Mapping the incredible performance of our stage control systems will take you on a journey through time from the Cultural Palace Prague, to the National Theater Budapest and to the high seas aboard the cruise ship AIDAnova. Technology. In the spotlight Our stage control system with axis panel, first took center stage in 1980. The Cultural Palace Prague and National Theatre in Prague were the first to adopt this technology along with the Salzburg Festival in 1984. Within its first decade of existence, the VTB1000 was launched, at which point the system became known as stage control system. In 1989 the AC5 axis controller was also developed as our first stage technical axis controller with integrated safety functions (AK5). The growing success of the system meant it was rapidly introduced into the Staatsoper Stuttgart, Bayreuth Festival, the Residenztheater Munich (München) and the Burgtheater Vienna (Wien) along with many more. By 1994, a compact control panel was introduced for the first time in Gothenburg. The SCI panel was a revolution in the market, which utilized an MSDos operating system. This was the first ‘touch system’ for stage technology, at a time when no ‘touch’ applications were currently in use.
Our graphical user interface was also revolutionary - considering that only 2 years previously Windows 3.1 had been introduced, as the first Microsoft operating system with graphical user interface. At this time, graphical user interfaces and touch systems were unheard of in the realms of the stage technology and even in industry. The control system VTB2000 and the control panel SCI was rapidly adopted by the Opera House Gothenburg, the Vienna Volksoper and the National Theater Warsaw. During 1998, the AC5 was replaced as axis controller by the BAC 360 with integrated safety functions according SIL3. From this point forward, the axis controller (2-channel) were installed in a BLE directly on the drive, enabling wiring costs for the axis sensors to be drastically reduced.
The connection was now made via Ethernet and hub technology. A 10Mbits / s real-time network protocol was developed and called MR10Bus, which was patented. The BAC 360 was also used for the master controllers, which were in the SCI panel. At this point, the control system SYB2000, control panel SCI was introduced at the Staatstheater Hannover, the Grand Theater de Geneve, the Staatstheater Mainz and the National Theater Budapest and several houses across europe. In 2001, the new control panel (SCII) was launched. For the first time, an external design company was commissioned to create a console housing as the interface between man and machine. The SCII console now had 2 levers for manual mode. The two BAC360, which were used as master controllers, were still housed in the control panel. The control system SYB2000 with control panel SCII was immediately taken on by the Oldenburgisches Staatstheater. The SCII console underwent a complete redesign in 2008. Whilst the housing remained unchanged, a significant difference was the introduction of a safety console controller BPC. The signals from the safety-related components, such as drive levers, start buttons and deadman buttons, were now wired to the console controller. The master controller was outsourced to the control cabinet. The introduction of the console controller now enabled the first WLAN operated console. Control SYB2000 with control panel SCIII and control panel CPW was first adopted by the Norwegian Opera House in Oslo. In 2011, the BAC360 was replaced as master controller by the newly developed BAC860. This meant it was now possible to start and control 4 movements per panel simultaneously. The number of drives which could be moved simultaneously on the panel increased dramatically from 16 to up to 90. Control system SYB2500 and the control panel SCIII were introduced at the Bolschoi Theater. During 2013 the SCIV panel was developed. The design of this panel was conducted from the technical department of stage technology visualization. Thanks to their specialized knowledge a product could be created, which is holistically optimized for use in the stage environment. The first capacitive multitouch display with 22’’ screen and extreme robust and fan-less housing in the sound sensitive stage area. Up to 2019 it is still the most compact stage panel with a huge 22” screen on the market. 2014 saw the MR10Bus replaced by SYBNet, a 100Mbit / s real-time network based on the latest switch technology. At the same time, the BLE4 was introduced with the BAC 5500 as axis controller. The control system SYB3.0, control panel SCIV and control panel CP were adopted at the New Theater Pilsen and the Burgtheater Wien. By 2018, the CPII was introduced as a compact, robust, stationary and mobile console, as well as a wired or wireless mobile device. Handling and weight were taken into consideration for mobile use, whilst the stationary console utilized the VESA bracket for flat mounting. After comprehensive design studies, a new route to production was developed. The combination of the proven stiff aluminum front, which is important for the fan-less cooling system, and the lightweight organic housing through the latest 3D printing techniques. This revolutionary manufacturing process has opened up new design methods that have significantly reduced the cost of the compact console. In 2018, the control system SYB3.0, control panel SCIV and control panel CPII were introduced onboard the cruise ship AIDAnova. By 2019 the SYB Frames and the SCIV neo panel were introduced at the fair in Berlin. SCIV underwent a renewal to SCIV neo. With the SYB Frames the SCIV neo panel gets customizable extensions to be more flexible for the special needs of different costumers. Different hardware components can be easily integrated and adopted to the SCIV neo panel. From the development of our first stage control system with axis panel in 1980 to our Stage Control System 3.0 with the multi-touch systems SCIV neo with up to two 22” screens expandable by the SYB Frames or the compact and mobile CP II with 13” screen– our technology has taken center stage delivering entertainment in leading theaters, festivals and opera houses around the world.
