Bosch Rexroth

How much does a robot cost?

by Adam Steger, Kassow Robots

Navigating the complex world of robotics integration can be daunting, especially when faced with the varied costs and technical specifications.

The question, “How much does a robot cost?” is not easily answered as the price is influenced by various factors, such as; technology, application, and design. 

In this article, we’ll navigate through the confusing world of robot pricing to provide a clear and detailed breakdown of the costs involved.

By understanding these key elements, you’ll be better equipped to make informed decisions that suit your budget and operational goals. 

Stay with us as we discuss the specifics and shed light on how to effectively manage these investments.

Key Takeaways

Cost Influences

  • Technology Level: Advanced technologies such as AI, machine learning, and real-time data processing greatly increase a robot’s cost.
  • Design Customization: Custom features tailored to specific tasks or environments can escalate costs due to specialized design and production.
  • Application Specificity: Robots designed for specific industries or critical tasks often come with a higher price tag due to the specialized capabilities and certifications required.

Types and Costs

  • Industrial Robots: Essential for tasks like welding and assembly, with prices typically ranging from [$25,000 to $400,000] depending on functionality and sophistication.
  • Cobots: Designed for safe interaction with humans in shared spaces, generally cost between [$15,000 and $45,000], reflecting their accessibility and technological features.
  • Cartesian Robots: Ideal for precise linear motions, used in applications such as 3D printing, priced between [$10,000 and $50,000] based on size and precision capabilities.
  • Humanoids: Advanced robots mimicking human behaviour, significantly more expensive, typically starting at [$100,000 and can exceed $1 million], due to high-level AI and mobility technologies.

Considerations

  • Application Suitability: Ensure the robot’s capabilities align with the intended tasks and operational demands.
  • System Compatibility: Assess integration needs with existing systems to avoid additional costs for modifications.
  • Maintenance Expenses: Consider ongoing maintenance costs, availability of parts, and technical support to ensure sustainable operations.
  • Training and Integration Costs: Significant resources are needed for training on the proper use and maintenance of new robotics systems to ensure safety and efficiency.
  • Adaptability and Longevity: Robots that can be easily reprogrammed or upgraded can adapt to changes and extend their useful life, offering better long-term value.
  • ROI Metrics: It’s crucial to define metrics to assess the return on investment from robotics, considering financial returns as well as quality, efficiency, and customer satisfaction improvements.

What influences the price of a robot

When considering a robot purchase, it’s important to understand the characteristics that contribute to its price.

The cost can be greatly influenced by the robot’s design complexity, materials used, the technology it incorporates, and its intended application. 

Factors such as the precision of tasks it performs, the software it requires, and additional features like sensing and vision systems also play a role. 

For more detailed insights on a specific robot model, like the 7-axis collaborative robot models from Kassow Robots , each specification adds layers to the cost.

Technology and Software

The sophistication of the technology and software within a robot influences its price. High-end robots incorporate advanced algorithms for pathfinding, autonomous decision-making, and machine learning, which require substantial investment in research and development. 

Additionally, user interface software that enhances the usability and functionality of the robot also adds to the cost. 

These systems must be continually updated and optimized to handle complex tasks and easily interact with human operators and other automated systems. 

The integration of Internet of Things (IoT) connectivity and real-time data processing capabilities further escalates the price, making the robot more adaptable and efficient but also more expensive.

Design and Customization

The level of design and customization involved in a robot’s creation directly impacts its cost.

Robots designed with specific requirements for particular industrial tasks, such as extra limbs, specialized tools, or enhanced mobility features, require unique engineering and design solutions. 

Each custom feature needs to be planned and tested, which increases the research and development cost. 

Furthermore, specialized designs often necessitate the use of unique components and technologies not typically found in standard robots, driving up manufacturing complexity and costs. 

This custom engineering ensures the robot can perform designated tasks efficiently but also results in a higher price tag due to the increased labour and material costs involved in its production.

Material and Build Quality

The choice of materials in robot construction is essential as it affects both the durability and functionality of the robot, which influences its cost. 

