renault reference frame - bosch globalpublish date: 12-feb-2015 file: renault reference frame...

Machinery and Equipment Specification Document Electrical Engineering

Program Book / Guidelines

Control and Drives Products by

Renault Reference Frame

Version: V3.0

Published Date: 12-Feb-2015

Specification created and approved by:

Renault and Bosch Rexroth

Approval signatures on file at Renault

Document Management Information

File: Renault Reference Frame Version V3.0

of 32 Published Date: 12-Feb-2015

This Specification shall take effect as of the Published Date of the document.

The controlled version of this document is the one posted on the Renault web site. Any printed copy is an uncontrolled copy.

Any questions or comments with respect to this specification should be directed to the Renault responsible for the project.

Revision History

Published Version Section Number Change Description & Impact

28.08.2008 ALL First Edition

28.01.2015 V03.1 ALL MAJOR UPDATE

Program Book – Guidelines

Page No.: 3 of 32 Version V3.0

Publish Date: 12-Feb-2015



1 Introduction ..........................................................................................................................................................4

1.1 Foreword .............................................................................................................................................................4 1.2 Scope of Document ............................................................................................................................................4 1.3 Content explanation ............................................................................................................................................4 1.4 Bosch Rexroth contacts ......................................................................................................................................5 1.5 Document Approval and Responsibility ..............................................................................................................6 1.6 Further technical information ..............................................................................................................................6 1.7 Training ...............................................................................................................................................................6

2 Overview ...............................................................................................................................................................7

2.1 Basic technical definitions ...................................................................................................................................7 2.2 Performance criteria for controller hardware selection .......................................................................................7 2.3 Machine Architectures ........................................................................................................................................7 2.4 Flexible cell .........................................................................................................................................................8 2.5 Machining control layout (CNC application with MTX) .......................................................................................9 2.6 PLC based machines ....................................................................................................................................... 10

3 Product information – control parts ............................................................................................................... 11

3.1 IndraControl CMLx5 ......................................................................................................................................... 11 3.2 Standard CNC control configuration - IndraMotion MTX ................................................................................. 12 3.3 Operator panels VR21xx ................................................................................................................................. 14 3.4 Machine control panel VAM 40.2 ..................................................................................................................... 14 3.5 Mobile Operator panel VH21 ........................................................................................................................... 15 3.6 Connector module VAC30 ............................................................................................................................... 16 3.7 PC keyboardsVAK40 ....................................................................................................................................... 16 3.8 IP20 IO-modules - Rexroth Inline .................................................................................................................... 17 3.9 IP67 IO-modules - Company Lumberg ............................................................................................................ 17

4 Product information – drive system ............................................................................................................... 18

4.1 Drives components - overview ......................................................................................................................... 18 4.2 Motors .............................................................................................................................................................. 18 4.3 Kit motors ......................................................................................................................................................... 21 4.4 Indradrive power supplies and power sections ................................................................................................ 22 4.5 Indradrive control sections to be used with Indradrive C or Indradrive M power sections .............................. 23

5 System Software IndraWorks .......................................................................................................................... 25

5.1 System software IndraLogic ............................................................................................................................ 26 5.2 HMI design with WinStudio .............................................................................................................................. 26 5.3 IndraWorks-Drives ........................................................................................................................................... 26

6 Integration rules ................................................................................................................................................ 28

6.1 CNC ................................................................................................................................................................. 28 6.2 PLC .................................................................................................................................................................. 28 6.3 HMI................................................................................................................................................................... 29 6.4 Safety ............................................................................................................................................................... 30 6.5 Predisposition for the Renault Backup/Restore tool ........................................................................................ 30 6.6 Ethernet connection ......................................................................................................................................... 31 6.7 SAM (Maintenance help system) ..................................................................................................................... 31 6.8 Master .............................................................................................................................................................. 31

7 Further Information ........................................................................................................................................... 32

7.1 Product information .......................................................................................................................................... 32 7.2 Training ............................................................................................................................................................ 32






1 Introduction

1.1 Foreword

The documentation specifies the approved Bosch Rexroth automation control concepts for the Renault program. The machine builder must also utilize the relevant Approved Component List as shown inside the chapters “2, 3 and 4”.

1.2 Scope of Document

Bosch Rexroth has worked closely with Renault to develop this Program Book. The intention is that the contents of this book shall be used as a guideline for the proper selection and use of Bosch Rexroth products. Equipment suppliers who are bidding on Renault programs are expected to use this book as a reference while preparing their quotations for Renault. It is based on the following objectives:

Minimize costs with defined function contents

Apply international standards

Reduce time from concept/bidding phase to commissioning (inclusive)

Simplified modular retrofitting in the case of design changes of the work pieces

Minimization and long-term orientation of expenditures for software development and electrical construction Beyond the function contents, the company-specific user philosophy and the realization of consistent standardized data traffic have been requirements applied to the present control system concept.

!

The present documents do not release the supplier (OEM) from his responsibility to select the devices in accordance with the manufacturing requirements, the law of the country in which the machine or facility will be delivered and to take account of the reserves required. !

Deviations with this Components List have to be agreed with Renault in writing approved before placing of order. In the case of any conflict between this document and Renault program specifications, the Renault program documents should be adhered to.

1.3 Content explanation

The products listed are those which should be considered as long as they are applied properly for the application. If the products listed do not suit the needs of a special application, please contact the support personnel listed below or the responsible Renault engineer. There are certain considerations to be taken by the equipment supplier to integrated components as part of a plant or a system, and depending on its particular area of application. The equipment supplier must observe all product guidelines and specifications so in order to prevent from damages. These considerations such as voltage, timing, torque etc are available in the relevant product documentation. See chap. 5.3






1.4 Bosch Rexroth contacts

The project manager is responsible for project-specific coordination of the technical and commercial projects between Bosch Rexroth, the machine manufacturer and Renault.

