Bosch Rexroth

Classic qualities remain in demand

Guest Contributor: Thomas Fey, Bosch Rexroth

Machine tools are rightly considered to be technology carriers and trailblazers for other industries in mechanical engineering. They frequently are the first to try new technologies and optimize existing ones. For this reason, machinery users expect every new piece of equipment to increase productivity.

The users of machine tools face global competition. When they invest in new machines, they generally have two main issues in mind: cycle times per processing step and throughput times for the completely processed component. At the same time, they continue to increase their requirements for surface quality and tolerances. Machine tool makers respond with higher dynamics in all movements and the integration of additional processing technologies. Increasing numbers of sensors are now monitoring the processing job to create reproducible quality.

These three trends – more speed, more completeness and more precision – place increasing demands on the control system. Every gain in speed requires shorter control cycles. The CNC control unit must provide additional capacities to integrate additional processing stations and technologies. At the same time, data transmissions in a machine are rising inordinately because of the sensors.

In this regard, Bosch Rexroth has significantly raised the bar with its new generation of the CNC system MTX. The smallest version is a compact solution for up to 12 axes. The highest performance level extends all the way to 250 axes with a hardware control system. In the controllers, high-performance, multi-core processors intelligently assign the different tasks for CNC, PLC and communications. Fluctuating processor utilization levels that vary based on the configuration for the application remain non-reactive and ensure constant overall performance. This is important because the CNC system solution provides the shortest PLC and CNC cycle times even as the number of axes rises, even for high-speed processing. In the process, machine manufacturers can significantly increase the dynamics of their products.

More computing power for increased processing quality and the parallel exchange of information with superior IT applications: Rexroth’s CNC system MTX. *(Source: Bosch Rexroth AG)*

At the same time, more and more users, particularly automotive industry suppliers, are investing in production lines for complete processing. To reduce wrapping and handling times, they are looking for multi-technology solutions. For this reason, machine manufacturers are increasingly combining classic processes like drilling, milling and grinding into one system. They are also increasingly adding non-cutting technologies like laser cutting and welding or additive processes. The printed components are given their final shape in subsequent processing. These technologies are sometimes very computationally intensive. They are also done simultaneously with other processing steps. The idea of offsetting these performance peaks by using separate control systems with a machine’s own hardware significantly increases the complexity of automation. The MTX offers sufficient power reserves here to display all currently known uses on hardware. This is also the case for the automation of machine tools. A number of manufacturers have said that between 50 percent and 80 of all machines they deliver have integrated loading and unloading systems. The MTX also takes on this task.

Increased productivity through complete processing: Manufacturers are increasingly combining cutting and non-cutting technologies like laser cutting and welding as well as additive processes in a single machine. *(Source: Bosch Rexroth AG)*

While these trends move forward, machine manufacturers are also increasingly adding more and more sensors. These data support process optimization and monitor the processing in situ. With fast I/O, the MTX ensures that the sensor data are transferred and analyzed in real time. In the process, it lays the foundation for short control cycles that measurably increase the precision of processing and surface quality.

In short: To achieve the classic qualities of increased productivity, all roads lead to higher-performance CNC system solutions. The MTX currently offers the highest computing capacity and system capability for rising demands by offering increased dynamics, technology combinations and amount of sensors.

Learn more: CNC system solution MTX

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.

More efficient automation with explosion protection

Guest Contributor: Frank Kaufmann, Bosch Rexroth

You think that drives for potentially explosive areas are complex to implement or technologically suboptimal? In this way you simplify your engineering and play in the first league on the automation side.

Are you automating in potentially explosive areas and tired of having to make compromises when choosing a drive solution? Regarding performance, intelligence, connection technology, …? In fact, it has not been easy to combine explosion protection, modern servo technology and efficient engineering. The common practice, including the declaration of conformity for the acceptance, is tedious and time-consuming. Especially if you have to design, have certified and apply a special enclosure for a non-ex motor. How much easier would it be if you could simply select a ready-to-install ATEX servo motor with declaration of conformity and the latest technology and immediately concentrate on the essential machine or plant construction? That’s exactly what you can do now.

First ATEX servo motor with single cable connection

Bosch Rexroth has developed the first ATEX-certified servo motor with single-cable connection in order to merge modern features such as high drive performance, simple integration into the machine, safety-on-board and i4.0 features into a complete solution. The new MS2E series is based on the MS2N standard series in terms of design and therefore achieves the same optimum values in terms of dynamics, precision and connectivity. It is also suitable for all ATEX applications up to device group II and device category 3 for gas (zone 2) and dust (zone 22). In practice, this means that an MS2E engine remains safe even if other safety-relevant or safety-specific components fail. If, for example, a combustible atmosphere is created due to a defective extraction unit, this cannot be ignited by the engine.

Fast and accurate design – with safety

Because time is money and errors cost time and money, the design within the IndraSize engineering tool is based on a virtually exact engine model. The result: the design of the MS2E corresponds exactly to the real operation. Do you want even more efficiency? With SafeMotion applications, you achieve the greatest possible machine safety thanks to high-resolution 20-bit single or multiturn encoders in SIL2 PLd. Additional practical options include holding brakes or shafts with feather keyway.

Compact power packs for downsizing

Without the right power density, an ATEX-certified engine is only half the fun. For this reason, Bosch Rexroth pays special attention to compact design. The extremely high torque density of the MS2E motors is up to 30 percent higher than that of the predecessor series – a new motor design with optimized electromagnetic design makes this possible. As a machine manufacturer, you benefit in two ways: You can solve your existing drive tasks with smaller motors and achieve more performance with the specified installation space. For the purpose of such downsizing, the self-cooled MS2E motors are available in five sizes with overlapping torque ranges up to a maximum of 119 Nm, each with up to five times the overload capacity and consistently low rotor inertia. What does this mean for your application? Full of dynamics and performance. A further plus point: because high-quality materials and optimized winding technology reduce internal losses, you can also work at higher speeds in continuous operation. As a result, you achieve significantly improved energy efficiency with sustainably reduced operating costs.

