Linear Transport Systems Move Packaging Machines Forward Smaller, Smarter...water and steam from...

Linear Transport Systems Move Packaging Machines Forward

Innovation Stage | Pack Expo 2019

linear

Linear Transport Systems – combine rotary and linear technology

rotary


Linear Transport Systems – benefits

Eliminate Downtime

change lot sizes via

software functionality

Unlimited Applications

flexible use of motion &

mechanical tooling

Increased Efficiency

by enabling coutinuous

product flow

Reduced Footprint

ability to create space-

saving geometries

Reduce Time to Market

simplifies software and

hardware engineering


Linear Transport Systems – increase packaging output and efficiency

Outstanding dynamics allows

selective processing without

interrupting coutinuous product flow.

Individual movers accelerate before

and after process points and

seamlessly re-join product flow.

Products can be transported

individually or in groups.

Synchronization with selective

stopping and starting at any position.

Maximum positioning accuracy and

jerk-free accelerations.


Linear Transport Systems – reduce packaging machine footprint

Freely-selectable track layouts

and number of movers.

Individual and group

controllability

Ease of integration into existing

enviroments.

Implements motion and handling

tasks to allow new and invoative

mechanical designs.


Linear Transport Systems – reduce and eliminate downtime

Change lot sizes via software instead

of mechancial changeovers

Allows for long or short production

runs

Individual control of movers makes

lot sizes of one possible

Industrie 4.0 concepts are easlily

implemented

Able to track product throughout the

process

Linear Transport Systems – the new approach to machine design

Transfer between machines

is either controlled via a

robot or uncontrolled with

conveyors.

With conventional

conveyors, the product

tracking is lost when the

product leaves the machine.

The product must be

“rediscovered“ or

unscrambled when it

reaches the next machine.

Three machines with product handover Linear transport systems reduce footprint by

combining them into one highly efficient machine.


How can linear transport systems increase throughput per sq-ft?

Different tasks require different processing time

Traditional transport systems move all products the same distance at the

same time

All processing locations must be equally spaced

Production rate is dependent upon the slowest process plus the time to

transfer between processes

Part rate of 800/hr. (1 part every 4.5s)


1s 0.6s0.4s 4s0.2s

0.5s


Simplest solution to increase production

Reduce the longest process time

Usually detrimental to the process

Results in small production rate increases

Part rate of 847/hr.


1s 0.6s0.4s 3.75s0.2s

0.5s


Second simplest solution to increase production

More machines

Part rate of 3,200/hr. – but 4x space required


1s 0.6s0.4s 4s0.2s

1s 0.6s0.4s 4s0.2s

1s 0.6s0.4s 4s0.2s

1s 0.6s0.4s 4s0.2s

0.5s

0.5s

0.5s

0.5s


Third solution

More of every station

Further distance to transfer = longer transfer time

Part rate of 3,030/hr. (2 parts every 4.75s)


1s 0.4s0.2s 0.2s1s 0.4s 0.6s4s 0.6s4s

1s 0.4s0.2s 0.2s1s 0.4s 0.6s4s 0.6s4s

0.75s

0.75s


Best solution

Multiply the slow stations only

Fast motion with dynamically adjustable speed, acceleration and jerk

Processing locations no longer need to be equidistant

Movers can queue between, allowing for shorter transfer distance/time

3,200 parts per minute (3,000 parts per minute if process 1 is not doubled)


1s 4s0.4s0.2s 4s 4s 0.6s4sQueue

0.5s

Queue

0.2s


How can linear transport systems improve quality and throughput per sq-ft?

Slow processes can be as slow as necessary to perform the process optimally

Still achieves 3,400 parts per minute


1s 4.5s0.4s0.2s 4.5s 4.5s 0.6s4.5sQueue

0.75s

Queue4.5s1s


Linear Transport Systems – unlimited application possibilities

Push product or change spacing.

Reduce or increase product speed.

Clamp and move product.

Apply kinematics in linear motion for lifting

or pressing operations.



Can function as a distribution system,

splitting random incoming product stream

into multiple streams.

Can transport and discharge products.



Kinematics in linear motion for turning

product or closing a cap.

Synchronize random product flow to

downstream processes.