High-quality materials that can withstand high stress, wear, and environmental conditions are necessary to ensure the longevity and reliability of the robot. These materials often come at a premium, especially when they are lightweight yet strong metals or composites that offer superior performance. 

Additionally, the precision required in machining and assembling these high-grade materials increases manufacturing costs. 

Robots built with less expensive materials may reduce upfront costs but can lead to higher maintenance expenses and shorter lifespans, which could increase overall costs in the long run.

Application and Industry

Robots are increasingly tailored for specific industries, which can affect their costs. For example, robots designed for the healthcare sector may require precise and gentle handling capabilities, sophisticated diagnostic tools, and compliance with strict regulatory standards. 

Similarly, robots used in manufacturing might need to handle heavy loads, perform at high speeds, and operate continuously. These specialized capabilities need advanced technology and strong construction, which increases the costs. 

Additionally, the critical nature of tasks performed by these robots often requires extensive safety features and redundancy systems, further increasing their price.

Image Source: Alexander Burkle / Kassow Robots

Production Volume and Economies of Scale

The production volume of robots can also influence their cost. Limited production runs are more expensive on a per-unit basis because they cannot capitalize on the economies of scale enjoyed by mass-produced models. 

Custom or low-volume robots often require specialized assembly processes and parts, which are more expensive than those used in high-volume manufacturing. 

Conversely, when robots are produced in large quantities, the cost per unit decreases due to more streamlined manufacturing processes and bulk purchasing of materials. Therefore, companies looking to use robots extensively might find it more cost-effective to invest in models that are produced on a larger scale.

Research and Development Costs

The investment in research and development (R&D) impacts the cost of robots. Developing clever robotic technologies often requires time and resources in R&D to create, test, and refine advanced systems. 

This includes the costs associated with prototyping, simulation, and field testing to ensure that the robots meet specific performance criteria and safety standards. 

Regulatory Compliance and Certification

Robots must often meet various regulatory and safety standards, which can vary widely depending on the industry and the region in which they are sold. 

Compliance with these regulations can involve additional costs related to certification processes, modifications to meet specific legal requirements and ongoing compliance monitoring. 

For example, robots used in pharmaceutical or food production environments must adhere to especially strict standards, adding to their overall cost.

Training and Support Services

The complexity of modern robots often requires training for end-users. The cost of providing training programs, user manuals, and technical support can be considerable. 

Additionally, ongoing support services, including maintenance and updates to software and hardware, also contribute to the total cost of ownership of a robot.

Supply Chain and Logistics

The cost of parts and the complexity of the supply chain logistics involved in sourcing and assembling robot parts can affect the final price of the robot. 

Fluctuations in material costs, tariffs, and transportation fees, as well as the efficiency of the supply chain, can all impact costs. 

Robust supply chains are essential for timely and cost-effective production but can be expensive to establish and maintain.

Brand and Market Positioning

The brand reputation and market positioning of the robot manufacturer can also play a role in pricing. 

Established brands with a proven track record of reliability and excellent service might charge a premium for their robots. 

Additionally, pricing strategies may vary based on market positioning, with some brands positioning themselves as providers of cost-effective solutions while others target the luxury or high-performance segment of the market

Types of robots and their price tags

Industrial robots

Industrial robots are essential in modern manufacturing, capable of performing a variety of tasks including welding, painting, and assembly with incredible precision and efficiency. 

The cost of these robots is determined by factors such as payload capacity, reach, speed, and the level of customization required. 

Basic models start at lower prices, which typically include a controller and basic software. More advanced models with comprehensive customization options, higher payload capacities, and enhanced capabilities will have a higher price tag. 

Such price variations reflect the various needs of different industries, from automotive to electronics, where the demands on robotic systems differ widely. 

The substantial range in prices ([$25,000 – $400,000]) accommodates businesses of all sizes, from small manufacturers to large enterprises with heavy-duty requirements​.

Cobots

Collaborative robots, or cobots such as the Kassow Robots 7-axes cobot, are designed to interact directly with human operators, emphasizing safety and flexibility in shared workspaces. 

Unlike traditional industrial robots, cobots are equipped with advanced sensors and safety features to ensure safe operation without the need for protective barriers. 

