Robots without safety guards: people and machines working hand in hand
The APAS family continues to grow: collaborative robotics are on the rise
The APAS workstation: intelligently connected workplace with integrated robot
IT Shopfloor Solutions: scalable automation system for the production and logistics chain
Stuttgart/Hannover – At the 2016 Hannover Messe, Bosch presents combined hard- and software solutions for the flexible, networked factories of tomorrow. These Connected Shopfloor Solutions are the essential link at the heart of Industry 4.0, and are already in use today, at Bosch and elsewhere: mobile assistance systems work side by side with their human operators and without the need for safety fences, while modular automation systems analyze, report on and control a wide range of production processes. Yet people remain at the center of it all: “Given the spectrum of work processes in today’s manufacturing, people are now needed more than ever as decision-makers and overseers,” explains Volker Hartmann, Deputy Vice President Business Unit Assembly Systems and Special Machinery at Bosch. “Our robots are there to free human operators from tasks that are potentially unsafe, overly simple and monotonous, or ergonomically challenging.”
A fresh face: the APAS workstation Accordingly, when it comes to developing new solutions, Bosch consistently adopts the perspective of the operator. The most recent example of this user-centered automation: the APAS workstation, which will first be unveiled in Hannover. The APAS is the first standardized workstation to offer direct and safe man-machine collaboration. Offering a truly versatile solution, it integrates a collaborative robot kinematics system (APAS safekin) and further automation components. The APAS workstation takes advantage of new collaborative models that place the focus squarely on the operator. Successfully combining human beings’ inimitable problem-solving skills with the tirelessness and precision offered by robots, they deliver more efficient processes and higher productivity. The integrated robot kinematics system supports the operator, lending him or her a “third hand.” Yet the operator remains the focus, and can enjoy an individually tailored, ergonomically optimized work setting: the worktable height and lighting automatically adjust to the operator, while the adjustable see-through digital display allows them to see all essential production data at a glance. The flexible APAS workstation can be used with or without an integrated robot, and can network with further assistance systems as needed.
APAS safekin: seamless integration The robot kinematics system, dubbed APAS safekin, can also be used independently of the mobile APAS base or an APAS workstation – then recommended as a fixed installation in a dedication production segment. The new automation component can be easily integrated into IEC61131 applications that conform to the standard international norm for programming languages. This allows projects to be rapidly implemented, humans and machines to work together safely, and existing facilities to be readily upgraded. No robotics programming is needed for the creation of individual robot movements; the jobs can easily be prepared, configured and managed using the graphic interface.
APAS family: constantly growing In addition to the newly introduced APAS workstation, the APAS family includes three other mobile, collaborative assistance systems. The APAS inspector is equipped with a high-resolution, high-speed camera and innovative 3D mapping technologies. Thanks to interchangeable testing modules, the station can be used in various production contexts – like high-precision surface inspections or completeness testing. In turn, the APAS flexpress is the candidate of choice for highly flexible, high-precision joining – which, by the way, is one of the most common work steps in production lines. Its integrated safety features ensure that it can seamlessly support its human operator. The same is true for the APAS assistant, which features a six-axis industrial robotic arm, sensitive three-finger gripper, and 3D camera system. The APAS assistant was the first assistance system to be certified by the German occupational health and safety agency. Thanks to its specially designed sensor skin, it can collaborate directly and contact-free with its human operator without the need for further precautions.
As an available option, the APAS speedswitch can be set to vary the APAS assistant’s operating speed, depending on whether or not human beings are nearby. The extended vicinity is monitored by the speedswitch interface and, provided no employees are nearby, the kinematics system operates at maximum speed. If someone approaches the APAS assistant, it automatically drops to a safe speed. The result: increased productivity without sacrificing workplace safety.
IT Shopfloor Solutions Meanwhile, behind the scenes Bosch’s IT Shopfloor Solutions deliver safety, flexibility and transparency throughout the production chain. For more than 15 years now, the modular and scalable software solutions have been continually refined within the Bosch Group and used to manage hundreds of production facilities around the globe. Thanks to a broad range of software modules for Shopfloor Management, machinery can be networked regardless of the product or brand, product defects and the need for maintenance can be recognized early on, and production data can be analyzed in real-time. Thanks to intuitive, graphic tools, operators can more quickly recognize critical situations, more easily localize errors, and more promptly respond to them. The focus is on user-friendliness, and here, too, the collaboration of man and machine reduces complexity. Further, maintenance-relevant parameters can be viewed at any time on a wide range of devices. Depending on the application, a central dashboard can also gather all essential information at a glance. All IT Shopfloor Solutions are based on a shared control platform and standardized software concept, helping to ensure that work processes can be made not only faster and more efficient, but also significantly more flexible and operator-friendly.
