Drive and control solutions for metalforming and ... - Bosch Rexroth

IAE 68248/02-01 

Drive and control solutions 

for metalforming and 

press automation

The metalforming motion control strategy 

that improves your bottom line 

More profit, fewer problems 

Metalformers achieve maximum 

profitability with the advantages 

of Rexroth Indramat servo motion 

systems: 

• Improved uptime with reliable 

hardware, designed for high 

shock and vibration 

environments 

• Full-featured software with all 

functionalities needed for 

metalforming 

• Modular, scalable servo solutions 

allow common product for all 

metalforming applications 

throughout the plant, from 

simple roll feeds to complex coil 

processing lines 

• Smaller spare part inventories 

• Improved synchronization of 

complete metalforming lines 

reduces scrap and improves 

part quality 

• Built-in safety features protect 

personnel, dies and equipment 

• Commonality of equipment 

reduces training and support costs 

• You are dealing with a qualified 

single-source vendor with 30 years 

of metalforming and press 

automation experience 

Product range covers all 

applications in your plant 

Rexroth Indramat supplies the full 

power and performance range of 

metalforming machine servo control 

— all the way from drives for small 

press feeders to large 800 HP 

variable frequency/vector drives 

for powering the presses. 

• Brushless servo and vector 

drives from 1/4 to 500 HP (200 

Watt to 375 Kw) 

• Variable frequency/vector 

drives (VFDs) from 2 to 800 HP 

for straighteners, levelers and 

main press drives 

• Single-axis stand-alone controllers 

for roll feeds... up to 

32-axis motion controllers for 

complex multi-axis systems 

• VisualMotion ® Windows-based 

programming software for 

easy parameterization and 

troubleshooting of your 

metalforming machines 

Rollfeed In-die transfer Flying cutoff 

2

VisualMotion graphical user interface 

Text editor interface 

Benefit from modular, 

open architecture 

controls 

Rexroth Indramat increases 

your return on investment by 

replacing proprietary controllers with 

a modular, open architecture 

control strategy. 

Open architecture components, plus 

a common Windows look and feel 

for programmers and operators, 

provide for easy connectivity. 

Modularity and scalability allow you 

to use a family of standard servo 

products for all applications 

throughout your plant — from 

single axis roll feed applications to 

complex multi-axis coil processing 

line applications, pick-and-place 

robots and crossbar transfer 

systems. This scalability results in a 

common look and feel throughout 

the plant, reducing your need for 

training, maintenance/service 

support, and spares. And Rexroth 

Indramat’s modular systems make 

it easy to expand as production 

needs change. 

Rexroth Indramat supports open 

digital communications standards for 

networking servo drives, controllers, 

HMIs, PLCs, sensors and other 

devices. Our drives are easily 

integrated with all popular PLCs, and 

drives are available with support for: 

The SERCOS (SErial Realtime COmmunications 

System) interface is the international 

standard (IEC/EN 61491) for communications 

between digital drives and controls. 

Rexroth Indramat vigorously supports this 

essential standard. 

 

I/O map editor 

Connectivity to all standard 

communications buses 

A fundamental reason for open 

architecture industrial control 

is better information flow between 

enterprise systems and the 

production floor via standard 

communications buses. 

Ethernet 

 

Blanking and shearing line Press-to-press transfer Crossbar transfer press 

3

Complete functionality for metalforming 

Extensive metalforming 

industry experience 

Rexroth Indramat brings you 30 

years of experience in metalforming 

and press automation. We incorporate 

metalforming functionalities 

into our standard servo products, 

so machine builders don’t have to 

start from scratch to create a 

metalforming control system. 

Industry-leading OEMs have 

chosen Rexroth Indramat for 

applications including: 

• Blanking lines 

• Coil processing lines 

• Crossbar transfers 

• Flying cutoffs/shears 

• Gantries 

• Gripper feeds 

• In-die transfers 

• Press-to-press transfers 

• Progressive die feeds 

• Push-pull feeds 

• Roll feeds 

• Roll forming lines 

• Oscillating shears 

• Stackers/destackers 

• Tube/pipe benders 

• Wire benders 

• Zig-zag feeds 

High Productivity 

Rexroth Indramat systems are 

designed to maintain high 

productivity of your metalforming 

system. We offer a wide range of 

low inertia, high torque synchronous 

linear and rotary motors to precisely 

meet the needs of each type of 

metalforming machine. Our products 

are highly reliable, designed for high 

MTBF, and are proven in operation in 

harsh, demanding environments. 

