HNC100® Series 3X from Rexroth.The Motion Control System for Electrohydraulic Axes

Scalable closed loop control system for up to four axes

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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 pur-pose 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 com-plexity and is thus able to realize the most demanding motion control tasks in real time.

Overview of current axis controllers and motion controls

MAC-8HNC100-3X

HNC100-2X

2–32 axes1–4 axes1–2 axes

IAC-R

1 axis

Axis Controller Motion Controls

Power increase

HACD

1 axis

SYDFE

pQ controller 1 axis

IAC-P

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

Proven mechanics, digital closed loop control technology, high-resolution sensors – this is the scope of Drive & Control from Rexroth. In addition Rexroth offers for modern machine sol-utions the following: intelligent, communication-capable and highly flexible modules for real-time diagnostics and easy access to all parameters.

Rexroth makes complex machine processes even easier to master – impacting productivity by reduc-ing 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 in-creased system performance reduces scanning time consider-ably. Users can simply use their know-how, acquired with the current HNC programs and apply them to the new generation.

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MAC-8HNC100-3X

HNC100-2X

2–32 axes1–4 axes1–2 axes

IAC-R

1 axis

Axis Controller Motion Controls

Power increase

HACD

1 axis

SYDFE

pQ controller 1 axis

IAC-P

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.

· NC functionality· Hydraulics-specific controller· Sequential control (NC programs)· Compact design · DIN rail mounting

The extension of the proven, modu-lar 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.

Global bus

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Compact 1 axisVT-HNC100-C-3X

CPU + 1 axisVT-HNC100-1-3X

CPU + 2 axesVT-HNC100-2-3X

HNC100®-3X: The Decentralized, Compactand Modular Automation System

Communication with the higher-level control system

· With SERCOS no NC functionality

· Only available in the single-axis version

Higher level control (PLC or PC) and visual display (HMI)

Digital inputs/outputs or fieldbus (Profibus DP V0, Interbus-S, CANopen, SERCOS*)

PC SPS HMI

CPU + 4 axesVT-HNC100-4-3X

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CPU + 3 axesVT-HNC100-3-3X

CPU + 2 axesVT-HNC100-2-3X

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.

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.

The fieldbus systems connect the hydraulic drives to the machine control via a real-time interface.

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Interfaces for the position transducers:· Incremental TTL· Digital absolute SSI· Analog (voltage ± 10V

or current 4 – 20 mA)

Interfaces for pressure/force control:· Analog (voltage ± 10V or current 4 – 20 mA)

Free analog inputs:· For flexible use in

NC programs

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

1 to 4 AxesCompact

COM (RS232)for PC

Address for Profibus DP V0, CAN-Bus

Fieldbus(Profibus DP V0,CANopen)

Digital position transducer:

SSI, incremental TTL

Analog inputs 2 x U, 2 x I

Analog outputs 1 x U, 1 x I

11 digital I/O(freely configurable)

Baud rate for CAN-Bus

Voltage supply 24 V

SSI Digital position transducer

6 digital I/O (4 x In, 2 x Out)

Address for Profibus

DP V0

Voltage supply 24 V

Analog inputs 1 x U, 2 x I

Analog outputs2 x U

Profibus DP V0

CANopen

COM (RS232) for PC

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 outputs2 x U

SERCOS interface

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.

The HNC100®-3X works through the tasks independently of the cycle time of the higher-level open loop control.

Furthermore, the noticeably in-creased system performance of the new generation has shortened response time to a mere 0.5 ms in single-axis operation.