*The motor with single-cable connection reduces cabling, simplifies installation and accelerates time-to-market. (Photo: Bosch Rexroth)*

Produce faster with fewer cables

You can use a real novelty in the Ex area if you use the characteristic single cable connection of the MS2E. The advantage: you need much less material as well as plug-in points and space in the cable duct. Fewer cables and interfaces also mean faster and more cost-effective assembly and installation. This reduces your costs and increases productivity – especially in applications with drag chains. Because they become lighter, you can drive at higher speeds.

Industry 4.0 without limits – the motor as sensor

If you also want to implement industrial 4.0 applications in potentially explosive areas cost-effectively and without additional components, you will be particularly pleased about this feature: As with the MS2N series, the MS2E can also be used as a sensor and data source. With a view to future requirements – keyword factory of the future – expand your intelligence in this way up to the engine. The individual measured values including saturation and temperature data are stored in the motor data memory and thus form the basis for various i4.0 applications. Because the IndraDrive controllers also access the data and process it in real time, you benefit from an additional increase in torque accuracy during operation, while the tolerance range is reduced to a fraction of the previously usual values.

Two problems with one solution

With the new ATEX motor MS2E, you have a solution: you guarantee maximum safety and play in the top league on the drive side, even in potentially explosive areas – in terms of power density, functionality and engineering. Together with the flameproof encapsulated MKE motor series, you now have a stringent overall portfolio at your disposal with which you can quickly implement your ideas – with identical performance and up to Zone 1. Interested? Learn more.

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

The product carousel turns – cabinet free into the future

Guest contributor: Reinhard Mansius, Bosch Rexroth

Do you ask yourself how to produce smallest quantities in an economically viable manner? That is no problem in the factory of the future: You are able to move your machines within the factory hall or take processing stations out of a production line, reposition them and then continue production at the push of a button. Cabinet-free drive technology is a key technology here with decentralized intelligence and comprehensive communication capabilities.

Looking in any supermarket will reveal promotional packs with twenty percent extra free or special products for Easter, summer, Halloween and Christmas. The product carousel is turning at an ever increasing pace. However, the life cycles of furniture, electronic products and cars are becoming shorter and shorter as well. At the same time, online retail accounts for an increasing share of the market. Consumers like to use online configurators in order to customize their products. As a result of this, you as a manufacturer may have to make production changes several times a week instead of producing the same products over many years. In the future, even this might not be enough and refitting may be necessary on an hourly basis.

On the basis of customer applications and numerous automation projects in our own plants, we have analyzed the requirements of such varied production processes and developed a vision for the factory of the future. Only the ceiling, the walls and the floor of the factory hall will be immovable. In contrast, it will be possible to configure machines and processing stations to create new production lines which will communicate wirelessly with each other. As a result of this approach, control cabinets will be obsolete or will no longer play a central role.

Control cabinets on their way out

The aim in automation: Making production changes primarily via software, with no manual cabling work. With traditional automation concepts, all cables lead from the actuators and sensors to the control cabinet and back again. In practice, this represents a bottleneck when it comes to installation and refitting. In contrast, the IndraDrive Mi servo drives are geared to and integrated into motors. They reduce the amount of cabling work required and take up no space in the control cabinet. They are installed with all necessary supply components in a decentralized manner in the machine or processing station. Up to 30 servo drives form a drive group on a hybrid cable string for power and communication. Only the first drive has an external connection to the higher-level control systems so that changes do not require cabling work on the control cabinet.

Bild1_36475-1200x848 — The IndraDrive Mi servo drives are geared to and integrated into motors.

Switch off, reposition, switch on and carry on producing

This flexibility is available for a wide power range – from 0.4 kW to 11 kW. The drives without control cabinets have as standard four digital, freely configurable I/O connections for peripherals and sensors on board. Two of these can be used as quick measuring probes. By decoupling control communication, constructors can integrate further I/O modules, sensors and actuators for pneumatics or hydraulics. This means that automation is completely decentralized. As a result, it is very easy to make changes to the factory of the future later on. Simply switch off the station, pull out one or two plugs, push the machine to its new location, switch it on and carry on producing.

Simple, reliable commissioning

You as a machine manufacturer have scarce engineering resources which need to be used efficiently. Pre-defined, pre-programmed technology functions allow many tasks such as those involving cam discs or cam gears to be performed more quickly. With the integrated Motion Logic for individual axes, the drives take on axis-related processes independently of the central control system.

Engineering tools geared to the tasks make integration into modern concepts easier and save time. The Drive System software allows quick and reliable commissioning because its reads and applies the mechanical data from the motor encoders of the Rexroth motors. At the same time, the IndraDrive Service Tool offers easy access to service and diagnostic functions and also allows the software to be parametrized and updated. The tool which is independent of operating systems runs on HTML5-capable browsers and uses the web server which is integrated into the drive. This architecture makes it easier to replace components, while the tool offers practical access management with guest and service rights.

Bild_4_29539-1200x902 — Regardless of the sector – cabinet-free drive technology is revolutionizing mechanical engineering, significantly reducing costs and improving flexibility.

Communicative in a wide range of environments

Another key requirement for the factory of the future is that it can fit into connected environments and share information flexibly. You as a machine manufacturers are looking for drive solutions which allow them to cater for the different protocols in specific regions and sectors with a single item of hardware and thus simplify their entire logistics from ordering to the supply of spare parts. Cabinet-free drive technology meets this requirement with its multi-Ethernet interface. It supports all common protocols via software selection.

Ready for high-level language functions

Bosch Rexroth’s Open Core Engineering software technology allows you to access core drive functions and the integrated Motion Logic alongside PLC automation with high-level language programs.

In the future, you will be able to use Open Core Engineering for Drives to develop or purchase previously unseen web and cloud-based functions in high-level languages. This will establish a link between intelligent servo drive and server- and cloud-based applications. High-level language programming will open up entirely new connectivity options for you. Without complex PLC interfaces, you will be able to digitize the value stream – from recording an order in the ERP system and the MES systems to the drive.

