IndraMotion

01_1 st Headline_36 pt/14.4 mm
for Metal Forming
second
System line
solutions for forming
technology
2
 Content  3

Content

4 IndraMotion for Metal Forming

6 Safety on Board

7 Energy efficiency

8 Scalable hardware architecture

9 Integrated technology functions

10 Program frame

12 Turnkey single-axis solutions for

rollfeeds

14 Turnkey solution for flying shear

Rexroth is a specialist for control and 16 Rotary shear technology function

drive technology for all areas of metal 18 Sequential Motion Control
forming. You too can enjoy the benefit
20 Multi-axis solutions for blanking lines
of our industry expertise through
IndraMotion for Metal Forming, 22 New concepts for electronically
whether it‘s a standardized single-axis controlled press transfer

or a complex multi-axis application 24 Automation of crossbar transfer and

you want to realize. compact crossbar transfer systems

26 Motion logic integration for tandem

press lines and feeder

28 Optimal process adaptation for

servo presses

30 System solution and hardware

32 System features in detail

34 Scalable system components

4 IndraMotion for Metal Forming

IndraMotion for Metal Forming –

cost-effective material transport for
press lines, punches and shears
IndraMotion for Metal Forming is the modular, scalable motion control
system for particularly cost-effective single- and multi-axis applications on
metal forming systems. Pre-programmed controls, compact operator termi-
nals and intelligent drives with a wide range of rotary and linear motors
ensure maximum productivity.

With IndraMotion for Metal Forming, motion control techno-

logy and standardized PLC functionality merge into a perfect
motion control system. Expanded with the integrated appli-
cation-specific technology functions, it is tailored exactly to
the requirements of modern production facilities. Indra-
Motion for Metal Forming handles all synchronization and
positioning tasks particularly efficiently. It is available for
the following applications:

Single-axis applications with IndraMotion MLD-S

ff rollfeeds, feed straighteners
ff flying shear
ff rotary shear
ff unwinders
ff straighteners

Multi-axis applications with IndraMotion MLD-M and

IndraMotion MLC
ff blanking lines
ff profiling systems
ff perforating presses (incl. shear computer)
ff zig-zag feeds cc IndraMotion for Metal
Forming is the highly
ff push pull feeder
productive system
ff stacker and destacker solution for presses,
ff electronic controlled press transfer shears and blanking
ff tandem press lines lines.
ff crossbar transfer and compact crossbar transfer systems
ff stacking devices
ff servo presses
 IndraMotion for Metal Forming  5

IndraMotion for Metal Forming makes uncompromising use ff low installation expenditure and rapid commissioning
of recognized worldwide standards and unlocks the door to thanks to configured system components
consistent, open system solutions which are based on
standardized hardware and software architectures. Increased plant safety thanks to:
ff redundant encoders
IndraMotion for Metal Forming is characterized by: ff safety in case of mains failure
ff preconfigured controls
ff scalable drive platforms with high dynamic motors with Increased productivity thanks to:
a power range from 0.1 kW to 630 kW ff programmable online collision monitoring
ff IEC-compliant programming with PLCopen modules ff intelligent monitoring function for preventative mainte-
ff certified safety technology compliant with EN ISO nance
13849-1, Cat. 3 PL e and EN 62061 SIL 3
ff integrated engineering framework for project planning,
programming, visualization and diagnosis
ff optional technology and communication interfaces
ff operational technology functions as a basis for applica-
tion-specific ready-to-apply solutions
ff easy integration of decentral drive solutions into existing
or newly designed control concepts
6 Safety on Board

Safety on Board – certified safety in

metal forming technology

C Standard Machine typ Safety-related control functions according to EN ISO 13849-1 and EN 62061

Set-up and test strokes Separating guards

(fixed, mobile or locked)

EN 692: Feb. 08 Mechanical presses and servo presse Safe Operation Stop (SS2, SOS), Safe Maximum Speed (SMS) against parts
Safely Limited Speed (SLS) < 10 mm/s, being catapulted out,
Safe Monitored Direction (SDI), Safe Door Locking (SDL),
EN 693: Apr. 01 Electrical transfer in hydraulic presses, Safely Limited Position (SLP), Safe Torque Off (STO),
variable-speed pump drives Safely Limited Increment (SLI) Safely Monitored Deceleration (SMD),
Safe I/O (SIO)

EN 13675: Sept. 04 Tube forming and rolling mills If access to a hazard zone
SS2, SOS, SLS, SDI, SLP, SLI

Certified safety functions in the high-dynamic, intelligent

IndraLogic
servo drives from Rexroth provide a reliable means of pre-
venting collisions and therefore increase the availability of
the overall system.
IndraMotion MLC IndraMotion MLC
SafeLogic and SafeMotion, the safety functions from Rex-
Redundant
roth, make it easier to implement safe machine concepts press encoder
and minimize unproductive downtimes. IndraDrive/IndraDyn IndraDrive/IndraDyn

sercos

Operators need safe access to the press compartment for Redundant

motor encoder
tool changing, manual loading, unloading and troubleshoot-
sercos safety
ing. When guard doors are open, functions such as „Safe or PROFIsafe
Operating Stop“, or „Safe Reduced Speed“ protect person- Inline SIL 2 IO SIL 3 IO
nel from uncontrolled axis movements. The reliable monito-
ring of movement ranges prevents hazards caused by unac-
ceptable axis positions of for example press feeders.
Reliable speed monitoring is also possible in automatic
Auto Manual
mode in the interest of process optimization.
 Energy efficiency  7

Energy efficiency from Rexroth –

benchmark for energy savings

Rexroth supports your mechatronic system optimization and with the 4EE concept,
has developed solutions aimed at reducing energy consumption in production pro-
cesses and in plant and machinery. IndraMotion for Metal Forming consistently turns
this concept into reality, helping you secure a competitive edge by keeping energy con-
sumption to a minimum. The key factors are innovative drive technology, a user-friendly
configuration tool and energy-optimized motion design.

