DOK-IWORKS-SIMU----V01-AW03-EN-P - Rexroth IndraWorks Simulation.pdf

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Rexroth IndraWorksimulation

11 1

dition 03

Electric Drivesand Controls Pneumatics Service

Linear Motion andAssembly TechnologiesHydraulics



Rexroth IndraWorks

Simulation

Application Description

DOK-IWORKS-SIMU****V01-AW03-EN-P

RS-de78b78b0a6846ac009c70d0829c30df-3-en-US-2

This documentation describes the functions of simulation component View3D,virtual control panel, virtual control and its operation in IndraWorks.

Edition Release Date Notes

120-2700-B304-01/EN 06.2006 First edition

120-2700-B304-02/EN 10.2006 Supplements

120-2700-B304-03/EN 02.2007 Supplements

Copyright © 2006 Bosch Rexroth AG

Copying this document, giving it to others and the use or communication of thecontents thereof without express authourity, are forbidden. Offenders are liablefor the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).

Validity The specified data is for product description purposes only and may not bedeemed to be guaranteed unless expressly confirmed in the contract. All rightsare reserved with respect to the content of this documentation and the availa‐bility of the product.

Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 ■ D-97816 Lohr a. Main

Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85

http://www.boschrexroth.com/

System Development Machine Tools M. Brohm (DiLe)Note This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Record of Revision

Bosch Rexroth AG

| Electric Drives

and Controls

Rexroth IndraWorks

|Application Description



Table of Contents

Page

1 General.......................................................................................................................... 11.1 Why Simulation?..................................................................................................................................... 1

1.2 What is Simulated?................................................................................................................................. 1

1.3 Goals of Simulation in IndraWorks......................................................................................................... 1

2 Important Instructions on Use........................................................................................ 3

2.1 Intended Use.......................................................................................................................................... 3

2.1.1 Introduction.......................................................................................................................................... 3

2.1.2 Area of Use and Application ............................................................................................................... 3

2.2 Improper Use.......................................................................................................................................... 3

3 Safety Instructions for Electric Drives and Controls ...................................................... 5

3.1 Safety Instructions - General Information............................................................................................... 5

3.1.1 Using the Safety Instructions and Passing them on to Others............................................................ 5

3.1.2 How to Employ the Safety Instructions................................................................................................ 5

3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness.............................................. 6

3.1.4 Hazards by Improper Use.................................................................................................................... 7

3.2 Instructions with Regard to Specific Dangers......................................................................................... 8

3.2.1 Protection Against Contact with Electrical Parts and Housings........................................................... 8

3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage................................................... 9

3.2.3 Protection Against Dangerous Movements......................................................................................... 9

3.2.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 123.2.5 Protection Against Contact with Hot Parts......................................................................................... 12

3.2.6 Protection During Handling and Mounting......................................................................................... 12

3.2.7 Battery Safety.................................................................................................................................... 13

3.2.8 Protection Against Pressurized Systems........................................................................................... 13

4 Quick Start................................................................................................................... 15

5 Components of the Simulation .................................................................................... 17

5.1 Project Explorer ................................................................................................................................... 17

5.2 3D Visualization.................................................................................................................................... 17

5.2.1 General Description........................................................................................................................... 17

5.2.2 Model Visualization ........................................................................................................................... 19

Basic functions............................................................................................................................... 19

Functions for manipulating 3D objects .......................................................................................... 21

5.2.3 Scene Tree ....................................................................................................................................... 21

General........................................................................................................................................... 21

Object properties ........................................................................................................................... 22

Assignment..................................................................................................................................... 23

5.2.4 OPC Configuration ........................................................................................................................... 23

5.2.5 Assignment List ................................................................................................................................ 24

5.2.6 Properties of the View3D Model ....................................................................................................... 25


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Page

5.3 Virtual User Panel................................................................................................................................. 25


5.3.2 Configurator....................................................................................................................................... 265.3.3 The Application.................................................................................................................................. 27

5.4 Virtual Control....................................................................................................................................... 27


6 Operation in IndraWorks.............................................................................................. 29

6.1 Creating a Model.................................................................................................................................. 29

6.1.1 General.............................................................................................................................................. 29

6.1.2 Creating a Simple 3D Model ............................................................................................................. 29

6.1.3 Importing eM-RealNC Models .......................................................................................................... 29

6.2 Using the Virtual User Panel................................................................................................................. 29

6.2.1 Configuration..................................................................................................................................... 29

Configuration in IndraWorks........................................................................................................... 29

Supplements to the configuration file ............................................................................................ 30

6.2.2 Connection to Virtual Control ............................................................................................................ 31

6.2.3 Start................................................................................................................................................... 32

6.2.4 Contextual Menu in the Virtual User Panel ....................................................................................... 32

6.2.5 Error Messages and Remedies......................................................................................................... 33

6.3 Using 3D Visualization.......................................................................................................................... 33

6.3.1 3D Models in IndraWorks.................................................................................................................. 33

Importing 3D models ..................................................................................................................... 33

Opening, renaming and deleting 3D models ................................................................................. 356.3.2 Process Connection.......................................................................................................................... 35

Connecting 3D objects with IndraMotion MTX axis values ............................................................ 35

Configuring the process connection .............................................................................................. 35

Establishing a connection to the control ........................................................................................ 37

6.3.3 3D Visualization Operation................................................................................................................ 37

Basic 3D visualization functions .................................................................................................... 37

Manipulating 3D objects ................................................................................................................ 38

Changing settings of the View3D model ........................................................................................ 38

6.4 Using the Virtual Control....................................................................................................................... 38

6.4.1 Installation of MTX Emulation............................................................................................................ 38

General........................................................................................................................................... 38

6.4.2 Projecting Emulation.......................................................................................................................... 39

Restoring an existing project.......................................................................................................... 39

6.4.3 Projecting the HMI............................................................................................................................. 39

General........................................................................................................................................... 39

6.4.4 Designing the NC Core...................................................................................................................... 41

General........................................................................................................................................... 41

6.4.5 Projecting the PLC............................................................................................................................. 45

General........................................................................................................................................... 45

6.4.6 Starting and Exiting MTX Emulation.................................................................................................. 47

General........................................................................................................................................... 47

6.4.7 Starting Operation Desktop............................................................................................................... 48

II/III Bosch Rexroth AG

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Table of Contents



Page

7 Communication............................................................................................................ 49

7.1 OPC...................................................................................................................................................... 49

7.2 SCP...................................................................................................................................................... 49

8 Service & Support........................................................................................................ 51

8.1 Helpdesk............................................................................................................................................... 51

8.2 Service Hotline...................................................................................................................................... 51

8.3 Internet.................................................................................................................................................. 51

8.4 Helpful Information................................................................................................................................ 51

Index............................................................................................................................ 53


|Rexroth IndraWorks

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|Bosch Rexroth AG III/III

Table of Contents



Bosch Rexroth AG

| Electric Drives

and Controls

Rexroth IndraWorks




1 General

1.1 Why Simulation?

Due to the ever-increasing competitive pressure among the manufacturers of machines, we are always looking for new ways of minimizing the costs for amachine project. This includes every phase of the machine life cycle (construc‐tion, commissioning, production). Due to more and more powerful computer systems, simulation is becoming more and more important: in the future, theremay even be virtual factories in which all the processes of a production plantcan be reproduced virtually. One component of this virtual factory is the virtualmachine, which can be used, with the help of suitable simulation tools, to sup‐port the individual phases of the machine life cycle.

1.2 What is Simulated?

There are suitable simulation techniques for every phase of the machine lifecycle. These simulation techniques are clearly delimited from one another, butalso have shared points of intersection, such as the transfer of construction datafor the machine from the CAD system to the 3D visualization system.

For example, FEM (Finite Element Method) analysis or MBS (Multi-Body Sim‐ulation) analysis is used in the construction phase of a machine, while thecommissioning phase is more concerned with behavioral simulation. For pro‐duction, on the other hand, process optimization (e.g. cycle time optimization)is in the foreground.

Now, if we examine the simulation techniques during the commissioning phase,we can make a further distinction. On the one hand, there is hardware-in-the-loop simulation; on the other, there is software-in-the-loop simulation.

Hardware-in-

the-loop

In this simulation technique, a real control is a component of the simulation setup. All other components are simulated onone or more computers. Communication between the real con‐trol and the simulation components is implemented using, for example, Profibus slave cards.

Software-in-

the-loop

In this simulation technique, all the components are simulatedon one or more computers.

1.3 Goals of Simulation in IndraWorks

The emphasis for applying simulation techniques at Bosch Rexroth in the areaof system development for Motion Control lies on optimizing the commissioningof controls and machine tools. This involves mainly behavioral simulation, such

as tests of the PLC program or of the NC program.Components such as a virtual control (NC and PLC), a virtual control panel,virtual drives, a 3D viewer and a peripherals simulation (I/O simulation) arerequired to attain this goal. Only the interplay of all these components permitseffective behavioral simulation.

In addition to the shortening of commissioning times, however, there are other areas of application for simulation that result in cost and time savings for theuser.

