i4. nowConnected Automation

R999001199 (2016-06)© Bosch Rexroth AG 2016Subject to changes!

The data specified only serve to describe the product.As our products are constantly being further developed, no statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

Bosch Rexroth AGPostfach 13 5797803 Lohr, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr, GermanyTel. +49 9352 18-0Fax. +49 9352 18-8400www.boschrexroth.com/factoryautomation

Connected Automation:Showcase Manufacturing i4.0

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Connected Automation: Showcase Manufacturing i4.0Experience a manufacturing line,which customizes mass production according to i4.0 criteria.

100 % virtual image and simulation – allows for a shorter system development stage and the simulation of all relevant manufacturing processes.

Consistent horizontal and vertical networking – all relevant information is made available everywhere in real-time via open interfaces.

Data analysis – predefined mathematical and statistical methods of data analysis enable process and quality enhancements.

Interactive shopfloor visualization – ActiveCockpit supports managers and staff during continuous improvement processes.

i4.0 Upgrade Kit – connects existing manufacturing lines and modules, which previously could not be integrated into i4.0 networks, with superordinated IT systems.

Self-controlled products – by means of RFID technologies, the product itself transmits its required manufacturing data to the line.

Highly flexible and modular manufacturing layout – depending on the current requirements, manual and automated work stations can be flexibly arranged to facilitate different manufacturing sequences.

The modular manufacturing line demonstrates on the basis of versatile processing and assembly that increased produc-tivity and flexibility can be achieved by means of Industry 4.0 even today. All stations are consistently connected vertically and horizontally via open interfaces and provide all relevant information in real-time. The flexible manufacturing concept combines fully automa-ted and manual work stations into a consistent manufactu-

ring solution by means of cutting-edge automation and IT technologies. All necessary information is being shared seamlessly with superordinated IT systems, including the cloud.The products themselves transmit their required production data and thus provide the basis for the efficient manufactu-ring of batch size 1 at change over 0.

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Connectivity and Software Integration

Lua high-level script language for the programming of robots in connection with Open Core Interface, integrated into Bosch Rexroth controllers.

Java Virtual Machine integrated into Bosch Rexroth controllers for the platform-indepen-dent programming of application software.

Dassault Systèmes Dymola for the simulation of dynamic models such as a delta robot in Modelica.

Open Core Engineering from Bosch Rexroth, for the easy integra-tion of IT and auto- mation as well as for the reduction of engi-neering efforts by up to 30 %.

MES solution for manufacturing control. Direct connec-tion to automation controllers via OPC UA.

mxAutomation for the connection and control of a KUKA articulated- arm robot via a Bosch Rexroth controller.

Bosch IoT Cloud and Process Quality Manager for the cloud-based, quality- oriented analysis of data from the Bosch Rexroth tightening system.

i4.0 Upgrade Kit from Bosch Rexroth, for the connection of existing machines, mod-ules or lines to IT environments.

WebConnector from Bosch Rexroth, a trans- lator between the web and the automation world, based on HTML5, Java, and OPC UA.

Data Analytics Server from Bosch Rex-roth, in connection with MATLAB Simulink, for the statistical analysis and visualization of data.

ActiveCockpit from Bosch Rexroth: Web-based shop-floor visualization software, expand-able with apps and widgets.

Controller

Manufacturing order

OPC UAOPC UA

Data Analytics Server

Simulation Digital Service Assistant /  Service Portal

Ticketing Video Knowledge

Customer orderInformation on order, logistics, and requirements

VisualizeCheck

AssembleTightenLoadDispense

ERP

MES

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The i4.0 Upgrade Kit connects existing machines, modules or lines without sufficient connectivity to Industry 4.0 topol-ogies. Their data can be automatically processed in super-ordinated systems and can be used for condition monitor-ing and data mining purposes. The implementation does not require any modifications of the existing automation solution. The web-based configuration of the i4.0 Upgrade Kit can be carried out without any specific programming skills.

i4.0 Upgrade Kit Process Quality Manager with cloud connectionThe Process Quality Manager safely and reliably monitors and documents tightening processes. Trend deviations from the standard process are detected in time to prevent the manufacturing of faulty workpieces. The user benefits from direct notifications on faults in the manufacturing process. The data can be stored in customer-specific clouds or in the Bosch IoT Cloud. This ensures the worldwide availability of data.

Interactive shopfloor visualizationActiveCockpit is an interactive communication platform for the immediate processing, filtering, and visualization of manufacturing data according to individual requirements. ActiveCockpit facilitates the networking of IT applications such as production planning, quality data management, and e-mail dispatch, with the software functions of manufacturing plants. The information serves as a basis for decisions and the optimization of processes involving humans, machines, and manufacturing processes at the shopfloor.

