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 complex automation tasks directly into the control platform.

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
• large selection of EtherCAT-compatible sensors and actuators on the market
• flexible connection of other fieldbus systems, such as CANopen, IO-Link, and PROFINET
• reduced cabling effort 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

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 combines 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 revolutionizes 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 for the economic production of small lot sizes.

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 the curves are used to transport materials, there are no empty trips, making for a faster overall packaging process. The packaging steps are optimally synchronized, which minimizes downtimes. Machine footprints can be reduced by up to 50% with the XTS.

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 functionality
• hygienic version available for food and pharmaceutical applications

XTS with NCT reduces the footprint of packaging machines

Recent developments concerning an increasing number of variants in a rapidly growing engineering market, as well as the scarcity of raw materials and production space, mean that every machine needs to be used in the most efficient and versatile manner. The addition of No Cable Technology (NCT) to the XTS modular system, which has proven itself in the packaging industry, opens up further degrees of freedom in system design. NCT for the XTS enables contactless, continuous power supply and synchronous real-time data transmission to the XTS movers.

The advantages of XTS with NCT at a glance:

• processing steps and quality checks take place in the regular process flow directly on the mover
• XTS system becomes an active part of the production process
• increase in plant efficiency
• reduction of machine footprint thanks to savings on machining or test stations

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.
• 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.