Renault Reference Frame

Transcription

1 Machinery and Equipment Specification Document Electrical Engineering Program Book / Guidelines Control and Drives Products by Renault Reference Frame Version: V3.0 Specification created and approved by: Renault and Bosch Rexroth Approval signatures on file at Renault

2 Document Management Information This Specification shall take effect as of the Published Date of the document. The controlled version of this document is the one posted on the Renault web site. Any printed copy is an uncontrolled copy. Any questions or comments with respect to this specification should be directed to the Renault responsible for the project. Revision History Published Version Section Number Change Description & Impact ALL First Edition V03.1 ALL MAJOR UPDATE Page 2 of 32

3 Program Book Guidelines Page No.: 3 of 32 Publish Date: 12-Feb Introduction Foreword Scope of Document Content explanation Bosch Rexroth contacts Document Approval and Responsibility Further technical information Training Overview Basic technical definitions Performance criteria for controller hardware selection Machine Architectures Flexible cell Machining control layout (CNC application with MTX) PLC based machines Product information control parts IndraControl CMLx Standard CNC control configuration - IndraMotion MTX Operator panels VR21xx Machine control panel VAM Mobile Operator panel VH Connector module VAC PC keyboardsvak IP20 IO-modules - Rexroth Inline IP67 IO-modules - Company Lumberg Product information drive system Drives components - overview Motors Kit motors Indradrive power supplies and power sections Indradrive control sections to be used with Indradrive C or Indradrive M power sections System Software IndraWorks System software IndraLogic HMI design with WinStudio IndraWorks-Drives Integration rules CNC PLC HMI Safety Predisposition for the Renault Backup/Restore tool Ethernet connection SAM (Maintenance help system) Master Further Information Product information Training Page 3 of 32

4 Program Book Guidelines Page No.: 4 of 32 Publish Date: 12-Feb Introduction 1.1 Foreword The documentation specifies the approved Bosch Rexroth automation control concepts for the Renault program. The machine builder must also utilize the relevant Approved Component List as shown inside the chapters 2, 3 and Scope of Document Bosch Rexroth has worked closely with Renault to develop this Program Book. The intention is that the contents of this book shall be used as a guideline for the proper selection and use of Bosch Rexroth products. Equipment suppliers who are bidding on Renault programs are expected to use this book as a reference while preparing their quotations for Renault. It is based on the following objectives: Minimize costs with defined function contents Apply international standards Reduce time from concept/bidding phase to commissioning (inclusive) Simplified modular retrofitting in the case of design changes of the work pieces Minimization and long-term orientation of expenditures for software development and electrical construction Beyond the function contents, the company-specific user philosophy and the realization of consistent standardized data traffic have been requirements applied to the present control system concept.! The present documents do not release the supplier (OEM) from his responsibility to select the devices in accordance with the manufacturing requirements, the law of the country in which the machine or facility will be delivered and to take account of the reserves required.! Deviations with this Components List have to be agreed with Renault in writing approved before placing of order. In the case of any conflict between this document and Renault program specifications, the Renault program documents should be adhered to. 1.3 Content explanation The products listed are those which should be considered as long as they are applied properly for the application. If the products listed do not suit the needs of a special application, please contact the support personnel listed below or the responsible Renault engineer. There are certain considerations to be taken by the equipment supplier to integrated components as part of a plant or a system, and depending on its particular area of application. The equipment supplier must observe all product guidelines and specifications so in order to prevent from damages. These considerations such as voltage, timing, torque etc are available in the relevant product documentation. See chap. 5.3 Page 4 of 32

5 Program Book Guidelines Page No.: 5 of 32 Publish Date: 12-Feb Bosch Rexroth contacts The project manager is responsible for project-specific coordination of the technical and commercial projects between Bosch Rexroth, the machine manufacturer and Renault. Project management Bosch Rexroth SAS France Fabrice BOUTRON B.P. 74 ZI de la trentaine Chelles Cedex France Tel: +33 (0) fabrice.boutron@boschrexroth.fr Bosch Rexroth AG Germany Joachim LINDE Dept. Technical support DC-IA/SFA13 Bgm.-Dr.-Nebel-Str Lohr am Main, Germany Tel: +49 (0) joachim.linde@boschrexroth.de Other worldwide contacts Bosch Rexroth Spain/Portugal Bixen CATELIN Francisco Grandmontagne, 2 Parque Empresarial Zuatzu San Sebastian Spain Tel: Fax: bixen.catelin@goimendi.es Bosch Rexroth SPA Italy Biagio SCALONE Bosch Rexroth spa S.S. Padana Superiore 11, n Cernusco s/n (MI) ITALIA Tel : biagio.scalone@boschrexroth.it Bosch Rexroth AS Turkey No: Sefaköy, ISTANBUL TURKEY Tel : Fax : East Electric Roumania Iuliu STOCKLOSA B-dul Basarabla nr. 250 sector 3 Bucuresti ROMANIA Tel : iuliu.stocklosa@eastelectric.ro Bosch India Limited PRADEEP,R.S. Plot 96,Phase III Peenya Industrial Area Bangalore INDIA Tel : pradeep.rs@boschrexroth.co.in Page 5 of 32

