Introduction to itrak

Transcription

1 Introduction to itrak Technology and Solution Overview Hayo Koppelmans Motion Solutions Consultant EMEA Rev 5058-CO900E

2 itrak intro 2

3 Current Technology vs. itrak Chains = Limitations Inflexible High maintenance Low performance itrak Linear Magnetic Drive Flexible Tool independence Software control Low maintenance High performance 3

4 The Value of itrak to Manufacturers Increased Throughput Traditional Machines Process options are limited Continuous and intermittent motion cannot coexist Mechanical drivetrains limit speed itrak Based Machine Faster machines because of new capabilities Continuous and intermittent processes can be mixed for maximum productivity Linear motors improve throughput 4

5 The Value of itrak to Manufacturers Minimized Change Over Time Traditional Machines Multiple tool sets Labor intensive part changes Many hours of lost production Inflexible production scheduling itrak Based Machine Single tool set Programmatic part changes Maximized production time Flexible production scheduling OEE 5

6 The Value of itrak to Manufacturers Reduced Machine Footprint Traditional Machines Extra mechanical drive trains Space required so all processes are in same time of motion itrak Based Machines Pitchless machine Direct drive tooling minimizes footprint and mass Mixing continuous and intermittent motion optimizes footprint Track shape opens up new opportunities for optimization Traditional Machine itrak Machine 10% - 50% Smaller! 6

7 The Value of itrak to Manufacturers Improved Production Flexibility Traditional Machine Long production runs required for profitability Complex supply chain Hard scheduling requirements itrak Based Machine Shorter production runs are possible, getting closer to Just In Time manufacturing Realize full potential of Connected Enterprise Flexible production scheduling 7

8 The Value of itrak The benefits to manufacturers Increased production rates 50% or more! Reduced downtime for changeovers Reduced machine footprint Shorter runs can still be profitable Reduced periodic maintenance The benefits to machinery suppliers Market leading machine output 50% or more Increased flexibility with a single design Greater focus on adding value for End Users Differentiated machine design 8

9 Technology Basis Magnets move over independently energized coils Magnets and movers have no intelligence Coils are stationary No flexing cable wear or need for slip rings Absolute positions are measured with closed loop servo control Technology can be applied to straight or curved motors 9

10 Parts of itrak Solution Exploded and Assembled itrak Solution Power and Control Module Movers Track Plates: Top and Bottom Drive and Motor Sections Bearing Rails Machine Frame 10

11 itrak Linear Module Multiphase Coils Standard length of 400 mm Stainless steel motor cover for durability Wash-down IP65 to be part of the machine Three coil lengths for the right amount of force (50, 100, 150 mm) Communication Multiphase Drives Power 11

12 itrak Curve Module Communication Multiphase Coils Power Multiphase Drives Standard arc length of 400 mm Radius of 254 mm Quarter-turn curves make layouts adjustable Stainless steel motor cover for durability Wash-down IP65 to be part of the machine Three coil lengths for the right amount of force (50, 100, 150 mm) Dedicated catalog numbers for Left and Right turns 12

13 itrak Configurations Modular & Scalable Orientation Oval Horizontal Rectangle Square Stand-Up 90 o Linear / Straight Vertical 13

14 itrak Mover Position Magnet Motor Magnet Standard mover and bearing designs are available Suitable for most applications Long life through lubrication Uses high strength steel vee wheels Customers can design their own Build to suit your application Differentiate your machine Vee Rollers Bearing Track 14

15 Power and Control Module Power supply and shunting for motor and drive segments itrak Gateway for drive communication Branch circuit protection and isolation Integrated disconnect and Emergency Stop safety circuitry Power and communication distribution Power Module

16 itrak Product Range Speeds up to 5 m/s IP65 Up to 10g Acceleration Up to 100kg Payloads Tolerances are based on standard supplied mechanics Stop Repeatability +/- 0.1 mm Mover tolerance in straight section 0.5 mm position error Mover tolerance in curves section 8 12 mm Type Width Length Fpeak Fcont Vmax Linear W050 L Linear W050 L Curve W050 L Curve W050 L Linear W100 L Linear W100 L Curve W100 L Curve W100 L Linear W150 L Linear W150 L Curve W150 L Curve W150 L

17 itrak Applications Examples Pouching HFFS Fill & Seal Collating/Grouping/Stacking Flow Wrapping Cartoning Web Converting Assembly

18 Application Examples Enables new performance levels and creative solutions to packaging line needs. Customer Testimonial IndeCart 2 High Speed Collating Machine itrak transfers incoming product to a continuous motion end load cartoner Accepts product with random spacing and syncs it First production unit sold, now taking orders 18

