2-stroke diesel marine engines with FIVA valves from Bosch Rexroth consume less fuel and operate with minimum emissions. The specially tailored maintenance program oﬀered by Bosch Rexroth‘s Marine Service forms the basis for ensuing optimum performance is maintained costeﬃciently throughout the entire life cycle. Owners, superintendents and crew members can draw on the ﬁve measures outlined below to make their ship operation even more proﬁtable, simpler and safer.
Ships‘ engines must operate reliably around the clock. At the same time, however, they should also ensure the lowest possible emissions and minimum operating costs. This can only be achieved with optimum control of the fuel injection and exhaust gas outlet. Bosch Rexroth‘s hydraulic servo valve is designed to follow the performance curve of large 2-stroke diesel engines precisely, thus allowing fuel consumption and NOX emissions to be minimized. When it comes to ensuring reliable operation, another key aspect is optimum ease of handling: Bosch Rexroth‘s FIVA valve fulﬁ lls this requirement thanks to its integrated electronics. The complete valve can be replaced during a service call without adjustment. This signiﬁcantly reduces failure times, unproductive layovers and ultimately maintenance costs. The total cost of ownership can be further reduced however by drawing on the special maintenance oﬀ ered by Bosch Rexroth‘s Marine Service. Why is this the case? These are the reasons why:
WHY DO BREAKDOWNS HAPPEN AT SEA? The best engine is only as good as its components. When shipping companies opt for FIVA valves from Bosch Rexroth, they know that they have chosen a robust and high-precision solution. Yet, like any hydraulic valve, this component does not remain wear-free either and also operates under harsh conditions. In extreme situations and where maintenance is deﬁcient or neglected, spontaneous failures can also happen on occasion.
Cause 1: Overheating of the electronic controls The temperature exerts an enormous inﬂuence on the lifecycle of the electronics. If FIVA valves are used with a proportional valve as a pilot, electronics failures caused by overheating represent the most frequent cause of failure during operation. The reason for this is that the mechanical principle of operation requires high currents of up to 3.5 A. In contrast, the FIVA valve from Bosch Rexroth with servo pilot valve is controlled with just up to 0.03 A. Compared with proportional valves, considerably less waste heat is therefore generated, which together with the high temperatures and vibrations in the engine room loads the electronic controls and can lead to premature failure. Cause 2: Contaminated engine oil Control valves in marine diesel engines do not have their own hydraulic circuit, rather use engine oil, which is fed by the pump through a ﬁlter system. The problem with this is that if the oil cleanliness is inadequate, smaller particles can impair the precision of the pilot valve and main stage of the FIVA valve over time. If the particles are larger, clogging in the pilot valve can even cause malfunctions. Simple plug & play replacement of the pilot valve provided as a spare part can help here (see point 4).
5 POINTS FOR RELIABLE ENGINE PERFORMANCE The following ﬁve measures will help you to avoid unnecessary costs and ensure smooth and optimum operation: You want to know more about this topic? Download the complete Whitepaper below.
Author: Volker Tenhaeff Job title: Head of Global Service Support
Volker is the head of Global Service Support for Industrial Hydraulics at Bosch Rexroth. He has more than 8 years of global experience in sales, service and application engineering in hydraulic drive systems for various industry sectors like metallurgy, marine & power generation. He holds a Master of Engineering in mechanical engineering from Technical University Munich, Germany.
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Talking about digitalization, we often tend to focus on the evolution of technology. We talk about smart products, digital twins or even predictive maintenance, which definitely is great. But how about the effects of digitalization in the Buying process?
Learning from Silicon Valley
Do you remember the last time when you searched for an apartment on Airbnb? You may recall a nicely designed Smartphone App where you can easily select your favorite apartment based on filter parameters representing your individual needs. But let´s have a closer look on why it is such a great experience.
The whole concept bases on ease-of-use and trust. With its intuitive functionality, even kids are able to get a handful of fitting proposals within minutes. Because of the direct, almost personal link to the host and supported by detailed ratings by former guests you feel confident to narrow it down to the most promising offer that you potentially book with your preferred payment method. And how did you like the ´discoveries´ that feel handpicked based on your former searches and bookings?
