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USAlocal01 | 2016
Connecting the potential of Industry 4.0 with real manufacturing16Bosch Rexroth provides hydraulic technology for the Jupiter mission05
Groninger customizes VarioFlow plus for compact filling machine 08
Dear valued customers:The drive&control local magazine you are reading is a tribute to you.
The new technologies presented here, the customer appreciation stories, the forward-looking viewpoint articles – they're all here because of your ongoing loyalty to Bosch Rexroth. Your drive to succeed in your business is what drives us to help you succeed.
As we near the end of 2016, it is worth noting that next year Bosch Rexroth will celebrate its 50th anniversary of operations in the United States. We’ve made a remarkable journey over that time, growing from a small hydraulics office in Easton, Pennsylvania, to a leading supplier of the entire range of drive and control technologies, with sales offices and distributors throughout the country, and multiple US-based production and customizing plants. Our manufacturing campus in Fountain Inn, South Carolina was recently named 2016 Assembly Plant of the Year by ASSEMBLY magazine. We are very proud of this. And while we are proud of this achievement, we know that we would not have achieved this without you: Your ongoing challenge to us… to be better, to deliver faster, and to keep getting better and faster— it’s this challenge that helped us win the award.
So as we move into the next five decades of Rexroth in the United States, we will continue to put you, our customers, in
the center of everything we do. It’s an exciting time. Together with you, we can now take advantage of the amazing capabilities of connected technologies to re-invent our industry. In the current issue of drive&control local, you’ll find a number of articles on the topic of Industry 4.0, including a viewpoint article on how to connect the potential of Industry 4.0 with real manufacturing (page 16). You’ll also read a short article about our award-winning Industry 4.0 assembly line in Homburg, Germany (“Competitive Edge 4.0,” page 12), as well as a short introduction to one of our i4.0-enabling technologies, Open Core Engineering (page 15). By implementing these technologies in our own plants, we aim to gain experience to help you get the most out your future automation investments.
Of course, this issue of drive&control local also includes stories about exciting drive&control applications from customers in a variety of industries. You’ll read how Bosch Rexroth is helping track Juno as it orbits around Jupiter. You’ll learn how Groninger put us to the test in delivering custom VarioFlow plus components in a very short time frame for their new lite-F filling machine. And you’ll learn how VITS International achieved industry-best performance in the print industry with their SPRINT Variable Data Finishing System thanks to Rexroth’s electric drives and controls.
Helping you succeed: That’s what we’re here to do, whatever drive&control challenge you face. We’re proud that you rely on us, and we will do our utmost to continue earning your trust for another 50 years. I hope you enjoy this issue of drive&control local.
Sincerely,
Paul Cooke President & CEO Bosch Rexroth Americas
drive & control localEDITORIAL
5
SPECIAL02 What’s new with GoTo™
TECH FEATURES10 Electric drive technology options for plastics machines
FEATURES 08 Groninger customizes VarioFlow plus for compact
filling machine
12 Competitive Edge 4.0
18 New variable data finishing system matches digital printing growth
NEWS 03 Bosch Rexroth Corporation reaches 5,000 in resource
kit distribution
03 Rexroth’s North American GoTo™ Focused Delivery Program continues growth with improved lead times and app-based eShop checkout
04 Bosch Rexroth Bethlehem Service gets new SSTB600 pump and motor test stand
04 Bosch Rexroth’s plant in Fountain Inn, SC wins Assembly Plant of the Year Award
13 Rexroth’s IndraDrive Mi wins Golden Mousetrap Award from Design News magazine
13 Rexroth’s Hägglunds CA 10-40 Hydraulic Motor wins Golden Mousetrap Award from Design News magazine
TECHNOLOGY05 Rexroth’s IndraMotion MTX micro wins Engineers’
Choice Award
05 Bosch Rexroth provides hydraulic technology for the Jupiter mission
06 Rexroth’s GoPak™ hydraulic power unit and GoDesigner™ configuration tool offers millions of combinations with quick lead times
07 Electromechanical cylinder from Rexroth: powerful with a hygienic design
14 Modular Conveyor System for Quick Assembly
14 Rexroth IMS-I and IMS-A Integrated Measuring Systems set the standard for precision
15 Rexroth’s Open Core Interface allows machine builders to create individual functions without a PLC
VIEWPOINT16 Connecting the potential of Industry 4.0 with real
manufacturing
20 Optimizing machining processes with cycle time and energy analysis tools
10 16
813
CREDITSdrive&control local is the magazine for Rexroth US customers.
Published by:Bosch Rexroth CorporationCorporate Communications, Charlotte, NC Kevin Gingerich (responsible for content)
Editor-in-Chief: Susan Strauss [email protected]
Editing and design:Phase 3 Marketing and Communications, www.phase3mc.com
Printed by: Phase 3 Marketing and Communications, www.phase3mc.com All rights reserved. Any reproduction or copying, either in part or whole, requires prior permission of the publisher. drive&control local is mailed using automated data processing.
01 | 2016 USA1
CONTENTS
Rexroth’s GoTo™ Products app version 4.5 for iPhones, iPads and Android devices just got better with the integration of the user-friendly eShop checkout function. This makes the GoTo™ Products app the fastest and easiest way to purchase and schedule market-best delivery of thousands of in-demand drive, motion and control products. Rexroth’s eShop lets users find products, add them to a shopping cart, save favorites and process their orders.
Registered eShop users get full access to the eShop outside of the GoTo™ Products app. This includes the ability to browse and evaluate the full range of Rexroth products and solutions, select specific models, order online, and get local prices, product offers, GoTo™ products in their region and configuration support tools.
