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Bosch Rexroth AG 

Training system mMS 4.0 | R901429162/04.16 

Set-up, installation and commissioning 

  

9.4

 

Installing installation and stations 

 

 
 
Pneumatic supply 
 

 

The air feed should be connected to the station at the extreme left. 

Connect the Ø6mm air supply hose to the maintenance unit. 
 

 
 
 
 
 
 
 
 
 
 
 
 
 

 

Fig. 21:

 

Compressed air feed connection 

 CAUTION 

Danger caused by lashing hoses.  
Risk of injurycaused by compressed air! 

 

Before switching on the system, make sure all compressed air hoses have 

been depressurized. 

 

Do not connect pneumatic hoses under pressure. 

 CAUTION 

Dangerous electrical voltage.  
Death or serious injury! 

 

Extracting current from the mains supply is prohibited! 

 

Do not make any modifications to conductive parts! 

Summary of Contents for REXROTH mMS 4.0

Page 1: ...R901429162 04 16 Operating manual Replaces R901429162 09 15 English Training system mMS 4 0 ...

Page 2: ...obligation to conduct his own assessments and tests Our products are subject to a natural process of wear and aging This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG We retain all rights of use including the rights of reproduction and distribution An example configuration is shown on the title page The delivered pr...

Page 3: ...ties of the operator 13 2 9 Safety installations 14 2 10 Operator operating positions 15 3 General instructions concerning property damage and product damage 16 4 Scope of supply 17 5 About this product 18 5 1 General information 18 5 2 Product Description 18 Control box left side exterior 19 Control box right side exterior 19 5 2 1 Rack work piece detection station 20 Control box 21 5 2 2 Process...

Page 4: ... Setting up the mMS 4 0 training system 45 9 2 Check the pneumatic supply 46 9 3 Check electric installation 47 9 4 Installing installation and stations 48 9 5 Commissioning the training system 52 9 6 Check the EMERGENCY STOP circuit 52 10 Description of the operating functions 53 10 1 Select the operating mode 53 10 2 Manual mode operation 54 10 3 Operating Single Step mode 54 10 4 Automatic mode...

Page 5: ...lowing signs and symbols are used in this manual Activity symbol The text next to this symbol describe activities which are to be carried out from top to bottom in the indicated sequence 1 3 Required and supplementary documentation In addition to this manual on the turnkey mMS 4 0 training system the following additional documentation applies All user manuals for the components These can be viewed...

Page 6: ...d WARNING Identifies a dangerous situation that could result in death or serious injuries if it not avoided prevented CAUTION Identifies a dangerous situation that could result in minor to serious injuries if not avoided prevented NOTE Indicates property damage The product or the damage can sustain damage 1 4 2 Symbols The following symbols denote suggestions which are not safety relevant but impr...

Page 7: ...is documentation Table 3 Abbreviations Abbreviation Meaning OCE Open Core Engineering mMS 4 0 Modular Mechatronics System for Industry 4 0 Smart Device Android or iOS smart phone or tablet HMI Human Machine Interface Station One of three mMS 4 0 stations Installation All three mMS 4 0 stations together MDI Machine Data Interface CNC manual data entry ...

Page 8: ...tion is only permitted under the indicated operating conditions The mMS 4 0 training system is only intended for professional and not for private use The mMS 4 0 training system made by Bosch Rexroth has been designed and is intended for industrial power supply networks Supplying the demo system from different supply network requires additional disturbance suppression measures line filter throttle...

Page 9: ...ining system Under direct supervision after being given appropriate instructions by a instructor or trained member of staff The instructor working with the mMS 4 0 training system must be a trained specialist familiar with the electrical pneumatic and mechanical device and the mechatronics field The instructor must give clear instructions when students or participants in the training program are r...

Page 10: ...fied electrician is someone who can recognize possible hazards and implement the appropriate safety measures due to their professional training knowledge and experience as well as their understanding of the relevant conditions pertaining to the work to be done Only skilled personnel with special expertise and experience in pneumatic components are allowed to work on the pneumatic system Special kn...