Downtime is minimized by absolute 

encoders, downloadable parameters 

and easy-swap motors and drives. 

Flexibility where it counts 

Rexroth Indramat offers a wide 

range of HMIs to suit various needs, 

all offering a common look and feel 

for the operator. Our software 

includes built-in application-specific 

features to make metalforming 

machine control design/applications 

easier to implement. And our motor 

line ranges from fractional to 800 HP 

to meet all your needs. 

Easy system startup 

Easy to service and support 

Rexroth Indramat motors and drives 

are preventive-maintenance free. 

Our motion controls and drives 

feature powerful diagnostic 

capabilities (that can be accessed 

remotely) to aid in quickly resolving 

both machine and control system 

problems. Analog outputs on the 

drives are provided for monitoring 

internal siginals and variables. 

Removable personality modules 

make it easy to replace drives. 

Simply pop an old drive out, put its 

personality module into a 

replacement unit, hook the new 

drive up and run. Rexroth Indramat 

even builds EEPROM devices into the 

motors to communicate diagnostics 

and automatically send default 

parameters to the drives, avoiding 

extensive tuning. 

Simplified setup and 

homing 

Rexroth Indramat servomotors 

incorporate economical absolute 

feedback mechanisms that 

remember position information even 

if power is lost. This eliminates the 

need for homing and makes setup 

and restarts faster and easier. 

Setting up the drive is simple with 

Rexroth Indramat’s Windows-based 

software. 

4

Fast, flexible changeovers 

Programmable motion lets you 

perform product changeovers 

quickly. When a job changes, the 

operator sets up the machine by 

selecting a new program at the 

control panel. Electronic gearing 

ratios, camming setpoints and 

motion profiles change automatically 

in seconds. 

Fewer mechanical components 

In metalforming systems such as 

coil processing lines, in-die transfers 

and automated press lines, Rexroth 

Indramat servos can reduce the 

quantity of unreliable mechanical 

components on your machine. 

This results in lower maintenance 

costs, less downtime, better part 

quality and improved part 

handling accuracy. 

Electronic cams for 

greater flexibility 

High-resolution electronic cam 

tables in the drives provide for 

high-precision non-linear motion, 

eliminating expensive, inflexible 

mechanical drivetrain solutions. 

Programmable limit 

switch cuts costs 

Operator, die and 

equipment protection 

Rexroth Indramat's metalforming 

software includes features to insure 

operator safety and protect 

valuable dies and equipment, 

especially in case of power failures. 

The control system utilizes 

regenerative drives with sufficient 

stored energy to bring the system to 

a controlled halt upon power failure, 

avoiding damage to expensive dies 

and machines. 

Software interlocks ensure that feeds 

can occur only during the correct 

press opening angles to avoid 

damage to press and dies. 

A dry-run functionality allows 

emulating a production cycle without 

press movement to check for proper 

feed operation and avoid collisions. 

This is especially important in 

progressive die, press-to-press 

transfer and crossbar transfer press 

applications. 

Systems are designed with optional 

redundant encoders, so if a primary 

encoder is lost, the line can be 

brought to a controlled stop running 

off the secondary encoder. 

Built-in programmable limit switch 

functionality eliminates the need for 

extra-cost add-on programmable 

limit switch controllers, mechanical 

position cams and proximity sensors. 

5

Open control strategy for metalforming machines 

Unlike competitors who provide you 

with a “black box” control and allow 

access only to the menu items they 

provide, Rexroth Indramat takes an 

open-architecture approach to 

metalforming control that offers 

flexibility and choices. 

Our controls and drives incorporate 

familiar industry standards, such as 

PC-hardware; Windows-based 

software; the SERCOS interface for 

motion control; ControlNet, 

DeviceNet, Profibus, Interbus and 

CANopen for I/O; and Ethernet for 

connectivity to enterprise systems 

or the Internet. 

