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10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
New Generation Controllers & Industry 4.0
Ken Rayden & Dave Cameron
CMA/Flodyne/Hydradyne – Drive for Technology
1
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
2
Heterogeneous programming and parameterization
software and controller structures
MAC-8
MACPRO WIN-PED BODAC WinHPT
HNC100
IAC
Controller A Controller B Controller C
HACD
Controller D
Andy Kevin Edgar Don
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
New Controller Lineup
CMA/Flodyne/Hydradyne – Drive for Technology
XM2x
3
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
4
General platform
MLC+H IAC 2X HNC100/HACD follower DFE control electronics
with IAC-2X technology
IndraWorks IEC61131-3 Best-in-class controllers
HMC
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
5
Configurable Toolbar
Project Explorer
Device Library
Task List, Output Message, etc…
Work Area
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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IndraWorks - programming
Modern concept:
Arrays, structures…
Multi-tasking
Libraries
PLCopen
…
Consistent programming and runtime concept
Programs or program components may be
incorporated into other systems without problem!
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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IndraMotion MLC – Functions
Multi-axes synchronization Electronic Line Shafting
Positioning
Virtual master axes
Real master axes Encoder axes
Electronic gears
Electronic cams
Cross communication Link axes
MotionProfile Master-axes related motion
profiles
Master axes cascading
FlexProfile Master-axes or time related
motion profiles
PLCopen Standardized function blocks
for Motion Control
Logic control according to IEC 61131-3 with
extensions
Robot control Tools and functions for
coordinated motion
Linear interpolation
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
8
IndraMotion MLC – Hydraulic Specific Functions
Best-in-class controller Centrally processed “Best of“ controller for
hydraulic axes -
fast, modular and flexible
„best of“ Regler
Ablösende Regelung
Alternating control Positioning with automatic transition to force
control and back
Synchronization controller Centrally processed synchronization controller -
specifically for hydraulic axes,
position active and force passive
Gleichlauf Regler
WAB
Position-dependent braking Open-loop controlled positioning with deceleration
to target position
Variable-speed pump drives controller Centrally processed DVP controller for
hybrid axes
DVP Regler
M
WinView Diagnostic Tool – Free stand alone tool
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
9
Best in Class Control
Best in Class Motion Control Axis controller
Position control ●
Force control ●
Pressure control ●
Velocity control ●
Closed-loop- flow control -
Open-loop flow control ●
Alternating control (Position / Force) ●
State control ●
Command value feed forward ●
Fine positioning ●
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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Hydraulic specific features Axis controller
Valce characteristic compensation ●
Valve overlap compensation ●
Direction-dependent gain ●
Command value generation
Valve direct control ●
Drive-controlled position control ●
Drive-controlled positioning ●
Positioning block mode ●
Monitoring / error reactions
Cable break detection (sensors) ●
Communication errors ●
Best in Class Control
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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IndraWorks Ds
Explorer
Parameter setup
Diagnosis
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the event of applications for industrial property rights.
VT-HMC
CMA/Flodyne/Hydradyne – Drive for Technology
VT-HMC
12
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
Hardware
Multi-Ethernet Interface
Multi-Encoder Interface
Digital Inputs/Outputs
Analog Inputs/Outputs
SD Slot
13
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the event of applications for industrial property rights.
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Multi-encoder interface
PROFIBUS DP
Analog inputs
Analog outputs
SD slot
Multi-Ethernet
Interface
Digital inputs
Digital outputs
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the event of applications for industrial property rights.
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Digital IO
Digital inputs
4 digital inputs
Digital outputs
2 digital outputs
Max. current 50 mA
Customer benefits
- Fast digital IO (cycle time)
- Short-circuit-proof
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the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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Multi-Ethernet Interface
Bus systems
Sercos
PROFINET
Ethernet/IP
EtherCAT
PROFBUS DP
Ethernet-based bus system is
switchable (P4089-0.1).
Service interface TCP/IP
Customer benefits:
Multi-Ethernet Interface
Reduced no. of variants
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SD Slot
Saving of projects
Function update of HMC
Transfer of projects
Customer benefit
- Fast start-up
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
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Analog inputs
4 analog inputs.
Resolution : 14 Bit
Configurable I/U
Analog outputs
2 analog outputs
Resolution 16 Bit
Configurable I/U
Customer benefit
- Higher precision by high-resolution
Inputs/outputs
- Configurable I/U, change of wiring
isn‘t necessary.