Are you ready for new flexibility?

By modular concepts you will be able to streamline your processes or machines and stations and set them up flexibly and without control cabinet modifications to create new production lines geared to specific order requirements: the factory of the future is an evolutionary process which has already begun. Cabinet-free drive technology is helping you to meet the new requirements as regards flexibility economically, intelligently and safely – today.

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

SAVING UP TO 90% OF TIME WITH PLC-FREE PROGRAMMING AND COMMISSIONING

Guest contributor, Frank Kaufmann, Bosch Rexroth

However efficient PLC programming for complex tasks may be, it is often relatively time-consuming for simple and moderately complex automation solutions. In light of scarce internal resources, machine manufacturers are looking for ways to speed up engineering and shorten delivery times. A new solution is Sequential Motion Control SMC, a virtually universal technology function for IndraDrive servo drives. It reduces users’ programming and commissioning work by up to 90 percent compared to PLC programming.

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Career portals clearly show the lack of skilled labor: in Germany alone, there are more than ten thousand vacancies for PLC programming and commissioning specialists. The situation is no better in other countries. The lack of skilled labor not only lengthens the time to market for new machines – it also makes it more difficult to develop lucrative services, for example adapting installed stations to new tasks.

If orders are delayed owing to capacity bottlenecks, this annoys customers. This makes it all the more important to come up with an alternative to complex, time-consuming PLC programming. This is where drive-based Sequential Motion Control SMC comes in. It uses the intelligence of servo drives for applications with up to six axes yet requires no external motion control system. The integrated motion control system, on-board I/Os and expandable I/O cards reduce hardware costs and make system integration easier.

Ten automation solutions in the time it would take for one

Lean engineering offers particularly exciting opportunities for machine manufacturers as it allows them to put in place up to ten automation solutions in the time it would normally take for one. As a result, they can step up the pace instantly and ultimately increase their turnover. Independent investigations and empirical findings show that the PLC programming and commissioning work for a flying cutter takes slightly more than a man-week. With SMC, the same result can be achieved in just four man-hours.

With a single command, SMC controls complete motion sequences which the user arranges one after another. These sequences are based on a wealth of automation experience in areas ranging from wood processing to the packaging industry and can cope with simple and moderately complex tasks in a virtually universal manner. With pre-defined commands, users can achieve independent positioning axes, axis and master axis couplings, synchronous axis operation, cam profile applications and sequential movements. Applications range from handling systems, processing stations and test stands to flying cut-off. A wide range of special functions are available: With just a few lines, users can activate head cutting, parts movements, maximum lifting routines, reverse optimization, short length processing and other functions.

90 percent faster engineering – with SMC for IndraDrive, axis couplings, synchronous axes and sequential motion sequences can be achieved much more quickly.

With SMC, users can achieve independent positioning axes, axis and master axis couplings, synchronous axis operation, cam disc applications and sequential movements with pre-defined commands.

Eight commands replace 200 lines of PLC code

When engineering, routine tasks such as defining operating modes, diagnostics and error handling take up significant amounts of time. Up until now, these tasks which are often unpopular accounted for up to two thirds of overall programming time although they barely contribute towards the specific solution. With the SMC option, the drives are pre-configured in the factory, thus eliminating these routine tasks. Thanks to this pre-configuration, users can begin task programming and commissioning straight away.

Sequential programming also helps less experienced technicians to create automation solutions geared to particular applications quickly. A practical example: in an open PLC such as the IEC 61131-3, the programming code for a pair of flying shears is more than 200 lines long. With SMC, the user arranges eight commands one after another and then only needs to optimize the processing procedure. Users merely need to learn around 70 commands. They include complete applications and command up to six axes at the same time with one instruction. Users issue step and motion control commands, use closed-loop force and torque controls and query I/Os.

PLC code with just eight commands reduced to 14 lines. With SMC, programming and commissioning a pair of flying shears takes less than half a day.

Optimizing variables directly

SMC includes a manual mode for setting up and referencing axes, a parameterization mode and an automatic mode for working through the programs. In automatic mode, the solutions can control up to four tasks in parallel. At the same time, a cyclic task allows statuses and diagnoses to be called up at any time. Users can therefore observe and optimize variables while the program is running.

Quick solutions for emerging markets

The level of automation in China and other emerging markets is increasing very quickly at the moment. At the same time, there is a lack of programmers with an expert knowledge of PLC in these countries. With online help, watch-listen and tools for debugging or program management, the free SMC Editor helps even technicians with little experience. If necessary, users can use ready-made templates for visualization or create their own.

Owing to increasingly short product life cycles, rapid automation is also becoming more important in mature markets. Concepts such as Bosch Rexroth’s Factory of the Future are highly flexible and allow the production of very small quantities – even down to a batch size of 1. In the future, end users will be able to adapt their production lines flexibly according to orders at very short intervals and will require new motion sequences and additional processing stations at short notice.

The new processing stations must also fit into connected production lines. As a result, an open system for sharing data and information with other machines and higher-level IT systems is a must. The Sercos automation bus allows real-time cross-communication – an important requirement when it comes to precise synchronization with other process movements. Via software, the user selects in the multi-Ethernet interface one of the common protocols such as Sercos, PROFINET IO, EtherNet/IP and EtherCAT as well as the safety protocols CIP Safety on Sercos, Fail Safe over EtherCat and PROFIsafe on PROFINET.

Another task which only very experienced programmers were able to cope with relates to machine safety. Rexroth’s SafeMotion reduces the time required with certified safety functions. As a result, users do not need any additional safety control system in order to meet the requirements and standards of the Machinery Directive.

Increasing turnover with existing resources

The lack of skilled labor will remain a problem for the global mechanical engineering sector in the long term. SMC is a practically oriented approach for simplifying programming and commissioning. Machine manufacturers can therefore significantly increase the number of automation solutions that they supply even without additional PLC programmers. At the same time, the available specialists can concentrate on automating more complex tasks and here too reduce the time to market considerably.

