Manufacturing industry is working together on 5G to achieve the best possible outcomes. Here, Andreas Mueller, Head of Communication and Network Technology at Bosch Corporate Research, and Chairman of the 5G Alliance for Connected Industries and Automation (5G-ACIA) , looks at why collaboration is important to the 5G-ACIA . In the past, mobile communications and factory automation had little in common. In order to ensure that 5G becomes a success in the industrial domain, close collaboration is required between the ICT (information and communication technology) industry and OT (operational technology) industry. The 5G-ACIA has been established as the central and global forum for bringing all these different stakeholders together with one paramount objective: ensuring that 5G meets the needs of the manufacturing and process industries. This is done by addressing, discussing and evaluating relevant technical, regulatory and business-related aspects. Leading the way For Bosch, industrial 5G and therefore also 5G-ACIA, are important from two different perspectives: On the one hand, we’re big end-users ourselves, with more than 280 plants and factories worldwide, so 5G will help us to be more competitive and support Industry 4.0 developments. On the other hand, we’re also a major provider of components and solutions for industrial automation, especially through Bosch Rexroth. These developments help us in our aim to become the leader in offering innovative and exciting new products and solutions based on 5G, which in turn helps our customers to gain a competitive edge. For all these reasons, we were one of the early initiators and drivers of 5G-ACIA. A global movement The 5G-ACIA was initiated in Germany in April 2018, but it also had members from other countries, including China, Japan and the United States, from the very beginning. Today, there are additional members from other important regions, such as Taiwan, France, Italy and Korea, and the alliance is constantly growing. In 2019, we’ve had meetings in Korea, the US, Germany, China and France. Everybody with an interest in the topic is very welcome and is encouraged to join the 5G-ACIA. In these meetings, we’re currently considering use cases and requirements in preparation for the next version of the 5G standard (also known as Release-17). We’ve also worked on various other topics, such as security, testing and certification, and how best to integrate 5G into existing industrial connectivity infrastructures. This includes both established Industrial Ethernet systems, as well as time-sensitive networking (TSN). We’ve just started a new work item for preparing a test bed framework for 5G-ACIA, which will form the basis for future joint test bed activities.
Author: Andreas Mueller Job title: Head of Communication and Network Technology at Bosch Corporate Research, and Chairman of the 5G Alliance for Connected Industries and Automation (5G-ACIA)
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Who’d have thought that our upcoming stars of the factory floor would take center stage at this year’s German Business Film Awards? That’s exactly what happened when our teaser film for the new ActiveShuttle autonomous transport system picked up a gong for second place at this year’s prestigious award ceremony. German Federal Minister for Economic Affairs and Energy, Peter Altmaier, personally presented the awards to us in Berlin. This was the 52 nd time that the competition for the best business films has taken place. Apart from a business focus, the competition sets out to showcase the professionalism of artists and fosters creativity in the film industry. Stealing the show Our show stopping performance included some very familiar faces in the form of our own ActiveShuttle fleet. When the last employee clocks off for the day, the ActiveShuttle team really springs into action! The animation showcases the intralogistics experts of the future as part of a playful onscreen performance. The autonomous transport system magically showcases some of its standout features with almost lifelike energy and joie de vivre! You’ll also recognize “Now. Next. Beyond.” as a reference to our current “Factory of the Future” campaign. A truly remarkable event The German Business Film Awards are a unique event that recognizes the talent of those who portray German business in a way that captures the interest of the general public. The competition’s primary goal is to raise the profile of business innovative and make it more relevant and tangible for people from all walks of life . The appointed panel of judges was tasked with nominating the best five in each of the following categories from all of the entries submitted: Business well explained / Business well presented / Innovative production / Films by up-and-coming filmmakers / Panel award (the 2019 key theme was sustainability). And a truly remarkable accolade! The Bosch Rexroth brand is all about innovative solutions which are safe, efficient, smart and high-performance. The successful visualization of products and their benefits in film helps to generate transparency, curiosity and awareness. It also demonstrates how our products and solutions are making a decisive contribution towards delivering the Factory of the Future. The film managed to portray exactly all this in a charming way that was engaging and understandable. The recognition from the German Film Award is a huge accolade and an acknowledgment that we’re are achieving our goals! Our congratulations got to all of the Marketing and ActiveShuttle product team for their successful collaboration with ECHOFABRIK Filmproduktion GmbH. Experience their creative masterpiece for yourself at: https://www.youtube.com/watch?v=cRE5JMrBRQk
