The ETA factory consumes 40 percent less energy than conventional production. This is the result of the ETA Factory research project led by the PTW (Institute for Production Management, Technology and Machine Tools) at the Technical University of Darmstadt. Scientists and production experts optimized energy efficiency holistically using the example of multi-stage production of a series component from Bosch Rexroth. Bosch Rexroth was involved in the project, which has now been completed, as an industrial and research partner.

As part of the research project, the machines in a real process chain were optimized with the classic steps of machining, hardening and cleaning to produce a hydraulic component. The key to the high increase in efficiency was a holistic concept for exchanging and reusing energy between the machines and with the factory building.

Bosch Rexroth is currently incorporating the research results from the ETA factory into its plants as part of the Gogreen project. In addition, the findings of the research project are being incorporated into the energy efficiency consultations that Bosch Rexroth offers industrial companies, as well as the Drive & Control Academy training program, and are included in the recently published "Energy Efficiency Manual".

Energy monitoring and controlling
As a technology partner, Bosch Rexroth has also contributed to the energy monitoring and controlling of the ETA factory at control and field level. Consumption is recorded across all energy forms down to component level. Targeted switching of the machines and their auxiliary consumers to energy-saving modes reduces energy consumption. The energy modes can be activated manually by the machine operator, from the PLC and autonomously from the production control system (MES).

This energy management functionality has its origins in the existing Rexroth 4EE - Rexroth for Energy Efficiency system. With Rexroth 4EE, the company taps into all potential savings across all technologies and applications. To make optimum use of the available energy, Rexroth relies on four technological levers: the overall systemic view, efficient components, energy storage and recovery, and demand-controlled energy use.

Following the completion of the ETA-Fabrik project launched in 2013, two related follow-up projects focusing on energy flexibility have been launched there: Synergie and PHI-Factory. In view of the increasing proportion of renewable energy sources such as wind and solar power and the associated greater fluctuation in energy availability, new challenges are arising for an efficient and stable power supply. The aim of the two research projects is to upgrade industrial processes for energy flexibilization. Bosch Rexroth is also actively involved in the development of sustainable solutions in these fundamental studies. as