Bosch Rexroth’s GoTo™ Products app with eShop improves delivery
What’s new with GoTo™Stay on top of what’s new with the GoTo™ Focused Delivery Program
Learn more about the GoTo™ Focused Delivery Program
SPECIAL
How to Register with eShop:Registering as an eShop user establishes a formal business relationship with Bosch Rexroth. The online registration form requests specific business information and can be completed on a desktop or laptop computer. The information required includes:
• Complete company information (company, personal user name, address, phone and email)
• Business and tax-related information
• Creating unique username and password
Ò Your application will be reviewed and once registration is approved, your access will be activated within two to three days.
2drive & control local
With the 2016 fall update, Rexroth has expanded the offering by over 200 products, shortened lead times, and updated GoTo™ Products app with faster synchronization and direct checkout for U.S. customers via the Rexroth eShop.
The latest round of GoTo™ updates features new products across many drive and control technology product lines, and continues to grow in its seventh year. Rexroth also continues to improve GoTo™ lead times; 99 percent of the products in the program ship in 10 days or less.
Over 130 hydraulics additions include 26 MCR radial piston motor part numbers, and 24 additions to the linear motion selection are highlighted by newly-added roller rails with SP accuracy. The growing electric drives and controls portfolio includes IndraDrive Cs drive units with associated firmware and a software module for MLD-based multi-axis control. Recent assembly technologies additions include new stainless steel VarioFlow plus conveyor components along with curve, drive and return units for added configuration possibilities.
Ò For more information, visit www.boschrexroth-us.com/GoTo.
Rexroth’s North American GoTo™ Focused Delivery Program continues growth with improved lead times and app-based eShop checkoutOver 200 product additions, shorter lead times and an updated GoTo™ Products app highlight fall enhancements to Rexroth’s fast delivery program
Bosch Rexroth Corporation reaches 5,000 in resource kit distributionRexroth Resource Kits include handbook excerpts, case studies, technical papers, videos and online tools
Bosch Rexroth has reached a new milestone as it hits 5,000 resource kits distributed since the very first Rexroth resource kit was launched in 2013.
By requesting the Lean Production and Automation Insights Resource Kit, customers are able to discover creative
ways to accelerate improvements in factories. For those in need of mechatronics solutions, look no further than Rexroth’s Linear Motion & Mechatronics @ Work Resource Kit for engineering support and technology development tools.
Automation-driven factories can turn to the Advancing Factory Automation Resource Kit for smart, productive technologies, and increasing demands for improved energy efficiency and machine safety.
As the world leader in drive and control technology, Rexroth’s Hydraulics
Performance Resource Kit will help improve hydraulic system performance. Also the world leader in mobile hydraulics solutions, Rexroth’s Mobile Hydraulics Solutions Resource Kit offers expert insight and technology.
To meet today’s demanding challenges, the Packaging and Printing Results Resource Kit helps supply needed results.
Ò All Rexroth Resource Kits are delivered on a 2 GB flash drive free of charge and can be ordered from www.boschrexroth-us.com/resourcekits.
01 | 2016 USA3
NEWS
Bosch Rexroth’s plant in Fountain Inn, SC wins Assembly Plant of the Year Award Annual award presented by ASSEMBLY magazine
ASSEMBLY magazine recognizes Bosch Rexroth’s plant in Fountain Inn, SC as its 2016 Plant of the Year Award winner.
Rexroth’s plant at Fountain Inn has doubled in size over the past four years while driving significant improvements in assembly technology and related lean logistics to support it. These advanced technologies have reduced cost while improving the quality of manufactured items, associate training and process capabilities.
Fountain Inn uses Rexroth’s well-known BPS and CIP tools to shorten its time-to-market processes. In 2014, it achieved
“Zero Landfill” status by reselling, reusing or converting waste-energy, instead of sending it to the landfill for disposal. Value streams are continuously being updated, local engineering capabilities are growing, and product performance can be reviewed and improved locally to continue Rexroth’s maturity as a world class manufacturer.
The Assembly Plant of the Year award showcases state-of-the-art manufacturing facilities that apply world-class processes to reduce production cost, increase productivity, shorten time to market and improve product quality. ASSEMBLY magazine presented the 2016 award to Bosch Rexroth during The Assembly Show in Rosemont, IL, on October 26, 2016.
Ò To learn more about Fountain Inn and the Plant of the Year Award, visit www.boschrexroth-us.com/plant_of_the_year.
Bosch Rexroth Bethlehem Service gets new SSTB600 pump and motor test stand New equipment increases service quality, testing and repair times
Bosch Rexroth is committed to providing the latest technology in testing standards across the world. For that reason, Rexroth acquired and installed a new SSTB600 test stand in its Bethlehem, PA service department. This helps Rexroth achieve an even more refined process for testing, thus improving quality and creating a faster turnover time in pump repair. The unique test stand is the only one in the U.S. that has submersible pump and foot pad mount testing capabilities for A2V series pumps. Additional capabilities include up to 600kw testing, 550 bar constant pressure, a dual circuit open/closed loop design that allows up to 8000 psi and 0-395 GPM and tandem pump combination testing. The SSTB600 test stand is an original factory certified test bench and only Bosch Rexroth service has direct access to lead plant test specifications.
Manufactured by Bosch Rexroth Czech Republic, the test stand arrived in Bethlehem in April and took roughly six weeks to install.
Ò For more information, visit www.boschrexroth-us.com/service. New Bosch Rexroth hydrostatic transmission test bench
Bosch Rexroth Fountain Inn is a high-mix, low volume facility.
4drive & control localNEWS
Rexroth’s IndraMotion MTX micro wins Engineers’ Choice AwardAutomation professionals recognize IndraMotion MTX micro as the best in Machine & Embedded Control – CNCs, Board-level Products.
