120 years ago, the world’s first automotive spark plug was born. Robert Bosch invented this key component in the gasoline engine, and today the Bosch Bamberg plant is using the most advanced manufacturing methods to provide this component to the global market. Since 2020, the auto parts supplier has been operating in a way that ensures climate neutrality; They are not only focusing on process reliability, but also doing their best to reduce CO2 emissions. This means that they must improve the intelligence and sustainability of industrial hydraulic systems.

New core of Panat press

In the latest modernisation project aimed at improving energy efficiency, the plant has added six presses to the short-cycle production line. Each press is equipped with five Panat (conductive glass filled) drivers, which are pressed together with the ceramic housing of the spark plug under high pressure (135bar). In bringing long cylindrical products into production, the plant needed to increase the stroke length and flow rate of the press, and the newly launched production plan provided an opportunity for hydraulic renewal. This time, the factory did not use the traditional large hydraulic accumulator assembly, but instead used Bosch Rexroth’s intelligent stand-alone solution CytroBox.

Fast upgrade, lower carbon emissions

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From a traditional perspective, CytroBox’s performance is very different: it is not only compact, quiet and smart, but also helps to save energy and reduce CO2 emissions. There is no need for electrical installation, additional sensors, soundproofing or separate oil trays, so installation requires significantly less work than previous units. Users only need to connect the power supply, hydraulic hose and line controls. The installation is managed through a software wizard and takes only a few minutes to complete.

Intelligent pressure supply ensures process safety

Using only half the footprint of the original equipment, CytroBox ensures reliable process flow and efficient intelligent pressure supply, which is highly appreciated by Bosch Bamberg. The finely controlled electro-hydraulic system makes an important contribution to quality assurance by ensuring accurate pressure curves and rapid pressure building, and effectively preventing pressure overshoot or overload in the system.

Simulation and calculation

CytroBox’s modular design makes it easy and cost-effective to implement important safety functions such as emergency stops with optional modules. The device also uses a standardized interface to quickly complete the integration of the production line. In addition, CytroBox is also praised for its excellent interconnection performance, which is also a basic requirement for modern production. It is also important to note that CytroBox is pre-equipped with condition monitoring technology, which provides a solid foundation for continuous process improvement and predictive maintenance.

Reduce electricity consumption and CO2 emissions by 59%

CytroBox uses a flow optimization design and a variable speed system based on the principle of energy consumption on demand, which reduces power consumption by 59%. In addition, the precise and controllable displacement control device only generates pressure when required in the press assembly cycle, otherwise it automatically enters an energy-saving standby operation, which greatly increases the energy saving potential. Another advantage of intelligent interaction between servo motors, pumps, and modules produced using 3D core printing is that CytroBox operates so quietly that the line operator can barely hear anything even if he is nearby.

Lay a solid foundation for the further upgrade of the hydraulic system

In addition, the reliability of the power units in the Bosch Rexroth interconnected hydraulic portfolio has satisfied plant managers. Team lead Daniel Link says he hasn’t heard from Cytro since installing CytroBox