Rexroth SYNAX 200 Modular system solution for shaftless printing and converting machines. Flexible printing with high productivity

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1 Rexroth SYNAX 200 Modular system solution for shaftless printing and converting machines Flexible printing with high productivity

2 2 Rexroth SYNAX 200, your route to a more productive future Greater flexibility, more speed, higher precision the market has high demands in modern printing and converting machines. How can you meet these demands, provide security for the future and stay ahead of your competitors? The solution is SYNAX 200 from Rexroth the pioneer of shaftless drive technology. Our experience your advantage With our shaftless motion control systems solution, we successfully pioneered a new era of modern mechanical engineering as early as Thus, our global net of system specialists has the longest practical experience with printing and converting machines worldwide. In close cooperation with our customers, our innovative systems have been continually developed and optimized resulting in a technical and economic advantage for machine manufacturers and end-users. One system solution for all applications Large newspaper plants, printing machines for packaging or commercial printing, narrow web machines for labels and forms or converting of paper, foil, cardboard and corrugated board the systems solution SYNAX 200 offers suitable motion control functions for all types of applications. More than 6,000 control systems in over 2,000 highly-productive printing and converting machines around the world prove that our customers have confidence in Rexroth shaftless motion and drive technology. Convincing advantages standardized machine units maximum manufacturing performance fast format and product change reduced paper waste highest product quality less energy consumption simple operation high reliability lower maintenance costs reduced total costs for manufacturing easy expansion of the installation

3 3 Newspaper printing Commercial printing Rotogravure printing for packaging Flexogravure printing Corrugated board printing Label printing Forms printing Converting Shaftless driven for the advantages of Rexroth shaftless drive technology Bag production Folding box production Corrugated converting

4 4 The decisive advantages in competition innovation with high economic efficiency Innovative machine concepts Rexroth modular controls and drives are the basis for the development of new and innovative machines with the electronic line shaft. With a decentralized or centralized automation concept using SYNAX 200, you as a machine manufacturer will be at the forefront of the technological trend in the market. With SYNAX 200, the user will enjoy the advantages of highlyflexible and efficient production machines. Getting more out of your machine, and increasing your competitiveness that s what shaftless driven stands for. More flexibility Simpler standardization of machine units because of fewer mechanical components and auxiliary equipment opens the way to serial production. Thus, you ll be flexible in the configuration of your machine. Setting up for a new product takes place at the push of a button. The result: a minimum of mechanical retooling, machine setting in record time, and thus very short order change times. Maximum availability The fast, format-controlled parameterization of the drive system and the possibility of driving machine axes independently allows the user to enjoy maximum utilization of their installations. Experience shows that availability is increased by dramatically reduced down times and consequently, economic efficiency and productivity is high. Highest accuracy Highly dynamic handling of the process signals is guaranteed by the synchronization via the international standard SERCOS interface (IEC 61491/EN 61491), the intelligent digital drives and the flexible motion control functions. Thus, highest accuracy is guaranteed at all machine speeds.

5 5 Diagnostics at the push of a button Clear, plain-text messages in SYNAX 200 allow quick diagnostics during commissioning or machine operation. Thus, any malfunctions in the individual machine modules can be visualized quickly and easily in chronological sequence via the operator control terminals. Less paper waste Processing material is expensive. Therefore, SYNAX 200 provides minimum torsional elasticity and reduced backlash, resulting in higher registration accuracy. This significantly reduces start-up waste. You as an end-user will lower your production costs, even the smallest productions will still be economical. Reduced energy consumption Digital individual drives reduce energy consumption and noise. Furthermore, machine components can be separately isolated now. With SYNAX 200, shaftless machines are even more efficient with lower pollution. Quality according to QS-9000 TE Rexroth's Electric Drives and Controls Division was the first German company to introduce quality management according to QS-9000 TE and DIN EN ISO 9001:2000. Experience shows our system components have maximum reliability and optimum maintenance characteristics. Single source solution With the systems solution SYNAX 200, you ll need only one supplier for the total solution. Use the harmonized modular Rexroth system technology to your advantage. From HMI and PLC to motion control and drives. From advising and project planning to commissioning and service Rexroth can offer you all the advantages of the leader of the global market.