Energy saving drive units Software tools for machine

ff common DC bus optimization
ff power supply units with ff controller-integrated
energy recovery capability software tool for cycle
ff efficiency of 97 % and energy efficiency
analysis
Highly efficient motors ff integrated energy con-
ff optimized winding techno- sumption meter in drive
logy units (kWh metering)
ff efficiency > 95 %
Mechatronic support
Decentral and integrated service
drive technology ff holistic analysis of the
ff one hybrid cable – up to mechatronic behaviour
85 % reduction in cabling of the system to achieve
ff up to 70 % reduction in optimum process effici-
required cabinet size ency
ff use of a range of simula-
IndraSize software tool for tion tools
design optimization
ff selection of the mechanical Energy efficiency
components ff Energy System Design
ff predefined motion profiles ff Energy Efficient Compo-
ff database with optimized nents
motor and controller com- ff Energy on Demand
binations ff Energy Recovery
8 Scalable hardware architecture

Scalable hardware architecture for maximum

efficiency

Motion logic Motion logic Motion logic

drive-based drive-based controller-based

Engineering
Engineering Operation
Operation

Ethernet
Ethernet Ethernet
Ethernet Ethernet
Ethernet

Fieldbus
Fieldbus Fiedbus
Fiedbus

Ethernet
Ethernet Ethernet
Ethernet Cross
Cross communication
communication

Fieldbus
Fieldbus

IndraControl
IndraControl VV IndraControl
IndraControl VV IndraControl
IndraControl LL IndraControl
IndraControl VV

Inline
Inline

MLD
MLD MLD
MLD

IndraDrive
IndraDrive Inline
Inline Inline
Inline IndraDrive
IndraDrive Pneumatics
Pneumatics IndraDrive
IndraDrive

IndraDyn
IndraDyn IndraDyn
IndraDyn IndraDyn
IndraDyn

Hydraulics
Hydraulics

IndraMotion MLD-S IndraMotion MLD-M IndraMotion MLC

(optional SMC)

ff consistent automation system for drive and controller- ff standardized IndraWorks engineering framework for
based applications motion, logic, HMI and drives
ff open communications standards and standardized ff plug-and-play system solutions and application-
IEC 61131-3 compliant PLC platform specific technology functions
ff end-to-end sercos III system bus for controllers, ff Sequential Motion Control – the modular 6-axis control
drives, I/O and safety devices for fast programming
 Integrated technology functions  9

Integrated technology functions – easy

engineering

Large-scale and sophisticated applications can be handled

with our ready-to-use function libraries and predefined
technology functions. You then use the IndraWorks engineer-
ing framework to add these functions to your applications
program and speed up configuration and parameterization
of the entire system.

Benefits
Easy realization of common forming tasks through drive
integrated firmware functions, e.g.:
ff cam tables
ff electronic motion profile
ff measuring wheel mode
ff parameter set switching
ff positioning block mode (up to 64 position sets)
ff drive positive stop procedure
ff redundant motor and press encoder
ff virtual master axis generator

Portfolio
The rapid implementation of complex automation tasks
through tailored technology functions:
ff crank kinematics
ff cross communication
ff cross cutter/rotary shear
ff feeder
ff FlexProfile
ff flying shear
ff gantry axes
ff loop control
ff master/slave
ff perforation feeder
ff preventive diagnosis
ff programmable limit switches
ff real master encoder
ff robotic kinematics
ff tension control
ff winder/unwinder
10 Program frame

Program frame – be up and running

quicker with Rexroth system solutions

The program frame allows for fast and simple programming for machine
manufacturers. It offers high-performance, scalable project templates that
are ready for switch-on. This offers a simple solution for modular machine
concepts and increasingly complex tasks.

Features Benefits
The program frame is a template project by means of which ff engineering costs reduced by up to 60 %
a motion application including visualization (WinStudio) ff fast initial commissioning
can be generated and commissioned within a few minutes. ff open for extensions due to IEC-compliant programming
ff basic functions like operating mode handling and error with PLCopen modules
diagnosis (including PROFIBUS diagnosis) ff fast and simple adjustment to the periphery: drives,
ff simple implementation of own application-specific visualization, inputs/outputs etc.
errors with language-dependent display as well as own
messages as information to the user Axis interface
Rexroth has developed the axis interface with the aim to
reduce the complexity of motion logic systems. The axis
Program frame visualization
interface simplifies the commanding of the axes by
PLCopen and comprises additional special functions like
e.g. the FlexProfile. In this way, programming errors are
minimized.

FlexProfile and CamBuilder

In modern, high-performance forming machines, optimized
motion sequences increase the production output and
reduce the mechanical wear. Using the FlexProfile, you can
define an individual motion sequence for each axis, on the
basis of a library of more than 20 laws of motion or a table
of support points.

By means of the CamBuilder, the motion profiles can be

generated very easily in a graphically supported form. The
CamBuilder is able to compare several profiles in a simula-
ted form and to load the curve parameters into the control
or to automatically generate PLC function modules.
 Program frame  11

Turnkey solution for the 3D press transfer

One application of the program frame is the 3D press trans- Nominal operating torque range monitoring for press
fer. The template project contains all required functions for a transfer
press transfer like setup, manual, automatic and simulation. Use of this function is particularly useful in series production
where the products have reproducible torque curves
ff setup: separate movement of the axes and correct throughout the whole production period. The monitoring
alignment of distorted mechanical transfer components, function notifies when the measurement curve deviates from
if necessary the torque reference curve within a tolerance band.
ff manual: movement of synchronized axis groups (lifting,
closing and shifting) Deviations may e.g. result from mechanical wear and preven-
ff automatic: the transfer follows the press encoder tative maintenance can be carried out outside the produc-
ff simulation: simulation of a press in order to be able to tion periods in a planned manner. If the monitoring function
also carry out the transfer without real press and to also notifies that the suction device has lost material, the press
move the transfer into basic position in case of error or can be stopped immediately and in this form, more far-reach-
press stop ing damage can be prevented.