Project management Bosch Rexroth SAS France Fabrice BOUTRON B.P. 74 ZI de la trentaine 77503 Chelles Cedex France Tel: +33 (0) 680 34 6211 [email protected]

Bosch Rexroth AG Germany

Joachim LINDE Dept. Technical support DC-IA/SFA13 Bgm.-Dr.-Nebel-Str. 2

97816 Lohr am Main, Germany

Tel: +49 (0) 9352 18-5808

[email protected]

Other worldwide contacts Bosch Rexroth Spain/Portugal Bixen CATELIN Francisco Grandmontagne, 2 Parque Empresarial Zuatzu 20018 San Sebastian Spain Tel: +34 943 318456 Fax: +34 943 318460 [email protected]

Bosch Rexroth AS Turkey No:3 34295 Sefaköy, ISTANBUL TURKEY Tel : +90 212 411 13 49 Fax : +90 212 411 13 17

Bosch Rexroth SPA Italy Biagio SCALONE Bosch Rexroth spa S.S. Padana Superiore 11, n. 41 20063 Cernusco s/N (MI) ITALIA Tel : +39 02 92365 835 [email protected]

East Electric Roumania

Iuliu STOCKLOSA B-dul Basarabla nr. 250 sector 3 Bucuresti 030352 ROMANIA Tel : +40212104824 [email protected]

Bosch India Limited PRADEEP,R.S. Plot 96 ,Phase III Peenya Industrial Area Bangalore - 560 058 INDIA Tel : +919844101734 [email protected]

mailto:[email protected]











1.5 Document Approval and Responsibility

Created, edited and checked by Fabrice BOUTRON and Joachim LINDE, Bosch Rexroth Coordination for Renault Alain ROLLAND (Renault Cléon service 3022 ) Issued by Bosch Rexroth and Renault

1.6 Further technical information

This control and drive concept was created by Bosch Rexroth in collaboration with Renault controls team. This project manual describes all elements of a control architecture which has been adapted to the requirements of automated production. As a systems supplier, Bosch Rexroth offers hardware and software, engineering services, replacement parts, training and support.

Further technical information, necessary accessories for installation, etc. are available for components listed in this document in chapter 2 and following chapters. Application and use of these components is the responsibility of the user of this document. Application assistance is available by contacting the support personnel listed in Section “1.4 Bosch Rexroth contacts” of this document, or by visiting the website www.boschrexroth.com. Complete and current data sheets such as 2D and 3D drawings, ePLAN ® Makros and Data have to be found on the web side too.

1.7 Training

Equipment supplier shall document sufficient knowledge implementing the desired products and solutions given in this released parts list. Training is mandatory for first-time equipment supplier using a solution. Renault reserves a right to verify proof of training of the main program developer. Details see in chap “7.2 Training”.

http://www.boschrexroth.com/



2 Overview

2.1 Basic technical definitions

The basis for all layouts, all components described within this project book is the current Bosch Rexroth product portfolio. The software basis is IndraWorks 14VRS.

2.2 Performance criteria for controller hardware selection

Criteria Maximum Value

RAM memory usage 80%

CPU load 64%

PLC scan time 15ms

Sercos cycle time <2ms

2.3 Machine Architectures

Machine Architectures

Machine Type Architecture Page

Production line layout Flexible cell 8

CNC Machine Advanced CNC control with MTX PC based, Engineering on Board 9

PLC based Machine Assembly line - PLC application 10



2.4 Flexible cell

The following layout shows an example of a flexible cell (line) consisting mainly of CNC machines and few PLC machine.

Machine Production cells can be realized depending on the process requirements with a CNC or a PLC control, layout details for all kinds of machines are shown below. The machine ProfiNet bus system should be a ring topology.

VDP & VPB VDP HMI panels with VPB40 Industrial PC boxes feature high performance and offer the possibility to

run additional PCI hardware like tool monitoring systems.

CMLx5 Control hardware of CNC or PLC machines.

Intelligent Device

Devices with ProfiNet and Ethernet connection: With “CNC:CMLx5” – controllers a separate Ethernet connection is required to connect to the MES system. With “PLC:CMLx5” – controllers the Ethernet communication can be routed directly to the plant IT network.

*1 Switch to connect all machine internal Ethernet participants, e.g. CMLx5 control with HMI.

*2 Switch for ProfiNet real time communication between the controls. ProfiNet is connected as “star” topology from the cell controller to the machines. The switch is located in the cabinet of the Gantry.



2.5 Machining control layout (CNC application with MTX)

2.5.1 Advanced CNC control with MTX PC based, Engineering on Board

The advanced CNC control shall be used for high end machine tool, e.g. complex machining centers, high performance grinding machines, gear cutting machines and time critical operations.

The HMI Panel features the IndraWorks Operation and Engineering application, OEM screens and special applications like MES systems.

This advanced CNC control solution has to be approved by RENAULT.