6 Program Book Guidelines Page No.: 6 of 32 Publish Date: 12-Feb Document Approval and Responsibility Created, edited and checked by Fabrice BOUTRON and Joachim LINDE, Bosch Rexroth Coordination for Renault Alain ROLLAND (Renault Cléon service 3022 ) Issued by Bosch Rexroth and Renault 1.6 Further technical information This control and drive concept was created by Bosch Rexroth in collaboration with Renault controls team. This project manual describes all elements of a control architecture which has been adapted to the requirements of automated production. As a systems supplier, Bosch Rexroth offers hardware and software, engineering services, replacement parts, training and support. Further technical information, necessary accessories for installation, etc. are available for components listed in this document in chapter 2 and following chapters. Application and use of these components is the responsibility of the user of this document. Application assistance is available by contacting the support personnel listed in Section 1.4 Bosch Rexroth contacts of this document, or by visiting the website Complete and current data sheets such as 2D and 3D drawings, eplan Makros and Data have to be found on the web side too. 1.7 Training Equipment supplier shall document sufficient knowledge implementing the desired products and solutions given in this released parts list. Training is mandatory for first-time equipment supplier using a solution. Renault reserves a right to verify proof of training of the main program developer. Details see in chap 7.2 Training. Page 6 of 32

7 2 Overview 2.1 Basic technical definitions The basis for all layouts, all components described within this project book is the current Bosch Rexroth product portfolio. The software basis is IndraWorks 14VRS. 2.2 Performance criteria for controller hardware selection Criteria Maximum Value RAM memory usage 80% CPU load 64% PLC scan time 15ms Sercos cycle time <2ms 2.3 Machine Architectures Machine Architectures Machine Type Architecture Page Production line layout Flexible cell 8 CNC Machine Advanced CNC control with MTX PC based, Engineering on Board 9 PLC based Machine Assembly line - PLC application 10 Page 7 of 32

8 2.4 Flexible cell The following layout shows an example of a flexible cell (line) consisting mainly of CNC machines and few PLC machine. Machine VDP & VPB CMLx5 Intelligent Device Production cells can be realized depending on the process requirements with a CNC or a PLC control, layout details for all kinds of machines are shown below. The machine ProfiNet bus system should be a ring topology. VDP HMI panels with VPB40 Industrial PC boxes feature high performance and offer the possibility to run additional PCI hardware like tool monitoring systems. Control hardware of CNC or PLC machines. Devices with ProfiNet and Ethernet connection: With CNC:CMLx5 controllers a separate Ethernet connection is required to connect to the MES system. With PLC:CMLx5 controllers the Ethernet communication can be routed directly to the plant IT network. *1 Switch to connect all machine internal Ethernet participants, e.g. CMLx5 control with HMI. *2 Switch for ProfiNet real time communication between the controls. ProfiNet is connected as star topology from the cell controller to the machines. The switch is located in the cabinet of the Gantry. Page 8 of 32

9 2.5 Machining control layout (CNC application with MTX) Advanced CNC control with MTX PC based, Engineering on Board The advanced CNC control shall be used for high end machine tool, e.g. complex machining centers, high performance grinding machines, gear cutting machines and time critical operations. The HMI Panel features the IndraWorks Operation and Engineering application, OEM screens and special applications like MES systems. This advanced CNC control solution has to be approved by RENAULT. Advanced CNC control with MTX PC based, Engineering on Board Machine part Abbrev. in Pic. Bosch Rexroth Product Motion control MTX CNC:CMLx5 CML85 Realtime Ethernet module CNC:CMLx5 CFL01.1-TP, not required for standalone machine PLC safety module CNC:CMLx5 CFL01.1-F1 HMI main VDP + VPB VDP VPB40.3, with IndraWorks Operation and Engineering application HMI secondary * VH21* VH21 Mobile Operation panel VH21 VR21* VR2107 Machine control panel VAMx2 VAM40.2 Keyboard VAKxx VAK40 Drives IndraDrive IndraDrive M, IndraDrive C with Sercos I/O devices Inline /Fieldline Inline, Iumberg IP67 Lion Link Switch (*1 *1 = Switch for local machine Ethernet, * Usage requires approval by RENAULT Page 9 of 32

10 2.6 PLC based machines Assembly line - PLC application Standard operator panels are VR21 with a WinStudio Application. The Ethernet telegrams of the CML-control must be filtered by a NAT router. They shall not leave the machine Ethernet network. The manufactures and types of Ethernet switches and NAT units have to be approved by RENAULT. The line ProfiNet bus system must be a star topology. Manual stations may be integrated in other stations. If manual stations do not have their own controller, the solution has to be approved by RENAULT. The number of manual stations per PLC is limited by the performance of the control and shall be approved by RENAULT and Bosch Rexroth. *) Usage of more than one manual station with one (1) PLC controller requires the approval by RENAULT. Page 10 of 32

