Drive & Control 02|2014

02 | 2014

18 Full control, with an app: Open Core Engineering makes for intuitive machine control

The Bosch Rexroth Magazine

26 Lasting the life of a forklift: Higher performance for counterbalance forklifts with hydrostatic drives

Time to market: How software makes us faster 10

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Putting the right spin on things All-electric presses and injection molding machines are ascending to ever better performance. This increases demands on the mechanics of the shafts and axles since they have to transfer higher forces, too. Rexroth is now satisfying these needs with larger planetary screw assemblies. Exhibiting diameters of up to 75 millimeters and leads of as much as 20 millimeters, these screw assemblies are true powerhouses, in the small-est of spaces. Their engineering design makes this possible. Here planets with a closely defined contact profile rotate in a nut, moving in parallel around a spindle. The new sizes offer dynamic load ratings of up to 544 kilonewtons and static load capacities of up to 1,496 kilonewtons.

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“You simply can not program trust. That is why the human

factor will continue to be so important in the future.”

Sincerely yours,

Dr. Karl Tragl, Chairman of the

Executive Board at Bosch Rexroth AG

Dear Readers,

How often do you suppose this magazine

uses terms like “fast” or “quick” or “speed”?

A quick answer to that question is calculated

by software specialized to do this*. That

brings us right around to the topic: Anyone

who wishes to assume a market lead will

have to offer better products – and they

have to be quicker than the competition in

terms of development and delivery periods.

We use innovation to meet this, which is a

central expectation held by our customers.

For example, high-level simulation software

can shorten – by as much as 75 percent –

the time between forming the idea and com-

missioning the machine or system. And

there’s also networking in manufacturing,

which quickly brings to mind the term

Connected Industry. In the future this will

enable industrial users to respond more

flexibly, independently and faster than ever

before.

Technology is fascinating – there’s no ques-

tion about it. But in spite of all our excite-

ment, we are firmly convinced that human

beings will continue to play the leading role

in the future. Especially where speed is of

the essence, good relations between the

vendor and the customer are an essential

foundation. You see, there is no way to pro-

gram “trust”, and assurance cannot be auto-

mated. Only a mature and resilient network

of people makes it possible to exchange

information and data with complete confi-

dence. This creates the necessary basis –

so that software will have something to cal-

culate and networks can find someone to

connect to. That is why we put our faith not

in technology, but in people. Our employees

help devise all the necessary changes and

push them forward ever faster. They are the

people who work to earn your trust – every

day, applying experience and expertise.

*fast 13 times, quick or quickly 20 times, speed 17 times

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06 For great heights and depths | Reliably filled| Golden

jubilee | Automatically golden | Ordering more quickly in

Europe | It couldn’t be more accurate | Powerful drive |

Two winners | Picture-perfect casting | Constant climate

control

PREsEnT

10 Time to market: How software makes us faster Shorter

product life cycles and smaller batch sizes are exerting

tremendous pressure on industry. But with innovative

software concepts, even a one-off item can be manufac-

tured quickly and profitably.

PAsT

15 At home around the world More than 100 years ago,

Rexroth products made their way into the wide, wide

world. We want to show you how the company developed

to become both a global player and local vendor.

fuTuRE

16 “Make your development process public!” He issues a

call for greater transparency and finds that businesses

could learn a great deal from interpersonal relationships.

Corporate consultant Jerry Michalski redefines “cus-

tomer centricity”.

TEcHnologY

18 Full control, with an app Operating machinery simply by

tilting a tablet PC. Does that sound like something from

the future? At Glaub Automation & Engineering that has

already become reality, thanks to Open Core Engineering.

4conTEnTs drive & control4

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29 Prints everything Regardless of whether paper, card-

board or film, the flexographic printing presses made by

Expert, an Italian manufacturer, lend appeal to packaging.

30 Rethought Using the VarioFlow chain conveyor system,

headliners for passenger cars are moved automatically

from one machining station to the next.

Know-How

32 The purity requirement They are miniscule, but they

can bring an entire system to a screeching stop: dirt

particles in hydraulic fluid. The right choice of hydraulic

system filters and proper service ease the situation.

TEcHQuiZ / cREdiTs

34 Wanted: Innovation If you read drive&control carefully,

then you’re on the road to winning a prize!

21 A powerhouse Using a system solution devised by

Rexroth, a Chinese manufacturer aims to improve the

efficiency of its wheeled loader.

22 Fuel-saver on the high seas With the Turbo Hydraulic

System from a Japanese shipbuilder, fuel consumption

in maritime travel can be reduced all around the world.

24 Routing at guaranteed prices Quick, precise, and

economical, too. The new gantry-style milling machines

by KOMO make that possible. A well thought out CNC

solution helps.

26 Lasting the life of a forklift Hydrostatic drives improve

not only the efficiency but also the driving and working

properties of counterbalance forklifts. Daniel Rösch, of

the product management at Jungheinrich Moosburg

GmbH, reports on advantages and new developments.

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The Shanghai Tower, with 580 meters architectural height and

overall height of 632 meters, is China’s tallest skyscraper and is

slated to be open to the public in 2015. During the building of the

tower SANY, a Chinese manufacturer of construction machinery,

put forward impressive figures, both below grade and at dizzying

heights. When building the structure, it pumped concrete upwards

to a maximum of 580 meters. Poured for the foundation plate were

an inconceivable 60,000 cubic meters of concrete. At the heart of

the SANY concrete pump are drive and boom pumps made by

Rexroth. Both are distinguished by constant output and pressure

relief units. SANY was, in fact, able to cast the tower’s foundation

plate – 121 meters in diameter and six meters deep – within sixty

hours. In addition to providing these pumps, Bosch Rexroth also

supported the project by commissioning the pumps onsite and

with ongoing technical service.

www.boschrexroth.com/concrete-pumps

For great heights and depths

� On solid footing – the Shanghai Tower.

Reliably filled

� The bagging station fills as many as 900 sacks per hour.

Packing bags of flour by hand is a thing of the past. This assignment is handled today

by the Maia MWPG bagging station, built by Bühler, a Swiss company specializing in

plant and equipment. Each hour, a single machine can fill powdered products, such as

flour, into as many as 900 paper or plastic bags with volumes of from 20 to 65 liters.

Servomotors built by Rexroth deliver reliable operating power at minimum energy

consumption. These motors were engineered especially for low-dust filling and sealing.

“We wanted to develop the most reliable bagging station ever seen,” says Andreas

Kleiner, project manager at Bühler. “Bosch Rexroth supported us throughout this

project. What we especially appreciate about their contributions are their knowledge,

commitment to the work, and willingness to seek the best possible solution – and

then to implement it quickly and efficiently.

www.boschrexroth.com

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Golden jubileeThis is a double anniversary for Bosch Rexroth in Brazil.

Firstly, the regional subsidiary, headquartered at Atibaia,

about 60 kilometers north of São Paulo, is celebrating its

fiftieth anniversary. Corks will be popping at the plant in

Pomerode, as well, since production commenced there

25 years ago. The manufacturing operations in Pomerode

concentrate on hydraulic products for industrial and

mobile applications. Both anniversaries bear witness to a

gratifying success story in Brazil.

www.boschrexroth.com.br

Ordering more quickly in EuropeAfter its successful launch in the USA, the “GoTo” program is

now also available in many parts of Europe. European custom-

ers will now be able to respond more quickly to unanticipated

demands in production, short-term needs from the prototyp-

ing department, or other requests for small volumes. GoTo

reduces inventories and tied-up capital. Here, customers can

rely on unabated availability of the most common Rexroth

products and will receive preferred service, too. About 2,500

items are available at all times for order from Bosch Rexroth

and its distribution points – by e-mail, fax, post or e-com-

merce portals. The product portfolio, uniform for all of

Europe, includes products from every Rexroth technology –

from industrial and mobile hydraulics to electric drive and

control technologies, and even on to linear motion and

assembly technology.

www.boschrexroth.com/goto

� GoTo lets customers access some 2,500 Rexroth items, in short order.