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

Bosch puts a face to the connected factory

Guest Contributor: Bosch Media Service

Hannover Messe 2018 (hall 17, booth A40)

1.5 meter tall 3D avatars represent the Factory of the Future
Smart soccer table teaches itself with artificial intelligence
New portfolio pools software and services for the connected value stream

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Stuttgart and Hannover, Germany – According to the slogan “Factory of the future. Now. Next. Beyond”, the Bosch Group is presenting at Hannover Messe what the company already offers (now) for connected factories, what solutions will soon be available (next) and what it is developing for the future (beyond). Despite all connectivity and automation, humans and their creativity are indispensable in the Industry 4.0 era. Robots support them with complex and time-consuming tasks like data processing and quality control. This is also the message of 1.5 meter tall, Pixar-style 3D avatars. They take centre stage in Hannover and move around the virtual factory. All avatars are mock-ups of market-ready applications or pilot projects. Allow us to introduce them:ActiveCockpit – the Data CollectorThe intelligent communication platform ActiveCockpit from Bosch Rexroth visualizes data to make it easy to understand for everyone. Its gigantic screen informs employees about the production status by processing and visualizing production data in real time. As a result, manufacturing becomes more transparent, while faster information processing enables clear analyses and efficient procedures. Users and companies both benefit from the immediate identification of problems. This reduces downtimes and avoids potential recall costs; the quality level increases.IoT Gateway – the Personal TrainerDespite the Industry 4.0 hype, some companies have not yet arrived in the digital age. The machines lack sensors, software or the connection to enterprise IT systems – and hence important prerequisites for the connected factory. The Rexroth IoT Gateway can quickly and easily connect both old and new machines for Industry 4.0. The IoT Gateway unites sensors, software and IoT-compatible industrial controls, making it possible to detect the condition of machines. Even operators of older machines can reap the benefits of the connected industry without large investments.

APAS assistant – the Team Player

Humans are key players in the factory of the future: creative intelligence is in the employees’ minds. They are supported by digital devices and robots. The collaborative production assistant APAS assistant, for instance, supports employees with monotonous and ergonomically challenging tasks – without a safety fence. This human-robot collaboration is made possible by an intelligent safety concept. Thanks to its sensor skin, the APAS assistant recognizes its human colleagues without touching them and stops before a collision happens. Once the employee has left the immediate vicinity, the robot independently resumes its work exactly where it stopped before. This interaction of human and machine leads to higher efficiency, and sustainable optimization of the overall productivity, since employees can concentrate on more complex tasks.

ActiveShuttle – the Delivery Guy

Robots also support with internal transport processes. They drive through the factory and, for instance, transport material cases from storage to the production station. With the ActiveShuttle, Bosch Rexroth presents a concept for an intelligent, driverless transport system that automates the internal flow of material and goods. The integrated lifting platform automatically unloads goods in the logistics and manufacturing areas. Cyclical transport or a consumption-based material supply can also be realized with ActiveShuttle.

XDK – the Messenger

The universally programmable IoT multisensor XDK (Cross Domain Development Kit) is the “midwife“ for companies, who want to develop their own applications quickly and flexibly. In a compact box, the XDK combines a variety of MEMS sensors, for instance to measure acceleration, rotation angle, humidity, air pressure or temperature, with a powerful processor for the analysis, processing and transmission of the sensor data. Be it for predictive maintenance, monitoring or retrofitting: the XDK can be deployed universally; the programming language XDK Mita facilitates programming.

Apart from the avatars, Bosch is exhibiting the following highlights:

Foosball: learning by playing thanks to artificial intelligence

Table soccer has to be learned. To do so, we absorb and digest information with our senses, in this case the eyes. With the help of our brain, we learn systematically how to hold, play or pass the ball with the right force at the right time. Artificial intelligence (AI) works according to the same principle: instead of the brain, software processes the information with algorithms; cameras and sensors replace our senses. The soccer table, also called foosball or KI-cker (KI is the German abbreviation for artificial intelligence), teaches itself and optimizes its soccer abilities with every new co-player. Industrial applications such as robots or autonomous vehicles can also learn numerous tasks and optimize their performance thanks to AI. Their biggest advantage: even after the umpteenth try, they will not be frustrated.

Smart Cab for connected farming

Smart Cab, co-developed by Bosch as a member of the CAB concept cluster, turns agricultural vehicles into connected control centres in the field. All components – vehicles, cameras and drones alike – can interact with each other. Via the cloud, camera drones send detailed pictures of the condition of crops to the driver’s cab, and operators are warned by the object recognition camera about living obstacles such as deer. Vehicle users can download specific functions from a feature store over the air directly to the machines. Depending on the weather or soil conditions, for example, the nozzle settings can be adjusted.

Nexeed – new Industry 4.0 software for production and logistics

Connecting the entire value stream

Hardware applications need innovative software solutions running in the background to provide the necessary connectivity. At Hannover Messe, Bosch is presenting its Nexeed new software portfolio, which pools Bosch software and services for production and logistics. The Nexeed solutions make day-to-day work easier for employees and optimize production and logistics processes in terms of transparency, agility, cost, quality and time. The portfolio ranges from the sensor, over machine automation to the cloud. Nexeed solutions can be combined to connect individual lines, entire plants and plant networks, as well as their intralogistics and external goods flow.

Systematic production improvement

The Nexeed Production Performance Manager, for example, ensures systematic improvement of production by helping employees with decision making. For this purpose, the software collects and harmonizes production and machine data from many different sources and “translates” them into a common language. Subject-specific functions like the Ticket Manager, which was developed for the lighting company Osram, make it possible for the employees to complete their tasks faster and more purposeful. Using an app, employees are informed about the status of their more than 80 connected machines at all times. Upcoming tasks such as maintenance work or subsequent material deliveries are displayed, evaluated and assigned to the employee with the appropriate qualification.