● Demonstrator for sales at the customer location

● Testing program procedures (both CNC and PLC)

● Setting the parameters of the control and the drives

● Application for training purposes


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General



● Reproduction of problems (trouble-shooting)

● Validation of error solutions

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General



2 Important Instructions on Use

2.1 Intended Use

2.1.1 Introduction

The Bosch Rexroth products are developed and manufactured according to thelatest state of the art. Before delivery, they are checked for operational safety.

The products may only be used in the proper manner. When they are not usedas intended, situations may arise which result in damage to person or material.

Bosch Rexroth, as the manufacturer of the products, will not as‐sume any warranty, liability or payment of damages in case of damage resulting from a non-intended use of the products. If hefails to use the products as intended, the user will be solely respon‐sible for any resulting risks.

Before using the Bosch Rexroth products, the following prerequisites must befulfilled to ensure that they are used as intended:

● Everyone who in any way deals with one of our products must read andunderstand the corresponding notes regarding safety and regarding prop‐er use.

● If the products are hardware, they must be kept in their original state, i.e.no constructional modifications may be made. Software products may notbe decompiled; their source codes may not be modified.

● Damaged or improperly working products must not be installed or put intooperation.

● It must be ensured that the products are installed according to the regu‐

lations mentioned in the documentation.

2.1.2 Area of Use and Application

In IndraWorks, simulation tools are used to

● Shorten the response times

● verify the application programs

● visualize the machine cinematics

The simulation consists of several components which must be com‐patible to each other.

The virtual control panel is used in connection with the control emulation. Duringutilizing the virtual control panel of the real control it has to be considered thatthe signals can not arrive between virtual control panel and control because of communication errors. Therefore a PLC program and a producing machine canno longer be stopped via control.

2.2 Improper Use

Using the devices outside of the above-referenced areas of application or under operating conditions other than described in the document and the technicaldata specified is defined as "inappropriate use".

The Rexroth simulation tools may not be used if


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Important Instructions on Use



● Bosch Rexroth has not specifically released them for that intended pur‐pose. In this connection, observance of the statements in the GeneralSafety Notes is imperative!


| Electric Drives

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Important Instructions on Use



3 Safety Instructions for Electric Drives and Controls

3.1 Safety Instructions - General Information

3.1.1 Using the Safety Instructions and Passing them on to Others

Do not attempt to install or commission this device without first reading all doc‐umentation provided with the product. Read and understand these safetyinstructions and all user documentation prior to working with the device. If youdo not have the user documentation for the device, contact your responsibleBosch Rexroth sales representative. Ask for these documents to be sent im‐mediately to the person or persons responsible for the safe operation of thedevice.

If the device is resold, rented and/or passed on to others in any other form,these safety instructions must be delivered with the device in the official lan‐guage of the user's country.

WARNING

Improper use of these devices, failure to follow the safety instructions in

this document or tampering with the product, including disabling of safe‐

ty devices, may result in material damage, bodily harm, electric shock

or even death

Observe the safety instructions!

3.1.2 How to Employ the Safety Instructions

Read these instructions before initial commissioning of the equipment in order to eliminate the risk of bodily harm and/or material damage. Follow these safetyinstructions at all times.

● Bosch Rexroth AG is not liable for damages resulting from failure to ob‐serve the warnings provided in this documentation.

● Read the operating, maintenance and safety instructions in your languagebefore commissioning the machine. If you find that you cannot completelyunderstand the documentation for your product, please ask your supplier to clarify.

● Proper and correct transport, storage, assembly and installation, as wellas care in operation and maintenance, are prerequisites for optimal andsafe operation of this device.

● Only assign trained and qualified persons to work with electrical installa‐tions:

– Only persons who are trained and qualified for the use and operationof the device may work on this device or within its proximity. Thepersons are qualified if they have sufficient knowledge of the assem‐bly, installation and operation of the product, as well as an under‐standing of all warnings and precautionary measures noted in theseinstructions.

– Furthermore, they must be trained, instructed and qualified to switchelectrical circuits and devices on and off in accordance with technicalsafety regulations, to ground them and to mark them according to therequirements of safe work practices. They must have adequate safe‐ty equipment and be trained in first aid.

● Only use spare parts and accessories approved by the manufacturer.


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Safety Instructions for Electric Drives and Controls



● Follow all safety regulations and requirements for the specific applicationas practiced in the country of use.

● The devices have been designed for installation in industrial machinery.

● The ambient conditions given in the product documentation must be ob‐

served.

● Only use safety-relevant applications that are clearly and explicitly ap‐proved in the Project Planning Manual. If this is not the case, they areexcluded. Safety-relevant are all such applications which can cause dan‐ger to persons and material damage.

● The information given in the documentation of the product with regard tothe use of the delivered components contains only examples of applica‐tions and suggestions.

The machine and installation manufacturer must

– make sure that the delivered components are suited for his individualapplication and check the information given in this documentation

with regard to the use of the components, – make sure that his application complies with the applicable safety

regulations and standards and carry out the required measures,modifications and complements.

● Commissioning of the delivered components is only permitted once it issure that the machine or installation in which they are installed complieswith the national regulations, safety specifications and standards of theapplication.

● Operation is only permitted if the national EMC regulations for the appli‐cation are met.

● The instructions for installation in accordance with EMC requirements canbe found in the section on EMC in the respective documentation (Project

Planning Manuals of components and system).

The machine or installation manufacturer is responsible for compliancewith the limiting values as prescribed in the national regulations.

● Technical data, connection and installation conditions are specified in theproduct documentation and must be followed at all times.

National regulations which the user must take into account

● European countries: according to European EN standards

● United States of America (USA):

– National Electrical Code (NEC)

– National Electrical Manufacturers Association (NEMA), as well as

local engineering regulations – regulations of the National Fire Protection Association (NFPA)

● Canada: Canadian Standards Association (CSA)

● Other countries:

– International Organization for Standardization (ISO)

– International Electrotechnical Commission (IEC)

3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness

The safety instructions describe the following degrees of hazard seriousness.The degree of hazard seriousness informs about the consequences resulting

from non-compliance with the safety instructions:


| Electric Drives

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Warning symbol Signal word

Degree of hazard serious‐

ness acc. to ANSI Z

535.4-2002

Danger

Death or severe bodily harm

will occur.

WarningDeath or severe bodily harm

may occur.

Caution

Minor or moderate bodily

harm or material damage

may occur.

Fig.3-1: Hazard classification (according to ANSI Z 535)

3.1.4 Hazards by Improper Use

DANGER

High electric voltage and high working current Risk of death or severe

bodily injury by electric shock


DANGER

Dangerous movements Danger to life, severe bodily harm or material

damage by unintentional motor movements


WARNING

High electric voltage because of incorrect connection Risk of death or

bodily injury by electric shock


WARNING

Health hazard for persons with heart pacemakers, metal implants and

hearing aids in proximity to electrical equipment


CAUTION

Hot surfaces on device housing Danger of injury Danger of burns


CAUTION

Risk of injury by improper handling Risk of bodily injury by bruising,

shearing, cutting, hitting or improper handling of pressurized lines



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CAUTION

Risk of injury by improper handling of batteries


3.2 Instructions with Regard to Specific Dangers

3.2.1 Protection Against Contact with Electrical Parts and Housings

This section concerns devices and drive components with voltagesof more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personal

danger and electric shock. When operating electrical equipment, it is unavoid‐able that some parts of the units conduct dangerous voltage.

DANGER

High electrical voltage Danger to life, electric shock and severe bodily

injury

● Only those trained and qualified to work with or on electrical equipmentare permitted to operate, maintain and repair this equipment.

● Follow general construction and safety regulations when working on elec‐trical power installations.

● Before switching on the device, the equipment grounding conductor musthave been permanently connected to all electrical equipment in accord‐ance with the connection diagram.

● Do not operate electrical equipment at any time, even for brief measure‐ments or tests, if the equipment grounding conductor is not permanentlyconnected to the mounting points of the components provided for thispurpose.

● Before working with electrical parts with voltage potentials higher than50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection.

● For electrical drive and filter components, observe the following:

Wait 30 minutes after switching off power to allow capacitors to dis‐

charge before beginning to work. Measure the electrical voltage on thecapacitors before beginning to work to make sure that the equipment is

safe to touch.● Never touch the electrical connection points of a component while power

is turned on.

● Install the covers and guards provided with the equipment properly beforeswitching the device on. Before switching the equipment on, cover andsafeguard live parts safely to prevent contact with those parts.

● A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device according to the relevantstandards.

● Secure built-in devices from direct touching of electrical parts by providingan external housing, for example a control cabinet.


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For electrical drive and filter components with voltages of more than

50 volts, observe the following additional safety instructions.

DANGER

High housing voltage and high leakage current Risk of death or bodily

injury by electric shock

● Before switching on, the housings of all electrical equipment and motorsmust be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests.

● The equipment grounding conductor of the electrical equipment and thedevices must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 mA.

● Over the total length, use copper wire of a cross section of a minimum of

10 mm2 for this equipment grounding connection!

● Before commissioning, also in trial runs, always attach the equipmentgrounding conductor or connect to the ground wire. Otherwise, high vol‐

tages may occur at the housing causing electric shock.

3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage

Protective extra-low voltage is used to allow connecting devices with basic in‐sulation to extra-low voltage circuits.

