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GuardLogix在輪胎行業(yè)的應(yīng)用
解決方案
基于羅克韋爾自動化產(chǎn)品的解決方案，其中包括：
• MAXX系列全自動裁斷機和成型機
• 物料自動裝卸系統(tǒng)，如自動卸胎
• 用于精確定位成型鼓、裁斷裝置和傳送帶的22臺伺服驅(qū)動器
• 用于控制胎面膠張力的驅(qū)動器
• 用于實現(xiàn)安全和運動控制的Allen-Bradley GuardLogix 控制器
結(jié)果
• 將每個輪胎的成型階段制造從50至60 秒縮短到38秒
• 使得OEE達到80%以上成為可能
• 自動化操作可省略了一部分人工操作
• 冠帶纏繞速度從 6m/s 提升到 8m/s
• 在單次連續(xù)運動中即可完成內(nèi)襯層胎側(cè)預(yù)貼合組件與胎體簾布的貼合
• 生產(chǎn)率、安全性和人體工學(xué)并重
• 漢堡“輪胎技術(shù) 2009”商展會期間獲得“創(chuàng)新和卓越獎”
• MAXX 鞏固了 VMI 的市場領(lǐng)先地位
背景
速度、質(zhì)量和安全是生產(chǎn)汽車輪胎的要義所在。因此，VMI Holland在2009 年推出了新的專用機床產(chǎn)品線MAXX，該產(chǎn)品線能夠幫助輪胎制造企業(yè)大幅提升投資回報率。MAXX受到了熱烈的歡迎：在德國漢堡“輪胎技術(shù)2009”商展會期間，VMI Holland被授予“創(chuàng)新和卓
越獎”。
位于Epe的VMI Holland的研發(fā)經(jīng)理 Jan Grashuis 及其團隊共花了兩年時間將原始概念轉(zhuǎn)化為 MAXX 工程樣機?！拔覀兿Ｍㄟ^實施新型機電一體化機器概念來使質(zhì)量更上一層樓?！盙rashuis解釋道，“我們的目標(biāo)是同時在盡可能多的領(lǐng)域內(nèi)獲得最大程度的改進。你甚至可以理解為，我們又重新進行了一遍基礎(chǔ)工程設(shè)計。我們也花了很長時間深入思考新MAXX機器產(chǎn)品線背后的基本原理。設(shè)計這一新機器概念的同時，我們吸收了VMI在過去十年間積累起來的所有實踐經(jīng)驗。因此，我們現(xiàn)在得以提供
今日自動化 2013年9月 | 33
現(xiàn) 場
應(yīng) 用
一種集質(zhì)量、人體工學(xué)、易用性、速度、安全和生產(chǎn)率于一體的機器，這些成就，一定程度上歸功于羅克韋爾自
動化。”
面臨的挑戰(zhàn)
輪胎成型機(TBM)是汽車輪胎生產(chǎn)過程中最重要的元素之一。輪胎成型機用于將一系列膠部件，如胎面、胎側(cè)內(nèi)襯層等，通過導(dǎo)開、裁斷、貼合等工藝制成生胎。
各膠部件從(工字輪等)料卷架上導(dǎo)開，依次在鼓上貼合各層膠部件。在本階段中，材料的供給精度、長度以及定位非常重要。這些可變因素由TBM中的攝像機監(jiān)視。Grashuis解釋道：“生產(chǎn)汽車輪胎的一個重要方面是加工每個輪胎所花的時間。這個時間應(yīng)盡可能短。不久之前，TBM加工每個輪胎需要50至60 秒。而新型MAXX TBM則可在短短38秒內(nèi)完成此過程。
客戶可實現(xiàn)高達80%的OEE(設(shè)備綜合效率)，能否達到此效率在一定程度上取決于客戶的料卷尺寸及尺寸變更次數(shù)等可變因素。更短的周期時間加上更高的OEE即意味著更大的輸出量。MAXX機器完全無需手動操作，操作員的主要任務(wù)是裝載材料軸。許多重要參數(shù)實施配方控制，因此準(zhǔn)確性和重復(fù)性極佳。
解決方案
通過伺服控制系統(tǒng)，鼓在軌道上實現(xiàn)了直線運動，在縮短周期時間上發(fā)揮著極大作用。憑借直線伺服技術(shù)，這一過程變得更加快速、更加精準(zhǔn)。
VMI使用22個伺服軸控制MAXX TBM中所有不同運動。帶有集成運動控制模塊的Allen-Bradley ControlLogix控制器與Allen-Bradley Kinetix伺服驅(qū)動器共同控制所有不同單元的同步運動過程。冠帶纏繞工藝階段，加快過程速度同樣非常重要，輪胎制造商希望冠帶條貼合時也要對張力實現(xiàn)可控。
取得的成果
由于速度的提高，對控制器的要求也日益嚴(yán)格。事實證明，采用羅克韋爾自動化技術(shù)的冠帶條張力控制是極佳的解決方案。最終帶來了雙倍的運轉(zhuǎn)速度。最初運轉(zhuǎn)速度為4m/s，后來提升至6m/s，而新型機器則達到了8m/s的
速度。
伺服技術(shù)的應(yīng)用同樣使貼合或拼接過程更加精準(zhǔn)、更加快速。過去，操作員需要在此步驟中手動操作某些元件。
速度的提升同樣適用于預(yù)復(fù)合件和胎體層的應(yīng)用。在MAXX中，這些操作在單個運動中執(zhí)行，部件逐個連續(xù)快速貼合。另一個由手動操作改為機器人操作的過程是將三角膠裝載到機器中以及成品生胎的自動卸胎搬運。這些改動也有利于節(jié)省時間，并且有助于改善員工的工作環(huán)境。
安全
為了最大程度地降低操作員被卷入機器運動部位的可能性，我們對設(shè)備整體實施了功能性風(fēng)險評估，風(fēng)險評估的結(jié)果表明，參照安全標(biāo)準(zhǔn)EN ISO 13849-1，設(shè)備安全性性能等級需要達到PLe級別，根據(jù)風(fēng)險評估結(jié)果，設(shè)備安裝了一系列相應(yīng)的安全設(shè)備。
在員工可能接近機器移動部位范圍內(nèi)的情形下，采用各種光幕、門開關(guān)和激光掃描儀進行預(yù)防。這些安全設(shè)備與羅克韋爾自動化的安全遠程I/O-1791 DS/ES CompactBlock Guard I/O模塊相連。這些I/O模塊再通過網(wǎng)絡(luò)與 GuardLogix控制器進行通信，這款控制器是利用單個控制器同時監(jiān)控安全功能與“常規(guī)”運動控制功能的安全 PAC。
其它信息
www.rockwellautomation.nl
以上僅說明VMI Holland使用羅克韋爾自動化產(chǎn)品和服務(wù)以及其它產(chǎn)品所取得的成果。其他客戶取得的成果可能會有所不同。
位于 Epe 的 VMI Holland 的研發(fā)經(jīng)理 Jan Grashuis 及其團隊共花了兩年時間將原始概念轉(zhuǎn)化為 MAXX 工程樣機

