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Tough application, ingenious solution. Product innovations in 2014

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The solution has to be perfect: Innovation from Bosch Rexroth

All over the world, there are completely different ideas about "innovation": In industrial countries, it is mostly technology-driven, and is generally about "faster, higher, further". In other regions, it refers to solving a task using minimum resources and a design which is concentrated solely on functionality – only those who understand the local require-ments and develop customized solutions on-site with researchers and developers can satisfy local needs in a global economy.

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At Bosch Rexroth, regional developers work in a network in close collaboration with their international colleagues. This results in innovations in virtually every field of application and in all industries. They set worldwide standards and help customers on-site, every day.

For this to happen, we invest substantial sums of money and the creativity of thousands of engineers in research and development – year in and year out. Our R&D quota has been above the industry average for years. More than 2,100 specialists work at Rexroth on new products, solu-tions and services. They identify long-term megatrends which serve as indicators for changes in the markets, society and legislation. From this, we can systematically derive short- and medium-term requirements which we fulfill with developments based on known technologies.

At the same time, we continue to develop existing solution principles for the long term, or look for new approaches. For us, innovation is always multi-dimensional, and always means improvements for machine manufacturers and users. A Rexroth solution therefore not only reduces climate-dam-aging carbon dioxide emissions, for example, but increases productivity at the same time. This is a requirement for innovation which we, as a worldwide market leader, also have in your industry. Here you can discover some of the most important innova-tions of the past and next six months.

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From the latest components to global multi-technologies, such as variable-speed pump drives: this brochure pro-vides you with an overview of recent innovations at Bosch Rexroth. Completely new developments and significant improvements are detailed with technical highlights that will help you to increase your productivity and lower your operating costs in a sustainable way.

Overview

Let us inspire you to make your processes, systems and machinery more economical and future-proof, piece by piece.

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06 Hydraulics07 Hägglunds CBM 2000-1000 motor08 Hägglunds CB 1120 motor09 Hägglunds DUe ATEX drive unit 10 HSR subplate configurator11 Configurator for ABAPG motor-pump

assemblies12 IndraMotion MLC 13VRS motion logic

for hydraulics13 VT-HMC digital axis control system14 4WRLD..3X pilot-operated IAC

Multi-Ethernet control valve15 New high-response valve platform16 Configurable medium-range

standard power pack17 CIMS MK IV cylinder displacement

measuring system18 Fit4Filter filter transcoding app 19 BFSK25-125 filtration20 OPM II online particle filtration monitor21 A6VLM500 ATEX axial piston motor

22 Electric Drives and Controls23 IndraMotion MLC 13VRS motion logic24 IndraMotion MLD 13VRS motion logic25 IndraMotion MTX 13VRS CNC system26 SafeLogic safety technology27 SafeLogic compact safety technology28 Safe Motion safety technology29 IndraControl XM21/22 control hardware30 IndraControl S20 I/O modules31 IndraControl S67 I/O modules32 SERCANS Sercos master module33 IndraControl V Multi-touch HMI34 Open Core Engineering software36 IndraWorks 13VRS engineering

framework37 WinStudio visualization software38 EasyWizard commissioning wizard39 Indra Drive Mi decentralized drive

technology40 IndraDrive M, 300 A inverter drives41 IndraDrive ML large electric drives42 IndraDrive HMV drives with

smart energy mode43 EFC 3610/5610 frequency converters44 MSK133 synchronous servo motor45 IndraDyn MSM motors

46 Nexo tightening technology47 PSI 64CO welding technology

48 Linear Motion Technology49 IMS-I integrated measuring system50 RSHP roller rail system high precision51 BSHP ball rail system high precision52 PLSA planetary screw assembly –

2nd expansion stage53 Ball screw assembly – Asian nut series54 EMC-HD electromechanical cylinder –

heavy duty55 EMC electromechanical cylinder –

2nd generation56 CKL compact module with ironless

linear motor57 EasyHandling basic:

online motor mounting configurator58 EasyHandling basic:

online connection technique selector

59 Assembly Technology60 Case lifter61 VarioFlow plus

chain conveyor62 TS 2plus transfer system63 Energy efficient motors in all

transfer systems

64 Multi-Technology Sytronix variable-speed pump

drives65 Sytronix FcP 5010 and FcP 7010 66 Sytronix SvP 701067 Sytronix DFE 5010 and DFE 7010

This brochure contains information on new products. Accurate information about availability can be obtained from your responsible contact person in Sales.

6 Hydraulics | Product Innovations

Hydraulic product innovations: for greater availability, higher perfor-mance and more uniform engineeringWhether it is a question of more torque in a very confined space for direct drives, more intelligent online configurators, more efficient control valve platforms, mobile smart-phone apps, powerful ATEX actuating drives, best-in-class hydraulic controllers or uni-form motion-logic engineering tools, Rexroth system expertise is perceivable in every detail in the new hydraulic components. Take advantage of it!

7Drives | Hydraulics

Hägglunds CBM 2000-1000:the most powerful direct drive on the market

Less weight, more torque, 1,000 kNm/barThe advanced CBM motor is the answer to the market's requirements for increasingly higher performance, more compact design and reduced mass. The heart of the closed drive system is a low speed hydraulic motor that is mounted directly on the drive shaft and enables maximum torque, even at minimum speed. Direct mounting means that gears, belts, chains, etc. are superfluous. The design principle makes optimum use of the advantages of hydraulics. The power can be controlled precisely and made available across the entire power range. The speed range was able to be increased once again to 70 rpm with the new CBM 2000-1000 motor and the weight reduced further – for extremely high productivity.

Advantages resulting from special product features f Low weight f Optimum torque-to-weight ratio for greater efficiency f High torque in an extremely small space f Increased speed range f Compact design for flexible use

The new CBM motor is the optimal extension of the Hägglunds CBM 2000-series: This robust lightweight motor covers the special torque range of 1,000 kNm/bar in an extremely small space. And at 70 rpm it attains the highest speed in the series. Your advantage: a very high torque-to-weight ratio. Mounted directly on the drive shaft, it will open up completely new applications for you. Machine and housing have become smaller, lighter and simpler.

Key technical data f Specific torque: 1,000 kNm/bar f Maximum rotational speed: 70 rpm f Maximum working pressure: 350 bar f Displacement: 63,108 cm3/rev

8 Hydraulics | Drives

Hägglunds CB 1120: more power in an extremely small space

New materials for a longer service lifeThe proven CB 1120 will be given a substantial upgrade, which is only noticeable in its upgraded performance. The new materials used make it possible to increase the service life of these legendary direct drives by a factor of four. Its torque capacity is now also more than 35 % greater. Its design-related benefits have of course been retained in the process: low weight, compact design, reduced mass, the high torque-to-weight ratio. The result is a particularly small and particularly lightweight power pack with an exception-ally long service life.

Advantages resulting from special product features f Low weight f Large speed range f High torque-to-weight ratio f Compact design

New material, proven advantages: The CB 1120 hydraulic motor has been upgraded with the same new materials as used on the Hägglunds CBM 2000-1000. They signifi-cantly improve its longevity. At the same time it has remained small and powerful with an optimum torque-to-weight ratio.

Key technical data f Specific torque: 880 to 1,120 kNm/bar f Maximum rotational speed: 34 rpm f Maximum pressure: 350 bar f Displacement: 55,300 to 70,400 cm3/rev

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Hägglunds DUe ATEX: the drive unit for explosion-risk areas

Perfected, proven in practice and now ATEX safeThe Hägglunds DUe drive unit has proven itself in practice in countless applications. The modular system can be adapted with exceptional ease to meet all requirements. Customers value the high degree of flexibility, the per-fected standard functionalities and the compact design.

This well-known piece of engineering is now also available with ATEX approval and for temperature class T4 so that even in difficult environments you can control your drives and adapt them to suit your needs safely and in the way you are accustomed to doing.

Advantages resulting from special product features f Adaptable very flexibly to customer applications f Proven standard functions (identical to the

conventional DUe) f Compact design f Very easy installation f Well proven technical solution

The proven modular Hägglunds drive unit is now also available with ATEX certification for hazardous environments. With the scope of performance of the classic DUe: flexibly and easily configurable to meet all customer wishes, with all well-known standard functions. And all of this in an extremely small space.

Key technical data f ATEX II 3 G certification f Temperature class: T4 f Maximum pressure: 350 bar f Maximum flow rate: 2,823 L/min (50 Hz), 3,417 L/min (50 Hz)

Drives | Hydraulics

10 Hydraulics | Configurators

HSR subplate configurator: faster from hydraulic circuit design to product selection

Direct configuration via circuit symbols, without any detailed knowledgeFor the first time the HSR subplate configurator provides the user with the possibility of fully exploiting the advan-tages of an online configuration. In addition to the classic configuration facilities, it has been expanded by an intui-tive, function-oriented graphics feature. The user no longer selects material numbers or material designations, but can pass on their requirements directly via the circuit diagram without having any detailed knowledge of the product. The user selects the symbols and the configurator translates them into the corresponding components that fit: thanks to the integrated collision checking and collision rectification feature. And because standard components are provided throughout in the modular system, fast availability is ensured as well.

Advantages resulting from special product features f Configuration via circuit symbols for quicker, direct

implementation f A modular system consisting of standard components

with extremely fast availability f No design adaptations necessary f Configuration of the base plate on one page f Expert mode (input optionally via type designation or

material number) f Collision checking/rectification in the configurator saves

time f Output in the form of a component list or 2D/3D data

Configure directly via the circuit diagram – it just couldn't be easier or quicker: Bosch Rexroth enables genuinely user-optimized product configuration with its new HSR configurator. The configurator translates your functional requirements directly into the corresponding products. This significantly accelerates the path to the suitable solution.

Key technical data f 120 standard base plates (nom. sizes 6 and 10) f Over 1,000 valve functions f Distributable over a maximum of 10 stations and 8 levels f Full backend integration into SAP VC

11Configurators | Hydraulics

Configurator for ABAPG motor pump assemblies: the individual modular solution

Fast and product-neutral configuration, fast deliveryThe product configurator for motor pump assemblies puts a practical tool in your hand. The drive unit can be individu-ally configured product-neutrally, without any detailed product knowledge and without design adaptations. The modular system provides comprehensive documentation immediately after creating the solution. Through the output of 3D data the finished product can be immediately imple-mented in the application. If a special solution is required that is not mapped in the product construction kit, the construction can be based on the configuration in a dialog with the sales department.

Advantages resulting from special product features f No design adaptations necessary f Fast configuration of components, each on a separate

page f Functional entry (input via application parameters) f Output in the form of a component list or 2D/3D data

Motor pump assemblies can be assembled more quickly and easily with the new APAPG configurator: Users without any detailed product knowledge, such as sales personnel, can individually configure the central drive unit for power packs based on application needs. A practical, product-neutral modular system delivers 3D data that can be immediately used, saving time.

Key technical data f 350 motors from the manufacturers Hoyer, Siemens and VEM f 280 Rexroth pumps f Full backend integration into SAP VC

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Key technical data f Motion control axes: decentralized up to 64,

centralized up to 32 f 1,000 statements (combined) 35 to 5 µs f Number of function modules 2 to 4 f Min. Sercos cycle time 1 to 0.25 ms f Up to 512 local I/Os

IndraMotion MLC 13VRS: motion-logic control for hydraulic drives

Fast programming, planning, and commissioningUsers of the new version of IndraMotion MLC will notice in every detail the know-how that we have gained from many thousands of applications: with the intuitive operator con-trol of all drives, the IndraControl S20 module support for incremental encoders, the easy wizard-supported configu-ration, the open controller interfaces and the tailor-made scalable product range – you will manage to achieve the cross-technological project planning of your drives with a single tool. You can program, plan, commission, localize errors and rectify errors faster.

