Successful pilot project with Bosch Rexroth AG: elumatec AG enables lean and fast processes in automated production

A “unique, cleverly thought-out process” for fully automated configuration and production of customised aluminium profiles – on elumatec machines

Mühlacker, March 2023. At Schmalz+Schön, a partner of Bosch Rexroth AG, all work for machining customised aluminium profiles – from configuration and producing drawings to starting up the elumatec machine – have been fully automated since the beginning of March.

This forward-looking process optimisation was made possible by a trio of innovation drivers: Bosch Rexroth controls the process from its own online store, it-motive AG programs the automatic drawing generation which then generates a QR code that the operator of the elumatec machine scans – and then production can start. And elumatec’s open and communication-enabled machine software also plays its part. The goal of everyone involved is to give customers future-proof, lean and largely automated production across the entire value chain.

Staff on the elumatec SBZ 122/74: automation ensures more efficient processes and faster production.
Picture credit: Bosch Rexroth AG

Francesco Zeccola, overall project manager at Bosch Rexroth, sees the pilot project as a big step in this direction: “We have created a unique, cleverly thought-out process which allows us to supply our customers quickly to suit their individual needs. We were able to transfer our Quick & Easy configuration system to new elumatec profile machining centres, and enhance the machining options. At the same time, the whole process is now leaner and simpler.”

The elumatec machines provide connectivity to accelerate the project. By configuring machines and providing suitable interfaces, the software team in Mühlacker has proved that elumatec is now more than just a machine manufacturer. Paolo F. Bianchi, CEO of elumatec, believes the successful partnership is a real-world case study of the success of the company’s strategy: “We’re positioning ourselves as a solution provider for fully digital production, and our software solutions are already helping customers achieve this. This joint project shows how elumatec machines will enable production of the future – it takes everyone involved to the next level of industrial machine communication.”

The elumatec SBZ 122/74 at Bosch Rexroth: taking machine communication to the next level.
Picture credit: Bosch Rexroth AG

The process: configuration, QR code, machining

Logistics company Schmalz+Schön, based in Fellbach near Stuttgart, is also benefiting from the project. In addition to storing goods at its site, the company handles customer orders for Bosch Rexroth in profile machining – guaranteeing short transport distances and quick delivery times. The production process at Schmalz+Schön is now automated, from the customer order and configuration through to the finished profile. Customers describe the desired profile in the configurator in the Bosch Rexroth online store, where they also place the order. Drawings are created automatically in a process programmed by it-motive, a software company based in Duisburg.

Joachim Finkensiep, Head of CAD Development at it-motive for Bosch Rexroth,  describes  the core idea behind the project: “All production orders result in a drawing with a QR code on the back containing all the profile machining data.” All the operator on the machine has to do is scan it, and the QR code interpreter from it-motive then generates an intermediate machine code which is converted by the elumatec machine software into the “G-code” commonly used for CNC machines. This code ensures that the CNC machine automatically carries out the appropriate machining steps in the optimum sequence – including automatic tool changes.

The spindle of the elumatec SBZ 122/74 enables automated tool changes.
Picture credit: Bosch Rexroth AG

Digitally accelerated manufacturing

For Felix Schlachter, Head of Software Development at elumatec, comments the project is “a fully digital solution from the moment customer orders are placed in the online store to production. As an enabler for Bosch Rexroth, this is a clear demonstration of our expertise in the software sector.” In fact, the fully automated transfer of the profile data ordered by the customer to the machine is an enormous leap forward compared to manufacturing with manual labour. Originally, orders received in the online store had to be printed out and then taken to the machine, where the program was entered by the operator and the profile was loaded – and only then did production begin. The interface developed by elumatec paves the way for full integration of the machine into smart production systems. “We’re exactly the right partner for this,” says Schlachter: “Our interface is part of the machine and can be customised to suit each customer’s requirements and processes.”

The concept for automation was submitted by Bosch Rexroth in 2022 and subsequently fine-tuned in coordination with the partners. The programming was carried out by it-motive, which had previously created the configurator for Bosch Rexroth’s online store. At elumatec, the communication interface was adapted to the SBZ 122/74 profile machining centre and MGS 142 mitre saw used by Schmalz+Schön. As the solution developed could not be implemented with machines from other manufacturers, elumatec’s expertise in smart production was indispensable in the pilot project.

The elumatec SBZ 122/74 gives customers the innovative edge.
Picture credit: Bosch Rexroth AG

The advantages: quicker delivery times, global rollout

“Quick & Easy” is the name of the manufacturing process at Bosch Rexroth that enables efficient and customised profile machining. It’s simple for customers to enter the material, length, and machining parameters for their desired profile in the online configurator. Transferring the QR code developed in the pilot project speeds up the manufacturing process and offers a number of other advantages:

• fast automated production of single, customised profiles,
• quicker delivery times,
• an automated process that prevents errors,
• global rollout with a stand-alone solution thanks to intelligent QR code
• scalability through the use of standard tools and interfaces from project partners.

Concept design for the project started at the beginning of 2022, and implementation began in November. Less than half a year later, production is up and running at Schmalz+Schön. Project manager Francesco Zeccola is quick to highlight the “smooth cooperation”: together with its partners, Bosch Rexroth has developed an internationally applicable standard concept that enables fast and error-free processes despite the enormous range of profile machining services. “Everyone involved has secured the innovative edge over the competition,” adds Schlachter – and with it the best possible prospects for the automated production of tomorrow.

The elumatec SBZ 122/74 is a 4-axis machine for metal construction customers and industrial users.

More about Bosch Rexroth:

www.boschrexroth.com