PI 048-16 Lohr a. Main, 2016-06-20

Future-proof Automation Solutions for Connected Environments

Field-tested and future-proof: automation solutions from Rexroth prove themselves in Industry 4.0 applications in numerous plants of Bosch Group and in pilot plants like the Industry 4.0 Showcase.

Bosch Rexroth connects new and existing production lines by means of open standards

Manufacturers of assembly lines and production facilities are increasingly faced with the challenge that their customers need Industry 4.0-enabled solutions for the multi-variant production. The designers achieve that already today through decentralized intelligent automation solutions with open interfaces for horizontal and vertical networking. The components, modules and software from Rexroth cover automatic and manual stations equally and seamlessly exchange information in real-time with the company IT. Additionally, the IoT gateway economically integrates existing stations and machines into connected environments and thus protects the investments of the operators.

In Industry 4.0-enabled multi product lines, Bosch Rexroth exemplarily shows, how connected already available drives and controls are. The stations identify the work pieces via RFID, for example, and connect with their decentralized intelligence the relevant virtual image with the necessary working steps. Therefore, they exchange information among each other and other systems during the process via open interfaces to all common Ethernet protocols like integrated OPC UA servers. The software technology Open Core Engineering furthermore enables the programming of functions in a wide range of high-level languages and thus simplifies for example the integration of diverse robots. With the IoT gateway, plant manufacturers subsequently connect modules and stations, which were so far unable to communicate. The Kits capture events and operating states with their own sensors and transmit the data to superordinate systems. Thereby, users can use their existing plants also within Industry 4.0 environments and thus substantially reduce the necessary investment costs.

Especially in connected productions, humans play an important role also in the future. Digital assistance systems support him better than ever before. The system solution ActiveAssist guides the employees through the working process with individually prepared work instructions. It marks the components to be used and also their installation position on the work piece. Sensors and digital assistance systems of the ActiveAssist are modularly configurable and expandable. The communication platform ActiveCockpit captures and analyzes all relevant data of the Industry 4.0-enabled multi product lines. The evaluation and visualization in real-time provides important notes for the fault management and the continuous process improvement.

Industry 4.0 also found its way into the interconnection of individual stations. The Linear Motion System on the basis of high-dynamic and precise linear motors enables the optimization of cycle times by means of individual control of the work piece carriers. The transfer system is now part of the handling. Thus, plant manufacturers reduce unproductive idle times and increase productivity. Moreover, handling systems can be designed more easily and cost-efficiently.

The automation solutions from Rexroth are initially used in the Bosch Group plants and have to prove themselves in running production. The experience gained here will be used in continuous development and benefits all users. They use sophisticated solutions, proven in Industry 4.0 environments.

Economical, precise, safe, and energy efficient: drive and control technology from Bosch Rexroth moves machines and systems of any size. The company bundles global application experience in the market segments of Mobile Applications, Machinery Applications and Engineering, and Factory Automation to develop innovative components as well as tailored system solutions and services. Bosch Rexroth offers its customers hydraulics, electric drives and controls, gear technology, and linear motion and assembly technology all from one source. With locations in over 80 countries, more than 31.100 associates generated sales revenue of approximately 5.4 billion euros in 2015.

To learn more, please visit

The Bosch Group is a leading global supplier of technology and services. It employs roughly 375,000 associates worldwide (as of December 31, 2015). The company generated sales of 70.6 billion euros in 2015. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiaries and regional companies in some 60 countries. Including sales and service partners, Bosch’s global manufacturing and sales network covers some 150 countries. The basis for the company’s future growth is its innovative strength. Bosch employs 55,800 associates in research and development at 118 locations across the globe. The Bosch Group’s strategic objective is to deliver innovations for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.”

Additional information is available online at , ,


Search press releases


Johanna Rauch
Maria-Theresien-Straße 23
97816 Lohr am Main
Phone: +49 9352 18-1358

Related Articles


The factory of the future – how far we have come and where we are going

Imagine a factory where you could change everything apart from the floor, roof and walls within a few days or even hours? Full flexibility, individuality and scalability. This is exactly what the factory of the future is about.

Press Information

The five most expensive savings ideas for the maintenance of machinery and equipment

Machine downtime is always expensive, especially if a whole production line comes to a standstill as a result. For new machinery, the machine manufacturer is still liable, but afterwards the responsibility for maintenance lies solely with the user. Maintenance staff must constantly justify their "unproductive" costs and, hence, try to reduce them. However, some short-term saving ideas lead to nothing but higher total costs in the end. The following are the five most expensive, and unfortunately, not uncommon errors when it comes to machine maintenance.