Punching, Cutting, Forming – Standardized, Optimal Drive

RE 08101-02/11.12 1/24 Punching, Cutting, Forming – Replaces: 03.12 Standardized, optimal Drive & Control-Solutions

Technical Information

Punch Force 200 kN and 300 kN

Table of Contents

Contents Page Features, Function Principle 2 Drive & Control-Solutions 19 - 20 Performance Table/Technical Data – Cylinder Axis 3 Components for Automation Systems 20 - 22 General Motion Sequence 3 Documentation 23 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 – "Standard Performance" 600 Strokes 11 Cylinder Axis 300 kN – "Standard Performance" 750 Strokes 12 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 2/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Features

– Highly dynamic, "flow-optimized" valves (booster/servo tech- – Highly dynamic digital controller with cycle times of less than nology), reduction in switching time of approx. 40%. 0.5 ms includes a selection of diverse operating modes such – Very compact build-design of the cylinder axis, approx. 20% as: less installation space required. - Punching and nibbling. – Consistent concept with standardized, optimized 200 kN - Engraving/signing. and 300 kN punching cylinder axes. - Soft punching (noise reduction). – Ideal use of the products in nibbling machines with 600, - Deep-drawing/forming. 900, 1200 and 1600 strokes 1/min in typical nibbling modes, - Thread-cutting and much more, all with very high precision. as well as in: – Maximum availability thanks to robust valve and sensor - Notching and perforating machines. technology. - Cutting presses. – Energy-efficient punching/forming using energy-optimized - Hole punching machines and copy punching machines. (HP-LP-circuit). - Automatic punching machines, slot punching machines and – Standardized power units with optimized power adjustment turret punching machines. (pressure control pumps). - Embossing machines with high stroke rates. – Reduction of power unit stand-by power by 50% – Following stroke rates are possible in engraving/marking (zero-pressure circulation). modes. – Technically optimized, coordinated and service-proven ~3000 strokes 1/min with 3 mm stroke or products guarantee: ~4000 strokes 1/min with 1 mm stroke. - More productivity, very high reliability and long service life. – Cylinders with low-friction seal suitable for top speeds - Very high dynamics paired with maximum precision and > 2 m/s, tolerances < 0,01 mm and smallest strokes 1 mm. outstanding functionality. – Digital position sensor (5 µm resolution) enables the very – Further customer-specific options: high positioning accuracy and prevents temperature drift. - Cylinder forces and cylinder stroke lengths. – Standardized, clear-cut and simple mechanics/hydraulics/ - Customer-specific power units/punching axes. electrics interface for integration in the machine concept. - Customer-specific interfaces/mounting options. - Customer-specific hardware and software at the controller. Function Principle

Standard Performance Advanced Performance HP LP High Performance SPHP SPLP Po rt_D Po rt_D Po rt_R T

P A A A

B B A B A B

A A

B B B

Po rt_U Po rt_U Po rt_U Po rt_U Po rt_U Po rt_U Po rt_U SPLP LP HP T SPLP LP HP T HP LP

LP LP

HP LP T

Po rt_U

Po rt_D Po rt_U Po rt_U Po rt_U Po rt_U RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 3/24

Performance Table/Technical Data - Cylinder Axis

200 kN 300 kN Standard Ad- High Standard Ad- High 600 750 vanced 1200 1600 600 750 vanced 1200 1600 Possible stroke frequency [1/min] of 600 750 900 1200 1600 600 750 900 1200 1600 punching machine at 4 mm stroke

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

Typical selection of the power unit 7, 5 7, 5 7, 5 11 15 11 11 11 15 18,5 according to power, E-motor [KW] 3 mm 24 20 16 30 24 20 4 mm 48 38 28 24 18 50 40 34 28 22 Punch stroke time [ms] 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 Working time Waiting time (plate advance)

Min. idle stroke Positioning window POP

Position [mm]Position above plate

Ram POP 0

2 Plate NRG PRG 3

4 Bottom die Positioning window PUP PUP 5 Min. idle stroke below plate Total stroke 6 Time [ms] 0 10 20 30 40 50 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); 4/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Modes

Nibbling/Punching Engraving/Signing – Performance of individual punching strokes. – The SYEHL punching axis moves without synchronization – SYEHL punching axis moves synchronously to the axes that with the “X and Y” axes, which move the steel sheet. move the steel sheet with the “X and Y” axes. – 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.

X X PTE PTE POP POP Plate PUP PUP

Plate t t

IN IN OUT OUT

Soft punch Deep drawing – The SYEHL punching cylinder moves between positions – Embossing or forming with special tools. PSP 1 and PSP 2 (position Soft Punch 1 and 2); – POP is the rest position above the steel sheet, and PUP the downward velocity is slower to minimize strike shocks. the position within the sheet steel.

X X PTE PTE

POP POP

PSP1 PSP2 Plate PUP PUP Plate Holding time

t t

IN IN OUT OUT1 OUT2 RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 5/24

Power-Management

HNC function example => pump control

A10VSO...ER Analogue amplifier module H NC100 Controller

Stroke example "punch modi" Energy ......