11 3 Product information control parts 3.1 IndraControl CMLx5 IndraControl CMLx5 are cabinet DIN rail mounted hardware platforms used for PLC control IndraLogic XLC and for the CNC control IndraMotion MTX. They are used for decentralized machine concepts and together with an optional hardware module also as Safety control. Sercos is used for communication to the drives. ProfiNet is used for communication to the actuators and sensors. The CML x5 is available in 4 performance versions which differ in the type of technology modules and the firmware version. CML85 with Sercos for MTX Operation and engineering is done via scalable embedded panels and visualization devices connected via Ethernet. The PLC system IndraLogic XLC uses L45 controllers. The CNC system IndraMotion MTX uses L85 controllers. CML45 with ProfiBus and ProfiNet for XLC only CML - controller - technical data overview Processor Memory RAM CML45 Intel Low Volt Celeron 500 MHz 256 MB DRAM, min. 256 kbyte NvRAM opt. static mem 8MB CML85 Intel Core2Duo 1,2GHz 1024 MB DRAM, min. 256 kbyte NvRAM opt. static mem 16MB* Sercos + + ProfiNet Master / Slave +/+ +/+ XLC / MTX +/+ -/+ Page 11 of 32

12 3.2 Standard CNC control configuration - IndraMotion MTX IndraMotion MTX comprises CNC, Motion Control and PLC functionality in a single hardware. Up to 99 digital axes (thereof up to 32 spindles) can be coordinated. 60 independent NC-Channels are available. It is easy to upgrade CNC IndraWorks projects between the scalable hardware versions CML45, CML65 and CML85. For RENAULT L85 with SafeLogic (SL) is defined as standard CNC controller. IndraControl IndraMotion MTX CML85 CNC controlled axis Thereof spindle drives 32 Independent CNC channels Max. number of interpolating axis per channels 4..8* Minimum IPO cycle time 0.25ms NC Block- Look-Ahead 1000 Static Memory RAM Memory 16MB 1024MB The following table shows the preferred Bosch Rexroth components, type codes and part numbers to order the IndraMotion MTX products. Standard CNC control configuration - IndraMotion MTX Component Type code Part number Motion control MTX CML85.1-3P-705-FA-NNNN-NW R CML85 Firmware FWA-CML85*-MTX-14VRS-NN R CML Connector set R-IB IL CML S01-PLSET R PLC safety module CFL01.1-F1 R Realtime Ethernet module CFL01.1-TP R HMI standard VPB40.3D1Q-2G0NN-D4D-DN-NN-FW R VDP40.3BIN-D1-NN-MX R MTX HMI and Engineeing SWA-IWORKS-MTX-14VRS-D0-INST R SWL-IWORKS-MTX-NNVRS-D0-OPDENG R Engineering license SWL-IWORKS-MTX-NNVRS-D0-WORKSTATION R ) * in Type code = standard Bosch Rexroth placeholder for future options SWA-IWORKS-MTX-14VRS-D0-DVD**-SAFELOGIC R Page 12 of 32

13 3.2.1 Standard PLC control configuration - IndraLogic XLC IndraLogic XLC comprises PLC and Motion Control functionality in a single hardware. It is easy to upgrade PLC IndraWorks projects between the scalable hardware versions CML25, CML45 and CML65. For RENAULT CMLx5 with SafeLogic (SL) and VR2109 with a WinStudio installation are defined as standard. IndraLogic XLC IndraControl CML45 User memory Memory RAM Remanent data memory 24MB 256MB Sercos + 256kB ProfiNet IO Master / Slave +/+ Function modules 4 Freely configurable tasks 20 Typical processing time for 1000 instruction command mix Bool operations Word operatios 30us 30us 30us Min. PLC cycle time, Synchronized with system cycle Sercos cycle 1ms 0.5ms Standard PLC solution Control component Type code Part number CML45 with PN CML45.1-NP-500-NA-NNNN-NW R CML45 with PN and Sercos CML45.1-3P-500-NA-NNNN-NW R R-IB IL CML S01-PLSET FWA-CML45*-XLC-14VRS-D0 R R PLC safety module CFL01.1-F1 R SWS-IWORKS-SM*-01VRS-D0 R HMI standard VR N2-NNN-AA R Options HMI optional **) VEP50.5DFN-2G02E-A3D-NNN-NN-FW R FWA-VEP*05-W7*-01VRS-D0-A* 32 CFM G0-N-LBA-NN-NW R R Operation Desktop SWL-IWORKS-ML*-14VRS-D0-OPD R SWA-IWORKS-ML*-14VRS-D0-INST* R Engineering license *) SWL-IWORKS-ML*-14VRS-D0-ENG R SWA-IWORKS-ML*-14VRS-D0-DVD**-SAFELOGIC SWA-IWORKS-ML*-14VRS-D0-DVD** *) installation only on PC based Hardware, e.g. VPB, VPP and Notebooks **) approval from RENAULT needed R R Page 13 of 32

14 3.3 Operator panels VR21xx VR21 operator panels can be used as small operator panels. The small touch operator panels VR21 are available in 2 sizes: 7 and 9. The VR21 panels are provided with Windows 7 embedded system which runs Winstudio as HMI application. The connection to the control is done via Ethernet. Operator panels VR21xx *) Device Typecode Partnumber Panel Medium 7 VR N2-NNN-AA R Option *) Panel Big 9 VR N2-NNN-AA R *) Usage requires approval by RENAULT * in Typcodes means = reserved regarding Bosch Rexroth type code standards VEP - Technical Data VR2107 VR2109 Operating System: Windows embedded compact 7 Processor Central processing unit ARM Cortex -A8, 800 MHz with real-time clock RAM: Flash memory 256 MByte, LPDDR memory 512 MByte Interfaces: Ethernet 1x 10/100 Base-T Fast Ethernet USB x available Display: mm TFT (7") mm TFT (9") Dimensions: (H B) (H B) 3.4 Machine control panel VAM 40.2 The VAM40.2 supplements the machine operating panel for standard machines. It features PLC push buttons with LEDs, emergency stop, feed and spindle override. Machine control panel VAM 4 Device Typecode Partnumber VAM standard VAM40.2-PB-NA-TA-TA-VB-MA-1608-NN R Page 14 of 32

