One of the West Midlands’s fastest growing manufacturers is dismissing uncertainty surrounding Brexit by investing more than £1m on a new factory extension.
PP Control & Automation has pressed the button on ambitious expansion plans that will see it add 1,000 sq metres of production space to its existing site in Cheslyn Hay, including a new logistics department and clean assembly area.

With consumer buying trends influencing greater product diversification, production and packing facilities throughout the UK and Europe are increasingly leaning towards flexible robots that straddle several lines and perform multiple tasks. As testament, Pacepacker Services reports that enquires for single robots dedicated to the entire end-of-line palletising station has doubled in the last 12 months as customers move away from traditional application-specific palletising work cells.

Addressing the issue of frequent product changeovers, the FANUC M410 series has the payload and multitasking capability of stacking anything, ranging from 25kg potato sacks, to tubs of animal feed and bales of pet bedding. For increased flexibility, this high-speed robot can be fitted with different multi-purpose end effectors to suit the application. What’s more, the robot can be easily moved to other production areas to suit business demands, boosting a packer’s investment even further.

Designed specifically for palletising tasks, the M410 robot family is capable of multiple palletising configurations and features a large vertical work envelope. Pacepacker’s Commercial & Information Systems Manager, Paul Wilkinson, explains: “We are increasingly designing palletising cells with three to four in-feed conveyor lines, often carrying different product sizes, packaging types and weights. Thanks to the maximum 3.1m reach of the M410, one robot can pick up different pack formats from multiple lines simultaneously and stack up to three pallets up to 2.4 metres high.

“Because of the choice of end-effectors available, we can select a multifunctional tooling that automatically adjusts to all of the functions it has to perform: picking pallets and slip sheets before palletising commences, as well as bags and boxes,” continues Paul. Adding to its flexibility, hundreds of pallet patterns can be programmed and stored by the robot. And even if operatives need to change the end-effector for a specific pack format, quick changeovers means this can be done in just a few minutes, minimising production downtime.

Palletising payloads within the M410 family range from 140kg to 700kg, and the robots are capable of completing 1,700 cycles per hour. The robot’s generous payload also opens up possibilities for handling and palletising several heavy items simultaneously, for example two filled keys of beer or several sacks of aggregate.

In order to provide stability and strength, Pacepacker typically recommends integrating a four-axis robot for palletising operations. For maximum flexibility the robot can be floor, angle, wall or ceiling mounted, although typically customers opt for a pedestal base with integral controller or a compact base with remote controller, claims Paul. Pacepacker has even designed a portable palletising cell, mounting an M410 onto a base plate with a conveyor and safety guarding, so it can be transported by a teleporter to another production location.

To extend the life of the gripper, the most recent additions – the M410-iC range – features a hollow upper arm and wrist to prevent snagging, tearing and rubbing of the connecting cables.

For more information please contact: www.pacepacker.com

SKF launches new spring insulating automotive suspension

Advanced chemical and mechanical bonding enables reduced part count, improved durability and lower total suspension cost

SKF are launching a new product designed to offer greater durability, improved comfort and reduced noise and vibration in automotive suspension applications.

The spring insulating suspension bearing takes SKF’s robust, proven main suspension bearing unit (MSBU) technology and incorporates a polymer spring that is mechanically and chemically bonded to the lower bearing washer.

The spring insulator plays a critical role in automotive suspension systems, damping road vibrations that pass from the spring, through the bearing and into the passenger compartment. Conventional spring insulators are installed separately from the MBSU.

This approach creates a potential failure point in the vehicle suspension, since the insulator is susceptible to damage due to the ingress of dirt and contamination between it and the bearing.

The new spring insulating suspension bearing eliminates this point of weakness by building the bearing and spring insulator as a single component, with high strength chemical bonding used to connect the spring to the bearing. Additional optimisation of the bearing geometry ensures a secure mechanical connection between the two elements.

For manufacturers, the spring insulating suspension bearing offers further advantages, reducing the number of components required in the suspension system and simplifying assembly to reduce total suspension cost. The material selected for the spring element can be adapted to suit the precise requirements of the application, and SKF can offer a wide range of material options, all optimised for high volume manufacturing using injection moulding.

SKF has applied for no less than three patents covering innovative features of the new design, including the spring material, insulator design and fixation technology. Prototype units are already undergoing evaluation by leading Automotive OEMS.

