HNC100 Series 3X from Rexroth. The Motion Control System for Electrohydraulic Axes Scalable closed loop control system for up to four axes
The Intelligence of a New Generation: HNC100 Series 3X Motion Control The high level of modularity of hydraulics permits the realization of drive tasks with absolute precision in functionality and performance in a wide range of application areas. To this purpose Rexroth combines the technological advantages offered by a wide range of motion control systems for electrohydraulics from integrated single-axis control to high-end motion control. Only Rexroth is able to master hydraulics and control technology to this level of complexity and is thus able to realize the most demanding motion control tasks in real time. Overview of current axis controllers and motion controls Axis Controller pq controller SYDFE 1 axis IAC-P 1 axis IAC-R 1 axis HACD
Proven mechanics, digital closed loop control technology, highresolution sensors this is the scope of Drive & Control from Rexroth. In addition Rexroth offers for modern machine solutions the following: intelligent, communication-capable and highly flexible modules for realtime diagnostics and easy access to all parameters. Rexroth makes complex machine processes even easier to master impacting productivity by reducing downtime to an absolute minimum. The new HNC100-3X Motion Control Generation has increased the range of applications of the HNC100 Electrohydraulic NC Control Family. The modular generation can control up to four electrohydraulic axes. The increased system performance reduces scanning time considerably. Users can simply use their know-how, acquired with the current HNC programs and apply them to the new generation. System Overview 4 Open and Closed Loop Control Algorithms 6 NC Functionalities 7 Programming with WIN-PED 6 10 Communication Variants SERCOS 12 Support 14 Application Areas 15 Type Code 16 Motion Controls 1 2 axes 1 4 axes 2 32 axes HNC100-2X HNC100-3X MAC-8 Power increase
HNC100-3X: The Decentralized, Compact and Modular Automation System Whether just one axis or up to four the modularity of the HNC100 Series 3X Motion Control produces what is required to construct a completely modular machine. Global bus NC functionality Hydraulics-specific controller Sequential control (NC programs) Compact design DIN rail mounting The extension of the proven, modular control system offers maximum flexibility. The new compact version of the HNC100 Series 3X for single-axis applications has added a reduced version of the HNC100 to the portfolio. The complete version of the HNC100 Series 3X is available in controller format with the capability of closed loop control of up to four axes. With this latest product, Rexroth has drastically reduced controller dimensions to 120 x 48 x 118 mm. Only the width of the closed loop control electronics varies, as this will depend on the number of axis. Thanks to the available fieldbuses and its compact design, the HNC 100 Series 3X has also gained in significance as a decentralized unit used in the immediate vicinity of the drives. Compact 1 axis VT-HNC100-C-3X CPU + 2 axes VT-HNC100-2-3X CPU + 1 axis VT-HNC100-1-3X
Connection to the higher level system control takes place via internationally standardized bus systems such as Profibus DP V0, CANopen or SERCOS interface*. This enables the HNC100-3X to be optimally integrated into automation concepts. Higher level control (PLC or PC) and visual display (HMI) PC SPS HMI Communication with the higher-level control system Digital inputs/outputs or fieldbus (Profibus DP V0, Interbus-S, CANopen, SERCOS*) CPU + 3 axes VT-HNC100-3-3X CPU + 4 axes VT-HNC100-4-3X With SERCOS no NC functionality Only available in the single-axis version
Flexible Communication for Flexible Solutions The standardized interfaces of the HNC100 Series 3X Motion Control also support SERCOS interface in single-axis operation, in addition to the fieldbus systems Profibus DP V0 and CANopen. Interfaces for the position transducers: Incremental TTL Digital absolute SSI Analog (voltage ± 10V or current 4 20 ma) Compact SSI Digital position transducer Interfaces for pressure/ force control: Analog (voltage ± 10V or current 4 20 ma) Free analog inputs: For flexible use in NC programs 6 digital I/O (4 x In, 2 x Out) Interfaces for open loop drive control: Analog (voltage ± 10V or current 4 20 ma) Fieldbus systems: Profibus DP V0 CANopen SERCOS interface (output bus) Process connection to higher-level control: Freely configurable digital inputs/outputs Analog inputs/outputs The fieldbus systems connect the hydraulic drives to the machine control via a real-time interface. COM (RS232) for PC Address for Profibus DP V0 SSI Digital position transducer COM (RS232) for PC 6 digital I/O (4 x In, 2 x Out) Voltage supply 24 V Analog inputs 1 x U, 2 x I Analog outputs 2 x U Profibus DP V0 CANopen Voltage supply 24 V Analog inputs 1 x U, 2 x I SERCOS interface Analog outputs 2 x U SERCOS model