15 3.5 Mobile Operator panel VH21 The handheld device VH21 is used to control a machine from different locations, e.g. for gantries or other complex or extended machines or for the set-up of machines with open safety gates. It can be configured either with an individual IndraWorks HMI project () or via Remote Desktop. The VH21 is only allowed as secondary controls panel at machines or at gantries. The usage of PC mobile operator panels VH21 requires approval by RENAULT. Mobile Operator panel VH21 Device Typecode Partnumber Mobile Panel VH N3-111-CA R Fixture VAS NNN-NN R VH21 - Technical Data Operating System: Windows embedded compact 7 Processor: ARM Cortex A9 RAM: 512 MB / 512 MB Interfaces: Ethernet 10/100 Mbit Display: 10,1 widescreen (16:9), resolution 1280 x 800, colors (18bit), multi touch Dimensions: 1280 x 800 Switches: Stop: 2 channel, Enable control: 2 channel, 3 steps, Protection category: IP54 Safety Standards DIN EN ISO Page 15 of 32

16 3.6 Connector module VAC30 The connector module VAC30 is used for a flexible connection of the handheld terminal VH21. The settings of the VH21 are stored in module. The safety features are ensured. Connector module VAC30 Device Typecode Partnumber Connector module VAC30.2N-NN R VAC31 Technical data Power supply: 24 VDC Protection category: Front panel basic model IP65 Interface: Ethernet Dimensions: 169 mm x 85 mm x 55 mm (W x H x D) Weight: Approx. 0.5 kg Connections: Dual channel stop switch, dual channel enable switch, RJ45 Ethernet 100 Mbit 3.7 PC keyboardsvak40 The Bosch Rexroth keyboards are slide-in keyboards with an integrated mouse pointer. Features: all the functions of a conventional PC keyboard, an integrated mouse to makes it possible to navigate within graphical user interfaces USB plug to connect to PC s and operator panels. VAK40 Device Typecode Partnumber Keyboard for 15 HMI VAK40.1E-EN-U-MPNN R Page 16 of 32

17 3.8 IP20 IO-modules - Rexroth Inline The I/O units of the Rexroth Inline series are constructed in a compact housing. The modular system allows an ideal adaptation to the respective control tasks. Acceptable bus systems to communicate with the PLC: ProfiNet Typecode R-IL PN BK DI8 DO4-PAC R-IB IL 24 PWR IN-PAC R-IB IL 24 SEG/F-PAC R-IB IL 24 DI 8-PAC R-IB IL 24 DI 16-PAC R-IB IL 24 DO 8-2A-PAC R-IB IL 24 DO 8-PAC R-IB IL 24 DO 16-PAC IP20 IO-modules - Rexroth Inline Description Inline PROFINET bus coupler with 8 inputs and 4 outputs, complete with accessories Fieldline feed clamp Inline segment clamp, 24 V DC With fuse and diagnostics, incl. connector and label 8 Digitale inputs, 24V DC incl. connector and label 16 Digitale inputs, 24V DC incl. connector and label 8 Digitale outputs, 24V DC, 2A incl. connector and label 8 Digitale outputs, 24V DC, 500mA incl connector and label 16 Digitale outputs, 24V DC, 500mA R-IB IL PSDI 8 8/4 Digital Safe inputs R-IL 24 PSDO8-PAC 8/4 Digital Safe outputs R-IB IL PSDO 4/4 Digital Safe Outputs p/n 4 p/n switching (double wired) 4 p switching (single wired) R-IB IL PSDOR 4 4 Safety relay ouputs up to SIL 3 2 if double wired 4 if single wired 3.9 IP67 IO-modules - Company Lumberg Lion Link - Series Module IP67 IO-modules - Company Lumberg Description Page 17 of 32

18 4 Product information drive system 4.1 Drives components - overview Scalable and modular System The IndraDrive drive system offers you a wide range of converters inverters, power supplies, controller modules, as well the necessary firmware versions. Extensive functions The drive technology offers a wide range of functions such as positioning block mode, angle and motor speed synchronization, axis lag compensations or main spindle functions function or an integrated control axis generator. Various motor encoder systems permit either absolute or relative position detection. By offering a second feedback sensor input, all typical sensor types can be used as separate position sensors. Convenient and time-saving startup The IndraWorks Drive graphical engineering and diagnostics tool guides you quickly and reliably through the individual startup settings. Current drive-internal state variables are displayed in the process. Further help texts support you along the way. Selection criteria for drives power modules Single axis IndraDrive C compact converter for low inertia machines without line regeneration Power range form 1 to 110 kw with maximum current up to 210 A - Direct electric supply up to 500V - Internal control voltage supply, partially optional Multi axis and Machine tool IndraDrive M modular inverter with line regeneration power supply Power range from 1 to 120 kw with maximum current up to 210 A - Double axis inverter with maximum current from 12 A to 36 A - Feeding is possible via converter or supply module 4.2 Motors Encoder Renault specifies the use of absolute encoders (multiturn) : EnDat encoders M2 are mandatory for machining axis ; Hiperface encoders M1 are allowed for auxiliary axis (gantries, tool magazine)... ; Single turn EnDat encoder S2 are allowed on direct spindle motors (without gearboxes) Protection Motors with IP65 protection and no pressurization. Renault specifies the use of motors with plain shafts Brakes During the projects stages, Renault will check the braking efficiency, more particularly for vertical axes. Page 18 of 32

