Rexroth IndraWorks Simulation

Transcription

1 Electric Drives Linear Motion and Hydraulics Assembly Technologies Pneumatics Service Rexroth IndraWorks Simulation R Edition 02 Application Description

2 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Title Type of Documentation Document Typecode Internal File Reference Purpose of Documentation Record of Revision Rexroth IndraWorks Simulation Application Description DOK-IWORKS-SIMU****V01-AW02-EN-P RS-de78b78b0a6846ac009c70d0829c30df-2-en-US-2 This documentation describes the functions of simulation component View3D, virtual control panel, virtual control and its operation in IndraWorks. Edition Release Date Notes B304-01/EN First edition B304-02/EN Supplements Copyright Validity Published by Note 2006 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authourity, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Phone +49 (0)93 52/ 40-0 Fax +49 (0)93 52/ Dept. BRC/ESM4 (MiBr), BRC/ESM6 (DiLe) This document has been printed on chlorine-free bleached paper.

3 Application Description Rexroth IndraWorks Electric Drives Table of Contents Bosch Rexroth AG I/III Table of Contents 1 General Why Simulation? What is Simulated? Goals of Simulation in IndraWorks Important Instructions on Use Intended Use Introduction Area of Use and Application Improper Use... 3 Page 3 Safety Instructions for Electric Drives Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others How to Employ the Safety Instructions Explanation of Warning Symbols and Degrees of Hazard Seriousness Hazards by Improper Use Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings Protection Against Electric Shock by Protective Extra-Low Voltage Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protection Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Systems Quick Start Components of the Simulation Project Explorer D Visualization General Description Model Visualization Basic functions Functions for manipulating 3D objects Scene Tree General Object properties Assignment OPC Configuration Assignment List Properties of the View3D Model... 25

4 II/III Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Table of Contents Page 5.3 Virtual User Panel General Description Configurator The Application Virtual Control General Description Operation in IndraWorks Creating a Model General Creating a Simple 3D Model Importing em-realnc Models Using the Virtual User Panel Configuration Configuration in IndraWorks Supplements to the configuration file Connection to Virtual Control Start Error Messages and Remedies Using 3D Visualization D Models in IndraWorks Importing 3D models Opening, renaming and deleting 3D models Process Connection Connecting 3D objects with IndraMotion MTX axis values Configuring the process connection Establishing a connection to the control D Visualization Operation Basic 3D visualization functions Manipulating 3D objects Changing settings of the View3D model Using the Virtual Control Installation of MTX Emulation General Projecting Emulation Restoring an existing project Projecting the HMI General Designing the NC Core General Projecting the PLC General Starting and Exiting MTX Emulation General Starting Operation Desktop... 47

5 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG III/III Table of Contents Page 7 Communication OPC SCP Service & Support Helpdesk Service Hotline Internet Helpful Information Index... 53

6 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description

7 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 1/53 General 1 General 1.1 Why Simulation? 1.2 What is Simulated? Due to the ever-increasing competitive pressure among the manufacturers of machines, we are always looking for new ways of minimizing the costs for a machine project. This includes every phase of the machine life cycle (construction, commissioning, production). Due to more and more powerful computer systems, simulation is becoming more and more important: in the future, there may even be virtual factories in which all the processes of a production plant can be reproduced virtually. One component of this virtual factory is the virtual machine, which can be used, with the help of suitable simulation tools, to support the individual phases of the machine life cycle. There are suitable simulation techniques for every phase of the machine life cycle. These simulation techniques are clearly delimited from one another, but also have shared points of intersection, such as the transfer of construction data for the machine from the CAD system to the 3D visualization system. For example, FEM (Finite Element Method) analysis or MBS (Multi-Body Simulation) analysis is used in the construction phase of a machine, while the commissioning phase is more concerned with behavioral simulation. For production, on the other hand, process optimization (e.g. cycle time optimization) is in the foreground. Now, if we examine the simulation techniques during the commissioning phase, we can make a further distinction. On the one hand, there is hardware-in-theloop simulation; on the other, there is software-in-the-loop simulation. Hardware-inthe-loop Software-inthe-loop 1.3 Goals of Simulation in IndraWorks In this simulation technique, a real control is a component of the simulation setup. All other components are simulated on one or more computers. Communication between the real control and the simulation components is implemented using, for example, Profibus slave cards. In this simulation technique, all the components are simulated on one or more computers. The emphasis for applying simulation techniques at Bosch Rexroth in the area of system development for Motion Control lies on optimizing the commissioning of controls and machine tools. This involves mainly behavioral simulation, such as tests of the PLC program or of the NC program. Components such as a virtual control (NC and PLC), a virtual control panel, virtual drives, a 3D viewer and a peripherals simulation (I/O simulation) are required to attain this goal. Only the interplay of all these components permits effective behavioral simulation. In addition to the shortening of commissioning times, however, there are other areas of application for simulation that result in cost and time savings for the user. Demonstrator for sales at the customer location Testing program procedures (both CNC and PLC) Setting the parameters of the control and the drives Application for training purposes

8 2/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description General Reproduction of problems (trouble-shooting) Validation of error solutions

9 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 3/53 Important Instructions on Use 2 Important Instructions on Use 2.1 Intended Use Introduction Area of Use and Application 2.2 Improper Use The Bosch Rexroth products are developed and manufactured according to the latest state of the art. Before delivery, they are checked for operational safety. The products may only be used in the proper manner. When they are not used as intended, situations may arise which result in damage to person or material. Bosch Rexroth, as the manufacturer of the products, will not assume any warranty, liability or payment of damages in case of damage resulting from a non-intended use of the products. If he fails to use the products as intended, the user will be solely responsible for any resulting risks. Before using the Bosch Rexroth products, the following prerequisites must be fulfilled to ensure that they are used as intended: Everyone who in any way deals with one of our products must read and understand the corresponding notes regarding safety and regarding proper use. If the products are hardware, they must be kept in their original state, i.e. no constructional modifications may be made. Software products may not be decompiled; their source codes may not be modified. Damaged or improperly working products must not be installed or put into operation. It must be ensured that the products are installed according to the regulations mentioned in the documentation. In IndraWorks, simulation tools are used to Shorten the response times verify the application programs visualize the machine cinematics The simulation consists of several components which must be compatible to each other. The virtual control panel is used in connection with the control emulation. During utilizing the virtual control panel of the real control it has to be considered that the signals can not arrive between virtual control panel and control because of communication errors. Therefore a PLC program and a producing machine can no longer be stopped via control. Using the devices outside of the above-referenced areas of application or under operating conditions other than described in the document and the technical data specified is defined as "inappropriate use". The Rexroth simulation tools may not be used if

10 4/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Important Instructions on Use Bosch Rexroth has not specifically released them for that intended purpose. In this connection, observance of the statements in the General Safety Notes is imperative!