Rexroth Indramat offers a family of 

controls, scalable to meet any 

metalforming need. They connect 

the same, operate the same, use 

Internet 

Optional Visualization Unit 

similar software and connect to a 

scalable family of drives and motors, 

providing a common look and feel 

throughout the plant. 

Controls range from single-axis 

position controllers to multi-axis 

PC-based and rack-mount controllers 

with PLC and motion control 

capabilities. We offer a family of 

powerful, configurable HMIs, from 

a simple stand-alone display/keypad 

to a powerful PC-based universal 

control and programming terminal. 

And we offer a wide range of 

servomotors and induction motors – 

all operable from any type of 

Rexroth Indramat drive, via 

swappable firmware modules. 

VisualMotion ® Windows-based 

programming software provides for 

easy setup, parameterization and 

troubleshooting of your metalforming 

machines. And, if desired, our 

software can easily be accessed and 

modified by OEMS or end users. 

All Rexroth Indramat systems 

incorporate a comprehensive set of 

diagnostics for quick troubleshooting 

and problem solving, all the way 

from drives to the system and 

machine level. And our systems can 

be remotely diagnosed via a local 

modem or over the Internet. 

HMI 

CNC, HMI 

SERCOS interface 

Common Power Supply 

Variable 

Frequency 

/Vector 

REFUdrive 

Fieldbus 

Modem/Ethernet 

Motion 

Control 

& I/O 

Variable 

Frequency 

/Vector 

REFUdrives 

DIAX04 Servo 

Drives 

Optional 

Cross-Communication Link 

Motion 

Control 

& I/O 

6 

Vector Motors Servomotors Linear Motors Induction Motors

One control strategy throughout your plant 

from roll feeds... 

Rexroth Indramat provides an ideal 

solution for control of roll feeds. 

These feeds can be standalone, or 

can easily be integrated into a 

complete line control. 

Rexroth Indramat’s roll feed control 

handles all applications, from long 

feeds to the quick, short feeds 

required for perforating presses. 

High-performance 

brushless AC servo drive 

provides accurate, 

consistent feeds 

Our standard software 

solution provides the built-in 

functionality required by 

roll feeds: 

• Precise, accurate feeds — Rexroth 

Indramat servos provide ±.5 arc 

min resolution 

• Setup mode provides progressive 

die protection 

• Jog +/- 

• Choice of operating mode: feed 

before press, press before feed 

or intermittent 

• Die gagging controls through I/O 

• Automatic roll lifting 

• Feed to registration mark 

• Batching (program storage) for up 

to 99 parts, including: 

▼ Speed ▼ Length ▼ Tools 

▼ Feed angle, with single turn 

absolute encoder. (Programmable 

limit switch - PLS) 

▼ Gags ▼ Part recipes 

• Micro-adjust for fine-tuning of 

feed length on the fly 

High-performance brushless 

AC servo drive for precise 

feed control 

Servo drives a ball rail-mounted 

zig-zag carriage via a ball screw or 

timing belt. Precise zig-zag motion 

allows nesting of parts on coil 

• Status and diagnostic screens 

• Jerk-limiting S-curve smooths the 

feeder motion, minimizes roll slip 

and improves accuracy 

• Short settling time allows for 

quick feeds 

• Programmable limit switch (PLS) 

eliminates the need for an 

external feed angle limit switch 

• Feed angle and roll lift angle 

can be directly programmed at 

the operator terminal 

• Percent of feed angle used is 

displayed, so press stroke rate can 

be optimized 

Plus, an open programming 

environment allows you to 

add additional functions! 

Benefits include: 

• Quick, easy job setup with 

existing press controls 

• Multi-batch runs 

• Excellent part quality 

• Higher production, more parts 

with reduced scrap 

• Reduced downtime 

• Easy to use 

7


...to in-die transfers... 

Rexroth Indramat has the perfect 

control and drive solution for in-die 

transfers, replacing expensive, 

maintenance-prone mechanical cams 

and press linkages with servos. 