. . . .

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

Pressure/energy adjusted to the demanded force.

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

...... Time

Performance Curves for Pump, A10VSO18...

70 qv max 68 qv Null 66 [dB(A)] A 64 n = 1500 min-1 62 60 Noise level 58 Measured in an anechoic chamber Geräuschpegel L Geräuschpegel Distance from microphone to pump = 1 m 56 Measuring error: ± 2 dB (A) 0 50 100 150 200 250 280 Operating pressure p [bar] (Fluid: Hydraulic oil to ISO VG 46 DIN 51519, t = 50° C) 6/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Performance Curves Cylinder Axes and Power Unit

Standard 600 – 200 kN Standard 750 – 200 kN Stroke frequency [1/min] Stroke frequency [1/min]

1000 1000 750 600

4 Stroke [mm] 4 Stroke [mm]

Advanced 900 – 200 kN High 1200 – 200 kN Stroke frequency [1/min] Stroke frequency [1/min]

1000 1000 1200 900

4 Stroke [mm] 4 Stroke [mm]

Theoretical calculated stroke frequency with: Theoretical calculated stroke frequency with: – Auxiliary times for example table movement – Power unit size (motor, pump) – Cylinder stroke time by control valve – Cylinder size Auxiliary time e. g. Max. power unit performance

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

30 [ms] at cylinder axis 600, 750 and 900 2) 11 [kW] 20 [ms] at cylinder axis 1200 60 [ms] at cylinder axis 600, 750 and 900 2) 15 [kW] 40 [ms] at cylinder axis 1200

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- Typical operating point of a punch machine. mance and simultaneous 100% duty-cycle. The performance curves shows typical working points of the 1) Engraving/signing mode electro-hydraulic punch systems. 2) Nibbling/punching mode Detailed info's on request. RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 7/24

Performance Curves Cylinder Axes and Power Unit

Standard 600 – 300 kN Standard 750 – 300 kN Stroke frequency [1/min] Stroke frequency [1/min]

1000 1000

600 750

4 Stroke [mm] 4 Stroke [mm]

Advanced 900 – 300 kN High 1200 – 300 kN Stroke frequency [1/min] Stroke frequency [1/min]

1200 1000 1000 900

4 Stroke [mm] 4 Stroke [mm]

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

30 [ms] at cylinder axis 600, 750 and 900 2) 11 [kW] 20 [ms] at cylinder axis 1200 60 [ms] at cylinder axis 600, 750 and 900 2) 15 [kW] 40 [ms] at cylinder axis 1200

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- Typical operating point of a punch machine. mance and simultaneous 100% duty-cycle. The performance curves shows typical working points of the 1) Engraving/signing mode electro-hydraulic punch systems. 2) Nibbling/punching mode Detailed info's on request. 8/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

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

ca. 189 ca. 163 140 40 mm cylinder stroke. 72.5 40 Other stroke lengths on request. Hole 30 30 Ø 12 H11 25 mm deep for locating pin 175 ca. 0.5 0.3 ` + 145 80 200 180 145 ca.

6 x M20-35/45 deep Permissible tightening torque 400 Nm 30 30 72.5 145 200 `0.3

1:2 278 ca. +0. 5

275 25 27 16 10 RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 9/24

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

ca. 206 180 Hole 140 40 mm cylinder stroke. 72.5 40 Ø 12 H11 Other stroke lengths on request. 25 mm deep 30 30 for locating pin 0. 5 0. 3 + ` 80 145 180 200 14 8 ca.

30 30 72.5 6 x M20-35/45 deep 145 Permissible tightening 200`0.3 torque 400 Nm M14x1,5 For pipe connection 8L

342 1:2 ca. +0. 5 315 25 27 16 10 10/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Unit Dimensions: Cylinder Axis 200 kN – "High Performance" 1200 Strokes Hole 72.5 40 Ø 12 H11 30 30 25 mm deep 40 mm cylinder stroke. for locating pin Other stroke lengths on request. 163 ca. 0. 3 ` 80 145 200 0. 5 + 180 189 ca. 6 x M20-35/45 deep 30 Permissible tightening torque 400 Nm 30 72.5 145 114 200 `0.3 80 M14x1,5 For pipe connection 8L 345

2:5 +0. 5

370 25 27 16 10 RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 11/24

Unit Dimensions: Cylinder Axis 300 kN – "Standard Performance" 600 Strokes

ca. 189 ca. 163 140 40 mm cylinder stroke. Hole 82.5 40 Other stroke lengths on request. Ø 12 H11 30 30 25 mm deep for locating pin 174 ca. 0.3 ` 165 80 200 145 ca.

6 x M20-35/45 deep 30 30 Permissible tightening torque 400 Nm 82.5 165 200 `0.3

278 1:2 ca. +0.5

275 27 16 10 12/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Unit Dimensions: Cylinder Axis 300 kN – "Standard Performance" 750 Strokes

ca. 189 ca. 163 140 Hole 40 mm cylinder stroke. 82.5 40 Ø 12 H11 Other stroke lengths on request. 25 mm deep 30 30 for locating pin 180 ca. 0.3 165 ` 80 200 145 ca.

