Assembly operations that use handling, joining, and pressing tools for a range of production applications — including fastener manufacturing — continually seek to improve the versatility, ease of use, production time, and quality of such operations.
In today’s digital world, this means adding smarter, Industry 4.0 capabilities to production platforms. For efficiency, this must entail data tracking of a machine’s production and performance with real-time sharing capabilities.
As manufacturers begin to incorporate the benefits of Industry 4.0 technology, a new concept called “smart mechatronics” has evolved, offering more intelligence and functionality in handling and joining. Mechatronic systems are devices that have fully integrated mechanical and electrical components, thanks to the combination of sensors, circuits, and motion-control applications.
In some ways, mechatronic systems could be considered a forerunner of Industry 4.0 technology. They combine disparate mechanical and electronic components into solutions for specific product assembly and transport tasks, such as Cartesian robots (capable of moving in multiple linear directions) and forming and crimping tools.
Meeting industry needs at one time, mechatronic solutions were integrated with components from multiple suppliers. That’s no longer the case. Mechatronics suppliers are replacing that time-consuming acquisition and integration step with complete solutions that are “plug and produce.” This includes the software necessary, which is preprogrammed and delivered as a single production tool. Manufacturers should know that all of the components for a complete mechatronic solution — a Cartesian robot or a pressing or joining tool — can now be specified.
Assembly operations are shifting away from individual products toward complete system kits for manufacturing equipment that produces fast solutions for handling, joining, and pressing tools — along with real-time data.
Users can enter parameters such as stroke, workpiece weight, and cycle time, which generates an output that can be verified in the CAD environment.
It’s clear end users require precise control and execution of motion sequences, but also automated tracking of production data and easy connectivity with machine-level and plantwide production management systems.
Additionally, there’s a demand for easier and faster changeovers. Many production lines or mid-sized shops seek tools that make it easier to produce a range of batch sizes — from the low end of only a few thousand parts up to hundreds of thousands — without extensive effort to reprogram tools for a new part.
The price point also matters. End users require cost-effective measures that meet budgets and readily support manufacturing orders. Kitted solutions that provide flexibility in a space-saving envelope with minimal integration time are highly desired.
Easier, faster commissioning is one significant advance provided by newer, smarter mechatronic systems and the technology that supports them. Equally valuable are the improved efficiency, flexibility, and productivity it provides end users looking for easy-to-automate solutions.
For those wanting to integrate mechatronics and update production lines, consider systems that:
Combine all the hardware and software into a single solution to support a broader range of applications, including pressing and joining, logistics, packaging, pick-and-place, palletizing, assembly operations, and more
Feature an easy-to-use graphical user interface that lets operators build production sequences simply and intuitively
Require no special motion-control or programming skills
Monitor systematic data such as position, velocity, and acceleration
Include kitted solutions that offer simple integration, flexibility, and tracking options, providing users with the ability to set conditions for automated quality control
Provide real-time updates and recordings as requested
Offer a multi-axis system that can interface with individual peripheral tools such as gripping devices, nozzles, and actuators
Times are changing, and so are industry requirements and processes. To keep up, fastener manufacturers are wise to digitalize their operations with Industry 4.0 technology.
Smart mechatronics solutions leverage easy to-use tools, such as drag and-drop functionality and simple programming. Bosch Rexroth’s Smart MechatroniX system for pressing and joining applications is one example that demonstrates this intuitive model.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Greater freedom and precision in the area of contactless high-performance transport and positioning
6D planar system added to the ctrlX AUTOMATION portfolio
Movers move in six degrees of freedom, even where space is very limited
Control system ctrlX CORE with apps for planar systems
Planar systems offer enormous potential for a variety of industry segments. With ctrlX FLOW6D, Bosch Rexroth has raised contactless high-performance transport and positioning to a new level. Free-floating transport platforms, so-called movers, are moved on a horizontal, vertical or overhead working surface. Each mover acts in six degrees of freedom at high speed and with great precision – without any friction or pollution. Integration into the automation toolkit ctrlX AUTOMATION results in an overall solution with a compact control system and apps to increase the range of functions.
A planar system serves as a contactless levitation system for the efficient and safe transport, positioning and handling of loads. On a working surface which can be adapted in a modular fashion, a number of differently shaped and sized movers can be controlled in six dimensions. Strong, specially arranged permanent magnets make this possible. Given their modularity and easily adaptable nature, planar systems can be used in numerous industrial sectors, for example in the semiconductor industry, the food sector, the pharmaceuticals industry or in assembly systems.
The ctrlX FLOW6D planar system allows contactless high-performance transport and positioning in six dimensions.
New planar system takes off
ctrlX FLOW6D offers new room for maneuver and innovative concepts for production systems. Bosch Rexroth has given the system numerous properties to make it stand out from other well-known technologies. Much larger movement ranges, for example a floating height of 20 mm, a 10° tilting angle and endless rotation in any location set new standards. The six degrees of freedom of each mover can be combined with each other as required. For example, rotation and tilting are possible during travel. Vertical or overhead system operation is also possible.
The movers are connected: Power and data are available to users on the floating platform. A mover can be converted into an active agent by adding actuators, sensors and handling components.
This and other properties allow entirely new system concepts and workflows. For example, movers can be operated in a process chamber, transport and process tasks can be combined seamlessly and transport systems can be standardized. The additional degrees of freedom mean that fewer peripheral devices are needed. As a result, the system becomes more compact and cheaper.
