Shortcuts in working with office software applications have long been part of everyday use. Shortcuts, templates, online help, automated error displays and the ability to move content to different applications are part and parcel of office software applications. Machine manufacturers are also insisting now on similar ways to make processes easier–across the entire engineering process. Therefore, over the last two years, Rexroth has transferred this approach to its mechanical engineering solutions. While “engineering” and “shortcuts” are generally not considered to go hand in hand, the use of intelligent tools to streamline project development and implementation tasks can offer a new kind of “shortcut.” Thanks to these innovative tools for ‘shortcut-assisted engineering’, machine manufacturers and system integrators can achieve their goals much more quickly:

Shortcut 1: standardized engineering environment for all tasks

A standardized engineering environment for all tasks from project planning and programming, to commissioning and diagnostics, creates the transparency required and simplifies the engineering process. Data is recorded just once and is available to all software tools, without the need for entering it multiple times. As in office software applications, content is easy to add to other applications with the click of a mouse. This shortcut reduces the need for training and keeps sources of error to a minimum.

Shortcut 2: using templates for modular software

A program framework provides a modular software structure, dividing projects into several modules with a clear overview. Thanks to this modular design, tasks can be clearly defined and quickly processed.

Shortcut 3: focusing capacities with engineering team

Regardless of location, always work in parallel and be up to date: version control systems store all amendments made with a time and the user ID. This system creates transparency and guarantees that complex projects have a consistently high quality level.

Shortcut 4: object-oriented programming

Widespread object-oriented programming in high-level language is also finding its way into automation. Modern program frameworks enable the encapsulated insertion of items, without the need for high-level language.

Shortcut 5: creating graphical cam disks

Software tools allow graphical cam disks to be created; the tools then automatically generate the relevant machine code from these cams. And there’s more: Intelligent functional modules automatically adapt all other parameters when one parameter is modified.

Shortcut 6: parameterizing instead of programming

Default functionalities reduce the need for programming because even complex movements need only to be parameterized.

Shortcut 7: using standards

Internationally valid standards, such as IEC 61131-3 or sercos, reduce the need for training and open up the option of combining components and software modules from different manufacturers and still meet the requirements of the application.

Shortcut 8: software wizards

These wizards do the tasks that were previously performed manually, thereby accelerating the engineering process and eliminating sources of error. One example is intelligent start-up wizards that access mechanical parameters of the attached linear system when a serial number is entered. This wizard reduces the time spent on this task by up to 90%.

Shortcut 9: achieving optimum dynamism quicker

Optimization during the commissioning phase is often particularly timeconsuming. Modern software tools support the technician during machine commissioning by optimizing the movement guidance. The result is increased dynamism and reduced energy consumption, without the need for lengthy tests.

Shortcut 10: detecting wear without the need for sensors

Sophisticated software tools can detect upcoming wear from the drive data already recorded. The tools do not require any additional sensors and will send warnings to ensure that the machine does not come to a stop. These tools considerably reduce the amount of service work required.

Modern engineering tools assist machine manufacturers in completing more projects at a quicker pace, but still using the existing personnel resources. “On the Production floor, automation solutions have been continuously increasing productivity for years. Today’s software solutions help to further boost efficiency across the engineering process,” reiterates Dr. Steffen Haack, Senior Vice President of Sales, Factory Automation Industry Sector of Bosch Rexroth AG.

The ultimate swivel fitting from Variacor which provides free orientation for hydraulic and pneumatic hoses and tools across a wide range of industrial applications has been introduced. The coupling ensures hosing can be flexible and multi-directional. For example, the innovative design of the coupling ensures optimum flexibility which results in less wear on hoses and less strain on the operator. Minimal flow loss compared to conventional couplers and hi durability also compliment a long list of features

The coupling for hydraulic hose applications provides free rotation through 360° for both sides of the fitting while the pneumatic option ensures free rotation of 360° for one side of the fitting and 90° for the other. This 360° / 90° combination also applies to the coupling which is designed for wash guns.

This coupling is ideal for connecting two runs of rigid pipe or flexible hose, or an end fitting, such as a nozzle or gun. It is a simple, but highly effective means of changing the angle of flow direction, axially between 180° and 90°, with a full 360° swivel at either, or both ends. Adjustments are manual, instant and can be free or lockable. Directional change is achieved by a simple slide turn of the outlet section against the inlet section of the connector. Contact CORE’s professional sales team for a demonstration!