Automatically goldenAt the AUTOMATICON 2014 in Warsaw Bosch Rexroth won

the Gold Medal. Since 1997, the medal has been granted

as an award for innovative products and presented at this

international fair for industrial automation. This year the

software concept Open Core Engineering prevailed over

five other participants. With the interface technology,

engineers are able to directly access the control core in a

number of different programming languages. Open Core

Engineering is bridging the gap between machine software

and the IT world.

www.boschrexroth.com/oce

� Accepting the gold medal were Magdalena Chmielewska, marketing manager at Bosch Rexroth in Poland, and her sales colleague Pawel Orzech.

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The Bosch Rexroth subsidiary in the U.S. has good reason to be

happy about two honors received this year. At the end of Febru-

ary, Bosch Rexroth Corporation in Bethlehem, Pennsylvania,

was ranked third among large companies in the Lehigh

Valley’s Top Workplace Survey. The honor is awarded each

year by the largest local daily newspaper.

At the beginning of March, the headquarters office in

Charlotte, North Carolina, was recognized for the best

innovation by receiving the Advanced Manufacturing

Award. In its plant for linear motion and assembly tech-

nology, a materials management system lets employees

make use of remnants, reducing the scrap rate from 18

to seven percent.

www.boschrexroth-us.com

Two winners

� Commercial plant manager Andreas Torell and Technical plant manager Manfred Hahn are mighty pleased about the Top Workplace Award.

Powerful driveShorter cycle times, more reliable temperature regulation, lower

noise levels, and improved machine safety. These characteristics

make Hägglunds CBP motors by Rexroth especially appealing to

the rubber and tire industry. When used in direct drives, they can

transfer up to three megawatts of power with superb efficiency.

They can be flanged to the machine or a torque arm is used to

capture the resulting torque. The rotation speed, torque and power

can be matched as needed to fit the product’s requirements. This

helps to optimize the production process and, as a consequence,

to lower energy consumption. To improve operating safety even

further, the motors can also be equipped with quick-stop valves.

www.boschrexroth.com/rubber

� CBP motors are frequently used in the rubber industry.

It couldn’t be more accurateEven though cooling lubricant and filings are splashed

around the workplace, the IMS-I Integrated Measuring

System carries out its tasks extremely precisely. The

advanced incremental measuring system for ball- and

roller rail systems, with repeat positioning accuracy of

0.25 micrometers, offers almost the same performance

as glass scales. The system is suitable for a wealth of

applications, including positioning tasks in laser cutters

or in high-speed removal of PET bottles.

www.boschrexroth.com/ims-i

� Resistant to grime and interference. The IMS-I.

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Picture-perfect castingWhen making up cores for castings, the Bosch Rexroth foundry at

Lohr am Main, Germany, has adopted the innovative 3D printing

process. This lets the company overcome the technological limitations

of the traditional core shooting process, where sand is forced into

a mold at high pressure. Both for prototypes and for short production

runs, two 3D printers make it possible to fabricate molds and cores

without tooling. Since printing is possible in every direction, even

complex geometries and molds can be achieved. This shortens

development periods and lowers costs. Consequently, short runs and

spare parts can be produced at greater efficiency and, in turn, at

optimized costs. This is a way for Bosch Rexroth to respond to cus-

tomer demands both quickly and flexibly. One important factor is the

steadily increasing number of variations in product while the number

of items produced for each variation is declining. Being used here are

a furan resin machine and a phenolic resin printer. The latter is a new

process in which the foundry, together with the supplier of the printer,

is doing pioneering work in the field of 3D printing.

www.boschrexroth.com

� The 3D printing process makes it possible to produce complex geometries in casting cores.

� Perfect climate control in rooms at the Emirates Grand Hotel.

Constant climate controlThe climate control system at the Emirates Grand Hotel in Dubai

failed to produce uniform output. The hotel’s upper floors were

warmer than the lower floors. The cause: The chilled water was

simply too warm. To make things worse, the pumps ran constantly

at full speed. This was a situation that the hotel wanted to eliminate

because the guest rooms were not at the desired temperatures and

power consumption was too high.

Seeking to achieve reliable control over the system, the cooling

contractors at Getco turned to Bosch Rexroth to identify the right

solution. A variable-speed pump drive now generates exactly the

pressure needed in the system. This holds the water at the desired

temperature and keeps electricity costs low. “We decided on the

variable-speed pump drive by Rexroth since it is the most depend-

able on the market,” emphasizes Dr. Taoufik A. Hadi, technical

manager at Getco.

www.boschrexroth.com/sytronix

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Engineering, simulation and networking are powerful answers to the demand for shorter product life cycles and smaller batch sizes.

Time to market: How software makes us faster

Shorter product life cycles and smaller batch sizes are exerting tremendous pressure on development and delivery periods. One example from the motor vehicles in-dustry illustrates the changes in re-quirements. Through to the 1990s, permanently linked transfer lines let manufacturers produce large numbers of a single engine type in a short period of time. This was the ideal production concept. Ever larger numbers of models and shorter product life cycles, however, called for greater flexibility. Today, many different engine models are pro-duced on a single line. Highly flexible ma-chining centers work together, within a pro-duction cell, on any given item. But this evolutionary increase in flexibility for machine technology and manufactur-ing organization has largely played out. Innovative software concepts have now come to the fore, making it possible to pro-duce single items both quickly and profitably.

no prototype, but no stressSimulation tools come into the picture right at

the beginning of a product’s life cycle. They shorten development times drastically

and make it possible, right from the 3D design phase, to influence a product’s properties. System simulation can also be used to observe a machine’s dynamic behavior, in all its facets, since tangible machine tasks and

drive processes are translated into mathematical contexts which can then

be calculated. This significantly re-duces long trial periods on test beds; po-

tential faults are detected early on and can be eliminated at reasonable expense. This is a

highly relevant magnitude if one considers that the expenditures to eliminate faults – from initial product

conception to market readiness – rises by a factor of ten with each successive phase.Shortened test phases are, however, only one lever with which time and costs can be saved. Right at the very start of develop-

Seven software solutions to make everyday life more efficient.

Faster to market, more reliable in operation

With the help of the Simster simulation software, Rexroth

has already engineered drives for presses, self-sufficient

compact axes, and underwater turbines. Filed in the

model library are all the specifications for all the hydraulic

and electrical drives made by Rexroth. That means that

this tool will supply – quickly and reliably and with just a

few clicks – all the relevant physical factors such as posi-

tion, power and volumetric flow rate.

A few clicks away from engineering success

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ment work, simulation helps verify the general feasibility of the product without having to make up time-consuming and expen-sive prototypes. When designing components, using these tools avoids over-dimensioning and leads to the solution most effi-cient in terms of materials and energy use. During commission-ing, the software simulates the employment of the completed machine or components on site and makes possible fine-tuning without interfering with the flow of operations.That is what makes simulation an efficient tool for cost reduction, quality assurance, and shorter times to market. Examples have shown that simulation tools can shorten development times from two years to as little as six months – a reduction of 75 percent.

