaging industry

Guest contributor: Hans Michael Krause, Bosch Rexroth

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i4.0 in practice: the 5 automation trends in the packaging industry

Next-generation packaging machines are being designed without control cabinets and are increasingly vertically and horizontally connected. Big data analyses, smart maintenance and model-based engineering have unleashed tremendous potential. But even conventional automation tasks can be handled more easily with open interfaces and integrated functions. What are the five major automation trends in detail?

What the packaging lines of tomorrow will be able to do

When I look at the highly dynamic packaging industry, I see four major challenges faced by machine builders: more individuality when it comes to packaging, more flexibility in terms of formats, higher availability and less space required for machines and lines. These challenges lead to five major trends in automation:

(1) Connected – the connectivity trend

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As a user, I need transparency, whether I want to improve system availability through smart maintenance, make my line more flexible, or optimize complex packaging processes. Without knowledge of subprocesses and plant conditions, I can’t analyze anything – neither on premise nor via the cloud. Modern automation technology and sensor systems now provide all the necessary data. I have to retrofit existing systems, but preferably without the need for programming or intervention in the automation. The IoT gateway fulfills this requirement extremely elegantly and can be set up in just five minutes. Machine builders can also opt for Starter Kit, which includes the Software Production Performance Manager (PPM), for a complete analysis platform from a single source.

The sweet side of Industry 4.0

There is also enormous potential in cross-vendor and system-wide networking via IIoT protocols such as MQTT or the open i4.0 standard OPC UA. At interpack, four machine builders and Bosch Rexroth will showcase the “ChoConnect” project as an exciting example of authentic M2M communication: Four locally distributed exhibition machines from LÖSCH Verpackungstechnik, SOLLICH, THEEGARTEN-PACTEC and WINKLER and DÜNNEBIER Süsswaren exchange information as a virtual production line for chocolate products using OPC UA in accordance with the Weihenstephan standard and create an end-to-end transparent value chain at the shopfloor level – without the need for an MES or control system. The individual steps of mass processing, molding, primary and secondary packaging automatically adjust performance according to individual capacities. The production process becomes more flexible; system efficiency increases.

Merging of automation, IT and IIoT

The fact that inflexible line PLCs will soon be obsolete is also a consequence of a merging of automation, IT and IIoT. With open interfaces such as Open Core Interface, ERP systems can be directly linked to machine automation, simplifying inventory management for machine components. Obviously, there must be also be a security strategy for regulating access to the control system.

(2) Simple – Make it simple!

The current trend towards fewer personnel per line has increased the need for intuitive control units such as HMI with multi-touch. Transparent and seamless visualization solutions are required – on the production line itself and at other locations in the company – in order to continuously improve processes and respond quickly when necessary. The ActiveCockpit interactive communication platform shows that such solutions are already available today.

Companies often need the ability to easily integrate new machines or lines into existing systems – this can already be done mechanically using standardized chain conveyor systems such as VarioFlow plus in combination with the MTpro planning tool. In the future, open M2M interfaces will allow for easy electrical integration.

With the growing need to simplify diagnostics and maintenance, we will see even more web-based service tools and innovative LED concepts at machines in the future. Augmented and virtual reality are sure to play a part here, too. It has been repeatedly demonstrated at trade shows how the digital twin integrates itself into the real picture using open interfaces so that complex technical relationships can be visualized and understood more quickly. A product orientation module for beverage packages by WestRock will be showcased at interpack.

(3) Efficient – end-to-end digital engineering

Ever more complex design needs and shorter time-to-market requirements are fueling the demand for model-based engineering with simulations and virtual commissioning. As a technology partner with industry expertise, Open Core Engineering not only ensures seamless integration of the machine control with simulation platforms such as MATLAB/Simulink or 3DEXPERIENCE by Dassault Systèmes. For immediate creation of a digital twin that can be simultaneously used by mechanics, electricians and software programmers, Bosch Rexroth delivers digital behavior models of its automation products as standard.

Bosch Rexroth also provides a comprehensive library of prepared technology functions along with the machine control. By emphasizing parameterizing instead of programming, flow wrappers, secondary packaging systems, fillers or sealing machines can be commissioned more quickly. Integrated standard kinematics and functions for delta, parallel and palletizing robots are also available. Object-oriented PLC programming and high-level languages, such as Java and C++, facilitate creation of the machine control software. The controllers feature a web server for easy integration of Internet technologies such as visualization using HTML5. Of course, standardized programming templates support the creation of machine programs following OMAC/PackML standards as well as the Weihenstephan standard and PLCopen.

