Renault Reference Frame - Robert Bosch GmbH
Machinery and Equipment Specification DocumentElectrical EngineeringProgram Book / GuidelinesControl and Drives Products byRenault Reference FrameVersion: V3.0Published Date: 12-Feb-2015Specification created and approved by:Renault and Bosch RexrothApproval signatures on file at Renault
Document Management InformationThis Specification shall take effect as of the Published Date of the document.The controlled version of this document is the one posted on the Renault web site. Any printed copy is an uncontrolledcopy.Any questions or comments with respect to this specification should be directed to the Renault responsible for theproject.Revision le: Renault Reference FrameVersion V3.0SectionNumberChange Description & ImpactALLFirst EditionALLMAJOR UPDATEPage 2 of 32Published Date: 12-Feb-2015
Program Book – .25.366.16.26.36.46.56.66.76.877.17.2Page No.: 3 of 32Version V3.0Publish Date: 12-Feb-2015Introduction .4Foreword .4Scope of Document .4Content explanation .4Bosch Rexroth contacts .5Document Approval and Responsibility .6Further technical information .6Training .6Overview .7Basic technical definitions .7Performance criteria for controller hardware selection .7Machine Architectures .7Flexible cell .8Machining control layout (CNC application with MTX) .9PLC based machines . 10Product information – control parts . 11IndraControl CMLx5 . 11Standard CNC control configuration - IndraMotion MTX . 12Operator panels VR21xx . 14Machine control panel VAM 40.2 . 14Mobile Operator panel VH21 . 15Connector module VAC30 . 16PC keyboardsVAK40 . 16IP20 IO-modules - Rexroth Inline . 17IP67 IO-modules - Company Lumberg . 17Product information – drive system . 18Drives components - overview . 18Motors . 18Kit motors . 21Indradrive power supplies and power sections . 22Indradrive control sections to be used with Indradrive C or Indradrive M power sections . 23System Software IndraWorks . 25System software IndraLogic . 26HMI design with WinStudio . 26IndraWorks-Drives . 26Integration rules . 28CNC . 28PLC . 28HMI. 29Safety . 30Predisposition for the Renault Backup/Restore tool . 30Ethernet connection . 31SAM (Maintenance help system) . 31Master . 31Further Information . 32Product information . 32Training . 32File: Renault Reference FrameVersion V3.0Page 3 of 32Published Date: 12-Feb-2015
Program Book – GuidelinesPage No.: 4 of 32Version V3.0Publish Date: 12-Feb-20151 Introduction1.1ForewordThe documentation specifies the approved Bosch Rexroth automation control concepts for the Renault program.The machine builder must also utilize the relevant Approved Component List as shown inside the chapters “2, 3and 4”.1.2Scope of DocumentBosch Rexroth has worked closely with Renault to develop this Program Book. The intention is that the contentsof this book shall be used as a guideline for the proper selection and use of Bosch Rexroth products. Equipmentsuppliers who are bidding on Renault programs are expected to use this book as a reference while preparing theirquotations for Renault.It is based on the following objectives: Minimize costs with defined function contentsApply international standardsReduce time from concept/bidding phase to commissioning (inclusive)Simplified modular retrofitting in the case of design changes of the work piecesMinimization and long-term orientation of expenditures for software development and electrical constructionBeyond the function contents, the company-specific user philosophy and the realization of consistentstandardized data traffic have been requirements applied to the present control system concept.!The present documents do not release the supplier (OEM) from his responsibility to selectthe devices in accordance with the manufacturing requirements, the law of the country inwhich the machine or facility will be delivered