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
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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
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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
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When Liburdi, a global leader in automated welding systems, asked us to help them develop a mechatronic gantry system, we provided a ready-to-install solution that reduced their assembly time from 14 working days to 3 hours. The Liburdi Group has been providing specialist metallurgical, welding and software technologies, systems and services to the aerospace and medical industries, where high tolerance and precision are key, for over 30 years. With headquarters in Ontario and main production plants and laboratories in Canada and the USA, Liburdi provides services to major gas turbine operators in over 30 countries. Choosing the right partner It was during the development of their 3-axis automated welding system for repairing turbine blades, that Liburdi turned to us to supply the gantry system, which provides the motion capabilities of the welding machine. “We chose Bosch Rexroth because of its high precision, compact design and on-time delivery engineering services”, explains JJ Sixsmith, General Manager of Liburdi Automation. Meeting the requirements The gantry system had to deliver the required precision, speed and component rigidity, as well as perfectly fitting into Liburdi’s machine frame. Our challenge was to provide a system to a time-critical delivery date, that would accommodate the work envelope of the welding system’s tasks while maintaining a small footprint. The system includes TKK linear modules, servo motors, an IMS-A integrated measuring system, which ensures the necessary precision and repeatability, and a bellow that protects the drive system from spatter and other contaminants. Within a day of its arrival, Liburdi had the system installed on their machine frame and were able to start wiring and testing the components. They were so pleased with the outcome that they already have another gantry system on order. Making extensive time savings JJ Sixmith explains why the high-precision units we supply, which arrive as a drilled and dowelled package, make such a difference to Liburdi’s timeframe. “It would have taken us 12 to 14 days to complete a single system. But with these pre-engineered units, it takes us about two-and-a-half to three hours to complete a system.” By working with Liburdi to identify their needs and solve their underlying issues, we’ve demonstrated that we’re not only a components supplier, but a multi-technology solution provider too.
To see this technology in action, watch the video.
Author: Connor Robinson Job title: Technical Sales Consultant and Author: Brian Rundle Job title: Linear Motion Product Manager
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In the Factory of the Future, the floor, walls and ceiling are the only things that are fixed. All machines and systems are movable and modular, enabling a production line to be added or extended, with autonomous guided vehicles (AGVs) handling the flow of goods to the point of need. It’s an intelligent floor that makes this possible. We’re developing a floor system that identifies devices and machines, manages them, exchanges data with them and supplies them with electricity, media and more. This intelligent floor is part of our Factory of the Future portfolio – all components of which can be easily combined as needed to meet the requirements of individual customers. Responsive to change The floor is constructed from 1m² panels, each with its own control system. The grid controller (a higher-level control system) in the production hall or in the cloud, evaluates pending order requirements, and simulates the grouping of devices and machines. Because each plate continuously monitors the force imposed upon it, the floor can respond to circumstances – so for instance, equipment in transit can be stopped or moved if another object approaches. With the simulation complete, production machines will move independently to the areas assigned to them, and non-contact energy transmission units will supply them with power. They’ll be supplied with information wirelessly via the new 5G radio connection standard. Production machines won’t even need to shut down during transit, enabling maximum productivity. The intelligent surface has two layers, so necessities such as piping for water, compressed air and lubricants can take place in the space in between. Smart and flexible Production is simpler if more of the intelligence is built into the floor, rather than into the devices and machines. For example, instead of equipping AGVs with complex localization systems, large energy storage units and powerful computers, they can simply have a control unit. This control unit enables the AGVs to navigate using a dynamic lane system of embedded LEDs, which guides them like an “electronic dog leash.” The AGVs obtain their drive energy from the contactless energy transmission units in the ground. Intelligent floors can be introduced step-by-step in areas of a production line where the need for flexibility is greater. Individual panels can be configured according to their function: not all of them require contactless power transmission or media supply elements. In edge areas or on defined paths, panels without additional functions can also be laid, reducing costs. 4 key benefits Whether intelligent floors are installed in stages or in one step, their advantages are plain:
They make planning flexible, as well as production.
They can work with IoT-enabled devices, for instance to help workers locate specific batches currently in production.
Machine status can be visualized via colors and/or size of the LED display.
Floor LEDs can also be used to indicate AGV routes for safety purposes.
All of which is great news for manufacturing companies – because the smarter the floor, the better the business is able to operate.
To see this technology in action, watch the video.
Author: Javier Stillig Job title: Engineering and Solutions for Factory of the Future
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