Automation solutions for sustainable packaging processes

PC-based control throughout: from primary to secondary packaging

Due to increasing requirements in terms of quality and speed, the complexity of packaging applications is continuously growing. More and more work steps are having to be linked together, and added to this is the increasing need for the individualization of products. Flexibility, connectivity, and efficiency are the criteria that lead to sustainable success in such a performance-driven industry – starting with the control architecture. This is where our PC-based control technology comes in to provide you with a future-proof solution:

• openness in software and hardware: automate individual packaging machines or the entire process chain of complete packaging lines
• consistency: control all work steps via a uniform software platform
• scalability: use the exact control that fits your requirements in terms of performance, design, and price
• performance of modern processors: integrate sophisticated automation tasks directly into the control

EtherCAT – the fast fieldbus: global standard for packaging machines

EtherCAT technology was launched by Beckhoff in 2003 and made available as an open automation technology standard. With outstanding performance, flexible topology selection, comprehensive diagnostics, and simple configuration, EtherCAT is ideally suited for use in packaging applications.

EtherCAT highlights for the packaging industry:

• extremely fast cycle times for precise and efficient processes
• wide selection of EtherCAT-compatible sensors and actuators on the market
• flexible integration of other fieldbus systems, such as CANopen, IO-Link, and PROFINET
• reduced cabling work thanks to the EtherCAT P single-cable solution
• maximum performance with speeds of 1 Gbit/s or 10 Gbit/s with EtherCAT G

Integrated automation with TwinCAT

The TwinCAT 3 automation software integrates all engineering and runtime processes, and features a consistent development environment for implementing all control tasks in the packaging industry. Programming is carried out uniformly with TwinCAT Engineering (XAE) according to the programming standards of IEC 61131-3 with C++, MATLAB^®, and Simulink^®. Microsoft Visual Studio is used as the standard programming workbench as it supports different version management systems and simplifies team-based programming.

TwinCAT highlights for the packaging industry:

• direct integration of all TwinCAT functions, from HMI and XTS through to Vision, facilitates the execution of different applications with a single software
• pre-built packaging software blocks and support for PackML standards for straightforward engineering
• extensive libraries for motion control as well as supplements for different robot kinematics
• TwinCAT PLC++ reduces throughput times and boosts the performance of packaging machines
• TwinCAT CoAgent supports development and diagnostics in packaging machines

Control cabinet-free automation with the MX-System

For the first time, the MX-System enables completely control cabinet-free automation solutions in machine and system engineering. The combination of baseplate and function modules in this modular system encompasses all the tasks and properties of a control cabinet: power supply, fuse protection, and power distribution; generation and monitoring of auxiliary voltages; sequence control with inputs and outputs; control of motors and actuators; and the connection level for the field devices. The consistently systemic approach greatly reduces the effort required for planning, machine installation, and maintenance. The system footprint is reduced, and system availability and flexibility are also increased.

The advantages of the MX-System at a glance:

• more compact than a control cabinet, saving installation space
• robust design with IP67 protection rating
• decentralized system
• shortened time-to-market
• rapid diagnostics and service for increased availability

XPlanar is revolutionizing the packaging industry with flying motion

With the intelligent XPlanar transport system, free-floating planar movers glide smoothly over freely arrangeable planar tiles along six axes, without colliding with each other. With XPlanar, packaging machines can be designed in entirely new ways. Since the XPlanar tiles can be arranged to suit any machine design, product streams can be freely directed. Quick setup changeovers shorten the machine downtime and allow small lot sizes to be produced economically.

Intelligent product transport with XPlanar:

• free positioning and flexible movement of the movers across the entire system
• application-specific arrangement of tiles in any geometry
• movers available in different formats and for different loads
• suitable for use in the food and pharmaceutical industries or in cleanrooms
• dynamic motion sequences prevent liquids from spilling over

XTS opens up entirely new packaging concepts

The XTS combines the advantages of a linear transport system with those of a rotary solution. Products can be transported independently of each other. Since both straight sections and curves are used to transport materials, there are no empty trips, making for a faster overall packaging process. The packaging steps are perfectly synchronized, keeping downtimes to a minimum. Machine footprints can be reduced by up to 50% with the XTS.

Additional extensions such as XTS No Cable Technology (NCT) and XTS EcoLine tap into more areas of potential for machine design. While NCT allows processing and testing steps to be conducted directly on the mover, XTS EcoLine makes it possible to design transport-only routes in a way that is efficient and conserves resources.

Efficient packaging processes with the XTS:

• application-specific set-ups thanks to different motor module geometries
• rapid format and product changes through purely software-based adjustments
• maintenance activities can be performed without interrupting the regular product flow using XTS’s Track Management software function
• hygienic version available for food and pharmaceutical applications
• cost-effective design of transport routes due to EcoLine motor modules

Price-conscious, compact, and integrated: the economy drive system

Many packaging machines – and especially those in cost-driven applications and markets – require reliable drive solutions with an optimized price/performance ratio. At the same time, requirements for compact designs, energy efficiency, and simple integration are becoming more stringent. This is precisely where our economy drive system comes in, making it possible to create drive concepts for packaging machines without compromising on performance or quality.

The AM1000 economy servomotor in combination with the AX1000 economy servo drive forms a powerful, space-saving, and ideally matched servo drive system for versatile packaging applications. Complementing the range is the AF1000 economy variable frequency drive, which offers compact and versatile drive solutions for simple movement and transport tasks in packaging machines.

How you benefit from the economy drive system:

• optimized price/performance ratio for cost-optimized packaging machines
• minimal space required in the control cabinet and machine due to compact designs
• available as a single-axis or highly cost-effective dual-axis version
• reduced engineering, commissioning, and diagnostic work in TwinCAT

ATRO: Automation Technology for Robotics

The ATRO system is a modular industrial robot system that can be used to assemble robot structures for different packaging industry applications on an individual and flexible basis. Standardized motor modules in various sizes, together with link modules in a variety of designs, are combined on a base module for cable and media feeds. Complete integration into the TwinCAT control platform offers access to a wide range of proven automation functions. The link with XPlanar and XTS, as well as the precise synchronization of all components into the robotics system, allows for completely new machine concepts.

The advantages of the ATRO system for packaging applications:

• modular system enables a tailor-made solution for a wide range of products waiting to be packaged
• faster cycle times due to exact synchronization of all components of the machine
• modular set-up reduces maintenance and downtime
• internal media feed increases the standard of hygiene