CONVEYING TECHNOLOGY LOADING TECHNOLOGY PALLETIZING TECHNOLOGY PACKAGING TECHNOLOGY SORTATION AND DISTRIBUTION SYSTEMS

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1 CONVEYING TECHNOLOGY LOADING TECHNOLOGY PALLETIZING TECHNOLOGY PACKAGING TECHNOLOGY SORTATION AND DISTRIBUTION SYSTEMS Control systems for machines and installations Software for the production management Teleservice 1 U1

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3 Owners gain maximum benefit from their machines and installations if the mechanical and process engineering are completed by custom-tailored automation technology. BEUMER provides optimum, comprehensive solutions for both, single machines, and complex installations. Our automation engineers have profound knowledge of the requirements of machines and processes and can efficiently and reliably use their experience to fulfil project-related requirements. Software for the production management is the link between the production unit and our customers ERP systems. BEUMER provides individual solutions for this software, as well, based on the standards of software development. BEUMER does not only offer standard solutions, but also designs, constructs, and erects installations customized in detail to meet the individual customer s requirements. Our customers appreciate both, our convincing technology, and its reliability. 3

4 Electrical equipment for machines Guidelines The high standard of quality applied to BEUMER machines is also valid for the corresponding electrical equipment which is designed according to the requirements on the world market. Control cabinet design Control cabinet housing fabricated from mild steel plate protection class IP 55, if separately driven fans are used protection class IP 54 Power and control circuitry in one cabinet, designed to be electromagnetically compatible Electrical design without fuses International touch protection class IP2X (safe from finger-touch) Colour coding of cores according to IEC All external connections on termi nal strips or plug-in connections Emergency stop function by means of redundant switching device assembly Test according to EN Standards and requirements Standard equipment meets the requirements of European norms and regulations, especially the machine regulation and the EN 60204, Electrical equipment for machines. Thanks to the international standardization within the ICE, the standard equipment largely conforms to regulations in countries outside the EU. All country specific requirements can be met. 4

5 Safety The safety interlock concept consists of the following modules: Lockable safety switch for the entire machine Emergency stop pushbuttons at possible danger zones Protective covering with a safety fence; access possible through monitored doors Monitoring of conveying routes with safety photocells at the material feeding and discharge points, where necessary due to the possibility of danger For every machine or installation, there is a thorough safety interlock system which takes into consideration the corresponding valid EU requirements relating to the CE marking. The design of these safety interlocks is individually tailored to the customer's requirements. The equipment in the control cabinet is labelled on the equipment itself and on the mounting plate. Terminal strips are used to optimize the machine installation. Labels are permanently fixed on all clamps and cables. Cabling is done with flexible cables. All cores are identified with colours or numbers and their ends are provided with connector sleeves. 5

6 Electrical equipment for machines Operation For the efficient use of a machine, the interface to the operator is designed to be optimally ergonomic. The operation of the machines is affected by means of graphical control terminals, enabling as well the simple handling of more complex machines. Overview of the most important information In all images, the headline at the top edge of the display shows the status of the machine. The information on the display changes according to the selected function. The F-keys (function keys) have different functions depending on the respective menu. The last message is always displayed here. Visible selection area for the control and input fields. The selection is done by means of self-explanatory icons. The K-keys (constant) always have the same function. They can be used to activate often needed functions with one push. 6

7 Manual functions are provided for use during troubleshooting and for maintenance purposes. By means of graphics, the needed function can be selected. The activating function key is shown in the graphic. Parameters Machine parameters can be entered with the keyboard field. They are stored by product in the PLC. All fault and operating messages are stored with time stamp in a ring memory. With each message, the reference number of the concerned equipment is indicated. Password protection The entry of machine parameters is password protected. 7

8 Electrical equipment for machines - Option BEUMER Machine Terminal BeMa The BEUMER Machine Terminal BeMa offers a more comfortable operation and is thus the correct choice for machines with various special functions. Advantages: 12 TFT flat screen Robust hardware for use at the machine Additional function keys for a fast operation Graphically supported entry of preselections and parameters and fault analysis Hierarchical structure The main image shows an overview of the entire installation. By activating the corresponding key, the operator opens the image of the selected machine module. Fault messages of the individual modules are displayed by means of a colour change of the corresponding key on the overview. 8

