Punching, Cutting, Forming – Standardized, optimal Drive ...

1/24Punching, Cutting, Forming –Standardized, optimalDrive & Control-Solutions

Technical Information

RE 08101-02/11.12Replaces: 03.12

Table of Contents

Contents Page

Features, Function Principle 2

Performance Table/Technical Data – Cylinder Axis 3

General Motion Sequence 3

Modes 4

Power-Management 5

Performance Curves Cylinder Axes and Power Unit 6

Performance Curves Cylinder Axes and Power Unit 7

Unit Dimensions:

Cylinder Axis 200 kN – "Standard Performance" 600 Strokes 8

Cylinder Axis 200 kN – "Advanced Performance" 900 Strokes 9

Cylinder Axis 200 kN – "High Performance" 1200 Strokes 10



Cylinder Axis 300 kN – "Advanced Performance" 900 Strokes 13

Cylinder Axis 300 kN – "High Performance" 1200 Strokes 14

Unit Dimensions:

Power Unit : 7,5 kW, 11 kW, 15 kW 15 - 17

HNC100-axis Control , Unit Dimensions 18

WINPED7: Engineering and Commissioning Tool 18

Drive & Control-Solutions 19 - 20

Components for Automation Systems 20 - 22

Documentation 23

Punch Force 200 kN and 300 kN

2/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Features

– Highly dynamic, "flow-optimized" valves (booster/servo tech-nology), reduction in switching time of approx. 40%.

– Very compact build-design of the cylinder axis, approx. 20% less installation space required.

– Consistent concept with standardized, optimized 200 kN and 300 kN punching cylinder axes.

– Ideal use of the products in nibbling machines with 600, 900, 1200 and 1600 strokes 1/min in typical nibbling modes, as well as in:

- Notching and perforating machines.

- Cutting presses.

- Hole punching machines and copy punching machines.

- Automatic punching machines, slot punching machines and turret punching machines.

- Embossing machines with high stroke rates.

– Following stroke rates are possible in engraving/marking modes.

~3000 strokes 1/min with 3 mm stroke or

~4000 strokes 1/min with 1 mm stroke.

– Cylinders with low-friction seal suitable for top speeds > 2 m/s, tolerances < 0,01 mm and smallest strokes 1 mm.

– Digital position sensor (5 µm resolution) enables the very high positioning accuracy and prevents temperature drift.

– Standardized, clear-cut and simple mechanics/hydraulics/electrics interface for integration in the machine concept.

Function Principle

– Highly dynamic digital controller with cycle times of less than 0.5 ms includes a selection of diverse operating modes such as:

- Punching and nibbling.

- Engraving/signing.

- Soft punching (noise reduction).

- Deep-drawing/forming.

- Thread-cutting and much more, all with very high precision.

– Maximum availability thanks to robust valve and sensor technology.

– Energy-efficient punching/forming using energy-optimized (HP-LP-circuit).

– Standardized power units with optimized power adjustment (pressure control pumps).

– Reduction of power unit stand-by power by 50% (zero-pressure circulation).

– Technically optimized, coordinated and service-proven products guarantee:

- More productivity, very high reliability and long service life.

- Very high dynamics paired with maximum precision and outstanding functionality.

– Further customer-specific options:

- Cylinder forces and cylinder stroke lengths.

- Customer-specific power units/punching axes.

- Customer-specific interfaces/mounting options.

- Customer-specific hardware and software at the controller.

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Standard Performance Advanced Performance High Performance

Hydraulics Bosch Rexroth AGRE 08101-02/11.12 Technical Information 3/24

Performance Table/Technical Data - Cylinder Axis

200 kN 300 kN

Standard Ad-vanced

High Standard Ad-vanced

High

600 750 1200 1600 600 750 1200 1600

Possible stroke frequency [1/min] of punching machine at 4 mm stroke

600 750 900 1200 1600 600 750 900 1200 1600

Engraving/signing 1 mm 1100 1) 1100 1) 2600 4000 4000 950 1) 1100 1) 2200 3000 3500

