Rexroth the Automation Partner for Injection Molding Machines. All drive and control solutions from a single source

Transcription

1 Rexroth the Automation Partner for Injection Molding Machines All drive and control solutions from a single source

2 2 Our Goal: To Be World Market Leader in Providing Benefits to Customers With our broad portfolio of products and services we are geared to responding swiftly and flexibly to all your requirements starting from development and production, right through to sales and service. Our products, our proximity to our customers worldwide, combined with our high level of consulting expertise, will give you that decisive competitive advantage at the same time minimizing your technical and financial outlay, yet offering the highest level of quality. Worldwide benchmark for drive, control and motion Electric drives and controls, industrial and mobile hydraulics, linear and assembly technology, pneumatics: only Rexroth offers all drive and control technologies, both specialized and integrated. Our infrastructure with around 28,000 employees in over 80 countries around the world is designed always with partnership and customer proximity in mind. As a company Bosch Rexroth can look back on over 200 years of tradition. As a wholly-owned subsidiary of Robert Bosch GmbH we are part of a globally-operating technology group. All this is both our drive and our commitment. And it s unique like Bosch Rexroth. The Drive & Control Company.

3 3 Experience for Innovations Additional detailed brochures on plastics processing machines: Blow molding machines Extruders Rexroth s competence in all drive and control technologies, worldwide application experience and deep understanding of the requirements for injection molding machine automation are concentrated in the Application Center for Plastics Machines. The industry specialists concentrate on developing the best possible automation solution for every injection molding machine. Here, the spectrum ranges from highly configurable components for hydraulic and electric drive technology through modules with pre-parameterized functions to system solutions that span the borders between different technologies. As a permanent partner in discussions within the industry, the Application Center initiates special development projects for automa- ting injection molding machines and continually redefines the state of the art with its innovations. In close cooperation with machine manufacturers, Rexroth develops tailor-made automation solutions and examines these with the very latest simulation tools even before they are put into practice. The supply of ready-to-connect solutions in the best possible quality shortens assembly and commissioning times and thus reduces manufacturing costs. With its worldwide presence in more than 80 countries, Rexroth focuses this competence all around the world, supporting the manufacturers of injection molding machines in the global competition with a comprehensive range of services. Whether the need is for tailored automation solutions for newly developed injection molding machine concepts, a reliable partnership for series production, or worldwide service: As a competent automation partner, Rexroth accompanies the manufacturers of injection molding machines with knowhow gathered all around the world for the entire life cycle of the machines.

4 4 Plastics Processing in Injection Molding Machines They are the workhorses of the plastics industry: Injection molding machines cover the almost infinite range of plastic products, from simple standard applications to large-area multi-component structural parts. Rexroth always offers the right automation solution for short cycle times and reproducible quality. Plastify, shape, eject. The principle is a proven one, and yet again and again innovative detailed solutions create a competitive edge. Rexroth supports machine manufacturers with an unrivaled range of crosstechnology system solutions and modules with pre-parameterized functions, optimized for injection molding machines. As The Drive & Control Company, Rexroth has a unique advantage: The manufacturer of all drive and control technologies sees its task in the specific movement required, not in any particular technology, which always gives it the free choice between hydraulics and electromechanical systems. The machine manufacturer decides whether Rexroth should be a part-ner for components, complete modules with open interfaces, or the system partner for the entire automation project. Here, the different Rexroth components work in perfect synthesis. Motion functions optimized for injection molding applications reduce the complexity of engineering and commissioning and optimize the efficiency of the machines. This means that the machine manufacturer s development engineers are able to focus on their core competence of process control, and to integrate their know-how with the best possible opportunity for success. On target: Linear technology for precise movement Rexroth s range covers a finely layered program of linear guidance systems for simple handling tasks all the way through to heavy-duty roller rail systems with static load ratings of up to 2,000 kn in all four principal load directions. The roller bearing technology reduces friction and increases the precision of movement significantly with extremely low wear. Ball screw assemblies and linear motion systems precisely tuned to the electric motors and drive systems provide for a high level of repeat precision and zero-play movement. Foto: OWI GmbH, Lohr am Main

5 5 Engineering Controls Drives Actuators

6 6 Solutions with System: IndraMotion for Plastics Optimally tuning all the axes of an injection molding machine regardless of the drive technology used, and at the same time dynamically setting the hydraulic pump so that it saves energy and minimizes noise emissions: The IndraMotion for Plastics system solution can be perfectly adapted to any injection molding machine. As a finely scaleable system solution, IndraMotion for Plastics covers the entire automation of injection molding machines, from visualization, through the control system, the electric and hydraulic actuators to handling. The ready-to-use, preconfigured basic application shortens the implementation of new machine concepts. Predefined functions specifically for injection molding, for example closed-loop injection regulators and multi-channel temperature regulation with auto tuning or plastification with ram pressure regulation accelerate commissioning and provide for a high level of reproducibility in production. As the manufacturer of all drive and control technologies, Rexroth offers this platform as the ideal solution for hydraulic, electric and hybrid drive concepts. IndraMotion for Plastics is scaleable in both hardware and software and comes in three versions, Compact, Universal and Performance to cover the different performance requirements of injection molding machines.