Advantages resulting from special product features f Best-in-class motion control for hydraulics with opti-

mized controllers for speed, position, power and for variable-speed pump drives

f Open communication and programming, support of all common Ethernet bus systems (Sercos, EtherNet/IP, PROFINET RT)

f Simple and clear programming of motion sequences by means of sequential programming

f Automatic code generation by means of a GAT template f Wizard-supported configuration

IndraMotion MLC is a complete motion logic system that can be used for the operation of electric, hydraulic or hybrid drives. Open programming and interfaces, scalable hard-ware and software, and uniformly easy to use; you will reduce your engineering costs by up to 50 % with it. Extremely helpful in this process is, among other things, a function tool kit that is specially oriented for hydraulic drive tasks.

Hydraulics | Motion control

13Motion control | Hydraulics

VT-HMC hydraulic motion control: for better control of electro-hydraulic axes

Best in class: simple, open, scalableThe central keyword for the VT-HMC is simplicity: simple highly dynamic control in all facets (position, speed, pres-sure/force control, release control [position/pressure/force] and status feedback). Simple engineering through-out. Simple communication and programming via open interfaces and all common bus systems for control, service and diagnostics. Electro-hydraulic axes are controlled better by a simply better control.

Advantages resulting from special product features f A best-in-class hydraulic controller with optimized struc-

tures: valve integrated and therefore highly dynamic f Openness in communication: support of all popular

Ethernet bus systems (Sercos, EtherCAT, EtherNet/IP, PROFINET RT and PROFIBUS DP)

f Simple engineering throughout thanks to fast param-eterization and extremely easy operation by means of IndraWorks DS

f Future-proof with cost benefits thanks to the full scal-ability in hardware and software

f Robustness and reliability due to the extended tempera-ture range

f IEC61131-3 PLC functionality, simple and fast program-ming of a wide variety of functions

The new VT-HMC motion controller is a digital control unit with an integrated axis con-troller and IEC61131-3 PLC functionality. A motion logic system specially optimized for electro-hydraulic axes – open in its programming, easy to use, and interfaces with future-proof scalability.

Key technical data f Bus connection/service interface (Sercos, EtherCAT,

EtherNet/IP, PROFINET RT, PROFIBUS DP) f PLC functionality in accordance with IEC 61131-3 f Increased temperature range: 60 °C f Sampling time: 0.5 ms for force controller,

1 ms for positioning controller f Actual value acquisition: 2 x configurable analog sensors

(current/voltage), 1 x linear path measuring system (SSI or incremental)

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Pilot-operated IAC multi-Ethernet control valve: control dynamically, adapt flexibly, save easily

4WRLD..3X – a robust, best-in-class hydraulic controllerDue to the different communication and sensor interfaces, this new generation of control valves can be integrated flexibly into host control networks. Complex engineering and hardware adaptations are no longer required – this saves time and money. The combination of proven control valve technology and intelligent electronics enables tailor-made, precise and functional solutions for hydraulic drives at minimal cost. Together with the IndraWorks DS 13VRS software tool, more uniform engineering is made possible – you can respond to requirements quickly and at low cost.

Advantages resulting from special product features f Hydraulically optimized, scalable controller structure

for highly dynamic closed-loop control systems f Openness in communication: supports all popular

Ethernet bus systems f Uniform engineering with the IndraWorks DS 13VRS

engineering tool: simple and fast commissioning, all components and support from a single source

f Flexibly scalable: a large selection of valve types for greater flexibility in use and at minimal cost

f Robust and reliable: extended temperature and vibra-tion range

Rexroth is expanding its IAC multi-Ethernet product portfolio by a pilot-operated control valve with an integrated axis controller. The IAC Multi-Ethernet valves are robust and user friendly. They support all the important bus systems, are individually scalable and have impressive hydraulically optimized controller structures. The IndraWorks DS 13VRS engineering environment provides intuitive operation for fast and simple commissioning, parameterization and diagnostics.

Key technical data f Bus connection/service interface

(Sercos, EtherCAT, EtherNet/IP, PROFINET RT, Varan) f Maximum operating pressure: 315 bar f Maximum flow: 450 L/min f Sampling time: 0.5 ms for force controller, 1 ms for

positioning controller f Actual value acquisition: 2 x configurable analog sensors

(current/voltage), 1 x linear path measuring system (SSI, EnDat 2.2 or 1 Vss)

Hydraulics | Motion control

15Valves | Hydraulics

New high-response valves platform: higher performance, greater dynamics and electronics on board

4WRPE10-3X, 4WRPEH6-3X and 4WRLE16,25,27-4X: Maximum performance in the new designThe on-board electronics and new materials have been built into an extremely small space. This gives proven products a performance boost. As 4/3-way directional control valves they are suitable for electro-hydraulic position, speed, pressure and force control with medium to high dynamic requirements. As an extended variant with a zero overlap gate that extends the area of application to sophis-ticated applications. Or as a 4/4-way directional control valve with a control piston and sleeve in servo quality, highly suitable for control systems with high dynamics and precision. In brief: an innovative valve series that increases productivity and energy efficiency and opens up new areas of application.

Advantages resulting from special product features f More efficient: best performance through high-grade

materials and a robust design f More dynamic: higher control performance, shorter

cycle times, greater stability f More robust and more reliable: extended temperature

and vibration range f More economical: maximum performance with an opti-

mum price-performance ratio f More flexible: with our GoTo program, extremely short

delivery times for preferred types

Pressure cannot be controlled any better or any more economically: In the case of this valve generation not only have updated robust electronics been integrated, but the tried-and-tested technology has also been significantly improved. This now allows a operating pressure of up to 350 bar and increases the maximum flow by up to 85 % – all with the same overall size.

Key technical data f Maximum operating pressure: up to 350 bar (channels P, A, B) f New increased nominal flow levels on pilot-controlled valves

with a zero overlap gate of up to 600 L/min f Maximum permissible flow: up to 1,850 L/min f Maximum permissible ambient temperature:

from –20 °C to +60 °C f Improvements in the dynamic properties (step response time

and frequency response: –90 °) f Increase in the vibration resistance

16 Hydraulics | Power packs

Key technical data f Reservoir volume: 100–1,000 liters f Maximum flow: 200 L/min f Maximum operating pressure: 315 bar f Multi-function block f Sytronix option (modular system FcP 5010 and

Sytronix SvP 7010) f Integrated attenuation function

The intelligent medium-range standard power pack: configurable, modular, energy efficient

Tailored savingCost optimized all round and future-proof: with the two versions of the modular standard power pack you can respond quickly and flexibly to customer and market requirements. Using an online configurator you can assemble individual motor pump assemblies, control blocks, filters and the accessories. The Sytronix construction kit can also be used optionally for increased energy efficiency. Everything is com- prehensively documented and comes at a specific price. Supported by open interfaces and in the case of the "High value line" variant even by a service portal and condition monitoring via smart devices. This all saves costs and energy when in use. And when selected from the GoTo program it also saves time, with extremely short delivery times.

Advantages resulting from special product features f Service portal and condition monitoring via smart

devices (high value line models) f Configurator for the individual selection of components

for greater flexibility f Optimized reservoir volume f Multi-function block with all basic functions f Open bus interfaces CAN/Ethernet in accordance with

the IEC61131-3 standard for intelligent Internet connec-tivity and visualization

f Combinable with Sytronix FcP and SvP for an energy efficient drive

Intelligent and tailor-made: with the new medium-range standard power pack you are able to achieve individual solutions quickly and at optimal cost. Easily configurable using the online configurator, with comprehensive documentation and intelligent com-munication via open interfaces. Fast delivery, because predominantly components from the GoTo program are used. Energy saving in daily use.

17Displacement measuring systems | Hydraulics

CIMS MK IV cylinder displacement measuring system: easy contactless measurement of piston position

Plug and play: easy installation, contactless measure-mentFor over 20 years the sensors of Rexroth's Cylinder Inte-grated Measuring System (CIMS) have been measuring the piston rod position in thousands of hydraulic cylinders, reliably and with precision, all over the world.

The latest generation has been developed in close coopera-tion with Bosch's automotive experts. The state-of-the-art techniques from the automotive sector have been further refined for this purpose and optimized for extremely harsh industrial environments. The result: a contactless, high-precision measuring system that is easy to install and easy to put into operation. This system automatically compen-sates for external influences and its status can be easily monitored at any time.

Advantages resulting from special product features f Contactless measurement: no impairment of the piston

or sensor; a completely enclosed housing f Easy installation and commissioning: plug and play

without manual calibration f CIMS monitoring: easy diagnostics via PC or PLC f Extended performance range f Downward compatible f Absolutely reliable position measurement at any time

The latest generation of the CIMS measuring system that is fully integrated into the hydraulic cylinder is based on the latest developments from the automotive sector. The position of the piston can be measured contactlessly with ultra-high precision, even in extremely harsh conditions, for example, on the open sea. Reliable, with Bosch Rexroth quality.

Key technical data f High accuracy: non-linearity < ±1 mm f RS-422 output signal (1,024 pulses/com) f Wide temperature range from –40 °C to +70 °C f High pressure resistance in (sea) water (IP68, 10 bar) f Certified for potentially explosive environments

(ATEX zone 1)

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Fit4Filter transcoding app: The correct spare part? Searched for and found!

Usable anywhere and always up to dateThe new Fit4Filter app provides a fast and simple search facility for spare elements for your Rexroth fluid filter. Navigation is easy, it has a convenient search function and stores all your contact information and personal settings. The spare element can be quickly identified via the part designation or item number (even an element from another manufacturer).

In addition you can obtain detailed technical ordering information on the filter element, as well as details of your designated point of contact. Send off the order inquiry by email and it's all done.

The database is regularly updated and provides you with the latest product information at all times.

Advantages resulting from special product features f Native smartphone app for iOS and Android: usable

anywhere and always up to date f QR reader: fast product identification saves time f Element database with over 30,000 products:

no laborious catalog searching f Transcoding of elements from 13 manufacturers f Order inquiry by email (an e-shop is planned). f The nearest distribution/service partner is identifiable

via GPS data

This will be the quickest you have ever found the spare filter elements you need. With the new Fit4Filter smartphone app, you will find the right spare element for your Bosch Rexroth fluid filter quickly and easily. Irrespective of manufacturer and complete with transcoding and initiation of the purchase order.

Key technical data f Requires iOS 4.3 or later. Compatible with iPhone, iPad and

iPod touch f Requires Android 2.3 or later f Database with more than 30,000 filter elements

Hydraulics | Filtration

19Filtration | Hydraulics

BFSK25-125 supply and exhaust air ventilation filter: filtering and drying all in one

Granulate and filter individually replaceableThe new BFSK supply and exhaust air ventilation filter consists mainly of an unscrewable replaceable cartridge with an integrated, stellar-pleated filter element and an air filter housing. The filter housing is filled with a water-absorbent granulate. Each of these can be replaced independently of the other. Check valves are optionally integrated (e.g. for use in wind turbines). Practical: The water saturation is shown in color by indicator beads and an optional optical maintenance indicator provides information as to the sta-tus of the replaceable filter.

Advantages resulting from special product features f An all-in-one package: smaller space requirement, lower

costs f Not entirely a disposable unit: the granulate and air filter

can be replaced individually, i.e. lower subsequent costs, environmentally friendly

f Optionally with a check valve: no air exchange on no-load operation, longer service life

f Service- and operator-friendly: with a water saturation indicator and an optional optical maintenance indicator for the cartridge

f Stainless steel inner cylinder (from size 40 upwards) for increased stability

f Environmentally friendly: the granulate is non-toxic and its disposal therefore requires no special care.

