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									automotion
SPECIAL EDITION: PACKAGING
OCME: Engineering turns green
SIG Combibloc: Award-winning design
Thinking machine modularity through to the end




                                                 Perfection in Automation
                                                       www.br-automation.com
    Contents




     22




     19                                                                30




     7                                                                 12

      automotion: The B&R customer magazine

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2   automotion
                                                                                                Editorial

Technology
	15	   Certified	safety	in	the	drive	increases	employee	safety
       AND productivity
	27	   Innovative	packaging	as	a	crucial	distinguishing	feature
	 	    at	the	point	of	sale
39     These companies trust in B&R
	42	   openSAFETY:	What's	in	it	for	you?
50     ACOPOSmulti65: Thinking machine modularity through
       to the end
56     Automation Studio - More than just a programming tool
63     Scalable hardware as a key to success
                                                                    The way something is packaged sets it
	72	   Modular	hardware	for	modular	machines                        apart from similar products from other
                                                                    manufacturers. Not only that, but
74     The	automation	partner	for	the		food	and	beverage	industry   there's a constant balancing act taking
Interview                                                           place between function and design as
                                                                    well as technical implementation and
10     PackML	-	The	standard	for	packaging	machine	automation       cost. Harmonizing these conflicting
 11    Functional	safety	in	machine	manufacturing:	An	option	or     factors therefore requires innovative,
                                                                    flexible and fully automated packaging
	 	    an	obligation?
                                                                    machines.
	36	   A	safe	start	into	a	safe	future
                                                                    In this special edition of automotion,
Application                                                         we will be presenting a wide spectrum
 4     Rügenwalder	Mühle:	A	rich	tradition	and	promising	future     of the most advanced technologies
                                                                    currently being used in this industry.
 7     SIG Combibloc: Concentrating on the important things         The growth being experienced by the
	12	   CFS:	Perfect	cut	and	placement                               packaging industry throughout the
                                                                    world is largely due to the explosive
19     De La Ballina: 18,000 baguettes per hour                     growth of the world's consumer class.
22     OCME: Engineering turns green                                It was exactly this reason that led
                                                                    B&R to form the Packaging Solutions
24     Veltins: Veltins and B&R mix up the beer market              division, an international group of ex-
                                                                    perts who are specifically focused on
30     Modular Packaging Systems: A strong trend toward
                                                                    the needs of multinational packaged
       integration                                                  goods manufacturers and packaging
	31	   Extreme	Packaging:	Extreme	efficiency	with	B&R	servo         system suppliers.

       technology                                                   From rapidly emerging markets to
	32	   Ilapak:	The	future	of	packaging                              fully industrialized economies, B&R
                                                                    is always standing by with the latest
40     Blumer: Step by step label production                        automation technology, engineering
	44	   G.	Mondini:	Handling	different	formats?	That's	easy!         expertise and an international support
                                                                    network.
46     Hayssen Sandiacre: High-speed packaging
48     Thimonnier: Innovative packaging                             Whatever your requirements, we have
                                                                    the solution.
53     Graphic Packaging International: Sustainable labeling
                                                                    Have fun reading!
54     STM: Grabbing the bottle by the neck
                                                                    Sincerely,
	59	   Fratelli	Beretta:	A	recipe	for	success
67     Hastamat: Modern automation technology reduces
       packaging costs
70     Tauras	Fenix:	Intelligent	packaging	solutions	for            Maurizio Tarozzi
                                                                    Global Technology Manager
       demanding products                                           Packaging Solutions, B&R


                                                                                            automotion        3
    Application




    A rich tradition and
    promising	future
    Products	 from	 the	 Rügenwalder	      Even today, the over 170-year-old         up-to-date guidelines and regula-
    Mühle are making mouths wa-            recipes from the early days of the        tions.
    ter. The renowned sausage and          Rügenwalder Mühle form the basis
    ham producer, together with its        of the company's products, which          With their decision to replace exist-
    products,	 has	 remained	 one	 of	     includes such well-known products         ing visualization and control technol-
    Germany's most well-known and          as Schinkenspicker (ham sausage)          ogy with B&R technology on a broad
    enjoyed	 brands	 for	 decades.	 Rü-    and Rügenwalder Teewurst (tea             scale, Rügenwalder Mühle has laid
    genwalder has achieved this po-        sausage). Even with today's mod-          the foundation for meeting the high-
    sition through exact processing        ern manufacturing methods and             est future demands.
    and excellent product quality. In      the company's annual production of
    order to honor this tradition and      many million packages of sausage,         Comprehensive          visualization
    to maintain the highest possible       this sausage and ham product pro-         system
    standards, the company invests in      ducer has steadfastly honored its         The technical director at Rügenwalder,
    state-of-the-art,	 safe	 production	   skilled tradition and meticulous pro-     Horst Jacob, states the determining
    systems.	 To	 make	 the	 vision	 of	   cessing.                                  factors for discontinuing the use of
    integrated visualization, optimum                                                the prior technology: "In the future,
    production resource management         Those responsible insist upon using       we want to control our systems more
    and marked cost-savings a reality,     the best ingredients and strict quality   precisely, comprehensively display
    Rügenwalder	opted	for	B&R	tech-        controls, and they also strive to run     and document the interrelation of
    nology	for	a	wide	range	of	uses.       an environmentally-friendly manu-         machines and systems and further
                                           facturing process in compliance with      improve production resource man-




4   automotion
                                                                                                                   Application

agement. Without discontinuing the            A considerable amount of water              "The old control system for the cur-
use of the visualization and control          leaves the sausage during this pro-         ing chambers has reached its limits.
systems from our previous supplier,           cess. This water loss must be com-          It was not freely programmable and,
this would be nearly impossible due           pensated for by adding an additional        as a result, lacked the desired degree
to the high costs involved."                  quantity when filling the skin.             of flexibility. It also lacked sufficient
                                                                                          precision and computing power," ex-
This is not surprising because many           "If we can reduce the weight by just        plains the smoking system specialist
factors influence the quality of a sau-       one gram and still guarantee that           with 30 years experience in the field
sage. Recognizing the potential for           the consumer receives the declared          of "smokers". Many parameters (e.g.
cost reduction in all production areas        nominal filling quantity as required        temperature and humidity) must be
                                                                                          accurately measured and monitored,
 "We wanted to control our systems more precisely, compre-                                and the air circulation precisely con-
                                                                                          trolled in order to ensure that the
 hensively display and document the interrelation of machines                             sausage is evenly dried and is not
 and systems and further improve production resource man-                                 damaged. If external air is used in the
                                                                                          drying process to save energy costs,
 agement."                                                                                which Rügenwalder has planned for
 Horst Jacob
                                                                                          the future, additional parameters
 Technical Director
 Rügenwalder                                                                              must be considered and the air man-
                                                                                          agement system must be refined.
and further optimizing the process            by the pre-packaging authorities,           "It is no longer acceptable to simply
control system places high demands            then that naturally results in signifi-     open or close ventilation flaps or just
on process visualization and control.         cant cost reduction for our compa-          measure the relative humidity of the
A further intricacy is that particular        ny," emphasizes Horst Jacob.                air as it once was in the past. We have
procedures must be implemented in                                                         welcomed the fact that Rügenwalder
order to achieve the desired result           Cost cutting through precise                has taken the initiative and are ready
that significantly influence the qual-        process control                             to forge new paths with B&R tech-
ity of the sausage (smoking, curing).         This type of filling process optimiza-      nology." The controllers used until
                                              tion requires precise control of the        now are not the only technology that
To produce spreadable, raw sau-               drying process. "For this, many cubic       does not meet the demands of the
sage, the meat is minced in a meat            meters of air with the correct tem-         future, as Host Jacob emphasizes:
grinder, spices are added, it is put          perature and humidity must be cir-          "The extremely limited visualization
in skin and then smoked over beech            culated and distributed in elaborated       and documentation options of the
wood fire in special smoke cham-              steps," states Holger Landwehr, busi-       solutions used until now also do not
bers with a capacity of several thou-         ness manager of Landwehr GmbH,              fulfill our requirements."
sand sausages. Then the sausage is            Rügenwalder's supplier of cooking
allowed to cure for a certain amount          and smoking systems and the per-            Insufficient visualization options
of time in climate-controlled rooms           son responsible for modernizing the         were the actual cause for Rügen-
with tons of other sausages in order          current systems using B&R technol-          walder Mühle's reorientation of its
to develop their characteristic taste.        ogy.                                        control and visualization technology.
                                                                                          In the first step, a new visualization
                                                                                          system based on B&R products was
                                                                                          connected to the control system
                                                                                          used previously. In a second step,
                                                                                          the control system itself was re-
                                                                                          placed. "We've chosen the complete
                                                                                          solution from B&R because of the
                                                                                          openness of B&R controllers and
                                                                                          especially the B&R product policy,
                                                                                          which encompasses their own man-
                                                                                          ufacturing facilities and, as a result,
                                                                                          ensures long-term availability."

                                                                                          Competitive       edge     with    B&R
                                                                                          technology
                                                                                          Holger Landwehr, who together with
                                                                                          his team developed the new control-
                                                                                          ler for the smoking systems based
                                                                                          on the B&R Power Panel, is excited
  Temperature, moisture and airflow are precisely monitored and controlled by the Land-   by the options B&R technology of-
  wehr solution, all using B&R hardware.                                                  fers: "With B&R products, we were
                                                                                          able to increase the effectiveness >>

                                                                                                                    automotion        5
    Application




      Rügenwalder's diverse products are subject to stringent inspections during production in order to ensure the quality and excellent taste
      of the sausage.


    of our systems, which gives us an               about the future: "The implemented
    advantage over our competition. But             B&R technology allows the integra-
    not only that: We also receive better           tion of additional areas of Rügen-
    service than before and can provide             walder's operations. Product safety
    the new controllers at lower prices."           and process monitoring can be opti-
                                                    mized and improved on a continuing
    At Rügenwalder, Mr. Jacob is also               basis. The openness of the controller
                                                    and B&R's long-term product policy


      "Using the implemented B&R technology allowed us to opti-
      mize and improve product safety and process monitoring on
      a continuing basis. The openness of the controller and B&R's
      long-term product policy guarantee the sustainability of the
      solution."
      Holger Landwehr
      Business Manager
      Landwehr GmbH


    convinced of the new control system:            guarantee the sustainability of the
    "Installing and commissioning the new           solution. The problems we faced
    system took very little time and ran            with prior solutions—cancellations
    without any problems whatsoever. As             and exorbitant procurement costs                    Rügenwalder:
    we expected, the panel we implement-            for replacement devices—are now
    ed still operates without any problems.         part of the past."
    From the very beginning, the opera-
    tors, some of whom have worked for
    decades with other controllers, experi-
    enced no difficulty familiarizing them-
    selves with the new devices."
                                                                                                        Established: 1834 in Rügenwald
    This operators' positive experience bol-                                                            Locations: Bad Zwischenahn (Ger-
    sters management and those respon-                                                                     many)
    sible for technology at Rügenwalder                                                                 Products & Services: Specialty sau-
    to further pursue the path they have                                                                   sage products like Rügenwalder
    started. "We now have a controller that                                                                Teewurst    (Rügenwalder     tea
    offers us more freedom and allows us                                                                   sausage), Pommersche Gutsle-
    to raise the bar with our visualization.                                                               berwurst (Pomeranian liver sau-
    The integration of several system com-                                                                 sage), Schinkenspicker (Pomera-
    ponents in a new visualization or con-                                                                 nian ham sausage) and Pommern
    trol system based on B&R technology                                                                    Spiess (Pomeranian boiled ham)
    is within reach," remarks Horst Jacob.
                                                                                                        www.ruegenwalder.de
    Holger Landwehr is also optimistic                                                                  www.landwehrgmbh.de

6   automotion
                                                                                                              Application

                                                                                     Operating complex processes
                                                                                     around the clock—easily and
                                                                                     without accidents—is the ulti-
                                                                                     mate	 challenge	 for	 owners	 and	
                                                                                     users	 of	 modern	 machines	 and	
                                                                                     systems. This is especially impor-
                                                                                     tant when they're operating high-
                                                                                     performance	systems	for	process-
                                                                                     ing	foodstuffs.	A	manufacturer	of	
                                                                                     cardboard	 packaging	 and	 filling	
                                                                                     machines	 has	 therefore	 made	
                                                                                     user-friendliness	 and	 reliability	
                                                                                     a priority when developing the
                                                                                     latest	 human	 machine	 interface	
                                                                                     (HMI)	for	its	filling	machines.	This	
                                                                                     new system, developed in close
                                                                                     cooperation with B&R and the us-
                                                                                     ability	 expert	 Prof.	 Hofmann,	 has	
                                                                                     proven	 itself	 under	 demanding	
                                                                                     operating conditions and received
                                                                                     several awards.




   Concentrating on the
   important things
"For companies producing and fill-       ing up to 24,000 small-format pack-         when it began redesigning their HMI
ing foodstuffs, even a few hours of      ages per hour.                              systems from the ground up. One of
machine downtime per year is unac-                                                   the central requirements of the new
ceptable," explains Peter Holzkäm-       "If the human machine interface used        operating solution was to eliminate the
per, who is responsible for the visu-    with the high-performance machine           observed weaknesses of the previous
alization systems at SIG Combiblock.     fails, the entire system goes down.         system with regard to construction
This is not a case of users being        Exchanging the operating unit can           and production while ensuring that
nitpicky, but rather a matter of sur-    quickly cause delivery bottlenecks          no new problems were created in the
vival in an intensely competitive in-    to develop, which in the worst case         process.
ternational market, which quickly be-    could result in empty shelves at the
comes clear when one takes a closer      supermarket," says Holzkämper, illus-       By selecting the automation specialists
look at modern production systems        trating how a defect in the visualization   B&R as the hardware supplier and us-
and their high level of output.          system can tarnish the reputation of a      ing B&R's combination of a 19" panel
                                         supplier or even result in the termina-     and an industrial PC, this goal was
As one of the worldwide leading          tion of a contract.                         achieved, concludes Peter Holzkäm-
manufacturers of cardboard packag-                                                   per: "At the time of the evaluation, not
ing and filling systems for foodstuffs   Absolutely moisture resistant:              only did B&R have a completely inte-
and beverages, SIG Combibloc's           The integrated display                      grated display with the large dimen-
portfolio also includes high-speed       The company defined the list of re-         sions we were looking for, they also
solutions capable of aseptically fill-   quirements with exactly this in mind        had a very impressive amount of >>

                                                                                                              automotion        7
    Application

    experience and the capability to inno-
    vate very quickly."

    Winner	of	multiple	awards
    The display, winner of the coveted IF
    Product Design Award, fits into an ex-
    tremely slender housing, distinguishes
    itself with its minimalist design and,
    thanks to a swing-arm, can be moved
    by the user into an optimal reading po-
    sition. "B&R accommodated our spe-
    cial requests by modifying a standard
    display to match our requirements.
    This further increased the user-friend-
    liness and functionality of our HMI,"
    adds Holzkämper.

    The visualization expert from SIG
    Combibloc also gives a positive review
    of the industrial PC used in SIG Com-
    bibloc's new user interface: "The APC
    from B&R is extremely compact and
    definitely lives up to the title 'Industrial   ing the ability to develop and produce            es Holzkämper. "And the B&R comput-
    PC'." In addition to the robust design of      customized circuit boards, not to men-            ers have long-term availability—over
    B&R's industrial computers, Holzkäm-           tion the well as the all-around expertise         10 years. This is a requirement that no
    per was also impressed with B&R's in-          of the automation supplier. "The whole            other supplier had been able to offer
    house industrial PC assembly, includ-          package just works for us," summariz-             with such matter-of-factness."

                                                                                                     The industrial PCs run a visualization
                                                                                                     application based on the Zenon HMI/
                                                                                                     SCADA software from Copa-Data,
                                                                                                     which was developed together with
                                                                                                     Prof. Thomas Hofmann. "In addition
                                                                                                     to reliability, the user-friendliness of
                                                                                                     the human machine interface was ex-
                                                                                                     tremely important to us," explains Hol-
                                                                                                     zkämper. "This is why we brought in
                                                                                                     Prof. Hofmann as a design and usabil-
                                                                                                     ity expert. The cooperation was clearly
                                                                                                     fruitful: the HMI was distinguished with
                                                                                                     the reddot design award. The jury thus
                                                                                                     recognized the logical menu structure,
                                                                                                     the graphic implementation and the
                                                                                                     resulting user-friendliness of the com-
                                                                                                     munication platform, which were all
                                                                                                     oriented around the user's habits."

                                                                                                     Retrofitting	customers
                                                                                                     Even in demanding practical situations,
                                                                                                     the new communication platform has
                                                                                                     already proven itself a success, as the
                                                                                                     visualization expert from SIG Combi-
                                                                                                     bloc reports: "We have equipped pro-
                                                                                                     totype machines ordered by two of our
                                                                                                     most demanding customers with the
                                                                                                     new human machine interface. So far
                                                                                                     everything is running smoothly and
                                                                         With the development of     reliably." On one occasion a converter
                                                                      high-speed filling machines,   board did need to be exchanged, Hol-
                                                                    SIG Combibloc can fullfill the
                                                     market's demands for speed and high out-
                                                                                                     zkämper admits: "But the problem was
                                                     put - while keeping up maximum quality          corrected with exemplary service -
                                                     and flexibility.                                quickly, reliably and with high-quality."

8   automotion
                                                                                                       Application


  Award-winning design




  Through modification of the display, B&R provides a product solution that
  meets the special requirements of SIG Combibloc. The minimalist design and
  a support arm assembly are now features of the innovative HMI from the Ger-
  man machine manufacturer.
                                        With the new operator terminal con-
                                        sisting of three illuminated square
                                        keys, SIG Combibloc expands its HMI
                                        product line with an additional func-
                                        tional operating element.




"B&R accommodated our                   Because of the positive experiences so
                                        far, the company is already integrating
special requests by modifying           the new HMI into another series of ma-
a standard display to match             chines.
our requirements. This further
                                        SIG Combibloc now has a standard
increased the user-friendliness         interface that optimally matches the
and functionality of our HMI."          requirements of a filling machine and
Peter Holzkämper                        its operators. "However, the entire line
Visualization Systems Specialist        is composed of multiple machines,"
SIG Combibloc                           emphasizes Holzkämper. The machines
                                        that come before and after the filling     SIG Combibloc:
                                        machine perform less complex tasks
                                        and therefore do not require the numer-
                                        ous functions and display options pro-
                                        vided by the SIG Combibloc standard
                                        interface. "That would be like using a
                                        sledgehammer to crack a nut," says the     Established: 1853 (Schweizerische
                                        visualization expert. "We therefore de-       Industrie-Gesellschaft)
                                        cided to develop an entire HMI kit that    Locations: Packaging plants and
                                        covers all the various requirements of        subsidiaries in 40 countries
                                        the machines that make up the line."       Products and services: SIG Com-
                                                                                      bibloc is a worldwide leading
                                        As a second step, SIG Combibloc de-           manufacturer of cardboard pack-
                                        signed an operator terminal based on          aging and filling machines for
                                        the B&R X20 System with three illumi-         beverages and foodstuffs.
                                        nated ring keys to cover the lower end
                                        of the HMI system.                         www.sig.biz

                                                                                                       automotion       9
 Interview



  PackML	-	The	standard	for	
  packaging machine
  automation
                 Requested	by	end	users	and	developed	with	the	use	of	substantial	tech-
                 nical resources provided by system suppliers, the PackML standard de-
                 veloped	by	OMAC	ensures	maximum	system	efficiency.	Leading	pack-
                 aging	 machine	 manufacturers—companies	 like	 ADCO,	 Ilapak,	 Pearson	
                 and Pro Mach—already rely on this standard and are promoting its use
                 throughout the entire packaging industry.



                 In addition to important interface descriptions for packaging machines, PackML
                 also includes classifications of line types and defines machine states and modes.
                 Another advantage is that—as with OPC guidelines (OLE for Process Control)—it
                 defines uniform data acquisition for important trends such as safety and MES
                 (manufacturing execution systems). This results in a much tighter integration of
    John Kowal   packaging guidelines and leads to a substantial increase in the total efficiency of
    OMAC
                 the entire machine or system.

                 Since 1994, OMAC has endeavored to develop and implement standards that
                 reach across the packaging industry. One of the chief aims of the OMAC Pack-
                 aging Workgroup is to optimize the total business value of packaging machines
                 through improved automation guidelines. Machine manufacturers and end users
                 are thus able to profit from the highest levels of flexibility and the increased power
                 of their packaging solutions while considerably reducing system integration costs
                 at the same time.

                 The following are some of the main goals set forth by the OMAC:

                 ■ To improve flexibility and interoperability through the use of Connect-and-Pack
                   guidelines in order to better meet the needs of end users and machine manu-
                   facturers
                 ■ To encourage automation suppliers, OEMs, and trade groups worldwide to sup-
                   port these Connect-and-Pack guidelines in their products and practices
                 ■ To address the educational and training needs of the automated packaging ma-
                   chine industry
                 ■ To create a win-win-win situation between end users, technology providers and
                   packaging machinery OEMs
                 ■ To work with industry groups and standards bodies to have Connect-and-Pack
                   guidelines implemented as industry standards
                 ■ To develop Connect-and-Pack guidelines that provide easier horizontal integra-
                   tion between processing and packaging machines and lines, as well as vertical
                   integration to MES, OEE and related production management systems




                                                                  Connect
                   PackML                                         and Pack
10 automotion
                                                                                                                 Interview




  Functional	safety	in	ma-
          chine	manufac-
          turing: An option
          or	an	obligation?
                                          The	 increasing	 level	 of	 automation	 in	 machines	 and	 systems	 makes	
  Peter	Früauf                            it	more	and	more	essential	to	create	flexible	links	between	individual	
  VDMA                                    safety	functions.	Open,	standardized	communication	solutions	are	be-
                                          coming	increasingly	important.	Peter	Früauf,	manager	of	the	Electrical	
                                          Automation	division	of	the	German	engineering	federation	VDMA,	ex-
                                          plains why.

