Automated and Intelligent Assembly Assistance

Last May, Bosch Rexroth presented some new products at SPS, including ActiveAssist, an assembly assistance system, and the MTpro software, for a customized composition of the ActiveMover transfer system. These are proposals in view of Industry 4.0 and human-machine collaboration.

by Andrea Pascoli

The Italian branch of Bosch Rexroth – whose overall turnover was 316 million euro in 2017 (+13% compared to the previous year) – presented at SPS Italia new modular, connected and interactive assembly assistance systems, applicable to a wide range of industries and applications. These technologies are proposed as safe and reliable alternatives, and, in the context of Industry 4.0, focus on human-machine collaboration in the various phases of the work, creating a dialogue between physical assembly stations and virtual environment or robot.

Intelligent assembly
One of these products is ActiveAssist, an assembly assistance system that supports employees in their tasks by connected solutions. ActiveAssist identifies the workpiece and loads the required work plan on the user’s monitor. The work instructions are then projected directly onto the work surface using a projector and the correct grab container is marked. The employee’s movements can also be tracked via 3D cameras, making it possible to automatically confirm individual work steps. ActiveAssist has a modular design and is freely configurable. Users can equip each assembly station with different assistance functions. With starter kits for different functional expansion stages, Bosch Rexroth guarantees a simple needs-based start-up as well as shorter set-up times and also provides a cost-optimized all-in-one solution. Thanks to its web-based software, ActiveAssist is a flexible and open system that allows numerous systems and assembly stations to be thoroughly connected. All data can be processed in real time, and, by incorporating touchscreens, 3D cameras and projectors, various interactive assistance functions can be realized.

Linear motor for quick planning
Bosch Rexroth also presented at SPS the MTpro software, to assemble their made-to-measure ActiveMover built from straight and curved sections with a vertical-mounted linear motor.
The system automatically generates the order lists, including all the accessories. The user can individually manage an unlimited number of workpiece pallets and freely program them in the direction of travel, acceleration and target position, with a repeat accuracy of +/- 0.01 mm. Using direct drive technology, they accelerate in a highly dynamic manner with up to 4 g and therefore shortens cycle times. Users can also install very gentle sequences of movements to bring loosely mounted assemblies safely to the next station.
ActiveMover is already being used by numerous customers from the automotive industry as well as in cleanrooms in electrical/electronics production and in healthcare applications.