Trends and Topics Case Studies Rexroth integrated motor/drive control system helps streamline new generation of servo-driven case packers Challenge: Design a new line of side-loading case packers to increase speed, lower machine costs, save energy and reduce space Rexroth Solution: IndraDrive Mi integrated servo motor/drive platform with built-in I/O IndraMotion MLC L40 motion logic controller with SERCOS communication and Flex Profile functionality Windows CE-based IndraControl VEP40 HMI Rexroth Results: Eliminated more than 200 moving parts Reduced overall machine footprint Reduced costs by one third Reduced cabling by 80 percent Energy savings of up to 25 percent Reduced packaging and product waste Reduced control cabinet space by 25 percent Distributed I/O saves wiring and component cost FlexProfile optimizes motion performance Modular machine design where additional functionality can be added without significant changes to the control cabinet Download the complete case study (PDF - 687 KB) Rexroth Helps Streamline Servo-driven Case Packers The efficiency and compact size of Rexroth IndraDrive and IndraMotion technology is the foundation for the next generation case packer machines developed by Brenton Engineering, a large provider of packaging and palletizing equipment. Overall, the key features of integrated Rexroth controls gave Brenton Engineering the means to create an all-servo version of its popular BentonPro Mach-2 case packer. Servo control reduces energy consumption and costs while occupying a smaller footprint, to meet or exceed “green manufacturing” end user needs. Brenton Engineering had previously used pneumatics to perform many of their case packers’ functions. But based on customer feedback, the machine builder decided to replace pneumatics with integrated servos and drives, permitting high speed with fewer moving parts. Rexroth capabilities played a big role in this decision. The new BentonPro Mach-2 combines three major Rexroth drive and control technologies: an IndraDrive Mi integrated motor/drive platform with SERCOS distributor I/O, an IndraMotion MCL motion logic controller and the Rexroth IndraControl VEP human machine interface (HMI). Working closely with local Bosch Rexroth distributor Motion Tech Automation, Brenton Engineering was able to eliminate more than 200 moving parts with the all-servo design. The IndraDrive Mi has the potential to reduce a machine’s cabling needs by more than 80%. Mounted on the machine frame, the Rexroth IndraControl HMI uses a Windows CE-based platform and integrates easily with the rest of the control system. The multi-axis machine reaches speeds of up to 25 cases per minute and can accommodate a variety of cases, including RSC, HSC, tray, wrap-around, knock-down and harness for cartons, bottles, cans and tubs. On average, the Mach-2 is expected to generate energy savings of up to 25 percent compared with the first generation machine. The IndraDrive Mi is also 50 percent smaller than a traditional servo system, and combining each servo motor and drive amplifier into one compact unit could reduce the machine’s cabling needs by more than 80 percent. For Brenton Engineering, the Mach-2 is a textbook example of the many benefits that integrated Rexroth drive and control systems can provide in terms of saving space, costs, development time and energy consumption. Learn more about this technology and download the complete case study (PDF - 687 KB)