“ctrlX FLOW6D forms the backbone of a flexible and efficient production facility. As an open system, it can interact seamlessly with various other systems. Software-controlled production allows it to be adapted to changing products or processes quickly,” explained Steffen Winkler, Vice President Sales, Business Unit Automation & Electrification Solutions at Bosch Rexroth.
By incorporating ctrlX FLOW6D into its automation world, Bosch Rexroth has created an integrated, agile system. “ctrlX AUTOMATION provides the software platform for design, simulation, engineering, operation and service. With ctrlX CORE, we offer a compact, high-performance control system which allows users to make optimum use of the new planar system technology. New functions can easily be added as apps available from the ctrlX Store. As a result, full use of the potential of levitation can be made,” said Steffen Winkler.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Six practical steps to greater productivity for manufacturers.
Bosch Rexroth
Finding ways to increase productivity has always been an important part of manufacturing. But against the current backdrop of demand volatility, inflation, a shortage of skilled workers and the requirement for smaller batch sizes, increasing productivity is now essential to a business’s competitiveness. Discover our six practical steps to greater productivity and find out about a new initiative that’s helping to boost productivity in factories.
Connecting machines by building an edge platform
Edge devices are important in the factory of the future because the connection of machines to the internet or the cloud dramatically increases the range of functions and the performance of machines.
The solution: An edge device can take over the activities around the machine. It receives orders from the MES, for example, and controls the machine via an integrated PLC, or it can be linked to the existing control system. By linking the MES and ERP system, edge devices can also enable the commissioning of maintenance and procurement of spare parts.
The result: Productivity is increased by 10 percent. Because edge devices enable data to be captured and processed closer to the source, rather than sending it to servers, the data can be gathered and analyzed on the factory floor in real time. This has enormous benefits in terms of predictive maintenance, improving product quality and increasing throughput.
Implementing a digital twin
A digital twin is a virtual model designed to accurately reflect a physical object. There are various types, and the biggest difference between these is in the area of application. This ranges from a basic component to assets to a complete system or unit. Process twins reveal how systems work together to create an entire production facility.
The solution: Our digital twin solution is a virtual representation or model of physical assets in a real factory. We use harmonized and standardized information models and interfaces (APIs) to create an interoperable environment of interconnected components. It provides a solution set to model and execute production processes. In Industry 4.0 systems, each I4.0 component is represented by a standardized AAS (asset administration shell), which forms an information shell for an asset or hierarchy of assets. So, our digital twin solution offers a ready-to-use implementation of a smart manufacturing platform based on AASs. Once installed, it provides complete transparency and shows how the different components in a production process work together. This enables you to validate concepts and test processes and procedures before implementing them – resulting in fast adoption and integration of applications.
The result: Our digital twin solution makes the integration and commissioning process at least 35 percent faster. Complex simulation, analysis and monitoring of systems can be carried out in real time, and problems can be detected and dealt with before they occur. New products and processes can be tested and perfected virtually first, saving time and effort.
Resource optimization through targeted energy management
Energy management plays a major role for companies that want to save money. However, it’s important to get reliable, tangible data from the process when making decisions about reducing energy usage.
The solution: One option is to implement an electrical energy management system, which gives you transparency in your energy consumption and enables you to avoid peak loads, shut down plant components or put devices into sleep mode. Reactive power has an additional cost, because unusable reactive power that exceeds the threshold is often charged to the manufacturing company.
The result: Up to a 20 percent reduction in electrical energy costs can be achieved from using our solutions. There are also environmental benefits from the associated reduction in CO₂ emissions. By implementing management systems that help you monitor and reduce energy usage across these areas, considerable cost saving can be made.
Detecting and evaluating faults in processes and plants
Downtime, particularly unplanned downtime, can result in huge revenue losses and disappointed customers, not to mention the inconvenience and man-hours required to fix the problem.
The solution: By connecting and monitoring your machinery in real-time and having the data in a format that’s clear and transparent, production processes can be continually improved, and technical errors can be diagnosed and resolved before they lead to a breakdown. Our ActiveCockpit provides real-time information and enables the exchange of information between people, machines and the production process on the shop floor.
The result: This leads to an improvement in the overall equipment effectiveness (OEE) – in some cases of at least 8 percent. By identifying technical errors and malfunctions before they happen, you can minimize downtime and disruption, while also improving the quality of your products and service.
Automatic order confirmation and recording of delivered components
Global networks are steadily replacing self-contained value chains, as manufacturers try to maximize efficiency throughout the entire production and distribution process by means of seamless data transparency.
The solution: RFID technology enables logistics processes to be sped-up and recording processes to be automated. The state of the art option is a camera-based system that automatically captures the DMC, QR code or barcode, so no scanners are needed. The image is then processed and digitally recorded.
The result: These solutions reduce manual work steps by up to 25 percent, saving time in production and logistics. The process becomes more transparent, with parts being tracked and processes confirmed as they happen. Data and malfunctions can be visualized, even on mobile devices. Supply chain management can be expanded, for example, to include traceability of components, material availability and inventory transparency.
Controlled supply, mixing and process monitoring of liquids
Whether you’re mixing gases or liquids, eliminating irregularities and reducing manual effort are essential to more effective and cost-efficient production.