All connections and terminals with voltages between 5 and 50 volts at Rexroth

products are PELV systems. 1) It is therefore allowed to connect devicesequipped with basic insulation (such as programming devices, PCs, notebooks,display units) to these connections and terminals.

WARNING

High electric voltage by incorrect connection Risk of death or bodily

injury by electric shock

If extra-low voltage circuits of devices containing voltages and circuits of morethan 50 volts (e.g. the mains connection) are connected to Rexroth products,the connected extra-low voltage circuits must comply with the requirements for

PELV. 2)

3.2.3 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of connected motors.Some common examples are:

● improper or wrong wiring of cable connections● incorrect operation of the equipment components

● wrong input of parameters before operation

● malfunction of sensors, encoders and monitoring devices

● defective components

● software or firmware errors

These errors can occur immediately after equipment is switched on or evenafter an unspecified time of trouble-free operation.

1) “Protective Extra-Low Voltage”

2) “Protective Extra-Low Voltage”


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The monitoring in the drive components will normally be sufficient to avoid faultyoperation in the connected drives. Regarding personal safety, especially thedanger of bodily harm and/or material damage, this alone cannot be relied uponto ensure complete safety. Until the integrated monitoring functions becomeeffective, it must be assumed in any case that faulty drive movements will occur.The extent of faulty drive movements depends upon the type of control and thestate of operation.


| Electric Drives

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DANGER

Dangerous movements Danger to life, risk of injury, severe bodily harm

or material damage

● For the above reasons, ensure personal safety by means of qualified andtested higher-level monitoring devices or measures integrated in the in‐stallation.

They have to be provided for by the user according to the specific condi‐tions within the installation and a hazard and fault analysis. The safetyregulations applicable for the installation have to be taken into consider‐ation. Unintended machine motion or other malfunction is possible if safetydevices are disabled, bypassed or not activated.

To avoid accidents, bodily harm and/or material damage:

● Keep free and clear of the machine’s range of motion and moving parts.Possible measures to prevent people from accidentally entering themachine’s range of motion:

– use safety fences

– use safety guards

– use protective coverings

– install light curtains or light barriers

● Fences and coverings must be strong enough to resist maximum possiblemomentum.

● Mount the emergency stop switch in the immediate reach of the operator.Verify that the emergency stop works before commissioning. Do not op‐erate the device if the emergency stop switch is not working.

● Isolate the drive power connection by means of an emergency stop circuitor use a safety related starting lockout to prevent unintentional start.

● Make sure that the drives are brought to a safe standstill before accessingor entering the danger zone.

● Additionally secure vertical axes against falling or dropping after switchingoff the motor power by, for example:

– mechanically securing the vertical axes,

– adding an external braking/arrester/clamping mechanism or

– ensuring sufficient equilibration of the vertical axes.

● The standard equipment motor brake or an external brake controlled bythe drive controller are not sufficient to guarantee personal safety!

● Disconnect electrical power to the equipment using a master switch andsecure the switch against reconnection for:

– maintenance and repair work – cleaning of equipment

– long periods of discontinued equipment use

● Prevent the operation of high-frequency, remote control and radio equip‐ment near electronics circuits and supply leads. If the use of such devicescannot be avoided, verify the system and the installation for possible mal‐functions in all possible positions of normal use before initial commission‐ing. If necessary, perform a special electromagnetic compatibility (EMC)test on the installation.


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3.2.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐

ation and Mounting

Magnetic and electromagnetic fields generated by current-carrying conductors

and permanent magnets in motors represent a serious personal danger tothose with heart pacemakers, metal implants and hearing aids.

WARNING

Health hazard for persons with heart pacemakers, metal implants and

hearing aids in proximity to electrical equipment

● Persons with heart pacemakers and metal implants are not permitted toenter following areas:

– Areas in which electrical equipment and parts are mounted, beingoperated or commissioned.

– Areas in which parts of motors with permanent magnets are beingstored, repaired or mounted.

● If it is necessary for somebody with a pacemaker to enter such an area,

a doctor must be consulted prior to doing so. The noise immunity of pres‐ent or future implanted heart pacemakers differs greatly so that no generalrules can be given.

● Those with metal implants or metal pieces, as well as with hearing aids,must consult a doctor before they enter the areas described above. Oth‐erwise health hazards may occur.

3.2.5 Protection Against Contact with Hot Parts

CAUTION

Hot surfaces at motor housings, on drive controllers or chokes Danger

of injury Danger of burns

● Do not touch surfaces of device housings and chokes in the proximity of heat sources! Danger of burns!

● Do not touch housing surfaces of motors! Danger of burns!

● According to the operating conditions, temperatures can be higher than

60 °C, 140 °F during or after operation.

● Before accessing motors after having switched them off, let them cooldown for a sufficiently long time. Cooling down can require up to 140 mi‐

nutes! Roughly estimated, the time required for cooling down is five timesthe thermal time constant specified in the Technical Data.

● After switching drive controllers or chokes off, wait 15 minutes to allowthem to cool down before touching them.

● Wear safety gloves or do not work at hot surfaces.

● For certain applications, the manufacturer of the end product, machine or installation, according to the respective safety regulations, has to takemeasures to avoid injuries caused by burns in the end application. Thesemeasures can be, for example: warnings, guards (shielding or barrier),technical documentation.

3.2.6 Protection During Handling and Mounting

In unfavorable conditions, handling and mounting certain parts and compo‐nents in an improper way can cause injuries.


| Electric Drives

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CAUTION

Risk of injury by improper handling Bodily injury by bruising, shearing,

cutting, hitting

● Observe the general construction and safety regulations on handling andmounting.

● Use suitable devices for mounting and transport.

● Avoid jamming and bruising by appropriate measures.

● Always use suitable tools. Use special tools if specified.

● Use lifting equipment and tools in the correct manner.

● If necessary, use suitable protective equipment (for example safety gog‐gles, safety shoes, safety gloves).

● Do not stand under hanging loads.

● Immediately clean up any spilled liquids because of the danger of skidding.

3.2.7 Battery Safety

Batteries consist of active chemicals enclosed in a solid housing. Therefore,improper handling can cause injury or material damage.

CAUTION

Risk of injury by improper handling

● Do not attempt to reactivate low batteries by heating or other methods (riskof explosion and cauterization).

● Do not recharge the batteries as this may cause leakage or explosion.

● Do not throw batteries into open flames.

● Do not dismantle batteries.

● When replacing the battery/batteries do not damage electrical parts in‐stalled in the devices.

● Only use the battery types specified by the manufacturer.

Environmental protection and disposal! The batteries contained inthe product are considered dangerous goods during land, air, andsea transport (risk of explosion) in the sense of the legal regulations.Dispose of used batteries separate from other waste. Observe thelocal regulations in the country of assembly.

3.2.8 Protection Against Pressurized Systems

According to the information given in the Project Planning Manuals, motorscooled with liquid and compressed air, as well as drive controllers, can be par‐tially supplied with externally fed, pressurized media, such as compressed air,hydraulics oil, cooling liquids and cooling lubricating agents. Improper handlingof the connected supply systems, supply lines or connections can cause injuriesor material damage.


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CAUTION

Risk of injury by improper handling of pressurized lines

● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐sion).

● Observe the respective manufacturer's operating instructions.● Before dismounting lines, relieve pressure and empty medium.

● Use suitable protective equipment (for example safety goggles, safetyshoes, safety gloves).

● Immediately clean up any spilled liquids from the floor.

Environmental protection and disposal! The agents used to operatethe product might not be economically friendly. Dispose of ecolog‐ically harmful agents separately from other waste. Observe the localregulations in the country of assembly.


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4 Quick Start

In the following, the execution sequence that makes it possible to sensibly op‐erate the various simulation components of IndraWorks is described for an

IndraMotion MTX project. It is not suitable for a user who has no prior knowledgeof the simulation components. The inexperienced user should first read theentire documentation to become familiar with the subject matter.

Execute the following steps to be able to simulate an IndraMotion MTX projecton a PC:

1. Start IndraWorks using the link on the desktop

2. Load the desired IndraMotion MTX project into IndraWorks

3. Start the IndraMotion MTX emulation (also see chapter 6.4.6 "Startingand Exiting MTX Emulation" on page 47)

4. Set the communication settings for the IndraMotion MTX and the PLC to“localhost”.

5. The PLC must be stopped.6. The NC kernel data must be restored (also see chapter 6.4.4 "Designing

the NC Core" on page 41).

7. The PLC program must be loaded and started (also see chapter 6.4.5"Projecting the PLC" on page 45)

8. Activate the IndraWorks project for Operation Desktop (also see chapter 6.4.3 "Projecting the HMI" on page 39)

9. Create the virtual control panel in IndraWorks Engineering (also seechapter "Creating a Virtual User Panel" on page 29) and configure it(also see chapter 6.2.1 "Configuration" on page 29)

10. Start the Windows program “Virtual Control Panel” (also seechapter 6.2.2

"Connection to Virtual Control " on page 31).

You can find detailed information about IndraMotion MTX emulationin the “Virtual Commissioning of the MTX” chapter of the documen‐tation “IndraMotion MTX Commissioning”.

