Bosch Rexroth Automation Concepts for the Solar Industry
Project Book
Document ID: [Not Specified]
Release Version: 3.0
Release Date: 01/2010
Organization unit: Bosch Rexroth Electric Drives and Controls GmbH
Document Approval and Responsibility
Created or edited by: A. Gryglewski, Bosch Rexroth; G. Eichelsdörfer, Bosch Rexroth
Revision History
| Version | Date | Page/Chapter | Revisions | Autor |
|---|---|---|---|---|
| 2.0 | 11.11.2009 | Update DCL | DC-IA/SFS | |
| 3.0 | 27.11.2009 | Update DCP | DC-IA/SFS | |
| 3.0 | 19.08.2011 | Layout, Easy Handling, CSS/F | DC-IA/SFS |
Typographical conventions
Main chapter: Bold text
Subchapter: Bold and italic text
Topic: Normal text
Topic in subchapter: Normal text
Remarks, Note: Italic text
In development, technical clarification/Initial modification or revision: Underlined text
Introduction and Objective
This project manual describes elements of control architecture adapted for the Solar Industry. Bosch Rexroth, as a systems supplier, offers hardware, software, engineering services, replacement parts, training, and support. Products include PLC controls, CNC controls, operating and visualization devices, Industrial PCs, open interfaces, I/O components, drives, and software packages used in wafer production, cell production, and module production.
Applications include handling, vacuum transport, laminators, and related processes.
Project Management
The project manager coordinates technical and commercial aspects between Bosch Rexroth, machine manufacturers, and end customers. Key decisions on deadlines, approvals, and functions are made collaboratively. The automated series production tool aims to reduce costs, ensure high availability through standard software and operating concepts, and facilitate integration of third-party components via standard interfaces. Using specified components ensures maximum productivity and availability throughout the equipment's service life. Points not detailed in the manual should be arranged with the OEM project manager. The system supplier remains responsible for properly constructed systems meeting local regulations and documentation standards.
1.0 Automation Concepts
This section details various automation concepts and example applications within the solar industry.
1.1 Example "Process- and operation routing section"
This concept involves:
- Technical control connection to the process routing section.
- Local diagnostic and breakdown localization capabilities.
- Technical control connection to the operation routing section.
- Functionality integration with MES software.
- Interface to the SAP system.
- Visualization on the process section using IPC-VPP.
- VPP with WinStudio for visualization.
- Industry PC technology (IndraControl V).
Diagram Description: A block diagram illustrating the connection between the Operation routing section and the Process routing section, highlighting key functionalities like MES integration, IPC technology, SAP interface, local diagnostics, and visualization.
1.2 Example: "Ingot – Saw"
This application utilizes:
- Motion Logic System: IndraMotion MLC
- HMI: IndraControl V
- I/O Technology: Rexroth Inline
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
Diagram Description: A system overview showing connections between components like VCP, Handheld VCH 08, VEP 30, IndraMotion MLC, IndraDrive units, and Inline I/O, illustrating a typical setup for ingot sawing automation.
1.3 Handling for cell production
1.3.1 Example: "Conversion": 2 axes Cartesian – controller-based
This setup features:
- Motion System: IndraMotion for Handling, IndraControl L40 (controller-based)
- HMI: IndraControl Vxx
- I/O Technology: Rexroth Inline
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
- Construction Kit: CamoLine
- Gripper Technology: NCT
- Pneumatics: Valve/pressure regulator
Diagram Description: A network diagram showing TCP/IP Ethernet connection, data interface, IndraMotion for Handling, IndraControl L40, IndraControl Vxx, Vision System, and I/O components like Gripper Position switch, Temperature Sensor, Contactor, Valve/pressure regulator, and NCT. It indicates a z-axis and mentions max 126 Profibus axes and max 4 different kinematics.
1.3.2 Example: "Conversion": 2 axes Cartesian – drive-based
This setup features:
- Motion System: IndraMotion for Handling, IndraMotion MLD (drive-based)
- HMI: IndraControl Vxx
- I/O Technology: Rexroth Inline
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
- Construction Kit: Camoline
- Gripper Technology: NCT
- Pneumatics: Valve/pressure regulator
Diagram Description: A network diagram showing TCP/IP Ethernet connection, data interface, IndraMotion MLD, IndraControl Vxx, Vision System, SERCOS III Block I/O, and I/O components like Valve/pressure regulator and NCT. It indicates a z-axis (electric) and mentions the use of SERCOS III.
1.3.3 Example: "Sorting": 3 axes Cartesian
This setup features:
- Motion System: IndraMotion for Handling, IndraControl L40 (controller-based)
- HMI: IndraControl V / Handheld
- I/O Technology: Rexroth Inline
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
- Construction Kit: Camoline
- Gripper Technology: NCT
Diagram Description: A network diagram showing TCP/IP Ethernet connection, data interface, IndraMotion for Handling, IndraControl L40, IndraControl Vxx automation interface, Vision System, and I/O components like gripper position switch, temperature sensor, contactor. It indicates a z-axis (electric) and mentions max 29 Sercos axes and max 4 different kinematics.