Making complex technology easy to buy
Now think about requesting technically complex, highly individualized, presumably old-fashioned hydraulic technology. Not a lot of machinery suppliers believe that they can reach the same easiness and outstanding customer experience of Top B2C applications. Let us show you why we do !
Online research shows that the majority of our customers are searching via Google or on our website with the main target to get detailed information on a product. This information used to be hidden in Data Sheets that you have to find and download, but with our online catalog pages you now get all information offered centrally in a mobile friendly way. We also understand that our web users are mainly hydraulic engineers, that is why on the online product pages we also offer your presumably most relevant information – 2D drawings and 3D models.
You may state that hydraulic business is living from unique solutions. That is why since almost a decade we work hard to extend our portfolio of free online product configurators and expert software.
Comparable to the big automotive companies our configurators enable you to generate your individual variant and initially get a full documentation package (including CAD drawings). Another nice effect of these standard-based solutions is that they can be requested or directly bought online with a quicker availability. Imagine that you get a sensor-packed, 600l power unit or a 1000KN hydraulic mill-type cylinder in your specific color within 4 weeks!
There is even more
But thinking back to our target of outstanding functionality in Digital Buying, you even will expect more. How about 24h online chat, application-based product selection, an individual web portal with curated product information or ordering spare parts directly in your ordering system? Just challenge our website and discover how you may benefit from digitalization beyond connected products.
Author: Stefan Lehnert Job title: Head of Digital Sales & User Experience Industrial Hydraulics
Since 2014 Stefan is working in optimizing the digital customer touchpoints. Coming from product management in hydraulics with worldwide focus, he has intense business knowledge and sees radical changes in user interaction especially with younger generations. As Design Thinking champion Stefan supports project leaders in customer-oriented, agile development.
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Ports are the hubs of national and international trade. Thus, the capacities of container ships have risen in world sea trade since 1980 by 23 times. This trend also appears in an increase of traffic worldwide in harbors and the challenges arising from it in their infrastructure and water ways. In order to maneuver the ships with continuously rising sizes precisely and safe in narrow harbors, tug boats are applied.
They help long and heavy vessels to get into the intended mooring area, to changing location or to leave the harbor again. Especially a precise lateral movement is a problem for large ships. For these tasks, tug boats are essential. To be able to master this demanding task every day, the small powerful movers need a reliable, safe and modern technical equipment. Since many years Damen Shipyard is a world leader in the development and construction of tugboats. The Damen Shipyard tugboats distinguish themselves by high quality & heavy duty capability in combination with high stability & maneuverability. Damen Shipyard meets the growing pricing pressure in the market with the strategy of a strongly standardized design as well as with the introduction of various innovative technology on board of the tug boats.
Clear goals: more simple, modular, less expensive and innovative
At that time, Bosch Rexroth was contacted. In close cooperation with Damen Shipyard the engineers of Bosch Rexroth developed a new modular winch drive. Depending on the application and customer request, the winch drive can be optimized by optional functions for the specific application. The render-recovery feature is one of those options. When hauling heavy loads, this feature reduces the peak loads that can be experienced in tugboats in rough conditions due to waves. The rendering covers line speeds of up to 80 m / min with a line force of 110 tons, enabling optimum maneuvering of heavy loads even in rough seas. The recovery is possible up to a belt speed of 40 m / min with a belt force of 30 tons. In close cooperation with the customer, it has been possible to develop a simpler, more modular and cost-effective double drum winch system with the new innovative render-recovery function. The optimized user interface simplifies operation and installation. Bosch Rexroth supplies Damen Shipyard with a turnkey complete solution consisting of the entire hydraulic drive train including the associated electric control technology in the control cabinet.
