Harmonized components and software modules simplify design and commissioning and increase productivity

The K 2019 trade fair motto “A world of pioneers” is especially relevant for hydraulics. Machine manufacturers are uncovering new dimensions in productivity and cost-effectiveness thanks to the fusion of fl uid technology with digital control systems and the networking of the fi eld level with higher-level systems. Intelligent, connected hydraulics for plastics processing machines enhances the repetition

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INTELLIGENT, CONNECTED HYDRAULICS FOR PLASTICS PROCESSING MACHINES:

Higher process reliability and availability

Bosch Rexroth AG

accuracy, process reliability, energy effi ciency and availability in equal measure. That’s why manufacturers are switching in increasing numbers from analog hydraulic components to digitally connected hydraulic solutions. They are therefore continuing to exploit the benefi ts of fl uid technology, such as power density, robustness and virtual maintenance-free operation, and combining these with the possibilities of digital communication.

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The fusion of sensor technology and communication technology is only half a step on the path toward digitalization. Intelligent, connected hydraulics offers added value thanks to decentral intelligence and application know-how that is replicated in the software. The components are tailored optimally to each other in terms of hardware and software. Universal software tools simplify engineering and commissioning. In terms of operation, this enhances productivity and increases availability thanks to rapid error diagnosis through to cloud-based predictive maintenance with artifi cial intelligence. Rexroth bundles this under the term Connected Hydraulics.

Connected Hydraulics drive solutions ensure demand-driven, energy-effi cient pressure supply of hydraulic actuators. Digitally responsive, distributed intelligent hydraulic components and subsystems open up new levels of freedom for optimizing basic machine functions such as injection, opening/closing of forms, ejectors and nozzle systems. The repetition accuracy can also be improved over the entire life cycle at the same time.

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DRIVE TECHNOLOGY: POWER MEETS INTELLIGENCE

Changes are afoot in hydraulic drive technology following many quiet years. CytroBox, the new generation of hydraulic power units, shows how Connected Hydraulics fl uid technology is integrated with the Internet of Things (IoT) and therefore simplifi es design and commissioning. With its compact and modular design, it provides a new solution approach for the medium performance range from 7.5 to 30 kW and is ideally suited for pressure supply of additional functions such as core pulls. Thanks to integrated sensor technology and condition monitoring functions, it is also the blueprint for IoT integration of larger power units. As a plug & run solution, the power unit reduces the commissioning effort quite considerably.

CytroBox brings together all components in a compact design, which requires 50 percent less installation space than previous units. Sytronix variable-speed pump drives with inherent intelligence adapt the speed to suit demand using predefi ned controllers. This reduces the power consumption of the hydraulics in cyclical applications by up to 80 percent. The tank with optimized degassing and fl ow reduces the oil volume by 75 percent, from 600 liters to a mere 150 liters. Moreover, the noise emission of the CytroBox is less than 75 dB(A) – even at full load.

SMART, CONNECTED CONDITION MONITORING

The new generation also increases the availability of machines while lowering maintenance costs. CytroBox links fl uid technology as standard with the IoT for this purpose. The integrated CytroConnect software solution uses sen-sors to record all relevant performance and operating data, such as oil level, oil quality and temperature over time. The software processes the data decentrally and sends it encrypted to the cloud. Using the browser-based interface, maintenance technicians can wirelessly dial into the CytroConnect service and retrieve the information inde-pendently of their location, whether inside or outside the factory. This saves time and long journeys. Machine manu-facturers and end users can integrate CytroConnect as a module into their own digital IoT maintenance concepts.

▲ The hydraulic power unit CytroBox raises the level of production to the next higher level.

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As a plug & play solution that is already installed in the CytroBox, CytroConnect provides the basic functions of the software free of charge in a Freemium model. Machine manufacturers and end users can also book other additional options in the subscription model. The “Maintain” module reports errors as a push service, processes additional status information and provides maintenance instructions. The “Predict” service package uses rules and algorithms for predictive maintenance concepts, for example by integrating Rexroth’s Online Diagnostic Network (ODiN). Bosch Rexroth has integrated its hydraulic domain know-how as a service package into the software, and uses AI-based analysis algorithms to create a health index for the power unit. This can also be expanded to all other connected machines and hydraulic systems if required. These analyses provide the building blocks for predictive maintenance concepts and thus maximum availability.

INTELLIGENT SOLUTIONS FOR EVERY PERFORMANCE RANGE

Plastics processing machines generally require a high-performance central pressure supply, which provides the necessary energy for the machine axes as energy-effi ciently and quietly as possible. The variable-speed pump drives in the Sytronix family, which are also used in the CytroBox, are state of the art in this respect. They are based on the same intelligent drive controllers and software solutions as Rexroth’s electrical axes. This simplifi es commissioning considerably through the use of identical software tools.