1.3.4 Example: "Conversion": SCARA Robot
This setup features:
- Robot Control: IndraMotion MLC - RobotControl
- HMI/Handheld: IndraControl V
- I/O Technology: Rexroth Inline
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
Diagram Description: A network diagram showing TCP/IP Ethernet connection, data interface, IndraMotion MLC RoCo, IndraControl L40, SRAM Module, IndraControl Vxx automation interface, Vision System, and I/O components like gripper position switch, temperature sensor, contactor. It indicates max 29 Sercos axes and max 16 kinematics.
1.3.5 Example: "Sorting": Delta Robot
This setup features:
- Robot Control: IndraMotion MLC - RobotControl
- HMI/Handheld: IndraControl V
- I/O Technology: Rexroth Inline
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
Diagram Description: A network diagram showing TCP/IP Ethernet connection, data interface, IndraMotion MLC RoCo, IndraControl L40, SRAM module, IndraControl Vxx automation interface, Vision System, and I/O components like gripper position switch, temperature sensor, contactor. It indicates max 29 Sercos axes and max 16 kinematics.
1.4 Example: "feeding screen-printing and turnaround device"
This setup features:
- Motion System: IndraMotion for Handling
- Controller: IndraControl L40
- HMI: IndraControl Vxx (small operation terminal)
- I/O Technology: Rexroth Inline
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
Diagram Description: A network diagram showing TCP/IP Ethernet connection, data interface, IndraMotion for Handling, IndraControl L40, IndraControl Vxx automation interface, Vision System. It illustrates components like feeding, 1 electric axis (MSK), 1 pneumatic axis (MSC), and conveyor belts with 1-n axes depending on the transport roadway.
1.5 Example: "Laser - structuring" and "Laser edge-cutting"
This application utilizes:
- Automation Solution: IndraMotion MTX
- Automation Solution: NYCe 4000
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
Diagram Description: This section does not contain a diagram but lists the automation solutions and drive technologies used for laser structuring and edge-cutting processes.
1.6 Example: "Screw technology"
This setup features:
- Motion System: IndraMotion for Handling
- Controller: IndraControl L40
- HMI: IndraControl Vxx (small operation terminal)
- Electrical Drive Technology: IndraDrive C + IndraDrive Cs
- Drives: IndraDyn
- Screw Technology components
- Rexroth Pneumatics: compact-cylinder CCI series, mini-cylinder OCT series, turnaround-module, valve-carrier-system HF03-LG series
- Construction Kit: CamoLine
Diagram Description: A network diagram showing TCP/IP Ethernet connection, data interface, IndraMotion for Handling, IndraControl L40, IndraControl Vxx automation. It indicates the presence of 1-n axes and other unspecified components.
1.7 Example: "Transport of components in clean-room and vacuum"
This application involves transporting materials and components under specific process conditions such as clean-room, vacuum, rare gas, higher temperatures, or in the chemical sector. Benefits include no lead-through for motor shafts and wires, less abrasion leading to low maintenance, and easy access to components outside the processing room.
Function Overview:
- Freely programmable in C and C++.
- Up to 28 inductors in one configuration.
- Detailed startup tools.
- High precision positioning (repeat accuracy <50 µm).
- Independent carrier movement for complex automation.
- Speeds up to 5 m/s.
Topology:
- Components: IndraLogic, IndraDrive FC, Fieldline I/O, Inline, NYCe 4000.
- System connections shown via E01, E02, E03, LMS, and Fieldline I/O connecting to Indradrive FC machine control.
Diagram Description: A topology diagram illustrating the setup for transporting components in clean-room and vacuum environments, showing connections between IndraLogic, LMS, Fieldline I/O, Indradrive FC, and NYCe 4000.
1.8 Example: "Technical control connection of the Bernoulli gripper"
Component Overview:
- I/O Technology: Rexroth Inline
- Gripper: NCT
- Pneumatics: Pressure preparation, Valve/pressure regulator
Diagram Description: This section does not contain a diagram but lists the components involved in the technical control connection of a Bernoulli gripper.
2.0 IndraMotion for Handling - Turn Key solution for automation
IndraMotion for Handling is a system solution for efficient axis movement coordination in fully automated production. It is based on a unified drive and control platform and international software standards, offering flexibility for handling applications. Key functions include free PLC functionality (IEC 61131-3), comprehensive PLC libraries and PLCopen logic arrays, easy teaching and programming via HMI/PC/PLC, Cartesian kinematics, movement in machine coordinates without transformation, up to 4 kinematics per control, up to 6 axes per kinematic, and sluring motions.
2.1 IndraMotion MLC – controller-based Motion Logic System
The IndraMotion MLC is a compact, controller-based motion-logic system designed for modern machine automation, offering flexibility through innovative software/firmware functions, easy engineering, and open system interfaces. It is an integrated system solution from Bosch Rexroth, with ready-to-use technology functions to accelerate engineering.
Motion - Logic
The IndraMotion MLC provides flexibility for consistent and modern machine automation with innovative software and firmware functions, easy engineering, and open system interfaces.
