building the factory of the future – one step at a time€¦ · building the factory of the...

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www.boschrexroth-us.com/atxwest

Building the Factory of the Future –

One Step at a Time

ATX West 2020, Booth 4400

EXHIBIT FLOOR PLAN

4201

4504

4311

HALL

ENT

RANC

E

4500

Mechatronics@Work

MGEAluminumFraming

ManualProduction

Systems

VarioFlow+

Smart Function

Kit

Industry 4.0Technology

Cube

ActiveMover Transfer SystemSmart

Assembly 4.0

Workstation

EcoS

hape

Flow

Rac

k

Cas

e Li

fter

LT E-Tools

LT Total Line

Automation

Tightening Systemswith position tracking

Info

Step 1 – Lean Principle Implementation Aluminum Framing 4Step 2 – Technology Integration Operator Guidance Systems 5Step 3 – Data Collection Mechatronics@Work 6

Step 4 – Data Analysis and Visualization i4.0 Technology Cube 7Step 5 – Monitoring Machine Health

ActiveMover 10Step 6 – Factory-wide Intelligence

Smart Assembly 4.0 11

Smart Function Kit 12GoSelect™ Product Selector 13LT Total Line Automation 14LT Applications & E-Tools 15

Table of Contents

Building the Factory of the Future — One Step at a Time!The manufacturing industry is changing faster than ever before. As consumers demand more variety, manufacturers have to adapt, producing more product variations in the same amount of time and space, in order to stay profitable. Gone are the days of set-it-and-forget-it; the successful factory of the future is a puzzle with infinite combinations. And while the fully connected Factory of the Future is attainable, even the most innovative and optimistic companies should not expect the pieces to come together all at once.

While there are many steps along the way to the fully connected factory—there are some key milestones that will help you identify where you are and how to begin.

Whether you’re implementing manual solutions, looking to add modular technology, or are ready to implement full i4.0 connectivity in your factory, we’re here to guide you. The steps are many, and our job is to make them manageable—meeting you and your organization where you are. This booklet will help you get started on your i4.0 journey. Follow the steps throughout our booth and let our experts guide you along the way.

For the latest information about Bosch Rexroth and the Factory of the Future, visit www.boschrexroth-us.com/atxwest.

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Lean is a culture in which people use tools to continuously solve problems. In a Lean organization, tools are used to visualize problems and people are trained to solve these problems. Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity.Lightweight and versatile aluminum structural framing improves ergonomics which will maximize your productivity and is a simple solution that allows for lightweight, adjustable workstations while removing the old steel, stationary workstations of the past.

ALUMINUM STRUCTURAL FRAMINGRexroth’s Aluminum Structural Framing System can be used to build anything you can imagine. With over 100 different strut profiles, our aluminum framing system not only offers a wide range of application options, but also numerous competitive advantages. Everything to build anything.

How it relates to i4.0

• Aluminum Structural Framing helps build physical structures that support a lean manufacturing and connected industry environment

Benefits• Largest modular profile system worldwide with 120 profile cross sections

• Minimal planning and design efforts

• Fast assembly time with minimal assembly tools

• Flexible design for easy removal and conversion

Applications• Customized workstations and flow racks

• Material handling carts and racks

• Machine guards, protective panels, and enclosures

Lean Principle Implementation

Not sure where to start? Contact us for a consultation at [email protected]

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Once the physical environment and assembly process begins to become efficient, it is a natural progression to upgrade the workstation technology by adding worker guidance that provides error-proofing and data capture. This might be as simple as deploying sensor tech-nology to troubleshoot or identify problem areas, followed by the utilization of sensors for full-time monitoring that feeds information into an already existing data collection system.

OPERATOR GUIDANCE SYSTEMSRexroth can help create stations for working that improve the accuracy and speed by putting everything at the operator’s fingertips. With easy integration into a standard workstation, fully interactive assembly worker guidance tools use open platforms to connect to most MES/ERP systems.

The Operator Guidance System is a digitally-based guide that provides on-screen step-by-step guidance, process documen-tation and high flexibility for mobile and stationary stations.


• Uses technology to assist in complex manual tightening processes

• Data captured to record status, operating instructions, error reports and last results

• Flexible integration of additional devices such as socket trays, click wrenches, identification systems, scanners, etc.