7 With all three versions, Rexroth employs an efficient running time system based on the globally accepted standard IEC Individual program sections or entire programs can be freely copied and used between the different versions. A consistent engineering environment is enough for project planning, parameterizing and diagnostics on all hydraulic and electric drive and control system this makes customerspecific scaling of machines considerably simpler and provides the best possible know-how protection for the machine manufacturer. IndraMotion for Plastics combines a high degree of efficiency with the currently fastest guidance communication system available, SERCOS III. It combines hard, real-time mechanisms that have been proven in more than 1.7 million nodes with open ethernet physics. In this way, Rexroth supports both centralized and decentralized control architecture. In addition, IndraMotion for Plastics is equipped with interfaces to all common field buses, allowing the simple integration of 3rd-party software. For decentralized concepts, Rexroth, the manufacturer of all drive and control solutions, is able to supply a finely scaleable range of motion control systems for electrohydraulic regulation and a wide spectrum of intelligent servo drives.

8 8 Performance and Functionality: Electric Injection Molding Machines The trend is clear: Electric injection molding machines are breaking into ever higher performance classes and setting standards for dynamics and precision. Rexroth offers exactly the right intelligent drive technology with open interfaces for maximum productivity. Fully electric injection molding machines benefit from the enormous increase in the power of decentralized electric drive technology. Movements synchronized in real time boost the dynamics of the entire injection molding machine and shorten cycle times. At the same time, precision enhances the high-quality mold protection, guaranteeing lasting reproducibility. The finely scaleable IndraDrive drive platform covers the power range from 0.25 to 160 kw and includes both rotational motors and linear and torque motors and innovative, integrated motorregulator combinations and watercooled drive regulators for the upper power range. The ultra fast position controls of our system solution offer a high degree of performanced. The control loop update time for current is a low 62.5 µs, 125 µs for speed control and 250 µs for position. These IndraMotion for Plastics Control system for plastics processing machines IndraControl VCH 08 Controller-based mobile hand-held controls loops decentrally control the changeover point detection and the injection pressure with their own motion logic, regardless of the higher-order control system cycle time. This guarantees a high degree of repetitive precision in the complete injection molding process. By incorporating safety functions complying with European and American standards within the drive systems, Rexroth defines the state of the art. In the event of an error, the system responds within the space of 2 ms to protect both man and machine from damage. In addition, energy recovery supply modules further reduce the already low energy requirements, lowering the total cost of ownership. A further contribution to this is the option of connecting the drive for the entire handling directly to the modular controllers, incorporating them seamlessly into the process through real-time cross-communications. IndraDrive Scalable drive family

9 9 Fully electric injection molding machine with servo drives. Integrated removal systems with decentralized ultra-compact drives IndraDyn S Synchronous motor for the highest standards IndraDyn T Synchronous torque motor for direct drive

10 10 Performance, Precision and Economy: Hydraulic Injection Molding Machines No other drive technology is able to offer manufacturers of injection molding machines such long-term stability as hydraulics. The combination of robust drive technology and digital control systems opens up new dimensions in dynamics and precision. The high power density of hydraulics and the direct generation of linear motion, plus the ability to maintain high forces precisely and effortlessly make hydraulics predestined for use in injection molding machines. Their compact design and high degree of freedom from wear make it certain that hydraulics will continue to enjoy a permanent place as an economical drive technology, not only in highperformance machines. The high degree of modularity of hydraulics on a component level make tailor-made drive concepts possible, in which the machine manufacturer is able to finely scale both power and function. In conjunction with digitally controlled axial movements, they achieve new dimensions in both the dynamics and precision of movement. The SY-DFE Electrohydraulic control system for pressure and flow IndraMotion for Plastics Control system for plastics processing machines motion control systems take into account the specific characteristics of fluid technology and communicate with the higher-order control system through all common field bus systems. In this way, electrohydraulics considerably simplify commissioning, parameterization and diagnostics, even on complex control systems. Rexroth uses modern variable pumps and variable-speed pumps to drastically reduce energy consumption across the entire performance spectrum, while lowering noise emissions from the hydraulics to a new level. Decades of experience have shown that hydraulics installed in millions of machines set the standards for longevity and work largely free from wear. WRLE Directional control valve, pilot control, with electric spool-travel feedback IAC-R Rexroth control valve with integrated axle controller

