Electric Drives. Linear Motion and

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Rexroth IndraMotion for Metal Forming 07VRS Flying Shear

Reference Book

DOK-IMMLD-TFSPF**V07-RE02-EN-P

RS-127d7105502b0cba0a6846a001b01dcb-2-en-US-14

This document describes the Flying Shear turn-key solution. It details the sys‐

tem hardware and firmware features and functionalities. It also details the system setup and commissioning as well as troubleshooting information.

Edition Release Date Notes

120-2950-B318/EN -01 07.2009 Released version

120-2950-B318/EN -02 01.2010 Edition 02

Copyright © Bosch Rexroth AG, 2010

Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).

Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availa‐

bility of the product.

Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 ■ D-97816 Lohr a. Main

Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85 http://www.boschrexroth.com/

System Development Automation Motion Logic Control, ElAh (SyMu) Note This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation Document Typecode Internal File Reference Purpose of Documentation

Record of Revision

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1 Flying Shear Turn-Key Solution

1.1 Introduction and Overview

The Bosch Rexroth Flying Shear turn-key solution combines MLD-M Sercos III IndraDrives and VCP IndraControls to provide a complete solution for Flying Shear applications.

In typical Flying Shear applications, material (sheet metal, plastic, foil etc…) is fed continuously past a servo driven cutoff carriage. The carriage contains cut‐

ting or punching devices (shear, saw, dies, etc…) that are used to cut the material. Since it is not desirable to stop the material, the cutoff carriage must accelerate and synchronize to the velocity of the material before executing a cut. Once the carriage is synchronized with the material, a tool program is called to perform a cut. After the cut is performed and the Minimum Stroke Position is reached, the carriage returns to the return position where it waits to synchronize to the next cut. A measuring wheel is used to accurately determine the position and velocity of the material. The measuring wheel rides on the material and is connected to the IndraDrive's second encoder port.

1.2 System Overview

1.2.1 Parallel I/O Interface

The Bosch Rexroth Flying Shear turn-key solution is a complete system con‐

sisting of an IndraDrive MLD-M drive system and a VCP 08 HMI interface. The IndraDrive with a CSH01.3 control section and secondary encoder interface communicates with the VCP 08 via an Ethernet or serial interface cable. All required system parameter setup and machine setup is done via the VCP 08.

System I/O interfacing between the machine and drive system is supported by the drive's parallel I/O interface.

Fig.1-1: Flying Shear System Overview with Parallel I/O

1.2.2 Profibus Fieldbus Interface

In addition to a parallel I/O interface, the Flying Shear application also supports

the Profibus fieldbus interface. This interface allows the Flying Shear applica‐

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tion to communicate with larger systems that use a host PLC. All required system parameter setup and machine setup can be done via the Profibus in‐

terface.

Fig.1-2: Flying Shear System Configuration with Profibus Interface

1.3 Flying Shear Technical Features

The Bosch Rexroth Flying Shear turn-key solution supports the following fea‐

tures for typical flying shear applications:

● Communication Interfaces:

– Parallel I/O – Profibus Fieldbus

● Operation Modes – Manual Mode

– Jogging (Plus or Minus)

– Homing

– Auto / Production Mode

● Various Cut Types – Crop Cut – Immediate Cut – Test Cut – Inhibit Cut

● Tool and Part Setup

– 100 User-defined Parts

– 20 User-defined Tools

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● Application and System Status – Current Part Data

– Current Tool Data – System Status

– Drive and Machine Status Information

● Tool Programs

– 20 PLC Tool Programs (user configurable)

● Optimized Return with Reduced Acceleration

● Short Part Handling

● Registration

– Mode 0: Disabled

– Mode 1: Standard Registration with Monitoring Window – Mode 2: Registration with Min Length Detection

– Mode 3: Mark Counting

● Bad Material Handling

● Material Clamping

● Material Separation

● Maximum Part Length Monitoring

● Material Travel Pulse

● PreSync Signal

1.4 System Components

1.4.1 Hardware Components

Overview

The Flying Shear system supports both a parallel I/O and a Profibus fieldbus interface for communicating with the machine's I/O. These interfaces are or‐

dered as part of the IndraDrive control section. IndraDrive controllers are comprised of a power section and a control section.

IndraDrive Control Section The control sections described in this section are not the only control section configurations that are supported by the Flying Shear system. They are listed as typical configurations only. The actual control section configuration that is ordered is dependent on the application's requirements.

The only restrictions when ordering an IndraDrive control section is that it must be one of the following types:

● CSH01.3C-PL (Parallel I/O Interface)

● CSH01.3C-PB (Profibus Fieldbus)

The encoder interfaces that can be ordered for the control sections are de‐

pendent on the primary motor and secondary measuring wheel encoders that are required for the specific application.

Refer to the following documentation for details:

● Rexroth IndraDrive Drive Controllers Control Sections - Project Planning Manual (Material No. R911295012)

IndraDrive Power Section The IndraDrive power section and motor combination is application specific and must be sized and ordered accordingly.

Refer to the following documentation for details:

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● Rexroth IndraDrive Drive System - Project Planning Manual (Material No.

R911309636)

Motor power and feedback cable assemblies are ordered based on the specific motor/drive combination. Refer to the relevant IndraDrive controller documentation for details.

