Casos de Exito
Turck is supplying Movexx with most of the equipment required for an automated guided vehicle, including the programming of the Codesys controller on the HMI VT250
In the suspension systems production area at the Dutch company VDL Weweler, an automated guided vehicle (AGV) supplied by Movexx transports components for suspension systems from the basic production area to the paint line. Turck’s HMI VT250 with a Codesys controller is controlling how the vehicle finds its destination, supported via photoelectric sensors, an RFID system, angle sensors, and status indication systems from the Turck portfolio. Turck B.V. demonstrated its genuine solution expertise by not only supplying components but also programming the controller. Since the AGVs have taken up their duties in production, the error rate for the transport of components has rapidly dropped.
Three fibers with connected amplifiers are installed for the bidirectional control of each direction
The AGV receives the order wirelessly to move the frame with metal carriers to the painting line
RFID tags that provide the AGV with position information are embedded in the floor
”The transport solution had to be as flexible as possible” – Bert Eilander, VDL Weweler
Turck’s VT250 communicates wirelessly with the IMS and controls virtually all systems of the vehicle
Turck’s contactless angle sensor measures the angle of steer
Three fibers with connected amplifiers are installed for the bidirectional control of each direction
The AGV receives the order wirelessly to move the frame with metal carriers to the painting line
The responsible production planners saw the need for optimization in the transport of support elements and suspensions for truck trailers. Up to the middle of 2015, these components were still being transported via lift trucks between the basic production area and the paint line.
Manual transport lacked precision
The disadvantage of this solution was that it required a lot of physical effort from the employees. Furthermore, colleagues could not always work as precisely as an automated vehicle, so the production was endangered. Therefore, in 2014 the decision makers at VDL Weweler decided to automate the transport of the frames.
Movexx develops new automated guided vehicle
The company turned to the transport specialists at Movexx International B.V. to develop an automated transport solution. Movexx is a Dutch manufacturer of industrial trucks, including many customer-specific products. The manufacturer had already developed and built so-called AGVs (automated guided vehicles). However, a new solution had to be developed for this task.
The AGV needed to move in both directions because it was only possible to reverse out of the target stations. The hydraulic lifting platform raises the frame two centimeters from the floor in order to transport it.
Comprehensive automation solution from Turck B.V.
To develop the transport vehicle, Andreas Versteeg got Turck on board during the planning phase. Movexx had previously used the Turck sensors and LED lights in its products. However, this project also required solution expertise as well as capable components.
The greatest challenge was the bidirectional control of the AGV on the factory floor. Turck suggested a combined RFID contrast strip control.
RFID system for destination control
Optimum line tracking is combined with RFID tags which are stuck to the factory floor at key points along the lines. The tags at the turnout points indicate to the AGV whether it is to continue driving or stop. The AGV does not itself make decisions. The intelligence is in the networking of the AGV with the higher-level IMS (integrated manufacturing system), which instructs the AGV to move to a specified point.
Turck’s VT250 HMI-PLC operates on the AGV. It communicates with the IMS via a wireless TCP/IP connection and responds as a Profibus master with a BL20 gateway containing the inputs and outputs to which all signals of the vehicle are connected.
The automation of a production line for exhaust systems enables Turck to demonstrate the flexibility of its BL20 multiprotocol gateway in conjunction with the IO-Link-capable TBIL hubs
Turck’s IO-Link portfolio ranges from sensor to connection technology and I/O solutions
Tailored solution: IO-Link, multiprotocol Ethernet, and I/Os for many inputs and outputs
Flexibility was the greatest challenge in planning the new production line for exhaust silencers
Turck’s IO-Link portfolio ranges from sensor to connection technology and I/O solutions
Flexible Silencer Production
One of the leading manufacturers of exhaust systems chose Turck’s BL20 modular I/O system in order to provide a highly flexible I/O solution. A special feature of the new production line is that fieldbus systems have to communicate with different controllers – an ideal application field for Turck’s BL20 modular IP20 I/O system. The multiprotocol gateways, which feature the necessary I/O slices, speak PROFINET, EtherNet/IP, and Modbus TCP. This enables the BL20 system to bring different types of signal to the controller and also link different valve blocks on the production line. The system integrator, Teknodrom Robotik ve Otomasyon, was responsible for the installation and integration of the entire automation solution. Teknodrom spoke to Turck about the sensor and I/O requirements for the new production line already in the design phase.
