Rexroth SYNAX 200Modular system solution for shaftlessprinting and converting machines

Flexible printing with high productivity

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Our experience – your advantageWith our shaftless motion controlsystems solution, we successfullypioneered a new era of modernmechanical engineering as early as1994. Thus, our global net ofsystem specialists has the longestpractical experience with printingand converting machines world-wide.In close cooperation with ourcustomers, our innovative systemshave been continually developedand optimized – resulting in atechnical and economic advantagefor machine manufacturers andend-users.

One system solution– for all applicationsLarge newspaper plants, printingmachines for packaging or com-mercial printing, narrow webmachines for labels and forms orconverting of paper, foil, cardboardand corrugated board – the systemssolution SYNAX 200 offers suitablemotion control functions for alltypes of applications.More than 6,000 control systemsin over 2,000 highly-productiveprinting and converting machinesaround the world prove that ourcustomers have confidence inRexroth shaftless motion anddrive technology.

Greater flexibility, more speed, higher precision – the market has high demandsin modern printing and converting machines. How can you meet these demands,provide security for the future and stay ahead of your competitors?The solution is SYNAX 200 from Rexroth – the pioneer of shaftless drive technology.

Convincing advantages• standardized machine units• maximum manufacturing performance• fast format and product change• reduced paper waste• highest product quality• less energy consumption• simple operation• high reliability• lower maintenance costs• reduced total costs for manufacturing• easy expansion of the installation

Rexroth SYNAX 200,– your route to a more productive future

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“Shaftless driven” – for the advantages ofRexroth shaftless drive technology

Newspaper printing

Commercial printing

Rotogravure printingfor packaging

Flexogravure printing

Corrugated board printing

Label printing

Forms printing

Converting

Bag production

Folding box production

Corrugated converting

Innovative machine conceptsRexroth modular controls anddrives are the basis for the devel-opment of new and innovativemachines with the “electronic lineshaft”.With a decentralized or centralizedautomation concept – usingSYNAX 200, you as a machinemanufacturer will be at the fore-front of the technological trendin the market.With SYNAX 200, the user willenjoy the advantages of highly-flexible and efficient productionmachines. Getting more out ofyour machine, and increasing yourcompetitiveness – that’s what“shaftless driven” stands for.

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More flexibilitySimpler standardization of machineunits because of fewer mechanicalcomponents and auxiliary equip-ment opens the way to serial pro-duction. Thus, you’ll be flexible inthe configuration of your machine.Setting up for a new product takesplace at the push of a button. Theresult: a minimum of mechanicalretooling, machine setting inrecord time, and thus very shortorder change times.

Maximum availabilityThe fast, format-controlled para-meterization of the drive systemand the possibility of drivingmachine axes independently allowsthe user to enjoy maximum utili-zation of their installations.Experience shows that availabilityis increased by dramatically reduceddown times – and consequently,economic efficiency and produc-tivity is high.

Highest accuracyHighly dynamic handling of theprocess signals is guaranteed by the synchronization via the inter-national standard SERCOS interface(IEC 61491/EN 61491), the intelli-gent digital drives and the flexiblemotion control functions. Thus,highest accuracy is guaranteed atall machine speeds.

The decisive advantages in competition– innovation with high economic efficiency

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Diagnostics at the push of a buttonClear, plain-text messages inSYNAX 200 allow quick diagnos-tics during commissioning ormachine operation. Thus, any mal-functions in the individual machinemodules can be visualized quicklyand easily in chronological sequencevia the operator control terminals.

Less paper wasteProcessing material is expensive.Therefore, SYNAX 200 providesminimum torsional elasticity andreduced backlash, resulting inhigher registration accuracy.This significantly reduces start-upwaste. You as an end-user willlower your production costs, eventhe smallest productions will stillbe economical.

Reduced energy consumptionDigital individual drives reduceenergy consumption and noise.Furthermore, machine compo-nents can be separately isolatednow. With SYNAX 200, shaftlessmachines are even more efficientwith lower pollution.