30 30 6 x M20-35/45 deep Permissible tightening 82.5 torque 400 Nm 165 200 `0.3 M14x1,5 For pipe connection 8L

338 1:2 ca.

For pipe connection 42L +0. 5 275 27 16 10 RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 13/24

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

ca. 206 ca. 180 Hole 140 40 mm cylinder stroke. 82.5 40 Ø 12 H11 Other stroke lengths on request. 25 mm deep 30 30 for locating pin 0. 3 ` 80 165 200 150 ca.

30 30 6 x M20-35/45 deep 82.5 Permissible tightening 165 torque 400 Nm 200`0.3

M14x1,5 For pipe connection 8L 342 ca.

1:2 +0. 5 315 27 16 10 14/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

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

Hole 82.5 40 Ø 12 H11 30 30 40 mm cylinder stroke. 25 mm deep Other stroke lengths on request. for locating pin 16 3 ca. 0. 3 ` 80 165 200 189 ca.

6 x M20-35/45 deep 30 Permissible tightening torque 400 Nm 30 82.5 165 114 200`0.3 80

M14x1,5 For pipe connection 8L 34 5

2:5 +0. 5

37 0 27 16 10 RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 15/24

Unit Dimensions: Power Unit 7,5 kW ca. 1430 864

4xØ11 121

810 20 450 75 850 600 ca. 650

B D L/Y HD

T 16/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Unit Dimensions: Power Unit 11 kW ca. 1510 864

4xØ11 121

810 20 450 75 850 ca. 52 600 ca. 902 ca. 650

B D L/Y HD ND

T RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 17/24

Unit Dimensions: Power Unit 15 kW ca. 1510 864

4xØ11 121

810 20 450 75 850 ca.52 600 ca. 902 ca.650

B A L/Y HD ND

T 18/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

HNC100-axis Control

– 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. Unit Dimensions: HNC100 (nominal dimensions in mm)

Mounting on top-hat rail TH 35-7,5 or TH 35-15 to EN 60715 48 118

slot1 RS232 encoder

X3C X8M1 120

GND GND power 18-30V X1S GND X2D1 AIO DP/CANopen X7P/C X2A1

2,5 6 124

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). RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 19/24

Drive & Control-Solutions

– Rexroth has decades of experience in the cutting and punch- – Special shock-resistant servo-motors and dynamic high- ing technology. response valves are available. – Special punching press functions are available for – Drive & Control system solutions are available with hydraulic IndraMotion MTX (HNC100). punching head. – Clear interfaces are available, which are mechanically, hy- – A common commissioning tool for the electrical and hydrau- draulically and electrically adjusted to provide easily integra- lic NC IndraWorks is available. tion into the customer’s concept.

IndraMotion MTX Standard

E/A's (power control) IndraControl Ethernet IndraLogic Nominal/actual IndraControl value IndraControl Fast I/O‘s Sensors More I/O's PROFIBUS

H NC100 controller

SYEHL ABSBG PROFIBUS cylinder axis power unit sercos

IndraDyn IndraDrive Inline I/O

IndraMotion MTX Micro

E/A's (power control) IndraDrive DVI IndraLogic IndraControl Nominal/actual value IndraControl Fast I/O‘s Sensors

TCP/IP More I/O's

H NC100 controller

SYEHL ABSBG cylinder axis power unit sercos

IndraDyn

IndraDyn IndraDrive 20/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Drive & Control-Solutions

IndraMotion MTX CNC/SPS

H NC100 controller IndraControl V

SYEHL cylinder axis

IndraControl L ABSBG power unit

Mechanical movement IndraDyn IndraDrive elements Maintenance units

Components for Automation Systems

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

Control and Visualization Handling and Motion – Drive-based, controller-based and PC-based control sys- – Pneumatic and electromechanical linear systems. tems. – Electrical and pneumatic rotary systems. – Consistent visualization concept from small control terminals – Pneumatic gripping systems. to industrial PC. – Vacuum handling systems. – Linear guides. Control – Ball screw drives. – Modular I/O technology for control cabinet assembly (IP20) – Intelligent servo drives and frequency converters. or field use (IP67). – Highly dynamic servomotors. – Consistent communication via sercos III, Ethernet TCP/IP or field bus. – Pneumatic solenoid valves with multi-pin or field bus interface. RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 21/24

Components for Automation Systems

Control and Visualization IndraControl V Rexroth IndraControl V is the comprehensive range of HMI devices for individual control, operation and monitoring in all industry 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. 22/24 Bosch Rexroth AG Hydraulics Technical Information RE 08101-02/11.12

Components for Automation Systems

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 axes Linear 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 components No 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. RE 08101-02/11.12 Technical Information Hydraulics Bosch Rexroth AG 23/24

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

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