Bosch Rexroth provides hydraulic technology for the Jupiter missionEach Deep Space Network site has one, 70-meter (230-foot) diameter antenna controlled by Bosch Rexroth A2FM45 hydraulic motors
Bosch Rexroth’s IndraMotion MTX micro won Control Engineering's 2016 Engineers’ Choice Award in the Machine & Embedded Control – CNCs, Board-level Products category.
Winners of the 29th annual Control Engineering Engineers’ Choice Awards were announced in a special supplement that accompanied the February edition and were listed online. The publication’s readers – who are responsible for technology purchases and have day-to-day interaction with many of the products – reviewed more than 100 nominations from 60 companies to select winners and honorable mentions for 27 categories. Winners were chosen based
on technological advancement, service to the industry and market impact.
Quick to commission, the IndraMotion MTX micro features a large library of technology cycles and comprehensive programming tools, making it very easy to program. Additionally, it is ideal for extremely fast, efficient and cost-effective turning, milling, drilling, grinding and gear cutting. The IndraMotion MTX is compact in size, cost-effective and offers two CNC processing channels. Rexroth and other award winners were recognized on March 21, 2016 in Chicago.
Ò For more information, visit www.boschrexroth-us.com/engineers_choice_award.
Juno, NASA’s most ambitious mission to Jupiter, entered orbit on July 4, 2016, after a five-year journey that included an accelerating swing past Jupiter in which it became the fastest human-made object ever (165,000 mph). Juno passed just 2,800 miles above Jupiter’s cloud tops to begin the first of 37 orbits it will make over the next 20 months. It will explore some of Jupiter’s most lingering secrets, including what is at Jupiter’s core, what drives its extreme magnetic fields, and how this gas-giant world evolved at the creation of our solar system.
Uninterrupted communications with the spacecraft will be assured by the ground stations of NASA’s Deep Space Network (DSN). The three 70-meter parabolic antennas are strategically located around Earth to receive data and images, and send control commands to Juno. The fine positioning of these antennas, made possible by Bosch Rexroth’s high-performance hydraulic motors, enables the high data transmission rates required to support Juno as it orbits Jupiter more than 1 billion kilometers (~1 light-hour) away.
Ò For more information, visit www.boschrexroth-us.com/Jupiter_mission.
Each Deep Space Network site has one, 70-meter (230-foot) diameter antenna controlled by Bosch Rexroth motors. The 70-meter antennas are the largest and most sensitive DSN antennas, capable of tracking a spacecraft traveling tens of billions of miles (kilometers) from Earth. (Photo: NASA/JPL-Caltech)
01 | 2016 USA5
TECHNOLOGY
Rexroth GoPak™ hydraulic power units (HPU), formerly offered as RexPak units, uniquely combine high-quality engineering, competitive pricing and rapid delivery with exceptionally short lead times using the company’s powerful GoDesigner™ product configurator. Available online, on iOS and Android tablet devices and with limited functionality on smartphones, the GoDesigner™
tool streamlines customization for fixed and variable displacement pumps, motors and thousands of additional options and accessories.
Unlike typical product selectors and configurators producing an invariable design, different parameters can be dynamically changed in the GoDesigner™ tool to fine-tune a design around
Rexroth’s GoPak™ hydraulic power unit and GoDesigner™ configuration tool offers millions of combinations with quick lead timesBosch Rexroth GoPak™ hydraulic power units (HPU) bridge the gap between standard market products and engineered-to-order power units
Configure your next hydraulic power pack with the Bosch Rexroth GoPak™ hydraulic power unit platform and the GoDesigner™ design configurator.
6drive & control localTECHNOLOGY
functionality, price or delivery. In addition, units are optimized to yield the smallest footprint possible without sacrificing functionality and maintainability.
The GoDesigner™ configurator incorporates the latest components for valve assemblies, pressure sensors and gauges, filters and other accessories to meet rapidly changing application requirements. Competitively priced quotes are available in one business day and lead times can be as short as three weeks when using Rexroth’s GoTo™ product offerings. GoPak™ Champion personnel are also available to help with configuration questions.
At the time of the quote, a comprehensive documentation package specific to the configuration is available, which includes a bill of materials, general hydraulic schematic, 2-D general assembly drawing, 3-D model and data sheets for all components, if requested.
The GoPak™ power unit offering and GoDesigner™ system are based on years of Rexroth design intelligence, hydraulic engineering expertise and rules-based programming. GoPak™ units use the same high-quality components found on all Rexroth HPUs, and every component has been pre-selected and tested by applications engineering specialists to meet the high standards of workmanship and dependability expected from Rexroth products.
Ò Rexroth is continually expanding its GoPak™ product offering to meet more industry applications.
For further information or to configure a GoPak™ HPU, visit the GoPak™ website at www.boschrexroth-us.com/GoPak.
Electromechanical cylinder from Rexroth: powerful with a hygienic designWith the second generation EMC electromechanical cylinder, Rexroth expands possibilities
With the EMC-HD electromechanical cylinders from Rexroth, force, position and speed can be freely parameterized by the user and adapted at all times to new tasks via the drive system. Without an additional position sensor, the EMC-HD achieves a repeatability accuracy of up to ± 0.01 mm and they do so for any number of freely selectable positions within the travel range of up to 1,200 mm.
The electromechanical cylinders for heavy loads are driven either by ball or planetary screw assemblies, depending on the dynamic and power requirements. The high-precision, backlash-free, preloaded Rexroth screw assemblies are available in various sizes and leads to cover a wide range of application demands. Rexroth offers the EMC-HD both as finished, purely mechanical axes as well as a complete system with precisely matched gears, servo motors and controllers from the IndraDrive product line.
