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GuardLogix在轮胎行业的应用
解决方案
基于罗克韦尔自动化产品的解决方案，其中包括：
• MAXX系列全自动裁断机和成型机
• 物料自动装卸系统，如自动卸胎
• 用于精确定位成型鼓、裁断装置和传送带的22台伺服驱动器
• 用于控制胎面胶张力的驱动器
• 用于实现安全和运动控制的Allen-Bradley GuardLogix 控制器
结果
• 将每个轮胎的成型阶段制造从50至60 秒缩短到38秒
• 使得OEE达到80%以上成为可能
• 自动化操作可省略了一部分人工操作
• 冠带缠绕速度从 6m/s 提升到 8m/s
• 在单次连续运动中即可完成内衬层胎侧预贴合组件与胎体帘布的贴合
• 生产率、安全性和人体工学并重
• 汉堡“轮胎技术 2009”商展会期间获得“创新和卓越奖”
• MAXX 巩固了 VMI 的市场领先地位
背景
速度、质量和安全是生产汽车轮胎的要义所在。因此，VMI Holland在2009 年推出了新的专用机床产品线MAXX，该产品线能够帮助轮胎制造企业大幅提升投资回报率。MAXX受到了热烈的欢迎：在德国汉堡“轮胎技术2009”商展会期间，VMI Holland被授予“创新和卓
越奖”。
位于Epe的VMI Holland的研发经理 Jan Grashuis 及其团队共花了两年时间将原始概念转化为 MAXX 工程样机。“我们希望通过实施新型机电一体化机器概念来使质量更上一层楼。”Grashuis解释道，“我们的目标是同时在尽可能多的领域内获得最大程度的改进。你甚至可以理解为，我们又重新进行了一遍基础工程设计。我们也花了很长时间深入思考新MAXX机器产品线背后的基本原理。设计这一新机器概念的同时，我们吸收了VMI在过去十年间积累起来的所有实践经验。因此，我们现在得以提供
今日自动化 2013年9月 | 33
现 场
应 用
一种集质量、人体工学、易用性、速度、安全和生产率于一体的机器，这些成就，一定程度上归功于罗克韦尔自
动化。”
面临的挑战
轮胎成型机(TBM)是汽车轮胎生产过程中最重要的元素之一。轮胎成型机用于将一系列胶部件，如胎面、胎侧内衬层等，通过导开、裁断、贴合等工艺制成生胎。
各胶部件从(工字轮等)料卷架上导开，依次在鼓上贴合各层胶部件。在本阶段中，材料的供给精度、长度以及定位非常重要。这些可变因素由TBM中的摄像机监视。Grashuis解释道：“生产汽车轮胎的一个重要方面是加工每个轮胎所花的时间。这个时间应尽可能短。不久之前，TBM加工每个轮胎需要50至60 秒。而新型MAXX TBM则可在短短38秒内完成此过程。
客户可实现高达80%的OEE(设备综合效率)，能否达到此效率在一定程度上取决于客户的料卷尺寸及尺寸变更次数等可变因素。更短的周期时间加上更高的OEE即意味着更大的输出量。MAXX机器完全无需手动操作，操作员的主要任务是装载材料轴。许多重要参数实施配方控制，因此准确性和重复性极佳。
解决方案
通过伺服控制系统，鼓在轨道上实现了直线运动，在缩短周期时间上发挥着极大作用。凭借直线伺服技术，这一过程变得更加快速、更加精准。
VMI使用22个伺服轴控制MAXX TBM中所有不同运动。带有集成运动控制模块的Allen-Bradley ControlLogix控制器与Allen-Bradley Kinetix伺服驱动器共同控制所有不同单元的同步运动过程。冠带缠绕工艺阶段，加快过程速度同样非常重要，轮胎制造商希望冠带条贴合时也要对张力实现可控。
取得的成果
由于速度的提高，对控制器的要求也日益严格。事实证明，采用罗克韦尔自动化技术的冠带条张力控制是极佳的解决方案。最终带来了双倍的运转速度。最初运转速度为4m/s，后来提升至6m/s，而新型机器则达到了8m/s的
速度。
伺服技术的应用同样使贴合或拼接过程更加精准、更加快速。过去，操作员需要在此步骤中手动操作某些元件。
速度的提升同样适用于预复合件和胎体层的应用。在MAXX中，这些操作在单个运动中执行，部件逐个连续快速贴合。另一个由手动操作改为机器人操作的过程是将三角胶装载到机器中以及成品生胎的自动卸胎搬运。这些改动也有利于节省时间，并且有助于改善员工的工作环境。
安全
为了最大程度地降低操作员被卷入机器运动部位的可能性，我们对设备整体实施了功能性风险评估，风险评估的结果表明，参照安全标准EN ISO 13849-1，设备安全性性能等级需要达到PLe级别，根据风险评估结果，设备安装了一系列相应的安全设备。
在员工可能接近机器移动部位范围内的情形下，采用各种光幕、门开关和激光扫描仪进行预防。这些安全设备与罗克韦尔自动化的安全远程I/O-1791 DS/ES CompactBlock Guard I/O模块相连。这些I/O模块再通过网络与 GuardLogix控制器进行通信，这款控制器是利用单个控制器同时监控安全功能与“常规”运动控制功能的安全 PAC。
其它信息
www.rockwellautomation.nl
以上仅说明VMI Holland使用罗克韦尔自动化产品和服务以及其它产品所取得的成果。其他客户取得的成果可能会有所不同。
位于 Epe 的 VMI Holland 的研发经理 Jan Grashuis 及其团队共花了两年时间将原始概念转化为 MAXX 工程样机