Space saving, cost saving: The new BFSK filters are desiccants and air filters all in one package. Despite this, the water absorbing granulate and air filter cartridge can be replaced separately – which saves costs and protects the environment. Their high flow rate, extremely easy operation and service friendliness are also impressive.

Key technical data f Maximum working pressure: 1 bar f Maximum flow rate: 1,500 L/min f Connection: G3/8 to G1 1/4 BSP f Adapter plates for connection with a 6-hole drilling pattern

20 Hydraulics | Filtration

OPM II online particle filtration monitor: An easy way of keeping an eye on contamination

Low cost, precise, space-savingThe new OPM II operates on the light extinction principle. The contamination level and the fluid purity trend in hydraulic systems can be precisely monitored and recorded by this means. When limit values are exceeded, the alarm enables a fast reaction. The small, space-saving particle moni-tor can be operated and configured easily via the display. It is also suitable for mineral oils, bio-oils and diesel fuel.

Advantages resulting from special product features f Precise: display of the purity class is in conformity with

ISO 4406:99 or SAE AS4059E. f Easy: to operate and configure via the display f Recording: with integrated data memory f Clear layout: display in 4 size classes f Flexible: space-saving dimensions f Safe: an alarm is emitted if the limit value is exceeded

The contamination level of fluids in hydraulic systems can be easily monitored at low cost with the new OPM II– and at that, digitally recorded with high precision. If the limit values are exceeded, the alarm sounds and you can react quickly. Indication of the purity level is in conformity with ISO 4406:99 or SAE AS4059E.

Key technical data f Permissible working pressure: 420 bar f Permissible flow rate: 50 to 400 ml/min f Calibrated measuring range: 10 ... 22 in ordinal numbers f Measuring accuracy: ±1 ordinal number f Interfaces: RS232, CANopen

21Motors | Hydraulics

A6VLM500 ATEX axial piston motor: displaces with infinite variation up to 500 cm3

The right power for hydrostatic drives at all timesAt last there is a bent axis variable displacement motor with a displacement of 500 cm3 and ATEX approval. This robust motor is able to provide its design-related advantages even under the harshest conditions and in explosion-risk areas: the precise, infinitely variable torque, which enables smooth starting and a highly effective drive at low speeds. With an incomparable power density of 0 to 500 cm3. Perfect for use in mobile and industrial applications. In open and closed circuits.

Advantages resulting from special product features f ATEX certification: recorded safety, for use even in the

most challenging environments (certified in accordance with 94/9/EC)

f Bent axis design: very good starting efficiency, highly effective even at low speeds

f Hydraulic displacement that is control-pressure depen-dent: infinitely variable adjustment of the displacement in accordance with the control pressure signal

f High power density, wide control range: for a flexible and wide range of applications – mobile or industrial

High power density even under the harshest conditions; that was the aim during the development of this robust variable motor. The result: an ATEX-certified, highly effective power pack with good starting efficiency, a large control range and an infinitely variable displacement.

Key technical data f ATEX type code: Ex II2G IIB T3 f Maximum torque: 2785 Nm f Displacement from Vgmin to Vgmax = 500 cm3 f Nominal pressure: pnom 350 bar absolute

Maximum pressure: pnom 400 bar absolute f For hydrostatic drives in an open or closed circuit

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Product innovations in the field of Electric Drives and Controls: for maxi-mum flexibility and greater efficiency

Electric Drives and Controls | Product innovations

Whether it's a question of megawatt-sized universal inverters, the first aluminum welding control unit in the world or complete Open Core Engineering for individual real-time control – with these new drive and control tools you can make your operations high-performance, easy-to-handle and future-proof.

23Controls | Electric Drives and Controls

IndraMotion MLC 13VRS: the complete system for all control tasks

IndraMotion MLC is the first really complete automation solution: Motion, robotic and logic control merge into a uniform overall system for all control tasks. Uniformly designed, with open standards, you can synchronize all drive types for high perfor-mance. Cost-optimized and with maximum flexibility, the IndraMotion MLC 13VRS gives you all the freedom you need for uniform machine automation.

Uniform, open, highly flexibleThis is what modern automation looks like – IndraMotion MLC provides you with the optimal platform. The IndraControl L scaled device series enables integrated system solutions with a uniform design. IndraMotion MLC 13VRS is flexibly integrated via the automation bus Sercos and optionally via PROFINET, PROFIBUS or EtherNet/IP into a wide range of topologies.

Key technical data f PLC programming in accordance with IEC 61131-3 f Up to 64 axes in one control unit with synchronized and

coordinated movements f Sercos, flexible multi-connectivity with Ethernet

(PROFINET, EtherNet/IP) and PROFIBUS f PLC cycle times of up to 250 µs f IndraControl L scaled device series with flexible

expansion facilities (function modules and local I/O modules)

You can synchronize complex multi-axis applications with particular ease using the high-performance motion-logic runtime system and in the case of the system version 13VRS with the further improved toolkits. All drive types, includ-ing electric, hydraulic and hybrid drives, are supported. And the Open Core Interface gives you all the freedom you need in engineering at all times.

Advantages thanks to enhancements in Open Core Engineering

f "Safety Manager" function toolkit: programming the optional SafeLogic safety control system

f "Robot Control" function toolkit: a kinematics data interface, the new version 2 has PLC-based program-ming

f "Technology" function toolkit: new function blocks, e.g. for winders, ingot sawing and Magic Belt

f Open Core Interface: interface technology for high-level language based applications (real-time/non real-time)

f "Sercos" open standards: redundancy function for increased machine availability and engineering enhance-ments

f "EtherNet/IP scanner" open standards: increased inte-gration capability in heterogeneous network structures

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IndraMotion MLD 13VRS: up to 10 axes easily under control, quickly automated

Electric Drives and Controls | Controls

For better, faster communication between drives: The new IndraMotion MLD 13VRS with the modern editors of the new PLC version simplifies engineering considerably. It provides all the additional functions needed to automate a complete small line easily, even when using electric and hydraulic drives. Very fast axis couplings provide for maxi-mum productivity and the Sercos link for extremely easy communication.

Highly synchronous axis coupling, faster cycle timesThe IndraMotion MLD 13VRS integrated automation solu-tion is based on the IndraDrive scalable drive platform. High-performance motion control and PLC functions merge to form a complete automation system for modern machine concepts. The drive-based solution is perfectly suited for applications with up to 10 axes. With the new 13VRS sys-tem version, up to four fieldbus couplers can be used with a variety of different I/O modules. The integration of Indra-Motion MLD 13VRS into the automation concept is simpli-fied by open technology interfaces and communication interfaces. In brief: efficient Open Core Engineering.

Advantages thanks to enhancements in Open Core Engineering

f "Damage Prevention" function toolkit: functions for protection against damage

f "Visualization" function toolkit: implementation of machine operating/monitoring now also available with WinStudio

f "Enhanced Control" function toolkit: higher dynamics and precision of control functions

f "Condition Monitoring" function toolkit: error detection and preventive maintenance

f "Energy Management" function toolkit: integrated energy and power measurement

f "Enhanced Axis Coupling" function toolkit: enhanced coupling of axes for synchronization

Key technical data f A max. of 10 motion control axes f A max. of 4 peripheral devices connectable via the Sercos

automation bus f Minimum Sercos cycle time: 250 µs f Minimum PLC cycle time: 1 ms f New version also with object-oriented programming in

accordance with IEC 61131-3

25

IndraMotion MTX 13VRS: the unique multi-core CNC system

A real multi-talent: IndraMotion MTX 13VRS is a unique, individually scalable CNC platform with an integrated PLC. The outstanding performance specifications and com-prehensive technology functions open up new horizons even on sophisticated, highly dynamic multi-technology machines. For successful machining and forming concepts, for maximum productivity and flexibility, choose IndraMotion MTX.

Individually scalable, even for the most sophisticated multi-technologiesThe proven IndraMotion system has been resolutely further developed with the current system version 13. You can control up to 12 independent channels and 64 axes with a CNC. With extremely fast PLC and CNC cycle times. With technology protection by means of easy encryption, which means easy know-how protection for the OEM. With Fast Actions, which means fast communication between the PLC and CNC at the interpolation cycle rate, with mini-mized non-production times. And with measuring cycles manually or automatically, which ensures easy, safe and fast measuring of workpieces for very short setup times and fewer errors. It is simply an all-round multi-talent.

Advantages resulting from special product features f Technology protection: effective know-how protection

for OEMs by means of easy encryption f Fast Actions: fast PLC/CNC communication for reduced

cycle times f Measuring cycles manual or automatic: easy, safe and

fast measuring of workpieces for reduced setup times and fewer errors

Key technical data f Up to 12 independent channels with one CNC f Up to 64 axes with one CNC f Very fast PLC and CNC cycle times f Multi-core CNC (IndraMotion MTX 13VRS advanced)

Controls | Electric Drives and Controls

26

SafeLogic: more safety, simplified engineering

The new SafeLogic safety control unit rounds off the portfolio of safe logic processing as an optional expansion of the IndraControl L standard control platform. SafeLogic is efficient, can be programmed freely and enables integrated engineering – perfect for machines and interlinked extensive systems with comprehensive safety peripherals.

The option for safer machines and systemsIncrease your engineering efficiency and make it uniformly safe. With the new SafeLogic safety controller, you can connect a wide safety portfolio via Sercos and PROFIsafe (PROFIBUS or PROFINET) using the Multi-Safety Master function. As there is no interaction between the standard control system and the safety technology, you can expand the system optionally without any problems. In this way, variants of series machines are significantly easier to cre-ate. You can use SafeLogic extremely efficiently as an inte-grated part of the standard control systems to make your machines and systems safer.

Advantages resulting from special product features f Multi-Safety-Master – CIP Safety-Originator and

PROFIsafe host f Modular system design thanks to optional safety func-

tion module f No interaction between standard control system and

safety technology f Safe communication for integration of the decentralized

safety periphery via Sercos (CIP Safety on Sercos), PROFIBUS or PROFINET (PROFIsafe)

f Integrated engineering of the standard control system and the safety technology with IndraWorks 13VRS

f Standardized safety programming with PLCopen-Safety

Key technical data f Complete safety PLC, programmable with IndraWorks 13VRS

and the Safety Manager function toolkit f Compact function module hardware with a construction

width of 20 mm f Safety solutions up to PL e/Cat 4 (EN ISO 13849-1) or

SIL 3 (IEC 62061) f Integrated system expansion with a max. of 96 safe peers f Digital input/output modules for Sercos or PROFIsafe

Electric Drives and Controls | Safety technology

27

Key technical data f Secure logic processing up to PL e/Cat. 4 (ISO 13849) or

SIL 3 (IEC 62061) f CPU modules with/without EFI interface f Gateway modules for flexible system integration f Digital input/output modules f Relay modules with feedback contacts

SafeLogic compact: the decentralized and flexible safety control system

Modular and efficient control with direct integration into SercosSafeLogic compact is the decentralized safety control solution with high flexibility and ease of use: Thanks to the modular system design you can reduce your control cabinet volume – and the hardware costs. Your engineering be-comes easier and more efficient thanks to the intuitive programming with various modules and functions. By inte- grating the control unit into the Sercos network and inte-grating the direct linking of the safety-certified IndraDrive drive series you are able to implement modular and safety-oriented machine concepts even more easily.