Key for the success: Easy configuration, flexibility, high-performance and connected
The key components of the system include the Hägglunds high torque motor (type CB560 or CB840 for R&R) in the hydraulic system and the Marine Certified XM22 controller in the control system. In previous systems Damen Shipyard used a Marex controller in combination with a separate RC-controller. These controllers has been replaced by a single XM22 controller which results in smaller space claim inside the cabinet and a more easy configurable control system.
Also the fact that M4 hydraulic valves can be controlled directly by the XM22 contributes to leaner design than the previous system where a separate control module was required between the M4-valves and the PLC. Also a big plus of the XM22 is that it works on an IndraWorks platform with its special modules to control hydraulic systems. IndraWorks also allows the engineers to get access to the controller (remote or direct) via a Bosch Rexroth standard service interfaces.
The XM22 controller developed and manufactured in Rexroth`s Erbach factory has been optimized especially for use in harsh environmental conditions. It is therefore particularly robust against elevated temperature environments, EMC radiation as well as mechanical vibration and shock loads. Therefore, the XM22 is ideal for application in Marine & Offshore, , which is checked and approved in regular audits by the leading certification companies such as ABS, BV, DNV-GL, LR, RINA and ABS.
Ship operators rely on the safe and robust tugboats from Damen Shipyard
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Machine manufacturers are uncovering new dimensions in productivity and cost-eﬀectiveness thanks to the fusion of ﬂuid technology with digital control systems and the networking of the ﬁeld level with higher-level systems. Intelligent, connected hydraulics for plastics processing machines enhances the repetition accuracy, process reliability, energy eﬃciency and availability in equal measure. That’s why manufacturers are switching in increasing numbers from analog hydraulic components to digitally networked hydraulic solutions. They are therefore continuing to exploit the beneﬁts of ﬂuid technology, such as power density, robustness and virtual maintenance-free operation, and combining these with the possibilities of digital communication.
The fusion of sensor technology and communication technology is only half a step on the path toward digitalization. Intelligent, connected hydraulics oﬀers added value thanks to distributed intelligence and application know-how that is replicated in the software. The components are tailored optimally to each other in terms of hardware and software. Universal software tools simplify engineering and commissioning. In terms of operation, this enhances productivity and increases availability thanks to rapid error diagnosis through to cloud-based predictive maintenance with artiﬁcial intelligence. Rexroth bundles this under the term Connected Hydraulics. Connected Hydraulics drive solutions ensure demanddriven, energy-eﬃcient pressure supply of hydraulic actuators. Digitally responsive, distributed intelligent hydraulic components and subsystems open up new levels of freedom for optimizing basic machine functions such as injection, opening/closing of forms, ejectors and nozzle systems. The repetition accuracy can also be improved over the entire life cycle at the same time.
DRIVE TECHNOLOGY: POWER MEETS INTELLIGENCE CytroBox, the new generation of hydraulic power units, shows how Connected Hydraulics ﬂuid technology is integrated with the Internet of Things (IoT) and therefore simpliﬁes design and commissioning. With its compact and modular design, it provides a new solution approach for the medium performance range from 7.5 to 30 kW and is ideally suited for pressure supply of additional functions such as core pulls. Thanks to integrated sensor technology and condition monitoring functions, it is also the blueprint for IoT integration of larger power units. As a plug & run solution, the power unit reduces the commissioning eﬀort quite considerably. CytroBox brings together all components in a compact housing, which requires 50 percent less installation space than previous units. Sytronix variable-speed pump drives with inherent intelligence adapt the speed to suit demand using predeﬁned controllers. This reducest hep ower consumption of the hydraulics in cyclical applications by up to 80 percent. The tank with optimized degassing and ﬂow reduces the oil volume by 75 percent, from 600 liters to a mere 150 liters. Moreover, the noise emission of the CytroBox is less than 75 dB(A) – even at full load.
The hydraulic power unit CytroBox raises the level of production to the next higher level.