Advanced CNC control with MTX PC based, Engineering on Board

Machine part Abbrev. in Pic. Bosch Rexroth Product

Motion control MTX CNC:CMLx5 CML85

Realtime Ethernet module CNC:CMLx5 CFL01.1-TP, not required for standalone machine

PLC safety module CNC:CMLx5 CFL01.1-F1

HMI main VDP + VPB VDP40.3 + VPB40.3, with IndraWorks Operation and Engineering application

HMI secondary * VH21* VH21 Mobile Operation panel VH21

VR21* VR2107

Machine control panel VAMx2 VAM40.2

Keyboard VAKxx VAK40

Drives IndraDrive IndraDrive M, IndraDrive C with Sercos

I/O devices Inline /Fieldline Inline, Iumberg IP67 Lion Link

Switch (*1 *1 = Switch for local machine Ethernet,

* Usage requires approval by RENAULT



2.6 PLC based machines

2.6.1 Assembly line - PLC application

Standard operator panels are VR21 with a WinStudio Application.

The Ethernet telegrams of the CML-control must be filtered by a NAT router. They shall not

leave the machine Ethernet network. The manufactures and types of Ethernet switches and

NAT units have to be approved by RENAULT.

The line ProfiNet bus system must be a star topology.

Manual stations may be integrated in other stations. If manual stations do not have their own

controller, the solution has to be approved by RENAULT. The number of manual stations per

PLC is limited by the performance of the control and shall be approved by RENAULT and Bosch

Rexroth.

*) Usage of more than one manual station with one (1) PLC controller requires the approval by

RENAULT.



3 Product information – control parts

3.1 IndraControl CMLx5

IndraControl CMLx5 are cabinet DIN rail mounted hardware platforms used for PLC control IndraLogic XLC and for the CNC control IndraMotion MTX. They are used for decentralized machine concepts and together with an optional hardware module also as Safety control. Sercos is used for communication to the drives. ProfiNet is used for communication to the actuators and sensors. The CML x5 is available in 4 performance versions which differ in the type of technology modules and the firmware version. Operation and engineering is done via scalable embedded panels and visualization devices connected via Ethernet. The PLC system IndraLogic XLC uses L45 controllers. The CNC system IndraMotion MTX uses L85 controllers.

CML85 with Sercos for MTX

CML45 with ProfiBus and ProfiNet for XLC only

CML - controller - technical data overview

CML45 CML85

Processor Intel Low Volt Celeron 500 MHz Intel Core2Duo 1,2GHz

Memory RAM 256 MB DRAM,

min. 256 kByte NvRAM opt. static mem 8MB

1024 MB DRAM, min. 256 kByte NvRAM opt. static mem 16MB*

Sercos + +

ProfiNet Master / Slave +/+ +/+

XLC / MTX +/+ -/+

https://brmv2.kittelberger.net/borexmvz2-internet/Category.jsp;jsessionid=87A654C8F58245AAB5A0C375734A003E.borex-tc?publication=NET&ccat_id=13500&remindCcat=on

http://www.boschrexroth.com/dcc/Vornavigation/Vornavi.cfm?Language=EN&VHist=g97568,g96071&PageID=p509994

http://www.boschrexroth.com/dcc/Vornavigation/VorNavi.cfm?Language=EN&VHist=g97568&PageID=g96072



3.2 Standard CNC control configuration - IndraMotion MTX

IndraMotion MTX comprises CNC, Motion Control and PLC functionality in a single hardware. Up to 99 digital axes (thereof up to 32 spindles) can be coordinated. 60 independent NC-Channels are available. It is easy to upgrade CNC IndraWorks projects between the scalable hardware versions CML45, CML65 and CML85. For RENAULT L85 with SafeLogic (SL) is defined as standard CNC controller.

IndraMotion MTX IndraControl

CML85

CNC controlled axis 8..99

Thereof spindle drives 32

Independent CNC channels 3..60

Max. number of interpolating axis per channels

4..8*

Minimum IPO cycle time 0.25ms

NC Block- Look-Ahead 1000

Static Memory 16MB

RAM Memory 1024MB

The following table shows the preferred Bosch Rexroth components, type codes and part numbers to order the IndraMotion MTX products.

Standard CNC control configuration - IndraMotion MTX

Component Type code Part number

Motion control MTX CML85.1-3P-705-FA-NNNN-NW R911171674

CML85 Firmware FWA-CML85*-MTX-14VRS-NN R911342877

CML Connector set R-IB IL CML S01-PLSET R911299856

PLC safety module CFL01.1-F1 R911170129

Realtime Ethernet module CFL01.1-TP R911170832

HMI standard VPB40.3D1Q-2G0NN-D4D-DN-NN-FW R911173637

VDP40.3BIN-D1-NN-MX R911171444

MTX HMI and Engineeing SWA-IWORKS-MTX-14VRS-D0-INST R911342879

SWL-IWORKS-MTX-NNVRS-D0-OPDENG R911331690

Engineering license SWL-IWORKS-MTX-NNVRS-D0-WORKSTATION R911334886

SWA-IWORKS-MTX-14VRS-D0-DVD**-SAFELOGIC R911340457 1) * in Type code = standard Bosch Rexroth placeholder for future options



3.2.1 Standard PLC control configuration - IndraLogic XLC

IndraLogic XLC comprises PLC and Motion Control functionality in a single hardware. It is easy to upgrade PLC IndraWorks projects between the scalable hardware versions CML25, CML45 and CML65. For RENAULT CMLx5 with SafeLogic (SL) and VR2109 with a WinStudio installation are defined as standard.