For the adjustment of the transfer curves (FlexProfile), data

can be entered.

Automatic operating mode Outer circle monitoring

12 Turnkey single-axis solutions for rollfeeds

Rollfeeders – turnkey single-axis

solutions

Based on the IndraDrive, the intelligent drive platform, and the drive-inte-
grated single-axis automation system MLD-S, IndraMotion for Metal Forming
offers plug-and-play solutions for rollfeeder applications.

The predefined rollfeed solutions are available in two varia-

Motion logic
drive-based tions to ensure rapid implementation and commissioning of
your application:

Rollfeed Standard (RFS)

This is the complete single-axis controller for standard
Engineering
rollfeeder systems and includes the operator control units Operation

Ethernet andEthernet
HMIs. No need to program – just enter
Ethernet the production
data and production can begin!
Fieldbus Fiedbus

Rollfeed Extended (RFE)

RFE offers all the functions of RFS as well as the following:
Ethernet
ff 8 tools including input or time acknowledgment
Ethernet Cross communication
ff integrated programmable limit switches Fieldbus
(8 PLS in
250 μs)
IndraControl V IndraControl V IndraControl L IndraControl V
ff press encoder
ff part and product data linking (batching)

Inline

MLD MLD

IndraDrive Inline Inline IndraDrive Pneumatics IndraDrive

IndraDyn IndraDyn IndraDyn

Hydraulics

IndraMotion MLD-S
 Turnkey single-axis solutions for rollfeeds  13

Benefits Roll feed solutions RFS RFE1)

ff less installation expense thanks to configured versions Operating modes (parameter, manual, automatic, l l
setup)
ff rapid commissioning and short initiation periods due to
Feed before press (single stroke, continuous) l l
menu-driven navigation Press before feed (single stroke, continuous) l l
ff scalable in power and functionality Product counter l l
ff certified safety technology conforming to EN ISO Clear text diagnosis l l
13849-1, Cat. 3 PL e and EN 62061 SIL 3 Multilingual operator terminal l l
I/O status l l
ff wide range of high-dynamic rotary and linear motors Production data
ff easy device exchange thanks to central data storage on ffFeed angle utilization as % l l
ffStrokes per minute l l
flash card (MMC) ffAverage web speed l l
ff use of flash memory eliminates the need for batteries Measuring wheel  
for data buffering Analog speed override l1) l
ff unified control platform reduces variants and number Micro-adjust l l
of spare parts Roll lifting (manual/auto) l l
ff less mechanical wear due to automatic feed angle Data management for 99 products
adjustment ffFeed length l l
ffSpeed l l
ffAcceleration l l
ffJerk l l
ffPiece counter l l
Flash card (MMC) for central data storage l l

Preconfigured HMI screens l l

Rollfeed PC-less commissioning l l

Serial pass-through mode (2 x Com-Port) e.g.
l l
for communication with the press control
Control communication
ffParallel/PROFIBUS / /
ffDeviceNet/sercos III q/q q/q

Start/stop/cycle stop l l

Reset product counter, piece counter l l

Flexible I/O-Logic l l
Integrated safety technology certified to
2) 
EN ISO 13849-1 and EN 62061
Master axis coupling (motion profiles) via virtual
l l
or real encoders
Press encoder interface – l

Up to 6 feed lengths per product – l

Batching (linking of products), up to 594 feeds – l

Tools before and after the feeder – 8

Automatic feed angle optimization – l

Number of PLS (integrated, dynamic programmable
– 8
limit switch)
l Default  Optional q In preparation – Not available
1) ADVANCED control unit 2) With BASIC „Safe Torque Off“ control unit
14 Turnkey solution for flying shear

Flying shear – turnkey solution for

continuous production

Roller profiles, welded pipes, particle boards and press profiles place high
demands on production and storage. The products cannot be winded up.
In order for the production to remain economical, the products are cut to a
defined length during production.

Motion logic
drive-based

Engineering Operation

Ethernet Ethernet Ethernet

Fieldbus Fiedbus

The IndraMotion for Metal Forming SPF (Synchronous

Process Flying Shear) solution that is ready for switch-on
Ethernet
is ideal Ethernet
for the production of pipes, plates and profiles.
Cross communication
The latter are cut to production length immediately
Fieldbus after
the production.
IndraControl V IndraControl V IndraControl L IndraControl V

The complete package is comprised of an IndraDrive drive

controller with integrated motion logic (IndraMotion MLD),
Inline
a HMI, a wide range of rotary and linear motors and pre-
MLD assembled
MLD cables. The easy to use IndraWorks engineering
framework makes the job of commissioning much simpler.
Flying shear systems
IndraDrive Inline The system can optionally
Inline be expanded to meet your speci-
IndraDrive Pneumatics IndraDrive
fic requirements by adding additional I/O modules or exter-
nal encoders.
IndraDyn IndraDyn IndraDyn

Hydraulics

IndraMotion MLD-S
 Turnkey solution for flying shear  15

Features Flying shear SPF 1)

ff 3 different registration modes Operating modes

ff tool and product data administrator included ffParameter, manual, automatic l
ff advance signal to prestart hydraulic and pneumatic ffTest mode (simulation mode) l
system valves Various cutting modes, like crop cut, immediate cut, test cut and l
ff integrated crop cut, immediate cut and test cut inhibit cut
Preconfigured HMI screens l
ff drive integrated certified safety technology conforming to
Clear text diagnosis l
EN ISO 13849-1 and EN 62061, plus auxiliary monitoring
Multilingual operator terminal l
systems for maximum part lengths, travel ranges, etc.
I/O status l
ff open PLC interfaces for versatile, specific optimization
Simple start-up
alternatives
ffDirect access to all parameters via HMI and PC l

