Electric Drives and Controls Integrated Motor/Drive technology with Rockwell connectivity 1
Integrated Motor/Drives with Rockwell Connectivity 1. Market Trends for OEM s builders & Systems Integrators today 2. New Drive Technology Innovation to address the trends Revolutionary Integrated Motor/Drives Compact Multi-Ethernet Drives 3. Demo of Rexroth Drives connected to Rockwell PLC s 1. SERCOS II fiber optic Architectures 2. Ethernet IP Architectures 4. Demo of Rexroth Drives connected to Rexroth PAC 3. Ethernet SERCOS III Architectures What you get with our Controls that you don't get with a Rockwell PLC 5. Closing thoughts to consider 2
Your Presenters 1. Dan Throne- Rexroth, Sales & Marketing Manager 24 years experience in applying servo and control systems to machinery 2. Fernando Martinez- Rexroth, Manager Packaging Industry 14 years experience in applying servo and control systems to machinery 3. Ralph Maguire- Rexroth, Principal Applications Engineer Packaging Industry 30 years experience in applying servo and control systems to machinery 4. David Arens- Rexroth, Applications Engineer Packaging Industry 17 years experience in applying servo and control systems to machinery 3
Rexroth Technologies Electric Drives and Controls Linear Motion Technologies Gears Assembly Technologies Hydraulics, Industrial Pneumatics Hydraulics, Mobile Service and Training 4
Rexroth Technologies- Electric Drives and Controls CNC system solutions scalable in power and functionality high performance easy operation and programming Powerful PLC platforms Open IEC-compliant programming extensive libraries and modules compliant with the PLCopen versatile functions Integrated motion logic control systems scalable hardware and software automation solutions for specific industry segments centralized and distributed architectures Intelligent servo drives and frequency converters large power range from 0.1-630 kw integrated technology functions certified safety technology Distributed drives with motor-integrated electronics 50 % less space 70 % reduction in control cabinet volume 85 % less wiring Versatile range of motors high-performance synchronous and asynchronous motors complete portfolio of kit motors with linear, high-speed and hightorque motors Integrated resistance welding system innovative system solution for MF and AC welding high-quality welds through permanent process monitoring Scalable system for stationary and mobile tightening compact tightening controller with integrated logic powerful tightening spindle ergonomic handheld tightener 5
Market drivers effecting OEM builders 1. Changing Competitive Landscape 2. Increased Price Pressure 3. Need for Modular Machine Designs 4. Sustainability & Energy Efficiency Requirements 5. End User Specification Requirements if any of these apply to you- your in luck! 6
Typical Packaging Manufacturing Line Final Packaging Secondary Packaging Processing Infeed Systems Primary Packaging 7
TODAY: Traditional automation architecture Ethernet Electrical Enclosure HMI Motion & Logic Traditional separate Motor & Drives Motion Bus (Ethernet-based) Servo Drives Horizontal Flow-Wrapper Sensors Motors 8
A revolution in automation for machines- Integrated Motor/Drives Ethernet HMI Integrated Motor/Drives IndraDrive Mi drives Electrical Enclosure Sensors Horizontal Flow wrapper Power Supply + Converter 9
A revolution in automation for machines- Integrated Motor/Drives + = IndraDrive Mi the combination of a servo motor & drive is a revolution in automation for machinery 10
Electrical Cabinets are expensive, custom engineered, custom built, labor intensive, take up large % of machine real estate, and need A/C units 11
12 Large custom electrical cabinets are a thing of the past
Large custom electrical cabinets are a thing of the past 6-20 axes cabinet now contains: Power supply Communication converter (KCU Module) Switch gear, fuses, etc.. Controls Few terminal strips 13