Electromechanical cylinders are extremely energy efficient because they use energy on demand and implement it with high efficiency in a linear motion. Rexroth IndraDrive servo drives offer numerous opportunities for intelligent energy management. In this way, the drives can regain and store braking energy, along with making it available for other axes of the machine or equipment. As a result, users reduce operating costs over the entire operating life while reducing their CO2 emissions.
Ò To learn more about EMCs, visit www.boschrexroth-us.com/emc.
Without slots and recesses: second generation EMC electromechanical cylinder with hygienic design
The GoDesigner™ design configurator tool gives you a step-by-step process to go from millions of possible combinations to the exact unit that’s right for your needs.
01 | 2016 USA7
TECHNOLOGY
Groninger customizes VarioFlow plus for compact filling machine VarioFlow plus flexible chain conveyor featuring optimized sliding characteristics for the chains and slide rails and less friction in the curves
Groninger liked that Rexroth’s VarioFlow plus is engineered to be a cost-effective conveyor solution for a broad range of applications in the food, packaging and healthcare fields.
8drive & control localFEATURE
Groninger (http://ow.ly/bpAB305OyQ0 , Charlotte, NC), a Germany-based company with operations in North America, supplies customized filling and packaging machines to the global pharmaceutical and cosmetics industries.
The company recently launched the lite-F filling machine, targeting the growing ranks of private-label and start-up companies in the cosmetics industry. Key to the efficiency and flexibility the lite-F system offers is the machine’s conveyor—the VarioFlow plus from Bosch Rexroth (Charlotte, NC.).
New system targets entry-level packagersGroninger’s portfolio includes fully automated high-speed production systems for filling, closing and handling vials, syringes and bottles for pharmaceutical and healthcare products, as well as filling, sealing and handling machines for cosmetics such as perfumes, lotions, hair care products and makeup.
Recently, the company expanded its machine portfolio to fill the gap between manual table top units and fully automated high-speed production lines. “We recognized the need for smaller, versatile filling and closing machines, to give growing private-label and start-up companies the chance to automate their production with a minimal investment,” said Lothar Burger, managing director of Groninger USA.
Demo puts VarioFlow plus to workThe lite series are the first Groninger machines to be designed and manufactured at the company’s Charlotte, North Carolina, headquarters. For Groninger’s customers, the cost-effective systems increase productivity by using a combination of manual processes and automation.
According to Dave Gozlan, business development manager for Groninger USA, at the time that the design for the lite-F was being finalized, senior executives from the company had the opportunity to see a VarioFlow plus demonstration.
Always looking for ways to innovate, Groninger appreciated several aspects of the conveyor’s design, as well as Bosch Rexroth’s openness to quickly custom-configure conveyor elements — in a very short timeframe — to better fit the lite-F’s design.
Tight turnaroundThe new generation of Rexroth flexible chain conveyors, VarioFlow plus, is engineered to be a cost-effective conveyor solution for a broad range of applications in the food, packaging and healthcare fields. It has optimized sliding characteristics for the chains and slide rails, fewer joints with low-friction materials, gliding surfaces that do not require machining, and connection technology engineered for easy assembly and modification.
The main challenge the Rexroth team faced was fitting the VarioFlow plus into the existing lite-F design —which was nearly ready for fabricating and was scheduled to debut at a major tradeshow in less than three months’ time. This required the creation of two custom curves, one with a seven-degree angle and another with a 15-degree angle and modified/ customized connection points with longer infeed and discharge sections to fit the conveyor’s closed-loop around the filling station equipment.
One key tool that aided the team in meeting the tight deadlines was Rexroth’s exclusive MTpro software. It is a Windows-based program for designing and configuring conveyor systems. Easy to learn, it lets users combine catalog components to form assemblies and systems in a virtual 3-D format with support of a built-in rule engine to ensure the solution will work in the real world.
Compact and flexible transportVarioFlow plus has features that help Groninger design the lite-F to fit the needs of the machine’s target markets. This includes its compact size to keep the overall machine’s footprint down for the smaller private-label manufacturers with limited plant floor space.
In addition, according to Gozlan, VarioFlow plus has easy assembly and interchangeable design features that enable manufacturers to modify or expand their footprint in the future. “The flexibility of the VarioFlow plus design makes it possible to connect the lite-F to upstream or downstream machines, if the end user wants to increase their level of automation in the future.”
A new partnershipBoth companies are pleased with the results and the efficient, productive relationship they have established.
Ò For more information, visit www.boschrexroth-us.com/Groninger.
Contact: Matthias Schiedeck, Product Manager - VarioFlow plus Email: [email protected]
Whether for vertical or horizontal conveying, VarioFlow plus’s wide selection of standardized curves and arcs opens up new planning and implementation possibilities.
01 | 2016 USA9
FEATURE
In modern plastic machines, the motive force powering the machine can take several forms and technologies. Traditionally most machines were hydraulically driven by a fixed (constant speed) electric motor.
Newer drive technologiesToday, new technologies are available to drive large-tonnage injection machines, technologies that offer higher speeds, greatly improved energy efficiencies and higher reliability. These new technologies build on existing motor drive systems present in all machines and fit into three basic drive types:
• Variable Frequency Drives (VFD) utilizing V/f technology
• VFD Drives using vector drive technology
• Electric Servo Drives
Variable frequency drivesVariable frequency drives generate an output to drive a conventional AC induction motor. With V/f technology, the output can be varied in its frequency, which correspondingly
varies the RPM of the motor. Due to the electrical characteristics of the motor, the output voltage is also varied in proportion to the frequency, thus the V/f designation.
Vector drive technologyIn the 1980s, a new technology for VFDs emerged called vector drive technology. Utilizing microcontrollers, drive output could be manipulated to precisely control torque of a standard AC induction motor–even to zero RPM when the motor is at standstill. This technology allowed servo-like control of the motor for a small additional cost.
