With HYDAC on the

way to Industrie 4.0

Automation of
added value
networks

New
business models Digitisation

Industrie
4.0
Connectivity,
Flexibility Smart
Factory
commun­i­
cation
Industrial
Internet of Things
(IIoT)

Increased Information
efficiency available
in real time
E 10.159.0/03.17
 Automa
With HYDAC on the way added
to Industrie 4.0 netw

Technology and ever shortening product life cycles,

increased individualisation of customer wishes,
resources becoming scarce and globalisation
are bringing about enormous challenges for
the manufacturing industry.
The resulting problems do, however, create a high
potential for innovative solutions. For machinery and
system builders, there are diverse opportunities to
generate competitive advantages. Connectivity and
digitisation will play a key role here.
On this basis, it will be possible to develop new
business models as well as new product and service
offers. The changes that industry is aiming for are
deemed so extensive that in Germany there is talk of a
fourth industrial revolution or, put simply, “Industrie 4.0”.
In other parts of the world, corresponding developments
are being advanced under terms such as Smart
Factory or Industrial Internet of Things (IIoT).

What is the best way to describe

‟Industrie 4.0”?

Many different definitions have been put forward.

In brief, ‟Industrie 4.0” is often defined as ‟the merger
of cutting-edge information and communication
technology with the manufacturing industry” or as
the ‟Internet of things and services” in the industrial
sector.
The very far-reaching vision and goals of Industrie 4.0
are illustrated by the in-depth definition of ‟Platform Industrie 4.0”:
‟Industrie 4.0” stands for a new level of organisation and
control of the entire value chain across the life cycle
of products.
This cycle is orientated towards the ever increasing individualised
customer requirements, encompassing the idea, the development,
the assignment, the manufacturing, the delivery of the product to the
end customer and the recycling, including the associated services.
The basis is the availability of all relevant information in real time by
connectivity of all instances involved in value creation and the ability to derive
the optimum value creation flow from the data at each point in time.
Linking people, objects and systems creates cross-company added value networks that
E 10.159.0/03.17

are dynamic, real-time optimised and self-organising and that can be optimised in
accordance with criteria such as costs, availability and resource useage.

2
 ation of
d value Targets
works Industrie 4.0

zzMore extensive digitisation and automation

of value chains/ networks
zzNew business models and new forms
of added value
zzEfficient production of customised
products “batch size of one”
zzFlexibilisation
zzFurther increase in efficiency
(in terms of productivity and resource efficiency)
zz Improved information
and transparency as a basis for optimising
decisions and processes
zz New design for work

 thus overall increase in competitiveness in global competition.

To allow the far-reaching vision of I 4.0 to be realised, comprehensive foundations
must be laid, particularly in relation to the security of networked systems, legal
frameworks, standardisation and research & development.

2015 2018 2025 2035

MIGRATION STRATEGY

INDUSTRIE 4.0

The industry is currently at the beginning of this development

and is first of all pursuing a migration strategy towards I 4.0.
The I 4.0 solutions currently offered are often isolated solutions,
such as distinct production units or assistance systems,
that use available solutions directed towards I 4.0.
At the same time, existing components and systems are naturally
also used, if their characteristics meet the current requirements
for the development towards to I 4.0 or can be adapted to do so.

HYDAC offer a wide range of products and services and possess in-depth
application knowledge, making HYDAC a partner for all kinds of I 4.0 developments.
Furthermore, we work with our customers on future-focused products, digital
services and new business models.
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3
 Fluid Conditioning Fluid Condition Condition CO3 hydraulic AutoFilt® RF3 / TestCube
Systems Monitoring Monitoring Unit power unit with RF4 Control Unit TCM-800
Sensors CMU 1000 fieldbus interface ACU
Automation of Continuously working, self-cleaning
End-of-line testing as integral part of
series production of machines and
Stationary and mobile Sensors for recording solid and System for recording and processing added value automatic back-flushing filter for separating systems
Variable-speed, pressure-controlled
fluid conditioning systems for
filtering, dewatering, degassing
liquid contamination in fluids such as wear particles,
dirt particles, water and external fluids
measured data for up to 8 sensors networks zz Communication direct or via fieldbus
particles from low-viscosity fluids
zz Open connectivity to all standard customer­
zz Automated workflow for production-specific
test functions with documentation.
zz Simple programmability of
and conditioning operating fluids zz Measurement data provision via Ethernet interface measured-value evaluation and processing zz Provision of process and operation data interfaces (1x Ethernet, 1x serial RS-232 C / RS 485) zz Provision of measured values, diagnostic data and reports
and standard fieldbus protocols such as pressure, oil temperature, frequency, current zz Remote monitoring possible with smartphone or tablet locally and via standard interfaces to the customer system
zz Control and system integration via standardised network zz Generation of smart data
consumption, running time zz Self-diagnosis, system diagnosis, process monitoring (Modbus TCP / OPC).
interfaces (e.g. Ethernet, TCP/IP) zz Parameterisable threshold value monitoring (action recommendations/warnings)
zz Connectivity via Ethernet zz Bidirectional communication of component activity
Digitisation
Digitising data makes it possible to shift business activities
from the real world to the virtual one.
Digital replication or virtual representation of
information, products, functions, processes and value creation
Fluid Condition Machine Condition Smart Smart accumulator –
HYDAC Groundlab