Page 11: ...he manufacturer to prevent hazards to persons owing to unsuitable spare parts Adhere to the technical data and environmental conditions given in the product documentation If unsuitable products are installed or used in safety relevant applications unintended operating states may arise in the application which could cause personal injury and or property damage Therefore only use the product in safe...

Page 12: ...necting additional consumers to the mMS 4 0 training system only use ones approved by the manufacturer Only operate the mMS 4 0 training system from a supply with a functioning FI circuit breaker or protective earthing The energy cables which carry 230 V AC must not be disconnected from the drive while the system is in operation Manipulated and or non functioning safety devices and safeguards Majo...

Page 13: ... by him to carry out the work he shall in particular make sure that the underground the surface of the table has sufficient load bearing capacity is level and horizontal shall ensure compliance with accident prevention regulations UVV safety regulations of the trade associations and other in house local requirements He shall instruct his employees and or third party firm employees on possible haza...

Page 14: ...nue to be powered by electricity The training system may only be operated at a maximum pneumatic operating pressure of 5 6 bars The pressure setting is made at the factory The compressed air is switched off when an EMERGENCY STOP is actuated The maximum hydraulic operating pressure for the training system is 50 bar The pressure setting is made at the factory The hydraulic power unit is switched of...

Page 15: ... space is provided for the mMS 4 0 training system Fig 1 Space requirement in cm mMS 4 0 training system Fig 2 Space requirement in cm mMS 4 0 training system The following teaching stations are provided depending on how the mMS 4 0 training system is used Table 4 Teaching stations for an mMS 4 0 training system Work step Number of persons working on the system Number of persons working on the sys...

Page 16: ...tions and components while the system is under pressure Do not undo any plug connections while the installation remains energized De energize the mMS 4 0 training system Incorrect adjustment of the pressure relief valves and pressure switches in pneumatic and hydraulic components Damage to property The pneumatic and hydraulic components must only be operated at the stipulated pressure values Risk ...

Page 17: ...ooden boxes Designation Unit Value Dimension Length mm 2 100 Width mm 800 Height mm 1 800 Table 6 Weight of the wooden boxes Designation Unit Value Weight kg 100 Fig 3 Crate with marking The following information appears on the crate 1 Transport instructions or warning notices as required 2 Shipping code barcode 3 Delivery note in a plastic pouch 4 Printed label Gross where applicable net weight 5...

Page 18: ...duct Description The cube assembly installation comprises three stations Rack workpiece detection station Processing with pneumatic press station High rack storage station The three stations rack workpiece detection processing with pneumatic press and warehouse are arranged next to each other They are connected to each other mechanically pneumatically and electrically The cube assembly installatio...

Page 19: ...xterior 1 Main switch of station 2 Transition plug signals and emergency stop circuit 3 Connection cable 230 V AC 4 Ethernet feed through 5 Maintenance unit Control box right side exterior Identical for all stations Fig 6 Control box right side exterior 1 Ethernet feed through 2 Connection socket 230 V AC 3 Transition plug signals and emergency stop circuit 4 Compressed air feed through ...

Page 20: ...C L25 with supplied PLC software Two separation racks offer space for 10 work pieces each The placement status is monitored by microswitches A pneumatic cylinder pushes the bottom most workpiece in the stack onto a conveyor that runs it past four test stations One optical capacitative and inductive sensor each acquires the material properties with a pneumatic cylinder acquiring the contour The tes...

Page 21: ...1429162 04 16 Bosch Rexroth AG 21 68 About this product Control box Fig 8 Control box station rack 1 3 emergency stop relays 2 Programmable logic controller 8 inputs outputs 3 Switching relay 4 Fuses 5 Power supply unit 3 4 2 5 1 ...