(4) Adaptive – the adaptivity trend

What if the packaging line automatically adjusted the product stream in the event of a fault, instead of jamming and displaying a lot of error messages? Prefabricated software functions such as intelligent infeeds or product grouping are already available, even for these trend-setting M2M scenarios. For the use of robots and flexible transport system a separate controller is not needed anymore. These are managed by the standard machine controller, and the number of interfaces and the effort required to use transport systems or robotics are reduced.

In view of increasingly complex packaging processes, there is also a need for machines to automatically adjust to their environment. Machines require Smart Sensor Nodes with MEM technology like XDK in order to “learn” from their current state. Virtual sensors like servo motors and drives, including the intelligent MS2N servo motor, provide useful information.

Last but not least, next-generation packaging machines automatically adjust to the current format and regulate process speed as well as product handling. Adaptive software functions have also been developed for this scenario of the future. The spectrum ranges from flexible electronic cams in the machine control (FlexProfile), drive functions such as auto-tuning and anti-vibration to frequency response measurements and innovative filter functions for minimizing resonance frequencies in mechanical parts.

(5) Cabinet-free – much more than just space saving

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This trend in packaging is not just about saving space in the automation technology, machine footprint and control cabinet space. Instead, it’s about a modular machine configuration that allows machine operators and customers to respond flexibly to different requirements. The individual modules are connected to one another only by a single hybrid cable and can be easily integrated into the machine or retrofitted later. This reduces the installation area and increases servo density in favor of greater flexibility. Installation space, cabling and maintenance costs are also reduced. Such modular approaches are especially useful for secondary packaging and rotary machines such as filling and capping machines as well as retrofit projects.

Solutions for these packaging trends are already available. Use them now!

Manufacturers and users of packaging machines already have numerous options for boosting their competitiveness through intelligent and connected automation solutions. But to achieve this, they need an industry-oriented, expert partner with a broad ecosystem of solutions. At interpack 2017, Bosch Rexroth will give visitors the opportunity to experience the trade show theme of “Connected Automation i4.0 now live in all of its facets – including modern networking, simple design, model-based engineering and groundbreaking service. The future of automation has already begun and is ready for “installation” in the latest generation of packaging machines. Now!

 

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Decentralized Control Systems to the Rescue

Guest contributor,  Bob White, Kollmorgen

Less Cabling, Smaller controls cabinet, Less heat…wow, that’s all great stuff.  I can achieve this all with a decentralized solution? Absolutely – and even more! 

Decentralized Control Architecture means shifting the motion control drives from the crowded cabinets, and moving them near to the motors – out on the machine where the action is.  Immediately you can see that this can reduce the size of the controls cabinet, moving all of those drives out onto the machine – but how do I see these other advantages?

Decentralized ArchitectureIt’s not JUST about moving the drives out onto the machine, near or integrated with the motors, but also how you design your entire control system.  Think about a conventional Centralized Control Architecture – all of your drives, power supplies and other I/O are jammed into a large cabinet and cables are run to each motor – and since we are talking conventional, this likely means multiple cables (power and feedback for each motor). So in a decentralized solution, the motor, feedback and fieldbus communication needs to be run through a single cable, and the control architecture  allows communications to function over the fieldbus loop.

So thinking about it that way, with an 8 axis machine – Control cabinet 5 meters from the initial motor, and subsequent axes 3 meters apart – this adds up quickly to almost 250 meters of cabling (Power and Feedback) using a centralized approach.

Centralized vs Decentralized ImageImagine now – A decentralized solution, drives located within a meter of the motor they are driving – you cut cabling down to a mere 35 meters!  Do the math – an 86% reduction!  Throw in extended I/O and your savings jumps to almost 90%  SO – Point 1 – Substantially reduced cables cost – not just from the mere reduction in cable length, but in reduced costs associated form cable management trays and even the labor to run the cables.

But there’s more (or do I mean less).  Smaller cabinet, less electronics, means less heat to dissipate – electronics usually don’t like the heat, so they tend to get some cool air, provided by some nice air conditioning system.  Less heat, less need for an expensive air conditioning unit, AND less energy consumption.

