• HydroXpert PLC Function Block
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Hydraulic Technology Functions

Revolutionizing Hydraulic System Performance with Cutting-Edge Technology Functions

HydroXpert: Multi-Axis Full-Featured Solution with Advanced Coordination for Hydraulic Axes

  • Compatible with various PLC Platforms
  • Hydraulic Axis Position,Speed and Acceleration Control
  • Pressure/Force Control
  • Overload Protection
  • Multi Axis Compatibility
  • Synchronization Control
  • Leveling/Tilt Control

Achieve seamless multi-axis synchronization, enhanced safety, and superior control in your hydraulic systems with our cutting-edge technology function, HydroXpert. By integrating the proven, high-precision capabilities of HydroXGuard with the advanced multi-axis coordination provided by HydroSynchronizer, HydroXpert empowers you to manage up to five hydraulic axes in unison. This unified solution ensures precise alignment, stable motion, and automatic maintenance of defined inclinations—all tailored to your application’s needs.

Multi-Axis Position and Speed Control with Overload Protection

  • Coordinated Positioning: Precisely control the position and speed of multiple hydraulic axes simultaneously, using defined parameters for velocity, acceleration, and jerk across each axis.
  • System-Wide Overload Prevention: Apply maximum force limits to each axis, safeguarding against overloads and extending component life.
  • Perfect for Complex Tasks: Ideal for operations demanding synchronized motion across multiple axes.

Ideal Applications for HydroXpert:

  • Multi-axis forming and bending machines
  • Synchronized press lines
  • Large-scale material handling systems

By consolidating advanced motion control, robust overload protection, and precise multi-axis synchronization into one comprehensive solution, HydroXpert enables you to achieve unmatched accuracy, reliability, and efficiency across your most demanding hydraulic applications.

Why Choose HydroXpert?

Universal PLC Integration: Free yourself from the constraints of specialized technology CPUs. HydroXpert runs on widely used PLC platforms, including Siemens S7, Siemens TIA Portal, Rockwell Studio AIO, Rockwell RSLogix 5000, Rexroth IndraWorks, B&R Automation Studio, and Beckhoff TwinCAT, ensuring high performance across different environments.

Broad Compatibility with Hydraulic Axis Types: Each individual HydroXGuard within the HydroXpert framework is easy to parameterize, compatible with various hydraulic configurations, and suited for linear servo or proportional valves.

Easy Integration into Existing Systems: Expand and enhance your current automation setup without extensive re-engineering. HydroXpert’s function blocks can be quickly integrated into your existing PLC programs, reducing setup time and streamlining commissioning.

Closed and Open-Loop Flexibility: Benefit from both closed and open-loop control strategies for unparalleled Stability and precision . 

Advanced Trajectory Planning for Each Axis: Just like HydroXGuard, HydroXpert incorporates a sophisticated trajectory generator with trapezoidal acceleration profiles. Each axis receives an optimal motion plan, resulting in smooth, precise positioning.

Built-In Overload Protection for All Axes: Safeguard your machinery against damaging force overshoots. The integrated overload protection ensures that none of the synchronized axes exceed pre-set force limits.

User-Friendly Commissioning and Parameterization: Comprehensive I/O documentation, detailed examples, and intuitive configuration tools make setting up and tuning HydroXpert straightforward.

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Function Description 

The HydroXpert function integrates the capabilities of two specialized PLC function blocks—HydroXGuard and HydroSynchronizer—to deliver advanced, synchronized hydraulic motion control across multiple axes. This combined solution is ideal for complex applications where precise coordination of up to five individual hydraulic axes is essential.

HydroSynchronizer serves as the central coordinator, calculating up to five target position values and up to five supplementary control signals. These supplementary signals are specifically designed to be connected to the respective HydroXGuard blocks managing each axis. By providing these control inputs, HydroSynchronizer ensures that every axis, under the governance of its dedicated HydroXGuard controller, maintains a predefined inclination or positional relationship set by the user.

HydroXGuard, as the per-axis control component, manages advanced motion or force regulation for each hydraulic axis. With the superimposed control signals from HydroSynchronizer, it can precisely follow the computed trajectory, meeting the user-defined performance criteria for both position and force.

