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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.

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

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.

Time is money: snappy automation of testing machines

Guest contributor: Andreas Sokoll, Bosch Rexroth

Usefully combining automation and IT is not only typical of Industry 4.0. In the engineering of measuring and testing machines, open interfaces also unleash great potential for efficiency. With the aid of National Instruments’ LabVIEW graphic programming environment and Open Core Engineering, they can now be modelled and automated in an integrated manner without creating a separate PLC code. The effect: a significantly quicker time to market!

Why complicate things if they can be actually be done simply

The idea of precisely modeling customer-specific measuring and testing machines without having to acquire and coordinate an additional PLC programmer is very attractive to many manufacturers. That’s because, until now, they had to program I/O queries and axis motions separately and transfer them into a joint machine program throughout all the development phases. An irksome and time-consuming task, which introduces additional sources of errors. However, this cost and quality-related factor can be minimized if the development environment communicates directly with the control core.

Modeling measuring and testing machines without additional PLC programming: in National Instruments’ LabVIEW programming environment, manufacturers can execute the motion sequences as well as measuring and testing tasks. The Open Core Interface acts as an open interface between the control system and the PC.

Parameterizing instead of programming

National Instruments’ LabVIEW graphic programming environment, which is widely used in the measuring and testing machines field, satisfies this requirement by supporting Bosch Rexroth’s Open Core Interface. Development engineers therefore get direct access to the control functions via their usual interface. Device drivers and functions can consequently be quickly and simply selected as graphic modules (Virtual Instruments) and then only need to be parameterized. This also speeds up commissioning. This is because, in addition to the measuring and testing applications, the full machine workflow can now be mapped in LabVIEW, and consequently in a joint project. There’s no need for the PLC code to be written in parallel and continually coordinated.

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Reduced engineering workload: Since LabVIEW supports Bosch Rexroth’s Open Core Interface, machine developers no longer have to work in two environments. The axis motions can also now be produced directly in LabVIEW.

Over 550 VIs to be parameterized

With its Open Core Interface, Bosch Rexroth has established the basis for not only the graphic LabVIEW language but also other modern high-level languages, software solutions from the simulation and model-based engineering fields, and open i4.0 standards such as OPC-UA being able to access control functions directly. The seamless integration in the respective programming environment is achieved by using a software development kit (SDK). In the case of LabVIEW, it contains more than 550 Virtual Instruments (VIs). They control the connection set up (ApiLib), access to direct motion commands (MotionLib), and access to the control system (SytemLib) or the drive and control parameters (ParameterLib) among other things. They are clearly structured in function libraries and they can be simply dragged & dropped into the project and then parameterized.

Motion PLC, drive and control functions: The LabVIEW SDK contains eight libraries with over 550 additional Virtual Instruments.

Fully fledged HMI for M2M communication

Both the “front panel” and “block diagram” programming windows that are typical of LabIEW now form a fully fledged user interface for man-machine communication. The block diagram shows the flow logic in the form of VIs and links, and all the control and display elements appear in the front panel, e.g. buttons, switches or graphical displays. So direct operation of the machine is also possible. For instance, in order to move an axis, the programmer simply activates the corresponding VI. The SDK provides numerous example projects illustrating the initial steps. The HMI templates that they contain can be quickly adapted to the respective requirements.

Simple block diagram: In this example, the logically linked Virtual Instruments read a value from the control unit.

Force measurement practical example

Force measurements are by far the most common form of test task. Including handling tasks, an estimated 90 to 95 percent of all measuring and testing tasks can in practice be carried out just by using LabVIEW. Here’s an example of the monitoring of a joining process:

A DIN 625 industrial bearing is to be pressed into a tolerance ring in a controlled manner. In order to control the linear axis motion, measure the pressing force and compare it with the tolerance range, the programmer divides the project into five steps: Connect, move (axes into position), start force control and measuring, measurement completed, and retract axis. The programming takes place purely in LabVIEW with the aid of self-explanatory VIs such as “Standstill”, “MoveVelocity”, “Continuous Motion” or “Stop”. The VIs are linked by connections in the graphical user interface and are activated and deactivated via target and transfer values such as “TRUE” and “FALSE”.

Quick access to the desired operating interfaces: The SDK for LabVIEW comes with lots of example projects in which the HMI can be quickly and easily adjusted.

Complete control set from a single source

In addition to pure modeling and programming in LabVIEW, as a system manufacturer Bosch Rexroth provides even more ways of increasing engineering efficiency. In the practical example shown for instance, the press-fit procedure is carried out via an energy-efficient electromechanical cylinder (EMC) with an integrated force sensor and drive. In combination with an IndraControl XM control this produces a fast, higher-level control loop in which the mechanical and electrical components work together optimally with short cycle times of 250 µs. The test system is quick to set up so it can precisely control the force moments which arise, run at constant speeds and position the work piece in a highly dynamic, flexible and precise manner depending on the requirements. A Bosch Rexroth linear motion technology tolerance ring is used as a frictionally engaged connection element for the insertion of the bearing.

Quicker to market due to large time savings

With the aid of LabVIEW and the Open Core Interface technology, together with Bosch Rexroth’s modern automation solutions, precise movements can be carried out in measuring and testing machines even without any PLC programming – including interfaces, handshakes and synchronization. For users this results in an enormous saving of time, especially since troubleshooting can also concentrate on one instead of two programming environments. This considerable time saving enables manufacturers of measuring and testing machines to bring innovative and complex products to market much more quickly and also inexpensively than before – but without compromising on quality.