Advantages resulting from special product features f Comprehensive module libraries for evaluation, diagnos-

tics and logic processing of peripheral signals f EFI interface for secure networking of up to 32 stations f Comprehensive interface portfolio for flexible integra-

tion into the overall automation process f Sercos gateway module for the safety-oriented linkage

of IndraDrive f PC-free hardware replacement using memory plug with

integrated application memory f Fast shut-off function for fast shut-down of outputs f Convenient report function for fast application verifica-

tion and documentation

With the SafeLogic compact programmable small safety control system, safe logic processing can be implemented easily and efficiently in small- to medium-sized machines. The control system grows flexibly with the number of peripheral signals. Defined function modules and graphic wiring simplify configuration and speed up the commissioning process.

Safety technology | Electric Drives and Controls

28

IndraDrive with Safe Motion: the new control unit genera-tion for greater productivity

No matter which IndraDrive series you use, with the new control unit generation you will increase the productivity of all machines that require comprehensive drive-inte-grated safety functions. Fast and safe. And it is cost-saving because, for example, the safe logic functions are integrated into the drive and commissioning is now even easier.

For all IndraDrive seriesWhether it is a question of simple Safe Torque Off or com-plex Safe Motion safety functions – Safety on Board pro-vides for the maximum safety level in all models of the IndraDrive series. It also increases productivity wherever safe deceleration, stopping, motion and position monitor-ing are needed. Selection of the safety function via CIP Safety on Sercos (less wiring work) or the integration of secure logic functions directly into the drive (no external logic modules) saves time and costs. Exactly the same as when a PC-less device is being replaced. Above all, however, Safe Motion increases one thing: safety in your facilities.

Advantages resulting from special product features f Extensive: drive integrated safety functions for braking,

stopping, moving and position monitoring f Flexible: selection of the safety function via CIP Safety

on Sercos or optionally via discrete 24 V signals f Intelligent: safe logic functions integrated into the drive f Productive: higher machine productivity at reduced

costs f Uniform: in all IndraDrive product series, i.e. Cs, C, M,

Mi and ML

Key technical data f Maximum safety level (Cat. 4, PL e, SIL3) for all functions

without encoder involvement f Standard safety level (Cat. 3, PL d, SIL2) for all functions for

the purpose of motion monitoring f Reduced commissioning costs due to semi-automatic sup-

port f PC-less device replacement when servicing

Electric Drives and Controls | Safety technology

29

Easy configuration, high-performance data processingThe IndraControl XM control platform is available for a variety of motion-logic applications. Local activation of the modules of the new IndraControl S20 I/O series expands the control system flexibly for high-performance process linkage. Decentralized I/Os, drives and additional system machinery are connected via Sercos as standard. Optional extension modules expand the integration options. The service-friendly design simply reduces installation and assembly costs.

Advantages resulting from special product features f Easy and flexible system configuration with modular I/O

expansion f Complete control system with high-performance pro-

cess data processing f High real-time capability of the overall system f Sercos as a universal automation bus for system-wide

networking f Maintenance-free through the waiving of wear parts

such as fans and batteries f The IndraMotion MLC scalable system firmware for

motion logic applications

IndraControl XM21/22: flexible control in real-time

The first devices of the new IndraControl XM modular control hardware: they combine the speed of the Sercos automation bus with the new IndraControl S20 I/O series into one modular and functionally complete control system – for all applications in factory automation.

Key technical data f Protection class: IP20 f Onboard Sercos master with a cycle time of 250 µs f High control performance via Intel ATOM processor architec-

ture with 600 MHz or 1,300 MHz f Gigabyte Ethernet, USB, SD card slot, diagnostics LED f Modular expansion options with extension modules and I/O

modules f Extended temperature range from –25 °C to +60 °C


30

Key technical data f Protection class: IP20 f Fieldbus interface connections for Sercos, PROFINET and

PROFIBUS f Cycle times of 250 µs f Short module reaction times of 1 µs per module f Extended temperature range from –25 °C to +60 °C f Electrical interference immunity in accordance with EN

61000-4 f Noise emission class B in accordance with EN 61000-6-3

IndraControl S20: the fastest I/O components of all time

Optimum system integrationWith IndraControl S20, real-time requirements with short cycle times can be easily implemented. Through the decen-tralized linkage via Sercos as a high-performance automa-tion bus, very short I/O reaction times can be achieved for efficient production cycles. This facilitates the most chal-lenging applications, even under extreme conditions, thanks to the optimized design.

Thanks to its flexibility, the modular I/O system optimally links together with a range of control topologies. Together with the new IndraControl XM control platform, the full functionality and efficiency are also available as a high-per-formance I/O extension. With the new modules you now have even more options for the signal processing of mea-suring systems and intelligent sensors.

Advantages resulting from special product features f High-performance and intelligent local bus with opti-

mized data communication for extremely fast and cycle-synchronous signal processing

f High EMC protection f Easy device replacement and tool-free installation f Diagnostic and status indicators f Technology module for the control of hydraulic axes

Also for the most sophisticated applications: The full performance and functionality of the fastest I/O technology with protection class IP20 is now at your disposal everywhere with the Ethernet-based automation bus Sercos. Withoptimum system integration, real time is no longer a dream.

Electric Drives and Controls | Controls

31

IndraControl S67:the best solution for a wide range of performance requirements

Key technical data f Protection class: IP67 f Fully encapsulated for tough ambient conditions f Fieldbus interface connections for Sercos, PROFIBUS,

PROFINET and EtherNet/IP f Up to 64 I/O modules/520 channels per station f Up to 50 m gap between two modules,

up to 500 m total length per station f Extended temperature range from –25 °C to +60 °C

The I/O system with protection class IP67 efficiently meets technically sophisticated requirements from all sectors of control-cabinet-free automation engineering and is future-proof. Thanks to the modular design and easy handling, you can react quickly and flexibly to a wide range of challenges.

React quickly and flexibly – anytime and anywhereThe IndraControl S67 provides you with the latest and most powerful I/O system with IP67 on the market: its robust design with high EMC protection enables you to use it in even the most extreme ambient conditions. In conjunction with Sercos, the signal processing takes place cycle-syn-chronously in the system bus. The modular structure enables particularly fast and easy assembly and easy link-age to your system. Commissioning is also performed in an extremely short time. In summary: this is technically and commercially the best solution for a variety of require-ments.

Advantages resulting from special product features f A high-performance and intelligent system bus with

optimized data communication (very fast, cycle-synchro-nous signal processing with Sercos)

f Robust design with IP67 with high EMC protection for use even under the most extreme conditions

f An optimized power supply concept for longer module spacing

f Quick and tool-free installation using M8 and M12 con-nectors and a prefabricated cable

f Diagnostic and status indicators f The new communication and technology modules

expand the options for the signal processing of measur-ing systems and intelligent sensors


32

SERCANS Sercos master module: equipping control units easily with an automation bus

You have never equipped control units as easily as with Sercos, the automation bus: simply plug in the SERCANS card and off you go. The new firmware 03VRS is already fully prepared for a dual master control unit with EtherNet/IP and the Sercos automa-tion bus.

Easy and low-cost implementationThe new SERCANS III module is a simple and low-cost possibility of implementing Sercos in control units. With firmware version 3, Sercos and EtherNet/IP devices can now be easily and conveniently connected to the same Ethernet connector, provided that a soft stack is available for EtherNet/IP. They then provide all of the known advan-tages: very fast axis coupling and I/O communication is ensured by direct cross-communication between the peripheral devices. This not only increases the productivity through faster cycle times, but also the quality. A new wizard ensures easy engineering of the necessary connec-tions.

Advantages resulting from special product features f Very fast axis coupling and I/O communication is

ensured by direct cross-communication between the peripheral devices

f Increased productivity through fast cycle times f Increased quality through precise time synchronization

between the axes f Easy engineering of the necessary connections thanks

to a new wizard f Reduced wiring costs through activation of the safety

functions via CIP Safety on Sercos f Replacement of safe data with comprehensive safety

peripherals for widespread systems via CIP Safety on Sercos

Key technical data f Minimum cycle time of 125 µs f PCI or PCI Express interface available f Up to 128 Sercos devices per card and 512 per PC f Clearly structured memory interface for: cyclic data, system

and diagnostic data, configuration data, HMI and motion control, standard Ethernet data

f SMP protocol for the transmission of non time-critical data f System expansion by a max. of 120 safe peers via

CIP Safety on Sercos per card and 480 per PC

Electric Drives and Controls | Communication

33

IndraControl V Multi-touch:operation and visualization with a modern flair

At last, easier operating of processes, systems and machinery – Rexroth's new multi-touch displays make this possible. New intuitive operation and visualization concepts, as known from smart devices, now gain a new brilliant basis that is optimally matched to tough everyday industrial environments. With high-resolution, anti-reflective wide-screens, robust fronts and a long service life.

Robust, resistant to interference and industry approvedMulti-touch operating is simple, fast and flexible. Thanks to the robust and powerful operator displays the functions that are well known from smartphones and tablet PCs, such as zoom, wipe, move, rotate, etc., can now be used in the industrial environment. The thermally tempered anti-reflective glass front and the metal peripheral edge protec-tion safeguard the device against mechanical damage and protect it effectively against environmental influences.

IndraControl V supports new operation concepts in a multi-tude of applications. The projective capacitive touchscreen detects touch by up to 10 fingers. Display sizes from 7" to 21" for use in portrait or landscape orientation and enclo-sure variants for control cabinet installation or direct sup-port arm installation offer solutions for an extremely wide range of applications.

Advantages resulting from special product features f Multi-touch operating: detects multiple touches simul-

taneously; the optimal basis for intuitive operating concepts well known from the smartphone

f High-resolution widescreens: for brilliant visualizations, better readability and a larger display surface

f Non-reflective glass surfaces with anti-reflective etch-ing: no disturbing reflections, better legibility

f Time saving through easy installation and connection techniques

Key technical data f Robust industry-compliant multi-touch operation displays f 7", 15", 18" and 21" display diagonals f Operation displays for control cabinet PCs for data trans-

mission of up to 100 m f Panel PC as an HMI unit or system platform for control

cabinet installation f Complete operation terminals for direct support arm instal-

lation with protection class IP65

Operation and visualization | Electric Drives and Controls

34 Electric Drives and Controls | Engineering

Open Core Engineering:freedom and efficiency redefined

Open Core Engineering not only accelerates and simplifies your software engineering, it also gives you more freedom and flexibility for the production of tomorrow. State- of-the-art software tools and technology-oriented function packages increase efficiency on the basis of international standards. With the interface technology of Open Core Interface you can connect your PLC-based automation solution to high-level language based applications and the latest IT automation technologies.

Unique flexibility in programmingOpen Core Engineering bundles the engineering portfolio for all software-based and intelligent solutions together with all drive and control technologies. Software tools such as IndraWorks cover the whole engineering workflow, while function toolkits simplify the engineering of complex ma-chine processes and enable the accelerated integration of new and innovative machine functions. In addition the Open Core Interface technology enables direct access to

control and drive functions with high-level language based applications. This enables machine control units to be connected seamlessly to IT automation devices, data and services. Open Core Engineering thus opens up new degrees of freedom in automation and merges the previ-ously separate worlds of PLC and IT automation in an integrated portfolio.

Advantages resulting from special product features f Flexible: a universal engineering framework for all auto-

mation tasks f Efficient: technology-oriented function packages for

reducing complexity f Innovative: the implementation of new solutions by

building a bridge to IT automation f Individual: OEM-specific real-time functions on control

systems f Future-proof: multi-technology solutions with the sup-

port of open standards and interfaces

Software tools These cover all steps in the workflow – project planning, programming, parameterization, commissioning and ser-vice. Consistent open standards are used in all engineering and communication interfaces to safeguard the investment and the integration of future technologies. The focus here is on IndraWorks, the engineering framework: It provides all the basic tools for PLC-based automation, including the homogeneously integrated CoDeSys V3.

35

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Engineering | Electric Drives and Controls

IndraWorks offers integrated operating based on the latest Windows technologies with centralized project manage-ment and wizard-supported project planning of control units, drives and peripherals.