Together, the HydroXpert framework enables:

  • Multi-Axis Coordination: Seamless synchronization of up to five hydraulic axes, each guided by its own HydroXGuard.
  • Flexible Control Inputs: Integration of dynamically computed supplementary control signals (SupImpCtrl) to refine motion profiles.
  • Consistent Inclination Maintenance: Automatic adjustment of individual axes to uphold the specified positional relationship or inclination.
  • User-Defined Customization: Adaptation to a wide range of hydraulic motion requirements, with scalable control parameters for all axes involved.

By uniting the precision and stability of HydroXGuard control with the synchronized trajectory generation and coordination capabilities of HydroSynchronizer, HydroXpert delivers a comprehensive, robust, and fully customizable solution for multi-axis hydraulic control systems.

 

Block Diagram

HydroSynchronizer Input Description 

This input enables or disables the function block. When EnbIn is set to False, the block stops responding to input changes. The resulting behavior of the outputs in this state is detailed in Table 1.

EnbOut TgtPosOut SynchCtrlOut
EnbIn = False False Each element reflects the actual position of the corresponding axis 0.0
Enb = True true Calculated based on the TgtPos and SetPntTilt Calculated by the Synchron controller
Table 1: Output signals with the different states of EnbIn input

This parameter specifies the maximum possible value for the SynchCtrlOut output. It uses the same unit of measurement as TgtPos.

This parameter specifies the minimum possible value for the SynchCtrlOut output. It uses the same unit of measurement as TgtPos.

Note:
For optimal performance, it’s recommended to choose symmetric values for MaxOut and MinOut (e.g., MaxOut = +X and MinOut = -X). This symmetrical range allows the internal synchronization controller to operate more consistently and effectively.

This input specifies a common position target for all hydraulic axes, and it can be provided in various units (e.g., micrometers, millimeters, centimeters, or meters).

  • Any change in the TgtPos value triggers a new movement of the hydraulic axes.
  • If TgtPos is changed during an ongoing movement, the new movement will only start after the Busy signal for all axes has returned to False, indicating that the previous movement has completed.

For more details on how TgtPos interacts with tilt settings and affects individual axes, refer to the descriptions of SetPntTilt and TgtPosOut. See also Example1 and Example2

General Concept:
SetPntTilt defines the positional “tilt” or inclination between the outermost axes. When you have multiple axes arranged linearly, the first and last axes are shifted equally but in opposite directions from the central reference position (TgtPos). For intermediate axes, their target positions are interpolated between these outer axes. The AxesDistance inputs indicate how close each intermediate axis is to the centerline, affecting how the interpolation is performed.

  • If SetPntTilt > 0: The first axis is placed higher (or more positively offset) than TgtPos and the last axis is placed lower (or more negatively offset) than TgtPos.
  • If SetPntTilt < 0: The first axis is placed lower and the last axis higher relative to TgtPos.

For intermediate axes, AxesDistance values determine how far each axis is from the midpoint.

  • A positive AxesDistance value means the axis is closer to the first axis.
  • A negative AxesDistance value means the axis is closer to the last axis.
  • A value of zero means it is exactly in the middle between the first and last axes.

Note:
Any change in the value of TiltSetPnt will trigger the function block to adjust the inclination of the hydraulic axes.

  • If TiltSetPnt changes during an ongoing movement, the adjustment will only occur after the Busy signals for all axes have returned to False, indicating that the current movement has completed.

This ensures that inclination adjustments are performed smoothly and do not interfere with active movements.

Two Axes

Axes: 1 and 2

  • TgtPosOut.Axis1 = TgtPos + (SetPntTilt/2)
  • TgtPosOut.Axis2 = TgtPos – (SetPntTilt/2)

Here, each axis is offset by half of SetPntTilt from the central TgtPos, one in the positive direction and one in the negative.



