Bosch Rexroth SERCOS..

Bosch Rexroth SERCOS III 

Automation Solutions & Applications 

Chris Cooper 

Regional Sales Manager 

Southeast & Southwest Territories

Agenda- Automation Solutions & Applications 

• Introduction to Bosch Rexroth 

• Automation Solutions 

• De-centralized Drives 

• High Performance Controls 

• SERCOS III Ethernet Based System Architectures 

• SERCOS III Application Examples 

Electric Drives and Controls l Bosch Rexroth - Solution Provider for Food & Packaging l V08 l Steffen Winkler, BRC/SIF 

© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications. We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. 

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Bosch Rexroth in the Americas 



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The Company – The Technology Areas 

Everything from one source – specialized and integrated 

Components, modules, systems, as well as services and engineering 

services in the areas 

Electric drives 

and controls 

Hydraulics 

Linear and 

assembly 

technologies 

Pneumatics 

Service 



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The Company – The Markets 

Rexroth services are used worldwide 

in nearly all industries ... 

500,000 Customers worldwide! 

• Food and Packaging 

• Cutting and forming 

machine tools 

• Automotive industry 

• Printing and converting 

• Assembly/handling 

• Logging industry 

• Rubber and injectionmolding 

machines 

• Tunnel and mining 

industry 

• Civil engineering 

• Entertainment 

• Offshore technology 

• Shipbuilding 

• Maritime applications 

... and much more 



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Rexroth Automation House 



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IndraDrive TM 

The new drive generation for all applications 

• Worldwide first provider of servo- and frequency converter on one 

platform 

• SERCOS II & III Interfaces 

Open architecture connectivity 

• Drive-integrated safety technology 

for safe stop and safe motion 

(certified acc. to EN 954-1, safety category 3) 

• Single- and multi-axes Motion Logic 

acc. to IEC 61131-3 and PLCopen 

Drives and motors 

• Scalable power, functionality and 

performance for best application fit 

• Fast and easy start-up assistant incl. 

automatic motor identification and 

auto-tuning 



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IndraDyn 

Next generation of motors 

• IndraDyn S 

Synchronous servo motors up to 240 Nm 

• IndraDyn A 

Asynchronous servo motors up to 100 kW 

• IndraDyn L 

Synchronous linear motors up to 22.000 N 

• IndraDyn T 

Synchronous torque motors 

up to 13.800 Nm 

Drives and motors 

• IndraDyn H 

Synchronous high-speed motors 

up to 30.000 min -1 

• Planetary gearboxes 



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IndraControl V 

Controls and HMI 

• Controller based terminals 

From text displays up to graphical touch screen 

• Windows CE Embedded based terminals 

Visualization and PLC runtime in one device 

• Standard industrial PC‟s 

Cost-effective solutions by standardised PC hardware 

• High-end industrial PC‟s 

For highest demands in industrial environment 

• Complete PC-based operator 

terminals 

Visualization and PLC control in one device 


• Visualization software 

Useable on different platforms 

(Win XP, CE, Web) 

• Accessories 

Machine operator panels, keyboards, … 



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IndraControl L 


• IndraControl L 

The most compact embedded control with Ethernet, 

SERCOS II, III and PROFIBUS interfaces in their class 

• Rexroth Inline 

The flexible I/O portfolio for 

cabinet installation with degree of protection IP20 

• Rexroth Fieldline 

The rugged I/O technique for 

field installation with degree of 

protection IP67 


• Scalable in power and functionality 

• Modular and flexible with many 

open communication standards 

• Fast and tool-less installation 



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IndraLogic 

The uniform and open PLC solution 

• Uniform PLC runtime for all Rexroth systems: 

Motion Control, CNC and PLC system solutions 

• Scalable in performance and control platform: 

• Drive-based 

for drive-based applications with integrated 

motion-logic 

• Controller-based 

based on IndraControl L and direct 

connection of the I/O portfolio 

Rexroth Inline 

PLC 

• PC-based 

combined with integrated Visualization 

based on IndraControl V 

• Programming according to IEC 61131-3 

• Common PLCopen library with 

standardised motion functions 

• Complete engineering with IndraWorks 



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Architectures 

MLD 

Motion Logic Drive-based 

MLC 

Motion Logic Controller-based 

MLP 

Motion Logic PC-based 

WEB, MES, ERP 

MLD 

Motion Logic 

MLC 

Motion Logic 

MLP 

Motion Logic 

HMI 

HMI 

HMI 

I/O 

I/O 

I/O 

Drives 

Drives 

Drives 

Economic solution for 

low to medium demands 

• up to 8 axes 

Standard solution for 

medium to high demands 


High integrated solution for 

medium demands 


Uniform general technology functions and program templates 

Uniform system bus for motion, drives, safety and I/O„s: SERCOS III 

Open standards and uniform PLC platform acc. to IEC 61131-3 

Uniform engineering for motion, logic, HMI and drives with IndraWorks 



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Architectures 

MLD 


MLC 


MLP 


WEB, MES, ERP 

MLD 

Motion Logic 

MLC 

Motion Logic 

MLP 

Motion Logic 

HMI 

HMI 

HMI 

I/O 

I/O 

I/O 

Drives 

Drives 

Drives 
















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MLD Systems - Motion Logic Drive-based 

Sercos-III Ethernet Master with Sercos-III Slave´s 

HMI 

Line-Controller 

with fieldbus 

(optional) 