Expertise and automationTo be able to achieve these successes at all, it is necessary to define clearly, right at the outset, what is actually to be devel-oped. Without the expertise of the sales department – with its experience, contacts with the customers, and familiarity with the market – even the best technology will be of no avail. Fur-ther improvements will be made largely through more inten-sive cooperation with the development partners. This is also true for the next step in this field – something like automating sales. This option is speculated upon by Prof. Alexander Verl, Executive Vice President for Technology Marketing and Busi-ness Models at the Fraunhofer Society, in an interview starting on page 12.

software creates valueIn the manufacturing process, efficiency can be boosted by con-sistently networking factory automation with the IT environ-ment – the key word here is Connected Industry. This linkage of worlds – which had previously been separate – makes it possible for industrial users to combine the widest variety of machines one with another and, together with the company’s IT resources,

to make it an autonomous system. If demands change, then the system will carry out coordination work and adapt to the new situation. The factory’s own production processes are more flexible, faster and thus more economical. If the customer’s ma-chines are also integrated into the network – using the cloud, for example – then delivery periods can also be reduced. Fault de-tection alarms reach the service department immediately and production orders for the required spare parts can be for-warded directly to production.In each individual case it is necessary to determine whether the effort required for additional interfaces, cloud capacity and the intelligence installed in the system will actually pay off. If users consider this idea in lean automation, then networked, modular production solutions will greatly change the operating environ-ment. Even more so than at present, software will be the deter-minant factor in value creation, efficiency, and innovation for machinery concepts. This will turn the factory into a value cre-ation network.

speaking all the programming languagesAs great as the advantages of networking might be, the com-munications hurdles standing in the way of its implementation are even higher. The world of factory automation speaks the PLC dialect while the IT universe communicates in so-called high-level languages like C++, Java or PHP. For a long time, di-rect networking was possible only by way of workarounds. To-day, operators and machinery engineers should be able to pro-gram in the language they know best. “Anyone who offers open core control has many advantages, of course, since this addresses the next generation of programmers,” emphasizes Professor Verl. “In this way, one reaches more programmers, can write more elegant programs, and use more powerful tools very effectively. All this has a positive effect on the time to market.”

Cerutti, the Italian manufacturer of rotogravure presses, has already

utilized Rexroth simulation models to design its “Aurora” series. This

avoided over-dimensioning during the engineering process. In combi-

nation with an entirely shaft-free automation solution, Cerutti was

able to reduce its time to market by a third. Delivery was made after

twelve instead of 18 months.

12 instead of 18 months A few clicks away from engineering success

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Prof. Alexander Verl on the significance of automation, expertise and working ethics when accelerating the production process in mechanical engineering.

“People won’t be relinquishing control”

One machine manufacturer, Kraus Automatisierungstechnik GmbH, special-

izes in custom solutions for manufacturing and testing assignments. With the

Open Core Interface, the company can now program twice as many machines

with the same staff. This interface concept combines the worlds of automation

and information technology, since the Open Core Interface supports a number

of programming languages for the controls. This is how it reduces the engi-

neering effort and shortens delivery times.

How the company of Glaub Automation & Engineering GmbH uses the Open

Core Interface to control machines by way of an app – that’s the story told on

page 18.

interpreter for the controls

When construction machinery is being developed, an

analytical simulation of the system, followed by a

virtual test drive based on a model, makes it possible

to optimize the intended functions and the efficiency

well before the engine is ever revved up. Simulating the

machine’s complex motions, sometimes superimposed

and affecting each other, costs and the time to market

can both be reduced.

simulation for heavy-duty work

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what does the market expect of mechanical engineering in regard to times to market?The long-term objective in manufacturing is personalized mass production. Dealing with complexity is a major topic here. Procedures, machines, user interfaces are becoming ever more demanding but, in fact, it should be possible to operate the machine with only two to three com-mands. In terms of control technology, we should be driven by the pursuit of more elegant solutions. The essence of me-chanical engineering is to implement the customer’s specifications in a way that is as precise, user-friendly and economical as possible.That is why it all boils down to achieving a degree of automation that is so high that the customer can configure the product he desires, without the help of an expert, inte-grate that item directly into the production pro-cess and, while doing so, have complete control of the technology and the costs. Some carmakers are already preparing apps with which customers can configure their own dream vehicle. Finally, the app cites a price and the customer can take all this to the dealer. This is also to be possi-ble for machinery in the future. Mechani-

cal engineering companies will have to respond to this wish, expressed by the customers. To do so, they have to make configurators available and modularize their products. If, in addition to individ-ual configuration capabilities, the system provides information on how the prod-uct can be automatically manufactured, then this accelerates the entire product creation process.

How can simulation and networking help to shorten this period?Manufacturers of automation equipment have long had networking and self-orga-nizing abilities. The task now requiring great diligence is to make use of these networks. The final stage of “Industry 4.0” will not mean that every device

speaks with every other device and that hierarchies in auto-

mation will have disap -peared. Those who find the right balance between self-configuration, net-working, and providing

production data will enjoy considerable advantages.

Simulation technology will help in the entire process. In the

ideal case, salespeople will use simula-tion when talking with the customer to clarify whether they have actually grasped the customer’s ideas. In addition,

the best components – those already available – can be selected, saving devel-opment engineers unnecessary effort. The developer, in turn, can use simula-tion to ensure that manufacturing specifi-cations comply with the customer’s re-quests. If the simulation is accurate enough, then it will behave exactly like the ultimate machine. If the controls are trouble-free in the simulation, they will be equally trouble-free in the real-world machine. In the meantime, many ma-chines have become so complex that they can no longer be put into operation prof-itably without simulation. Using simula-tions can also be continued through to machine commissioning and, in fact, during later maintenance operations. If an exact model of the customer’s applica-tion is at hand, then the service depart-ment, working from a remote location, can analyze very exactly any problems that might arise or the customer’s wishes for changes.

what part will the human dimension play here, one example being the co-operation between the customer and the vendor?During the process of acceleration, a great deal will depend upon the extent to which the customer gives us access to data. Today, software can make machines almost fail-proof. The software would,

Time was short. It was necessary to get the new RS15 control valve,

intended for smaller construction machines, to the market as quickly

as possible. To do so, Bosch Rexroth set up a network for an interna-

tional project team drawn from its sites in France, China and Ger-

many. Thanks to the use of several simulation tools, the team was

able to dispense with a sampling phase and a prototype. This made

overall development a full six months faster. At the same time the

valve, thanks to software-supported design, was so efficient in

operation that machines equipped with this valve use about 20

percent less fuel.

development under pressure

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Condition monitoring concepts reduce long-term operating costs in

wind turbines and make them more profitable. For the first time in

history ACoS, the Advanced Condition Monitoring System devised

by Rexroth, links together in a network the condition monitoring

sensors for all the components in the drive train and combines the

measured data they supply. In addition, ACoS is the first system ever

to incorporate detection of damage to the rotor blades – a feature

certified by German Lloyd. The system also recognizes ice formation

and enables autonomous restarting once the sensors signal that the

blades are free of ice.

An eye on power costs

however, also record very precisely how the human actually uses the machine. This is, of course, a touchy point. During discussions with the customer, expertise plays an important role. This is true above all when the ideal situation in simulation has actually been achieved and where sales work can be “automated”. An interesting study in this respect has been published by the International Fed-eration of Robotics*. It shows that in countries where robotics has been used to achieve a particularly high degree of automation, unemployment is especially low. This is because when a nation has al-ready achieved a high degree of automa-tion, wage costs play an ever less impor-tant role. Manufacturers who in the past had put more faith in low wages cannot simply jump on the band wagon, because the investment levels are too high. Armed with this knowledge, sales can be opti-mized by digital means, using appropri-ate software tools, so that other manufac-turers would first have to invest heavily to catch up.