Additional axes ffPreconfigured screen masks on HMI and PC l

The integrated cross communication module (CCD) enables Second encoder (measuring wheel) l

additional axes such as tool axes to be controlled. The cross Certified, integrated safety technology conforming to EN ISO 
13849-1 and EN 62061
communication is based on the powerful, service-proven
Tool management l
sercos III protocol and therefore offers the highest possible
ffUser-defined tool programs 20
precision and speed based on Ethernet.
Product management l

ffUser-defined parts 100

Benefits
Presignal l
ff high degree of flexibility thanks to the open PLC interface
Monitors maximum part length and material length pulse l
ff elimination of external controllers offers potential for
Control communication system via parallel interface and field- l
savings
buses (e.g. PROFIBUS)
ff increased productivity thanks to electronic cams and Flash card (MMC) for central data storage l
high-performance drive technology Optimized return l
ff safety on board to minimize idle time Registration mode (3 modes)
ff absolute precision thanks to fastest possible probe ffExpectation window for corrections l
processing ffCut on registration signal (incl. mask out section and offset l
ff scalable drive technology reduces different configurations dimension)
ffCounter mode (incl. offset) l

Probe input for maximum precision 4 µs

Handling of short parts l

Bad material detection l

Ethernet communication to PC and HMI l

sercos III Ethernet interface l

sercos III Inline Block I/O (16DI/16DIO)  (up to 4)

Control of additional axes via CCD 

l Default  Optional
1) ADVANCED control unit CSH01.2 incl. CCD
16 Rotary shear technology function

Rotary shear – technology function

for rotary cutters and shears

A rotary shear is generally based on a rotating cylinder with one or more

knives attached to it. In the rotation, the knives cut the material path running
through according to an exactly defined length. In this connection, Indra-
Motion for Metal Forming synchronizes the knives exactly to the material
path running through.

The drive-integrated motion logic adjusts the velocity of the

Motion logic A graphic operator interface supports
drive-based knives to position-dependent characteristics. In applica- commissioning
tions in which the knife’s motion speed exceeds that of the
material by a certain factor (overspeed factor), parts of the
knife have to be kept exactly at material speed during
cutting.
Engineering Operation

Ethernet Features
Ethernet Ethernet
ff large format range from 0.2 to 30 times the circum-
Fieldbus ference
Fiedbus of the cutting cylinder
ff overspeed in the cutting range
ff cosine-beta compensation for thicker materials
ff push-out function for separation of cut products
Ethernet Ethernet Cross communication
ff slippage and offset compensation
Fieldbus
ff auto-tuning assistant
IndraControl V IndraControl
ff suitable for rotary V
cutters IndraControl L
and guillotines IndraControl V

Benefits
Rotary shear (guillotine)
ff on-the-fly format changeover using electronic synchroni-
Inline

zation
MLD MLD
ff high-precision drive synchronization using sercos III
ff drive-integrated safety technology to minimize idle time
IndraDrive Inline Inline IndraDrive Pneumatics IndraDrive
ff more flexibility through standardized communication
interfaces such as PROFIBUS, DeviceNet, Ethernet
ff open programming standards (IEC 61131-3, PLCopen)
IndraDyn IndraDyn IndraDyn
ff low costs through process-specific function libraries and
technology functions Hydraulics

ff fewer scraps thanks to highest possible cutting preci-

IndraMotion MLD-S sion
ff optimized cams for minimal energy consumption
 Rotary shear technology function  17

Rotary shear Technology function

System platform IndraMotion MLD, MLC

Operating modes

ffParameter (entry of plant data) 

ffManual (jog) 

ffAutomatic 

ffTest mode (simulation mode) 

Format lengths (x-times synchronous format) 0.2 to 30

“On-the-fly” format changeover l

One or more (equidistant) knives l

User selectable cutting range l

Typical profile for short format lengths
Various compensation profiles

ffOverspeed in the cutting range l

ffCosine compensation in the cutting range l

ffPush-Out function l

Combination of cosine compensation and push-out l

Position [mm]
Oscillation, incl. oscillation limitation l

Energy-optimized operation
l
(acceleration-optimized, torque-optimized, etc.)

Real and virtual master axis encoders l

Speed [mm/s] Measuring wheel 

Slippage and offset compensation 

Acceleration [ms2] Correction factor for measuring wheel feed constant 

Automatic cutting profile creation l

Option of 3 cam resolution levels l

0 60 129 180 240 300 360 Cutting counter l

Control communication via parallel interface or field-

Cylinder rotation in ° l
bus

Production data display

ffActual cut length of product 

ffNext product length 

Graphical programming and commissioning


support

Certified, integrated safety technology conforming to


EN ISO 13849-1 and EN 62061

Ethernet communication to PC and HMI 

sercos III Ethernet interface 

sercos III Inline Block I/O (16DI/16DIO)  (up to 4)

Control of additional positioning axes via drive cross


communication (CCD)

l Part of the technology function

 Part of the example applications program or an option
18 Sequential Motion Control

Sequential Motion Control – fast and

effective programming

The Sequential Motion Control is an easily programmable NC control by

Rexroth. Fast familiarization for the user, shorter commissioning time and
openness for customer extensions are only some advantages of this control
solution.