- All standard signals available.
Analog IO
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the event of applications for industrial property rights.
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Multi-Encoder Interface
SSI encoder
Incremental encoder
EnDat2.2
Customer benefit
Multi-encoder Interface
Encoder voltage supply on board
Short-circuit-proof
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
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Environmental
Ambient temperature
-20° to 60°
Type of protection IP20
Switch cabinet
CE mark
Customer benefit:
Simple termination technique
Operation within extended
temperature range
-20°
60
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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Summary
All Ethernet bus systems on board
Multi-encoder interface
Operation within extended
temperature range from -20° to +60°
Only 2 variants
22 10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
Agenda Software Properties
Indraworks
Diagnostics
Best-in-class controller
IEC 61131
Application example
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
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Best-in-Class Controller
Position control
Force control
Pressure control
Active damping
Alternating control
Velocity control
Benefit:
Best-in-class controller
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
Programming Language
IEC 61131
ST (Structured Text)
FBD (Function Block Diagram)
LD (Ladder Diagram)
Sequential Function Chart
(SFC)
IL (Instruction List)
Library
PLCopen
Function library
PLCopen
Standardized
function blocks
for
Motion Control
Library
Predefined
function blocks
Logic Control
PLC IEC61131
with extension
24
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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VT-HPC
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the event of applications for industrial property rights.
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26
HPC vs VT-VPCD
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the event of applications for industrial property rights.
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Product comparison HPC vs. VPCD
Faster cycle time 2msec 0,5msec
Control valve without feedback
Swivel angle sensor has analog signal
All bus systems onboard
Temperature range from -20° up to +60° Celcius
Rexroth offers 2 variant of HPC
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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Comparision HPC VPCD / Performance
VT-HPC VT-VPCD
Controller sample rate
0.5msec 2msec
Interface Ethernet RS232
Voltage supply 24 VDC 18 - 30 VDC
Temperature -20° - 60° 0° - 50°
CE
Diagnosis IndraWorks Winview
Operator tool IndraWorks BODAC
= exists/advantage
= In preparation
= not exist
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
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Sensors
VT-HPC VT-VPCD
Swivel angle
Analog
LVDT --
= exists/advantage
= In preparation
= not exist
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
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Bus system
VT-HPC VT-VPCD
sercos
PROFINET
EtherNet/IP
EtherCAT
POWERLINK
PROFIBUS DP
DeviceNet --
CANopen --
= exists/advantage
= In preparation
= not exist
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
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Controller
VT-HPC VT-VPCD
Swivel angle
Pressure
Mooring
Power limitation
Speed variable
Master Slave
Best in Class
= exist/advantage
= In preparation
= not exist
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
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Analoge Input
VT-HPC VT-VPCD
Number (pcs.) 6 (U/I) 6 (U/I)
Resolution 14Bit 12Bit
0 .. 10V
-10V .. +10V
0 ..20mA
4 .. 20mA
User define
= exist/advantage
= In preparation
= not exist
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
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Analoge Output VT-HPC VT-VPCD
Number (pcs.) 2 2
Resolution 16 Bit 14 Bit
0 .. 10V
-10V .. +10V
0 ..20mA
4 .. 20mA
Short-circuit protection
User-defined
= exist/advantage
= In preparation
= not exist
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
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IAC- MultiEthernet
4WRPDH, 4WRLD
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Decentralized, fast closed-loop
control
Low cabling effort
Low space requirement
Ready to use component
Flexible for extensions / adjustments
of the control architecture (e.g.
number of axis, sensor interfaces
etc)
Integrated Axis Controller
Advantages Components
Drive control valve
+ + =
Drive
controller
High-
response
directional
valve
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Valve with integrated axis control Axis control features
Position control:
Scan time 1ms
PDT1 controller with switchable
integrator
Fine interpolation
State control
Pressure control:
Scan time 0.5ms
PI-controller
Alternating control
(Position/Pressure)
System adaption
(Valve, cylinder)
Comand value feed forward
(lagless position control)
Drive integrated command
value generator
Command value profiles
Positioning block mode
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
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Integrated Axis Controller
Control structure
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the event of applications for industrial property rights.