IndraLogic XLC

IndraControl CML45

User memory 24MB

Memory RAM 256MB

Remanent data memory 256kB

Sercos +

ProfiNet IO Master / Slave +/+

Function modules 4

Freely configurable tasks 20

Typical processing time for 1000 instruction

command mix

Bool operations

Word operatios

30us 30us 30us

Min. PLC cycle time, Synchronized with

system cycle

Sercos cycle

1ms 0.5ms

Standard PLC solution

Control component Type code Part number

CML45 with PN CML45.1-NP-500-NA-NNNN-NW R911170938

CML45 with PN and Sercos CML45.1-3P-500-NA-NNNN-NW R911170828

R-IB IL CML S01-PLSET R911299856

FWA-CML45*-XLC-14VRS-D0 R911342983

PLC safety module CFL01.1-F1 R911170129

SWS-IWORKS-SM*-01VRS-D0 R911322463

HMI standard VR2109.01-00-01-N2-NNN-AA R911340051

Options

HMI optional **) VEP50.5DFN-2G02E-A3D-NNN-NN-FW R911172937

FWA-VEP*05-W7*-01VRS-D0-A* 32 R911337389

CFM01.1-08G0-N-LBA-NN-NW R911173621

Operation Desktop SWL-IWORKS-ML*-14VRS-D0-OPD R911342963

SWA-IWORKS-ML*-14VRS-D0-INST* R911342953

Engineering license *) SWL-IWORKS-ML*-14VRS-D0-ENG R911342959

SWA-IWORKS-ML*-14VRS-D0-DVD**-SAFELOGIC R911345264

SWA-IWORKS-ML*-14VRS-D0-DVD** R911342878

*) installation only on PC based Hardware, e.g. VPB, VPP and Notebooks **) approval from RENAULT needed



3.3 Operator panels VR21xx

VR21 operator panels can be used as small operator panels. The small touch operator panels VR21 are available in 2 sizes: 7’ and 9’. The VR21 panels are provided with Windows 7 embedded system which runs Winstudio as HMI application. The connection to the control is done via Ethernet.

Operator panels VR21xx *) Device Typecode Partnumber

Panel – Medium 7’ VR2107.01-00-01-N2-NNN-AA R911340503

Option *)

Panel – Big 9’ VR2109.01-00-01-N2-NNN-AA R911340051 *) Usage requires approval by RENAULT “*” in Typcodes means = “reserved regarding Bosch Rexroth type code standards”

VEP - Technical Data VR2107 VR2109

Operating System: Windows embedded compact 7

Processor Central processing unit ARM Cortex™-A8, 800 MHz with real-time clock

RAM: Flash memory 256 MByte, LPDDR memory 512 MByte

Interfaces:

Ethernet 1x 10/100 Base-T Fast Ethernet

USB 2.0 2 x available

Display: 177.8 mm TFT (7") 228.6 mm TFT (9")

Dimensions: 91.4 × 152.4 (H × B) 117 × 195 (H × B)

3.4 Machine control panel VAM 40.2

The VAM40.2 supplements the machine operating panel for standard machines. It features PLC push buttons with LEDs, emergency stop, feed and spindle override.

Machine control panel VAM 4

Device Typecode Partnumber

VAM40.2 - standard VAM40.2-PB-NA-TA-TA-VB-MA-1608-NN R911170772




3.5 Mobile Operator panel VH21

The handheld device VH21 is used to control a machine from different locations, e.g. for gantries or other complex or extended machines or for the set-up of machines with open safety gates. It can be configured either with an individual IndraWorks HMI project () or via Remote Desktop. The VH21 is only allowed as secondary controls panel at machines or at gantries.

The usage of PC mobile operator panels VH21 requires approval by RENAULT.

Mobile Operator panel VH21


Mobile Panel VH2110.01-00-02-N3-111-CA R911173736

Fixture VAS01.1-003-NNN-NN R911173896

VH21 - Technical Data

Operating System: Windows embedded compact 7

Processor: ARM Cortex A9

RAM: 512 MB / 512 MB

Interfaces: Ethernet 10/100 Mbit

Display: 10,1“ widescreen (16:9), resolution 1280 x 800, colors 262144 (18bit), multi touch

Dimensions: 1280 x 800

Switches: Stop: 2 channel, Enable control: 2 channel, 3 steps,

Protection category: IP54

Safety Standards DIN EN ISO 13849-1



3.6 Connector module VAC30

The connector module VAC30 is used for a flexible connection of the handheld terminal VH21. The settings of the VH21 are stored in module. The safety features are ensured.

Connector module VAC30


Connector module VAC30.2N-NN R911171054

VAC31 – Technical data

Power supply: 24 VDC

Protection category: Front panel basic model IP65

Interface: Ethernet

Dimensions: 169 mm x 85 mm x 55 mm (W x H x D)

Weight: Approx. 0.5 kg

Connections: Dual channel stop switch, dual channel enable switch, RJ45 Ethernet 100 Mbit

3.7 PC keyboardsVAK40

The Bosch Rexroth keyboards are slide-in keyboards with an integrated mouse pointer. Features:

all the functions of a conventional PC keyboard,

an integrated mouse to makes it possible to navigate within graphical user interfaces

USB plug to connect to PC’s and operator panels.