11 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 5/53 Safety Instructions for Electric Drives 3 Safety Instructions for Electric Drives 3.1 Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others Do not attempt to install or commission this device without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent immediately to the person or persons responsible for the safe operation of the device. If the device is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the device in the official language of the user's country. WARNING Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! Observe the safety instructions! How to Employ the Safety Instructions Read these instructions before initial commissioning of the equipment in order to eliminate the risk of bodily harm and/or material damage. Follow these safety instructions at all times. Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before commissioning the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of this device. Only assign trained and qualified persons to work with electrical installations: Only persons who are trained and qualified for the use and operation of the device may work on this device or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the product, as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and devices on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer.

12 6/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Safety Instructions for Electric Drives Follow all safety regulations and requirements for the specific application as practiced in the country of use. The devices have been designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Only use safety-relevant applications that are clearly and explicitly approved in the Project Planning Manual. If this is not the case, they are excluded. Safety-relevant are all such applications which can cause danger to persons and material damage. The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. Commissioning of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application. Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective documentation (Project Planning Manuals of components and system). The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connection and installation conditions are specified in the product documentation and must be followed at all times. National regulations which the user must take into account European countries: according to European EN standards United States of America (USA): National Electrical Code (NEC) National Electrical Manufacturers Association (NEMA), as well as local engineering regulations regulations of the National Fire Protection Association (NFPA) Canada: Canadian Standards Association (CSA) Other countries: International Organization for Standardization (ISO) International Electrotechnical Commission (IEC) Explanation of Warning Symbols and Degrees of Hazard Seriousness The safety instructions describe the following degrees of hazard seriousness. The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions:

13 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 7/53 Safety Instructions for Electric Drives Warning symbolsignal worddegree of hazard seriousness acc. to ANSI Z Danger Death or severe bodily harm will occur. Warning Death or severe bodily harm may occur. Caution Minor or moderate bodily harm or material damage may occur. Fig.3-1: Hazard classification (according to ANSI Z 535) Hazards by Improper Use DANGER High electric voltage and high working current! Risk of death or severe bodily injury by electric shock! Observe the safety instructions! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! Observe the safety instructions! WARNING High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock! Observe the safety instructions! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Observe the safety instructions! Hot surfaces on device housing! Danger of injury! Danger of burns! Observe the safety instructions! CAUTION CAUTION Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting or improper handling of pressurized lines! Observe the safety instructions!

14 8/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of batteries! Observe the safety instructions! 3.2 Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings This section concerns devices and drive components with voltages of more than 50 volts. Contact with parts conducting voltages above 50 volts can cause personal danger and electric shock. When operating electrical equipment, it is unavoidable that some parts of the units conduct dangerous voltage. DANGER High electrical voltage! Danger to life, electric shock and severe bodily injury! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain and repair this equipment. Follow general construction and safety regulations when working on electrical power installations. Before switching on the device, the equipment grounding conductor must have been permanently connected to all electrical equipment in accordance with the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the equipment grounding conductor is not permanently connected to the mounting points of the components provided for this purpose. Before working with electrical parts with voltage potentials higher than 50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection. For electrical drive and filter components, observe the following: Wait 30 minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the electrical voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the device on. Before switching the equipment on, cover and safeguard live parts safely to prevent contact with those parts. A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device according to the relevant standards. Secure built-in devices from direct touching of electrical parts by providing an external housing, for example a control cabinet.

15 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 9/53 Safety Instructions for Electric Drives For electrical drive and filter components with voltages of more than 50 volts, observe the following additional safety instructions. DANGER High housing voltage and high leakage current! Risk of death or bodily injury by electric shock! Before switching on, the housings of all electrical equipment and motors must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests. The equipment grounding conductor of the electrical equipment and the devices must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 ma. Over the total length, use copper wire of a cross section of a minimum of 10 mm 2 for this equipment grounding connection! Before commissioning, also in trial runs, always attach the equipment grounding conductor or connect to the ground wire. Otherwise, high voltages may occur at the housing causing electric shock Protection Against Electric Shock by Protective Extra-Low Voltage Protective extra-low voltage is used to allow connecting devices with basic insulation to extra-low voltage circuits. All connections and terminals with voltages between 5 and 50 volts at Rexroth products are PELV systems. 1) It is therefore allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections and terminals. WARNING High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock! If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g. the mains connection) are connected to Rexroth products, the connected extra-low voltage circuits must comply with the requirements for PELV. 2) Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors These errors can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. 1) Protective Extra-Low Voltage 2) Protective Extra-Low Voltage

16 10/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Safety Instructions for Electric Drives The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and/or material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

17 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 11/53 Safety Instructions for Electric Drives DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! For the above reasons, ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. They have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possible if safety devices are disabled, bypassed or not activated. To avoid accidents, bodily harm and/or material damage: Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: use safety fences use safety guards use protective coverings install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before commissioning. Do not operate the device if the emergency stop switch is not working. Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Additionally secure vertical axes against falling or dropping after switching off the motor power by, for example: mechanically securing the vertical axes, adding an external braking/arrester/clamping mechanism or ensuring sufficient equilibration of the vertical axes. The standard equipment motor brake or an external brake controlled by the drive controller are not sufficient to guarantee personal safety! Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: maintenance and repair work cleaning of equipment long periods of discontinued equipment use Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such devices cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial commissioning. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.

18 12/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Safety Instructions for Electric Drives Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious personal danger to those with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers and metal implants are not permitted to enter following areas: Areas in which electrical equipment and parts are mounted, being operated or commissioned. Areas in which parts of motors with permanent magnets are being stored, repaired or mounted. If it is necessary for somebody with a pacemaker to enter such an area, a doctor must be consulted prior to doing so. The noise immunity of present or future implanted heart pacemakers differs greatly so that no general rules can be given. Those with metal implants or metal pieces, as well as with hearing aids, must consult a doctor before they enter the areas described above. Otherwise health hazards may occur Protection Against Contact with Hot Parts CAUTION Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns! Do not touch surfaces of device housings and chokes in the proximity of heat sources! Danger of burns! Do not touch housing surfaces of motors! Danger of burns! According to the operating conditions, temperatures can be higher than 60 C, 140 F during or after operation. Before accessing motors after having switched them off, let them cool down for a sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated, the time required for cooling down is five times the thermal time constant specified in the Technical Data. After switching drive controllers or chokes off, wait 15 minutes to allow them to cool down before touching them. Wear safety gloves or do not work at hot surfaces. For certain applications, the manufacturer of the end product, machine or installation, according to the respective safety regulations, has to take measures to avoid injuries caused by burns in the end application. These measures can be, for example: warnings, guards (shielding or barrier), technical documentation Protection During Handling and Mounting In unfavorable conditions, handling and mounting certain parts and components in an improper way can cause injuries.