Servo Drive Technology: Electric servo motors are permanent magnet AC motors that are designed for minimal inertia and have peak torque two to three times higher than steady state torque, so highly dynamic speed changes are possible
Drive selection for different applications Both simple and vector VFDs are well established in extrusion machines. Servo motors are also the standard in all-electric
Electric drive technology options for plastics machines New technologies are being used to support improved energy efficiency and operational flexibility
10drive & control localTECH FEATURE
molding machines. Hydraulic machines, the vast majority of plastic molding machines, are increasingly adopting these drive technologies to power their hydraulic systems.
An emerging and more efficient approach is to utilize variable speed motors and drives to accurately and dynamically control pump speed.
Plastics machines with lower performance requirements can use lower cost VFD vector drives with pumps suited for the wide range of RPM operation.
Advantages of using VFD drives with “intelligent” hydraulic pumps In order to improve machine performance when using VFD drives, the addition of an “intelligent” hydraulic pump can reduce the negative characteristics of the motor drive dynamics.
One advantage of this technology is that it can be applied to machine rebuild and retrofits for service life extension, achieving targeted efficiency improvements that would otherwise require replacement with servo driven machines.
Other machine applications Any machine that requires fast, precise motions that may have overlapping cycles can also benefit from modern drive technologies. One example is a blow molding machine. Parison and mold motions often overlap and must be precisely controlled at high speeds. Hydraulic systems often utilize fluid storage accumulators to supply large flows, while a pump supplies average demand.
These and other “hydraulic accumulator” based systems can use the newer drive technologies to save energy.
Electrical considerations All of the drive technologies discussed in this article can generate varying degrees of electrical interference into a plant’s power grid. Known as harmonic distortion, the generation of high frequency, high current and high voltage signals can cause undesirable effects on a plant’s power system.
Effects range from electronic disturbance to device failure. These issues should be considered when selecting supplier equipment and become more critical in plants using these technologies to retrofit or rebuild existing machines, as well as plants that are adding more machines using this technology.
Newer drive technology offers long-term savings These drive technologies generate savings on power usage that can be attractive in many applications. The cost of drive technology needs to be weighed against the expected energy savings. These technologies have become dominant in the new plastic injection machine market.
While there is additional cost, return on investment and total cost of ownership make a strong case for assessing the use of these technologies, in both new machines and retrofit/upgrade applications. Machine OEMs and users can benefit from the advantages of reduced energy consumption and low noise operation, while enjoying the advantage of improved machine performance.
Ò For more information, visit
www.boschrexroth-us.com/plastics-drive-options.
Contact: Paul Stavrou, Applications Engineering Manager Email: [email protected]
The newest generation of plastics processing machines are increasingly incorporating a range of all-electric drive systems into their designs, such as variable frequency and servo drives, to support improved energy efficiency and operational flexibility.
In certain molding machine applications, electric servo drives are used with variable displacement pumps to accurately and dynamically control pump speed, which can match the performance of all but the top tier of servo valve control technology.
01 | 2016 USA11
TECH FEATURE
Rexroth Production Planner Nicole Arendt vividly remembers the hottest day of June 2013, when the go-ahead was given for a forward-thinking project at the Rexroth assembly plant in Homburg, Germany. Not the best of days to be at your most creative, but that was exactly what was required of the project team when they were given the task of building a versatile
‘Industry 4.0’ line.
The connected industry line had its grand unveiling at the production conference in Horb, Germany in 2014 and is used to produce electrohydraulic valves for tractors.
The line is packed full of features that make the job easier for associates. The assembly stations adjust themselves individually to associates and display text in the appropriate font size and language on a monitor screen. Each associate carries a Bluetooth tag that stores the necessary information and automatically transmits it to the assembly station. “Our focus has always been on connecting humans, machines and products to increase agility, accelerate processes and manage the wide variety of products,” explains Tim Brügge, assistant to the technical plant manager in Homburg.
Brügge believes it is all about managing complexity using connected industry and networking. “There are three
important requirements for Rexroth: to increase our ability to absorb rapid changes in the market, to be able to get our products on the market quicker and to be able to cover the wide range of products with lower costs. Overall, we see this as a way to increase our competiveness, including at site level,” explains Frank Hess, technical plant manager. In the future, the networked approach will make this possible.
One floor below, Arendt and Logistics Manager Moritz Hoffmann were working on making sure this happened. Together, they considered how provision of materials to the new line might work. This was no easy task, as Hoffmann explains: “A multiproduct line does have a lot more components. This makes it more challenging to make sure we always have everything in the in the right place at the right time.”
Ò For more information, visit www.boschrexroth-us.com/Homburg.
Competitive Edge 4.0 Rexroth builds self-adjusting assembly stations
Each associate carries a Bluetooth tag that stores the necessary information and automatically transmits it to the assembly station which then adjusts itself based on the preferences of the associate.
12drive & control localFEATURE
Design News magazine recognizes Rexroth’s Hägglunds CA 10-40 hydraulic motor for its extreme power density and high flexibility in lighter applications.
Nicknamed the Hidden Beast, the new Hägglunds CA 10-40 motors are smaller and lighter with unmatched power density, and have the unique ability to deliver full torque and speed simultaneously.
Rexroth has reduced the motor diameter while refining the internal construction to achieve this power density. For customers, this means energy and production efficiency. Compared to competitor solutions, CA 10-40 motors provide 10 to 15 percent more torque for the amount of energy put in.
Further efficiency comes from the series’ flexibility, which includes four basic models and a wide variety of displacements. Using two mechanical interfaces, 14 configurations in small torque steps allow for tight dimensioning and full optimization in relation to the hydraulic pumps.