Motion - Robotic
General: Supports up to 32/64 axes, 16 kinematics, and 16 axes per kinematic. It enables coordination transformations for Cartesian, SCARA, and Delta robots, with approximately 90 other transformations available. Multi-kinematic setups allow mixing different types and synchronous operation on one band.
Programming: Uses Robot Control Language (RCL), supporting PTP, LINEAR, and CIRCULAR motions with conditional interruption, digital output control, time-controlled motion, and programmable speed/acceleration. Modularization via RCL subroutines and a debugger are available.
Miscellaneous: Features band synchronization (up to 4 bands), set-slope and program-slope, override, and teach pendant as an AWP.
2.2 IndraMotion MLD – drive-based Motion Logic System
IndraMotion MLD integrates motion and PLC functions into an open automation platform for modular machine designs. Its distributed control architecture creates a compact motion-logic system based on the scalable IndraDrive platform, eliminating the need for higher-order controls. It supports single-axis and multi-axis control (up to 8 axes). Ready-to-use function libraries and PLCopen-conforming function blocks simplify the use of intelligent drive functions. Open technology and communication interfaces facilitate integration.
2.3 IndraLogic - open PLC-system
IndraLogic is an open PLC system that connects in-/outputs, drives, and visualizations via Profibus. It is suitable for carcass and assembly applications and is offered in controller-based and PC-based versions.
IndraLogic – controller-based
Components include control hardware (CML xx), operation terminal (IndraControl V), powered fieldbus-subscribers (I/O modules), and drives (via Profibus). Optional machine control panel (VAM xx) is available.
IndraLogic – PC-based
Components include control panel (IndraControl V), powered fieldbus-subscribers (I/O modules), and drives (via Profibus). Optional machine control panel (VAM xx) or keyboard is available.
2.4 CNC – automation solution IndraMotion MTX
IndraMotion MTX is a comprehensive solution combining CNC, motion control, and PLC functionality. It supports up to 64 digital drives (max. 32 shafts) and 12 independent NC-channels, including laser power control for applications like laser structuring or edge-cutting.
MTX performance: Features CMP 60 control hardware, IndraControl V display, VAM xx control panel, fieldbus subscribers, and SERCOS 2 drives. Supports up to 12 channels, 250 µs block-cyclic time, 250 µs SERCOS 2 cyclic time, 64 operable axes, 32 possible shafts, and 8 interpolate axes per channel.
MTX standard: Based on VSP xx and CMP 40 hardware. Supports 2 channels, 6 ms block-cyclic time, 6 ms SERCOS 2 cyclic time, 8 operable axes, 2 possible shafts, and 4 interpolate axes per channel.
MTX compact: Based on CML 40 hardware. Supports 2 channels, 6 ms block-cyclic time, 6 ms SERCOS 2 cyclic time, 8 operable axes, 2 possible shafts, and 4 interpolate axes per channel.
2.5 NYCe 4000 - Motion control for precision-small-drives
The NYCe 4000 motion control is ideal for applications requiring various small drives with different transmitter types. It is a compact, freely programmable controller meeting requirements for high speed and programming freedom. It supports up to 10 drives, 100 digital and 20 analog I/Os per controller, and up to 60 controls in one configuration. It is suitable for high-precision tasks with a feedback position control clock of 32 kHz.
I/O Capabilities: Up to 10 fast digital inputs, 40 standard digital inputs, 10 fast digital outputs, 20 standard digital outputs, 10 analog inputs (12-bit), 10 analog outputs (16-bit).
Motor/Encoder Support: Up to 10 motors per control, 256 per configuration. Supports DC Servo, AC Servo, EC Servo, stepper, linear, and piezo motors. Encoder types include incremental, 10V SinCos, EnDat 2.1/2.2, Hiperface, Panasonic, and Yaskawa.
Tools: Includes configuration, tuning, and scope tools for system parameterization, fine-tuning, and real-time data visualization. Offers simulation capabilities.
Diagram Description: A sample configuration diagram showing a NYCe 4000 controller connected via Ethernet to a Standard PC, with flexible control nodes supporting servo, stepper, linear, and piezo motors, and power supply voltages of 75V and 150V.
3.0 Control Technology
3.1. IndraControl V
The IndraControl V series includes panel-PCs and box-PCs with improved performance and compact dimensions, based on long-term available components. They are designed for demanding environments. PC-based devices are offered as visualization devices (VDP) combined with industrial PCs (VxB), or as panel PCs where the PC is integrated into the display. These devices integrate CNC and PLC functions. Devices can be linked via Ethernet for data exchange and connection of local operation/display systems. An external keyboard can be connected for programming.
Industry PC
VPB 40: Used with operator systems, available in 4 versions. Integrates CNC and PLC. Data transmission between VDP and VPB 40 up to 80m. Technical data includes Windows XP OS, CoreDuo/Core2Duo processors, 1GB RAM (expandable), 80GB HDD/SSD, 24 VDC power supply, various interfaces (Ethernet, DVI, USB 2.0), and protection class IP20. Physical dimensions vary based on slot configuration (1, 2, 4 slots).