19 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 13/53 Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting! Observe the general construction and safety regulations on handling and mounting. Use suitable devices for mounting and transport. Avoid jamming and bruising by appropriate measures. Always use suitable tools. Use special tools if specified. Use lifting equipment and tools in the correct manner. If necessary, use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Do not stand under hanging loads. Immediately clean up any spilled liquids because of the danger of skidding Battery Safety Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or material damage. CAUTION Risk of injury by improper handling! Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and cauterization). Do not recharge the batteries as this may cause leakage or explosion. Do not throw batteries into open flames. Do not dismantle batteries. When replacing the battery/batteries do not damage electrical parts installed in the devices. Only use the battery types specified by the manufacturer. Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations. Dispose of used batteries separate from other waste. Observe the local regulations in the country of assembly Protection Against Pressurized Systems According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids and cooling lubricating agents. Improper handling of the connected supply systems, supply lines or connections can cause injuries or material damage.

20 14/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of pressurized lines! Do not attempt to disconnect, open or cut pressurized lines (risk of explosion). Observe the respective manufacturer's operating instructions. Before dismounting lines, relieve pressure and empty medium. Use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Immediately clean up any spilled liquids from the floor. Environmental protection and disposal! The agents used to operate the product might not be economically friendly. Dispose of ecologically harmful agents separately from other waste. Observe the local regulations in the country of assembly.

21 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 15/53 Quick Start 4 Quick Start In the following, the execution sequence that makes it possible to sensibly operate the various simulation components of IndraWorks is described for an IndraMotion MTX project. It is not suitable for a user who has no prior knowledge of the simulation components. The inexperienced user should first read the entire documentation to become familiar with the subject matter. Execute the following steps to be able to simulate an IndraMotion MTX project on a PC: 1. Start IndraWorks using the link on the desktop 2. Load the desired IndraMotion MTX project into IndraWorks 3. Start the IndraMotion MTX emulation (also see chapter "Starting and Exiting MTX Emulation" on page 46) 4. Set the communication settings for the IndraMotion MTX and the PLC to localhost. 5. The PLC must be stopped. 6. The NC kernel data must be restored (also see chapter "Designing the NC Core" on page 40). 7. The PLC program must be loaded and started (also see chapter "Projecting the PLC" on page 44) 8. Activate the IndraWorks project for Operation Desktop (also see chapter "Projecting the HMI" on page 38) 9. Create the virtual control panel in IndraWorks Engineering (also see chapter "Creating a Virtual User Panel" on page 29) and configure it (also see chapter "Configuration" on page 29) 10. Start the Windows program Virtual Control Panel (also seechapter "Connection to Virtual Control " on page 31). You can find detailed information about IndraMotion MTX emulation in the Virtual Commissioning of the MTX chapter of the documentation IndraMotion MTX Commissioning. If a machine model exists, it can be loaded into the 3D viewer and controlled using data from the emulation via OPC. To do this, proceed as follows: 1. Add a new model to the project (also see chapter "Importing 3D models " on page 32) 2. Link the OPC items to the objects of the model (also see chapter "Connecting 3D objects with IndraMotion MTX axis values " on page 34) 3. Start the simulation of the model in IndraWorks

22 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description

23 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 17/53 Components of the Simulation 5 Components of the Simulation 5.1 Project Explorer The simulation components can be found in the Project Explorer in the node Simulation -> 3D Visualization. Project node Simulation Fig.5-1: Project Explorer Within node Simulation, you can find the entry Virtual Control Panel, which can be used to open the Configuration dialog box of the Virtual Control Panel. If the node Simulation and/or the entry Virtual Control Panel does not exist, it can be added as follows using the project node: Call menu item Add... in the contextual menu of the project node. In the dialog box Add new element, open the template Virtual Control Panel from the category Virtual Components. The entry Virtual Control Panel is added to the project tree within the node Simulation. Project node 3D Visualization Node 3D Visualization can be used to access 3D models of the View3D application. New 3D models can be added using the contextual menu Add... on node 3D Visualization. See also chapter "Handling instruction: Importing a 3D model" on page D Visualization General Description If node 3D Visualization does not exist, a new 3D model can be added using the contextual menu Add... of the project node. See also chapter "Handling instruction: Importing a 3D model" on page 32. A View3D model can be opened using the contextual menu Open... of the corresponding node in the Project Explorer or by double-clicking it. Furthermore, models can be renamed or deleted in the Project Explorer. See also chapter "Opening, renaming and deleting 3D models " on page 34. The View3D 3D visualization system is used to represent a machine model as a three-dimensional volume model (3D scene).

24 18/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Components of the Simulation Individual objects in the 3D scene can be combined with process values of the IndraMotion MTX within View3D. If the NC program of the machine is executed using the virtual control (also seechapter 5.4 "Virtual Control" on page 27), the axis movements of the machine can be traced in the three-dimensional machine model. Additional functions in View3D include: Rotating a 3D scene Zoom function Wireframe representation Saving of camera positions (viewpoints) Fig.5-2: View3D in IndraWorks The View3D application consists of the following 4 areas: 1. 3D view The 3D view is used to display the 3D scene (see chapter "Model Visualization " on page 19). 2. Scene tree The scene tree represents the logical and kinematic structure of the scene. Individual objects of the model can be marked for further processing in the scene tree (for example, objects can be hidden in the 3D view).

25 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 19/53 Components of the Simulation Switching languages in View3D See chapter "Scene Tree " on page OPC server You can access the OPC server of the control in order to communicate with the IndraMotion MTX here (see chapter 5.2 "3D Visualization" on page 17). 4. OPC assignment list The assignments between the 3D model and the process values (OPC items) of the control are shown in the OPC assignment list (see chapter 5.2 "3D Visualization" on page 17). To change the language in View3D, use the IndraWorks language switching method Model Visualization Basic functions Coordinate system In the current version, portions of View3D are available only in English. The following figure shows the basic arrangement of the main coordinate system of a View3D model.