Benefits

• Reduce operator’s strain
• Increase hose life without sacrificing air flow
• No more kinks
• Extremely durable
• Fits all applications

Call us today with your requirements.

• Phone: (519) 748-9092
• Fax: (519) 894-5082
• Email: support4core@coretooltech.com

Bosch has significantly revised its series of Exact industrial cordless screwdrivers. The new screwdrivers from the market leader in this sector have a brushless motor manufactured by Bosch, which has no rotary position encoder. Thanks to the very high efficiency of this “SEC motor”, the screwdrivers in all torque ranges work with the lightweight 9.6V battery. All in all, the power-to-weight ratio of the center grip screwdrivers has been improved by around 70 percent compared to the previous models. Contactless switches and the new electronics also considerably extend the lifetime of the screwdrivers; the average operating time (MTBF, mean-time-between-failure) offers previously unachieved values.

The unique drive technology of the new cordless screwdrivers also offers considerably higher screwdriver speeds, which surpass previous values by 70 to 80 percent. For example, the Exact 1106 with torques of up to six newton meters delivers 1,100 revolutions per minute; the Exact 610 with ten newton meters delivers 600 revolutions per minute.

The weight reduction is, above all, a result of using the 9.6V battery. The new twelve-newton-meter screwdriver Exact 412, for example, weighs only 1.3 kilograms including the battery pack, making it 20 percent lighter than its predecessor.

The brushless motor is virtually wear-free due to its EC technology. Intelligent control electronics perform the function of the rotary encoder usually fitted in these kinds of motors. The switches work with hall-effect sensors, meaning that they have no moving contact points. The electronics of the screwdriver have also been completely redesigned: all connections between motor, switch and LED display are pluggable. This reduces repair times to an absolute minimum; due to the plug-and-play system, there is virtually no chance of errors being made in the repair work.

Proven features have been kept

Bosch has kept the tried and tested features of the Exact series in the new screwdrivers. For example, the shut-off clutch remains unchanged in the new generation. This guarantees the well-known, good shut-off accuracies of the Bosch Screwdrivers. The machine capability index cmk of all models in the series significantly surpasses the value of 1.67 (calculated in accordance with DIN 5393) demanded by the industry.

The outer geometry of the screwdrivers, which is highly rated by users, with its excellent ergonomics with regard to balance, grip and operation has not been changed, either. However, additional ergonomic advantages and features that make work easier will be discovered when using the new models. These advantages stem from both the weight reduction and the short screwdriving times resulting from the high speeds. What’s more, the new drive technology makes it possible to optimize the braking behavior after the screwdriving process is deactivated, so that the operator experiences only slight reaction torques. Bosch has ascertained the optimum parameters in extensive tests with users.

Bosch offers the new Exact cordless screwdrivers with torques between 0.5 and twelve newton meters. These new screwdrivers enable users to work considerably more efficiently and ergonomically than before – and lifecycle costs are also significantly reduced. In addition to this, the Bosch range also includes slowly rotating screwdrivers, e.g. for use with plastic screw connections.

One major challenge in primary aluminum production is the crust which constantly forms on the bath surface. To keep the aluminum production process going at a steady rate, it needs to be punctured by the crust breaker. Rexroth developed the System Optimizer for this process. It measures and monitors process data, thus controlling the processes in the potroom. As for the advantages over conventional systems: the System Optimizer from Rexroth provides data – for instance on the bath level – which results in improvements to the production process. With its highly precise controller, the pneumatic crust breaker is used exactly where it is needed to minimize contact with the bath. This improves production results, ensures efficient implementation, and optimizes the service life of the individual components.

The cyrolite crust that develops during the production process in the potroom needs to be broken up regularly. This ensures a successful production process resulting in high quality aluminum. A pneumatic cylinder is used to chisel through the surface of the crust from above. The patented System Optimizer was developed to ensure that the cylinder piston is submerged only for the right amount of time and exactly where it is needed. The System Optimizer controls the cylinder, retracting it as soon as it makes contact with the bath. This prevents the accumulation of deposits on the piston and rod.

