The integrated cheese cheese automation reduces costs and accelerates the ending of the project

The demo ‘Packer', that presented for the first time in the Interpack 2011, shows once again that B&R keeps on being pioneer regarding the control of applications highly dynamic, in which distinct individual axles, levy electronic and robots have to be synchronised with the maximum precision. Designed and programmed only with the end to show the technology of B&R, this demo integrates the last developments in manipulation, artificial vision, hygiene, control and supervision.

Three distinct robot – an arm articulated, a trípode and one of axles cartesianos – with cinematic characteristics totally different move of form synchronised around a table giratoria to pack and unpack balls of golf. The complete system, that consists of fifteen axles, the control and the visualisation, operates by means of an alone CPU, in this case an industrial PC. The different cinematic of the three robots are perfectly integrated cheese cheese in the control by means of an interface opened. Said interface allows to implement any type of cinematic specific of the customer. Because of the flexibility of the interpreter, so much can use standard commandos, as they can define specific commandos more notable for the process. This allows to shorten drastically the necessary time to create the sequence of the program of manipulation.

Image 1: Cell of folded of Trumpf. An alone CPU of B&R controls all the cell of folded, that consists of a plegadora electrical and two robots.

The distinct stations mecatrónicas used in the demo packer are connected by means of an only line of communication by Powerlink, what allows to add or remove optional modules in hot. When this occurs, the new configuration is detected automatically, and the necessary software is enabled or deshabilitado, as it suit. The accionamientos that control the robots manipuladores are the same that some of which use for the rest of motors of the process, what allows to use a compact system of modules in which the accionamientos of both types of axles mount one at the side of another, reducing the costs. You consign them of position for the axles of the robots manipuladores generate in the central controller of the machine using the Generic Motion Control (GMC).

Image 2: The demo Packer integrates the last developments in manipulation, artificial vision, hygiene, control and supervision.

This also allows that the data of the robots and the ones of the process are shared in a same database of transparent form and totally synchronised. Thanks to the utilisation of this system, delete totally the necks of bottle that was used to to have in the communications by means of bus of field between the PLC and the controller of the robot in the traditional solutions. The handle of transparent form of this database also allows to add new functionalities in the machine that previously were impossible to implement because of the retardos added by the communication by means of the bus of field. This allows to optimise the processes of manipulation, increasing like this the rhythm of production and the availability of the machine. Have to pay by a controller devoted for the robot, a separate electrical cupboard and an interface of communication has happened to the history.

By means of the utilisation of motors step by step, variators of frequency and servo-accionamientos, said demo shows that it is possible to combine different technologies of transparent form. This allows to use the most adapted technology in each case. For example, can use synchronous motors –newspapers or linear– when they require movements very dynamic with big precision, whereas the motors step by step –with or without realimentación– are the perfect solution for changes of format. The asynchronous motors controlled by tension-frequency, that also are totally integrated cheese cheese in the surroundings of programming, are a solution of low cost when the precision or the dynamic behaviour are not essential for the application.

The dynamics and the synchronisation that achieves by means of Generic Motion Control no only increase the quality of the product, but also the capacity of production. The changes of format can do to the flight. All the different types of accionamiento run on the same base, and because of this program of the same form, with what the time of programming reduces . This makes possible retardar the decision of which type of accionamiento goes to use until the hour of the set up, with what the manufacturer of the machine has of total flexibility. The total integration that achieves with Generic Motion Control allows a complete escalabilidad so much in the technology as in the performance.

Image 3: The time of answer ultrarrápido of the combination openSafety-Powerlink shows by means of the immediate activation of the function Safely Limited Speed when an operario interacts with the machine.

The visitors can interactuar directly with the machine through a small gifted opening of a barrier of light. When the operator approaches, the barrier of light informs to the machine and this happens to move with a safe speed immediately. The direct communication and decentralised by means of Powerlink, that connects all the components of hygiene with the controller SafeLogic by means of the protocol openSafety, ensures an immediate answer of the machine. They exist more than 20 different functions of ‘safe motion' that they can use to shorten the necessary time for the development of an application that handle robots. For example, in this demo uses the ‘Safely Limited Speed at the Tool Center Point' (SLS@TCP). Of this form, the data of position of the distinct axles of the robot are envoys to the SafeLogic, that by means of the use of the cinematic of the robot calculates the speed of the extreme with which manipulates the balls of golf. In place to limit of safe form the speed of each one of the axles, the utilisation of the maximum speed in the TCP increases substantially the productivity during the set up. The time of reaction sure faster of the world – because of the combination of openSafety and Powerlink –reduces the distance of braked until 100 times with regard to the traditional systems, in case of rape of a function of hygiene–. These times of reaction faster allow to build machines with a lower separation between the process and the cover, and therefore of dimensions more reduced.

If the visitors enter false “balls” through the opening, his different colour is detected by the system of artificial vision, and are descartadas. The communication between the system of artificial vision and the CPU also does by means of Powerlink. The times of fast cycle, in the order of microseconds, as well as a fluctuation underneath of the μs allow an of particular use deterministic communication in the case of machines of high performance. The system of vision previously mentioned is totally integrated cheese cheese in ACE, with what all the variables shared between the controller and said system are available from the beginning. This deletes the costly time of programming and parametrisation.

The machine also implements the technology of PackML, that allows an identical operation of the machine by means of ways of standard operation and a uniform communication with systems MONTH (Management execution system) or ERP (Enterprise resource planning), independently of the platform of control used by the different manufacturers of machinery.

Image 4: The System Diagnostics Manager uses an only interface to access to the data of diagnostic of all the machine from any corner of the planet.

The visitors can access so much to the system of visualisation of the machine as to the System Diagnostics Manager (SDM) of wireless form by means of an iPad. Thanks to the SDM, the personnel of maintenance can realise a local or remote diagnostic. Using the pages of diagnostic implemented in the firmware, can verify of simple form the function of all the components of the machine from an only interface. The robots, the process, the technology of hygiene and the application of visualisation can of this form diagnose from any corner of the planet. The functions that were used to to be so complicated to implement now already are available from the first moment in the SDM, simplifying the process of diagnostic and reducing the necessary time to finish the project.

Because of the elimination of the limitations that was used to to have between the system of vision and the controller of the machine, the controller of the robot and the one of the process and between the standard controllers and the ones of hygiene, the solutions of automation of B&R make possible to implement functions that considered impossible. An example of this is the cell of folded faster of the world that the manufacturer of machine tool Trumpf presented the year happened in the fair EuroBLECH. In this case, a CPU of B&R controls entirely the cell of folded, that consists of a machine plegadora electrical and two robots. Thanks to the ease to the hour to share information in the controller, the robot can do adjust “to the flight” jointly with the rear corner of the plegadora. The surprising results can measure : the greater part of adjust them finalise in less than 300 ms. The innovation yace in that the controller of the machine controls it everything, from the control of the robot until the complex functions of hygiene, like the speed limited of safe form in the TCP of the robot. With controllers of robot encapsulados like which used in the past was totally impossible to realise adjust like these.

The manufacturers of machinery save a big part of the time of programming thanks to the perfect integration of the components of automation, with which reduces substantially the necessary time to complete the projects. A considerable advantage comes given by the elimination of the limitations of the system, by what can implement new functionalities in the machine. The economic savings come given by the escalabilidad of the components of automation used. This allows to choose exactly the optimum technology for each process in function of his requirements. Besides, since the code of the machine can develop independently of the hardware that will use , is possible to realise modular machines. Of this form, can implement distinct configurations of machine, that use distinct hardware, but share the same software, ensuring the investment and shortening the necessary time to develop them.