Rexroth System Solutions Hydraulics - Ready for Industry 4.0

Transcription

1 Tech-Day Helsinki Rexroth System Solutions Hydraulics - Ready for Industry 4.0 Stefan Schmidt Director Sales Technical Support Application Development Drive & Control System Solutions DC-IA/STS3 stefan.schmidt@boschrexroth.de 1 3/2016 S. Schmidt DC-IA/STS3 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

2 ?full-electric??full-hydraulic??hybrid? Premise: Industrial hydraulics and mechanics are electrically driven gear boxes Electric motor, electronic control, sensors and software are part of the system solution 2 3/2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

3 Drive & Control and Industry 4.0 Connected Industry: The 4 th Industrial Revolution 4. industrial revolution 1. industrial revolution Mechanisation Mech. control (cam disc, cam) Energy: water / steam power 2. industrial revolution Electrification Punch cards as program memory Conveyer belts Master shafts Energy: electrical 3. industrial revolution Digitalisation Freely programmable control units PLC and PC based control units Field busses (ethernet based) Flexible production systems Electronical data storage Connection / Internet Usage of internet standards Integrated IPconnection Identifiable and communicating objects Mobile operation Scalable systems (cloud as storage,..) Self-optimising systems Cyber physical systems Industry 1.0 Industry 2.0 Industry 3.0 Technologies (Connectivity, increased computational power) enable new applications/functions to create added value Industry /2016 DC-IA/EHC1-Deubel Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

4 ?full-electric??full-hydraulic??hybrid? Premise: Industrial hydraulics and mechanics are electrically driven gear boxes Electric motor, electronic control, sensors and software are part of the system solution Thesis: Fulfillment of superordinated trends & requirements such as energy efficiency, security, usability, networking, health monitoring,... goes hand in hand with the electrification and digitization technology. 4 3/2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

5 Digitalization of hydraulics as game changer, disruptive technology yesterday today... dynamic, accuracy, energy efficiency, CO2 reduction, controller robustness, space requirement, invest-cost, TCO, requested oil quality, fluids, lifetime, redundancy, safety, availability, product variance, stock management, service, remote maintenance, condition monitoring, networking, competitive market position, portfolio strategy fit, functional differentiation, use of resources, employee qualification, substitution... PLC & CNC Controls 100% digital Amplifier Controller 50% digital Valves in development Pumps Motors SvP 100% dig. Cylinder in development Converter in development Disruptive technology and market development New developments are compared on the basis of characteristics of the existing technology. The market changed when an improvement is achieved in the basic features. DigitalHydraulic LLC The new technology offers additional features, which are not possible with the previous technology Finally the new technology replaces the old technology completely. Technological environment and timing are critical to the TUTsuccess of an innovation! The new solutions are characterized by their high technical complexity. Norrhydro Buck-Converter Uni-Linz (LCM) Managing complexity: Expert teams and customer orientation 5 3/2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

6 Sytronix: Speed-variable pump drives - Motivation Drive Gear Features Valve/pump, hydraulic gear Power density, robustness, imax Control effort Power split E-motor (constant) hydraulic pump Control valve Hydro motor,-cylinder + Physical properties Noise emission Energy efficency Automation integration effort Hydraulic gear and variable-speed drive Automation & integration effort Noise emission -20 db(a) Energy efficency save 80% Controller E-motor Pump Zylinder/Hydromotor Power density, robustness, imax Control effort Power split + Functionality, automation Mechanical gear Automation & integration effort Noise effort Energy efficency Controller E-Motor Gear Screw drive Power split Force, 6 3/2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

7 Sytronix: HydroGear Software Functions 4. Smart High Speed Maximum Speed Cavitation Protection Knock sensor for pumps EM2013/7808 & valves EM2015/ Smart Noise 6. Smart Mode /2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