Operation and Visualisation System VPP 40
The VPP 40 terminals are designed for automated series production, emphasizing communication continuity and cost-saving standardization. They integrate CNC and PLC functions and can be networked via Ethernet. Features include Windows XP OS, CoreDuo/Core2Duo processors, 1GB RAM (expandable), 80GB HDD/SSD, 24 VDC power supply, various interfaces (Ethernet, DVI, USB 2.0), and a 15" or 17" TFT color display with 1024x768 resolution. Includes machine/operating keyboard and protection class IP65 (front panel).
Operation and Visualisation Device VPP 16
Similar to VPP 40, the VPP 16 terminals are for automated series production, integrating CNC and PLC. Features Windows XP OS, CoreDuo/Core2Duo processors, 1GB RAM (expandable), 80GB HDD/SSD, 24 VDC power supply, Ethernet, DVI, USB 2.0, and a 12" TFT color display with 800x600 resolution. Includes machine/operating keyboard and protection class IP65 (front panel).
HMI Control Element
Operation and Visualisation Device VDP: Reduced visualization device used with VxB40 control cabinet PCs. Offers small installation depth and allows connection of up to four VDP panels to one VxB 40 (Thin-Client solutions). Available in VDP 40 (15"/17" touch-screen), VDP 16 (12" touch-screen), and VDP 08 (8.4" touch-screen) versions. All feature TFT color displays, IP65 front panel protection, and 24 V DC power supply.
Operation Terminal VDP40.3 CG: A complete device with a 15" TFT touchscreen, 3 keys, and emergency-off. Connects to VxB 40 via CDI-Interface. Features VESA mounting and a closed housing for easy installation.
Operation Terminal VEP 50 Embedded
An economic HMI terminal with Windows XP Embedded OS. Supports Soft-PLC or pure HMI functions, connectable via Ethernet and/or fieldbus. Project development via IndraWorks. Features a 15" touch-screen display (1024x768 XVGA), 65000 colors, TFT display, IP65 front panel protection, and 24 V DC power supply.
Operation Terminal VEP 40 Embedded
Similar to VEP 50, this economic HMI terminal uses Windows XP Embedded. Supports Soft-PLC or HMI functions, connectable via Ethernet and/or fieldbus. Features a 12" TFT display (800x600 SVGA), 65000 colors, TFT display, IP65 front panel protection, and 24 V DC power supply. Available in key-touch version (40.4).
Operation Terminal VEP 30 Embedded
An economic HMI terminal with Windows XP Embedded OS. Supports Soft-PLC or HMI functions, connectable via Ethernet and/or fieldbus. Features an 8.4" display (800x600 SVGA), 65000 colors, TFT display, IP65 front panel protection, and 24 V DC power supply. Available in key-touch version (30.4) and as a unit in IP40 housing.
Operation Terminal VCP
Touch terminals (VCP 11, VCP 35, VCP 25, VCP 20, VCP 08, VCP 05) for diagnostics and operating states. Connectable via Fieldbus or Ethernet. Feature Windows CE.NET 5.0, RISC ARM9 processors, various display sizes (3.8" to 10.4"), and IP65 front panel protection. Project planning via VI-Composer.
Diagram Description: Frontal views of VCP 11, VCP 35, VCP 25, VCP 20, VCP 08, and VCP 05 terminals are shown, illustrating their physical appearance and key features.
Manual Control Unit VEH 30
A handheld manual control unit connectable to controls via VAM xx or VAC 30. Allows operation in unclear areas and station handling. Features Windows CE OS, 300 MHz NS-Geode processor, 128 MB RAM, 8.4" TFT display (800x600 SVGA), IP65 protection, and Ethernet connection. Optionally available with electronic hand wheel and override switch.
Diagram Description: Frontal view of the VEH 30 manual control unit is shown, highlighting its ergonomic design and display.
Manual Control Unit VCH 08
A handheld manual control unit connectable to controls via VAC 30. Features Windows CE OS, 400 MHz PXA270 processor, 64 MB RAM, 3.8" FSTN display (320x240), IP65 protection, and Ethernet connection. Optionally available with electronic hand wheel and override switch.
Diagram Description: Frontal view of the VCH 08 manual control unit is shown, highlighting its design and display.
3.2. IndraControl L
The IndraControl L is a controller-based control platform for central and distributed architectures, offering technical and economic optimization. The CML-series hardware serves as a base for stand-alone PLC "IndraLogic".
Function Modules
Modules like PROFIBUS DP-Master, SERCOS III, DeviceNet-Master, cross communication, routing axis sensor, fast I/O, cam-controller, and SRAM-module allow integration into heterogeneous control landscapes. The SRAM-technology-module "CFL01.1-Y1" forms the hardware base for IndraMotion MTX compact and MLC RobotControl.
CML 65
A compact, modular, and scalable control with a high-performance processor for demanding Motion and Logic Control applications. Combines embedded-PC architecture with a standardized I/O system. Expandable with function modules and up to 63 Inline I/O modules. Stores application programs on a Compact-Flash medium.
Technical Data: x86 compatible CPU (1000 MHz), 512 MB RAM, 256 KB remanent storage, CF-Card storage (128 MB to 1 GB), integrated real-time clock. IP 20 protection. Interfaces include Inline, Ethernet TCP/IP, SERCOS III, PROFINET IO Master, PROFIBUS DP, EtherNet/IP Master, DeviceNet Master. Supports up to 8 galvanically isolated Inputs and 8 Outputs, expandable with up to 63 Inline I/O modules.