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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

Position-dependent braking:· Open-loop controlled start-

up, closed loop controlled braking (linear, root-shaped, or sinusoidal characteris-tics)*

· The same parameters used for the position controller are also used for closed-loop controlled braking*

Closed loop velocity control:· PI controller

Closed-loop pressure/ force control:· PIDT1 controller*· Differential pressure evalu-

ation 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

1 to 4 AxesCompact

COM (RS232)for PC

Address for Profibus DP V0, CAN-Bus

Fieldbus(Profibus DP V0,CANopen)

Digital position transducer:

SSI, incremental TTL

Analog inputs 2 x U, 2 x I

Analog outputs 1 x U, 1 x I

11 digital I/O(freely configurable)

Baud rate for CAN-Bus

Voltage supply 24 V

SSI Digital position transducer

6 digital I/O (4 x In, 2 x Out)

Address for Profibus

DP V0

Voltage supply 24 V

Analog inputs 1 x U, 2 x I

Analog outputs2 x U

Profibus DP V0

CANopen

COM (RS232) for PC

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 outputs2 x U

SERCOS interface

SERCOS model

Flexibility for Hydraulic Drives:Expanded NC Programming

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 separa-tion of operation and monitoring

The set of commands was modeled on the syntax (DIN 66025) com-monly used in the machine tool industry. Besides standard com-mands, special NC commands have been implemented that are tailored to the particular features of hydraulic axes and their applica-tions. 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 func-tionalities includes synchroniza-tion 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.

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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

Curve functionThe “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”).

· 12 curves · 1,200 interpolation

points· Curves as a function of

- time - actual value - internal process values

Excerpt from the list of NC commands

Definition part:/TRIG/OVER

NC interpreter:KurveKKPCLRSETIFJMP

JSRBCLxxxR

G64BINEBINA

Sequence control:G01G30

BREAK

STOP

G53/G54

M33/M34

G26

G25

G27/G28

G60G61G62M22

G04M00M90M91M35M36

* NC commands functions tailored to the specific requirements electrohydraulic drives

Example of NC Programming

;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

L00IF S1.DI.5=1 JMP L100 ;jump: input 5 is setIF S1.DI.6=1 JMP L200 ;jump: input 6 is setJMP L00

L100g01 xR205 i1000 j850 fR210 R211 ;Traversing to rapid speed positiong01 xR201 i1000 j850 fR211 0 ;Traversing to end position

L110IF S1.DI.5=1 JMP L110 ;Waiting until input ;is resetJMP L00

L200g01 xR200 i1000 j80 fR210 0 ;Returning to the initial position

L210IF S1.DI.6=1 JMP L210 ;Waiting until input ;is reset JMP L00

M02 ;End of program

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Definition of a switching point*Velocity override

Start and stop of curve function*Voltage outputChange in controller gain*Reset output or flagSet output or flagConditional branchingJump to a label (L0 … L1999)Subroutine callVariable for global variablesVariable for local variablesJump labelValue assignment for an R parameterControl value limitation*Read binary-coded inputsOutput to binary coded outputs

Point-to-point travel*Point-to-point travel for oscillating movementsInterrupt call-off commandsInterrupt G01 or G30Decelerate and complete G01, G30“On/Off” zero point compen-sation*“Activate/deactivate” position controller*Closed-loop controlled traver-sing 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 timeWaiting for input or flagSet output or flagRe-set output or flagActivate synchronizationDeactivate synchronization

Start inputsE5 Motion start

Range: R200±R206

Set output no. 10 Set output no. 11

Range: R201±R208

Motion start E6

Position = R200 Position = R201

v = R210

v = R212

v = R211

Motion sequencePosition

Switch position

Velo

city

Parameterizing and Programming,Editing and Diagnostics:with WIN-PED® 6 from Rexroth

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· Managing data from one or more HNCs in one project

· Data security and initial- ization 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 higher-level controller

· Integrated “Online Manual” for direct access to the complete HNC documen- tation

· 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 applica-tion. 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 context-related information on the program as well as completing documenta-tion on the HNC100®-3X, such as a description of NC commands or machine data.

Diagnostics function

Connection via standardized bus systemsOptional 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 automa-tion concepts with the necessary data transparency.

Bus managerCommunication 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

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Rexroth offers a communication model, via the SERCOS interface, that is specifically designed for applications in the field of interpo-lating axes. The position command values are cyclically transmitted by the control via SERCOS interface, with the HNC100® Series 3X closing the position control circuit.