Electronic camming ensures the 

highest possible throughput while 

insuring safety of the die and press. 

A Virtual Master in software 

overcomes mechanical constraints on 

loss of power or top stop. In these 

situations, the Virtual Master, rather 

than the press-mounted encoder, 

controls the feed, allowing the transfer 

stroke to be smoothly completed, 

bringing the transfer mechanism into 

the correct stopped position without 

damaging or losing parts. 

Built-in functionality includes: 

• Electronic cams are synchronized 

to the main press encoder as well 

as a virtual master for accuracy 

at all speeds 

• Customizable cam tables and 

programmable limit switch 

values are easily downloaded 

to the drives 

• Synchronized at all press speeds 

• Built-in protection features prevent 

damage to expensive dies 

• Programmable error reaction in the 

motion control and drives allows 

you to specify the proper drive 

action should an error occur 

• Virtual master allows synchronizing 

cams independently of the 

press encoder, allowing easy 

setup (manually stroke press) 

• Press and motor absolute encoders 

remember position even if power 

fails, providing a quick restart 

• Excellent diagnostics for quick 

troubleshooting 


• Improved part handling with 

fewer misfeeds 

• Higher throughput/productivity 

• Select ”softer“ motion for 

hard-to-handle parts; aggressive 

motion for simpler parts to 

minimize wear on system 

mechanics 

• Avoids die crashing, downtime 

and repair costs 

• Provides flexibility for production 

of a wide range of parts 

Optional features include: 

• Real master encoder filter — 

smooths the operation of the 

transfer mechanism, isolating the 

master encoder from the shock 

and vibration of the press 

• Redundant press encoders 

provide added safety 

• Redundant motor encoders 

provide added safety 

• Extra capacitance for the drive 

provides continuity on loss of 

incoming power 

• Linear motors can provide direct 

drive with high acceleration and 

traverse speeds for maximum 

performance 

8

High power REFUdrive 

regenerative variable 

frequency/vector drive 

powers the press 

Hydraulic controlled clutch 

from Rexroth Hydraulics 

Press-mounted 

absolute master 

encoder provides 

synchronization for 

the line 

High performance servo 

drives provide accurate 

grip, lift and shuttle of 

parts between press 

strokes 

Rexroth Indramat motion 

controller electronically 

integrates the motion 

of all axes and I/O logic to 

afford the smoothest, 

tightest synchronization 

available 

Produces higher 

quality parts 

with fewer 

rejects 

9


...blanking and shearing lines... 

Rexroth Indramat provides electronic 

synchronization of all axes in a 

blanking or shearing line, with all 

processes linked to and synchronized 

to the press/shear position: 

• Uncoiler 

• Leveller/straightener 

• Loop control 

• Roll feed 

• Part stacker 

• Takeout conveyor 


• Precise synchronization of the 

intermittent motion feeder with 

the continuous motion uncoiler/ 

leveler/straightener for maximum 

productivity 

• Controlled programmable 

shutdown on power loss 

• Easy interface to press/shear 

control system, fieldbuses, and 

typical PC front ends, such as 

Wonderware ® , Intellution ® , Visual 

Basic ® , Steeplechase ® and 

WINCC * 

• Wide range of servo, vector and 

variable frequency/vector drives 

provide the high power and 

performance to handle coil 

processing lines of all sizes 

• High-dynamic servo drives 

• Common dc-bus 

*Trademarks owned by respective companies. 


• Higher production rates 

• Improved part quality 

• Less scrap 

• Improved system uptime 

• Faster setups 

• Easy to use 

Photo eye or ultrasonic sensor provides 

input to Rexroth Indramat controller to 

adjust loop length 

High performance 

regenerative servo or 

vector drive for precise 

tension control 

Rexroth hydraulics drive 

the coil transfer 

REFUdrive runs 

straightener to remove coil 

set, operating at a speed 

based on the press rate. 