 Figure 1: Relation between target position of Axis1 and Axis2 when SetPntTilt>0



Figure 2: Relation between target position of Axis1 and Axis2 when SetPntTilt<0

Three Axes

Axes: 1, 2, and 3

  • TgtPosOut.Axis1 = TgtPos + (SetPntTilt/2)
  • TgtPosOut.Axis3 = TgtPos – (SetPntTilt/2)

The middle axis (Axis2) is then interpolated between Axis1 and Axis3. Its exact position depends on AxesDistance.Axis2ToCent:

  • If AxesDistance.Axis2ToCent = 0, Axis2 is exactly in the middle.
  • If AxesDistance.Axis2ToCent > 0, Axis2 is positioned closer to Axis1.
  • If AxesDistance.Axis2ToCent < 0, Axis2 is positioned closer to Axis3.

Note:

  • AxesDistance.Axis1ToCent > 0 and AxesDistance.Axis3ToCent < 0
  • abs(AxesDistance.Axis1ToCent) = abs(AxesDistance.Axis3ToCent)



 Figure 3: Relation between target position of Axis1, Axis 2 and Axis3 when SetPntTilt>0 and AxesDistance.Axis2ToCent>0



Figure 4: Relation between target position of Axis1, Axis 2 and Axis3 when SetPntTilt>0 and AxesDistance.Axis2ToCent<0



Figure 5: Relation between target position of Axis1, Axis 2 and Axis3 when SetPntTilt<0 and AxesDistance.Axis2ToCent>0



Figure 6: Relation between target position of Axis1, Axis 2 and Axis3 when SetPntTilt<0 and AxesDistance.Axis2ToCent<0

Four Axes

Axes: 1, 2, 3, and 4

  • TgtPosOut.Axis1 = TgtPos + (SetPntTilt/2)
  • TgtPosOut.Axis4 = TgtPos – (SetPntTilt/2)

The inner axes (Axis2 and Axis3) are linearly interpolated between Axis1 and Axis4. Their positions depend on their respective AxesDistance values:

  • If AxesDistance.Axis2ToCent = 0, Axis2 is halfway between Axis1 and Axis4.
  • If AxesDistance.Axis2ToCent > 0, Axis2 is closer to Axis1.
  • If AxesDistance.Axis2ToCent < 0, Axis2 is closer to Axis4.

Similarly for Axis3:

  • If AxesDistance.Axis3ToCent = 0, Axis3 is halfway between Axis1 and Axis4.
  • If AxesDistance.Axis3ToCent > 0, Axis3 is closer to Axis1.
  • If AxesDistance.Axis3ToCent < 0, Axis3 is closer to Axis4.

Note:

  • AxesDistance.Axis1ToCent > 0 and AxesDistance.Axis4ToCent < 0
  • abs(AxesDistance.Axis1ToCent) = abs(AxesDistance.Axis4ToCent)



 Figure 7: Relation between target position of Axis1, Axis 2, Axis3 and Axis 4 when SetPntTilt>0 and AxesDistance.Axis2ToCent>0 and AxesDistance.Axis3ToCent<0


Figure 8: Relation between target position of Axis1, Axis 2, Axis3 and Axis 4 when SetPntTilt>0 and AxesDistance.Axis2ToCent>0 and AxesDistance.Axis3ToCent>0

Five Axes

Axes: 1, 2, 3, 4 and 5

  • TgtPosOut.Axis1 = TgtPos + (SetPntTilt/2)
  • TgtPosOut.Axis5 = TgtPos – (SetPntTilt/2)

The inner axes (Axis2, Axis3 and Axis4) are linearly interpolated between Axis1 and Axis5. Their positions depend on their respective AxesDistance values:

  • If AxesDistance.Axis2ToCent = 0, Axis2 is halfway between Axis1 and Axis5.
  • If AxesDistance.Axis2ToCent > 0, Axis2 is closer to Axis1.
  • If AxesDistance.Axis2ToCent < 0, Axis2 is closer to Axis5.

for Axis3:

  • If AxesDistance.Axis3ToCent = 0, Axis3 is halfway between Axis1 and Axis5.
  • If AxesDistance.Axis3ToCent > 0, Axis3 is closer to Axis1.
  • If AxesDistance.Axis3ToCent < 0, Axis3 is closer to Axis5.

Similarly for Axis4:

  • If AxesDistance.Axis4ToCent = 0, Axis3 is halfway between Axis1 and Axis5.
  • If AxesDistance.Axis4ToCent > 0, Axis3 is closer to Axis1.
  • If AxesDistance.Axis4ToCent < 0, Axis3 is closer to Axis5.