CML 40
A compact controller-based platform for PLC and Motion applications. Available in different versions with varying technology modules. Handles and programs via Ethernet connected devices. Joins the Rexroth Inline Construction Kit for economic installation. Features 8 interrupt-able I/Os in the basic version, expandable up to 63 Inline-modules (512 I/Os).
Technical Data: Intel Low Voltage Celeron 500 MHz processor, min. 64 MByte DRAM, max. 2.6 A current input, IP20 protection, 24 VDC power supply. Interfaces include Ethernet (10/100 Base-T), Profibus DP, RS232, and 8 local I/Os. Features an LCD display with 8 signs. Physical dimensions: 175 mm x 120 mm x 76 mm.
CML 20
A compact, controller-based platform for distributed machine concepts, serving as a light-performance version of the L40. Not configurable with technology-modules. Handles and programs via Ethernet connected devices. Joins the Rexroth Inline Construction Kit. Features 8 interrupt-able I/Os in the basic version, expandable up to 63 Inline-modules (256 I/Os). Usable as a stand-alone "IndraLogic L20" PLC.
Technical Data: ST Microelectronics ST40 processor (min. 192 MHz), min. 16 MByte DRAM, max. 1.5 A current input, IP20 protection, 24 VDC power supply. Interfaces include Ethernet (10/100 Base-T), Profibus DP, RS232, and 8 local I/Os. Features an LCD display with 8 signs. Physical dimensions: 175 mm x 120 mm x 76 mm.
CML 10
A controller-based platform for the IndraLogic PLC control system, used in distributed machine concepts. Rounds down the performance range of the CML-series and is not configurable with technology-modules. Handles and programs via Ethernet connected devices. Joins the Rexroth Inline Construction Kit. Features 8 interrupt-able I/Os in the basic version, expandable up to 63 Inline-modules (256 I/Os). Usable as a stand-alone "IndraLogic L10" PLC.
Technical Data: STMicroelectronics ST40 processor (min. 192 MHz), 32 MB SRAM + Flash, max. 1.25 A current input, IP20 protection, 24 VDC power supply. Interfaces include Ethernet (10/100 Base-T, RJ45) and 8 local I/Os. Physical dimensions: 121 mm x 123 mm x 71 mm.
I/O - Periphery
active IP-20 module Rexroth Inline: Compact, modular I/O modules communicating via Fieldbus. Adaptable to control tasks. Includes Profibus-DP fieldbus couplers, feeding/segment terminals, digital input/output terminals, analog input/output terminals, temperature input terminals, and DDL Master for Rexroth Pneumatics.
IP67 module Rexroth Fieldline: Stand-alone and modular I/O modules with M12 connectors for easier handling. Reduces wiring costs. Supports Interbus, Profibus, and DeviceNet. Features integrated monitoring functions like undervoltage, overcurrent, short-circuit, and module supply monitoring.
Diagram Description: Images of various Rexroth Inline and Fieldline I/O modules are presented, along with their Module-IDs and descriptions, detailing their functionality and connectivity.
4.0 Drive Technology
Bosch Rexroth drive systems offer outstanding performance, sector-specific functions, and optimized scalability for assembly automation.
4.1. General Features
Extensive Functions: Includes positioning set operation, angle/speed synchronization, cam disc/switch functions, and an integrated routing axis generator. Supports absolute or relative position acquisition via various motor-encoder systems, with an option for a second encoder input.
Comfortable and time-saving startup: The graphical startup tool IW-Drives guides users through setup steps on a control terminal or PC, displaying drive states and providing diagnostic functions. Manuals offer further support.
4.2. Servo drive with IndraDyn S
Synchronous Motor MSK: Suitable for assembly and production automation up to 448 Nm, demanding high position accuracy, machining quality, and rate. Standard protection class IP65 with single-turn encoder. Optional multi-turn absolute encoder, holding brake, or feather key groove available.
Diagram Description: A diagram shows the MSK motor series, illustrating different sizes and mounting configurations.
Synchronous Motor MSM: Maintenance-free motors available in 5 sizes up to 750 Watt continuous power. Protection class IP54, equipped with an absolute value encoder, optionally with or without holding brake. Operates on 3 AC 230V supply. Higher power ratings (up to 3.5kW) available with IndraDyn motor program.
Diagram Description: A table presents technical data for MSM motors (MSM019A, MSM019B, MSM031B, MSM031C, MSM041B) including continuous power, torque, current, speed, inertia, mass, and dimensions.
4.3. AC-Main Spindle Drives
IndraDyn A – Asynchronous motors MAD/MAF: MAD (surface aerated) and MAF (liquid-cooled) motors are used for main spindles and servo drives, with power ratings up to 120 kW. They offer high dynamics, wide speed control range, and excellent concentricity quality. Optional holding brake available.
4.4. Linear Drive Technology IndraDyn L
Linear drives eliminate mechanical transmission elements, benefiting high-speed applications like chipping, grinding, and laser processing. They offer higher speed, precision, and peak forces from 800 N to 21,500 N. The encapsulated primary part protects the motor from environmental influences.
