Richt- Anschneidemaschine

Success Story

Redesign of a dri­ve and con­trol system

Complete technical new development of a machine control for a high-precision lining and cutting machine for thin wires.
Pre­ci­sion­Cut MJCE


In 2006 we devel­oped a dri­ve and con­trol sys­tem for a high-pre­ci­sion Wire Cut­ting machine for the com­pa­ny Jouh­sen Bünd­gens Maschi­nen­bau GmbH. The con­trol based on a SIMAT­IC-S7-300-SPS and ser­vo reg­u­la­tors of ETEL, that are par­tic­u­lar­ly dis­tin­guished by a quick and pre­cise posi­tion control.


Unfor­tu­nate­ly the sales of these Etel-con­troller was mean­while stopped. New dri­ve reg­u­la­tors have to be found, that on the one hand offer a com­pa­ra­ble con­troller per­for­mance and on the oth­er hand full­fil the demands of the present safe­ty stan­dards in dri­ve engi­neer­ing. That can­not be man­aged in a sim­ple way.

Mas­ter­ly approach

M. Eng. Adri­an Majew­s­ki, at that time still study­ing at the Fach­hochschule Aachen, took that chal­lenge as top­ic of his mas­ter the­sis. He analysed the advan­tages and dis­ad­van­tages of the con­troller by a state con­troller, as already used at Etel, and the usu­al cas­cade con­troller with speed ser­vo con­trol of oth­er sup­pli­ers. The excel­lent pre­sen­ta­tion of the­o­ret­i­cal rela­tions of the con­trolled sys­tem and the dif­fer­ent con­trol prin­ci­ples as well as the sim­u­la­tion in Lab­VIEW and the suc­cess­ful analy­sis of suit­abil­i­ty of some reg­u­la­tors of dif­fer­ent sup­pli­ers bestowed the top grade 1.0 for his the­sis. We would like to say thank you to Prof. Dr.-Ing. Ulrich Hoff­mann for his excel­lent assis­tance. M. Eng. Adri­an Majew­s­ki is mean­while one of our staff.

Our solu­tion

We decid­ed in favor of the ser­vo reg­u­la­tor HCS01.1E of Bosch-Rexroth. This reg­u­la­tor dis­pos­es of a quick posi­tion and speed con­trol as well as of the inte­grat­ed safe­ty tech­nol­o­gy „Safe Motion“.

Ser­vo reg­u­la­tor Rexroth HCS01.1E

The syn­chro­ni­sa­tion of the dri­ves is done by the new Indra­Con­trol XM21 of Bosch-Rexroth. This Motion-con­trol is able to trig­ger all four ser­vo motors via SER­COS III – Bus. Fur­ther­more, all oth­er func­tions of the machine like the count­ing of the prod­ucts, the acti­va­tion of the cen­tralised lubri­ca­tion sys­tem are tak­en over by this control.

Rexroth XM21

The con­trol sys­tem is com­plet­ed by the use of the also new Safe­L­og­ic exten­sion XFE01.1 of Bosch-Rexroth. By this all safe­ty rel­e­vant func­tions like emer­gency stop­ping or safe stop­ping in case of opened machine cov­er can be pro­grammed and val­i­dat­ed. The trans­fer of safe sig­nals to the ser­vo reg­u­la­tor is also done by SER­COS-III-Bus by means of the CSos-pro­to­col „CIP safe­ty on ser­cos“. The oper­at­ing of the machine is done by a 7“ – touch pan­el, VR2107 of Bosch-Rexroth. All machine para­me­ters can be insert­ed there in a com­fort­able way. Oper­at­ing data and fault indi­ca­tions are displayed.


The soft­ware of the machine con­trol, the para­me­ter cal­cu­la­tion and the dri­ve syn­chro­ni­sa­tion were pre­pared and test­ed in our lab­o­ra­to­ry before real­i­sa­tion of the machine by using an exper­i­men­tal set-up.

Exper­i­men­tal set-up with lin­ear drive

The cir­cuit dia­grams were drawn and the switch­board cab­i­net was built by our elec­tri­cal con­struc­tion team as well. After the com­pa­ny Jouh­sen Bünd­gens Maschi­nen­bau GmbH had set up the machine mecani­cal­ly we mount­ed the cab­i­net and con­nect­ed all elec­tri­cal and elec­tron­ic com­po­nents. The start­up of the dri­ve and con­trol tech­nol­o­gy fol­lowed. Togeth­er with our cus­tomer we sub­se­quent­ly val­i­dat­ed the process and the length tol­er­ances of the prod­ucts successfully.


Sub­se­quent­ly the machine was accept­ed by the end cus­tomer and was deliv­ered in time.

Contact Person
QA Mitarbeiter Thomas Peukmann
Dipl.-Ing. Thomas Peukmann
Software Development
Specializations: data communication, development of high-level languages, databases, automation and servo drive technology
customer profile

Function of the equipment

The equipment adjusts and cuts wires with a diameter of 0,2 mm to 1,5 mm, in lengths of 4 mm to 1 m. The lenghts tolerance in case of cuts up to 35 mm only comes to ±0,03 mm at a number of cycles up to 800 cuts per minute. An absolute challenge for the servo regulators.

The control of all movements necessary for the handling is realized by three complete-synchronized maintenance-free linear motors and one torque motor. The wire feeder works contin-uously with constant speed. The cutting of the wire is done „flying“. The cutting lenght and the machine capacity are adjusta-ble at will via touch panel.

The following supervising func-tions are realized: wire end, wire diameter, wire bend, wire lubrication, compressed air, centralised lubrication system, counter for operating hours and production quantity.