and to take account of the reserves required.!Deviations with this Components List have to be agreed with Renault in writing approved before placing of order.In the case of any conflict between this document and Renault program specifications, the Renault programdocuments should be adhered to.1.3Content explanationThe products listed are those which should be considered as long as they are applied properly for the application.If the products listed do not suit the needs of a special application, please contact the support personnel listedbelow or the responsible Renault engineer.There are certain considerations to be taken by the equipment supplier to integrated components as part of aplant or a system, and depending on its particular area of application. The equipment supplier must observe allproduct guidelines and specifications so in order to prevent from damages.These considerations such as voltage, timing, torque etc are available in the relevant product documentation.See chap. 5.3File: Renault Reference FrameVersion V3.0Page 4 of 32Published Date: 12-Feb-2015
Page No.: 5 of 32Version V3.0Publish Date: 12-Feb-2015Program Book – Guidelines1.4Bosch Rexroth contactsThe project manager is responsible for project-specific coordination of the technical andcommercial projects between Bosch Rexroth, the machine manufacturer and Renault.Project managementBosch Rexroth SAS FranceFabrice BOUTRONB.P. 74ZI de la trentaine77503 Chelles Cedex FranceBosch Rexroth AG GermanyJoachim LINDEDept. Technical support DC-IA/SFA13Bgm.-Dr.-Nebel-Str. 297816 Lohr am Main, GermanyTel: 33 (0) 680 34 6211fabrice.boutron@boschrexroth.frTel: 49 (0) 9352 18-5808joachim.linde@boschrexroth.deOther worldwide contactsBosch Rexroth Spain/PortugalBixen CATELINFrancisco Grandmontagne, 2Parque Empresarial Zuatzu20018 San Sebastian SpainTel: 34 943 318456Fax: 34 943 318460bixen.catelin@goimendi.esBosch Rexroth AS TurkeyBosch Rexroth SPA ItalyBiagio SCALONEBosch Rexroth spaS.S. Padana Superiore 11, n. 4120063 Cernusco s/N (MI) ITALIATel : 39 02 92365 835biagio.scalone@boschrexroth.itEast Electric RoumaniaIuliu STOCKLOSAB-dul Basarabla nr. 250sector 3Bucuresti 030352 ROMANIATel : 40212104824iuliu.stocklosa@eastelectric.roNo:3 34295 Sefaköy,ISTANBUL TURKEYTelFax: 90 212 411 13 49: 90 212 411 13 17Bosch India LimitedPRADEEP,R.S.Plot 96 ,Phase IIIPeenya Industrial AreaBangalore - 560 058 INDIATel : 919844101734pradeep.rs@boschrexroth.co.inFile: Renault Reference FrameVersion V3.0Page 5 of 32Published Date: 12-Feb-2015
Page No.: 6 of 32Version V3.0Publish Date: 12-Feb-2015Program Book – Guidelines1.5Document Approval and ResponsibilityCreated, edited and checked byFabrice BOUTRON and Joachim LINDE, Bosch RexrothCoordination for RenaultAlain ROLLANDIssued byBosch Rexroth and Renault1.6(Renault Cléon service 3022 )Further technical informationThis control and drive concept was created by Bosch Rexroth in collaboration with Renault controls team.This project manual describes all elements of a control architecture which has been adapted to the requirementsof automated production. As a systems supplier, Bosch Rexroth offers hardware and software, engineeringservices, replacement parts, training and support.Further technical information, necessary accessories for installation, etc. are available for components listed inthis document in chapter 2 and following chapters. Application and use of these components is the responsibilityof the user of this document. Application assistance is available by contacting the support personnel listed inSection “1.4 Bosch Rexroth contacts” of this document, or by visiting the website www.boschrexroth.com.Complete and current data sheets such as 2D and 3D drawings, ePLAN Makros and Data have to be found onthe web side too.1.7TrainingEquipment supplier shall document sufficient knowledge implementing the desired products and solutions given inthis released parts list. Training is mandatory for first-time equipment supplier using a solution. Renault reserves aright to verify proof of training of the main program developer. Details see in chap “7.2 Training”.File: Renault Reference FrameVersion V3.0Page 6 of 32Published Date: 12-Feb-2015