Benefits

• Minimize the risk of errors

• Enhance the quality in your production and optimize production times

• Combine stationary stations and assembly steps in the flow production

• Ensure high process reliability despite a wide product variety

Applications

• Assembly flow production

TechnologyIntegration


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DataCollection

After the technology has been integrated, you have the ability to gather information from each source about the process that allows for data-informed decision-making. When con-sidering this phase it is important to ensure the use of open, scalable and flexible protocols to ensure your current and future technologies can be integrated and won’t hold you back.

MECHATRONICS@WORKMechatronics@Work from Rexroth combines high performance mechanical technologies and motion control systems with open, user-friendly programming environments to create the most accessible, easy-to-use Cartesian motion robots.


• Collects and displays machine and production data from various software platforms to produce custom product batches

• Rexroth Motors, Drives, and Controls enable monitoring of system and individual axes performance while showing how custom orders are produced inside a factory at the machine level

Benefits

• Easy connection to the internet using the IoT Gateway Rack

• Flexible integration of Rexroth’s linear motion, assembly, and automation solutions

Applications

• Machine data collection through various sensors and IoT-

ready products

• Cloud-based software to collect, analyze and display machine

and production data


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INDUSTRY 4.0TECHNOLOGIES CUBE

Data Analysis &Visualization

The key pieces of data that are relevant to your vision and pre-defined goals will allow you to make the right analysis and provide the foundation for making smart, fast and informed decisions. Capturing, analyzing, and displaying the data in a transparent format keeps all staff informed and opens up a whole host of opportunities to connect, test and learn about the performance of production for the optimal result.

As both a lead provider and user of Industry 4.0 technology, Bosch Rexroth has first-hand experience of what these technologies can do for the thousands of employees that come to work in our facilities every day. The manual processes of the past required large amounts of time to report problems and troubleshoot solutions with the right personnel. Today’s technology like the Nexeed Production Performance Manager, pulls the relevant data and performs real-time analysis. This, coupled with visualization software on the ActiveCockpit allows everyone to view the status immediately from anywhere in the plant. This also allows for the ability to compare performance over time paving the way for predictive analytics.


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The IoT Gateway is an integrated hardware that includes software communication solutions for easy connection to Industry 4.0 environments without intervention in automation logic.


• Rexroth IoT Gateway connects machine edge devices like I/O, sensors and 3rd party PLCs with IT-based higher level systems such as various Cloud services, MES and databases

Benefits

• Enables Industry 4.0 solutions on any automation machine irrelevant of machine manufacturing date

• Boosts productivity and efficiency

• No programming is needed. Configuration is done with simple application setup via web-based interface

• Future-proof with open standard software architecture

Applications

• Any automation application where connectivity to IT platform is needed for OEE improvement

The IoT Gateway connects with the Rexroth designed IoT Insights software solution, which addresses a market need for simple dashboard-based local analytics, visualization, and remote alert algorithms for immedi-ate notification. IoT Insights and IoT Gateway rack offer a complete i4.0 solution to various industries.

For example, these solutions help to optimize a line for high production throughput. With huge streams of data coming from each individual tool it is important to manage the data in a simple but effective way. IoT Insights software in combination with IoT Gateway offer OEMs and end users alike a quick and efficient entry into the Connected Automation realm.

In addition, Bosch offers unique sensing products like CiSS, Connected Industrial Sensor Solution, that help to increase Overall Equipment Efficiency (OEE) by monitoring, in real-time, automation processes, overall machine health and environmental conditions like humidity, temperature and vibration. Sensors are easily integrated in the IoT Gateway Rack, adding another innovative product in Rexroth’s i4.0 solutions portfolio.

Popular dashboards such as Grafana and Power BI can easily connect to the data streaming from the IoT Gateway.

DATA ANALYSIS AND VISUALIZATION WITH THE I4.0 TECHNOLOGIES CUBE

The Nexeed Production Performance Manager is the Industry 4.0 software solution for systematic production improvement. The software helps quality and maintenance management staff in decision-making and makes their everyday work easier.