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JonRie InterTech is a leader in the design, manufacture and start-up of marine winch systems, based in New Jersey, USA. For many years, the company has provided tugboats, dredgers and other types of vessels with exceptional winch solutions – all built with Hägglunds hydraulic motors from Bosch Rexroth. Controlling winch tension – and letting go Durability, however, is just one side of the Hägglunds motor equation. The other is control, especially when it comes to winch tension. “Tension control is very important in ship docking, for example, where you’re managing the tension that’s between your tug and the ship,” says Brandon Durar, founder and president of JonRie InterTech. “Basically, you set your tension and control it with the Hägglunds motor and the hydraulics, not the brake.” Besides offering the best possible tension control, Hägglunds motors have free-wheeling capability, and in Durar’s mind the two features are inseparable. To explain why, he describes a tugboat letting out the line as it quickly moves away from its tow, repositioning itself for the next move. “It’s what I call controlled free-wheeling, which is basically back-tensioning the line a little so that it stays out of the water and doesn’t go slack,” Durar says. “A tugboat has screws for propulsion, so you don’t want the line in the water at any point. It’s the other aspect of tension control. Clearing the deck with power density As tough and versatile as Hägglunds motors are, JonRie has no difficulties incorporating them into the winches. On the contrary, the motors’ high power density ensures that both power and function can be packed into a small amount of deck space. JonRie relies mainly on motors from the Hägglunds Compact series, which includes the Hägglunds CA, CB and CBm, as well as the newer Hägglunds CAb. “Deck space is always a premium,” says Durar. “The Hägglunds CAb is a very small Hägglunds motor, and we’ve been experimenting with it on our level winds. It’s a nice stout motor in a good little package, and the principle is the same. It takes a licking but keeps on ticking.” Keeping winches and their owners in business For JonRie customers, the advantages of hydraulics with Hägglunds motors add up to productivity. At the end of the day a boat is an enterprise, and Durar finds that the uptime provided by Hägglunds motors is key to turning a profit. “Our customers are sold on the reliability,” Durar says. “If you’re repairing a winch every four or five years, it’s a budget eater. When you have it in service for 15 years without doing anything to it, it makes you money.” Service on Hägglunds motors, says Durar, is never frequent. If customers filter their oil properly, the motors commonly run for 20 or 25 years. “We just had two motors serviced, one of which had been in service for 28 years,” he relates. “After 28 years, I think it deserves some service!” Although JonRie does its own service for winches, the company turns to Bosch Rexroth if more than a seal change is required in a Hägglunds motor. When it comes to getting the job done right, only the Hägglunds team has Durar’s trust.
“When they do a repair at their US Hägglunds service centers in Ohio and Texas, we know it’s 100%,” says Durar. “
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So much more than just fast internet for smart phones, 5G will be a significant breakthrough for manufacturing industry. In the coming years, 5G will offer ten times higher data rates than 4G, will be able to serve a massively higher number of subscribers or IoT devices, will enable real-time transmission with latency times of up to 1ms or even less, and will reduce energy consumption per bit. This will create entirely new possibilities for manufacturing industry and for making the Factory of the Future a reality. We’ve invested in the development of our own local 5G network, in order to develop and validate new use cases:
Augmented reality: Using data goggles, our Hägglunds specialists in heavy-duty drives guide maintenance personnel from the service center in Sweden through diagnosis and troubleshooting at any location.
IoT Gateway: IoT Gateway software uses sensors to network older machines without interfering with the existing cabling or control system. In the future, IoT Gateway will also support 5G, and thus integrate installed machines into wireless networking.
3D printing – closed loop edge control: With the 3D printer manufacturer BigRep, we’ve used 5G technologies to demonstrate that real-time control of complex 3D printing processes is possible wirelessly in an external server. The approach can detect and correct deviations of the actual process from the digital twin in real time, based on the the machine data, significantly reducing errors and increasing productivity to a level required for mass production.
Quality assurance with artificial intelligence: Manufacturers are increasingly using industrial image processing and machine learning for quality assurance. The exchange of the large amounts of data required for this is wireless. Software programs already support quality assurance in other applications, such as tightening technology. They record each screw connection in the context of the component and the specifications, and check whether the correct torque has been applied.