For more information please contact: www.skf.com

Technology-shy businesses are being offered the chance to discover the benefits of robots by leading robotics expert Jeremy Hadall.
Hadall, chief technologist for robotics and automation at The Manufacturing Technology Centre (MTC) in Coventry, will host a two-day course next month – Improving Competitiveness Through Automation – targeting key ‘decision makers’ to understand the benefits of automation and robotics.

In Robotics: manufacturing the future, an article he co-authored for the Institution of Engineering and Technology, Hadall states: “Britain still lags behind its major economic rivals in the uptake of robots. Statistics from the International Federation of Robotics on robot densities reveal the UK has only 33 robots per 10,000 employees compared to Japan (213), Germany (170) and Sweden (154).

“So how do we encourage UK industry to invest in robotics and automation to reap these benefits? Perhaps the first step is as simple as demonstrating that these benefits are truly benefits.”

Hadall, is looking to demonstrate the tangible benefits via the course on March 8th and 9th. Limited to just 20 attendees, it will provide the necessary tools, techniques and processes to evaluate the opportunity, develop the business case and deploy the implementation plan to integrate automation into business.

This two-day course is being supported by ROBOTT-NET, a collaboration between the following leading European research organisations: Danish Technological Institute, Germany’s Fraunhofer IPA and Spain’s Tecnalia.

The price for the course is £600 plus VAT. For more information go to the events section of www.the-mtc.org.

The ever-expanding range of industrial robot applications has led to the development and introduction of new models from the worlds leading six axis robot manufacturers that can handle vast payloads of up to 1,300 kg. Although easily capable of manipulating these impressive weights, the horizontal reach of these robots, generally less than 4.0m, can still be a limiting factor in certain applications.

Güdel Track Motion products have always been recognised as a robust and reliable method of extending the work envelope of robot systems, and the company’s latest TMF-5 linear track has been developed to provide this enhanced functionality to the new generation of heavy-duty robots.

Güdel is the only company dedicated solely to auxiliary linear motion for robots and automation, and adding this new TMF module to its heavy-duty range, further reinforces the company’s reputation as a valued partner to the world’s leading robot integrators.

The TMF-5 is currently the only standard module available on the market that can move an articulated robot weighing over six tonnes, with a payload of 1300Kg, and sustain a static payload of over ten tonnes. Working as a fully integrated seventh axis for robots, the TMF-5 opens up new possibilities in a number of production processes. A range of adaptor plates, designed to suit the increasing number of heavy-duty robots now available, maximises the potential for integration with different manufacturers and their respective robot models.

With the capability to accommodate up to four independently driven carriages, multiple robots are able to share the same track if required, delivering the highest levels of utilisation and flexibility for heavy-duty applications. The carriages used on the TMF track have been designed to handle the often-high dynamic loads of a moving robot, including those associated with emergency stop conditions.

The use of hardened and ground helical racks, coupled with planetary gearboxes, deliver the highest levels of positional repeatability (+/-0.05mm) plus smooth and quiet operation. The TMF-5 is also available as an enclosed version to meet the demands of specific operating environments such as those found within a cleanroom.

Available in lengths from 3m to 100m in 1m increments, the optimum track length can be specified for any particular application. Another feature of the TMF track range is that the length can be extended, should this be required to increase flexibility or to future-proof existing installations.

Güdel’s reputation for quality and engineering excellence is clearly evident in the design, the materials used and build standard of the TMF-5 linear track, ensuring high uptimes and a long service life. From a maintenance perspective, the ability to adjust the guide-way rollers from the outside of the unit and the availability of an automatic lubrication system for the rack & pinion, will keep planned maintenance times to a minimum.

Güdel’s linear track range can be found operating within the automotive, tyre, metal, rail, intra-logistics, pharmaceutical, renewable energy, wood and aerospace industries.

Güdel not only provides sophisticated automation solutions but is a manufacturer of high-precision machine components including linear guide-ways, racks, pinions and drives. These high quality components are at the heart of all Güdel linear axes and gantry robots.

For more information, please contact: www.gudel.com

Effective site-wide energy management is a key function of the new control system which is being used to synchronise heat systems that include new biomass boilers.
A grain drying and storage facility that supplies some of Scotland’s leading distilleries has installed a new Movicon SCADA (supervisory control and data acquisition) system from Products4Automation (P4A) to consolidate series of plant upgrades and expansions. The new software is providing control and visualisation for product movement, processing and storage, including the integration of biomass boilers and heat recovery systems.