8 Customer demand: Consistency of functions & solution PositionForceControl SHA Identical Drive IndraMotion ElectroMechanic Cylinder EMC-HD Up to 1,6m/s Up to 290kN Self-contained elektrohydraulic Linear Axis SHA Up to 2m/s Up to 2500kN (larger on request) 8 3/2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

9 SHA010 SHA020 SHA040 SHA080 SHA120 SHA250 Self-contained Hydraulic Axis SHA Modular design SHA Servo-hydraulic actuator SHA, controlled positioning system, drive by wire Product range covering nominal forces of Metric tons Maximum travel speed: 1 m/s Maximum travel distance: up to 1800 mm MSK servo motor and HCS servo drive Includes modular PFC software for closedloop control of position and/or force SHA250 SHA040 Ready for Industry 4.0 High system competence through integration of Rexroth s own D&C technologies Integrierte Motion Controller + Hydraulikregler + digitale Sollwertvorgabe + Parametrierung SHA /2016 Industrial Controls (IC) Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

10 SHA010 SHA020 SHA040 SHA080 SHA120 SHA250 Self-contained Hydraulic Axis SHA Modular design SHA Servo-hydraulic actuator SHA, controlled positioning system, drive by wire Product range covering nominal forces of Metric tons Maximum travel speed: 1 m/s Maximum travel distance: up to 1800 mm Includes modular PFC software for closedloop control of position and/or force SHA250 SHA040 Ready for Industry 4.0 High system competence through integration of Rexroth s own D&C technologies Integrierte Motion Controller + Hydraulikregler + digitale Sollwertvorgabe + Parametrierung SHA /2016 Industrial Controls (IC) Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

11 Hydraulic Power Unit with IndraControl FM Enabled REXROTH USP s Plug&Play solution: HPU subsystem can be pre-assembled and pre-configured Comprehensive condition monitoring for the whole HPU unit ensures safe operation Enabling HydraulicPowerUjnit for Industry4.0 with OpenCoreInterface and several communication interfaces (WLANSD, MultiEthernet3 rd party controls, ) Minimized system cost due to reduced wiring effort with decentralized IO-nodes 11 3/2016 DC-IA/SPF3 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

12 ABPAC Ready for Industry ABPAC Connected Product Sensor Node IP65 protected CM-App Predictive Maintenance Display Sensor Value Filter 27% Valve 10% pressure: 175 bar Evaluate Sensor Value Analyze Sensor Value Trend 12 3/2016 Andreas Guender (DC-IA/EPM3) Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

13 Folienüberschrift Cytro-Pac The Power Unit Revolution 13 3/2016 DC-IA/EPM Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

14 Cytro-Pac Technical Features Pressure up to 100 bar Hydraulic power up to 4 kw Flow rate up to 35 l/min Oil volume up to 25 l Integrated frequency inverter for variable speed operation Integrated sensors for Condition Monitoring Innovative cooling concept Degassing optimized reservoir 14 3/2016 DC-IA/EPM Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

15 Cytro-Pac CytroPac - Ready for i /2016 DC-IA/EPM Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

16 Hannover Fair 2015 Bosch Fair 2015 Hydraulics fit for Industry 4.0 Up to 4 MW LHD* HydroGear Virtual Engineering HiL Hardware in the loop AR Augmented Reality Main drive Kinetic buffer Die cushion 16 3/2016 DC-IA/STS3 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

17 1x 24V Netzgerät 1x HNA 1x HMU05.1N 1x CSB02.5B Bleeder 1x HMU05.1N 1x CSH02.5B-ET 1x HMU05.1N 1x CSH02.5B-ET 1x HMU05.1N 1x CSH02.5B-ET 1x HCS01 (bereits eingebaut) 1x KCU02 System-Layout Servo-Press Dynamic electro-hydrostatic drives with large power ETH MLC65 14V06 mit Safety-Funktionsmodul sercos CIP Safety on sercos IndraControl S20 mit Safety-E/As DC-Drossel HydroGear L-C-L Drossel Kinetic Buffer Netzfilter Hauptschalter Power supply Main drive Excenter Die cushion Kinetic buffer Power unit Handling transfer bars 6x KSM02 Main voltage 3 ~400V 17 3/2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