Combined with AC servo drives, the modular 6-axis control

Sequential Motion Control
Sequential Motion Control (SMC) becomes a high-perfor-
mance and economic control and drive system. Due to the
modern drive family IndraDrive with Safety on Board, the
system satisfies the current safety requirements according
to latest standards.
Engineering

Ethernet TCP/UDP/IP
Typical areas of application
ff feed axes
ff flying shear systems
IndraControl L ff linear and area portals
Fieldbus ff packaging machines
IndraControl V ff thermal forming machines
ff handling devices and transfer equipment
ff processing stations (drilling, milling, etc.)
SMC ff applications with cams

Measuring IndraDrive Inline Features

wheel
ff short familiarization and commissioning times
ff hardware-related addressing of the inputs and outputs
ff 3,000 NC sets
ff optional PLC programming according to IEC 61131-3
IndraDyn
(editors IL, LD, FBD, SFC, ST, CFC already included)
ff communication via Ethernet
Analogue drive Hydraulics
ff synchronization of several axes via sercos III
ff stand alone program editor and compiler, also for use in
own PC interfaces
 Sequential Motion Control  19

Example flying shear

ee Visualization to the
The flying shear application can be realized with 12 NC Sequential Motion
lines of Sequential Motion Control code: Control control system
ff synchronization of the knives to the material path
running through
ff cut according to defined length synchronous to the
material speed
ff counting of the produced parts

Operating mode switch-over, error and diagnosis handling

as well as an optional visualization are already included in SMC equipment features if completely equipped
the Sequential Motion Control control system. Control Modular control
Fieldbuses (PROFIBUS) l
Multi-Ethernet (sercos III, PROFINET IO, EtherNet/IP) q

Number of axes 6
Operating modes
ffParameter mode l
ffManual l
ffAutomatic l
ffSetup l
ffSingle step l
Complete program of a flying shear Program data 3,000 sets
ffFree markers (volatile) 1,000
ffFree markers (remanent) 200
ffFree variables (volatile) 1,000
ffFree variables (remanent) 200
ffSystem markers l
ffSystem variables l
Inputs
ffDigital 175
ffAnalog 10
Outputs
ffDigital 120
ffAnalog 6 for SAW/2 free
Encoder 12
2 encoders SSI
Integrated special functions
ffMeasuring wheel function l
ffPerforation processing l
ffCams l

l Basic equipment q In preparation

20 Multi-axis solutions for blanking lines

Blanking lines –
automated intelligently with multi-axis
solutions
IndraMotion for Metal Forming is the scalable automation solution for com-
plex applications such as blanking lines, flying shear systems and profiling
systems. IndraMotion MLD-M, the drive-based control system, and Indra-
Motion MLC, the controller-based multi-axis control, are the ideal founda-
tion.

Extensive firmware and technology functions are available

Motion logic Motion logic
drive-based controller-based end to end for both platforms. Equipping individual stations
or automating a complete system – whatever you want to
do, the modular system will meet all the requirements of
your business.

Engineering Both
Operation Operation systems offer the following:
Ethernet Ethernet
Ethernet ff communication with higher-level control systems
ff modular I/O components
Fiedbus ff internationally recognized interfaces such as sercos,
PROFIBUS, DeviceNet, parallel interface and Multi-
Ethernet
ff standardized engineering framework
Ethernet CrossCross communication
communication
ff IEC 61131-3 and PLCopen-compliant programming
Fieldbus
Fieldbus
ff virtual and real master axes
IndraControl V IndraControl
IndraControl L L IndraControl V

IndraMotion MLD-M is designed for applications with up to

10 axes and low requirements on I/O peripherals and sen-
Inline sors. Fully integrated into the drive unit, it allows the per-
formance capability of this modular and flexible drive
MLD
system to be utilized to the maximum.

Inline IndraDrive
IndraDrive Pneumatics
Pneumatics IndraDrive
IndraMotion MLC is the right choice if you have enhanced
requirements on your peripherals – up to 64 axes are possi-
ble. IndraMotion MLC also permits cross communication
IndraDyn
IndraDyn IndraDyn
with additional control systems through sercos.
Hydraulics
Hydraulics

IndraMotion MLD-M IndraMotion MLC

(optional SMC)
 Multi-axis solutions for blanking lines  21

Blanking line

+ +
Handling and transport systems with
Rexroth servo drives remove, transport
and stack the finished parts. Fast
unloading of parts makes it possible to
realize high production rates.

Straightening unit driven

by a Rexroth drive.

A high dynamic servo drive system feeds the

material into the press precisely and reliably. The
synchronization with the press is effected through
Drives by Rexroth for precise tension control cam switches or alternatively through electronic
and hydraulic coil changing system. cams via a press encoder.

Features Benefits
ff open system architecture thanks to support of all ff greater machine availability because of the reliable drive
common fieldbus systems, Ethernet, OPC and sercos and control equipment and global support
ff flexible, high-performance motion logic integration ff higher stroke numbers due to the high dynamic servo
ff system solution with continuity for all applications in axes and short system cycle times
the press shop ff protection of the mechanical system through selectable
ff full range of high dynamic, robust servo drives sequences of motion – high dynamic or soft motions
depending on the respective part and material
ff fast product change thanks to shorter tool set up times
ff low energy consumption through DC links of all axes
22 New concepts for electronically controlled press transfer

Electronically controlled press

transfer – new concepts for absolute
precision
IndraMotion for Metal Forming replaces expensive and high maintenance
mechanical elements in your press transfer system: for example, high-pre-
cision servo drives are used instead of cams or limit switches. Further-
more, the highly valuable flexibility of the motion control system enables
new machine concepts to be realized with high precision.

The synchronization of all processes is achieved through

Motion logic
controller-based the programmable motion sequences – also between the
electronically controlled press transfer and hydraulically
controlled press.