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 environ-ment, this means that the complete range of soft- ware tools is available,

offering the user a unified look-and-feel for commissioning, parameterizing and diagnostics functions of the electric and hydraulic drives and open loop control systems.

HNC100®-3X with SERCOS Interfacefor 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 Conform-ity 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, per-fect interaction with Bosch Rexroth control systems goes without saying.

IndraWorks

MTX

IndraDrive HNC100®-3X

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MTX MTX Compact MLC

Engineering IndraWorks • • •

Platform

Controller-based • •

PC-based •

Motion logic function

Max. no. of axes 64 8 64

Integrated Motion Logic System • • •

Closed loop control operating mode • • •

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) SERCOS interface SERCOS interface SERCOS interface

Ethernet TCP/IP, UDP • • •

Command values for HNC100®-3X

Sentence mode •

Cyclic mode • • •

VT-HNC100-C-3X/S VT-HNC100-1-3X/S

Engineering IndraWorks • •

Interfaces

Master communication (Synchronization) SERCOS interface SERCOS interface

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 •

Motion Logic Function

Closed loop position control • •

Closed loop force/pressure control • •

Change of position/pressure • •

Lower level closed loop speed controller • •

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Rexroth is Always There for You

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Internet Supportwww.boschrexroth.com/hnc100The extensive download section on the Bosch Rexroth website offers the latest software updates and information on tools and configu-rations. In addition to comprehen-sive 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 con-solidate your knowledge of the HNC100® – take advantage of the extensive download section on the Bosch Rexroth website!

Individual supportOur experts can be contacted via e-mail:

support.nc-systems@boschrexroth.de

Bosch Rexroth offers direct support for the HNC100®-3X, divided into three areas:· Customized training· Application-oriented

NC programming· Start-up on site

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 com-municate the necessary knowledge for the respective application so that the user can generate NC pro-grams independently as well as undertaking the start-up procedure.

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.

Your digital control system can be quickly updated online and users can receive direct support via e-mail.

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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

Foundries and rolling mills· Stretching units· Oscillating molds· Rolling mill machines· Rotary furnace control· Roll stands· Transfer systems

Where Drives are Controlled

Based on the unique and exten-sive technological and branch know-how gained over decades Rexroth is continuously and consistently developing automa-tion systems.

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

Woodworking machinesAnd many more

These developments are proving themselves worldwide in numer-ous applications.

*OnlywithProfibusDPV0andSSIsensor,compactversion

Dimensions (W x H x D)

VT-HNC100-1-3X 48x120x124mmVT-HNC100-2-3X 65x120x124mmVT-HNC100-3-3X 82x120x124mmVT-HNC100-4-3X 99x120x124mmVT-HNC100-C-3X 34x120x104mm

1234

C

OPCS

I

S

00

000

G02

G03

G04

HNC100®-3X–FunctionDeterminesFormat

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:

Axes· 1axis· 2axes· 3axes· 4axes· Compact

1axis*

Bus connection·WithoutBus·ProfibusDPV0·CANopen·SERCOS

Sensors· Incremental/

SSI(Standard)· SSIforModel

“C”*

Additional functions·None

Software options·Without· Synchronization

with2axes· Synchronization

with3axes· Synchronization

with4axes

VT-HNC100®- - 3X/ - - /

Electric Drives and Controls

Hydraulics

LinearMotion andAssemblyTechnologies

Pneumatics

Service

The Drive & Control CompanyRexroth is unique. No other brand on the world market can offer all drive and control technologies, both on a specialized and inte-grated 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 tech-nology leader.

Intelligent Hydraulics in New DimensionsWhether it’s a case of raising or lowering loads smoothly, undertaking linear or rotational movements, achieving even acceleration or accurate posi-tioning, 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 competi-tive than ever.

Printed in GermanyRE 09956/06.07

Bosch Rexroth AGHydraulicsZum Eisengießer 197816 Lohr, GermanyPhone: +49(0)9352/18-0Fax: +49(0)9352/18-36 95support.nc-systems@ boschrexroth.dewww.boschrexroth.com/hnc100