Directive 2006/42/EC obligates manu-      nothing but cause complications and         cause the increasing level of machine
facturers and operators of machin-        increase expenses. Yet more and             automation demands flexible links
ery and systems to ensure that their      more machine and system manu-               between individual safety functions.
equipment does not pose a risk to         facturers are beginning to recognize        Here it helps to evaluate existing find-
humans. It requires them to take          the competitive advantages that can         ings, such as the VDMA guide on the
measures to prevent accidents. Sys-       be gained through a modern safety           use of programmable safety technol-
tematic risk assessments play a large     solution: Integrated safety solutions       ogy in the field of mechanical engi-
role in this.                             with improved error localization and        neering. Close cooperation between
                                          diagnostics can reduce failure rates        machine and system manufacturers
Certification for the applicable stan-    and lend the production process a           as well as suppliers of automation
dards significantly increases legal       flexible new design.                        components and solutions results in
certainty with regard to conforming                                                   a wealth of experience and success-
to the machinery directive and ful-       Safety technology often has a mis-          ful approaches that can help identify
filling the burden of proof. However,     leading reputation as a conservative        and eliminate risk. Managers and su-
this does not free the individual from    affair. Yet it thrives on the experiences   pervisors in electrical and mechanical
his or her responsibilities. After all,   of users who have discovered that           fields must be able to evaluate safety
standards have certain tolerances         certain practices have proven them-         technology, make decisions and do
when evaluating risk or planning and      selves over time. Safety technology         what is necessary to implement a
implementing the actual safety func-      utilizes rules and techniques derived       technical solution. These days, com-
tions. Even product-specific Type C       from user feedback to define the re-        panies cannot afford to do without
standards don't dictate clear-cut rules   quirements for high-quality safety          programmable safety technology.
for each and every situation.             technology. This is one reason why          However, developing safety-related
                                          technical trends often appear later in      software and hardware involves long
A successful safety solution must also    this area than they do in conventional      development times and high invest-
prevent safety functions from being       automation.                                 ment with a comparatively low re-
circumvented. What good is a safety                                                   turn. From a cost perspective, then, a
gate if the operator can simply climb     Early on, for example, safety relays        safety solution with open communi-
over it to perform his task? This not     were used to implement individual           cation is the optimal answer.
only risks human injury and damage        safety functions such as E-stop
to the machine, but also carries ad-      switches. As time passed, however,
ditional financial consequences. An       the demands placed on the auto-
accident can result in long production    mation, personnel protection and
downtimes and negative publicity          functional safety have continually
that can damage a company's image.        increased. A scalable range of pow-
In the worst case, the company can        erful, flexible and adaptable compo-
end up spending years fighting legal      nents consequentially took the place
battles.                                  of the safety relay.

Some companies view safety mea-           Today, programmable safety control-
sures as a necessary evil that does       lers are state of the art, chiefly be-

                                                                                                               automotion 11
 Application
 Applikation




                                 Perfect	cut	and	
                                 placement
  Ready-packed sliced sausages            The corrugated blade on the CFS           minimizing the 'give away' and ensur-
  and cheeses are strong consumer         MegaSlicer rotates around its axis up     ing simple and safe handling."
  favorites.	Yet	despite	this,	manu-      to two thousand times, cutting easily
  facturers	 in	 the	 food	 processing	   through lunch meats and cheese. Per-      A similar approach to increasing
  branch remain under consid-             fectly cut slices fall away faster than   throughput is increasing the speed of
  erable price pressure in retail         the eye can see. Speed is important,      the blade. Of course, the properties of
  markets, making it important to         but not everything, as pointed out by     the products that have to be cut can
  seek innovative ways to increase        Jörg Schmeiser, Director of Product       vary greatly. In addition, the decisive
  production	 performance.	 The	 re-      Management at CFS: "Whenever we           parameters are usually temperature-
  nowned	 slicer	 manufacturer	 CFS	      start out designing a machine, we         dependent. Therefore, the rotational
  continues to raise the bar. They        take the entire production process        speed of the blade must adapt to the
  offer	a	complete	portfolio	of	slic-     and advancement of performance into       product and can only be increased
  ers—from	manually	loaded	slicers	       consideration. Therefore, in addition     within certain limitations. Cutting
  to	 automatic	 high-performance	        to increasing throughput, we also con-    speed is also restricted by the feed
  slicers—that	 feature	 the	 highest	    centrate on maximizing the yield while    and portioning procedures as well
  degree	 of	 flexibility	 and	 produc-
  tivity	for	the	production	of	sliced	
  sausages.




12 automotion
                                                                                                                     Application



                                               The MegaSlicer from CFS permits an output rate of up to 600 cuts per minute.




                                                                                          put by raising the blade speed while
                                                                                          also having to add blank steps.
                                                                                          When operating at a speed of 1,200
                                                                                          RPM, there are only a few millisec-
                                                                                          onds between the withdrawal of the
                                                                                          corrugated blade from the meat and
                                                                                          its re-insertion. "In this brief window
                                                                                          of time, the blade must be clear from
                                                                                          the product area for the addition of
                                                                                          blank steps. When the cutting pro-
                                                                                          cess starts again, it must also be po-
                                                                                          sitioned in such a way that the blade
                                                                                          cuts off a slice that has exactly the
                                                                                          same thickness as before the gap,
                                                                                          without wasting any of the product,"
                                                                                          explains Jörg Schmeiser.

                                                                                          If this high level of performance is still
                                                                                          not enough, Interpack 2008 definitely
                                                                                          provided the answer. With their lat-
                                                                                          est innovation, CFS presented select
                                                                                          machines from the company's wide
                                                                                          range of products, including packag-
                                                                                          ing materials, individual machines
                                                                                          and even complete production lines
as the removal procedures whose            dynamic properties of the positioning          for preparing, marinating, further
speed must be regulated according          axes. POWERLINK is a manufacturer-             processing, slicing and packaging
to the mass being moved. "However,         neutral, high-speed, real-time commu-          primarily meat, poultry, fish, sea food
the MegaSlicer does the job without        nication bus. It features an extremely         and cheese products. Another debut
interrupting the cutting process, even     short cycle time and a low amount              presented was the high-capacity
at a throughput of 600 cuts per min-       of jitter. This is necessary in order to       slicer, which set new standards in
ute," explains Jörg Schmeiser. "To         achieve maximum synchronization                regard to throughput performance
increase throughput, we simply add         and repeat positioning precision.              and "give-away" and which no lon-
blank steps in the cutting procedure                                                      ger has to move the meat backwards
to allow enough time for accumulating      Maximum synchronization and                    when adding blank steps thanks to a
portions and transporting them from        repeat positioning precision                   patented cycle rotor procedure. >>
the machine. To do this, our slicers use   Repeat precision is of particular im-
the rotating blade to slice the product    portance when increasing through-
in mere thousandths of second. This
requires high precision and highly-dy-
namic drive technology, in which up to
17 servo motors have to work together
accurately," says the product represen-
tative from CFS.

For this very reason, the company
uses drive technology from the Aus-
trian automation specialists B&R for
their drive system. Servo drives from
the ACOPOS series, networked via
POWERLINK, drive the servo motors
and provide the required precision and



   Dynamic motion technology from B&R guarantees maximum precision.



                                                                                                                     automotion 13
 Application



     A high-performance PLC from B&R guarantees exact dosage and maximum yield.




  Compliance with pre-packaging
  guidelines guaranteed
  Even with regard to yield, CFS has
  again managed to raise the bar set
  by the MegaSlicer. Whereas the
  MegaSlicer was able to process
  meat and cheese sticks with a length
  of up to 185 cm, its new "big brother"
  can handle products with lengths
  up to 3.2 m. "This directly affects
  the yield because the front and end
  tips of the sticks cannot be used for
  slicing," states the product manager
  from CFS. "For example, customers
  can increase their yield by approxi-        That's why the food processing com-
  mately 1 to 1.5% by extending the           pany needs a particularly productive
  stick length from 180 cm to 250 cm."        machine that can also be quickly and
                                              easily changed over to new appear-
  Minimizing the "give-away," which           ance and packaging formats. In addi-
  affects the filling weight, is an addi-     tion to the usual presentation forms,
  tional approach for preventing loss         the machine owner can also use a
  and thereby improving the machine           B&R touch panel on the MegaSlicer
  owner's performance. "Our slicers           to generate portion forms and there-
  have such a high level of precision         by create letters or customer logos.
  that, in principle, the 'give-away'         "This degree of flexibility is largely
  could be reduced to zero. However,          made possible by the drive technol-
  machine owners will generally run           ogy from B&R," reveals Tilmann.
  production with approximately 0.2
  to 0.3 percent give-away in order to        Operating the machine only requires
  ensure that the specifications set by       setting a few input values. "When
  the pre-packaging authorities are ful-      changes are made, the controller
  filled," explains Jörg Schmeiser.           automatically checks whether the
                                              changes are feasible and then makes
  Exact measurement of give-away is           the calculation and settings for all
  possible by weighing each portion           other parameters required for pro-
  before it leaves the slicer. The inte-      duction," shares the software expert
  grated controller—based on a soft           from CFS. "The closely-knit integra-
  PLC—in combination with an indus-           tion of PLC, drive and visualization      CFS:
  trial PC from B&R reacts immediately        technology as offered by B&R made
  when specified tolerance values are         it considerably easier for us to imple-
  exceeded and makes necessary ad-            ment an online help system, diagnos-
  justments within milliseconds. "We          tics, remote maintenance and other
  make highly precise adjustments to          additional functions. Based on B&R
  the slice thickness by changing the         technology, we are able to equip our      Established: 1997 (management
  offset at a hundredth of a millimeter,"     machines with characteristics that are       buy-out of the Convenience Food
  stresses the CFS expert.                    decisive to staying competitive."            Division from Tetra Laval)
                                                                                        Employees: 2,200
  Despite the high level of perfor-                                                     Locations: More than 60 worldwide
  mance, however, the machine must                                                      Products & Services: Packaging
  remain flexible and easy to operate,                                                     materials, individual machines
  as explained by Tilmann Näher, Soft-                                                     and complete production lines
  ware Conceptual Designer at CFS:                                                         for preparing, marinating, further
  "Flexibility is important because,                                                       processing and packaging primar-
  particularly in the area of private la-                                                  ily meat, poultry, fish, seafood and
  bel products, hard discounters often                                                     cheese products.
  only offer contracts that bind the
  customer to a few months of supply."                                                  www.cfs.com

14 automotion
                                                                       Technology




Certified	safety	in	the	
drive increases employee
safety	AND	productivity
        Providing employees optimum protection against injury or death and
        maximizing	 machine	 capacity	 seem	 to	 be	 conflicting	 goals.	 Neverthe-
        less,	the	safe	servo	drives	from	B&R's	ACOPOSmulti	series	can	be	seam-
        lessly integrated in POWERLINK-based networks via openSAFETY and
        used to monitor motors in real time. This allows B&R to reduce reaction
        times	 to	 errors	 by	 a	 factor	 of	 10—and	 the	 resulting	 maximum	 impact	
        energy	by	a	factor	of	100—compared	to	traditional	safety	circuits.	Im-
        proved	machine	dynamics	with	increased	safety	is	no	longer	a	contra-
        diction.                                                                  >>



                                                                       automotion 15
 Technology

  When it comes to protecting the lives and well-being of their employees, com-        Safety Functions                B&R
  panies must make no compromise. That compromises are made nonetheless                SBC                               
  can be attributed to several factors: The workers themselves are confronted
  with a choice between operating machines more safely and operating them              STO                               
  more efficiently. Secondly, there is an even broader conflict of interest for a      STO, single-channel               
  company's management. A company must not only protect its qualified work-
                                                                                       SS1, time-based monitoring        
  force and capital investments, but ensure that both are able to provide maxi-
  mum productivity. Furthermore, there's no such thing as a perfect technical          SS1, ramp-based monitoring        
  solution or a moving machine part that can be stopped instantaneously.
                                                                                       SS2, time-based monitoring        
  Even traditional safety circuits with cut-off relays are subject to response times   SS2, ramp-based monitoring        
  inherent in the system, comparable to the moment of shock a driver experi-           SOS                               
  ences before slamming on the brakes. The error detection and response time,
  for example when the safe maximum speed is exceeded in setup mode, is                SLS                               
  generally around 80 ms. If the error was caused by an incorrect setpoint from        SSM                               
  the control system, this delay would be sufficient for the drive to accelerate to
                                                                                       SMS                               
  its maximum speed before the usual torque cut-off and any additionally acti-
  vated short-circuit breaking procedure is initialized. This affects the amount of    SLI                               
  force with which an obstacle would be hit, and of course lengthens the total
                                                                                       SDI                               
  stopping distance. The permissible maximum speed must therefore be set
  accordingly in order to maintain the necessary level of safety.                      SLP                               
                                                                                       SMP                               
  100	times	more	safety
  By integrating safety technology right in its servo drives and servo motors,         SPS                               
  B&R has redefined how stopping distances and impact energy are calculated.
  The relay-free SafeMC safety circuit, installed in all ACOPOSmulti drive units,       The intelligent safety functions re-
  automatically monitors every reaction of the motor to the instructions from           ferred to as “Smart Safe Reaction” are
                                                                                        certified. They help ensure optimized
  the servo drive. This is done using safe, fully digital, high-precision, high-res-    usage of safety equipment.
  olution encoders that are mounted to the motor shaft on all B&R synchronous
  servo motors and are certified to EN ISO 13849 standard. The electronics are
  integrated directly in the drive to avoid additional response times. This has
  enabled B&R to shorten the error response time to 7 ms. In the event of er-




    Seamlessly integrated in POWERLINK-
    based safety networks, SafeMC rounds
    off the safety system as a complete so-
    lution without complicated wiring.




16 automotion
                                                                                                                Technology


                                                                                  Object-oriented safety programming with
                                                                                  SafeDESIGNER in B&R Automation Studio.




ror, the motor now has less than a tenth of the time to accelerate and to gain
hazardous momentum.

Because the kinetic energy and corresponding response distance increase
with the square of the speed, these two critical characteristics are reduced to
less than 1/100 compared to conventional solutions. "This not only improves
workplace safety, it also increases productivity on the machine," states Dipl.-
Ing. Alois Holzleitner, business manager for motion products at B&R.
"Depending on the priority, the reduction of these characteristics and
the resulting shorter braking distances make it possible to reduce the
safety distances, thereby allowing for smaller machine dimensions
and/or increased permissible speed limits during operation with Safe
Limited Speed."

Seamless integration in existing systems
The safety logic included in the ACOPOSmulti servo drives is identical
to the proven Safe I/O components from the X20 series. "This gives
users the peace of mind that comes with using electronic compo-
nents that have proven themselves thousands of times in the field,"
says Holzleitner. "Plus, the resulting synergy has a direct effect on
costs and uniformity during system development."

ACOPOSmulti with SafeMC can be seamlessly integrated into the ex-
isting system with the SafeLOGIC safety controller and the X20 Safe
I/O system. For developers, the ACOPOSmulti with SafeMC units
are addressed no differently than the X20 I/O channels. Of course,
they are also managed within the same development environment:
SafeDESIGNER in B&R's Automation Studio. Autonomous configura-
tion of the SafeMC components and the embedded parameter chip
allow quicker and easier configuration during maintenance. Logging
and password protection make it possible to track maintenance ac-
tions.

A major advantage of B&R's "Integrated Safety Technology" is the
elimination of redundant cabling and external monitoring modules
for the safety technology. Data is transferred with virtual wiring via the        In February 2010, B&R received certification
machine bus system in an intrinsically safe protocol called openSAFETY,           from TÜV Rheinland for the safety-oriented
which enables easy data communication with the control system while               drive system.
reliably excluding feedback. B&R automation solutions do this using >>

                                                                                                                automotion 17
 Technology

  "The reduction of kinetic energy
  and response distance to less
  than 1/100 compared to conven-
  tional solutions not only improves
  workplace safety, but also
  increases the productivity of the
  machine."
  Dipl.-Ing. Alois Holzleitner
  Business Manager Motion
  B&R




  POWERLINK. As the name implies, openSAFETY is not tied to a specific man-
  ufacturer and can be used on any fieldbus system, preferably in industrial
  Ethernet networks. This makes it easy to integrate the safe drives regardless
  of the controller being used.

  A further advantage of virtual wiring over the network is the possibility of
  designing modular machine concepts. Without the complicated wiring of E-
  stop chains, it is simple to connect ready-made machine parts, including safe
  drives. This allows a single safeLOGIC safety controller to access up to 80 safe
  drives from our ACOPOSmulti series, which ranges up to 120 kW.

  Certified	intelligence
  In February 2010, B&R received certification from TÜV Rheinland for the
  safety-oriented drive system and its intelligent safety functions, which B&R
  calls Smart Safe Reaction and which helps ensure optimum usage of safety
  equipment. This was followed by the certification of the functions STO (Safe
  Torque Off), SBC (Safe Brake Control) and SS1 (Safe Stop 1) up to Cat. 4/
  PL.e in accordance with EN ISO 13849-1 and up to SIL 3 in accordance with
  EN 62061/IEC 61508. Certification up to Cat. 3 PL.d and SIL3 is sufficient for
  the remaining functions SOS (Safe Operating Stop), SS2 (Safe Stop 2), SLS
  (Safety Limited Speed), SMS (Safe Maximum Speed), SDI (Safe Direction)
  and SLI (Safety Limited Increments).

  A clear benefit of the system intelligence in ACOPOSmulti SafeMC is the uni-
  versal availability of diagnostics provided by the integrated trace and oscillo-
  scope functions. Together with the control and status functions, these can be
  used to display the monitored safety limits and speeds. Thanks to the simple
  data transmission to the process control system provided by the bus con-
  nection, the diagnostics can also be integrated in the machine's visualization
  and control systems. This provides machine operators and supervisors with          About the author:
  in-depth, easy-to-understand information about the cause and type of safety
  violations as well as the system's response, and enables them to respond           After completing a degree in
  immediately.                                                                       electrical engineering, Alois Holz-
                                                                                     leitner began his career in Swit-
  "SafeMC with ACOPOSmulti and B&R synchronous servo motors are based                zerland developing machine tool
  on the open network-based safety standard openSAFETY. This combination             controllers. Upon joining B&R in
  is the logical complement to the portfolio of integrated safety components for     1992 he first served as product
  machine and systems manufacturing, which has proven itself in the field and        manager for positioning control-
  has been certified for quite some time," says Alois Holzleitner. "This makes       lers. Since 1998, Holzleitner has
  B&R one of the first manufacturers to provide a fully network-integrated safety    led the Servo Drive Business Unit
  system including intelligent drive safety functions. Such a system increases       at corporate headquarters in Eg-
  machine efficiency and productivity, while at the same time improving work-        gelsberg, Austria.
  place safety."

18 automotion
                                                                                                          Application




18,000 baguettes
per hour
Aveyron,	 in	 the	 southwest	 of	         De La Ballina, a supplier of packaging   facturing process, there is a special
France, has a distinct agricultural       products located in Villefranche-de-     emphasis on packaging processes
tradition. High-quality products,         Rouergue, specializes in the packag-     such as quality control, sorting and
such	 as	 the	 famous	 Roquefort	         ing of industrial baked goods such       movement of food products, as well
sheep's milk blue cheese, have es-        as unbaked, prebaked, and frozen         as the various types of packaging
tablished the region's reputation         baguettes, croissants and various        (bulk and case packaging as well
around the world. Thanks to this          rolls.                                   as pallets). The company supplies
tradition	 and	 the	 beautiful	 land-                                              important food companies such as
scape, Aveyron radiates a sense           From development to production,          Boulangerie Paul, Brioche Dorée, In-
of	authenticity.	As	an	origin	of	the	     the company handles all steps in-        termarché, Panavi and Bridor, just to
finest	pleasures,	the	region	is	also	     house. Throughout the entire manu-       name a few.                      >>
home	 to	 a	 successful	 high-tech	
industry	 specializing	 in	 food	 pro-
cessing	and	machine	manufactur-
ing.




                           The modern transport mechanism
                           from De La Ballina can handle up
                           to 18,000 baguettes per hour.