19 4.2.4 Motor temperature Monitoring of the motor temperature is ensured via the temperature sensor of type KTY84, which is built into the stator. The measured motor temperature is controlled via the following threshold values: Motor-warning temperature (140 C) Motor-disconnection temperature (150 C) Renault and Bosch Rexroth recommend to use the 60K motor characteristics. For further information please refer on the documentation Rexroth IndraDyn S Synchronous Motors (R ) for MSK motors and Rexroth IndraDyn A Series Asynchronous Motors MAD/MAF (R ) for MAD motors. A motor temperature higher than 80 C (probe) must be justified by the OEM to Renault Synchronous motors MSK for axis. The synchronous MSK motors are suitable for all areas of applications in manufacturing and production and provide a wide range of speed and torque. Three-phase servo motors, Synchronous Version MSK (synchronous servo motors for standard applications) Synchronous servo motor IndraDyn S (3,0-5,0 Nm) Synchronous servo motor IndraDyn S (5,0-8,0 Nm) Synchronous servo motor IndraDyn S (13-23 Nm) Synchronous servo motor IndraDyn S (17,5-23 Nm) Synchronous servo motor IndraDyn S (28-48 Nm) Synchronous servo motor IndraDyn S (32-70 Nm) MSK NN-Mx-.Gx-NNNN MSK NN-Mx-.Gx-NNNN MSK NN-Mx.-.Gx-.NNN MSK NN-Mx-.Gx-.NNN MSK NN-Mx-.Gx-RNNN MSK NN-Mx-.Gx-RNNN Synchronous motors MSK Restricted options Allowed options Example Encoder Encoder options: M1, M2, S1*, S2*!* = for Spindle applications only! MSK060C-0600-NN-M2-UG0-NNNN Smooth shaft Shaft = G MSK060C-0600-NN-S2-UG1-NNNN Holding break Break option code = 0, 1, 2, 3 MSK060C-0600-NN-S2-UG1-NNNN Shaft runout Shaft runout = N MSK060C-0600-NN-S2-UG1-NNNN Page 19 of 32

20 4.2.6 AC main spindle drives IndraDyn A Asynchronous motors MAD MAD motors (air cooled) are primarily used as main spindle or sometimes as servo drives. Several motor sizes are available offering a power output of up to 62 kw. Optionally, the motors can be supplied with a holding brake. Three-phase servo/main spindle motors, asynchronous Version MAD (asynchronous spindle motors) Asynchronous servo motor IndraDyn A (1,8-11,3 kw) Asynchronous servo motor IndraDyn A (5,0-31,4 kw) Asynchronous servo motor IndraDyn A (11-44 kw) Asynchronous servo motor IndraDyn A (18,8-62,8 kw) MAD SA-..-.G MAD SA-..-.G.-x5-.. MAD SA-..-.G.-x5-.. MAD SA-..-.G.-x5-.. AC main spindle drives IndraDyn A Restricted options Allowed options Example Encoder Encoder options: S2, M2 MAD100C-0100-SA-S2-AH0-05-N1 Smooth shaft Shaft with IP65 = G MAD100C-0100-SA-S2-AG0-05-N1 Vibration severity Flange and shaft accuracy R S Page 20 of 32