Penetration of rolls can be 

servo controlled 

For levelers, a Rexroth 

Indramat servo is used to 

adjust roll parallelism to 

remove crossbow or 

camber from the coil 

10

Rexroth Indramat REFUdrive 

variable frequency/vector drive 

powers the press 

Rexroth Indramat servos 

precisely index scissor lifts 

as blanks are stacked 

A servo drives a magnetic 

overhead takeout conveyor 

to quickly and accurately 

transport blanks to the 

takeout stackers 

Press-mounted absolute master encoder is 

monitored by Rexroth Indramat controller 

to provide precise synchronization of 

motors and drives 

Servos allow automatic pass 

line height adjustment 

REFUdrive variable frequency/vector 

drives power takeout stackers for 

seamless finished-part handling 

without stopping the line 

Servo feeds a precise length at a rate 

based upon press speed 

11


...press-to-press automation... 


operate a multi-axis gantry 

system to smoothly handle 

part infeed 

Servo controlled robotic unloaders and loaders 

efficiently control part flow between presses to 

avoid bottlenecks 

REFUdrive variable frequency/ 

vector drive accurately 

synchronizes infeed conveyor 

to the speed of the press 

Optional servo-controlled 

stock guide adjustments 

Rexroth Indramat servo motor 

with Rexroth Star Linear 

module can be used for 

high-speed part shuttle 

between presses 

12

Rexroth Indramat REFUdrive 

variable frequency/vector 

drives power the presses 

Built-in safety features of Rexroth 

Indramat motion control system prevent 

costly die crashes and downtime 

Rexroth Indramat system precisely 

controls kinematics of swing-arm 

loaders and unloaders 

Part takeaway and 

stacker systems are 

controlled by Rexroth 

Indramat servos 

Complex part positioning is handled 

perfectly by Rexroth Indramat-controlled 

multi-axis orientation station 

A Rexroth Indramat servo system 

provides smooth coordination of 

part transfer between multiple 

presses at high speeds with 

improved safety features. This 

includes control of destackers, 

shuttles, setup axes, orientation 

stations, part turnovers, die carts, 

robotics and main press drives. 


• Precise coordinated motion from 

setup axes to the complex 

kinematics of robotic part loaders 

• Optional redundant press 

and motor encoders ensure 

system safety 

• Electronic cams for press loaders, 

unloaders, CNC-feeds and swing 

arm feeders provide the ability 

to program a smoother move 

based on the characteristics of 

individual parts 

• Programmable error reaction in 

the motion control and drives 

allows you to specify the proper 

drive action should an error occur 

• Line regenerative drives with a 

common DC bus store energy, 

allowing for a safe, controlled 

stop upon power loss 

• Collision protection is provided by 

built-in math functions and 

programmable limit switch 

functions 

• Analog outputs and digital 

oscilloscope functions provide for 

improved diagnostics 

• Absolute encoders permit fast 

recovery after stopping, with 

no need to home or reference 

the axes 

• High performance drives improve 

production rates and improve 

accuracy 



• Reduced possibility of die crashes 

• Elimination of large, expensive, 

inflexible mechanical cams 


• High reliability 


• Less power consumed 

• Detailed diagnostics assist 

preventive maintenance 

13


...crossbar press transfers... 

Rexroth Indramat controls the 

motion and synchronization of the 

crossbar transfer system. Multiple 

controllers synchronize multiple 

drives for smooth, precise control, 

from destacker, to die carts to 

in-press transfer mechanisms to 

stackers and conveyors. And 

Rexroth Indramat provides variable 

frequency/vector drives for the main 

press drive, synchronized with the 

rest of the control system. 


• Precise coordinated motion for 

independent complex moves on 

the part orientation stations 

between the presses 

• The Rexroth Indramat 

controller controls I/O for 

suction, sensors, etc. 

• The system interfaces easily to 

any PLC, PC or fieldbus 

• Programmable error reaction in 

the motion control and drives 

allows you to specify the proper 

drive action should an error occur 

Optional features include: 

• Line regenerative drives with a 

common DC bus store energy, 

allowing for a safe, controlled 

stop upon power loss 

• Redundant press and motor 

encoders ensure system safety 



• Improved part quality with fewer 

reject parts 



• Higher reliability 

Multiple electronically synchronized servos control part transfer 

and orientation stations, on signals from the press encoder 

14

The entire system works more efficiently with 

Rexroth Indramat motion controllers and servos, 

resulting in higher production rates 

The Rexroth Indramat system assures accurate 

parts placement and avoids costly die crashes 

Electronically synchronized servo 

motion eliminates mechanical wear 

and tear, minimizing repair time 

Suction cups and grippers equipped 

with Rexroth Mecman pneumatics 

15


...flying cutoff... 

