Rexroth Motion Control System NYCe 4000 – modular, compact and cost saving

Maximum functionality, minimum fitting space – the new NYCe 4000 and NYCe 4000 LMS

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Bosch Rexroth has extended its range of motion control systems with new versions of the NYCe 4000 – the rugged, functional and compact multi-axis industrial motion control system, with integrated drive technology. NYCe 4000 and NYCe 4000 LMS control complex equipment and are offered in a single unit that significantly reduces space requirements and cabling, cutting system and integration costs. It also extends machine availability and greatly improves serviceability.

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The NYCe 4000 motion control system gives you an unparal-leled degree of freedom. Sophisticated hardware designed to handle complex operations combined with open software architecture provides the ideal platform for tailored motion solutions and simple integration into your automation land-scape. Whatever is your industry segment, Semiconductor, Plastic Electronics or Solar, Rexroth NYCe 4000 motion control system helps you to:

▶ Reduce your time to market ▶ Optimize total cost of ownership ▶ Increase machine performance ▶ Improve machine availability

NYCe is one of the core components of the Rexroth Linear Motion System LMS, the branch solution for assembly under extremely fastidious or harsh environmental conditions.

Short time to market

Market introduction is always critical. The timely introduction of new equipment and machines to market has consequences on reaching target markets with the desired value. It is very important that, during the development and production of new equip-ment, your motion control system enables you to reach your business goals.

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Our mechatronic experts can assist during the design phase of your new machine. With our expertise in all indus-tries we can help you perfect your prototype machine in an early development stage. This saves valuable time and results in optimal machine performance. During the imple-mentation phase our application engineers are available for support. With their in-depth knowledge of the NYCe 4000 control system, they will optimize the performance of your specific application. NYCe 4000 provides the technology with functionality and flexibility as if it was your own design. Using NYCe 4000 will save you valuable effort, time and money. Not only do you streamline development of your machine through expert motion control, but you also enhance your ability to keep pace with new developments throughout its life-cycle.

NYCe 4000 includes a simulation environment. This is a valuable tool for your application software developers to

test their applications without having a control system or machine connected. They can simply test the application on a PC at a very early stage, even before the new machine is available.

Open Core Engineering – The complete package for maximum engineering efficiencyThe software tools, function toolkits and multi-technology solutions associated with Open Core Engineering accelerate the engineering workflow. This offers benefits in every step of the engineering process, from initial configuration to pro- duction operations.

Unprecedented freedom for individualization Rexroth is opening controls up right down to their core to enable the independent creation of customized functions supported by the existing firmware. Open Core Engineering permits the machine manufacturer to create and program real-time capable applications in C/C++ and provides it to end-users as extension of the control firmware.

Open Core Interface for independent development of unique functions

▶ Individual real-time applications on the control ▶ Competitive advantage that stands out from the rest ▶ Protection of machine manufacturers’ special expertise

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Connectivity and cabling in a machine are factors that often include significant hidden costs. Cabling from all devices in a machine (motors, encoders, sensors, relays, switches) are usually connected to the control platform. In most control systems external drives as well as an I/O distribu-tion board are needed. The new, streamlined solution is the NYCe 4000 with integrated drives and I/O. The motion control system can handle up to 120 digital and analogue I/Os in parallel in real time. You implement complex process operations on standardized hardware. Pre-defined software algorithms ensure zero-vibration and zero-backlash.

The NYCe 4000 saves costs, takes up less space and im- proves machine uptime by removing part of the vulnerable cabling.

Optimize total cost of ownership

In a highly competitive market it is important to optimize the efficiency and yield of your machine. The NYCe 4000 and NYCe 4000 LMS with their optimized performance focused system architecture introduce a structural method of integrating and maintain-ing motion control in your machine. They enable efficiency of operation without sacrific-ing machine functionality.

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Increase machine performance

Faster machines require improved control algorithms to compensate for mechanical shortcomings. The modular multi-axis controller contains all of the control and drive hardware in an extremely compact housing. High-level programming languages allow you to write complex motion control programs. Extremely high-speed control loops with 32 kHz (31.25 μs) position and velocity loop deliver maximum precision and dynamic performance.