Equipped with bath surface sensing technology, the System Optimizer is a unique and highly reliable system. The pot controller operates with two signals: one signal for motion and the other for pressure. The crust module, which takes a precise measurement of the bath level in the pot, sends direct signals to the pot controller that simultaneously indicate the piston’s contact with the bath and its position. This enables a direct display of the process status in the bath.

The system operates using low pressure and also saves compressed air with cylinder strokes that are shorter on the average compared to conventional systems, thus conserving energy. The robust ISO cylinder, which is predestined for use in this harsh environment, is a diverse, adaptable component with a high load capacity. The low-maintenance cylinder is made of aluminum, with steel end covers. Its physical form guarantees the secure, direct mounting of the valves. The cylinder is optionally available with different scrapers, cushioning kits and sensors.

At the Hannover Messe industrial trade fair, Bosch Rexroth has been declared the overall winner of the ‘INDUSTRIEPREIS 2011′ industrial award for the SILENCE PLUS external gear pump. More than 500 applications with innovative industrial solutions were received by the publisher ‘Huber Verlag für Neue Medien’, which was presenting the award for the sixth time. The jury, which was made up of professors, scientists, technical journalists, sector and industrial experts, acknowledged the engineering development that allows the SILENCE PLUS to work substantially quieter than conventional external gear pumps.

On average, the noise level of the SILENCE PLUS is 15 dB(A) lower than that of conventional pumps. In addition, the new external gear pump also has a deeper and thus less unpleasant sound. In low-pressure ranges below 50 bar for refrigerant, filter and lubricant circuits, the SILENCE PLUS works practically noiselessly.

This is especially beneficial to the operators of tooling and paper cutting machines, of personnel and parking lifts and of garbage compactors. Other possible applications for the SILENCE PLUS are mobile materials handling equipment such as electric forklift trucks, electric hand pallet trucks or truck-mounted piggy-back trucks.

In many applications, the reduced noise level means that the secondary noise insulation measures are no longer necessary. In this way, the costs for the overall machine can be reduced.

For the ‘INDUSTRIEPREIS’ industrial award, the jury of experts assessed all products submitted according to defined criteria, for example innovation content or product and industrial benefit. In each of the 14 categories, they identified a category winner and two further nominees. The outstanding solution among all category winners was finally declared overall winner.

Bosch Production Grade Batteries – The Best in the Business
Ask the Expert – Clap Force is What You Want
Ask the Expert – Screw Types and Tooling Choices

Bosch Production Grade Batteries – The Best in the Business

We all have them; battery tools you buy from your local depot store. They work great for a while, and then die down slowly but surely. The list of battery basics goes on forever: Lithium Ion, GEL lithium Ion, regular Ni-Cad and so on. Although Lithium Ion seems to be the battery for the future, the problem lies in the fact that the battery may be more of a marketing driven product than a performance driven product. Great strides have been made in the ever-so changing battery technology, but Lithium Ion batteries have yet to reach the performance levels required for sustained high-amperage duty cycles for production tool use. Until the Bosch production tool batteries came into the picture.

Bosch Production Tool Batteries Benefits:

• High grade batteries
• Class “Zero” cells
• Extended charging life
• Top performing batteries in the industry

Bosch Production tool batteries are not just your average Ni-cad battery. Their batteries may resemble a conventional Bosch battery from the outside, but the cells inside the batteries are unique in the world of power tools. Bosch uses class “Zero” cells to produce the longest-lasting, best performing batteries in the business. These high grade battery cells are manufactured in limited batches using improved tolerances and processes over standard Ni-cad cells. You can expect up to 3,000 charge cycles using our 30-minute charger.

Now that we are aware that these Bosch Production tool batteries last, just think about air consumption compressor costs when comparing air versus battery tools.

Competitors’ Air Powered Tool

Annual Energy Cost: $175.58
Three-Year Energy cost of compressed air: $562.74
Three-Year Air cost of 1000 competitors’ tools: $526,740

Bosch EXACT Cordless Tool Annual Energy Cost: $2.05
Three-Year Energy cost of cordless charging: $6.15
Three-year Electricity cost of 1000 Bosch Cordless tools: $6,150

Have an Air Leak? It’s Not Free! See the chart below for details of the costs:

Walk the plant on a long holiday and weekend and listen for the “hiss” of money flying out the door. With rising energy costs and the environmental impact placed on increased consumption, we have a responsibility to investigate ways of decreasing costs. As an enviable side effect, we get to improve quality as well as fastener costs and capital equipment costs.