IndraDrive Control Section with Parallel I/O Interface

The Flying Shear system with parallel I/O interface is comprised of the following hardware:

Hardware Typecode Material Number

IndraDrive Control Section with Parallel I/O Interface CSH01.3C-PL-ENS-EN2-CCD-NN-S-NN-FW R911327681

Parallel I/O Interface Cable RKS0006 (variable length) R911318646

The RKS0006 is used to connect the X15 (37 pin) connector on the IndraDrive's CSH control section to a terminal strip.

Fig.1-3: IndraDrive Parallel I/O Control Section and Cable

Refer to fig. 4-101 "RKS0006 Cable Assembly Wiring Diagram" on page 107 for details on the parallel I/O interface.

IndraDrive Control Section with Profibus Fieldbus Interface

The Flying Shear system with Profibus fieldbus interface is comprised of the following hardware:

Hardware Typecode Material Number

IndraDrive Control Section with Profibus fieldbus CSH01.3C-PB-ENS-EN2-CCD-NN-S-NN-FW R911329309

Profibus fieldbus cable assembly IKB0033 (variable length) R911291808

The IKB0033 is used to connect the X30 connector on the IndraDrive's CSH control section to the MLC01.2 X7P connector.

Fig.1-4: IndraDrive Profibus Control Section and Cable

Refer to chapter 6 "Profibus Interface for Flying Shear" on page 171 for details on the Profibus fieldbus interface.

MMC Memory Card

The MMC (Multi Media Card) is provided with either the parallel I/O or the Profibus fieldbus interface and contains the following Flying Shear system files:

● Flying Shear system documentation

● Drive firmware

● System and drive parameters

● Retain data archive

● VCP 08 user screen file

● IndraWorks project archive with complete PLC project

Refer to chapter 5.2 "Multi Media Card" on page 115 for complete details.

1.4.2 Firmware Components

The following firmware is required for use with the above mentioned Bosch

Rexroth hardware components:

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Hardware Typecode Material Number

IndraDrive firmware FWA-INDRV*-MPC-07VRS-D5-1-SNC-ML R911328762

MMC card with Flying Shear application FWS-MLDTFA-SPF-07VRS-D0 R911328979 Fig.1-5: Firmware Components

1.4.3 Measuring Wheel Encoder

The following Rexroth encoder is the recommended type:

Hardware Typecode Material Number

Rexroth GDS2.1 encoder GDS02.1-2048-5.0V-H12.0 R911305629

Motor encoder cable assembly (GDS to IndraDrive EN2 option card)

IKS4038 (variable length) R911290936

Motor encoder cable extension IKS4191 (variable length) R911281618

Fig.1-6: Rexroth GDS2.1 Encoder Hardware and Accessories

The length of the IKS4038 and IKS4191 cable assemblies are specified at the time of order. These cable assemblies can be or‐

dered to a maximum length of 75 meters, in increments of 0.5 meters.

Refer to the following documentation for details: for details.

● Rexroth GDS/GDM2.1 Leading Axis Encoder - Project Planning Manual (Material No. R911308045)

● Rexroth Connection Cables - Selection Data (Material No. R911282688)

1.4.4 IndraControl VCP 08 HMI

The following IndraControl VCP 08 hardware can be used with the parallel I/O or the Profibus fieldbus control section:

Hardware Typecode Material Number

IndraControl VCP 08 HMI interface VCP08.2DTN-003-SR-NN-PW R911311498

Serial Cable (HMI to IndraDrive) RKB0004 (2 meters) R911309311

Ethernet Cable (HMI to IndraDrive) RKB0007/002,5 R911170147

Fig.1-7: VCP 08 Hardware and Accessories

For a complete list of available serial and Ethernet cables, refer to chapter "Cable Assemblies" on page 130 for details.

1.4.5 Software Components

The following PC software is required for creating user-defined Tool Programs:

● Rexroth IndraWorks engineering tool versions:

– 09V08 or greater, or – 10V04 or greater

1.4.6 Additional Hardware Components

In addition to the standard Bosch Rexroth components, the following compo‐

nents are used with the Flying Shear system:

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● USB flash drive (not included)

– The USB flash drive is used to copy the Flying Shear HMI screens to the VCP 08

● PC multi media card reader for archiving project data to the PC.

1.4.7 Documentation over the Internet

The documentation described in this manual can be viewed and downloaded as PDF files from the following Bosch Rexroth web site:

● www.boschrexroth.com

Using the links on the left-hand side, select Products and Solution and then Documentation and Brochures.

Once the Rexroth Media Directory page opens, enter the R911 material number (e.g., R911295012) in the search field. The following figure shows an example of the document that is returned from a search:

Fig.1-8: Search Documents on the Internet

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2 Important Directions for Use

2.1 Appropriate Use

2.1.1 Introduction

Rexroth products represent state-of-the-art developments and manufacturing.

They are tested prior to delivery to ensure operating safety and reliability.

Personal injury and property damage caused by incorrect use of the products!

WARNING

The products have been designed for use in the industrial environment and may only be used in the appropriate way. If they are not used in the appropriate way, situations resulting in property damage and personal injury can occur.

Rexroth as manufacturer is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfei‐

ted. The user alone carries all responsibility of the risks.