One other element not so readily apparent with a good decentralized design – flexibility!  Designing with a decentralized drive architecture in mind from the start opens up new possibilities.  This allows more flexibility in modularization.  We’ll cover this modularization concept in a follow on blog topic next time…

All of these advantages help the OEM build a more efficient machine, with less components, reduction in assembly time, and more flexibility in design – improving the marketability of the machine.  End users enjoy the lower cost of ownership and increase reliability – and potentially space savings on their factory floor.

Decentralized Machine Vision

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CMA/Flodyne/Hydradyne is an authorized  Kollmorgen distributor in Illinois, Wisconsin, Iowa and Northern Indiana.In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Five trends that support intelligent linear motion technology in practice

Guest contributor; Dr. Steffen Haack, Bosch Rexroth AG

When it comes to progress in linear motion technology, one thing is immediately clear: linear guides and systems move increasingly larger loads more regularly and with increasingly higher positioning accuracy and repeatability. Anyone with an understanding of the interplay between the drive technologies will know the potential resulting from it.

Through a combination of electrics, sensors and software, linear motion technology makes a crucial contribution for integrated factory. Here are the five trends that support intelligent linear motion technology in practice:

Figure 1: Modularization and flexibilityBild1

Ready-to-install electromechanical cylinders combine mechanics with the flexibility of electric drives. A software command to the electric drive and the cylinder move them to any position and carry out complicated movement profiles. Without an additional position measuring system, they can achieve repeatability of up to ± 0.01 mm. Load measuring pins transmit the values analogously to the electric drive or the control and enable a decentralized process management.

Figure 2: Functional integration reduces complexityA006_C010_0101XP

If the precision requirements are high but the environment conditions are rough, conventional measuring systems soon reach their limits. Absolute measuring systems integrated into ball rail and roller rail systems detect the absolute position of the axis with a resolution of 0.025 μm. They immediately recognize the absolute position of the axis when the machine is switched on and report it to the controller without carrying out a reference run. In addition, modern systems do not require buffer batteries that need to be replaced regularly.

Figure 3: Predictive maintenance increases availabilityA008_C023_0101C0

Sensors measure temperature peaks and vibrations. This data forms the basis for future approaches to predictive maintenance. However, it is only significant if it is compared with life cycle models. In load tests, the newly developed runner blocks have demonstrated twice the service life through increased load capacities with the same size. Together with the detected operating conditions and predictive maintenance, they significantly increase the availability of machines and systems.

Figure 4: Digitally supported commissioningBild4

Previously, an experienced technician could easily have spent twenty minutes commissioning a linear axis. With the new mechatronic linear axes and actuators, the commissioning takes only three to five minutes. A digital assistant supports the application engineer with this. The technician only has to enter a few pieces of axis-specific data and can then immediately program or parameterize the drive. In the future, this functionality will automatically be available via the QR code.

Figure 5: Digital engineering for secure and quick dimensioningBild5

More and more engineering departments are changing to integrated digital workflows. With selection guides or sizing tools, design engineers find the correct linear motion technology components and mechatronic systems through intuitive user guidance, which can even be application-specifically configured. The electronically generated data are then integrated directly into the digital construction model and enables the virtual simulation of complex machine movements, for example.

Do you have questions about this post?  Please contact us:


ABOUT US

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CMA/Flodyne/Hydradyne is an authorized  Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

 

Why Rexroth? Top Four Reasons to Choose Rexroth Drives & Controls

Todd Sharp, Motion Control Sales Manager, CMA/Flodyne/Hydradyne

CMA/Flodyne/Hydradyne is a leader in the design and commission of drive and control
systems for our customers for over 30 years, and one question that we often hear is “Why is Rexroth the best?”  There are many brands competing for the drive and control market, and here at CMAFH, we have working experience with most if not all of them. Our engineers program,  repair and upgrade many of the brands of control systems, and we have the ability to integrate any brand into our custom projects at our customer’s request. Having specialized in Bosch Rexroth products for many years, we understand the unique strengths of the product line.

Rexroth drives and controls can be differentiated from competing brands in four very distinct ways.