21 4.3 Kit motors Kit motors IndraDyn H These motors are especially well-suited as main spindles for modern turning, milling and grinding machines as well as machining centers. Liquid cooling and the large spindle opening allow you to directly integrate the kit motors into the spindle head. Torque motors, Synchronous Version MBS (Synchous high speed kit motors for standard applications) Synchronous kit motor IndraDyn H (8,96 21,8 kw) Synchronous kit motor IndraDyn H (20,2 38,9 kw) Synchronous kit motor IndraDyn H (20,9 29,2 kw) Synchronous kit motor IndraDyn H (1,25 41,9 kw) Synchronous kit motor IndraDyn H (22 51,3 kw) Synchronous kit motor IndraDyn H (26,2 27,7 kw) Synchronous kit motor IndraDyn H (27,2 33,5 kw) Synchronous kit motor IndraDyn H (23,8 97,9 kw) Synchronous kit motor IndraDyn H (36 40,9 kw) Synchronous kit motor IndraDyn H (25,1kW) MSS102-NNN-FA-N0CN-NNNN MSS142-NNN-FA-N0CN-NNNN MSS162-NNN-FA-N0CN-NNNN MSS182-NNN-FA-N0CN-NNNN MSS202-NNN-FA-N0CN-NNNN MSS242-NNN-FA-N0CN-NNNN MSS272-NNN-FA-N0CN-NNNN MSS312-NNN-FA-N0CN-NNNN MSS382-NNN-FA-N0CN-NNNN MSS482-NNN-FA-N0CN-NNNN Linear technology IndraDyn L Linear drives do not require mechanical transmission elements. That is why they are ideally suited for high speed chipping, grinding and laser processing. Significantly higher speeds with higher precision and peak torque values of up to 22 kn are the outstanding features of this drive technology. The encapsulated construction of the primary part simplifies motor installation and protects the motor from environmental effects. Linear motors, Synchronous Version MLF (Synchous linear motors for standard applications) Synchronous linear motor IndraDyn L (0, kn) Synchronous linear motor IndraDyn L (2,0 3,8 kn) Synchronous linear motor IndraDyn L (3, kn) Synchronous linear motor IndraDyn L (5,2 10,0 kn) Synchronous linear motor IndraDyn L (7,45 17,5 kn) Synchronous linear motor IndraDyn L (11,0 21,5 kn) MLP040-NNN-FS-N0CN-NNNN MLP070-NNN-FS-N0CN-NNNN MLP100-NNN-FS-N0CN-NNNN MLP140-NNN-FS-N0CN-NNNN MLP200-NNN-FS-N0CN-NNNN MLP300-NNN-FS-N0CN-NNNN Page 21 of 32

22 4.3.3 High torque ring motors IndraDyn T Torque motors MBT are used for rotary axis or swiveling axis in machining centers. These direct drive motors eliminate the need for mechanical transfer elements that wear easily. At the same time, dynamics and precision are increased considerably. Torque values of over 13,800 Nm are possible with the MBT motors. Torque motors, Synchronous Version MBT (Synchous torque motors for standard applications) Synchronous torque motor IndraDyn T (15 65 Nm) Synchronous torque motor IndraDyn T ( Nm) Synchronous torque motor IndraDyn T ( Nm) Synchronous torque motor IndraDyn T ( Nm) Synchronous torque motor IndraDyn T ( Nm) Synchronous torque motor IndraDyn T ( Nm) Synchronous torque motor IndraDyn T ( Nm) MST130-NNN-FT-N0CN-NNNN MST160-NNN-FT-N0CN-NNNN MST210-NNN-FT-N0CN-NNNN MST290-NNN-FT-N0CN-NNNN MST360-NNN-FT-N0CN-NNNN MST450-NNN-FT-N0CN-NNNN MST530-NNN-FT-N0CN-NNNN 4.4 Indradrive power supplies and power sections Supply modules for Indradrive M Feed-in/ Feed-out module Feed-in/ Feed-out module 18, 45, 65, 120 kw, regulated Type HMV01.1R-Wyyyy 1 -A-07-NNNN Drive system INDRADRIVE "M" Drive regulation devices Drive regulation device, 1-axis, 36A Drive regulation device, 1-axis, 54A Drive regulation device, 1-axis, 70A Drive regulation device, 1-axis, 110A Drive regulation device, 1-axis, 150A Drive regulation device, 1-axis, 210A Drive regulation device, 2-axes, 36A Type HMS01.1N-W0036-A-07-NNNN HMS01.1N-W0054-A-07-NNNN HMS01.1N-W0070-A-07-NNNN HMS01.1N-W0110-A-07-NNNN HMS01.1N-W0150-A-07-NNNN HMS01.1N-W0210-A-07-NNNN HMD01.1N-W0036-A-07-NNNN Drive system INDRADRIVE "C" Drive regulation devices Compact converter, 1 axis, max. current 12A Compact converter, 1 axis, max. current 28A Compact converter, 1 axis, max. current 54A Compact converter, 1 axis, max. current 70A Compact converter, 1 axis, max. current 100A, 24V integrated Compact converter, 1 axis, max. current 150A, 24V integrated Compact converter, 1 axis, max. current 210A, 24V integrated Type HCS02.1E-W0012-A-03-NNNN HCS02.1E-W0028-A-03-NNNN HCS02.1E-W0054-A-03-NNNN HCS02.1E-W0070-A-03-NNNN HCS03.1E-W0100-A-05-NNBV HCS03.1E-W0150-A-05-NNBV HCS03.1E-W0210-A-05-NNBV Page 22 of 32

23 4.5 IndraDrive control sections to be used with IndraDrive C or M power sections Consultation with RENAULT is necessary if the solutions for the safety functions should not be used, because functions like safe operation stop and safely reduced speed are used to setup the machines while the machine access doors are open for maintenance by RENAULT. - Drive firmware MPx19VRS Firmware function packages FWA- -MPB- single axis BASIC, standard servo application, automation FWA- -MPH- single axis ADVANCED, servo application, main drive application, machine tools high-end FWA- -MPD- double axis BASIC, servo application, machine tools Page 23 of 32