If a machine model exists, it can be loaded into the 3D viewer and controlledusing data from the emulation via OPC. To do this, proceed as follows:

1. Add a new model to the project (also see chapter "Importing 3D models "on page 33)

2. Link the OPC items to the objects of the model (also see chapter "Con‐necting 3D objects with IndraMotion MTX axis values " on page 35)

3. Start the simulation of the model in IndraWorks


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5 Components of the Simulation

5.1 Project Explorer

The simulation components can be found in the Project Explorer in the nodeSimulation -> 3D Visualization.

Fig.5-1: Project Explorer

Project node Simulation Within node Simulation, you can find the entry Virtual Control Panel, which canbe used to open the Configuration dialog box of the Virtual Control Panel.

If the node Simulation and/or the entry Virtual Control Panel doesnot exist, it can be added as follows using the project node:

● Call menu item Add... in the contextual menu of the projectnode.

● In the dialog box Add new element, open the template Virtual

Control Panel from the category Virtual Components.

The entry Virtual Control Panel is added to the project treewithin the node Simulation.

Project node 3D Visualization Node 3D Visualization can be used to access 3D models of the View3D appli‐cation.

New 3D models can be added using the contextual menu Add... on node 3D

Visualization.

See also chapter "Handling instruction: Importing a 3D model" on page 33.

If node 3D Visualization does not exist, a new 3D model can beadded using the contextual menu Add... of the project node. Seealso chapter "Handling instruction: Importing a 3D model" on page33.

A View3D model can be opened using the contextual menu Open ... of thecorresponding node in the Project Explorer or by double-clicking it.

Furthermore, models can be renamed or deleted in the Project Explorer.

See also chapter "Opening, renaming and deleting 3D models " on page35.

5.2 3D Visualization

5.2.1 General Description

The View3D 3D visualization system is used to represent a machine model as

a three-dimensional volume model (3D scene).


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Individual objects in the 3D scene can be combined with process values of theIndraMotion MTX within View3D. If the NC program of the machine is executedusing the virtual control (also seechapter 5.4 "Virtual Control" on page 27),the axis movements of the machine can be traced in the three-dimensionalmachine model.

Additional functions in View3D include:

● Rotating a 3D scene

● Zoom function

● Wireframe representation

● Saving of camera positions (viewpoints)

Fig.5-2: View3D in IndraWorks

The View3D application consists of the following 4 areas:

1. 3D view

The 3D view is used to display the 3D scene (see chapter 5.2.2 "ModelVisualization " on page 19).

2. Scene tree

The scene tree represents the logical and kinematic structure of the scene.Individual objects of the model can be marked for further processing in the

scene tree (for example, objects can be hidden in the 3D view).


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See chapter 5.2.3 "Scene Tree " on page 21.

3. OPC server

You can access the OPC server of the control in order to communicatewith the IndraMotion MTX here (see chapter 5.2 "3D Visualization" on

page 17).

4. OPC assignment list

The assignments between the 3D model and the process values (OPCitems) of the control are shown in the OPC assignment list (see chapter 5.2 "3D Visualization" on page 17).

Switching languages in View3D To change the language in View3D, use the IndraWorks language switchingmethod.

In the current version, portions of View3D are available only in Eng‐lish.

5.2.2 Model Visualization

Basic functions

Coordinate system The following figure shows the basic arrangement of the main coordinate sys‐tem of a View3D model.


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Fig.5-3: Coordinate system Marking 3D objects An object can be marked by clicking the left mouse button; this is indicated by

a yellow frame. A marked object is also highlighted in the scene tree. Con‐versely, clicking the left mouse button on a part of the scene tree highlights thecorresponding part in the model with a yellow frame.

The marking can be removed by clicking the left mouse button on a blank spaceoutside of the model.

Rotating a 3D scene To allow the 3D model to be viewed from every perspective, the 3D scene can

be rotated.

● Mouse operation

If the mouse is moved within the 3D view with the left mouse button helddown, the model rotates according to the mouse movements. If the mouseis moved to the left or right, the model rotates around the Y-axis. If themouse is moved up or down, the model rotates around the X-axis.

● Keyboard operation

The model can be rotated around the Y-axis using keys <Ins> and<Del>.

Moving a 3D scene To position the 3D model, the 3D scene can be moved in View3D.

If the mouse is moved within the 3D view with the center mouse button held

down, the 3D scene is positioned according to the mouse movement.


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Zooming a 3D scene To be able to better see the details in the 3D model, you can zoom into the 3Dscene.

● Mouse operation

If the mouse is moved within the 3D view with the right mouse button held

down, the view “zooms” into the 3D scene. Moving the mouse upwardszooms out of the model. Moving the mouse downwards zooms into themodel.

● Keyboard operation

You can zoom within the 3D view using the <PgUp> and <PgDn> keys.Pressing the <PgUp> key zooms into the model; pressing the <PgDn> keyzooms out of the model.

Functions for manipulating 3D objects

Control reset Pressing key <Pos 1> moves the 3D scene into a predefined camera position.This is an internal basic setting that cannot be changed.

For these functions, the entry Rendering always active must havebeen switched on in dialog box Model properties (also see chapter 5.2.6 "Properties of the View3D Model " on page 25).

Moving/rotating objects To move an object, it must be marked beforehand. Then press one of the keys<X>, <Y> or <Z> to select the desired axis direction for the move. In addition,you must now move the mouse (with the left mouse button held down) to theleft or right in order to move the object.

If you press and hold the right mouse button instead of the left one, the objectis rotated around the selected axis.

Saving camera positions Keys <0> to <9> can be used to save and call 10 different camera positions.To do this - see the explanation in chapter "Basic functions" on page 19 - thecamera position is changed and then saved using key combination <Ctrl+num‐

ber>. A camera position (viewpoint) can be called again by pressing one of the keys<0> to <9>.

For these functions, the entryRendering always active

must havebeen switched on in dialog box Model properties (also see chapter 5.2.6 "Properties of the View3D Model " on page 25).

Explosion/implosion Pressing the <End> key brings manipulated objects back to the basic position(implosion).

If you then press the <E> key, the objects move back to the manipulated posi‐tion (explosion).

For these functions, the entry Rendering always active must havebeen switched on in dialog box

Model properties

(also see chapter 5.2.6 "Properties of the View3D Model " on page 25).

5.2.3 Scene Tree

General

The object structure of the 3D scenes is shown in the scene tree. Each indi‐vidual kinematics object has 6 degrees of freedom: X-Y-Z translation and X-Y-Z rotation. The degrees of freedom are a component of the objects listed in thetree, but are not shown explicitly. The individual nodes of the tree have acheckbox with which they can shown or hidden in the 3D model. If an OPC itemis assigned to at least one of the degrees of freedom of the kinematics object,the corresponding icon in the tree node changes.


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Fig.5-4: Scene tree

Object properties

The properties of a 3D object can be changed using the Object properties dialogbox.

Fig.5-5: Object properties

The dialog box can be opened by calling contextual menu Properties for a 3Dobject in the scene tree.

The menu item is active only if the selected node has subnodes.

The point of rotation and the angle of a kinematics object can be modified inthe Object properties dialog box.

Also see chapter "Handling instruction: Rotating a View3D object around auser-defined point of rotation" on page 36 and chapter "Handling instruction:Moving a View3D object in any direction in space" on page 36


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Assignment

Using drag-and-drop, an OPC item can be assigned to a degree of freedom of a kinematics object. If an OPC item from the OPC tree is dropped onto a nodeof the scene tree, the following dialog box opens.

Fig.5-6: Assigning an object

The dialog box contains a selection box in which you must specify precisely towhich of the 6 degrees of freedom the OPC item is assigned. An offset, whichis included in the calculation of the OPC item's value, can also be specified.

5.2.4 OPC Configuration

The OPC Server window is used to access process data via an OPC server.

All the OPC servers that are locally installed on the computer are located innode “Local”. Use tree node “Manual” to explicitly search the network for acomputer whose locally installed OPC servers are listed.

All standard OPC items of an OPC server are listed in the node called “BasicItems”. The items of the IndraMotion MTX OPC servers (OPC.IwSCP.1) aregrouped into “NC Axes”, “NC Corrections” and “NC Spindles”.


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Fig.5-7: OPC server

The contextual menu of node “Manual” contains menu items “Add Computer”and “Remove Computer”. The first menu item can be used to search the net‐work for a computer using its name or IP address. The second menu item isactive only if the computer found within the network is selected; it can be usedto remove the computer from the list.

5.2.5 Assignment List

General The assignment list indicates the assignment of the OPC item to a correspond‐ing degree of freedom of a kinematics object. It contains the columns “OPCItem”, “Offset”, “OPC Server” and “Computer”. This information precisely de‐fines an OPC item.

Fig.5-8: OPC assignment list Assignment Using drag-and-drop, an OPC item can be assigned to a degree of freedom of

the kinematics object selected in the scene tree. If the OPC item from the OPCtree is dropped onto an appropriate line in the assignment list, the individualinformation data are encrypted and written to the corresponding column of theassignment list.


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5.2.6 Properties of the View3D Model

The Properties of the View3D model dialog box can be used to make settingsfor the View3D model and for OPC.

Fig.5-9: Properties of the View3D model

See also chapter "Changing settings of the View3D model " on page 38.

Scaling factor for process values The scaling factor affects all the process values that are associated with 3D

objects in the View3D model.It is used to globally adapt the scaling of the View3D model to the processvalues.