Note:

  • AxesDistance.Axis1ToCent > 0 and AxesDistance.Axis5ToCent < 0
  • abs(AxesDistance.Axis1ToCent) = abs(AxesDistance.Axis5ToCent)
Busy
Axis1
Axis2
Axis3
Axis4
Axis5

Since the HydroSynchronizer works in combination with HydroGurad Technology function, Here the Busy Output of the individual HydroGaurd Functions must be connected.

The input specifies the current measured position of Axis1. It is used in the error signal calculation of the internal synchron controller. It should be provided in the same unit as TgtPos.

The input specifies the current measured position of Axis2. It is used in the error signal calculation of the internal synchron controller. It should be provided in the same unit as TgtPos.

The input specifies the current measured position of Axis3. It is used in the error signal calculation of the internal synchron controller. It should be provided in the same unit as TgtPos.

The input specifies the current measured position of Axis4. It is used in the error signal calculation of the internal synchron controller. It should be provided in the same unit as TgtPos.

The input specifies the current measured position of Axis5. It is used in the error signal calculation of the internal synchron controller. It should be provided in the same unit as TgtPos.

This parameter specifies the distance of Axis 1 from the central reference point. It must be a positive value and represents how far Axis 1 is positioned away from the midpoint between the outermost axes.

This parameter defines the relative position of Axis 2 with respect to the midpoint between the outermost axes. Unlike AxesDistance.Axis1ToCent, which must be positive, AxesDistance.Axis2ToCent can be positive, negative, or zero.

  • A value of zero means Axis 2 is exactly centered between the first and the last axis.
  • A positive value moves Axis 2 closer to the first axis.
  • A negative value shifts Axis 2 closer to the last axis.

For Two-Axis Configurations:
When there are only two axes, AxesDistance.Axis1ToCent must be a positive value, and AxesDistance.Axis2ToCent must be the same value but negative. This ensures a symmetric layout around the central reference point. For example, if AxesDistance.Axis1ToCent is +10, then AxesDistance.Axis2ToCent should be -10.

For Three-Axis Configurations:
When there are three axes, AxesDistance.Axis1ToCent must be a positive value, and AxesDistance.Axis3ToCent must be the same value but negative. This ensures a symmetric layout around the central reference point. For example, if AxesDistance.Axis1ToCent is +10, then AxesDistance.Axis3ToCent should be -10.

For more than Three-Axis Configurations:
This parameter defines the relative position of Axis 3 with respect to the midpoint between the outermost axes. Unlike AxesDistance.Axis1ToCent, which must be positive, AxesDistance.Axis3ToCent can be positive, negative, or zero.

  • A value of zero means Axis 3 is exactly centered between the first and the last axis.
  • A positive value moves Axis 3 closer to the first axis.
  • A negative value shifts Axis 3 closer to the last axis.

For Four-Axis Configurations:
When there are four axes, AxesDistance.Axis1ToCent must be a positive value, and AxesDistance.Axis4ToCent must be the same value but negative. This ensures a symmetric layout around the central reference point. For example, if AxesDistance.Axis1ToCent is +10, then AxesDistance.Axis4ToCent should be -10.

For Five-Axis Configurations:
This parameter defines the relative position of Axis 4 with respect to the midpoint between the outermost axes. Unlike AxesDistance.Axis1ToCent, which must be positive, AxesDistance.Axis4ToCent can be positive, negative, or zero.

  • A value of zero means Axis 4 is exactly centered between the first and the last axis.
  • A positive value moves Axis 4 closer to the first axis.
  • A negative value shifts Axis 4 closer to the last axis.

For Five-Axis Configurations:
When there are five axes, AxesDistance.Axis1ToCent must be a positive value, and AxesDistance.Axis5ToCent must be the same value but negative. This ensures a symmetric layout around the central reference point. For example, if AxesDistance.Axis1ToCent is +10, then AxesDistance.Axis5ToCent should be -10.