Quality according to QS-9000 TERexroth's Electric Drives andControls Division was the firstGerman company to introducequality management according toQS-9000 TE and DIN EN ISO9001:2000. Experience shows oursystem components have maxi-mum reliability and optimummaintenance characteristics.

Single source solutionWith the systems solution SYNAX200, you’ll need only one supplierfor the total solution. Use theharmonized modular Rexrothsystem technology to your ad-vantage. From HMI and PLC tomotion control and drives.From advising and project plan-ning to commissioning and service– Rexroth can offer you all theadvantages of the leader of the global market.

Mechanical drive solutions arecomplex and expensive. They areaffected by wear and lack the flexi-bility required in today’s markets.Any change of product or formatcosts time and work and reducesproductivity.The future of modern printing andconverting machines lies in mecha-nically and electronically advancedsystems solutions.

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Digital and transparent SYNAX 200 replaces mechanicaltransmission elements with effi-cient motion control functionsand integrated PLC.SYNAX 200 makes shaftless drivetechnology transparent by meansof digital communication. Thus,all the potential for enhancingprinting system flexibility is avail-able to the user.

Precise and interference-freeThe motion control system ofSYNAX 200 determines the posi-tion of the “virtual master axis”with digital precision.Optional cascading of these multi-turn control axes enables thestraightforward integration ofmachine modules in interlinkedand synchronized productionprocesses.SERCOS interface provides theinterference-free transmission tothe individual machine drives.This makes the highly precise, syn-chronous movement of all processmodules possible.

Flexible electronics instead of rigid mechanics– the electronic line shaft of SYNAX 200

Couplings

Differential gearbox

Gearbox with variabletransmission ratio

Cog wheelMechanical cam

Conventionally driven machines are less flexible, changes ofproduct and format go to the expense of productivity

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Simple system expansionComplex automation solutions canbe realized by means of a combi-nation of several motion controlsystems and master axes. Thus,there is practically no limit to thenumber of synchronized drives; itis finally possible to break down amachine into independent sections.With SYNAX 200 technology,shaftless machine units can be cou-pled to conventionally drivenmachines by using an encoder as a“real master axis”. Thus, existingproduction plants can be extendedand updated very easily, economi-cally and efficiently.

Flexible integrationWith the wide range of SYNAX200 drive systems, the connectionto the machine can be realized inmany different ways.Using a framed or framelessmotor, with reduction gearing ordirect drive – SYNAX 200 with the“electronic line shaft” offers you theoptimum motion control conceptfor each application.

Framed motor with reduction gearing andoptional position feedback at the cylinder

Direct drive with frameless motor andposition feedback at the cylinder

Direct drive with framed motor andposition feedback at the cylinder

The future in the printing and converting industrybelongs to machines with an "electronic line shaft"

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Crossing mechanical limits– flexible motion control functions

Primary master axis

Secondary master axis

Printing and converting

Gear ratioGear ratiofine adjustment

Easy and quick access to motioncontrol functions and their para-meterization is the key to the eco-nomical integration of the "elec-tronic shaft" in modern machinesystems. SYNAX 200 is not a"black box" for the user – itsmotion control functions aredesigned to be transparent andconsistent from start to finish. Theelectronic gears, for example, haveuniform structures for cascadablemultiturn control axes as well asfor servo drives. This makes motioncontrol both easy to understandand easy to use, even without manyyears of experience in modern servodrive technology.

Universal structure of SYNAX 200electronic gears

• easily-parameterized technologymodules

• integrated IEC 61131-3 PLC (optional)

• up to 40 slave axes per PPC control

• 2 cascadable master axes per PPC control

• up to 32 PPC controls in the group

• flexible, switchable operating modes, e.g. cams or anglesynchronization

• high-resolution electronic gears with universal structure

• electronic coupling• online switchable electronic

cams• electronic high-speed cam

switch group

• integrated process functions:- winders- dancer axis control- tension control- register control

Flexible motion control

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Precision without wear– electronic gears

Mechanical gearboxes are replacedby SYNAX 200 highest precisionelectronic gears. Mechanical pro-cesses are standardized and thefunctionality of machine modulesincreased accordingly. You are ableto handle a large number of formatvariations without mechanicalmodifications, e.g. by the quicksetting of longitudinal registerswith maximum resolution.