The solution: Productivity can be maximized with an inline measuring method that determines the volume flow, and a system for measuring the current mixing ratio. Actuators and a smart control unit can be implemented. We provide software solutions and can also install a user interface, so you can view and monitor information.
The result: We’ve found that costs can be cut by up to 12 percent by reducing manual effort and saving resources with these solutions. Manual work steps are reduced and the re-ordering process can be automated. The process becomes more reliable, while more efficient use of raw materials and less waste means lower recycling costs and greater sustainability.
The Productivity Boosters
We’re working on an initiative to help boost customers’ productivity. We spoke to Juliane Hess, a member of The Productivity Boosters team, to find out about this European initiative.
Can you tell us about this initiative?
Our Productivity Boosters initiative is a brownfield, shop floor-oriented approach, which addresses the pain points of our manufacturing customers. We combine our smart products with add-ons, services, and, where suitable, partnering. It’s scalable and can be tailored to the customer’s individual needs, type of production and conditions – for example, their existing IT infrastructure.
By bundling our manufacturing and digitalization expertise – on the shop floor and the edge – along with our experienced production and IT specialists, we can harness our customers’ full productivity potential and improve their production figures. It’s this added value approach that makes our offering stand out.
What made you decide to set up this initiative?
Industrial Internet of Things (IIoT) platforms are beginning to replace MES functions and related applications, including production, maintenance, quality, and inventory management, which are a mix of information technology (IT) and operational technology (OT).
Process-oriented digitalization with the right data is essential in today’s factories because digital technology can collect data, identify trends and help make better business decisions. A lot of the data and information that’s collected still isn’t used productively. Professionals who are skilled in control engineering and OT-IT – two areas where there’s currently a shortage of experts – are needed. This is what the Productivity Boosters provide.
What type of business is it suitable for?
Manufacturing companies with heterogeneous production equipment and IT infrastructure or systems, that want to improve productivity and reduce costs.
We’ve already put this method into practice in several projects in Europe. Despite them being across diverse industry sectors, we see clear parallels in the solutions they need, but with different parameters and data. So, we scale the solution according to the customer.
What are the most important findings from your work?
Manufacturers want solutions to solve their production problems. So, increasingly, they’re looking for experienced manufacturing technology partners for the long-term. They want solutions rather than individual components.
We’ve also found that customers go to OEMs and integrators with their requirements for solutions and products. We’re feeding back these requirements to our development departments to improve our products.
Are you working on any partner projects in this area?
We’re working with SAP on a plug and play solution to implement intelligent device onboarding. This will enable machines to be more easily connected to IT via an edge device and interfaced with the IoT maintenance services of SAP. This solution will give customers the health score of a product, energy optimization, predictive maintenance and OEE improvement.
What advice would you give to SMEs that want to improve their productivity, but don’t have big budgets?
Our customers are end customers and SME’s driven by their economic environment that want to make use of new technologies, but without heavy and binding investment. Even the smallest improvements can make all the difference. Together with our customers, we use our analysis to define the main measures to work on – the ones that will bring about the most improvement in productivity.
That’s why we also provide small and cost-effective solutions that suit the prerequisites of the customer. Sometimes it’s advantageous to start small and still think big.
Juliane Hess
If you’d like to know more about our solutions that boost productivity, visit your local Bosch Rexroth site or speak to your local Bosch Rexroth support team.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Hydraulic drives move high loads and ensure safety-relevant functions. Their failure can result in tremendous downtime costs. It is therefore important to maintain the interaction between material, surface quality and fluid as coordinated by the manufacturer. With spare parts and repairs according to original specifications, operators can secure original performance over a long period of time.
Every year, millions of euros are invested in the development of new hydraulic components. Each new generation of solutions is even more powerful, energy efficient and reliable than the one before. The underlying field of research is called tribology – the science of friction, lubrication and wear.
Ensuring smooth performance
Tribology investigates all frictional processes that occur between two surfaces moving in relation to each other and considers the type of material, surface quality and the lubricant (fluid) as the main influencing variables. If hydraulic components are developed according to tribological principles, important savings can be made both in energy and material consumption and in production and maintenance. How can operators secure the advantages of the latest product generation for as long as possible?
Figure 1: Material, surface and lubrication: The scientific field of tribology investigates the friction between two bodies and seeks optimal conditions for minimal wear.
Change a perfect system? Better not!
Hydraulic components in which materials, surfaces and fluid are matched to each other in such a way that they achieve optimum efficiency with minimum wear are called a “tribological system”. This perfect interaction stands and falls with maintenance. If only a single parameter is changed, the system loses its balance, i.e. the optimum efficiency is no longer achieved, energy consumption and electricity costs increase and the service life is negatively affected. This happens, for example, if spare parts made of a different material or with a lower surface quality are used, if components are improperly repaired or a fluid is used that does not match the material.
Figure 2: Fluid-related damage to various components of an axial piston pump.
Play it safe: Spare parts from the manufacturer
To prevent operators from suffering functional losses and damage, Bosch Rexroth subjects the evaluation of fluids to strict requirements that go far beyond the recommended standard. The manufacturer also sets the same high-quality standards for its own spare part production as for the original. Replicas, on the other hand, offer neither the same material composition nor the same surface quality. The consequences are unplanned outages, significantly higher life cycle costs and premature new investments. Choosing original spare part is already worthwhile with the smallest parts. For example, Bosch Rexroth provides completely ready-to-install seal kits in original equipment quality – including parts list and exploded drawing. Thanks to the precise instructions, the average time required for dismantling, cleaning and reassembling a pump is reduced from a good two hours to less than 60 minutes.