Before using Rexroth products, make sure that all the pre-requisites for an ap‐

propriate use of the products are satisfied:

● Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with ap‐

propriate use.

● If the products take the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes.

● Do not mount damaged or faulty products or use them in operation.

● Make sure that the products have been installed in the manner described in the relevant documentation.

2.1.2 Areas of Use and Application

MLD drives made by Rexroth are designed to control electrical motors and monitor their operation.

Control and monitoring of the MLD drives may require additional sensors and actors.

The drive controllers may only used with the accessories and parts specified in this documentation. If a component has not been spe‐

cifically named, then it may neither be mounted nor connected. The same applies to cables and lines.

Operation is only permitted in the specified configurations and com‐

binations of components using the software and firmware as speci‐

fied in the relevant Functional Descriptions.

MLD drives have to be programmed before commissioning, making it possible for the motor to execute the specific functions of an application.

MLD drives of the IndraDrive line have been developed for use in single- and multi-axis drive and control tasks.

To ensure application-specific use of MLD drives, device types of different drive

power and different interfaces are available.

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Typical applications include:

● handling and mounting systems,

● packaging and food machines,

● printing and paper processing machines and

● machine tools.

MLD drives may only be operated under the assembly and installation condi‐

tions described in this documentation, in the specified position of normal use and under the ambient conditions as described (temperature, degree of pro‐

tection, humidity, EMC, etc.).

2.2 Inappropriate Use

Using the MLD drives outside of the operating conditions described in this doc‐

umentation and outside of the indicated technical data and specifications is defined as "inappropriate use".

MLD drives must not be used, if …

● they are subject to operating conditions that do not meet the specified ambient conditions. This includes, for example, operation under water, under extreme temperature fluctuations or extremely high maximum tem‐

peratures.

● Furthermore, MLD drives must not be used in applications which have not been expressly authorized by Rexroth. Please carefully follow the speci‐

fications outlined in the general Safety Instructions!

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3 Safety Instructions for Electric Drives and Controls

3.1 Definitions of Terms

Application Documentation Application documentation comprises the entire documentation used to inform the user of the product about the use and safety-relevant features for config‐

uring, integrating, installing, mounting, commissioning, operating, maintaining, repairing and decommissioning the product. The following terms are also used for this kind of documentation: User Guide, Operation Manual, Commissioning Manual, Instruction Manual, Project Planning Manual, Application Manual, etc.

Component A component is a combination of elements with a specified function, which are part of a piece of equipment, device or system. Components of the electric drive and control system are, for example, supply units, drive controllers, mains choke, mains filter, motors, cables, etc.

Control System A control system comprises several interconnected control components placed on the market as a single functional unit.

Device A device is a finished product with a defined function, intended for users and placed on the market as an individual piece of merchandise.

Electrical Equipment Electrical equipment encompasses all devices used to generate, convert, trans‐

mit, distribute or apply electrical energy, such as electric motors, transformers, switching devices, cables, lines, power-consuming devices, circuit board as‐

semblies, plug-in units, control cabinets, etc.

Electric Drive System An electric drive system comprises all components from mains supply to motor shaft; this includes, for example, electric motor(s), motor encoder(s), supply units and drive controllers, as well as auxiliary and additional components, such as mains filter, mains choke and the corresponding lines and cables.

Installation An installation consists of several devices or systems interconnected for a de‐

fined purpose and on a defined site which, however, are not intended to be placed on the market as a single functional unit.

Machine A machine is the entirety of interconnected parts or units at least one of which is movable. Thus, a machine consists of the appropriate machine drive ele‐

ments, as well as control and power circuits, which have been assembled for a specific application. A machine is, for example, intended for processing, treatment, movement or packaging of a material. The term "machine" also cov‐

ers a combination of machines which are arranged and controlled in such a way that they function as a unified whole.

Manufacturer The manufacturer is an individual or legal entity bearing responsibility for the design and manufacture of a product which is placed on the market in the in‐

dividual's or legal entity's name. The manufacturer can use finished products, finished parts or finished elements, or contract out work to subcontractors.

However, the manufacturer must always have overall control and possess the required authority to take responsibility for the product.

Product Examples of a product: Device, component, part, system, software, firmware, among other things.

Project Planning Manual A project planning manual is part of the application documentation used to support the sizing and planning of systems, machines or installations.

Qualified Persons In terms of this application documentation, qualified persons are those persons

who are familiar with the installation, mounting, commissioning and operation

of the components of the electric drive and control system, as well as with the

hazards this implies, and who possess the qualifications their work requires. To

comply with these qualifications, it is necessary, among other things,

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1) to be trained, instructed or authorized to switch electric circuits and devices safely on and off, to ground them and to mark them

2) to be trained or instructed to maintain and use adequate safety equipment 3) to attend a course of instruction in first aid

User A user is a person installing, commissioning or using a product which has been placed on the market.

3.2 General Information

3.2.1 Using the Safety Instructions and Passing Them on to Others

Do not attempt to install and operate the components of the electric drive and control system without first reading all documentation provided with the product.

Read and understand these safety instructions and all user documentation prior to working with these components. If you do not have the user documentation for the components, contact your responsible Bosch Rexroth sales partner. Ask for these documents to be sent immediately to the person or persons respon‐

sible for the safe operation of the components.