VAK40


Keyboard for 15’ HMI VAK40.1E-EN-U-MPNN R911171081


https://brmv2.kittelberger.net/borexmvz2-internet/Category.jsp;jsessionid=786BED010DC4200920AB95569BE9B8A0.borex-tc?publication=NET&ccat_id=13690&remindCcat=on



3.8 IP20 IO-modules - Rexroth Inline

The I/O units of the Rexroth Inline series are constructed in a compact housing. The modular system allows an ideal adaptation to the respective control tasks. Acceptable bus systems to communicate with the PLC: ProfiNet

IP20 IO-modules - Rexroth Inline

Typecode Description R-IL PN BK DI8 DO4-PAC

Inline PROFINET bus coupler with 8 inputs and 4 outputs, complete with accessories

R-IB IL 24 PWR IN-PAC

Fieldline feed clamp

R-IB IL 24 SEG/F-PAC

Inline segment clamp, 24 V DC With fuse and diagnostics, incl. connector and label

R-IB IL 24 DI 8-PAC 8 Digitale inputs, 24V DC incl. connector and label

R-IB IL 24 DI 16-PAC 16 Digitale inputs, 24V DC incl. connector and label

R-IB IL 24 DO 8-2A-PAC 8 Digitale outputs, 24V DC, 2A incl. connector and label

R-IB IL 24 DO 8-PAC

8 Digitale outputs, 24V DC, 500mA incl connector and label

R-IB IL 24 DO 16-PAC 16 Digitale outputs, 24V DC, 500mA

R-IB IL PSDI 8 8/4 Digital Safe inputs

R-IL 24 PSDO8-PAC 8/4 Digital Safe outputs

R-IB IL PSDO 4/4 Digital Safe Outputs p/n

4 p/n switching (double wired)

4 p switching (single wired)

R-IB IL PSDOR 4 4 Safety relay ouputs up to SIL 3

2 if double wired

4 if single wired

3.9 IP67 IO-modules - Company Lumberg

Lion Link - Series

IP67 IO-modules - Company Lumberg

Module Description

https://brmv2.kittelberger.net/borexmvz2-intranet/Category.jsp;jsessionid=6AC3B1668A82918BB2D600FF4CC12186.borex-tc?publication=NET&ccat_id=13800



4 Product information – drive system

4.1 Drives components - overview

Scalable and modular System

The IndraDrive drive system offers you a wide range of converters inverters, power supplies, controller modules, as well the necessary firmware versions.

Extensive functions

The drive technology offers a wide range of functions such as positioning block mode, angle and motor speed synchronization, axis lag compensations or main spindle functions function or an integrated control axis generator.

Various motor encoder systems permit either absolute or relative position detection. By offering a second feedback sensor input, all typical sensor types can be used as separate position sensors.

Convenient and time-saving startup

The IndraWorks Drive graphical engineering and diagnostics tool guides you quickly and reliably through the individual startup settings. Current drive-internal state variables are displayed in the process. Further help texts support you along the way.

Selection criteria for drives power modules

Single axis IndraDrive C compact converter for low inertia machines without line regeneration

Power range form 1 to 110 kW with maximum current up to 210 A - Direct electric supply up to 500V - Internal control voltage supply, partially optional

Multi axis and Machine tool IndraDrive M modular inverter with line regeneration power supply

Power range from 1 to 120 kW with maximum current up to 210 A - Double axis inverter with maximum current from 12 A to 36 A - Feeding is possible via converter or supply module

4.2 Motors

4.2.1 Encoder

Renault specifies the use of absolute encoders (multiturn) : EnDat encoders M2 are mandatory for machining axis ; Hiperface encoders M1 are allowed for auxiliary axis (gantries, tool magazine)... ; Single turn EnDat encoder S2 are allowed on direct spindle motors (without gearboxes)

4.2.2 Protection

Motors with IP65 protection and no pressurization. Renault specifies the use of motors with plain shafts.

4.2.3 Brakes

During the projects stages, Renault will check the braking efficiency, more particularly for vertical axes.



4.2.4 Motor temperature

Monitoring of the motor temperature is ensured via the temperature sensor of type KTY84, which is built into the stator. The measured motor temperature is controlled via the following threshold values:

● Motor-warning temperature (140 °C) ● Motor-disconnection temperature (150 °C)

Renault and Bosch Rexroth recommend to use the “60K motor characteristics”. For further information please refer on the documentation “Rexroth IndraDyn S Synchronous Motors” (R911296289) for MSK motors and “Rexroth IndraDyn A Series Asynchronous Motors MAD/MAF “(R911295781) for MAD motors.

A motor temperature higher than 80°C (probe) must be justified by the OEM to Renault

4.2.5 Synchronous motors MSK for axis.

The synchronous MSK motors are suitable for all areas of applications in manufacturing and production and provide a wide range of speed and torque.

Three-phase servo motors, Synchronous

Version MSK (synchronous servo motors for standard applications)

Synchronous servo motor IndraDyn S (3,0 - 5,0 Nm) MSK050.-....-NN-Mx-.Gx-NNNN

Synchronous servo motor IndraDyn S (5,0 - 8,0 Nm) MSK060.-....-NN-Mx-.Gx-NNNN

Synchronous servo motor IndraDyn S (13 - 23 Nm) MSK070.-....-NN-Mx.-.Gx-.NNN

Synchronous servo motor IndraDyn S (17,5 - 23 Nm) MSK071.-....-NN-Mx-.Gx-.NNN

Synchronous servo motor IndraDyn S (28 - 48 Nm) MSK100.-....-NN-Mx-.Gx-RNNN

Synchronous servo motor IndraDyn S (32 - 70 Nm) MSK101.-....-NN-Mx-.Gx-RNNN

Synchronous motors MSK

Restricted options Allowed options Example

Encoder Encoder options: M1, M2, S1*, S2* !* = for Spindle applications only! MSK060C-0600-NN-M2-UG0-NNNN

Smooth shaft Shaft = G MSK060C-0600-NN-S2-UG1-NNNN

Holding break Break option code = 0, 1, 2, 3 MSK060C-0600-NN-S2-UG1-NNNN

Shaft runout Shaft runout = N MSK060C-0600-NN-S2-UG1-NNNN

https://brmv2.kittelberger.net/borexmvz2-intranet/Category.jsp;jsessionid=CA6EC8FD198134513FC325A126D1D371.borex-tc?publication=NET&ccat_id=11680&remindCcat=on



4.2.6 AC main spindle drives IndraDyn A

Asynchronous motors MAD

MAD motors (air cooled) are primarily used as main spindle or sometimes as servo drives. Several motor sizes are available offering a power output of up to 62 kW. Optionally, the motors can be supplied with a holding brake.

