At the 2016 Hannover Messe, Bosch Rexroth demonstrated the flexibility and efficiency of its networked production solutions to attendees by showcasing how processing control could be achieved through the SAP-ME manufacturing execution system on a production line consisting of five independent workstations.
How to maintain the vitality of a company's future? How to gain tangible benefits from digitalization? These are questions many business managers are currently facing, especially small businesses that remain somewhat cautious when discussing the currently popular topic of "Industry 4.0." A third-party supplier showcased a device with wireless network connectivity. According to the supplier, the unique feature of the demonstrated solution is that it can be used not only for newly developed equipment but also installed on existing equipment. Through intelligent transformation, it can also transmit the operating status and production data of previously unconnected equipment to the upper-level system.
Digital production
Industry 4.0 modular manufacturing production line
The entire production process is networked across five workstations, from hot melt adhesive application to assembly, tightening, manual installation, and testing. Process control is achieved through the Manufacturing Execution System (MES) SAP-ME. Bosch Rexroth uses an open interface to support a common MES. In addition, to leverage big data analytics for operational monitoring of the tightening process, Bosch Rexroth's IoT cloud computing is connected. A remote status monitoring system ensures high availability of the production line and provides rapid assistance when needed, while also performing long-term diagnostics on equipment status.
The advantages are as follows:
● Modular construction offers greater flexibility;
●The Bosch Rexroth linear motion system used can be expanded at any time with more workpiece conveying devices and line segments;
●End users are thus able to integrate more workstations or increase processing capacity as needed with minimal investment;
● All data is managed in real time, resulting in greater transparency.
The manufacturer states that all workpieces can be clearly identified in real time using Radio Frequency Identification (RFID) technology to determine their type and status. Workstations constantly retrieve the latest relevant work plans and bills of materials, and transmit process data back after processing, for purposes such as quality or process progress monitoring. The Activecockpit communication platform is used to communicate, filter, and display all relevant data, and also serves as an interactive communication platform between various software tools, aiming to create transparency and consistency in all relevant processing data.
Increased equipment availability
The data analysis methods described above enable the monitoring of the status of connected machines. In addition to being used for remote status monitoring, this data can also be used for quality monitoring, process improvement, and preventive maintenance, thereby improving the availability of the machines and equipment.
The Activeassist system assists workers in performing various manual installation tasks.
The Activeassist system assists workers in various manual installation tasks, with light signals indicating which components on which containers must be removed. The system identifies workers via Bluetooth tags and adjusts operating instructions based on their knowledge level and preferred language. Activeassist then checks the completeness and accuracy of the installation steps, reducing errors and workload.
Users can simulate and optimize new motion processes during production runs through so-called model-based design. During the demonstration, Bosch Rexroth also showcased a solution using software from Dassault Systems.
A virtual model is created during the initial equipment design phase, and this model is used in subsequent development stages. According to the supplier, code that can be directly executed on the control system can be generated from existing information, thereby shortening the machine's development time and accelerating the modification and adjustment of the machine when changing workpieces and types. In this way, machine manufacturers can perform virtual control while installing hardware.
For more information, please visit the Industrial Robots channel.