26 20/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Components of the Simulation Marking 3D objects Rotating a 3D scene Moving a 3D scene Fig.5-3: Coordinate system An object can be marked by clicking the left mouse button; this is indicated by a yellow frame. A marked object is also highlighted in the scene tree. Conversely, clicking the left mouse button on a part of the scene tree highlights the corresponding part in the model with a yellow frame. The marking can be removed by clicking the left mouse button on a blank space outside of the model. To allow the 3D model to be viewed from every perspective, the 3D scene can be rotated. Mouse operation If the mouse is moved within the 3D view with the left mouse button held down, the model rotates according to the mouse movements. If the mouse is moved to the left or right, the model rotates around the Y-axis. If the mouse is moved up or down, the model rotates around the X-axis. Keyboard operation The model can be rotated around the Y-axis using keys <Ins> and <Del>. To position the 3D model, the 3D scene can be moved in View3D.

27 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 21/53 Components of the Simulation Zooming a 3D scene Functions for manipulating 3D objects Control reset If the mouse is moved within the 3D view with the center mouse button held down, the 3D scene is positioned according to the mouse movement. To be able to better see the details in the 3D model, you can zoom into the 3D scene. Mouse operation If the mouse is moved within the 3D view with the right mouse button held down, the view zooms into the 3D scene. Moving the mouse upwards zooms out of the model. Moving the mouse downwards zooms into the model. Keyboard operation You can zoom within the 3D view using the <PgUp> and <PgDn> keys. Pressing the <PgUp> key zooms into the model; pressing the <PgDn> key zooms out of the model. Pressing key <Pos 1> moves the 3D scene into a predefined camera position. This is an internal basic setting that cannot be changed. For these functions, the entry Rendering always active must have been switched on in dialog box Model properties (also see chapter "Properties of the View3D Model " on page 25). Moving/rotating objects Saving camera positions To move an object, it must be marked beforehand. Then press one of the keys <X>, <Y> or <Z> to select the desired axis direction for the move. In addition, you must now move the mouse (with the left mouse button held down) to the left or right in order to move the object. If you press and hold the right mouse button instead of the left one, the object is rotated around the selected axis. Keys <0> to <9> can be used to save and call 10 different camera positions. To do this - see the explanation in chapter "Basic functions" on page 19 - the camera position is changed and then saved using key combination <Ctrl+number>. A camera position (viewpoint) can be called again by pressing one of the keys <0> to <9>. For these functions, the entry Rendering always active must have been switched on in dialog box Model properties (also see chapter "Properties of the View3D Model " on page 25). Explosion/implosion Pressing the <End> key brings manipulated objects back to the basic position (implosion). If you then press the <E> key, the objects move back to the manipulated position (explosion). For these functions, the entry Rendering always active must have been switched on in dialog box Model properties (also see chapter "Properties of the View3D Model " on page 25) Scene Tree General The object structure of the 3D scenes is shown in the scene tree. Each individual kinematics object has 6 degrees of freedom: X-Y-Z translation and X-Y-

28 22/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Components of the Simulation Z rotation. The degrees of freedom are a component of the objects listed in the tree, but are not shown explicitly. The individual nodes of the tree have a checkbox with which they can shown or hidden in the 3D model. If an OPC item is assigned to at least one of the degrees of freedom of the kinematics object, the corresponding icon in the tree node changes. Object properties Fig.5-4: Scene tree The properties of a 3D object can be changed using the Object properties dialog box. Fig.5-5: Object properties The dialog box can be opened by calling contextual menu Properties for a 3D object in the scene tree. The menu item is active only if the selected node has subnodes.

29 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 23/53 Components of the Simulation Assignment The point of rotation and the angle of a kinematics object can be modified in the Object properties dialog box. Also see chapter "Handling instruction: Rotating a View3D object around a user-defined point of rotation" on page 35 and chapter "Handling instruction: Moving a View3D object in any direction in space" on page 35 Using drag-and-drop, an OPC item can be assigned to a degree of freedom of a kinematics object. If an OPC item from the OPC tree is dropped onto a node of the scene tree, the following dialog box opens. Fig.5-6: OPC Configuration Assigning an object The dialog box contains a selection box in which you must specify precisely to which of the 6 degrees of freedom the OPC item is assigned. An offset, which is included in the calculation of the OPC item's value, can also be specified. The OPC Server window is used to access process data via an OPC server. All the OPC servers that are locally installed on the computer are located in node Local. Use tree node Manual to explicitly search the network for a computer whose locally installed OPC servers are listed. All standard OPC items of an OPC server are listed in the node called Basic Items. The items of the IndraMotion MTX OPC servers (OPC.IwSCP.1) are grouped into NC Axes, NC Corrections and NC Spindles.

30 24/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Components of the Simulation Assignment List General Fig.5-7: OPC server The contextual menu of node Manual contains menu items Add Computer and Remove Computer. The first menu item can be used to search the network for a computer using its name or IP address. The second menu item is active only if the computer found within the network is selected; it can be used to remove the computer from the list. The assignment list indicates the assignment of the OPC item to a corresponding degree of freedom of a kinematics object. It contains the columns OPC Item, Offset, OPC Server and Computer. This information precisely defines an OPC item. Assignment Fig.5-8: OPC assignment list Using drag-and-drop, an OPC item can be assigned to a degree of freedom of the kinematics object selected in the scene tree. If the OPC item from the OPC tree is dropped onto an appropriate line in the assignment list, the individual information data are encrypted and written to the corresponding column of the assignment list.

31 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 25/53 Components of the Simulation Properties of the View3D Model The Properties of the View3D model dialog box can be used to make settings for the View3D model and for OPC. Scaling factor for process values Rendering always active Fig.5-9: Properties of the View3D model See also chapter "Changing settings of the View3D model " on page 37. The scaling factor affects all the process values that are associated with 3D objects in the View3D model. It is used to globally adapt the scaling of the View3D model to the process values. See also chapter "Handling instruction Changing the scaling factor for process values" on page 34. When this setting is active, the 3D model is continuously rerendered (i.e. the 3D model is continuously recalculated). This is a good idea if, for example, you want to switch between various viewpoints at the touch of a button. When the process connection is active, rendering is automatically activated. OPC group name OPC update rate This is the name of the OPC group that is used when someone logs onto an OPC server. The OPC update rate specifies the time (in milliseconds) in which process values are updated by the OPC server. 5.3 Virtual User Panel General Description The Virtual User Panel is used as a replacement for the real VAM 40 during emulation. The appearance and functions replicate the real VAM 40. In the current version, the texts are available only in English and German.