How do you see the course of develop-ment in this field? where will we be in five years?There will be a convergence at the inter-national level, but in Asia the topics of networking and “batch size 1” will not be of much interest in the coming five years.

This is because employee fluctuation in Asia is far too high. Expertise drains away continuously and new employees have to be taught. The problem is that govern-ment-planned growth in high-tech fields doesn’t work all that well. You can see an example of that in Germany, where the planned “transition to green energy” is not evolving as originally envisioned. As regards mechanical engineering, we will continue to enjoy a lead in Europe al-though China might have already over-taken us in other industries.

Are there new technologies that will be revolutionizing the topic in the future?One can quite sensibly use augmented re-ality for this purpose. At our institute, we make videos of people as they do their

work and use those videos to create ava-tars, which do the same work in a virtual environment. In this way we can deter-mine physical burdens very exactly and optimize working procedures. Powered exoskeletons will also be a subject for the future. This might be the case at a smaller scale, by helping a nurse to move prop-erly when lifting and shifting patients. But cognition – or artificial intelligence – will also appear on the scene at some fu-ture moment. At present, however, it is impossible to foresee whether we humans will be willing to relinquish control.

* “Positive Impact of Industrial Robots on Employment”, International Federation of Robotics, London 2011

In its own product development, too, Bosch Rexroth draws on

the benefits of software-supported processes. When devel-

oping the innovative SILENCE PLUS external gear pump,

simulation models helped engineers to efficiently combine

and implement the many differing ways to

approach a problem. The advantage for the

customer: an extremely reliable component

and one that cuts resource use, as well.

combining approaches

Prof. Alexander Verl, dr. Eng. dr. h. c. mult.

has been Executive Vice President for Technology

Marketing and Business Models at the Fraunhofer

Society since April 2014. He previously headed up

the Fraunhofer Institute for Manufacturing Engineer-

ing and Automation and occupied a chair of control

technology for machine tools and manufacturing

equipment at the University of Stuttgart, Germany.

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Customer relations in the B2B sector, according to Jerry Michalski, are based on an outdated concept of the secretive business environment. This independent corporate consultant instead places faith in the positive effects of transparency when dealing with customers, in order to further the innovation process.

“Make your development process public!”

nowadays everybody is talking about “customer proximity”. But what’s the meaning of this term from your point of view?It’s funny. In the U.S. since the early days of the Internet there was the idea of being customer centric. Unfortunately most companies mean by that, that the customer is in the crosshairs of a gunsight. The customer is a target of their marketing ma-chine to spend more. Customer relationship management is re-ally about managing information for the benefit of the vendor not the customer so much.If you think about it, the language of marketing and advertising is one of a military campaign: You launch a campaign, send flights of messages against target demographics. You try to

reach market penetration. This is how we were raised to do marketing and advertising – but it’s not how to build a relation-ship. If you want to be trusted, you have to come up in a com-pletely different way. Partly what’s happening is the re-leveling of power relations. Which means that the things that work be-tween humans on a friendly basis are the kind of things that have to be mastered by companies and governments.

what are the characteristics of a successful customer relationship?We could talk about what makes good service, which is interest-ing and people are getting better and better at that. But if I don’t

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Jerry michalski is an independent corporate consultant. Among his

many interests, he analyzes the effects of increasing

digital networking on relationships between vendors

and customers.

www.theREXpedition.com

feel safe in a relationship I might not buy from you at all. In these days vendor brand loyalty is still strong for some things but diminishing for a lot of other things: Safety has a lot to do with privacy and respecting people.In B2B the really interesting thing is about design: How do you really start to mingle your insights, your feedback, your design between different participants in a product web or service web? How can you innovate within these boundaries? How can you learn enough about what everyone is doing and trust each other enough to create breakthrough products?

does new media play an important role even in B2B rela-tionships?Definitely, because everybody’s talking! The wall around com-panies used to be impenetrable and whatever happened inside companies was successfully kept inside. Now that everybody is using a smartphone, Facebook or LinkedIn a lot of what they do and say is visible outside. So like it or not, people are using new media and that makes it easier to put useful things in front of other people.You simply have to go back to the basics of how people build trust in a relationship with other people and connect that thought with what is useful for the person you are trying to build a relationship with. And that naturally leads to inventing things or doing things with or for them.

what has changed? does the client of today have more in-dividual or different needs than some decades ago? How can companies achieve enough flexibility to fulfill these needs?It depends how far they have gone into the new way of doing business. If companies are stepping into what is happening, the refresh cycle of new product development and how products are developed is shifting dramatically. The sources of innova-tion and of your ideas on how to offer them are changing. And the ability to filter these things to bring them in is crucial! So there are many different ways of how to talk to prospective buy-ers, to design the thing you’re offering them, of how much trans-parency you offer into your own process, of whether or not you are using open source tools or making your plans open – which then would affect your business model in some ways. These things are cascading around the industry right now.

How do successful customer relationship and innovative ability correlate?That’s one of the big areas where relationship can be built: For example hackathons, open spaces and other sorts of events and meetings where people from different companies come to-gether. That’s how innovation is happening these days a lot. In the old school innovation was something the research depart-ment did. The new way is to prototype in public. Everybody is using beta software because that’s the perfect way to perfect your product. If you’re selling somebody an automotive trans-mission you probably don’t want the beta but if you’re innovat-ing in transmissions you may well want to innovate in public and use inventions that other people are creating. Innovation is happening worldwide in lots of different scales and ways.

Read the complete interview with Jerry michalski at

www.boschrexroth.com/trends-and-topics

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Using gestures and motions to operate mobile devices has long been standard in personal life. Glaub Automation & Engineering GmbH is one of the first companies to implement this kind of control in manufacturing, with the assistance of Bosch Rexroth.

Full control, with an app

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Fleischer explains. When developing the app, Glaub placed great emphasis on a simple and intuitive user interface. A toolbar at the edge of the screen lets users access the main menus most fre-quently used. These include manual operation, automatic opera-tion, starting page, moving to the home position, and adjust-ments. Various submenus can be selected from each main menu. In manual operation, for instance, users can select from a num-ber of different modes in order to move the axes to a defined po-sition. In addition to machine movements controlled by the ac-celerometers integrated into the smart device, the user can also control the system of axes with gestures executed on the touch screen. There is also a diagnosis button in the header for the app. The operator can use this button to obtain information on the states of the axes and the controls; he can have individual para-meters for the drives shown or he can read out the logfile.

“Implementing these functions was amazingly simple,” explains Niko Glaub. “After configuring and programming the PLC with the IndraWorks engineering tool, we only had to integrate the header and library files provided by Bosch Rexroth.” Thus developers, af-ter just a few hours of work, were able to start programming the functions in the high-level languages Objective-C or Java.

intuitive operationSince users are already familiar with dealing with smart devices in their personal lives, they have instant rapport with the new control concepts using apps. Niko Glaub is convinced of this.

“We are now in a position to realize very simple machine control concepts. That will save training costs for the machine’s owner. In addition, we can largely do away with language-based compo-nents in operator prompts and that is interesting for the indus-trial environment in a worldwide production network.”

In a building used by Glaub Automation & Engineering GmbH in the German town of Salzgitter, Matthias Fleischer is standing in front of a three-axis system with a gripper arm. The software developer has a tablet PC in his hand and its display shows a schematic depiction of the axes. Fleischer places his thumbs on two marked spots and tilts the tablet PC. As if by magic, the sys-tem of axes and the gripper arm move. The more the mobile de-vice is tilted, the faster the movement. As soon as he removes either of his thumbs, the system stops. The extremely simple control of this training and demonstration unit is made possi-ble by Rexroth’s Open Core Engineering together with the Open Core Interface.