6 6 Flexible electronics instead of rigid mechanics the electronic line shaft of SYNAX 200 Mechanical drive solutions are complex and expensive. They are affected by wear and lack the flexibility required in today s markets. Any change of product or format costs time and work and reduces productivity. The future of modern printing and converting machines lies in mechanically and electronically advanced systems solutions. Digital and transparent SYNAX 200 replaces mechanical transmission elements with efficient motion control functions and integrated PLC. SYNAX 200 makes shaftless drive technology transparent by means of digital communication. Thus, all the potential for enhancing printing system flexibility is available to the user. Precise and interference-free The motion control system of SYNAX 200 determines the position of the virtual master axis with digital precision. Optional cascading of these multiturn control axes enables the straightforward integration of machine modules in interlinked and synchronized production processes. SERCOS interface provides the interference-free transmission to the individual machine drives. This makes the highly precise, synchronous movement of all process modules possible. Couplings Differential gearbox Gearbox with variable transmission ratio Cog wheel Mechanical cam Conventionally driven machines are less flexible, changes of product and format go to the expense of productivity

7 7 Simple system expansion Complex automation solutions can be realized by means of a combination of several motion control systems and master axes. Thus, there is practically no limit to the number of synchronized drives; it is finally possible to break down a machine into independent sections. With SYNAX 200 technology, shaftless machine units can be coupled to conventionally driven machines by using an encoder as a real master axis. Thus, existing production plants can be extended and updated very easily, economically and efficiently. Flexible integration With the wide range of SYNAX 200 drive systems, the connection to the machine can be realized in many different ways. Using a framed or frameless motor, with reduction gearing or direct drive SYNAX 200 with the electronic line shaft offers you the optimum motion control concept for each application. Framed motor with reduction gearing and optional position feedback at the cylinder Direct drive with framed motor and position feedback at the cylinder Direct drive with frameless motor and position feedback at the cylinder The future in the printing and converting industry belongs to machines with an "electronic line shaft"

8 8 Crossing mechanical limits flexible motion control functions Easy and quick access to motion control functions and their parameterization is the key to the economical integration of the "electronic shaft" in modern machine systems. SYNAX 200 is not a "black box" for the user its motion control functions are designed to be transparent and consistent from start to finish. The electronic gears, for example, have uniform structures for cascadable multiturn control axes as well as for servo drives. This makes motion control both easy to understand and easy to use, even without many years of experience in modern servo drive technology. Primary master axis Secondary master axis Printing and converting Universal structure of SYNAX 200 electronic gears Gear ratio Gear ratio fine adjustment Flexible motion control easily-parameterized technology modules integrated IEC PLC (optional) up to 40 slave axes per PPC control 2 cascadable master axes per PPC control up to 32 PPC controls in the group flexible, switchable operating modes, e.g. cams or angle synchronization high-resolution electronic gears with universal structure electronic coupling online switchable electronic cams electronic high-speed cam switch group integrated process functions: - winders - dancer axis control - tension control - register control

9 9 Precision without wear electronic gears Without mechanical limits electronic cams Highest precision the integrated register control Mechanical gearboxes are replaced by SYNAX 200 highest precision electronic gears. Mechanical processes are standardized and the functionality of machine modules increased accordingly. You are able to handle a large number of format variations without mechanical modifications, e.g. by the quick setting of longitudinal registers with maximum resolution. Non-uniform relationships between the master axis and individual drives are defined by electronic cams. These cams are selectable "on-the-fly". Cross cutters are synchronized for cutting of the material according to format. Settings are made by quick and simple parameter changes. The integrated register control automatically corrects the angular position of an individual drive in relation to the position of the product. This eliminates costs for external register controls or for additional actuators and special drives. And helps you to achieve highest product quality with a significant reduction in waste. Get web tension under control the tension control Time is money on the fly job change From reel to reel winding control The integrated tension control keeps web tension constant in the material to be printed. Depending on the actual measured value and the digital or analog tension setpoint, SYNAX 200 precisely controls the tension. External electronic control devices are no longer necessary. The highest printing precision is already guaranteed at the start of production. SYNAX 200 makes it possible to start and run up a module into angular synchronism with a machine already operating at production speed. For the first time, the quick product change at full machine speed is possible. This is an innovative feature in classical mechanical engineering. Shorter down and retooling times reduce the current manufacturing costs. All functions are integrated for center driven winders for winders without external sensors or for winders in combination with dancer rolls or load cells. The winder axes are controlled according to the setpoint values. Thanks to the direct processing of the measured variables and the integrated diameter calculator, there are no additional costs for external winding controllers.