See also chapter "Handling instruction Changing the scaling factor for processvalues" on page 35.

Rendering always active When this setting is active, the 3D model is continuously rerendered (i.e. the3D model is continuously recalculated). This is a good idea if, for example, youwant to switch between various viewpoints at the touch of a button.

When the process connection is active, rendering is automaticallyactivated.

OPC group name This is the name of the OPC group that is used when someone logs onto an

OPC server.OPC update rate The OPC update rate specifies the time (in milliseconds) in which process val‐

ues are updated by the OPC server.

5.3 Virtual User Panel


The Virtual User Panel is used as a replacement for the real VAM 40 duringemulation. The appearance and functions replicate the real VAM 40. In thecurrent version, the texts are available only in English and German.


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Fig.5-10: Virtual User Panel

5.3.2 Configurator

The Virtual User Panel is configured in IndraWorks Engineering. Then the con‐figuration file of the Virtual User Panel must be supplemented by the user (also

see chapter "Supplements to the configuration file " on page 30).

Fig.5-11: Configuration in IndraWorks

Project node Simulation with sub‐

node Virtual User Panel

Project node Virtual User Panel is used to call the pages for configuring thevirtual VAM 40.

The configuration page of the key-

operated switch

The individual switch settings are labeled on the configuration page of the key-operated switch.


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The configuration page of the key‐

pads

This page is used to label the keypads with texts or previously generated im‐ages. Each individual key can be allocated by entering a text or by draggingand dropping an image from the symbol list.

The configuration page of the

quick-stop module

The configuration page of the quick-stop module can be used to make varioussettings for the two keys:

● Labelling the key

● Function

Since the keys on the real VAM 40 are hardware-wired and the switchesare equipped with make and break contacts, these settings can also beselected here. If a key is not wired, “None” can be set.

● Mutual locking of the keys

Since the keys are switches, the signals are continuously activated. Tomutually reset these signals, mutual locking of the two keys can be se‐lected.

The labels for the EMERGENCY STOP and the spindle and fee‐drate override are not affected.

The configuration file The configuration file contains the assignment of the individual keys. In addition,the user must enter all the PLC variables that are required for communicationwith the Virtual User Panel (also see chapter "Supplements to the configurationfile " on page 30).The individual keys, switch settings, lamps and overrides can then use thesesettings to control the PLC program and to display the status.

5.3.3 The Application

The application is separate; it is used to control the PLC program in IndraMotionMTX emulation. This can be started independently of IndraWorks Engineering

or IndraWorks Operation. When the Virtual User Panel is started, the configu‐ration is read out of the currently active project.

In this version, there must be a connection to the emulation whenthe Virtual User Panel is started. This can be implemented, for ex‐ample, by triggering a connection test in the contextual menu of theMTX project node.

5.4 Virtual Control


A virtual control is the most important simulation component because, just like

the real control, it regulates the entire process. It contains the same functionsas the real control and is identically parametrized, programmed and operated.Therefore, the method of operation does not change for the user if he switchesbetween a virtual control and a real one; only the communication parametersof the Engineering interface must be reset. However, since the virtual controlruns under Windows, its only limitation is that it is not real-time-capable.

With the emulation of the IndraMotion MTX machine tool control, Bosch Rexrothhas such a virtual control.

For further information regarding IndraMotion MTX emulation, see chapter 6.4"Using the Virtual Control" on page 38.


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6 Operation in IndraWorks

6.1 Creating a Model

6.1.1 General

The import format for 3D scenes into View3D is VRML (Virtual Reality ModelingLanguage). Files in the format VRML 2.0 (or VRML97) are supported.

VRML files are recognized by the file extension “.wrl” (world).

Most 3D modelling tools can export 3D scenes in VRML format.

The import of compressed VRML files (the file extension is also“.wrl”) is not supported by View3D.

6.1.2 Creating a Simple 3D Model

As a rule, any 3D modelling tool with VRML export can be used to create 3Dmodels. However, not all modelling tools can be used to create kinematic re‐lationships between individual 3D objects.

Kinematic relationships have a fundamental significance for machine models.In a compound table, for example, the X-axis also moves when the Y-axis ismoved.

A simple modelling tool to generate 3D scenes with kinematic relationships is,for example, Vizx3D by “Virtock Technologies, Inc.” (http://www.vizx3d.com).

6.1.3 Importing eM-RealNC Models

View3D can also import VRML models that have been created using the NCsimulation software “Tecnomatix eM-RealNC” from Unigraphics Solutions

GmbH (http://www.tecnomatix.de). Tecnomatix eM-RealNC has provided aVRML export interface for this purpose.

6.2 Using the Virtual User Panel

6.2.1 Configuration

Configuration in IndraWorks

Creating a Virtual User Panel

In order to be able to configure a Virtual User Panel, a project must have beencreated in IndraWorks.

A Virtual User Panel is created in an existing project in IndraWorks by selectingand confirming Project node ▶ right mouse button ▶ Add new element ▶ Virtual

User Panel. This then appears in the Simulation node as subnode “Virtual User Panel”.

By <double-clicking> (or clicking the right mouse button on ▶ Open) the nodeof the Virtual User Panel, the configuration pages open.

Configuration of the key-operated switch

By highlighting the key-operated switch in the display of the virtual VAM 40, itsconfiguration page opens. The switch positions are labelled in the individualtext fields.

The number of characters for the texts is unlimited; the new label appears im‐mediately in the display of the Virtual User Panel.


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Operation in IndraWorks



Configuration of the keypads

The configuration page of the keypads is opened by highlighting a key on thekeypad.

Assigning text to the keys When labelling an individual key, first highlight the desired key on the keypad.Then switch to the text field of “Labelling the key” and enter the text.

Assigning images to the keys The keys are assigned using drag-and-drop. First select any image in the“Symbols” category. Then press the left mouse button and drag the cursor tothe desired key.

If only the image of VAM or the symbols can be seen because of too less place,a bitmap can be assigned alternatively via the key context menu. This can bereached via

focussing the key in image ▶ selecting the bitmaps ▶ right mouse

button ▶ assign bitmap of the last focussed key.

Configuration of the quick-stop module

The configuration page of the quick-stop module is opened by selecting thequick-stop module in the display of the virtual VAM 40.

Labelling the keys The new labels can be entered in the text fields of the “(Top) key” and “(Bottom)key”. Line breaks and line lengths are not taken into account. However, thelabel is immediately shown in the VAM 40 display.

Functions of the keys Since the keys on the real VAM 40 are hardware-wired and the switches areequipped with make and break contacts, these settings must be selected here.This is accomplished by setting function “Break-contact” or “Make-contact”. If the key was not wired, set “None”.

To execute mutual locking of the two keys, the checkmark “Mutual locking of the keys” must be set.

Supplements to the configuration file

In order to supplement the configuration file, the hard disk path of the project

that was just edited in IndraWorks Engineering must be determined. Then openin Simulation ▶ config the configuration file “VirtualControlPanel_VAM40.xml”using the Editor. The following settings for communicating with the PLC varia‐bles of the current PLC program in the control must be made:

Pay attention to capitalization!

Use only BOOL variables to communicate with the elements!

BYTE variables must be used for the overrides!

1. Enter the name of the logical device under “Logical_Device\ NameLG”.

e.g. <NameLD>IndraMotion_MTX_P60</NameLD>

2. Enter the PLC variables for the individual keys in the keypad under keypad1 and 2.

e.g. <KY_X1Y3>iStart</KY_X1Y3>

3. Enter the PLC variables for each individual LED under LED_Keypad_1and LED_Keypad_2

e.g. <LED_X2Y2Y>qStart</LED_X2Y2>

4. Enter the PLC variables for the spindle and feedrate override under thepoint “Override”

e.g. <OVR1>iFeedrate</OVR1> for the spindle and feedrate override

5. Enter the PLC variables for the key-operated switch under “Key_operated_Switch/KEY_P1...4”


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e.g. <KEY_P1>iVAM_KEY_S1</KEY_P1> for the first switch setting fromthe left

6. Enter the PLC variables for the functions of the quick-stop module keysunder “Quick_Stop_Module”

e.g. (Top) key <MOD_KY1>iK_Pow_On</MOD_KY1>

7. Enter the PLC variable for the LED in (Top) key under “Quick_Stop_Mod‐ule”

e.g. <MOD_LED_KY1>qL_Pow_On</MOD_LED_KY1>

8. Enter the PLC variables for the simulation of the EMERGENCY STOPunder “Emergency_Stop”

e.g. <KY>iEmergency_stop</KY>

After making the supplements, save the file and close it.

6.2.2 Connection to Virtual Control

Before the Virtual User Panel can be started, a few things must be carried outsuccessfully for the connection:

Preparations in IndraWorks

Engineering

● Set the project in which the Virtual User Panel was configured to Active.This is accomplished by selecting and executing menu item Project ▶ Ac‐

tivate for IndraWorks Operation.

● Execute a connection test via the control, e.g.IndraMotion_MTX_P60 ▶ right mouse button ▶ Connection test.

Preparations in IndraLogic .


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Fig.6-1: Preparations in IndraLogic

● In the PLC program, create all the variables that are to receive a connec‐tion with the Virtual User Panel as “Global variables”. These variables areused to activate the individual switch settings, buttons, lamps and over‐rides.