SMART, CONNECTED CONDITION MONITORING The new generation also increases the availability of machines while lowering maintenance costs. CytroBox links ﬂuid technology as standard with the IoT for this purpose. The integrated CytroConnect software solution uses sen-sors to record all relevant performance and operating data, such as oil level, oil quality and temperature over time. The software processes the data decentrally and sends it encrypted to the cloud. Using the browser-based interface, maintenance technicians can wirelessly dial into the CytroConnect service and retrieve the information inde-pendently of their location, whether inside or outside the factory. This saves time and long journeys. Machine manu-facturers and end users can integrate CytroConnect as a module into their own digital IoT maintenance concepts.
The integrated CytroConnect software solution uses sensors to record all relevant performance and operating data, such as oil level, oil quality and temperature over time.
INTELLIGENT SOLUTIONS FOR EVERY PERFORMANCE RANGE Plastics processing machines generally require a highperformance central pressure supply, which provides the necessary energy for the machine axes as energy-eﬃciently and quietly as possible. The variable-speed pump drives in the Sytronix family, which are also used in the CytroBox, are state of the art in this respect. They are based on the same intelligent drive controllers and software solutions as Rexroth’s electrical axes. This simpliﬁes commissioning considerably through the use of identical software tools.
Sytronix SvP typically oﬀers the ideal solution for injection molding machines with small and average closing forces. Synchronous servo motors with permanent magnets and servo control oﬀer optimum dynamic performance in this context and closed-loop accuracy up to a power level of 80 kW. They cover a wide range of functionalities from pressure control and closed-loop pressure ﬂow control right through to closed-loop position control and force control. Advanced monitoring functions increase system availability. A protective pump function extends the life cycle and avoids machine downtime. All Sytronix variants can be integrated in the widest variety of automation architectures via a multiEthernet interface for the most commonplace real-time Ethernet protocols.
In the case of machines with large closing forces, Sytronix DFEn with p/Q control systems cover the performance range up to 630 kW. The DFEn connects an axial piston variable displacement pump optionally with a synchronous or asynchronous motor and harmonized drive controllers. It combines the closed-loop speed control of the drive with a variable displacement pump. Dual-quadrant operation provides access to comprehensive electrical and electrohydraulic control options to inﬂuence the ﬂow smoothly in accordance with demand. This creates additional potential to optimize the dynamics and precision of processes in plastics machine processing.
DIGITALIZED INTERFACES FOR CONNECTED I4.0 HYDRAULIC APPLICATIONS Work to connect all actuators in mechanical and plant engineering – also in the plastic machinery industry - is progressing quickly. The requirements here range from simple status queries to decentralized, synchronized movements. With application-oriented solutions, Rexroth opens up new ways of connecting hydraulic valves digitally in an economical manner. Only with a digital interface can users change parameters via software during operation in order to react ﬂexibly to new requirements. It also allows quick diagnostics and condition monitoring and thus increases machine availability. Rexroth caters for various concepts and is the only manufacturer at the moment that caters for your own speciﬁc requirements.
You want to know more about this topic? Download the complete Whitepaper below.
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IoT-capable hydraulic power unit ensures efficient production
With the newly developed, intelligent CytroBox unit, Rexroth combines the benefits of hydraulics with low energy consumption and software-based functions. The integrated CytroConnect IoT service ensures higher availability and avoids unplanned downtimes. With this IoT service, operators can monitor operating statuses and plan maintenance in a cost-effective manner. As a result, fluid technology has taken a further step towards the factory of the future.
The digitalization of mechanical and plant engineering means more than decentralized intelligence, integrated sensors and connectivity. This applies to hydraulics too. With its power density and immunity to impacts and vibrations, hydraulics plays a central role as an important drive technology in Industry 4.0 too. The compact CytroBox unit is revolutionizing hydraulic pressure supply. CytroBox is a modular hydraulic power unit for the medium performance range from 7.5 kW to 30 kW. It comprises optimally tailored, impressively compact components. Compared to previous units, considerable amounts of space can be saved.