Figure 3: Surface comparison: In contrast to the original from Bosch Rexroth (left), the plagiarism (right) shows large scores. The unfavorable flow conditions decrease efficiency. Leakage and cavitation are increased, especially under high pressure.
Figure 4: Serious quality differences in material and processing: The plagiarism (right) cannot withstand high pressure and “breaks”. The result: premature wear and tear and damage due to liquid contamination.
Original repair receives manufacturer specification
Repairs that are not commissioned at the manufacturer or certified partners often also result in unforeseen expenses. This is because without access to current data and parts lists, without in-depth know-how and without the right test benches, other suppliers cannot restore the original specification including functional reliability. In the worst case, there is even a risk of liability.
What ultimately distinguishes an original repair from an uncertified one? Here’s an example: When a Bosch Rexroth axial piston pump is inspected and repaired by trained service personnel in a specially equipped, ISO 9001-certified service center, it undergoes qualified testing and repair according to standard guidelines and processes. All failure-critical components are replaced and the original manufacturer’s specification is tested and confirmed on the test bench.
Replacement is better than rework
Non-certified suppliers frequently rework components, thereby destroying the original surface quality of highly stressed components such as pistons with slide shoe, control plates or sliding disks. Control valves on pumps are usually only cleaned and reinstalled. This short-sighted repair practice leads to increased leakage and consequently to a strong vibration tendency. Both accelerate wear, reduce efficiency and shorten the service life. By repairing with original Rexroth spare parts from the manufacturer, however, operators can ensure the original performance and availability for the next few years, including a twelve-month warranty on new parts. In addition, fixed-price repairs and agreed throughput times ensure cost security. This way, operators are protected from surprises and can plan ahead.
Figure 5: Rework vs. replacement: Leakage oil measurements on a remanufactured pump controller (A4VSO) show significantly higher values than when the original component is replaced: Vibrations, increased wear and early failures can be the result.
Avoiding liability risks
In some countries, improper repairs can also result in liability risks for the operator. In Germany, for example, the manufacturer is not liable under § 1 Sections 2 and 3 ProdHaftG (German Product Liability Act ) for defects that occur after the product has been placed on the market. Instead, the operator is responsible for the consequences of improper repairs. If the operational safety according to the CE mark is no longer given, the insurance company might not pay for damages.
Our conclusion: Sometimes saving money doesn’t pay off – preserve values instead
Those who want to save costs in the short term – by using counterfeit products and non-original repairs – pay extra in the long term. To benefit permanently from the original performance and a long service life, it pays off to include the manufacturer’s expertise in terms of technology, industry and application in maintenance, too. Only with proven manufacturer specifications can the original performance data and resulting function, productivity and efficiency be guaranteed.
Close cooperation with Bosch Rexroth is also worthwhile for other reasons: for example for engineering support, for professional instruction and training of operating and maintenance personnel, or to update the cost-effectiveness, energy efficiency and safety of existing systems. This way, a supplier relationship becomes a profitable partnership for a perfectly smooth operation.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Let’s be honest: Over many years, automation has for the most part ignored the developments in the consumer area – and thereby missed countless opportunities for user-friendly approaches. With ctrlX AUTOMATION we have asked ourselves the provocative question: What would automation look like if it were reinvented by Google, Apple or another digital company? We did not have to search long for an answer: It would follow the example of a smartphone, with the highest level of functional integration possible and a flexible app technology thanks to which users can easily individualize their devices. With ctrlX AUTOMATION, we have gotten very close to this idea. At the heart of this solution is the new generation of control systems, ctrlX CORE.
YOUR OWN SOFTWARE TRANSFERRED TO INDUSTRY CONTROL SYSTEM
The new generation of control systems decouples the hardware from the software. This fundamental difference to other control systems creates numerous advantages. Rexroth makes it much easier for all users to update the control system or to transfer the programmed contents to another control.
Standard control systems from large manufacturers are proprietary. This often prevents small manufacturers from implementing their expert knowledge for special applications. Developing their own electronics is usually not an option for them, so they often use an IPC-system in addition to the actual control system. Problems associated with this, such as the integration effort for continuous high-speed data communication or the uncertain long-term availability of PC-based technology, must be accepted.
Now, these machine manufacturers can directly transfer their specialist knowledge to ctrlX CORE as their dedicated industry control system, thereby securing the long-term availability of their solutions. ctrlX CORE combines an open architecture with industrial-grade capabilities and a serviceability of at least 25 years. Developers also face significantly reduced engineering efforts: In addition to their own functions, they have the option of simply installing additional apps from Rexroth instead of programming them themselves, such as data gateways for MES and IT connections, VPN client, firewall or OPC UA. End-to-end data communication is automatically supplied by ctrlX CORE.
ONE COMPACT CONTROL SYSTEM FOR ALL PLATFORMS
The decoupling of hardware and software comes with further consequences. ctrlX CORE puts an end to the separation of the individual automation architectures. The control system is integrated in the drive and requires no additional space, resulting in particularly compact automation solutions with no performance limitations. As an embedded control system, the ctrlX CORE can simply be extended with I/O and performance modules such as 5G or additional storage. As a plug-in card for the IPC, ctrlX CORE combines a real-time capable control solution and edge computing in one platform.
