, 2017-02-15

Network to prevent downtime

For its new machinery, KRAIBURG uses predictive maintenance services from Rexroth including the Online Diagnostics Network (ODiN). (photo credit: KRAIBURG GmbH &Co. KG)

Predictive maintenance makes maintenance in the rubber industry more efficient

As roll mills run in three-shift mode almost continuously, machine availability plays a hugely important role. Failures on a single machine ultimately delay the entire production process and thus cause extremely high costs. To prevent this, machines are normally maintained after a certain number of operating hours. On its new roll mill, KRAIBURG wanted to find out how to do this differently and took its first step toward the maintenance method of the future.

For some time, Hägglunds hydraulic radial piston motors from Bosch Rexroth have been driving the roll mills used to homogenize and roll out the rubber compounds. For its new machinery, KRAIBURG uses predictive maintenance services from Rexroth including the Online Diagnostics Network (ODiN). The core idea of this service package is to carry out maintenance work before a machine stands still by using a combination of sensors, cloud-based applications, and machine learning methods. In the new machinery at KRAIBURG, sensors first record detailed data about the oil tank, pumps, motors, and electric drive. The measurements taken include temperatures, oil levels, flow rates, and pressures.

The data collected is then sent to a Bosch Rexroth server, where it is analyzed using complex algorithms. The collected data, separately encrypted and handled for each customer, is transferred to the ODiN system. It is stored and processed on comprehensively secured Bosch servers in compliance with the Group's very stringent data protection guidelines.

Clever prediction

After installation of the new roll mill, ODiN initially collected data on all monitored components over a training phase lasting several months. Based on these signals, a machine learning algorithm determines a normal health condition for the roll mill. After the learning phase, ODiN uses a data-based model to continuously monitor the roll mill's health index. If a single measured value moves outside the tolerance range for a short time, this does not necessarily lead to a – possibly unjustified – warning, as wear can rarely be detected with just one single signal. However, if the health index deteriorates due to changes in the data from several sensors, the system warns of a problem – even if the individual changes are within the defined limits. In the health index reports created on a regular basis, ODiN uses machine learning to provide appropriate information and helps to create specific recommendations for action.


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.
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The Bosch Group is a leading global supplier of technology and services. It employs roughly 390,000 associates worldwide (as of December 31, 2016). According to preliminary figures, the company generated sales of 73.1 billion euros in 2016. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. As a leading IoT company, Bosch offers innovative solutions for smart homes, smart cities, connected mobility, and connected industry. It uses its expertise in sensor technology, software, and services, as well as its own IoT cloud, to offer its customers connected, cross-domain solutions from a single source. The Bosch Group’s strategic objective is to create solutions for a connected life, and to improve quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.” The Bosch Group comprises Robert Bosch GmbH and its roughly 450 subsidiaries and regional companies in some 60 countries. Including sales and service partners, Bosch’s global manufacturing, engineering, and sales network covers nearly every country in the world. The basis for the company’s future growth is its innovative strength. At 120 locations across the globe, Bosch employs 59,000 associates in research and development.
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