4.4. Rotary table drives with IndraDyn T
Torque motors MBT are used in rotary tables and swiveling axes of machining centers, providing direct drive benefits by eliminating attrition-prone mechanical transmission elements. They increase dynamics and precision, offering torques from 15 Nm to 13,800 Nm.
4.5. Servo-gears GTE and GTM
GTE Servo-planetary gears: For standard applications, available in single- or double-staged versions with plane shaft or feather key groove.
GTM Servo-planetary gears: For highest requirements, available in single- or double-staged versions with plane shaft or feather key groove, and optionally with twisted torsional stiffness.
4.6. Drive-Control Unit IndraDrive
The modular IndraDrive system offers increased flexibility, productivity, and precision, covering a performance range from 0.1 to 132 kW. It supports various communication protocols like SERCOS 2/3, PROFIBUS, CANopen, DeviceNet, INTERBUS, and analog/parallel interfaces.
The IndraDrive Family:
- IndraDrive C: Converters (1-630kW, peak currents up to 1300A). Compact setup, direct power supply up to 500V, high overload capability.
- IndraDrive Cs: Compact Converters (0.1-3kW). Compact setup (IP20/IP54), integrated safety technology (optional), Multi-Ethernet connection. Supports SERCOS III, PROFINET IO, EtherNET/IP, EtherCat, and Multi-Encoder. Compatible with motors from 0.05 to 3.5 kW.
- IndraDrive Fc: Frequency Converters (0.25-7.5kW). Compact for open-loop applications, easy installation/startup. Fieldbus modules for Profibus, CANopen, DeviceNet available.
- IndraDrive M: Inverters (1-132kW, peak currents up to 350A). Double-axis inverters, space-saving for multi-axis solutions, energy-efficient supply modules.
- IndraDrive Mi: Combined module (motor + control) (9.4-35 Nm). Minimal space requirement, integrated Motion-Logic (IEC 61131-3).
IndraDrive C and M: Modular series for machine tool and general automation. Features integrated PLC (IEC 61131-3) and extensive function packages optimized for servo applications, main-drive, and machine tools. Firmware packages include FWA-....-MPB-... (basic), FWA-....-MPH-... (advanced), and FWA-....-MPD-... (double-axes). Expansion packages offer features like axis error correction, synchronization, and safety technology.
Safety Functions: Certified according to IEC61508, including Safe-Stop, Safe Operation-Stop, Safe Reduced Speed, Safe Limited Absolute Position, and Safe Brake-Management. Other functions include safe drive interlock, safe maximum speed, and safe rotation direction.
Diagram Description: Overviews of IndraDrive M Power Elements (single and double-axis), Supply Devices, and IndraDrive C Power Elements are presented with their respective current ratings and model numbers.
Diagram Description: Technical characteristics of IndraDrive Cs are listed, including voltage ranges, power output, protocol support (SERCOS III, PROFINET IO, EtherNET/IP, EtherCat), and encoder types (EnDat, Hiperface, incremental, resolver).
Diagram Description: Baugrösse A, B, C, D diagrams for IndraDrive Fc converters are shown.
5. Rexroth Pneumatics
Rexroth offers a broad range of pneumatic electronic and electro-pneumatic components and systems for machine and production facility automation.
5.1 Gripping, Moving, Turning and Controlling
Non Contact Transfer NTC: Not described in detail.
Grippers GSP: Available in Parallel, Angular, Radial, and Centric types. Features include high gripping force in small packages, Easy-2-Combine interface, centering sleeves, repeatability of 0.02 mm, and sensor slots. Specifications for gripping force, payload, stroke angle, and finger length are provided for each type.
Diagram Description: A table and diagrams illustrate the different types of GSP grippers (Parallel, Angular, Radial, Centric) with their key features, benefits, and strengths, including comparisons to competitors.
Rack & Pinion Rotary Drive RCM: Available in SE (Elastic Cushioning) and SH (Hydraulic Cushioning) versions, with additional AP (Air duct) and IP (Intermediate) options. Sizes range from 6 to 25. Specifications for torque, moment of inertia, repetitive precision, and angle adjustment are provided. Benefits include higher capacity for moments of inertia and Easy-2-Combine interface.
Diagram Description: A table and diagrams detail the RCM rotary drive specifications for different sizes and configurations (SE, SH, AP, IP), highlighting benefits and strengths.
Rodless Cylinder RTC BV: Available in CG, EG, HD versions. Features include magnetic outer band, oval piston for flat design, optimization for fast cycle times, and comprehensive guide options. Specifications for size, max stroke, max speed, and guide rail are provided.
Diagram Description: A table and diagrams illustrate the different RTC rodless cylinder types (BV, CG, EG, HD) with their sizes, stroke, speed, guide rail specifications, benefits, and strengths.
Mini Slide MSC: Available in sizes 8, 12, 16, 20, 25. Features Easy-2-Combine interface, repeatability of 0.02 mm, and combinability with electric axes. Specifications for stroke, static/dynamic moments, velocity, and force are provided.