24 Function overview control parts for IndraDrive C/M For RENAULT projects use only Sercos III and ProfiNet control parts for IndraDrive. For detailed information on the controls parts please use the documents shown in the Bosch Rexroth Mediadirectory. Advanced SERCOS CSH 2.1B-S3-EC-xx-.. Onboard interfaces - digital and analog I/O - relay output Lead communications - Sercos and ProfiNet Screen element - standard and comfort HMI Option 1 - Combined encoder interface Option 2 - Multi Ethernet - Combined encoder interface - analog I/O extension - encoder emulation Option 3 safety technology - Drive interlock and safety I/O - STO, SS1, safe motion, etc. Option 3 - Combined encoder interface - analog I/O extension - encoder emulation - digital I/O extension Option 4 - analog interface - multi encoder interface - encoder emulation Basic CSB 2.1B-ET-EC-xx-.. Onboard interfaces - digital and analog I/O - relay output Lead communications - MultiEthernet (Sercos / ProfiNet) Screen element - standard and comfort HMI Option 1 - Combined encoder interface Option 2 - Combined encoder interface - lead communication - encoder emulation Option 3 Safety - Drive interlock - safe motion Option 4 - Combined encoder interface - analog I/O extension - encoder emulation - digital I/O extension Basic SERCOS Double axis CDB 2.1B-ET-EC-xx-.. Onboard interfaces - digital and analog I/O - relay output Lead communications - MultiEthernet (Sercos / ProfiNet) Screen element - standard and comfort HMI Options - Combined encoder interface - analog I/O extension - encoder emulation OPTION safety - Drive interlock - safe motion Combined encoder interface - IndraDyn motors - Hiperface Each control section must be equipped with a Micro SD card as Flash EPROM, in order to simplify drive exchange. Page 24 of 32

25 5 System Software IndraWorks The IndraWorks Framework from Bosch Rexroth is a scalable frame for modular engineering solutions. The following components can be integrated as IndraWorks. The specific engineering tools (packages) of different technologies integrate themselves step by step as Plug Ins into the collective framework. Framework and tools are separated and developed independently. IndraWorks software version 14VRS must be used. Page 25 of 32

26 The System Software IndraWorks includes all necessary software components to realize standard machine tools or machine equipments for high production. All components are integrated in the IndraWorks Framework into one Engineering tool. Engineering Framework IndraWorks for CNC and PLC with integrated functions: Profinet, Profibus and I/O configurator IndraLogic V2 (PLC programming system) WinStudio (HMI design tool) Common Tools (Logic Analyzer, graphical NC programming, NC simulation...) IW-Drives (Startup tool for drives) System add-ons available for: IndraLogic applications (Demos, libraries, destination device information...) IndraMotion MTX application (Demos, libraries, destination device information, tools...) Renault HMI A basic DVD master Bosch Renault V2.0 including automatic installation of: Windows 7, IndraWorks engineering and Operating Desktop 14VRS, and a basic template project MTX_RRS_Standard will be supplied to the OEM. 5.1 System software IndraLogic The IndraLogic programming system is used to logically implement all PLC tasks. It is integrated in the IndraWorks Engineering tool IndraLogic is usable on all kinds of hardware platforms and is the basic programming system to achieve all PLC tasks. For CNC applications with IndraMotion MTX, IndraLogic is also used for PLC programming and provides the necessary interfaces for communication there. The programming system IndraLogic can also be installed without a connection to the PLC or the plant as an independent application on any PC. This makes it possible to plan offline. IndraLogic is fully compatible with EN standard in terms of data types and programming languages. 5.2 HMI design with WinStudio Standard tool for user graphic screens design for standard VDP screens and small HMIs VR21 It is possible to create both single containers and full screens with WinStudio. The functional options of WinStudio refer to the number of available tags (Process variables) which can be mapped. These options are partitioned as follows: Basic license package (Light version, maximum 500 tags) onboard and free in every control unit Editor license package (scalable in the number of available tags, easy upgrade with activation codes and additional installation) 5.3 IndraWorks-Drives IW-Drives is the Rexroth Drive Technology setup tool. All required parameter settings are achieved with IW-Drives. Page 26 of 32

27 The relevant function data such as mode selection (for example settings for positioning the drive) and current speed values are entered on the standard screen in the guided startup procedure. Predefined parameter sets, for example for linear axes or spindles, also simplify the startup procedure. The software tool which is integrated into IndraWorks also allows you to re-optimize individual parameters directly at the machine and provides diagnostic functions in the control. The extensive oscilloscope function simplifies the documentation and the checking of the control loops. Page 27 of 32

28 6 Integration rules All the machines for Renault will be approved by means of a Bosch Rexroth checklist during the steps of the project. For a good integration of the Bosch Rexroth products, we recommend you to use the Bosch Rexroth Checklist. We advise you to verify yourself your machine by means of the checklist documents. BR_CHECK_Indradrive_C_EN for Drives with compact converters HCS02 or HCS03 BR_CHECK_Indradrive_M_EN for Drives with inverters HMS or HMD and power supply HMV BR_CHECK_Indramotion_MTX_EN for MTX CNC architecture 6.1 CNC Part program It is recommended to comment every program and subroutines in the customer language. For the CNC program related to the workpiece, Renault recommends to use the ISO programming language. The programming structures must abide by the Renault specifications listed in the Renault guide Tool management The so called tool management is usually defined in close interaction between machine manufacturer and Bosch Rexroth as it is an essential and unique part of a machine tool. The functionality of the tool management is usually spread in different tasks mainly handled in the CNC (e.g. search, activation and deactivation of tool data; search for sectors or pockets; description of necessary movements and sequences during the tool change) but as well partly in the PLC (e.g. determining and calculation of tool life time). For machines without tool storage use D-corrector. For machines with tool storage use ED-corrector. For detailed information and clarification get in touch with Bosch Rexroth Encoder evaluation Encoders or linear scales are monitored inside the drive system. Regarding the direct measuring system, the control bit must be active. In case this bit would cause untimely standstills, the OEM will have to inform Renault and Bosch Rexroth about this problem. An investigation will be carried out by Bosch Rexroth and Renault. See documentation RRD_Encoder_Evaluation 6.2 PLC Hardware configuration The hardware configuration (local I/O & Profinet) should be declared in the IndraWorks project (default setting) Programming language According to Renault specification, only 2 languages are accepted: LD (Ladder Diagram) Machine mode management Automatic cycle Motion command Fault detection Page 28 of 32