Highland Grains Ltd is an agricultural cooperative, owned by its 89 members, which dries, conditions and stores malting barley and other crops. It primarily supplies the Scotch whisky distilling industry, but also exports high quality grain to other countries.

Based just north of Inverness, Highland Grains was founded in 1978 with a capacity to handle 4,400 tonnes of barley a year. Steady expansion has seen its annual throughput grow to over 40,000 tonnes. Today the plant consists of five continuous flow dryers, seven wet and fifteen dry storage silos (ranging from 250 tonnes to 2,300 tonnes) and two warehouse-like flat stores of 7,500 tonnes each. Committed to constant development, the site also includes innovations such as heat recovery on its drying systems, power synchronisation and biomass boilers.

 
The facilities were always automated, and the control system and software were frequently expanded to meet new requirements and accommodate new equipment. The control system has been maintained and developed over many years by specialist local firm Coldcurve Ltd, which most recently was commissioned to replace the existing much-extended control system with an efficient state of the art one.

The project was lead by Coldcurve engineer Daniel Castle, who explains that although the site’s operations are relatively complicated, a simple system architecture was achieved: “Lorries are constantly delivering grain from the growers, while others collect dried malting barley for the distilleries – it’s a 24/7 process at busy times, plus there are several different drying processes. There are also a number of subsidiary processes to control, such as incoming and outgoing weighbridges, boiler operations and heat recovery for energy efficiency.”
The whole site is now controlled from a single, powerful PLC supporting 29 separate I/O cards. There are also two PCs and a number of touchscreen HMI’s on the system, providing main and secondary control stations.
“The system now runs Movicon SCADA software,” says Daniel, “which has been used successfully in many food and beverage applications, as well as for materials handling and in many other industries.”

Movicon provides constant real-time production process information, collecting data from multiple sensors on the plant and processing it into high level information. This allows Highland Grains to efficiently manage its plant and processes to meet customers changing needs.

Movicon is based on an XML technology that offers an all-in-one development environment for managing all HMI, SCADA and statistical production data analysis applications. This allowed Highland and Coldcurve to minimise project development times and also to achieve a powerful, open, solution that is easy to maintain and flexible so that it can accommodate future developments.
Movicon also supports web services, scalable vector graphics, OPC, SQL, ODBC, and many other functions that allow highly integrated information and control systems to be developed, whether they be large or small.

Paul Hurst of Products4Automation offers an expert view on today’s SCADA: “Flexibility is one of the major needs in modern automation. Plant operators increasingly insist that their control systems have the ability to easily adapt to new demands.”

Movicon protects plant owners’ investments because it is able to satisfy all automation application needs from field control level (PLCs, HMIs, sensors etc) right through to SCADA/MES and enterprise management levels. Thus it can provide a systems architecture that is as simple as possible, containing initial set up costs and allowing easy subsequent developments.
“Movicon is a real-time flexible platform with high levels of connectivity, capable of adapting to all modern automation application typologies, so is the only software needed in the system,” says Hurst.

Movicon includes a large number of tools for easily creating powerful visualisation and control projects and its comprehensive connectivity capabilities means simple integration with other, related systems such as MES, ERP and the web. This ability reduces initial project costs and goes on to control total lifetime operating costs.
Highland Grains has been successful over nearly forty years because of its willingness to adapt to new and changing demands. Now, with the Scotch whisky industry once again resurgent (it is worth about £5bn to the UK economy and growing at 5% a year according to the ‘Scotch Whisky Association’), it is expecting to further develop its site and facilities over the coming years. The simplicity of its control architecture and flexibility of the Movicon software should make this as straightforward and efficient as possible.

 
Products4Automation (P4A) is a specialist supplier of new and innovative software and hardware solutions to the UK market. Product ranges available from P4A include the latest touch-screen HMI’s and flat panel PCs, SCADA software and plug-ins, a wide range of SCADA enabled hardware, Alarm plug-in software for large automation systems, and a full range of Production Intelligence software solutions.

For more information please contact: www.products4automation.co.uk

Morgan Advanced Materials, a global leader in the development and application of advanced material technologies, has launched a flexible rotary distributor to help customers in the automotive industry maximise efficiencies and reduce maintenance costs.

The latest innovation from Morgan’s Electrical Carbon business, can be used in six axis robots, welding turntables and trunnions. The component allows for cumbersome cables to be replaced by a slip ring transmitter, which also comprises a full 360-degree rotating axis, with an unlimited angle manoeuvrability that eliminates defective drag chains.  As a result, the unit can offer continuous rotation. As the system does not have to operate in reverse, this can deliver cost and time savings, while offering customers greater flexibility in terms of programming.