75% less oil
One of CytroBox’s unique selling points is it compactness. This is possible because the hydraulic power unit can be integrated into a factory like a control cabinet, i.e. upright. The tank no longer supports all other components – Rexroth developed a special supporting structure for this purpose. In addition, a degassing flow-optimized tank is used. On the basis of extensive CFD simulations, the developers improved the tank geometry so skillfully that the new unit needs only a quarter of the oil required by classic designs: instead of 600 liters, 150 liters are now enough – with at least the same service life. The drive unit – a component which usually takes up a large amount of space in hydraulic power units – is equally compact. The asynchronous servo motor has been replaced by a synchronous servo motor. This is the most efficient motor design, producing the same torque even though it is 80 to 90% smaller. The manifold too was redesigned: thanks to 3D printed sand cores, the block including the internal flow geometry is now cast. As a result of this flow-optimized inner structure, less material and space are required. Thanks to all these measures, the CytroBox has a footprint of just 0.5 square meters instead of one and a half to two square meters. This represents a saving of up to 75%. On top of this, there are energy savings of up to 80% as well as a 10 dB(A) reduction in noise emissions. As a result, noise emissions are lower than 75 dB(A).
Connected for the factory of the future
In the CytroBox, machine manufacturers will find a ready-configured drive controller with numerous integrated functions. Various sensors provide information on the current filter, oil or drive status. The collected sensor data are bundled via IO-LinkMaster and pre-processed by the drive controller so that they can be integrated flexibly into modern machine designs. This means that the CytroBox is IoT-ready.
With the CytroConnect digital service, operators have all information regarding the CytroBox at their fingertips at all times – whether it be information regarding the standardized visualization of the component and operating status or chargeable IoT services such as forthcoming maintenance work and predictive maintenance analyses using Rexroth’s Online Diagnostics Network (ODiN).
The data collected are transferred to the browser-based CytroConnect Monitor web dashboard via Multi-Ethernet or 4G-LTE. As a result, operators can be kept up to date regarding the current operating status and key status indicators on any end device (tablet, smartphone, PC). This plug and play service is free of charge and can be used without additional installation work. CytroConnect is implemented in the CytroBox as standard.
Greater availability thanks to additional analysis functions
In addition to the CytroBox’s automatic status monitoring, maintenance personnel and maintenance managers can add extra solutions for various applications as add-ons. These pay-per-use payment models include additional IoT analysis tools and can be subscribed to on a monthly basis.
For optimizing maintenance processes, the CytroConnect Maintain module offers access to historical sensor data as well as messages if maintenance is required or in the event of critical operating statuses. Pre-defined and custom rules allow customers to improve their maintenance strategy on an ongoing basis. Customers benefit from scalable software solutions from the Bosch IoT portfolio such as the Nexeed Production Performance Manager and the integrated know-how of the Rexroth domain specialists. The Nexeed Production Performance Manager is a condition monitoring software solution for systematic production optimization.
With CytroConnect Maintain, data concerning the most important components for reliability and operating life (the hydraulic oil and the drive unit) are assessed. Comprehensive insights into the correlation between the speed of the servo motor and the flow allow the monitoring of system leakage, while correlations between motor data and the operating pressure allow conclusions regarding drive behavior. The leakage sensor, temperature and level sensor, particle sensor, water sensor and oxygen sensor are additional data sources which can be used to make a status diagnosis.
Planning predictive maintenance efficiently
A further add-on, CytroConnect Predict, uses the machine learning algorithms of the Rexroth Online Diagnostics Network (ODiN) for a predictive analysis of the system. With this IoT service, the power curves for a wide range of components are recorded for data analysis purposes. In the event of deviations, the system automatically calculates the expected remaining operating life of the relevant component and informs the operator immediately via a push message. As a result, predictive maintenance application cases can be taken into account predictively in the operator’s maintenance plans, thus ensuring maximum availability. Conclusion
This new form of hydraulics is energy-efficient, quiet, space-saving and intelligent. With the integrated CytroConnect IoT service, the CytroBox offers anything from transparent, efficient machine monitoring to intelligent predictive maintenance measures. Thanks to the CytroBox, fluid technology is now one step closer to the factory of the future.
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