To ensure that flow-wrapping and cartoning machines can be used flexibly, it is important that the system can be optimally adapted to changing packaging formats. Rovema relies on monitored format adjustment with the help of the AP10 electronic position indicators with IO-Link from SIKO.
Powdered milk formula for babies is a sensitive product that needs to be filled gently and safely into appropriate film pouches and outer packaging. Rovema offers Comprehensive turnkey systems from primary packaging in tubular bags to presentation-ready secondary packaging for sales and tertiary packaging for transport.
For its cartoning and flow-wrapping machines, Rovema relies on the AP10 electronic position indicators with IO-Link interface from SIKO for monitored and safe format adjustment. Up to 40 adjustment points may be required within a turn-key system of this type, as designed for the packaging of infant formula, in order to adapt all functions to a product variant. Adjustment with purely mechanical position indicators is very susceptible to errors and inaccuracies. With the AP10 from SIKO, position indicators can be used as IO-Link devices. Easy to integrate into the machine control system.
„IO-Link is a communication standard that is becoming increasingly popular in the automation sector and is already being used more and more by us as an interface for sensors and actuators. It was therefore obvious to consider this for format adjustment as well and to enquire with SIKO. We already have many years of constructive co-operation in the field of mechanical position indicators.“
Ingo Hamel, Head of Innovation R&D at ROVEMA
From powder to outer carton
In the complete system mentioned at the beginning, Infant Formula is used in powder form in Pack sizes from 200 to 800 grams packed. According to the respective packaging sizes all 40 adjustment points along the system to the new dimensions. Most of the adjustment points are located in the area of cartoning and final packaging, less with the flow-wrapping machine.
For a new format, the corresponding recipe is selected in the control system, whereby all electronic position indicators receive the new set values directly via the IO-Link interface and show them clearly on the backlit display. The LEDs on the displays switch to red immediately, as the current position is no longer correct. The operator now mechanically sets all the corresponding points to the new values.
Another ergonomic advantage: the AP10 uses LEDs and the LCD with corresponding arrows to indicate the direction to the setpoint, so that it is clear where the operator needs to adjust. If the position and target values match exactly, the LED display changes to green: position reached. The advantages for the operator: no more paperwork, no more long lists of values that need to be ticked off and documented, just All values are already available electronically and are transmitted directly to the position indicators.
Adjustment is also faster and safer, as the Clear feedback from the LED lights is. The system can only be restarted when all the corresponding position indicators light up green. In the meantime use approx. 50 per cent of Rovema customers This option for monitored format adjustment in cartoning and end-of-line packaging technology.
IO-Link is on the advance
IO-Link is a Communication standard, which is gaining ground internationally. Anyone who uses IO-Link for their automation, benefits from many advantages. As a standardised communication protocol that is subject to an international standard, IO-Link is manufacturer-independent. Devices and masters can be developed accordingly as communication participants.
Integration is possible via simple Point-to-point connections at the lowest network level and the wiring effort is extremely low compared to fieldbus interfaces. The AP10 displays are considered IO-Link devices, which are each connected to a port on an IO-Link master, which usually has eight ports.
From the master, communication with the control unit takes place via another High-performance protocol, in this case SERCOS III (EtherNet/IP is also frequently used at Rovema). The reasons for not using EtherNet/IP for communication across the board, for example, are as follows Moritz Müller, Product Manager PositionLine at SIKO: „IO-Link is the essential More cost-effective interface, which also has significantly lower wiring requirements and is therefore easy to connect.“
There is also a Simple diagnostic function. IO-Link quickly shows which device may have a fault or needs to be optimised. The position indicators can be replaced during operation without having to laboriously disconnect an entire network ring. Thanks to the star-shaped plug connection to the IO-Link master, the affected device can be Simply unplug the device and replace it with a new one. The parameterisation can then be loaded directly from the IO-Link master into the new (identical) device and thus adopted.
Source: Rovema