Apps for ios and AndroidTo control this triaxial system, Glaub uses a control and diag-nostics app for iOS and Android in order to obtain initial expe-rience and get to know more about how the technology func-tions. CEO Niko Glaub is enthusiastic about the options. “With its Open Core Engineering concept, Bosch Rexroth is setting something significant in motion. It is assuming a leadership role when merging the world of manufacturing with the IT in-frastructure used in offices. It is unleashing all the advantages we know today in the control of mobile devices.”

simple programmingDirect access to the control functions and to the variables in the PLC is implemented by Glaub with the help of three high-level languages: C++, Objective-C and Java. “Now I can shift complex logic away from the PLC. This is a great help, since some pro-gramming in high-level languages is far simpler than using the ladder diagram, instruction list or structured text,” Matthias

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As a system integrator for Bosch Rexroth, Glaub has already implemented a suc-cessful Open Core Engineering applica-tion for a customer. The company de-veloped a Windows application for a manufacturer of roller and axle dynamometers for vehicles. Here Rexroth supplied the control and drive technology while Glaub developed the user interface, based on the C++ language. It ac-cesses the controls directly via the Open Core Interface. Thus the technician can generate even complex motion patterns and then transfer them to individual axes or wheels. During testing the torque, rotation speed, power and speed can be varied and visual-ized for up to three axles, with two wheels each. In concrete terms, up to six servo axles can be controlled separately. Thanks to the Open Core Interface, it will even be possible to implement this user interface as an app on a smart device, without having to mod-ify the current program sequence for the PLC.

An exciting futureBased on his initial experiences, Niko Glaub looks positively into the future. “I see major opportunities in manufacturing automa-tion using Open Core Engineering. It lets us create user interfaces

for machines that don’t scare operators away, but instead are fun to use. This means greater employee motivation. Seen against the background provided by Open Core Engineering, we are looking forward to an exciting future. The topic of Connected Industry came at just the right time, since it offers us a huge playing field and lots of potential that we’re looking forward to using.”

contact: Michael Haun, Bosch Rexroth AG, Germany,

Phone: +49 9352 18-4538, [email protected]

A bridge between automation and the iT world

Open Core Engineering links PLCs and IT in a range of solutions comprising

open standards, software tools, functional tool kits, and the Open Core

Interface. At the same time, Bosch Rexroth has opened the control core for

expanded access. Machinery manufacturers can now use a variety of high-

level languages and operating systems to write specific functions and employ

them without making any changes in the PLC’s routine. In addition, machine

manufacturers can, for instance, also fully integrate smart devices into the

automation environment and make use of their control functions. In 2013 the

virtues of Open Core Engineering were recognized with the presentation of

the renowned Hermes Award by the HANNOVER MESSE.

“with open core Engineering we create user interfaces that are fun to use.”

t Niko Glaub (right) and Matthias Fleischer use Open Core Engineering to operate a system used for training purposes.


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A powerhouse

In ports, mines and rail transshipment yards, wheeled loaders are indispensable when offloading and backloading cargo. De-mand is growing not only in China’s rapidly expanding markets, but around the world, as well. Shandong Lingong Construction Machinery Co. Ltd. is the leading manufacturer of construction machinery in China and the company has made a name for itself in foreign markets, too.

Advancing to a higher levelWith the new LG989 wheeled loader, boasting 235 kilowatts of en-gine power and a payload of eight tons, this building machine spe-cialist now intends to move into the world’s high-end segment.This 30-ton Chinese machine is equipped with a comprehen-sive system built by Rexroth. “The demand in the Chinese mar-ket is more for medium-capacity wheeled loaders with less ex-otic technology,” explains Feng Chi, manager of the technical center at Shandong Lingong. In machines that can move more than six tons, expectations are higher. When developing the new wheeled loader, the company focused on efficiency and convenience, among other things. Shandong Lingong decided to adopt a system solution developed by Rexroth. This means that the working hydraulics, cooling system and brakes all come from a single source.

intelligence at the heartAt the core of the drive for the working hydraulics is an M6-22 control block, operating in conjunction with two A10VO110 variable displacement pumps, all made by Rexroth. The compo-nents utilize flow-sharing control (LUDV). While a constant dis-placement pump in this type of wheeled loader always moves about 400 liters per minute of fluid through the hydraulic sys-

tem, the adjustable pumps deliver only as much fluid as the sys-tem needs to maintain a certain operating pressure. This elimi-nates the need to return excess fluid to the reservoir and that saves energy. Particularly when working at partial load, the savings potentials for the LG989 are high. In normal operation, this averages out to four liters of diesel fuel per hour. And that means about 10,000 euros per year. The fan system for the wheeled loader also matches needs ex-actly. The engine, thanks to the variable-speed pump, delivers just the amount of power that is really needed. An electronic BODAS controller, also made by Rexroth, regulates the fluid, coolant and air temperatures. To enhance convenience, the LT17 dual-circuit power brake valve was selected. This hydrau-lic brake valve is compact in design and the brake pedal is al-ready mounted. This valve is highly responsive, making for precise control. The Rexroth RSM stabilization module reduces pitching in the wheeled loader and in this way increases the machine’s productivity and convenience even further.By including the LG989, Shandong Lingong has added to its line a piece of equipment that is absolutely up to date in technical terms. It is easy to operate, flexible in use, and reliable. Two other factors are especially important to international clientele

– energy savings and high performance.

contact: Can Lin, Shanghai Bosch Rexroth Hydraulics & Automation Ltd., PR China,


The wheeled loader built by a Chinese manufacturer – thanks to a system engi-neered by Rexroth – is about to become highly efficient.

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Fuel-saver on the high seasWith the Turbo Hydraulic System from Japanese shipbuilding company MES, freighters can recover the energy in their exhaust gases. In this way, fuel consumption in global shipping can be reduced.

p With the Turbo Hydraulic System, a cargo ship can reduce daily consumption by several tons of diesel fuel.


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Seaways are the major arteries of international trade. Thou-sands of cargo vessels cruise across the seven seas and are re-sponsible for around 90 percent of global commodity exchange. With such an immense volume of traffic, the potential for a re-duction in worldwide fuel consumption and thus emissions of greenhouse gases is correspondingly great. Especially progres-sive propulsion systems can make an enormous difference here. Every percent of increased efficiency prevents tons of fuel con-sumption and carbon dioxide emissions. Sufficient grounds for the Japanese government to institute a promotional program for developments in this field in 2007. Shipbuilding giant Mitsui Engineering and Shipbuilding (MES) took up the challenge. In the future, the Turbo Hydraulic System is to make an effective reduction in the fuel consumption of large-scale engines by re-covering the energy from the exhaust gases.

The quarter wastedWhen you realize that around 50 percent of every liter of fuel combusted is dissipated as losses, you rapidly recognize the po-tential of the exhaust gases. At 25 percent, they account for the greatest part of this waste heat. Up to now, it has not been pos-sible to use that reservoir of energy satisfactorily. There have been thermal waste heat recovery systems on the market for quite some time, but these solutions have been very expensive up to now and take up a lot of space in the engine room. Retrofit-ting, above all, is therefore often a complicated process.Consequently, the MES team took a totally new route with a purely hydraulic solution. No simple task. This approach only became possible in the first place with the improvements in turbocharger efficiency in recent years. Nowadays, turbo-chargers can remove energy that is not needed to charge the engine from the flow of exhaust gas. The development work, ambitious in any case, had to cope with the extreme operating conditions, not to mention the cost targets. In order to be really interesting to shipowners, the Turbo Hydraulic System had to be capable of paying for itself

in a reasonable period of time. Expensive special develop-ments of individual components were therefore to be avoided.