                                                                                                          automotion 19
 Application




                                                                                             "The high performance of
                                                                                             POWERLINK and the open
                                                                                             structure with remote X20 I/Os
                                                                                             were the deciding criteria for
                                                                                             us."
                                                                                             Thierry De Lazzari
              Fast product data acquisition thanks to a sophisticated computer-aided
                                                                                             Technical Manager
              system. For years, De La Ballina has been a pioneer in this field.
                                                                                             De La Ballina



  Thanks to a concentration on re-            considerable increase in product               chines can handle 18,000 baguettes
  search and development, De La               diversification. Thierry De Lazzari,           per hour. With a three-dimensional
  Ballina's innovation gives it a clear       Technical Manager at De La Ballina,            visualization system, the machine
  competitive advantage. Strict quality       is convinced that customers will be            guarantees 100% quality control. Us-
  control requirements are an equally         making configuration changes more              ing a valve controlled suction pump
  important factor in the company's           and more frequently in order to con-           and five axes, products that pass in-
  success. For example, the company           tinue to develop their range of prod-          spection are picked up and moved to
  uses a special visiometric system           ucts. The operation of production              subsequent conveyor belts for pack-
  that utilizes imaging to monitor the        lines therefore has to be designed as          aging. All machines are equipped with
  shape and texture of baked goods.           simply as possible.                            full automation solutions from B&R. In
  For years, De La Ballina has been a                                                        addition to a PC-based Power Panel
  pioneer in the area of quality control      100% quality control                           as the central control and monitoring
  using computer-aided visualization.         To be able to meet these expectations,         unit, the solution uses ACOPOS servo
  Numerous patents are a testament            De La Ballina recently developed a             drives on a POWERLINK network for
  to the company's innovation in this         new generation of machines equipped            axis control and XV modules for valve
  area.                                       with modern counting, monitoring               control.
                                              and conveying functions. These ma-
  Increased requirements
  Over the past few years, the require-
  ments placed on the baked goods                         The innovative visiometric system recognizes shape and surface of the baked
                                                          goods and ensures seamless quality control.
  industry with respect to packaging,
  performance and flexibility have
  increased drastically. As a result,
  the use of computer-aided, high-
  performance quality control systems
  has increased in importance. "Due to
  the increasing price of raw materials
  such as wheat, our customers are
  being forced to reduce their produc-
  tion costs. On top of this, production
  volume in Europe is increasing by
  10% every year; therefore, higher
  production rates are absolutely es-
  sential. In light of this development,
  fully automated packaging lines are
  taking on a central role," explains
  De La Ballina's CEO, Benjamin De
  Chilly. With respect to future mar-
  ket demands, the company expects
  increasing production rates and a

20 automotion
                                                                                                             Application



                                                                                 Fast configuration changes and increased
                                                                                 capacity of De La Ballina's manufacturing
                                                                                 lines ensure full customer satisfaction.




According to Thierry De Lazzari, the    by B&R's X20 System with an inte-
high performance of the POWER-          grated TCP/IP interface and a Mod-
LINK network and the open structure     bus interface, made it easy to con-
of the architecture with remote X20     nect additional peripheral devices.
I/Os, which permits distances of up     One of the improvements made to
to 100 meters between stations,         the machines, according to Thierry
were the deciding criteria that led     De Lazzari, was the ability to per-
to the selection of B&R as the sup-     form remote maintenance via TCP/
plier of automation equipment. The      IP while also being able to store data
simple integration of valve blocks      centrally in a single controller.
into the control system using XV
modules, along with the wide selec-     Project success with B&R
tion of I/O modules, proved to be       De La Ballina now feels well-prepared
the perfect solution for the special    for future market demands. Modern
requirements of the application. One    B&R technology supports the com-
of the greatest challenges was the      pany in adapting to ever-changing
integration of the visiometric qual-    customer needs. The new machines
ity control system and the Modbus-      allow for quicker configuration
based frequency inverter into the       changes and increased production
conveyor system.                        volume. These new developments
                                        from De La Ballina will ensure that
The flexible integration options pro-   their customers will move into the
vided by the Automation Studio pro-     future ready to meet the competition
gramming tool from B&R, as well as      head on.                                    De La Ballina:
the open communication provided




                                                                                    Established: 1962
                                                                                    Locations: Corporate headquar-
                                                                                       ters in Villefranche-de-Rouergue
                                                                                       (France), subsidiary in Pointe
                                                                                       Claire (Canada)
                                                                                    Products & Services: Design and
                                                                                       manufacture of complete pack-
                                                                                       aging lines for baked goods
                                                                                       (quality control, sorting, convey-
                                                                                       ing, bulk and case packaging,
                                                                                       palletization).

                                                                                    www.delaballina.com

                                                                                                             automotion 21
 Application




                                         Engineering turns
                                         green
  The increased sensitivity in the       For more than 50 years, OCME has been counted among the leading packaging
  packaging	 industry	 for	 environ-     machine manufacturers in Italy. 400 employees at their headquarters in Parma
  mental issues was the catalyst         provide comprehensive customer support in the food, beverage, textile and
  for	 Italian	 machine	 manufacturer	   chemical industries. In addition to supplying machine components that can
  OCME to develop a new shrink           be integrated into 3rd-party applications, OCME offers complete solutions at
  wrap packaging machine concept         an optimal price/performance ratio. "In a very competitive market like this, the
  that saves energy and valuable         added value cannot be limited to low price," says Antonio Mosca, Technical
  raw materials. Initial testing car-    Manager at OCME. "Other aspects like constant service availability, complete
  ried out in cooperation with the       reliability and consistent production capability are also critical throughout the
  well-known Italian mineral water       long service life of the application." Satisfying customers abroad is very im-
  bottler Fonti di Vinadio produced      portant in this regard, as a full 70% of the company's total revenue is currently
  outstanding results with regard        achieved in foreign markets.
  to energy returned on energy in-
  vested.                                Modular packaging solution
                                         In recent applications, OCME has been trying to increasingly modify its own
                                         technology to replace heavy mechanical parts related to axis movement with
                                         electronic parts for axis control. This step has become necessary as explained
                                         by Mosca: "Our applications cannot be considered flexible if the gearing and
                                         cams are implemented using a mechanical approach. That's why we decided
                                         to introduce electronic components into our motion control systems. A few
                                         years ago, we adopted B&R as our main supplier of motion technology since
                                         the automation solutions they offer were the best fit for our high end ma-
                                         chines and could best be adapted to our own particular wishes. We were
                                         particularly impressed by the modularity of the ACOPOS drive system as well
                                         as the X20 and X67 I/O modules; these factors played an important role in our
                                         decision to go with B&R as a supplier."

                                         B&R servo technology conserves resources
                                         Maximum flexibility and conserving valuable energy were the most impor-
                                         tant aspects of a new project to upgrade the VEGA HT shrink wrapping ma-
                                         chine. To increase machine efficiency, OCME relied on a large selection of
                                         B&R servo motors. Servo motors with direct drives replaced the older chain




22 automotion
                                                                                                                  Application




"B&R components are extremely
modular, which worked out
great for us while we were up-
grading to a more flexible and
energy-efficient machine solu-             Thanks to the new, flexible machine concept, format changes are a matter of mere min-
                                           utes.
tion for manufacturing shrink
wrap packaging machines."
Antonio Mosca                            30% energy saved
Technical Electrical Manager             Over a period of three hours of testing at Fonti di Vinadio, a long-time custom-
OCME                                     er of OCME, the new VEGA HT produced outstanding results. It was able to
                                         produce 3,922 bundles while consuming 145 kWh for heating, which is equal
                                         to about 30% less power consumed in comparison to the previous VEGA
                                         generation. With these results extended over 3 shifts for 6,000 hours per year,
drives, which also made it possible      Fonti di Vinadio will be able to save 120,000 kWh of heating power.
to eliminate the gearboxes. A total of
17 brushless motors are now being        In recent years, OCME was pushed by end users to improve their HMI sys-
used.                                    tems, which were previously based on operator panels. OCME therefore de-
                                         cided to implement a new Windows-based visualization system. For this new
The infeed and and collating sections    HMI project, OCME adopted a B&R Panel PC solution, which is now being
have been completely redesigned          used for every machine series.
so that two operators can complete
a format change in five minutes or
less. Another important advantage is
that the new VEGA HT machine can
handle very thin film (down to 30 mi-
crons) to save costs and protect the
environment.




                                                                                          Ocme:




                                                                                          Established: 1954
                                                                                          Locations: Parma (Italy), Locations in
                                                                                             France, UK, USA, China
                                                                                          Products & Services: Packaging ma-
                                                                                             chines and bottling lines

                                                                                          www.ocme.it

                                                                                                                  automotion 23
 Application




         Veltins and B&R mix up
         the beer market
  The C. & A. Veltins brewery and B&R set themselves an ambitious goal:           "Of course we could have chosen
  Together, they wanted to establish the APROL process control system             an existing process control solution
  as	a	standard	solution	for	the	brewing	industry,	while	simultaneously	          from one of the established suppliers
  implementing	the	new	system	in	sections	of	the	private	brewery's	pro-           to modernize our systems. But we
  duction	facilities	without	interrupting	production.	And	they	wanted	to	         made a conscious decision to take
  do	this	during	the	World	Cup—a	seasonal	highlight	for	the	brewing	in-           a new approach," explains Dirk Bart-
  dustry. The two companies succeeded in this mammoth task thanks                 mann, who is responsible for process
  to	their	flexibility,	innovative	spirit	and	future-oriented	thinking.	At	the	   control technology at Veltins.
  same time they managed to bring the APROL process control system an
  important	step	forward.	B&R	now	sees	itself	as	a	serious	competitor	for	        "We have always been convinced
  the brewing industry's traditional standard solution suppliers and looks        that a new, innovative supplier can
  forward	to	mixing	up	the	market.	Veltins	is	the	first	brewery	to	imple-         bring new insight and stimulate
  ment the B&R solution.                                                          fresh ideas," the Veltins expert con-

24 automotion
                                                                                                                     Application

tinues. "B&R seemed to be just the            partner Actemium was brought in to
right partner for this task. On the one       help plan and implement the project,
hand, their APROL process control             including the construction and instal-
system was well suited to be devel-           lation of the switching cabinets.
oped into a standard solution for our
industry. On the other, we found that,        The extensive design specifications
as a mid-sized company, B&R had               were to be implemented without
the flexibility and innovative spirit it      hindering Veltins' operations, and
takes to handle such a daunting chal-         only short breaks in production were
lenge."                                       available for switching connections.
                                              To make this possible, the project was
Shared	 effort:	 APROL	 solution	             divided into several phases. In areas
for	breweries                                 of the facilities that Veltins needed
These attributes were most certainly          during the week for beer production,
tested, as B&R was faced with not             a single weekend without produc-
only adapting APROL to the needs              tion was utilized to rewire the entire
of the brewing industry, but also with        electronic infrastructure managed by
modernizing Veltins' fermenting and           the controllers. To start, the I/O chan-
storage cellar as well as the neigh-          nels were then reconnected to the
boring processing facilities.                 old controllers, and they continued
                                              to use the old automation programs            A visual inspection confirms: Production
All in all, 50,000 image macros, more         for the time being. Later production          continues without missing a beat.
than 11,000 function diagrams and             phases were then used to gradually
nearly 2,000 process images needed            transfer the functionality from the old
to be created. In addition, the major-        systems to the new controllers.             processes and limited diagnostics,
ity of the outdated automation tech-                                                      the project was very sensitive during
nology, including the control room,           A clear victory                             the transition phase.
was to be replaced by B&R products,           Overwhelming evidence that the
and the rest of the equipment—main-           phased switch-over was a success:           Veltins recognized quickly that the
ly PROFIBUS components such as                the peak production during the 2006         B&R automation solution, with its
frequency inverters and other PROFI-          World Cup didn't create a single            reliable products and long-term
BUS devices such as cooling control-          bottleneck at the Veltins brewery,          availability, would not only solve
lers—was to be integrated.                    although the event took place right         the known problems, but also cre-
                                              in the middle of the modernization          ate many new opportunities for im-
A total of 25,000 hardware I/O chan-          project.                                    provement.
nels were replaced with the B&R's
System 2005 I/O system, and 30                "Even while the transition was still un-    "In the fermentation and storage cel-
stand-alone and 50 wall-mounted               derway, we were able to avoid what          lar, APROL made it possible for us
control cabinets were rewired and             had been one of the main reasons            to automate many production areas
equipped with the new technology,             for the modernization: production           that had previously still been con-
including 13 B&R System 2005 con-             downtime," explains Bartmann. Due           trolled manually. This allowed us to
trollers. Experienced B&R system              to the interconnected production            eliminate all manual operation en-
                                                                                          tirely, which further improved prod-
                                                                                          uct quality," illustrates Bartmann. "A
                                                                                          deciding factor was that APROL is
                                                                                          based on LINUX, which as an open
                                                                                          source solution gives it a high degree
                                                                                          of flexibility. It was therefore no prob-
                                                                                          lem to integrate Profibus automation
                                                                                          components with S5 and S7 control-
                                                                                                                            ,
                                                                                          lers into the system via TCP/IP or in-
                                                                                          dustrial notebooks that communicate
                                                                                          with APROL via WLAN."

                                                                                          An eye on the process - Anytime,
                                                                                          anywhere
                                                                                          The robust notebooks give the op-
                                                                                          erators an overview of the entire
                                                                                          process and allow them to make
 The integration of the company's EPLAN data directly into the APROL system resulted in   any necessary settings, even when
 a fast and virtually error-free commissioning process.                                   they're not in the new control room
                                                                                          with its nine operator stations and >>

                                                                                                                      automotion 25
 Application

                                                                                            tion that we can access much more
                                                                                            quickly. This allows us to identify and
                                                                                            correct errors sooner and makes it
                                                                                            easier to optimize processes," adds
                                                                                            Bartmann.

                                                                                            Service and maintenance have been
                                                                                            greatly simplified since Veltins took
                                                                                            advantage of the modernization and
                                                                                            reorganized the automation technol-
                                                                                            ogy so that equipment and auto-
                                                                                            mation components with common
                                                                                            functions are now arranged in decen-
                                                                                            tralized groups.

                                                                                            In light of the many benefits and new
    With the APROL system's "concurrent engineering," up to 10 engineers worked in
                                                                                            possibilities provided by APROL and
    parallel to implement the specified processes.                                          B&R automation technology, Dirk
                                                                                            Bartmann has these positive words
                                                                                            to say in closing: "We have created
  separate monitoring station. The               since data, symbols and names don't        a uniform solution from the control
  system keeps the operators in-                 need to be converted. This certainly       level to the field level, with unrestrict-
  formed about all processes, so they            contributed to our ability to process      ed access and high availability and
  are even updated about events that             higher volumes at shorter intervals        adaptability. I am confident that we
  occur far from their current location.         through the individual steps of the        have brought APROL a tangible step
  "And I don't just get an error mes-            transition," reasons Bartmann. "What is    forward and established it as an ideal
  sage - I can immediately check what            more, the maintenance personnel can        system for the brewing industry."
  caused the error. For example, I can           determine where an error occurred
  see what caused a valve to lock up             and what replacement part is needed
  without having to first go get the pro-        without having to flip through ring
  gramming device like I used to. The            binders or walk all the way down to
  employees really like that," reports           the fermenting and storage cellar. All
  Bartmann.                                      they have to do is call up the CADISON
                                                 database from the APROL application."
  Another popular feature is that the
  APROL system makes it relatively               Using data already provided within AP-
  easy to create interfaces with soft-           ROL and collected with internal func-
  ware tools from other manufacturers            tions such as Audit Trail—at Veltins
  in cases where they weren't already            APROL manages more than 7.5 million
  available. "The seamless integra-              process variables—the brewery has
  tion of tools such as EPLAN View               extensive information about the brew-
  or CADISON simplifies engineering              ing processes and production at its fin-
                                                 gertips. This brings clear advantages,
                                                 as Dirk Bartmann can confirm: "Much
                                                 of this information was available be-
                                                 fore we switched over to APROL, but
                                                 often only in the form of Excel tables
                                                 or hand-written logs. Extracting this
                                                 data to create documentation such as
                                                 inventory reports was understandably         Veltins:
                                                 time-intensive. APROL enables us to
                                                 automate many of these tasks and eas-
                                                 ily group and link data together."

                                                 Veltins is now able to trace individual
                                                 batches back through production,             Established: 1824
                                                 and if there were to be a customer           Locations: Meschede-Grevenstein
                                                 complaint—which has yet to occur—               (Germany)
                                                 Veltins could find out where the prob-       Products and services: Premium
    The clearly organized and maintenance-       lem occurred and determine if any               beers and beer-based mixed
    friendly System 2005 - B&R's modular I/O     other batches were affected. "APROL             drinks
    and control system - in action at Veltins.
                                                 gives us considerably more informa-          www.veltins.de

26 automotion
                                                                                                            Technology




  Innovative packaging as a
  crucial	distinguishing	fea-
  ture	at	the	point	of	sale




Around	the	world,	entire	armies	of	   As requirements increase with regard to product convenience, product traceabil-
branding and marketing experts        ity, packaging functionality and design, the demands being placed on packaging
are involved with the purchas-        machines have risen dramatically. In order to compensate for the additional costs
ing decisions we make daily at        of new packaging solutions, today's packaging machines must be able to offer
the supermarket. In addition to a     maximum product output while keeping material waste to an absolute minimum.
product's price, brand recognition    In addition, a single machine very often has to be able to handle several different
and	position	on	the	shelf,	product	   product types, which means that changeover times also have to be reduced as
convenience and its appearance        much as possible.
play a major role. For the last two
factors,	packaging	plays	a	central	   And if all of that weren't enough, strict governmental safety regulations and care-
role.                                 fully thought out safety concepts need to be implemented in order to avoid hazard-
                                      ous situations for production personnel and consumers. A simple E-stop button to
                                      bring the entire machine to a standstill is simply no longer sufficient. When it comes
                                      to safety-oriented functions, the machine must be able to differentiate between
                                      maintenance and configuration work being carried out by trained experts and ac-
                                      tual production by personnel who might not be as technically knowledgeable. >>

                                                                                                             automotion 27
 Technology

  On top of that, the packaging machine      100%
  must be able to record important pro-
  duction data for every single package
  in real time and pass this informa-




                                              Product price
  tion on to the higher-level production
  planning and control systems. This
  includes being able to clearly identify
  whoever happens to be working with
  the machine at any particular time.
  With all of this complexity, machine
                                                   0%
  operation itself needs to be kept as                          Phase 1               Phase 2                Phase 3          Phase 4
  simple as conceivably possible—ide-                          Mechanics        Electro-mechanics          Mechanics,       Mechatronics
  ally, this would entail intuitive opera-                                                             Electro-mechanics,
                                                                                                           Electronics
  tion that doesn't require an excessive
  amount of training for operating per-                       Mechanics          Electro-mechanics           Electronics       Software
  sonnel.
                                                               Transition to next product generation
  Technology	 standards	 instead	 of	            Software is increasingly replacing expensive mechanical components, thereby re-
  manufacturer	specifications	                   ducing product costs.
  It's no wonder, then, that these de-
  mands have resulted in enormous
  changes in the automation paradigms
  that currently exist in production         dustrial standards have arisen that govern everything from the basic behavior of
  plants. It has become increasingly         production machines, their integration into machine lines as well as how data is
  rare, for example, for local technicians   exchanged between the control level, the line level and the machine itself, all the
  to intervene in the core areas of ma-      while trying to make overall configuration even easier. Organizations like OMAC,
  chine controllers, primarily owing to      ISA and IEC were established as venues where the technology standards of the
  the complexity of modern packaging         future could be discussed and refined (e.g. PackML). Represented in all of the
  machines. Instead, overarching in-         relevant committees and bodies, B&R has been an active participant in this stan-
                                             dardization process for many years.

                                             B&R Inside
                                             In the last ten years, more and more leading packaging machine manufacturers
                                             have decided to go with B&R. As a result, machines with "B&R Inside" can be
                                             found in a large number of innovative plants around the world. These machines
                                             are typically the result of an intensive, mechatronics-oriented process of optimiz-
                                             ing performance and costs. More often than not, this optimization leads to close
                                             cooperation between packaging machine manufacturers and B&R. That's because
                                             B&R is able to offer the following unique advantages to the innovative machine
                                             manufacturer:

                                             ■ Engineers with outstanding expertise in the industry
                                             ■ Direct access to PackML technology functions and know-how
                                             ■ Seamless integration of operation and control, data management and commu-
                                               nication, safety technology, motion control, robotics, CNC and visual inspection
                                             ■ The option of using model-based design for simulation and automatic code
                                               generation based on MATLAB/Simulink as well as the possibility to easily com-
                                               bine object-oriented programming in C/C++ with classical IEC languages
                                             ■ Powerful software functions geared toward the packaging industry that reduce
                                               time to market by allowing the development of reusable software for modular,
                                               scalable machine solutions
                                             ■ One network for everything: POWERLINK offers the fastest cycle times—in the
     Connect                                   µs range—with synchronization < 100 µs AND high data throughput rates

     and Pack                                ■ A complete line of modular hardware for modular machines

                                             Software:	The	decisive	element
                                             While packaging machines in the 1970s were purely electromechanical in nature,
                                             today the focus is definitely on the software.

                                             Qualitatively high-grade software is generally based on the core expertise of the
                                             machine manufacturer—the actual process engineering—that has been imple-
                                             mented in the software.