If the component is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the component in the official language of the user's country.

Improper use of these components, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety de‐

vices, could result in property damage, injury, electric shock or even death.

3.2.2 Requirements for Safe Use

Read the following instructions before initial commissioning of the components of the electric drive and control system in order to eliminate the risk of injury and/or property damage. You must follow these safety instructions.

● Bosch Rexroth is not liable for damages resulting from failure to observe the safety instructions.

● Read the operating, maintenance and safety instructions in your language before commissioning. If you find that you cannot completely understand the application documentation in the available language, please ask your supplier to clarify.

● Proper and correct transport, storage, mounting and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of the component.

● Only qualified persons may work with components of the electric drive and control system or within its proximity.

● Only use accessories and spare parts approved by Bosch Rexroth.

● Follow the safety regulations and requirements of the country in which the components of the electric drive and control system are operated.

● Only use the components of the electric drive and control system in the manner that is defined as appropriate. See chapter "Appropriate Use".

● The ambient and operating conditions given in the available application documentation must be observed.

● Applications for functional safety are only allowed if clearly and explicitly specified in the application documentation "Integrated Safety Technolo‐

gy". If this is not the case, they are excluded. Functional safety is a safety

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concept in which measures of risk reduction for personal safety depend on electrical, electronic or programmable control systems.

● The information given in the application documentation with regard to the use of the delivered components contains only examples of applications and suggestions.

The machine and installation manufacturers must

– make sure that the delivered components are suited for their individ‐

ual application and check the information given in this application documentation with regard to the use of the components,

– make sure that their individual application complies with the appli‐

cable safety regulations and standards and carry out the required measures, modifications and complements.

● Commissioning of the delivered components is only allowed once it is sure that the machine or installation in which the components are installed complies with the national regulations, safety specifications and standards of the application.

● Operation is only allowed if the national EMC regulations for the applica‐

tion are met.

● The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective application documenta‐

tion.

The machine or installation manufacturer is responsible for compliance with the limit values as prescribed in the national regulations.

● The technical data, connection and installation conditions of the compo‐

nents are specified in the respective application documentations and must be followed at all times.

National regulations which the user must take into account

● European countries: In accordance with European EN standards

● United States of America (USA):

– National Electrical Code (NEC)

– National Electrical Manufacturers Association (NEMA), as well as local engineering regulations

– Regulations of the National Fire Protection Association (NFPA)

● Canada: Canadian Standards Association (CSA)

● Other countries:

– International Organization for Standardization (ISO) – International Electrotechnical Commission (IEC)

3.2.3 Hazards by Improper Use

● High electrical voltage and high working current! Danger to life or serious injury by electric shock!

● High electrical voltage by incorrect connection! Danger to life or injury by electric shock!

● Dangerous movements! Danger to life, serious injury or property damage by unintended motor movements!

● Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electric drive systems!

● Risk of burns by hot housing surfaces!

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● Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!

● Risk of injury by improper handling of batteries!

● Risk of injury by improper handling of pressurized lines!

3.3 Instructions with Regard to Specific Dangers

3.3.1 Protection Against Contact with Electrical Parts and Housings

This section concerns components of the electric drive and control system with voltages of more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personal danger and electric shock. When operating components of the electric drive and control system, it is unavoidable that some parts of these components conduct dangerous voltage.

High electrical voltage! Danger to life, risk of injury by electric shock or serious injury!

● Only qualified persons are allowed to operate, maintain and/or repair the components of the electric drive and control system.

● Follow the general installation and safety regulations when working on power installations.

● Before switching on, the equipment grounding conductor must have been permanently connected to all electric components in accordance with the connection diagram.

● Even for brief measurements or tests, operation is only allowed if the equipment grounding conductor has been permanently connected to the points of the components provided for this purpose.

● Before accessing electrical parts with voltage potentials higher than 50 V, you must disconnect electric components from the mains or from the pow‐

er supply unit. Secure the electric component from reconnection.

● With electric components, observe the following aspects:

Always wait 30 minutes after switching off power to allow live capacitors to discharge before accessing an electric component. Measure the elec‐

trical voltage of live parts before beginning to work to make sure that the equipment is safe to touch.

● Install the covers and guards provided for this purpose before switching on.

● Never touch electrical connection points of the components while power is turned on.

● Do not remove or plug in connectors when the component has been pow‐

ered.

● Under specific conditions, electric drive systems can be operated at mains protected by residual-current-operated circuit-breakers sensitive to uni‐

versal current (RCDs/RCMs).

● Secure built-in devices from penetrating foreign objects and water, as well

as from direct contact, by providing an external housing, for example a

control cabinet.

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High housing voltage and high leakage current! Danger to life, risk of injury by electric shock!

● Before switching on and before commissioning, ground or connect the components of the electric drive and control system to the equipment grounding conductor at the grounding points.

● Connect the equipment grounding conductor of the components of the electric drive and control system permanently to the main power supply at all times. The leakage current is greater than 3.5 mA.

● Establish an equipment grounding connection with a copper wire of a cross section of at least 10 mm

²

(8 AWG) or additionally run a second equipment grounding conductor of the same cross section as the original equipment grounding conductor.

3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock

Protective extra-low voltage is used to allow connecting devices with basic in‐

sulation to extra-low voltage circuits.