Sytronix SvP typically offers the ideal solution for injection molding machines with small and average closing forces. Synchronous servo motors with permanent magnets and servo control offer optimum dynamic performance in this context and closed-loop accuracy up to a power level of 80 kW. They cover a wide range of functionalities from pressure control and closed-loop pressure fl ow control right through to closed-loop position control and force control. Advanced monitoring functions increase system availability. A protective pump function extends the life cycle and avoids machine downtime. All Sytronix variants can be integrated in the widest variety of automation architectures via a multi-Ethernet interface for the most commonplace real-time Ethernet protocols.

In the case of machines with large closing forces, Sytronix DFEn with p/Q control systems cover the performance range up to 630 kW. The DFEn connects an axial piston variable displacement pump optionally with a synchronous or asynchronous motor and harmonized drive controllers. It combines the closed-loop speed control of the drive with a variable displacement pump. Dual-quadrant operation provides access to comprehensive electrical and electro-hydraulic control options to infl uence the fl ow smoothly in accordance with demand. This creates additional potential to optimize the dynamics and precision of processes in plastics machine processing. A teach-in method can be applied in cyclically operating machines in order to accelerate the system again in good time before an increase in the fl ow.

◀ The integrated CytroConnect software solution uses sensors to record all relevant performance and operating data, such as oil level, oil quality and temperature over time.

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DIGITALIZED INTERFACES FOR CONNECTED I4.0 HYDRAULIC APPLICATIONS

Work to connect all actuators in mechanical and plant engineering – also in the plastic machinery industry - is progressing quickly. The requirements here range from simple status queries to decentralized, synchronized movements. With application-oriented solutions, Rexroth opens up new ways of connecting hydraulic valves digitally in an economical manner. Only with a digital interface can users change parameters via software during operation in order to react fl exibly to new requirements. It also allows quick diagnostics and condition monitoring and thus increases machine availability. Rexroth caters for various concepts and is the only manufacturer at the moment that caters for your own specifi c requirements.

FIELD BUS VALVES WITH MULTI-ETHERNET INTERFACE (IFB)

IFB directional control valves with multi-Ethernet interface are integrated by machine manufacturers independently of the control system used. With Connected Hydraulics, they reduce system costs and offer integrated safety and additional functions. Users can implement pressure and force control optionally with internal or external pressure sensors. The integrated control functions for pressure and force control help to reduce planning and commissioning outlay. The integrated safety interface (EN13849 Kat4Ple), which allows a single-channel shut-off, also reduces the costs of safety applications.

The intuitive commissioning software tool ensures rapid parameterization and confi guration without unwieldy programming. The short cycle times of the valve controller of <1ms improve accuracy and cycle times. Moreover, the valves provide data for condition monitoring and predictive maintenance during operation and enable rapid replacement of devices in service cases. Above all, they are already Industry 4.0-ready and support the vertical fl ow of information from the fi eld level up to the cloud.

▲ With application-oriented solutions, Rexroth opens up new ways of connecting hydraulic valves digitally in an economical manner.

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IO-LINK: “USB OF AUTOMATION”

With IO-Link, Rexroth offers highly effi cient, end-to-end communication with sensors and actuators at fi eld level for analog-controlled valves regardless of the fi eld bus used. Hydraulic components can thus be integrated intelligently, easily and cost-effectively into digital communication. Similiar to an USB interface, IO-Link enables easy connection in hardware and software and allows fl exible adjustment of hydraulic valves for varying production processes. Advanced diagnostic information supports status-driven and predictive maintenance concepts and shortens downtime and maintenance times signifi cantly. IO-Link valves record the running time and temperature and produce a histogram with details of the running time/temperature range with three set thresholds. This information is retrieved by users and service engineers via the IO-Link interface.

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The standardized wiring and electronic name plate facilitate commissioning and increase availability. As plug & produce components, they do not require any additional engineering tools. In addition, the IO-Link open standard enables future-proof integration of hydraulic valves into connected struc-tures as Industry 4.0 components with all their related features.

DISTRIBUTED INTELLIGENCE SUPPORTS MODULARIZATION

The new DFEF control pump with fi eld bus interface in the valve links the intelligent valves with a variable-speed pump drive and a variable displacement pump. The subsystem closes the control loop decentrally. It communicates with the machine control via the interface to all commonplace real-time protocols.

SUMMARY

Connected Hydraulics simplifi es the engineering phase by relocating functions to the software. Designers can use the identical hardware to implement a broad range of variants. In addition, the commissioning outlay is reduced signifi cantly. The connected hydraulics with harmonized components and software modules increases process reliability and repetition accuracy throughout the entire life cycle. It is also possible to reduce power consumption and thereby lower operating costs and ultimately increase profi tability. Manufacturers can uncover new options for condition monitoring thanks to connectivity. End users can use predictive maintenance concepts through to cloud-based systems, such as ODiN, and thereby increase the availability of their machines and systems considerably.

Author: Frank Hoehn (DC-IH/SAL1)

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◀ With IO-Link, Rexroth offers highly effi cient, end-to-end communication with sensors and actuators at fi eld level for analog-controlled valves regardless of the fi eld bus used.