Connected Automation: Showcase Manufacturing i4.0

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1 Bosch Rexroth AG Postfach Lohr, Germany Bgm.-Dr.-Nebel-Str Lohr, Germany Tel Fax Connected Automation: Showcase Manufacturing i4.0 R ( ) Bosch Rexroth AG 2016 Subject to changes! The data specified only serve to describe the product. As our products are constantly being further developed, no statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging. Connected Automation i4. now

2 2 3 Connected Automation: Showcase Manufacturing i4.0 Experience a manufacturing line, which customizes mass production according to i4.0 criteria. The modular manufacturing line demonstrates on the basis of versatile processing and assembly that increased productivity and flexibility can be achieved by means of Industry 4.0 even today. All stations are consistently connected vertically and horizontally via open interfaces and provide all relevant information in real-time. The flexible manufacturing concept combines fully automated and manual work stations into a consistent manufacturing solution by means of cutting-edge automation and IT technologies. All necessary information is being shared seamlessly with superordinated IT systems, including the cloud. The products themselves transmit their required production data and thus provide the basis for the efficient manufacturing of batch size 1 at change over % virtual image and simulation allows for a shorter system development stage and the simulation of all relevant manufacturing processes. Highly flexible and modular manufacturing layout depending on the current requirements, manual and automated work stations can be flexibly arranged to facilitate different manufacturing sequences. Consistent horizontal and vertical networking all relevant information is made available everywhere in real-time via open interfaces. Interactive shopfloor visualization ActiveCockpit supports managers and staff during continuous improvement processes. Data analysis predefined mathematical and statistical methods of data analysis enable process and quality enhancements. Self-controlled products by means of RFID technologies, the product itself transmits its required manufacturing data to the line. Intelligent workplace system ActiveAssist provides intelligent worker support for multi-variant assemblies. i4.0 Upgrade Kit connects existing manufacturing lines and modules, which previously could not be integrated into i4.0 networks, with superordinated IT systems.

3 4 5 Connectivity and Software Integration Simulation Digital Service Assistant / Service Portal Ticketing Video Knowledge Customer order Information on order, logistics, and requirements Manufacturing order Data Analytics Server OPC UA OPC UA Controller Check Visualize Dispense Load Tighten Assemble MES solution for manufacturing control. Direct connection to automation controllers via OPC UA. Open Core Engineering from Bosch Rexroth, for the easy integration of IT and automation as well as for the reduction of engineering efforts by up to 30 %. Dassault Systèmes Dymola for the simulation of dynamic models such as a delta robot in Modelica. Java Virtual Machine integrated into Bosch Rexroth controllers for the platform-independent programming of application software. Lua high-level script language for the programming of robots in connection with Open Core Interface, integrated into Bosch Rexroth controllers. mxautomation for the connection and control of a KUKA articulatedarm robot via a Bosch Rexroth controller. Bosch IoT Cloud and Process Quality Manager for the cloudbased, qualityoriented analysis of data from the Bosch Rexroth tightening system. i4.0 Upgrade Kit from Bosch Rexroth, for the connection of existing machines, modules or lines to IT environments. WebConnector from Bosch Rexroth, a translator between the web and the automation world, based on HTML5, Java, and OPC UA. Data Analytics Server from Bosch Rexroth, in connection with MATLAB Simulink, for the statistical analysis and visualization of data. ActiveCockpit from Bosch Rexroth: Web-based shopfloor visualization software, expandable with apps and widgets.

4 6 7 i4.0 Upgrade Kit Process Quality Manager Connectivity to superordinated IT systems with cloud connection The i4.0 Upgrade Kit connects existing machines, modules or lines without sufficient connectivity to Industry 4.0 topologies. Their data can be automatically processed in superordinated systems and can be used for condition monitoring and data mining purposes. The implementation does not require any modifications of the existing automation solution. The web-based configuration of the i4.0 Upgrade Kit can be carried out without any specific programming skills. WebConnector Java Linux Connectivity Web based configuration of connector Sensors provide the machine data The Process Quality Manager safely and reliably monitors and documents tightening processes. Trend deviations from the standard process are detected in time to prevent the manufacturing of faulty workpieces. The user benefits from direct notifications on faults in the manufacturing process. The data can be stored in customer-specific clouds or in the Bosch IoT Cloud. This ensures the worldwide availability of data. Cloud Data Analytics Server Interactive shopfloor visualization The web-based Data Analytics Server consolidates and analyzes machine and process data in order to increase the availability and productivity of manufacturing lines. By means of predefined mathematical methods and visualization, the software ensures the easy analysis of processing data the ideal solution for quality assurance, process improvement, and predictive maintenance. ActiveCockpit is an interactive communication platform for the immediate processing, filtering, and visualization of manufacturing data according to individual requirements. ActiveCockpit facilitates the networking of IT applications such as production planning, quality data management, and dispatch, with the software functions of manufacturing plants. The information serves as a basis for decisions and the optimization of processes involving humans, machines, and manufacturing processes at the shopfloor. Integration MES The open architecture of Bosch Rexroth s automation platform facilitates the direct connection between the Manufacturing Execution System (MES) and distributed control systems, and thus allows for the real-time control and monitoring of production processes as well as the access to actuators and sensors. ERP MES Corporate Management Level Internet (Cloud) Production Management Level MES Process Control Level Intelligent manual workplace system ActiveAssist offers worker support for multi-variant assembly processes. RFID technologies facilitate the clear identification of products. The staff receives the required work instructions and is guided through the manufacturing steps via beamer or pick-to-light displays. Assembly steps are monitored and approved by means of cameras, ultrasonic systems, or the torque of a tool. Worker guidance Pick-2-light, projector Nutrunner positioning Ultrasound Interactive Worker Instructions Projector, Touchscreen Hand Tracking 3D Camera Product identification RFID