Typical selection of the power unit according to power, E-motor [KW]

7,5 7,5 7,5 11 15 11 11 11 15 18,5

Punch stroke time [ms]

3 mm 24 20 16 30 24 20

4 mm 48 38 28 24 18 50 40 34 28 22

6 mm 54 44 34 30 24 65 55 40 34 28

10 mm 98 70 50 40 32 105 80 56 44 38

1) at 4 mm signing stroke

Example, see performance table above:

200 kN, High Performance 1200 stroke 1/min 200 kN, High Performance 1600 stroke 1/min

Punch stroke time for 4 mm stroke: 24 ms Punch stroke time for 4 mm stroke: 18 ms

Typical plate movement time: 26 ms Typical plate movement time: 19 ms

Total time: 50 ms Total time: 37 ms

Resulting from a stroke frequency: 1200 stroke 1/min Resulting from a stroke frequency: 1600 stroke 1/min

More cylinder axis sizes on request.

General Motion Sequence

PTE = Position Tool Exchange;

POP = Position Over the Plate;

PUP = Position Under the Plate;

NRG = Negative Ramp Gradient (velocity forwards);

PRG = Positive Ramp Gradient (velocity backwards);

0

1

2

3

4

5

6

0 10 20 30 40 50Time [ms]

PTE

Working time Waiting time (plate advance)

Ram

Plate

Bottom die

POP

Min. idle stroke above plate

Min. idle stroke below plate

Positioning window PUPPUP

Positioning window POP

Total stroke

Pos

ition

[m

m]

NRG PRG


Nibbling/Punching Engraving/Signing

– Performance of individual punching strokes.

– SYEHL punching axis moves synchronously to the axes that move the steel sheet with the “X and Y” axes.

– The SYEHL punching axis moves without synchronization with the “X and Y” axes, which move the steel sheet.

– The steel sheet moves continuously and does not stop when the tool penetrates the steel sheet.

– Engraving is utilized for impressing writings or symbols on steel sheets.

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Soft punch Deep drawing

– The SYEHL punching cylinder moves between positions PSP 1 and PSP 2 (position Soft Punch 1 and 2); the downward velocity is slower to minimize strike shocks.

– Embossing or forming with special tools.

– POP is the rest position above the steel sheet, and PUP the position within the sheet steel.

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Holding time

Modes

Plate

Plate

Plate

Plate


Power-Management

HNC100 Controller

A10VSO...ER

HNC function example => pump control

Analogue amplifier module

Noise level

Measured in an anechoic chamber

Distance from microphone to pump = 1 m

Measuring error: ± 2 dB (A)

(Fluid: Hydraulic oil to ISO VG 46 DIN 51519, t = 50° C)

Energy

Energy

Time

Time

Pressure/energy adjusted to the demanded force.

Hydraulic Standby power ER-pump e.g. ~ 1,5 kW

Energy consumption during „punch modi“ HP/LP system with variable pump.

Stroke example "punch modi"

. . . . . . . . . . . .

. . . .

. . . . . . . .

0 28025020015010056

58

60

62

64

66

68

70

Ger

äusc

hpeg

el L

A [

dB(A

)]

Operating pressure p [bar]

Performance Curves for Pump, A10VSO18...

qv max

qv Null

n = 1500 min-1

50


Performance Curves Cylinder Axes and Power Unit

4

1000

Stroke frequency [1/min]

Stroke [mm]

Standard 600 – 200 kN Standard 750 – 200 kN

Theoretical calculated stroke frequency with:

– Auxiliary times for example table movement

– Cylinder stroke time by control valve


– Power unit size (motor, pump)

– Cylinder size

Auxiliary time e. g. Max. power unit performance

1) 0 [ms] 7,5 [kW]

2) 30 [ms] at cylinder axis 600, 750 and 900 20 [ms] at cylinder axis 1200

11 [kW]


15 [kW]

Typical performance range of a punch system. Performance curves shows the system performance of cylinder axis and power unit:

Punching machines are usually don't work with max. perfor-mance and simultaneous 100% duty-cycle.

