Open Core Engineering : More efficient engineering and new degrees of freedom

On Sep 1, 2014

Machinery manufacturers and users require more engineering efficiency for a faster time to market and future-proof automation solutions in order to protect their investments. At the same time, they are looking for possibilities to customize their machines economically with new automation ideas for machine processes and functionalities to meet the needs of individual customers. This is how they can set themselves apart from the competition. As a result, the wish for more flexibility to implement these customized concepts rounds out the list of new requirements.

Rexroth meets these requirements with Open Core Engineering. Open Core Engineering represents Rexroth’s comprehensive package of solutions that increase engineering efficiency along the entire value stream for all drive and control technologies. Users benefit from accelerated engineering at lower cost and increased future-readiness based on open industry standards. At the same time, Open Core Engineering provides new degrees of freedom for customization and the flexibility for various programming languages and device classes. With Open Core Engineering, Rexroth helps machinery manufacturers focus on their core competency – the machine process.

Open Core Engineering uses the Open Core Interface to connect previous engineering, which is based on the newest IEC standards. As a bridge between two separate environments, the Open Core Interface allows the integration of various device platforms into integrated automation architectures.

Engineering efficiency
Open Core Engineering accelerates engineering efficiency decisively with software tools, function packages and multi-technology solutions. Open Core Engineering makes contributions at every step, from project planning to programming and parameterization, commissioning to service. The engineering framework IndraWorks provides all required tools for the engineering of all technologies. In complex projects and tasks, innovative function packages accelerate the work processes. For example, the “Generic Application Template” (GAT) creates the optimal requirements for the development of modular machine software.

Based on templates, GAT uses wizard support to automatically generate an executable machine program to match the specifications of the project planner, thereby significantly increasing engineering speed. With team engineering and the linking of version control systems, several engineers can work very efficiently at the same time on the project planning of machines and entire systems.

Interfaces such as the Automation Interface further increase engineering efficiency. With the Automation Interface, engineering tasks can be carried out in an automated manner according to a script, and interfaces to eCAD systems. Open Core Engineering replaces time-consuming programming of complex machine processes through simple parameterization of customized technological functions. The FlexProfile example: with this function, machinery manufacturers can easily fulfill their customers’ requests for more flexibility and retrofits at the push of a button. Based on analytical motion profiles, FlexProfile automatically adapts all drive movements to changed parameters in the production process.

Future-proof solutions
Choosing an automation system means a big investment for machinery manufacturers. Open Core Engineering protects this investment through the consistent use of open standards. Open Core Engineering uses the IEC 61131-3 and PLCopen standards for open PLC programming. The automation bus Sercos can be homogeneously integrated into all solutions to this end. With its high performance, application flexibility and the number of available field devices on the market, a highly functional and more future-ready Ethernet field bus is available as the backbone for state- of-the-art machine concepts. Open Core Engineering continues to integrate the newest standards such as FDT/DTM for tool integration or OPC UA for M2M communication.

Through multi-Ethernet interfaces, Rexroth drives can also be integrated into heterogeneous automation topologies which allows machinery manufacturers to create customized versions with regionally preferred communication systems without additional effort. Thanks to the library concept in engineering and the scalability of the automation portfolio, machinery manufacturers can reuse entire programs or individual program modules on larger or smaller versions of their machines with a control unit that complies with the requirements. They can place the corresponding content into the new project via drag and drop, hence saving time. Open Core Engineering safeguards major investments in modern, software-based solutions, today and in the future.

Individualization
In the past, applications requiring access to all functions of the control core, could only be accomplished by the drive manufacturer. With the Open Core Interface, Rexroth opens the door into a new world of automation and offers machinery manufacturers entirely new degrees of freedom, with room for individual solutions. In order to increase productivity, increasing amounts of information from various sources at the production and control system level must be exchanged quickly. By adapting Ethernet-based communication for fast production processes and integrating it into automation systems, as happened with Sercos, the data network stemming from the IT environment has become the current backbone of modern machines.

The Open Core Interface also expands the software tools and function packages of Open Core Engineering and creates additional degrees of freedom in the engineering of machines and systems. Rexroth opens its drives down to the core and provides methods for economically creating individual functions oneself. With the Open Core Interface, applications based on high-level programming languages on external devices receive flexible access to all control and drive functions down to the core. Applications become executable based on C/C++ directly in the real-time environment of the drives. Machinery manufacturers can use the Open Core Interface to implement firmware analytical motion profiles, FlexProfile automatically adapts all drive movements to changed parameters in the production process.

Open Core Engineering uses the IEC 61131-3 and PLCopen standards for open PLC programming. The automation bus Sercos can be homogeneously integrated into all solutions to this end. With its high performance, application flexibility and the number of available field devices on the market, a highly functional and more future-ready Ethernet field bus is available as the backbone for state- of-the-art machine concepts. Open Core Engineering continues to integrate the newest standards such as FDT/DTM for tool integration or OPC UA for M2M communication. Through multi-Ethernet interfaces, Rexroth drives can also be integrated into heterogeneous automation topologies—which allows machinery manufacturers to create customized versions with regionally preferred communication systems without additional effort.