2 Overview2.1Basic technical definitionsThe basis for all layouts, all components described within this project book is the current Bosch Rexroth productportfolio. The software basis is IndraWorks 14VRS.2.2Performance criteria for controller hardware selectionCriteriaMaximum ValueRAM memory usage80%CPU load64%PLC scan time15msSercos cycle time 2ms2.3Machine ArchitecturesMachine ArchitecturesPageMachine TypeArchitectureProduction line layoutFlexible cell8CNC MachineAdvanced CNC control with MTX PC based, Engineering on Board9PLC based MachineAssembly line - PLC application10File: Renault Reference FrameVersion V3.0Page 7 of 32Published Date: 12-Feb-2015
2.4Flexible cellThe following layout shows an example of a flexible cell (line) consisting mainly of CNC machines and few PLCmachine.MachineProduction cells can be realized depending on the process requirements with a CNC or a PLCcontrol, layout details for all kinds of machines are shown below. The machine ProfiNet bus systemshould be a ring topology.VDP & VPBVDP HMI panels with VPB40 Industrial PC boxes feature high performance and offer the possibility torun additional PCI hardware like tool monitoring systems.CMLx5Control hardware of CNC or PLC machines.IntelligentDeviceDevices with ProfiNet and Ethernet connection: With “CNC:CMLx5” – controllers a separate Ethernetconnection is required to connect to the MES system. With “PLC:CMLx5” – controllers the Ethernetcommunication can be routed directly to the plant IT network.*1Switch to connect all machine internal Ethernet participants, e.g. CMLx5 control with HMI.*2Switch for ProfiNet real time communication between the controls. ProfiNet is connected as “star”topology from the cell controller to the machines. The switch is located in the cabinet of the Gantry.File: Renault Reference FrameVersion V3.0Page 8 of 32Published Date: 12-Feb-2015
2.52.5.1Machining control layout (CNC application with MTX)Advanced CNC control with MTX PC based, Engineering on BoardThe advanced CNC control shall be used for high end machine tool, e.g. complex machining centers, highperformance grinding machines, gear cutting machines and time critical operations.The HMI Panel features the IndraWorks Operation and Engineering application, OEM screens and specialapplications like MES systems. This advanced CNC control solution has to be approved by RENAULT.Advanced CNC control with MTX PC based, Engineering on BoardAbbrev. in Pic.Machine partBosch Rexroth ProductMotion control MTXCNC:CMLx5CML85Realtime Ethernet moduleCNC:CMLx5CFL01.1-TP, not required for standalone machinePLC safety moduleCNC:CMLx5HMI mainVDP VPBHMI secondary *VH21*CFL01.1-F1VDP40.3 VPB40.3, with IndraWorks Operation and EngineeringapplicationVH21 Mobile Operation panel VH21VR21*VR2107Machine control eIndraDrive M, IndraDrive C with SercosI/O devicesInline /FieldlineInline, Iumberg IP67 Lion LinkSwitch (*1* Usage requires approval by RENAULTFile: Renault Reference FrameVersion V3.0*1 Switch for local machine Ethernet,Page 9 of 32Published Date: 12-Feb-2015
2.62.6.1PLC based machinesAssembly line - PLC application Standard operator panels are VR21 with a WinStudio Application. The Ethernet telegrams of the CML-control must be filtered by a NAT router. They shall notleave the machine Ethernet network. The manufactures and types of Ethernet switches andNAT units have to be approved by RENAULT. The line ProfiNet bus system must be a star topology. Manual stations may be integrated in other stations. If manual stations do not have their owncontroller, the solution has to be approved by RENAULT. The number of manual stations perPLC is limited by the performance of the control and shall be approved by RENAULT and BoschRexroth. *) Usage of more than one manual station with one (1) PLC controller requires the approval byRENAULT.File: Renault Reference FrameVersion V3.0Page 10 of 32Published Date: 12-Feb-2015