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Best in Class
Connectivit
y
Best-in-Class control
valve-integrated axis-control
easy installation and compact
design
High performance valve
program
wide range of products with
approved technology
Robust and reliable
protection class = IP65
ambient temperature = 60° C long
term stress
CE-mark
Support
worldwide support over Ethernet
Learning
Knowing
Living
Optimum
hydraulic-technology
Applications
sustained business success
Techn
olo
gy
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open in communication
Multi-ethernet and bus profile support
1 x Bus In, 1 x Bus Out (M12)
parametrization and service over
standard Ethernet
Staus LED’s
digital and analog I/O (11+PE)
Valve internal safety function
Preventing unintentional start-up
Open sensor interfaces
max. 2 external pressure sensors
- 4…20 mA or 0..10 V, resolution 12 bit
position transducer (digital)
- SSI
- EnDat 2.2
- 1 Vpp
Ethernet bus electronics (IAC-2x)
Communication interfaces
Sensor interfaces
M12 interface
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
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11+PE interface
Power supply
Enable for valve output stage
Acknowledge of valve output stage active
Configurable Analog IN and OUT (+-10V or 4…20mA)
2 Analog-/Digital inputs
1 Analog output
Error output
Internal saftey function
Preventing unintentional start-up (direction P => A)
for the use up to category 4 / PL e
according to EN 13849-1
(with appropriate system integration)
Can be used up to category 4/PL e according to EN 13849-1
11+PE
Safety function
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
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Valve with internal safety function Symbols
Linear P: Non-linear 60%
Internal saftey function
Preventing unintentional start-up (direction P => A)
for the use up to category 4 / PL e
according to EN 13849-1
(with appropriate system integration)
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Valve with internal safety function
Coding A
M12 5-pole
Coding D
M12 5-pole
M12 8-pole
After the signal at the enable input has been removed, the output stage, and thus the solenoid of the valve, are internally separated
from the available supply voltage. The enable acknowledgement will only be activated after the safe control spool position has been achieved.
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DFEn – Multi-Ethernet
Engineering tool IndraWorks DS
Configuration of digital signals by
means of software (no fixed pin
configuration)
Powerful oscilloscope function
Extended diagnosis high reliability
Simple storing of project data
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Control portfolio starting from 14VRS
Reference L65:
100%Performance -> real machine with 20-24 axes, with 8ms/ 2ms scan
and an “extensive” application.
L65
100% L75
120%
VPx
200%-
300%
L45
40%
XM21
30%
XM22
60%
XM4
?% XM10
?%
HMC
1Achs
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
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IndraMotion MLC
45
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
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XM and MLC-H
XM2x :
In combination with S20 2-Axes-module
Integration of the new hardware (XM, S20 modules)
for hydraulic applications e.g. Axis Wizard
New license model:
Optional are e.g. hydraulic functions
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Drive control
Interface
I/O module for four drives HACD
Command values
Actual values
MLC
Decentralized control structure Central control structure
MLC for hydraulic drives
Interface
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Decentralized I/O's
Centralized I/O's
+
Inline I/O
Block modular
Inline I/O modular
IndraControl S20 IndraControl S67
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Inline Block I/O – Configure
Double click on Axis
Change to User Parameter
Double click on Value to open pull down
menu
Press Enter to confirm changes
4 x
SS
I Encoder
12 x
Analo
gue In
put
4 x
Analo
gue O
utp
ut
10/27/2015 | DCUS-ME | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
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Best in Class – Hydraulic controller
IndraMotion MLC with tailored hydraulic controls:
Optimized synchronization Active and passive position synchronization and load allocation
Mixed synchronized groups (electric, hydraulic and hybrid drives)
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Best in Class – Hydraulic controller
IndraMotion MLC with tailored hydraulic controls:
Synchronization - Concept
Motion-Application
Synchronized axis
(control axis)
Achse 1 axis 2 axis 3
Actual
values
axis 1 axis n
Slave axis handling (options):
Command value calculation for
cascaded position control
Command value calculation for
cascaded speed control
Command value calculation for
cascaded force control
Synchronization mode:
Determine the synchronization
reference value
Synchronization error detection
Target positioning (Integrator) Command
values
10/27/2015 | DC-IA/SPF3 | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
CMA/Flodyne/Hydradyne – Drive for Technology
Thank you for your attention! Questions ?
52