Opening the data treasure chest with Data Analytics

The production process produces a large quantity of data of various types – the most important raw material of Industry 4.0. With Nexeed Data Analytics, this data can be used intelligently to identify new optimization potential. Customers do not have to deal with Data Analytics themselves; this task is entirely up to the Bosch experts. They gain important insights from product, process and machine data, which can be used to achieve improvements regarding quality, cost and delivery performance. Customers receive an individual service from the first data analysis to comprehensive prediction models.

Intralogistics en route to the digital age

Compared to modern production, the intralogistics sector is lagging behind regarding connectivity. Nexeed Intralogistics Execution deals with the three big challenges: keeping an eye on the vehicle fleet, optimizing material storage and designing transport routes dynamically. Information on all intralogistics processes are available in real-time. By unifying relevant data from different sources – for example RFID in the internal supermarket, forklift localisation and inventory information – the solution not only helps logistics specialist with the daily work, but also allows long-term planning.

Seamless transparency throughout the supply chain

These days frequent travellers can easily share information about their whereabouts. With Nexeed Track and Trace, Bosch has developed a logistics solution that enables the freight to record a digital travel diary. The software not only shares the current location, but also regularly sends information about temperature, vibration and humidity to the cloud via wireless sensors and gateways. This way, supply chains can be traced and permanently optimized. The international freight forwarding and logistics company Panalpina makes use of these benefits. They use Nexeed Track and Trace for a transparent supply chain – not only on the road, but also in the air. On the first test route between Germany and the recipient plant in the U.S, each package was equipped with a sensor. It records regularly relevant parameters such as vibrations. At each gateway, for instance when unloading the truck at the terminal or loading the airplane on the runway, data and the location of the time-sensitive goods are transmitted to the cloud. The Panalpina sees whether the goods have been loaded into the airplane and how they are doing.

Video: https://youtu.be/gqCNU87dgz4

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

Saving up to 90% time with PLC-free programming and commissioning

Guest contributor: Frank Kaufmann, Bosch Rexroth

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Ten automation solutions in the time it would take for one

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90 percent faster engineering – with SMC for IndraDrive, axis couplings, synchronous axes and sequential motion sequences can be achieved much more quickly.

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With SMC, users can achieve independent positioning axes, axis and master axis couplings, synchronous axis operation, cam disc applications and sequential movements with pre-defined commands.

Eight commands replace 200 lines of PLC code

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PLC code with just eight commands reduced to 14 lines. With SMC, programming and commissioning a pair of flying shears takes less than half a day.

Optimizing variables directly

Quick solutions for emerging markets

Owing to increasingly short product life cycles, rapid automation is also becoming more important in mature markets. Concepts such as Bosch Rexroth’s factory of the future are highly flexible and allow the production of very small quantities – even down to a batch size of 1. In the future, end users will be able to adapt their production lines flexibly according to orders at very short intervals and will require new motion sequences and additional processing stations at short notice.

Increasing turnover with existing resources

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

THE LARGEST FLOW ON THE MARKET

When it comes to valves, maintaining performance with an increased flow rate can be extremely good news for manufacturers. It allows them to meet the same requirements with a smaller machine size or maximize manufacturing performance with a minimized footprint.

Our brand-new WRC-4X directional high-response cartridge valves not only meet high dynamics and flow requirements, they can also be integrated into networked environments.

As they feature integrated electronics with a multi-Ethernet interface and OCI for Drives, WRC-4X valves can be integrated into networked environments even with an analog signal input.

Next generation thinking

Once again, we’re pleased to be moving technology forward – increasing performance and communication for hydraulic actuators with our next generation of WRC-4X directional high-response cartridge valves. These valves are more dynamic and consistently achieve flows that could previously only be met by using the next highest available size. In fact, they provide the largest flow on the market.

Integrated electronics (OBE) allow the new valve series to be networked via open interfaces with higher-level control units and Industry 4.0 environments, even when used with an analog signal input. This means that the valves are ready be integrated right away into even the most cutting edge automation concepts and can benefit from predictive maintenance.

Flexing to future challenges

Our new cartridge valve blocks are ideal for applications with high flow and dynamics requirements, such as:

Presses
Die-casting
Injection molding machines

Using sophisticated co-simulations with flow analyses and strength calculations, our developers have optimized channel geometries and enabled different sized valves to achieve significantly higher flow levels. This means they can consistently achieve values that would previously have only been possible by using valves the next size up.

The valves can be operated via digital and analog control signal input. In both cases, the integrated electronics (OBE) enable the valves to be seamlessly integrated into digitally networked automation environments and Industry 4.0 applications. WRC-4X valves also feature an open interface that enables communication with a range of programs. So machine manufacturers and operators can incorporate the valves into condition monitoring systems and benefit from predictive maintenance.

Learn more: https://www.boschrexroth.com/en/xc/products/product-groups/industrial-hydraulics/index

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

Embedding axis controllers made by any manufacturer

Guest contributor: Theobald Herrmann, Bosch Rexroth

Automating hydraulic drives as easily and conveniently as electrical ones with combined monitoring and remote maintenance of all the technologies used – this increasingly important economic requirement can be fulfilled using valves with integrated axis controllers (IAC). What can they offer and how easy is it to implement manufacturer-independent integration at controller level?

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Bus systems play a key role in automation. They provide a flexible way of saving time and money when integrating hydraulic drives into higher-level control networks. However, in order to give the engineering plenty of freedom, this should ideally be independent of the controller manufacturer.

Ethernet – open communications standard

The basis for this manufacturer-independent communication is the network standard Ethernet. Thanks to the large address space and switch cascading facilities, networks can then be scaled to any size and can give an almost unlimited number of participants equal bus access. The most common Ethernet-based bus systems used in industrial automation to control hydraulic axes are SERCOS, Profinet RT, Ethernet/IP, EtherCAT, Powerlink and Varan.
All these bus systems can use multi-Ethernet interfaces to provide flexible availability – both for the engineering and for the end user.

What can IAC valves achieve with multi-Ethernet interfaces?