State of the art control algorithms with feed forward con-trol, filters and notches can all be set by the user, even when the machine is moving. User friendly tuning software, specific control algorithms and the possibility to include your own control algorithms, assure that even the most demanding applications can rely on optimal control algo-rithms.

As machines become faster, the motion aspect needs to be faster and more accurate, as does the interaction between motion and I/O in the machine. Therefore NYCe 4000 inte- grates functions that directly link motion and I/O action, such as latches, markers and event handling. Quickly res-ponsive and programmable applications can be integrated in the NYCe 4000 system. Using the sequencer, running on the motion control unit, C-applications can be downloaded and run in real-time directly on the NYCe 4000.

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Improve machine availability

A machine is expected to run continuously, without getting into an error state. In case this still happens, it is of utmost importance that the machine is up and running as soon as possible. The NYCe 4000 series contains several key features designed to improve your machine availability.

The NYCe 4000 series supports several levels of monitor-ing. The standard method is based on software triggering reacting to a signal that is generated by your machine. This signal can be a digital input or an analog input value that reached a predefined limit or a temperature in the system. The system automatically generates events on motion re- lated exceptions, i.e. large position errors, reaching end-switches etc.

Another monitoring feature is based on the sample- synchronized logging of data. With the use of standard software tooling you can look in detail to the performance of your motion system at any moment in time with depend-able values. You can, for example, log several axes positions and when small deviations from the expected value are detected you might decide to do preventive maintenance or replace machine parts preventively.

When an error occurs on the NYCe 4000 system, the de-fective module can be exchanged by a spare one. This can be done without removing any cabling and without setting jumpers or switches. Once the new module has been inserted, the NYCe 4000 automatically reconfigures and will run the original software, thus allowing fast module exchange at minimal risk.

Using these features, the user can avoid machine stops by responding fast to exceptional situations.

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Roll-to-Roll –The New Production Method

Roll-to-roll processing as it applies to plastic electronics is new and innovative. Rexroth leverages many years of experience and com-prehensive know-how in the printing industry when it comes to thin-film production on thin, flexible materials.

Designed to meet complex requirements, united with simplicity of operation, the modular architecture allows fast and error free design-in. Using a standard PC and the motion control unit, a wide range of motors and encoders are supported. Programming the system is simple using standard function blocks. The open controller architecture gives you complete freedom to define your own customized kinematics. An intuitive, dialogue-based user interface with numerous wizards makes development work much easier, simplifying the commissioning process and reducing time to market.

NYCe 4000 architecture

IndraControl V

MSM Motors

IndraDrive Cs

IndraDyn S

NYCe 4000

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Product overview

NYCe 4000 ▶ Integrated drive and control platform ▶ High bandwidth control loops ▶ Powerful tuning and visualization software ▶ Open architecture ▶ Modular and compact design

NYCe 4000 LMS ▶ Inverted linear motor principle ▶ Enables motion under difficult process conditions ▶ Individual carrier control ▶ Carrier tracking

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▶ Compact design for small footprint

- Compact size - Integrated motion control, drives and I/O - Modular design allows scalable solutions

▼ Conventional solution needs more space

Roll-to-Roll –The New Production MethodNYCe 4000 – your benefits at glance

▶ Synchronized motion and I/O for fast control systems

- Directly linked actions between motion and I/O - High speed data collection, 32 channels @ 32 kHz - Fast digital inputs and outputs < 2 µs delay - Optimal metrology support

▶ High motors connectivity - Up to 620 controlled axes in a system - Various motor types - External drives via analogue output and enable/disable function - IndraDrive C/Cs via Sercos connectable

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▶ Smooth and vibration free movements

- 4th order set point generation - Full PVT support - 5 filters for optimal loop shaping

▲ High dynamics - Extensive feed forward control - 32 kHz position and velocity loops - Maximum software flexibility

▶ Fast engineering and commissioning

- Wide range of commissioning tools - Full support for software simulation (parallel engineering) - Standard programming languages like C / C++ / .NET

Bosch Rexroth AGBgm.-Dr. Nebel-Str. 297816 Lohr, Germanywww.boschrexroth.com

Find your local contact person here:www.boschrexroth.com/contact

Further information:www.boschrexroth.com/nyce

R999000379 (2014-04)© Bosch Rexroth AG 2014Subject to revisions!

The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.