Preheater reduces heating energy consumption by up to 30 percent
Modularization leads to shorter delivery times
Bosch Packaging Technology has developed a new generation of pure media systems with optimized performance and energy efficiency, including pure steam generators and distillation units for the production of sterile, pyrogen-free pure steam or WFI (water for injection). “We contribute to a significantly more efficient production of pure media and to more sustainability in the pharmaceutical industry,” says Dr John Medina, sales director at the Bosch subsidiary Pharmatec. For instance, the preheater reduces heating energy consumption by up to 30 percent.
Focus on energy efficiency and sustainability Pure steam and WFI are key components of pharmaceutical production. While WFI is predominantly needed for the production of infusion and injection solutions, pure steam is mainly used for sterilizing equipment components like preparation vessels, piping systems and filling machines. In addition, pure steam is employed for the humidification of air in cleanrooms.
Bosch delivers the new distillation units with a preheater by default. From the second column onwards, it uses pure steam from the previous column to preheat the feed water. As a result, heating energy demand is significantly reduced. For pure steam generators, a preheater is available as an option. It is fed with condensate from the heating steam. Using this stored energy leads to reduced heating steam consumption.
High thermal efficiency and reduced blowdown Evaporation is a basic operation in the production of pure steam and WFI. The equipment’s evaporator operates according to the proven natural circulation principle. The water, which is fed for evaporation, continually circulates between the evaporation chamber and the heat exchanger. A high thermal transfer enables the system to be heated up smoothly without causing temperature stress for the evaporator. This process only needs electrical energy or heating steam; no further process steps or functional modules such as a compressor are required.
“The new, compact design of the evaporator contributes to optimal thermal use of heating energy, leading to high yields and low operating costs”, explains Medina. “Since the production of pure steam and WFI is particularly energy-intensive, improvements in efficiency play an important role in sustainability and climate protection.” The geometry of both evaporators and condensers has been optimized for the new product range. For instance, Bosch adjusted the evaporator’s diameter as well as number and formation of the heating pipes. Subsequently, the machines can achieve 20 percent higher performance rates compared to previous models. Bosch also succeeded in reducing the amount of water loss, which results from the disposal of endotoxins (blowdown) in the feed water, from between five and eight to no more than four percent.
From 100 to 7,500 kilograms per hour With these new developments, Bosch has streamlined the product range, compiling a consistent set of machines. The number of different sizes was reduced from eleven to six pure steam generators and from fourteen to ten distillation units. “Customers profit from shorter delivery times, lower acquisition costs due to a higher degree of standardization and modularization,” says Medina. The series now encompasses a performance range of 100 to 7,500 kilograms per hour. In order to enable quick set-up, feed water pumps with frequency regulation are used for all sizes. The equipment can be further adapted to the respective operating conditions.
Contact: Klaus Schreiber phone: +49 351 28278-833
Contact person for press inquiries: Christin Poenisch phone: +49 711 811-58502
Measurement of high-precise rotationally symmetrical parts in manufacturing
Optimized machine design for shop floor application
Impact of oscillations, temperature variations and wear minimized in the design
Patented interferometrical probe
Stuttgart – With its new optical measuring machine for form and roughness, Bosch presents a complete solution optimized consistently for use in production at the Control 2016, the international trade fair for quality assurance in Stuttgart. Precise measurements directly or close to the manufacturing process are the key to ensure high quality while minimizing the rejection rate. Using automated production-integrated solutions significantly reduces effort and costs for a 100% inspection. At the moment, about 40 of these application-oriented systems are implemented in industrial applications and make a significant contribution to the high quality of the products.
The new Bosch optical form measuring machine FMS100 The FMS100 was developed for verification of rotationally symmetrical industrial precision parts. Rotational speeds up to 200 revolutions per minute and contact-free optical probe arms enable rapid measurements of inside and outside geometries. Typical tasks include measurement of roundness, straightness, taper, roughness and diameter. The contact-free optical probe arms allow the measurement of the parallelism of very thin objects without changing them through the contact force. The solutions have been proven in the Bosch manufacturing and enable the economic and automated use of measurement technology for highest precision in the production environment.