Open and Closed-loop Algorithms for Optimum System Performance The features of closed-loop controlled drives are critically dependent on the closed-loop algorithms used. The closed loop electronics of the HNC100 Series 3X is particularly optimized to the specific physical behavior of hydraulics with its powerful hydraulic controller structures and specially tailored NC commands. Closed-loop position control: PDT1 controller Linear gain characteristic curve Direction-dependent gain* Inflected gain characteristic curve (linearization of valve curves) Gain can be changed via the NC program Fine positioning (switching integrator)* Residual voltage principle/ overlap jump* Compensation of valve offset Status feedback (Acceleration/pressure)* Command value feed forward Limitation of control value via the NC program The HNC100-3X works through the tasks independently of the cycle time of the higher-level open loop control. Furthermore, the noticeably increased system performance of the new generation has shortened response time to a mere 0.5 ms in single-axis operation. 1 to 4 Axes COM (RS232) for PC Address for Profibus DP V0, CAN-Bus Digital position transducer: SSI, incremental TTL Closed loop velocity control: PI controller 11 digital I/O (freely configurable) Baud rate for CAN-Bus Voltage supply 24 V Fieldbus (Profibus DP V0, CANopen) Position-dependent braking: Open-loop controlled startup, closed loop controlled braking (linear, root-shaped, or sinusoidal characteristics)* The same parameters used for the position controller are also used for closedloop controlled braking* Analog inputs 2 x U, 2 x I Analog outputs 1 x U, 1 x I Closed-loop pressure/ force control: PIDT1 controller* Differential pressure evaluation for closed-loop force control* Pressure limitation* Position monitoring Alternating closed-loop control: Closed-loop position control closed-loop pressure control* Synchronization control 2 4 axes: Master-slave principle Average value principle * Controller functions tailored to the specific requirements of electrohydraulic drives
Flexibility for Hydraulic Drives: Expanded NC Programming Some further functions: Flexible cam controller for position, pressure, process and internal variables Arithmetic in NC programs Variable (R parameters) for exchanging values with the higher-level controller and visual display systems Additional NC program for coordinating and monitoring functions Internal variables Users can define the motion sequences of the axes using freely programmable NC programs. This offers decisive advantages such as: Maximum flexibility with regard to defining the motion sequences User know-how is protected in terms of the process engineering of machines and systems Less complexity due to separation of operation and monitoring The set of commands was modeled on the syntax (DIN 66025) commonly used in the machine tool industry. Besides standard commands, special NC commands have been implemented that are tailored to the particular features of hydraulic axes and their applications. These include the fields of closed-loop force/pressure control and limitation, the transition from closed-loop control of position to that of pressure, control variable limitation and the influencing of controller functions. Furthermore, the range of functionalities includes synchronization of up to four axes, greatly improved curve functionalities, as well as extended diagnostics options such as online trend an oscilloscope function for continual monitoring of commissioning and service operations. WINPED PC software is used to generate NC programs. The NC programs are then loaded into the HNC100-3X via serial interfaces, where they are stored in Flash. Excerpt from the list of NC commands Definition part: /TRIG /OVER NC interpreter: Kurve K KP CLR SET IF JMP JSR B C Lxxx R G64 BINE BINA Sequence control: G01 G30 BREAK Curve function The Curve function allows users to generate a command value in the form of a polygonal sequence (e.g. force in relation to travel or travel in relation to travel ). STOP 12 curves 1,200 interpolation points Curves as a function of - time - actual value - internal process values G27/G28 G53/G54 M33/M34 G26 G25 G60 G61 G62 M22 G04 M00 M90 M91 M35 M36
Example of NC Programming E5 Motion start Motion start E6 Start inputs v = R210 Definition of a switching point* Velocity override Start and stop of curve function* Voltage output Change in controller gain* Reset output or flag Set output or flag Conditional branching Jump to a label (L0 L1999) Subroutine call Variable for global variables Variable for local variables Jump label Value assignment for an R parameter Control value limitation* Read binary-coded inputs Output to binary coded outputs Point-to-point travel* Point-to-point travel for oscillating movements Interrupt call-off commands Interrupt G01 or G30 Decelerate and complete G01, G30 On/Off zero point compensation* Activate/deactivate position controller* Closed-loop controlled traversing to limit stop* Open-loop controlled traversing to limit stop* Activate pressure