revolution in automation for packaging machines 1st Place Automation Award 2005 1st Place Product of the year in Automation, Journal Electronics, 2006 Product Innovation of the Year 2007 North American Motors & Drives 14
Energy Efficiency of Integrated Motor/Drives Capacitive modules Energy storage Energy savings approx. 3% DC shared power supply Energy exchange between accelerating & regenerating motors Energy savings approx. 15% Further savings Fewer components: cabling, line shafts, control cabinets etc. Eliminates A/C unit & energy Regenerative Power supply Regen of braking energy back to the power company Energy savings approx. 20% High-efficient motors High-energy permanent magnets in rotor, stators in exciter coil technology Energy savings approx. 3% Smaller, lighter machines Less air consumption 15
Rockwell Control Logix Architecture RS5000 V16 or V17 SERCOS M08SEG Card (Pack Profile firmware) Electrical Cabinet IndraDrive Mi 16
17 Demo of Rockwell Control Logix Architecture RS5000 V16 or V17 SERCOS M08SEG Card (Pack Profile firmware)
Compact Multi-Ethernet Drives Low Cost Ethernet Architectures Ethernet MLC IndraControl V IndraWorks IndraWorks IndraDrive Cs IndraDyn 18
Compact Multi-Ethernet Drives Multi Ethernet communication supports SERCOS III, PROFINET IO, Ethernet/IP and EtherCat Universal Multi Encoder interface supports Hiperface, EnDat 2.1, EnDat 2.2 1), 1V pp, 5V TTL, SSI 1), Resolver and Rexroth MSM motors Integrated Motion Logic according to IEC 61131-31 Integrated Safety technology according to IEC 61508 Extremely compact design Intelligent operation panel with programming module function no PC is required for start-up and replacement On-board: digital inputs and outputs, analog input, integrated brake resistor, temperature protection, motor brake control, bus sharing. 19
Compact Multi-Ethernet Drives Ethernet IP communications to Rexroth IndraDrives C-Logix Ethernet IP Master L23 Ethernet IP Master 10.107.84.80 10.107.84.80 IndraDrive CIndraDrive CIndraDrive C 10.107.84.7010.107.84.71 10.107.84.72 IndraDrive Cs IndraDrive Cs 10.107.84.70 10.107.84.71 IndraDrive Cs 10.107.84.72 20
Compact Multi-Ethernet Drives Ethernet IP to separate Indradrives Ethernet IP to 3 drives with MLD L23 or C-Logix Ethernet IP Master 21 IndraDrive C CSH01.2 CCD IndraDrive C CSH01.1C-ET IndraDrive Cs IndraDrive C CSH01.2 CCD Option IndraDrive C CSB01.1C- S3 Option IndraDrive C CSB01.1C- S3 Option
Ethernet IP Rockwell PLC Performance Ethernet/IP Cycle Times 18 16 14 RPI (ms) 12 10 8 6 4 2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Number of Drives 1769-L23E 1769-L32E/L35E 1756-ENBT 1756-EN2T Data taken from Ethernet/IP Capacity Tool v1.4 from Rockwell assuming the use of a managed Ethernet switch FlexLogix series follows L32E/L35E performance Compact Logix ENBT V2/V1 cards follow 1756-ENBT performance Multiple Ethernet cards can be used to extend axis count More drives possible with MLD mode as each CCD group would look like one drive. (One packet of data from PLC for all drives in that group) 22
When to use Ethernet IP drive Vs when not to use YES NO Function Blocks Single Axis Moves Positioning Velocity Moves X31/X32 I/O 1 Probe per drive function Homing Relative/Absolute Motion Open Loop Virtual Master Camming Gearing EIP is not deterministic and not synced to drive control loop. If sync is needed, use Ethernet SERCOS III with MLD or MLC instead. No Function Blocks Torque Mode 2 Probe Functions Data Transfer to MLD control System 23
Ethernet IP Motion Function Blocks BRCFieldbusDriveComms_In / BRCFieldbusDriveComms_Out MSOBRC - Power On MSFBRC - Power Off MAFRBRC - Motion Axis Fault Reset MAHBRC - Motion Axis Home MAJBRC - Motion Axis Jog MASBRC - Motion Axis Stop MAMBRC - Motion Axis Move MAWBRC - Motion Arm Watch MDWBRC - Motion Disable Watch BRC_Probe BRC_Probe_Disable BRC_DistanceAccum 24
Demo of Rockwell Control Logix Ethernet IP C-Logix Ethernet IP Master 10.107.84.80 IndraDrive CIndraDrive CIndraDrive C 10.107.84.7010.107.84.71 10.107.84.72 25