The performance curves shows typical working points of the electro-hydraulic punch systems.

Detailed info's on request.

Typical operating point of a punch machine.

1) Engraving/signing mode2) Nibbling/punching mode

Advanced 900 – 200 kN


4

1000900

Stroke [mm]

High 1200 – 200 kN

4

1000750


Stroke [mm]

4

1000


Stroke [mm]

600

1200


Performance Curves Cylinder Axes and Power Unit

4


Stroke [mm]

Standard 600 – 300 kN Standard 750 – 300 kN


– Auxiliary times for example table movement

– Cylinder stroke time by control valve


– Power unit size (motor, pump)

– Cylinder size

Auxiliary time e. g. Max. power unit performance

1) 0 [ms] 7,5 [kW]


11 [kW]


15 [kW]

Typical performance range of a punch system. Performance curves shows the system performance of cylinder axis and power unit:

Punching machines are usually don't work with max. perfor-mance and simultaneous 100% duty-cycle.

The performance curves shows typical working points of the electro-hydraulic punch systems.

Detailed info's on request.

Typical operating point of a punch machine.

1) Engraving/signing mode2) Nibbling/punching mode

Advanced 900 – 300 kN


4

900

Stroke [mm]

High 1200 – 300 kN

4

750


Stroke [mm]

4


Stroke [mm]

600

1200

1000

1000

1000

1000


ca. 2

7827

1016

275+0

.5

ca. 1

75ca

. 145

145

145

30

30

72.5

72.5

ca. 163ca. 189

30

30

200

0̀.3

200 `0.3

40

140

180+

0.5

25

80

6 x M20-35/45 deepPermissible tightening torque 400 Nm

Unit Dimensions: Cylinder Axis 200 kN – "Standard Performance" 600 Strokes

1:2

40 mm cylinder stroke. Other stroke lengths on request.