1. Product Breadth

The IndraDrive product family spans the power range from 100W to 4MW. This product family can operate as an open loop frequency drive/sensor less vector drive up to a multi-axis integrated motion and logic controller that can be either stand alone or drive resident. The IndraDrive product family also includes a cabinet free drive integrated motor. This entire IndraDrive product family is supported by the same software.Indradrive 2016 13187

  • Power range from 100W to 4MW
  • Range of technology from open loop V/F and sensor-less vector control to multi-axis integrated motion and logic control
  •  Integrated motion and logic control – controller or drive resident
  •  Cabinet free drive integrated motor

2. Connectivity

Rexroth’s drive and control platform supports all common communication buses including Ethernet I/P, EtherCAT, Profinet, SERCOS, CANopen, Powerlink, Profibus.
We can control 3rd party motors regardless of brand or type, and we can operate all common feedback types including TTL, 1vpp, Endat, Hiperface, SSI, resolver. Our drives are available with a 2nd encoder input with a 1MHZ input frequency. Our control supports all common machine programming languages like ladder, FB, ST, IL… plus all common IT and engineering languages like C#, C++, Java, Labview, Matlab.

  • Supports all common communication buses including, Ethernet I/P, EtherCAT, ProfiNet, SERCOS, CANopen, Keyvisual_inkl_Logos_w486Powerlink, Profibus
  • Controls all 3rd party motors regardless of brand or technology type
  • Operates all common feedback types (TTL, 1vpp, ENDAT, Hiperface, SSI, resolver) with drive based second encoder input with up to 1MHZ input frequency
  • Supports all common machine programming languages (ladder, FB, structured text, instruction list) plus all common IT and engineering type languages like C#, C++, Java, Labview, Matlab

3. Functionality

Whether it’s drive or controller based, Rexroth offers multi-zone tension control, vibration dampening/anti-slosh control, high speed registration control, advanced electronic camming and hydraulic control. We also support zoned safety control with safe torque off and full safe motion; controller or drive based. Yes, drive based safe motion control!

  • PMK2801_02R_WEBMulti -zone tension control
  • Vibration dampening/anti-slosh control
  • High speed registration control
  • Advanced electronic camming
  • Supports all common hydraulic functions
  • Integrated safe torque off and safe motion control

 

4. Support

Rexroth designs, engineers and manufactures all products they sell. All are standard and sold throughout the world. In the US, hundreds of local high-tech distributors are Rexroth trained and certified to provide full sales, service and application support.  Additionally, Rexroth maintains sales, service and application support facilities in every region of the US, plus scores more globally.

  •  All products are standard and sold throughout the world
  • Bosch Rexroth maintains sales, service and application support facilities in every region of the US and scores more globally
  • In the US hundreds of local high-tech distributors are Rexroth trained and certified to provide additional sales, service and application support

Bosch Rexroth_2012

Do you have questions about this post?  Please contact us:

About CMA/Flodyne/Hydradyne

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CMA/Flodyne/Hydradyne is an authorized  Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

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Press productivity improves with controller upgrade

Guest contributor: Richard Meyerhoefer, Delta Computer Systems

Fastener stamping machine output triples after tuning the motion with a solution from Delta Computer Systems.

Improving the productivity of a manufacturing process by speeding up the operation of an old machine can be very difficult, driving plant managers to purchase new equipment. It’s often possible, however, to replace the control system, maintaining the old mechanics, and get the performance of a new machine for much lower cost. Hydraulics distributor CMA/Flodyne/Hydradyne (CMAFH) of Hanover Park, Illinois, recently assisted in such an upgrade for a manufacturer of fastening components. The machine was a press used to imprint patterns on the surface of metal fasteners with a punch that fits into the bottom of a 4″ bore hydraulic cylinder (Figure 1). As the punch comes down it reshapes the top of the fastener and its edges to provide a locking feature.

Motion controller selection

Figure 1. Diagram showing motion controller connections in the fastener press machine

In the past, the manufacturer used a programmable logic controller (PLC) to operate a two-position, bang-bang valve to drive the cylinder, but company engineers found imprecise results that limited production to around 60-to-70 parts per minute. As a result, the company moved to a proportional valve and closed-loop controller that operated the valve based on cylinder position/acceleration. The controller would open the valve quickly and then back off the valve as the cylinder got closer to making contact with the fastener. This method enabled an increase in production to approximately 140 parts per minute. But to meet competitive pressures, company managers demanded the rate be increased, driving the need for a new electro-hydraulic motion controller.

Company engineers called CMAFH, with whom they had worked on automation solutions for more than 20 years, to recommend a new controller for the company’s old bang-bang machine.