Diagram Description: A table and diagrams detail the MSC mini slide specifications, including sizes, stroke, moments, velocity, force, benefits, and strengths.
Valves Series LS04: Available in XS (extra small), AF (all functions), and VTS (Modular valve terminal system) versions. Specifications for nominal flow, pneumatic function, connection, switching time, working pressure, and electrical connection are provided.
Diagram Description: A table compares the LS04 valve series (XS, AF, VTS) based on nominal flow, function, connection, switching time, pressure range, electrical connection, dimensions, and weight.
Valve Terminal System LP04: Modular system for 4-16 valves, expandable. Temperature range -5°C to 50°C. Operating pressure 3-8 bar (internal), -1 to 10 bar (external). Valve functions include 2x3/2, 5/2, 5/3. Electrical connections via D-sub, Profibus DB, DeviceNet, DDL. Flow rate 300 l/min.
Valve Terminal Series HF04: Modular system for 2-12 valves, expandable. Temperature range 0°C to 50°C. Operating pressure 3-8 bar (internal), -1 to 10 bar (external). Valve functions include 2x3/2, 5/2, 5/3. Electrical connections via D-sub, Profibus DB, AS-i. Flow rate 400 l/min.
Air Preparation Units: AS2, AS3, AS5 units with nominal sizes 1/4, 3/8, 3/4 respectively. Feature pressure gauge connection, maximum pressure range of 16 bar, and permissible temperature range of -10°C to +50°C. ATEX approval for Zone 1 and Zone 21. Flow rate specifications measured according to ISO 6953.
Diagram Description: A table lists the specifications for AS2, AS3, and AS5 air preparation units, including nominal size, air connection, pressure gauge connection, maximum pressure, temperature range, ATEX approval, and flow rate specifications.
Easy-2-Combine: An automation system comprising pneumatic and electric drive modules with standardized mounting interfaces and interlocking connections for pick & place, linear, and area gantry applications. Features standardized interfaces, direct mounting, comprehensive connection kits, interlocking connections, high-load guides, and a universal mounting raster.
Diagram Description: Diagrams illustrate application examples for Easy-2-Combine: Pick and place, Linear gantry, and Area gantry, showing the modular components and their arrangement.
6. Rexroth TS Transfer Systems
Bosch offers transfer systems for component transport, with different sizes supporting workpiece carriers from 3 kg to 250 kg.
Transfer System TS1
For weights up to 3 kg, speeds up to 15 m/min. Features three workpiece pallet sizes (80x80, 120x120, 160x160 mm), small dimensions, precision, fast change times, and ESD compatibility.
Transfer System TS2
For weights up to 100 kg, speeds up to 18 m/min. Workpiece pallet dimensions from 160x160 mm to 800x1040 mm. Suitable for rough ambient conditions and clean rooms, ESD compatible.
Transfer System Varioflow
For weights up to 20 kg, speeds up to 60 m/min. Features simple planning and assembly with preassembled modules and high chain tensile force (1,250 N). Includes VarioFlow and VarioFlow S chain conveyor systems in various sizes and configurations, including stainless steel versions.
Transfer System TS Solar
Designed for transporting hot glass modules up to 150°C. Features silicone-free operation, no open grease/oils, 100% usable in ESD environments, suitable for class 6 clean-rooms. Available in 2-, 3-, 4-, and 5-tracked solutions with optional continuous speed control.
Diagram Description: Diagrams illustrate product variants like CSS/B, CSS/BM, CSS/F, CSS/NT, CSS/B-cell, CSS/BM-cell, and LTS cross-lift unit, detailing their transport media, temperature capabilities, design features, and actuator types.
7. Handling-Systems from Bosch Rexroth
Bosch Rexroth offers integrated mechatronic solutions for handling systems, combining mechanics, pneumatics, drive systems, and control systems.
EasyHandling: Categorized into Basic, Comfort, and Advanced levels. EasyHandling Basic includes mechanical and pneumatic components, grippers, rotary modules, motors, and sensors. Comfort adds pre-parameterized servo drives and a commissioning assistant. Advanced includes pre-configured, scalable controls.
Diagram Description: A diagram shows the structure of EasyHandling systems, categorizing them into Mechanics, Pneumatics, Drive systems, Control systems, and Mechatronic system solutions, with further breakdown into Basic, Comfort, and Advanced levels.
Easy Handling components: Lists Motor and Drives, Electrical axes, Pneumatic axes, rotary modules and grippers. Provides specifications for standard applications like pick-and-place, Cartesian systems, and linear gantries, including max stroke, max load capacity.
Diagram Description: Diagrams illustrate standard handling applications: pick-and-place, Cartesian system (arm), linear gantry, and Cartesian system (gantry), showing their stroke dimensions and load capacities.
Calculation- and Dimensioning-Tools: Includes IndraWorks for drive/control setup, IndraSize for servo motors, LinSize for linear/multi-axis systems, Linear Motion Designer for profile rail guiding, Easy-2-Combine for pneumatic components, and CAD-Konfigurator.
8. Rexroth Tightening Systems
Rexroth Tightening Systems are designed for flexible market requirements with a modular construction kit principle for easy installation.