The slip ring can be utilised for continuous rotating transmission across a host of precision applications including welding, handling and gluing. Significantly, the system can operate 24 hours a day, for between five and eight years. Effectively eliminating the need for any costly downtime or recurring maintenance works, it delivers a full return on investment in as little as 12 months.

In contrast, a traditional cable carrier system has an average life-cycle of just 12 months. At any given time, the robot is limited to +-310 degree turns in either direction.  A traditional system is also constrained by ongoing maintenance costs as a result of trailing cables and potential subsequent damage to the robot.

The endless rotating robot axis from Morgan’s Refoka^® product offering provides a comprehensive solution as the system is capable of housing both data, media and electrical currents, within a single compact interface.

Ingo Carnott, Key Account Manager – Automation, at Morgan comments: “In an on-demand environment, product optimisation and performance remain critical components of the global automotive industry. As a value-add partner to the sector, we have therefore invested heavily in developing new problem-solving tools. Critically, these solutions not only enable customers to meet engineering challenges, safely and efficiently, they also deliver wider commercial benefits as a result of their ability to boost overall productivity through improved operational effectiveness.”

The advanced technology, which has a high current >200amp and 24V power supply, provides a range of flexible programming options which can help streamline data through a fast PROFINET certified Ethernet cable/connection, or for the transmission of video signals and media such as air, cooling water, primer or oil. Crucially, the components are all contained within a single robust housing unit, offering a level of protection in line with IP67.

The technology is also supported by a remote diagnostic facility. Customers can benefit from live data analysis across the whole PROFINET-certified system.

Thanks to the internal shielding and metal housing unit, the system is fully protected, ensuring full functionality in Electromagnetic compatibility-critical environments, particularly those where welding equipment is used.

Morgan offers a range of standard solutions to meet the varied automation demands of the automotive industry, and can offer custom-made solutions to meet specific customer requirements.

For further information, please visit: www.morganelectricalmaterials.com/rotating-axis

A Dutch manufacturer of pre-packed meat products has automated its in-house logistics using an IT solution from CSB-Automation and CSB-System. The new system is helping ProMessa BV meet the needs of its customers more efficiently, with a delivery performance of over 99 percent, and therefore enhance its market position.

With the CSB solution, the entire materials flow at ProMessa has been automated – from packaging following production, to storage and picking, and loading onto trucks. In the past, goods and crates were moved manually, whereas today, state-of-the-art robotic technology, conveyor systems, sorters and the CSB software work seamlessly together to get the job done.

The software organises and monitors a network of machines, including two automatic crate storages, robot units, four automatic weigh labelling lines with connected sorters, a dispatch warehouse and a conveyor system. Integrated production scheduling ensures precise tuning of workflows in terms of time and quantity. Any important details, such as up-to-date order, production and inventory data, are captured and processed in real time. This high degree of networking facilitates fast and error-free processes and enormous productivity.

“We deliver a vast range of products to about 1,200 supermarkets,” explains ProMessa’s Managing Director Harold Rouweler. “The logistics system helps us to pick and deliver even small quantities in an efficient manner. Our customers can order any item even on short notice. Everyone who places their orders in time usually will receive the goods on the very same day.

“We have nearly doubled our output – sometimes to more than 100,000 packages per day,” he continues. “We would never have achieved such growth rates without the new logistics system, which was established in the existing buildings without any major staff increase.”

In accordance with the company’s FIFO policy (first in, first out), the software from CSB-System constantly reorganises the warehouse by re-stacking the plastic storage containers. Next, it groups together order data, products and containers, before supplying them to the picking lines for weigh labelling. It also calculates quantities and volumes, necessary material flows and optimal conveyor tracks for loading the trucks. At special CSB-Racks, staff can easily see which order is being processed, which products and quantities belong to what order, and which labels need to be attached.

“Our staff at the sorters can handle numerous orders in parallel without any errors, and pick items directly for the dispatch crates,” says Harold Rouweler. “The work stations have an ergonomic design, avoiding unnecessary motion. As a result, we can process our large variety of products in an efficient manner, irrespective of the quantities ordered by our customers. The order quantity virtually has no effect anymore on the logistics costs.”