Hole Ø 12 H11 25 mm deep for locating pin


ca. 1

48

ca. 3

42

2714

5

145

30

30

180ca. 206

16

10

72.5

72.5

30

30

315+0

.5

200`

0.3

200 0̀.3

80

40140

M14x1,5

25

180+

0.5

Unit Dimensions: Cylinder Axis 200 kN – "Advanced Performance" 900 Strokes

1:2



Hole Ø 12 H11

25 mm deep for locating pin

For pipe connection 8L


ca. 1

89

345

2714

5

145

30

30

80114

16

1072.5

72.5

ca. 1

63

3040

30

370+0

.5

20

0`

0.3

200 `0.3

80

M14x1,5

25

180+

0.5

Unit Dimensions: Cylinder Axis 200 kN – "High Performance" 1200 Strokes


2:5



Hole Ø 12 H11



ca. 1

45

165

165

30

30

82.5

82.5

ca. 163ca. 189

ca. 1

74

30

30

200

0̀.3

200 0̀.3

80

40140

ca. 2

7827

1016

275+0

.5



1:2


Hole Ø 12 H11

25 mm deep for locating

pin


ca. 3

3827

1016

M14x1,5

275+0

.5

ca. 1

45

165

165

30

30

82.5

82.5

ca. 163ca. 189

ca. 1

80

30

30

200`

0.3

200 0̀.3

80

40

140



1:2




Hole Ø 12 H11

25 mm deep for locating

pin


Unit Dimensions: Cylinder Axis 300 kN – "Advanced Performance" 900 Strokes


ca. 1

50

165

165

30

30

ca. 180ca. 206

82.5

82.5

30

30

200

0̀.3

200`0.3

80

40140

27 16

10

ca. 3

4231

5+0.5

M14x1,5

1:2



Hole Ø 12 H11



Unit Dimensions: Cylinder Axis 300 kN – "High Performance" 1200 Strokes


ca. 1

89

345

2716

5

165

30

30

80114

16

1082.5

82.5

ca. 1

63

30

30

40

370+0

.5

200`

0.3

200`0.3

80

M14x1,5

2:5



Hole Ø 12 H11



Unit Dimensions: Power Unit 7,5 kW

75450600

ca. 650

ND

HD

L/Y

B

T

D

810850

20

864

ca. 1

430

1214xØ11


Unit Dimensions: Power Unit 11 kW

810850

20

864

75450600

ca. 650

121

ca. 1

510

ca. 902ca. 52

4xØ11

NDHD

L/YDB

T


Unit Dimensions: Power Unit 15 kW

810850

20

864

75450600

ca.650

121

ca. 1

510

ca. 902ca.52

4xØ11

NDHD

L/YAB

T


– The axis control is based on the Rexroth standard control HNC100 (closed-loop control for up to four hydraulic axes, scanning rate < 0,5 ms, communication with the higher-level control via PROFIBUS DP.

– CANopen, PROFINET, sercos, NC-programming on request.– The data exchange (parametrizing) is made via PROFIBUS, start/stop signals

exchange is made via fast I/O´s. – For further data, pin assignments, component dimensions etc. see data sheets

RE 30139, RE 30139-B, RE 30139-U, RE 30160-B. – The HNC100 axis control is optimized for highly dynamic operating modes, e.g.

for punching, engraving, soft punch, deep drawing / embossing, forming, signing, flanging, cutting. No additional programming required.

– The HNC100 offers the possibility, that more axes can be operated as shear axis or hydraulic blank holder (stripper).

– Optimization of the control loop of the existing operating modes with the help of R-parameters.

– Use of oscilloscope function to simplify commissioning, optimization of the control circuit and fault diagnosis.

– Optional connection of analog and digital SSI position measuring systems.

HNC100-axis Control

Mounting on top-hat rail TH 35-7,5 or TH 35-15 to EN 6071548

124

118

62,5

enco

der

X8M1

GND

X3C

RS

232

X2D1

GND

GND

18-30V

pow

er

X1S

AIO

X2A1X7P/C

DP

/CA

Nop

en

120

Unit Dimensions: HNC100 (nominal dimensions in mm)

slot1

WINPED7: Engineering and Commissioning Tool

Simplifies engineering and commissioning:

– Project management.

– Parameterization of HNC100.

– Creation of NC programs.

– Bus manager to configure the data exchange.

– Diagnostic functions, standard nibbling software (fixed functionality).


Drive & Control-Solutions

– Rexroth has decades of experience in the cutting and punch-ing technology.

– Special punching press functions are available for IndraMotion MTX (HNC100).

– Clear interfaces are available, which are mechanically, hy-draulically and electrically adjusted to provide easily integra-tion into the customer’s concept.

– Special shock-resistant servo-motors and dynamic high-response valves are available.

– Drive & Control system solutions are available with hydraulic punching head.

– A common commissioning tool for the electrical and hydrau-lic NC IndraWorks is available.

IndraMotion MTX Standard

Ethernet

Fast I/O‘s

serc

os PROFIBUS

IndraDyn IndraDrive Inline I/O

HNC100 controller

SYEHL cylinder axis

IndraControl

IndraDyn

ABSBG power unit

PROFIBUS

IndraControl

IndraMotion MTX Micro

E/A's (power control)

Nominal/actual value

Sensors

More I/O's

IndraDrive

serc

os

IndraDyn

Fast I/O‘s

TCP/IP

HNC100 controller

SYEHL cylinder axis

ABSBG power unit

E/A's (power control)

Sensors

More I/O's

DVIIndraDrive IndraLogic IndraControl

IndraControl

IndraLogic IndraControl

Nominal/actual value


Components for Automation Systems

Drive & Control-Solutions

Rexroth offers you specific components for all areas of automa-tion. From process control to handling – comprehensive and cross-technological.

Control and Visualization

– Drive-based, controller-based and PC-based control sys-tems.

– Consistent visualization concept from small control terminals to industrial PC.

Control

– Modular I/O technology for control cabinet assembly (IP20)or field use (IP67).

– Consistent communication via sercos III, Ethernet TCP/IP or field bus.

– Pneumatic solenoid valves with multi-pin or field bus inter-face.