32 26/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Components of the Simulation Configurator Fig.5-10: Virtual User Panel The Virtual User Panel is configured in IndraWorks Engineering. Then the configuration file of the Virtual User Panel must be supplemented by the user (also see chapter "Supplements to the configuration file " on page 30). Project node Simulation with subnode Virtual User Panel The configuration page of the keyoperated switch Fig.5-11: Configuration in IndraWorks Project node Virtual User Panel is used to call the pages for configuring the virtual VAM 40. The individual switch settings are labeled on the configuration page of the keyoperated switch.

33 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 27/53 Components of the Simulation The configuration page of the keypads The configuration page of the quick-stop module This page is used to label the keypads with texts or previously generated images. Each individual key can be allocated by entering a text or by dragging and dropping an image from the symbol list. The configuration page of the quick-stop module can be used to make various settings for the two keys: Labelling the key Function Since the keys on the real VAM 40 are hardware-wired and the switches are equipped with make and break contacts, these settings can also be selected here. If a key is not wired, None can be set. Mutual locking of the keys Since the keys are switches, the signals are continuously activated. To mutually reset these signals, mutual locking of the two keys can be selected. The configuration file The Application 5.4 Virtual Control General Description The labels for the EMERGENCY STOP and the spindle and feedrate override are not affected. The configuration file contains the assignment of the individual keys. In addition, the user must enter all the PLC variables that are required for communication with the Virtual User Panel (also see chapter "Supplements to the configuration file " on page 30). The individual keys, switch settings, lamps and overrides can then use these settings to control the PLC program and to display the status. The application is separate; it is used to control the PLC program in IndraMotion MTX emulation. This can be started independently of IndraWorks Engineering or IndraWorks Operation. When the Virtual User Panel is started, the configuration is read out of the currently active project. In this version, there must be a connection to the emulation when the Virtual User Panel is started. This can be implemented, for example, by triggering a connection test in the contextual menu of the MTX project node. A virtual control is the most important simulation component because, just like the real control, it regulates the entire process. It contains the same functions as the real control and is identically parametrized, programmed and operated. Therefore, the method of operation does not change for the user if he switches between a virtual control and a real one; only the communication parameters of the Engineering interface must be reset. However, since the virtual control runs under Windows, its only limitation is that it is not real-time-capable. With the emulation of the IndraMotion MTX machine tool control, Bosch Rexroth has such a virtual control. For further information regarding IndraMotion MTX emulation, see chapter 6.4 "Using the Virtual Control" on page 37.

34 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description

35 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 29/53 Operation in IndraWorks 6 Operation in IndraWorks 6.1 Creating a Model General Creating a Simple 3D Model Importing em-realnc Models 6.2 Using the Virtual User Panel Configuration Configuration in IndraWorks The import format for 3D scenes into View3D is VRML (Virtual Reality Modeling Language). Files in the format VRML 2.0 (or VRML97) are supported. VRML files are recognized by the file extension.wrl (world). Most 3D modelling tools can export 3D scenes in VRML format. The import of compressed VRML files (the file extension is also.wrl ) is not supported by View3D. As a rule, any 3D modelling tool with VRML export can be used to create 3D models. However, not all modelling tools can be used to create kinematic relationships between individual 3D objects. Kinematic relationships have a fundamental significance for machine models. In a compound table, for example, the X-axis also moves when the Y-axis is moved. A simple modelling tool to generate 3D scenes with kinematic relationships is, for example, Vizx3D by Virtock Technologies, Inc. ( View3D can also import VRML models that have been created using the NC simulation software Tecnomatix em-realnc from Unigraphics Solutions GmbH ( Tecnomatix em-realnc has provided a VRML export interface for this purpose. Creating a Virtual User Panel In order to be able to configure a Virtual User Panel, a project must have been created in IndraWorks. A Virtual User Panel is created in an existing project in IndraWorks by selecting and confirming Project node right mouse button Add new element Virtual User Panel. This then appears in the Simulation node as subnode Virtual User Panel. By <double-clicking> (or clicking the right mouse button on Open) the node of the Virtual User Panel, the configuration pages open. Configuration of the key-operated switch By highlighting the key-operated switch in the display of the virtual VAM 40, its configuration page opens. The switch positions are labelled in the individual text fields. The number of characters for the texts is unlimited; the new label appears immediately in the display of the Virtual User Panel.

36 30/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Operation in IndraWorks Assigning text to the keys Assigning images to the keys Labelling the keys Functions of the keys Supplements to the configuration file Configuration of the keypads The configuration page of the keypads is opened by highlighting a key on the keypad. When labelling an individual key, first highlight the desired key on the keypad. Then switch to the text field of Labelling the key and enter the text. The keys are assigned using drag-and-drop. First select any image in the Symbols category. Then press the left mouse button and drag the cursor to the desired key. Configuration of the quick-stop module The configuration page of the quick-stop module is opened by selecting the quick-stop module in the display of the virtual VAM 40. The new labels can be entered in the text fields of the (Top) key and (Bottom) key. Line breaks and line lengths are not taken into account. However, the label is immediately shown in the VAM 40 display. Since the keys on the real VAM 40 are hardware-wired and the switches are equipped with make and break contacts, these settings must be selected here. This is accomplished by setting function Break-contact or Make-contact. If the key was not wired, set None. To execute mutual locking of the two keys, the checkmark Mutual locking of the keys must be set. In order to supplement the configuration file, the hard disk path of the project that was just edited in IndraWorks Engineering must be determined. Then open in Simulation config the configuration file VirtualControlPanel_VAM40.xml using the Editor. The following settings for communicating with the PLC variables of the current PLC program in the control must be made: Pay attention to capitalization! Use only BOOL variables to communicate with the elements! BYTE variables must be used for the overrides! 1. Enter the name of the logical device under Logical_Device\ NameLD. e.g. <NameLD>IndraMotion_MTX_P60</NameLD> 2. Enter the PLC variables for the individual keys in the keypad under Keypad 1 and 2. e.g. <KY_X1Y3>iStart</KY_X1Y3> 3. Enter the PLC variables for each individual LED under LED_Keypad_1 and LED_Keypad_2 e.g. <LED_X2Y2Y>qStart</LED_X2Y2> 4. Enter the PLC variables for the spindle and feedrate override under the point Override e.g. <OVR1>iFeedrate</OVR1> for the spindle and feedrate override 5. Enter the PLC variables for the key-operated switch under Key-operated switch/key_p1-4 e.g. <KEY_P1>iVAM_KEY_S1</KEY_P1> for the first switch setting from the left 6. Enter the PLC variables for the functions of the quick-stop module keys under Module_QuickStop

37 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 31/53 Operation in IndraWorks Connection to Virtual Control Preparations in IndraWorks Engineering Preparations in IndraLogic e.g. (Top) key <MOD_KY1>iK_Pow_On</MOD_KY1> 7. Enter the PLC variable for the LED in (Top) key under Module_QuickStop e.g. <MOD_LED_KY1>qL_Pow_On</MOD_LED_KY1> 8. Enter the PLC variables for the simulation of the EMERGENCY STOP under Emergency stop e.g. <KY>iEmergency_stop</KY> After making the supplements, save the file and close it. Before the Virtual User Panel can be started, a few things must be carried out successfully for the connection: Set the project in which the Virtual User Panel was configured to Active. This is accomplished by selecting and executing menu item Project Activate for IndraWorks Operation. Execute a connection test via the control, e.g. IndraMotion_MTX_P60 right mouse button Connection test.. Fig.6-1: Preparations in IndraLogic In the PLC program, create all the variables that are to receive a connection with the Virtual User Panel as Global variables. These variables are used to activate the individual switch settings, buttons, lamps and overrides.