Electric Drives and Controls Rexroth Controls -What you get with our Controls? MLC Control What about Motion Control and Ease of Use??? 64 axes!! MLC L65 ROBOT CONTROL 26
Electric Drives and Controls Axis Interface Features and Benefits Less MOTION knowledge required Faster MOTION program development Predefined Diagnostics Point to Point & Synchronized MOTION. Axis Interface simplifies motion programming! 27
Electric Drives and Controls Axis Interface implementation One Function Block instance per axis. What About ADVANCED/Camming Motion??? 28
Electric Drives and Controls FlexProfile Features and benefits Single cam interface that solves a wide range of motion problems. The FlexProfile reduces and simplifies: Development time Changeover Error Reaction Recovery FlexProfile is part of the Axis Interface! 29
Electric Drives and Controls FlexProfile Application VFFS 30
Electric Drives and Controls FlexProfile Easy to use interface Fine-tune motion or new recipes without creating complex calculations. Spreadsheet style interface Easily select motion types via drop-menu Automatic verification of motion 31
Electric Drives and Controls Demo of MLC with Ethernet SERCOS III with Axis interface/ Flex Profile 32
Conclusions Consider the annual costs of the traditional controls approaches you have used until this point. Consider the benefits in cost reduction, enhanced performance & modularity that these new architectures provide. Consult with one of the Automation Specialist at CMA/Flodyne for a detailed analysis of your machines! 33
Closing thoughts to consider 1. How much would 70% smaller cabinets save you per machine? 2. How much would 85% less wiring save you per machine? 3. How much does it cost you to design custom cabinets for several machines? 4. How much lower could you sell your machines if they were 40% less expensive to produce? 5. How many more orders could be realized by quicker machine delivery? What if this could provide for a total annual Savings of $150K- 750K/year! 34
Thank You! 35 A4
Contact list Dan Throne- dan.throne@boschrexroth-us.com (847) 645-3749 Fernando Martinez- fernando.martinez@boschrexroth-us.com (847) 645-4093 Ralph Maguire- ralph.maguire@boschrexroth-us.com (847) 645-3674 David Arens- david.arens@boschrexroth-us.com (847) 645-3751 36
FAQ s Price of new systems? The price of the Mi system is nearly equivalent to traditional Rexroth drives of same size, savings is realized for the OEM in installation savings. The price for the Cs Ethernet drives significantly less than IndraDrive (12 amp). The price for the MLC is typically 30+% less than a Rockwell PLC with 8 axes of motion. Rexroth Software & free tech support even more so. Installation costs? Installation costs are significantly less because you install the drive & motor together outside of the cabinet. Using a daisy chain cable system. Training on Rexroth Drives or Controls & Software? Regular training is offered on Drives, Controls and software but much of what you know in IEC61131-3 PLC programming applies. Rexroth Brand Recognition? The Rexroth brand recognition is strong with End Users in many markets. However many customers still refer to Rexroth as Indramat. Support? Both CMA and Rexroth provide local as well as International support to assist OEM builders to automate and maintain their machinery. 37
38 Global Sales, Service & Support
Cost Savings with Integrated Motor/Drive Technology 39 Smaller Cabinets (70%) Smaller Machines (10-20%) Lower cost machines to produce (30-40%) Less time engineering custom cabinets Same cabinet for multiple machine types (build to stock) Labor savings due to less wiring (85%) Take less time to mount (drill & mount) Less cable trays Eliminate an air conditioner (and filter maintenance) Fewer parts to inventory & stock (reduces overhead) Quicker machine delivery (more competitive) Less spare parts to ship out for commissioning Increased reliability with fewer components Faster troubleshooting due to reduced parts Total Annual Savings can be $150K- 750K/year (depends on cost, number & type of machines)