In a compact space, the ARM architecture’s processor holds enough reserve capacity for all potential applications, optimally distributed to the four cores of the 64-bit multicore CPU. With 1 GB of RAM, ctrlX CORE offers enough room for individual functions. The 4 GB of permanent memory and the additional external microSD card offer enough storage space for future application extensions, thus reducing the variance of the hardware customers and user need. The high-performance 1 Gigabit Ethernet interfaces are optimized for the fast communication of large quantities of data in highly connected systems, equipping users perfectly for the factory of the future.
Thanks to the modern and open software architecture, operators can make use of their own software and apps. This is because the container technology of Linux, the world’s most stable and secure real-time operating system, for the first time in automation opens up all possibilities of integrating functions with separate apps. The ctrlX Data Layer, which can be described as the central nervous system, grants central authorized access to all real time and non-real time data from the installed apps, enabling eight million potential accesses per second. ctrlX Data Layer does not need to be configured, as the apps automatically recognize the hardware and can use the data available in the system.
For the field communication of ctrlX CORE, we rely on the EtherCAT ecosystem as a standard. This opens up the entire range of EtherCAT peripheral devices to designers, who can simply integrate them into their own control architecture. It also reduces the effort for writing interfaces and allows for the combination of components best suited for the application in question. In addition, the control system supports further customary real-time Ethernet protocols as well as more than 30 IT and IoT standards and protocols.
UP TO 50 PERCENT LESS ENGINEERING EFFORT
The engineering apps reduce engineering efforts by up to 50 percent. The control system supplies a web server for simple browser-based engineering. With ctrlX WORKS, the user programs every single function in the PLC app (according to IEC 61131), G-Code, C/C++, Python, Blockly or other languages at the click of a mouse. The digital nameplates of the connected devices are recognized automatically and integrated in ctrlX WORKS. The integrated web server simplifies the visualization on browser-based end devices such as web-panels or consumer tablets and supports wireless diagnostic solutions with smart devices via WiFi and Bluetooth. In addition, the control system includes a simulation environment in which functions can be tested virtually and then applied to the control system.
COMPACT, OPEN, POWERFUL
ctrlX CORE decouples the hardware from the software and offers users the most modern software architecture in the world of automation. This openness gives machine manufacturers and end users an unprecedented level of freedom by allowing them to implement their own expertise into an industry-grade control system and to transfer pre-written functions as apps. What’s more, Bosch Rexroth consequently mirrors the user-friendliness of consumer electronics, making automation as easy as handling a smart phone – even without Google or Apple.
Guest Contributor: Dr. Steffen Haack, Bosch Rexroth
No drive technology is more efficient, compact and robust than hydraulics when dealing with forces in excess of 600 kN. So why is it that the importance of hydraulics is often overlooked in the training and development of our young engineers?
In the modern manufacturing setting, movement is everything along with the resulting data. Little thought is given to hydraulic technology, that is until drive physics comes into play. This is when hydraulic technology comes into its own in managing large forces and delivering robust performance.
Here’s a connected hydraulics ‘Myth Buster’ that demonstrates how the latest smart hydraulics are more versatile and cost-effective than you ever imagined.
THE MYTH: Installation is complex
BUSTED: Designers are no longer required to develop an in-depth knowledge of fluid mechanics and technology and increasingly look for plug & produce modules. These ready-to-install modules simply need an electrical current and a connection to the control communication.
THE MYTH: Commissioning takes time
BUSTED: Our smart, connected hydraulics are now commissioned with the same engineering tools as electric drives and control systems. Functions previously carried out hydromechanically are handled by the latest drive software. There are even software assistants available to guide technicians through the commissioning process and suggest suitable parameters.
THE MYTH: Hydraulics waste energy
BUSTED: There’s a preconception that hydraulics are more energy-intensive than other technologies, but things have changed dramatically. Variable-speed pump drives generate the flow in line with demand and reduce speeds accordingly under partial load conditions. Compared to constantly driven pumps, they reduce power consumption by up to 80 percent – a level consistent with that of electric drives of the same size.
THE MYTH: Hydraulics aren’t IoT ready
BUSTED: Smart hydraulics are a well-established part of IoT in production. Analog valves can be made digitally visible cost-effectively thanks to IO-Link and exchange data available through the control system. Smart valves, with their own control electronics and state of the art field bus connection, are as convenient to use as electric drives.
THE MYTH: Hydraulics are high maintenance
BUSTED: Hydraulics offer a distinct advantage when monitoring operating states and deducing possible wear and expected life cycle. With a few pieces of sensor data, such as pressure differential, oil temperature, optically measured contamination or pressure increase over time, software can assess the health of the system.
This myth busting technology is included in our latest generation of hydraulic power units, allowing young designers and businesses to benefit from all the advantages of our modern, connected innovations.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Many customers aim to increase productivity in short-cycle applications, but the space available for the planned systems is limited and often set in stone. That means that our challenge is to potentially double the quantities being produced, whilst using as little space as possible.
Sounds impossible? Actually, it isn’t.
In North America, we’ve already achieved the impossible for one of our customers. The decisive solution that made all the difference was our highly flexible ActiveMover transfer system. It has enabled the customer to consolidate two stations into one, reduce the footprint by 44% per line and produce almost two and a half times the quantity in the same amount of time over virtually the same surface area.
