PI 070-13 2013-07-16

Highly flexible and resource-efficient: new paint shop at Bosch Rexroth sets standards

The new facility reduces energy consumption by about 75 percent.

Painting in lot size 1, and very eco-friendly at that: in Mellansel in Sweden, Bosch Rexroth has put a trend-setting paint shop into service for European mechanical engineering. The new facility reduces energy consumption by about 75 percent. At the same time, it sets new standards for networking: RFID chips on each component that are coded by the order fulfillment system provide detailed instructions to the individual stations for the respective paint job.

As if controlled by magic, the driverless transporters (AGV – Automated Guided Vehicle) automatically move with Hägglunds heavy-duty hydraulic motors, which can weigh up to 10 tons, from station to station. Prior to each work step, a scanner reads the information for each motor from an RFID chip and then proceeds with the individually defined cleaning and coating. The paint stations are so flexible that components can be passed through in random sequence, regardless of coating system, paint type and color.

The heavy-duty motors manufactured by Rexroth in Mellansel are used for ships and off-shore applications, extraction of raw materials, heavy-lift handling, and recycling facilities. Motors that are later exposed to salt water receive a multi-layer corrosion protection with special coatings.

The new fully-automatic paint shop also sets new standards in terms of resource conservation. In the past, coating of the hydraulic motors, which was done with conventional equipment, was subcontracted to an outside supplier. Now, CO2 emissions previously generated during transport are completely avoided.

Temperature and water/color pigment ratio are closely monitored in the newly established paint shop on the plant premises, and excess heat is recovered. Energy consumption is thus reduced by 75 percent overall. Motors are cleaned based on the counterflow principle, meaning that the dirtiest water is always used for the first cleaning step, which considerably extends the life of the cleaning baths and reduces the amount of waste water.

By changing to water-based paints, Bosch Rexroth was able to reduce the use of solvents by about 80 percent. Paint robots apply the exact amount of paint without over-spraying, thereby further reducing consumption. They are so flexible that they can process a color change for each component. Since each robot is enclosed in an individual booth, the paint spray is contained in a very limited space and can easily be collected.

In its new automatic processing line, Bosch Rexroth coats 40 to 60 motors each day, depending on shift pattern. The capacity will be increased from 12,000 to 16,000 motors per year in the next expansion phase.

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, Factory Automation, and Renewable Energies to develop innovative components as well as tailored system solutions and services. Bosch Rexroth offers its customers hydraulics, electric drives and controls, pneumatics, gear technology, and linear motion and assembly technology all from one source. With locations in over 80 countries, more than 37,500 associates generated sales revenue of approximately 6.5 billion euros in 2012.

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The Bosch Group is a leading global supplier of technology and services. In fiscal year 2012, its roughly 306,000 associates generated sales of 52.5 billion euros. Since the beginning of 2013, its operations have been divided into four business sectors: Automotive Technology, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 360 subsidiaries and regional companies in some 50 countries. Including its sales and service partners, Bosch is represented in roughly 150 countries. This worldwide development, manufacturing and sales network is the foundation for further growth. Bosch spent some 4.8 billion euros for research and development in 2012, and applied for nearly 4,800 patents worldwide. The Bosch Group’s products and services are designed to improve the quality of life by providing solutions which are innovative, beneficial and inspirational. In this way, the company offers technology worldwide that is “Invented for life.”

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