The cost of cobots varies depending on their design, payload, and the complexity of the tasks they are programmed to perform. 

Prices for simpler models that perform light duties have a smaller price tag when compared with more advanced models equipped with high-tech features such as vision systems and enhanced learning capabilities. 

This price range [$10,000 – $50,000] reflects the growing market for robots that are accessible to small and medium-sized enterprises and not just large manufacturing facilities.

Interested in our solutions?

Browse our range of cobot series and contact our sales to get more information.

Browse products

Cartesian Robot

Cartesian robots are characterized by their three principal axes of movement — X, Y, and Z — which makes them ideal for precise linear applications such as 3D printing, CNC machining, and assembly operations where high accuracy is required. 

The simplicity of their design generally makes them more affordable than more complex robotic systems. 

Prices for Cartesian robots can range from about [$10,000 – $50,000] with the more basic models costing a lot less than models with better reach and load capacity, precision capabilities, and customized control systems. 

This cost range supports industries that require precise, repetitive movements in a controlled environment.

Humanoids

Humanoid robots are among the most technologically advanced types of robots, designed to replicate human motion and interaction. 

They use sophisticated AI, machine learning algorithms, and sensory systems to navigate complex conditions and perform varied tasks. 

Due to their sophistication and the technology required, humanoid robots are typically the most expensive. 

Prices range from roughly [$100,000 – $1 million] with the more advanced models, equipped with the most advanced features and capabilities, having the highest prices

These robots are mainly used in research, healthcare, and service industries where human-like interaction and adaptability are crucial. 

This price bracket highlights the cutting-edge nature of humanoid robotics and the investment required for their development and deployment.

What to consider before buying a robot

Before purchasing a robot, it’s essential to define your needs and consider factors like compatibility with existing systems, long-term costs, and potential operational enhancements. 

We are here to help you select a robot that aligns with your operational goals, ensuring efficiency, compliance, and a solid return on investment. 

Let’s take a deeper look. 

Define the Purpose and Requirements

Before investing in a robot, clearly define what you need the robot to achieve. Consider the tasks it will perform — whether it’s assembly, packaging, inspection, palletizing, labelling, or quality control. 

This will help determine the type of robot you need, such as industrial, collaborative, or service robots. 

Different tasks require different levels of precision, speed, and payload capacity. Aligning your business needs with the robot’s application capabilities ensures that you select a robot that can meet your operational goals without overspending on unnecessary features.

Compatibility With Existing Systems

Evaluate the compatibility of the new robot with your current machinery and software systems.

It’s important to make sure that the robot can integrate into existing production lines or work environments. Check if additional equipment or software is needed for integration and whether the robot supports the communication protocols used in your facility. 

Incompatibility can lead to additional costs for modifications or updates to your systems, so prior confirmation will save time and resources in the long run.

Scalability and Flexibility

Consider the scalability of the robotic system. As your business grows, your robotic needs might change, requiring different functionalities or additional units. 

Choose robots that are known for their flexibility in handling various tasks or those that can be easily upgraded with new capabilities. 

Investing in scalable and flexible systems can prevent future bottlenecks and reduce the need for complete overhauls as your operation expands.

Maintenance and Support

Understanding the maintenance needs and the support available for a robot is essential. Ask about the maintenance schedule, availability of spare parts, and the technical support provided by the manufacturer. 

Robots with high maintenance costs can affect the total cost of ownership. Also, consider the availability of local service technicians who can perform repairs and regular maintenance to minimize downtime.

Total Cost of Ownership

Beyond the initial purchase price, assess the total cost of ownership, which includes installation, maintenance, training, and potential downtime costs. 

Estimate energy requirements, consumables, and whether the robot will need regular software updates. A cost analysis will help in making an informed decision by comparing the long-term financial impacts of different robotic systems on your operations.

Regulatory Compliance and Safety Standards

Before investing in a robot, ensure it meets all relevant regulatory and safety standards for your industry and region. Compliance is vital in sectors such as healthcare, food processing, and automotive manufacturing, where safety and precision are important. 

Non-compliance can lead to legal issues, fines, or operational halts, which can be costly. Understanding the certifications that the robot has, such as ISO standards or specific industry compliance, is needed to protect your operations and ensure worker safety.