Three-phase servo/main spindle motors, asynchronous

Version MAD (asynchronous spindle motors)

Asynchronous servo motor IndraDyn A (1,8 - 11,3 kW) MAD100.-...-SA-..-.G.-05-..

Asynchronous servo motor IndraDyn A (5,0 - 31,4 kW) MAD130.-....-SA-..-.G.-x5-..

Asynchronous servo motor IndraDyn A (11 - 44 kW) MAD160.-....-SA-..-.G.-x5-..

Asynchronous servo motor IndraDyn A (18,8 - 62,8 kW) MAD180.-....-SA-..-.G.-x5-..

AC main spindle drives IndraDyn A

Restricted options Allowed options Example

Encoder Encoder options: S2, M2 MAD100C-0100-SA-S2-AH0-05-N1

Smooth shaft Shaft with IP65 = G MAD100C-0100-SA-S2-AG0-05-N1

Vibration severity S

Flange and shaft accuracy R



4.3 Kit motors

4.3.1 Kit motors IndraDyn H

These motors are especially well-suited as main spindles for modern turning, milling and grinding machines as well as machining centers. Liquid cooling and the large spindle opening allow you to directly integrate the kit motors into the spindle head.

Torque motors, Synchronous

Version MBS (Synchous high speed kit motors for standard applications)

Synchronous kit motor IndraDyn H (8,96 – 21,8 kW) MSS102-NNN-FA-N0CN-NNNN




Synchronous kit motor IndraDyn H (22 – 51,3 kW) MSS202-NNN-FA-N0CN-NNNN

Synchronous kit motor IndraDyn H (26,2– 27,7 kW) MSS242-NNN-FA-N0CN-NNNN



Synchronous kit motor IndraDyn H (36– 40,9 kW) MSS382-NNN-FA-N0CN-NNNN

Synchronous kit motor IndraDyn H (25,1kW) MSS482-NNN-FA-N0CN-NNNN

4.3.2 Linear technology IndraDyn L

Linear drives do not require mechanical transmission elements. That is why they are ideally suited for high speed chipping, grinding and laser processing. Significantly higher speeds with higher precision and peak torque values of up to 22 kN are the outstanding features of this drive technology. The encapsulated construction of the primary part simplifies motor installation and protects the motor from environmental effects.

Linear motors, Synchronous

Version MLF (Synchous linear motors for standard applications)

Synchronous linear motor IndraDyn L (0,8 – 1.125 kN) MLP040-NNN-FS-N0CN-NNNN

Synchronous linear motor IndraDyn L (2,0 – 3,8 kN) MLP070-NNN-FS-N0CN-NNNN

Synchronous linear motor IndraDyn L (3,75 – 7.150 kN) MLP100-NNN-FS-N0CN-NNNN






4.3.3 High torque ring motors IndraDyn T

Torque motors MBT are used for rotary axis or swiveling axis in machining centers. These direct drive motors eliminate the need for mechanical transfer elements that wear easily. At the same time, dynamics and precision are increased considerably. Torque values of over 13,800 Nm are possible with the MBT motors.

Torque motors, Synchronous

Version MBT (Synchous torque motors for standard applications)

Synchronous torque motor IndraDyn T (15 – 65 Nm) MST130-NNN-FT-N0CN-NNNN







4.4 Indradrive power supplies and power sections

Supply modules for Indradrive M

Feed-in/ Feed-out module Type

Feed-in/ Feed-out module 18, 45, 65, 120 kW, regulated HMV01.1R-Wyyyy1-A-07-NNNN

Drive system INDRADRIVE "M"

Drive regulation devices Type

Drive regulation device, 1-axis, 36A HMS01.1N-W0036-A-07-NNNN






Drive regulation device, 2-axes, 36A HMD01.1N-W0036-A-07-NNNN

Drive system INDRADRIVE "C"

Drive regulation devices Type

Compact converter, 1 axis, max. current 12A HCS02.1E-W0012-A-03-NNNN




Compact converter, 1 axis, max. current 100A, 24V integrated HCS03.1E-W0100-A-05-NNBV





4.5 IndraDrive control sections to be used with IndraDrive C or M power sections

Consultation with RENAULT is necessary if the solutions for the safety functions should not be used, because functions like “safe operation stop“ and „safely reduced speed” are used to setup the machines while the machine access doors are open for maintenance by RENAULT. - Drive firmware MPx19VRS

4.5.1.1 Firmware function packages

FWA- -MPB- single axis BASIC, standard servo application, automation

FWA- -MPH- single axis ADVANCED, servo application, main drive application, machine tools high-end

FWA- -MPD- double axis BASIC, servo application, machine tools



4.5.1.2 Function overview control parts for IndraDrive C/M

For RENAULT projects use only Sercos III and ProfiNet control parts for IndraDrive. For detailed information on the controls parts please use the documents shown in the Bosch Rexroth Mediadirectory.

Advanced SERCOS CSH 2.1B-S3-EC-xx-.. Basic CSB 2.1B-ET-EC-xx-..