10 10 Protect existing investments open communication at all levels With the Rexroth systems solution SYNAX 200 you ll get all the options for the integration of modern motion control into existing automation systems as well as in your newly developed machine concepts based on the electronic line shaft. The ideal system module kit From the single-web inline machine to multi-web newspaper printing machines SYNAX 200 covers the overall control and drive requirements of your individual application. Compose your system from the efficient and innovative standard components of the SYNAX 200 suite of modules according to your specific requirements. SYNAX 200 the complete systems solution flexible motion control user-friendly software tools easily programmable PLC highly-dynamic digital servo ergonomic visualization and drives operating devices modular input/output components Utilization of open standards The open architecture of SYNAX 200 protects the investments you have already made in engineering and control components. Thanks to this open character, the dialog between hardware and software solutions of different manufacturers is trouble free and makes future extensions of existing production plants easy. The utilization of SYNAX 200 open communication standards consequently reduces time and effort and therefore the cost of integration into your automation system, e.g. via Arcnet DeviceNet Ethernet INTERBUS PROFIBUS ControlNet SERCOS interface

11 11 Superior connections to PLC and HMI The PLC performs control tasks in close connection with the motion control, either for the whole machine or for modular machine units. Thus, fast process signals, complex instructions and parameters are exchanged directly between the system components. Ergonomic terminals visualize the machine status and offer the whole range of possibilities for operation and data input. The SYNAX 200 software tools support you in engineering and operation processes. The most economic solution Turn your shaftless machine into a flexible, high-performance production system with open communication paths and motion control functions that are easy to parameterize and program. Modulation and scaling characteristics of the components, together with the integrated process functions, make SYNAX 200 the most technically and economically advantageous systems solution. With all single- and multi-axis applications you as machine manufacturer or end-user will profit from the advantages of Rexroth s shaftless drive technology. Automation with SYNAX 200 Online maintenance and diagnostics Winding Unit Printing Unit Processing Unit Extension Unit Internet Operating and visualization Motion control, PLC and I/O Ethernet (TCP/IP) Fieldbus Machine console and PLC Fieldbus Cross communication Fieldbus Decentral I/O Decentral I/O SERCOS interface SERCOS interface SERCOS interface SERCOS interface Digital intelligent drive controller

12 12 Integration of motion control and logic transparent and consistent The best system tools With its advanced software tools for total automation, SYNAX 200 will result in significant cost reductions for engineering, commissioning and maintenance of your machine and automation system. With our system components you will get integrated solutions to increase the economic efficiency of your machine or plant. Motion and logic combined SYNAX 200 integrates on a single platform the easy parameterization of motion control with the flexibility of PLC logic in accordance with IEC The user-friendly and economical performance of all motion and control functions is thus possible with uniform hardware. Whether rack or PC based, the coordinated modular system of the SYNAX 200 provides the necessary flexibility of hardware configuration. Programming of the PLC logic takes place with the IndraLogic engineering tool. Through the functions library you have direct access to motion control functions. The latter are parameterized practically at the press of a button by means of the SynTop software tool. Electronic gears, for example, are quickly and easily set without any programming. And process functions for register controls, winders, tension and dancer axes are integrated in the application without any effort. At the same time, SYNAX 200 offers all the functions and libraries based on IEC , thus providing every freedom for implementing all possible automation applications in the printing and converting sector. HMI Application program PLC IEC languages and function library Motion logic library Motion control Synchronization Cross communication Technology components Servo drives PPC control SYNAX 200 Motion control and PLC all integrated in the SYNAX system architecture Commissioning and service with SynTop dialog-guided operation quick access to the motion control functions extensive online help numerous diagnostic options convenient drive supervision integrated oscilloscope for drive optimization back-up of parameter sets online/offline operation mode well-proven software concept