28 automotion
                                                                                                                 Technology

From	 "One	 machine	 -	 One	 software	 solution"	 to	 mechatronic	 building	            The full range of diagnostics options
blocks                                                                                  is available—again, without limita-
The entire B&R software environment contributes decisively to reducing costs. It is     tions—either locally or from a remote
able to achieve this by eliminating the need for expensive mechanical components        location. Integrating vision systems
such as vertical shafts, cams and cam switches while increasing both flexibility        anywhere in the process, a very pow-
and process quality. The ability to reuse individual software modules—regardless        erful tool for product inspection, for
of the hardware being used—and to combine them in any way depending on the              example, also presents no problem
machine type or customer demands represents the challenge of the future. Where          whatsoever for POWERLINK.
others are only talking about the trends of the future, B&R Automation Studio has
provided a way to develop application software in this vein for years. Ready-made       Consistent integration and maximum
technology functions for flying saws, registration mark control, winders/unwind-        flexibility are also achieved with the
ers and many other applications are based on the PLCopen interface, thereby             network-based openSAFETY stan-
accelerating their implementation into the software itself.                             dard. With this technology, there are
                                                                                        no technical limitations on the place-
Hardware-independent programming                                                        ment of sensors and actuators. This
Automation Studio makes it possible to develop software independently of the            allows the safety technology to only
hardware platform being used while also allowing it to be reused as often as            intervene when it's actually necessary.
necessary in a project. In turn, this allows different machine types or different       The use of state-of-the-art technolo-
variations of a single machine type to be managed in a single project.                  gies such as Safely Limited Speed,
                                                                                        Safe Direction, Safely Limited Incre-
The demands being placed on application software continue to increase. As a             ment, etc. make it possible for person-
result, a state-of-the-art software solution combines motion control and robot-         nel to work in high-risk areas of the
                                                                                        machine in a way that is monitored to
                                                                                        ensure safety.
 Automation Studio

       Application software

            User point-of-view



                   Machine               Machine                Machine
                   variant 1             variant 2              variant 3




                                                                                      With Automation Studio, software can be
                                                                                      developed independently of the employed
                                                                                      hardware platform and reused as often as
                                                                                      necessary.



ics into a single application. A single PLC can thus handle motion control and
robotics tasks and, depending on the machine variation, enable/disable individual
drives or groups of drives during development or even during runtime. Automa-
tion Studio is able to handle these tasks using Generic Motion Control (GMC). The
different areas—motion control, robotics and CNC—can thus be tuned perfectly
to customer requirements using a single integrative application. This also allows
different axis types, such as those controlled by stepper motors, servo motors,           About the author:
DC motors, etc., to be coupled using GMC, which provides another level of con-
sistency in the process. The application designer can therefore concentrate fully         Christoph Trappl
on developing the actual machine processes while leaving the control of the dif-          International Applications Manager
ferent hardware devices completely up to GMC.                                             B&R Eggelsberg

Consistent integration establishes trust and guarantees investment se-                    Christoph Trappl has been work-
curity                                                                                    ing at B&R since 2000. Thanks to
Consistent integration means reducing the number of interfaces, optimally                 extensive international projects,
matching hardware and software and taking command of the process to be                    he has gained precise insight into
implemented. This also makes the use of consistent fieldbus technology essen-             the demands of B&R's custom-
tial. In this regard, POWERLINK becomes the backbone of the machine. Short                ers and their solutions. Currently,
cycle times and jitter less than 100 µs in no way impede high data throughput             Trappl is responsible for the Inter-
and complete diagnostics down to the drive—without limiting performance a                 national Applications department.
single bit.

                                                                                                                 automotion 29
 Application




                                                A strong trend
                                                toward integration
                                                                                    With	its	full	focus	on	tablet	counting	
                                                                                    and	bottle	filling,	Modular	Packaging	
                                                                                    Systems has emerged as the author-
                                                                                    ity in turnkey line integration. From
                                                                                    engineering development and layout,
                                                                                    mechanical assembly and testing, and
                                                                                    installation and training, they provide
                                                                                    extensive customer support over the
                                                                                    entire	life	cycle	of	their	machines.	The	
                                                                                    company's	products	range	from	small	
                                                                                    clinical lines to high-speed automat-
                                                                                    ed	filling	and	packaging	systems.




  As engineering resources become more constrained, particularly among pharmaceutical producers, Modular Packaging
  Systems' integration capability has risen to center stage. Its ability to tie each of the machine controls into a productivity-en-
  hancing central monitoring system has become popular. Due to the ease with which all B&R components could be integrated
  into their existing systems, Modular Packaging Systems selected B&R as its partner for automation products.

  Well sorted and selected
  The EC-12 uses Modular Packaging Systems' newest technology to achieve up to 55 100-count bottles of ¼" tablets per
  minute. The EC-12 is capable of discriminating oversized and undersized product from good product. This makes it possible
  to track unwanted product and reject it from the line. A reject station will take any bottle off line that contains a product that
  does not fall within a specified tablet "size" range. Customized visualization devices such as the B&R Power Panel, compact
  X20 I/O modules and high-performance drive components such as variable frequency drives, stepper motors and servo
  drives ensure maximum reliability and processing speed for the electronic EC-12 counting controller.

  Another machine from Modular Packaging Systems is the MC-2, a semi-automatic dual lane vibratory counting machine for
  small production runs or check counter applications. It provides accurate counts into hand-fed bottles and can handle a large
  range of product sizes and shapes. The machine can also be fitted to an automated base, with a conveying system delivering
  bottles to the machine automatically. This compact bench-top machine can run at speeds of up to 8 bottles per minute for
  100 count bottles of ¼" tablets.

                   Critical to its systems integration business, Modular Packaging Systems offers a wide variety of container
                       handling options designed to customize conveying and optimize efficiency and speed throughout the
                                         line. All conveyor and container handling equipment is constructed with high-grade
                                             stainless steel and designed to integrate easily and seamlessly together. Designing
                                               or redesigning a packaging line with conveyor systems from Modular Packaging
                                                Systems is very straightforward. The adjustable components require no tools to
                                                 adjust, making changeover fast and simple.



                                                www.modularpackaging.com




30 automotion
                                                                                                                Application




  Extreme	efficiency	with	
  B&R servo technology


The combination of slender design
and maximum performance makes the new
servo shrink wrapper from Extreme Packag-
ing an extremely efficient solution. Modern
B&R servo technology helped boost processing
speed from 70 to 100 cycles per minute. End us-
ers benefit directly from shortened cycle times and
increased machine productivity. For the first time, visitors
at the PACK EXPO 2010 had the opportunity to experience
the advantages of the new machine solution firsthand.

Servos replace pneumatic axes
The previous solution was composed of a controller and a separate visualization device, as well as two separate temperature
controllers, each programmed with different software. These four devices have been replaced with a single compact Power
Panel. In order to speed up the cycle time, the pneumatic cylinders for the horizontal and vertical seal belts were replaced by
servo motors. The high-performance Power Panel controls the position of the servo drives and regulates the dwell time and
contact pressure. Three variable frequency drives control infeed, side seal and the traveling cross seal belt. The real-time
operating system allows all the axes to be synchronized.

With these upgrades, the Extreme Packaging engineers were able to replace the entire pneumatic solution (the pneumatic
hoses, compressor, air filters and
pneumatic controller), thus simplifying  The use of cutting-edge B&R technology allows machine production to be raised up to
mechanical fabrication and reducing      200 cycles per minute.
costs. All of the axes can be equipped
with servos as needed. This makes it
possible to boost production up to 200
cycles per minute.

One	software	platform
Automation Studio makes it possible
to program and configure all compo-
nents using a single tool, which elimi-
nates inconvenient interfaces. B&R's
software tool also helps reduce com-
missioning times and simplifies main-
tenance work for the end user.



www.extremepkg.com




                                                                                                                automotion 31
 Application




  The	future	of	packaging
                                                                           Reprint from Packaging World Magazine, Dec. 2010
                                                                           Author: Pat Reynolds, Editor-in-Chief




  In	some	parts	of	Europe,	frozen	pizza	is	being	replaced	by	fresh	pizza.	It's	typically	brought	to	market	in	a	
  vacuum-packaged	format.	While	this	approach	is	satisfactory	enough	from	a	shelf	life	standpoint,	it	isn't	the	
  most	 pleasing	 from	 a	 presentation	 perspective.	 Consumers	 just	 aren't	 wild	 about	 the	 "crushed"	 look	 that	
  comes	with	vacuum	packaging.	So	flow	wrapping	has	emerged	lately	as	an	alternative.


  Among the packaging machinery builders that have come up with flow-wrap sys-          heat seal tooling to enclose the pizza in
  tems for fresh pizza is Ilapak. The firm is now in its second or third generation     its modified atmosphere. Refrigerated
  of a system that is essentially a three-legged stool: infeed conveyor, evacuation     shelf life is about three weeks.
  system, and back-flush/flow wrap. Called the Delta Vac-Map, the 17-axis servo-
  driven system relies on motors, drives, and controls that are all supplied by B&R.    Standardized controls
  While infeed and flow wrap are essential, it's the evacuation/backflush system        According to Flavio Cecconello, R&D
  that is most innovative. This is a rotary machine with nine stations that operates    software engineer at Ilapak, a key
  at 60 pizzas/min. Individual pizzas on paperboard sheets are conveyed into the        goal behind the development of this
  evacuation/backflushing carousel on a flighted conveyor that maintains the nec-       pizza-packaging system was to use
  essary spacing. In each vacuum station, the top and bottom halves of the vacuum       widely accepted standards wherever
  chamber close on a pizza. Then, as the closed chamber moves around its circular       possible. So PLCopen is the program-
  track, ambient air is evacuated and carbon dioxide and nitrogen are backflushed       ming language standard that Cecco-
  in. The chamber opens and the pizza enters immediately into the film tube of a        nello relied on in this implementation.
  flow wrapper that again backflushes carbon dioxide and nitrogen before using          Focused around IEC 61131-3, which

32 automotion
                                                                                                                     Application

is said to be the only global standard
for industrial control programming,
PLCopen harmonizes the way people
design and operate industrial controls
by standardizing the programming
interface. Cecconello provides this
example as a way of illustrating the
benefits that PLCopen brings.

"Take a standard function, like 'turn
power on,' for example. I can use a
standard PLCopen function block as
my interface for that function. I select
which axis of motion I want, the way
in which I want to turn on the power,
and the 'execute' command to the right
PIN [Pulse Input] to turn the power on.
Not only is this programming standard
successful with the platform I'm using
in this particular implementation, it's
also suitable for other technology sup-      Pizzas on paperboard sheets are conveyed into one of nine vacuum stations so that oxygen
pliers who support this standard way         can be evacuated from the pizza itself.
of programming machines. If I stay
within the PLCopen standard, I should
be able to migrate the code from one
technology supplier's platform to an-      Workgroup. It was adopted as part of the ISA88 industry standard in August 2008.
other without a complete rebuild of the
software or the control."                  "PackML gives us a couple of benefits," says Cecconello. "First, the steps a machine
                                           has to follow in the various phases of operation are already defined—startup, for
In addition to relying on the PLCopen      example, or during a package format change or during maintenance or during
standard at the motion control level,      standard running time. All of this is documented and specified within PackML, so
Cecconello also wanted a standardized      it's a guideline to help us organize the way we interface, for example, the standard
way of handling how machine state          HMI with the machine controls. It's a three-layer organization. The upper layer is
transitions are implemented within his     the interface with the operator, the second layer is the logic we implement to our
code. He liked what he saw in PackML,      machine, and the third layer is the PackML state model. If I ever need to change
the "Packaging Machine Language"           the controls platform, because I'm organizing the machine based on PackML, the
developed by the OMAC Packaging            only thing I'd have to change would be the lower layer of the interface, where >>




                                                                                                                     automotion 33
 Application


     Another	view	of	the	machine	controls
     Additional insight into how Ilapak's standards-based Vac-Map system was programmed
     comes from Lorenzo Passaglia, a Ph.D in engineering and technical manager at B&R.

     "All machines need modes and states. On this machine I wanted them based on standards.
     I remembered a presentation on OMAC Packaging Guidelines and decided to apply the
     concept.

     "Ilapak agreed to use structured text as much as possible because it is well accepted in
     Europe and it is flexible. The application could just as readily be developed using Ladder
     Diagram if a customer preferred it.

     "We needed manual, production, setup, and several other modes, and all are implemented with OMAC's PackML stan-
     dard states. Ilapak's engineers liked the ability to split the project into modules with references. We began with a 'virtual'
     OMAC mode, called 'base,' as a template where we defined all the state transitions—idle, start, executing, aborting, etc.
     We were then able to create references to the basic mode file and make only the changes required for the new mode.

     "Ilapak was surprised how easy it is to create software libraries in Automation Studio, the B&R software development
     environment. For example, parameters for interpolation required some complex calculations. By using libraries, com-
     plex software routines can be hidden behind a simplified user interface so that the software can be optimized without
     the end user needing to be a programming expert. Visual Components allowed a direct link from the HMI project to the
     machine project since the same database is shared.

     "Axis control is performed using the PLCopen library. In addition to standard PLCopen motion function blocks, we drew
     from a set of fully PLCopen-compliant function blocks developed by B&R that provide additional functionality. In this
     way, the standard allows a common look and feel without sacrificing competitive advantage.

     "For example, the 'Cam automat' function block is a tool unique to B&R for interpolating a slave to a master axis. It
     defines interpolation states with a cam and allows you to define events. Let's say you want to interrupt the motion but
     the slave needs to reach a specific position. The automat function block is a state machine that automatically performs
     these control tasks."




  you have the interaction with the address, with the drives and so on. But even
  there the amount of rebuilding or reprogramming would be minimized because
  of my reliance on PLCopen. If another supplier is using PLCopen, even that lower
  level would not have to be completely rewritten. So from a development point of
  view, that is the first benefit of PackML.

  "Second is the standardization of interface and communication to other systems.
  This means our PackML-compliant machine and other PackML-compliant ma-
  chines will have the same kind of interface, so it will be easier to debug problems
  and investigate errors. This is the first time we've used PackML and PLCopen to
  this extent."

  Cecconello notes that the B&R controls package makes a significant contribution.
  "The B&R components support the PLCopen programming standard," says Cec-
  conello. "Programming structures are there for us, so we don't have to build them.
  It's a well designed, well thought out interface." Also a welcome feature, notes
  Cecconello, is that one software program covers motion, logic, and HMI.

  Remote accessibility
  When widely recognized standards like PLCopen and PackML are made part of a
  packaging machinery system like this one, it paves the way to things like Web-en-
  abled remote access via Virtual Network Computing (VNC). In Ilapak's case, for ex-
  ample, the control platform makes it possible to have a secure VPN (Virtual Private

34 automotion
                                                                                                                  Application

Network) connection over the Internet
that Ilapak engineers can use to access
the pizza-packaging system from any
location where an Internet connection
is available. Flavio calls this remote ac-
cess capability "one of the major ben-
efits of open architecture."

"B&R pays close attention to this," he
continues. "They have inside their con-
trols platform two important features.
The first is the VNC server. It gives us
a graphical laptop sharing system to
remotely access our machine and see
exactly what the machine operator is
seeing on his HMI. All we have to do is
install freeware that is downloaded at
no cost. The second feature is the OPC
server that's already installed on the
controls platform. OPC is commonly
used by SCADA or ERP systems to
connect to machines and extract data.
Typically it's a standard that is only
Windows-based, so up until about a
year ago you needed a dedicated PC           A final note on why this Ilapak system points the way to the future. It takes advan-
to serve as a bridge between Windows         tage of the latest in mainstream computing rather than following a traditionally
and your SCADA or ERP system. B&R            industrial approach where dedicated hardware and software are more typically
lets us do away with this bridge be-         the norm. One look at its graphical user interface makes this clear. It looks more
cause they are one of the first to inte-     like something out of the gaming world than the manufacturing scene.
grate the OPC server directly on their
platform. With just the B&R platform
and an OPC client, a customer can
provide packaging machine states to
his SCADA or ERP system. On these
particular packaging machines, this is
accomplished using the PackML stan-
dard, so our customer's IT department
already has everything they need for
them to get data out of our machines.
It's all documented in a standard way."




                                                                                           Ilapak:




                                                                                           Established: 1970
                                                                                           Locations: Head office in Lugano (CH);
                                                                                              manufacturing facilities in Switzer-
                                                                                              land, Italy (2 plants), China, USA
                                                                                           Products & Services: Industrial
                                                                                              wrapping machinery for primary
                                                                                              packaging using flexible wrap-
                                                                                              ping materials

                                                                                           www.ilapak.com

                                                                                                                  automotion 35
 Interview




  A	safe	start	into	a	
  safe	future
  Leading	 up	 to	 the	 implementation	 of	 the	 new	 ma-            In 2004, B&R's technology development department formed
  chine	 guidelines,	 safe	 data	 transfer	 via	 industrial	         a project team for safety-oriented control technology using
  networks dominated discussions. Since then things                  POWERLINK and began development in this area. In the early
  have quieted down a bit. automotion caught up                      definition phase, the group agreed that a safety system can
  with	Franz	Kaufleitner,	and	asked	him	where	B&R's	                 only be successful in the long-term if it is not tied to a specific
  Safety	products	stand	on	the	market,	and	what	de-                  bus and transfer protocol. After all, machine manufacturers
  velopments we can expect in this area in the near                  aren't always free to choose which controller and which In-
  future.	Franz	is	B&R's	product	manager	for	Integrat-               dustrial Ethernet system they use. That's why we defined a
  ed	Safety	Technology.                                              safety protocol that is completely independent of the trans-
                                                                     fer mechanism and can travel on any bus system. Today this
  automotion: Around the turn of the century, the topic of           concept is well-known under the name openSAFETY.
  network-based safety technology first entered industry-wide
  discussions. When did B&R start thinking seriously about this      automotion: How long did development take, and when did
  subject?                                                           B&R products for functional safety actually become available
                                                                     as easily integrated hardware?
  Kaufleitner: Safety technology has existed at B&R since the
  year 2000. It was then that the first concepts were developed      Kaufleitner: From start to finish, projects in the area of func-
  for equipping the ACOPOS motion control devices with safety        tional safety must be executed with precision, documented in
  functions. Today this first safety function is called STO - Safe   detail and certified by the TÜV. As a result, new developments
  Torque Off.                                                        are known to take much longer than normal.

36 automotion
                                                                                                                      Interview




                                                                                            All products enhanced by B&R's Inte-
                                                                                            grated Safety Technology are inter-
                                                                                            nationally recognized and have been
                                                                                            certified by the respective governing
                                                                                            bodies.


It was especially important to view the safety technology as      Compared to B&R, hardly any other company on the market
an integrated component of the overall system. Our design         offers such a broad spectrum of completely certified safety
would have to work under all circumstances and be com-            technology. And none of them comes close to the level of
patible with various control systems. Additionally, we had to     integration in the control technology or the development en-
ensure compatibility with future components, whose exact          vironment as B&R does.
specifications we had no way of knowing.
                                                                  automotion: Yet network-based safety technology is not
The programming environment needed to be seamlessly in-           only offered by control system manufacturers. There are
tegrated in Automation Studio. In order for the real wiring to    certainly solutions available from suppliers in the safety sec-
be replaced by virtual wiring, we needed certified function       tor. What's the advantage of B&R compared to these systems?
blocks. Here, too, we committed to creating an open stan-
dard from the very beginning and were one of the first manu-      Kaufleitner: Independent safety systems all share the disad-
facturers to implement the PLCopen Safety specification.          vantage that they can only utilize network communication on
                                                                  the safety bus internally. All decisions must be made by a
Since 2008, B&R offers a complete system of fully certified       separate safety component. This component alone is respon-
safety products. These include a line of SafeLOGIC safe con-      sible for initiating all actions. A standard controller (without
trollers, the SafeIO modules integrated in the X20 System,        safety functionality) must use additional communication ser-
the SafeDESIGNER development add-on for Automation                vices to read status information from the safety application
Studio, and of course the openSAFETY safe network pro-            or to read keywords for switching actuators in the individual
tocol.                                                            safety components.

automotion: These days, there are hardly any control sys-         With integrated, network-based safety technology, functional
tems manufacturers who don't offer some sort of integrated        control has direct read access to safety-related data. This
safety technology. Where is B&R in comparison?                    completely does away with additional wiring and interfaces.
                                                                  Furthermore, this type of data access is also available for di-
Kaufleitner: The new machine guidelines appeared in 2009,         agnostics tools. The profile and trace tools integrated in Au-
and leading up to that we saw a burst of announcements            tomation Studio are therefore suitable for analyzing problems
from various manufacturers from 2007 to 2009. The safety          in the safety products. None of the independent safety sys-
technology offered by many of our competitors is at about         tems available on the market offers these types of convenient
the level B&R was at in 2008.                                     diagnostics options without additional work and expense.

Our developers, on the other hand, haven't rested on their        automotion: B&R is always emphasizing the issue of short
laurels. The work continued, and still does. A whole line of      response times. Why is this so important?
new safety-oriented products has already been certified and
introduced to the market. Since early 2010, B&R now offers        Kaufleitner:	 In safety technology it is key that the safe re-
IP67 versions of the X20 SafeIO modules. Safe motion con-         sponse occurs as quickly as possible. Just like with driving
trol based on the ACOPOSmulti servo drives with SafeMC            a car, what matters is the total stopping distance, which in-
is also fully certified and available in series production. In    cludes both the distance traveled before a response and the
cooperation with the high-precision, fully digital encoders for   actual braking distance itself. This determines the required
B&R motors, they make it possible to respond to safety viola-     safety clearance. In the case of production machines, this
tions with Smart Safe Reactions rather than a hard machine        affects the overall size of the machine, and in turn its foot-
shutdown.                                                         print, manufacturing cost and energy consumption. With >>

                                                                                                                   automotion 37
 Interview




    Intelligent, decentralized and integrated safety technology that is simple to operate and that achieves extremely high response times
    opens up an entirely new range of machine safety concepts.




  openSAFETY via POWERLINK we achieve 10 times faster re-               labor back in 2004, when we first set our course towards a
  sponse times. This allows our decentralized, network-based            high-performance platform.
  safety technology to compete with the few high-speed sys-
  tems on the market with a purely monolithic design and no             automotion: What are the benefits for machine manufactur-
  network.                                                              ers and users?

