REXROTH VT3024

Description

Product Overview and Description

The REXROTH VT3024 is a high-performance motion control module from Bosch Rexroth, specifically designed as a positioning controller for their IndraDrive servo drive system. This module is not a general-purpose PLC but a specialized, intelligent single-axis motion controller that integrates directly into the IndraDrive amplifier unit. The primary function of the REXROTH VT3024 is to execute complex point-to-point positioning, synchronous motion, and velocity control tasks for a single servo axis with high precision and dynamic response. It offloads the trajectory calculation and closed-loop control from a central PLC, enabling distributed, high-performance motion architecture. By integrating the VT3024 into an IndraDrive, the drive becomes a self-contained motion controller capable of handling cam profiles, gearing, and complex sequences locally. This design is central to Rexroth’s system approach, providing a seamless and powerful solution for demanding automation tasks in packaging, printing, and machine tool applications.

Product Parameters and Specifications

• Product Type: Single-Axis Positioning Controller Module (Motion Controller)

• Manufacturer Part Number (MPN): VT3024

• Brand: Bosch Rexroth

• System Compatibility: Rexroth IndraDrive servo drive family (e.g., M, H, C series frames). Plugs into the “controller slot” of the drive.

• Control Functions: Point-to-point positioning, homing, velocity control, torque control, electronic gearing, electronic camming, and synchronized motion.

• Programming: Programmed using Rexroth’s IndraWorks engineering software with PLCopen Motion Control function blocks or dedicated motion languages.

• I/O Connectivity: Provides integrated digital inputs and outputs for direct connection to sensors (e.g., homing switches, probes) and actuators relevant to the axis.

• Feedback Systems: Supports various feedback systems via the drive’s internal interfaces, including resolver, sin/cos encoder, and absolute encoders (EnDat, Hiperface).

• Communication Interfaces:

  • Drive Bus: Internal high-speed link to the drive’s power and feedback sections.

  • Fieldbus: Integrates into the overall machine network via the host drive’s fieldbus interface (e.g., SERCOS III, PROFINET, EtherCAT, Ethernet/IP).

• Performance: Features a fast control cycle time (typically in the sub-millisecond range) for high dynamic performance.

• Memory: Sufficient non-volatile memory for storing multiple motion programs and parameters.

Key Advantages and Features

The key advantage of the REXROTH VT3024 is its tight integration with the IndraDrive platform, creating a single, compact unit that combines power amplification, feedback processing, and intelligent motion control. This integration minimizes wiring, reduces cabinet space, and optimizes performance by keeping control loops extremely short and deterministic. It offers a rich set of advanced motion functions out-of-the-box, such as flying saw cuts or registration mark correction, which would require significant programming effort in a central PLC. The module supports centralized (PLC-based) or decentralized (autonomous) control strategies, offering great flexibility. Its use of standard PLCopen function blocks simplifies programming for engineers familiar with this standard. The robust design ensures reliable operation in industrial environments, and the comprehensive diagnostics available through IndraWorks aid in rapid troubleshooting and maintenance.

Application Scenarios and Use Cases

The REXROTH VT3024 is deployed in high-performance machinery requiring precise coordinated or standalone axis control. In packaging machines, it controls the precise positioning of a filling head, a sealing jaw, or a label applicator, often synchronized with a main encoder (electronic gearing). For printing presses, it manages the registration of print cylinders. In machine tools, it can control a single axis for a grinding wheel feed or a tool changer. On converting equipment (e.g., slitters, winders), it performs tension control and winding diameter calculations. It is also ideal for material handling robots for simple pick-and-place units or conveyor tracking applications. Essentially, any machine axis requiring more than simple start/stop velocity control, especially those needing precise positioning or synchronization, is a candidate for this controller.

Comparison with Competing Products

The REXROTH VT3024 competes with other single-axis “drive-based” or “distributed” motion controllers from manufacturers like Siemens (SINAMICS S210 with Integrated Controller), Beckhoff (AX5000 with TwinCAT NC PTP), B&R (ACOPOSmotor with embedded controller), and Yaskawa (Sigma-7 with MP3300iec controller). Compared to controlling a servo axis directly from a central PLC’s motion CPU (e.g., Siemens T-CPU, Rockwell Kinetix 5700), the VT3024 decentralizes the control intelligence, which can reduce the computational load on the main PLC and simplify the control architecture. Its main differentiator is its native, plug-in integration with the extensive IndraDrive ecosystem, offering a consistent software environment (IndraWorks) for configuration, programming, and diagnostics of both the drive and the motion controller.

Selection Guidelines and Important Notes

Selection Advice:

1. Drive Compatibility: The REXROTH VT3024 must be matched with a compatible IndraDrive unit that has a free controller slot. Verify the specific drive model and frame size compatibility list.

2. Motion Task Analysis: Clearly define the axis requirements: Is it point-to-point, continuous path, synchronized? Ensure the VT3024’s feature set (gearing, camming) meets the application needs.

3. I/O Requirements: Check the number of integrated digital I/O on the VT3024. For complex sensor/actuator setups, an additional I/O module may be required on the drive or network.

4. Network Integration: Select the fieldbus option (e.g., PROFINET, EtherCAT) on the host IndraDrive that matches the machine’s main network.

5. Software Necessity: Programming and configuration require Bosch Rexroth’s IndraWorks software with the appropriate licenses. Ensure access is available.

Important Precautions:

• Electrostatic Discharge (ESD): Handle the module as a sensitive electronic component. Use proper ESD precautions during installation.

• Firmware Compatibility: Ensure the firmware versions of the VT3024, the host IndraDrive, and the IndraWorks engineering software are compatible. Mismatches can cause communication failures.

• Backup Parameters: Always create a complete backup of the drive and controller parameters using IndraWorks before making changes or replacing the module.

• Safe Torque Off (STO): Understand that the VT3024 controls motion, but safety functions like Safe Torque Off (STO) are typically handled by separate safety terminals on the drive or an external safety relay. Do not confuse control with safety.

• Commissioning Safety: During commissioning, use reduced torque/velocity limits and ensure mechanical components are clear to prevent unexpected motion that could cause injury or damage.

• Heat Dissipation: The VT3024 generates heat within the drive enclosure. Ensure the drive’s cooling system (fans, heatsink) is functional and that ambient temperature limits are not exceeded.

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