Thanks to the library concept in engineering and the scalability of the automation portfolio, machinery manufacturers can reuse entire programs or individual program modules on larger or smaller versions of their machines with a control unit that complies with the requirements. They can place the corresponding content into the new project via drag and drop, hence saving time. Open Core Engineering safeguards major investments in modern, software-based solutions, today and in the future.

In order to increase productivity, increasing amounts of information from various sources at the production and control system level must be exchanged quickly. By adapting Ethernet-based communication for fast production processes and integrating it into automation systems, as happened with Sercos, the data network stemming from the IT environment has become the current backbone of modern machines.

The Open Core Interface also expands the software tools and function packages of Open Core Engineering and creates additional degrees of freedom in the engineering of machines and systems. Rexroth opens its drives down to the core and provides methods for economically creating individual functions oneself. With the Open Core Interface, applications based on high-level programming languages on external devices receive flexible access to all control and drive functions down to the core. Applications become executable based on C/C++ directly in the real-time environment of the drives. Machinery manufacturers can use the Open Core Interface to implement firmware expansions of the Rexroth motion logic drives by themselves.

Flexibility
The penetration of smart devices into the consumer world has also opened up new communication channels between humans and machines. In the future, intelligent control systems will adapt even more easily to human communication, thereby making interaction at the user level faster, more intuitive, more intercultural and more flexible.

The Open Core Interface is already turning such innovative machine concepts into reality. The wide support for open programming and data interfaces in the IT world enables a high degree of flexibility in the selection of programming languages and device platforms. Hence, the user is free to choose between C/C++, C# (.NET), Visual Basic, VBA (Office), LabVIEW G, Objective-C, Java as well as all programming environments that support the integration of Microsoft COM libraries.

The Open Core Interface supports Apple® iOS and Google® AndroidTM, currently the two most important operating systems for smart devices such as smartphones and tablets. Machinery manufacturers can therefore implement native apps for Apple iPhones®, iPads® or Google Android smartphones and tablets. Users can simultaneously connect to several control units or access a control unit from various user applications at the same time.

With the Operation App for Handling you operate a machine using tablet PCs. Setting up and commissioning the system is possible via functions for teaching, jogging and referencing. There exist manual functions to execute user specific switching functions of the system. Machine specific programs can be selected, started, stopped and debugged. With maintenance functions for linear systems the cycles are calculated in which the lubricants are to be renewed or topped and warnings are displayed. All these functions can also be simulated, so this app can also be used to show the functionality without a connected control.

Apps for smart devices also increase the efficiency of maintenance work in the production arena. Unlike in the past, the user needs no special consoles with a physical connection to the control unit. For example, a technician can simply use his/her smart device to scan a QR code on the machine a QR code that contains the access data to the control unit. The app immediately provides the user with wireless access to this control unit and allows him or her to call up all diagnostic data. With the appropriate infrastructure and authorization, diagnoses can be performed from any desired site. In the event of a malfunction, for example, the control unit can send error messages directly to the smart device per SMS or email, and allow the technician to access the control unit directly for remote troubleshooting.

For commissioning, diagnosis and operation, in the long term, smart devices will therefore replace the HMI devices that were necessary in the past. For example, users will be able to use a tablet PC to operate several machines, which in turn no longer need their own dedicated HMI devices.

Conclusion
Open Core Engineering combines a high degree of engineering efficiency and future-readiness with same degrees of freedom available with modern high-level languages and IT-based technologies in new production machines. This combination enables the customization of machine concepts and increases the application’s flexibility.

Engineering Network – the community of Open Core Engineering for developers

Open Core Engineering and the Open Core Interface technology provide the basis for a variety of new solutions and innovations. To implement fast product ideas, specific questions of programming must be resolved quickly. To do this, the Engineering Network of Rexroth offers users a modern information portal “from developer to developer”. In a discussion forum, you will find answers to general or application-specific topics related to tools, functions and interfaces. Practice-oriented example programs and online documentation to Open Core Interface simplify the entry and provide valuable clues in the different high-level language programming. Open Core Engineering and the Engineering Network allow for efficient engineering and the rapid implementation of innovative products.

To learn more, please visit www.boschrexroth.com/network

Open Core Engineering – outstanding technology builds bridges between
automation and the IT world

As the first pure software solution, Open Core Engineering from Rexroth was awarded the prestigious HERMES AWARD technology prize in 2013. Open Core Engineering combines the previously separate worlds of PLC and IT with a comprehensive range of solutions comprising of open standards, software tools, function toolkits and the Open Core Interface. Rexroth has opened the control core to enhanced access. Machine manufacturers can now create their own individual functions in a variety of high-level languages and operating systems that run parallel to the firmware directly on the control or on external devices. This enables the machine manufacturer to, for example, fully integrate smart devices into the automation system and use their operating functions.

To learn more, please visit www.boschrexroth.com/OCE

For more information
Web: www.boschrexroth.com

Bosch Rexroth (India) Pvt Ltd