Page 22: ...y stop relays Field bus Profibus Programmable logic controller XLC L25 with supplied PLC software The work piece is moved from the previous conveyor belt to the conveyor for this station It passes a light barrier and 2 pins are applied to it in the pinning unit Afterwards it is moved further along by the conveyor belt until the work piece is transferred into the press with the portal vacuum suctio...

Page 23: ...cessing station 1 3 emergency stop relays 2 Programmable logic controller 8 inputs outputs field line 3 Switching relay 4 Fuses 5 Power supply unit Circuit diagram for hydraulic press The circuit diagram for the press with hydraulically cylinder is shown as follows Fig 11 Hydraulic power unit circuit diagram 3 4 2 5 1 ...

Page 24: ...off depressurised circulation and activate the system pressure Afterwards the application can be switched optionally with the manually operated or electrically operated 4 3 way valve Fig 12 Hydraulic power unit set up 1 Engine with internal gear pump 2 10l oil tank 3 Pressure gage 4 Pressure relief valve 5 Electrically operated 4 2 directional control valve 6 Manual 4 3 directional control valve 7...

Page 25: ...iers Electrical supply with signal processing Main switch on left hand side of the system Connector to right hand left hand station Mains supply fuses 3 emergency stop relays Field bus Profibus SERCOS III Programmable logic controller MLC L45 with supplied PLC software The high bay warehouse provides 15 spaces The work pieces are transported by a cartesian robot to their storage locations where a ...

Page 26: ... this product Control box Fig 14 Control box high stack storage station 1 3 emergency stop relays 2 Programmable logic controller 8 inputs outputs field line 3 Switching relay 4 Mains contactors 5 Fuses 6 Power supply unit 7 Line filter 8 Drive controller 3 5 2 6 4 7 8 1 ...

Page 27: ... is empty and replaced the zero reference position is to be settled again Both axes must be moved to the position of the zero point Doin this in the program in explained in the documentation of the IndraDrive Cs The axes must be move mechanically to the right position The right position is Horizontal axis Outer left edge to edge of carriage 120mm Vertical axis Lower edge of extrusion body to upper...

Page 28: ...ght barrier downstream of the picking unit Do not remove the light barriers from ends of conveyor Contact protection for the deflectors Fig 2 Conveyor R901371451 5 2 5 Separating rack R115801073 Separating rack to house at least 10 work pieces with dimensions 50 x 50 x 25 mm LxWxH Can also hold workpieces with inserted pins Pushed out through pneumatic cylinders Monitoring of filling level height ...

Page 29: ...ating racks with workpieces proceed as follows Load aluminum cube half 50 x 50 x 25 mm into the right hand rack from above while open Load the workpiece using two fingers and guide it as you move it down Load black plastic cube half 50 x 50 x 25 mm into the left hand rack downward while open Fig 4 Sliding in workpieces ...

Page 30: ...n be arranged flexibly on either side of the conveyor R901371451 Fig 5 Picking unit R115801073 5 2 7 Sensors Sensors from left to right comprising an optical sensor R115801076 inductive sensor R115801074 pneumatic cylinder R115801075 and capacitive sensor R115801077 for determining the quality of work pieces Can be mounted flexibly on each side of the conveyor R901371451 Fig 6 Sensors ...

Page 31: ...01371451 Fig 7 Light conductor 5 2 9 Machine control panel VAM 40 R115801080 For controlling the training system With attachment system lockable for grooved plates With 30 short stroke buttons a authorization key switch a feed override dial a spindle override dial an On Off button and 1 EMERGENCY STOP button The VAM40 must be connected to ensure the EMERGENCY STOP button of the entire system is cl...

Page 32: ...ressure control valve for lowered compressed air supply with pressure gauge Pressure switch for switching off feed when air pressure is too low Electrically operated shut off valve for EMERGENCY STOP situation Fig 9 Maintenance unit 5 2 11 Light barrier R901396882 Light barrier with emitter and receiver in M12 round construction Can be mounted flexibly onto the conveyor R901371451 Fig 10 Light bar...