networks in virtual reality is the basis for:

V01.10 R01 HYDAC Filter Systems GmbH

REPORT for hydraulic fluids

Date: 11-DEC-2015 Time: 13:43

Monitoring and Performance accumulator thanks to Bladder

A/C Tail No: RDPL-34188 A/C Description: Airbus A320-214
A/C Serial No: MSN-04596 A/C Hours: 4711

A/C Hydraulic system: Blue

New business models and zzMore extensive automation of production processes

modules and Reporting thanks to p0 guard Integrity System (BIS)
Test No: 1
Number of Runs: 3
Volume per Run: 100 mL

additional value creation steps zzMore extensive automation of added value steps
Airbus Recommended

systems
Limits

Acid Number, mg KOH/g …………….. 0.71 1.5 Max

and value chains Detection of deviating accumulator

Water, % ………………………………………. 0.35 0.50/0.80 Max

Compact fluid sensor modules

Particle Count……………………………….
5 to 15 microns (Class) /100mL …….
----------
248500 (10)
----------
128000 Max

e.g. on the basis of Detection of defects

System condition reports pre-charge pressure (p0)
15 to 25 microns (Class) /100mL ….. 26825 (10) 22600 Max

zzNew added value steps, additional digital services in accumulator bladder

25 to 50 microns (Class) /100mL ….. 10570 (11) 4050 Max

and solutions for assessing

50 to 100 microns (Class) /100mL … 1690 (11) 720 Max
>100 microns (Class) /100mL ……….. 135 (10) 128 Max

the fluid condition. and action recommendations AS 4059 / NAS 1638 Class ……………..

Scavenger depletion rate, % …………

11

70
Class 9 Max

zzAdditional digital services (e.g. digital service and commissioning) zz by means of pressure monitoring
zz Detects liquid in the bladder
compiled on basis of measured on fluid side
zz Measurement data provision and system integration fluid and non-fluid data and process parameters zzDigitally charged products zzOptimisation of development, simulation, virtual testing zz Stand-alone data interpretation
zz Provides accumulator condition data
(e.g. central control and condition monitoring systems) via zz HART protocol for data output
standardised interfaces and protocols zz Cyclic and event-based delivery of system condition zzMarketing of products “as a service”, for zzIn all, therefore, for cyber physical systems (CPS)/
zz Alarm in the case of pressure deviation
zz Plannable accumulator service  system availability
zz Parameterisable threshold value monitoring reports via e-mail example: Industrie 4.0 / IIoT
zzRental models
zzOperator models
zzOutcome-based remuneration New
business models Digitisation
Smart Filter industry Remaining Sensors with Combination sensors IO-Link
with HPT 500 IO-Link service life self-diagnosis sensors
prediction for
smart filters
Measurement of pressure, Sensors to measure pressure,
Filters with sensors for recording Algorithm for Pressure/temperature, distance/position/temperature, differential pressure, distance,
distance/position, angle
the differential pressure
zz determining the dirt load percentage
Flexibility zz Independent check of fluid level/temperature, temperature/humidity/ temperature, fluid level, humidity and oil ageing
zz Bidirectional communication via IO-Link zz determining the expected remaining service life Developments such as the desire for individualised correct function conductivity/DC (HLB), pressure/temperature/integrity zz Bidirectional communication via IO-Link
provision of measured values
Industrie of accumulator bags (BIS) zz In addition to switching output, measured values and
in digital form/IO-Link on basis of differential pressure, flow rate products with mass production pricing zz Increased machine availability and efficiency
diagnostic data provided in standardised digital format
and temperature in case of service (no need for fault-finding) zz Process/condition data
zz Digital quality protection (thus ultimately for individualised mass
production), shorter and shorter technology, 4.0 Connectivity, Connectivity and communication zz Only one process interface and one electrical interface