  The safe motion control provided by SafeMC, which reaches             Kaufleitner:	 One of our priorities during development is to
  from the ACOPOSmulti servo drives to the servo motors, is             keep the entry threshold as low as possible. One way we do
  a decisive advance. The focus here is on live monitoring of           this is by creating compact units that allow smaller safety ap-
  setpoints. Every reduction in the response time results in an         plications to be implemented at minimal cost. At the same
  exponentially higher reduction in the braking distance and            time, however, we ensure that the solutions are scalable
  impact force.                                                         enough to handle large networks and any conceivable topolo-
                                                                        gy. This gives users the advantages of B&R's integrated safety
  automotion: What does the future of openSAFETY look like?             technology consistently on all versions of their machines.
  What products can we expect to see next?
                                                                        automotion: Thank you for the interview.
  Kaufleitner:	Safe analog inputs are currently in very advanced
  stages of development. These can be used to safely integrate
  analog sensors into the B&R system. This ability to process              About the author:
  analog signals especially highlights how powerful our safe
  control products are, as well as the flexible programming op-
  tions of SafeDESIGNER. And in the end, it's openSAFETY that
  makes it possible to safely transfer analog data, with consider-
  ably larger amounts of reference data, over the network. This
  is where the wheat is separated from the chaff.                          Franz	Kaufleitner
                                                                           Product manager for
  The second thing you'll be seeing in the near future are safety          Integrated Safety Technology
  functions for robotics. The idea here is to combine the existing         B&R Eggelsberg
  safety functions of multiple individual axes and provide safety
  monitoring of the entire axis group in kinematic space. Here,            Franz Kaufleitner has been at B&R since 2004 and has
  too, the computational and bus performance requirements                  played an important role in the development of B&R's
  are higher than most other available systems can handle.                 safety technology since the very beginning.
  And again, we at B&R are building upon our solid foundation              He is a member of the PLCopen Safety workgroup and
  of SafeLOGIC and SafeDESIGNER products, along with the                   head of the Ethernet Powerlink Standardization Group's
  openSAFETY protocol. We're now enjoying the fruits of our                openSAFETY workgroup.

38 automotion
                                                            Technology




                                                               These companies trust in B&R
UNIVISION
INSPECTION TECHNOLOGY




                        Modular   Packaging Systems, Inc®




                                                            automotion 39
       Step by step
       label production
  When	shopping,	consumers	tend	to	orient	themselves	to	the	information	provided	on	the	label,	but	hardly	
  anyone	thinks	about	the	production	of	the	labels	themselves.	Blumer	Maschinenbau	AG,	based	in	Otelfingen,	
  Switzerland,	is	one	of	the	leading	worldwide	manufacturers	of	systems	for	label	processing.	They	produce,	
  for	example,	special	systems	that	cut	or	die-cut	various	forms	of	labels	from	printed	stacks	of	strips.


  In particular, labels for the food and beverage industry as well as telephone cards,    example for beer and mineral water
  ID cards, game cards or loyalty cards made of plastic and cardboard are die-cut         labels or aluminum foil bottle neck
  to the desired form and banded for further use using card and label production          labels, and has already been suc-
  systems manufactured by Blumer Maschinenbau AG. When building these types               cessfully implemented by over 400
  of systems, quality and cost-effectiveness are at the top of the priority list. Users   users. For example, the Atlas1110LS
  appreciate systems from Blumer because, for one, their advanced developments            label die-cutting system mainly con-
  continually provide possibilities to further optimize processes on the machines.        sists of a loading table, strip feed unit,
  The company places high demands on itself and also on its suppliers, such as B&R,       cutting unit, break-through
  regarding the modularity, uniformity and reliability of systems and components.         die-cutting machine and
                                                                                          banding module. On this
  The degree of automation on the systems is mainly determined by the type of             system,         the
  products being manufactured, the printing process used and the infrastructure           labels,      which
  available to the user. In 2003, Blumer had already started changing over the con-       have          been
  trol systems for their entire machine manufacturing line to products from B&R.          printed but are
  PLCs, drives, operator interfaces and visualization systems now come from a             still connected
  single manufacturer. And since the changeover, all devices can be programmed            in strips, can be
  with the uniform programming tool Automation Studio. Training of customers and          cut and die-cut
  employees was also significantly simplified by the uniform programming interface.       into all conceiv-
                                                                                          able forms.
  From	stacks	of	strips	to	bundles	of	labels
  The modular line of Atlas systems, which can be adapted perfectly to specific
  conditions, was designed especially for the efficient processing of labels, for

40 automotion
                                                                                                                       Application




Strip feeding, stack separation, banding, output: the new machine concept allows complete processing, from strip stacks to label
bundles.



Automation	components	from	one	source                                                        development of control systems.
The entire control system comes from B&R, including the PLC functions,                       The company counts on the profes-
drives and visualization systems for the machines. And this is not only the                  sional expertise of its technicians for
case with all of the new machines and systems because machines that have                     the successful development, con-
already been in use for years are also retrofitted with the current automation               struction and manufacturing of its
system.                                                                                      products. Of course, they handle all
                                                                                             engineering in-house, including the
Products from B&R's ACOPOS servo drive line are being used, for example,                     implementation of the control sys-
for positioning the paper strips. With their 400 µs scan times, these servo                  tems. In this regard, Roger Loeliger,
drives are able to react to application-specific events very quickly. Because                who is in charge of the electrical sys-
they use the embedded parameter chip on the motor with all the relevant                      tems, stresses the fact that Blumer's
mechanical and electronic data, it's not necessary for machine manufacturers                 clear machine concepts and B&R's
to make time-consuming and error-prone parameter settings, which shortens                    equally clear automation concepts
commissioning times substantially. During service work, additional relevant                  are designed with a very straightfor-
data can be queried. The servo drives perform outstandingly well for precise                 ward structure and therefore harmo-
measurement tasks with two highly precise trigger inputs. A servo motor with                 nize excellently.
an ACOPOS drive is used on each machine on the back gauge feed unit where
the strips are pushed under the pressing bar and the cutting blades. Because
the multi-turn encoder for the motor is capable of absolute position measure-
ment, lengthy homing procedures are no longer necessary and no additional
measuring systems are needed on the workpiece.

The system has approximately 80 digital and analog I/O modules as well as
temperature modules from the X20 System for querying sensors and move-
ments as well as for controlling pneumatic and hydraulic valves.

The X20 System is more than a remote I/O system, it meets all requirements
for a complete control solution. Especially for modularly designed systems, it
is a huge advantage if the software for the bus module automatically detects
the components in the system and provides the necessary functions. Since
the terminal blocks can be separated from the electronic module, complete
switching cabinets equipped with X20 System devices can be pre-wired.

Convenient visualization and operation
In order to be able to set various parameters individually, Blumer uses a Pow-
er Panel as the central operating and control unit. The individual control, drive              Blumer:
                   and visualization components are networked via the CAN
                      bus and X2X bus.

                       Power Panels like the PP41 are especially suited for auto-
                        mating small and mid-sized machines and systems that                   Established: 1897
                            require maximum component density. In addition                     Locations: Otelfingen (Switzerland),
                                to a powerful PLC, they also include a visual-                    subsidiaries in the USA and Hong
                                 ization system and digital I/O.                                  Kong
                                                                                               Products & Services: Blumer builds
                                    A	 clear	 automation	 concept	 for	 a	 clear	                 production lines for labels and
                                    system concept                                                cards satisfying the most varied
                                    Blumer Maschinenbau AG has many decades                       requirements
                                    of practical experience in both the manu-
                                    facturing of mechanical equipment and the                  www.blumerag.com

                                                                                                                       automotion 41
 Technology




     openSAFETY:
     What's	in	it	for	you?



                  POWERLINK               SERCOS               Modbus             EtherNet/IP               PROFINET
                        Machine 1            Machine 2            Machine 3            Machine 4                Machine 5




                                                 In	the	young	field	of	network-based	safety	data	communication,	open-
                                                 SAFETY	 is	 a	 response	 to	 the	 long-stated	 demand	 for	 uniformity	 and	
                                                 interoperability	across	all	systems.	This	level	of	openness	and	indepen-
                                                 dence	 is	 considerably	 more	 useful	 than	 proprietary	 systems,	 and	 not	
                                                 only	for	machine	manufacturers.	The	manufacturers	of	sensors	and	ac-
                                                 tuators	as	well	as	safety-related	end	devices	profit	from	only	having	to	
                                                 invest	once	in	development	and	certification.	However,	machine	users	
                                                 benefit	the	most	from	cost	advantages	and	the	possibility	of	seamless	
                                                 safeguarding	of	entire	production	facilities.	


  Meanwhile, safety systems triggered a sweeping revolution with safe signal transfer              Interoperability thanks to Black
  via the fieldbus, primarily via Ethernet-based networks such as POWERLINK. The ad-               Channel
  vantages over traditional systems are hard to ignore: The elimination of the majority            "A network-based safety system doesn't
  of cabling significantly reduces costs and removes a notorious source of errors. At              offer this independence, which is too
  least in safety systems that use direct communication without detouring through the              high of a price to pay for its other ad-
  controller, the required safety standard can be achieved at significantly higher move-           vantages," explains Stefan Schönegger.
  ment speeds, which in turn increases productivity. Last but not least, the integration of        "One of the central development goals
  drives and motors, as in B&R SafeMC, shortens the stopping distance and allows for               for openSAFETY was to not compro-
  smaller safety clearances, making it possible to build smaller and more economical               mise this autonomy of the safety system
  machines.                                                                                        from the system bus." The solution was
                                                                                                   found in the Black Channel principle,
  This makes it easy to see why all leading manufacturers of control and automation                which enables safe data transfer that is
  technology advocate Safety over Industrial Ethernet. "There's only one catch," says              independent of the transport protocol
  Stefan Schönegger, B&R Business Unit Manager for Open Automation, whose job it                   being used, also allowing it to be carried
  is to make B&R technologies as easy as possible for other system manufacturers and               out on any fieldbus.
  integrators to use. "With just one exception, all of these systems can only be oper-
  ated together with the control hardware or field network system from the respective              This benefits more than just the machine
  manufacturer. This is due partly to technical reasons, but also other unnecessary fac-           manufacturers. Device manufacturers
  tors such as monopoly-driven market politics." This can cause headaches for machine              also get a headstart with shorter time-
  manufacturers because they aren't always able to choose which controllers to use in              to-market since they only have to go
  their products, but instead must often follow their customers' demands. This high-               through development and certification
  lights the only real advantage of hard-wired systems: Installed once, certified once,            once. In addition to being time consum-
  the solution remains the same regardless of the controller that is being used.                   ing and expensive, a uniform solution

42 automotion
                                                                                                                      Technology

                                                                                             owners can also benefit directly from
                                                                                             openSAFETY. The uniform nature and
                                                                                             universal application possibilities also
                                                                                             limit the expenditures for technician
                                                                                             training courses and the cost for procur-
                                                                                             ing replacement parts. "However, a com-
                                                                                             pletely new possibility also opened up
                                                                                             that reaches much further," says Stefan
                                                                                             Schönegger. "Thanks to openSAFETY's
                                                                                             independence from the system bus,
                                                                                             they are able to efficiently equip entire
                                                                                             groups of different machines, robots
                                                                                             and handling equipment with one com-
                                                                                             prehensive, shared, modern safety sys-
                                                                                             tem, thereby creating new benefits for
                                                                                             productivity, that could not be achieved
                                                                                             in the past using conventional technolo-
                                                                                             gies."

                                                                                             Proprietary is yesterday. The future be-
                                                                                             longs to manufacturer-independent,
                                                                                             open solutions like openSAFETY.




also requires less special knowledge and limits the logistical expenditure that comes
with a bloated range of variations.

Dr. Georg Plasberg, division head for the development of industrial safety systems
and member of the management team at Sick AG, a renowned German manufacturer
of sensors, agrees: "In many other electronic applications, interoperability of different
systems has become practically a requirement. Although we will continue to integrate
the full range of proprietary solutions in our products, I believe that only those who
can overcome network limitations using open communication standards will have
long-term success in industrial applications. Of course, we strive for this level of open-
ness beyond the specification level and right up to the interface level of the engineer-
ing systems."
                                                                                               About the author:
Benefits	for	device	and	machine	manufacturers
As managing director of the worldwide exporting company TRUMPF Maschinen
Austria Ges. mbH & Co. KG, Dr. Alfred Hutterer knows the disadvantages that stem
from the lack of interoperability seen in most safety systems. "This lack of interoper-
ability between different systems is not only expensive, it also lengthens the time-to-
market and prevents a reasonable second-source policy on the purchasing end," he
recently stated at a discussion held by a leading Austrian trade magazine regarding
current technology. He continued, "The different schools of thought evangelizing their
individual technologies make it difficult for manufacturers of field devices to develop
hardware that is compatible with the different networks."

Machine manufacturers such as TRUMPF also benefit from the standardized open-
SAFETY product portfolio with fewer devices compared to proprietary solutions and
from the ability to use alternative suppliers when necessary. "This is no minor factor,        Stefan Schönegger (30) began work-
because availability always plays an important role in making sales and ensuring con-          ing at B&R in 2006. After working as
tinued customer satisfaction," explains Stefan Schönegger. "The topic of know-how              product manager for POWERLINK
also comes into play for machine manufacturers because with openSAFETY, service                technologies, Schönegger has been
technicians only need to be trained on one technology."                                        managing the Open Automation Tech-
                                                                                               nologies Business Unit at B&R since
Benefits	for	production	plants	as	well                                                         the beginning of 2010. He also serves
In addition to the cost advantages that device manufacturers are able to pass on to            as Managing Director of the Ethernet
the machine manufacturers and their customers, production companies and machine                POWERLINK Standardization Group.

                                                                                                                      automotion 43
 Application




  Handling	different	for-
  mats?	That's	easy!
  In	 today's	 fast-paced	 consumer	
  goods	 market,	 a	 key	 factor	 for	
  the	 success	 of	 food	 corporations	
  is	flexibility	throughout	the	entire	
  production chain. Being able to
  quickly and easily adapt produc-
  tion to meet the market's "just
  in time" requirements is now a
  must. With their new tray sealing
  machine concept, G. Mondini has
  developed an innovative solution
  to	handle	different	packaging	for-
  mats with a single system.




  In 1972, Giovanni Mondini revolutionized the international packaging market by             One	system,	many	formats
  introducing an innovative rigid container for packaging food. The advantages               Food producers are increasingly de-
  were threefold: simplified logistics, improved product quality and a considerably          manding more flexible machine solu-
  longer shelf life.                                                                         tions; as a result, it has become im-
                                                                                             portant that machines are able to be
  Today, Mondini employs 160 workers and has become a leading manufacturer                   retooled as quickly as possible. The
  of packaging and dosing machines with more than 6,000 systems in use all over              new EVO 384 offers exactly this kind
  the world. From complex lines for producing and packaging ready-made dishes                of flexibility: a tray sealing machine
  to single-tube filling machines in simple or modified atmospheres, G. Mondini              that can handle many different kinds
  ensures superior machine quality and reliability. One particular innovation is the         of packaging formats. In addition, the
  Fresh M.A.P System, a complete packaging line for meat and fish. Through the               EVO machine series is able to achieve
  use of a new type of container and barrier film, products are packaged in a vacu-          a high level of productivity while not
  um or an atmosphere that extends the shelf life of the product considerably. The           taking up a lot of space.
  user profits from this extended shelf life as well as the fact that the taste, smell and
  color of the packaged products are not affected in any way.                                Advanced ACOPOSmulti servo drives
                                                                                             are used to control the servo motors.
                                                                                             Power regeneration capabilities, which




44 automotion
                                                                                                            Application


  Visual Components sup-
  ported the implementation
  of an intuitive user inter-
  face.




prevent kinetic brake energy from be-      The use of powerful industrial PCs means that different automation tasks such
ing converted to heat, allow users to      as motion control, visualization, etc. are combined on a single system platform.
profit from an energy-efficient and en-    Communication between the control system and the new EVO 384 is handled us-
vironmentally friendly solution.           ing POWERLINK. This allows food manufacturers to profit from high-speed data
                                           exchange and maximize their network performance in real time.
Adherence to international pack-
aging standards
The software solution used for motion
control conforms to PLCopen stan-
dards (in accordance with IEC 61131-
3). In addition, the machines meet
the requirements set forth by PackML
guidelines, which clearly define pos-
sible machine states as well as the
changes they undergo. In this regard,
the EVO 384 complies with the most
important international standards rel-
evant to the packaging industry.

User-friendly	operator	interface
In order to meet customer demands
for a simple, intuitive operating con-
cept, Mauro Cocchetti, manager of
automation at G.Mondini, decided to
introduce a new PC-based visualiza-
tion system. A completely customized
touch screen display with integrated
RFID technology provides secure ac-
cess to the system.

B&R Visual Components for Windows
also makes it possible to integrate a
comprehensive PDF-based help sys-
tem. Recipe management is supported
with corresponding high-resolution
JPG images. Integrated videos also aid
in operation and maintenance. In ad-
dition, all system parameters can be
exported to and imported from a CSV
file on a USB flash drive. Video and au-
dio files can be played using Windows
Media Player, and Internet Explorer
can be used to display HTML files;
both of these programs are integrated
in the Runtime Visual Components for
Windows environment, which doesn't
require a license to operate.


                                                                                                             automotion 45
 Application




  High-speed packaging
  Fast product throughput in a pack-       HayssenSandiacre Europe Ltd, located         machines or as horizontal tubular bag
  aging process requires a control         in Nottingham (UK) and a member              machines, depending on the applica-
  system that is reliable and robust.      of Barry-Wehmiller Companies Inc.,           tion.
  The	integration	of	B&R	technology	       develops and produces flexible pack-
  ensures	the	English	manufacturer	        aging machines for the international         The main market is the foodstuffs in-
  HayssenSandiacre maximum reli-           market. The machine lines Hayssen,           dustry—especially applications for
  ability	 with	 significantly	 reduced	   Sandiacre and Rose Forgrove are de-          filling and packaging candy, snacks,
  maintenance costs.                       signed either as vertical form-fill-seal     frozen foods and various drinks. Cus-
                                                                                        tomers for pharmaceutical and medi-
                                                                                        cal care products also utilize this so-
                                                                                        phisticated technology.

                                                                                        Increased	performance
                                                                                        The integration of B&R control compo-
                                                                                        nents into the horizontal tubular bag
                                                                                        machines from Rose Forgrove made
                                                                                        it possible to further expand the prod-
                                                                                        uct pallet. "Over the last two to three




                                                                                      Through the use of B&R control technology,
                                                                                      Hayssen Sandiacre was able to reduce the
                                                                                      number of interfaces and clearly reduce ca-
                                                                                      bling requirements.

46 automotion
                                                                                                                      Application

                                                                                             connection. An Ethernet connection
                                                                                             provides high-speed exchange of pro-
                                                                                             duction and machine data with SCADA
                                                                                             systems.

                                                                                             Each Automation PC is equipped with
                                                                                             application-specific software. The op-
                                                                                             erator is led through the program in-
                                                                                             tuitively and can easily set important
                                                                                             process parameters such as product
                                                                                             size, machine speed, bag length, foil
                                                                                             orientation, etc., while also being able
                                                                                             to store and retrieve recipes. "All pro-
                                                                                             cessing parameters can be changed
                                                                                             on the fly by the operator. For our
                                                                                             customers this means machine setup
The user-friendly operating concept allows charges to be changed
                                                                                             times are minimized when changing
quickly, which makes it possible to set up the machine in the short-
est amount of time.                                                                          batches," explains LaPare.

                                                                                             Worldwide support
                                                                                             "When we need new functions, B&R
years, sales of machines have steadily            Quick parameter entry thanks to            Support is always quick to respond.
increased," says Mike LaPare, Director            intuitive HMI                              Our customers around the world also
of Rose Forgrove proudly. "This growth            The experts from HayssenSandiacre          benefit from the worldwide presence
can be attributed to the increased reli-          decided on the powerful Automation         of our automation partner, who pro-
ability and optimized performance of              PC to handle the machine's visualiza-      vides fast local support on-site. For us
our machines."                                    tion since this device is able to handle   this is a valuable addition to our inter-
                                                  all the demands for control and opera-     national sales efforts," says LaPare in
Cost	efficiency	through	reliability               tion in a single unit. The Automation      closing.
"Downtime during production can                   PC is also equipped with additional
be extremely costly for the producer.             interfaces that make it easy to con-
Food producers are especially sensi-              nect devices from other manufactur-
tive in this respect," explains LaPare.           ers. Analog signals such as those for
He continues, "As the machine pro-                equipment production rates can easily
vider, we must therefore be confident             be transmitted as I/O or via a fieldbus
that our suppliers are providing us
with high-quality, reliable control com-
ponents that aren't going to fail."

In the various packaging machines,
ACOPOS servo drives are used for
all movement tasks, as well as the
X20 System in combination with the
robust 10.4" APC. With the use of
Automation Studio for programming,
HayssenSandiacre profits from a short
commissioning time and considerably
reduced maintenance costs.                        "The high throughput speeds of
                                                  our packaging machines require
Fewer	 interfaces	 means	 less	 ca-                                                            HayssenSandiacre:
bling                                             reliable control solutions. B&R
An important advantage of B&R prod-               offers components that meet
ucts is the level of integration in the
system. The controller and HMI are
                                                  the highest industrial standards             Established: 1906
combined in a single compact unit.                and guarantee top quality."                  Employees: 120
This significantly reduces the amount             Mike LaPare                                  Annual revenue: £20 million
of cabling required. "Fewer connec-               Director                                     Locations: Nottingham (UK)
tions on a machine means fewer po-                Rose Forgrove                                Products & services: Development
tential sources of error during produc-                                                           and production of flexible pack-
tion. Machine downtime can therefore                                                              aging machines
be prevented at the machine build
stage," says LaPare.                                                                           www.hayssensandiacre.co.uk

                                                                                                                       automotion 47
 Application




  Innovative packaging
                In	 1830,	 the	 famous	 inventor	 of	 the	       As in the early days, the company's re-
                sewing machine, Barthélémy Thimon-               cent history is also marked by numer-
                nier	 from	 Lyon,	 France	 founded	 the	         ous innovations: In 1957, Thimonnier
                world's	 first	 machine-based	 clothing	         introduced the first machine for pack-
                factory.	The	company	exists	to	this	day	         aging pasteurized milk in polyethylene
                and	 is	 located	 in	 the	 town	 of	 Saint-      "pillow" pouches to the market. Just
                Germain-au-Mont-d'Or.	 After	 entering	          five years later the well-known Doy-
                the	raincoat	business	shortly	after	the	         pack, a flexible stand-up pouch, was
                Second World War, the company began              invented. In 1998 the company once
                shifting	 focus	 to	 the	 plastics	 industry.	   again attracted attention by introduc-
                With Thimonnier's specially developed            ing the first non-PVC medical bag pro-
                high-frequency	sealing	machine,	which	           ducing machine for IV solutions, blood
                uses	heating	pads	to	fuse	plastic	piec-          bags and CAPD bags.
                es	together,	the	importance	of	the	sew-
                ing	 machine	 gradually	 faded.	 Today,	         Yet another innovation came with the
                Thimonnier now has a comprehensive               first sterile high-speed packaging ma-
                assortment	 of	 sealing	 and	 filling	 ma-       chine for UHT milk (ultra heat treated
                chines	 for	 the	 foodstuffs	 and	 medical	      milk) with a volume of 12,000 bags per
                industries.                                      hour.