Increasing capacity in limited spaces.
The customer was faced with unexpectedly high demand for a complex product, which required a rapid increase in production. As the plant only had limited space for new systems the customer was forced to connect two machines with different cycle times via a classic conveyor belt with a limited buffer capacity.
The system occupied a space measuring around 80 m². Three multi-stations in the system covered longer processes in order to shorten lead times. The entire process involved a total of nine work steps.
The engineers knew that this current set-up was never going to manage more than 50 products a minute and any planned capacity increase would require the basic layout to be changed.
That’s where we stepped in.
Our team suggested using the ActiveMover transfer system as the central element to the operation. It is composed of straight sections and curved units, with vertically installed, low-wear linear motors, which form a closed oval shape. Workpiece pallets travel across the entire section to precisely specified positions independently of each other. They can even approach several positions within one station, one after the other, and change their direction of travel. The individual processing stations are installed on the ActiveMover’s oval shape from outside which make them easily accessible.
240% more productive with the same surface area.
The engineers were able to integrate all the stations in the ActiveMover in two steps. This allowed them to decouple processing stations with different cycle times and save on a range of multi-stations. The result: as opposed to the original system’s footprint of 80 m², the customer now needs less than 45 m². That corresponds to a space saving of 44%. At the same time, the output per system has increased by 20%. The customer has more or less installed two machines with increased productivity in the original space available, thereby increasing productivity by 240%.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Hydraulic valves: Directional valve with integrated digital axis controller
What are the current market requirements for hydraulic valves?
We are currently experiencing a transition from classic, analogous hydraulics to connectable digital fluid technology. European machine manufacturers in particular are increasingly digitizing their machine designs and expect that hydraulics can be seamlessly embedded into these connected environments. This means that regarding the level of automation, hydraulics are on a par with electromechanical drives. One of the decisive features in this respect is the seamless integration of intelligent hydraulic valves into different automation topologies via open standards such as multiple Ethernet interfaces.
Which new technical possibilities are available to meet these requirements?
Smart single-axis controllers are already remotely regulating hydraulic motions in a closed control loop. In addition, a powerful motion control is integrated into the on-board electronics of the valve. It performs the target-actual comparison on site and regulates accurately to a few micrometers. The control quality of the system is exclusively determined by the resolution of the measurement systems. These motion controls without control cabinet are increasingly used in saw lines, paper mills and machine tools. In addition, there are smart variable speed pump drives and smart pump controls. They provide completely new possibilities of replacing the throttle controls, which were predominantly used up to now, by more energy-efficient displacement controls. In this way, functions which were previously executed by valves are relocated to the software.
What about the integration of sensor technology into hydraulic valves?
The mass production of sensors for the automotive or the consumer products industry has significantly reduced the costs. Now, sensors are increasingly used in hydraulics. In our opinion, the integration of sensor technology of this kind into existing valve housings is the next step. Regarding condition monitoring, sensors could collect information on fluid quality, temperature, vibrations and performed switching cycles. Via deep learning algorithms, users can then detect wear before it causes malfunction.
Which other possibilities of mechanization does a valve provide?
The degree of freedom regarding connection geometries is already limited by standard requirements. The hydraulics industry discussed the topic of digital hydraulics in great depth some time ago. The idea was and is to control flows in a “stepped” or “clocked” way using single- or multi-bit strategies. In certain applications, this can constitute an advantage compared to continuously variable technology.
Which other innovations in hydraulic valves are relevant in your company?
It is no longer a question whether hydraulic valve technology will benefit from connectivity or not. The only question is when. The current discussions around Industry 4.0 clearly show how important it is to define all required functions and functionalities. Only if mechanisms and sensor technology are standardized across different manufacturers will active connectivity and communication be possible. Even in the future, not every hydraulic-mechanical pressure valve will have digital electronics on board or be connected to a control system or other valves. An imprinted QR code with information on the manufacturer’s settings, functional descriptions or information on replacement seals are a first step towards connectivity. In the area of new materials and production technologies, Rexroth has many innovations in the pipeline. 3D printing of cores for cast housings or direct printing considerably lowers energy consumption during the operation of valves. While the divisibility of the core mold had to be taken into account in the design of the core, this is no longer necessary today thanks to core printing. This means that we can use other channel designs which allow for lower pressure losses and improve energy consumption. For a valve with a flow of 10,000 l/min, the reduction of flow resistance by 10 to 20 percent significantly reduces the operating expenses.
How do these trends affect your products?
With the IAC (integrated axis controller) valves, Bosch Rexroth offers motion control without control cabinet which is completely integrated into valve electronics. It can be fully connected via open interfaces. The same applies to servo-hydraulic axes with their own fluid circuit. In these ready-to-mount axes, pump, valves and cylinders form an assembly to which the machine manufacturer only has to connect power supply and control communication. They use the same commissioning tools and user interfaces which means that all drive technologies provide the same look and feel. Classic servo valves, however, can also be improved further. New plug-in amplifiers with pulse width modulation for on/off valves by Rexroth reduce the surface temperature of the connectors by more than 80 degrees to only 50 degrees. This is particularly interesting for saw lines where easily inflammable sawdust constitutes an explosion hazard.
Outlook: How will valve technology change in the next 10 years?