This input specifies how many hydraulic axes are involved in the synchronization. Its value determines how SetPntTilt and the various AxesDistance parameters influence the positioning of each axis. For example, if you set NumberOfAxes to 2, only two target positions are computed. If you set it to 3, three target positions are computed, and so forth. Increasing the number of axes results in additional interpolation points and more complex positioning relationships, allowing you to control a greater number of axes in a coordinated and balanced manner.

This input represents the amplification factor of the P-controller within the Synchron controller. A higher Kp value can enhance control accuracy. However, caution is advised: setting the Kp value excessively high may render the closed-loop system unstable. For optimal results and to maintain system stability, it’s recommended to initiate with a modest value and incrementally adjust upwards to achieve the desired precision.

Output Description

This output field represents the computed target position for Axis 1. Its value is determined based on the configured SetPntTilt, the specified number of axes, and the relevant AxesDistance parameters. By adjusting these inputs, TgtPosOut.Axis1 will reflect the appropriate tilted or centered position that aligns Axis 1 correctly within the overall multi-axis arrangement. See Example1 and Example2

This output provides the computed target position for Axis 2. Its value depends on the number of axes, the specified SetPntTilt, and the AxesDistance parameters. For configurations with more than two  axes, TgtPosOut.Axis2 is determined by interpolating between the target positions of the outermost axes, taking into account whether Axis 2 is positioned closer to the first or last axis, or directly centered. This ensures a correct and balanced positional arrangement in multi-axis setups.

This output provides the computed target position for Axis 3. Its value depends on the number of axes, the specified SetPntTilt, and the AxesDistance parameters. For configurations with more than three axes, TgtPosOut.Axis3 is determined by interpolating between the target positions of the outermost axes, taking into account whether Axis 3 is positioned closer to the first or last axis, or directly centered. This ensures a correct and balanced positional arrangement in multi-axis setups.

This output provides the computed target position for Axis 4. Its value depends on the number of axes, the specified SetPntTilt, and the AxesDistance parameters. For configurations with more than four axes, TgtPosOut.Axis4 is determined by interpolating between the target positions of the outermost axes, taking into account whether Axis 4 is positioned closer to the first or last axis, or directly centered. This ensures a correct and balanced positional arrangement in multi-axis setups.

This output provides the computed target position for Axis 5. Its value depends on the number of axes and the specified SetPntTilt. 

These outputs are the position synchronization control signals computed by the synchronizer controller for each hydraulic axis. They are specifically designed to connect to the GenPar.SupImpCtrl input of the corresponding HydroXGuard function block managing each axis.

Each output (SyncCtrlOut.Axis1, SyncCtrlOut.Axis2, …, SyncCtrlOut.Axis5) provides an adjustment signal that ensures precise coordination and alignment of the respective hydraulic axis in the multi-axis system. The values are dynamically calculated based on the inputs SetPntTilt, TgtPos, and AxesDistance, ensuring smooth and synchronized operation.

For configurations with fewer than five axes, unused outputs can remain unconnected. For example, if number of axes is 3, only SyncCtrlOut.Axis1, SyncCtrlOut.Axis2, and SyncCtrlOut.Axis3 are used, while SyncCtrlOut.Axis4 and SyncCtrlOut.Axis5 are left unassigned. See Example1 and Example2

This boolean output indicates the activation status of the function block and must be connected to the Enb input of all individual HydroXGuard function blocks controlling the hydraulic axes.

When EnbOut is True, it enables all connected HydroXGuard blocks, allowing them to operate and respond to their respective inputs. If EnbOut is False, it disables all connected HydroXGuard blocks, ensuring they no longer respond to input signals. This unified control ensures synchronized activation or deactivation of all axes within the system.

The Error output is a boolean array with three elements, each representing a specific validation check for the function block’s configuration. If any of these elements is True, it indicates an error condition, and the function block will deactivate as described below.

  1. `Error(1): Invalid Number of Axes
    • This element is True if the value of NumAxes is invalid (i.e., less than 2 or greater than 5). A valid configuration requires at least 2 and at most 5 axes.
  2. `Error(2): Inconsistent AxesDistance for First and Last Axes
    • This element is True if the values of AxesDistance for the first and last axes are not equal in magnitude or if the first axis does not have a positive value and the last axis does not have a negative value. For example for 3 axes configuration:
      • AxesDistance.Axis1ToCent should be positive.
      • AxesDisatnce.Axis3 should be negative.
    • abs(AxesDisOut.Axis1) ≠ abs(AxesDisOut.AxisLast) triggers this error.
  3. `Error(3): Invalid AxesDistance for Intermediate Axes
    • This element is True if any intermediate axis (Axes2, Axes3, etc.) has a value that is greater than AxesDisance.Axis1 or less than AxesDistance.AxisLast. Intermediate axes must always lie within the bounds defined by the first and last axes.