Rexroth's Hägglunds CA 10-40 hydraulic motor was also awarded a Golden Mousetrap Award for best product in the Automation & Control: Fluid Power Technologies category at the ceremony in Anaheim.
Ò Learn more about Hägglunds motors by visiting www.boschrexroth-us.com/hagglunds.
Rexroth’s Hägglunds CA 10-40 Hydraulic Motor wins Golden Mousetrap Award from Design News magazine Named best product in Automation & Control: Fluid Power Technologies category
Rexroth’s IndraDrive Mi wins Golden Mousetrap Award from Design News magazineNamed best product in Automation & Control: Drives category
Design News magazine editors recognize Rexroth’s IndraDrive Mi for being cabinet-free and modular. Complete reallocation of all electric drive components to the machine saves production space, which is in high demand amongst end-users.
Rexroth has made this possible with its proven motor-integrated and near-motor IndraDrive Mi drives, as well as its decentralized supply and mains module, which are designed with IP65 classification to protect against dust and water stream ingress for robust use directly in the machine.
With the decentralized modules, machine manufacturers can connect up to 20 IndraDrive Mi units in series, allowing more drives to be switched.
In adjacent Rexroth near-motor drives, a newly developed hybrid connector can be plugged into the IndraDrive Mi unit to further reduce assembly work. The cabinet-free drive technology also extends the possibilities of modularized machine concepts.
Design News magazine announced the winners of its annual Golden Mousetrap Awards during a ceremony February 9, 2016, at the Anaheim Convention Center, in Anaheim, California, held in conjunction with the Pacific Design & Manufacturing trade show.
Ò For more information on Rexroth’s IndraDrive Mi, visit www.boschrexroth-us.com/edc.
Smaller, yet more powerful, Hägglunds CA 10-40 hydraulic motor
The IndraDrive Mi enables machine manufacturers to integrate all electric drive components directly into the machine
Bosch Rexroth was the recent recipient of two Golden Mousetrap Awards from Design News.
01 | 2016 USA13
NEWS
Rexroth IMS-I and IMS-A Integrated Measuring Systems set the standard for precision Rexroth’s Integrated Measuring System (IMS) integrates into profiled rail systems The IMS-I (incremental) and IMS-A (absolute) integrated measuring systems combine highly rigid Rexroth ball rail and roller rail systems with a non-contact, inductive length measuring system. Offering measurement accuracy comparable to that of high-precision glass scales, both systems offer simplified design with components completely integrated into the linear guide and no attachments required. The IMS-I is capable of resisting extreme vibrations and impacts of up to 50G. The IMS-A is best suited for applications requiring highly dynamic and accurate absolute positioning in high rigidity mechanical systems. The integration of additional temperature and motion sensors makes IMS prepared for the future requirements of Industry 4.0. With options in both incremental and absolute, IMS offers the right precision and features for any application.
Ò For more information, visit www.boschrexroth-us.com/ims.
Modular Conveyor System for Quick AssemblyVarioFlow plus modular chain conveyor system offers universal and quick application, as well as easy planning and assembly
Noise reduction is attracting increasing attention as a way to continuously improve factory work environments. VarioFlow plus is one of Bosch Rexroth’s major contributions to noise reduction, with particularly low-noise operation thanks to sliding bars with lateral fixation, low-friction materials and patented hinge bolts. At the same time, VarioFlow plus provides optimum sliding properties for reduced wear, even with chain tensile forces up to 1,250 Newtons.
An example of VarioFlow plus’ flexible application can be found in the automotive industry. In order to improve handling and save space during transport, an innovative manufacturing cell based on VarioFlow plus is able to convey roof linings at a height of approximately three meters directly to a robotic unit at a processing station. Attaching and uncoupling the finished roof linings are the only manual procedures required in this fully automated solution. This results in increased productivity as factory personnel may use this time savings to complete other tasks. Currently, this automotive manufacturer operates four complete manufacturing lines using the same application of VarioFlow plus.
Ò To learn more, visit www.boschrexroth-us.com/VarioFlow.
Rexroth’s Integrated Measuring System (IMS) is seamlessly integrated into profiled rail systems making it ideal for applications requiring highly dynamic and accurate absolute positioning in high rigidity mechanical systems.
Optimized throughout for speed and efficiency: The VarioFlow plus modular chain conveyor system offers universal and quick application and easy planning and assembly. The system also boasts extremely quiet and low-wear operation.
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There are often no economical alternatives to standard control systems. As a result, machine manufacturers were previously limited to implementing the same functions available to all other competitors. Rexroth has now done away with this limitation. For the first time, machine manufacturers can create individual and real-time machine functions outside of the PLC program with Rexroth’s Open Core Interface technology.
The standard Rexroth control platforms IndraLogic XLC (PLC), IndraMotion MLC (motion-logic) and IndraMotion MTX (CNC) support the direct implementation of individual high-level language programs into the control system. The programs have direct access to the firmware, enabling machine manufacturers to create control algorithms for complex functions and kinematics quickly and independently. The programmers do not require any PLC skills and can use standard high-level languages such as C/C++ instead.
Rexroth also provides machine manufacturers with an extensive library that programmers can use to directly access the control function when developing individual functions. This enables them to directly control axes without writing a single line of a PLC program. Using Open Core Interface is therefore the ideal way to protect the machine manufacturers’ expertise.
Shorter cycle times and higher productivityThis new degree of freedom replaces the additional control hardware previously required for complex process functions such as quality assurance with camera systems, register control for optimized material processing, or decentralized order scheduling at the machine. Previously, machine manufacturers had to perform these process flows–which are programmed in high-level languages–outside of the machine system on a separate control. The need to communicate between both control systems increased the complexity of the automation architecture and the engineering workload.
