In 2019, i2CAT joined 11 distinguished partners in the 5G-CLARITY project, with a clear ambition: to develop a Beyond 5G framework for private networks. This framework integrates multiple wireless technologies, managed by AI-based autonomic networking. Our vision found its ideal proving ground at the Bosch Aranjuez plant, a high-technology facility producing over 60 million components annually, committed to becoming a world-class digitalised hub. Our partnership deepened with the 6GSMART project, part of the Spanish UNICO I+D 6G programme, promoted by the Spanish Government with NextGenerationEU funding, which focuses on how 5G Advanced and 6G technologies can significantly boost manufacturing productivity. Collaborating with Neutroon Technologies, i2CAT’s spin-off, we deployed and tested a groundbreaking private network architecture, fundamentally transforming Bosch’s production lines.
Before our intervention, Bosch, like many industrial leaders, faced common challenges with traditional connectivity. Reliance on Ethernet-based networks incurred high maintenance costs and prolonged deployment times for new production lines. The extensive use of copper and plastic cabling also contributed to an undesirable carbon footprint. Critical industrial use cases demanded robust connectivity for:
Our core solution at Bosch Aranjuez is a new private network architecture that converges private 5G, Wi-Fi 6, and LiFi under a single platform. This innovation seamlessly replaced Bosch’s existing Ethernet network without requiring changes to line equipment, demonstrating its practical integration.
A key innovation is our multi-connectivity framework, a sophisticated software system that intelligently controls packet transmission across these diverse networks. For scenarios that demand extremely high peak data rates, we combine Wi-Fi 6’s speed with 5G’s excellent coverage, creating an aggregate data pipe. For applications requiring extreme reliability and low latency, such as critical production lines connected to manufacturing execution servers, our system can duplicate transmissions across multiple wireless access technologies, ensuring continuous communication even if one network fails.
For the 6GSMART project, we implemented an AI-based visual inspection system. This system utilises advanced cameras to capture component images (e.g., the AC Interface connector in electric vehicles) and transmits them via 5G and Wi-Fi 6 to a central server. Leveraging Nomad 5G by Neutroon, a “5G in a Box” solution integrating all 5G Standalone network elements, edge processing, and Wi-Fi access, robust AI algorithms (specifically YOLO) process these images in real-time for defect detection. The server then sends an immediate response to allow or block the part, eliminating the need for physical cables in this crucial inspection process. We also focused on simplifying network operation, enabling non-5G experts to utilise the technology efficiently.
The impact of our collaboration at Bosch Aranjuez has been truly transformative. Bosch has achieved optimised quality control, significantly reduced costs, and improved efficiency in its production processes through automated visual inspection. Replacing the wired Ethernet with our wireless architecture resulted in substantial reductions in maintenance costs and a quicker deployment of new production lines. Furthermore, the reduction in cabling contributed to a lower carbon footprint for Bosch.
Technically, our achievements are highly significant. Through 5G and Wi-Fi aggregation, we practically achieved a stable 600 Mbps downlink and 400 Mbps uplink, providing Bosch with a more flexible and economical connectivity solution than Ethernet, all without increasing process cycle time. Our solutions effectively cater to industrial use cases that require both high data rates and mobility, as well as stringent latency/reliability requirements. We also developed four indoor positioning systems, two using radio waves and two using visible light, achieving precision ranging from a few meters down to a few millimetres. Manuel Bruna, Technical Functions Manager at Bosch, affirmed that “The results of the 6GSMART project represent a significant advance in the connectivity of our machines, laying the foundations for the future integration of artificial intelligence in high-performance industrial environments”. This project has enabled Bosch to take a crucial technological leap, preparing it for future integration with AI.
Our success with Bosch is a cornerstone of a larger, ongoing vision. The 5G-CLARITY project continued its vital mission to drive Europe’s leadership in the growing markets of 5G private networks, factory automation, and the consolidation of Industry 4.0. Our spin-off, Neutroon, launched in 2020, perfectly exemplifies this commitment, offering the first Software as a Service (NaaS) platform that simplifies the management and orchestration of multiple distributed private networks, with integrated LTE, 5G, and Wi-Fi capabilities. Neutron’s Customer Portal enables companies to intuitively configure and manage their systems, scaling to meet evolving needs. The ongoing 6GSMART project continues to explore 5G Advanced and 6G technologies to further enhance industrial productivity. Bosch’s commitment to transforming its plant into a “world-class facility in terms of digitalisation” and building a “connected plant” resonates deeply with our mission. At i2CAT, we are proud to be instrumental in Bosch’s journey, helping to secure a sustainable, intelligent, and technologically advanced future for European industry.