Function toolkitsThese expand the PLC-based engineering by means of function-oriented solution packages, accelerate the imple-mentation of machine processes, optimize project work-flows and enable the integration of advanced machine func-tions.

Examples of system-based function toolkits f Generic Application Template: automated, template-

based creation of machine projects f FlexProfile: A toolbox for the implementation of non-

linear motion profiles f Robot Control: a toolbox for the implementation of

multi-dimensional motion control f SafetyManager: programming of the integrated safety

control system SafeLogic

Examples of system-independent function toolkits f Automation Interface: for accessing project data f Communication: for OPC/OPC UA communication f Team Engineering: links version control systems f Visualization: for designing HMI

Open standardsOpen standards in machine automation are the basis for the flexible integration of software-based solutions into the engineering and system environments of the user and for the migration of new technologies into existing automation structures.

Open Core Interface and its advantagesThe bridge-building between PLC- and IT-based auto-mation expands the impact of your control systems with an innovative interface technology. It gives high-level language based applications on external devices flexible access to all control and drive functions.

f Extensive support of high-level language based engineering platforms

f Independent integration of smart devices for human-machine communication

f Simplified simulation and optimization of machine processes with MATLAB® and LabVIEW®

f Easy linkage of Windows-based applications for IT automation

f Direct integration of real-time functions into the control system (system dependent)

36

Key technical data f Consistent software framework – the uniform engineering

of all Rexroth control systems f PLC and motion logic programming based on CoDeSys V3

with object-orientated language extensions f Comprehensive functions for motion control: point-to-point,

axis interpolation, robot control, CNC, hydraulics f Standardized interfaces for easy integration into the existing

engineering environment: FDT/DTM, automation interface, linkage to version control systems

IndraWorks 13VRS: the universal tool for efficient software engineering

The first consistent engineering tool for motion logicAs part of the range of Open Core Engineering solutions, IndraWorks is the universal engineering framework for automation systems from Bosch Rexroth. It offers central-ized project management as well as all of the tools needed for project planning, programming, commissioning, visual-ization and diagnostics. The basic functions that have been further developed in the new 13VRS system version and the powerful function toolkits provide for fast and efficient implementation of your automation tasks.

Advantages from expansions and function toolkits f Comprehensive basic functions: project planning, para-

meterization, programming, diagnostics, visualization f Intuitive interface based on current Windows technolo-

gies with centralized project management and wizard support

f "Generic Application" function toolkit: automated, tem-plate-based creation of modularized machine software for reusable applications

f Application-related function toolkits: Safety Manager, Robot Control, Hydraulics, Visualization

f Meaningful diagnostics: new oscilloscope toolbox, trace, pre-compile, tool tips, context-sensitive help

IndraWorks is the first engineering framework that has CoDeSys V3 integrated with both market and usage maturity. With IndraWorks, Rexroth is the market leader in the engineering of motion logic applications with comprehensive wizards and powerful solution toolboxes. You therefore save a significant amount of time, money and pro-gramming effort, with increased quality. Especially so with the new system version.

Electric Drives and Controls | Engineering

37

HMI Toolbox WinStudio: the engineering tool for multi-touch applications

For easy single-touch applications through to individual gesture controls – from now on user interfaces can be made more intuitive, clearer and safer. A universal toolbox from Rexroth for all HMI targets: you can now project plan easily and uniformly without any additional cost. When it is integrated into the "Visualization" function toolkit, engineering becomes an exciting exercise in breaking new ground.

Uniform project planning – from a simple compact operation panel to an industrial PCThe multi-touch technology in WinStudio now enables easy implementation of new visualization and operation con-cepts, for example, two-handed operation or intuitive image navigation via gesture control. Functions such as zooming in on trend graphs and scrolling through alarm and event lists are available without any additional project planning effort. Other multi-touch functions can be easily config-ured. Extensive interfaces for the programming of individ-ual multi-touch gestures are available via operating system events. You thus obtain a flexible tool for the consistent project planning of all Rexroth HMI devices, which makes state-of-the-art operator interfaces implementable.

Advantages resulting from special product features f Innovative Editor: a tool for all HMI target and uniform

project planning f Multi-touch runtime support: state-of-the-art user inter-

faces with gesture control become implementable f Product data management: all data are available in an

IndraWorks project, including linked graphic objects f Extensive programming interfaces for touch events: for

versatile application of the new multi-touch technology

Key technical data f WinStudio for multi-touch operating is a component part of

the IndraWorks engineering framework f IndraWorks 13VRS supports development of the new multi-

touch panels by means of HMI templates in 16:9 format f Intuitive support for all Rexroth multi-touch devices running

Windows 7® embedded standard operating systems f Multi-touch function available in all license forms, even in the

WinStudio Lite license

Operation and visualization | Electric Drives and Controls

38

Key technical data f Input of the linear motion system's mechanical data f Optional input of the maintenance period of the linear

motion system f Setting the absolute dimension f Setting the limit values f Opening of Easy Startup mode

EasyWizard software engineering: ready to start in three minutes

Fast, easy and reliable startupNever before were the IndraDrive Cs compact drives able to be put into operation faster, yet safely. The commission-ing time has been reduced from the previous time of 90 minutes to around 3 minutes. The linear motion system data can now be entered easily and intuitively; it is even possible to read in the mechanical data using QR codes. A type plate matched to the wizard on the linear motion systems makes commissioning easier than ever before.

Advantages resulting from special product features f Simple, fast and intuitive commissioning of drives f An extremely short commissioning time of around three

minutes is possible f Reading in of mechanical data also using QR codes f Text-based and graphical online help for individual input

fields f Incorrect parameterization is minimized by homoge-

neous arrangement of data on the type plate and the wizard input screen

f Plausibility check during free data input f Suitable for all linear motion systems from Rexroth –

and now also available for linear motion systems from other manufacturers

f For system optimization, the axes can be run in test mode after parameterization has been completed

f Besides IndraWorks DS, now also available in the Indra-Works versions of the IndraLogic XLC, IndraMotion MLD 13VRS and IndraMotion MLC 13VRS control systems

EasyWizard is a new, extremely fast commissioning assistant within the IndraWorks VR13 engineering framework. It guarantees easy and error-free commissioning of the drive controllers in conjunction with linear motion systems from the EasyHandling modular system.

Electric Drives and Controls | Engineering

39

IndraDrive Mi: the most flexible cabinet-free drive system

An all-rounder with integrated safety technologyThe new IndraDrive Mi, with its many new and advanced features, gives you all-round flexibility: its multi-protocol capability makes it universally usable with all products from the leading control system manufacturers. The inte-grated motion logic combines drive, motion control and processing logic, so that you can carry out complex motion sequences purely on the drive level, without a host control system.

The integrated safety technology creates effective protec-tion for man and machine without additional open-loop control: certified in accordance with EN ISO 13849-1 for Safe Torque Off and Safe Motion, it saves on hardware and reduces the wiring costs.

Advantages resulting from special product features f Multi-protocol capability: compatible with all relevant

Ethernet protocols and therefore all commonly used control products

f Integrated safety technology: for optimum protection without additional open-loop control (certified in accor-dance with EN ISO 13849-1; Safe Torque Off and Safe Motion)

f Integrated motion logic: for the implementation of complex motion sequences without a host control system

f Energy-efficient power supply

The new IndraDrive Mi generation can be adapted to individual conditions unlike virtually any other decentralized drive system. This makes it ideally suited for use in all modular machines – for maximum flexibility in the smallest of spaces.

Key technical data f Up to 20 drives on a hybrid cable of up to 200 m in length f Multi-Ethernet – Sercos, EtherNet/IP, PROFINET, EtherCat f Safety technology – Safe Torque Off and Safe Motion f Integrated motion logic according to IEC 61131-3 f Integration of machinery by uncoupling the control commu-

nication

Drives | Electric Drives and Controls

40

IndraDrive M, 300 A inverter: a compact peak load drive

The compact, modular inverter with a maximum current of 300 A is made for typical servo applications with high peak loads: Due to its high overload ratio you can use it ideally in injection molding machines, punch operations, on infeed axes, and more. Extensive hardware and software options are based on the IndraDrive M series.

For dynamic applications with high power densityThe new 300 A inverter extends the IndraDrive M modular drive series for the peak load range. With outstanding power density, it still remains compact, which saves space in the control cabinet. As with the IndraDrive M series, it provides impressive extensive hardware options, multi-encoder interfaces and multi-Ethernet interfaces. And of course the Safety on Board technology and the IndraMotion MLD 13VRS motion logic are also integrated. Way ahead of the field.

Advantages resulting from special product features f High power density: the compact design saves control

cabinet space f Extensive hardware options through the modular design f Multi-encoder interface and multi-Ethernet interface for

easy activation f Future-proof: integrated Safety on Board and

IndraMotion MLD 13VRS motion logic

Key technical data f Maximum current: 300 A f Continuous current: 150 A f Supply voltage: DC 254-750 V f Type of cooling: air cooling

Electric Drives and Controls | Drives

41

IndraDrive ML large drive: the megawatt-sized universal inverter

The new IndraDrive ML extends the IndraDrive series into the upper power range: individually up to 500 kW, connected in parallel up to 8 devices and up to 4 MW. These space-saving, modular inverters are real all-rounders – they can be used as a mains power inverter or as a motor inverter. This minimizes the variants, simplifies handling and reduces your storage costs. And you save energy at the same time.

Modular, compact and energy-savingThese modular universal inverters are predestined for all kinds of multi-axis applications. They are powerful, flexible drives for the megawatt range. Universally usable for stan-dard and servo applications, with extensive additional options for perfect energy-saving adaptation to a wide range of applications. And with everything that characterizes the proven IndraDrive series – from certified Safety on Board, to drive-integrated motion logic solutions, multi-encoder interfaces and multi-Ethernet communication. Simply universal.

Advantages resulting from special product features f Modular universal inverters for multi-axis applications:

minimize type diversity, simplify handling, reduce storage costs

f Application-optimized concepts for energy saving: flexibly adapted to each application, they save energy and reduce network load

f High power density: the compact design saves space in the cabinet

f Small coolant volume at a high coolant temperature: enables the use of a compact heat exchanger and effi-cient heat recovery

Key technical data f Device settings from 110 kW to 500 kW in 8 graduations f System output of up to 4 MW by means of parallel connec-

tion f Supply voltage: 3 AC 380‒500 V/50‒60 Hz/TN, TT and

IT network f Types of cooling: liquid cooling, air cooling f 1.5-fold overload for 60 s

Servo drives | Electric Drives and Controls

42

IndraDrive HMV drives with Smart Energy Mode: the intelligent supply device

Electric Drives and Controls | Drives

Proof of what difference an intelligent energy management system makes and how much you can save by using it is the new IndraDrive HMV. Theses smart supply devices are optimal wherever rapid acceleration and braking are required. For example, in punching and nibbling machines or crosscutters. Get the same machine performance-with a considerable reduction in energy consumption.

Modular, cleverly controlled and highly energy efficientModular supply devices with Smart Energy Mode combine backfeeding and infeeding supplier principles in one device. There are many advantages. The energy remains in the system thanks to intelligent energy management with inter-mediate storage – ideal, especially for rapid acceleration and braking cycles. By reducing peaks in power consump-tion, network access components can frequently be smaller, which saves energy and installation costs and also reduces power loss in the cabinet (less cooling necessary). Reduc-tion of the pulse load of the network ensures uniform flow, which also reduces the costs at high power peaks. Simply smart.