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20 Application Examples This technology will forever change the way that pouching is done. Roger Calabrese, Competence Center Manager, KHS Innopouch K400 Simplex/Duplex Form, Fill and Seal Pouching Machine itrak makes it pitch-less Capable of handling large one-up pouches or small two-up pouches Machine footprint & changeover times drastically reduced with itrak First production unit sold, now taking orders 20

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22 Application Examples You have to see it to believe it. Packaging stand up pouches at these speeds really benefits from the use of this new technology. Dale Andersen, President and CEO of Delkor HSP-400 High-Speed Case Packing Machine Pouches are lined up with robot to optimize cycle time Vastly increased throughput First production units sold, now taking orders

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24 Application Examples This cartoning machine is the most popular system among the ones proposed by Cama and it is now showcased in a totally new version, which includes the no-chains intelligent track system Riccardo Panepinto, Operations Director at Cama Group CL 175 High Speed Case Packing Machine itrak handles the cases using two carriers to carry each box This allows the machine to handle any size box without tool changes Machine footprint & changeover times drastically reduced with itrak Introduced at interpack 2014, now ordering second machine with itrak 24

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26 Application Examples This cartoning machine is the most popular system among the ones proposed by Cama and it is now showcased in a totally new version, which includes the no-chains intelligent track system Riccardo Panepinto, Operations Director at Cama Group CL 175 High Speed Case Packing Machine itrak handles the cases using two carriers to carry each box This allows the machine to handle any size box without tool changes Machine footprint & changeover times drastically reduced with itrak Introduced at interpack 2014, now ordering second machine with itrak 26

27 Merge & Divert 27

28 itrak to Controller Interface Gateway itrak Synchronizes with Kinetix drives, motors and encoders Uses standard motion instructions Configuration and Programing in RSLogix 5000 Compatible with CompactLogix and ControlLogix

29 itrak Programmed in Logix Programmed with Studio 5000 Logix Designer itrak AOI provides interface today Fully integrated Kinetix interface in future Each itrak mover is a virtual axis All motion commands available PCAM, MAM, etc. Full synchronization with all objects Servos, I/O, etc.

30 itrak Programming Designed for Studio 5000 and Logix Any experienced motion programmer can easily adapt to itrak Inexperienced motion users are not target accounts Configuration of the system is done through an AOI AOP is planned to alleviate some configuration Programming uses standard motion instructions Movers are configured as Virtual Axes Synchronized motion planning with any other axis Control Module (gateway) handles heavy computational requirements Managing which section has which mover Communications routing Imminent collision detection and avoidance 30

31 itrak AOI AOI provides Ethernet interface Data Time Sync Data Position Values Velocity Values Configuration Fault information Tuning Values Called in Motion Event Task to provide tight synchronization 31

32 Motion Commands 32

33 Programming with Logix Designer Sample Code is available to speed up development Application examples have been created Queuing, Grouping, Synchronizing Solves complex math and sequencing requirements Familiar tools and instructions 33

34 Motion Solutions Group itrak Products and Solutions Portfolio Power Modules Mover Magnets Position Magnets Power/Control Cables Multiple Sizes 50mm,100mm,150mm Straight, Left, Right Multiple Sizes 50mm,100mm,150mm 1 Stack, 2 Stack, 3 Stack Feedback Magnets North and South Polarity 1 Power Rating Power and Control 9 Standard Part Numbers 9 Standard Part Numbers 2 Standard Part Numbers 1 Standard Part Number 14 Standard Part Numbers Bearing Design Machine Design Mover Design Application Development Post Sales Support Standard Bearings Designs Track Plates Design and Fabrication Standard Movers Available Standard RSLogix Application Templates Warranty Support Custom Bearing Design Consultation Turn-key Machine Delivery Custom Mover Design Consultation RSLogix Programming Custom Firmware Billable Support Services 35

35 Specifications and Capabilities Wide range of forces and speeds, sized for your application Speeds up to 5 m/s Continuous: 46 N to 417 N Peak: 88 N to 793 N Absolute positioning up to 0.5 mm, repeatability up to 0.1 mm High acceleration Up to 10 g Tight mover-to-mover pitch As close as 65mm center to center Smaller tooling and more varied product handling capabilities Payloads can be up to 100 kg Bearings designed for variety of loads and long life 36

36 Return on Investment Factors to Consider Throughput Increase Product Change Time Decrease Maintenance Cost Decrease Floor Space Decrease Why itrak Wins Faster Production Speeds Reduced Downtime for Maintenance and Changes More Flexibility in Design Smaller Footprint for Machine and Parts Easy Programming Typical Payback Period: 6-24 months 37

37 Application Criteria itrak is a good fit when: Current application uses chains or belts Existing system is experiencing speed limitations Process gains from mixing intermittent and continuous motion There is a need for frequent changeovers Considering a next-generation design A pitch-less machine could add value to current processes Maintenance costs are out of control Take the leap to a better machine! 38

38 Thank you, any questions? Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. Rev 5058-CO900F