38 32/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Operation in IndraWorks Start These are created as follows: Variable name: BOOL, e.g. istart: BOOL; Do not assign an address; remove it if necessary! Reset the PLC program, log in and start Error Messages and Remedies Error box No active project exists! Error box No virtual user panel configured! Error box No connection to the PLC Error box Error writing PLC variables 6.3 Using 3D Visualization D Models in IndraWorks Importing 3D models The Virtual User Panel is started via Start Program Files IndraWorks Virtual User Panel or using the IndraWorks Virtual User Panel icon on the desktop. Remedy: Open IndraWorks Engineering and set the project in which the Virtual User Panel was configured to Active. This is accomplished by selecting menu item Project Activate for IndraWorks Operation. Then restart the IndraWorks Virtual User Panel. Remedy: Open IndraWorks Engineering and create an existing or new project. Within it, create a Virtual User Panel via Project node right mouse button Add new element Virtual User Panel. Then proceed according to chapter "Configuration in IndraWorks" on page 29. Remedy: Close the Virtual User Panel, call IndraWorks Engineering and reestablish the connection via Control e.g. IndraMotion_MTX_P60 right mouse button Execute connection test. This error message can have various causes; therefore various remedies are available: 1. Check whether the variable name in the configuration file is written correctly. 2. Check whether the PLC variables were stored under Global variables and are of type BOOL. Exception: Override activation uses BYTE variables. 3. Check the communication to the PLC and reestablish the connection if necessary. General In order to be able to open a 3D model in the View3D 3D visualization system, it must first be imported into the IndraWorks project. Models in VRML format and in the internal d3d format are accepted as the import format (also seechapter 6.1 "Creating a Model" on page 29). Handling instruction: Importing a 3D model Importing of a 3D model into the IndraWorks project is described here. IW Engineering / Simulation: Importing a 3D model In the Project Explorer on node 3D visualization (or on the project node if node 3D visualization does not yet exist), select the contextual menu Add Add new element... In the dialog box Add new element, open the template 3D model from the category Virtual components.

39 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 33/53 Operation in IndraWorks Fig.6-2: Adding a new element Enter a name for the View3D model. Select an import file for the 3D scene. Press the <Browse...> button to open a file selection dialog box in which the 3D model (VRML/d3d) can be selected. Fig.6-3: Adding a View3D model

40 34/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Operation in IndraWorks Opening, renaming and deleting 3D models Opening a 3D model in View3D Renaming a 3D model Deleting a 3D model Process Connection Press the <Finish> key. The View3D model is added to node 3D visualization in the project tree. Highlight the desired View3D model within node 3D visualization using the mouse or the cursor keys and open it using contextual menu Open or by doubleclicking. The name of the View3D model can be changed in the Project Explorer. To do this, select contextual menu Rename on the View3D model in the Project Explorer or press key <F2>. Then the name can be changed and entered by pressing the <Enter> key. A View3D model can be deleted from the IndraWorks project in the Project Explorer using contextual menu Delete or with key <Del>. Connecting 3D objects with IndraMotion MTX axis values Boundary condition Configuring the process connection Handling instruction: Controlling a View3D object using an IndraMotion MTX process value The procedure for connecting a 3D object in View3D with an IndraMotion MTX process value is described here. Communication with the IndraMotion MTX must have been established in order to be able to access IndraMotion MTX OPC items. To establish communication to the IndraMotion MTX, one of the following steps must be carried out once before opening a 3D model in View3D: Execute a connection test on node IndraMotion MTX in the Project Explorer Open IndraWorks Operation Desktop IW Engineering / Simulation: Connecting a 3D object with an OPC item The object that is to be connected to an OPC item must be selected in the 3D view or in the scene tree. The actions translation (movement in axis direction X, Y or Z) and rotation (turning around axis X, Y or Z) appear in the OPC assignment list for the selected object. In window OPC Server, open the node for the IndraMotion MTX OPC server (OPC.IwSCP.1) in node Local (local OPC server). Select an OPC item and, with the left mouse button held down, drag it onto a translation or rotation action in the OPC assignment list (e.g. in group NC Axes X (Phys.No.=1), command position, ACS for the command position of the X-axis in the axis coordinate system). The data of the OPC item now appear in the OPC assignment list. The object receives a green marking in the scene tree. Handling instruction Changing the scaling factor for process values Adapting the scaling of a 3D model to the process values of the OPC item is described here. IW Engineering / Simulation: Changing the scaling of a View3D model Using menu item View3D Model properties... in the main menu, open dialog box Properties of the View3D model. The scaling of the 3D model can be adapted to the values of the OPC item using Scaling factor for process values.

41 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 35/53 Operation in IndraWorks The scaling factor can also be changed while a process connection is active. In this way, the 3D model can be used to immediately check the changes. If the scaling factor is set too high, the 3D objects move beyond the end position (they may even be moved out of the visible area of the 3D Viewer). If the scaling factor is too low, it may be impossible to detect the movement of the 3D objects. Boundary condition Handling instruction Changing the offset for process values An offset can be added to each process value of an OPC item. The entry of offset values is described in this handling instruction. IW Engineering / Simulation: Adding an offset to the process value of a View3D object Select a 3D object with a configured process connection from the scene tree (can be recognized by the green marking). Change the offset value of the OPC item in the OPC assignment list. Handling instruction: Rotating a View3D object around a user-defined point of rotation If a 3D object is to be rotated by a process value (OPC item is connected with the action rotation in the OPC assignment list), the point of rotation of the object may need to be adapted. This handling instruction can be used to change the point of rotation of a View3D object. It is not possible to change the point of rotation using end elements of the scene tree. IW Engineering / Simulation: Changing the point of rotation of a View3D object Select contextual menu Properties on the desired 3D object in the scene tree in order to open dialog box Object properties. See also chapter "Object properties " on page 22. Enter the X, Y and Z coordinates of the point of rotation and activate the values by pressing the <OK> or <Accept> button. The coordinates for the point of rotation can be determined using the cursor function. See chapter "Basic 3D visualization functions " on page 36. Boundary condition Handling instruction: Moving a View3D object in any direction in space If a 3D object is to be moved by a process value in a direction in space that does not correspond to one of the X, Y or Z coordinate axes, the angle of the object must be adapted accordingly. It is not possible to change the angle using end elements of the scene tree. IW Engineering / Simulation: Changing the angle of a View3D object Open dialog box Object properties using contextual menu Properties on the desired 3D object in the scene tree. See also chapter "Object properties " on page 22. Enter the angles for the X, Y and Z coordinates and confirm these by pressing the <OK> or <Accept> button. Example: If a machining station in the XY plane is rotated by 30 relative to the main coordinate system, this angle must be entered for the Z coor