Environmental Considerations

Environmental factors such as temperature, humidity, dust, and exposure to chemicals can impact a robot’s performance and lifespan. Choose a robot designed to withstand the specific conditions of its working environment. 

For example, robots in heavy industrial settings may require strong construction and protective measures against heat and particulates, whereas cleanroom robots need specific designs to prevent contamination.

Staff Training and Adaptation

Evaluate the level of training your staff will need to operate and maintain the new robotic system. 

Assess whether you have the right skills available internally or if you will need to hire new staff or provide training to existing employees. 

The ease of use of the robotic system and the availability of vendor training programs can also be a decisive factor. Ensuring your team is well-prepared can improve productivity and reduce downtime due to operational errors.

Future-Proofing Technology

Invest in technology that can adapt to future advancements. This includes considering whether the robotic system is equipped with abilities such as machine learning, adaptability to new software updates, and compatibility with newer technologies. 

Choosing a robot that is suitable for upgrades can extend its useful life and protect your investment.

Return on Investment (ROI)

Calculate the expected return on investment (ROI) for the robotic system. This includes analyzing productivity gains, cost savings from labour reductions, and improvements in quality and consistency. 

A clear understanding of the financial impact and payback period will help justify the investment and ensure that the robot meets your business objectives. 

Financial planning is key to ensuring that the robot contributes positively to your bottom line.

Interested in our solutions?

Browse our range of cobot series and contact our sales to get more information.

Browse products

FAQs

How much in approximative costs can you expect to save on an assembly line with the help of cobots? 

Integrating cobots (collaborative robots) on an assembly line can lead to cost savings of approximately 20-30% by enhancing operational efficiency and reducing labour costs. These savings are achieved through the automation of repetitive tasks and allowing human workers to focus on more complex operations.

What is the average price tag of a robot?

The cost of robots varies widely, from a few thousand dollars for basic models to several hundred thousand or more for advanced, specialized machinery.

How long does it typically take to see a return on investment from a robot purchase?

The time it takes to see a return on investment (ROI) from a robot can vary based on the type of robot and its application. However, for industrial and manufacturing settings, companies often report seeing an ROI within two to three years, especially when robots are used in high-volume or high-labor-cost tasks.

Can robots be leased or rented instead of purchased outright?

Yes, robots can be leased or rented, providing a more flexible financial option for businesses that need robotic technology but may not be ready to commit to a full purchase. Leasing or renting can also offer the advantage of keeping the technology up-to-date, as companies can upgrade to newer models at the end of the lease term.

What are the ongoing costs associated with operating a robot?

Beyond the initial purchase, the ongoing costs of operating a robot include maintenance, repairs, software updates, and possibly energy consumption. Training for personnel on how to operate and maintain the robot also adds to the costs.

Final Thoughts

Understanding the cost of robots involves considering their technological complexity, design, materials, and intended application. 

This guide provides a foundational understanding to help you navigate the initial investment and long-term benefits of robotic integration.

Equipped with this knowledge, businesses can make informed decisions on their investments in robotics, ensuring they meet their operational needs and maximize return on investment. 

With careful planning and consideration, integrating robotics can be a transformative investment for any enterprise.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth and Kassow Robots distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

Handling small parts the easy way

Author: Jürgen Fischer Position: Product Manager Linear Motion Technology, Bosch Rexroth AG

Whether it be consumer goods, medical technology or 3D printing: Countless small parts need to be moved precisely and cost-effectively. This is now much easier.

When you hear “SMS”, you don’t immediately think of linear modules. But you should remember the term in this context as well. After all, these three letters refer to a cutting-edge, particularly cost-effective solution for handling the small parts found in a wide range of sectors. They include the consumer goods and packaging industry, semiconductor and battery production, 3D printing, the automotive sector, medical technology and mechanical engineering.

Small Modules SMS: Handling small parts the easy way

Exact positioning, compact and low maintenance requirements

Many of these applications require a high repeatability of up to ± 0.005 mm with low to medium dynamics. And if the design is compact, robust and requires little maintenance – all the better! The new SMS linear modules from Bosch Rexroth meet exactly these requirements and help to reduce system and life cycle costs. They also welcome an alternative to pneumatically driven axes and provide a good opportunity for electrification with all of the associated benefits.

