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DC/812 United Kingdom, 2018-06-08

Bosch Rexroth takes engineering into a new age with Industry 4.0 Compact Power Unit

Zuse Hüller Hille, a premium German machine tool manufacturer, is future-proofing its horizontal machining centres with a connected, frequency-controlled compact power unit from technology partner Bosch Rexroth.

The company has adopted the CytroPac to optimise power consumption, space requirements and time to market for its hydraulic functions, while taking advantage of its Industry 4.0-ready connectivity in answering critical challenges. The company’s machining centres are characterised by high accuracy and performance, with high-speed motor spindles unleashing up to 80 kW drive power and 2,600 Nm torque, all to achieve precise, rapid machining of vehicle, aircraft and machine components.

In terms of hydraulic tasks in its facilities, a wide variety are carried out at a range of anywhere between 75 and 250 bar pressure. In light of new energy regulations – and the advent of Industry 4.0 – the company needed an economical way of reducing pressure ranges through a single system. Bosch Rexroth had the answer.

The CytroPac provides a Sytronix variable-speed pump drive with frequency converter, sensor technology and data interface – all within one compact, space-saving power unit. With an energy requirement of up to 80% less than conventional units, it can aid compliance with the EU’s Ecodesign Directive, as well as the strict regulations of the automotive industry. CytroPac also uses up to 53% less oil, and has an integrated tank optimised for degassing. Its sensors monitor all relevant data, from pressure and temperature to volume flow, before passing the data in real time to control systems via Sercos or a multi-Ethernet interface. All interfaces are pluggable too, eliminating the need for wiring.

A key benefit of the unit, beside energy-saving and the fact it requires only 50% of the floor space of comparable conventional units, is that it only needs to be configured after all interfaces are connected, for faster and simpler commissioning. Another advantage observed by the team at Zuse Hüller Hille is the unit’s low noise levels, barely being audible over background production noise. Finally, there’s the crucial benefit of faster time to market, with a speedier process in terms of engineering, component availability and assembly through the unit’s connected technology.

Speaking about the adoption of CytroPac, Georg Lörch, Team Leader for Hardware/Fluid at Zuse Hüller Hille, said: “Bosch Rexroth told us about a new development during discussions about Industry 4.0. We had done some tests with frequency-controlled power units previously, and were excited about the performance and cost-effectiveness of this solution. Thanks to Bosch Rexroth’s support, we’ve made a huge step forward – and the same can be said for our vision of autonomous machines. Intelligence, connectivity and configurability are vital for achieving it.”

With CytroPac, Zuse Hüller Hille has implemented a future-oriented hydraulic solution in rapid time, as well as making engineering and logistics leaner and more efficient. As it sets out its next steps for condition monitoring, building on this, it’s clear that the company is taking full advantage of the connected future heralded by Industry 4.0.


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