3 Product information – control parts3.1IndraControl CMLx5IndraControl CMLx5 are cabinet DIN rail mounted hardware platformsused for PLC control IndraLogic XLC and for the CNC controlIndraMotion MTX. They are used for decentralized machine conceptsand together with an optional hardware module also as Safety control.Sercos is used for communication to the drives. ProfiNet is used forcommunication to the actuators and sensors.The CML x5 is available in 4 performance versions which differ in thetype of technology modules and the firmware version.CML85 with Sercos for MTXOperation and engineering is done via scalable embedded panels andvisualization devices connected via Ethernet.The PLC system IndraLogic XLC uses L45 controllers.The CNC system IndraMotion MTX uses L85 controllers.CML45 with ProfiBus and ProfiNet for XLConlyCML - controller - technical data overviewCML45CML85256 MB DRAM,min. 256 kByte NvRAMopt. static mem 8MBIntel Core2Duo1,2GHz1024 MB DRAM,min. 256 kByte NvRAMopt. static mem 16MB* ProfiNet Master / Slave / / XLC / MTX / -/ ProcessorMemory RAMSercosFile: Renault Reference FrameVersion V3.0Intel Low Volt Celeron 500 MHzPage 11 of 32Published Date: 12-Feb-2015
3.2Standard CNC control configuration - IndraMotion MTXIndraMotion MTX comprises CNC, Motion Control and PLC functionality in a single hardware. Up to 99digital axes (thereof up to 32 spindles) can be coordinated. 60 independent NC-Channels are available.It is easy to upgrade CNC IndraWorks projects between the scalable hardware versions CML45, CML65and CML85. For RENAULT L85 with SafeLogic (SL) is defined as standard CNC controller.IndraMotion MTXIndraControlCML85CNC controlled axis8.99Thereof spindle drives32Independent CNC channelsMax. number of interpolatingaxis per channelsMinimum IPO cycle time3.604.8*0.25msNC Block- Look-Ahead1000Static Memory16MBRAM Memory1024MBThe following table shows the preferred Bosch Rexroth components, type codes and part numbers to orderthe IndraMotion MTX products.Standard CNC control configuration - IndraMotion MTXComponentType codePart numberMotion control MTXCML85.1-3P-705-FA-NNNN-NWR911171674CML85 FirmwareFWA-CML85*-MTX-14VRS-NNR911342877CML Connector setR-IB IL CML S01-PLSETR911299856PLC safety moduleCFL01.1-F1R911170129Realtime Ethernet moduleCFL01.1-TPR911170832HMI X HMI and EngineeingEngineering license1)* in Type code standard Bosch Rexroth placeholder for future optionsFile: Renault Reference FrameVersion V3.0Page 12 of 32Published Date: 12-Feb-2015
3.2.1Standard PLC control configuration - IndraLogic XLCIndraLogic XLC comprises PLC and Motion Control functionality in a single hardware.It is easy to upgrade PLC IndraWorks projects between the scalable hardware versions CML25, CML45and CML65. For RENAULT CMLx5 with SafeLogic (SL) and VR2109 with a WinStudio installation aredefined as standard.IndraControlCML45IndraLogic XLCUser memory24MBMemory RAM256MBRemanent data memory256kBSercos ProfiNet IO Master / Slave / Function modules4Freely configurable tasks20Typical processing time for 1000 instruction command mix Bool operations Word operatios30us30us30usMin. PLC cycle time, Synchronized with system cycle Sercos cycle1ms0.5msStandard PLC solutionControl componentType codeCML45 with PNCML45.1-NP-500-NA-NNNN-NWCML45 with PN and Sercos CML45.1-3P-500-NA-NNNN-NWPart numberR911170938R911170828R-IB IL CML 22463HMI HMI optional *05-W7*-01VRS-D0-A* 11345264SWA-IWORKS-ML*-14VRS-D0-DVD**R911342878PLC safety moduleOperation DesktopEngineering license *)*) installation only on PC based Hardware, e.g. VPB, VPP and Notebooks**) approval from RENAULT neededFile: Renault Reference FrameVersion V3.0Page 13 of 32Published Date: 12-Feb-2015