Wireless safety: With 5G, safety-critical tasks can be performed wirelessly in accordance with standards for the first time, without the need for permanently wired control units with emergency stop switches.
Intelligent assembly and ActiveCockpit: Our ActiveAssist sends production data, including work instructions for each individual product, to people at the assembly stations; and ActiveCockpit, our interactive communication platform, monitors all controls and sensors on a line in real time. It immediately detects process deviations and errors and reports them to employees and/or other defined departments.
Intralogistics: Automated Guided Vehicles (AGVs), such as our ActiveShuttle, orient themselves independently and make deliveries from a central store to an assembly point on the production line, coordinated by the merchandise management system. They exchange information with the IT systems and with each other, recognizing new obstacles, alerting other AGVs in the fleet in real time, and immediately calculating alternative routes.
In time, equipment optimized to take advantage of 5G will deliver even greater benefits. But 5G can also be retrofitted in existing factories, both as a private network and by subscription to public networks. Also, inside existing machines, the sensors can transmit their data via cable to 5G-capable gateways, which then transmit them wirelessly. We’re already using this approach today to network machines installed with IoT Gateways.
Author: Dr. Gunther May Job title: Director of Technology and Innovation in the Automation and Electrification Solutions Business Unit
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Hydraulics are used on dredgers for a range of movements, such as lifting and lowering spuds. But they make a real difference on winches and cutter heads, where our Hägglunds hydraulic solutions excel.
Dredging has never been easy. Marine conditions are harsh, both above and below the surface. Add the time pressure that dredgers often work under, and you can see why the demands on equipment are high. Performance and reliability are everything. Bosch Rexroth’s scope of supply includes many different systems for dredgers, all with their own remarkable abilities. Among them are our Hägglunds hydraulic direct drives, which have long been appreciated for the way they keep winches and cutter heads going strong.
Saving valuable space on board Hägglunds solutions stand out for their size, which is far smaller than that of traditional electromechanical drives. Space comes at a premium on board, especially when equipment has to be retrofitted rather than designed into the vessel from the beginning. Compact and lightweight, but also powerful, Hägglunds hydraulic motors mount directly on what they turn – in this case the winch drum or cutter head shaft. Since their force and direction is determined by a flow of oil, they require no gearbox, which has the added benefit of eliminating hassles with lube oil. However, it isn’t all size and simplicity. Ultimately, it's performance that dredgers are after.
The most efficient drive for winches The winch is a classic application for a Hägglunds system, and there are often multiple winches on a dredger. Though it first appeared over 50 years ago, the Hägglunds Viking motor was specifically developed for marine winches, and it remains the standard for them today. Capable of free-wheeling, it has a rotating casing that allows direct mounting of a DNV ATEX brake. More importantly, the Hägglunds Viking has unbeaten starting efficiency, which is the make-it-or-break-it feature for a winch. Compared to a typical starting efficiency of 85%, the Hägglunds Viking has a starting efficiency of up to 98%. In addition, its full torque is available from zero to full speed, so there’s full lifting or turning power from the moment it’s needed.
Powering and protecting cutter heads The availability of full torque from zero to full speed is also a crucial advantage for dredger cutter heads. Submersible to depths of 40 meters or more, Hägglunds motors supply exceptional force for cutting through stubborn materials on the water bottom. The most difficult obstacles often appear suddenly, but Hägglunds drive systems withstand damage even when the work becomes rough. Not only do they minimize vibration, they provide built-in overload protection that protects the cutter head from unexpected shocks. If the head gets stuck, there’s no risk of overheating. On the contrary, the drive’s low moment of inertia makes it easy to change direction and work it loose again.
A lasting solution that’s easy to upgrade With such high durability, it’s no surprise that Hägglunds solutions have a long service life. As hard as dredging is, they can serve a dredger for many, many years – even decades. Nonetheless, our development of Hägglunds solutions continues, and there can be substantial benefits to modernizing. Cutter head drives, in particular, can benefit from upgrading Hägglunds MB (Marathon) motors to our next generation: Hägglunds CBm. The Häggunds CBm packs 50% more torque into a motor that’s smaller and lighter, giving it higher power density than any other. To make upgrading easier, we’ve created a convenient Hägglunds CBm upgrade package especially for cutter head drives. If you’d like to learn how to take advantage of it, or any of the other solutions we offer for dredging, simply get in touch.
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