Sytronix Solutions with IndraDrive on Press Brakes · Press brakes often have a main controller (Cybelec, Delem, etc.) which outputs analogue set point values for speed and torque

RE 08100-01, Edition: 2014-12, Bosch Rexroth AG

Sytronix Solutions with IndraDrive on Press Brakes

Contents

Introduction 2Hydraulic Circuit Diagram 2Components 3Electrical EquipmentBlock Diagram 3Dimensioning Data 4Parameterization 5Drive Optimization 6Possible Error Messages 7Velocity Control Loop Monitoring 8

RE 08100-01Edition: 2014-12Technical Information

2/8 Technical Information | Sytronix Solutions with IndraDrive on Press Brakes

Bosch Rexroth AG, RE 08100-01, Edition: 2014-12

Introduction

Hydraulic press brakes, which are used for precision sheet metal forming by means of defined bending, are increas-ingly being equipped with variable speed drives in order to save energy. The solution for this from Bosch Rexroth is called „Sytronix“.

Hydraulic Circuit Diagram of a Press Brake

Example of a hydraulic circuit diagram for press brakes

X2.2

X1.2

X2.1

X1.1

M1.1 M1.2

M2.1 BA M2.2

M1A P1A P1B T Y M2A P2A P2B M2BM1B

Sytronix Solutions with IndraDrive on Press Brakes | Technical Information 3/8


Required Components for a Solution Sytronix

The system consists of an axial piston pump optimized for variable-speed operation, a synchronous servo motor and servo controllers together with the appropriate accesso-ries. For the operation of the servo motor the following com-ponents are required:

▶ Drive controller HCS or HMS (with HMS a power supply is still required) with analogue control unit

▶ Fusing ▶ Transformer (optional) ▶ Line filter (optional) ▶ Choke ▶ Mains contactor ▶ Power and feedback cables ▶ Servo motor

Axial piston pumpSynchronous servo motor

Controller

Block Diagram of the Electrical Components

Mains

DST HNF HNL Con- tactor

HCS

Cable Motor

Quantity Name Type Explanation1 Axis 1 MSK071E-0300-NN-S1-UG0-NNNN Motor1 Axis 1 INDRADRIVE HCS02 Drive controller:1 Axis 1 HCS02.1E-W0054-A-03-NNNN Power section1 Axis 1 CSB01.1N-AN-ENS-NNN-NN-S-NN-FW Control part1 Axis 1 FWA-INDRV*-MPB-08VRS-D5-1-NNN-NN Firmware1 Axis 1 HAS01.1-105-072-CN Accessory1 Axis 1 HAS02.1-002-NNN-NN Accessory1 Axis 1 HNL01.1E-0600-N0032-A-500-NNNN Mains choke1 Axis 1 NFD03.1-480-030 Mains filter1 Axis 1 RKL4307/005,0 Power cable1 Axis 1 RKG4200/005,0 Encoder cable1 Axis 2 MSK071E-0300-NN-S1-UG0-NNNN Motor1 Axis 2 INDRADRIVE HMS02 Drive controller:1 Axis 2 HMS02.1E-W0054-A-07-NNNN Power section1 Axis 2 CSB01.1N-AN-ENS-NNN-NN-S-NN-FW Control part1 Axis 2 FWA-INDRV*-MPB-08VRS-D5-1-NNN-NN Firmware1 Axis 2 HAS02.1-010-NNN-NN Accessory1 Axis 2 RKL4307/005,0 Power cable1 Axis 2 RKG4200/005,0 Encoder cable

Example of electrical Equipment



Pressing kN

Number of cylinders 1 or 2

Cylinder diameter piston side mm

Diameter of the piston rod mm

Weight of beam kg

Fast approach

Stroke mm

Speed mm/s

Acceleration / deceleration m/s2

Stroke muting position to clamp position 6 mm acc. to EN13857

Speed mm/s


Bending stroke mm

Speed mm/s


Pressure holding in BDG s

Decompression s

Return - slow

Stroke mm

Speed mm/s


Return - fast

Stroke mm

Speed mm/s


Idle - long stroke (e.g. insert material manually) s

Idle - short stroke(e.g. insert material automatically) s

Required Customer Data for Dimensioning

The case with shortest pause time is important. This case requires the highest continuous power rating of the electrical drive.

For the design of the drive a Bosch Rexroth software tool is available on enquiry to Bosch Rexroth Lohr am Main.

Fast approach

Slow closing

PressingPressure holding

Decompression

Return fast

Posi

tion

/ di

stan

ce

Time

Returnslow

Muting position

Clamping position



Parameterization of the IndraDrive Control Unit

Press brakes often have a main controller (Cybelec, Delem, etc.) which outputs analogue set point values for speed and torque to the IndraDrive. Therefore the following control modules are required:

▶ CSH01.1C-NN-ENS-NNN-MA1-NN-S-NN-FW or ▶ CSB01.1N-AN-ENS-NNN-NN-S-NN-FW

The drive is therefore fundamentally used in the operating mode “speed control”. The positioning of the drive is carried out by the main controller which also evaluates the external measuring systems. An internal PLC-program in the drive controller (MLD) is not required in this appli-cation and type of control because the main control calculates the analogue set point values and outputs the correct values. A conversion of the set point value into pressure and flow rate is not necessary.

Processing and assignment of the analogue voltage at the analogue inputs of the IndraDrive is necessary so that the set point value causes the required rotary speed or out-put torque of the drive.For the required rotary speed the analogue input 1 is allocated to the speed set point S-0-0036. In order to limit the output torque via an analogue voltage the ana-logue input 2 is allocated to the output torque limit value S-0-0092.

Processing of the analog input for the torque limit

Selected mode

Review of the analog input for driving speed



Drive Optimization

Torque curve during the pressing processComplete cycle

Drive parameter optimization

Dependent upon system design of the press brake, an optimization of the drive may be necessary.For this the parameters of the rotary speed control loop and current* control loop can be adjusted.A smoothing of the rotary speed controller can also be integrated.

Attention: Changes to the current controller parameters may only be carried out after consultation with Bosch Rexroth.



Possible Error Messages (F8078)

In this application it is possible that the drive cannot follow the required speed due to reduction of the output torque or due to hydraulic pressures. It is also possible that hydraulic pressure causes movement of the drive when the required speed is zero. In these cases the error message F8078 (error in rotary speed control loop) will be displayed.

This error message should be disabled in such applica-tions by means of the parameterP-0-0556 with bit 1 = 1P-0-0556Axis controller configuration: 1000.0000.0001.0011

Attention: In such cases the hydraulic anti-cavitation pipe work and anti-cavitation valve should be checked. It is probable that the valve is not being switched correctly. The switching of the valve is normally carried out by the safety PLC or the CNC.

Output torque required value in S92 approx. 10%

Required rotary speed in S36 approx. 340 RPM

Actual rotary speed in S40 approx. 0 RPM



Bosch Rexroth AG HydraulicsZum Eisengießer 197816 Lohr am Main, Germany Phone +49 (0) 93 52 / 18-0 [email protected] www.boschrexroth.de

© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

Velocity Control Loop Monitoring

Deactivation of the velocity control loop monitoring

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Sytronix Solutions with IndraDrive on Press Brakes · Press brakes often have a main controller (Cybelec, Delem, etc.) which outputs analogue set point values for speed and torque