Rexroth SYNAX 200 Modular system solution for ... - Bosch Rexroth

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

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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
1994. 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

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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

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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.

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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.

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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

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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"

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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 61131-3 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

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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.

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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

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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

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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 61131-3. 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 61131-3, thus providing
every freedom for implementing
all possible automation applications
in the printing and converting sector.
HMI
Application program
PLC
• IEC 61131-3 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

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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 61131-3
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 61131-3, 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 61131-3
• instruction list (IL)
• function block diagram (FBD)
• ladder diagram (LD)
• sequential function chart (SFC)
• structured text (ST)
• continuous function chart (CFC)
• standard IEC 61131-3 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

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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.

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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
• e-mail 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)

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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

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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 61131-3 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 -
480 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

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Rexroth SYNAX 200 – successful
in all applications around the world

Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 93 52-40-0
Fax +49 93 52-40-48 85
www.boschrexroth.com
Presented by:
71 217 AE/04-04 – A13 – HW
© Bosch Rexroth AG 2004
Subject to revisions!
Printed in Germany