The project gathers speedDuring intensive meetings between engineers from MES and Bosch Rexroth in Japan, a further pleasing development gradu-ally emerged: The complete hydraulic system could be con-structed using standard Rexroth components. The key compo-nent of the Turbo Hydraulic System is a Hägglunds radial piston motor from Rexroth, which is directly coupled to the crankshaft of the large engine. Hydraulic axial piston pumps are connected to this turbocharger via a gearbox. By means of this connection, the pumps withdraw energy from the flow of exhaust gas and transform it into hydraulically usable energy which the hydrau-lic motor then feeds back into the engine.At full engine load, the system saves up to four percent of fuel – several tons per day at sea. Furthermore, the Turbo Hydraulic System fulfills all the demands of the developer team. The di-mensions are compact and the complete system can be easily retrofitted to large engines which have already been installed. As the investment costs are relatively low, the Turbo Hydraulic System is the optimum solution for small and medium-sized en-gines. Its suitability for use in practice was proven in extensive tests in 2012. These arguments have already convinced the first customers, and the first cargo ships equipped with this system are planned to set sail in 2014.

contact: Yoshikazu Homma, Bosch Rexroth Corporation, Japan,


t The Turbo Hydraulic System makes use of the waste heat in the exhaust of a marine diesel – using standard hydraulic components.


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Routing at guaranteed prices

The new series of gantry-style routers, the Mach One GT MTX by KOMO Machine Inc. in Lakewood, New Jersey, is precise when working solid wood panels, plastics, and even light sheet metals. No matter whether you are working a solid wood door or the fin-est of ornamentation, the result is always the same: precisely ma-chined surfaces, at or above the industry production standard.

“We’re known for offering high-end, fast, responsive machines that deliver profitable performance,” says Jeff Erickson, execu-tive vice-president at KOMO. “Our goal with the Mach One GT MTX is to maintain that quality and performance, but with a ma-chine that is more affordable for a broader range of shops.”

on the moveTo keep this promise for the new line, the developers at KOMO concentrated on a particular component: the CNC unit that con-trols the machine’s X, Y, Z, spindle and tool changer axes. The machine price is actually dependent on this element. However, simply choosing the most cost-favorable variation on the mar-ket does not fit with the KOMO philosophy. The company de-mands maximum precision in the machines. Mike Kolibas, KOMO president, knows who to turn to when searching for the appropriate solution. “We were familiar with Rexroth from our work with them. We also know they have an excellent reputation

The new gantry-style milling machines made by KOMO operate more quickly and pre-cisely than their predecessors, while passing additional cost savings on to their users. This is made possible by a CNC concept incorporating IndraMotion MTX micro.


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in the controls marketplace, and that gave us confidence,” he adds. “We had opportunities to work with smaller controls sup-pliers, but we chose Bosch Rexroth because we knew they would be there for the long haul.”

A well-rounded packageThe folks at Bosch Rexroth came up with the right solution al-most at once. A CNC concept, the IndraMotion MTX micro, eas-ily satisfies all requirements. The controls are compact, easy to operate and still extremely high in performance. A single prod-uct demonstration was enough to convince the experts at KOMO. The complete package, including the Rexroth servo mo-tors, was especially attractive. These motors respond perfectly to the control signals for the axes and also fit in the current ba-sic layout of the Mach One series.

commissioning made easy“The package is well-integrated, which allows us to shave time off our assembly of the machine,” says Steve Ostermann, engi-neering manager at KOMO. He uses an example to demonstrate how much simpler this system is when compared with the pre-decessor. In the past, each individual axis had to be driven with a separate interface and that meant additional effort. The new CNC concept features an I/O interface so powerful that it can handle all the signals at once. The work required for program-ming is also lessened since there is no separate human-machine interface (HMI) to be modified to match the system. Instead, the HMI is already fully integrated.

Perfect for the next stageDuring a training session, the KOMO team discovered the ad-vantages deriving from a user interface optimized in this way. The PC-based training, using the MTX micro Trainer, let them program all the woodworking functions and test them by simu-lation even before the actual production runs. This is not the only point that made for extremely satisfactory progress through the project. Vice-president Jeff Erickson confirms that:

“It’s a faster machine than what our competitors offer, and we expect it will deliver much higher productivity, which makes it perfect for those shops that need to step up to the next effi-ciency level.”

contact: Brian Van Laar, Bosch Rexroth Corporation, USA,


� The Mach One GT MTX series of gantry-style milling machines made by KOMO can work solid wood doors and delicate wood ornamentation at the same degree of precision. � The user interface for the milling machine is optimized to match the application.


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When building its counterbalance forklifts for heavy-duty work, Jungheinrich has used hydrostatic drives for many years now. Daniel Rösch, of product management at the Jungheinrich Moosburg GmbH, reports on the advantages, challenges and further devel-opment of the 4s series.

Lasting the life of a forklift

We have used hydrostatic drives in our counterbalance forklifts for quite some time. This drive system is interesting especially when total cost of ownership and the vehicle’s ride are impor-tant. High performance is essential in transshipping for logistics operations and in the beverage, paper and recycling industries. Here speed is of the essence and the forklifts never take a break. In two- or three-shift operations, where the forklift frequently reverses, where short paths are involved, and where trucks are unloaded and loaded in parallel, for instance, the advantages of the hydrostatic drive make it the right choice. It enables precise, and at the same time, powerful acceleration and braking; it is both rugged and easy to service. In addition, depending on the

exact application, the hydrostatic drive uses as much as 30 per-cent less fuel than comparable vehicles equipped with a torque converter. The efficiency, the ride and the working properties are simply better.

Arguments in favor of the new developmentThree considerations gave us the impetus to pursue new devel-opments in counterbalance forklifts equipped with hydrostatic drives. Firstly, we wanted to position ourselves as a full-line ven-dor in every segment. That meant we had to offer the appropri-ate vehicle for every application. Secondly, users’ expectations for the product had been rising continuously. Thirdly, the re-


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strictions on exhaust emissions had become more stringent all around the world, especially for diesel engines. That is why the decision was made to develop a completely new generation of vehicles to meet these requirements. We quickly identified Bosch Rexroth as a premium develop-ment partner in the hydrostatics sector, since it delivers entire subsystems from a single source, in superb quality, and with a focus on energy efficiency.

implementing the platform conceptWorking with this partner let us implement perfectly our con-cept for the common platform, on the basis of which three dif-ferent forklift series were created. The development project with Bosch Rexroth started with the 4s series, which has a payload of from 2.5 to 3.5 tons. It covers about 50 percent of the market’s volume. We unveiled this series at the end of 2007 and it was followed by the 3s series – with payloads of 1.6 to 2 tons – and the 5s series carrying 4 to 5 tons. Design elements, the body shape and the operator’s cab are identical in all three series, varying only in size. The situation is similar for compo-nents in the hydrostatic drive. They all come from one product group and we use them for various series, differing only in their dimensioning.

forklift operators’ preferencesOnce our development department in the Bavarian town of Moosburg had established the basic dimensions, we forwarded these specifications to Bosch Rexroth. In an intense exchange of ideas, we then constructed and tested prototypes incorporating several variations in the pumps and motors at the wheels. The major challenge was to design the vehicle so that it runs smoothly. To achieve this, it was necessary to harmonize the components in the hydrostatic drive, the work functions, the internal combus-tion engines, and the controls for each. Especially demanding was fine tuning for the engines, the drive pump and the controls – and this task fell primarily to our software developers at Jung-heinrich. Their first job was to analyze the context and the mu-tual influences of the various systems and the effects on the sys-tem and on the ride and working properties. Then it was necessary to draw the proper conclusions. It is true that a vehicle’s behavior can be tested or simulated on the test bed only to a certain extent. Experienced forklift opera-tors have clear – but sometimes far different – expectations for the vehicle. These can be tested only in actual operation.To be able to satisfy driver preferences and meet the conditions for use, the operator can select one of five operating modes at the display panel – from gentle starting and stopping to very

� Transloading cargo has to be fast. Here the forklift truck is in continuous use.