18 Innovation project: Position detection with virtual sensor Status Innovation study, series development in planning Today Additional position sensor for detection Tomorrow Detection of position without an extra sensor (pin compatible) Further expansions steps Solenoid current Position information Spool Anchor CM-Functions Shift position Switching time Broken Spring Coil interturn fault jammed anchor coil temperature PWM-operation Optimizing boost and holding currents, fast switching, energy saving, reproducible switching, soft switching Increase switching capacity Lowering the magnet temperature Multi voltage solenoids Low continuous currents 0,5A I/Os, smaller power supplies 18 3/2016 DC-IA/EHC1 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

19 Drive & Control and Connected Industry Changed skills in software engineering Industrie 1.0 Mechanization Industrie 2.0 Electrification Industrie 3.0 Digitalization Industrie 4.0 Internet based networking If you went to bed last night as an industrial company, you're going to wake up today as a software and analytics company GE 19 3/2016 DC-IA/STS1 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

20 Drive & Control and Connected Industry Rapid development of the connection of people and things Industrie IoTS - cyber physical systems billion connected people billion connected things million computers on the internet million connected people More than 50 billion connected devices in /2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

21 Drive & Control und Industrie 4.0 Industry 4.0 (Connected Industry) Hype oder Revolution? Digital Factory Cloud Cyber-Physical Systems Semantic interoperability IoTS predictive maintenance Embedded systems RFID Smart Hydraulics augmented reality Real Time Smart Factory HiL Remote Monitoring Context awareness Networked objects Autonomous Self-organized 21 3/2016 DC-IA/EHC1-Deubel Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

22 Drive & Control and Industry 4.0 Connected Industry: Motivation and interpretations Digital Factory Main targets for Industry 4.0 Virtuell Engineering 1. higher planning quality provide virtual engineering and system solutions Teleservice Condition Monitoring 2. faster start up provide in-house startups, including piping & wiring 3. higher production stability provide proofed solutions & CM-functions /2016 DC-IA/STS3 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

23 SPS IPC Drives 2015 Automation with Connected Intelligence Connected Intelligence for new business models Example: Connected to Oracle Cloud Solutions 23 3/2016 DC-IA/SPC2 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

24 NEW Range of services Bosch Rexroth Drive&Control System Solutions ETO Systems und Prototyping Customer Solutions Preparing Series for customer or TE In-house startup Pilot Plants Test and Trail Runs Conception Drafts & Versions Solution Technical Advising Assembly Piping Wiring Control Cabinets BOM Lists Documentation Circuit Diagrams Simulation Design Calculations Dimensioning Construction Quotations 24 3/2016 DC-IA/STS3 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

25 Sensors key technology for internet of things and services IOTS Bosch Sensortec Is worldwide leader in MEMS* sensors Four billion *Micro-electro-mechanical Systems 25 3/2016 DC-IA/STS3 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

26 Drive & Control and Industry 4.0, Why Bosch? Bosch Smart Factory Bosch is supplier and user OpenCoreEngineering OCE Industrie 4.0-Award for Bosch Rexroth AG Journal Produktion und Unternehmensberatung ROI awarded innovativ Industry 4.0-solution One line, two hundred modules In a multi-product line in Homburg, Bosch produces highly flexible two hundred different hydraulic modules up to lot size 1. The nine stations of the multi-product line are intelligently connected. With a RFID chip on the workpiece is defined how the finished product should be assembled and what steps are necessary. 26 3/2016 DC-IA/STS3 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

27 Tech-Day Helsinki Thank you for your attention! 27 3/2016 DC-IA/STS3, S. Schmidt Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.