Rexroth Indramat servos ensure 

precisely sheared parts from your 

continuous motion coil lines via 

control of a flying shear that 

precisely synchronizes a cutoff 

carriage with the moving line, then 

shears the part without slowing 

the production rate. 


• High resolution feedback insures 

highly accurate speed control for 

tight synchronization of cutoff 

carriage speed to line speed 

• Digital intelligent drives control 

line synchronization, freeing 

the motion controller for 

supervisory functions 

• Lagless velocity control ensures 

accurate parts at all speeds from 

start to finish 

• Large power range of servo 

drives using the same controllers 

ensures easy scalability from 

small to large systems 


• Excellent part length accuracy 

• Higher operating speeds 

• Precision material cuts 

• Less scrap 

16

Brushless servo drive or REFUdrive 

variable frequency/vector drive 

provides the power to shear the 

moving part 

A servo drives the end-stops 

to position the completed 

parts for batching 

Measuring wheel on the strip 

provides input to the controller 

to insure part length accuracy 

REFUdrive variable 

frequency/vector 

drive powers the 

forming rolls 

High-performance linear direct 

drive provides high acceleration 

and traverse speed, precisely 

matching cutoff carriage speed 

to line speed for maximum 

system performance 

Brushless servo drive or 


frequency/vector drive 

powers the takeout 

conveyor 

17


...and tube/pipe bending machines. 

Rexroth Indramat controller 

precisely controls all axes for 

best quality bends at the 

highest production rates 


perfectly perform twisting 

and indexing motions of 

the tube 

Bend head is driven 

by Rexroth Indramat 

brushless servo drive 

Automated setup axes 

can easily be added to 

the system 

Rexroth Indramat provides an 

excellent solution for tube and pipe 

bending machines, providing motion 

control of multiple axes for bending, 

setup and auxiliary functions. 


• Precisely coordinated motion 

• Control of I/O for pneumatic 

and hydraulic motion — 

i.e., the bend head 

• Complete status and 

diagnostic functions 

• Absolute position feedback option 

on servomotors remembers 

position even if power fails, 

allowing fast and easy setups plus 

a quick restart without homing 

• Easy interface to any PC or PLC 

system controller 

• Complete geometry control and 

calculations performed in motion 

controller 

• Communications via serial port to 

third party front end, e.g., 

Steeplechase ® , Wonderware ® , 

Intellution ® , and WINCC 

software packages* 


• Precise, quality bends 

• Quick, easy setup 

• Interfaces easily to existing 

controls 

• Easy to troubleshoot 

• No homing necessary 

• Electric servos, mechanical slides, 

pneumatics and hydraulics all 

provided by one source — 

Rexroth 

• Interfaces to all major fieldbuses 

*Trademarks owned by 

respective companies. 

18

Control strategy for metalforming machines 

Are you supporting too many 

motion control supplier’s 

products in your metalforming 

plant? Then consider how 

many of your machines could 

be more economically 

controlled by specifying 

Rexroth Indramat. 

Our modular product design 

even makes hardware, 

firmware and motor types 

interchangeable, reducing your 

spares support costs. 

From low-cost roll feeders to large 

automated press lines with robotic 

parts handling, Rexroth Indramat 

combines the performance, 

functionality and power range to 

do it all. 

Global, enterprise solutions 

Rexroth Indramat is specified by 

some of the world’s largest, most 

profitable metalforming manufacturers. 

These businesses are leveraging 

our technologies and connectivity to 

implement enterprise-wide 

automation strategies. We‘d also like 

to put our metalforming control 

expertise to work for you! 

Rexroth Indramat offers its 

customers detailed application 

knowledge and engineering 

support that often are not 

available from other suppliers. 

Unlike some localized 

competitors, Rexroth Indramat 

has the reach to support our 

customers around the world. 