13 13 Commissioning and diagnostics The commissioning and service tool SynTop is based on Rexroth s decades of know-how in control and drive technology. Via userfriendly dialogs and extensive online help, SynTop guides you through commissioning, clearly shows diagnostics and drive data, and leads you to achieve your target quickly and easily. Programming according to IEC The PLC module is programmed via the engineering tool IndraLogic. In addition to the support of programming languages and standard functions according to standard IEC , you can integrate your own function libraries. The system engineer will quickly be familiar with the user-friendly programming. Unique functionality The transparent representation of program code, import/export functions, the reversible online/ offline mode, as well as user and password administration make it easy to work with this efficient PLC. The permanently available online help for all language elements allows quick access to the documented functions. The utilization of the integrated 20 channel logic analyzer for supervision of all program parameters, the active syntax check color, as well as the constantly updated cross-reference list will support you in programming and troubleshooting. Special function components provide easy communication with the motion control via its fast data interface. Simple programming and parameterizing with SYNAX 200 Engineering with IndraLogic programming languages according to IEC instruction list (IL) function block diagram (FBD) ladder diagram (LD) sequential function chart (SFC) structured text (ST) continuous function chart (CFC) standard IEC library PLCopen library integration of user-defined libraries communication library 16 time, cycle and event controlled tasks online/offline programming mode online change integrated 20 channel logic analyzer simulation, monitoring and debugging import/export functions user and password administration multi-language support

14 14 Operation and visualization with Rexroth WinStudio easy and user-friendly Rexroth SYNAX 200 is the complete automation system for shaftless printing and converting machines in a matching system of modules. The new WinStudio software tool is the related easy-to-operate, comprehensive visualization software tool for all SYNAX 200 automation solutions. Rexroth WinStudio offers the project engineer all functionality for creating system-specific operating screens in a simple drag-and-drop, point-and-click development environment. WinStudio supports different graphics formats and interfaces such as Active-X. All process variables and communications parameters defined in the SYNAX 200 MotionLogic are available in WinStudio for visualization. Multilingual database support and automatic language translation at runtime eliminates efforts for creating specific HMI screens. SYNAX 200 also supports the integration of 3rd party applications via the integrated OPC interface. Used in conjunction with the new family of PC-based operator terminals, Rexroth IndraControl V, WinStudio is the ideal platform for man-machine communication for all types of shaftless printing and converting machines.

15 15 Quick and easy creation of system-specific operation and visualization masks Operator panels with integrated industrial PC Convenient operation and visualization user-friendly PC-based visualization and operation dynamic graphic screens, trends, alarms, reports and orders alarms management system with free formats and filters automatic language translation at runtime import/export of orders, reports and real-time data in XML format and web interface seamless integration in Windows environment interfaces to other 3rd party packages such as Java, C, C++, and Visual Basic Simplified project planning simple and object-oriented environment for screen and object reusability full-featured screen objects and dynamics with customizable object properties flexible database with boolean, real, string and array tags extensive, graphical libraries flexible programming via easy-to-use scripting language conforms to industry standards such as OPC, DDE, ODBC, XML, ActiveX import of 15 different graphics formats for enhanced and realistic screens internationalization using unicode Rexroth IndraControl V the operator terminals field-proven industrial PC ETX format CPU and chipset 12 and 15 TFT displays touchscreen integrated SVGA graphics controller on-board 10/100 MB Ethernet serial, parallel and USB interfaces PROFIBUS interface (option) integrated UPS (option) EMV-certified with IP65/IP20 protection completion by more operator controls and visualization units (option)

16 16 The perfect team for your automation the modular system components Modular control hardware Comfortable HMI devices Input/output modules motion control PPC Rack or PC plug-in card local I/O modules interfaces for fieldbus, Ethernet, cross communication and decentralized I/O direct coupling of operating and visualization terminals integrated displays for quick device diagnostics software tools for parameterization and programming from motion control and PLC clear, understandable visualization, operation and diagnostics uniform operation philosophy with easiest handling industrial PC with touchscreen or operating keys LCD operating terminals with different performance levels and graphic displays and freelyprogrammable function keys simple software tools for programming the HMIs scalable I/O modules with IP20 protection for local or decentralized control architecture decentralized sensor/actuator boxes with IP65 protection communication via fieldbus interfaces PROFIBUS or DeviceNet simple interconnection

17 17 Intelligent drive system IndraDrive Highly-dynamic servo motors IndraDyn wide power range from 1 kw to 110 kw compact converters and modular inverters integrated safety functions (EN 954-1, Category 3) integrated motion control using IEC compliant PLC process-oriented technology packages scalable through extensive hardware options and software modules openness through broad range of interfaces direct connection to a 380 V V line and power recovery integrated line contactor and braking resistor little installation work and easy initial startup enclosed motors, kit motors and linear motors in synchronous or asynchronous designs high dynamics, power density and load rigidity high peak torques up to 13,800 Nm servo motors for potentially explosive areas conforming to ATEX and UL/CSA high-resolution transmitter systems absolute or incremental position scanning

18 18 Rexroth SYNAX 200 successful in all applications around the world

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