Advantages resulting from special product features f Reduced power consumption: smaller components with

reduced consumption save on energy and installation costs

f Reduced power loss in the cabinet: smaller, lower-cost components require less cooling

f Reduction of the pulse load on the network: for uniform energy flow, reducing the cost of provision for high power peaks

Key technical data f Power range: from 15 kW to 120 kW in 5 graduations f Supply voltage: 3 AC 380‒480 V/50‒60 Hz/TN, TT network f Type of cooling: air cooling

43

Key technical data f Expanded power range of up to 22 kW f V/f control (EFC 3610) or vector control (EFC 5610) f 1 AC (220 V, 0.4 to 2.2 kW), 3 AC (400 V, 0.4 to 4 kW) f High overload capability: 200 % for 1 s, 150 % for 60 s f 50 °C ambient temperature without derating f Motor temperature monitoring (NTC/PTC) f Fan can be replaced without tools (devices up to 0.75 kW

have no fan) f Integrated brake chopper and mains filter (EN 61800-3 C3)

EFC 3610/5610 frequency converters:universally deployable, for perfect integration

Saves time and space – and adds more qualityEfficient speed control forms the basis of energy savings and low CO2 emissions; these further improved frequency converters have therefore been packed with intelligent features that do justice to all engineering and usability requirements. Compact, with practical side-by-side instal-lation, pluggable I/O connecting terminals, clever optional modules and the absence of external components, they make installation and space-saving extremely easy. Opti-mum handling is ensured not only by the removable oper-ating unit with memory function for fast parameter trans-fer, but also by the use of harmonized parameters across the entire series – this saves time, improves quality and facilitates series commissioning.

Advantages resulting from special product features f Compact and complete: space-saving side-by-side

assembly, pluggable I/O connecting terminals, brake chopper and mains filter integrated – for extremely easy installation and integration

f Simply practical: removable operator control unit with memory function, convenient LED display, easy para-meter input, harmonized parameters across the entire series – for fast, reliable series commissioning

f Extremely flexible: optionally with U/f control or vector control, optional additional interfaces for I/O or field buses – for universal use and easy function expansion

This new frequency converter series can be used universally in a wide range of applica-tions thanks to their randomly definable V/f characteristic curve or alternatively vector-controlled operation, scalable option modules, compact design, integrated brake chop-per and mains filter. They are particularly easy to install, without any additional peripheral devices.

Drives | Electric Drives and Controls

44

MSK133 synchronous servo motor: more power and more efficiency, continuously

The new MSK133 is perfectly optimized for high continuous power: Thanks to its special design principle, the continuous torque can be increased significantly – by an increased power of up to 15 % more than conventional synchronous servo motors. Ideal as a main drive in production machinery and servo pumps, where extremely high power density and the best possible efficiency are required on a constant basis.

Up to 15 % more continuous power than conventional synchronous motorsThe MSK133 extends the MSK series by a synchronous servo motor that has been specially optimized for high continuous power. Thanks to a specific rotor design and con-trol process in the IndraDrive, the continuous torque can be significantly increased and achieves an approximate 10 to 15 % higher power than conventional synchronous servo motors. At an axis height of 130 mm, continuous powers of up to 67 kW with air cooling or 79 kW with liquid cooling are therefore possible. And all this with protection class IP65. The MSK133 is therefore suitable for applications as the main drive in production machinery or servo pumps. As an option Rexroth also offers a version with a directly mounted internal gear pump – thus making available a very compact unit without a clutch.

Advantages resulting from special product features f High power density: due to which, a small installation

space, less space required f Liquid cooling with stainless steel: to prevent corrosion

and provide a low-cost cooling circuit f Synchronous servo motor with permanent magnets:

high efficiency, low energy costs

Key technical data f Continuous standstill torque of 152 to 342 Nm f Maximum torques of 300 to 631 Nm f Continuous power of up to 67 kW with air cooling and 79 kW

with liquid cooling f Liquid cooling with stainless steel f 2 encoder performance levels in single- and multi-turn

versions f Optional version for pump extension available (MPA01)

Electric Drives and Controls | Motors

45

IndraDyn MSM synchronous servo motor: Small, strong and with an M17 connector

The new compact MSM servo motors are highly dynamic and perfectly matched to the IndraDrive Cs compact drives. Five types with a continuous power of 50 to 750 W are available. With higher power density, a short overall length and minimized flange dimen-sions they can be used flexibly in a wide range of applications.

Perfect for IndraDrive Cs compact drivesFor the new MSM motor generation the connection tech-nology has been standardized via M17 connectors and the encoder resolution further improved (20-bit encoder). The MSM maintenance-free servo motors are available in 5 types and with a continuous power of 50 to 750 watts. The high power density with a short overall length and minimized flange dimensions give you maximum flexibility to use in a wide range of applications. The motors with protection class IP54 are equipped with an absolute encoder and are optionally available with or without a holding brake. They are intended for operation on IndraDrive Cs drive units with 3 AC 230 V mains connection.

Advantages resulting from special product features f M17 connection technology: M17 standard metal con-

nector for a short installation length, smaller space requirement and standardized connection cable

f 20-bit encoder: now with a higher resolution and higher precision

f High power density: for efficient use in a wide range of applications

Key technical data f Maximum torques of up to 7.1 Nm f Maximum speeds of up to 5,000 rpm f Continuous power of 50 to 750 W f New: optical multi-turn 20-bit absolute encoder f New: compact M17 connection technology

Motors | Electric Drives and Controls

46

Nexo cordless Wi-Fi nutrunner:the smartest manual nutrunner in the world

Electric Drives and Controls | Tightening technology

Really clever: on the Nexo the complete control unit is actually in the nutrunner – the first like it in the world. High-quality measuring electronics for the evaluation of torque and angle of rotation have been integrated directly into the device and can be incorpo-rated without any additional hardware into your network. And all of this without cords – it couldn't be any easier or more cost efficient.

Large display, best resultsRexroth is now putting the intelligence required for sophis-ticated tightening operations directly in your hands – and cordlessly! The Nexo makes do without an external control unit because the complete control unit is on the tool. It can communicate directly with your servers, because its browser-based operation system is suitable for any OS plat-form. This saves costs. A precision transducer ensures the most accurate of results, practically displaying its Nm values directly onto the large display, keeping your machine operators in the picture at all times.

Advantages resulting from special product features f Complete control unit on the nutrunner: no additional

hardware, lower costs f Large display: operator-proximate information in view at

all times f High-precision measuring system: for high-precision

torque and angle of rotation acquisition

Key technical data f Rotational speeds of up to 1,500 rpm f Torque of up to 50 Nm in the output expansion stage f Acquisition of torque and angle of rotation possible f 2.4 and 5 GHz Wi-Fi f Integrated screw point lighting f Suitable for class A tightening connections in accordance

with VDI/VDE2862

47

The PSI 64CO aluminum welding control unit – a world premiere: welding aluminum like steel

With this worldwide unique system solution from Rexroth, for the first time automotive manufacturers are now able to weld aluminum in body shop process reliably and at the cost level of steel. The welding process can be fully monitored and controlled. The result: high weld quality and an extremely high degree of economy.

Welding technology | Electric Drives and Controls

Optimum welding results: fully monitored and controlledThe specialists at Bosch Rexroth developed the PSI 64CO adaptive welding inverter specifically for aluminum appli-cations: it takes into consideration not only the physical properties of the material, but for the first time enables complete monitoring and control of the welding procedure during the process. This reduces the inspection work and significantly increases the cost effectiveness of aluminum welding. You can also define the welding quality according to your requirements and refine it in small steps as neces-sary; the PSI 64CO reliably ensures process stability. So you always obtain optimal welding results. With optimal cost effectiveness.

Advantages resulting from special product features f Complete monitoring and control of the welding proce-

dure: less inspection work, high cost effectiveness f Comprehensive control and regulation functions for an

extremely high degree of process stability: they allow the definition of and dependable compliance with the customized welding quality

f Numerous diagnostic functions: the welding quality can be refined in extremely small steps as necessary

Key technical data f Supply voltage range: 400 to 480 V f Mains rated current (max. continuous thermal current):

220 A f Maximum primary current: 1,600 A f Maximum secondary current: 60 kA f Required connection cross-section: 95 mm²

48 Linear Motion Technology | Product innovations

Products innovations in Linear Motion Technology: work more precisely, more powerfully and more efficientlyMeasuring positions contactlessly, moving heavy loads with high precision and config-uring components quickly and easily online. When it comes to Linear Motion Technology Bosch Rexroth can provide proof of its know-how of processes and practical require-ments in a wide range of applications, industries and markets.

49Ball rail and roller rail systems | Linear Motion Technology

Key technical data f Signal period: 40 µm (1 Vss) f Indexing accuracy: ± 3 µm/m f Ball rail system: sizes 20/25/30/35/45 f Roller rail system: sizes 35/45/55 f Rail lengths: up to 4,500 mm in one piece

IMS-I integrated measuring system: high-precision guidance and measurement

Inductive measuring with a 40 µm signal periodThe IMS-I provides you with a precision instrument that guarantees excellent workpiece quality through accurate position measuring. Thanks to the inductive, contactless measuring principle, the system functions wear-free, which reduces your downtimes. In addition, it is particularly compact thanks to the integration of the systems, which saves installation space.

Advantages resulting from special product features f High system accuracy f Inductive, contactless measuring principle f Measuring function integrated into the guideway f Resistant to contamination without any additional mea-

sures

This integrated measuring system combines ball rail and roller rail systems with an incre-mental length measuring system in our new IMS-I product. The system accuracy of this inductive measuring system is comparable to high-precision glass scales and is therefore ideally suited for use in external measuring systems on machine tools.

50

RSHP roller rail system high precision:never before have heavy loads been moved so precisely

Linear Motion Technology | Ball rail and roller rail systems

High-performance machine tools also require a high-performance rail guide: Extremely heavy loads can be moved with unequaled care and precision using the latest genera-tion of roller rail systems with their patented rolling element run-in. This offers best machining results and optimal surface quality.

The patented rolling element run-in ensures a high-preci-sion effectWith the new RSHP roller rail system generation, Rexroth has expanded its range with a high-precision guide rail and a guide carriage that permits optimal quality due to its particularly quiet running behavior. The patented rolling element run-in provides for the high-precision effect: the run-in zone is optimized and adapted to the load. This allows you to achieve the best results and an unmatched surface quality in the machining process. With the RSHP you also profit from an optimized lubrication channel, which allows longer service intervals, and from a simpler type selection with 67 % fewer variants.

Advantages resulting from special product features f Patented rolling element run-in with a high-precision

effect f Optimized lubrication channel for minimum oil con-

sumption and longer service intervals f 67 % fewer guide carriage variants: for faster and simpler

type selection and reduced inventory f Extreme rigidity and durability: with significantly higher

static and dynamic load ratings

Key technical data f Load ratings: 30,300 N to 295,900 N f Maximum speed: 4.0 m/s f Maximum acceleration: 150 m/s² f Lubrication: oil/grease f Ambient temperature range: –10 °C to +80 °C

51Ball rail and roller rail systems | Linear Motion Technology

BSHP ball rail system high precision:with an innovative run-in specific to the operating load

The high-precision technology of the new BSHP ball rail systems offers many benefits: the run-in zone adapts individually to the respective operating load of the ball carriage, which ensures optimum running accuracy, extremely low frictional fluctuations, the latter providing in turn significant quality improvements. And the best thing is: the BSHP is available for all sizes, versions and classes of accuracy, which increases the dynamic load ratings and doubles the service life.

HP technology in all classesThe new BSHP ball rail systems with HP technology have an innovative run-in zone that significantly increases the quality: the steel inlays are not supported in the end zone by the ball carriage and can therefore be elastically de-formed. The run-in zone adapts itself individually to the current operating load of the ball carriage. As a result the balls run harmoniously without any impulse load into the support zone. The result: very high running accuracy, very low frictional fluctuations and thus optimal machining results. The increased load ratings (26 % better dynamic and up to 50 % better static ratings) are at your disposal across all classes with the BSHP.