11 11 HACD Digital control electronics for plastics machines EHL Electrohydraulic linear axis WRCE /P 2 and 3-way fitted control valves with integrated control electronics DvP Variable-speed pump drive

12 12 Hybrid Drive Concepts: The Best of all Worlds. An ideal combination: In hybrid concepts, the advantages of electric drive technology are married with those of hydraulic drive technology to create even more productive automation solutions. Rexroth s product portfolio comprises components and modules from all drive and control technologies all perfectly matched to each other to exploit their individual advantages in practical application. Hydraulic core pullers, electric fastenings, hydraulic injection and electric ejector: The possible combinations for hybrid injection molding machines open up new degrees of manufacturing freedom. Rexroth, the manufacturer of all drive and control technology, creates the ideal conditions for this: A control system optimized for the specific characteristics of both drive technologies and a wide range of scaleable hydraulic and electric actuators. IndraMotion for Plastics supports all conceivable concepts for centralized and decentralized architecture for mixed operation. Here, it guarantees consistent real-time communications with all electric and hydraulic drive systems, even in decentralized concepts. Intelligent motion controls regulate their motion profiles with maximum dynamics and precision, regardless of the technology concerned. Rexroth thus creates the basis for a new dimension in modularization of machine concepts. The manu-

13 13 Scheme Hybrid machine facturer is able to freely combine the drive technologies for all movements needed by a model series on a single automation platform according to the customer s wishes. Here, the SPS complying with IEC used on all drive and control systems, and uniform engineering tools ensure minimum adaptation expense. It is precisely in the project planning of hew hybrid concepts that Rexroth offers more than just automation solutions from a single source. The specialists at the Application Center for Plastics Machines have intensive worldwide experience in combining different drive technologies in one machine, with one control system. As a development partner, Rexroth uses this know-how to support manufacturers of injection molding machines with tailor-made and reliable automation solutions from a single source.

14 14 As Global as the Plastics Processing Industry Wherever plastics are manufactured and processed: Rexroth is always close at hand to offer comprehensive support. Rexroth has a long history of cooperation with the plastics industry across all continents. Design engineers, machine manufacturers and machine operators: Rexroth s best-in-class products and system solutions have demonstrated their reliability and productivity in thousands of plants all around the planet. It simply doesn t matter where a new plastic processing plant is to be built. Rexroth is already there! A dense network of sales and service outlets is already established in more than 80 countries and continues to grow. Bosch Rexroth AG focuses the application expertise garnered from its global activities on each individual site, anywhere in the world, and combines it with local competence. Project planning, commissioning, training and service: Rexroth always speaks the same language as its customers.

15 Many Tasks One Contact Person Faster and easier: This applies to automation and in daily collaboration. Rexroth s Global Account Management coordinates the entire array of joint activities with the plastics industry and its top suppliers. Doing business with Rexroth is simple, even if the tasks are complex. Regardless of the continent or technology, the Global Account Management Specialist, in his role as the central contact person and consultant consistently brings the best professionals to the table for a fast and reliable response to the challenges that arise. Rexroth employs the same processes and standards all around the world reflecting the practices of the plastics industry. International cooperation with a single automation partner offers another advantage: It simplifies the global implementation of defined specifications for the plastics industry to actively foster standardization. Lifelong partnership Tailor-Made Service This reliability applies to the entire product and service life cycle. The comprehensive service network reliably ensures a rapid response. Here, Rexroth s understanding of service goes way beyond the supply of spare parts. Rexroth Service personnel work on-site at the client s plant in close cooperation with each user. Condition monitoring and remote maintenance concepts combine with an innovative service package for all drive and control technologies to enhance equipment availability and improve the planning of maintenance cycles. From project-planning stage and operation all the way to retrofitting, Rexroth accompanies the plastics industry user through the entire life cycle of the automation system in what is, in reality, a lifelong partnership.

16 Bosch Rexroth AG Zum Eisengießer Lohr, Germany Phone: +49(0)9352/ Fax: +49(0)9352/ plastics_diecast@boschrexroth.de Printed in Germany RE /04.08 substitutes RE /10.07