Short measuring times allow for the measurement of high quantities in a short period of time. Its low-maintenance and low-wear design guarantees trouble-free operation round-the-clock next to the processing machine and in this way a fast feedback on the current quality status. The fast planar measurement visualizes the surface of the component, giving the user indications regarding corrective interventions in the process. The automated measuring process and the easy operation of the software significantly reduce the amount of training required and possible sources of error for the machine operator. At contact, the automatic probe arm protection prevents that the probe will be damaged. This ensures a high-quality control of the machining process. The extensive safety concept includes an integrated cabin protecting from unauthorized access. The stand-alone machine with small footprint can be installed quickly and easily directly next to the processing machine.
The contact-free optical probing with the patented interferometrical touch probe enables the measurement of sensitive surfaces, thin needles as well as inner contours which are hard to reach.
FTP40 – optical 3D Flatness Measuring System from Bosch The FTP40 system enables a rapid measurement of two opposed parallel surfaces in a single measurement, without moving the measuring object. This permits a very high precision and reduces cycle time significantly. The system is used for rapid measurement of flatness, thickness and parallelism in the laboratory and in production. The FTP40 is particularly characterized by high resolution and accuracy, short cycle time, contact-free and wear-free measurement.
Bosch presents its solutions at the Control 2016, the international trade fair for quality assurance in Stuttgart, from 26th to 29th April 2016, in hall 1, booth 1420.
Modular and scalable for small and large product batches
Patented format changeover – quick, tool-less and reproducible
Great format and pack style flexibility on one machine
Bosch Packaging Technology, a leading supplier of process and packaging technology, has added a new topload cartoner to its well-known TTM product portfolio. “The Sigpack TTMP enhances our product portfolio with an efficient and highly flexible cartoning solution, especially for pharmaceutical customers. It is based on our successful TTM platform, which is already used around the world,” explains Michael Haas, product manager at Bosch Packaging Systems.
Specifically for the pharmaceutical industry The proven features of the TTM platform have been advanced specifically for the packaging of ampoules, vials, syringes, pens and further products from the pharmaceutical industry. A simple and safe changeover concept, high process safety and a broad format and product flexibility characterize the machine. Due to its modular design, the machine layout can be adjusted to different product infeeds. With an output of 30 up to 200 cartons, the TTMP provides individual solutions for both small and large production batches.
The Sigpack TTMP can be seamlessly combined with the Sigpack TTMC case packer. This offers customers a uniform, user-friendly operating concept for the entire line.
Great flexibility and smooth handling Thanks to the patented format changeover concept, tool-less format changes with vertical restart can be carried out within a few minutes. The open and easily accessible machine design provides for a very fast line clearance. “The patented changeover concept enables our customers to flexibly and quickly package various pack styles on one machine. This is especially important for increasingly small batch sizes,” Haas says.
A wide range of product infeed solutions and loading possibilities ensure the gentle handling of sensitive products such as vials, ampoules, syringes and injection pens. Various gripper technologies provide for smooth packaging of the products. Depending on requirements, different mechanic, vacuum-based or grippers with airflow technology are being used. Modules for forming and inserting partitioners, package inserts and tray denesting can also be integrated.
Maximum efficiency and 100 percent process safety The Sigpack TTMP is easily accessible and open. The compact, GMP-compliant design supports process safety. Additional Track & Trace-solutions such as the CPS module (Carton Printing System) from Bosch or third-party suppliers can be easily integrated. The machine can also be equipped with the Bosch CPI software, which manages serialization from the allocation of serial numbers through to the last aggregation step. Thus, the Sigpack TTMP fulfils the most recent serialization requirements for pharmaceutical products.
Various monitoring functions inspect the packaging process at several points. For instance, the carton blanks are already scanned at the infeed. Vision systems and code verification allow to examine carton contents, the correct infeed of the package inserts, as well as the intact shape of the cartons. Incorrect packs are automatically dispatched from the system by discharging devices. This concept ensures 100 percent process control and also speeds up line clearance during batch change.
Contact: Michael Haas, phone: +41 58 674-8594
Contact person for press inquiries: Christin Poenisch phone: +49 711 811-58502