... View more
Brazilian sugar producer Usina Ferrari puts high trust in the Hägglunds hydraulic direct drives that crush its cane. Over the past decade, the reliability and control offered by Hägglunds drive systems have helped the company thrive and expand.
Because Usina Ferrari is always looking to maximize uptime and output, the company expects reliability – both from its equipment and from its suppliers. One reason why the successful Brazilian sugar producer first turned to Bosch Rexroth was the strength of the references for Hägglunds drive systems as independent roller drives on sugar mills. Hägglunds hydraulic motors provide a compact and durable solution for driving mill rollers individually, allowing friction to be perfectly adjusted for maximum extraction. In 2008, Usina Ferrari installed them on a milling tandem with a crushing capacity of 640 tons per hour. “The investments in Bosch Rexroth equipment immediately brought us an increased milling rate and increased juice extraction, as well better utilization of the milling time,” says General Manager Hênio J. Rospendowski Jr. Henrique Fantinatti, Usina Ferrari Industrial Manager, agrees. “We achieved a lot of benefits we hadn’t seen before then,” he says. “It became possible for us to know the torque distribution in the mill and how it might affect the rollers. We could make the necessary adjustments in mill settings, scrapers and diameter compensation, and consequently have better performance and improved productivity.” Years of reliable performance The Hägglunds systems have also brought Usina Ferrari peace of mind, as the company spends little time maintaining the drives themselves. When one of the Hägglunds MB motors was removed for inspection after six years of uninterrupted operation, no wear could be seen at all – the cam rings, rollers, pistons, guide plates and bearings were all as good as new. “The number of working years with no external maintenance says it all,” says Usina Ferrari Maintenance Supervisor Paulo Cesar Benedito. “The Bosch Rexroth hydraulic system turns a new page when it comes to how to drive a mill. I see it as a paradigm shift, bringing reliability, ease of maintenance, ease of operation and high availability.” Moving forward with Hägglunds technology Having experienced such significant benefits, Usina Ferrari has gone on to install further Hägglunds systems. In 2018, the company upgraded its capacity with another mill, equipped with Hägglunds CBM3000 motors on its four main rollers. The Hägglunds CBM series is the successor to the Hägglunds MB series, packing 50% more torque into motors that are smaller and up to 50% lighter than their predecessors. At the same time, the company began implementing aspects of Hägglunds Inside Intelligence, Bosh Rexroth’s suite of connective technology and services for hydraulic drive systems. Taking advantage of connectivity will mean still more benefits for maintenance. “The computerization will help us in decision making,” Benedito says. “It will help us to foresee failures that might cause production stops. That will save us time – and reduce cost.”
“The use of Bosch Rexroth equipment has brought us high operational reliability, which, as we see it, is the main performance indicator for our area of industry,” says Hênio J. Rospendowski Jr. General Manager of Usina Ferrari.
... View more
At this year’s bauma, we showcased the opportunities awaiting manufacturers of construction equipment with our portfolio of components for the electrification of mobile applications. Modular software and compatible hydraulic pumps complement the new 700V motors, inverters and gear units. Our comprehensive system solutions are opening up new possibilities for OEMs, whilst also helping to meet future emission regulations. One element of this electric portfolio is our new eGFT8000 series, a variant of the GFT8000 compact drive that we launched previously. Thanks to eGFT8000 compact drives, mobile working machines can now benefit from a high-speed electric motor instead of a hydraulic motor. By combining a compact drive and electric motor, we’ve created a space-saving, local emission-free drive unit for wheeled or track-mounted vehicles and other mobile equipment. With our local emission-free drive, vehicles used underground or in enclosed spaces no longer require expensive ventilation solutions. The eGFT8000 range is also ideal for vehicles used in inner cities, as well as for heavy-duty vehicles and agricultural machinery. Efficient and compact High-mileage vehicles often use mechanical planetary gearboxes to transfer the torque and rotational speed between the travel drive and the wheels or continuous track. The main challenge our engineers faced was compensating for the performance differences between hydrostatic and electric motors. The newly developed compact gearbox doesn’t require any extra installation space compared to conventional hydrostatic gearboxes, yet boasts even greater efficiency. An additional planetary stage takes rotational speed and torque to hydraulic motor levels. The gearbox geometry is identical to that used in our already popular GFT8000 drive unit. So, the eGFT8000 is exchangeable with the GFT8000 and the flange surface for motor mounting is in the same location. Both gearboxes have the same impressive permissible load. An electric future The market for mobile applications is ready for electrification, as it answers the growing requirements to meet future emission regulations and increase efficiency. Here at Bosch Rexroth, we’re combining our expertise in electrical industrial solutions and mobile applications with the extensive experience Bosch has accumulated in the area of electromobility. The result is a portfolio of components for the electrification of mobile applications that open up new opportunities for OEMs. A holistic approach Our solution strategy considers the entire machine and enables manufacturers to expand their range of vehicles step by step. Our aim is to obtain a global leading position in this new segment by leveraging synergies in the Bosch Group and combining them with our deep application knowledge to create functional, comprehensive solutions based on proven and new electrical components. The electrification of off-highway applications is making rapid progress. With our products, we’re creating a future that will be more efficient, produce less noise and emit less air pollution. We’ll work as partners with our customers to find the best solution for their individual needs – for classic, partially-electric or fully-electric models.