Page 33: ...and a slide in cylinder For attachment onto the conveyor R901371451 Pins can be loaded easily from the top Filling level is monitored by sensors Fig 11 Pinning unit Replenishing pins To load the pinning unit with pins proceed as follows Add a sufficient quantity of pins to the plexiglas tubes on the left and right Make sure to continue reloading the pins and that sufficient numbers are present Fig...

Page 34: ...oduct 5 2 13 Portal R115701064 Portal for transporting work pieces in the pick and place application Slotted cylinder for transporting along the Y axis piston rod cylinder for conveying along the Z axis Vacuum suction gripper with Venturi nozzle acting as a gripper Fig 13 Portal ...

Page 35: ...0 x 50 x 25 mm LxWxH Cylinder with throttle check valves for pushing the work piece in and out Fig 14 Press pneumatic hydraulic 5 2 15 High stack storage R115701074 High stack storage for storing removal of work pieces Each of the three 3 rows can be used to store 5 work pieces 2 axis warehouse robot with servo motors Pneumatic rotary module cylinder and gripper Fig 15 High rack storages ...

Page 36: ... operating temperature C 20 Max operating temperature C 60 Place of installation Closed room Ambient temperature C 5 to 55 Max relative air humidity 90 at 20 C Max installation height m 1000 above sea level Pneumatics Max operating pressure bar 6 Min operating pressure bar 4 Supply Connection operating voltage V 115 230 AC Control voltage V 24 DC Frequency Hz 50 60 Nominal power kW Fuse A 16 Prote...

Page 37: ... system are also indicated here In order to identify the mMS 4 0 training system e g to order spare parts the name plate needs the following information on it 1 Material number 2 Material short text 3 Optional characteristic value of output 1 e g max operating pressure 50 bar 4 Optional characteristic value of output 2 e g displacement 1 6 cm U 5 Production state 6 Optional CE mark 7 Date of produ...

Page 38: ...the event of a risk to person or machine switch off the mMS 4 0 training system with the button Actuating the EMERGENCY STOP button interrupts the power supply All work procedures are stopped right away and any hazardous control currents servo drive and thus all movements are switched off There is a local EMERGENCY STOP circuit for the individual station and a global EMERGENCY STOP circuit for the...

Page 39: ...le step mode These are used to control the system They comprise the start stop and reset buttons These buttons can also be used in manual mode to control all actuators Use the Start with homing function button to initiate the programmed motion sequences The Stop button stops it again Use the Reset button to start the three EMERGENCY STOP relays The Reset button must be pressed before each start Th...

Page 40: ...8 Control elements in the training system small control panel VCP 1 HMI control panel 2 Snap In attachment system 3 Contact protected 4mm lab connector 24 V DC 0 V functional earth For control and monitoring of the workflow in a station from a touchscreen Attachment system for grooved plates with 8 mm grooves 25 mm grid Contact protected 4mm lab connector 24 V DC 0 V functional earth 1 HMI control...

Page 41: ... the mMS 4 0 training system down from the pallet and remove from the crate Carefully remove the cable ties and wire ties and dispose of them appropriately Dispose of the pallet and wooden box properly or store appropriately for subsequent use Any transport damage and defects must be noted right away and reported in a written damage report Required tool CAUTION Risk that the training system may fa...

Page 42: ...ing cables between the stations Move the training system to the new place of installation Move the mMS 4 0 training system on a fixed and level base Lock the parking brakes on the castors Connect up the electrical and pneumatic supplies to the system The mMS 4 0 training system can be put into storage or connected to the energy supply again Whenever putting the system down during transportation an...

Page 43: ...ng system from falling using belts or plastic ties You can use the original transport crates Protect each station of the mMS 4 0 training system against moisture Transport the pallet with the mMS 4 0 training system with a fork lift truck or similar Move the mMS 4 0 training system on a fixed and level base At the predesignated position carefully lift each station of the mMS 4 0 training system ou...