Error Handling:
If any of the Error elements is True, the function block deactivates, and the following behavior is applied:

  • TgtPosOut Outputs: For all axes  is set to the current position (ActualPos) of the corresponding axis.
  • SyncCtrlOut Outputs: For all axes, SyncCtrlOut is set to zero.

This ensures a safe and predictable fallback state when configuration errors are detected.

First Steps for Commissioning and Testing the Multi-Axis Hydraulic Configuration

Before integrating all axes into the multi-axis system with the HydroSynchronizer, each individual axis must first be commissioned and tested independently using only the HydroXGuard function block. This step ensures that every axis operates optimally and can accurately follow the position trajectory as outlined in the HydroXGuard documentation.

Individual Axis Commissioning Steps:

  1. Setup the Individual Axis:
    • Connect the axis to the HydroXGuard function block.
    • Configure the axis parameters such as speed, acceleration, jerk, and force limits.
  1. Parameterize the Axis:
    • Adjust and optimize the parameters of the HydroXGuard block to ensure smooth and precise motion control.
    • Ensure the axis responds correctly to position trajectory commands and operates within safety limits.
  1. Test the Axis:
    • Run the axis independently through various motion profiles to validate its performance.
    • Confirm that the axis can follow the position trajectory accurately under all operating conditions.
  1. Verify Stability:
    • Ensure the axis operates stably and without overshooting, oscillations, or deviations from the desired trajectory.

Once all individual axes have been commissioned and tested successfully, they are ready to be connected to the HydroSynchronizer for coordinated operation.

Important Notes for Multi-Axis Configuration:

  1. Unified Parameter Settings:
    After connecting all axes to the HydroSynchronizer, ensure that the following parameters are identical for all axes:

Having consistent values for these parameters across all axes is crucial for achieving synchronized and coordinated motion.

Configuration and Parameter Adjustment for a Two-Axis System

This guide provides detailed instructions on how to set up and configure the Technology Block HydroXpert for precise positioning tasks of a hydraulic axis. 

Important for all examples: The values of control parameters provided in the following sections are solely as examples to illustrate the approach for setting control parameters. Under no circumstances should these values be directly applied to your machine, not even as initial starting points. The control parameters must be explicitly adjusted for each machine individually.

    • Ensure that both axes are optimally configured using the HydroXGuard function block as per its documentation.
    • Verify that each axis can accurately follow the defined position trajectory.
    • Connect the HydroSynchronizer to the two HydroXGuard function blocks as below.
    • Set the MaxOut and MinOut values. These specify the maximum and minimum trajectory deviations that the synchronizer controller is allowed to compute to ensure synchronized motion.
    • A good starting point is MaxOut = +3 mm and MinOut = -3 mm (or equivalent in the chosen unit of TgtPos).
    • Set the target position for the axes. The positions for Axis1 and Axis2 are computed as follows:
      • TgtPos.Axis1 = TgtPos + (TiltSetPnt / 2)
      • TgtPos.Axis2 = TgtPos – (TiltSetPnt / 2)
    • Set the NumAxes input to 2 to indicate a two-axis configuration.
    • Set AxesDistance.Axis1toCen to a positive value and AxesDistance.Axis2toCen to the same value but negative (e.g., +10 mm and -10 mm).
    • Leave AxesDistance.Axis3toCen, AxesDis.Axis4toCen, and AxesDistance.Axis5toCen unassigned as they are not used in a two-axis setup.
    • Start with a very small value for the proportional gain (Kp) as the initial setting for the synchronization controller.
      • Enable the system by setting EnbIn to True.
      • Test the system by initiating different movements and changing the values of TgtPos or TiltSetPnt to observe the motion.