On components of an electric drive and control system provided by Bosch Rexroth, all connections and terminals with voltages between 5 and 50 volts are PELV ("Protective Extra-Low Voltage") systems. It is allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections.

Danger to life, risk of injury by electric shock! High electrical voltage by incorrect connection!

If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g., the mains connection) are connected to Bosch Rexroth products, the connected extra-low voltage circuits must comply with the re‐

quirements for PELV ("Protective Extra-Low Voltage").

3.3.3 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of connected motors.

Some common examples are:

● Improper or wrong wiring or cable connection

● Operator errors

● Wrong input of parameters before commissioning

● Malfunction of sensors and encoders

● Defective components

● Software or firmware errors

These errors can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation.

The monitoring functions in the components of the electric drive and control system will normally be sufficient to avoid malfunction in the connected drives.

Regarding personal safety, especially the danger of injury and/or property dam‐

age, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive move‐

ments depends upon the type of control and the state of operation.

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Dangerous movements! Danger to life, risk of injury, serious injury or property damage!

A risk assessment must be prepared for the installation or machine, with its specific conditions, in which the components of the electric drive and control system are installed.

As a result of the risk assessment, the user must provide for monitoring func‐

tions and higher-level measures on the installation side for personal safety. The safety regulations applicable to the installation or machine must be taken into consideration. Unintended machine movements or other malfunctions are pos‐

sible if safety devices are disabled, bypassed or not activated.

To avoid accidents, injury and/or property damage:

● Keep free and clear of the machine’s range of motion and moving machine parts. Prevent personnel from accidentally entering the machine’s range of motion by using, for example:

– Safety fences – Safety guards – Protective coverings – Light barriers

● Make sure the safety fences and protective coverings are strong enough to resist maximum possible kinetic energy.

● Mount emergency stopping switches in the immediate reach of the oper‐

ator. Before commissioning, verify that the emergency stopping equip‐

ment works. Do not operate the machine if the emergency stopping switch is not working.

● Prevent unintended start-up. Isolate the drive power connection by means of OFF switches/OFF buttons or use a safe starting lockout.

● Make sure that the drives are brought to safe standstill before accessing or entering the danger zone.

● Additionally secure vertical axes against falling or dropping after switching off the motor power by, for example,

– mechanically securing the vertical axes,

– adding an external braking/arrester/clamping mechanism or – ensuring sufficient counterbalancing of the vertical axes.

● The standard equipment motor holding brake or an external holding brake controlled by the drive controller is not sufficient to guarantee personal safety!

● Disconnect electrical power to the components of the electric drive and control system using the master switch and secure them from reconnec‐

tion ("lock out") for:

– Maintenance and repair work – Cleaning of equipment

– Long periods of discontinued equipment use

● Prevent the operation of high-frequency, remote control and radio equip‐

ment near components of the electric drive and control system and their supply leads. If the use of these devices cannot be avoided, check the machine or installation, at initial commissioning of the electric drive and control system, for possible malfunctions when operating such high-fre‐

quency, remote control and radio equipment in its possible positions of normal use. It might possibly be necessary to perform a special electro‐

magnetic compatibility (EMC) test.

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3.3.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐

ation and Mounting

Magnetic and electromagnetic fields generated by current-carrying conductors or permanent magnets of electric motors represent a serious danger to persons with heart pacemakers, metal implants and hearing aids.

Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electric components!

● Persons with heart pacemakers and metal implants are not allowed to enter the following areas:

– Areas in which components of the electric drive and control systems are mounted, commissioned and operated.

– Areas in which parts of motors with permanent magnets are stored, repaired or mounted.

● If it is necessary for somebody with a heart pacemaker to enter such an area, a doctor must be consulted prior to doing so. The noise immunity of implanted heart pacemakers differs so greatly that no general rules can be given.

● Those with metal implants or metal pieces, as well as with hearing aids, must consult a doctor before they enter the areas described above.

3.3.5 Protection Against Contact With Hot Parts

Hot surfaces of components of the electric drive and control system. Risk of burns!

● Do not touch hot surfaces of, for example, braking resistors, heat sinks, supply units and drive controllers, motors, windings and laminated cores!

● According to the operating conditions, temperatures of the surfaces can be higher than 60 °C (140 °F) during or after operation.

● Before touching motors after having switched them off, let them cool down for a sufficient period of time. Cooling down can require up to 140 mi‐

nutes! The time required for cooling down is approximately five times the thermal time constant specified in the technical data.

● After switching chokes, supply units and drive controllers off, wait 15 mi‐

nutes to allow them to cool down before touching them.

● Wear safety gloves or do not work at hot surfaces.

● For certain applications, and in accordance with the respective safety reg‐

ulations, the manufacturer of the machine or installation must take meas‐

ures to avoid injuries caused by burns in the final application. These measures can be, for example: Warnings at the machine or installation, guards (shieldings or barriers) or safety instructions in the application documentation.

3.3.6 Protection During Handling and Mounting

Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!

● Observe the relevant statutory regulations of accident prevention.

● Use suitable equipment for mounting and transport.

● Avoid jamming and crushing by appropriate measures.

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● Always use suitable tools. Use special tools if specified.

● Use lifting equipment and tools in the correct manner.