Contact Core Tool’s professional sales staff for an in-plant demonstration of this high quality equipment. See for yourself.

Always invest in high quality tooling!

Ask the Experts – Clamp Force is What You Want

The clamp force generated by a bolt can be indirectly controlled by regulating the applied torque. This method, known as torque control, is by far the most popular method of controlling a bolt’s clamp force. The initial clamp force generated by the bolt is frequently called “preload”.

There is a link between the torque applied to a bolt and the resulting preload. A problem exists where friction has a large influence on how much torque is converted into preload. Other than the torque required to stretch the bolt, torque is also required to overcome friction in the threads and under the nut face. Typically, 10 to 15% of the torque is used to stretch the bolt. Of the remaining torque, around 30% is dissipated in the threads and 50 to 55% under the nut face. Because friction is an important factor in the relationship between torque and preload, variations in friction have a significant influence on the bolt’s preload. Different bolt surface finishes generally have different friction values.

E-coats can be particularly problematic. The torque required for a socket head screw will not be the same as that required for the same size standard hexagon bolt. The larger bearing face of the standard bolt will result in an increased torque being required compared to a socket headed screw. This is because more torque is being dissipated between the nut face and the joint surface.

Stresses indicated into a Bolt:

When a bolt is tightened, the shank and thread sustain a direct (tensile) stress due to it being stretched. In addition, a torsional stress is induced due to the torque acting on the threads. These two stressed are combined into a single equivalent stress to allow a comparison to be made to the bolt’s yield strength. In order to effectively utilize the strength of the bolt yet leave some margin for any loading the bolt would sustain in service, an equivalent stress of 90% of yield is commonly used. This is a fairly common approach. This approach has a number of advantages over the method where a direct stress, and hence preload value, is assumed in the bolt. For high thread friction values, a high torsional stress results in the bolt. Less of the available strength of the bolt is being utilized in such a case to generate preload. In the extreme case when a nut has seized on the bolt thread, all the applied torque is sustained as torsional stress with no preload being available. In the other extreme, low thread friction results in higher preloads.

Note: The information is provided to assist Engineers wishing to establish the theoretical torque values because the preload and torque is dependent upon the friction values selected. This article is meant as a guide only. It is recommended that torque values derived from a formula should not be used without comparison to figures obtained using practical tests, although we all realize environmental influences have a great impact on the final achieved values.

Ask the Experts – Screw Types and Tool Choices

As the fastening experts, we are constantly being asked which types of tools should be used where. Considering non-critical common bolt fastening, here’s a quick guide on torque controlled tooling types.

Machine Screw Hard Joint

The hard joint screw has low resistance to turning until the screw head reaches its seating, after which resistance rapidly increases. For rapid screw driving with moderate torque accuracy, choose a high speed tool. For close torque limit of when the quality of thread is uneven, choose a lower speed tool. This is also recommended for brittle material. The most suitable clutch is a shut-off type. An alternative choice is a slip type.

Machine Screw Soft Joint

The soft joint screw has low resistance to turning until the screw head reaches its seating, after which resistance slowly increases. A slower and more powerful tool should be used to seat the fastener properly to minimize relaxation in the joint. Most suitable clutch is the shut-off type, while a slip type is also possible.

Machine Screw Locking Element in Thread

This screw possesses relatively high resistance to turning before the screw head reaches its seating, after which resistance rapidly increases. Choose a tool with high torque from the lower speed range. If rapid driving is required, choose a larger tool with a higher speed. Suitable clutches are the shut-off and slip type.

Self-Drilling Screw

With this screw, the turning resistance gradually increases during the drilling and thread cutting, but more slowly than with self-threading screws. Choose a tool with a speed over 1000 rpm. A slip type clutch is generally suitable, but choose a shut-off clutch for thin materials.

Design News magazine, a leading mechanical and design engineering publication, recently named Rexroth’s IndraLogic XLC family as a 2011 “Golden Mousetrap Best Product Winner” in the Automation and Control category.