Multi-Ethernet interfaces are a key component of control valves with integrated digital axis controllers (IAC). The integrated switch (bus in and bus out)
makes it easy to comprehensively integrate your hydraulic drives into a uniform control concept. Using standardized M12 technology also enables you
to efficiently integrate a variety of sensors. The software-based control functions are particularly interesting to users. They enable the motion control
of a hydraulic drive to be handled in the same way as an electric one, ultimately depicting the operation and control of both types of drives in exactly the same way.

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Specific hydraulic axis control functions

Viewed precisely, an IAC (Integrated Axis Controller) is a digital controller equipped with control and regulation algorithms that is integrated into the valve together with all the necessary sensor interfaces for controlling position, pressure, force and flow. The extended function range includes alternating control (position, force) and status feedback for position control. This means that hydraulic motion sequences can be quickly implemented without the need for any programming. Another advantage is that control algorithms and parameters can be integrated into the valve and then selected by the higher-level controller as appropriate for the specific application. In this way, possibly supplemented by electric drives, they can be used as a cost-effective way of implementing tailored machine concepts and individual application requirements.

Commissioning, monitoring and engineering

Using standardized M12 technology reduces the cabling effort required and permits faster commissioning. Additional time and cost are saved by the wizard integrated into the software that guides the user through the few steps needed before final commissioning and also calculates all the necessary control parameters. Important for the plant’s availability are monitoring functions which, among other things, detect tracking errors and monitor the limits of travel.
In addition to these, some manufacturers also provide software tools to help motion control system users with commissioning and parameterization, and diagnostic functions such as multi-channel oscilloscopes and data loggers, so that the number of interfaces can be kept as low as possible – making the system faster and easier to configure.

Integrated machine safety (safe stop)

For the engineering IAC valves facilitate a modular construction system that can flexibly enhance system concepts. And not least, these include internally implemented DGUV-certificated safety functions. This gives you an economical and future-proof way to lay the foundations for safe stop, for instance by shutting down a channel as specified in EN 13849-1, and thus fulfill the requirements of the Machinery Directive even for large-scale plants.

Case study 1: High precision control tasks

The role that IAC valves play in the accuracy of machine tools is made very clear by the example of a new rotary transfer machine with 54 electrical and hydraulic CNC axes. For this new development the manufacturer not only made use of a powerful CNC system solution with real-time communication via SERCOS, but also incorporated a module in controller format with software that was already capable of taking into account all the special features of fluid technology and was thus able to separate the drive level from the control level. This enables the machine to be constructed more compactly and with lower heat input. Thanks to the stable temperature, the vibration-damped sleeves of the circular array of processing axes can achieve a repeatable precision in the hydraulic servo axes of less than +/- 1 μm, corresponding to 5 μm on the workpiece. The travel speed is up to 30m/min.

Case study 2: A retrofitted core shooting machine

In addition to new designs, IAC valves with multi-Ethernet interfaces also offer considerable potential when it comes to modernizing legacy machines. For example, the well thought-out retrofit of a 50 year old core shooter coupled with new hydraulic components resulted in significantly improved efficiency. A total of eight IAC valves regulate the hydraulic cylinders on the basis of the set positions given by a CNC controller. Their possibilities and high level of precise repeatability made it possible to reduce the figures for setup time (system changeover) and waste (nibs). Altogether, despite operating three shifts, the machine’s availability increased by more than 10%, corresponding to 500 hours. Using a secure logic controller meant that safety was also brought up to date.

Conclusion

IAC valves with multi-Ethernet interfaces and integrated axis controllers enable mechanical engineering companies to easily utilize the productivity potential offered by hydraulic and hybrid drives.

Combining them with engineering tools, including industry-specific and application-specific control structures makes it possible to cost-effectively
implement tailored machine concepts and modernizations, with the result that the manufactured results can be optimized faster and more easily.

More information: www.boschrexroth.com/iac

Movie: https://www.youtube.com/watch?v=fVBOYCP31P0

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

New hydraulic design for presses

Guest contributor: Stefan Zimmerman

New drive concept makes hydraulics economical and intelligent

By means of variable-speed pump drives, new, patented hydraulic axes simplify the design and control of presses of any kind. They considerably reduce the power consumption as well as the required oil quantity by up to 90 percent. To this extent, the control technology of a valve control moved into the software of intelligent servo drives of a displacer control. This reduces the complexity and opens up new levels of flexibility and of condition monitoring.

Worldwide, the climate change has increasingly drastic effects on the everyday life. Thus, governments and international organizations have defined climate targets in order to limit the CO₂emissions. What has already become standard in light bulbs and household devices also takes increasingly more effect in the industry. Energy-efficiency has become a decisive criterion for the machine users when it comes to the selection of machinery and systems. They expect a considerably increased output with clearly reduced current and resource consumption. Apart from that, numerous companies have already publicly obliged themselves to reduce their CO₂ emissions by defined quantities. They can only achieve these targets if new machinery and systems are considerably more energy-efficient. So it is the challenge of machine manufacturers to develop new concepts.

Using the hydraulic force density as required

In large systems with very high processing forces as they are required for forming methods, the hydraulics as main drive is one of the largest power consumers. The end users have accepted this for a long time as they wanted to have the maximum force available at any time, even if the process did not permanently require it. Modern hydraulic drives distinguish themselves by the physical unique selling points such as power density and robustness; however, they clearly reduce the power consumption by controlling the displacer as required. Thanks to its hybrid concept, the new hydraulicAxis patented by Bosch Rexroth for presses of different kinds, from low to high drive power, connects the advantages of hydraulics with those of the electric drive technology. First equipment according the new concept has shown that the power consumption can be reduced by more than 30 percent. The required oil quantity of the hydraulic installation can be reduced by up to 90 percent.

Conventional hydraulic systems

For decades, conventional systems have proven of value for presses in the medium and high performance range as drive technology of choice. In this connection, these systems mostly work with a central hydraulic power unit with several variable displacement pumps. Moreover they are operated by electric motors directly connected to the mains. Apart from that, central or decentralized manifolds with on/off and proportional servo valve technology are required in order to control the cylinder(s) in rapid traverse, working or pressing mode and in the so-called return.

