Indramat PPC Controls

What Are Indramat PPC Controls?

The Indramat PPC (Programmable Process Controller) is a high-performance motion and process control platform developed by Bosch Rexroth Indramat. Known for its exceptional reliability, modular flexibility, and deterministic control, the PPC controller is engineered to optimize the performance of complex automation systems such as:

• CNC machining centers

• Printing and packaging systems

• Textile automation

• Metal forming equipment

• Multi-axis gantry systems

PPC controllers serve as the central processing and coordination units in Rexroth’s legacy automation platforms and continue to power critical systems worldwide.

Key Features of Indramat PPC Controls

• Multi-Axis Synchronization: PPC controllers can coordinate up to 40 axes of motion with tight synchronization and seamless integration into Indramat drive systems.

• Modular Integration: Works with DIAX04 or ECODRIVE series drives, allowing scalability and modularity based on system size and axis count.

• Deterministic Real-Time Control: Designed for precise motion sequences with consistent timing—critical for production lines and robotic systems.

• Integrated PLC Functionality: Many PPC models support PLC logic, eliminating the need for external PLC hardware and simplifying system architecture.

• Fieldbus Communication: Supports SERCOS, Profibus, and other fieldbus protocols for integration into distributed automation networks.

• Flexible Programming Environment: Configuration and logic can be developed using Bosch Rexroth’s IndraWorks or VisualMotion software, depending on the model.

Common PPC Models

Some of the most frequently used models in the PPC family include:

These models are typically integrated with DDS, HDS, or MDD servo drives to form complete closed-loop motion control systems.

PPC System Architecture

In a typical Indramat motion system, the PPC controller acts as the master unit, issuing commands over a SERCOS network to connected drives. Here's a simplified breakdown of a PPC system layout:

1. PPC Control Unit: Processes programs, manages tasks, communicates over SERCOS.

2. SERCOS Interface: Real-time communication link between controller and drives.

3. Indramat Drives (e.g., DDS, HDS): Execute motion commands to connected servo motors.

4. Servo Motors: Perform physical movement—positioning, rotation, torque control.

5. Sensors and Feedback Devices: Relay real-time information for closed-loop regulation.

Applications and Use Cases

Indramat PPC controllers were commonly used in:

• Automated machine tools: Multi-axis lathes, CNC mills

• Packaging machinery: Cartoning, bottling, and shrink-wrapping machines

• Converting applications: Web tension and alignment for print and label production

• Textile machinery: Warp knitting, weaving, and winding processes

• Assembly automation: Pick-and-place systems, part alignment, and test stands

Their ability to maintain tight control of coordinated movements, while interfacing with I/O and safety functions, made them a key solution in 1990s and early 2000s automation environments.

Obsolescence and Retrofit Considerations

While the PPC platform is robust, many models are now classified as “Active Mature” or “Discontinued” by Bosch Rexroth. This means:

• Parts may be limited in availability

• Firmware support is no longer updated

• Newer systems may not be compatible without a full migration path

For facilities still running PPC controllers, it is often advisable to plan ahead by sourcing refurbished units or considering an upgrade path to the Rexroth IndraMotion MLC platform or IndraDrive with embedded control.

Final Thoughts

The Indramat PPC controller remains a powerful and proven solution in legacy systems. Its precision, real-time coordination, and robust communication options made it a cornerstone of motion automation for years. However, if you're working with PPC components today, it's critical to consider long-term support, maintenance, and retrofit options to keep your operations reliable and scalable.

For more information , contact PLG Automation:Email: sales@plgautomation.comPhone: 800-906-9271