The magazine announced the winners of its annual best products contest in the March issue and on its website at http://www.designnews.com/info/2392-Golden_Mousetrap_Winners_2011.php.

Golden Mousetrap Best Product awards were given in four major categories: Electronics and Test; Automation and Control; Design Tools; and Materials and Assembly. For more than 20 years the Design News awards program has recognized engineering innovation and creativity in product design.

Rexroth’s IndraLogic XLC family enables scalable, controller-based and embedded PC solutions in conjunction with the company’s latest IndraControl device platform. Rexroth advanced the PLC programming using state-of-the-art PLC kernel, IndraLogic 2G, integrated homogeneously into the company’s IndraWorks software tool and the multitasking runtime system. This allows users to take advantage of many new functions for creating modular software projects in an end-to-end overall system in less time than before.

Functions include convenient editor tools, object orientation as an extension to IEC 61131-3, and comprehensive function libraries as well as fast compilers for efficient generation of machine codes. The modular GATcompact (Generic Application Template) project template simplifies the process of designing new machines with enhanced software quality while reducing effort considerably.

End-to-end communication between the controller and decentralized system peripherals, such as inputs and outputs or drives, takes place via real-time Ethernet SERCOS III. Fast PLC cycles to 250 µs enable optimum response times for handling time-critical process signals. IndraLogic XLC controllers come with versatile motion control functions, integrated into the run-time systems, to enhance the previous IndraLogic systems.
With its motion control functionality, the XLC handles machine applications ranging from simple point-to-point motion to the synchronization of multiple axes that use Rexroth’s FlexProfile to integrate complex motion sequences. The graphical profile editor in the Rexroth IndraWorks software tool offers numerous offline and online functions for this purpose. Master and slave interfaces for PROFINET RT, PROFIBUS and EtherNet/IP are also available, in addition to SERCOS III, for integrating into a wide range of communication networks.

“The products highlighted in this year’s Golden Mousetrap winners and finalists clearly demonstrate both cutting-edge design ideas and the practical evolution of technologies for systems and product design engineers,” said Editorial Director David Greenfield. “Design News congratulates all the engineers and their companies who have been recognized with the Golden Mousetrap Award, and we are grateful for their contribution to this year’s competition.”

In addition, Design News named Rexroth’s IndraDrive Cs compact drive as a finalist in its Automation and Control category. That product was also named recently as Control Engineering magazine’s 2011 Engineers’ Choice award winner in the “Machine and Motion Control Servo Drives” category.

BOSCH “SEC” Brushless Cordless Torque Tools
Ask the Expert – Supplier Stock Levels
Happy New Year! – OK…Welcome to March

BOSCH “SEC” Brushless Cordless Torque Tools

Bosch SEC-Exact cordless assembly tools make the assembly process easier, faster, safer, and more accu-rate. Thanks to Bosch’s patented SEC motors, the ability to control shut-off via motor braking is better than ever. This means that the SEC-Exact is the most accurate cordless tool Bosch has ever made. The SEC-EXACT cordless series provides up to 100%speed increase over the standard EXACT range. Couple that with a weight reduction in select models that provides up to 70% better power to weight ratio, and your productivity is sure to dramatically improve.

For example, the new SEC EXACT 412 drops 300 grams compared to the standard EXACT 12, thanks to the use of a 9.6 volt battery. The increased motor efficiency of the SEC range means that all center-grip models need only a 9.6 volt battery to perform better than ever. The Bosch SEC motor has no brushes to wear out. But the most important feature is that this patented technology developed by Bosch does not need a sensor to know rotor speed and position!

This provides a very efficient, wear-free motor system compared to any other brushless motor from any manufacturer in the world. This 3-phase brushless, sensor-less motor is designed and manufactured by Bosch in Europe, thus insuring the highest quality standards are met and maintained.

Benefits:

Achieve faster line speeds thanks to shorter tightening cycles: Work moves faster thanks to speed increases up to 100%.

Improved ergonomics, weight and reaction force translates into satisfied, productive workers that like using the SEC-EXACT tools Reduces life-cycle costs due to wear-free components Bosch SEC motors are the most efficient, durable and economical motors of their type in the world.

Why use Bosch Cordless Technology?