9 BEUMER Machine Terminal BeMa Parameter entry To optimize packing patterns for palletizers, the actuators have to be adjusted to the product related setpoint values. This task can be easily carried out by the operators thanks to the position of the entry fields on the machine overview. Module overview The detail overview of the individual machine modules gives information on the position and the status of sensors and actuators. The parameters of the modules are displayed and can be modified here. 9

10 Electrical equipment for machines Standard Field busses PLC Field busses enable an economical and low-maintenance machine and installation configuration. The Profibus DP is used for the connection of complex automation components like operator panels, frequency converters and position encoders to the central PLC. Profibus DP Operator panel DP AS-i Link AS-i In the palletizing and packing technology, equipment such as photocells, proximity switches, and pneumatic actors are connected by means of the AS Interface. The amount of work required for cabling can be considerably reduced with this connection technology. Furthermore, this also offers the following information in order to increase machine s availability: Warning signal if photocells are dirty Message in case of defective proximity switches Fault message in case of failure of a sensor due to a broken cable Decentralized input card for the Profibus DP Motor with frequency converter Position encoder Control layout for a palletizing or packing machine Connection of an AS Interface participant to the standardized AS Interface cable with a piercing connection in IP68 An AS Interface device is of course included in the delivery. 10

11 Sensors/Actuators As sensors and actuators are very important for a machine s reliability, BEUMER only uses equipment of well-known manufacturers. High-quality photocells ensure reliable signals even in difficult environments e.g. with cement dust. Non-contact proximity switches ensure reliable signals. Pneumatic actuators are controlled and monitored by means of AS- Interface Air boxes. For the actual value detection of actuators, the motors revolutions are counted by the PLC. For this purpose, the standard drive unit is equipped with a fast proximity switch. Angle transmitters are used for the exact detection of positions of travel axes and axes of rotation, in all possible operating situations. Time consuming reference travels are no longer necessary. 11

12 Electrical equipment for machines - Option BEUMER also delivers: according to country-specific regulations according to works standards designed for explosion protection according to Atex The design of the electrical equipment is individually tailored to the customer s requirements The standard colour coding of wires in the control cabinet is carried out according to the voltage levels. The colour selection follows the IEC recommendations. The number is generated from the page number in the wiring diagram and a consecutive number per page. Some customers and markets require a unique identification of all wires with a potential number, in accordance with the documentation. Reference systems For the item designation of electrical equipment at machines and installations, a reference system is used, corresponding to the DIN system. This system leaves additional room for the definition of reference numbers for the equipment. BEUMER s interpretation of the DIN system ensures a technologically appropriate identification of the equipment, a logical adaptation to the machine structure, and an unambiguous reference to the documentation. The adaptation of the reference system to other systems (e.g. to works standards) is possible, but always has to be agreed in detail with BEUMER. To increase the machine capacity and to reduce wear and tear, motors are equipped with frequency converters. BEUMER prefers the integrated solution of motor and converter with the advantage that less space is necessary. The control cabinets are equipped with air conditioners where necessary due to higher environmental temperatures. The protection class is not affected. 12

13 The development of machines at reasonable prices, with high demand on capacity, operator convenience, and availability, is only possible by creating standards for the machine and installation controls. For regional markets or works standards, other standards can be the better solution. BEUMER also offers configurations for this purpose. For customers preferring control systems from company Rockwell, BEUMER provides appropriate solutions. The system MODICON QUANTUM from company Schneider is a high capacity process control. With the corresponding configuration, it can also be used for machine control. The system SIMATIC by the global player Siemens is the BEUMER standard as it offers a good price performance ratio. Rockwell ControlLogix / CompactLogix Installation network based on Ethernet Palletizing and packing machines are part of a production chain. Main control system For optimum production control, it is necessary to connect the machines with the production management systems. For this purpose, BEUMER offers interfaces designed to the customer s requirements. The preferred interfaces are based on Ethernet. Machine 1 Machine 2 Implementation into the customer s production management For an easy and low-cost implementation, standards like OPC are used. 13

14 Electrical equipment for machines The optimum solution for all requirements Cost-effective solutions according to the requirements are available for controlling belt conveyor systems or roller conveyors. A central control cabinet with directly connected motors is the most cost-effective solution if no control devices or safety switches are necessary directly at the motor. In other cases, the decentralized version is the better solution, consisting of a central power distribution unit and a PLC. The motor starters are directly installed at the motor. From the central unit, the power is looped from starter to starter. Bus systems are used for the signal exchange to the PLC. Transport control for roller conveyors with central control cabinet Central control cabinet Decentralized motor starters Factory-built motor starter Motor starter adjusted to the project 14