● Use suitable protective equipment (hard hat, safety goggles, safety shoes, safety gloves, for example).

● Do not stand under hanging loads.

● Immediately clean up any spilled liquids from the floor due to the risk of slipping.

3.3.7 Battery Safety

Batteries consist of active chemicals in a solid housing. Therefore, improper handling can cause injury or property damage.

Risk of injury by improper handling!

● Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and cauterization).

● Do not attempt to recharge the batteries as this may cause leakage or explosion.

● Do not throw batteries into open flames.

● Do not dismantle batteries.

● When replacing the battery/batteries, do not damage the electrical parts installed in the devices.

● Only use the battery types specified for the product.

Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations.

Dispose of used batteries separately from other waste. Observe the national regulations of your country.

3.3.8 Protection Against Pressurized Systems

According to the information given in the Project Planning Manuals, motors and components cooled with liquids and compressed air can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids and cooling lubricants. Improper handling of the connected sup‐

ply systems, supply lines or connections can cause injuries or property damage.

Risk of injury by improper handling of pressurized lines!

● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐

sion).

● Observe the respective manufacturer's operating instructions.

● Before dismounting lines, relieve pressure and empty medium.

● Use suitable protective equipment (safety goggles, safety shoes, safety gloves, for example).

● Immediately clean up any spilled liquids from the floor due to the risk of

slipping.

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Environmental protection and disposal! The agents (e.g., fluids) used to operate the product might not be environmentally friendly.

Dispose of agents harmful to the environment separately from other waste. Observe the national regulations of your country.

3.4 Explanation of Signal Words and the Safety Alert Symbol

The Safety Instructions in the available application documentation contain spe‐

cific signal words (DANGER, WARNING, CAUTION or NOTICE) and, where required, a safety alert symbol (in accordance with ANSI Z535.6-2006).

The signal word is meant to draw the reader's attention to the safety instruction and identifies the hazard severity.

The safety alert symbol (a triangle with an exclamation point), which precedes the signal words DANGER, WARNING and CAUTION, is used to alert the reader to personal injury hazards.

DANGER

In case of non-compliance with this safety instruction, death or serious injury will occur.

WARNING

In case of non-compliance with this safety instruction, death or serious injury could occur.

CAUTION

In case of non-compliance with this safety instruction, minor or moderate injury could occur.

NOTICE

In case of non-compliance with this safety instruction, property damage could

occur.

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4 Flying Shear System Overview and Operation

4.1 General System Operations

4.1.1 System Architecture

The Flying Shear system architecture is made up of the following components:

● IndraDrive MLD-M Drive with parallel I/O interface, or

– CSH01.3 Control Section (PLC, parallel I/O and secondary encoder interface)

● IndraDrive MLD-M Drive with Profibus fieldbus interface

– CSH01.3 Control Section (PLC, Profibus fieldbus and secondary en‐

coder interface)

● VCP 08 Human Machine Interface

– HMI required for data editing and error detection when the IndraWorks software environment is not available to the user.

● Measuring wheel encoder

Refer to chapter 1.2 "System Overview" on page 9 for an illustration of the Flying Shear components.

4.1.2 Operation Modes

Overview

The Flying Shear system supports the following operation modes:

● Manual mode

● Parameter mode (drive only)

● Automatic mode

● Test mode

The switching between manual mode and automatic mode is per‐

formed via the VCP 08 by toggling the AUTO key. The AUTO key displays a green LED in the upper right hand corner, that when lit, indicates the system is in automatic mode.

Only Positive Material Movement is Allowed WARNING

The Flying Shear system only expects the movement of material in a positive direction. A negative material movement is treated as an error condition. How‐

ever, the system will remain synchronized to the material until the cut position on the material exceeds the return position in a negative direction. At this point, the carriage will automatically desynchronize from the material.

Manual Mode

Manual mode is used for performing system and drive functions that require the system to be in a non-production state. The following functions are supported in manual mode:

● Homing the carriage

● Jogging the carriage in the positive or negative direction

● Editing system and drive parameters in parameter mode

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Manual mode also supports the following cut type:

● Immediate Cut

Switching to Manual Mode Use the following VCP 08 screen keys to disable power to the drive:

● From the Main screen, unselect the AUTO key and select Manual (F5 key) to switch to the Manual screen and then select PwrEnable (F5). The LED in the upper right hand corner of the F5 key will turn off indicating that power has been removed from the drive. A "Drive Not Ready" error will be issued. This error can be cleared once drive power is enable.

Parameter mode requires that power (PwrEnable) be disabled to the drive.

Switching the Drive to Parameter

Mode Use the following VCP 08 screen key to switch the system to parameter mode:

● Select the SETUP key to switch to the Production Setup screen. Next, select the F5 key (Machine) to switch to the Machine Setup screen. Finally, select the F5 key (PM) to switch the system to parameter mode.

Switching back to Sercos phase 4 requires approx. 10 seconds.

Only depress the F5 key once. The LED turns off when the system reaches Sercos phase 4.

Automatic Mode

In automatic mode, the Flying Shear application produces parts based on the user-defined parts and tools setup. Material velocity is inputted into the system via an external measuring wheel. All system status and error detections are processed by the system and available to the user via system parameters. The following cut types are supported in automatic mode:

● Crop cut

● Immediate cut

● Inhibit cut

● Test cut

Switching to automatic mode requires the carriage to be at the re‐

turn position. Before production can begin, the carriage has to be jogged to the return position in manual mode.