controller (depending on position or pressure)* Activate pressure controller* Switch on pressure limitation* Switch off pressure limitation* Set actual and command value Waiting time Waiting for input or flag Set output or flag Re-set output or flag Activate synchronization Deactivate synchronization Velocity v = R211 Position = R200 Position = R201 Motion sequence Position v = R212 Range: R200±R206 Range: R201±R208 Set output no. 10 Switch position Set output no. 11 ;Definition of switching position /Trig A S1.DO.10=1 XR200 B-R206 B+R206 <> /Trig A S1.DO.11=1 XR201 B-R208 B+R208 <> ;Program sequence ;Wait until input is set. ;With input 5, the movement to position R201 is started. ;and with input 6, the movement to position R200 L00 IF S1.DI.5=1 JMP L100 IF S1.DI.6=1 JMP L200 JMP L00 L100 g01 xr205 i1000 j850 fr210 R211 g01 xr201 i1000 j850 fr211 0 L110 IF S1.DI.5=1 JMP L110 JMP L00 L200 g01 xr200 i1000 j80 fr210 0 ;jump: input 5 is set ;jump: input 6 is set ;Traversing to rapid speed position ;Traversing to end position ;Waiting until input ;is reset ;Returning to the initial position L210 IF S1.DI.6=1 JMP L210 JMP L00 ;Waiting until input ;is reset M02 ;End of program * NC commands functions tailored to the specific requirements electrohydraulic drives
10 Parameterizing and Programming, Editing and Diagnostics: with WIN-PED 6 from Rexroth Managing data from one or more HNCs in one project Data security and initialization functionality for all HNC data Parameterizing the HNC100-3X Generating NC programs (editor with syntax test and compiler) Bus manager for easy configuration of the data exchange with the higherlevel controller Integrated Online Manual for direct access to the complete HNC documentation Diagnostics function - Software oscilloscope - Online trend - Parameter monitor Configuration and sequence programming of the HNC100-3X is carried out on a PC using Rexroth Software WIN-PED 6. The keyboard can be individually configured to the specific application. The NC programs are loaded into the motion control via the serial interface and are saved in Flash. The intuitive operation makes it considerably easier to familiarize yourself with WIN-PED 6. The integrated online documentation allows users to access contextrelated information on the program as well as completing documentation on the HNC100-3X, such as a description of NC commands or machine data. Diagnostics function
11 Connection via standardized bus systems Optional fieldbus systems Profibus DP V0, CANopen and SERCOS interface are all currently supported. These standard field buses make it possible to develop cost-effective, modular, decentralized automation concepts with the necessary data transparency. Bus manager Communication between control level and the HNCs is effected with the aid of the bus manager: Easy configuration of data to be exchanged on a cyclical basis Straightforward integration Flexibility of communication Priority-setting of data exchange Bus manager Parameterization: Controller settings
12 HNC100-3X with SERCOS Interface for Interpolating Axes Functionality: The command values are cyclically forwarded to the HNC100-3X (in the range of 1 64 ms) via SERCOS interface. The HNC100-3X works exclusively as a controller for an electrohydraulic axis. The NC functionality is dropped. A special closed-loop control algorithm provides maximum contour accuracy. All systems that meet the requirements of Conformity Class B as appropriate to SERCOS interface are basically suitable for use as a higher-level open loop CNC control. In accordance with the Drive & Control claim, perfect interaction with Bosch Rexroth control systems goes without saying. Rexroth offers a communication model, via the SERCOS interface, that is specifically designed for applications in the field of interpolating axes. The position command values are cyclically transmitted by the control via SERCOS interface, with the HNC100 Series 3X closing the position control circuit. offering the user a unified lookand-feel for commissioning, parameterizing and diagnostics functions of the electric and hydraulic drives and open loop control systems. IndraWorks Rexroth is thus extending the functional scope of IndraMotion MTX, the universal, scalable CNC open loop control concept, to include both electric and hydraulic interpolating axes. With IndraWorks, the modular, innovative engineering environment, this means that the complete range of software tools is available, MTX IndraDrive HNC100-3X
13 MTX MTX Compact MLC Engineering IndraWorks 64 8 64 Closed loop control operating mode Platform Controller-based PC-based Motion logic function Max. no. of axes Integrated Motion Logic System Closed loop force/pressure control mode Limitation of position/pressure Co-ordinated motion Travel to fixed stop/force reduction Rapid change of position/pressure Interfaces Master communication (Synchronization) Ethernet TCP/IP, UDP SERCOS interface SERCOS interface SERCOS interface Command values for HNC100-3X Sentence mode Cyclic mode VT-HNC100-C-3X/S VT-HNC100-1-3X/S Engineering IndraWorks SERCOS interface SERCOS interface Interfaces Master communication (Synchronization) Serial interface RS232 Digital inputs 4 1 digital output, fixed Digital outputs 2 10 I/Os freely configurable Analog inputs 3 4 Analog outputs 2 2 SSI position transducer TTL incremental position transducer Closed loop position control Motion Logic Function Closed loop force/pressure control Change of position/pressure Lower level closed loop speed controller