Efficient PLC automationIn addition to the new interface technology, Rexroth’s overall OCE platform includes all the software tools, function tool kits and open standards for efficient PLC automation. The predefined technology functions cover almost all standard tasks and lower engineering costs and effort.
Ò To learn more about Open Core Engineering, visit
www.boschrexroth-us.com/oce.
Rexroth’s Open Core Interface allows machine builders to create individual functions without a PLC Open Core Interface expands individual machine functions created with high-level programming languages
Rexroth’s standard control platforms support the company’s Open Core Interface, which allows the expansion of individual machine functions created with high-level programming languages.
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One of the most dominant topics across the automation and manufacturing industry landscape right now is Industry 4.0. However, among all of this discussion manufacturers must still focus on actual production that generates strong returns on investment. So how can machine builders and controls engineers translate Industry 4.0 concepts into practical technologies for deployment on the factory floor?
Industry 4.0 is the rapid transformation of industry, where the virtual world of information technology, the physical world of machines and the Internet have
Connecting the potential of Industry 4.0 with real manufacturing
In Industry 4.0, the operation of a machine tool or a packaging machine should allow for easy connections with smart devices such as phones or tablets.
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become one. Industry 4.0 centers on the integration of all areas of industry made possible by information technology. The proliferation of machine-to-machine communication and the vastly improved intelligence in those machines will lead to more automated processes, self-monitoring and results in real-time.
Key factors to consider for Industry 4.0 There are five qualities for devices designed around the Industrial Internet of Things (IIoT) which we believe need to work together to bring about the Industry 4.0 manufacturing environment: decentralized intelligence, rapid connectivity, open standards and systems, real-time integration and autonomous behavior.
Decentralized intelligence The first is decentralized intelligence, also called distributed intelligence, where intelligent drive and control technologies are designed to network with other devices with decentralized autonomy.
The ability to process data at the machine level and deciding what to do with it reflects our belief that you can equip the machine to do something with the process data and improve the process on its own — adjust throughput, utilize energy more efficiently and so forth —rather than depending on the cloud to handle all these tasks.
The machines are still connected, still communicating to higher line level, plant-level and enterprise-level networks, but they have the capacity and systems to make event-specific or product-specific adjustments in real-time.
Rapid connectivity Systems that facilitate instant vertical or horizontal connectivity to allow data to flow freely across the enterprise structure need continual investment and improvement.
These communication issues currently take up a substantial amount of time and cost in creating automation solutions, so eliminating barriers between various supplier systems and taking a more open approach to communications and controls platforms is more important than ever in the Industry 4.0 era.
Open standards and systems There needs to be a focus on expanding how “open” systems are, both in terms of support for emerging communications and software standards, and in how open individual components are, to make Industry 4.0 a reality.
The use of open standards allows the more flexible integration of software based solutions —with the possibility to migrate new technologies into existing automation structures. Our Open Core Engineering (OCE) control and engineering platform is a significant step in that direction. OCE bridges the gap between automation and IT software programming and opens up our controller kernel, through the Open Core Interface, to enable the creation of automation applications using common
high-level IT languages such as Java and C++.
Real-time context integrationIn Industry 4.0 factories, it will be possible to draw on real-time machine and plant performance data to change the way automation systems and production processes are managed. Instead of capturing and analyzing several months’ worth of data on throughput rates, machine downtime or energy consumption, Industry 4.0-enabled platforms will integrate that type of data into routine plant management reporting.
Autonomous behavior This is one aspect of Industry 4.0 where Bosch Rexroth has implemented real-world initiatives to make our own production more connected and demand-driven. We are deploying technology that allows the production line to become autonomous. The goal: workstations and modules that can adapt as needed to individual customer or product needs.
Moving toward Industry 4.0 is revolutionary and evolutionary Certainly the impact of Industry 4.0 will be as great as previous industrial revolutions. But it is an evolution, because it’s about moving manufacturing forward, day by day.
Our goal is to help machine builders and manufacturers implement Industry 4.0 features in the existing production environment and enable them take advantage of technologies like OCE that we have already deployed.
With Industry 4.0, we will also see a beneficial evolution of the role of people in the manufacturing environment.
Ò For more information, visit
www.boschrexroth-us.com/industry-4-0-manufacturing-potential.
Contact: Allen Tubbs, Product Manager Email: [email protected]
Automation components with decentralized intelligence equip the machine to do something with the process data and improve the process on its own—adjust throughput, utilize energy more efficiently and so forth—rather than depending on the cloud to handle all these tasks.
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VITS International (Blauvelt, NY) is a leading global supplier of variable repeat sheeting and finishing systems for the printing, packaging, digital and converting industries. They recognized that the digital printing market needed industrial-strength finishing systems that could deliver the speed, flexibility and ultra-precise registration control to sustain commercial printing production rates. To meet that need, VITS developed the SPRINT Variable Data Finishing System — created with a complete, state-of-the-art electric drive and control platform from Bosch Rexroth (Charlotte, NC).
Today’s digital inkjet printers are capable of high-speed web-fed output with speeds reaching near-commercial rates of 700 to 1,000 feet per minute (FPM). However, digital printing supports variable data printing: it can dynamically vary the content, images and page dimensions being produced, which complicates how the printed web roll is finished. This complexity was viewed as an opportunity for VITS.
The SPRINT Variable Data Finishing System transforms variable print material to finished product at industry-best production rates — up to 1,500 FPM. It utilizes patented “Clear Channel” registration control technology to cut thousands of pages per hour while keeping ultra-precise page registration.
“Our printing customers wanted to be able to produce much larger products at much faster rates of speed,” said Kim Markovich, VITS International Director of Product Applications and Regional Sales and Marketing Manager.