These are created as follows: Variable name: BOOL, e.g. iStart: BOOL;

Do not assign an address; remove it if necessary!

● Reset the PLC program, log in and start.

6.2.3 Start

The Virtual User Panel is started via Start ▶ Program Files ▶ IndraWorks ▶ Vir‐

tual User Panel or using the “IndraWorks Virtual User Panel” icon on thedesktop.

6.2.4 Contextual Menu in the Virtual User Panel

If the virtual user panel has been started, two functions can be activated/deac‐tivated using the right mouse button.

Function “Always in the foreground” Function “Always in the foreground” is used to always keep the virtual user panel in the foreground so that it does not disappear behind Operation Desktopwhen this is being used. It can be activated/deactivated at any time by selecting


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right mouse button ▶ Always in the foreground. However, it must be selectedeach time that the user panel is started.

“Transparent” Function With this function, the virtual control panel can be switched transparent to seethe application in the background. It can be activated/deactivated at any timeby selecting right mouse button ▶ Transparent.

6.2.5 Error Messages and Remedies

Error box “No active project exists ” Remedy: Open IndraWorks Engineering and set the project in which the VirtualUser Panel was configured to Active. This is accomplished by selecting menuitem Project ▶ Activate for IndraWorks Operation. Then restart the “IndraWorksVirtual User Panel”.

Error box “No virtual user panel

configured ”

Remedy: Open IndraWorks Engineering and create an existing or new project.Within it, create a Virtual User Panel via Project node ▶ right mouse

button ▶ Add new element ▶ Virtual User Panel . Then proceed according tochapter "Configuration in IndraWorks" on page 29.

Error box “No connection to the

PLC”

Remedy: Close the Virtual User Panel, call IndraWorks Engineering and rees‐tablish the connection via Control e.g. IndraMotion_MTX_P60 right mouse

button ▶ Execute connection test.Error box “Error writing PLC varia‐

bles”

This error message can have various causes; therefore various remedies areavailable:

1. Check whether the variable name in the configuration file is written cor‐rectly.

2. Check whether the PLC variables were stored under “Global variables”and are of type BOOL. Exception: Override activation uses BYTE varia‐bles.

3. Check the communication to the PLC and reestablish the connection if necessary.

6.3 Using 3D Visualization

6.3.1 3D Models in IndraWorks

Importing 3D models

General

In order to be able to open a 3D model in the View3D 3D visualization system,it must first be imported into the IndraWorks project. Models in VRML formatand in the internal d3d format are accepted as the import format (alsoseechapter 6.1 "Creating a Model" on page 29).

Handling instruction: Importing a 3D model

Importing of a 3D model into the IndraWorks project is described here.

IW Engineering / Simulation: Importing a 3D model

● In the Project Explorer on node 3D visualization (or on the project node if node 3D visualization does not yet exist), select the contextual menuAdd ▶ Add new element....

● In the dialog boxAdd new element

, open the template3D model

from thecategory Virtual components.


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Fig.6-2: Adding a new element

● Enter a name for the View3D model.

● Select an import file for the 3D scene. Press the <Browse...> button toopen a file selection dialog box in which the 3D model (VRML/d3d) canbe selected.

Fig.6-3: Adding a View3D model


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● Press the <Finish> key. The View3D model is added to node 3D visuali‐

zation in the project tree.

Opening, renaming and deleting 3D models

Opening a 3D model in View3D Highlight the desired View3D model within node 3D visualization using themouse or the cursor keys and open it using contextual menu Open or by double-clicking.

Renaming a 3D model The name of the View3D model can be changed in the Project Explorer. To dothis, select contextual menu

Rename

on the View3D model in the Project Ex‐plorer or press key <F2>. Then the name can be changed and entered bypressing the <Enter> key.

Deleting a 3D model A View3D model can be deleted from the IndraWorks project in the ProjectExplorer using contextual menu Delete or with key <Del>.

6.3.2 Process Connection

Connecting 3D objects with IndraMotion MTX axis values

Handling instruction: Controlling a View3D object using an IndraMotion

MTX process value

The procedure for connecting a 3D object in View3D with an IndraMotion MTXprocess value is described here.

Boundary condition Communication with the IndraMotion MTX must have been established in order to be able to access IndraMotion MTX OPC items.

To establish communication to the IndraMotion MTX, one of the following stepsmust be carried out once before opening a 3D model in View3D:

● Execute a connection test on node IndraMotion MTX in the Project Ex‐plorer

● Open IndraWorks Operation Desktop

IW Engineering / Simulation: Connecting a 3D object with an OPC item

● The object that is to be connected to an OPC item must be selected in the3D view or in the scene tree. The actions translation (movement in axisdirection X, Y or Z) and rotation (turning around axis X, Y or Z) appear inthe OPC assignment list for the selected object.

● In window OPC Server, open the node for the IndraMotion MTX OPCserver (OPC.IwSCP.1) in node Local (local OPC server).

● Select an OPC item and, with the left mouse button held down, drag it ontoa translation or rotation action in the OPC assignment list (e.g. in groupNC Axes “X (Phys.No.=1), command position, ACS” for the command po‐sition of the X-axis in the axis coordinate system).

● The data of the OPC item now appear in the OPC assignment list. The

object receives a green marking in the scene tree.

Configuring the process connection

Handling instruction Changing the scaling factor for process values

Adapting the scaling of a 3D model to the process values of the OPC item isdescribed here.

IW Engineering / Simulation: Changing the scaling of a View3D model

● Using menu item View3D ▶ Model properties... in the main menu, opendialog box Properties of the View3D model.

● The scaling of the 3D model can be adapted to the values of the OPC itemusing Scaling factor for process values.


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The scaling factor can also be changed while a process connectionis active. In this way, the 3D model can be used to immediatelycheck the changes.

● If the scaling factor is set too high, the 3D objects move beyond

the end position (they may even be moved out of the visiblearea of the 3D Viewer).

● If the scaling factor is too low, it may be impossible to detectthe movement of the 3D objects.

Handling instruction Changing the offset for process values

An offset can be added to each process value of an OPC item. The entry of offset values is described in this handling instruction.

IW Engineering / Simulation: Adding an offset to the process value of a View3D

object

● Select a 3D object with a configured process connection from the scene

tree (can be recognized by the green marking).

● Change the offset value of the OPC item in the OPC assignment list.

Handling instruction: Rotating a View3D object around a user-defined

point of rotation

If a 3D object is to be rotated by a process value (OPC item is connected withthe action rotation in the OPC assignment list), the point of rotation of the objectmay need to be adapted. This handling instruction can be used to change thepoint of rotation of a View3D object.

Boundary condition It is not possible to change the point of rotation using end elements of the scenetree.IW Engineering / Simulation: Changing the point of rotation of a View3D object

● Select contextual menu Properties on the desired 3D object in the scenetree in order to open dialog box Object properties.

See also chapter "Object properties " on page 22.

● Enter the X, Y and Z coordinates of the point of rotation and activate thevalues by pressing the <OK> or <Accept> button.

The coordinates for the point of rotation can be determined usingthe cursor function. See chapter "Basic 3D visualization functions "on page 37.

Handling instruction: Moving a View3D object in any direction in space

If a 3D object is to be moved by a process value in a direction in space thatdoes not correspond to one of the X, Y or Z coordinate axes, the angle of theobject must be adapted accordingly.

Boundary condition It is not possible to change the angle using end elements of the scene tree.IW Engineering / Simulation: Changing the angle of a View3D object

● Open dialog box Object properties using contextual menu Properties onthe desired 3D object in the scene tree.

See also chapter "Object properties " on page 22.

● Enter the angles for the X, Y and Z coordinates and confirm these bypressing the <OK> or <Accept> button.

Example: If a machining station in the XY plane is rotated by 30° relative

to the main coordinate system, this angle must be entered for the Z coor‐


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dinate (rotation around the Z-axis) to correct the direction of movement for the X- and Y-axes.

Establishing a connection to the control

Handling instruction: Starting a View3D process connection

This handling instruction describes how to activate the View3D process con‐nection in order to control 3D objects using process values.

Boundary condition Communication with the IndraMotion MTX must have been established in order to be able to access IndraMotion MTX OPC items.

To establish communication to the IndraMotion MTX, one of the following stepsmust be carried out once before opening a 3D model in View3D:

● Execute a connection test on node IndraMotion MTX in the Project Ex‐plorer

● Open IndraWorks Operation DesktopIW Engineering / Simulation: Establishing a View3D process connection for

control

In the main menu, select menu item View3D ▶ Start.

The following actions are now carried out:

● Windows OPC server and OPC assignment are hidden.

● The process connection is started and the 3D objects are supplied withthe process values of the control.

Handling instruction: Stopping a View3D process connection

An active process connection in View3D can be stopped using this handlinginstruction.

Boundary condition The process connection must be active (this can be recognized by the check‐

mark on menu item Start in the main View3D menu).IW Engineering / Simulation: Terminating a View3D process connection for

control

In the main menu, select menu item View3D ▶ Start.

The following actions are now carried out:

● The process connection is stopped.

● Windows OPC server and OPC assignment are displayed.

