Combitool AG, based in Bäretseil, Zurich, Switzerland, is a division of PackSys Global, the world's leading manufacturer of specialist packaging equipment, and offers innovative solutions for the production of aluminum-plastic tubes. The company is planning the production of a new generation of BLM aluminium can making machines, not only to make the entire system environmentally friendly, but also to increase availability and productivity by reducing configuration and on-machine times. It is the smart sensors with IO-Link interface that make this ambitious goal possible.
Improve the detection of printed marks with IO-Link
In order to make the labels on the aluminum-plastic tube can be arranged in unison and not crooked, it is necessary to detect the position of the printed mark. Combitool AG used a photoelectric contrast sensor for detection, but the complex process and time-consuming configuration and adjustment made the sensor the ideal target for optimization.
In the past, the operator set the sensor through the button and the teach-in mode, because the parameters are rarely repeated and the frequency of change is high, each adjustment needs to be reset, even if a configuration has been used several times, it needs to be constantly set back to the original parameters, which is quite time-consuming and labor-intensive.
As a result of the optimization, the company uses sensors with IO-Link interfaces, IO-Link master modules with USB interface from Balluff BNI0073 plug-and-play connection to IO-Link process devices using only 3-conductor unshielded wires from standard M12 for point-to-point digital connection.
All parameters are stored in the controller, and even if the sensor is changed frequently, it is automatically downloaded and updated when the system recognizes a new part.
In addition to machine information and diagnostic data, all parameters can now be transferred quickly, which facilitates in-line replacement of sizes, accessories, etc. in small batches of small batches.
By avoiding tedious work such as repetitive teaching, positioning, and adjustment, the operator can save 20-30 minutes every time he changes the product.
The BTL 6 with IO-Link interface completely replaces analogue sensors
At that time, the BLM aluminum can making machine also used an analog output photoelectric distance measuring sensor to continuously detect the thickness of the material film winding and control it at a pre-set position.
In search of a reliable, non-contact, maintenance-free absolute IO-Link sensor, Combitool AG turned to Balluff and opted for the external micropulse BTL 6, which uses the hysteresis principle and eliminates the need for repeated adjustments and regular cleaning compared to analogue sensors.
With this product, the end position of the roll film can be detected in advance, so that the material film can be changed in advance without interruption of the production process.
With a transmission rate of up to 230 kB, a cycle time of 1 ms and an accuracy of up to 5 μm, the BTL 6 enables more reliable detection of the entire production process.
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