控制與信息融合，實現(xiàn)全廠最優(yōu)化和提高機器制造商機器性能

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Tissue industry challenges addressed by open and scalable software solution coupled with effective relationships in technical development

Pulsar Srl, founded in 1989, is based in Casbmaggiore, near Bologna, in the heart of the “packaging valley” of Europe.

Its primary activities are based around the engineering, production and creation of conveying and transportation solutions. It also produces specialised automatic machinery for use in the tissue sector, including feeding, packaging and sorting for rolls and packages of toilet paper and paper towel, machinery for processing and packaging folded paper products and product movement units.

In just a few years, Pulsar has built more than 230 systems and eighteen complete plants for major tissue manufacturers.

Its continuous studies on the improvement of production line management has led it to create ideal hardware and software combinations that can manage and optimise entire lines integrating machinery with transport systems.

The company’s innovative ‘Layout Simulator’ software can design new systems by comparing process machinery present on the market and then simulating its productive capacity.

To this end, users can see various options aimed at specific production needs in real time and then buate the true value of their investment.

In a more recent development, Pulsar has developed the ‘Reds Platinum System’ a platb for SCADA systems –specifically designed for the measurement of Overall Equipment Effectiveness (OEE) in the tissue converting industry – which uses various elements of the FactoryTalk® Software suite from Rockwell Automation.

