Mechatronic systems have become an integral part of modern production environments. Their flexibility makes them an important building block for flexible, future-proof machines. This is where Bosch Rexroth comes in with its smart mechatronic solution platform Smart MechatroniX, opening up new possibilities for users in the factory of the future. The subsystems, consisting of linear technology, electrical control systems, software, electric motors and sensors, are suitable for a wide range of applications. And they offer many advantages - from simple, fast product selection and design to configuration and ordering via modern eTools. All this works with just a few mouse clicks, seven days a week, around the clock.

The right product for the respective requirement can be selected and configured with just a few clicks. CAD data is then available for various 2D and 3D systems. In future, a digital twin will accompany all Bosch Rexroth linear technology components and systems throughout their service life. By integrating it into a virtual environment, simulations can be carried out in advance and time-to-market and commissioning times can be reduced to a minimum. Sustainability and resource-saving production are playing an increasingly important role at Bosch Rexroth. Smart MechatroniX solutions are therefore modular, scalable and retrofittable. This also enables flexible use of mechanical components in the long term. In addition, production processes and machines can be quickly adapted to new customer and market requirements at any time - even for small batch sizes. The longevity of the components and the high overall system efficiency also save resources.

Bosch Rexroth presented its first mechatronics solution back in 2019: the Smart Function Kit for pressing and joining applications. It consists of an electromechanical cylinder, force sensor, motor, controller and control unit as well as a software package. Product selection and design are carried out using the LinSelect selection and design tool. During the ongoing process, the Smart Function Kit can be networked via open interfaces and conveniently monitored using a tablet. This enables maximum transparency, reduces downtimes and increases machine productivity. Whether assembly, joining, forming, checking or testing, the Smart Function Kit for pressing and joining applications is suitable for many standardized applications with forces from 2 to 30 kN.

A second solution is the new Smart Function Kit for handling tasks. It is based on a Cartesian multi-axis system that moves components or workpieces reliably and precisely in a defined space. Here too, Rexroth linear technology components are combined with control technology and software to create a perfectly coordinated system solution. Simple product selection via LinSelect, fast configuration with the online configurator and complete delivery in a single package make procurement easy. A wizard guides you quickly and intuitively through the commissioning process. The visual operating software enables graphical process configuration via drag and drop, without any programming knowledge. All this ensures a short time-to-market and a fast production start. The software also visualizes process and status information and documents it for quality purposes. The Smart Function Kit is the ideal ready-to-install positioning and handling solution for handling tasks and automation technology. It can be operated intuitively via HMI.

A third solution that is currently being developed is a sensor-based compensation module with independent kinematics in six degrees of freedom: the Smart Flex Effector. It increases precision, for example in handling robots, and opens up new areas of application for robots and Cartesian systems. The tactile technology used here reduces errors and saves time and costs during commissioning and operation. All six degrees of freedom can move independently of each other. This allows the tool or the gripped workpiece to be optimally aligned with the contact surfaces. With the Smart Flex Effector, the positional deviation of the tool or workpiece can be detected using high-resolution position sensors and translated into active corrective movements of the manipulator. The intelligent sensor system provides detailed process feedback and, in conjunction with the compensating kinematics, enables readjustment in real time. The measured values of the Smart Flex Effector provide information about the process quality and are suitable for quality monitoring and logging.

Mechatronics solutions with potential

In future, the Smart Flex Effector can be used as a compensation module for handling or joining processes with tight tolerances in automation technology or robotics - for example, for joining small tolerances, for quality documentation and tool center point detection or for the automated compensation of position drifts in the rotary axes and in the X, Y and Z directions.