6.3.3 3D Visualization Operation

Basic 3D visualization functions

Handling instruction: Determining the coordinates of a point in space

This handling instruction describes how the Cursor dialog box can be used todetermine the coordinates of a point in space.

IW Engineering / Simulation: Cursor function

● Open the Cursor dialog box via the main menu View3D ▶ Cursor ....

● If necessary, activate the cursor. The checkmark on entry Visible must beset.

● Using the arrow keys of the input fields for the X-, Y- and Z-coordinates,move the cursor to the desired point in space. The increment of the cursor movement can be set via Delta to “1” “0.1” “0.01” or “0.001”.

● The coordinates of the point can now be read in the Cursor dialog box.


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Wireframe representation

The representation of the 3D model can be switched between Solid and Wire‐

frame in View3D. If the checkmark on menu item Wireframe is set in the mainView3D menu, the model is displayed as a wireframe. Otherwise, the 3D model

is shown as a solid.

Manipulating 3D objects

Handling instruction: Moving a View3D object

This handling instruction describes how a single View3D object in the 3D modelcan be moved.

IW Engineering / Simulation: Moving a View3D object

● Select the 3D object using the left mouse button.

● Press the <X>, <Y> or <Z> key while simultaneously pressing the leftmouse button. The object can now be moved in the X, Y or Z coordinatedirection by moving the mouse to the left or right.

Handling instruction: Rotating a View3D object

The procedure for rotating a View3D object in the 3D scene is described here.

IW Engineering / Simulation: Rotating a View3D object

● Select the 3D object using the left mouse button.

● Press the <X>, <Y> or <Z> key while simultaneously pressing the rightmouse button. The object can now be rotated around the X, Y or Z coor‐dinate axis by moving the mouse to the left or right.

Changing settings of the View3D model

Settings of the View3D model are changed in the Properties of the View3D

modeldialog box.

See also chapter 5.2.6 "Properties of the View3D Model " on page 25.

The dialog box can be opened in the main menu using menu itemView3D ▶ Model properties....

Changing the scaling factor for

process values

The scaling factor for process values can be changed using the correspondinginput field in the dialog box.

Switching rendering on and off Rendering of the 3D scene can be switched on/off using the Rendering always

active checkmark.Changing the name of the OPC

group

The name of the OPC group can be changed in field Group name under OPC

settings.Changing the OPC update time The update time for the OPC group can be entered (in milliseconds) in input

field Update rate under OPC settings.

OPC settings can be changed only if the process is inactive.

6.4 Using the Virtual Control

6.4.1 Installation of MTX Emulation

General

Description

Brief Description MTX Emulation is copied from the installation CD; proceed according to thedialog boxes of the installation program. We recommend using the default val‐ues.


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Boundary conditions If the default memory size of 0.5 MB is not sufficient, the RAM file systemmemory of the emulation must be increased to 3 MB:

Handling instruction: Increasing the RAM file system memory of the

emulation

If the application requires more memory, proceed as follows to increase it:

Windows / Windows Explorer: Change file names

● In folder “D:\Program Files \Rexroth\IndraWorks\mtx\emu”

– rename file “t3usrfep.pxf” to “t3usrfep.pxf.1MB” and

– rename file “t3usrfep.pxf.3MB” to “t3usrfep.pxf”.

Figure Flowchart Example Instruction Documentation

Documentation :IndraWorks Commissioning In‐

structionsMTX Emulation

Fig.6-4: Link

6.4.2 Projecting Emulation

Restoring an existing project

General

Brief Description IndraWorks Engineering can be used to restore existing projects that were cre‐ated previously or on another computer for real systems or MTX emulation.

Description The transfer (= restoration) of an IndraWorks project from a real control to em‐ulation is described here. An IndraWorks project file contains, among other things, the control parameters, the Profibus configuration, the PLC program,the definition files for the M- and F-keys and the logbooks, as well as the user screens.

The project is restored using function “Restore” in menu “Project”.

Handling instruction Restoring an existing project for MTX emulation

The transfer (= restoration) of an IndraWorks project from a real control to em‐ulation is described here.

IW Engineering / Motion: Restore control data


Instruction : Restoring data

Documentation :IndraWorks Commissioning In‐

structionsData backup

Fig.6-5: Link

6.4.3 Projecting the HMI

General

Description

Brief Description The projected HMI data can be effective in the user interface only if they aredownloaded to the Runtime folder of the user interface.

Boundary conditions The Runtime folder need be set only if the installation path of the target control(emulation) differs from the installation path of the source control on which theproject was created.

Handling instruction Projecting the HMI for MTX emulation

This handling instruction describes how to make the HMI-specific settings that

are required to use MTX emulation.


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IW Engineering / HMI BTV 40: Open the Properties dialog box and make set‐

tings

● Click the right mouse button on the node of the HMI device in the ProjectNavigator.

Fig.6-6: IndraWorks project - Properties

● Select the Properties dialog box by clicking the left mouse button on“Properties”. The dialog box for setting the properties for the HMI projectopens.

Fig.6-7: IndraWorks project – “Properties” dialog box

● Enter the path for the Runtime installation of the MTX (this is usually iden‐tical to the installation path of the MTX).

● Exit the Properties dialog box by pressing “OK”.


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IW Engineering / Project: Activating an IndraWorks project

● The IndraWorks project is activated in the main menu under “Project / Ac‐tivate for operation”.

Fig.6-8: Activating a IndraWorks project

● Download the HMI project in the Runtime folder by pressing the Activatecommand.

● This IndraWorks project is displayed the next time that the MTX user in‐terface is started.

6.4.4 Designing the NC Core

General

Description

Brief Description Among other things, the NC core data contains the the usrfep and the root files,the machine data as well as the database tables for the system and tool data.The data of the NC core is located in the IndraWorks project tree below thedevice node “IndraMotion MTX P60”.

To restore the NC core data of a project, which has been created on a real

control, one first has to adapt the “Properties of the IndraMotion MTX P60” andthen activate the NC core data in two steps.

Handling Instruction: Designing the NC Core

The handling instruction contains instructions for adaptations for the NC corespecific to the use of the MTX Emulation. These instructions refer to existingdata which is to be activated by restoring them.

IW Engineering / IndraMotion MTX P60: Adapt the properties of the device

“IndraMotion MTX P60”

● With the right mouse key, click on the device node “IndraMotion MTXP60”. The properties dialog box of the “IndraMotion MTX P60” will open.


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Fig.6-9: IndraMotion - “Properties” dialog box

● Select the tab “Communication” using the left mouse key.

● In the input field “IP address”, select the entry “localhost” and exit the di‐alog box by pressing OK.

IW Engineering / IndraMotion MTX P60: Restore NC core data

● Start the IndraMotion MTX Emulation by executing the file “emu.bat”. Thefile “emu.bat” is located in the following directory: “...\Program Files\Rexroth\IndraWorks\mtx\emu\” (see also handling instruction “Start-up of

the Emulation”).

● Stopping of the IndraLogic in the Program “IndraLogic” by pressing “F5”.

● In IndraWorks, highlight the node “IndraMotion MTX P60\Motion” and callthe function “Restore” with the right mouse key.

● In the following dialog boxes, select the desired archive and, for the timebeing, load only the data of the “User FEPROM”.


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Fig.6-10: Restoring NC core data

● Afterwards exit IndraWorks Engineering and emulation.

● The emulation is closed by entering “14” in the DOS window.

Fig.6-11: DOS prompt for emulation

● Start the emulation and IndraWorks Engineering again (see handling in‐struction “Start-up of Emulation”).

● Stopping of the PLC via IndraLogic.

● Now, select and reload all NC core data, except for the already loadeddata of the user FEPROM.

● Close the emulation and IndraWorks Engineering again and restart them.The emulation is now working with the loaded NC core data.


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Any changed data (e.g. configuration parameter, tool data) will onlybe effective if the emulation is ended by entering “14” in the DOSwindow.

Characteristics during working with the MTX emulation

The MTX emulation does not have a “CMP60 Control” with which the startupmodus is set, the startup phase is observed and different commands to saveparameters, load Firmware, start/stop PLC,... can be executed. The followingsequence describes how this functions can be executed in the MTX emulation.

System restart of emulation (start‐

up mode 0)

It is necessary to restart the system for example to apply modifications for ma‐chine parameter (Macoda).

1. Exits IndraWorks.

2. Exit the emulation in the DOS window by entering “14”. The changed pa‐rameters are saved on the computer by writing the files “typ3ram.pxf” and“t3usrfep.pxf” on the PC and the changes become effective upon the next

startup of the emulation.3. Restart emulation.

4. Restart IndraWorks.Bootstrap (startup mode 6) Via bootstrap which can be compared to the execution of startup of a real MTX

with startup mode 6, the RAM file system of control is created again.

A new root file system is created via bootstrap; as a result, all thedata of the old file system are lost. If an intact user FEPROM filesystem exists, the PLC boot project and configuration data are loa‐ded from there.

Bootstrap is necessary to apply for example the modifications on the tool da‐

tabase size as well as the structure of tool data records.1. Copy modifications on tool data record into usrfep.


