BOSCH REXROTH FCS01.1E-W0011-A-04-NNBV (R911311065) – Integrated Motion Logic Controller

Description

Application Scenarios

A North American manufacturer of automated vial filling machines struggled with inconsistent dosing accuracy due to timing drift between servo-driven syringe actuators and rotary indexing tables. Their legacy solution used a third-party PLC with add-on motion modules, resulting in cycle jitter and frequent recalibration. After integrating the BOSCH REXROTH FCS01.1E-W0011-A-04-NNBV, they achieved microsecond-level synchronization across four axes using built-in electronic gearing and camming. The integrated safety PLC also enabled safe limited-speed operation during maintenance, reducing lockout/tagout downtime by 60%. Within three months, product reject rates dropped by 32%, and the engineering team reported that the FCS01.1E-W0011-A-04-NNBV “cut integration complexity in half while doubling machine responsiveness.”

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Technical Principles and Innovative Values

Innovation Point 1: Single-Kernel Convergence of Logic, Motion & Safety

Unlike hybrid systems that run motion and safety on separate processors, the FCS01.1E-W0011-A-04-NNBV executes all three functions—PLC logic, motion trajectories, and safety interlocks—on a unified real-time kernel, ensuring zero communication latency and guaranteed task determinism even under full load.

Innovation Point 2: Hardware-Optimized SERCOS III Master

The FCS01.1E-W0011-A-04-NNBV features a dedicated SERCOS III ASIC that achieves <1 µs cycle jitter and sub-microsecond drive synchronization—critical for high-dynamic applications like delta robots or web-guided cutters where EtherCAT may fall short in contour accuracy.

Innovation Point 3: Embedded Diagnostics & Data Historian

Onboard SSD stores motion traces, alarm logs, and oscilloscope captures for up to 30 days. Technicians can access this data via built-in web server or OPC UA—no external historian needed for root-cause analysis.

Innovation Point 4: Fanless, Industrial-Grade Reliability

With no moving parts and conformal-coated PCBs, the FCS01.1E-W0011-A-04-NNBV operates reliably in dusty, high-vibration environments common in food processing or automotive plants—reducing unplanned failures by up to 45% compared to fan-cooled alternatives.

Application Cases and Industry Value

In a European snack food packaging line, the BOSCH REXROTH FCS01.1E-W0011-A-04-NNBV replaced a legacy PLC + separate motion controller to manage a 5-axis form-fill-seal machine running at 120 cycles/minute. The controller synchronized film unwinding, vertical sealing, horizontal cutting, and product infeed—all while monitoring light curtains and emergency stops via its integrated safety PLC. Over six months, the line achieved 99.95% availability, with zero safety incidents during operator interventions. Maintenance staff used the built-in scope function to identify a resonance at 42 Hz in the horizontal knife actuator, adjusting the notch filter remotely without stopping production. The customer stated: “The FCS01.1E-W0011-A-04-NNBV didn’t just control our machine—it made it smarter.”

Related Product Combination Solutions

BOSCH REXROTH HCS02.1E-W0018-A-03-B-ET: Compact servo drive—natively synchronized with the FCS01.1E-W0011-A-04-NNBV via SERCOS III for seamless axis control.

BOSCH REXROTH IndraDrive Cs: Cabinet-free servo drive—ideal for decentralized architectures directly controlled by the FCS01.1E.

BOSCH REXROTH S20-I/O System: Modular I/O blocks—expand digital/analog connectivity over SERCOS III without extra bus couplers.

BOSCH REXROTH IndraWorks Ds: Unified engineering software—configure logic, motion, safety, and HMI for the FCS01.1E-W0011-A-04-NNBV in one project.

BOSCH REXROTH HMV01: Operator panel—tightly integrated visualization with live axis status and alarm history from the FCS01.1E.

BOSCH REXROTH MS2N-MA1-0100-N0: High-dynamic servo motor—optimized for rapid acceleration with the FCS01.1E-W0011-A-04-NNBV motion engine.

BOSCH REXROTH VEH01-08-1P0B-NNEV: Pneumatic valve terminal—controlled via integrated sequencing logic in the same runtime as motion tasks.

BOSCH REXROTH FWA-INDRV-MPH-07VRS*: Firmware upgrade package—enables EtherCAT master functionality on the FCS01.1E-W0011-A-04-NNBV for mixed-drive networks.

Installation, Maintenance, and Full-Cycle Support

Installing the BOSCH REXROTH FCS01.1E-W0011-A-04-NNBV is streamlined: mount it on a standard 35 mm DIN rail, connect 24 VDC power, link SERCOS III (via fiber or copper) to drives, and plug Ethernet into the plant network. Commissioning begins in IndraWorks Ds, where users create a single project for logic, motion sequences, safety circuits, and HMI—all validated in simulation before download. This unified workflow reduces engineering time by up to 50% compared to multi-vendor setups.

For ongoing operation, the unit features front-access USB for backup/restore and a web-based diagnostics portal accessible from any browser on the plant network. LED indicators provide instant status for power, CPU, SERCOS, and safety. In case of failure, the entire module can be swapped in under 10 minutes, with automatic parameter recovery from SD card or network archive. We provide comprehensive lifecycle support—including SERCOS topology validation, safety circuit certification assistance, firmware updates, and migration paths from legacy IndraLogic or third-party platforms. Every FCS01.1E-W0011-A-04-NNBV undergoes 72-hour burn-in testing with live motion and safety scenarios before shipment.

Contact us for a customized solution—whether you’re designing a new high-speed machine, modernizing legacy equipment, or seeking a compact SIL 3-ready controller, the BOSCH REXROTH FCS01.1E-W0011-A-04-NNBV delivers unmatched integration density, precision, and intelligence in a single box.