Robust linear modules with ball screw assembly

The compact SMS modules with ball screw assembly (Small Modules Screw driven) are manufactured to the usual Rexroth quality standards and impress with their flat aluminum profile offering integrated, precise guidance. In addition, a magnetically fixed steel cover strip protects the components inside.

Small Modules SMS available for five different sizes.

Quick selection, available from stock

To ensure the shortest possible delivery times, the SMS linear modules can be ordered from stock. The five tailored sizes range from 30 to 120 mm and are suitable for travel ranges of up to 1,200 mm. They can be selected and ordered easily from the Rexroth online shop with the help of a product selector. Optional attachment sets for popular servo motors are available – either as a belt side drive or a flange coupling. Naturally, a choice of motors and drive controllers from Bosch Rexroth is available too.

Conclusion: Expanded portfolio saves time and money

The SMS linear modules expand the range of linear axes, adding an ultra-compact series with a particularly flat design offering excellent value for money. Simple positioning and delivery tasks can thus be carried out economically – and at short notice. This opens up an attractive electrification path for greater precision, flexibility and energy efficiency in production – two key qualities in the Factory of the Future.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

Cobots: a key part of easy industrial automation

Cobots (collaborative robots) are becoming a vital way to help manufacturers improve their productivity. Strong, fast and simple to use, they can make production processes more efficient and business more competitive. We look at what cobots do, how they support production and how Kassow Robots has been growing since the majority stake acquisition by Bosch Rexroth.

A lot has happened in the year and a half since the Danish cobot manufacturer became part of Bosch Rexroth: With the move to a new location, it was possible to expand the production capacity in a highly professional manner and to increase revenue significantly. The team has grown: in Copenhagen, where the company was founded, at the subsidiary in Prague, and within the sales team based in Ulm. Kassow Robots has greatly expanded its global sales activities by participating in trade fairs in various countries and in events within Bosch Rexroth. The dynamic development has one constant: CEO and founder Kristian Kassow as an intensive driving force.

Cobot market continues to expand

Cobots are an important part of intelligent manufacturing and an effective measure to reduce the pressure on costs while securing production in times of workforce lack. They are increasingly used in industry to automate processes which are done in the same working space as human colleagues. Cobots enable small and medium-sized enterprises to automate with their own staff – because collaborative robots can be easily programmed and operated by almost anybody. There is already a high demand for them, and the market is set to continue expanding*.

They can perform a range of jobs easily and offer plenty of flexible automation options with significant benefits:

  • They can be integrated easily into the production process with minimal changes to the rest of the line – providing a cost-effective entry-point to robotic automation, which can be expanded over time.
  • They are fast and accurate, which improves production efficiency and helps lower overall operating costs.
  • They work safely alongside people.
  • Cobots take on laborious or repetitive tasks, enabling the human workforce to focus on more value adding tasks – which helps address skill shortages.

Seven axes and powerful flexibility

At Bosch Rexroth, we see cobots as an important and versatile part of future proof solutions for factory automation – which is why we’ve expanded our product range with the collaborative robots of Kassow Robots.

The company develops, produces and sells unique and efficient 7-axes lightweight collaborative robots for industrial applications. Their cobots are extremely user-friendly, giving companies great flexibility and enabling small and medium-sized enterprises without in-house robotics specialists to achieve complex automation and programming cost-effectively and independently.

Kassow Robots has designed its cobots to work in the tightest of production spaces. Equipped with seven axes, they can reach around corners like a human arm, and can lift a payload of up to 18 kg. Currently the product family comprises five collaborative robot models, with reaches of 850 to 1800 millimeters, and joint speeds of up to 225 degrees per second.

New products are continually in development. At this year’s Automatica, Kassow Robots presented the Edge Series: a prototype of a controller integrated into the cobot base, delivery of which will start in the beginning of 2024. With no extra controller cabinet to be placed near the cobot, the 7-axes cobots can then be used in even more flexible and space-saving ways, which is very important for mobile applications like AMRs (Autonomous Mobile Robots).