• Nexeed technologies enable you to monitor and optimize production performance and logistics in real time, all from a single login access point

Benefits

• Harmonizes production data from various sources

• The user is at the center of this software solution

• Open interfaces allow for combination with other solutions, such as an MES extension

• Condition monitoring, live process monitoring, predictive maintenance, and i4.0 general purpose tool

Applications

• Tightening

• Pressing

• Conveyor monitoring

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ActiveCockpit is an interactive data visualization and communications platform to support employees and management personnel with continuous process improve-ment. ActiveCockpit is the ideal communications hub for today’s smart factory.


• ActiveCockpit communicates, filters and visualizes all relevant production data in real time

• Interfaces to all current MES and ERP systems, including data streams from assembly systems and production machines

• Quickly reveals improvement opportunities to help increase productivity

• Displays opportunities to achieve higher energy efficiency

Benefits

• Efficient, targeted recognition of defects, performance trends and opportunities for improvement

• Enables fast response to deviations, aids in disruption management and continuous improvement

• Increases productivity through collaboration and visualization

Applications

• Manufacturing systems and equipment, assembly lines

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Smart solutions that employ flexible features such as free programming and control of each individual workpiece pallet allow adaptable realization of process flows and flexibility in retooling processes. With a visual display of what is happening in the systems, ActiveMover increases production efficiency by monitoring the state of power consumption, cycle events, lubrication, temperature and more. Virtual simulations allow for improvement of throughput by optimizing pallet use to ensure low maintenance interruptions. This paves the way for predicting the health of your machine to maintain as much uptime as possible.

ACTIVEMOVER TRANSFER SYSTEMThe ActiveMover is a linear motor transfer system that moves magnetic pallets at high speed with incredible accuracy. It is a pre-engineered solution that provides a user-friendly program-ming environment.

How it relates to i4.0• ActiveMover is a high speed linear motor transfer system with an open programming platform compatible with most PLCs

• Using the optional Rexroth PLC, the ActiveMover becomes an IoT gateway that can communicate with other IoT devices

• Collects and displays machine and production data with AMPro software and Nexeed PPM to analyze key data

• Employs sensors that monitor the quality of the machine health to better predict maintenance requirements

Benefits• Flexible integration – can be increased in length by 1 meter all the way up to 60 meters

• Built-in collision avoidance

• Pallets can be controlled individually at speeds over 2.5 meters/second and can move in either direction on the track

Applications• Machine data collection through various sensors and IoT-ready products

• Cloud-based software to collect, analyze and display machine and production data

• High speed conveying applications with high precision

MonitoringMachine Health


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The ultimate achievement in connectivity is the potential for predictive maintenance solutions that flag issues before downtime occurs. This allows for ecosystem partners to be notified of impending issues or follow up needs, and extends into automatic ordering capability of the machine through systems like SAP, ensuring parts are available before failures occur.

SMART ASSEMBLY 4.0 CONVEYORThe Smart Assembly 4.0 Conveyor is the ultimate achievement in connectivity with the integration of multiple technologies in a smart and flexible assembly system. With demands for a batch size of one, the Smart Assembly 4.0 Conveyor combines manual and automatic functions ideally suited for situations needing monitored manual rework.


• When viewing the system as a whole, including the sensors, controls, RFID, and other data-transfer and communication devices, the Smart Assembly 4.0 Conveyor is a backbone to Industry 4.0

• The system has an on-board IoT Gateway that can display any parameter on the system as well as communicate with other devices and display their data

Benefits• Designed with an energy-efficient pre-engineered building block

• Uniquely-designed aluminum structural framing and TS 2plus palletized assembly conveyor for payloads up to 240kg

• CKK Compact modules’ three combined linear axes create a Cartesian robot for automated assembly

• Cabinet-free design with Indradrive Mi

• Predictive maintenance capabilities with IoT Gateway & sensors

• Controlled by XM22 PLC with Safety PLC with Safe Torque & Safe Motion

• i4.0 data can be collected and shared with other systems for manufacturing transparency

Applications• Automated or manual assembly

• Automotive, electronics, medical device, consumer goods, machine tool, HVAC, and more

Factory-wideIntelligence


Whether assembly, joining, forming or testing the Smart Function Kit is suitable for many standardized applications in the field of pressing and joining. The modular system combines mechanical and electrical Rexroth components and software, providing a fast, ready-to-use mechatronic package for forces from 2 to 30 kN.