29 ST (Structured Text) Data analysis Specific process functions Variables declaration All the global variables must be organized by functionality in subfolders. In order to make the declaration of the variables easier, structured data like arrays and structures can be created: They must also be classified in folders and documented. All the mnemonics must be in French or after agreement from Renault in English, with French comments (or local language). All declared variables should be documented. All machine I/Os should be declared as in the global variables area. Global variables should not be directly used inside a Function Block (FB) Tasks The Rexroth PLCs are multi-task capable. At least one main PLC task must be created: This task must call a master program POU called prmain. This POU written in LD must call each of all the different POUs animating the complete machine with a enable condition which will be set to TRUE. 6.3 HMI The integration of the Renault Rexroth Screens is mandatory to design a HMI application according to the Renault specification. See project files MTx_RRS_STANDARD Available for VDP40. Page 29 of 32

30 6.4 Safety According to the risk analysis, if safety is necessary then the machine manufacturer has to use the safety option for all safety related drives, even for auxiliary axes. Use S4 option (Safety on Board) for all drives where necessary The OEM has to provide Renault with the following documents in writing: Hazard analysis and risk assessment of machine with PLs requested and those reached. Safety protocol using the example given in IndraWorks engineering in writing Safety acceptance instructions using the example given in IndraWorks engineering in writing Full safety acceptance test protocol similar to example given in Bosch Rexroth documentation : Safety_Protocol in writing 6.5 Predisposition for the Renault Backup/Restore tool To be well done interconnected with the Renault Backup/Restore tool, some data locations should be respected : NC-Program (MTx): Main part program: root\mnt ; root\usr\user Cycles/called part programm: root\usr\mtb Active Project: D:\OEM\RR_Project\<project name> All other specific datas (for example Artis datas): D:\OEM\Specific Data The drives Backup has to be individually saved and placed like this Drive 1: D\OEM\RR_Drives\<drive name 1>.par Drive n: D\OEM\RR_Drives\<drive name n>.par By using the Backup/Restore keys (available with the Renault Rexroth HMI, all MTx applicative data will automatically placed in this directory. D:\OEM\RR_Backup Then, this directory will contain the following data: NC compiled file: (*.tar) Extended data: (*.zip) IW project: (*.zip) Windows-Registry: (*.reg) Specific OEM datas (*.*) Page 30 of 32

31 Copy of RR_Drives directory The Renault Backup/Restore tool task is to get this directory content See MTX Backup Restore_FR.doc documentation 6.6 Ethernet connection MTX Use the Eth2 VPB40.3 connection to factory Ethernet SAM system. Use the Eth1 of VPB40.3 with a switch to connect CML85, small HMI and remote Engineering. PLC stations (XLC) The Ethernet port of CML45 must be connected via a NAT switch to the VR21 HMI and to the SAM network. 6.7 SAM (Maintenance help system) Use the standard function block (FB) RRS_SAM and the Winstudio screen integrated in the standard project MTx_RRS_STANDARD". 6.8 Master In order to have a reference software package, it s recommended to use the Renault Rexroth Master. The master is a tested and validated software package on a tested and validated hardware package. It has 2 mainly aims: To simplify the set-up of the machine: the OEM has a software reference package, ready to use. To simplify the machine maintenance: validated software integration in the Renault Production System. No need to install every single software separately. Page 31 of 32

32 7 Further Information 7.1 Product information Information on all Bosch Rexroth products mentioned inside this book will be found also on the Bosch Rexroth Website. For the Drive and Control components please visit The product documentation describes the universal functionality of the hardware and software components. The individual documents can be ordered in a printed version. from the Bosch Rexroth Media Directory from the website Training The BRC main training center is located in Erbach, Germany. Courses for machine designers and engineers are conducted by our training personnel in special classrooms using the latest training equipment. To better understand the Rexroth drive and control technology, the lessons are supplemented with practical exercises. Training can also be done on site. Special training sessions have been developed according to Renault needs. Bosch Rexroth AG Training Center BRS/DID2 Berliner Str Erbach Tel. +49 (0) Fax +49 (0) training.brs@boschrexroth.de Bosch Rexroth SAS France Antony MUTOMBO B.P. 74 ZI de la trentaine Chelles Cedex France Tel: +33 (0) Fax: +33 (0) antony.mutombo@boschrexroth.fr Page 32 of 32