15 Electrical equipment for large-scale belt conveyor systems Belt conveyor systems, especially curved belt conveyor systems, demand a lot from the drive unit system. The main target is to keep the tensile load on the belt in all operation situations as small as possible. A long service life and a reliable guiding of the belt in curves can thus be achieved. The requirements can be fulfilled by using modern motion control systems and application software especially designed for this purpose. 3 x 132 kw 3 x 132 kw Winch Control of a down-hill belt conveyor system, 4.5 km long. Under rated load, an electrical energy of approx. 600 kw is transferred into the supply network. The use of AFE (Active Front End) units is recommended for systems that transfer energy back into the supply network. Thus, a high functional reliability can be achieved, even in case of weak networks. Block diagram of the drive unit system. At the rear and at the head, 3 frequency controlled motors are installed that are coordinated by means of PROFIBUS. 15

16 BeMES BEUMER Manufacturing Execution System Software for production management offers a great potential for increasing productivity, both in the automated production, and in the distribution of goods (logistic chain). BEUMER has developed a software product for this area of product automation called BeMES. When designing software packages for this sector, BEUMER sticks to the definitions of the MESA (Manufacturing Enterprise Solution Association) with regard to functions, interfaces and IT standards. Enterprise Resource Planning ERP Advantages: Fast realisation of new projects Clear and thereby fast definition of interfaces Data exchange based on standards like XML Easy distribution of information via Internet Standardised interfaces to the production machines via OPC Inexpensive software products World-wide market of providers SCM Supply Chain Management Manuf acturing Execution Sy stem Machine Control CRM Customer Relationship Management MES SCADA PLC Sensors Hierarchy of production automation ERP Enterprise Resource Planning Ethernet Fieldbus HMI Actors BeMES Classification into the IT environment P/PE T/L Transport and Logistics BeMES e.g. Product Data Management Collaborative Manufacturing Commerce 16 Control systems Machine control systems CNC, PLC

17 BePro BEUMER Process Control System BePro BEUMER Process Control System The BEUMER BePro is the BEUMER MES solution for the automated distribution of bagged material. Thanks to its modular design, it can be extended according to the definitions of MES. Basic functions: Central system control Visualisation of the whole system with detailed displays of the individual machines Collection and processing of production data Fault history with statistical evaluations Data tracking within the production chain Interfaces to the machines with OPC Optional extensions: Management of batch orders Management of recipes Product tracking within the whole production chain Connection to ERP, SCM and WMS systems Quality management Maintenance management Document management Example of an installation overview in BePro Bagging machine paletpac stretch hood DPS Step 7 Messages Journal Faults Palletizing system Packaging system Communication structure of a dispatch area Local network TCP/IP Bulk Material Bagging ERP Company network TCP/IP Palletizing BePro Machine Control systems Film application Label Orders Identification Regulations Remote operation Material disposition Processing order Recipes Inventory Order Status Capacities Messages Material flow Operator inputs Machinestatus 17

18 BeSS BEUMER System Server BeSS BEUMER System Server The BEUMER BeSS is the BEUMER MES software integrating the BEUMER sorting and distributing systems optimally into logistic processes. It is designed in the modular way on the basis of the MES definitions to suit the varied requirements and can therefore be easily adjusted to different tasks. Basic functions: Central system control Sortation according to local sorting tables Real-time data exchange with the sorting machines Fault history with statistical evaluations Statistical evaluations of the sortation Optional extensions: Product tracking within the whole production chain Quality management Maintenance management Document management Modules for implementation of customer-specific requirements: Taking over sorting data from HOST systems (e.g. ERP, WMS) Preparing and carrying out sorting processes as batch runs Handling commissioning orders according to default data from the ERP system Dynamic allocation of sorting destinations with real-time data from the sorting process Integration of automatic reading systems or coding stations Message history BeSS for sortation and distribution technology PC network for a sorting process Overview of entire system with BeSS 18