Handling and Motion

– Pneumatic and electromechanical linear systems.

– Electrical and pneumatic rotary systems.

– Pneumatic gripping systems.

– Vacuum handling systems.

– Linear guides.

– Ball screw drives.

– Intelligent servo drives and frequency converters.

– Highly dynamic servomotors.

IndraDriveIndraDyn

HNC100 controller

SYEHL cylinder axis

IndraControl V

ABSBG power unit

IndraControl L

Mechanical movement elements Maintenance units

IndraMotion MTX CNC/SPS



Control and Visualization

IndraControl V

Rexroth IndraControl V is the comprehensive range of HMI de-vices for individual control, operation and monitoring in all in-dustry sectors.

The range extends from controller based devices to compact embedded PCs to high-performance industrial PCs.

With scalable hardware and software, IndraControl V can be adjusted exactly to your machine specific requirements.

IndraControl L

IndraControl L is the flexible, configurable hardware platform for open control architectures. It does not matter whether you want to implement a motion, robot or logic control application – you always use the same hardware, and the software alone deter-mines your application.

For optimal application adjustment, we offer a control platform with different performance levels to choose from. The open ar-chitecture and varied function modules make integration into heterogeneous system landscapes simple.

Control

Fieldline Rexroth Fieldline in protection class IP67 permits extremely reliable installation close to the machine, even in harsh environmental conditions.

Inline Rexroth Inline is the flexible modular I/O system with protection class IP20 for time-saving control cabinet installation.

Valve terminal systems The compact valve terminal system LS04 offer all the necessary valve functions and electrical connection options.

Maintenance units The maintenance units in the AS series not only perform the standard functions of filtration, regulation, and lubrication, they also allow for the integration of specific function requirements such as shut-off valves, filling valves, distributors, and non-return valves. They are set apart by excellent performance data, high flex-ibility, and exceptional energy efficiency, all thanks to optimized condensate drain valves, finely-tuned filter element sizes, and smooth and precise pressure regulators.


Handling and Motion

Electrical drives Intelligent IndraDrive servo drives and frequency converters, as well as the comprehensive IndraDyn motor program, make the highest level of dynamics possible.

Electrically driven axesLinear systems have integrated guides and drive elements, which reduce adjustment and assembly effort. They have been proven in a wide array of applications.

Basic mechanical componentsNo matter what you are building or must set into motion, we have precise motion elements and modular systems that are perfect for your application.

Ball transfer units in miniaturized configuration

Rexroth is supporting the trend to the miniaturization of convey-ing and automation systems with miniaturized configurations. The range includes e.g. compact motion elements with 17 and 23 mm outer diameter.



Documentation

RE 00208

Industrial Hydraulics – Hydraulic and Electronic Components

RE 71237

IndraMotion MTX The CNC system solution for perfect cutting and forming

RE 72604

Automation Systems and Control Components

R499050875

Effective Control with Air – An Overview of Pneumatic Valves and Valve Terminal Systems from Rexroth

R499050869

Ready At Any Time – An Overview of Pneumatic Cylinders from Rexroth

R499050547

Air Supply Management – An Overview of Compressed Air Preparation and Accessories from Rexroth

3 842 530 392

Move More in Less Time. Linear Motion and Assembly Technologies from Rexroth

R3102910

Ball Transfer Units

R3102001

Linear Technologies – efficiently and reliably motion

R499050646

Automation Solutions

Bosch Rexroth AG Sales Industry PressesZum Eisengießer 197816 Lohr am Main, Germany Phone +49 (0) 93 52 / 18-13 12 Fax +49 (0) 93 52 / 18-12 [email protected] www.boschrexroth.de/awz

© This document, as well as the data, specifications and other informationset forth in it, are the exclusive property of Bosch Rexroth AG. It maynot be reproduced or given to third parties without its consent.The data specified above only serve to describe the product. No state-mentsconcerning a certain condition or suitability for a certain applicationcan be derived from our information. The information given does notrelease the user from the obligation of own judgment and verification. Itmust be remembered that our products are subject to a natural processof wear and aging.


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