Features
Operation ff open system solution with standardized interfaces
Ethernet ff mechanical cams are replaced by flexible electronic
cams
ff electronic synchronization of the press transfer for
maximum press strokes
ff virtual master axis for checking the clearance of transfer
Cross communication
and tool
Fieldbus ff switching of press encoder and virtual master axis with
cycle end and block restart
IndraControl L
ff adaptable filtering of press encoder
ff redundant motor and press encoders
ff avoidance of collisions in the event of power failure

Benefits
ff higher stroke numbers due to the servo axes and short
IndraDrive Pneumatics system cycle times
ff shorter tool setup times due to the fast adjustment of all
motion functions
IndraDyn ff optimized part handling in all operating modes
Hydraulics
ff protection of the mechanical system through selectable
sequences of motion – powerful or soft motion depend-
ing on the respective part and material
IndraMotion MLC
ff avoidance of collisions, down-times and repair costs
 New concepts for electronically controlled press transfer  23

Electronically controlled press transfer

The motion control solution coordi-

nates the movements of all axes and
the addressing of the I/O logic in all
operating modes, thus ensuring
precise synchronization between
Hydraulically controlled Rexroth transfer and press.
coupling and brake combination.

Use of a redundant press encoder

enhances machine safety.

Intelligent servo drives for high dynamic

gripping, lifting, and transport of the
parts between the press sections.
Synchronization with power failure
protection due to DC bus coupling to the
main drive. Collisions between tool and
transfer are avoided by using redundant Finished parts of the highest
motor encoders. quality, produced with maximum
stroke rates and minimum scrap.
24 Automation of crossbar transfer and compact crossbar transfer systems

Crossbar transfer and compact

crossbar transfer systems – modular
and flexible automation
IndraMotion for Metal Forming by Rexroth economically and accurately syn-
chronizes all axes of the (compact) crossbar transfer system – from the
unstacking device via tool cars and transfer axes to the stacking device and
conveyor belts.

Up to 64 controls synchronize with a maximum of 64 servo

Motion logic Crossbar transfer system
controller-based drives on each control. Faster start up, easier servicing and
enhanced reliability thanks to the decentralized, modular
system architecture.
All movements of the servo axes are
referenced to the press motion through
Features electronic cams via redundant press
Operation ff open system solution with standardized interfaces encoders or a virtual master axis.
Ethernet ff expandable synchronization with up to 64 controls
ff electronic synchronization of the transfer to the press
for all press stroke rates
Reliable production due to well establis-
ff virtual master axis for checking for presence of obsta- hed strategies for collision avoidance.
cles of the press transfer and tooling
Cross communication
ff switching of press encoder and virtual master axis
Fieldbus with cycle end and block restart
ff adaptable filtering of press encoder Compact crossbar transfer system
IndraControl L
ff redundant motor and press encoders
ff mechanical cams are replaced by flexible electronic
Maximum availability and production
cams output performance with motion control
ff avoidance of collisions in event of power failure and servo drives.

IndraDrive Pneumatics

IndraDyn Optimization of transfer motion using

freely programmable motion profiles.
Hydraulics

IndraMotion MLC
 Automation of crossbar transfer and compact crossbar transfer systems  25

Benefits ff parts orientation between the tools, including parts

ff higher stroke rates and short system cycle times with complex geometries
ff shorter tool setup times due to the fast adjustment of ff faster start up, easier servicing and high reliability
all motion functions thanks to the modular system structure
ff optimized part handling in all operating modes ff avoidance of collisions, downtimes and repair costs
ff protection of the mechanical system through selectable
sequences of motion – powerful or soft motion depend-
ing on the respective part and material

Efficient production at increased rates

thanks to the motion logic system.

+ +

Protective functions such as redundant motor and press

encoders ensure that the production system is safe.
 26 Motion logic integration for tandem press lines and feeder

Tandem press lines and press feeder –

innovative motion logic integration

IndraMotion for Metal Forming ensures smooth transfer of parts between

presses at high rates and with state of the art safety characteristics. This
includes control of unstacking and conveying devices, setting stations,
orientation stations, part turning devices, tool changing devices, shuttles
and the main press drives.

Faster start up, easier servicing and enhanced reliability

Motion logic controller-based
thanks to the decentralized, modular system architecture

Features
ff precise coordinated movements from setting stations
to the complex kinematics
ng Operation ff electronic cams for programming smooth motion pro-
Ethernet cesses
ff high-performance, flexible programming system for
online warning and collision avoidance
ff intelligent monitoring function for preventative mainte-
nance (Productivity Agent)
Cross communication
ff absolute encoders allow for a fast restart without
Fieldbus repeated referencing
ff cross communication between the control systems
IndraControl L IndraControl V
ensures press synchronization

Benefits
Inline
ff higher stroke rates due to short system cycle times
ff avoiding collisions between the press tool and feeder
and between the feeders
IndraDrive Pneumatics IndraDrive ff greater machine availability
ff modular system structure for faster start up, easier
servicing and high reliability
IndraDyn IndraDyn

Hydraulics

IndraMotion MLC
 Motion logic integration for tandem press lines and feeder  27

Tandem press line and press feeder

+ + + +...

Expensive collisions and ensuing downtime are High dynamic servo drives on the press feeders
avoided thanks to the integrated safety functions. improve parts flow to the tandem press line.

Complex part positioning with a multi-axis Rexroth linear modules with intelligent The Rexroth motion control solution
orientation station – perfectly coordinated. drives ensure reliable production. providing high precision control of
complex kinematics for feeder systems.
28 Optimal process adaptation for servo presses

Servo press – optimal process adap-

tation and increased productivity

IndraMotion for Metal Forming opens up a whole new range of possibilities

for your servo presses. The FlexProfile technology function makes it possible
to adapt the motion profiles to the metal forming process, the tool and the
automation system to optimum effect. This means a significant increase in
strokes per minute for the same or even reduced drawing speed.

With FlexProfile, the motion curves can be optimally adjust-

Motion logic
controller-based ed, regardless of whether the servo press is used as an
automatic punching and forming unit, a transfer system or
cutter press, or integrated in fully automated press lines.