19 Teleservice The efficiency of production systems is mainly determined by their availability. Occurring irregularities must be remedied as quickly as possible. If the systems are complicated, the maintenance personnel might not be able to solve the problem, or the trained maintenance technician might not be immediately available. In these cases, the BEUMER specialists are able to offer immediate help. This service is available anywhere in the world, thanks to the today s telecommunication technology. Upon contractual agreement, BEUMER offers the following teleservice advantages: worldwide at any time of the day for all delivered machines. The technical implementation depends on the configuration of the installation and of the available local data and telephone networks. Customer s PC systems ERP, WMS, SCADA Customer Intranet BeSS BEUMER System Server BSC BEUMER Sorter Control Company network TCP/IP Modem S7-400 Teleservice Internet WAN VPN connection: analog ISDN DSL BEUMER Intranet BEUMER parent company BEUMER Service Center In bigger production plants, the PLCs and the PC systems work in a local communication network. The teleservice can be implemented by connecting the local network of the plant with the BEUMER Intranet. The network connection is either established via ISDN or via the Internet on the basis of VPN connections. 19

20 BEUMER stretch hood für die Verpackungsmittelindustrie An der Aufrichtvorrichtung werden gekippte Schalen wieder in ihre Grundstelkippte Schalen wieder in ihre Grundstel- An der Aufrichtvorrichtung Leitlinien prämien wider. Folien-format werden ausgewählt. ge- Das Verpacken lung gebracht, von Kartonagen bevor sie und erneut belegt lung gebracht, bevor Beim Einsatz des BEUMER stretch Nicht sie erneut nur die belegt systembedingt deutlich Kartonzuschnitten werden können. stellt besondere Aufrichtvorrichtungen werden können. Aufrichtvorrichtungen hood Verfahrens kann auf das höhere Durchsatzleistung der Anlage Anforderungen können an bzw. die müssen Technik. vor Hier Einschleusungen, BEUMER Horizontal- stretch und hood Vertikalkurven eingegen, Horizontal- und können bzw. müssen Schrumpfen völlig verzichtet werden. gegenüber vor Einschleusun- dem Schrumpfverfahren bietet das Aus einem Seitenfaltenschlauch wird trägt Vertikalkurven zur Zufriedenheit eingesetzt werden. der Anwender Verfahren setzt eine werden. innovative Technologie an, die Die wesentlich Aufrichtvorrichtung zur Verringe- besteht aus Die Aufrichtvorrichtung BEUMER is an international leading eine der Höhe des Packstapels entsprechende Haube geformt. Diese Hauben, bei. Auch die exzellente Optik der besteht welche aus rung manufacturer die Hochwertigkeit der einer Brandgefahr of Stahlkonstruktion intralogistic beim specialized Verpacken in the conveying, bei-trägt. len und loading, horizontalen palletizing Führungsschiene und len und horizontalen mit einer vertika- einer Stahlkonstruktion besteht aus elastischem Material und der Kartonverpackungen mit einer vertika- erst richtig kann vor dem Überziehen so weit gedehnt werden, dass sie sich gut über hervorragende zur Führungsschiene Geltung kommen und lässt und der and packaging wird beidseitig technology auf as well dem as Sortergerüst angebracht. and distribution eingesetzten Die horizontale systems. Führungsschiegebracht. Die horizontale wird beidseitig auf dem Sortergerüst Schutz an- vor negativen Bei in sortation der bisher den Stapel ziehen lässt. Danach legt Umwelteinflüssen Führungsschiene ist mit einem auswechselbaren auch bei längerer Schrumpf-hauben-Technologie ne ist mit einem auswechselbaren werden die über-gezogenen stoffbelag versehen, Hauben auf dem er- der Stößel stoffbelag versehen, Kunst- sie sich eng an das Paket an. Lagerung oder Kunst- Having approx. 