Core Tool Technologies line of cordless tools are ergonomic, lightweight, accurate, and repeatable. Bosch EXACT drivers use ONE HUNDRED (100) TIMES less electrical energy than equivalent assembly tools run by compressed air $5/yr vs. $250/yr with conventional air tools – you do the math!

Core Tool’s offering of Bosch EXACT drivers are among the most accurate assembly tools on the PLANET.

The Bosch EXACT drivers are available with Bluetooth wireless technology for error-proof assembly control.

The Production Link

Contact CORE TOOL’S professional sales staff for an in-plant demonstration of this high quality equipment.

See for yourself.

Always invest in high quality tooling!

Ask the Expert – Supplier Stock Levels

I am sure you have noticed, particularly over the past 3 years, that suppliers keep less and less stock of items, and more deliveries are 5 days or pushed out to 2-3 week or more.

The global economy and internet based sales are changing the way we do business. When there was a plenitude of manufacturing, enough for everybody’s fair share, there was also stock, as end users and suppliers worked together, which always balanced the line between stock & profit margins. Since the downturn in late 2008, it has been about cutting costs. Suppliers could not afford to keep as many  items on the shelf as they were “asked” to reduce costs either to meet or “price match” other suppliers. We are all consumers, regardless of geographic location.

Unfortunately, manufacturers, or more specifically, the automotive industry, is not a high profit business model. It takes a long time to get a return on your initial investment, particularly when supplying specialized products such as DC nut runners. There must be a commitment on both suppliers and end user sides, which has been lacking due to global economic recovery factors. Neither side should carry the burden solely. It’s only fair. The magic, all-encompassing word “partnership” should be maintained.

Always check your pricing; it keeps everybody honest, however, with some products, technical expertise is required to ensure you get the sales and support as a balance with price. There is no stopping some commodity items being low price and rightly so. However, there should always be discussions between engineering and purchasing to ensure some value. Suppliers and manufacturers must always weigh how they maintain stock levels, particularly when product models change often. Dead stock is expensive for everybody and ultimately the financial burden is passed on. Keep this in mind next time you hear “no stock, 1 week delivery!”

Whether you agree or disagree, we will welcome your comments.

Happy New Year! – OK … Welcome to March!

Here we go again. Are you an optimist or a pessimist? Is your company holding it’s own or is there revolving electrical black outs to conserve money?

If you read the news outside of Canada, it’s a disaster. Housing prices are still falling in the US, although job numbers are up slightly. Corporate profits are high and stocks have had some meaningful gains over the past 6 months. Yet, if you visit Arizona, Florida, California and 16 other states, including Illinois, there are foreclosure notices and sales on every street corner. The PIIG countries are insolvent and staring at a big mountain of debt and uncertainty. Political turmoil continues. Right wing groups are organizing particularly the young and impressionable, creating wide spread instability far-reaching to the western countries. This may be the theme of 2011. Germany seems to be growing steadily – and China is a machine trying to control double-digit growth.

Then there’s Canada, “Captain Resource”, not being No. 1, but maybe a good position right now. We have resources, and we have created jobs, for 95% of those who lost jobs in 2008, according to Stats Canada. A 14% increase in manufacturing shipments occurred as well as 10,000 new manufacturing jobs, according to the Ontario Manufacturing Council (OMC). The companies left over from the recession are at “full production”?

Question is, whose buying it all?

USA is our single largest trading partner, which is experiencing well-publicized problems. There must be a lot of consumers we don’t know about, or are inventories just being replenished after 2 years of depletion? Nobody seems to be able to really say. All depends on who you listen to, which is certainly not your average stockbroker!

Everybody wants the magical right answer, which we all know is manipulated on a daily basis by whatever special interest group or person is squeaking the most.

So now what? How about this: Let’s all put our heads down, roll up our sleeves and get to work. We can’t go down the “you owe me a job” attitude of the past. No greed, no whining; go to work, do your job well and lets keep moving forward. Nobody knows how long the ride will last, but based on the past those who put in the effort with a good plan seem to swim. We need to consider the world, but Canada needs to take care of Canada first. Who cares if we are No. 1, as long as we are trading with No. 1. You only have to be faster than the person you are with when you are trying to outrun a bear!

