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Tillmann Group puts a tried-and-tested profiling machine on course for the future with ctrlX AUTOMATION
When automation components reach the end of their life cycle, the risk of unplanned downtimes increases. Yet many companies want to continue using tried-and-tested machines. For this reason, the Tillmann Group collaborated with Bosch Rexroth to completely modernize a profiling machine. The existing third-party control system was retained while Bosch Rexroth modernized the machine itself with ctrlX AUTOMATION, enhancing the control system, the drive systems and the system safety. The outcome: a future-proof solution with a reduced space requirement and lower energy use.
In metal forming technology for the construction, automotive, and electrical industries, high precision, stable processes and flexible material processing are crucially important. Longer workpieces also have to be machined with high repeatability, sometimes with tolerances in the range of one-tenth of a millimeter. At the same time, many companies face the challenge of wanting to modernize their existing systems without letting go of effective production concepts. The Tillmann Group, a network of four companies with over 400 employees that specializes in profiling technology, faced this very challenge.
“Our profiling machine had been in reliable use for several years. It was also clear that we needed to modernize the automation technology to allow the system to be operated on a safe and cost-effective basis over the long term,” explains Martin Termast, head of the electrical department at the Tillmann Group. “Our goal was to future-proof the machine, reduce the risks of downtimes, and provide a basis for further modernization steps.”
Precision synchronization in ongoing profile production
The system is used for the production of profiles. During this process, metal strips on a coil are formed continuously in a roll forming line and cut to length. A key component is the moving cutting unit, including the flying saw, which cuts the material to the precise length as it moves. Then there’s the roller feeder, which guides the material flow to precision and has to be synchronized with the other movements of the machine.
This process sequence places high demands on automation. Differing materials – including stainless steel and high-strength steels – require reliable processing. Even minor deviations in the synchronization or cutting can have a direct impact on dimensional accuracy, quality and output. The modernized automation components also have to be available for the long term and compatible with future requirements (e.g., the Cyber Resilience Act).
An established collaboration as the basis for modernization
Tillmann chose Bosch Rexroth for the retrofit. The key factors in this decision were the long-standing collaboration in the area of service, the established trust in the on-site support and Bosch Rexroth’s existing application-related expertise – particularly in continuous machining applications such as the flying saw. Their experience with Bosch Rexroth solutions in the customer's environment was also a key consideration.
During the modernization, Bosch Rexroth focused specifically on the machine level while the third-party control system remained in place as the higher-level instance for the control of the peripherals. The core of the new solution consists of the control system ctrlX CORE, the drive solution ctrlX DRIVE and ctrlX SAFETY for the functional safety and the complementary MS2N and MAD type motors. On the software side, the ctrlX OS operating system provides an open app-based platform for features such as PLC, EtherCAT Master, Motion and Profinet Device. The PROFINET interface ensured a seamless integration into the third-party environment.
The CRA compliance of the Bosch Rexroth products used in this case, as well as the seamless integration of the Motion App with the flying saw's function block, were decisive factors in selecting Bosch Rexroth as the supplier.
“The crucial factor was the seamless integration of the new solution into the existing architecture, which enabled us to bring the actual machine automation up to date in terms of technology at the same time,” explains Andreas Fertig at Bosch Rexroth. “The combination of our open and modular automation system ctrlX AUTOMATION and retrofit expertise was a key success factor in this project.”
Tried-and-tested functions and project-specific implementation
The implementation was preceded by a preparation phase lasting several weeks. Bosch Rexroth started by validating the function block for the moving cutting unit in a pilot project. The function for the roller feed was simultaneously developed to meet the specific application requirements and integrated into the solution concept. This was supplemented by software adjustments, testing, and the fine-tuning of the technical factors according to the existing mechanics.
The actual machine modification and the subsequent commissioning and testing were completed within a few days. The work was based on an existing control cabinet, a detailed understanding of the application and mechanical components previously serviced by the customer. Existing functions, such as the synchronous operation, were also integrated into the new automation concept, enabling an efficient modernization and the optimum alignment with the actual production process. The interface for the operator and control system remained unchanged.
The commissioning process went smoothly; this was also due to the close support from the Bosch Rexroth technicians, who were consistently available during the project and provided on-site support whenever required.
Reduced space requirement, lower energy use, greater future-proofing
The retrofit resulted in measurable improvements for Tillmann: the space required in the control cabinet was reduced by 30 percent, while energy use fell by 25 percent – partially due to the regenerative power supply. The modernization also reduced the risk of unplanned downtimes due to outdated or discontinued automation components.
This retrofit not only improves the technical basis of the plant but also strengthens its future viability. Existing machines can continue to be used on a cost-effective basis and adapted to the latest requirements in automation, integration, availability as well as the regulations.
“The collaboration with Bosch Rexroth was consistently based on trust and a focus on solutions. The retrofit was completed on schedule, and we were able to significantly advance the technology of the system. This provides us with an important basis for modernizing proven existing systems to ensure their future viability.” explains Martin Termast.
A basis for further retrofit projects
The project therefore has a signaling effect for the Tillmann Group that extends beyond the individual machine. Following the positive experiences, additional systems are already being considered for modernization. The retrofit demonstrates how existing production facilities can be brought up to date with manageable interventions and equipped to meet future requirements.
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