• Can be networked via open interfaces and conveniently monitored via tablet during the ongoing process

• Provides maximum transparency, reduces downtime and increases your productivity

Benefits

• Preselected mechanical, electrical and software components are combined in various kits for forces from 2 to 30 kN

• All components from a single supplier – with proven Rexroth quality

• Delivered in a single package, including preinstalled operating software

• Automatic parameterization of the servo drive

• No programming knowledge required

Applications

• Assembly and joining

• Forming

• Testing

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Fast and efficient realization of easy joining applications

SMARTFUNCTION KIT

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GoSelect™, a new online ordering tool, is designed to streamline product selection and make cost quoting a breeze. The user-friendly interface offers pricing and availability on hundreds of products. Users can instantly download CAD drawings which are available in a variety of formats, including PDF3D, STEP, IGES and DXF. An intuitive filter system includes selection options like lead time and product specifications. Users can also build a wish list of products for future reference. The online tool also offers a live chat option where buyers can ask questions to application engineers in real time.

Easy ordering and configuration with

Benefits

• User-friendly interface

• Download CAD drawings

• Pricing and availability

• Eliminates guesswork

Available products:

• Profiled Rail System Selector

• Function Module Selector

• Directional Spool Valve Selector

For more information on GoSelect™, visit www.boschrexroth-us.com/goselect

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LT Total Line AutomationRexroth’s Linear Technology Total Line Automation display features a variety of our linear motion portfolio including the MKR-080 linear module, ball rail system NRFG, both screw and belt drive function modules, corrosion-resistant linear bushings and shafts, and ball screw assemblies.

How it relates to i4.0• The high-efficiency machine components help guide and drive loads

Benefits• High speed capability allows the machine builder to reduce cycle times

• Robust long lasting components and pre-engineered systems minimize machine down-time and offer extended lifetime ratings

• High efficiency driving and supporting of the load allows for reduced motor sizing and offers substantial cost savings upfront throughout the machine’s lifetime

Applications• Machining

• Pressing applications

• Material handling

• Food and Packaging

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1. Linear Module

2. Ball Screw Assemblies

3. Ball Rail Systems

4. Function Modules

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Thank You for visiting us at ATX West 2020

Linear Motion Applications and E-ToolsLinear Motion Technology by Rexroth supports you with modern eTools for product selection, configuration, and ordering, for a shorter time-to-market. The Linear Motion Designer (LMD) is the calculation program for Rexroth’s Profiled Rail Systems and screw assemblies. It covers the complete range of roller and ball rail systems as well as Ball and Planetary Screw Assemblies. A modern interface with extended help and safety functions simplifies operation and quickly leads to optimum results.

LinSelect software allows design engineers to find the optimal linear axes and actuators from around 100,000 possible Rexroth product variants in just five steps. The new selection tool completes the digital workflow from product selection right through to ordering in the Rexroth eShop. Here, selecting complete axes and actuators extends beyond the mechanicals– it also encompasses suitable Rexroth motors and drive controllers. A full range of Configurators assist with suitable product solutions.


• Design tools shorten the design and product selection phase via an intelligent product filter that calculates application parameters using intelligent algorithms to identify the right product fitting application

Benefits

• Includes application input guidance and builds in design safeguards to consider so that the user will not undersize the application

• Provides full report and detailed analysis for project and/or machine folder to be referenced for the life of the machine

• Easily transfers the optimum product variant into an online configurator with a mouse click to obtain CAD Models in a variety of formats

Applications

• Component-based or pre-engineered linear axes

• Assembly applications

Stop by Booth #4515 to see a demo of the DWFritz Flexible Platform (DFP 1000) using Bosch Rexroth technologies. Together, we can solve your high volume automation and inspection needs for any advanced manufacturing application.

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USCOR00174/01.2020©2020 Bosch Rexroth CorporationSubject to change without notice.ALL RIGHTS RESERVED

Bosch Rexroth Corporation14001 South Lakes Drive Charlotte, NC 28273Telephone (800) REXROTH (800) 739-7684www.boschrexroth-us.com

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building the factory of the future – one step at a time€¦ · building the factory of the...

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