Bosch Rexroth is breaking new ground in the industry with welding services such as remanufacturing and optimization of welding parameters.
Bosch Rexroth is breaking new ground in the industry with welding services such as remanufacturing and optimization of welding parameters.
Resistance Welding

The Value of Welding Services

Where does service begin and where does it end? Ideally, it will accompany the entire service life of a product – and beyond. However, services in the welding technology sector have been severely underrepresented up to now and are hardly ever offered. Bosch Rexroth is breaking new ground in the industry with its welding services, which are designed for the PSI6000 and PRC7000 welding controls. They ensure that the welding control systems are fit for the challenges of the future. Two services that are currently in particular demand from customers in the automotive sector are remanufacturing and optimized welding parameters.

Bosch Rexroth's range of services for resistance spot welding extends from commissioning to second life. For example, used control units are given a new lease of life through remanufacturing. This means that users benefit from a long service life of the welding control system – with no major downtimes and with plannable costs. In addition, this principle helps to conserve resources, as products or components are not disposed of but instead reconditioned and reused.

The second life: Remanufacturing lowers costs by 50%

A product cycle in the automotive industry is generally five to seven years. After that, the production line is rebuilt or modified to produce a new model. For cost and efficiency reasons, it makes sense to use an existing line for a second or even third product cycle. With remanufacturing, Bosch Rexroth offers the possibility to continue using the welding control system by replacing wear parts, according to the principle "from old to new". Demand for this service is growing rapidly as awareness of the need to conserve resources increases.

Specifically, this service includes the preventive replacement of all electrical and electromechanical wear parts, such as power semiconductors, fans, and electrolytic capacitors. Bosch Rexroth offers various remanufacturing levels from which the responsible parties can choose. This allows them to decide how much hardware is to be replaced. An individual selection is also possible, e.g. a specific fault focus or a safety function can be replaced.

Possible use case: The welding cabinets of an automotive manufacturer are collected from all branches worldwide and prepared or overhauled for new projects. A comprehensive overhaul takes place in accordance with Bosch Rexroth's "PÜ Smart" service. This includes cleaning and – in the area of control electronics and power electronics – the replacement of wear parts. The specialists then bring the solution up to the current hardware status, and a readjustment to all original data and parameters is carried out, as well as a function test and an endurance test. A high-voltage and insulation test is also carried out, and a new nameplate is issued. Documentation and archiving conclude the process.

Bosch Rexroth provides an ex-works warranty of twelve months on these cabinets. The cost savings potential of this service compared with new parts is around 50 percent. Added to this is the sustainability and environmental benefit gained.

There are also even more extensive remanufacturing services available, for which Bosch Rexroth offers a warranty period of 24 months (with an option of up to 60 months).

Achieving good welding results from the outset with the right parameters

Another service that is currently in high demand is the definition and optimization of welding parameters. This is because it is necessary to take into account the growing demands on the quality of spot welds and the process reliability of these joints, as newer material types and combinations are constantly being developed for special requirements. The market therefore demands a wide variety of joint combinations. The requirements are increasing and it is often a challenge to find basic parameters for an initial weld.

With its many years of experience and corresponding databases, Bosch Rexroth can create lists of initial parameters. With these parameters, users are able to achieve a good welding result immediately. This can be done even before commissioning, saving time and resources during the ramp-up of the equipment. The parameter data are made available for a fixed price and thus provide planning and budget certainty.

Optimizing existing parameters in plants so that they are production-safe and of high quality is also a challenge. With an installed base of well over 100,000 welding controllers, accompanying service, and the aid of special analysis tools, Bosch Rexroth helps customers to optimize their systems quickly and professionally. This can be done remotely or on site. The stable process achieved in this way saves users rework and increased testing efforts. In addition, errors are reduced and quality is improved.

Whether ensuring a longer product life for the welding controller or optimizing the welding process, these and other welding services from Bosch Rexroth are the key to a cost-conscious and sustainable future in resistance spot welding.

Author: Gunther Armgart

Position: Head of Fieldservice Resistance Welding, Bosch Rexroth AG


Author: Dennis Bartmann

Position: Head of Service Repair Welding Systems, Bosch Rexroth AG