“Particularly for the direct mail marketplace, being able to finish multiple webs and ribbons and accomplish perfect register control meant that our printing customers could take on more work and be more productive.”
The company developed its SPRINT system to support two variations: inline systems and offline multi-web finishing. The VITS team knew that the controls and drive technology they chose for the SPRINT system must have the highest levels of
New variable data finishing system matches digital printing growthVITS, Rexroth and Parks Consulting International find solution to digital printing technology
SPRINT Variable Data Finishing System
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versatility and sophistication — one of the key reasons they chose Rexroth.
Ultra-precise multi-web registration control The SPRINT Finishing System consists of modular, independently driven components controlled by a central Rexroth IndraMotion MLC motion control platform. The inline SPRINT system configuration typically has 10 to 12 driven axes, while the more advanced multi-web offline version can have up to 30 driven axes.
Each SPRINT module performs specific functions to convert a printed web into a completed book or direct mail piece — and each utilizes a specific set of Rexroth IndraDrive servo drives and proven IndraDyn servo motors.
Maintaining absolute registration control of the multiple webs —so that every page in every signature is cut to exactly the same dimension —was one of the most significant technical hurdles the team faced.
“Nothing is ever printed perfectly— the length of print can vary by plus or minus ten thousandths of an inch from page to page,” said John Salamone, Director of New Product Development for VITS.
VITS enlisted Bruce Parks of Parks Consulting International, a systems integrator with extensive experience using Rexroth printing system controls, to help develop the SPRINT automation solution. “We use the intelligence of Rexroth’s drives to maintain registration on the web in a dynamic fashion,
which then frees up the processing power of the central IndraMotion MLC controller,” Parks said.
The team used the industry-specific IndraMotion for Printing version of Rexroth’s IndraMotion MLC system as the automation platform, featuring IEC 61131-compliant motion-logic controls and PLC open function blocks along with extensive software libraries for printing and converting functions.
Collaboration provides the right chemistry This is the first system the company produced using a complete Rexroth drive and control platform — a decision that was made after a thorough evaluation, according to Deirdre Ryder, President and CEO of VITS International.
“Rexroth technology allowed us to develop our equipment much faster than our previous supplier, with world-class accuracy that none of our competitors have. We now have Rexroth-equipped machines located all around the world. Their performance and reliability is so good that I am proud to say they are working flawlessly,” said Ryder. “With a lot of input from our team, and the right technology, we were able to solve our challenges. It took all three partners — Bosch Rexroth, VITS International and Parks Consulting International — to go from ideas to working solutions.”
Ò For more information, visit www.boschrexroth-us.com/VITS.
Contact: Jim Hulman, Business Development-Packaging Email: [email protected]
The SPRINT Finishing System uses the Rexroth IndraMotion for Printing automation platform with modular, independently driven components controlled by a central IndraMotion MLC motion controller (similar to the one shown here).
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Optimizing machining processes with cycle time and energy analysis tools
In recent years, focus has shifted to data-driven manufacturing methods to achieve reduced energy costs and more importantly, CO2 emissions. While it is important to monitor data regarding production throughput, downtime and energy consumption to get a real-time picture, it is equally important to optimize your manufacturing equipment right from the start.
Only if the equipment is optimized for the shortest cycle times and minimized energy use can the goals of energy savings and CO2 reduction be achieved. A machine with an optimized cycle time will produce the desired workpieces in a shorter time and can be switched to idle when the production target is reached, or better yet, can lead to using fewer machines to meet the production goal.
Bosch Rexroth is at the forefront of the energy efficiency initiative with its 4EE (Rexroth for Energy Efficiency) strategy and has several onboard tools available with its IndraMotion MTX CNC control platform, bundled into an Efficiency Workbench — namely the Cycle Time Analyzer and Energy Analyzer.
The Cycle Time Analyzer (CTA) tool allows for real-time recording in the Rexroth IndraMotion MTX CNC system, the execution of NC-program sequences, detailed execution times,
interpolator motion settings and PLC logic functions. With the recorded details and software visualization tools, engineers can optimize programs in order to achieve the shortest workpiece cycle times.
It is important to note that machinery optimized for the shortest cycle time may still have room to reduce energy consumption, including peak energy consumption. As part of the Efficiency Workbench, Bosch Rexroth offers the Energy Analyzer (EGA) tool. Together with the Cycle Time Analyzer, the energy consumption of the machine’s main energy consumers are also recorded and visualized. This allows users to optimize the motion profiles of servo and spindle axes with the activation of other energy consumers.
With tools like the Cycle Time Analyzer and Energy Analyzer, programmers can record, visualize and save specific set-ups and recordings, enabling data-driven machine optimization and documentation.
Ò For more information, visit
www.boschrexroth-us.com/optimizing-machine-processes.
Contact: Karl Rapp, Industry Manager Email: [email protected]
Data-driven tools like Rexroth’s Cycle Time Analyzer and Energy Analyzer built into the CNC platform can help users optimize the machine for energy efficiency and productivity.
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Get started by ordering your free Advancing Factory Automation Resource Kit: www.boschrexroth-us.com/factoryautokit
For expert advice call 1-800-REXROTH (739-7684) or email us at [email protected]
Today’s automation-driven factories need smarter, more productive technologies, support for ultra-fast changeovers and greater flexibility, plus increasing demands for improved energy efficiency and machine safety. When you’re ready to take your factory automation to the next level, you’re ready for Bosch Rexroth with solutions that optimize both cycle time and energy efficiency. To move your business forward, make the move to Bosch Rexroth.
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Bosch Rexroth CorporationCorporate Communications14001 South Lakes DriveCharlotte, NC 28273
Telephone (800) 438-5983Facsimile (704) 583-0523E-Mail: [email protected]