innovation and product life cycles and resource zzIdentifiability

shortage keep applying new demands when it Flexibility Smart communi­
comes to flexibility. To this end, Factory cation zzBidirectional communication capability
Industrie 4.0 pursues goals such as: zzStandardised, digital interfaces and
Industrial protocols
zzThe adaptable factory Internet of Things
Intelligent Variable-speed drives Bluetooth Cooling
zzPlug & produce modules/systems (IIoT) zzRemote access to products,
valve X-efficiency pressure monitor
zzSmart production data and information
transmitter
Needs-based
zzSystems that can organise and zzSecurity for connected systems
Coaxial valve with water hammer damping, optimise themselves PC software for observing
energy provision Wireless pressure transmitter, all process parameters in the
switch position indicator, automatic holding current
reduction, adapter solution zz Increased efficiency of hydraulics zzSmart workpieces that control their production mainly for service and commissioning cooling system (passive or active cooler)
zz connectivity and data exchange zz Standard Bluetooth interface zz Communication via RS232, USB or Ethernet
zz Bidirectional communication via IO-Link zzSelf-learning machines and systems
zz Adaptive parameterisable interface for further customer-
at fieldbus level
zz Intelligent modular systems for control tasks zzFlexibilisation of value creation networks Information zz Sensor operation and provision, zz Visualisation, recording of temperature progression, output of
specific functions and workflows directly to the drive controller Increased available
visualisation and, as applicable, evaluation of measured
data
status messages (multiple language),
zz Remote control, remote diagnosis
zz Retrofittable
efficiency in real time
via smartphone/tablet and app

Increased efficiency Relevant information

zzProductivity available in real time
Online QR code on Remote Compressor Non-linear Eco-Box
configurators name plate commissioning zzResource efficiency zzProcess data coolers power control
kit zzCondition data
Dimensioning and configuring zzMachine availability System for increasing energy
of electro-cylinders and DVA kits QR code link Online commissioning zzSmart data efficiency (uses passive cooling
zz In download zone: on the corresponding product website support on customer side zzService, condition-based Model-based controller for precise and rapid control of operation in addition to compressor
or predictive maintenance (e.g. action recommendations) Active cooling system for water,
zz Data sheet of the configured product zz All product-relevant data can be viewed: zz Rapid assistance for commissioning and service oil and other fluids various heat exchangers cooling, where possible)
zz CAD data -- Parts list zz Kit easy to use
zzEnergy efficiency zzSmart products zz Bidirectional communication via RS232,
zz Data exchange via TCP/IP protocol zz Bidirectional communication to compressor
zz Preliminary customer design -- Operating instructions zz Higher productivity for the Profibus, ProfiNet or EtherCAT, CANopen, Ethernet zz Monitoring of cooling liquid supply, reporting of non- cooler via RS485
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E 10.159.0/03.17
zz Shorter run times of the ordering process -- Data sheets application engineers
zzMaterial consumption, zzCloud zz Modification of process parameters (e.g. target permitted operating states, logging of operating data such as zz Automatic closed-loop control of entire
zz Better options for system planning zz No connection to customer’s temperatures and cooling capacities systems composed
-- 3D data environmental impact temperature), output of diagnostic data
on the customer side network structure required (security) zzInternet/WWW zz Self-teaching of active and passive coolers

zzAssistance systems,
redesigned work structure

4 7
 Global Presence.

Accumulators 30.000
Local Expertise.
www.hydac.com
Fluid Filters 70.000
Process Technology 77.000
Filter Systems 79.000
Compact Hydraulics 53.000

HYDAC Headquarters
HYDAC Companies
HYDAC Sales and Service Partners
Accessories 61.000

HYDAC INTERNATIONAL Industriegebiet

GMBH 66280 Sulzbach/Saar
Germany
Telephone:
+49 6897 509-01
Electronics 180.000

Fax:
+49 6897 509-577
e-mail: info@hydac.com
Internet: www.hydac.com
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Cooling Systems 5.700