Sercos-III 

CCD Master 

FKM- 

Sercos-III 

Ethernet TCP/IP 

Programming 

and 

Parametrizing 

of all drives 

and I/O´s with 

IndraWorks 

w/o changing 

the socket 

Switch 

PLC in 

Drive 

MASTER 

Sercos III 

Ethernet based 

SLAVE 1 

SLAVE N 

Sercos-III I/O´s 



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Application Example #1 

BVK1300 HFFS Machine 

Foil Feed 

2 

Cross seal 

3 

Transport 

5 

1 

Lug Chain 

6 

Fin Seal 

4 

Rotary knife 



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BVK1300 HFFS Machine 

WinCE 

- Visualisation 

PLC Network 

variables 

A1 

Lug Chain 

A2 

Foil feed 

A3 

Cross Seal 

A4 

Rotary knife 

A5 

Transport 

A6 

Fin seal 

SIII 

PLC Basic Advanced 

MLD-Master 

Basic Basic Basic Basic 

I/Os 

Reference 

switch 

1 Probe Input 

2 Inputs 

1 PLS Output 

3 Outputs 

Reference 

switch 

Reference 

switch 

Reference 

switch 

Operating mode 

electronic motion 

profile 

Linear 

profile 

Linear profile 

Cross seal 

profile 

Non linear 

profile 





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Servo Requirements for a HFFS machine 

• High Speed handling of many Products per minute 

Depending on the product size and the machine design, the 

throughput requirements can be anywhere from 5 to 2000 

products per minute (250 to 500 typically) 

• Registration 

Accurate and high speed registration must be performed in 

order to align package labeling 

• ELS (Electronic Line Shafting) functionality 

Reduces mechanical components on the machine and 

significantly reduces setup and product change-over time 

• Electronic Camming allows for different knife profiles to be 

executed based on the product length & height 

• Lock-on, Lock-off cam profiles to achieve “No-product= Nowrap” 

functionality 



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Architectures 

MLD 


MLC 


MLP 


WEB, MES, ERP 

MLD 

Motion Logic 

MLC 

Motion Logic 

MLP 

Motion Logic 

HMI 

HMI 

HMI 

I/O 

I/O 

I/O 

Drives 

Drives 

Drives 
















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Robotics 

• Multi axis kinematic up to 8 axis 

• Over 100 kinematic transformations 

• Easy kinematic configuration 

• Zero offset, Override, Teach-In, … 

• Adaptive belt tracking (4 belts) 

• Easy integration of vision systems 

• Customer-defined kinematics 



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Robotics 

Axis 

Axis 



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Robotics 

Highlights: 

• Hardware: MLC V03 

• 7X SERCOS III Indradrive (2 ms SERCOS time) 

• Camera interface via Ethernet TCP/IP 

• HMI interface via Ethernet OPC 

• Belt synchron (Infeed and Outfeed belt) 

• Delta kinematics Transformation 



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IndraWorks 

Framework for all Rexroth System Solutions 

• Software tools for all engineering tasks included 

• Ergonomic, Windows conform graphical user 

interface 

• Wizards for configuration and parameter setup 

• Transparent project navigation with 

functional arrangement of device objects 

• Comfortable programming editors 

according to IEC 61131-3 and 

DIN 66025/RS247 

Engineering 

• Guaranteed future by the latest 

.net based system architecture 

• Openness by support of 

standardized software interfaces 



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SERCOS III – The Next Generation 

Rexroth System Products with SERCOS III 

IndraMotion 

MLD 

IndraMotion 

MLC 

IndraMotion 

MLP 

IndraControl L 

Option module 

(Master) 

IndraControl 

L15 

(Slave) 

Inline 

Bus coupler 

Inline 

Block I/O 

IndraControl VEP 

IndraControl L45 

IndraControl L65 

IndraDrive 

BDC 

Pneumatic 

Valve Manifold 

IAC-R 

Control Valve with 

integrated hydraulic 

axis control 

HNC100 

Hydraulic 

Axis control 



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Partial list of Rexroth SERCOS III Customers 

Pull nose box loader, Norway 

Conversion presses, Germany 

Roll forming machines, Belgium 

Tubular bag machine, USA/Germany 

System integrator, Canada 

Production of wheel hub motor „Active Wheel“ 

Switzerland 

Robot control, Germany 

Packaging machine, USA 

Engineering, USA 

Packaging machine 

Tea bag machines, Germany 

Injection molding machine, Canada 

Press systems, Canada 

Packaging machine 

Grinding machine, Japan 

Automation systems, Canada 

Pipe production machine, Germany 

Die and device bonding 

France/Sweden 

Board turner in saw mill, Canada 

Packaging machine, Germany 

Distributor, Automation 

Switzerland 

Packaging machine, Italy 

More than 100 customers 

in more than 20 countries 



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SERCOS III and Industrial Ethernet 

Reference customers (Rovema) 

• 

• Flow wrapper VPL260 

• PC based control architecture 

• ROVEMA P@ck-Control 

• with SERCOS III-Master 

(from AUTOMATA) 

• IndraDrive drives with SERCOS 

III 

• SERCOS III I/Os 

• presented at Interpack 2008 



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SERCOS III and Industrial Ethernet 

Reference customers (JTEKT) 

• Standard Grinding Machine 

• SERCANS III PCI card 

• IndraDrive Cs 

• IndraDyn Motors 

• IMTS, Chicago, 08-13 September 

2008 

• New Generation of 

High-End Grinding Machine 

• SERCANS III PCI board 

• IndraDrive M 

• Cross Communication & I/Os 

• IndraDyn Motors 



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Examples of SERCOS III Applications 

Test Stands 

Crank Shaft Grinding 

High Speed Milling 

Plastic Injection Molding 

Packaging Machines 

Printing Machines 

Profilers Roll Feeds Presses 



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For More Information, Contact: 

• Dan Throne, National Sales Manager – Hoffman Estates 

• 847-645-3749 

• Scott Hibbard, VP of Technology – Hoffman Estates 

• 847-645-3670 



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Bosch Rexroth SERCOS..

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