In 10 years, valves will allow for easier project planning, more comfortable commissioning and more efficient operation and will provide more information before a service case. If service is required, the valve may already have ordered its spare parts.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
IoT-capable hydraulic power unit ensures efficient production
With the newly developed, intelligent CytroBox unit, Rexroth combines the benefits of hydraulics with low energy consumption and software-based functions. The integrated CytroConnect IoT service ensures higher availability and avoids unplanned downtimes. With this IoT service, operators can monitor operating statuses and plan maintenance in a cost-effective manner. As a result, fluid technology has taken a further step towards the factory of the future.
The digitalization of mechanical and plant engineering means more than decentralized intelligence, integrated sensors and connectivity. This applies to hydraulics too. With its power density and immunity to impacts and vibrations, hydraulics plays a central role as an important drive technology in Industry 4.0 too. The compact CytroBox unit is revolutionizing hydraulic pressure supply. CytroBox is a modular hydraulic power unit for the medium performance range from 7.5 kW to 30 kW. It comprises optimally tailored, impressively compact components. Compared to previous units, considerable amounts of space can be saved.
75% less oil
One of CytroBox’s unique selling points is it compactness. This is possible because the hydraulic power unit can be integrated into a factory like a control cabinet, i.e. upright. The tank no longer supports all other components – Rexroth developed a special supporting structure for this purpose. In addition, a degassing flow-optimized tank is used. On the basis of extensive CFD simulations, the developers improved the tank geometry so skillfully that the new unit needs only a quarter of the oil required by classic designs: instead of 600 liters, 150 liters are now enough – with at least the same service life. The drive unit – a component which usually takes up a large amount of space in hydraulic power units – is equally compact. The asynchronous servo motor has been replaced by a synchronous servo motor. This is the most efficient motor design, producing the same torque even though it is 80 to 90% smaller. The manifold too was redesigned: thanks to 3D printed sand cores, the block including the internal flow geometry is now cast. As a result of this flow-optimized inner structure, less material and space are required. Thanks to all these measures, the CytroBox has a footprint of just 0.5 square meters instead of one and a half to two square meters. This represents a saving of up to 75%. On top of this, there are energy savings of up to 80% as well as a 10 dB(A) reduction in noise emissions. As a result, noise emissions are lower than 75 dB(A).
Connected for the factory of the future
In the CytroBox, machine manufacturers will find a ready-configured drive controller with numerous integrated functions. Various sensors provide information on the current filter, oil or drive status. The collected sensor data are bundled via IO-LinkMaster and pre-processed by the drive controller so that they can be integrated flexibly into modern machine designs. This means that the CytroBox is IoT-ready.
CytroConnect Monitor
With the CytroConnect digital service, operators have all information regarding the CytroBox at their fingertips at all times – whether it be information regarding the standardized visualization of the component and operating status or chargeable IoT services such as forthcoming maintenance work and predictive maintenance analyses using Rexroth’s Online Diagnostics Network (ODiN).
The data collected are transferred to the browser-based CytroConnect Monitor web dashboard via Multi-Ethernet or 4G-LTE. As a result, operators can be kept up to date regarding the current operating status and key status indicators on any end device (tablet, smartphone, PC). This plug and play service is free of charge and can be used without additional installation work. CytroConnect is implemented in the CytroBox as standard.
Greater availability thanks to additional analysis functions
In addition to the CytroBox’s automatic status monitoring, maintenance personnel and maintenance managers can add extra solutions for various applications as add-ons. These pay-per-use payment models include additional IoT analysis tools and can be subscribed to on a monthly basis.
For optimizing maintenance processes, the CytroConnect Maintain module offers access to historical sensor data as well as messages if maintenance is required or in the event of critical operating statuses. Pre-defined and custom rules allow customers to improve their maintenance strategy on an ongoing basis. Customers benefit from scalable software solutions from the Bosch IoT portfolio such as the Nexeed Production Performance Manager and the integrated know-how of the Rexroth domain specialists. The Nexeed Production Performance Manager is a condition monitoring software solution for systematic production optimization.
CytroConnect Maintain
With CytroConnect Maintain, data concerning the most important components for reliability and operating life (the hydraulic oil and the drive unit) are assessed. Comprehensive insights into the correlation between the speed of the servo motor and the flow allow the monitoring of system leakage, while correlations between motor data and the operating pressure allow conclusions regarding drive behavior. The leakage sensor, temperature and level sensor, particle sensor, water sensor and oxygen sensor are additional data sources which can be used to make a status diagnosis.
Planning predictive maintenance efficiently
A further add-on, CytroConnect Predict, uses the machine learning algorithms of the Rexroth Online Diagnostics Network (ODiN) for a predictive analysis of the system. With this IoT service, the power curves for a wide range of components are recorded for data analysis purposes. In the event of deviations, the system automatically calculates the expected remaining operating life of the relevant component and informs the operator immediately via a push message. As a result, predictive maintenance application cases can be taken into account predictively in the operator’s maintenance plans, thus ensuring maximum availability.
Conclusion
This new form of hydraulics is energy-efficient, quiet, space-saving and intelligent. With the integrated CytroConnect IoT service, the CytroBox offers anything from transparent, efficient machine monitoring to intelligent predictive maintenance measures. Thanks to the CytroBox, fluid technology is now one step closer to the factory of the future.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Time and cost savings through standardization and proven designs
Faster, simpler, more productive and cost-effective: Rexroth’s new modular system called ABMAXX speeds up the engineering and commissioning of large hydraulic power units in projects designed to modernize existing systems or construct new ones. The hydraulics specialists are able to create a quote complete with a hydraulic circuit diagram, a parts list, a 3D model and dimensions all within a maximum of five working days. As such, system manufacturers and end users can reduce engineering lead times alone by 80 %. The pre-configured ABMAXX modules are composed of highly available standard components. The modular approach reduces costs by up to 35 % and increases operational availability.