3.3Operator panels VR21xxVR21 operator panels can be used as small operatorpanels.The small touch operator panels VR21 are availablein 2 sizes: 7’ and 9’.The VR21 panels are provided with Windows 7embedded system which runs Winstudio as HMIapplication.The connection to the control is done via Ethernet.Operator panels VR21xx *)DeviceTypecodePartnumberPanel – Medium 0-01-N2-NNN-AAR911340051Option*)Panel – Big 9’*) Usage requires approval by RENAULT“*” in Typcodes means “reserved regarding Bosch Rexroth type code standards”VEP - Technical DataOperating System:ProcessorRAM:Interfaces:EthernetUSB 2.0Display:Dimensions:3.4VR2107VR2109Windows embedded compact 7Central processing unit ARM Cortex -A8, 800 MHz with real-time clockFlash memory 256 MByte, LPDDR memory 512 MByte1x 10/100 Base-T Fast Ethernet2 x available177.8 mm TFT (7")228.6 mm TFT (9")91.4 152.4 (H B)117 195 (H B)Machine control panel VAM 40.2The VAM40.2 supplements themachineoperatingpanelforstandard machines. It features PLCpush buttons with LEDs, emergencystop, feed and spindle override.Machine control panel VAM 4DeviceTypecodePartnumberVAM40.2 - 2File: Renault Reference FrameVersion V3.0Page 14 of 32Published Date: 12-Feb-2015
3.5Mobile Operator panel VH21The handheld device VH21 is used to control amachine from different locations, e.g. for gantries orother complex or extended machines or for the set-upof machines with open safety gates.It can be configured either with an individualIndraWorks HMI project () or via Remote Desktop.The VH21 is only allowed as secondary controlspanel at machines or at gantries.The usage of PC mobile operator panels VH21 requires approval by RENAULT.Mobile Operator panel VH21DeviceTypecodePartnumberMobile 01.1-003-NNN-NNR911173896VH21 - Technical DataOperating :Switches:Protection category:Safety StandardsFile: Renault Reference FrameVersion V3.0Windows embedded compact 7ARM Cortex A9512 MB / 512 MBEthernet 10/100 Mbit10,1“ widescreen (16:9), resolution 1280 x 800, colors 262144 (18bit), multi touch1280 x 800Stop: 2 channel, Enable control: 2 channel, 3 steps,IP54DIN EN ISO 13849-1Page 15 of 32Published Date: 12-Feb-2015
3.6Connector module VAC30The connector module VAC30 is used for aflexible connection of the handheld terminalVH21.The settings of the VH21 are stored in module.The safety features are ensured.Connector module VAC30DeviceTypecodePartnumberConnector moduleVAC30.2N-NNR911171054VAC31 – Technical dataPower supply:Protection .724 VDCFront panel basic model IP65Ethernet169 mm x 85 mm x 55 mm (W x H x D)Approx. 0.5 kgDual channel stop switch, dual channel enable switch, RJ45 Ethernet 100 MbitPC keyboardsVAK40The Bosch Rexroth keyboards are slide-in keyboards with an integratedmouse pointer.Features: all the functions of a conventional PC keyboard, an integrated mouse to makes it possible to navigate withingraphical user interfaces USB plug to connect to PC’s and operator panels.VAK40DeviceTypecodePartnumberKeyboard for 15’ HMIVAK40.1E-EN-U-MPNNR911171081File: Renault Reference FrameVersion V3.0Page 16 of 32Published Date: 12-Feb-2015