Without mechanical limits– electronic cams

Non-uniform relationshipsbetween the master axis and individual drives are defined byelectronic cams. These cams areselectable "on-the-fly". Cross cuttersare synchronized for cutting of thematerial according to format.Settings are made by quick and simple parameter changes.

Highest precision – theintegrated register control

The integrated register controlautomatically corrects the angularposition of an individual drive inrelation to the position of the pro-duct. This eliminates costs forexternal register controls or foradditional actuators and specialdrives. And helps you to achievehighest product quality with a significant reduction in waste.

Get web tension under control– the tension control

The integrated tension controlkeeps web tension constant in thematerial to be printed. Dependingon the actual measured value andthe digital or analog tension set-point, SYNAX 200 precisely con-trols the tension. External elec-tronic control devices are no longernecessary. The highest printingprecision is already guaranteedat the start of production.

Time is money– on the fly job change

SYNAX 200 makes it possible tostart and run up a module intoangular synchronism with amachine already operating at pro-duction speed. For the first time,the quick product change at fullmachine speed is possible. This isan innovative feature in classicalmechanical engineering. Shorterdown and retooling times reducethe current manufacturing costs.

From reel to reel– winding control

All functions are integrated for centerdriven winders – for winders with-out external sensors or for winders in combination with dancer rolls orload cells. The winder axes are controlled according to the setpointvalues. Thanks to the direct process-ing of the measured variables and theintegrated diameter calculator, thereare no additional costs for externalwinding controllers.

With the Rexroth systems solutionSYNAX 200 you’ll get all theoptions for the integration ofmodern motion control intoexisting automation systems aswell as in your newly developedmachine concepts based on the“electronic line shaft”.

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The ideal system module kitFrom the single-web inline machineto multi-web newspaper printingmachines – SYNAX 200 covers theoverall control and drive require-ments of your individual applica-tion. Compose your system fromthe efficient and innovative stan-dard components of the SYNAX 200suite of modules according to yourspecific requirements.

Utilization of open standardsThe open architecture of SYNAX200 protects the investments youhave already made in engineeringand control components. Thanksto this open character, the dialogbetween hardware and softwaresolutions of different manufactur-ers is trouble free and makes futureextensions of existing productionplants easy. The utilization ofSYNAX 200 open communicationstandards consequently reducestime and effort and therefore thecost of integration into your auto-mation system, e.g. via• Arcnet• DeviceNet• Ethernet• INTERBUS• PROFIBUS• ControlNet• SERCOS interface

Protect existing investments– open communication at all levels

• flexible motion control• easily programmable PLC• ergonomic visualization and

operating devices

• user-friendly software tools• highly-dynamic digital servo

drives• modular input/output

components

SYNAX 200 – the complete systems solution

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Superior connectionsto PLC and HMIThe PLC performs control tasks inclose connection with the motioncontrol, either for the whole ma-chine or for modular machineunits. Thus, fast process signals,complex instructions and para-meters are exchanged directlybetween the system components.Ergonomic terminals visualize themachine status and offer the whole

range of possibilities for operationand data input. The SYNAX 200software tools support you in engi-neering and operation processes.

The most economic solutionTurn your shaftless machine into aflexible, high-performance produc-tion system with open communi-cation paths and motion controlfunctions that are easy to para-meterize and program.

Modulation and scaling characteris-tics of the components, togetherwith the integrated process func-tions, make SYNAX 200 the mosttechnically and economicallyadvantageous systems solution.With all single- and multi-axisapplications you as machinemanufacturer or end-user willprofit from the advantages ofRexroth’s shaftless drive technology.