Onboard interfaces

- digital and analog I/O - relay output Lead communications

- Sercos and ProfiNet Screen element

- standard and comfort HMI Option 1

- Combined encoder interface Option 2

- Multi Ethernet - Combined encoder interface - analog I/O extension - encoder emulation Option 3 safety technology

- Drive interlock and safety I/O - STO, SS1, safe motion, etc. Option 3

- Combined encoder interface - analog I/O extension - encoder emulation - digital I/O extension Option 4

- analog interface - multi encoder interface - encoder emulation

Onboard interfaces - digital and analog I/O - relay output Lead communications - MultiEthernet (Sercos / ProfiNet) Screen element - standard and comfort HMI Option 1 - Combined encoder interface Option 2 - Combined encoder interface - lead communication - encoder emulation Option 3 Safety - Drive interlock - safe motion Option 4 - Combined encoder interface - analog I/O extension - encoder emulation - digital I/O extension

Basic SERCOS Double axis CDB 2.1B-ET-EC-xx-..

Onboard interfaces - digital and analog I/O - relay output Lead communications - MultiEthernet (Sercos / ProfiNet) Screen element - standard and comfort HMI Options - Combined encoder interface - analog I/O extension - encoder emulation OPTION safety

- Drive interlock - safe motion

Combined encoder interface - IndraDyn motors - Hiperface

Each control section must be equipped with a Micro SD card as Flash EPROM, in order to simplify drive exchange.

https://brmv2.kittelberger.net/borexmvz2-internet/Category.jsp;jsessionid=88F3771016950287D289445025940A84.borex-tc?publication=NET&ccat_id=10120&remindCcat=on



5 System Software IndraWorks The IndraWorks Framework from Bosch Rexroth is a scalable frame for modular engineering solutions. The following components can be integrated as IndraWorks.

The specific engineering tools (packages) of different technologies integrate themselves step by step as “Plug Ins“ into the collective framework. Framework and tools are separated and developed independently.

IndraWorks software version 14VRS must be used.

http://www.boschrexroth.com/IndraWorks



The System Software IndraWorks includes all necessary software components to realize standard machine tools or machine equipments for high production. All components are integrated in the IndraWorks Framework into one Engineering tool. Engineering Framework IndraWorks for CNC and PLC with integrated functions:

Profinet, Profibus and I/O configurator

IndraLogic V2 (PLC programming system)

WinStudio (HMI design tool)

Common Tools (Logic Analyzer, graphical NC programming, NC simulation...)

IW-Drives (Startup tool for drives) System add-ons available for:

IndraLogic applications (Demos, libraries, destination device information...)

IndraMotion MTX application (Demos, libraries, destination device information, tools...)

Renault HMI A basic DVD master Bosch Renault V2.0 including automatic installation of: Windows 7, IndraWorks engineering and Operating Desktop 14VRS, and a basic template project MTX_RRS_Standard will be supplied to the OEM.

5.1 System software IndraLogic

The IndraLogic programming system is used to logically implement all PLC tasks. It is integrated in the IndraWorks Engineering tool

IndraLogic is usable on all kinds of hardware platforms and is the basic programming system to achieve all PLC tasks. For CNC applications with IndraMotion MTX, IndraLogic is also used for PLC programming and provides the necessary interfaces for communication there. The programming system IndraLogic can also be installed without a connection to the PLC or the plant as an independent application on any PC. This makes it possible to plan offline. IndraLogic is fully compatible with EN 61131-3 standard in terms of data types and programming languages.

5.2 HMI design with WinStudio

Standard tool for user graphic screens design for standard VDP screens and small HMIs VR21 It is possible to create both single containers and full screens with WinStudio. The functional options of WinStudio refer to the number of available tags (Process variables) which can be mapped. These options are partitioned as follows:

Basic license package (Light version, maximum 500 tags) onboard and free in every control unit

Editor license package (scalable in the number of available tags, easy upgrade with activation codes and additional installation)

5.3 IndraWorks-Drives

IW-Drives is the Rexroth Drive Technology setup tool. All required parameter settings are achieved with IW-Drives.



The relevant function data such as mode selection (for example settings for positioning the drive) and current speed values are entered on the standard screen in the guided startup procedure. Predefined parameter sets, for example for linear axes or spindles, also simplify the startup procedure. The software tool which is integrated into IndraWorks also allows you to re-optimize individual parameters directly at the machine and provides diagnostic functions in the control. The extensive oscilloscope function simplifies the documentation and the checking of the control loops.



6 Integration rules

All the machines for Renault will be approved by means of a Bosch Rexroth checklist during the steps of the project. For a good integration of the Bosch Rexroth products, we recommend you to use the Bosch Rexroth Checklist. We advise you to verify yourself your machine by means of the checklist documents. “BR_CHECK_Indradrive_C_EN” for Drives with compact converters HCS02 or HCS03 “BR_CHECK_Indradrive_M_EN” for Drives with inverters HMS or HMD and power supply HMV “BR_CHECK_Indramotion_MTX_EN” for MTX CNC architecture

6.1 CNC

6.1.1 Part program

It is recommended to comment every program and subroutines in the customer language. For the CNC program related to the workpiece, Renault recommends to use the ISO programming language. The programming structures must abide by the Renault specifications listed in the Renault guide.

6.1.2 Tool management

The so called „tool management“ is usually defined in close interaction between machine manufacturer and Bosch Rexroth as it is an essential and unique part of a machine tool. The functionality of the tool management is usually spread in different tasks mainly handled in the CNC (e.g. search, activation and deactivation of tool data; search for sectors or pockets; description of necessary movements and sequences during the tool change) but as well partly in the PLC (e.g. determining and calculation of tool life time). For machines without tool storage use D-corrector. For machines with tool storage use ED-corrector. For detailed information and clarification get in touch with Bosch Rexroth.