IO-Link ensures efficient production
The user benefits enormously from the flexibility that IO-Link provides for the requirements of this system. Turck’s BL20-4IOL gateways with IO-Link master modules and the IO-Link capable IP67-TBIL I/O hubs bring up to 16 switching signals from the field to the control cabinet via a single four-wire cable. The TBIL functions as an IO-Link slave, bringing 16 binary signals to the IO-Link master on the BL20 gateway. This considerably reduces wiring effort and wiring errors. The alternative passive junctions with large multipole cables are more expensive and time consuming.
Flexibility with IO-Link
Another benefit of IO-Link in the production line becomes apparent when different tools are changed. “The clamping devices for the products have to be changed frequently in the plant. The IO-Link modules for BL20 offer a high level of flexibility. “During the installation, we can easily adapt the BL20 system by adding or reducing the number of signals,” says Selim Çağatay, the control technician responsible at the system integrator. “With every additional expansion or upgrade of the plant we benefit from this flexibility.”
Efficiency through decentralized IP67 I/Os
Even at the production lines for MIG (metal inert gas), the smart IO-Link solution is significantly simpler, faster, and more economical to implement than multipole cable systems. It also makes a major contribution to quality assurance. All signals are collected via Turck’s TBIL IP67 I/O hubs and then forwarded to the BL20 system via a single four-wire line. The IO-Link master and multiprotocol gateway handle the additional communication with the controllers via Ethernet. Thanks to the digital IO-Link transmission, the user can save on the expense of shielded cables and other EMC measures.
Another benefit of RFID technology is that the information is less susceptible to environmental influences because it is transferred electromagnetically via radio waves. While externally applied printed bar codes become unusable with high temperatures, dirt, or moisture, the special RFID data carriers and robust scanners allow the use of RFID systems under very rough conditions or through nontransparent media.
Rethinking in the automotive industry
High temperature tags are attachable to a carriage (also known as a skid) that transports the vehicle body throughout production. This is how the path of the vehicle can be tracked from shelling to the final assembly, as long as the transport system remains the same. The most commonly identified components include monorail conveyors, skids, or any other carriers that handle the vehicle body and larger vehicle parts, such as engines and axles.
If a data carrier is firmly connected to the vehicle body at the beginning of the production process, the body can be identified safely at any time – from shelling and painting to the final assembly and delivery.
Vehicle body identification demands UHF-system
When transport systems are equipped with tags, there are always relatively small, defined distances between the data carriers and the combined read/write heads. If the tag is attached to the vehicle body directly, the range is inevitably larger – it mostly varies between 30 and 100 cm. For this reason, HF-systems cannot be used in this instance because the transmission range is limited to 20 cm. The solution is to utilize the UHF-range, which allows distances of up to three meters.
From the supplier to the final assembly
The fact that UHF-challenges also can be mastered and carry considerably lower data carrier prices convinced many automobile manufacturers to equip the coming model ranges with data carriers on the vehicle bodies, which means that they can be identified throughout the entire process. Furthermore, in projects where Turck is involved, the possibilities are tested to also optimize the delivered parts of the suppliers with RFID, thereby optimizing the entire production process up to the final assembly with the wireless identification.
Pro Pack Systems, Inc. in Salinas, California, designs and builds custom case erectors and packers for manufacturers across many sectors. Their latest packaging machine, the Pro Print/EBS-HS-2, includes technology to turn their concept of a flexible packaging and printing solution into a reality.
To ensure safe operation in harsh environments, the Pro Pack engineers trust in Turck IP67 rated proximity sensors, pressure sensors, cables, and BL20 I/O stations.
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Manufacturers of the food and beverages we consume every day must adhere to strict requirements in order to produce high quality products that are safe. There are many checks within the system, including frequent cleaning by high pressure washdowns to maintain sanitary conditions within the plant.
Developing machinery that can withstand such cleaning is not an easy feat, considering that most electronics are not designed to get wet or to function in high moisture environments. Turck rises to the challenge with IP67 power supplies that thrive in harsh environments.