WindingUnit

PrintingUnit

ProcessingUnit

ExtensionUnit

Ethernet (TCP/IP)

Fieldbus

Cross communication

FieldbusMachineconsoleand PLC

Operating andvisualization

Motion control,PLC and I/O

Digital intelligentdrive controller

Internet

Onlinemaintenance

anddiagnostics

Fieldbus

Decentral I/O Decentral I/O

SERCOSinterface

SERCOSinterface

SERCOSinterface

SERCOSinterface

Automation with SYNAX 200

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• dialog-guided operation• quick access to the motion

control functions• extensive online help

• numerous diagnostic options• convenient drive supervision• integrated oscilloscope for

drive optimization

• back-up of parameter sets• online/offline operation mode• well-proven software concept

The best system toolsWith its advanced software toolsfor total automation, SYNAX 200will result in significant costreductions for engineering,commissioning and maintenanceof your machine and automationsystem. With our system compo-nents you will get integrated solu-tions to increase the economicefficiency of your machine or plant.

Motion and logic combinedSYNAX 200 integrates on a singleplatform the easy parameterizationof motion control with the flexi-bility of PLC logic in accordancewith IEC 61131-3. The user-friend-ly and economical performance ofall motion and control functions isthus possible with uniform hard-ware. Whether rack or PC based,the coordinated modular system ofthe SYNAX 200 provides thenecessary flexibility of hardwareconfiguration.

Programming of the PLC logictakes place with the IndraLogicengineering tool. Through thefunctions library you have directaccess to motion control functions.The latter are parameterized prac-tically at the press of a button bymeans of the SynTop software tool.Electronic gears, for example, arequickly and easily set without anyprogramming. And process func-tions for register controls, winders,tension and dancer axes are inte-grated in the application withoutany effort.At the same time, SYNAX 200 offersall the functions and libraries basedon IEC 61131-3, thus providingevery freedom for implementingall possible automation applicationsin the printing and converting sector.

Integration of motion control and logic– transparent and consistent

Commissioning and service with SynTop

HMI

Application program

PLC• IEC 61131-3 languages

and function library

Motion control• Synchronization

• Cross communication

Technology components

Servo drives

PPC control

SYNAX 200

Motion logic library

Motion control and PLC – all integratedin the SYNAX system architecture

• programming languages according to IEC 61131-3

• instruction list (IL)• function block diagram (FBD)• ladder diagram (LD)• sequential function chart (SFC)• structured text (ST)• continuous function chart (CFC)

• standard IEC 61131-3 library• PLCopen library• integration of user-defined

libraries• communication library• 16 time, cycle and event

controlled tasks• online/offline programming

mode

• online change• integrated 20 channel logic

analyzer• simulation, monitoring and

debugging• import/export functions• user and password

administration• multi-language support

Engineering with IndraLogic

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Commissioning and diagnosticsThe commissioning and servicetool SynTop is based on Rexroth’sdecades of know-how in controland drive technology. Via user-friendly dialogs and extensive online help, SynTop guides youthrough commissioning, clearlyshows diagnostics and drive data,and leads you to achieve your tar-get quickly and easily.

Programming according toIEC 61131-3 The PLC module is programmedvia the engineering tool IndraLogic.In addition to the support of pro-gramming languages and standardfunctions according to standardIEC 61131-3, you can integrateyour own function libraries. Thesystem engineer will quickly befamiliar with the user-friendly programming.

Unique functionalityThe transparent representation ofprogram code, import/exportfunctions, the reversible online/offline mode, as well as user and

password administration make iteasy to work with this efficientPLC. The permanently availableonline help for all language ele-ments allows quick access to thedocumented functions. The utiliza-tion of the integrated 20 channellogic analyzer for supervision of allprogram parameters, the activesyntax check color, as well as theconstantly updated cross-referencelist will support you in program-ming and troubleshooting.Special function components pro-vide easy communication with themotion control via its fast datainterface.

Simple program-ming and para-meterizing withSYNAX 200

Rexroth SYNAX 200 is the completeautomation system for shaftlessprinting and converting machinesin a matching system of modules.The new WinStudio software toolis the related easy-to-operate, com-prehensive visualization softwaretool for all SYNAX 200 automationsolutions.