3.8IP20 IO-modules - Rexroth InlineThe I/O units of the Rexroth Inline series are constructedin a compact housing. The modular system allows anideal adaptation to the respective control tasks.Acceptable bus systems to communicate with the PLC:ProfiNetTypecodeR-IL PN BK DI8 DO4-PACR-IB IL 24 PWR IN-PACR-IB IL 24 SEG/F-PACIP20 IO-modules - Rexroth InlineDescriptionInline PROFINET bus coupler with 8 inputs and 4 outputs, complete withaccessoriesFieldline feed clampR-IB IL 24 DO 16-PACInline segment clamp, 24 V DCWith fuse and diagnostics, incl. connector and label8 Digitale inputs, 24V DCincl. connector and label16 Digitale inputs, 24V DCincl. connector and label8 Digitale outputs, 24V DC, 2Aincl. connector and label8 Digitale outputs, 24V DC, 500mAincl connector and label16 Digitale outputs, 24V DC, 500mAR-IB IL PSDI 88/4 Digital Safe inputsR-IL 24 PSDO8-PAC8/4 Digital Safe outputsR-IB IL PSDO 4/4Digital Safe Outputs p/nR-IB IL 24 DI 8-PACR-IB IL 24 DI 16-PACR-IB IL 24 DO 8-2A-PACR-IB IL 24 DO 8-PACR-IB IL PSDOR 43.9 4 p/n switching (double wired) 4 p switching (single wired)4 Safety relay ouputs up to SIL 3 2 if double wired 4 if single wiredIP67 IO-modules - Company LumbergLion Link - SeriesIP67 IO-modules - Company LumbergModuleFile: Renault Reference FrameVersion V3.0DescriptionPage 17 of 32Published Date: 12-Feb-2015
4 Product information – drive system4.1Drives components - overviewScalable and modular SystemThe IndraDrive drive system offers you a wide range of convertersinverters, power supplies, controller modules, as well the necessaryfirmware versions.Extensive functionsThe drive technology offers a wide range of functions such aspositioning block mode, angle and motor speed synchronization,axis lag compensations or main spindle functions function or anintegrated control axis generator.Various motor encoder systems permit either absolute or relativeposition detection. By offering a second feedback sensor input, alltypical sensor types can be used as separate position sensors.Convenient and time-saving startupThe IndraWorks Drive graphical engineering and diagnostics tool guides you quickly and reliably through theindividual startup settings. Current drive-internal state variables are displayed in the process. Further help textssupport you along the way.Selection criteria for drives power modulesSingle axis IndraDrive C compact converter for low inertia machines without line regenerationPower range form 1 to 110 kW with maximum current up to 210 A- Direct electric supply up to 500V- Internal control voltage supply, partially optionalMulti axis and Machine tool IndraDrive M modular inverter with line regeneration power supplyPower range from 1 to 120 kW with maximum current up to 210 A- Double axis inverter with maximum current from 12 A to 36 A- Feeding is possible via converter or supply module4.2Motors4.2.1 EncoderRenault specifies the use of absolute encoders (multiturn) :EnDat encoders M2 are mandatory for machining axis ;Hiperface encoders M1 are allowed for auxiliary axis (gantries, tool magazine). ;Single turn EnDat encoder S2 are allowed on direct spindle motors (without gearboxes)4.2.2ProtectionMotors with IP65 protection and no pressurization.Renault specifies the use of motors with plain shafts.4.2.3 BrakesDuring the projects stages, Renault will check the braking efficiency, more particularly for vertical axes.File: Renault Reference FrameVersion V3.0Page 18 of 32Published Date: 12-Feb-2015
4.2.4 Motor temperatureMonitoring of the motor temperature is ensured via the temperature sensor of type KTY84, which is builtinto the stator. The measured motor temperature is controlled via the following threshold values: Motor-warning temperature (140 C) Motor-disconnection temperature (150 C)Renault and Bosch Rexroth recommend to use the “60K motor characteristics”. For further informationplease refer on the documentation “Rexroth IndraDyn S Synchronous Motors” (R911296289) for MSKmotors and “Rexroth IndraDyn A Series Asynchronous M
Renault and Bosch Rexroth Approval signatures on file at Renault. Document Management Information File: Renault Reference Frame Version V3.0 Page 2 of 32 . Drives IndraDrive IndraDrive M, IndraDrive C with Sercos I/O devices Inline /Fieldline Inline, Iumberg IP67 Lion Li
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