Field service engineers 

(and spare parts) are available 

to support you in the Americas, 

Europe, Africa, Asia and Australia— 

wherever you are shipping or 

operating equipment. They are 

familiar with local requirements and 

resources, assuring trouble free 

startup and reliable ongoing service. 

19

Rexroth Indramat System 200 family of components 

ELC single-axis position 

controller 

• Plugs into ECODRIVE servo 

drives 

• 16 inputs/12 outputs 

• Multi-tasking and logic capabilities 

can eliminate the need for a 

micro PLC 

• Available with DeviceNet and 

Profibus 

• Roll feed software supplied as 

ready to run module; unique 

functionalities can be added 

by OEM 

• Easy to use MotionManager ® 

Windows-based programming 

language 

• Variables, math, logic 

• Full multi-language control 

and diagnostics available at user 

interface 

• Typical applications — roll feed, 

setup axes, benders, indexers, 

stand-alone shuttles, conveyors 

CLM 4-axis positioning control 

• 32-bit microprocessor for 

variables, math and logic 

• Easy-to-use MotionManager ® 

Windows-based programming 

language 

• Runs all Indramat 

drives 

• 16 inputs/16 outputs, 

expandable 

to 88 in/51 out 

• Built-in 4-line 

illuminated display 

and keypad for 

operation and 

programming 

• User-selected 

multilingual 

display 

• Continuous system monitoring 

and diagnostic protection 

• Typical applications — zig-zag 

feeds, push-pull feeds, 2-4 axis 

gantries with basic motion 

PPC PC-based and 

rack-mount controllers 

• Machine controllers that run 

VisualMotion ® software to 

coordinate motion control, 

logic, I/O and HMI 

• VisualMotion software offers: 

