More openness, connectivity and sustainability across the value chain

Bosch Rexroth will present numerous open, easy-to-integrate automation solutions at HANNOVER MESSE 2023 and is continuing to drive forward the digital transformation in mechanical engineering. In hydraulics, the company is increasingly shifting functions to the software. The solutions use open standards throughout and thus increase the freedoms available to machine manufacturers and end users. At the same time, they reduce the consumption of energy and resources during use. With the recycling of used automation components and an innovative process solution for recycling batteries, Bosch Rexroth will also be presenting solutions for sustainable circular economy.

Automation: More openness and reduced consumption of energy and resources

Up until now, automation manufacturers closely linked software functions to their control hardware and thus tied customers to their product world. Although it was previously used exclusively on the ctrlX CORE control system, Bosch Rexroth is now making its real-time-capable, Linux-based ctrlX OS operating system available as a separate solution for industrial environments. ctrlX OS seamlessly connects even more automation components with the entire ctrlX AUTOMATION portfolio, including the partner solutions from the ctrlX World, in real time and independently of hardware. Machine manufacturers and system integrators can thus develop, install, update and operate software-based functions on any control systems even more easily and flexibly across all levels of the automation topology. As the first system and technology partner, WAGO offers the ctrlX OS operating system on its own devices and is working with Bosch Rexroth to develop new sector-specific solutions.

The ctrlX AUTOMATION toolkit also supports sustainability in industrial automation. More and more energy saving functions can be used – for example the Smart Energy Mode in servo drives. It ensures that energy is kept in the system intelligently and that peak loads are avoided as far as possible. Another trend is the reuse of automation components as part of the Remanufactured Products Program. Through professional reconditioning and the replacement of wear parts, a used servo motor for example can be restored to the quality standard of a new product, including a warranty. Around 75 percent of the components are reused, thus conserving resources.

Linear motion technology: The quicker way to tailored solutions

In the field of linear motion technology, Bosch Rexroth is speeding up the engineering processes for individual components and smart mechatronic subsystems with coordinated e-tools. During commissioning of the subsystems, the pre-installed operating software with a virtual assistant helps to save time. As Plug and Produce solutions, the Smart Function Kits for specific applications such as pressing and joining or handling and dispensing simplify and speed up the entire engineering process. The pre-installed operating software with a virtual assistant ensures that the commissioning time of these subsystems is reduced by up to 80 percent. Visual sequence programming using Drag and Drop function blocks saves even more time. The Smart Flex Effector opens up entirely new freedoms in automation. The sensor-based compensation module with independent kinematics in six degrees of freedom gives robots the sensitivity of a human hand. The Smart Flex Effector has been nominated for the Hermes Award 2023.

Thanks to longer lubrication intervals and optimum use of lubricants, the linear motion technology solutions reduce operating costs as well as the use of resources over the entire life cycle.

Battery recycling: Deep discharging in just a few minutes

The increasing proportion of battery-electric cars worldwide is creating high demand for solutions for recycling batteries and the raw materials such as lithium, cobalt or nickel that they contain. At HANNOVER MESSE, Bosch Rexroth will present an innovative automation solution which reduces the time taken to discharge batteries from 24 hours to less than 15 minutes. The system solution is made up of standard components from the ctrlX AUTOMATION toolkit and the TS 5 transfer system as well as modular software tailored to the process. The patented deep discharging prepares the batteries for the subsequent recycling processes. The automation solution feeds the energy released into an intermediate circuit which supplies other actuators in the line or feeds the energy back into the electricity grid. The solution sets a new milestone for electrified mobility as part of the circular economy.

Asset administration shell: Flexible and graphical orchestration of manufacturing

Bosch Rexroth consistently relies on open, cross-manufacturer standards and interfaces in all automation technologies, such as the asset administration shell. It functions as a standardized digital twin for all automation components and solutions – both from Bosch Rexroth and from other manufacturers. Users orchestrate their brownfield and greenfield equipment graphically in ISO/IEC-standardized process models, independent of lot size, with the new individually adaptable software platform for flexible and changeable manufacturing, and without downtime. The standardized data and process transparency permanently increases the agility and reactivity of production.

H4U hydraulics platform: Greater productivity and sustainability

With the new H4U (Hydraulics for You) software platform, Bosch Rexroth is raising industrial hydraulics to a new level. It transfers hydraulic functions that were previously hardware-bound into hardware-independent software modules. However, the classic advantages of hydraulics remain. At the same time, H4U makes it easier to integrate hydraulics into existing automation environments. With the H4U.apps, end users can increase their productivity and energy efficiency while reducing their CO2 footprint. Customers can already use an app for pressure/volume flow control in their applications. At HANNOVER MESSE 2023, other H4U.apps, for example a displacement/force control system for hydraulic axes, will be presented. As a result, the ctrlX AUTOMATION toolkit too has gained hydraulic functions.

eOC: Greater flexibility for mobile and stationary applications

On the basis of proven but mechatronically optimized hydraulic pumps for the open circuit, Bosch Rexroth presents the new eOC (electronic Open Circuit) hydraulic architecture. With these pumps for mobile and industrial applications, eOC technology allows operation with variable specifications for pressure, flow rate and power – in stationary applications and in highly dynamic transitions. eOC thus increases the stability of the function in the particular application. Efficiency advantages in components and the system network also increase efficiency. At the same time, energy recuperation solutions are made possible or can be simplified. The key to this is moving complex control processes from hardware controllers to the software level. This reduces the variance of pump adjustments and default settings. Less set-up work is needed too as the settings are configured only once per machine.

Hägglunds Quantum motor range: New peaks in performance and service life

Overcoming previously existing physical limits, the new Hägglunds Quantum hydraulic motor series offers a unique combination of torque and speed. With a top speed of more than 150 rpm, and at the same time being able to achieve maximum torque of more than 350 kNm they rewrite the rules of power density. By optimizing design and materials, Hägglunds has increased efficiency and tripled the average service life compared to previous series. The motors are suitable for crushers and internal mixers, for example, but also for mobile applications.

eLION platform: Bosch Rexroth continues to drive forward the electrification of mobile machines

The modular eLION platform was specially developed for global off-highway use and supports the full electrification of mobile machines. The motors’ nominal power ranges from 20 to 200 kW with peak power levels of up to 400 kW. Fully integrated functional safety features in accordance with ISO 13849 help to save time during engineering. eLION includes motors and inverters as well as important system components such as DC/DC converters, onboard chargers and high-voltage cables. Bosch Rexroth also provides BODAS software modules and suitable gearboxes as well as hydraulic components such as axial piston pumps for the entire eLION platform. Numerous machines equipped with eLION are already in use as part of pilot projects.

Bosch Rexroth at HANNOVER MESSE 2023: Hall 6, Stand D26