48 automotion
                                                                                                               Application




Sterile packaging
With a strong foundation built upon
nearly fifty years of experience in the field of packaging
and filling technologies, the French machine manufacturer continues
to successfully develop new market trends. "The use of flexible bags has ever-
increasing importance from both an economic as well as an environmental stand-
point: They are more cost-effective than other types of packaging and create less
waste. What's more, the demand for extremely clean and sterile technologies
continues to grow, particularly in the milk industry," explains Eric Duhoo, Sales
Director at Thimonnier. In order to meet these market demands, the company
worked together with B&R to find a reliable high-performance machine solution.        "B&R enabled us to significantly
                                                                                      lower the machine's total costs.
Complete	solution	provides	high	efficiency                                            Our machines are exported to
Based on the target markets—mainly emerging markets in North Africa and South         nearly 100 countries and can
America—a cost-effective and flexible automation system was needed that could
lower costs while increasing the ability to compete. "By integrating controller
                                                                                      be quickly adapted to meet the
functionality, visualization and drive technology into a single device, choosing      respective customer require-
the right machine architecture was not too difficult. Furthermore, the complete       ments."
integration of all automation tasks in a single Power Panel as well as the use of
POWERLINK significantly reduced our automation costs," explains Eric Duhoo.           Frédéric Roumanet
                                                                                      Manager of the Design Department
Another decisive factor was the seamless integration of different drive technolo-     Thimonnier
gies. B&R servo drives feature highly dynamic properties for the control of sealing
pads. With the compact ACOPOSmicro, Thimonnier is able to utilize all of the
benefits of stepper motor technology for simple and dynamic movements.

"B&R enabled us to significantly lower the machine's total costs. Our machines are
exported to nearly 100 countries and can be quickly adapted to meet the respec-          Thimonnier:
tive customer requirements," adds Frédéric Roumanet, Manager of the Design
Department.
                                                                                         Established: 1830
                                                                                         Employees: 55
                                                                                         Locations: Germain au Mont d'Or (FR)
                                                                                         Products & services: Molding,
                                                                                           filling and sealing machines,
                                                                                           primarily for the foodstuffs
                                                                                           industry

                                                                                         www.thimonnier.com

                                                                                                               automotion 49
 Technology



   ACOPOSmulti65:
   Thinking machine modu-
   larity through to the end
   From the very beginning, motion control devices
   in	 the	 ACOPOSmulti	 family	 from	 B&R	 have	 fo-
   cused	on	the	issue	of	modularity.	But	if	modular-
   ity	in	machine	manufacturing	is	carried	through	
   to its logical conclusion, it becomes clear
   that inverters also need to leave the con-
   trol cabinet behind and migrate to where
   the action takes place. This would allow
   configurable	 modules	 to	 become	 easily	
   connected mechatronic devices. It would
   also make it possible to reduce delivery
   times,	 free	 up	 valuable	 floor	 space	 and	
   simplify	commissioning.	With	the	ACO-
   POSmulti65, B&R has now introduced
   a	 decentralized	 inverter	 for	 motion	
   control onto the market that
   meets	all	of	these	demands.




                                       Just like in the automotive industry, the desire for adapting systems to individual
                                       requirements while adding different modular options is becoming increasingly
                                       prevalent in machine and systems manufacturing. The idea of a series production
                                       machine has degenerated to the point where it nearly no longer exists.

                                       The strong trend towards modularity
                                       From a control point of view, it is only possible to take advantage of the full ben-
                                       efits of optional devices and machine components if they can be easily connected
                                       with the primary machine—ideally with a single plug. In this case, the automation
                                       hardware would have to be integrated in the respective device from a location
                                       outside of the control cabinet. This is the only way to free up the valuable space
                                       inside the control cabinet as well as add expansions later in the game—or even

50 automotion
                                                                                                                                      Technology

after the machine has been commis-                              Control system
                                                                                                                            Motion control
sioned. Once this has been achieved,                            Visualization and operation

machine customers do not need to
                                                                                               POWERLINK
know every single aspect regarding
possible machine options, and the
time pressure involved in production
and commissioning is reduced.                                     Power Panel
                                                                                                                                   ACOPOSmulti

This trend towards machine modular-
                                                                                    ACOPOSmulti power supply and expansion
ity has been underway for quite some                                                module in the switching cabinet

time at B&R with regard to control
technology: the modular X20 system,                                                                     Hybrid cable connection includes power
which makes it easy to implement de-                                                                                   supply (24 VDC, DC bus),
                                                                                                                   network connection and STO
                                                                Switching cabinet
centralized control zones, is a perfect
example. This is also true for motion
control. ACOPOSmulti drive systems
can power servo, torque and linear
motors, making them a universal so-                                             ACOPOSmulti65 - The decentralized inverter

lution for any automation task in ma-
chine manufacturing. This particular
drive solution is especially cost effec-
tive when used with machines that
have several axes—the plastics, pack-
aging, printing and textile industries                                          Hybrid cable                        Hybrid cable
are prime examples. By tailoring the
power supplies, cooling and scalable
IGBT inverters to the application, the
                                                                             Connections	for	local
perfect drive solution can always be                                         I/O nodes
configured.
                                                   X67    X67                                                            X67       X67

Breaking	 free	 from	 the	 control	                  Sensors                                                               Sensors
                                                    Actuators                                                             Actuators
cabinet
It used to be the case that optional
modules always meant having to in-
stall separate control cabinets or pan-
els. But decentralized I/O modules and
drive controllers can only reach their        Decentralized system architecture with the ACOPOSmulti65
full potential with regard to cost effec-
tiveness if they completely rid them-
selves of these additional distribution
panels. This not only reduces costs,
but the space needed by the device as       Part of the proven ACOPOSmulti fam-                      handling equipment or other small de-
well. For these reasons, machine man-       ily, the robust external characteristics                 vices simply by plugging them into the
ufacturers have longed for liberating       of this system allow it to be mounted                    CPU makes it possible to upgrade the
control and drive components from           anywhere on the machine. And you                         machine over time to optimize produc-
the control cabinet for years.              guessed correctly: the number at the                     tion processes.
                                            end refers to its level of protection. In
In the area of control technology, the      accordance with this standard, the de-                   A conscious decision was made from
X67 System has long been an alterna-        vice is fully protected against contact                  the start to not mount the inverters
tive to rail-mounted input and output       and dust ingress; in addition, it can                    directly on the motors they would
modules for evaluating and controlling      withstand powerful water jets from                       be controlling. Although the motor-
sensors and actuators. This system          any direction. Nevertheless, the device                  mounted approach may seem to make
includes I/O modules with IP67 pro-         is still called ACOPOS and not AQUA-                     sense on the surface, the thermal con-
tection and can be used outside the         POS, as was heard a few times at the                     ditions are such that the performance
control cabinet in harsh industrial en-     last SPS/IPC/DRIVES fair in Nurem-                       of the motor is degraded. In addition,
vironments.                                 berg.                                                    the mounting position itself is often
                                                                                                     hidden, making it difficult to perform
Motion control is now the next area to      The device's decentralized mounting                      maintenance. Nevertheless, one of the
experience this liberation. Here, B&R's     reduces the amount of space needed                       biggest challenges when developing
answer to the trend towards increased,      in the control cabinet, a true advan-                    these new devices still involved how
simpler modularity in machine manu-         tage for machine users. The ability to                   to dissipate the heat to prevent any
facturing is called ACOPOSmulti65.          easily connect auxiliary components,                     loss of performance whatsoever. >>

                                                                                                                                      automotion 51
 Technology

  SafeMC	 and	 energy	 efficiency	 in-                                POWERLINK connection for
                                                                      external X67 nodes
  cluded                                                                                         24 VDC output
  One of the things that simplifies setup     POWERLINK input 1                                  for external X67 nodes
  and commissioning the most is the                                                                               POWERLINK connection for
  fact that these inverters can be wired      Hybrid cable output 2                                               external X67 nodes
  together in a line structure using only a
                                                                                                                               POWERLINK
  single hybrid cable for the supply volt-                                                                                     input 2
  age, DC bus, POWERLINK and STO,             Hybrid cable output 1
  the safe torque cutoff function. In addi-
  tion to this hard-wired safety function,
  the network-based SafeMC functions
  STO, SBC, SOS, SS1, SS2, SLS, SMS,
  SLI, SDI and SLP will be offered in the
  future, just as they are available now
  for existing ACOPOSmulti devices in
  the control cabinet.

  It also goes without saying that these
  new decentralized devices also come
  equipped with the full range of energy
  options available for the ACOPOSmulti
                                                                                                                               Hybrid cable
  series. These include power factor cor-                                                                                      output 4
  rection, which considerably reduces
                                              DC bus supply
  the connected load or current con-
  sumption of the machine, as well as
                                                                                                                      Hybrid cable output 3
  constant DC bus voltage to ensure op-
  timal performance of the inverter mod-                  STO 1 connection    STO 2 connection    24 VDC supply
  ules and motors. In addition, all active
  power supply modules have the ability
  to return braking energy back to the          The decentralized 8CVE connection box features IP65 protection and can be mounted
  power mains (power regeneration).             directly on the machine.

  The seamless integration of the ACO-
  POSmulti65 into a POWERLINK net-
  work allows the device to serve as a        area required by the entire machine is
  central node for implementing ad-           reduced is another undisputed advan-
  ditional expansion options while also       tage. And the ability to add expansion
  being able to connect inputs and out-       options as completely autonomous
  puts via its own interface. In this case,   devices is one more feature that il-
  it is sufficient to simply connect I/O      lustrates the pioneering nature of the
  modules from the X67 family to the          ACOPOSmulti65. Without making
  ACOPOSmulti65 directly on-site.             modifications in the control cabinet,
                                              without having to deal with difficult
  It is clear to see that the additional      wiring and without having to worry
  price of this robust decentralized de-      about when to upgrade—even after
  vice is more than offset by the savings     commissioning.
  achieved in the control cabinet as well
  as in the wiring itself. That the total




     About the author:

     After completing his studies in electrical engi-
     neering, Alois Holzleitner (48) began his career
     developing controllers for machine tools in Swit-
     zerland. Hired by B&R in 1992 as product manager
     for positioning controllers, Alois has managed the
     business unit for motion control at B&R headquar-
     ters in Eggelsberg, Austria since 1998.



52 automotion
                                                                                                                 Application




  Sustainable
  labeling


                                                                                        Finally	 a	 modern	 heat	 transfer	
                                                                                        decorating	 system	 for	 plastic	
                                                                                        containers that delivers brilliant
                                                                                        and durable image quality at
                                                                                        low costs. At PACK EXPO 2010,
                                                                                        Graphic Packaging International
                                                                                        demonstrated the DI-NA-CAL®
                                                                                        heat	 transfer	 decorating	 system,	
                                                                                        their	 exclusive	 process	 for	 label-
                                                                                        ing plastic containers. The label-
                                                                                        ing is 100% recyclable, making
                                                                                        this an optimal addition to a sus-
                                                                                        tainable packaging concept.


Branding with a no-label look
Labels that are optically matched to the plastic improve the overall impression of the packaging and attract the attention
of potential customers. That's why consumer marketers and brand managers recognize the competitive advantages of the
seamless no-label look. With the new DI-NA-CAL®, label images physically bond to the surface of the container and maintain
excellent brilliance and clarity without cracking, scuffing or peeling.

Graphic Packaging International—the leading supplier of heat transfer labeling systems in North America—trusts in modern
servo technology from B&R. This assures precise, consistent label positioning within 1/32 inch and virtually eliminates label
mismatches, even on oddly shaped or sized containers. Oval or conical, square or round, wide mouth or narrow neck, with
or without handles, from one ounce to 12 gallons, the automated system assures perfect labeling.

Heat transfer label application systems from Graphic Packaging are available in a range of line speeds, allowing labels to be
applied on the front, the back and even all four sides in a single pass. They can also work in-line with blow molding or filling
machines.

Innovative	heat	transfer	technology
DI-NA-CAL® uses reverse printed graphics using up to 9 colors. Labels are delivered in roll form and transferred using heat
and pressure. The end result is a highly decorative, durable and permanent label.

See-through heat transfer labels on PET containers offer exceptional product visibility and aesthetic appeal. Hot fill label
technology is available for 200+ degree Fahrenheit filling temperatures.



www.graphicpkg.com




                                                                                                                 automotion 53
  Grabbing the bottle
  by the neck
  For 25 years now, the Polish pro-         ARROW is a compact system used to         and opacity check as well as a flow
  duction company STM with head-            fill carbonated and non-carbonated        check, the CIP stations ensure fast
  quarters	 in	 Złocieniec	 has	 been	      beverages as well as various vege-        and easy cleaning of the respective
  providing	 filling	 systems	 for	 the	    table oils for the foodstuffs industry.   machine parts.
  foodstuffs	 industry.	 The	 new	 AR-      The machines fill both PET and glass
  ROW machine series is an innova-          bottles as well as large volume con-      Higher	flexibility	-	Lower	costs
  tive	 solution	 for	 handling	 bottles	   tainers that hold up to 7 liters.         The integrated rinsing system on the
  by	the	neck,	which	allows	for	vari-                                                 filling and capping machines was
  ations	in	the	size	and	shape	of	the	      Developed for a large range of fill-
  bottles. Integrated automation            ing speeds, the ARROW machines
  technology	 provides	 support	 for	       achieve a throughput of up to 14,000
  configuring	all	machine	functions	        units per hour. They can adapt to the
  and	offers	the	flexibility	needed	to	     different requirements and process
  react quickly to changing market          various types of bottles. In addition
  demands.                                  to the broad pallet of filling ma-
                                            chines, STM also offers various com-
                                            ponents for efficient bottle handling.
                                            This includes rinsing equipment for
                                            cleaning the inside of the bottles and
                                            capping machines for applying many
                                            different types of caps.

                                            Machine parts that come in direct
                                            contact with liquids during filling can
                                            be cleaned at CIP stations (cleaning-
                                            in-place). The entire cleaning pro-
                                            cess is contained in a closed system.
                                            The main element of the rinsing
                                            system is a central washing station.
                                            Equipped with a time, temperature

54 automotion
                                                                                                                 Application

originally operated using relay-based
control with a synoptic table. Today,
a Power Panel handles centralized
motion control and visualization of
all parts of the machine. The Power
Panel visualization system makes it
simple and intuitive for service per-
sonnel to enter all the necessary pro-
cess parameters. Various alarm sys-
tems and monitoring functions allow
seamless error diagnostics, which
results in significantly reduced ma-
chine downtimes.
                                            Motion control was implemented efficiently with Automation Studio.




                                         Thanks to the use of highly modern           fore one of our top priorities. Thanks
                                         I/O systems like the X20 as well as          to the combination of STM and B&R
                                         the X67 and XV modules that are              technology, we're able to provide
                                         mounted directly on the ARROW                internationally competitive niche
                                         machines, the installation and wir-          products for the foodstuffs industry,"
                                         ing costs were able to be consider-          stresses Tomasz Socik.
                                         ably reduced. The compact modular
                                         construction of the B&R components
                                         also considerably reduces the
"Thanks to a uniform automa-             amount of space required in the
                                         switching cabinet. This results in sig-
tion platform and the ability            nificant potential for reducing costs
to connect B&R components                for the end user while at the same
                                         time increasing flexibility and line
to systems from other manu-              speed.
facturers, we are now in the
position to optimally meet the           Because B&R components are open
                                         with respect to systems from other
individual requirements of our           manufacturers, STM profits from
customers."                              quick installation of its machines and
Tomasz Socik                             equipment in its customers' produc-
Technical Manager                        tion lines. "Through implementa-
STM                                      tion of the B&R control system, we
                                         were able to significantly increase
                                         the production capacity of our fill-
                                         ing systems. Thanks to a uniform
                                         automation platform and the ability
                                         to connect B&R components to sys-
                                         tems from other manufacturers, we
                                         are now in the position to optimally            STM:
                                         meet the individual requirements of
                                         our customers," explains Tomasz So-
                                         cik, Technical Manager at STM.

                                         Fast reactions to market de-
                                         mands                                           Established: 1984
                                         In the future, STM would make sup-              Employees: 40
                                         plying and installing complete pro-             Locations: Złocieniec (Poland)
                                         duction lines a priority. Thanks to the         Products & Services: Filling ma-
                                         use of B&R technology, the Polish                  chines for water, vegetable oil,
                                         supplier is now able to quickly adapt              juice; auxiliary equipment such as
                                         its filling, capping and cleaning sys-             CIP stations, saturators, mixers/
                                         tems to current market demands.                    saturators, integrated systems for
                                         "We are an especially service-orient-              material handling
                                         ed company. Ensuring an outstand-
                                         ing price/performance ratio is there-           www.strzala.com.pl

                                                                                                                 automotion 55
 Technology




  Automation Studio - More
  than just a programming
  tool
  Integrated automation has become a buzz
  word	 in	 the	 field	 of	 automation	 technol-
  ogy.	 So	 often	 used,	 it	 typically	 refers	 to	
  the	ability	to	start	multiple	software	tools	
  from	 a	 single	 program.	 For	 B&R	 this	 rep-
  resents	 but	 one	 of	 the	 many	 features	 of	
  a	 perfectly	 integrated	solution.	 In	 the	 fol-
  lowing, we will illustrate how Automation
  Studio supports a machine through its
  entire	life	cycle,	laying	the	foundation	for	
  the	complete	integration	of	a	development	
  tool into all business processes.




                                             Not too long ago, controllers were pro-    tions, drive technology and safety sys-
                                             grammed using special programming          tems have become essential compo-
                                             devices. These were separate electronic    nents of a modern automation solution.
                                             devices that combined a PC and a pro-      However, simply integrating all these
                                             gramming application. Quite a lot has      components into one tool falls far short
                                             changed in the automation industry         of providing the best possible support
                                             since then. Simply programming the         for machine manufacturers. In order to
                                             controllers - today using software pack-   pursue the idea of integrated automa-
                                             ages on conventional computers - is no     tion even further, the following trends in
                                             longer sufficient to automate a machine    the field of machine and systems manu-
                                             or system. Today, visualization applica-   facturing must also be considered.

56 automotion
                                                                                                                     Technology

Reduction	of	time	to	market
Technology-oriented consumer mar-
kets tend toward increasingly faster
cycles of innovation. To feed this hun-
ger for new technology, machine and
systems manufacturers must develop
and automate new machines in ever
shorter intervals. As a result, the de-
velopment tool provided by their au-
tomation partner must be able to keep
up with this trend. In addition to inte-
grating the various tools, we also un-
derstand the importance of perfectly
adapting the development tool to the
line of automation products. This is the
only way to utilize the full performance
of the products (be it the classical
controller, Automation PC or visualiza-
tion), and to avoid time-consuming
compromises.                                 The architecture dictates the possibilities.