Challenge

According to Angelo Bertini, General Manager at Pulsar: “The measurement of production line efficiencies in the manufacture of consumer goods is a major factor towards increasing competitiveness.

The tissue industry does not escape this logic; so the provision of a platb dedicated to the converting industries will give users a facilitated approach to measuring these all-important OEE figures.”

These measured variables, upon which the efficiency figures are calculated, include basic machine availability, product quality compared to overall production volumes, machine downtimes and transition times, either between production runs or, indeed between events such as unplanned downtime and stoppages.

According to Bertini: “The primary issue faced by the tissue industry is the niche nature of its operations; with limited manufacturers and limited machine and service suppliers. If companies in this industry want to implement efficiency platbs, they have to ask for the services of industry experts and then apply standard platbs in order to gradually develop the structure of the data collection and analysis required. These experts then, in turn, have to be told by the manufacturer which beters are to be monitored, where they are generated and how to record them.

“The process of creating such a platb,” he continues, “requires a series of cross-functional skills which are rarely in place within the software houses that normally develop these types of platbs, especially the bespoke skills and knowledge relating to the unique facets of the tissue industry. In addition to IT and data analysis skills, the developers also require knowledge about process, automation and IT infrastructures. Besides the identification of the data to be monitored, one also has to identify the availability of this data along the line, the bs of extrb and the subsequent communication to the analytics platb.”

Solution

Combining its knowledge and expertise in the tissue production process, automation and regarding the different machines and equipment currently being used in these lines, Pulsar has developed a dedicated OEE measurement platb for monitoring tissue converting lines, leaving the integrator only simple adaptations for specific applications.

The ‘Reds Platinum System’ is structured in such a way that it can take into account the process steps to be controlled, the machines involved and the beters that must be collected and monitored for the calculation of the OEE of the lines.

Developed using FactoryTalk View, FactoryTalk Metrics, FactoryTalk VantagePoint^® EMI and FactoryTalk Transb Manager software from Rockwell Automation, the ‘Reds Platinum System’ has benefited from this choice of software for multiple reasons. “In the first instance, Rockwell Automation is a brand leader in the field of industrial automation, Bertini explains.

“We also appreciate the worldwide presence of the company and the support possibilities no matter where we are. Of particular importance is the fact that all of the FactoryTalk software platbs we are using have been specially developed for each of their individual purposes: FactoryTalk View for HMI development, FactoryTalk Metrics for OEE measurement, FactoryTalk VantagePoint for inbation delivery and reporting and FactoryTalk Transb Manager for transb integration and management.”

Pulsar also sees the benefits of hardware and software being tightly integrated.

“We have seen much easier integration of the supervision platb with the automation components from Rockwell Automation, with no need for conversion cards or translation software,” Bertini explains. “The ability to access the partnerships that Rockwell Automation has developed, with companies such as Cisco, for instance, is incredibly attractive when it comes to the configuration of communications systems and security protocols; or with its other partners for jobs such as the network realisation and implementation or service.”

Results

By developing and deploying a system based on the FactoryTalk suite from Rockwell Automation, Pulsar has created an extremely attractive platb for business improvement.

The use of FactoryTalk software and its very tight integration with Allen-Bradley control products means that the solution is easier to install and can start delivering data very quickly after deployment. The system is capable of interrogating hardware from other vendors, but this requires additional hardware and software for communication, which ultimaby increases complexity and costs.

“Within this development,” Bertini adds, “we have defined a strategy in the area of smart machines and tools and we have already seen dramatic developments occurring within the realms of the IIoT (Industrial Internet of Things). We strongly believe in this evolution, which is why we have developed this system.  With the help of Rockwell Automation and its commitment to the Connected Enterprise, we see the collection of data and subsequent interrogation and disbursement of inbation as the norm rather than a luxury.

“Another reason we went with Rockwell Automation,” Bertini concludes, “is that in Italy, we found a group of professionals with whom we subsequently became friends. We had complete support, including tools and technology ‘loans’ for application development. We get great support from Rockwell Automation in Italy and in the EU and now we are heading into the USA. Their approach differs compared to other suppliers, in that they are really willing to support development of projects. They don’t just make the tools available, they also offer significant levels of help, which is not something I can say for some of their competitors.”