Advantages resulting from special product features f High-precision technology across all sizes and precision

classes: 26 % better dynamic and up to 50 % better static load ratings all-around

f Downsizing possible: through improved load ratings f Significant quality improvement: extremely high running

accuracy, better processing results, higher surface quality

f Optimal rigidity and robustness: double the service life f The material number is retained: no EDP costs

Key technical data f Dynamic load ratings: 3,900 N to 223,000 N f Maximum speed: 3‒10 m/s f Maximum acceleration: 250‒500 m/s² f Lubrication: oil/grease f Ambient temperature range: 0 °C to +80 °C

52

Key technical data f Principle: synchronization of the planets f Diameter: 15‒99 mm f Pitch: 5/10 or 10/20 mm depending on the diameter f Accuracy: T5, T7, T9 in accordance with ISO 3408 f Load ratings: up to C = 900 kN (dynamic),

up to C0 = 3,000 kN (static) f Lengths: up to 5,000 mm f D x n-value: 150,000 f As a rule, interchangeability with competitors is ensured

PLSA planetary screw assembly:high traversing speed, high bearing load, low costs

Compact, robust, economicalRexroth uses its experience-based lead gained from cost-efficient roller processes in the production of spindles; the planetary screw assemblies can consequently be supplied with the same output but at a lower price than the compe-tition. A higher load-bearing capacity than that of ball screw assemblies can be achieved in the same installation space. The numerous large contact surfaces also ensure a high level of rigidity, long service life and a high level of effi-ciency. And because there is no feedback and no contact between the planets, significantly higher movement speeds can be achieved.

Advantages resulting from special product features f High load-bearing capacity and rigidity thanks to the

numerous large contact surfaces f Small installation space due to the increased power

density f Quiet operation due to the guided planets f Different nut types available f Reduced lubricant consumption due to effective seals f An economic solution thanks to the rolled spindle

With the newly developed planetary screw assemblies, Rexroth has expanded the range of electromechanical applications with the fast traversing of heavy loads – all this with the same performance data and an unrivaled price-performance ratio.

Linear Motion Technology | Linear screw assemblies

53

Ball screw assembly, Asian series: proven in DIN, adapted in JIS

Linear screw assemblies | Linear Motion Technology

Different markets, different standards: Bosch Rexroth has expanded its range by the addition of ball screw assemblies with nuts with JIS dimensions so that you can also successfully serve the Asian market.

For faster success in AsiaThe proven ball screw assemblies with DIN dimensions now have Asian brothers, enabling easy and fast access to the Asian market. With all the advantages of the DIN series and special specifications: larger outer diameters and flange diameters, 2 nut designs (FEM, FDM), suitable spindle ends for Asian bearings and corresponding pedestal bear-ing housings. Existing components can be easily replaced.

Advantages resulting from special product features f JIS dimensions: for easier access to the Asian market f Direct replacement of existing components possible f Larger outer diameters and flange diameters, but the

same internal geometry f 2 nut designs (FEM, FDM) available f Spindle ends suitable for Asian bearings f Pedestal bearing housing in accordance with the Asian

series

Key technical data f D x n-value: 150,000 f Dynamic load rating is the same as the standard ball screw

assembly f External geometry in accordance with the Japanese stan-

dard (JIS)

54 Linear Motion Technology | Cylinders

EMC-HD electromechanical cylinder – heavy duty: energy-efficient solution for heavy load applications

The robust complete modular systemThe new electromechanical cylinders were created to provide long service life under harsh conditions: a high IP degree of protection and a high level of corrosion protec-tion are achieved with perfect sealing. The precision-rolled linear screw assemblies position accurately and powerfully, while featuring a high level of cost effectiveness, low oper-ating costs and high energy efficiency. The configurable servo drive can be freely programmed, and process param-eters can be changed easily – you can therefore also carry out complex processes accurately and adapt them at any time.

Advantages resulting from special product features f High energy efficiency and low environmental impact f No leakages f A simple, robust design for a long service life, even in

tough environments f A complete modular system and great variability for high

application flexibility f Exact positioning, high dynamics, powerful drive and

long service life through the use of high-precision linear screw drives

f Optional connection to a central lubrication system reduces downtime and saves time and money

f Low design and installation costs as the complete sys-tem is ready to install and turn on

f An intelligent drive system for free programmability and the implementation of complex traversing profiles

This robust electromechanical cylinder was developed for use in heavy load applica-tions. Designed as a completely modular system with an integrated planetary or re- circulating ball screw assembly, it is designed for cost-efficient work, even under tough conditions.

Key technical data f Basic dynamic load rating (Cdyn): 50 to 470 kN f Axial force: up to 290 kN (tension/compression) f Maximum traversing speed: 1 m/s f Stroke: up to 1,700 mm f Protection class: IP65

55

EMC electromechanical cylinder: compact, precise and more flexible

Cylinders | Linear Motion Technology

In the new EMC electromechanical cylinder you will notice the high system competence of Rexroth in every detail, thanks to the resolute integration of our proven proprietary technologies. The result is an actuator whose external geometry and mode of operation is equivalent to a pneumatic cylinder, which, however, is much more energy efficient and flexible. In many industries this makes it more than just an alternative to fluid power systems.

Complete system: hygienic design, variable, preciseIts high degree of variability is what makes the new EMC so interesting for many industries and applications. A low-cost simple basic cylinder can be adapted by means of count-less options to meet practically any customer requirement. Hygienic design, with a high degree of chemical resistance, perfect sealing and a high IP degree of protection. The available options provide for a long service life even when operated in demanding industrial environments. The pow-erful EMC works extremely efficiently and economically at all times.

Advantages resulting from special product features f Hygienic design: high resistance to chemicals and clean-

ing agents f Good sealing: degree of protection IP65, seal tight

against dirt and water from the outside and lubricant discharge from the cylinder

f Optimized lubrication concept: optional connection to a central lubrication system reduces downtime and saves time and money

f High-precision ball screw assemblies Asian series: for high performance with maximum cost effectiveness

f A complete modular system with a high degree of vari-ability: optimally adaptable to customer applications

f A complete system that is ready to install and turn on: low design and installation costs

f An intelligent drive system for free programmability and the implementation of complex traversing profiles

Key technical data f Basic dynamic load rating (Cdyn): 2.5 to 93 kN f Axial force: up to 55 kN (tension/compression) f Maximum traversing speed: 1.6 m/s f Stroke: up to 1,500 mm f Protection class: IP54, optionally IP65

56

CKL – compact module with ironless linear motor: ready to install and highly dynamic

Linear Motion Technology | Drives

The CKL compact module is the perfect linear motor axis for highly dynamic and preci-sion applications with small- to medium-sized workpiece weights. Utilize the benefits of this ready-to-install and compact solution and save significantly on engineering costs.

High dynamics for small- to medium-sized workpiecesWith the integrated functions of the ironless linear motor, the dual guide system and an optical measurement system, the new CKL compact module offers a compact, ready-to-install solution. For extremely high requirements of dynam-ics and precision.

The CKL is easy to configure and commissioning (optionally with the Rexroth startup wizard), which makes it ready for use in an extremely short time.

Advantages resulting from special product features f Simple: ready to install, compact design f Fast: high speeds and acceleration f Precise: high repetitive accuracy, very smooth running

properties f Configurable: numerous options available f Commissioning: simple, with the "EasyWizard" commis-

sioning wizard f Low maintenance: due to absence of mechanical drive

elements f High load capacity: due to the guidance via two parallel-

arranged rails and four guide carriages f High level of integrity: a mechatronic product with an

integrated linear guide, measuring system and linear motor

Key technical data f Traversing speed: up to 5 m/s f Acceleration: up to 100 m/s² f Repetitive accuracy: up to 1 µm f Stroke: up to 5,000 mm

57

EasyHandling basic motor mounting configurator: plan your mounting kits online

Configurators | Linear Motion Technology

Bosch Rexroth presents the first online configurator for customized motor mounting: you can now design your specific solution quickly and easily 24 hours a day, seven days a week. Select the mounting kit for the axis configuration that fits your motor. It saves time and money.

Configured easily, delivered quicklyOnce again Bosch Rexroth is a step ahead: With the new online configurator, ordering motor mounting kits for cus-tomer motors is now so quick and easy that it is unrivaled. The way that it is practically integrated into the Rexroth e-shop means that you can actually select the right mount-ing kit for a variety of popular servo motors during the online configuration of the linear axis. You are guided via image control through the configuration process to your specific solution. 2D and 3D data are available to download in all popular formats. Just go online. At any time. It couldn't be easier.

Advantages resulting from special product features f Quick and easy design using image-controlled configu-

ration f Configurator integrated into the e-shop f Ordering available 24 hours a day, seven days a week f 2D and 3D data available to download in all common

formats f Available online anytime and anywhere

Key technical data f Motor mounting kits for over 150 different series/types of

customer motor f Mounting kits complete with flange, clutch and belt gear f No reduction in the performance specifications of the linear

axes

58 Linear Motion Technology | Configurators

EasyHandling basic connec-tion technique selector: online for the right assembly

350 standard assemblies for over 2,000 connection options – it can seem complex, but never before has selecting connection elements been so quick and easy. Access all available standard connections of linear motion systems, gripping systems and rotary modules quickly with the aid of graphics. Reduce your design and project planning costs with just a few clicks, including ordering in our e-shop.

Freely combinable from 350 standard assembliesWith the new online selector the construction and project planning of handling systems have now become even more efficient and convenient. Rexroth has further simplified the task with the EasyHandling modular system: via a graphical, intuitive interface with variable combination options you are guided with just a few clicks to a results page with all the connection-technique-related information, such as material numbers, 3D CAD models, load data, installation instructions and documentation. Simply select the element and order it direct via the e-shop – and that’s it. The 3D CAD data provided can also be integrated immediately into your applications, which reduces your design costs.

Advantages resulting from special product features f Quick and easy design and project planning thanks to

the image-controlled selection procedure: reduces costs and possibility of errors

f Standard assemblies: ensure high availability, lower design costs and fast procurement

f Direct ordering in our e-shop at any time, round the clock

f 3D CAD models can be directly integrated into custom-ers' applications: saves time and money

f All necessary information is provided: clearly and com-prehensively

Key technical data f Contains connection elements from approx. 350 standard

assemblies for over 2,000 connection options f Product combinations of linear motion systems, gripping

systems and rotary modules f E-shop linkage f All connection elements available as standard for

EasyHandling

59Product innovations | Assembly Technology

Product innovations in Assembly Technology: move parts ergonomically, powerfully and future-proofWhether it is question of box-lifting devices providing ergonomical parts, market- leading transfer systems fetching extremely heavy workpieces or motors already meet-ing the energy efficiency classes of tomorrow – Bosch Rexroth is just as innovative in assembly technology as it is in other sectors. Benefit from our process know-how. And from our solutions, well thought-through right down to the last detail.

60 Assembly Technology | Ergonomics

Electric case lifter:this is where ergonomics come into play

Rexroth thinks things through right down to the finest detail when it comes to the opti-mal ergonomic provision of materials at the workplace case in point: these compact and mobile case lifters quickly and easily allow short gripping paths and noticeably relieve personnel of arduous work. Ideal for heavy loads. This is not only conducive to health and motivation, but also to production: According to MTM, up to 68 % can be saved on the time required for the provision of parts and the discharge conveyance.