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Rexroth WinStudio offers theproject engineer all functionalityfor creating system-specificoperating screens in a simpledrag-and-drop, point-and-clickdevelopment environment.WinStudio supports differentgraphics formats and interfacessuch as Active-X.All process variables and commu-nications parameters defined inthe SYNAX 200 MotionLogic areavailable in WinStudio for visuali-zation.

Multilingual database support andautomatic language translation atruntime eliminates efforts forcreating specific HMI screens.SYNAX 200 also supports theintegration of 3rd party appli-cations via the integrated OPCinterface. Used in conjunctionwith the new family of PC-basedoperator terminals, RexrothIndraControl V, WinStudio is theideal platform for man-machinecommunication for all types ofshaftless printing and convertingmachines.

Operation and visualization withRexroth WinStudio – easy and user-friendly

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Quick and easy creation ofsystem-specific operationand visualization masks

Convenient operation andvisualization• user-friendly PC-based

visualization and operation• dynamic graphic screens, trends,

alarms, reports and orders• alarms management system

with free formats and filters • automatic language translation

at runtime• import/export of orders,

reports and real-time data in XML format

• e-mail and web interface• seamless integration in

Windows environment • interfaces to other 3rd party

packages such as Java, C, C++,and Visual Basic

Simplified project planning• simple and object-oriented

environment for screen and object reusability

• full-featured screen objects and dynamics with customizable object properties

• flexible database with boolean,real, string and array tags

• extensive, graphical libraries • flexible programming via

easy-to-use scripting language • conforms to industry standards

such as OPC, DDE, ODBC,XML, ActiveX

• import of 15 different graphics formats for enhanced andrealistic screens

• internationalization usingunicode

Rexroth IndraControl V– the operator terminals• field-proven industrial PC• ETX format CPU and chipset• 12“ and 15“ TFT displays• touchscreen• integrated SVGA graphics

controller• on-board 10/100 MB

Ethernet• serial, parallel and USB

interfaces• PROFIBUS interface (option)• integrated UPS (option) • EMV-certified with

IP65/IP20 protection• completion by more operator

controls and visualization units (option)

Operator panels withintegrated industrial PC

Modular control hardware

• motion control PPC • Rack or PC plug-in card• local I/O modules• interfaces for fieldbus, Ethernet,

cross communication anddecentralized I/O

• direct coupling of operating and visualization terminals

• integrated displays for quick device diagnostics

• software tools for parameter-ization and programming from motion control and PLC

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Comfortable HMI devices

• clear, understandable visualiza-tion, operation and diagnostics

• uniform operation philosophy with easiest handling

• industrial PC with touchscreen or operating keys

• LCD operating terminals with different performance levels and graphic displays and freely-programmable function keys

• simple software tools for programming the HMIs

Input/output modules

• scalable I/O modules with IP20 protection

• for local or decentralized controlarchitecture

• decentralized sensor/actuator boxes with IP65 protection

• communication via fieldbus interfaces PROFIBUS or DeviceNet

• simple interconnection

The perfect team for your automation– the modular system components

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Intelligent drive systemIndraDrive

• wide power range from1 kW to 110 kW

• compact converters andmodular inverters

• integrated safety functions(EN 954-1, Category 3)

• integrated motion control using IEC 61131-3 compliant PLC

• process-oriented technology packages

• scalable through extensive hard-ware options and software modules

• openness through broad rangeof interfaces

• direct connection to a 380 V - 480 V line and power recovery

• integrated line contactor and braking resistor

• little installation work and easy initial startup

Highly-dynamic servo motorsIndraDyn

• enclosed motors, kit motors and linear motors in synchronous or asynchronous designs

• high dynamics, power density and load rigidity

• high peak torques up to 13,800 Nm• servo motors for potentially

explosive areas – conforming to ATEX and UL/CSA

• high-resolution transmitter systems

• absolute or incremental position scanning

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Rexroth SYNAX 200 – successfulin all applications around the world

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