Phase 1 (Initial State):

  • EnbIn: False (the function block is not active)
  • SetPntTilt: 0
  • TgtPos: 14 mm (common target position)
  • Axis Positions: Axis1 ~12 mm, Axis2 ~11 mm
    Since the function block is not enabled, the axes remain at their current positions with no attempt to synchronize or achieve the target position.

Phase 2 (Enable and Align Inclination):

  • EnbIn: True (the function block is activated)
  • SetPntTilt: 0
    Upon activation, the function block immediately adjusts both axes to achieve the desired inclination (here, zero difference). This means the two axes move so that their positions differ by the correct amount to reflect zero tilt—essentially aligning them relative to each other.

Phase 3 (Move to Target Position):

  • SetPntTilt: 0
  • TgtPos: 14 mm
    With the correct inclination now set, the axes move together in a synchronized fashion to reach the target position of 14 mm. Despite any difference in load or resistance, the two axes advance simultaneously toward this common goal.

Phase 4 (New Target Position):

  • TgtPos: 12 mm (changed from 14 mm)
    The system receives a new target position. The two axes, still maintaining zero tilt, move together down to the new position (12 mm). They remain synchronized even if one axis experiences significantly greater force than the other.

Phase 5 (Set a New Inclination):

  • SetPntTilt: 3
    A new inclination setpoint is introduced, meaning the axes must now position themselves so that one axis is higher than the other by the specified tilt amount. The system adjusts the axes to achieve and maintain this new inclined relationship while still under control.

Phase 6 (New Target Position):

  • TgtPos: 11 mm (changed from 12 mm)
    The system receives a new target position. The two axes, still maintaining inclination of 3, move together down to the new positions (12.5 and 9.5 mm). They remain synchronized even if one axis experiences significantly greater force than the other. See ProcessVal1.ActFr and ProcessVal2.ActFr

Phase 7 (New Target Position):

  • TgtPos: 13 mm (changed from 11 mm)
    The system receives a new target position. The two axes, still maintaining inclination of 3, move together down to the new positions (14.5 and 11.5 mm). They remain synchronized even if one axis experiences significantly greater force than the other. See ProcessVal1.ActFr and ProcessVal2.ActFr

Phase 8 (Set a New Inclination)::

  • SetPntTilt: -2
    A new inclination setpoint is introduced, meaning the axes must now position themselves so that one axis is higher than the other by the specified tilt amount. The system adjusts the axes toward 12mm and 14mm to achieve and maintain this new inclined relationship while still under control.

Example of two hydraulic axes controlled by HydroXGuard blocks, coordinated by the HydroSynchronizer



Phase 1 (Initial State):

  • EnbIn: False (the function block is not active)
  • SetPntTilt: 0
  • TgtPos: 14 mm (common target position)
  • Axis Positions: Axis1 ~12 mm, Axis2 ~11 mm
    Since the function block is not enabled, the axes remain at their current positions with no attempt to synchronize or achieve the target position.

Phase 2 (Enable and Align Inclination):

  • EnbIn: True (the function block is activated)
  • SetPntTilt: 0
    Upon activation, the function block immediately adjusts both axes to achieve the desired inclination (here, zero difference). This means the two axes move so that their positions differ by the correct amount to reflect zero tilt—essentially aligning them relative to each other.

Phase 3 (Move to Target Position):

  • SetPntTilt: 0
  • TgtPos: 14 mm
    With the correct inclination now set, the axes move together in a synchronized fashion to reach the target position of 14 mm. Despite any difference in load or resistance, the two axes advance simultaneously toward this common goal.

Phase 4 (New Target Position):

  • TgtPos: 12 mm (changed from 14 mm)
    The system receives a new target position. The two axes, still maintaining zero tilt, move together to the new position (12 mm). They remain synchronized even if axis1 experiences significantly greater force than the other.

Phase 5 (Set a New Inclination):

  • SetPntTilt: 3
    A new inclination setpoint is introduced, meaning the axes must now position themselves so that axis1 is higher than the axis2 by the specified tilt amount. The system adjusts the axes to achieve and maintain this new inclined relationship while still under control.