Hundreds of OEMs and many end-users rely on the precision and functionality of Rexroth’s IndraMotion MTX CNC solution, utilizing SERCOS fiber optics for precision motion, and Ethernet TCP/IP and Profibus DP for peripherals. Starting with the software Version 11, customers can choose the proven and compact DIN-rail mount hardware platform model CML 45 (IndraMotion MTX standard), CML 65 (IndraMotion MTX performance) or CML 85 (IndraMotion MTX advanced) – built on high-performance embedded technology with wide range of connectivity.

The controllers offer two real-time SERCOS III 100 Mbs Ethernet ports for highly synchronized motion and I/O control, including TCP/IP communication over SERCOS III for fast drive parameters access and backup. The user can configure two additional real-time Ethernet ports via Rexroth’s IndraWorks Engineering Suite for the preferred modern Fieldbus choice – ProfiNet or Ethernet/IP.

Traditional Profibus DP devices can be connected to the Profibus DP port which can be configured as a master or slave.

A dedicated Ethernet TCP/IP port can be used for executing large NC-programs via the mounted network (DNC) folders. The CNC and drive are commissioned by Ethernet connection using IndraWorks on a laptop or PC. Open communication is available by Ethernet TCP/IP from the PLC program and an integrated OPC UA server (i.p.). A wide range of PC-based machine HMI hardware using Windows XP or Windows XP embedded or small micro-controller based HMI devices are simply connected via Ethernet.

The wide range of inline slice I/O and interface modules can be attached to the local bus at the right of the controller, or to a remote bus coupler using SERCOS III Ethernet or Profibus DP.

Despite the very compact hardware, these IndraMotion MTX models offer a full IEC 61131-3 PLC with very fast execution time and a wide range of technology functions. Functional packages cover drilling, milling, five-axis machining, turning, grinding, gear cutting/hobbing, punching/nibbling, laser cutting/welding, waterjet, plasma/OXY fuel cutting and handling/assembly.

Users can choose the HMI hardware and CNC controller to meet their performance needs:

The IndraMotion MTX standard CML 45, with a 500 MHz CPU and plenty of memory, can control up to eight axes across two NC channels, with four-axis simultaneous interpolation.

The IndraMotion MTX performance CML 65 has a 1GHz processor and can control 8 to 64 axes (up to 32 spindles) across 3 to 12 NC channels depending on the applied options.

Rexroth’s IndraMotion MTX advanced CML 85 provides the absolute fastest PLC logic and NC-block processing times using CoreDuo processor hardware. It can control 8 to 64 axes (up to 32 spindles) across 3 to 12 NC channels depending on the applied options.

Shortly before completion of the product development cycle, new equipment is no longer testing in the lab. Instead, it is put through rigorous field testing in a real production environment. Harald Lukosz, head of Tightening Systems Development, explained the reasoning behind the new strategy: “The simultaneous engineering approach to product development is only efficient if all of the process flows, including the background activities, are functional”.

Rexoth conducted field testing on the modular 350 system in collaboration with GETRAG. The system has been designed to allow existing users of Rexroth tightening systems to easily upgrade their equipment and exploit the advantages of the new control system generation. All five tightening spindles in the tightening station were used during the field test. The existing supply lines were simply connected to the new servo amplifiers. A splash-proof SB356 system box replaced the control cabinets which housed the rack-mounted tightening controllers. There was another factor which made a major contribution to the smooth execution of the field test. Tightening programs for previous versions are compatible with the new controller generation. Programming and analysis takes place on the same familiar user interface.

GETRAG develops and produces technical solutions for all major car manufacturers, and it offers a broad portfolio of transmission and drive train components. GETRAG’s Rosenberg plant is the principal production facility for BMW transmissions which are installed on the 1, 3 and Mini series cars. VDI 2862 lists threaded fasteners on transmissions as function-critical parts, which means that they have to be documented. Rexroth tightening systems with direct measurement features are the solution of choice, because they support torque and angle control techniques.

Rexroth received a NoAE (Network of Automotive Excellence) Innovation Competition award in 2009, sharing the honors with 29 other entrants. The jury of experts was highly impressed with Rexroth’s integration of the logic into the tightening system, and it selected Rexroth’s solution as the best in the “Efficient and Flexible Production” category of the 380 entries which were submitted.