5 8 9 Robotics integration Complete virtual image Through the open architecture of Bosch Rexroth s automation platform, robots with different kinematics (e. g. Cartesian, delta, articulated arm) can be integrated and intelligently connected on several configuration levels. It is possible to command robots directly by means of Bosch Rexroth controllers with standard programming in PLCopen, high-level, or script languages. Starting with the construction of the machine, virtual images are being generated. This enables machine and line manufacturers to accelerate the development process up to the virtual commissioning. Model-based engineering helps line operators to adapt their machines to new products very quickly new motion sequences can be easily simulated and optimized. This reduces setup and retooling times during product and variant changes and increases the productivity without further efforts. real virtual Ultra-flexible transport system The Bosch Rexroth linear motion system (LMS) is a unique technical solution for the transport and positioning of materials and workpieces. It offers maximum accuracy, freely programmable synchronized motion sequences, and is faster than conventional systems. The entirely contactless drive concept ensures the particle-free transport and is based on linear motor technologies allowing the individual positioning of every single workpiece. Highly flexible production layout Bosch Rexroth manufacturing solutions are based on a consistently flexible, modular, and scalable model. According to the respective requirements, different manufacturing layouts consisting of manual and automated work stations with self-sustaining controls can be quickly realized. This makes it possible to easily integrate the modules, which may be required for additional process steps, via defined interfaces into the overall system. Option 1: I-shape Option 2: Y-shape 1 = Dispense 2 = Load 3 = Tighten = Transverse transport 5 = Manual workstation 6 = Check Smart tools The intelligent tightening systems from Bosch Rexroth are equipped with integrated torque and rotation sensors and intelligent software functionalities to ensure processreliable tightening connections. The tools can be integrated into the automation environment either via cable or wireless via WLAN by means of a wide range of interfaces and protocols for the exchange of commands and data. Digital Service Assistant With the Digital Service Assistant, Bosch Rexroth quickly provides the relevant information for troubleshooting. The operator receives the data of the involved components on smartphone or tablet and can access all related documentations via direct links to the Bosch Rexroth media server. The Service Assistant directly forwards queries on more complex issues to the Bosch Rexroth helpdesk.

6 10 11 Bosch Rexroth Solution Portfolio Bosch Rexroth is driving the next industrial revolution as a Connected Automation in manufacturing leads to a faster leading automation supplier and manufacturing company. and more flexible production process, greater efficiency of With a huge automation portfolio and production experience from our own plants worldwide, we can offer leading material, and reduction of complexity and downtime. automation and manufacturing solutions from single piece to high volume production. Connected Automation i4. now Factory Automation Products & Solutions Automation Solutions Manufacturing Solutions Consulting & Services Open Automation Platform Smart Products Controls & Software Electrohydraulics & mechanics Joining Technologies Engineering Tools Automation Apps & Library Connectivity Toolbox Complete Manufacturing Lines Intelligent Processing Subsystems Multi technology Automation Intelligent Workplace Systems Material Flow & Intralogistic Solutions IT- and Software Integration Availability Solutions (Service Assistent, Service Portal, Service Contracts, Condition Monitoring, Predictive Maintenance etc.) Project planning / Configuration Simulation (Material & Production flow, Machine & Processes, Resources e.g. Energy optimization) Consulting Production System i4.0 Brownfield Connection i4.0 Greenfield Concepts System Integration and Application Services Commissioning HMI Solutions Sensor Integration Data Analytics Didactics Cloud-based Solutions... Safety & Security... Contact: i4.0@boschrexroth.com