In the fast-paced world of consumer packaged goods, especially within the cosmetics and personal care sector, maintaining continuous production is paramount. This application showcases a turnkey automation solution designed to optimize production lines, particularly for highly sensitive body oil and body spray bottles. At the heart of the solution lies a dynamic buffer, powered by the future-oriented ctrlX automation platform from Bosch Rexroth, which actively ensures a seamless production flow.
This system addresses the critical challenge of linking two process steps – such as filling and capping machines – that inherently operate at different cycle rates. The core requirements for such an application are stringent: it must avoid production stoppages, meaning a standstill at one machine cannot bring the entire line to a halt, especially when transporting delicate bottles (e.g., Ø 55 mm) continuously and gently. Furthermore, the solution must offer flexible integration to seamlessly adapt to phased conversions within existing production facilities without disrupting overall output. Crucially, the customer often seeks a single point of contact to supply both the conveyor technology and the complete automation system, including complex software logic, to minimize interfaces and complexity. This Rexroth application delivers exactly that: a sophisticated turnkey solution that integrates seamlessly and prevents production bottlenecks.
Technical Solution
This smart buffering automation solution prevents production stoppages by dynamically varying conveyor belt speeds rather than just stopping them. An inductive sensor continuously detects the density of products on the conveyor. Based on this real-time data, the ctrlX AUTOMATION control system adjusts the speed of Bosch Rexroth frequency converters, thereby compensating for the different production rates of upstream and downstream machines. A pneumatic stopper provides additional control for precise product intake.
This intelligent system is realized entirely with proven components from Bosch Rexroth:
ctrlX CORE: The powerful and open control system serves as the brain, processing complex buffer logic in real-time.
ctrlX I/O: Provides seamless integration for all sensors and actuators.
Bosch Rexroth Frequency Converters: Ensure precise and variable speed control of the conveyor belts.
HMI (Human-Machine Interface): Allows for intuitive operation and monitoring of the entire line.
All engineering for the mechanics and the sophisticated software programming is handled in-house at Bosch Rexroth, demonstrating comprehensive system expertise from mechanical motion to connected, data-driven control.
Key Features & Benefits
Continuous Production: Achieves maximum plant availability by dynamically buffering products, preventing machine stoppages, and ensuring a highly efficient, uninterrupted production flow.
Enhanced Capacity: Optimizes the integration of machines with varying cycle rates, leading to increased production output and improved overall line capacity.
Gentle Product Handling: Transports delicate products like sensitive bottles continuously and smoothly, minimizing the risk of damage or quality degradation.
Flexible Integration: Seamlessly integrates into existing production facilities and supports phased conversions without disrupting ongoing operations or requiring major overhauls.
Turnkey Solution: Provides a comprehensive, single-source solution encompassing conveyor technology, automation hardware, and complex software logic, simplifying project management and reducing interfaces.
Build your Application with Bosch Rexroth Products
The solution shown here is based on a system that integrates various Bosch Rexroth components, including advanced software, drive technology, automation platform, and structural elements. Please note that you can also purchase these components individually from us to build your specific application. The links to the respective product pages are listed here.
Bosch Rexroth VarioFlow Belt Systems: Enable smooth and reliable transport of workpiece carriers up to 20 kg.
The Bosch Rexroth Aluminum Profiles and EcoSafe Protective Fence Components: Are flexible and ensure compliance and safety.
The ctrlX AUTOMATION Platform from Bosch Rexroth: Manages all processes and tasks and is a flexible gateway to other systems.