Hooking up the controller

The Delta RMC75E motion controller (Figure 2), recommended by CMAFH engineering manager Norman Dziedzic, accurately controls position and force, to control acceleration with more precision than the closed-loop controller previously used. Dziedzic programmed the motion controller to move the cylinder to a predetermined position while monitoring the force being applied by the punch. When the force reaches a particular value, the controller is switched to force control mode to ensure that adequate force is ultimately applied to the fastener. The old closed-loop control system used position control only, with some input from a load cell within the tool to verify that a certain minimum force was applied to the part.

“The Delta controller operates similar to that, but is easier to control,” says Richard Mellor, engineer at the fastener company. Every motion step made by the other controller was initiated by the PLC, and there was lag time in passing position information. “The beauty of the Delta controller is that the motion program now resides in the controller,” Mellor adds.

Now, the PLC just does overall machine control, triggering the Delta RMC to press the part at the appropriate time. When the pressing operation is complete, the Delta controller knows, based on the position and force ranges inputted to the controller, whether the pressed part is a good part or a bad one, and notifies the PLC. The Delta RMC75E gets cylinder position feedback from a linear magnetostrictive displacement transducer (LMDT) via a synchronous serial interface (SSI) to the controller. To measure force, the system uses a fatigue-rated (rugged) force transducer (shown in Figure 1).

Programming, tuning

Figure 2.  The Delta RMC75E motion controller can control up to two motion axes simultaneously

Dziedzic set up the motion program initially, and he fine-tuned the loop parameters working with a fastener company engineer. The two also developed the code to implement quality testing of the finished parts.

“I find the Delta very easy to program, but I have 30 years in as a controls engineer. If you’ve had anything to do with PLC or message display packages, it’s relatively intuitive to find your way around,” Mellor says

For tuning the motion, Dziedzic relied heavily on Delta Computer Systems’ Plot Manager software, which allows an engineer to view multiple key motion parameters versus time on a single graph (Figure 3). The plot shows three press cycles, where the red curve is the actual position of the press cylinder, the blue curve is the actual velocity of the cylinder, and the force being applied by the die to the work piece is shown by the black line. The cyan line is the target cylinder position. When the motion system is perfectly tuned, the actual cylinder position curve overlaps the target position, indicating that any positioning error caused by the mechanical aspects of the system – for example, the compressibility of the fluid or the friction of the moving parts – has been compensated for by the control algorithm. In Figure 3, the flat yellow line indicates the command force which must be applied to the part to make the press operation successful. The circle marked A highlights the point in time when the actual position (red line) begins to deviate from the target position (cyan line) as the tool comes into contact with the part. This is also when the force (black line) begins to climb. Then, at point B, the change in actual velocity (blue curve) shows force control taking over from position control. Area C in the plot shows when the actual force meets the target command force to signal a successful operation. Area D shows harmless motion transients that are caused by retracting the cylinder quickly to prepare for pressing the next part.

Using the Plot Manager, motion characteristics that occur too quickly to be visible to the naked eye can be analyzed and corrected if necessary, enabling the manufacturing process to be accelerated.

Results

Figure 3.  Delta’s RMCTools plot Manager software shows axis position and force versus time, enabling precise tuning of the motion.

One of the fastener company’s other key requirements on the controller upgrade project was to provide a means of accessing process data using the controller in order to do a pass/fail test on the finished parts.

“We track final position reached and maximum force achieved,” Dziedzic says. Previously, the company needed an external analog device to do this. Now, the Delta RMC75E eliminates this need by making process parameters available for the PLC to read directly over Ethernet. “The fact that the Delta controller can do this in addition to controlling the cylinder provides a huge benefit to them.”

“We have been very happy with the performance increase we have gotten with the Delta motion controller,” Mellor adds. “Even if we hadn’t gotten the performance, Delta’s ease of use in system setup and tuning would have made the difference.”

With the Delta RMC75E controlling the operation of the cylinder, the machine can now process up to 180 fasteners per minute.

“We can move faster because we have more control over the proportional valve, yielding tighter control loops and better control of the gain in the system,” Mellor says.

Another advantage of using the Delta RMC is operation repeatability; the controller is able to control the force exerted in each cycle to a tolerance of ±40 lb out of 10,000 lb applied.

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CMA/Flodyne/Hydradyne is an authorized  Delta Computer Systems distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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