Parts are under control more quickly, health of personnel is protected and output is increasedBosch Rexroth is constantly involved in the development of optimized workplaces in accordance with the rules of ergonomics and Methods Time Measurement (MTM). Compact, mobile case lifters are the latest development from the ideas factory: cost-optimized standard solutions that enable short gripping paths so that parts arrive quickly and simply into the correct gripping area by means of small load car-riers (SLCs) on floor rollers. This not only improves the ergonomics and protects personnel, it also significantly increases productivity.

Advantages resulting from special product features f The ergonomic provision of parts: promotes health and

motivation of employees f Cost optimized standard solution: ESD as standard,

simple electrical connection via GST connectors, easy changeover possible

f Maximum user friendliness: time saving of up to 68 % for provision of parts and discharge conveyance (in accordance with MTM)

f A compact, mobile design that is modular system com-patible: installation also possible under the transfer system for complete flexibility

Key technical data f Permissible load Fmax: 2,200 N f Lifting speed: 25 mm/s f Stroke: 500 mm or 900 mm f Connection: 230 V~/16 A max. f Protection class: IP40 IEC 529

61

VarioFlow plus chain conveyor: the modular system for quick assembly and quiet operation

Transfer systems | Assembly Technology

Easy to configure, three-dimensional, modular, fast and error-free assembly, quiet and economical in operation – if you could wish for a conveying system, this is what it would sound like. Rexroth has implemented all of this in the new VarioFlow plus generation. A flexible modular system for a wide range of applications in a wide range of industries. What more could you want?

Ingeniously simple to configure and economical to operateWhether as an interlinking system on assembly lines, in the food and packaging industry or in the interlinking of ma-chine tools, the new VarioFlow plus generation is impres-sive in a wide variety of applications due to its extremely fast assembly and its exceptionally economical and quiet operation. The modular building block concept and techni-cal details, such as its rivetless assembly and the optimized gliding properties, are what make this conveying system so practical to use and universally deployable. Off you go with your project planning: layout planning is ingeniously simple with MTpro.

Advantages resulting from special product features f Extremely easy project planning: thanks to the modular

building block concept and MTpro Layout Designer f Rivetless assembly of the glide rail for fast, error-free

construction and low-noise, maintenance-free operation f Low friction: for long conveying segments per drive, low

wear, low costs f Ingenious and simple system of compatible modules,

chains, and common spare parts offers flexibility with-out adding complexity

f Width and chain options to optimally match the trans-port need

Key technical data f Six chain widths of between 65 and 320 mm f Optionally available as aluminum or stainless steel versions

in all widths f FDA-compliant materials f Conveying speed of up to 60 m/min and in special cases

up to 100 m/min f Seven types of chain

62

Transfer system TS 2plus: wider, better and able to withstand greater loads

Proven thousands of times in practice, the leading transfer system on the market has now become even more efficient: TS 2plus now handles workpieces of up to 240 kg. Supplemented with new lifting-traversing and rotating units and track widths of 160 to 1,200 mm, it is the most comprehensive modular system offered. You will find an opti-mal economic solution for any application in this system.

An extremely wide system of building blocks with all optionsYou do not become a market leader by chance, but with better ideas. The conveying specialists at Bosch Rexroth have therefore packed even more practical features into the TS 2plus transfer system. The extended load range of up to 240 kg is particularly crucial for many industries. For other industries the universally used conductive compo-nents are decisive for safe use in EPA environments and suitability for clean rooms and dry rooms. The large range of track widths is available for all of them, though. And with MTpro the TS 2plus can be configured with unrivaled ease. A modular system that has it all: lots of good ideas.

Advantages resulting from special product features f 5 transfer media: enable an optimal solution and highly

effective overall system for any application f A wide, modular system of building blocks: for a wide

breadth of applications in a broad range of industries f Suitable for clean rooms and dry rooms: reliable even in

more challenging conditions (medical engineering, optical systems, battery production, and more)

Key technical data f Track width: 160 to 1,200 mm f Overall workpiece mass: up to 240 kg f Conveying speed: 6/9/12/15 or 18 m/min f Accumulation load: up to 2,200 kg per drive f Line load: up to 200 kg/m accumulated

Assembly Technology | Transfer systems

63

Energy efficient motors in all transfer systems: the efficiency class of the future

Transfer system | Assembly Technology

Drives with an extremely high degree of efficiency play a crucial role in the energy- efficieny of a system. Bosch Rexroth is now supplying transfer systems with motors that already meet the requirements of the future – for more economical and environ-mentally-friendly operations.

Help save energy, help the environmentWhat is required to be formulated in a complicated way in certificates and draft standards is implemented simply by the new 4EE motors: whether for efficiency class IE3 or certifications in accordance with CE, cURus or CCC, the new motor generation can be used internationally, not only for precision transfer, but also for cost and energy savings. With energy savings of approximately 15 % in comparison to the current industry standard and short amortization periods of 2 years at the maximum. With technical refine-ments such as start-stop operation, which saves even more energy. And with considerable responsibility for the envi-ronment.

Advantages resulting from special product features f The highest efficiency class IE3: an energy saving of

about 15 % in comparison to the industry standard, pays you back after 2 years at the maximum

f Start-stop operation: the transfer segment runs only when required, saving more energy

f Certified in accordance with CE, cURus and CCC: for international use in all major industrial countries

Key technical data f The degree of efficiency corresponds to class IE3

in accordance with IEC 60034-30 draft 2013-01 f Power class 0.09 kW to 0.75 kW (50 Hz) f Continuous operation S1 and start-stop mode

(S3, 70 % duty cycle) possible f Mains operation on 50 Hz and 60 Hz

64 Multi-technology | Product innovations

Sytronix variable-speed pump drives: provide energy savings of up to 80 % and are up to 20 dB(A) quieterSytronix, a combination of robust hydraulics and efficient electronics, is the intelligent answer to rising energy prices, cost pressure and stringent environmental requirements. In comparison to classic hydraulic concepts, with Sytronix you can control the speed of pump drives according to hydraulic energy demand via intelligent drive electronics with the latest firmware and software. The Sytronix portfolio offers you a finely scaled range of preconfigured sets consisting of a motor-pump assembly, an inverter with the firm-ware and software optimized for your application and accessories.

65Variable-speed pump drives | Multi-technology

Key technical data f Power rating up to 90 kW (higher on request) f MOT-FC motors with NEMA and IEC approvals f Use in constant pressure systems f For closed hydraulic systems f Single-quadrant operation f Motor-pump assemblies (MPE) can also be ordered separately f Ethernet-based communication (Sercos, EtherCAT,

PROFINET/IO, EtherNet/IP) and fieldbuses (PROFIBUS, CANopen, DeviceNet)

Sytronix FcP 5010/7010: low-cost complete sets of up to 90 kW

Basic performance, full efficiency – ideal for constant pressure systemsThrough the use of the new Rexroth Fv inverter series (on FcP 5010), the FcP series now serves an extended power range from 1.5 to 90 kW. This makes it an ideal drive for constant pressure systems, especially for systems with low dynamic requirements. In the lower power range (< 15 kW), for example, it is highly suitable for machine tools, and in the range up to 90 kW also for presses and in metallurgy. The FcP 7010, together with the IndraDrive controller, enables access to unique additional features, such as Safety on Board, Energy Monitoring and Ethernet-based commu-nication.

Advantages resulting from special product features f A low-cost drive solution for low dynamic requirements f Low startup costs due to the preconfigured sets f Optimized process controllers, application-specific

firmware f Operation-safe, thanks to the integrated protection

and monitoring functions f FcP 5010: easy operation, manual parameterization f FcP 7010: additional features, uniform engineering,

Ethernet-based communication

The area of application of the Sytronix FcP series has been significantly extended by the qualification of further components. Based on standard motors, the FcP system is a low-cost drive solution that is intended especially for applications with low dynamics requirements, for example, constant pressure systems. Preconfigured drive sets with fixed and variable pumps enable flexible use in a wide range of applications.

66 Multi-technology | Variable-speed pump drives

Key technical data f Effective power of up to 80 kW f For use in axis control systems f For open and closed hydraulic systems f 2- and 4-quadrant operation possible f Scalable performance: with basic and advanced control

components from the IndraDrive modular system f A shorter installation length of up to 150 mm: 25 % more

compact in the upper power range f Motor-pump assemblies (MPA) can also be ordered separately

Sytronix SvP 7010: more dynamic, more compact and more energy-efficient

High-performance – finely scalable, highly efficientThe SvP 7010 system consists of a pump that is optimized for variable-speed operation, a highly dynamic synchronous servo motor and a corresponding inverter together with accessories. In this context, a completely modular system with finely scaled performance levels has been created, which has been expanded to 480 L/min and can be opti-mally adapted to a wide range of requirements. SvP 7010 drives work in open hydraulic systems or apply 4-quadrant operation in closed hydraulic systems. When interconnec-ted in cascaded systems, SVP 7010 drives are ideal, even for extremely high performance requirements in plant manufacturing. SvP systems provide very high performance with optimum efficiency.

Advantages resulting from special product features f Lower noise levels and lower weight f More compact: without any additional coupling elements f Improved motor cooling thanks to better heat transfer

from motor to pump f Improved energy efficiency and dynamics due to the

reduced moment of inertia f Practical: pre-assembled motor-pump assembly f Universal: liquid-cooled motors also available with a

stainless steel cooling system f Application safe: thanks to integrated protection and

monitoring functions f Easy commissioning and optimization: through applica-

tion-specific controller structures

The diversified portfolio of preconfigured Sytronix SvP 7010 complete sets has been expanded by direct-coupling motor-pump assemblies (MPA01). Utilize the advantages of these tailor-made, compact solutions, which are easy to install and commission: in an extremely small space you can ensure not only less noise, but also high dynamics with an energy saving of up to 80 %.

67Variable-speed pump drives | Multi-technology

Key technical data f Effective power of up to 315 kW f For use in open hydraulic systems f Configuration of multi-circuit and master-slave systems

possible f Power control, constant pressure (p) and

axis control (p/Q) f 2-quadrant operation f Motor-pump assemblies (MPE) can also be ordered

separately

Sytronix DFE 5010/7010: high performance and high dynamics with variable pumps

Advanced performance – high power and high dynamicsWith Sytronix DFE, the load on the motor is reduced in pressure-maintaining mode. In optimal cases, the electrical components can be selected to be smaller than those in classic drives. The system can be operated in two function modes: In "Teach-in" mode, the cyclically recurring pressure and flow rate profiles are stored once in the electronics, so that the system is accelerated in good time prior to a flow rate increase. On the other hand, "Real-time mode" can be used in non-cyclical machines (e.g. wood working/metal-lurgy). In this case the controller calculates during the process the optimal combination of the rotational speed of the motor and the swivel angle position for maximum energy saving. Advantages resulting from special product features

f Low investment costs due to easy retrofitting f Good price-performance ratio in the upper power range

due to downsizing f Low commissioning costs due to the preconfigured sets f Versatile in use: available for A10 and A4 pumps f DFE 5010: easy operation, manual parameterization f DFE 7010: Safety on Board, Ethernet-based communica-

tion

The Sytronix DFE system sets each consist of an electrohydraulically-controlled axial piston pump driven by a variable speed asynchronous motor. Your advantage: An excel-lent price-performance ratio can be achieved – extending into the high power range – with the DFE drives by using standard motors of up to 315 kW and the proven and par-ticularly robust pressure and flow rate control systems type SYDFE.

Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 297816 Lohr, Germanywww.boschrexroth.com

The data specified above only serve to describe the product. As our products are constantly being further developed, no statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

R999000265 (2014-03)© Bosch Rexroth AG 2014Subject to revisions!

Find your local contact person here: www.boschrexroth.com/contact

Further informations:www.boschrexroth.com/productnews

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