42 36/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Operation in IndraWorks Establishing a connection to the control Boundary condition Boundary condition D Visualization Operation Basic 3D visualization functions dinate (rotation around the Z-axis) to correct the direction of movement for the X- and Y-axes. Handling instruction: Starting a View3D process connection This handling instruction describes how to activate the View3D process connection in order to control 3D objects using process values. Communication with the IndraMotion MTX must have been established in order to be able to access IndraMotion MTX OPC items. To establish communication to the IndraMotion MTX, one of the following steps must be carried out once before opening a 3D model in View3D: Execute a connection test on node IndraMotion MTX in the Project Explorer Open IndraWorks Operation Desktop IW Engineering / Simulation: Establishing a View3D process connection for control In the main menu, select menu item View3D Start. The following actions are now carried out: Windows OPC server and OPC assignment are hidden. The process connection is started and the 3D objects are supplied with the process values of the control. Handling instruction: Stopping a View3D process connection An active process connection in View3D can be stopped using this handling instruction. The process connection must be active (this can be recognized by the checkmark on menu item Start in the main View3D menu). IW Engineering / Simulation: Terminating a View3D process connection for control In the main menu, select menu item View3D Start. The following actions are now carried out: The process connection is stopped. Windows OPC server and OPC assignment are displayed. Handling instruction: Determining the coordinates of a point in space This handling instruction describes how the Cursor dialog box can be used to determine the coordinates of a point in space. IW Engineering / Simulation: Cursor function Open the Cursor dialog box via the main menu View3D Cursor... If necessary, activate the cursor. The checkmark on entry Visible must be set. Using the arrow keys of the input fields for the X-, Y- and Z-coordinates, move the cursor to the desired point in space. The increment of the cursor movement can be set via Delta to or The coordinates of the point can now be read in the Cursor dialog box.

43 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 37/53 Operation in IndraWorks Manipulating 3D objects Changing settings of the View3D model Changing the scaling factor for process values Switching rendering on and off Changing the name of the OPC group Changing the OPC update time Wireframe representation 6.4 Using the Virtual Control Installation of MTX Emulation General Brief Description The representation of the 3D model can be switched between Solid and Wireframe in View3D. If the checkmark on menu item Wireframe is set in the main View3D menu, the model is displayed as a wireframe. Otherwise, the 3D model is shown as a solid. Handling instruction: Moving a View3D object This handling instruction describes how a single View3D object in the 3D model can be moved. IW Engineering / Simulation: Moving a View3D object Select the 3D object using the left mouse button. Press the <X>, <Y> or <Z> key while simultaneously pressing the left mouse button. The object can now be moved in the X, Y or Z coordinate direction by moving the mouse to the left or right. Handling instruction: Rotating a View3D object The procedure for rotating a View3D object in the 3D scene is described here. IW Engineering / Simulation: Rotating a View3D object Select the 3D object using the left mouse button. Press the <X>, <Y> or <Z> key while simultaneously pressing the right mouse button. The object can now be rotated around the X, Y or Z coordinate axis by moving the mouse to the left or right. Settings of the View3D model are changed in the Properties of the View3D modeldialog box. See also chapter "Properties of the View3D Model " on page 25. The dialog box can be opened in the main menu using menu item View3D Model properties... The scaling factor for process values can be changed using the corresponding input field in the dialog box. Rendering of the 3D scene can be switched on/off using the Rendering always active checkmark. The name of the OPC group can be changed in field Group name under OPC settings. The update time for the OPC group can be entered (in milliseconds) in input field Update rate under OPC settings. Description OPC settings can be changed only if the process is inactive. MTX Emulation is copied from the installation CD; proceed according to the dialog boxes of the installation program. We recommend using the default values.

44 38/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Operation in IndraWorks Boundary conditions If the default memory size of 0.5 MB is not sufficient, the RAM file system memory of the emulation must be increased to 3 MB: Handling instruction: Increasing the RAM file system memory of the emulation If the application requires more memory, proceed as follows to increase it: Windows / Windows Explorer: Change file names In folder D:\Program Files \Rexroth\IndraWorks\mtx\emu rename file t3usrfep.pxf to t3usrfep.pxf.1mb and rename file t3usrfep.pxf.3mb to t3usrfep.pxf. Figure Flowchart Example Instruction Documentation Documentation : IndraWorks Commissioning Instructions MTX Emulation Fig.6-4: Projecting Emulation Restoring an existing project General Link IndraWorks Engineering can be used to restore existing projects that were created previously or on another computer for real systems or MTX emulation. The transfer (= restoration) of an IndraWorks project from a real control to emulation is described here. An IndraWorks project file contains, among other things, the control parameters, the Profibus configuration, the PLC program, the definition files for the M- and F-keys and the logbooks, as well as the user screens. The project is restored using function Restore in menu Project. Handling instruction Restoring an existing project for MTX emulation The transfer (= restoration) of an IndraWorks project from a real control to emulation is described here. IW Engineering / Motion: Restore control data Figure Flowchart Example Instruction Documentation Instruction : Restoring data Documentation : IndraWorks Commissioning Instructions Data backup Fig.6-5: Projecting the HMI General Brief Description Description Brief Description Boundary conditions Description Link The projected HMI data can be effective in the user interface only if they are downloaded to the Runtime folder of the user interface. The Runtime folder need be set only if the installation path of the target control (emulation) differs from the installation path of the source control on which the project was created. Handling instruction Projecting the HMI for MTX emulation This handling instruction describes how to make the HMI-specific settings that are required to use MTX emulation. IW Engineering / HMI BTV 40: Open the Properties dialog box and make settings