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Somakon Verfahrenstechnik uses Turck’s HMI/PLC solution – the VT250 – for intelligent control and operator guidance of its MP blender family
The blenders at Somakon are very popular at the research and development departments of renowned industrial users, because they can be adapted individually to most tasks because of their modular concept. To offer this flexibility at a good price performance ratio, Somakon uses Turck’s HMI/PLC, VT250, as efficient control and operation unit.
Blending, as an independent procedural step in development laboratories, has become more and more important over the last few years. Combined with the demand for small quantities and transferability to larger systems, only a select group of laboratories have the correct capabilities.
Wolfgang Naton, manager for Somakon Verfahrenstechnik, has dealt with the problem of mixing and granulating on a laboratory scale for the last ten years. Along with their entry model, the LB, which was designed as a pure blender, Somakon also offers the MP blender family.
Modular blender concept
“MP stands for multi-purpose, which means that we can configure the systems individually according to the requirements of the customer,” Naton explains. “Many customers start with a base model, but quickly request further functions. With our MP solution, we have the flexibility to update the base model according to our customers wishes, and add temperature, pressure or humidity measurements. With this you can handle entire processes.”
In addition to blending, the MP machines can be used for granulating, pelletizing, emulsifying, suspending, kneading, loading, crushing or drying – based on the configuration level. Along with the containers and tools, the blender is equipped with sensors and actuators, depending on the process steps that are performed. To offer the needed flexibility of its machines, Somakon turned away from mechanical control elements and classic controls, and tried the VT250 from Turck instead.
The VT250 is a compact operator terminal with a PLC that was developed especially for independent control and the operation of small and medium sized machines – the ideal solution for the MP blender family. The VT250 includes a 5.7″-QVGA-TFT touchscreen in a compact plastic housing; QViS visualization software provides the communication between human and machine, which is implemented by the common control software CoDeSys 3.
“With the VT250 from Turck, we have a PLC that meets all our requirements at an optimal price performance ratio,” Naton adds. “We have implemented the first project with Turck and received a lot of support during the set-up of the new machine. This includes the programming of the controls with CoDeSys.”
As well as using the VT250, Somakon uses the economy version of Turck’s BL20 I/O system to connect the sensors and drives of the blenders. The BL20 Ethernet gateway coordinates the communication with four I/O modules and serves as the interface to the controls within the VT250.
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Casos de Exito
Customer Requirement: Detect any defects on fiberglass and glass thread products as they are being spooled
Solution: SureCross® DX80 FlexPower® Gateway, SureCross® DX80 FlexPower® Node
Why Banner? Complete Wireless Operation – Battery powered Node and sensor communicate wirelessly to remotely located Gateway
CUSTOMER BENEFITS
Ease of Installation – Wireless system adapted to existing infrastructure
Low Maintenance – Expected battery life for node and sensor of two or more years
Quality Assurance – Early error detection and correction reduces material waste
BACKGROUND
A successful manufacturer of specialty industrial yarns makes fiberglass and glass thread products for applications in the automotive, aerospace, military and composite materials industries. To help maintain their high standards and minimize costly product returns, they established a goal of zero product defects. To meet this goal, the company needed an automated thread inspection system.
CHALLENGE
Industrial spooling machines rotate constantly at a high rate of speed, making standard wired monitoring solutions difficult to implement. The lack of an auxiliary power supply necessitates an independently powered solution. A customized wired solution would require equipment designed specifically to work on rotating machinery, raising costs and complicating system design and operation.
SOLUTION
The SureCross® DX80 FlexPower® wireless network was the ideal solution. The Node is protected by a rugged IP67 rated enclosure and deployed inside the winder. The open design of the Node made it easy to integrate a third-party inductive proximity sensor into the solution. One internal 3.6V lithium battery supplies power to the Node and the sensor and has an expected battery life of two or more years in this application.
System design was simple and effective. As the thread is spooled it passes through a die. In the event of a defect or a “blob,” the die will move. The movement is detected by the proximity sensor, communicated to the Node and transmitted to a remotely located Gateway. Because of the quick response time (63ms), the system can be stopped almost as soon as the error has been detected, allowing the operator to remove the “blob” and save the spool.