One disadvantage of this concept are idling losses during the standstill times. In the control of the cylinders, there are also throttle losses caused by the valve control. There is partly considerable heat introduction into the hydraulic oil, which must afterwards be compensated again by corresponding cooling.

Hydraulic axis replaces central power unit

A new, patented hydraulic concept replaces the previously common central power unit with valve control by a patented hydraulic axis with speed-controlled displacer control and a closed, decentralized fluid circuit. The hydraulic axis consists of a differential cylinder with a cylinder chamber and ring chamber. The cylinder chamber is for a powerful working movement and the ring chamber for the fast rapid traverse movement. An auxiliary cylinder takes up the oscillating volume during the different movements and in this way creates a closed circuit. A central oil tank is no longer necessary and thus completely omitted.

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The flow is generated by variable-speed pump drives. In order to satisfy the high precision and dynamics requirements, servomotors in combination with adjustable axial piston pumps lend themselves. Thus, all options of the 4-quadrant operation are available to the design engineers. With several cylinders, a corresponding number of Hydraulic axes is used. The synchronization control is performed by the software of the intelligent servo drives, synchronized by means of real-time communication.

Reversal of the movement by changing the direction of rotation

The area switchover for the relevant movement is effected by means of two valves. During the pressing process, the cylinder areas are large. Thus, the cylinders reach high forces at low velocity. During the return of the cylinders, however, the areas in the ring chamber are small in order to achieve the maximum rapid traverse velocity with low forces and to thus reduce the downtimes of the presses. For the reversal of the movement, the servomotors change their direction of rotation. If adjustable axial piston pumps are used, the swash plate of which can be swiveled through zero, the direction of the movement can also be changed by adjusting the swivel angle.

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Energy efficiency in practice: Presses consume more than 30 percent less

The hydraulic axis works in a strictly need-oriented manner. At partial load, the servo drive controllers reduce the speeds of the pump motors to the lowest value possible. During standstill times, e.g. for cooling down the tools, the motors are standing and do not consume any energy. During that time, safety valves support the return. Depending on the cycle times, variable-speed pump drives allow for energy savings of more than 80 percent as compared to constantly driven power units without variable displacement pumps. In practice, the first presses with hydraulic axes achieved reduced consumption of 30 percent as compared to already energetically optimized, conventional hydraulic solutions.

Regarding the Sytronix family, Rexroth offers more than one hundred pump drives with variable speed relating to power and function. These can be integrated into all usual automation structures thanks to multi-Ethernet interfaces.

Exceeding the savings due to the need-based closed-loop speed control, additional functions increase the energy efficiency of the presses even further. In the lowering movement, the servomotors recuperate the braking energy and either feed it into an electric accumulator, make it available to other actuators, e.g. handling axes, via an intermediate circuit or feed it back into the mains.

Synchronization control of the hydraulic cylinders via intelligent software

The synchronization control can be effected via all common real-time protocols such as PROFINET, Ethernet IP, EtherCat or Sercos if the servo drive controllers provide corresponding multi-Ethernet interfaces. Changes in motion sequences are only transmitted via the machine control by means of software command to the intelligent drives. Mechanical adjustment works at the hydraulic axis are not necessary. So due to short changeover times, end users gain flexibility. At the same time, you can continuously document the manufacturing processes of every component by means of the servo-drive data. This satisfies the increasing demands on the traceability of products.

90 percent less hydraulic oil – central tank omitted

Due to the new concept of the hydraulic axis, the movements are primarily controlled via variable-speed pumps rather than the throttling of the flow by the valves. So considerably less heat is introduced into the hydraulic oil and only minor agitation results. Result: In the first presses with hydraulic axes, the manufacturer could reduce the oil volume from e.g. 10,000 liters to only 900 liters. This saves space for the tank and reduces the operating costs as in an oil exchange, less than ten percent of the previously used oil quantity have to be purchased and disposed of.

An additional advantage is the clearly reduced average noise emission. With variable-speed pump drives, it is up to 20 db(A) below that of constantly driven pumps. During standstill, the noise level of the hydraulics falls to zero. Due to the omitted tank and complex piping for a power distribution, resonance bodies for the structure-borne sound are omitted. With the new concept, the expenses for the noise insulation are considerably lower.

Easier hydraulic construction with quick commissioning

For manufacturers of hydraulic presses, the conversion to hydraulic axes brings about considerable savings in the design, assembly and commissioning. Tank, cooling and piping are completely or largely omitted as is the valve technology. The variance of different motion sequences is moved from the valve technology into the drive controller software. Here, Bosch Rexroth has, for example, integrated best-in-class controllers for different force/path and synchronization controls. Due to the corresponding commissioning software, the engineers don’t even need in-depth hydraulic knowledge for the initial commissioning. Software wizards propose suitable parameters. This considerably shortens the commissioning phases of a hydraulic press.

Condition monitoring increases the availability

The data that is gathered by the intelligent servo drives anyway and that can be amended by more sensors is particularly interesting for end users. It forms the basis for condition monitoring strategies increasing the availability. Based on the analysis of the data, the corresponding software identifies wear and errors before they will lead to standstills. So machine downtimes are replaced by scheduled maintenance measures.

Find out more about self-contained hydraulic actuators here.

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

Economical and intelligent: Handling solutions re-conceived

Guest contributor: Andreas Gryglewski, Bosch Rexroth

The market for handling and robotic solutions is highly price-driven, yet still leaves room for disruptive ideas. Bosch Rexroth provides proof of this with an advanced solution package for Cartesian kinematics. It combines an economical industrial controller with state-of-the-art web technology and assured instruction via a standard tablet. The result: minimum investment costs and maximum efficiency – before and during operation.

Manufacturers of handling solutions for loading and unloading face fierce competition. The volume market demands cost-optimized, rugged and user-friendly solutions that optimally fulfill all requirements in terms of accuracy and cycle times. In addition, users expect quick commissioning with as little programming, instruction and training expenditures as possible. A high degree of productivity and flexibility is also required for the operational phase in order to reduce downtime and so that format or process changes can be more quickly implemented.