Test Mode

In test mode, actual material is not fed through the machine. Instead, the system uses a virtual master to simulate the feeding of material. In this mode, the dif‐

ferent parts and tools processed by the carriage can be tested without wasting any material.

4.1.3 Flying Shear Cut Types

Overview

Flying Shear cut types are available from the VCP 08 Main screen. Refer to Main Screen (MAIN) on page 35.

The following production cut types are supported by the Flying Shear applica‐

tion:

● Crop cut

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● Immediate cut

● Test cut

● Inhibit cut

All cut types are configured from the Cuts Setup screen. Refer to chapter "Cuts Setup Screens" on page 63 for details.

All cut types require the drive to be ready for operation. Ready for operation is defined as follows:

● Drive power must be enabled (AH)

● The drive must be homed

● The system must be in automatic or manual mode

● The nStop must be active for automatic mode. While in manual mode, the nStop is not used for an immediate cut.

Crop Cut

A crop cut is used to start a production run by provide a starting reference cut on the material before the first part is made. The piece of material that is pro‐

duced by a crop cut is discarded from the production run.

A crop cut is defined in the Cuts Setup screen. Refer to chapter "Cuts Setup Screens" on page 63 for details. It defines the length and the tool that will be used to perform the crop cut.

A crop cut can be enabled prior to or after the material has started running. It is performed before the production run and is not counted as part of the production. It can only be executed in automatic mode.

The crop cut is enabled by pressing the F2 (CropCut) key from the Main screen of the VCP 08.

The following condition must exist before a crop cut can be executed:

● The system must be in automatic and ready for operation.

● Crop cut settings must be defined in the Cuts Setup screen.

– The tool called for a crop cut must perform the appropriate shearing action.

● A valid starting part index must be specified in the Production Setup screen.

Immediate Cut

An immediate cut is used to establish a zero reference position on the material.

It can be enabled at any position within the boundaries of the carriage but is typically enabled by an operator after material is jogged into the carriage area and stopped. It can be performed in manual or automatic mode and while the system is ready for operation. Once enabled, an immediate cut causes the car‐

riage to synchronize to the material before performing a cut. Once complete, the global variable "stat_MaterialReferenced" is set TRUE and the material's length is set to zero. At this point, the carriage is referenced to the material and production can begin. By default, an immediate cut is programmed to use tool program 21.

An immediate cut is enabled by pressing the F2 (ImmCut) key from the Manual

screen of the VCP 08. When enabled, the carriage is synchronized to the ma‐

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terial and the tool program defined in the Cuts Setup screen for an immediate cut is called.

The following system conditions must exist before an immediate cut can be executed:

● The system must be ready for operation.

● The tool program for an immediate cut must be defined in the Cuts Setup screen.

– The tool program called for an immediate cut must have the following settings (Refer to chapter 4.5 "Tool Data Setup" on page 75 for details):

– Min. Cut Position = 0 – Min. Stroke Position = 0

If a tool program other than 21 is used for an immediate cut, the user must ensure that the Min. Cut Position and Min. Stroke Posi‐

tion are both set to 0 within the tool data. If these values are set to a value other than 0, and the material is at stand still, an immediate cut may not occur and the system will remain waiting for these con‐

ditions to be satisfied. This is because the conditions for Min. Cut Position and/or Min. Stroke Position cannot be achieved.

Manual Mode Operation In manual mode, an immediate cut can be performed whether the material is moving or at standstill. To perform an immediate cut with moving material, the

"Immediate Cut Sync" system configuration bit must be set to "With LockOn".

Refer to chapter "System Configuration" on page 60 for details.

If the material is moving, and the carriage is not at the return position, an im‐

mediate cut synchronizes with the material, performs the cut, and then returns to the return position.

If the material is not moving, an immediate cut synchronizes to the material performs the cut and remains at the position where the cut was performed.

If an immediate cut is performed away from the return position, jog the carriage back to the return position before switching to auto‐

matic mode.

Automatic Mode Operation In automatic mode, an immediate cut establishes a zero reference position on the material and then starts the production run.

Test Cut

A test cut is used to provide a sample cut of material that can be measured for quality control. A test cut is defined in the Cuts Setup screen. It defines the length and the tool that will be used to perform the test cut.

The test cut is enabled by pressing the F1 (TestCut) key from the Main screen.

When enabled, if a part is currently being produced, the next cut performed will be the test cut.

The following conditions must exist before a test cut can be executed:

● The system must be in automatic and ready for operation.

● Test cut settings must be defined in the Cuts Setup screen.

– The tool called for a test cut must perform the appropriate carriage

travel and shearing action.

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Test cuts are typically used during serial productions.

Inhibit Cut

The inhibit cut is used during production to prevent the carriage from synchro‐

nizing to the material and executing a cut. This function is enabled by pressing the F4 (InhibCut) key from the Main screen. It is useful when defect material is detected by the operator.

The behavior of the inhibit cut function can be set to either remain enabled while the operator holds down the F4 key (unlatched) or remain enabled with a single push of the F4 key (latched) until the START key is pressed to resume pro‐

duction. The default behavior (unlatched) requires the operator to hold the F4 key pressed in order to inhibit the carriage from synchronizing to the material.