Customer Requirements: Consistent, automated measurement of bread dough and baked loaves for quality control in high-volume bakery
Solution: A-GAGE® High-Resolution MINI-ARRAY®, L-GAGE® Q50 Series Sensor
Why Banner? Affordability –Strategically located sensors deployed on the baking line are a fraction of the cost of more complicated solutions
Simplicity – Sensors were easy to install and adapted to existing infrastructure, resulting in minimal production downtime
Support – Banner partner provided expert selection and installation assistance as well as offering on-going system support
CUSTOMER BENEFITS
Reliability – Q50 sensors use optical triangulation to measure for height and depth
Consistency – On the line monitoring enables early detection of potential problems and ensures product quality after baking
Accuracy – A-GAGE High-Resolution MINIARRAY features 120 sensing beams per foot to create a highly-accurate light screen for precise measurement
BACKGROUND
Over many decades of operation, an industry-leading bakery has earned a reputation for delivering high-quality fresh bread and other baked goods. Today, their products can be found in hundreds of thousands of kitchens throughout the Eastern United States. Meeting these demands requires large investments in raw ingredients, energy and machinery. The bakery relies upon skilled bakers and a knowledgeable staff to operate automated baking equipment, manage resources and ensure quality.
CHALLENGES
The bakery’s multi-staged baking process begins with mixing, kneading and fermentation and completes with proofing, baking and cooling. At each stage, experienced bakers perform quality checks for appearance, texture, size and weight. Loaves that do not meet the company’s standards are rejected for consumer sales. The company needed to build-in system capabilities to help them better manage their resources and maintain quality standards.
FIRST IMPLEMENTATION
Working with Shingle and Gibb Automation, a long-time Banner partner, the company deployed the A-GAGE® High-Resolution MINI-ARRAY® onto the baking conveyor line. This emitter and receiver pair features two columns of tightly spaced beams to create a precise light screen capable of distinguishing measured variances as small as 2.5 mm. The light screen measures each loaf as it cools on the conveyor line between the tunnel oven and the slicer. If a loaf does not meet bakery guidelines, a signal is sent to a compact control module, and the loaf is removed from the line.
The initial implementation of Banner sensors was highly successful, facilitating greater consistency in quality control on the baking line. However, there was a recognized opportunity to add resource management capabilities to the system using Banner sensors.
L-GAGE® Q50 Series Sensors used to detect the height of bread dough
SECOND IMPLEMENTATION
Shingle and Gibb deployed L-GAGE® Q-50 series sensors on the transfer conveyor. These LED-based linear displacement sensors use optical triangulation to detect for depth and height. As the dough emerges from the proofing oven, the Q50 measures the height of the dough inside the baking pan. Irregularly sized dough is identified, removed from the line prior to baking and saved for future use. The bakers can then make necessary adjustments to time, temperature and humidity at the proofing stage.
CONCLUSION
This high-volume bakery benefitted from the accuracy, reliability and simplicity of the Banner sensors. The L-GAGE Q50 with its laser-like performance proved ideal for measuring dough inside the pan, but with the safety and affordability of an LED sensor. The high-speed operation and precise monitoring of the A-GAGE High-Resolution MINI-ARRAY ensured that baked loaves that did not meet required standards could be identified and removed without disrupting the line. The Banner sensors provided the bakery with enhanced quality control and resource management functionalities without requiring complicated changes to system design or existing infrastructure.
Customer Requirements: Vivid illumination to aid inspections of webs of abrasive products
Solution: WLB32 LED Light Bars
Why Banner? Performance – WLB32 LED lights provide superior illumination, will last longer and are more energy efficient than the fluorescent lights had been
Value – The Banner lights cost less and were easier to mount and power than other LED lights Hermes had considered
Ease of Installation – Magnetic mounting brackets, used throughout the deployment, greatly simplified installation
CUSTOMER BENEFITS
Longevity – Each WLB32 light will provide 50,000 hours or more of vivid illumination and will never require a bulb or ballast replacement, minimizing maintenance costs and keeping the inspection stations running
BACKGROUND
Hermes Abrasives is a leading supplier of coated and bonded abrasives. Their products are used to shape and finish materials such as metal, wood, glass and plastic for manufacturers. Defects on abrasives can damage these materials.
Multiple inspection stations are set up throughout Hermes’ production facility. At each station, webs of abrasive products are continuously inspected and any defects mapped.
“Our requirements for quality have grown with our customers’ needs. Any defects that get out into the field are unacceptable.”