Batch size = 1 - For series machi-
nes
For some time, we have been observ-        turers with the best possible support,           mating a machine or system, it is
ing a trend toward ever smaller batch      a modern development tool must be                not a central element in the machine
sizes. Here, too, changes in the con-      able to integrate standard fieldbus sys-         manufacturer's process landscape. It
sumer market with respect to product       tems and offer affordable and direct             would be inappropriate and impracti-
variety and customization have a di-       access for proprietary protocols in the          cal to ask machine manufacturers to
rect effect on machine manufacturing.      form of libraries.                               adapt their processes to their auto-
This "mass-customization" requires                                                          mation supplier's development tool. It
machines that are highly flexible. This    Incorporation into the machine                   must nevertheless be made as simple
begins during manufacturing with cus-      manufacturer's	processes                         as possible to incorporate this tool
tom options packets for end custom-        Even though the development tool                 into the processes. The development
ers and continues on-site at the end       plays an important role when auto-               tool must have an open architecture
customer, where the range of func-                                                          with individual files in plain text for-
tions is expanded by enabling further                                                       mat as well as universal access to the
options. The development tool must                                                          programs, data and configuration op-
be able to handle all these machine                                                         tions of the automation project.
variants efficiently. Open interfaces to
ERP systems are indispensable.                                                              Total	 value	 added	 versus	 list	 of	
                                                                                            features
The machine as a link in the value                                                          When development tools are com-
creation chain                                                                              pared with one another, the focus is
A single machine—however flexible—                                                          usually on the individual functions.
is rarely responsible for manufactur-                                                       Conflicting philosophies make a de-
ing a complete product. Generally, it                                                       bate based solely on functions point-
is only one link in the value creation     "The development of Automa-                      less. Instead the focus should be on a
chain. This chain is created either by                                                      concept borrowed from economics:
the addition of half-finished compo-
                                           tion Studio is guided by the                     "total value added". This involves con-
nents that are produced separately         goal of supporting machine                       sideration of the added value through-
from the machine or through line in-       manufacturers in the implemen-                   out the entire area of use. Doing so
tegration, in which different machine                                                       opens up entirely new perspectives.
generations are connected directly to      tation of an idea, which means                   Where previously the discussion fo-
the respective machines. In this case,     through all stages of the life                   cused only on the areas of program-
it makes sense to link them in order                                                        ming and visualization, this more ho-
to optimize the overall capacity. In
                                           cycle."                                          listic approach accounts for the entire
                                           Werner Paulin
the past this was done with electrical     System Architect                                 life cycle of a machine. The develop-
signals (digital or analog), but today's   B&R Headquarters                                 ment of Automation Studio is guided
fieldbus systems open up efficient                                                          by the goal of supporting machine
new ways of linking machines to opti-                                                       manufacturers in the implementation
mize data flow and streamline cabling.                                                      of an idea, which means through all
In order to provide machine manufac-                                                        stages of the life cycle.           >>

                                                                                                                     automotion 57
 Technology




     Life cycle of a
     machine




   Added	lifecycle	value	thanks	to	Automation	Studio

  The figure above shows the general           the process, it is possible to generate
  life cycle of a machine from the per-        added value in this phase as well.         Support & service
  spective of the automation manufac-                                                     When the machine is on-site at the
  turer. The life cycle is divided into nine   Commissioning                              end customer's location, process
  phases and illustrates the potential for     Web-based diagnostics make it easy         analysis and configuration support
  support from the development tool.           for the electrician or mechanic to per-    is sometimes part of a maintenance
                                               form the initial commissioning. Soft-      contract. For this to be possible, you
  Design                                       ware developers aren't required until      need a powerful remote maintenance
  The blue curve shows that during the         much later in the commissioning pro-       concept that can be configured using
  design phase is where the develop-           cess. This saves time and costs.           the development tool.
  ment tool traditionally provides the
  best support. The ability to work in a       Field test                                 Conclusion
  team using a simple server connec-           In the field test phase, the precision     A modern development tool must sup-
  tion, to select any version manage-          of the analysis tools determines the       port the machine and system manu-
  ment system, or to group a machine's         quality of the tests. There's no smooth-   facturer in the implementation of an
  components into function units and           ing signal curves here. All tools must     idea. Using programming standards
  initially develop them with a non-hard-      therefore perfectly coordinate with the    guarantees long-term investments.
  ware-specific configuration all contrib-     runtime system.                            Open architecture enables the direct
  ute to a more effective kind of support.                                                connection of ERP and CAD systems.
                                               Production                                 This saves resources and reduces
  Simulation                                   As in the construction phase, there is     fixed costs in the design phase as well
  Usually, additional tools are used dur-      limited opportunity for using a devel-     as variable costs during machine pro-
  ing the simulation. What's important in      opment tool during production. Nev-        duction—a key competitive advantage
  this phase is that theses tools are con-     ertheless, with the direct connection      for machines.
  nected seamlessly. For example, link-        of ERP systems and the corresponding
  ing to MATLAB/Simulink enables the           ability to activate options packages
  correct simulation of complex models.        dynamically, it is possible to generate
  Automated code generation then en-           added value in this phase as well.
  sures that the controller also behaves
  according to the specifications during
  the real process.                              Automation Studio highlights
                                                 ■	 Open architecture
  Construction                                   ■			Flexible project organization
  The construction phase of the machine          ■			Hardware-neutral software design
  is usually outside the scope of a devel-       ■			Open for any version management system
  opment tool. Nevertheless, with the            ■				Increased efficiency with automatic code generation with MATLAB/Simulink
  direct connection of ECAD systems              ■			Team-oriented approach
  and the corresponding ability to set           ■			Web-based system diagnostics
  or change I/O assignments very late in

58 automotion
                                                                                                         Application




A	recipe	for	success




The	continued	commitment	of	the	Beretta	family,	united	by	a	love	of	               Two	centuries	of	tradition
tradition and authentic tastes, has created a brand recognized world-              Fratelli Beretta S.p.A. was founded
wide	 as	 a	 leader	 in	 the	 production	 of	 sausages	 and	 cured	 meat.	 To-     in 1812 as a small butcher shop in
day,	 after	 nearly	 two	 hundred	 years	 in	 business,	 Fratelli	 Beretta	 has	   Brianza, near Milan. Over the years,
maintained its dedication to high-quality production and the constant              they took on the responsibilities of
pursuit	of	innovation.	This	is	shown	in	the	search	for	new	products	de-            cattle herding while establishing 16
signed	for	markets	that	are	becoming	increasingly	large	and	complex	               new locations around the world, in-
while	never	losing	sight	of	the	importance	of	attention	to	detail.                 cluding one in China and two in the
                                                                                   USA. By developing new technolo-
                                                                                   gies, improving production process-
                                                                                   es and adding a wider range of ser-
                                                                                   vice companies, Fratelli Beretta was
                                                                                   able to make a qualitative leap. >>

                                                                                                         automotion 59
 Application

  "Despite the importance and num-
  ber of business graduates, Beretta
  Group companies still rely on Be-
  retta family members," explains
  Stefano Giovannoni. "They are still
  present today holding active roles
  in production management as well
  as in the decision-making process
  for new product development."
  From selecting raw materials to in-
  specting the final packaged prod-
  uct, family members are involved
  along every step of the way. Giovan-
  noni explains further, "This constant
  presence at the forefront
  of our operations has
  allowed us to not
  only pass down the
  requisite expertise
  from generation to
  generation, but also
  the culture of our
  products as well. This
  includes high-quality
  workmanship and pre-
  cision while pursuing
  the modernization of
  our production system
  by streamlining the pro-
  duction chain. It is the
                                                                B&R's stainless steel panels with special hygienic design guarantee
  goal of the Beretta Group                                     sterile and safe operation in challenging conditions such as those
  to manufacture innova-                                        found in the foodstuffs industry.
  tive products with our
  traditional brand and
  style while maintaining
  our high quality stan-
  dards."                                                       Continuous               analysis before a new supplier is
                                                                optimization             chosen. "For us, choosing a sup-
  Wuber: Quality and                                             of a product's          plier means choosing a long-term
  craftsmanship                                                  m a n u f a c t u r-    partner," states Giovannoni. "We are
  The     Wuber     com-                                          ing process            basically choosing to establish a re-
  pany is a division of                                           is not an              lationship that goes beyond the mere
  Fratelli Beretta S.p.A.                                         easy        task,      provision of goods and services. Our
  that specializes in                                             especially             suppliers assist us in implementing
  manufacturing       sau-                                      when the high            a wide range of different projects.
  sages, hams and snacks                                    quality standards            This cooperation therefore extends
  that cover a wide range of food         of the Beretta Group are on the line.          anywhere from introducing a new
  tastes and follow the latest market     One reason for this is that quality            product to developing new meth-
  trends. "Wuber's flagship product       and efficiency sometimes represent             ods of production. In any case, col-
  is a sausage that enjoys a greater      conflicting goals. Market success              laboration never ends after delivery;
  share of the market than any of our     is therefore determined by a com-              it continues over many years. This
  competitors," explains Giovannoni.      pany's ability to balance a consis-            approach might mean a drawn out
  "The main customers for Wuber's         tent level of quality with increased           selection process, but it ensures that
  products are large retailers who re-    efficiency.                                    the right decision is made in the end."
  quire a constant high level of prod-
  uct quality at an acceptable cost all   Solid partnerships are the key                 Maximum reliability with the
  the way down to the end customer.       to success                                     most modern PC technology
  We achieve this through a strategic     The Beretta Group has established              In recent years, the Beretta Group
  manufacturing policy and efficiency     close partnerships with several sup-           has sought to change the method-
  that is shaped by our long experi-      pliers over the years. In order to             ology used to manufacture their
  ence and know-how in the area of        keep this tradition going, Beretta             products. "Particularly in the food
  foodstuff production."                  makes sure to perform a thorough               industry, the manufacturing process

60 automotion
                                                                                                                         Application

                                                 changing customer demands. The                 PC solution to be used. The most
                                                 question then arises as to the tools           important factor had to do with re-
                                                 best suited to reach this goal. "In the        liability; introducing weak elements
                                                 foodstuffs industry, about 70% of              into the production system was to be
                                                 all downtime is related to electric or         avoided by all means. A second re-
                                                 electronic problems," says Giovanno-           quirement demanded that the PC be
                                                 ni. "This percentage is growing with           able to provide the versatility need-
                                                 the increasing presence of control             ed by the application. "The choice of
                                                 elements based more on electronics             an industrial PC from B&R was not
                                                 than mechanical components."                   based on its price," says Giovannoni,
                                                                                                "but mainly on its technical features,
                                                 This fact led directly to the selection        such as remote monitoring over long
                                                 of a PC solution with a maximum de-            distances, fan-free and disk-free sys-
                                                 gree of reliability as being the best          tems, and the ability to use displays
                                                 option for collecting essential data           with compact, rugged front and back
                                                 for analysis. Nonetheless, it was              covers with IP65 protection." In addi-
                                                 still an important requirement for             tion, he emphasizes the importance
  The Beretta family has been producing          the production analysis that no new            of having a customized product with
  top quality sausage products for several       control elements be introduced that            the Beretta logo, which emits the
  generations.
                                                 would cause downtime in either the             feeling of being "home". This avoids
                                                 plant or the production line itself.           giving an impression of invasion or




also involves the need to moni-
                                                   "We especially appreciate the strength of these panels. The
tor production costs and efficiency                machines are constructed in such a way that they can be used
standards," says Giovannoni. "It
                                                   in our often damp environments where we use high-pressure
must be possible to collect a range
of real-time data from every part of               water jets for cleaning."
the system. This includes important                Stefano	Giovannoni
information about feedback strate-                 Technical Manager
                                                   Fratelli Beretta
gies, 'dashboard' control efficiency
standards and quality requirements."

The resulting data provides essential            B&R as a strategic choice                      interference by other companies in
information that can be used to es-              When the Beretta Group decided to              the production cycle. "This custom-
tablish a standard that can be repeat-           implement a production data collec-            ization is not limited to the use of our
ed, along with the ability to adjust             tion system at Medolago, they had              logo and corporate colors, however.
productivity according to constantly             some essential requirements for the            B&R was also able to mount a stain-
                                                                                                less steel add-on keyboard that can
                                                                                                be used by the operator to enter data
                                                                                                into the PC."

                                                                                                Application	 for	 controlling	 pro-
                                                                                                duction
                                                                                                Medolago currently has about 60
                                                                                                PCs located in rooms with a con-
                                                                                                trolled temperature environment;
                                                                                                they are remotely connected to
                                                                                                control panels from the Automation
                                                                                                Panel series. The stainless steel 15"
                                                                                                and 19" panels meet the stringent
                                                                                                hygiene regulations of the food in-
                                                                                                dustry and are distributed across all
                                                                                                lines and departments.

                                                                                                Customized Beretta controllers are
                                                                                                located throughout the plant, from
                                                                                                the loading and storage of raw mate-
  By analyzing data at regular intervals, Beretta has been able to further develop the indus-   rials to palletization, along every step
  trialization process for their meat and sausage products.                                     of the way: grinding, mixing, cook-
                                                                                                ing, quality control, packaging, >>

                                                                                                                         automotion 61
 Application




    B&R Industrial PCs are used to collect and analyze production data. Top reliability and a wide range of functions are important charac-
    teristics for a modern industrial PC solution.




  marking and final testing. Every PC
  runs software for monitoring spe-
  cific data, which is exchanged over
  a fiber optic Ethernet network. All
  data is then transmitted to the data
  center.

  "We especially appreciate the
  strength of these panels," says
  Giovannoni. "The machines are con-
  structed in such a way that they can
  be used in our often damp environ-
  ments where we use high-pressure                                                                  Fratelli Beretta:
  water jets for cleaning. This is a
  significant advantage, especially be-
  cause a hygienic environment is our
  absolute first priority! With B&R, we
  have achieved objectives not just                                                                 Established: 1812
  limited to the Medolago location, but                                                             Locations: Trezzo sull'Adda (Milan
  which we will be able to implement                                                                  province), 16 subsidiaries in PDO
  at other locations as well—both in                                                                  (Protected Denomination of Ori-
  Italy as well as abroad."                                                                           gin) and PGI (Protected Geograph-
                                                                                                      ical Identification) countries (Italy)
                                                                                                    Products & services: Manufacturer
                                                                                                      of packaged meat and sausage
                                                                                                      products.

                                                                                                    www.berettafood.com

62 automotion
                                                                                      Technology




Scalable hardware as a
key to success
In	 today's	 market,	 automation	 software	 must	 be	 able	 to	 quickly	 and	 reli-
ably	 adapt	 to	 a	 broad	 range	 of	 customer	 requirements.	 Classic	 automa-
tion	solutions	do	this	by	simply	transferring	the	respective	project	to	the	
hardware.	This	takes	place	using	different	programming	tools	for	the	con-
troller, visualization and drive technology. However, as soon as additional
customer options enter the equation, this process becomes overly complex
and prone to errors.




This is why some automation suppliers suggest transferring the entire soft-
ware, with all options included, to the controller and only activating those op-
tions that the customer actually needs. Depending on the machine structure,
this may indeed be a practical solution. However, while this is convenient
for the control supplier, the machine manufacturer is stuck with the extra ex-
pense of the full software, which means paying too much for the controller.
Details such as I/O mapping are either disregarded altogether or are only ac-
counted for minimally. Machine manufacturers are left to cover the cost and
effort on their own.

How	well	do	you	know	your	customers?
Knowing the exact machine structure is a crucial requirement for un-
derstanding the machine manufacturer's demands. Let's
take the automotive industry as an example.
Essentially, the products being offered are
divided into three categories: compact,
mid-sized and luxury cars. In order to re-
main competitive, manufacturers must of-
fer a basic package for each class with an
attractive set of features at a competitive
price. At an added cost, optional features
can be added to meet the customer's spe-
cific needs.

This example can be applied to machine
manufacturing by considering the three >>

                                                                                      automotion 63
 Technology

  different machine types on the mar-
  ket: Economy (abbreviated ECO),
  medium range (MED) and high-end
  machines (HIGH).

  This means that the basic software
  for automation always has to be the
  same for all machine types—from
  ECO to HIGH—because certain ba-
  sic functions (such as machine logic,
  recipe management, alarm handling,
  remote connection and much more)
  are identical for all machine types.
  Therefore, a function that has been
  tested once can be used reliably for
  all machine models and the function
  and operating philosophy will always
  be the same. The ECO, MED and HIGH
  models generally differ by their dis-
  play size, production speed, machine                  Even the visualization can have a modular design that allows it to be easily adapted
  size and available range of functions.                to the unique requirements of a specific machine.

  There are two variants to consider
  when looking for the right controller.          like a useful solution, experience shows otherwise. Managing conventional
  While the first variant uses just one           controllers introduces a whole new set of problems due to high maintenance
  type of controller for all machine de-          costs. This is a major drawback for machine manufacturing.
  signs, the second involves using a
  controller that best matches the ma-            Scalability provides cost advantages
  chine's requirements according to the           Thanks to a long history in the field of automation and extensive knowledge
  machine type. A comparison shows                in a wide range of industries, B&R customers benefit from scalable solutions,
  that, with the first variant, the machine       which cover the full scope of machine manufacturing requirements.
  manufacturer is always forced to pay
  the price for the high-end machine be-          But how exactly does B&R meet the demands of the market using a scalable au-
  cause it determines which equipment             tomation solution? Let's have another look at the three machine types mentioned
  is used. Savings are only possible              earlier:
  when choosing the I/O.
                                                  In order to remain competitive, the economy-level machine cannot exceed
  The optimum adaptation of the au-               a certain price level. It must have comparable performance and a similar
  tomation technology provided with               scope of functions as the MED. The differences are in the display size and the
  the second variant enables the ma-              number of additional functions. To keep costs as low as possible, a compact
  chine manufacturer to benefit from              controller with integrated 5.7" display is used in the ECO. The MED uses a
  considerable price reductions and               PC-based controller with integrated 10.4" display. The high-end machine has a
  increased efficiency. Manufacturers             PC-based controller with Windows XP and a remote 19" touch screen display.
  pay only for the performance they
  really need. While this may sound               The decisive factor is now based on the use of different technologies, which




    With a controller that is adapted to the specific requirements of a machine, customers benefit from optimally scaled solutions for economy,
    mid-range and high-end machines (shown here symbolically). Pay only for the power you need.


64 automotion
                                                                                                        Technology

enable scaling and therefore price
optimization and the right level of
performance within the different
machine classes. Ideal scaling is
provided by the compiler, which
compiles the source code in an Inter-
mediate Language (IML) that is then
converted to machine code (proces-
sor language). This is a decisive step
that makes it possible to transfer the
same source code to the different
control technologies used on the
ECO, MED or HIGH machine.

Why can't a PC-based controller be
used in all cases? There is a natural
price resistance curve that creates
a lower limit for any PC-based con-
troller. This minimum price level can
only be overcome using other pro-
cessor technologies.

Reusability	for	investment	security
The IML makes it possible to use
software on different control tech-
nologies and for many controller
generations to come. This is particu-
larly important in regard to the total   solution, the machine manufacturer profits from a high level of investment
cost of ownership.                       security without having to repurchase different programmed applications for
                                         each new generation.
The existing software cannot be
reused for conventional controller       The	fastest	cycle	times	for	all	machine	types
solutions. The entire software must      The B&R real-time, multi-tasking operating system guarantees that a machine
be rewritten and tested again. More-     function that has been tested once will run on the ECO, MED and HIGH using
over, the company must also com-         the same cycle time. The cycle times needed for the machine functions are
mit further resources for the mainte-    mapped directly in Automation Studio. This means, for example, that axis
nance of the software.                   loop control or axis synchronization should run in the microsecond range and
                                         the machine logic should run in the millisecond range, while a temperature
B&R, on the other hand, enables soft-    loop controller should run in the 100 millisecond range. Other administrative
ware that was developed just once        functions such as recipe management are processed during idle time.      >>
to be reused for many controller
generations. Newly created func-
tion blocks are even integrated into
the old controller. This is known as
backward compatibility. With this




                                                                                                        automotion 65
 Technology


                                                                                     The modular structure of the X20 system
                                                                                     makes it possible to match the I/O solu-
                                                                                     tion to the required range of functions.




                                                                                     time investments and existing intel-
  Functions that have been tested           Hot-plugging	 for	 seamless	 ma-         lectual property for the long-term.
  once perform the same on all ma-          chine operation                          Automatically generated software
  chine types. These cycle times are        B&R stores all software components       and easy replacement of hardware
  guaranteed during operation, re-          and parameters on one mass memo-         also provide enormous potential
  gardless of the controller that has       ry medium, typically a CompactFlash      for significantly optimizing machine
  been selected. This saves time            card. When the machine is started,       production. This ideal combination
  during integration, which must be         all of the necessary software compo-     of automation strategies ensures
  considered when determining the           nents (firmware) and parameters are      that all B&R customers are provided
  total cost of ownership, and short-       automatically distributed to the auto-   the greatest possible competitive ad-
  ens time to market for new develop-       mation components connected to the       vantage.
  ments.                                    bus. This method makes it possible
                                            to replace hardware at any time with-
  The	 right	 software	 package	 for	       out having to stop the machine. Even
  any machine                               complex devices such as servo drives
  Incoming orders for machine pro-          can be replaced in this manner.
  duction are entered in the ERP sys-
  tem (Enterprise Resource Planning).       Thanks to the success of a highly co-
  This records all of the relevant data     ordinated market strategy, B&R is in
  from the machine type to the op-          the position to provide scaled auto-
  tions that were ordered. The right        mation solutions. This means having
  software must then be quickly and         the highest level of efficiency while
  correctly installed with the scope of     also saving costs at the same time.
  functions that have been ordered.         Reusability of the software for many
  This is made possible by exchang-         future machine generations secures
  ing data between the ERP system           the machine manufacturer's one-
  and Automation Studio. The EPR
  system stores information about
  which software packages are re-
  quired for which machine type.               About the author:
  The respective option packages are
  added according to the options that                                       Walter Burgstaller
  have been ordered. The integrated                                         International Sales Manager
  I/O mapping in the B&R real-time op-                                      B&R
  erating system makes it possible to
  allocate variables and the physical                                       Walter Burgstaller has been at B&R since
  I/O on the controller in accordance                                       1990. After working in Applications and as a
  with IEC standards. ePLAN can also                                        Key Account Manager for international cus-
  be used instead of the allocation list.                                   tomers, in 2005 Burgstaller began his cur-
  The software is generally installed                                       rent position as International Sales Manager
  directly via the LAN, and a special                                       for Italy.
  tool allows the controller to obtain
  the software from a server via LAN.
66 automotion
Modern automation tech-
nology reduces packaging
costs
A	 further	 reduction	 of	 costs	 for	   Production of machines for packag-        Custom      solutions     help     cut
plastic packaging by lowering            ing such fragile products as salted       costs
packaging densities is hardly            bread sticks, potato chips or choco-      Even packaging machine manufac-
possible anymore. This is why            late-covered baked goods is a task        turers cannot elude the noticeable
rationalization potentials in the        strictly for specialists. In order to     pricing pressure of the food indus-
manufacturing	 and	 operation	 of	       achieve optimal results when weigh-       try in Germany. This demand for
packaging machines are taking            ing/portioning the products as well       customized solutions means that
more	of	the	spotlight	these	days.	       as during the actual packaging pro-       machine and system functionality
Hastamat, the well-known Ger-            cess, specific requirements for both      is tailored directly to the application
man	 manufacturer	 of	 packaging	        the product and the machine owner         without costly features that remain
machines,	also	has	a	solution	for	       must be considered. The packaging         unused in the actual application.
this situation: Reliable machines        system must be customized accord-         Hastamat achieves this by modifying
customized directly to the ap-           ingly. This requires extensive applica-   field-tested standard solutions with
plication and highly-integrated          tion and machine know-how as well         a modular design and making >>
systems	 that	 offer	 higher	 per-       as the utmost flexibility when plan-
formance	 without	 unnecessary	          ning, commissioning and manufac-
costs.	 The	 foundation	 for	 the	       turing a machine.
achieved savings is the high-per-
formance	automation	technology	          Hastamat         Verpackungstechnik
from	B&R.                                GmbH, based in Lahnau, Germany
                                         meets these high demands and sets
                                         an exemplary standard. "Packaging
                                         of bar-shaped products is one of our
                                         main areas of expertise," explains An-
                                         dreas Hollmann, manager of Hasmat
                                         Verpackungstechnik GmbH. "Not only
                                         do we possess the required know-
                                         how and resources for developing
                                         and producing individually custom-
                                         ized machine and systems solutions
                                         for the packaging of superior prod-
                                         ucts, but we have also known the
                                         demands of different applications for
                                         decades."