▼ Graphical user interface and 

machine programming 

environment 

▼ Handles setup, parameters, 

job changes 

▼ Multi-threading, multi-tasking 

▼ Multiple electronic cams in 

control and drive 

▼ Cam indexer and cam build 

utility 

▼ Programmable limit switch 

functionality 

• Form factors include PCI-bus, 

and rack-mount cards 

• Simultaneously control 4 

independent processes and 

up to 32 servo drives 

• Multiple controllers can be 

synchronized to control even more 

axes and processes 

• Interfaces include SERCOS 

interface, plus ControlNet, 

DeviceNet, Interbus, Ethernet and 

Profibus for I/O 

• Typical applications — 

press-to-press transfer, in-die 

transfer, coil processing lines, 

complex gantries, robotics 

BTV family of humanmachine 

interfaces 

• Choose from a family of 

powerful, configurable humanmachine 

interfaces — from a 

simple stand-alone display/keypad 

to a powerful PC-based universal 

control and programming 

terminal 

• All HMIs provide a similar look 

and feel, no matter what type of 

machine they are on 

• Interface hardware/software 

provides ease of use, plainlanguage 

programming and 

comprehensive diagnostics for 

fast commissioning and startup 

and reduced system downtime 

• Support multiple languages 

20

Intelligent digital servo drives 

ECODRIVE servo drives 

• From 1/2 to 36 

HP continuous 

power 

• Built-in power 

supply, internal 

soft-start 

contactor relay 

and dynamic 

brake control 

• Snap-on programming 

modules 

• Extensive selection 

of programmable 

travel limits, 

position, torque, 

velocity 

• Use as self-contained single 

axis positioning drive with 

analog, parallel, SERCOS 

interface, Profibus, Interbus, 

DeviceNet or CANopen interface 

• Incremental quadrature encoder 

or absolute serial synchronous 

interface (SSI) to position loop or 

for monitoring 

• Absolute or incremental position 

measurement 

• RS-232/485 serial interface for 

setup, installation and diagnostics 

• Comprehensive error/warning 

detection and diagnostics 

messaging 

• Easy time-saving installation via 

DriveTop graphics program 

• 230-480 V autosensing input, 

with no transformer required 

• EMC compliant design 

• UL listing on all modules 

• Two cam profiles per drive 

• High speed probe inputs 

DIAX04 servo drive family 

• High power (4.5 to 100 HP 

continuous) and performance 

• For high speed, 

high precision, 

high power 

automation and 

handling 

applications 

• 750 Vdc bus 

system — high 

voltage allows 

use of smaller, 

less expensive 

cables plus the 

ability to run 

higher speed 

motors 

• Compact, space-saving drives 

minimize cabinet requirements 

• One modular direct-line-connect 

power supply supports multiple 

drives 

• PCMCIA firmware card allows 

programming and parameter 

downloading from a PC 

• Space-saving single- and 

dual-axis models 

• Support analog cards and SERCOS 

• Built-in contactor and bleeder 

• Time-saving Snap-on DIN rail 

mounting system shortens 

installation time 

• Comprehensive status and 

diagnostic functions 

• EMC compliant design 

• Internal soft-start circuit 

• Direct 380-480 V power line 

connection, with no transformer 

required 

• Absolute encoder 

• High speed probe inputs 


frequency/vector drives 

• High power from 2 to 800 HP 

• Control various types of 

synchronous and induction 

motors 

• Automatic motor adaptation 

using parameter identification 

routines 

• Removable operator panel with 

copy function 

• 4-line graphical display 

• Sercos interface and Peer-to-Peer 

interface available via fiber-optic 

cable; Profibus, Interbus, 

CANopen, RS232, RS485 and 

SynchroLink interfaces also 

available 

• Includes additional signal 

processor for highly dynamic 

applications 

• EMC compliant 

• Line regeneration available 

• Forced air or liquid cooling 

available 

• High overload capabilities 

21

DKR high-power vector drives 

• High power (35 to 300 HP 

continuous) 

• Servo-quality dynamic response 

• For high speed, high precision, 

high power metalforming 

applications 

• Direct 380-480 V power line 

connection with no transformer 

required 

• Integral line power regeneration 

capabilities 

• Integral power supply 

• Internal soft-start circuit eliminates 

external components 

• Electronic gearbox and cam 

functions built-in 

• Self-contained homing capability 

• Extensive diagnostic capability 

• Optional absolute encoder 

function 

High dynamic response linear 

direct drives 

• Permanent magnet synchronous 

frameless motors 

• Provide highest acceleration and 

traverse rates 

• Speeds to 200 m/min; force 

densities up to 20,000 N 

• No motor components 

subject to wear 

• Choice of traverse path lengths 

• Standard cover plate for the 

full traverse path 

• Integrated into the machine design 

• Absolute measuring system used 

for reliable operation 

• Absolute scale makes homing and 

limit switches superfluous 

• Simple commissioning, even with 

vertical axis 

• Thermal encapsulation for 

constant temperature at the 

mounting face 

• Integral cooling for primary, 

no cooling normally required 

for secondary 

• IP-65 protection type for 

fully-enclosed motor variants 

High dynamic response servo 

and vector motors 

• Full range of maintenance-free 

IP65-rated brushless AC servo and 

vector-duty induction motors 

• Optional high resolution absolute 

feedbacks for easy homing, feed 

rates and positioning 

• High resolution (4,000,000 PPR) 

feedbacks 

• Embedded EEPROMs simplify 

parameter setup and enable 

predictive maintenance 

monitoring. Provide automatic 

recognition and matching of drive 

to servomotor upon startup 

22

Complete range of motion 

systems from Rexroth 

Did you know that the Rexroth 

companies also offer a full range 

of hydraulic, pneumatic and 

linear motion systems, plus 

aluminum structure? 

We can simplify your engineering, 

commissioning and purchasing 

tasks by taking single source 

responsibility for all the motion 

control subsystems on your 

machinery. 

One call to Rexroth Automation 

Systems can even bring you expert 

integration support. Ask your 

Rexroth Indramat representative 

for details. 

23

Rexroth Indramat Division 

Rexroth Corporation 

5150 Prairie Stone Parkway 

Hoffman Estates, IL 60192-3707 

Tel: (847) 645-3600 

Fax: (847) 645-6201 

http://www.indramat.com 

info@indramat.com 

REV A 02/01 ARGUS 10M IAE 68248

Drive and control solutions for metalforming and ... - Bosch Rexroth

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