Features Servo press

Operation ff open system solution with standardized interfaces Excentric press
Ethernet ff electronic cams (FlexProfile) for optimum adaptation of
cc Motion profile of the
the motion kinematics servo press in normal
ff direct power input from the servo main drive operating mode compa-
ff full torque availability starts at stroke rate of 1 stroke/min red to an eccentric press

ff kinetic buffering and capacities for compensating mains

Cross communication
voltage failures and energy peaks
Fieldbus ff redundant motor and press encoders
ff avoidance of collisions in the event of power failure
IndraControl L
ff flexible test mode possible because the ram movement
is reversible in every position
Servo press

Mechanical press
Benefits
ff increased production output performance thanks to cc Motion profile of the
servo press in oscillating
individual adaptation of the motion profiles
mode compared to a
IndraDrive Pneumatics ff process optimization because all sub-processes are freely mechanical press
programmable
ff shorter tool setup times due to the fast adjustment of all
IndraDyn motion functions
Hydraulics
ff high output thanks to programmable ram motion kinema-
tics (oscillating mode)

IndraMotion MLC
 Optimal process adaptation for servo presses  29

Servo press

+ +

In combination with the servo drives the

Rexroth motion control solution offers
maximum motion model versatility and
minimum downtimes.

Collisions between tool and

transfer are avoided by using
redundant motor encoders.

Use of a redundant press encoder

enhances machine safety.
30 System solution and hardware

The appropriate system solution for

every application with IndraMotion
MLC
IndraMotion for Metal Forming meets all control and drive requirements for
press automation. The scalable system concept allows for automation of all
types of presses, from simple independent machines to complex produc-
tion plants.

You can rest assured that system integration even into and hydraulic axes is possible for IndraMotion for Metal
existing plants is easy thanks to the open structure of the Forming as it is operating the pneumatics system.
IndraMotion MLC motion control with standardized PLC
platform based on the IEC 61131-3 standard and the use The central or distributed logic functionality with analog
of internationally accepted fieldbus standards. and digital peripheral I/O rounds off the system and often
acts as a substitute for an additional PLC.
And with sercos there is virtually unlimited capacity for
expansion of production plants by extending cross commu-
nication between controls. Interpolation between electric

Operation
Ethernet

Cross communication
Redundant
press encoder IndraControl L 3rd party control

Inline Pneumatics Redundant

motor encoder

IndraDyn IndraDyn IndraDyn

Hydraulics
 System solution and hardware  31

Open hardware options through IndraControl L

MLC functional modules Description MLC functional modules Description

DeviceNet master ff CFL01.1-V1 sercos III ff CFL01.1-R3

ff Master functionality for DeviceNet ff Control communication
ff Transmission rates 125, 250, 500 kB ff Master axis cross communication
ff Medium: Ethernet
PROFIBUS master ff CFL01.1-P1
ff Data rate: 100 MB
ff PROFIBUS master functionality
ff With operation of the on board Encoder interface ff CFL01.1-G1
interface as slave (in development) ff 1 x EnDat interface
ff For (redundant) real ref. value encoder
Programmable limit ff CFL01.1-N1
switch ff 16 outputs Fast I/O ff CFL01.1-E2
ff Scanning frequency 125 µs ff Fast digital inputs/outputs
ff 8 inputs, 8 outputs
sercos II ff CFL01.1-Q2
ff 8 freely programmable I/O
ff Master axis cross communication
ff Medium: sercos FOC SRAM ff CFL01.1-Y1
ff MLC interface with max. 64 MLC (for robot control) ff Memory: 8 MB
ff Axis synchronization with MLC ff With battery back-up

IndraControl L, the space-saving control platform, offers With the use of function modules, IndraControl L can be
you a whole range of expansion options in different classes optimally integrated in heterogeneous control landscapes
of performance. and adapted to your specific functional requirements.

Encoder interface Programmable limit switch

sercos III Fast I/O

SRAM (for robot control) sercos II

PROFIBUS master DeviceNet master

32 System features in detail

System features in detail

Blanking line Servo press

(straightener and rollfeed)

Zig-Zag feeder Press transfer

Profiling system inc. flying shear system Tandem press line

Blanking line (Compact) Crossbar transfer

(unwinder with direct pull-off, straightener and rollfeed)
 System features in detail  33

1 Hardware IndraMotion 8 Functions IndraMotion

MLD MLC MLD MLC

1.1 Number of axes per controller 10 64 1) 8.1 Motion control

(real, virtual, encoder, network)
8.1.1 Single axis with torque control l l
1.2 Max. number of controllers network (C2C) – 4,096
8.1.2 Single axis with speed control l l
2 Supported drives 8.1.3 Single axis positioning l l

2.1 IndraDrive M, C, Mi, Cs l l 8.1.4 Electronic synchronization, phase synchronized l l

2.2 IndraDrive Fc (via fieldbus) – l 8.1.5 Electronic synchronization, velocity synchronized l l

2.3 Generic drives with sercos PackProfile – l 8.1.6 Cams drive-based 4 per drive
(max. 1.024 points)
2.4 Hydraulic drives – l
8.1.7 Cams controller-based – 99
2.5 Hybrid axis (FcP/SvP) l l
8.1.8 Points table for cam l l
3 Communication interfaces on board
8.1.9 Segmented cam profile (up to 16 segments) l l
3.1 sercos III l l
8.1.10 Rexroth FlexProfile – l
3.2 PROFIBUS V1 master/slave –/l l/l 2)
8.1.11 Virtual master l l
3.3 PROFINET IO controller/device –/l l/l 3)
8.1.12 Real master l l
3.4 EtherNet/IP scanner/adapter –/l –/l 3)
8.2 Robot control
3.5 Ethernet TCP/IP l l 8.2.1 Number of kinematics (number of robots) – 16