XTS – reduces time to market - modular system

motor module

control system

mover

guide rail


The modular system

The XTS motor module

motor module

control system

mover

guide rail


All in one – everything incorporated in a single mechatronic component

System properties

Max. force 100 N

80 N

at standstill

at 2 m/s

Continuous force 30 N (at < 30 °C temperature increase in the motor compared

to mounting frame)

Speed 4 m/s at 48 V DC supply

Acceleration > 100 m/s² (without payload)

Positioning accuracy < ±0.15 mm at 1.5 m/s possible within a straight module

Absolute accuracy < ±0.25 mm possible within a straight module

Repeatability < ± 10 μm (stillstand unidirectional)

Max. system length > 100 m (dependent on computing power, no system limit)

Power consumption

per motor module at

24 V DC

30 W/m for communication, electronics, position feedback

Length per infeed max. 3 m voltage supply, EtherCAT

Protection rating motor modules: IP 65

Approvals CE, UL

The XTS motor modules

All in one – everything incorporated in a single mechatronic component

180° curve

(clothoid)

in 500 mm

-22.5° curve

in 250 mm for

Ø 1273 mm

45° curve

in 250 mm for

Ø 637 mm

~200 mm

~310 mm

22.5° curve

in 250 mm for

Ø 1273 mm

250 mm straight • Motor, Coil Package

• Power Electronics

• Position Feedback

• EtherCAT

• Power Supply

• Mechanical Interfaces


Flexible track layouts

S-shape

Square

Rectangle

Straight, open track

… and others

Track sections can be moved.

Exchange movers between tracks.

Motor modules and movers remain fully

operational at all times.

Maximum flexibility without downtime.

Small footprint combined with maximum

parts buffer capacity.

XTS Track Management – new flexibility in motion


For demanding environmental conditions

in the food and pharmaceutical industries

IP 69K protection when assembled

Chemical resistance against

chemicals, acids, alkalines

aggressive cleaning agents

water and steam from high-pressure

spray

Hygienic design without any hidden

corners, edges or undercuts

easy to clean

XTS Hygienic: high flexibility and optimized cleaning


The modular system

System solution – guide rail and movers

motor module

control system

mover

guide rail

System solution – guide rail and movers

Comparison

Beckhoff system solution HepcoMotion system solution

higher loads

higher process forces

maximized service life

10kg loads

highest level of dynamics

low costs

lubricant-free

0.8/1.25kg load

Application example:

Cosmetics filling line – Groninger & Co. GmbH, Germany

Application example:

Optical inspection system – GEFASOFT, Germany

The modular system

The control system

motor module

control system

mover

guide rail

PC platform The XTS extension in TwinCAT 3

automation software decouples servo

algorithms from the hardware components

and calculates them centrally.

Control system – software and programming

Mover 1 Mover 2 Mover m

Virtual

connection

PLC

1st axis

TwinCAT Motion Control, PTP

2nd axis mth axis


Regarding application programming, a

mover appears like a “normal” servo

axis.

All motion control functions are available,

for example:

flying saw

electrical gear unit

cam plates

Functional extensions handle typical XTS

requirements:

automatic accumulation

collision and jerk avoidance

centrifugal force limitation


XTS extension / soft drive

NC functions

Application software

Customer application



XTS Configurator and XTS Viewer

Intuitive online visualization of

the moving movers in 2D.

Diagnostic and simulation tool.

System configuration is

automated to the greatest

possible extent.

Axis and control parameters

of the movers can be copied.

Xplanar – The NeXTStep


XPlanar system:

flying magnets with six degrees of freedom

XPlanar tile

highly integrated

flexible use

simple implementation

XPlanar floor

needs-based layout

choice of surface finishes

no wear

XPlanar Mover

passive component

no electroncs

no mechanics

easy to clean

XPlanar mover:

reaches every point in every way

carries loads of up

to 6 kg – even more in

a group

tilting by 5° for transport-

ing and handling liquids

special planar modules

for rotating movers by

360° – increased flexibility

lifting, lowering, weighing:

variable in height by up

to 5 mm

wall and ceiling travel:

vertical and upside down

6

5°

360°

two-dimensional move-

ment and positioning at

up to 4 m/s

Beckhoff Automation LLC

Headquarters

13130 Dakota Ave

Savage, MN 55378

USA

Contact

Phone: 952-890-0000

Fax: 952-890-2888

E-Mail: [email protected]

Web: www.beckhoffautomation.com

© Beckhoff Automation GmbH & Co. KG

All images are protected by copyright. The use and transfer to third parties is not permitted.

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE® and XFC® are registered trademarks of and licensed by Beckhoff Automation

GmbH. Other designations used in this presentation may be trademarks whose use by third parties for their own purposes could violate the rights of

the owners.

The information provided in this presentation contains merely general descriptions or characteristics of performance which in case of actual

application do not always apply as described or which may change as a result of further development of the products. An obligation to provide the

respective characteristics shall only exist if expressively agreed in the terms of contract.


Linear Transport Systems Move Packaging Machines Forward Smaller, Smarter...water and steam from...

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