Rexroth ErgoSpin and compact system CS351: A powerful hand-screw system designed with ergonomics in mind, featuring optimal operating elements and a turnable/lockable crosshead.
Rexroth-Screw-Jacks: Offer system safety and process safety through digital data transfer and high productivity in control-cabinet-less screw systems for up to 40 channels. Features include parameterization via Rexroth operating system, SVGA resolution on VxP in WinNT, Ethernet-based fieldbus, and 24V interfaces.
9. System software
9.1. IndraWorks
IndraWorks is a scalable framework for modular Engineering solutions, integrating specific engineering tools as plug-ins. Framework and tools are independently developable, ensuring openness. IW-Drives is the setup tool for Rexroth Drive Technology, guiding users through parameter settings, component detection, and offering diagnostic functions and an oscilloscope function for control loop analysis.
Diagram Description: A diagram illustrates the IndraWorks Framework structure, showing how specific Engineering Tools integrate as plug-ins.
Oscilloscope-function: Enables measurements and evaluation of diagrams, such as motor transient response, useful for drive startup and machine axis optimization.
HMI screen design with WinStudio
WinStudio allows unrestricted HMI screen design, supporting standard elements and custom screens. It includes a project planning version (one-time purchase, multi-control use) and a runtime component (per control unit). The limit of 500 tags is removed compared to the free MTX light version. Supports languages like Visual Studio 6 (VB6, C, C++) and Java, with additional functions like web-client assistance and OPC server.
System software IndraLogic
IndraLogic comprises software components for PLC machines and assembly applications, integrated into the IndraWorks Framework. Basic installation includes IndraWorks with Fieldbus/I/O configurator, IndraLogic (PLC programming system), criteria analysis, linkage/network functions, WinStudio for user interfaces, common tools (logic analyzer, NC programming), and IW-Drives. System add-ons are available for IndraLogic applications.
PLC programming system: Used for logical implementation of automation tasks, usable on different hardware platforms and as a soft PLC. Compatible with Windows XP. Integrated into IndraWorks desktop for project planning and HMI picture creation with WinStudio. Can be installed independently on any PC for offline planning.
Basic Functions: Includes editors (fieldbus configuration, declaration), compiler, printing capabilities, context-sensitive help, structured programming (resource, program, function block, etc.), programming via EN 61131-3 standard (Structured text, sequence language, function block language), standard keywords and data types, symbolic identifiers, predefined components, standard graphic representation, and text import/export function.
ProVi messages: Standard for PLC diagnostics, displaying malfunctions, warnings, and system errors in WinHMI.
PLCopen Function library: Supports standardized Motion Control functions for systems programmed under IEC 61131-3.
Common Tools:
- IndraStep: Step chain programming for PLC tasks, simplifying complex responsibilities and enabling module construction. Supports automatic identification/management of operation methods and diagnostics.
- Logic Analyzer: Facilitates PLC programming by recording trace screens in 8 channels.
- Visualisation of the task load: Shows task efficiency and helps identify weak spots in PLC projects.
9.2. VI-Composer 2.0
Software for simple project planning of VCP terminals without requiring programming knowledge. Can be started separately or via IndraWorks, including programming surface and download interface. VCP project data can be indicated in the IndraWorks project tree. Features "drag & drop" operation, direct PLC variable access, and integration of graphic/multilingual projects.
9.3. WinLOC
WinLoc restricts user access to the Operating System, limiting access to programs called from the "Startup" group. Unauthorized users cannot access the Windows environment. Requires special privileges to end Windows. Users must be authenticated to switch modes, log off, shut down, or restart. Allows assignment of defined access privileges for users to machines.
9.4. I-Remote remote control software
Provides comfortable remote control for disturbances or machine start-up, facilitating software updates. Reduces costs and increases productivity. Integrates with IndraWorks for remote maintenance, using system components like RAS or standard modems. Features include an integrated WEB server, remote control via WEB browser (no client installation), data compression, automatic screen updating, delta file transfer, file synchronization, system snapshot, audio support, record/playback, and a powerful script language. Supports MTX, IndraLogic, MLC, VEP, VEH systems. Interfaces include modem, network, or serial line connection with NetBEUI, TCP/IP, and IPX support.
Diagram Description: Diagrams illustrate the system architecture for I-Remote, showing connections between Service PC, Visualization/Control PC, and Embedded Control units via different network and modem options.
9.5. Rexroth data safety concept with Acronis
Acronis True Image is an add-on for backup functions, creating images of hard disks or partitions for complete backup and recovery of operating systems, programs, data, and settings. It can reconstruct disks and partitions even if the OS is not running.
Protection of user's data: Allows saving user data separately via a parallel interface or Ethernet to a central Backup server. This enables uniform data saving and central data attitude/archiving for all components.
10. Training
The Bosch Rexroth training center is located in Erbach, Germany, with global training capabilities. Courses are conducted for maintenance personnel, machine operators, designers, and engineers, supplemented with practical exercises. Contact information for the Training Center Erbach is provided.
11. Bosch Rexroth – info world
Visit Bosch Rexroth at www.boschrexroth.com/solar for new trends and technologies.