Page 44: ...erature C 55 Relative air humidity 25 70 Max installation height m 1000 above sea level Requirements for storing the stations of the training system Remove attachment parts and device sets that are not needed beforehand Remove the connecting cables Put the stations of the mMS 4 0 into storage as follows Place the stations of the training system onto a pallet Protect the training system from dust a...

Page 45: ... specifications see Fig 1 Space requirement in cm Any possible attachment parts should be taken into account Check the levelness of the installation surface Make sure that an electrical connection is present Make sure there is sufficient lighting at the place of installation The following must be taken into account during installation Check alignment of the mMS 4 0 training system at the place of ...

Page 46: ...gs whether any of the parts can be damaged whether all of the attachment parts are properly connected Fig 19 Pneumatic diagram profile trolley Connect each station s maintenance unit to the air supply which is on the extreme left Next connect the stations together by making a connection between the shutoff valve on each station with the maintenance unit of the next station Fig 20 mMS 4 0 installat...

Page 47: ...no cables are damaged The connection cables are installed in a way that prevents it from being crushed driven over kinked stressed or covered The electrical control box cannot be opened and tampered with No additional consumers are connected Check the electrical fuse protection is correct and sufficient Connect the mains plug to the first and last station to the power supply of the customer side s...

Page 48: ...upply hose to the maintenance unit Fig 21 Compressed air feed connection CAUTION Danger caused by lashing hoses Risk of injurycaused by compressed air Before switching on the system make sure all compressed air hoses have been depressurized Do not connect pneumatic hoses under pressure CAUTION Dangerous electrical voltage Death or serious injury Extracting current from the mains supply is prohibit...

Page 49: ...tion between two stations Setting the pressure reducer Notice The pressure reducer is set to a pressure of 6 bar at the factory If the pressure reducer needs to be re adjusted proceed as follows Pull the cap upwards Set the required pressure by turning the cap Press the cap downwards Do not adjust the system pressure The pressure switch for the emergency stop circuit is set to this 6 bar system pr...

Page 50: ...it must be pluggable on both sides If not plug the terminating plug socket onto the transfer module and screw in firmly The emergency stop circuit of the station is not closed until the terminating plug socket is plugged into the transfer connector Fig 23 Terminating connector plugged in The power supply connector is next to the main switch It must be connected to the electricity cable with an ear...

Page 51: ...for signals and emergency stop circuit as for the individual stations If not plug the terminating connector socket into the transfer module The emergency stop circuit of the installation is not closed until the terminating connector socket are plugged into the transfer connector and the stations are connected to each other Fig 25 Connecting the transfer and terminating connectors The power supply ...

Page 52: ...g unit is filled with workpieces Each time the exercise is set up examine the machine for Functional reliability Safety from injury Depending on the operating state note the following before switching it on Make sure the mains plug is plugged in for the power supply of the mMS 4 0 training system Where necessary unlock the EMERGENCY STOP button 9 6 Check the EMERGENCY STOP circuit A manual check o...

Page 53: ... operating panel to position 3 The workflow in the installation is the same as in automatic mode Every logical step must be passed on with the Start button Fig 27 Switching positions 0 3 of the authorization key switch Automatic mode Authorization key switches of the machine operating panel to position 2 The PLC program is processed automatically Work pieces are conveyed from right to left in the ...

Page 54: ...h of the machine operating panel to position 3 The buttons to be pressed flash Actuate the reset button Connect the Power on output Station 3 Press the Start button Press the Start button again after each logical step The PLC program runs automatically with each press of the Start button the work pieces must be removed by hand from the end of the conveyor and the ramp After a cycle has been run th...

Page 55: ... next station is possible Extended Operation visualization via a VCP touchpad integrating RFID and safety technology To launch the existing programs at each station in automatic mode proceed as follows Ensure that the EMERGENCY STOP button is unlocked The PLC must display RUN on the display Choose automatic mode using the authorization key switch of the machine operating panel to position 2 The bu...