All of these requirements are addressed by Bosch Rexroth with a particularly economical solution package for Cartesian kinematics that combines a high-performance motion controller with state-of-the-art web technologies and innovative value-added features. The automation experts make the solution package even more economical with an especially clever idea: users can perform the setup and assured teaching-in on any standard commercially available tablet.

Industrial control, web technology, consumer tablets

In its solution package for Cartesian kinematics, Bosch Rexroth combines a powerful motion controller with modern web technologies and innovative value-added features.

The disruptive solution approach for Cartesian handling from Bosch Rexroth is particularly suitable for machinery manufacturers and end users who want to implement flexibly and reliably adaptable pick-and-place tasks in a short time and at a low cost. Examples include the loading and unloading of injection-molded parts, the sorting of workpieces, or a wide range of intralogistics applications. Bosch Rexroth combines its proven industrial controller with a webserver and a bracket for a typical standard tablet, by means of which the user can visualize the connected handling solution and – graphically-supported – program, teach-in and adjust it as needed. The solution package is comprised of other basic components such as compact servo motors and drives for the kinematics movement, as well as a safety controller for connecting to the tablet bracket for safe teaching-in. From a single source, Bosch Rexroth also optionally offers the mechanical equipment, includinglinear axes with a belt or ball-screw drive and grabbers.

The utmost in connectivity and IT security

In its new handling solution, Bosch Rexroth placed special emphasis on the two key properties of i4.0 –connectivity and IT security. While the optional IoT Gateway ensures the horizontal and vertical networking, the security router with a newly developed IoT firewall, which is also optional, guarantees secure communication between the tablet and controller. Consequently, unauthorized persons can neither log into the controller nor can a virus attack the controller or spread throughout a company’s IT network.

Thanks to the newly developed solution packages, handling systems from Bosch Rexroth can be more quickly commissioned, easily programmed, and taught most economically using standard tablets.

Easy commissioning without parameterization

One of the numerous unique features is the operating concept for the handling solution: Immediately after a servo motor is connected with a drive, the latter reads out the stored parameter set from the feedback memory and thus already has all the characteristic data of the mechanical equipment. The result: a considerable time savings and prevention of errors during commissioning, because the user no longer has to manually enter up to 70 parameters. When Rexroth mechanical equipment is ordered in the future, the parameters will be stored in the feedback memory of the motor while still in the plant. If the user puts his own mechanical equipment into operation; the associated parameter file can also be stored in the feedback memory and is efficiently read into the drive upon connecting.

Safe teaching-in using a standard tablet

The disruptive character of the new handling solution becomes clear during setup, which can be performed wirelessly with almost any consumer tablet. It is expeditiously fastened in a bracket especially developed by Bosch Rexroth for teaching-in, which can be adjusted to the respective size and securely encloses the mobile device. On the top left is a combination emergency stop and enabling button that makes reliable and comfortable teaching-in possible for the user. While the left hand holds the tablet and can press the red button, the right hand is free for other operational tasks. The visualization and operation of the handling system is web-based and applies the HTML5 standard, hence is independent of the tablet OS. An optional security router with an integrated firewall provides for IT security.

Programming without programming knowledge

Bosch Rexroth also made the process programming, which precedes the teaching-in sequence, as uncomplicated as possible. Because it uses the graphical programming language Google Blockly, as is the case with the tablet, no programming skills in conventional terms are required. In order to move an axis from point A to point B, for example, only the start and end positions need to be specified, and a line to connect them with each other. The grabbers are also opened or closed by means of graphical elements. Thanks to variables, logical expressions and loops, it is possible to easily specify and clearly represent various processes, also complex ones if necessary.

Features for increasing productivity and quality

Positively contributing to the performance of an especially economical operating phase of the new handling solution are its versatile functions and expansion options. These ultimately also afford the user a high degree of flexibility for changes in process or format. For example, the “Active vibration damping” function, which provides greater product quality in combination with a sensor, or initiates the exact countermovements in the open-loop process in the linear module in order to prevent undesirable vibrations or to move sensitive products. Thus, for instance, the utmost in accuracy can be achieved when loading and unloading using the grabber sparing the mechanical equipment for a longer service life.

Preventive maintenance and IoT integration

Preventive maintenance can also be cost-efficiently realized in combined usage with the optional IoT Gateway. In order to collect data for analysis and evaluation of the service life, the motor decoder can also be used as an intelligent sensor. If the motor revolutions are converted into linear movements, the timing for lubrication intervals or the replacement of components can be derived, for example. Communication standards such as OPC UA can provide for easy integration into customer-specific IoT systems as needed.

Economical in every way

The solution package is especially suited for pick-and-place tasks that must be quickly and flexibly adaptable – such as for the loading and unloading of injection-molded parts, the sorting of workpieces, or for various intralogistics applications.

With the new solution package, Bosch Rexroth introduces a fresh impetus into the competitive market for Cartesian handling. Automation expertise, modern web and IoT technologies, and productivity-enhancing features are combined in a rugged and practical solution concept that takes into account current and future market requirements, and which generates disruptive energy. Consequently, machinery manufacturers and end users find quick and very economical way to implement a reliable, efficient and flexible handling solution that can be commissioned, taught, and adapted to current requirements without any significant knowledge of programming and parameterization.

Innovative approaches of the new handling system:

A comprehensive economic package comprising industrial controller, servo motor, drives, security zone module and teaching-in bracket for consumer tablets
Maximum security through a router with firewall (optional)
Minimal total cost of ownership thanks to:
- Commissioning without the need for parameterization: Drives automatically read stored mechanical parameters when connected with a motor
- Device-independent visualization and operation (HTML5)
- Safe teaching-in bracket for consumer tablets
- Simplified process flow design without programming knowledge, thanks to Google Blockly
Added value functions for productivity and quality – for example vibration absorption
Prepared for data tracking for preventive maintenance
Easy integration into IoT systems through open interfaces such as OPC UA

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