6.1.3 Encoder evaluation

Encoders or linear scales are monitored inside the drive system. Regarding the direct measuring system, the control bit must be active. In case this bit would cause untimely standstills, the OEM will have to inform Renault and Bosch Rexroth about this problem. An investigation will be carried out by Bosch Rexroth and Renault. See documentation “RRD_Encoder_Evaluation”

6.2 PLC

6.2.1 Hardware configuration

The hardware configuration (local I/O & Profinet) should be declared in the IndraWorks project (default setting).

6.2.2 Programming language

According to Renault specification, only 2 languages are accepted: LD (Ladder Diagram)

Machine mode management

Automatic cycle

Motion command

Fault detection



ST (Structured Text)

Data analysis

Specific process functions

6.2.3 Variables declaration

All the global variables must be organized by functionality in subfolders. In order to make the declaration of the variables easier, structured data like arrays and structures can be created: They must also be classified in folders and documented. All the mnemonics must be in French or after agreement from Renault in English, with French comments (or local language). All declared variables should be documented. All machine I/Os should be declared as in the global variables area. Global variables should not be directly used inside a Function Block (FB).

6.2.4 Tasks

The Rexroth PLCs are multi-task capable. At least one main PLC task must be created: This task must call a master program POU called “prMAIN”. This POU written in LD must call each of all the different POUs animating the complete machine with a enable condition which will be set to TRUE.

6.3 HMI

The integration of the “Renault Rexroth Screens” is mandatory to design a HMI application according to the Renault specification. See project files “MTx_RRS_STANDARD” Available for VDP40.



6.4 Safety

According to the risk analysis, if safety is necessary then the machine manufacturer has to use the safety option for all safety related drives, even for auxiliary axes. Use „S4“ option (Safety on Board) for all drives where necessary The OEM has to provide Renault with the following documents in writing:

Hazard analysis and risk assessment of machine with PLs requested and those reached.

Safety protocol using the example given in IndraWorks engineering in writing

Safety acceptance instructions using the example given in IndraWorks engineering in writing

Full safety acceptance test protocol similar to example given in Bosch Rexroth documentation : “Safety_Protocol” in writing

6.5 Predisposition for the Renault Backup/Restore tool

To be well done interconnected with the Renault Backup/Restore tool, some data locations should be respected :

NC-Program (MTx): Main part program: root\mnt ; root\usr\user Cycles/called part programm: root\usr\mtb

Active Project: D:\OEM\RR_Project\<project name>

All other specific datas (for example Artis datas): D:\OEM\Specific Data

The drives Backup has to be individually saved and placed like this Drive 1: D\OEM\RR_Drives\<drive name 1>.par Drive n: D\OEM\RR_Drives\<drive name n>.par

By using the Backup/Restore keys (available with the “Renault Rexroth HMI”, all MTx applicative data will automatically placed in this directory. D:\OEM\RR_Backup Then, this directory will contain the following data: NC compiled file: (*.tar) Extended data: (*.zip) IW project: (*.zip) Windows-Registry: (*.reg) Specific OEM datas (*.*)



Copy of RR_Drives directory The Renault Backup/Restore tool task is to get this directory content See “MTX Backup Restore_FR.doc” documentation

6.6 Ethernet connection

MTX Use the Eth2 VPB40.3 connection to factory Ethernet SAM system. Use the Eth1 of VPB40.3 with a switch to connect CML85, small HMI and remote Engineering.

PLC stations (XLC) The Ethernet port of CML45 must be connected via a NAT switch to the VR21 HMI and to the SAM

network.

6.7 SAM (Maintenance help system)

Use the standard function block (FB) “RRS_SAM” and the Winstudio screen integrated in the standard project “MTx_RRS_STANDARD".

6.8 Master

In order to have a reference software package, it’s recommended to use the “Renault Rexroth Master”. The master is a tested and validated software package on a tested and validated hardware package. It has 2 mainly aims:

To simplify the set-up of the machine: the OEM has a software reference package, ready to use.

To simplify the machine maintenance: validated software integration in the Renault Production System. No need to install every single software separately.



7 Further Information

7.1 Product information

Information on all Bosch Rexroth products mentioned inside this book will be found also on the Bosch Rexroth Website. For the Drive and Control components please visit http://www.boschrexroth.com/en/xc/products/product-groups/electric-drives-and-controls/index

The product documentation describes the universal functionality of the hardware and software components. The individual documents can be

ordered in a printed version.

from the Bosch Rexroth Media Directory from the website

http://www.boschrexroth.com/mediadirectory

7.2 Training

The BRC main training center is located in Erbach, Germany. Courses for machine designers and engineers are conducted by our training personnel in special classrooms using the latest training equipment. To better understand the Rexroth drive and control technology, the lessons are supplemented with practical exercises. Training can also be done on site. Special training sessions have been developed according to Renault needs.

Bosch Rexroth AG Training Center BRS/DID2 Berliner Str. 25 64711 Erbach Tel. +49 (0) 60 62-78-600 Fax +49 (0) 60 62-78-833 [email protected] www.boschrexroth.com/training

Bosch Rexroth SAS France Antony MUTOMBO B.P. 74 ZI de la trentaine 77503 Chelles Cedex France Tel: +33 (0) 1 64 72 63 28 Fax: +33 (0) 1 64 72 63 00

[email protected]

http://www.boschrexroth.com/en/xc/products/product-groups/electric-drives-and-controls/index

http://www.boschrexroth.com/mediadirectory


http://www.boschrexroth.com/training


renault reference frame - bosch globalpublish date: 12-feb-2015 file: renault reference frame...

Documents