The entire intralogistics system was designed to offer a high level of productivity and flexibility. For example, the high-performance despatch warehouse secures optimal picking of customer orders with the CSB-System generating individual sub-orders, depending on the availability of the goods. The four weigh labelling lines are capable of compiling between 5,000 and 7,500 packages per hour in mixed containers, depending on the order structure.

ProMessa can now also respond even quicker to reorders without having to build up large stocks. Daily deliveries to customers can be realised even with very short order lead times. The delivery performance is currently over 99 percent.

“This project has demonstrated the importance of choosing the right partners for the technical advancement of our production facilities,” concludes Harold Rouweler. “CSB-System and CSB-Automation are valuable partners for us because they always contribute new ideas and develop innovative, practical solutions that enhance our competitiveness sustainably.”

For more information please contact: www.csb.com

CKF Systems Ltd, the leading supplier of automated handling, robotic solutions and conveyor systems to manufacturing industry, has developed a range of cost effective robot handling cells designed specifically for those businesses currently operating a manual palletising line. The AC25, a direct replacement for existing manual operations, is exceptionally easy to install and operate and at a cost of just £80,000, will typically provide a payback in under two years.

“Our objective was to design a low cost robot palletising cell that can be installed as a standalone operation or combined for multiple feeds with a common discharge into secondary palletising operations such as spiral wrappers or pallet stacking, “explains Kevin Staines, Sales Director, CKF Systems Ltd. “All aspects of the cell are based on proven technologies and utilise user friendly interfaces for both operatives and engineers. The operational simplicity of this palletising cell means that we have addressed one of the biggest concerns of those SME’s still resistant to change; that their businesses are unprepared for the complexities of automation.”

A typical manual palletising line is, by its very nature, a labour intensive handling operation with inherent limitations in respect of box sizes, weight and restricted flow rates. The AC25 will operate at 15 cases per minute and, unlike a human operative, is not compromised by the introduction of layer cards or heavy boxes. Furthermore, current legislation restricts the maximum unit weight that an operative can lift and also defines the maximum achievable stack height on a pallet. The AC25 Robot Palletising Cell has none of these limitations, its versatility includes increased stack heights that provide better trailer utilisation, reducing transportation costs and therefore providing a subsequent environmental benefit.

Manufactured in the UK, the cell utilises an ABB 4-axis robot and industry standard equipment and comes with full support, including training and spares, a 12 month warranty and the option for a range of add-on features. It is capable of handling cases with dimensions of up 400mm long x 300mm wide x 250mm high and a net weight of 25kg. It is designed with enhanced handling capabilities and high reliability levels. The CKF Palletising Cell will handle Euro or UK pallets with layer cards as an option. In addition, the cell can easily be expanded to accommodate a series of additional modules such as vision cameras, layer cards, open-flap detection and pre-collation of boxes for increased throughputs and alternating pallet patterns.

Mike Wilson, Chairman of the British Automation and Robot Association (BARA) has welcomed this latest CKF initiative. “The pressures on operating costs and output levels and the difficulty of attracting people for arduous tasks are real threats to the long term sustainability of businesses that do not embrace automation. CKF’s AC25 is a cost effective solution that can significantly improve the overall efficiency and flexibility of a business. The cell works in a small footprint and removes all issues related to human interface such as repetitive strain problems, rest breaks and availability of labour. There is also the peace of mind of working with a proven system from an established UK provider with a long and successful history in the field of robots and automation.”

For more information please contact www.ckf.co.uk

Process control system facilitates sustainable alarm management

The alarm statistics report in B&R’s APROL provides a clear, intuitive overview and makes it easy to reduce the frequency of nuisance alarms. A sustainable approach to alarm management can relieve plant personnel and improve safety.

Clearly organized and intuitive

APROL helps users process alarms efficiently and reliably. The alarm statistics report provides an overview of alarms that is clearly organized and intuitive. It provides key performance indicators (KPIs) for efficient alarm management per the requirements of EEMUA 191, ANSI/ISA 18.2 and IEC 62682.

Fewer consequential alarms

The consequential alarm report effectively identifies cause-and-effect relationships between alarms to help minimize the occurrence of consequential alarms. APROL alarm reports are available via the intuitive web-based user interface that requires no additional software other than a web browser. With APROL, implementing alarm management could hardly be easier.

APROL helps users process alarms efficiently and reliably. The alarm statistics report provides an overview of alarms that is clearly organized and intuitive. For more information, visit www.br-automation.com