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Bosch Software Innovations

Software Innovations · Manufacturing

Process Quality Module for tightening processes
An early warning system that reduces error costs

Process Quality Module – process data firmly in hand

Detect and avoid deviations and faults as early as possible.

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Cut your error costs by as much as 10%
Reduce unplanned downtime by as much as 10%

Industry 4.0: intelligent software solutions for Connected Manufacturing

Reliably carrying out safety-critical tightening processes in industrial production and keeping an eye on the virtual models of these processes: these are crucial elements in achieving error-free and highly efficient production in an Industry 4.0 context. They are already possible thanks to the combination of two Bosch Industry 4.0 solutions: Bosch Rexroth’s intelligent tightening systems and Process Quality Module from Bosch Software Innovations.

With the Process Quality Moduler, you can monitor and document process data from multiple machines in real time. A cockpit visualizes the various performance indicators and tolerances so that you can identify and resolve problems more quickly. Specific analysis functions, definable rules for active notifications in the event of deviations, and comprehensive reporting functions are available, all of which allow you to continuously improve your production processes. Bosch Rexroth’s intelligent tightening technology is remarkable for its integrated sensors that measure torque and rotation angle as well as for ways to regulate and monitor these process values. These features also recommend it for use in safety-critical tightening processes. A special role is reserved here for Bosch Rexroth’s NEXO smart cordless nutrunner. All control functions are packed into the tool, as are the sophisticated measuring electronics for determining torque and rotation angle. The smart nutrunner can thus be connected to a production hall network without any additional hardware. The Process Quality Module can then evaluate the process data.

Tightening systems by Bosch Rexroth The Process Quality Module

The Process Quality Module in tightening processes: a case study

The Process Quality Module masters the constant challenges of safety-critical tightening processes.

Increased productivity:
Industrial manufacturing companies are constantly faced with the challenge of increasing productivity, reducing rework costs, and achieving rapid production ramp-ups. The cost pressure is intense. Faults in production are expensive and can cost you your competitiveness. You can master these challenges by continuously optimizing your process quality.

Continuous process transparency:
Processes have to be transparent for continuous improvement to be successful and to optimize the application of expertise. Tightening experts in the production environment are sought-after specialists, particularly for safety-critical tightening. Only a handful of tightening specialists have the expertise for such critical processes as well as detailed knowledge of the kinds of complications that can occur – in other words, what causes tightening problems and how they can be solved.

Handling large quantities of process data:
Every completed tightening generates a large amount of data – such as torque, rotation angle, and time – that the system records and stores. This quickly creates huge amounts of data that have to be prepared and processed. Companies therefore need to take an intelligent approach to handling these huge data quantities.

Early detection of faults:
Even a slight deviation from the target process can lead to serious failure costs. For this reason, you should identify errors and failures as they occur and proactively inform the tightening experts. Early detection allows you to take preventive action.

Highlights of the tightening data cockpit

Faster overview of all tightening processes

Managing users, roles, and rights:

The Process Quality Module enables the independent management of users, roles, and rights – including authentication. Different roles can be defined for users in dispersed and heterogeneous teams according to their responsibilities, along with the corresponding views and access rights.

Tree structure:

With its various levels, the tree structure enables quick navigation through plants, production halls, lines, stations, screw joints, right down to individual channels. Configurable color changes (red, yellow, green) at each level depend on the NOK status rates, and therefore inform the user about eventual process disruptions. At the channel level, a tightening system’s master data as well as the previous 100 screw fittings are displayed as bars in a row. A green bar means OK, a red bar means NOK.

General user interface with tree structure of the plants and tightening-system master data Icon lens
General user interface with tree structure of the plants and tightening-system master data

Analyzing tightening processes

With patented analysis functions, such as superimposing curves of spindle data or navigating bars for 100 data points, the Process Quality Module provides experts with helpful tools for detecting faults and deviations earlier so they can respond faster.

It is easy to compare processes per criteria such as parts, batches, stages, or certain intervals by means of several stacked process curves. Once you have identified the relevant process parameters, components of the Production Performance Manager can usually monitor the parameters in question.

Real time data acquisition

Process data is transmitted from the tool controller to the software in real time, stored in the database, and visualized in the web-based user interface. You can use any popular web browser to access the Process Quality Module. This grants you immediate access to all tightening process data so you can intervene if necessary.

Documentation: storage of component IDs

With the help of the Process Quality Module, the component IDs for every completed tightening process are also stored in the database. This information is of particular relevance if component tightenings need to be precisely analyzed at a later time.

Additional features

  • Rules: Expert knowledge can be visualized on an intuitive, graphically guided user interface. This makes it possible to define rules that make use of logical links to trigger targeted actions such as notifications (e.g. e-mail, ticketservice).
  • Notifications if defined thresholds of NOK rates are exceeded: You are notified in the form of a color change of the plant overview and in the most recent 100 completed tightening processes displayed.
  • Notification of atypical behavior: You receive a notification when trends or runs are detected as well as atypical behavior of critical readings.
  • Night view: At night the application features a darker layout, which makes it easier for the eyes to adjust during night shifts.

An example of a tried-and-true configuration

We would be happy to work with you to determine the viability of connecting tightening systems from other providers as well as other technologies.

  • 500 Bosch Rexroth tightening systems (firmware 2.4) with a cycle time of 10 seconds
  • Two Linux servers
  • Relational database
  • Web-enabled devices

System architecture – Tightening data cockpit Icon lens
System architecture – Tightening data cockpit