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dynamic responses aimed at high performance. These programs are regulated by the electronic controls. Here the hardware is built by Rexroth, the software is written by us.

The facelift saves up to ten percentAt mid-2014, Jungheinrich marketed a facelift for the 4s series, responding to more stringent exhaust emission regulations. As a vendor of premium equipment, we always aspire to continuously improve our vehicles. As regards the actuators, we had identified great potential for improving energy efficiency. In addition to the hydrostatic drive, we also employed a working pump by Rexroth in this upgraded version. The change from a constant-discharge pump to a variable-displacement pump made it possible, de-pending on the particular use, to increase efficiency by up to 20 percent in lifting and hydraulic functions. When joined by other factors, savings in the system as a whole came to about ten per-cent. In addition to boosting energy efficiency, we also intro-duced a new and user-friendly control concept with an improved armrest and individual adjustment options. A new generation of masts, featuring improved visibility, was also used.

Banning dirtPursuing the logical next step in the development of the series, Bosch Rexroth, in the course of product maintenance, further refined its radial piston motors especially for this heavy-duty use. The casing for Series 33 now projects over the hub (see the illustration) and is fitted with a new seal. Bits of plastic film or dirt on the floor, stirred up during travel, can now no longer be pulled into the motor at the wheel. Thus we are coming ever closer to our goal of making these costly items last for the en-tire life of the forklift.In addition, Rexroth includes in Series 33 separate, mirror-im-age motors for the right and left sides. The advantage here is that system components like the velocity sensors, for example, are better accessible, both in production and during service work.

improved TcoThis hydrostatic drive lets us achieve stepless changes in travel, superb precision, and highly responsive driving controls as well as parallel operations with automatic boosting of the engine speed. This is, in fact, the state of the art for this kind of travel drive, but – thanks to improved engineering and by selecting Bosch Rexroth as a supplier when we started development for the current hydrostatic system – we can offer an overall concept that is significantly more coherent. All in all, we have aligned this counterbalance forklift, with the Rexroth hydrostatic drive, with market demands in regard to the total cost of ownership – at Jungheinrich we call this BestInvest. We have attained this by adopting even tougher components. That lessens service costs and improves vehicle ergonomics and efficiency.

� Developed especially for tough, heavy-duty service: the new radial piston motors used to drive the wheels.

� A tiny detail with a huge effect. Thanks to the projection over the hub and a new seal, no grime can enter the housings in Series 33.

Author:

Daniel Rösch,

VFG product management,

Jungheinrich Moosburg GmbH,

Moosburg, Germany

www.jungheinrich.com

drive & controlTEcHnologY28

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Packaging makes a great impact on marketing, be-cause it is often the outer wrapper that determines whether a particular brand of muesli or a pasta dish will make its way into the shopping cart. This repre-sents a challenge to the printing industry, which has to accommodate a wealth of differing inks, shapes and materials, from plastics to wallpaper – all at low costs and high quality. That is why Expert S.r.l., lo-cated in the northern Italian community of San Mar-tino Buon Albergo and not far from Verona, special-izes in flexographic presses designed especially to print packaging materials. “The completeness of our line,” explains Leone Nardon, a representative for the company, “is basic to satisfying the widely vary-ing demands found in today’s printing market.”

Quick and economicalExpert offers a complete range of solutions to meet the continuously changing requirements of the packaging market. One example is the central im-pression press, which offers both speed and excel-lent registry. But Expert has generated special ex-citement with its stack flexo printing machines. They can be used for formats where a central im-pression press would be extremely costly but would not offer adequate flexibility. “The stack type ma-chines make it possible to print both sides of the substrate in a single pass, without need for a turn bar. It is therefore suitable to print on tubular mate-rials, also directly in-line with an extruder or bag maker. In the meantime, these machines guarantee the requested printing precision, also on materials of significantly different thicknesses,” is how Renato Giovannini, sales manager at Expert, explains the advantages of this press design. His colleague, Ale-

jandro Signorelli, adds to the list. “The stack type concept is highly flexible in adapting to various kinds of stock, including paper, cardboard and the flexible films used in many different industries – from food wrappers to packages for industrial prod-ucts – and even wallpaper printing.”

Highly adaptable and preciseAll this is enabled by Bosch Rexroth technology. Sep-arate servo motors from the IndraDyn S series drive the plate cylinder, anilox inking roll and impression cylinder. They are synchronized by Rexroth control technology. “Using an ‘electronic shaft’ to synchro-nize the printing cylinders lets us achieve precision comparable to a central impression press,” Nardon explains. The lack of mechanical coupling to gear-boxes makes it easier to adjust the press to handle differing stock thickness. Modularized units in the IndraDrive series power the unwinder and rewinder rollers with which Expert rounds out its product range. Linear motion technology by Rexroth adds the final touch to the system. Thanks to all this engineer-ing expertise, the stack type flexo presses attain printing speeds of 350 meters per minute and can be configured with four, six or eight color units.

contact: Luigi Franchini, Bosch Rexroth S.p.A., Italy,

Phone: +39 51 2986432, [email protected]

The demands on the printing used for packaging are in a state of constant change. An Italian manufacturer of flexo presses, Expert S.r.l., responds to this need with highly adaptable concepts.

Prints everything


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Using the VarioFlow chain conveyor system to suspend auto body parts while they are mov-ing saves space and simplifies handling. Bosch Rexroth developed an innovative solu-tion especially for one carmaker, making this concept practicable for roof interior trims, too.

RethoughtCustom equipment is a necessity in top-of-the-line vehicles. This is also true for the roof interior trim. Having twenty different versions for two to three models of a vehicle is hardly a rarity. To manufacture this broad variety, it is necessary to move the roof in-terior trim to a laser processing station. And the car-maker wanted a conveyor system that not only saved space, but also simplified handling.

A perfect matchWorking in close cooperation with the system inte-grator, the Woll company, Bosch Rexroth developed a specific solution for this customer, one that makes it possible to transport roof interior trims hanging on a track. To achieve this, the VarioFlow 90 chain con-veyor system was fitted with a longer version of the hanger, to which carriers are attached. Instead of ly-ing on the conveyor belt, these roof interior trims,

� It almost works on its own. Manual intervention is required only when filling the VarioFlow chain conveyor system and removing the completed roof


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weighing up to six kilograms, are suspended verti-cally from the conveyor, about three meters above the floor. The roof interior trims then float directly to the robot at the machining station. That robot picks them up and places them in a device that rotates them through 180 degrees and inserts them into the laser cutting station. After processing, this device once again turns the roof interior trim through 180 degrees and removes the complete piece from the station. The robot takes the roof interior trim and hangs it on the conveyor carrier again. From there, it is transported to the removal point.

