The Future of Industrial Hydraulics

Connecting machines and facilities with IT systems opens up enormous potential for more economical and intuitive processes. This is exactly where the CytroBox hydraulic power unit from Bosch Rexroth Corporation (Bethlehem, PA) comes in. Its intelligent, energy-efficient modular design provides a new solution for applications in the medium performance range up to 30 kW by integrating IoT technologies that pave the way for consistent Industry 4.0 implementation. The current consumption is parametrized and optimized with regard to the existing electrical cabinet. Pre-set controllers in variable-speed pump drives adjust energy requirements on an individual basis. The speed is switched off during no load in order to save energy and is controlled under full load in a closed loop to the exact pressure command value with a highly dynamic response – saving up to 60 percent of energy compared to conventional power units.

The high efficiency of the manifold block, which is manufactured using the 3D sand core printing method, also contributes to overall efficient operation. Made via additive manufacturing, this manifold block is up to 40 percent more compact and boasts improved flow channels for better oil flow, reduced pressure losses and fewer areas where leaks could occur because fewer plug screws are required. The hydraulic power unit is also equipped with an active dewatering unit to protect against external contamination. Equipped with a sensor package and open interfaces, CytroBox is ready for use in connected environments for condition monitoring. Integrated and wired sensors provide information regarding the current filter, oil or drive condition. The collected data is then processed by the drive controller. With the help of Open Core Interface, data can be further processed and integrated into modern machine concepts.

This hydraulic power unit also offers a connectivity option for operators that makes it easy to realize the potential of IoT technologies as a pay-per-use service without risk. All information regarding CytroBox – from the component and operating status to forthcoming maintenance work to predictive maintenance analyses – is available via Rexroth’s Online Diagnostics Network (ODiN) so that information is always close to hand. Because flexibility and space-saving designs are important criteria when selecting components, CytroBox combines a small footprint with a compact design that includes a tank with optimized de-gassing and flow. Thanks to CFD simulation, its oil volume is reduced by 75 percent, from 600 liters to a mere 150 liters. The use of synchronous technology also saves space: Its high-performance, water-cooled synchronous motors are up to 80 percent smaller than comparable asynchronous ones. All functions are brought together in a compact control cabinet that can easily be integrated into existing production lines in a flexible, space-saving manner.

Airborne sound is completely absorbed by the compact arrangement of components in one unitary housing and built-in sound-insulating mats that ensure no sound leaks out. To reduce noise emissions stemming from structure-borne noise, the motor pump group is rigidly affixed to a polymer-concrete foundation. The damping bearings that would typically transmit the noise to the tank are completely eliminated. Even at a full load, the noise emission from CytroBox is less than 75 dB(A). Comparable power units have an average noise level of 85 dB(A). This reduces the need for additional noise reduction measures, lowers costs and makes the work experience more pleasant, even when in direct proximity to the hydraulic power unit.

Bosch Rexroth Corporation, 2315 City Line Road, Bethlehem, PA 18017, 610-694-8352, www.boschrexroth.com/cytro.