Page 56: ...gh bay warehouse of the station on already existing pieces proceed as follows Choose homing mode using the authorization key switch of the machine operating panel to position 1 Actuate the start button System in home position Actuate start and stop button for approx 10 sec High bay warehouse checks stock for available work pieces and stores them New work pieces will be put to free storage places 1...

Page 57: ...OFF Connects the line to the drives Only used for CNC application All stations Only used for station 3 CONVEYOR BELT In manual mode the conveyor belt can be moved right and left All stations JOG JOG JOG RAPID In CNC mode the linear axes can be moved individually also quickly JOG RAPID Only used for CNC application All stations Only used for station 3 Separator rack 1 Separator rack 2 Issue per wor...

Page 58: ...d version extends press cylinder Only in Hand mode Station 2 workpiece processing Axis Axis X X High rack storage Moves the X axis service axis Station 3 workpiece to stock Axis Axis Y Y High rack storage Moves the Y axis service axis Station 3 workpiece to stock Cylinder Retract Z Cylinder Retract Z High rack storage Moves the Z axis pneumatic cylinder Station 3 workpiece to stock Gripper Turn To...

Page 59: ...1K3 do not light up The emergency stop circuit is open locally at the station to the left of this station Checks the left station to see whether the pressure switch has enough air pressure that an emergency stop is not pressed and all connecting cables are connected The Supply K1 and K2 LEDs on the emergency stop relays 51K2 and 51K3 do not light up The emergency stop circuit is open at all statio...

Page 60: ...he fault has been removed 1 Actuate the reset button The reset button is lit If the reset pushbutton continues to flash this means there is a fault 2 Remedy the fault then go to Step 1 3 Press the Start button Process can be continued Restarting after a power failure Remove all cubes and cube halves from the stations Empty the high stack storage Re establish the voltage The programmable logic cont...

Page 61: ...c parts with a lightweight damp cloth Only use water and a mild cleaning agent without chemical additives Never use solvents or aggressive cleaning agents Before using a cleaning agent examine the usage instructions and possible hazards in the user information and DIN safety data sheet Never blow out the training system with compressed air as sensors and valves of the functional assemblies may get...

Page 62: ...tem Clean and keep the working surfaces free Remove parts lying around When What Where Comments Weekly Overall training system Inspect electrical connection cables and lines for visible damage friction marks cracks cuts Have damage rectified by the responsible qualified electrician right away Connection elements Inspect electrical devices control boxes and switches buttons for visible damage crack...

Page 63: ... Possible breakdown High repair costs Observe the following instructions if anomalies faults and wear is identified during operation or during the inspection Immediately place the training system out of service Find the causes of the fault and fix the defects Replace the damaged part Do not put the mMS 4 0 training system back into operation where unsafe to do so ...

Page 64: ...terials 1 set open end wrench 1 set hexagon socket wrench 1 set screwdriver When What Where Comments Daily prior to each use EMERGENCY STOP button Check function Effect of sampling Does not start up when locked In the event of malfunction Place the installation out of service Notify a qualified electrician When What Where Comments Weekly Electronics Check all functions Fuses FI switches sockets bu...

Page 65: ...no risk to health falling slipping due to moisture etc Have a skilled person check the following after rectification of the wear and before the machine is put into operation Has the work been carried out properly Is the mMS 4 0 training system ready for operation without impairment 14 Disposal The training system is made of materials which are recyclable and can be reused Specialized firms cab rec...

Page 66: ...66 68 Bosch Rexroth AG Training system mMS 4 0 R901429162 04 16 Declaration of conformity 15 Declaration of conformity ...

Page 67: ......

Page 68: ...e Printed in Germany Mat No R901429162 Bosch Rexroth AG Drive Control Academy Bahnhofplatz 2 D 97070 Würzburg Germany Phone 09352 18 1920 Fax 09352 18 6882 trainingsystems boschrexroth de www boschrexroth com training ...

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