3. Exit the emulation in the DOS window by entering “14”.

4. Delete the RamFileSystem, i.e. delete the file “...\Program Files\Rexroth\IndraWorks\mtx\emu\typ3ram.pxf”.

5. Restart emulation.

6. Restart IndraWorks.Creation of the user FEPROM file

system (startup mode 7)

Creating a user FEPROM file system which can be compared to execution of startup mode 7 of real MTX is necessary if all project-specific data can be de‐leted on a control or if the user FEPROM file system can is damaged.

The user FEPROM is created via creation of the user FEPROM filesystem , but all the data of the old file system are lost. The root filesystem remains. The permanent CPL variables will be deleted.


2. Exit the emulation in the DOS window by entering “14”.

3. Delete the user FEPROM file system, i.e. delete the file “...\Program Files\Rexroth\IndraWorks\mtx\emu\typ3ram.pxf”.

4. Restart emulation.

5. Restart IndraWorks.


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6.4.5 Projecting the PLC

General

Description

Brief Description If the IndraWorks PLC project originates from a real control or if IndraWorkswas previously installed in a directory that is different from the active version,the communication settings of the PLC project must first be modified. Then thePLC project can be activated.

Handling instruction Restoring a PLC project

This handling instruction describes the steps involved in commissioning a PLCproject that has already run on a real control.

IW Engineering / Logic: Restoring a PLC project

● Highlight node “IndraMotion MTX P90\Logic” and use the right mousebutton to open the “Properties” dialog box.

● In the “Properties” dialog box, select tab “Communication settings”.

Fig.6-12: PLC communication parameters

● Press the “Communication parameters” button. The “Communication pa‐

rameters” dialog box opens.● Here, make the settings in dialog “communication parameter” shown in

the figure below and confirm them by pressing OK. The existing settingsmay need to be deleted first.


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Fig.6-13: Settings in the “Communication parameters” dialog box

● In the “Properties” dialog box (see above), open tab “IndraLogic directo‐ries” and, if necessary, change the path information for the installationpaths of the emulation. Only one path entry may be made.

Fig.6-14: Settings in the “Properties/Directories” dialog box

● Exit the Properties dialog box by pressing “OK”.

● In IndraWorks, click the right mouse button on node “Logic” and executecommand “Update”. The IndraLogic project is now set to “Emulation” andcan be started.

● Start IndraLogic by double-clicking node “Logic” and transfer and down‐load the PLC project.


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Documentation : IndraWorks System Description Working with projects

Fig.6-15: Link

6.4.6 Starting and Exiting MTX Emulation

General

Description

Brief Description Emulation covers both the NC kernel and the PLC; these can be started andstopped together. Windows application Sco.exe is provided for this purpose; itsfunctionality at runtime can be checked using a DOS window.

The emulation system must be restarted to, for example, transfer MACODAchanges or tool data configuration modifications.

Boundary conditions Emulation must always be started before beginning work with IndraWorksEngineering (project interface) and the IndraMotion MTX user interface.

Handling instruction: Starting Emulation

This handling instruction describes how to start emulation (CNC and PLC).

Windows: Starting emulation

● Emulation is started using batch file “...\Program Files\Rexroth\IndraWorks\ mtx\emu\emu.bat”.

● You can see if emulation has started up without errors if the feedback isthe following screen.

Fig.6-16: Starting emulation

Emulation must always be started before beginning work withIndraWorks Engineering and IndraMotion MTX. It is recommendedthat a link to the start of the batch file be created on the Windowsdesktop.


Documentation : IndraWorks Commissioning Starting emulation

Fig.6-17: Link

Handling instruction: Stopping emulation

This handling instruction describes how to stop emulation (CNC and PLC).

Windows: Starting emulation

● Emulation is exited by entering “14” in the DOS window.


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Fig.6-18: Stopping emulation

Modified data (e.g. machine parameters or tool data) are saved onlyafter emulation is exited by entering “14” in the DOS window.


Documentation : IndraWorks Commissioning Stopping emulation

Fig.6-19: Link

Handling instruction: Restarting the emulation system

This handling instruction describes how to restart emulation (CNC and PLC).The emulation system must be restarted to, for example, allow modified ma‐chine data to go into effect.

Windows: Restarting emulation

● Exit IndraWorks Engineering Desktop and/or Operation Desktop.

● Exit emulation by entering “14” in the DOS window. The modified param‐eters are saved by writing the files of file system typ3ram.pxf and the user feprom t3usrfep.pxf to the PC; the modifications go into effect the nexttime that emulation is started.

● Restart emulation.

● Restart IndraWorks Engineering Desktop and/or Operation Desktop.

Modified data (e.g. MACODA, tool data) go into effect only after emulation is exited by entering “14” in the DOS window. For MTXemulation, it is not necessary to set different startup modes.


Documentation : IndraWorks Commissioning Restarting the Emulation System

Fig.6-20: Link

6.4.7 Starting Operation Desktop

Brief Description The MTX user interface is started for a real application. To do this, a link(“IndraWorks HMI”) is placed on the desktop during the installation of MTXEmulation.


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7 Communication

7.1 OPC

The View3D 3D visualization system can access IndraMotion MTX processdata via OPC.

Data are exchanged with the IndraMotion MTX using OPC items, which areprovided by the IndraMotion MTX OPC server (OPC.Iw.SCP.1).

Queries are passed on internally to the OPC server using the Scalable Com‐munication Platform (SCP), which is also used for communication with theIndraMotion MTX user interface.

7.2 SCP

The SCP (Scalable Communication Platform) is the standardized IndraWorkscommunication platform. All communication between Bosch Rexroth products,

such as Virtual Control Panel and the PLC, is carried out using SCP.

Data are exchanged between Virtual Control Panel and the PLC using SCPitems, which consist of the names of PLC variables, starting with PLC.Pvl,.PLC

variable name.

You can find additional information in the SCP documentation.


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Communication



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8 Service & Support

8.1 Helpdesk

Our service helpdesk at our headquarters in Lohr, Germany, will assist you withall kinds of enquiries.

Contact us:

● By phone through the Service Call Entry Center,

Mo - Fr 7:00 am - 6:00 pm CET

+49 (0) 9352 40 50 60

● By Fax

+49 (0) 9352 40 49 41

● By email: [email protected]

8.2 Service Hotline

Out of helpdesk hours please contact our German service department directly:

+49 (0) 171 333 88 26

or

+49 (0) 172 660 04 06

Hotline numbers for other countries can be found in the addresses of eachregion (see below).

8.3 Internet

Additional notes regarding service, maintenance and training, as well as the

current addresses of our sales and service offices can be found on

http://www.boschrexroth.com

Outwith Germany please contact our sales/service office in your area first.

8.4 Helpful Information

For quick and efficient help please have the following information ready:

● detailed description of the fault and the circumstances

● information on the type plate of the affected products, especially type co‐des and serial numbers

● your phone / fax numbers and e-mail address so we can contact you in

case of questions


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Service & Support



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Index

Symbols

3D visualization

Assignment list 24Basic 3D visualization functions 37Changing settings of the View3D model 38Configuring the process connection 35Connecting 3D objects with IndraMotion MTX ax‐is values 35Creating a simple 3D model 29Establishing a connection to the control 37Functions for manipulating 3D objects 21Importing 3D models 33Importing eM-RealNC models 29Manipulating 3D objects 38Model visualization 19

Object properties 22OPC configuration 23Opening, renaming and deleting 3D models 35Properties of the View3D model 25Scene tree 21Wireframe representation 38

B

Behavioral simulation 1

C

Configuration file 26, 30Connection to virtual control 31

E

Error messages 33

F

FEM 1

H

Handling instructionChanging the offset for process values 36Changing the scaling factor for process values35

Controlling a View3D object using anIndraMotion MTX process value 35Determining the coordinates of a point in space37Importing a 3D model 33Increasing the R AM file system memory of theemulation 39Moving a View3D object 38Moving a View3D object in any direction in space36Projecting the HMI for MTX emulation 39Restarting the emulation system 48Restoring an existing project for MTX emulation

39

Restoring a PLC project 45Rotating a View3D object 38

Rotating a View3D object around a user-definedpoint of rotation 36Starting a View3D process connection 37Starting emulation 47Stopping a View3D process connection 37Stopping emulation 47

Handling InstructionDesigning the NC Core 41

Hardware-in-the-loop 1

I

Inappropriate use 3Intended Use

Applications 3Cases of Application 3Introduction 3

K

Key-operated switch 29

L

Language 19

M

Machine model 15

MBS 1

N

Non-Intended UseConsequences, Exclusion of Liability 3

P

Project explorer 17

Q

Quick-stop module 30

S

safety instructions f or electric drives and controls 5SCP 49Software-in-the-loop 1

V

Virtual factory 1Virtual machine 1Virtual user panel

Contextual menu 32Virtual User Panel 25


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Index



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Notes


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|Bosch Rexroth AG



Bosch Rexroth AG

ectr c r ves and ontro s

. . ox 1

7803 Lohr, Germany

Bgm.-Dr.-Nebel-Str. 2

7816 Lohr, Germany

hone +49 (0)93 52-40-50 60

ax +49 (0)93 52-40-49 41

ervce.svc boschrexroth.de

www.boschrexroth.com

mailto:[email protected]

http://www.boschrexroth.de/

http://www.boschrexroth.de/

mailto:[email protected]

DOK-IWORKS-SIMU----V01-AW03-EN-P - Rexroth IndraWorks Simulation.pdf

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