When constructing new or modernizing existing steelworks and rolling mills, large-scale presses and test systems or the central media supply of factories, hydraulics is and will continue to be the key drive technology both now and in the future on account of its high power density, robustness and durability. Thanks to the wide range of components available, there is plenty of scope for designing tailored solutions. In the past, system manufacturers and major end users defined their own standards which they implemented with their own resources in development. In light of ever increasing cost pressure and a global shortage of qualified specialists, these days they are increasingly scrutinizing that approach. Their main goal is to achieve pressure and quantity as cost-effectively as possible.
This is where Bosch Rexroth’s modular system ABMAXX comes in. The company is the first hydraulics manufacturer to come up with a modular solution with which system manufacturers and end users can significantly reduce the complexity of engineering large power units for 24/7 operations. On the one hand, it enables them to take advantage of all the economic benefits of cross-manufacturer standardization yet, on the other hand, the modular design provides ample opportunity for coming up with application-specific solutions.
Three pressure ratings and five modules
The concept initially covers tank sizes ranging from 2,000 to 12,500 l. With its three pressure ratings, namely 160, 210 and 315 bar, the concept satisfies the trend for higher operating pressures, thus ensuring it will be fit for the future. Achievable flows currently range from 345 l/min to 2,160 l/min. These basic conditions meet the typical requirements of numerous large plants.
In order to transform the benefits of standardization into shorter project lead times, Rexroth has defined five modules: tank, pump block, circulation unit, cooling and filter unit, and safety controls. Each module is based on proven constructions with a tried-and-tested design. As such, Rexroth is able to considerably reduce the risk of initial errors in the construction.
Simplify the design – Up to 80 % time savings in engineering: Offer in a maximum of five working days
The benefits of standardization and modularization are clear to see at the project planning phase. These days, depending on the level of complexity involved, planning customized individual power units in line with relevant company standards can take four to eight weeks. Rexroth is able to whittle this phase down to a maximum of five working days with its modular system ABMAXX. Rexroth is able to provide 3D models complete with dimensions and parts lists as well as the hydraulic circuit diagram and a quote all based on the customer’s specifications within just one week. This shortens the engineering effort by up to 80 %. This enables designers to save valuable time, which they can use on their projects, and enables system manufacturers to shorten the quote phase.
Streamline the installation – Up to 35 % lower costs through standardization
In comparison to using completely newly designed large power units each time, system manufacturers and end users achieve between up to 35 % direct cost savings on account of modularization and standardization. Internal costs are also reduced thanks to shorter project lead times and shorter time to market for system manufacturers. End users can also use individual ABMAXX modules such as the pump block in order to modernize their systems step by step and improve energy efficiency, for example. The wide range of Sytronix variable-speed pump drives is also able to unlock considerable potential here for reducing power consumption based on demand. Tried-and-tested safety controls help designers to comply with corresponding safety regulations and documentation requirements in line with standards. The choice of standard components also reduces delivery times and cuts costs.
Through its global production network, Rexroth also ensures high local added value and a quick response to customer requirements. Competence centers for power units construction in Europe, Asia and the Americas cover all major regions with short distances.
Maximize the productivity – Latest technology for maximum efficiency
At ABMAXX, Rexroth uses latest technology for all components and the hydraulic design. The components set standards in terms of dynamics and life time. Proven design principles increase productivity through high repeat accuracy and energy efficiency. The wide range of variable-speed pump drives in the Sytronix family opens up considerable potential for reducing energy consumption as required. This reduces life cycle costs sustainably.
With the three pressure stages up to 315 bar, the concept meets the current state of the art, but already reflects the trend towards higher working pressures.
Minimize the downtime – User and maintenance friendliness increases availability
The modules have been designed so as to ensure optimum component accessibility. What’s more, standardization reduces the required maintenance and servicing over the entire life cycle as the standard components used are available at short notice and will be part of the product range over the long term. The modules are composed of highly available Rexroth standard components. They are designed to deal with harsh environmental conditions including humidity, heat, dust, contamination and vibration.
The components are designed to work equally well with mineral oil as with water-based media such as (HFC) and synthetic water-free fluids (HFD). As such, Rexroth’s axial piston pumps achieve the same service life regardless of the media involved.
The pump block and the circulation unit are fundamentally equipped with stand-by units in order to guarantee maximum availability. The pump block and the circulation unit are always equipped with stand-by units for uninterrupted 24/7 operation.
First power units already in use
Bosch Rexroth has already made several ABMAXX as complete power units and individual modules for modernization projects. System manufacturers for metallurgical plants and operators of steelworks and rolling mills are among the first users. However, potential applications exist across all sectors of industry as well as in large-scale projects.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
The ctrlX FLOW6D planar system allows contactless high-performance transport and positioning in six dimensions.
No drive technology is more efficient, compact and robust than hydraulics when dealing with forces in excess of 600 kN. So why is it that the importance of hydraulics is often overlooked in the training and development of our young engineers?
CMA/Flodyne/Hydradyne
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