Omron's Motion Control Solution saves label manufacturer nearly $2 Million and reduces setup time by 66%.

Automobile electronics are constantly advancing, and electronic antennas on cars are an example of this. One of the market leaders in this technology is the company, BOSCH Telecom GmbH in Berlin.

With a proven history of success, Boschs innovation is the main motivation for a set of new advancements in this sector. Their latest is a new form of roof antennas designed to reduce wind noise at high speeds by incorporating spiral wire around the antenna.

Omron vision system secures quality and the success of tomorrow
To guarantee long-term success, companies are reliant on product quality more than ever. Once the individual components of the electronic roof antenna (antenna line and mechanical foot) are manually loaded, a soldering machine lays a fixed solder quantity on two plate positions. It is crucial that the solder is distributed evenly on both the upper and the lower part of the plate around the joints. The intelligent sensor visually examines the even distribution of the solder on both joints. With this examination a 100% quality is guaranteed. Omrons intelligent sensor works with a progressive scan camera. It guarantees that with an external trigger impulse, the image is captured immediately and the measurement occurs. This real time processing works at optimal speed and leads to excellent results. A monitor is also used for the system configuration and the visual inspection during the current process.

Intelligent sensor with modified object lighting
Utilizing a specially developed lighting system for this application developed by Omrons image processing partner Avicom (Berlin), the soldered joints are observed with red background lighting. In using this lighting, it was crucial that the glare of the soldered joints be removed, since shiny soldered joints affect detection. The applied lighting is critical to obtaining the correct quality results from the measurement.

All Boschs critical quality requirements in the system were met. Both the desired geometrical form of the soldered joints and their desired placement is evaluated with a good/ bad statement. They are also measuring locations where no solder may be found in order to prevent short-circuits.

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Food processing and pharmaceuticals are industries in which hygiene and absolute cleanliness have to be the focal point. Micro-organisms can multiply on equipment within a short period of time. Bacteria can flow into mechanical weak spots, such as threads, grooves and small cracks, and spread.

In cooperation with ENSINGER GmbH and Lumberg, a new approach was taken to reduce the risk of food contamination using anti-microbial material for sensor casings.

High performance plastics
ENSINGER GmbH is one of the leading European suppliers and processors of industrial plastics and high-temperature engineering plastics. Its high performance plastics are proven materials and are used extensively in machinery and plant construction in the automotive and aerospace industries, electronics and medical technology, as well as in many other sectors with high quality demands. In addition, Lumberg's core areas of expertise are development, manufacturing and sales of electromechanical and electronic components, of which connector systems and components comprise the principal part.

Antimicrobial additive Alphasan®
For the casing of the inductive sensor E2F-D, the ENSINGER plastic, TECADUR PBT, with the antimicrobial additive Alphasan® was the base material of choice. Such sensors are used in conveyor belts for food processing and filling plants, or as position controls for machine parts, e.g. in flap valves, conveyor belts, cutting tools or other moving metal parts. The Lumberg Food and Beverage product line meets stringent hygienic standards and is able to withstand strong commercial cleaning agents, harsh chemicals, as well as high pressure cleaning by use of V4A stainless-steel and PVC.

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When a Russian customer decided to build new packaging equipment for bottle wrapping, they had 3 key requirements: 50,000 bottles per hour throughput, longer machine availability and system flexibility to wrap various package sizes. With over 30 years experience in packaging systems, Novopac and Ci.ti.emme, were selected to design the new packaging line.

It was clear to both companies that the complete production process had to be continuous. Hence, fully synchronized multi-axis motion control was a must. To achieve this application, the Trajexia platform offered the best option.

The wrapping process
Fed randomly from a conveyor, the bottles are spaced, aligned and then fed in packs of 20 in full synchronization on the packaging tray. This complex task is performed by a 2-axis arm driven by two 850 W servodrives synchronized through a Cambox function. In order to avoid any collision at emergency stop the motors use absolute encoders. A third axis, driven by an 850 W servomotor and synchronized with the bottle tray, feeds a carton sheet underneath the packed bottles.

A fourth axis, driven by a 2900 W motor, unwinds the wrapping film over the bottles performing a Cambox function. Finally, a fifth axis driven by a 850 W motor cuts the film using a Movelink function. All axes are slaved to the master conveyor, which is driven by a 2900 W motor.

The motion-control system
Trajexias complete and integrated platform was chosen to handle the whole wrapping process. The TJ1 motion-control unit driving all 6 axes over the Mechatrolink II motion bus performed all complex motion tasks through simple and intuitive motion basic commands such as Cambox, Movelink and Connect commands.

The machine management, safety interlocks and operator interface tasks are performed by a CJ1 PLC and an NS8 terminal.

Modular, flexible and robust
The use of electronic synchronization allowed huge flexibility and adaptability of the machine to satisfy customer demands for various packing sizes and production rates. It is more compact and also easier to maintain thanks to the transparent communications down to the servo level. The clear separation between motion tasks and sequencing tasks also gave the machine builder greater flexibility to use other PLC brands if the end customer chooses.

Job well done
Thanks to the ease of use and the plug and work concept of Trajexia platform, the new production line was built and commissioned on schedule. Omrons fully integrated platform helps full operation at desired performance, with highest reliability. Also local or remote interaction with all devices on the machine allows full teleservicing. Trajexia makes motion easy.

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