Once released, the carriage immediately re-synchronizes with the material and production resumes. This behavior is set using the "InhibitCutOption" bit in the System Configuration screen. Refer to chapter "System Configuration" on page 60 for details.

Inhibit cuts are typically used during serial productions. The part being produced during an inhibit cut is not counted as part of the production run and will be reproduced.

4.2 VCP 08 HMI Screens

4.2.1 Overview

The IndraControl VCP 08 HMI is the main user interface to the Flying Shear turn-key solution. From the VCP 08, all relevant system setup is performed. The following section describes the various screens that are supported by the VCP 08 Flying Shear application and how the user interfaces with the system via these screens.

The VCP 08 is not a touch screen HMI. All selections to buttons displayed on the screen are done via the function buttons surround‐

ing the screen.

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Fig.4-1: VCP 08 Keypad Buttons

4.2.2 Flying Shear Screen Hierarchy

Main Screen Hierarchy

The Main screen is displayed when the system is initially powered up and when

the MAIN key is pressed from any other screen. The following figure shows the

hierarchy of all the options and screens that are accessible from the Main

screen:

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Fig.4-2: MAIN Screen Hierarchy

User Tool I/O Screen Hierarchy

The User Tool I/O screen is displayed when the F3 key (Status) is pressed from the Main screen. The following figure shows the hierarchy of all the options and screens that are accessible from the User Tool I/O screen:

Fig.4-3: User Tool I/O Screen Hierarchy

Setup Screen Hierarchy

The Production Setup screen is displayed when the SETUP key is pressed.

The following figure shows the hierarchy of all the options and screens that are

accessible from the Production Setup screen:

Electric Drives. Linear Motion and

Rexroth IndraMotion for Metal Forming 07VRS Flying Shear

Reference Book

DOK-IM*MLD-TF*SPF**V07-RE02-EN-P

RS-127d7105502b0cba0a6846a001b01dcb-2-en-US-14

This document describes the Flying Shear turn-key solution. It details the sys‐

tem hardware and firmware features and functionalities. It also details the system setup and commissioning as well as troubleshooting information.

Edition Release Date Notes

120-2950-B318/EN -01 07.2009 Released version

120-2950-B318/EN -02 01.2010 Edition 02

Copyright © Bosch Rexroth AG, 2010

Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availa‐

bility of the product.

Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 ■ D-97816 Lohr a. Main

Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85 http://www.boschrexroth.com/

System Development Automation Motion Logic Control, ElAh (SyMu) Note This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation Document Typecode Internal File Reference Purpose of Documentation

Record of Revision

Table of Contents

Page

1 Flying Shear Turn-Key Solution... 9

1.1 Introduction and Overview... 9

1.2 System Overview... 9

1.2.1 Parallel I/O Interface... 9

1.2.2 Profibus Fieldbus Interface... 9

1.3 Flying Shear Technical Features... 10

1.4 System Components... 11

1.4.1 Hardware Components... 11

Overview... 11

IndraDrive Control Section with Parallel I/O Interface... 12

IndraDrive Control Section with Profibus Fieldbus Interface... 12

MMC Memory Card... 12

1.4.2 Firmware Components... 12

1.4.3 Measuring Wheel Encoder... 13

1.4.4 IndraControl VCP 08 HMI... 13

1.4.5 Software Components... 13

1.4.6 Additional Hardware Components... 13

1.4.7 Documentation over the Internet... 14

2 Important Directions for Use ... 15

2.1 Appropriate Use ... 15

2.1.1 Introduction... 15

2.1.2 Areas of Use and Application... 15

2.2 Inappropriate Use... 16

3 Safety Instructions for Electric Drives and Controls ... 17

3.1 Definitions of Terms... 17

3.2 General Information... 18

3.2.1 Using the Safety Instructions and Passing Them on to Others... 18

3.2.2 Requirements for Safe Use... 18

3.2.3 Hazards by Improper Use... 19

3.3 Instructions with Regard to Specific Dangers... 20

3.3.1 Protection Against Contact with Electrical Parts and Housings... 20

3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ... 21

3.3.3 Protection Against Dangerous Movements... 21

3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting... 23

3.3.5 Protection Against Contact With Hot Parts... 23

3.3.6 Protection During Handling and Mounting... 23

3.3.7 Battery Safety... 24

3.3.8 Protection Against Pressurized Systems... 24

3.4 Explanation of Signal Words and the Safety Alert Symbol... 25

Page

4 Flying Shear System Overview and Operation... 27

4.1 General System Operations... 27

4.1.1 System Architecture... 27

4.1.2 Operation Modes... 27

Overview... 27

Manual Mode... 27

Automatic Mode... 28

Test Mode... 28

4.1.3 Flying Shear Cut Types... 28

Overview... 28

Crop Cut... 29

Immediate Cut... 29

Test Cut... 30

Inhibit Cut... 31

4.2 VCP 08 HMI Screens... 31

4.2.1 Overview... 31

4.2.2 Flying Shear Screen Hierarchy... 32

Main Screen Hierarchy... 32

DOK-IMMLD-TFSPF**V07-RE02-EN-P