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 A P A A A B B A B A B B A A 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 M 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 1 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] 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.