Setting business up for further growth

Thanks to the majority shareholding of Bosch Rexroth, Kassow Robots is now expanding its production and its sales activities worldwide. With CEO and co-owner Kristian Kassow leading the company, the team is primed to introduce their cobots on the world stage, through trade show participation and internal events as well as developing the sales partners network. It currently includes more than 60 partners worldwide, and it continues to grow.

Engineer working on Kassow Robots Edge Series

Electronics engineer Nikolaj Thorup Frederiksen working on the new KR Edge Series (image source: Kassow Robots).

To facilitate this growth, Kassow Robots moved to a new location one year ago. The modern building in Kastrup near Copenhagen offers sufficient space not only for increasing production capacity, but also for development activities and offices. Higher production capacity also means more square meters for testing – the Kassow Robot cobots run through an automated test program after assembly, before being packed for delivery.

 In the last almost 18 months we have gone through an exciting and challenging period of scaling up, which we mastered successfully thanks to our highly motivated team. Naturally our primary efforts have been to deliver cutting edge technology in high quality according to the market requirements. 

Kristian Kassow, CEO of Kassow Robots

How do cobots work with Bosch Rexroth products?

All five Kassow Robots lightweight cobots communicate seamlessly with the control platform ctrlX CORE. Additionally, an ecosystem of drivers for easy configuration of peripheral devices, communicating with robots, like grippers and cameras, is being further expanded. So the number of compatible end-of-arm-tools and devices is steadily growing, enlarging the scope of application day by day.

The cobots can also be equipped with the Smart Flex Effector from Bosch Rexroth, which facilitates joining processes, complicated assembly movements, or difficult handling tasks that were previously impossible to master mechanically. Through the unique combination of a sensor system, with kinematics operating independently in six degrees of freedom, this compensation module gives industrial robots a sense of touch similar to the human hand.

Convincing benefits: a major order for cobots from Project Service & Production

For the restocking of cabling machines with bobbins, Project S&P, system integrator and customer of Kassow Robots, specializing in the optimization of production processes, has worked out an automation solution for the textile industry.

Mobile handling solution with Kassow Robots cobot

A flexible solution for the restocking of cabling machines with bobbins (image source: Project S&P and Kassow Robots).

To ensure the smooth changeover of yarn packages, Project S&P developed and built a mobile handling solution with a cobot. The automated guided vehicles are equipped with a magazine, a handling system and a KR1018 cobot from Kassow Robots. A linear axis is part of the solution, so that the cobot can load the cabling machines at different heights.

Beyond taking over the workforce’s job of handling very heavy weights, the automation capabilities of the 7-axes KR1018 contributes to smoother yarn package changes. The triple effect of reduced personnel costs, of better quality at the same time due to more gentle package handling and of the ability of material traceability – all this is an achievement of this automation solution. It would not be possible with a conventional 6-axes robot. The success of this has meant that a larger number of cobots are being delivered to the customer.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

What is “smart mechatronics” and how can it support fastener manufacturing?

01/23/2023 

Brad Klippstein, Product Management – Mechatronics Bosch Rexroth

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.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

Bosch Rexroth breaks new ground with the planar system ctrlX FLOW6D

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.

To learn more, please visit www.boschrexroth.com

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

Step into a more productive factory
Web Editorial Team | Editor

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.

Digital Twin

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.

Active cockpit

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.

Productivity boosters

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

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.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

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PERFORMANT AS ON DAY ONE: WHY HYDRAULICS MUST BE REPAIRED THE ORIGINAL WAY

Guest Contributor, Bosch Rexroth

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?

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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.

Figure2.png

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.

Figure3.png

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.

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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.

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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.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

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The Smartphone of Automation

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.

5 HYDRAULICS MYTHS
Guest Contributor: Dr. Steffen Haack, Bosch Rexroth

br_hydrolicmyths_hero_dec19.jpgNo 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.

 

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

240% MORE PRODUCTIVITY IN THE SAME SPACE WITH ACTIVEMOVER

Guest Contributor: Jeroen Brands, Bosch Rexroth

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.

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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%.

 

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.