3.6 Master axis interface (cross communication) – l 8.2.2 Maximum number of axes per kinematic – 8
via sercos III
8.2.3 Linear/circular/point-to-point interpolation – l
4 Inputs/outputs on board
8.2.4 Movements with blendings – l
4.1 Highspeed digital inputs/digital outputs l 8/8
8.3 Logic control
4.2 Drive I/O (depending on configuration) l l
8.3.1 IndraLogic PLC kernel compliant with IEC 61131-3 l l
5 Optional function modules 8.3.2 Freely configurable tasks 4 8
(cyclical, free-running, event-controlled)
5.1 Real-time Ethernet/PROFIBUS master/slave – l
8.3.3 Minimal cycle time (sercos/motion) 0.25/1 0.25/1
5.2 sercos II master – l
ms ms
5.3 sercos III – l
8.3.4 Program memory 2 MB 8 MB
5.4 SRAM – l 8.3.5 Free memory for retain data 32 kB 256 kB
5.5 Highspeed PLS (125 µs/16 outputs) – l 8.4 Technology functions (selection)

5.6 Fast I/O: 8 inputs (typ. delay time of 40 µs), 8 in- – l 8.4.1 Adjusting l l
puts/outputs, 8 outputs (typ. delay time of 70 µs)
8.4.2 Rotary shear l l
6 Local inputs/outputs
8.4.3 On-the-fly machining l l
6.1 Inline – l
8.4.4 Roll feeder l l 4)
(IP20, digital I/O, analog I/O, temperature, etc.)
8.4.5 Probe l l
6.2 sercos III Inline Modular bus coupler l l
8.4.6 Crank kinematics l l
6.3 sercos III Inline Block I/O (analog/digital) l l
8.4.7 Loop control – l
6.4 Fieldline (IP67) – l
8.4.8 Tension control l l
7 HMI connectivity
8.4.9 Sensorless winding l/–/– l/l/l
7.1 IndraControl VCP (controller-based) Ethernet (controller/force transducer/dancers)

7.2 IndraControl VEP (embedded-PC-based) Ethernet 8.4.10 Productivity Agent l l 5)

7.3 IndraControl VSP (industrial PC-based) Ethernet 9 Engineering Framework

9.1 IEC 61131-3 compliant programming IL, ST, FBD,

languages LD, SFC, CFC

9.2 Cam editor/CamBuilder l l

l Default q In preparation – Not available
1) IndraControl L65 9.3 Online/offline switching l l
2) IndraControl L40: PROFIBUS master/slave, IndraControl L65: PROFIBUS master 9.4 Startup wizards l l
3) IndraControl L40: not available

4) Technology function in drive 9.5 Diagnostics and debugging l l

5) Extension pack in drive
34 Scalable system components

Scalable system components

for flexible automation

IndraMotion MLC – scalable motion-logic system

ff superior performance for synchronizing up to 64 drives
per control
ff easy expansion using function modules for communica-
tion and technology
ff direct connection for local inline I/Os, high-speed I/Os
already on board
ff sercos III, PROFIBUS, PROFINET IO, Ethernet/IP, Device-
Net, Ethernet TCP/IP, and RS232 communication inter-
faces
ff easy device exchange, since all data is on removable
media
ff future-proof thanks to extended hardware availability

IndraControl VCP, VCH, VEP and VEH – convenient HMI

ff economic HMI solutions for all applications
ff controller-based control panel IndraControl VCP – graphi-
cal versions with keys and touch screen, display sizes 7.6
to 26.4 cm (3“ to 10,4“)
ff embedded PC terminals IndraControl VEP with touch
screen, display sizes 21.3 to 38.1 cm (8.4” to 15“)
ff manual control unit IndraControl VCH and VEH for mobile
use
ff open interfaces for Ethernet, serial, PROFIBUS and
DeviceNet (type-dependent)
ff ergonomic software tools for the fast generation of
screen masks

IndraControl VPP and VSP – powerful industrial PC

ff standard and high-end versions with state-of-the-art
processor technology
ff wide range of panel and control cabinet PC with remote
displays as well as PC HMI
ff key or touch screen versions, with displays ranging from
30.5 to 48.3 (12.1“ to 19“) in size
ff extensive range of accessories such as terminals, mem-
brane keyboards and UPS
ff intuitive configuration with the engineering framework
IndraWorks and the integrated WinStudio
 Scalable system components  35

Inline – flexible I/O system in IP20

ff scalable I/O system for central or distributed connection
ff maximum selectivity of the digital modules with 2, 3 or
4-wire technology
ff cost-effective solutions with block I/O modules
ff wide portfolio with analog, function, relay and feeder
terminals
ff toolless assembly and space-saving design
ff flexible connection through permanent wiring and inter-
nal voltage supply
ff fieldbus couplers: PROFIBUS, DeviceNet, PROFINET IO
and sercos III

IndraControl S67 – the versatile IP67 I/O system

ff modular, ergonomic I/O system for distributed topologies
ff broad portfolio of I/O and technology modules and field-
bus couplers
ff compact IP 67 enclosure
ff latest hardware design supports maximum sensor and
actuator signal processing speeds
ff threaded or DIN rail mounting
ff M8 and M12 signal line terminals
ff prefabricated fieldbus, power and subbus cables

IndraDrive and IndraDyn – scalable drive platform

ff scalable outputs from 0.1 kW to 630 kW
ff highest performance and precision
ff Safety on Board conforming to EN ISO 13849-1, PL e
Cat. 3 and EN 62061 SIL 3
ff integrated drive PLC (optional)
ff power recovery and direct connection to mains supply
from 380 V to 480 V
ff infeeding power supply from 380 V to 500 V
ff integrated line contactor and braking resistor
 Bosch Rexroth AG
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 9352-40-0
Fax +49 9352-40-4885
www.boschrexroth.com

Find your local contact person here:

www.boschrexroth.com/addresses

The data specified above only serve to describe the product.

As our products are constantly being further developed, no statements
R999000041 (2011-12) concerning a certain condition or suitability for a certain application can be
© Bosch Rexroth AG 2011 derived from our information. The information given does not release the user
Subject to revisions! from the obligation of own judgment and verification. It must be remembered
Printed in Germany that our products are subject to a natural process of wear and aging.