45 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 39/53 Operation in IndraWorks Click the right mouse button on the node of the HMI device in the Project Navigator. Fig.6-6: IndraWorks project - Properties Select the Properties dialog box by clicking the left mouse button on Properties. The dialog box for setting the properties for the HMI project opens. Fig.6-7: IndraWorks project Properties dialog box Enter the path for the Runtime installation of the MTX (this is usually identical to the installation path of the MTX). Exit the Properties dialog box by pressing OK. IW Engineering / Project: Activating an IndraWorks project

46 40/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Operation in IndraWorks The IndraWorks project is activated in the main menu under Project / Activate for operation. Fig.6-8: Designing the NC Core General Brief Description Activating a IndraWorks project Download the HMI project in the Runtime folder by pressing the Activate command. This IndraWorks project is displayed the next time that the MTX user interface is started. Description Among other things, the NC core data contains the the usrfep and the root files, the machine data as well as the database tables for the system and tool data. The data of the NC core is located in the IndraWorks project tree below the device node IndraMotion MTX P60. To restore the NC core data of a project, which has been created on a real control, one first has to adapt the Properties of the IndraMotion MTX P60 and then activate the NC core data in two steps. Handling Instruction: Designing the NC Core The handling instruction contains instructions for adaptations for the NC core specific to the use of the MTX Emulation. These instructions refer to existing data which is to be activated by restoring them. IW Engineering / IndraMotion MTX P60: Adapt the properties of the device IndraMotion MTX P60 With the right mouse key, click on the device node IndraMotion MTX P60. The properties dialog box of the IndraMotion MTX P60 will open.

47 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 41/53 Operation in IndraWorks Fig.6-9: IndraMotion - Properties dialog box Select the tab Communication using the left mouse key. In the input field IP address, select the entry localhost and exit the dialog box by pressing OK. IW Engineering / IndraMotion MTX P60: Restore NC core data Start the IndraMotion MTX Emulation by executing the file emu.bat. The file emu.bat is located in the following directory:...\program Files \Rexroth\IndraWorks\mtx\emu\ (see also handling instruction Start-up of the Emulation ). Stopping of the IndraLogic in the Program IndraLogic by pressing F5. In IndraWorks, highlight the node IndraMotion MTX P60\Motion and call the function Restore with the right mouse key. In the following dialog boxes, select the desired archive and, for the time being, load only the data of the User FEPROM.

48 42/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Operation in IndraWorks Fig.6-10: Restoring NC core data Afterwards exit IndraWorks Engineering and emulation. The emulation is closed by entering 14 in the DOS window. Fig.6-11: DOS prompt for emulation Start the emulation and IndraWorks Engineering again (see handling instruction Start-up of Emulation ). Stopping of the PLC via IndraLogic. Now, select and reload all NC core data, except for the already loaded data of the user FEPROM. Close the emulation and IndraWorks Engineering again and restart them. The emulation is now working with the loaded NC core data.

49 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 43/53 Operation in IndraWorks Any changed data (e.g. configuration parameter, tool data) will only be effective if the emulation is ended by entering 14 in the DOS window. System restart of emulation (startup mode 0) Bootstrap (startup mode 6) Characteristics during working with the MTX emulation The MTX emulation does not have a CMP60 Control with which the startup modus is set, the startup phase is observed and different commands to save parameters, load Firmware, start/stop PLC,... can be executed. The following sequence describes how this functions can be executed in the MTX emulation. It is necessary to restart the system for example to apply modifications for machine parameter (Macoda). 1. Exits IndraWorks. 2. Exit the emulation in the DOS window by entering 14. The changed parameters are saved on the computer by writing the files typ3ram.pxf and t3usrfep.pxf on the PC and the changes become effective upon the next startup of the emulation. 3. Restart emulation. 4. Restart IndraWorks. Via bootstrap which can be compared to the execution of startup of a real MTX with startup mode 6, the RAM file system of control is created again. A new root file system is created via bootstrap; as a result, all the data of the old file system are lost. If an intact user FEPROM file system exists, the PLC boot project and configuration data are loaded from there. Creation of the user FEPROM file system (startup mode 7) Bootstrap is necessary to apply for example the modifications on the tool database size as well as the structure of tool data records. 1. Copy modifications on tool data record into usrfep. 2. Exits IndraWorks. 3. Exit the emulation in the DOS window by entering Delete the RamFileSystem, i.e. delete the file...\program Files\Rexroth \IndraWorks\mtx\emu\typ3ram.pxf. 5. Restart emulation. 6. Restart IndraWorks. Creating a user FEPROM file system which can be compared to execution of startup mode 7 of real MTX is necessary if all project-specific data can be deleted on a control or if the user FEPROM file system can is damaged. The user FEPROM is created via creation of the user FEPROM file system, but all the data of the old file system are lost. The root file system remains. The permanent CPL variables will be deleted. 1. Exits IndraWorks. 2. Exit the emulation in the DOS window by entering Delete the user FEPROM file system, i.e. delete the file...\program Files \Rexroth\IndraWorks\mtx\emu\typ3ram.pxf. 4. Restart emulation. 5. Restart IndraWorks.

50 44/53 Bosch Rexroth AG Electric Drives Rexroth IndraWorks Application Description Operation in IndraWorks Projecting the PLC General Brief Description Description If the IndraWorks PLC project originates from a real control or if IndraWorks was previously installed in a directory that is different from the active version, the communication settings of the PLC project must first be modified. Then the PLC project can be activated. Handling instruction Restoring a PLC project This handling instruction describes the steps involved in commissioning a PLC project that has already run on a real control. IW Engineering / Logic: Restoring a PLC project Highlight node IndraMotion MTX P90\Logic and use the right mouse button to open the Properties dialog box. In the Properties dialog box, select tab Communication settings. Fig.6-12: PLC communication parameters Press the Communication parameters button. The Communication parameters dialog box opens. Here, make the settings in dialog communication parameter shown in the figure below and confirm them by pressing OK. The existing settings may need to be deleted first.

51 Application Description Rexroth IndraWorks Electric Drives Bosch Rexroth AG 45/53 Operation in IndraWorks Fig.6-13: Settings in the Communication parameters dialog box In the Properties dialog box (see above), open tab IndraLogic directories and, if necessary, change the path information for the installation paths of the emulation. Only one path entry may be made. Fig.6-14: Settings in the Properties/Directories dialog box Exit the Properties dialog box by pressing OK. In IndraWorks, click the right mouse button on node Logic and execute command Update. The IndraLogic project is now set to Emulation and can be started. Start IndraLogic by double-clicking node Logic and transfer and download the PLC project.