700 employees and beim Transport sind ein auf wichtiges dem der Stößel a turnover of around 140 Mio. EUR, Verkaufsargument beim hitzt. Dadurch des gekippten schrumpfen sie und des gekippten Sowohl in der Umfangs- als auch in Endkunden. legen BEUMER sich Kippelementes has, eng with an subsidiaries die Zuschnitte beim and Durchfahren an. angehoben bei a und diesem worldwide entriegelt Ver- presence wird. Im Anschluss hoben und entriegelt Kippelementes beim Durchfahren ange- der Längsrichtung verbleibt eine Leider representations, kann Rest-dehnung in der Folie, die für eine sichere Fixierung des Stapels auf stretch Selbst wird. der Im Anschluss Preis einer BEUMER packungsverfahren for various an industries. die Entriegelung das Brandrisiko drückt die vertikale an die Entriegelung drückt die hood vertikale Verpackung ist günstiger als der nie ganz Schiene ausgeschlossen das Führungsstück werden, des Kippelementes information davon, die Grundposition ob die und richtet mentes in die Grundposition Schiene das Führungsstück der Palette sorgt. Die Folie bleibt des einer Kippele- vergleichbaren völlig For further unabhängig dauerhaft elastisch. Dadurch entfällt Schrumpfverpackung. und richtet Hier kommen Heißluft please visit durch damit us on: Gasverbrennung die Schale wieder oder auf. Mit Erreichen Heizelemente der Grundposition erzeugtendet die horizonchen der Grundposition damit die Schale wieder auch das lästige Nachschrumpfen, Energieeinsparung, auf. Mit Errei- geringerer Folien-verbrauch elektrische welches bei den untersten Paletten endet die durch horizontale Führungsschiene, den von BEUtale mehrfach übereinander gestapelter Pakete häufig erforderlich wie MER so patentierten dass die nun Biaxialstretch abfallende Stößelrolle so- das die Kippelement gegenüber verriegelt. den Wickelstretchfolien deutlich preiswerteren Folien ist. Die elastische Folie gleicht Die Verriegelung der im Gegensatz zur Schrumpf-folie zum Stößelrolle Tragen. wird durch eine weitere Führungsschiene, den einen etwaigen Volumenverlust durch wird. Auch Führungsschiene, entsprechende so Ab-dasdeckungelende helfen Stößelrolle nur begrenzt. das Kippelement verrie- die nun abfal- Niederhalter, sichergestellt. das Zusammendrücken der Kartonagen spielend aus. An der Aufrichtvorrichtung Sprechen sind Sie drei uns Licht- an! Haben Sie Fragen? Gerade der gelt. unvermeidliche Staub, schranken installiert: eine, bevor die welcher bei Die der Verriegelung Erstellung der Stößelrolle Karton-zuschnitte durch eine entsteht, weitere und Führungsschiene, das den wird Mit dem Einsatz des Schalen 4-Format-Kopfes wird das breite Spektrum den anderen, unter-nachdem die Schalen auf- aufgerichtet werden und die bei- leicht entflammbare Niederhalter, Produkt sichergestellt. erhöhen schied-licher Palettenformate gerichtet und worden sind. das Brandrisiko erheblich. Dieses An der Aufrichtvorrichtung sind Zuschnitt-größen drei Lichtschranken installiert: eine, bevor deckt. die Über entsprechende chanische Sensorik Position der Schale auf gekippt komplett Die erste abge- Lichtschranke überprüft die me- spiegelt sich nicht zuletzt auch in entsprechend hohen Versicherungs- Schalen aufgerichtet werden und wird die die beiden anderen, nachdem die Schalen letten auf- und Kartonagen schranke zuverlässig überwacht er- den Belegtzustand Größe der einlaufenden oder nicht gekippt. Pa- Die zweite Lichtgerichtet worden sind. fasst und das für die der jeweilige Schale. Verpackungsaufgabe die me- optimal die Signale geeignete beider Lichtschranken mit dem Die Sortersteuerung vergleicht Die erste Lichtschranke überprüft chanische Position der Schale auf gekippt logischen Status der Schale. Bei einer oder nicht gekippt. Die zweite Lichtschranke überwacht den Belegtzustand eine Alarmmeldung mit Angabe der Diskrepanz generiert die Sortersteuerung jewei- The information contained in this brochure merely serves as a non-binding description of our products and is without guarantee. Binding information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete inquiries. E BEUMER Maschinenfabrik GmbH & Co. KG Postfach D Beckum/Germany Tel.: (0) Fax: (0) BEUMER@BEUMER.com Internet: BEUMER Corporation Branchburg, NJ 08876/ USA Tel.: +1 (732) Fax: +1 (732) BEUMER Ltda. Campinas - SP/Brazil Tel.: +55 (0) Fax: +55 (0) BEUMER S.a.r.l. St. Ouen L Aumone/France Tel.: +33 (0) Fax: +33 (0) BEUMER Technology India Private Limited Mumbai /India Tel.: +91 (0) Fax: +91 (0) Asia Representative Office of BEUMER Bangkok/Thailand Ph.: +66 (0) Fax: +66 (0) (0) (0) Australian Representative Office of BEUMER North Ryde / Australia Ph.: +61(0) Fax: +61(0)