Almost on its ownOne very major advantage of the conveyor system is that employees can do something more productive while the roof interior trims are being machined. Manual intervention is required only when hanging

up and removing the completed roof interior trims. Once a batch has been hung on the conveyor, all the workpieces will be processed automatically, one after another, and then put in buffer storage. That makes it possible not only to remove them in a single phase, but whenever it is convenient, too. This means that the system can be run during breaks or even after the end of the shift.With this solution, unique in this form, the carmaker can serve four complete assembly lines.

contact: Frank Müller, Bosch Rexroth AG, Germany,


interior trims. Transportation to the robot at the laser machining station is fully automatic.


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They are miniscule, often visible only with the microscope, but can nevertheless bring an entire system to a stop: dirt particles in hydraulic fluid. Some 70 to 80 percent of malfunctions in hy-draulic systems can be traced back to contamination of the fluid. That makes filtering out this grime essential to system reliability. In addition to identifying the appropriate filter concept, proper service during ongoing operations is essential. That is because only regular and correct monitoring of the fluid’s purity can guarantee that the system will operate without interruptions, throughout its entire life cycle.

Selecting suitable hydraulic filters and using them properly will extend the service life of systems and minimize the total cost of ownership.

The purity require-ment

Exactly the right fitIn general, hydraulic fluids have to adhere to a certain

minimum purity class, as defined in ISO 4406. The purity

class for the system as a whole is oriented on the most

sensitive of all the individual components. It is for this

reason that, right from the design phase, the filters are

dimensioned and positioned to ensure that the degree of

purity required by the “weakest link” will be maintained

under all operating conditions. But the focus is not only

on the purity class. Filters also have to be able to collect

a large volume of contaminant and, when clean, should

induce only minimal pressure loss. They should be

compatible with the medium being filtered. Good charac-

teristics for volumetric flow fatigue are desirable, as is

mechanical stability of the support tube inside the filter

element.

Three values that make a difference

Good filter elements are characterized by ideal ratios

among these three factors: filtration grade, dirt absorp-

tion capacity, and differential pressure.

looking for causes and perfect solutionsTypical contaminants in hydraulic fluids and lubricating

oils are particles, foreign liquids and air. While particles

can increase friction and cause greater component

wear, water causes corrosion, affects the viscosity, and

reduces lubricating properties. Gases diminish valve

response behavior. Foaming in the medium will also

cause energy waste and pump damage.

Always watchfulDebris can enter from the outside, but it may also be

caused by the ongoing operation of the system itself. To

guarantee system reliability, it is important to continu-

ously monitor the hydraulic fluid. Regular inspections of

the filter element and the medium, matched to local

operating conditions, keep contaminants from affecting

the fluid circuit and provide information on the nature

and size of the residues. Thoughts on the source of the

pollution can be derived from this, and this is the best

approach to finding effective solutions.

βx

α∆p

Filtration grade

Dirt absorption

Differential pressure

drive & control32Know-How

Rexroth

Oil Cleanliness Booklet

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spare parts online and with smartphonesThe Fit4Filter app by Rexroth makes

for a quick and simple search for

replacement elements for Rexroth

fluid filters.

1 Protective casing 5 Main filter

� Multi-stage filters satisfy maximum requirements.

2 Support weave 6 Protective fleece

3 Protective fleece 7 Support weave

4 Pre-filter 8 Support tube

5 tips for users• Even new hydraulic fluids, right from the factory, are

often not pure enough. That is why filters of appropri-

ate fineness should be used when filling the system.

• Hydraulic fluids must correspond to the purity class

specified by the system’s manufacturer.

• To keep the maintenance effort for filter systems as low

as possible, it is necessary to pay attention to easy

accessibility right from the purchase of the system.

• Maintenance schedules tailored to prevailing conditions

guarantee uninterrupted operation.

• Contaminants can also enter the system from the

outside. That makes it necessary to carefully clean

the area around the filter housing before replacing the

filter element.

useful helpersThe amount of water and particles in hydraulic fluids

can be precisely measured with a variety of devices

made by Rexroth. Online condition monitoring sensors

continuously audit the quality of the hydraulic fluid. The

purpose is to detect deterioration at an early date and

to counteract it. Oil purification devices can also be

used to multiply the life of the hydraulic fluid itself,

reducing wear to system components and, as a conse-

quence, operating costs.

Basic knowledge on how to maintain

filter elements and hydraulic fluids

can be obtained from the Oil

Cleanliness Booklet written by

Bosch Rexroth.

www.boschrexroth.com/ oil_cleanliness_booklet

For iOS: For Android:

Rexroth

Oil Cleanliness Booklet

33Know-How02 | 2014

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Wanted: InnovationIf you’ve read drive&control carefully, then the information we’re looking for won’t puzzle you for very long.

The innovation we’re looking for is the perfect passenger. If you tell it where you want to go, then it will be sure to find that location – again and again. Right down to the micron. Here it is irrelevant whether the setting changes or the conditions are rough. If it is dusty or the engine vibrates severely or deep potholes line the route – that won’t throw it off the right course

any more than a change in the electromagnetic environment. Its compass is incorruptible. It is a very precise measuring tape, packed in stainless steel. It can easily survive impacts of up to 10 g. It is also good to know that this innovation can ride along on many different models and is thus suitable for many transportation tasks.

Submit, win and choose!Have you figured out which Rexroth innovation we’re looking for? Then just send your solution to [email protected] and you

can win a € 100 gift certificate for online shopping at Amazon. The final date for submission is August 31, 2014. The winner will be drawn from

all the entries with the correct answer. Any recourse to courts of law is excluded.

CREDITS

drive&control is the Bosch Rexroth magazine.

Published by: Bosch Rexroth AG

Marketing and Corporate Communications

Dr. Wiebke Wittschen (responsible for the content)

97816 Lohr am Main, Germany

ISSN 1618-5390

Editor-in-chief: Ingrid Alter, +49 711 811 - 30849

[email protected]

drive&control online: www.boschrexroth.com/trends-and-topics

Editing and design: pr+co GmbH, www.prco.de,

Steffen Beck (editor), Tanja Haller (design)

Translation: Stewart Lindemann, Wuppertal, Germany

Lithography: Reprotechnik Herzog GmbH, Stuttgart

Printing: Schleunungdruck GmbH, www.schleunungdruck.de

Photo credits: See note on the page.

Cover: Bosch Rexroth AG, pr+co GmbH

All rights reserved. Reprinting and reproduction, including photocopies, in whole or in part,

only with publisher’s prior written consent. drive&control is mailed using an address

database administered with electronic data processing technologies.

drive & control34TEcHQuiZ

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fast? A hummingbird beating its wings 50 times a second is pretty slow when compared with the new indracontrol Xm. in the time needed to move that wing just once, the control platform will “crunch” the machine’s process data 800 times. Because speed is essential to modular machine concepts. where higher produc-tivity is required, then automation will have to do more – so that more functions can be shifted to the software. indracon-trol Xm makes available greater computing power and makes possible real-time com-putation of complex sequences, including important networking with the iT automa-tion systems at the production level.

Tough application,ingenious solution Exactly

From oil rigs 100 meters above sea level to equipment 5,000 meters below: In the harsh

environment of offshore applications, technology must always be safe and reliable. Being the most

experienced system partner in the world, Rexroth develops tailored drive and control solutions in

cooperation with you. From the first idea through to commissioning and lifelong service we realize

package solutions across technologies with certified components for unique offshore projects as

well as for series equipment: Always safe, reliable and robust.

Ideal solutions and an ideal partner for you and your operations.

Bosch Rexroth Agwww.boschrexroth.com/offshore

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