Author: Matthias Kielbassa Job title: Project Director for the Electrification of Mobile Equipment
... View more
Two drive principles in one ship lock. That was our solution when asked to assist with the expansion of the ship lock in Eefde (Gelderland, the Netherlands). The project called for a new kind of hybrid drive technology that would combine the advantages of an electromechanical linear actuator with those of a conventional hydraulic drive. This would be the first application of its kind in the civil engineering world. A new definition of efficiency The new electro-hydraulic actuators drive the lock gates. They are completely closed systems with specially constructed cylinders that restrict oil movement between the chambers of each individual cylinder. This means that the system requires ten to twenty times less oil and makes the use of a large hydraulic reservoir unnecessary. A compact plug-and-play powerbox with servo motor and hydraulic pump sets the cylinder rod in motion. Thanks to this space-saving design, the ship lock doesn’t have to be accommodated within a space-consuming basement. The new technology is also 25 percent more efficient than traditional systems contributing to the energy efficiency of the ship lock. Collaborating to deliver a world’s first This hybrid technology was developed in a close collaboration between our experts and the Hollandia Infra team. It was their responsibility to design and build the lock gates on behalf of their clients Lock to Twente (L2T), a construction group consisting of Mobilis TBI and CroonWolter&Dros. Working together, the consortium was responsible for the construction of the second lock chamber in Eefde on behalf of Rijkswaterstaat, the Netherlands’ executive agency for the Ministry of Infrastructure and Water Management. Hollandia Infra’s design brings together two different types of lock gates, with classic mitre gates for the lower head and a radial gate for the upper head of the ship lock. We were commissioned to supply the new drive technology to power both types of doors. Hollandia Infra approached us in the early stages of the project, as they recognized the ground-breaking potential of using this type of hydraulic cylinder. We also delivered the drives for the leveling gates and the beam of the anti-collision device. Looking to the future This hybrid technology is an important step in the development of a new generation of ship locks. Both in the Netherlands and elsewhere in the world, we’re faced with the task of replacing a large number of ship locks in the coming decades. We must seize this opportunity to create ‘smarter’ ship locks. Standardization, such as Rijkswaterstaat’sMultiWaterWerk program, should be taken into account, but also new technologies. This new drive technology is a good example of how we’re making that happen.
Author: Patrick Hendriks Job title: Manager, Sales, Industrial Applications
... View more
In line with future industrial requirements, we’ve designed our innovative, new Smart Function Kit. It provides a mechatronic package that’s immediately ready for use across a wide range of applications, making it the perfect basis for system integrators or end-users with process know-how. Simple, fast and intuitive – the kit has been developed for pressing and joining applications in the range of 2 kN to 30 kN. The modular kit includes mechanical components, electrical components and software, and is particularly appealing because of its simplified product selection and configuration as well as commissioning. It can be connected via open interfaces in higher-level systems and conveniently monitored on a tablet during operations, reducing downtime and increasing productivity. Simple. Fast. Cost-effective It’s ideal for applications where simplicity, fast commissioning and an attractive price are all important. These include assembly and joining processes, such as press-fitting, crimping, assembling or inverting, as well as forming processes, such as bending and embossing. Another example of where the Smart Function Kit can be used is for testing as part of the development process or for quality assurance. It can either be used as a stand-alone solution or integrated into superior systems via field bus. Intuitive set-up and operation Selecting the right Smart Function Kit couldn’t be easier. After the LinSelect tool has helped you to choose the correct size, the final configuration process is carried out in the online configurator. CAD files can then be downloaded and the desired configuration ordered in our e-shop. Another highlight in addition to fast and simple product selection, is the intuitive commissioning and process configuration, for which no programming knowledge is needed. Pre-installed operating software, automatic parameterization of the servo drive, a set-up wizard and integrated motion control, make fast and simple commissioning possible. The result: a saving of up to 95% of engineering time and significantly reduced time-to-market. Easy to monitor During operation, the Smart Function Kit can be conveniently monitored on a tablet. The visualization of status information, process results, plus a live display of force-displacement curves, ensure maximum transparency. All current system parameters are available at a glance: whether as a status report, quality statistics or error messages, making error handling simplicity itself. As pioneers in the digitalization of Linear Motion Technology, we’re pleased to be able to offer this special solution for a wide range of pressing and joining processes, in order to reduce downtime and maximize productivity. Included in the Smart Function Kit:
Electromechanical cylinder with servo motor
Optional: force sensor
Servo drive and industrial PC
Author: Thorsten Smetak Job title: Sales Application Engineer for Linear Motion Systems
... View more