                                                                                                           automotion 67
 Application

  them available with numerous            power or multi-axis applications,"        the packaging machine controller.
  options. "We are also known for         says Martin Otto. "Without B&R, that      Thus, the company with roots in
  finding and implementing cus-           would not have been possible."            scale technology fulfilled its custom-
  tom solutions for applications that                                               ers wishes and implemented a cost
  other companies would not dare          Today, the packaging specialist has       reduction. "Customers do not want
  address," explains Dipl.-Ing. Peter     implemented its new automation            to keep many system replacement
  Lökös, head of marketing at Hasta-      system on a broad scale.                  parts and want the ability to remote-
  mat.                                                                              ly operate the system," explains to
                                          Using B&R technology, Hastamat is         Peter Lökös.
  Accordingly, the implemented au-        advancing with the integration of
  tomation solution must also prove       various packaging system compo-           "The tight connection required be-
  flexible and efficient while not put-   nents. Recent results of this integra-    tween the two system components
  ting extra pressure on the budget.      tion were showcased at Interpack          is difficult (i.e. expensive) or impos-
  "The product portfolio of the auto-
  mation technology manufacturer                                    "We are known for finding and implement-
  must, on the one hand, offer all the
  products needed for all applications                              ing custom solutions for applications that
  at an attractive price, but also must                             other companies would not dare address."
  not hinder the selection process                                  Peter Lökös
  with undue complexity," says Dipl.-                               Head of Marketing
  Ing Martin Otto, manager of electri-                              Hastamat
  cal construction at Hastamat. "The
  same applies to the automation
  components. Consistency with our
  requirements is indispensable so
  we can avoid expensive detours."
                                          2008. There, the company put one          sible to achieve if controllers from
  These criteria form the core of the     of its packaging machines from the        different manufacturers are used,"
  performance catalog that Hastamat       new RB series on display, which           says Martin Otto. There is also the
  has chosen in evaluating the con-       further consolidated the Hessians         fact that many companies in recent
  trol solutions of several well-known    product portfolio. The amply-sized        years (unlike Hastamat) have fo-
  providers of automation technol-        touch panel immediately grabs the         cused solely on one system compo-
  ogy, as they are seeking to modern-     eye, masking a Panel PC from the          nent—either the scale or the pack-
  ize their packaging machines.           B&R Power Panel family that con-          aging machine—and have taken
                                          trols the machine. This machine also      separate paths. Additionally, both of
  "We have defined separate required      offers exceptional user-friendliness      these system components place dif-
  and desired criteria in a points        and a safe accompanying process           ferent requirements on the control-
  system by comparing the prices          configuration and guide. "This is         ler regarding performance and the
  of each controller manufacturer,"       especially important for sensitive        particular algorithms used.
  explains the manager of electrical      products, so the user can quickly
  construction. B&R emerged at the        and easily select an optimal setting,"    Today—unlike a decade ago—
  top of this evaluation.                 according to the marketing leader at      modern standard controllers offer
                                          Hastamat.                                 sufficient performance to replace
  A complete automation system                                                      special controllers. "This is one of
  simplifies	system	integration           The advantages of the automation          the reasons why customers are not
  Hastamat has created a complete         system are best utilized in practi-       often dedicated to one specific con-
  automation system using B&R             cal applications that use a scale. A      trol systems manufacturer," states
  technology. "We can accomplish          multiheaded scale, normally com-          Peter Lökös. "Today, solutions for
  typical PLC tasks as easily as those    bined with a packaging machine,           task management and costreduc-
  requiring a great deal of computing     can be operated and controlled via        tion stand in the foreground."




68 automotion
                                                                                                      Application

New maintenance concepts re-
                                           High-performance
duce running costs                         multihead combina-
Because modern controllers handle          tion weigher from
such a large number of tasks, the          Hastamat from the
best solution is one that rarely re-       CP series for weigh-
                                           ing oddly shaped
quires on-site maintenance by ser-         products, such as
vice technicians. For the same rea-        snacks, confection-
son, users seldom require a specific       ery, granulates, metal
brand or type of control system,           or plastic parts etc.
but instead rely on the support of
the machine supplier. Knowledge
of new maintenance concepts are
needed for this. "The B&R techno-
logical concept is a perfect fit for
us," according to Martin Otto. "On
the one hand, an employee of the
machine owner without extensive
technical knowledge should be
able to change an ACOPOS drive,         ment parts. "B&R has accomplished
for example, because all required       a lot in this area in recent years and
configuration and application data      can now supply replacement parts
is stored on a flash drive that is      to remote parts of the world in the
inserted in the new drive. Ship-        rare event of a component failure,"
ping the drive for software instal-     Peter Lökös said of the automation
                                        specialist.

                                        The Hastamat business manager
                                        is convinced that, with Hastamat
                                        entering new markets with its new
                                        and innovative machine family RB,
                                        it will generate additional growth.
                                        "This machine family is character-
                                        ized—thanks in part to B&R tech-
                                        nology—by a very attractive price/
                                        performance ratio that will serve
                                        to ensure and increase sales. Has-
"We can accomplish typical              tamat has room for further expan-
                                        sion in an additional building at
PLC tasks as easily as those            their headquarters: administration,
requiring a great deal of com-          along with sales and support are
                                        now located in this facility. Plans
puting power or multi-axis              are also in the works for a new pro-
application. Without B&R, that          duction hall in Lahnau.
would not have been possible."
Martin Otto
Electrical Construction Manager
Hastamat                                                                         Hastamat:
lation is thus unnecessary. On the
other hand, B&R technology offers
the option of remote machine and
drive maintenance and diagnos-                                                   Established: 1953, a member of the
tics, so our experts can offer direct                                               Piepenbrock Group since 1986
and comprehensive support at any                                                 Locations: Lahnau, Germany; loca-
time."                                                                              tions in more than 40 countries
                                                                                 Products & Services: Hastamat de-
For the same purpose, Hastamat of-                                                  velops and manufactures scales,
fers a hotline and support services                                                 dosing devices, filling and seal-
that are available 24 hours a day,                                                  ing machines as well as packag-
all year round. Hastamat relies on                                                  ing machines.
the worldwide network of B&R net-
works for availability of replace-                                               www.hastamat.com

                                                                                                       automotion 69
 Application




  Intelligent packaging solu-
  tions	for	demanding	products
  Different	companies	choose	different	development	strategies	when	fac-
  ing shrinking demand on the market. Many decide to reduce person-
  nel	 and	 total	 production	 output.	 Only	 a	 few	 companies	 increase	 their	
  competitive edge by continuing to invest in research and development
  during	 difficult	 times.	 And	 Tauras-Fenix—a	 major	 Russian	 packaging	
  machine	manufacturer—is	one	of	them.	They	decided	to	expand	their	
  product range to provide their customers with machine models that
  have	 different	 production	 capacities.	 A	 B&R	 automation	 solution	 was	
  successfully	integrated	into	a	new	machine	concept	that	is	based	on	the	
  following	 core	 elements:	 modularity,	 flexibility,	 scalability	 and	 open-
  ness.




  Over the last 30 years, the Russian machine industry has
  changed dramatically. During the Soviet era, the leaders
  couldn't adapt their production facilities to satisfy the demand
  from new private companies that required packaging machines
  with low and medium production capacities. At this point in time, new
  machine manufacturing plants were founded that formed the foundation of the       product range currently consists of
  modern Russian packaging machinery market.                                        more than 100 machine models. In
                                                                                    addition to customers in the food in-
  In 1987, the young Lithuanian entrepreneur Sigitas Mitskus founded a private      dustry, Tarauras-Fenix also supplies
  company in St. Petersburg for manufacturing packaging machines. To ensure         end users in the chemical, construc-
  the success of his company, Mr. Mitskus specialized in manufacturing vacuum-      tion, cosmetics and pharmaceutical
  forming machines. There were no other similar machines on the market, so they     industries.
  were very successful.
                                                                                    Developing machines that meet
  The company that was founded more than 20 years ago is now called Tauras-         customer needs
  Fenix and is a major manufacturer of packaging, filling and sealing machines      Increased requirements in the pack-
  and food packaging equipment in Russia, the CIS and the Baltic countries. The     aging machine market as well as the

70 automotion
                                                                                                          Application

specific needs of customers from
different industries mean that more
flexible machine concepts must be
developed. "In 2008, we faced the
task of modernizing our range of
machines to optimize technical solu-
tions for various types of customers,"
recalls Nikolay Zalomov, Head of
Control Systems Department. "When
doing this, we had to consider the
variety of products to be packaged,
the raw materials used in the prod-
ucts and the size of the company. We
also decided to concentrate on the
development of in-house application
software solutions. This allowed us
to increase our company know-how
and also expand our product range."

Scalable      hardware       reduces
costs
Tauras-Fenix took total cost of own-
ership into consideration when se-
lecting an automation partner. "The
modularity and scalability of the
B&R hardware allowed us to reduce
the cost of the automation system         lines. A single programming tool can be used to develop all of our appli-
throughout the entire life cycle of the   cation software, which allows us to reduce the total time-to-market for new
machine," explains Nikolay Zalomov.       machines," says Nikolay Zalomov.
"In addition, the simple integration of
auxiliary equipment helped Tauras-        B&R technology is now used for various types of machines such as fill and
Fenix to design multi-purpose ma-         seal machines, horizontal and vertical packaging machines and feeders. "The
chines that can be quickly and easily     next step is to integrate a new safety system based on openSAFETY. We will
adapted to various product formats."      also finalize adapting our application software solutions to PackML standards,
                                          which will allow us to strengthen our technical leadership in the packaging
The production capacity of a pack-        machine market," concludes Nikolay Zalomov.
aging machine is a significant factor
for end customers when selecting
the equipment. The wide range of
B&R hardware allows Tauras-Fenix
to choose the optimal technical so-
lution for machines with different
production capacities. The Pastpak-R
rotary fill and seal machine line, for
example, with a production capac-
ity of 35 units per minute, is based                                                Tauras-Fenix:
on an induction motor controlled by
an ACOPOSinverter plus a Geneva
drive for table rotation. The Pastpak-
4R model, the high-end product in
the rotary machine family, is based
on an ACOPOSmicro servo drive,                                                      Established: 1987
which allows it to reach a produc-                                                  Locations: St. Petersburg, Moscow,
tion capacity of 120 packages per                                                      Novosibirsk, Ekaterinburg, Sama-
minute, comparable to much larger                                                      ra, Saratov (Russia), Cherkassy
linear machines.                                                                       (Ukraine)
                                                                                    Products & Services: Packaging
Efficient	development	tool                                                             machines, bottling and capping
"Thanks to the ANSI C programming                                                      machines, machines for the food
language implemented in B&R's                                                          industry
Automation Studio software tool,
we can generate efficient software                                                  www.taurasfenix.com
applications for all of our machine
                                                                                                          automotion 71
 Technology




                 Modular	hardware	for
                 modular machines
  What	good	is	the	best	modularization	in	the	software	if	the	hardware	is	limited	to	central	system	architec-
  tures	or	module	hardware	is	only	available	in	parts	of	the	system?	For	many	years	now,	B&R	has	already	been	
  providing	the	full	bandwidth	of	products	for	module	machine	manufacturing,	such	as	their	own	line	of	Au-
  tomation	PCs	and	control	panels,	innovative	controllers,	flexible	I/O	nodes,	servo	drives,	variable	frequency	
  drives, stepper motor solutions, and much more.


                                                                                                                                                             Example	of	a	modular	filling	line

                                         Entire line                                                                                                            Labeller                                  Capper




                                                                                                                                                                  Machine vision
                                                                             Internet                                              Remote access
                       Visualization
                                                                                                                                                                                                                     Light curtain
                                                                                                                                                                                                       Remote I/O


                                                                                                                                                             Stepper motors                                          Sensors
                                                                                                                                                                                                                     Actuators




                                 Safety CPU
                                                                                                                                                                                                       Remote I/O

                                                                                                                                                                                                                     2 Trigger inputs
                                                                                                                        Light curtain

                                                                                                                                                             Remote I/O
                                 Remote I/Os
                                                                                                                        E-stop
                                                                                                                                                                                                                         Servo motor
                                                                                                                                                                                                       Servo drive
                                   ACOPOSmulti



                                                 ACOPOSmulti



                                                               ACOPOSmulti



                                                                              ACOPOSmulti



                                                                                            ACOPOSmulti



                                                                                                          ACOPOSmulti
   Switching cabinet




                                 Servo drives                                                                                                                                 Torque motor
                                                                                                                                                             Servo drive
                                                                                                                                                                                                                        Torque motor
                                                                                                                                                                                                       Servo drive
                                                                                                                                                                                                                     2nd encoder
                                                                                                                                                                                                                     connection
                                                                                                                                                   Machine




                                                                                                                                                                                             Machine




                                 Remote connection box

                                                                                                                                                                              Servo motor                                Linear motor
                                                                                                                                                             Servo drive                               Servo drive




72 automotion
                                                                                                                                                                                                                                                   Technology




                                                                                                                                                                                Until now, it's been exactly these electronic components that have posed the most
                                                                                                                                                                                difficult problem in modularizing machines because they needed to be placed
                                                                                                                                                                                in switching cabinets to be protected from the surrounding conditions in a pro-
                                                        Palettizer
                                                                                                                                                                                duction plant. In modularly designed machines, this problem meant that either
                                                                                                                                                                                a separate switching cabinet was required for each mechatronic module or that
                                                                                                                                                                                the central switching cabinet needed to provide enough space for all potential
                                                                                                                                                                                machine options. B&R offers a solution to this machine manufacturing problem
                                                                                                                                                                                with a wide range of products ranging from IP67 I/O modules, IP65 servo drives,
                                                                                                                                                                                IP67 stepper and DC motor drivers to IP67 vision systems.

                                                                                                                                                                                Maximum modularity through decentralized IP65 servo drives
                                                                                                                                                                                The new IP65 B&R ACOPOSmulti servo drive is fully compatible with the stan-
                                                                                                                                                                                dard IP20 model and is also available with network-based safety technology. The
                                                                                                                                                                                modules can be combined with both passive and active rectifier units. Using the
                                                                                                                                                                                active version can significantly increase the machine's energy efficiency because
                                                                                                                                                                                the energy generated while braking an axis is made available to other electrical
                                                                                                                                                                                consumers instead of being converted to heat.

                                                                                                                                                                                In the specific case of a pharmaceutical packaging machine, the average amount
                                                                                                                                                                                of recovery power is 1,300 watts. That's 82% of the power that was previously lost
                                                                                                                                                                                in braking resistor heat. Together with the DC bus connection, this equals energy
                                                                                                                                                                                savings of at least 90% of the braking energy, or 46% of the total energy.

                                                                                                                                                                                Master encoder and registration mark data can be read by other POWERLINK sta-
                                                                                                                                                                                tions with µsec resolution, without significant delay and 100% in-sync. Depending
                                                                                                                                                                                on the characteristics of the packaging machine, this is done either right on the
                                                                                                                                                                                ACOPOSmulti65 or using cross-communication via POWERLINK.

                                                                                                                                                                                Furthermore, the ACOPOSmulti65 modules are also equipped with an output for
                                                                                                                                                                                supplying external components as well as a POWERLINK hub for connecting ad-
                                                                                                                                                                                ditional POWERLINK stations such as X67 I/O modules, variable frequency drives
                                                                                                                                                                                or vision systems.
                                                                                                         Servo drives

                                                                                                                                                                                Not only does it eliminate the need for a power supply and reduce the overall
                                                                                                                                                                                wiring, but the 24V from the DC bus network connecting the servo drives also
                                                                                                                                                                                ensures that the servo axes as well as the DC motors, stepper motors and I/O con-
                                                                                                                                                                                nected via IP67 modules are all shut down in sync when a power failure occurs.
                                                                                                                                                                                Synchronous control of valves and other actuators is also possible. This helps to
                                                                                                                                                                                prevent tearing of the continuous packaging material feed and reduces waste.
                    ACOPOSmulti



                                  ACOPOSmulti



                                                ACOPOSmulti



                                                               ACOPOSmulti



                                                                             ACOPOSmulti



                                                                                           ACOPOSmulti



                                                                                                          ACOPOSmulti



                                                                                                                        ACOPOSmulti



                                                                                                                                      ACOPOSmulti



                                                                                                                                                    ACOPOSmulti



                                                                                                                                                                  ACOPOSmulti
Switching cabinet




                                                                                                                                                                                This in turn increases machine availability and productivity.

                                                              Servo drives




                                                                                                                                                                                                                                                   automotion 73
 Technology



  The	automation	partner	for	the	




  Constant innovation and rapid          The extraordinary commitment of more than 2,300 employees has made B&R one
  internationalization are two areas     of the largest international private automation companies and a trendsetter whose
  that	 have	 characterized	 B&R	 for	   innovations in the area of automation and process control technology have become
  over	30	years.	By	offering	fully	de-   mainstays of the market. A global sales and support network in 70 countries makes
  veloped complete solutions and         it possible to provide comprehensive customer support anywhere in the world.
  a	full	range	of	products	based	on	
  internationally recognized indus-      The close relationship that exists between development and production at B&R
  trial standards—the company's          headquarters in Eggelsberg, Austria ensures cost-effective manufacturing as well
  strategy	 since	 its	 founding	 in	    as extremely short innovation cycles. Efficient methods of manufacturing are con-
  1979—B&R has become an expert          sidered early on in the product development stage. Thorough functionality and
  partner across all industries.         quality inspections guarantee maximum reliability of all automation components.

                                         Integrated complete solutions reduce costs
                                         From control, drive and visualization technology all the way to a comprehensive
                                         software platform, B&R offers a complete range of products that are based on inter-
                                         national industrial standards. Because all components are fully integrated into an ef-
                                         ficient automation system, customers profit from added value during development
                                         as well as over the entire service life of the machine. Special attention is given to
                                         making sure that hardware and software are harmonized perfectly. In addition, the
                                         integrated software tool Automation Studio provides customers with completely
                                         tailored software solutions with the highest degree of efficiency.

                                         International expertise, training and support at the local level
                                         In order to provide comprehensive support to customers around the world, cultural
                                         understanding is just as important as the expertise needed to find the right solution.
                                         An exceptionally trained sales team that is highly experienced in international ap-
                                         plications is more than capable of handling both of these demands. Engineers are
                                         always standing by to provide fast support for questions that arise from different
                                         countries.

                                         Long-term partnerships based on mutual trust are the key to every customer rela-
                                         tionship. That's why a primary goal of B&R is to offer solutions that provide custom-
                                         ers with a competitive edge by fully considering their individual requirements and
                                         wishes—this is an essential part of developing complete solutions for each and ev-
                                         ery manufacturer. 2,500 machine manufacturers throughout the world in industries
                                         like packaging, plastics, textiles, printing and paper, just to name a few, work hand
                                         in hand with qualified B&R technicians on the development and implementation of
                                         efficient automation concepts.

74 automotion
                                                                                                                   Technology



		food	and	beverage	industry




  Innovation vs. hype                        of consistent product concepts that offer the highest degree of design freedom
  Over 350 development engineers work        while also contributing substantially to reducing costs for the machine or systems
  around the clock to move ideas from        manufacturer.
  the drawing board to the marketplace
  as quickly as possible. This has very      Decisive industry expertise
  little to do with keeping up with short-   In addition to a highly trained application team, B&R also relies on the expertise of
  term trends, however; instead, the         industry specialists who are familiar with the expectations and concerns—down
  focus is on recognizing the long-term      to the slightest detail—of customers in individual sectors such as food, packag-
  needs of machine and system manu-          ing, filling, cosmetics, health care, pharmaceuticals, robotics and process appli-
  facturers so that innovative solutions     cations. This is just another of the many ways that B&R provides outstanding
  can be designed and implemented. To        expertise when it comes to creating solutions for all industries while still ensuring
  realize this ambitious goal, B&R cur-      comprehensive and individual customer support.
  rently reinvests around 17% of their
  total revenue into research and devel-
  opment every year. The most impor-
  tant aspect here is the development




                                                                                                                   automotion 75
MM-E01108.880

								
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