Phase 6 (New Target Position):

  • TgtPos: 11 mm (changed from 12 mm)
    The system receives a new target position. The two axes, still maintaining inclination of 3, move together down to the new positions (12.5 and 9.5 mm). They remain synchronized even if axis1 experiences significantly greater force than the other. See ProcessVal1.ActFr 

Phase 7 (New Target Position):

  • TgtPos: 13 mm (changed from 11 mm)
    The system receives a new target position. The two axes, still maintaining inclination of 3, move together to the new positions (14.5 and 11.5 mm). They remain synchronized even if axis1 experiences significantly greater force than the other. See ProcessVal1.ActFr and ProcessVal2.ActFr

Phase 8 (Set a New Inclination)::

  • SetPntTilt: -2
    A new inclination setpoint is introduced, meaning the axes must now position themselves so that axis1 is lower than the axis2 by the specified tilt amount. The system adjusts the axes toward 12mm and 14mm to achieve and maintain this new inclined relationship while still under control.

Important for all examples: The values of control parameters provided in the following sections are solely as examples to illustrate the approach for setting control parameters. Under no circumstances should these values be directly applied to your machine, not even as initial starting points. The control parameters must be explicitly adjusted for each machine individually.

Example of three hydraulic axes controlled by HydroXGuard blocks, coordinated by the HydroSynchronizer



Phase 1 (Initial State):

  • EnbIn: False (the function block is not active)
  • SetPntTilt: 0
  • TgtPos: 14 mm (common target position)
  • Axis Positions: Axis1 ~12 mm, Axis2 ~11 mm, Axis3 ~13 mm
  • AxesDistance.Axis1ToCent=+300mm
  • AxesDistance.Axis2ToCent=+100mm
  • AxesDistance.Axis3ToCent=-300mm.

Since the function block is not enabled, the axes remain at their current positions with no attempt to synchronize or achieve the target position.

Phase 2 (Enable and Align Inclination):

  • EnbIn: True (the function block is activated)
  • SetPntTilt: 0
    Upon activation, the function block immediately adjusts both axes to achieve the desired inclination (here, zero difference). This means the three axes move so that their positions differ by the correct amount to reflect zero tilt.

Phase 3 (Move to Target Position):

  • SetPntTilt: 0
  • TgtPos: 14 mm
    With the correct inclination now set, the axes move together in a synchronized fashion to reach the target position of 14 mm. Despite any difference in load or resistance, the three axes advance simultaneously toward this common goal.

Phase 4 (New Target Position):

  • TgtPos: 12 mm (changed from 14 mm)
    The system receives a new target position. The three axes, still maintaining zero tilt, move together down to the new position (12 mm). They remain synchronized even if one axis experiences significantly greater force than the other.

Phase 5 (Set a New Inclination):

  • SetPntTilt: 3
    A new inclination setpoint is introduced, meaning the axes must now position themselves so that axis1 is higher than the axis3 and axis2 is inetrpolated between these two target position. The system adjusts the axes to achieve and maintain this new inclined relationship while still under control.

Phase 6 (New Target Position):

  • TgtPos: 11 mm (changed from 12 mm)
    The system receives a new target position. The three axes, still maintaining inclination of 3, move together down to the new positions (12.5, 11.5 and 9.5 mm). They remain synchronized even if axis1 experiences significantly greater force than the others. See ProcessVal1.ActFr  

Phase 7 (New Target Position):

  • TgtPos: 13 mm (changed from 11 mm)
    The system receives a new target position. The three axes, still maintaining inclination of 3, move together to the new positions (14.5, 13.5and 11.5 mm). They remain synchronized even if one axis1 has significantly greater load force than the others. See ProcessVal1.ActFr 

Phase 8 (Set a New Inclination)::

  • SetPntTilt: -2
    A new inclination setpoint is introduced, meaning the axes must now position themselves so that axis1 and axis2 are lower than the axis3 by the specified tilt amount. The system adjusts the axes toward 12mm, 12.66mm and 14mm to achieve and maintain this new inclined relationship while still under control.

Important for all examples: The values of control parameters provided in the following sections are solely as examples to illustrate the approach for setting control parameters. Under no circumstances should these values be directly applied to your machine, not even as initial starting points. The control parameters must be explicitly adjusted for each machine individually.

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