“Lighting is one of the easiest solutions I can provide to help my team improve their inspection capabilities.”
– Eric Teunis, Production Manager, Hermes Abrasives
WLB32 Lighting for Web Detection Image
CHALLENGES
Fluorescent lights used to illuminate the webs were bolted onto and hardwired into inspection station machines. The lights required two to three bulb replacements each year, as well as periodic ballast replacements. Between bulb replacements, the lights gradually lost intensity and began to discolor, making inspections more difficult. Repeated replacements strained bulb holders, causing them to break off, which necessitated the replacement of the entire fixture. As maintenance complexity grew, so did the time and expense required for each repair
SOLUTION
In a direct comparison, the Banner lights outshined the fluorescent fixtures. They provided intense, daylight white illumination that distributed evenly across the inspection area. WLB32 LED lights have a 120° beam angle which directs the light toward the inspection area. The fluorescent lights distribute light all around at 360° from the bulbs. Competitive LED lights were considered. However, these were three times the price of the Banner lights, required a separate power supply, drew more amps and had to be hard mounted to the machines.
Unlike the fluorescent fixtures and the competitive LED lights, the WLB industrial LED light bars did not have to be hard mounted or wired into the machine. At most of Hermes’ inspection stations, the power supply to the fluorescent lights was simply cut, the fixtures removed and a plug was attached to the power cord. Two 1130 mm WLB32 LED lights were then installed on the machine using magnetic mounting brackets. After the first light was plugged into the machine, a second light was daisy-chained to it.
“All the Banner fixtures that I am using right now I have mounted using the magnet brackets. The installation is just so quick and easy, I could put ten of them up in an hour.”
-Eric Teunis, Production Manager, Hermes Abrasives
CONCLUSION
WLB32 industrial LED light bars have an operational lifespan of 50,000 hours or more. They will continue to bring brilliant illumination to the inspection area throughout their lifespan. With no bulb changes or ballast replacements required, Hermes will reduce maintenance expenses and increase inspection station uptime throughout their facility.
“It has been like night and day from where we were six months ago to where we are today. You walk into an inspection station and it is like the sun is shining.”
-Eric Teunis, Production Manager, Hermes Abrasives
Customer Requirements: Add vehicle detection capabilities to Fire Department dispatch and reporting systems
Solution: R-GAGE™ QT50R-RH radar-based sensors
Why Banner? Object Differentiation – Solid objects return radar to the sensor in a distinct way, enabling differentiation between vehicles and people
CUSTOMER BENEFITS
Asset Management – Vehicle detection capabilities provided dispatchers with access to reliable vehicle availability information
Reduced Insurance Rates – Documenting turnout times demonstrated department effectiveness and led to reduced insurance premiums for businesses and residents
BACKGROUND
In an emergency every second counts. Turnout time, an aspect of total response time, is measured from the moment a fire station is notified of an emergency until the departure of the first responding vehicle. The National Fire Protection Association (NFPA) has set the standard for turnout time to a fire at 80 seconds.
CHALLENGES
A large metropolitan fire department wanted to integrate vehicle detection capabilities into their dispatch and reporting systems. This would enable the department to better document turnout times and improve asset management. Photo eyes were tested for this task, but their inability to differentiate between human and vehicle movement in the drive bays resulted in incorrect outputs.
SOLUTION
Single R-GAGE™ retroreflective radar sensors were installed above each vehicle bay in the fire stations. Using the on-board DIP switches, the parameters of the sensing area of each R-GAGE was adjusted to optimize detection of the emergency vehicles and ignore objects outside of the sensing area.
The sensors emit beams of high frequency radio waves. A fire truck will absorb fewer radio waves and have a different amplitude signal than a person. Vehicle presence inside the sensing area alters the time delay of the return signal in a recognizable way, enabling the R-GAGE to differentiate vehicles from people.
Arrivals and departures of emergency vehicles are detected by the R-GAGE. The time of each event and vehicle availability status is recorded and sent to the dispatch system where it is linked to the alert notification time. Dispatchers access this information to determine how many vehicles a station has available for a fire call. Documentation confirmed turnout times consistently met NFPA standards and led to reduced insurance premiums for homes and businesses throughout the city.
Casos de Exito
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