14 Rexroth is Always There for You Bosch Rexroth offers direct support for the HNC100-3X, divided into three areas: Customized training Application-oriented NC programming Start-up on site Your digital control system can be quickly updated online and users can receive direct support via e-mail. As a rule, the training sessions last two to three days and are tailored to the user s individual needs. The aim of these courses is to communicate the necessary knowledge for the respective application so that the user can generate NC programs independently as well as undertaking the start-up procedure. Internet Support www.boschrexroth.com/hnc100 However, if Rexroth generates the NC program, this is done in close co-operation with the customer, using a jointly prepared customer specification. Rexroth can also provide start-up service support on site if required. The extensive download section on the Bosch Rexroth website offers the latest software updates and information on tools and configurations. In addition to comprehensive documentation you will find detailed answers to all your questions regarding digital closed loop control electronics. Whether you wish to update your WIN-PED 6 Software, acquire information on Rexroth firmware, familiarize yourself with the latest tools and configurations or consolidate your knowledge of the HNC100 take advantage of the extensive download section on the Bosch Rexroth website! Individual support Our experts can be contacted via e-mail: support.nc-systems@ boschrexroth.de
15 Where Drives are Controlled Based on the unique and extensive technological and branch know-how gained over decades Rexroth is continuously and consistently developing automation systems. Application examples Plastics processing machines Injection molding machines Blow-forming machines Rubber molding presses Calenders Die-casting machines Core molding machines Special machines Packaging machines Bending machines Calenders Shears Lifting devices Assembly machines These developments are proving themselves worldwide in numerous applications. Presses Drawing presses Extrusion presses Forging presses Nibbling machines Hydraulic forming systems Pipe-bending machines Bending presses Assembly presses Tile presses Chipboard presses Machine tooling Grinding machines Drilling machines Bending machines Milling machines Foundries and rolling mills Woodworking machines Stretching units Oscillating molds Rolling mill machines Rotary furnace control Roll stands Transfer systems And many more
HNC100-3X Function Determines Format The HNC100-3X is available with a range of different functions depending on requirements and the type of application. The Type code will help with the correct selection: VT-HNC100 - Axes 1 axis 2 axes 3 axes 4 axes C ompact 1 axis* C Bus connection Without Bus Profibus DP V0 CANopen SERCOS O P C S Sensors Incremental/ SSI (Standard) SSI for Model C * Additional functions None Software options Without Synchronization with 2 axes Synchronization with 3 axes Synchronization with 4 axes - 3X/ - - 1 2 3 4 I S 00 000 G02 G03 G04 * Only with Profibus DP V0 and SSI sensor, compact version Dimensions (W x H x D) VT-HNC100-1-3X VT-HNC100-2-3X VT-HNC100-3-3X VT-HNC100-4-3X VT-HNC100-C-3X 48 x 120 x 124 mm 65 x 120 x 124 mm 82 x 120 x 124 mm 99 x 120 x 124 mm 34 x 120 x 104 mm /
The Drive & Control Company Rexroth is unique. No other brand on the world market can offer all drive and control technologies, both on a specialized and integrated basis. With approximately 28,000 employees in more than 80 countries around the world, Rexroth has an infrastructure designed with partnership and customer proximity in mind. Over 500,000 customers worldwide utilize the know-how of the technology leader. Intelligent Hydraulics in New Dimensions Whether it s a case of raising or lowering loads smoothly, undertaking linear or rotational movements, achieving even acceleration or accurate positioning, maintaining preset speeds, transmitting power or linking motion sequences in fact, wherever economical power is required, this is where hydraulics comes into its own. Using hydraulic drive and control technology from Rexroth will help you become more competitive than ever. Electric Drives and Controls Hydraulics Linear Motion and Assembly Technologies Pneumatics Service
Bosch Rexroth AG Hydraulics Zum Eisengießer 1 97816 Lohr, Germany Phone: +49(0)9352/18-0 Fax: +49(0)9352/18-36 95 support.nc-systems@ boschrexroth.de www.boschrexroth.com/hnc100 Printed in Germany RE 09956/06.07