Bonfiglioli Active Cube

Bonfiglioli frequency inverter Active Cube series: the drive designed for all industrial applications

Bonfiglioli Active Cube series are specifically designed for automation machines. Allowing an extensive control of the motor, these series are fitting a wide range of industrial sectors. The Active Cube includes many features making it suitable for universal use, both as an effective “System drive”, and also as a “Servo drive”. Several enhanced functionalities are embedded in the Active Cube including Cyclic Synchronous Positioning (CSP) mode, brake control and encoder evaluation. Moreover, the new single axis for the control of servo motors, induction motors and synchronous reluctance motors, delivers high dynamic response, high performance and application versatility. Thanks to various communication protocols, the Active Cube offers the broadest connectivity with the most advanced control technology. Active Cube benefits from the full compatibility with the extensive program of Bonfiglioli synchronous servomotors and accessories (BMD series), which together provide the possibility of a total Bonfiglioli servo system. The combination of Active Cube and Bonfiglioli Synchronous Reluctance motor (BSR) offers new solutions for application demands regarding efficiency (IE4) and power density.

Option modules

Active Cube is designed to give the highest flexibility in drive hardware to suit every control requirement. Machine designers can select from an extensive range of possible expansion hardware modules that can be fitted directly into the 3 available slots on the standard Active Cube unit. Mounting and connection is fast and easy thanks to onboard fastening devices. Using option modules, Active Cube features and integration ability can be greatly expanded: the number of possible hardware configurations offers solutions for a wide variety of requirements and applications. Build the best hardware configuration of Active Cube for your machine!

Interface module
Connection of optional control unit KP500, serial interface adapter KP232, or the control unit remotization cable for accessory KPCMK

CM communication module
Connection panel for various communication protocols:
- CM-232, RS232 interface
- CM-485, RS485 interface
- CM-PDP V1, Profibus-DP interface
- CM-CAN, CANopen interface
- CM-DEV, Devicenet interface
- CM-EtherCAT®, EtherCAT® interface
- CM-ProfiNet, Profinet interface
- CM-VABus/TCP, Ethernet VA BUS TCP interface
- Other protocols on request

EM expansion module
Connection panel for adaptation of control inputs and outputs to the various applications on the basis of specific customer requirements:
- EM-IO, analog and digital inputs and outputs, available in 4 variants
- EM-ENC, speed sensor interface, frequency output and system bus, available in 5 variants
- EM-RES, resolver interface, frequency output and system bus, available in 3 variants
- EM-SYS, system bus for Systembus communication (on request, system bus combined with CM-CAN communication module)
- EM-ABS, absolute encoder module
- Other customised modules available on request

Control unit KP500

The KP500 control unit is equipped with a Parameters Copy function that allows the< user to upload parametric values from the inverter to a non-volatile memory installed in the KP500 device, allowing the same values to be subsequently downloaded to another inverter. The control unit makes it possible to set up the inverter for specific applications and allows the display of the service values of physical and electrical parameters. The inverter can also be controlled from the control unit for start/stop and frequency reference increase/decrease commands. Since the control unit is not essential for inverter operation it can be connected when the user considers it useful or necessary.

Engineering software

VPlus is a PC Windows-based engineering software tool that guides industrial automation designers through the steps towards the definition of the optimal configuration of Active Cube drives. Communication between VPlus and the drive is based on standard serial communication either through KP232, CM232, CM-485 or CM-VATCP interface. With VPlus a wide set of activities on Active Cube are possible: monitoring, diagnosis, inverter set up and parameter access, software customization, technology functions management, motor setup, commissioning, Active Cube oscilloscope graphic presentation.

Safe torque off (STO)

The safety function “Safe Torque Off” (STO) with the safety integrity level SIL 2 (see DIN EN 61508 and DIN IEC 61800-5-2) is implemented into standard Active Cube inverter range. The drive feature helps overall automation system to achieve “Safe Stop“ category 3, according to DIN EN 954-1. Thanks to STO function, energy supply from frequency inverter to motor is safely disabled.
Deactivation of the inverter supply is carried out via two switch off paths in no-signal current mode, thus performing redundant switch off control. Continuous monitoring tests are done by the inverter to detect possible control failures. “Safe Torque Off“ function greatly improves safety level of your automation system without the need of additional components.

Motion functions

Motion blocks
The “elemental software unit” of motion control in Active Cube is the “Motion Block”. One “Motion Block” completely outlines one point-to-point positioning step, including:
- target position
- speed
- acceleration
- deceleration
- ramps
- delays
Built-in motion control functions allow to combine up to 32 motion blocks in a conditional sequence, to program even most sophisticated point-to-point motion profiles.

Homing
A comprehensive set of homing functions, according to CANOpen DSP 4.02 standard is available in Active Cube. 36 different homing modes can be used to answer to the motion requirements of a wide range of machines. Homing search can be triggered by either digital input (e.g. hardware limit switches), or control word (if Fieldbus is used), or as an automatic procedure before first positioning sequence.

Rotary table function
When controlling a rotary working table target position is calculated and reached within one revolution. Rotary table function enables the drive to detect the shortest way to reach the desired angular position, considering the shaft revolutions needed to do a complete table rotation. Best sense of rotation, clockwise or anti-clockwise can also be detected, in order to minimize travel time and distance.

Jog and teach-in functions
In “jog mode” drive can be freely moved at fixed speed in both directions through the “manual” set of assigned digital inputs. During jog mode, several target positions can approached and saved through Teach-in function: when desired position is reached, teach-in function allows to take over actual position in the active travel record as target position.

Servo package

When using Active Cube in servo applications, you can get the best out of the drive when applied together with Bonfiglioli servomotors.
Active Cube and Bonfiglioli servomotors were, in fact, designed to exploit at best reciprocal synergies thus forming a servo “package”, able to provide significant advantages to users both in terms of enhanced performance and in terms of reduced setup time.
The Bonfiglioli servo system benefits from several specific solutions, involving the 2 product series:
- Active Cube has a preloaded parameter profile of Bonfiglioli servomotors
- Wiring the drive to motor is easier thanks to the availability of factory pre-wired cables and connectors
- “Motion“ functions are readily available