The web-based Data Analytics Server consolidates and analyzes machine and process data in order to increase the availability and productivity of manufacturing lines. By means of predefined mathematical methods and visualization, the software ensures the easy analysis of processing data – the ideal solution for quality assurance, process improvement, and predictive maintenance.

The open architecture of Bosch Rexroth’s automation platform facilitates the direct connection between the Manufacturing Execution System (MES) and distributed control systems, and thus allows for the real-time control and monitoring of production processes as well as the access to actuators and sensors.

Data Analytics Server

Integration MES

Sensors provide the machine data

Connectivity

Web based configuration of connector

▶ WebConnector▶ Java▶ Linux

▶ Connectivity to superordinated IT systems

Corporate Management Level Internet (Cloud)

Production Management Level

MES

Process Control Level

Cloud

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Bosch Rexroth manufacturing solutions are based on a consistently flexible, modular, and scalable model. According to the respective requirements, different manufacturing layouts consisting of manual and automated work stations with self-sustaining controls can be quickly realized. This makes it possible to easily integrate the modules, which may be required for additional process steps, via defined inter-faces into the overall system.

The Bosch Rexroth linear motion system (LMS) is a unique technical solution for the transport and positioning of materials and workpieces. It offers maximum accuracy, freely program-mable synchronized motion sequences, and is faster than conventional systems. The entirely contactless drive concept ensures the particle-free transport and is based on linear motor technologies allowing the individual positioning of every single workpiece.

Starting with the construction of the machine, virtual images are being generated. This enables machine and line manufac-turers to accelerate the development process up to the virtual commissioning. Model-based engineering helps line operators to adapt their machines to new products very quickly – new motion sequences can be easily simulated and optimized. This reduces setup and retooling times during product and variant changes and increases the productivity without further efforts.

The intelligent tightening systems from Bosch Rexroth are equipped with integrated torque and rotation sensors and intelligent software functionalities to ensure process- reliable tightening connections. The tools can be integrated into the automation environment either via cable or wire-less via WLAN by means of a wide range of interfaces and protocols for the exchange of commands and data.

Through the open architecture of Bosch Rexroth’s automation platform, robots with different kinematics (e. g. Cartesian, delta, articulated arm) can be integrated and intelligently connected on several configuration levels. It is possible to command robots directly by means of Bosch Rexroth controllers with standard programming in PLCopen, high-level, or script languages.

Highly flexible production layoutUltra-flexible transport system

Complete virtual image

Smart tools

Robotics integration

With the Digital Service Assistant, Bosch Rexroth quickly provides the relevant information for troubleshooting. The operator receives the data of the involved components on smartphone or tablet and can access all related documentations via direct links to the Bosch Rexroth media server. The Service Assistant directly forwards queries on more complex issues to the Bosch Rexroth helpdesk.

Digital Service Assistant

1 = Dispense2 = Load3 = Tighten

4 = Transverse transport5 = Manual workstation 6 = Check

Option 1: I-shape

real virtual

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Option 2: Y-shape

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i4. nowConnected Automation

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Bosch Rexroth is driving the next industrial revolution as a leading automation supplier and manufacturing company. With a huge automation portfolio and production experi-ence from our own plants worldwide, we can offer leading automation and manufacturing solutions – from single piece to high volume production.

Connected Automation in manufacturing leads to a faster and more flexible production process, greater efficiency of material, and reduction of complexity and downtime.

Bosch Rexroth Solution PortfolioFa

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Products & Solutions

Open Automation Platform

Smart Products

Controls & Software

Electrohydraulics & –mechanics

Joining Technologies

Engineering Tools

Automation Apps & Library

Connectivity Toolbox

HMI–Solutions

Sensor Integration

Cloud-based Solutions

Safety & Security

...

Complete Manufacturing Lines

Intelligent Processing Subsystems

Multi–technology Automation

Intelligent Workplace Systems

Material Flow & Intralogistic Solutions

IT- and Software Integration

Availability Solutions (Service Assistent, Service Portal, Service Contracts, Condition Monitoring, Predictive Maintenance etc.)

…

Project planning / Configuration

Simulation (Material & Production flow, Machine & Processes, Resources e.g. Energy optimization)

Consulting Production System

i4.0 – Brownfield Connection

i4.0 – Greenfield Concepts

System Integration and Application Services

Commissioning

Data Analytics

Didactics

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Automation Solutions Manufacturing Solutions Consulting & Services

Contact: i4.0@boschrexroth.com