控制与信息融合，实现全厂最优化和提高机器制造商机器性能

了解更多信息 ControlLogix可编程高性能自动化控制器概述 [PDF] 集成架构概述 [PDF] NetLinx选型指南 [PDF] PowerFlex 低压交流变频器简介 [PDF] 通过控制与信息系统的融合，集成架构可实现工厂级优化、机器制造商机器性能和可持续生产，以它为基础，您可以： 通过更好的资产利用率和系统性能来提高生产效率 通过轻松访问工厂范围的可执行信息，促进 全球化 通过延长产品生命周期和提高资产利用率，支持可持续发展 通过提高系统灵活性和缓解技术风险培育创新 基于 5 个业界领先的功能和 5 项核心技术，集成架构使最终用户和机器制造商以极具竞争力的方式响应动态需求。 业界领先的功能包括： 多领域控制：该功能采用通用设备与标准，适用于所有自动化应用。 可扩展的尺寸：按产品、架构和核心多领域控制功能提供规格适当的产品 EtherNet/IP：面向企业和工业应用项目的单一  友好网络 实时信息：控制系统和业务系统共享的可执行数据 知识集成：旨在最大限度利用和保护知识产权的设备和系统集成 核心技术包括： Logix：具有通用控制引擎和开发环境的可扩展、灵活的可编程自动化控制器 Kinetix：世界一流的高性能运动控制 Stratix：可满足任何应用项目和网络要求的可扩展网络解决方案 View：为每个行业、应用项目和制造环境提供关键实时数据的可视化产品 PowerFlex：适用于从低压到中压、从简单到复杂的马达控制 利用集成架构这一可无限优化工厂的创新自动化系统，最大程度发挥生产操作的潜力。

Tissue industry challenges addressed by open and scalable software solution coupled with effective relationships in technical development

Pulsar Srl, founded in 1989, is based in Casbmaggiore, near Bologna, in the heart of the “packaging valley” of Europe.

Its primary activities are based around the engineering, production and creation of conveying and transportation solutions. It also produces specialised automatic machinery for use in the tissue sector, including feeding, packaging and sorting for rolls and packages of toilet paper and paper towel, machinery for processing and packaging folded paper products and product movement units.

In just a few years, Pulsar has built more than 230 systems and eighteen complete plants for major tissue manufacturers.

Its continuous studies on the improvement of production line management has led it to create ideal hardware and software combinations that can manage and optimise entire lines integrating machinery with transport systems.

The company’s innovative ‘Layout Simulator’ software can design new systems by comparing process machinery present on the market and then simulating its productive capacity.

To this end, users can see various options aimed at specific production needs in real time and then buate the true value of their investment.

In a more recent development, Pulsar has developed the ‘Reds Platinum System’ a platb for SCADA systems –specifically designed for the measurement of Overall Equipment Effectiveness (OEE) in the tissue converting industry – which uses various elements of the FactoryTalk® Software suite from Rockwell Automation.

Challenge

According to Angelo Bertini, General Manager at Pulsar: “The measurement of production line efficiencies in the manufacture of consumer goods is a major factor towards increasing competitiveness.

The tissue industry does not escape this logic; so the provision of a platb dedicated to the converting industries will give users a facilitated approach to measuring these all-important OEE figures.”

These measured variables, upon which the efficiency figures are calculated, include basic machine availability, product quality compared to overall production volumes, machine downtimes and transition times, either between production runs or, indeed between events such as unplanned downtime and stoppages.

According to Bertini: “The primary issue faced by the tissue industry is the niche nature of its operations; with limited manufacturers and limited machine and service suppliers. If companies in this industry want to implement efficiency platbs, they have to ask for the services of industry experts and then apply standard platbs in order to gradually develop the structure of the data collection and analysis required. These experts then, in turn, have to be told by the manufacturer which beters are to be monitored, where they are generated and how to record them.

“The process of creating such a platb,” he continues, “requires a series of cross-functional skills which are rarely in place within the software houses that normally develop these types of platbs, especially the bespoke skills and knowledge relating to the unique facets of the tissue industry. In addition to IT and data analysis skills, the developers also require knowledge about process, automation and IT infrastructures. Besides the identification of the data to be monitored, one also has to identify the availability of this data along the line, the bs of extrb and the subsequent communication to the analytics platb.”

Solution

Combining its knowledge and expertise in the tissue production process, automation and regarding the different machines and equipment currently being used in these lines, Pulsar has developed a dedicated OEE measurement platb for monitoring tissue converting lines, leaving the integrator only simple adaptations for specific applications.

The ‘Reds Platinum System’ is structured in such a way that it can take into account the process steps to be controlled, the machines involved and the beters that must be collected and monitored for the calculation of the OEE of the lines.

Developed using FactoryTalk View, FactoryTalk Metrics, FactoryTalk VantagePoint^® EMI and FactoryTalk Transb Manager software from Rockwell Automation, the ‘Reds Platinum System’ has benefited from this choice of software for multiple reasons. “In the first instance, Rockwell Automation is a brand leader in the field of industrial automation, Bertini explains.

“We also appreciate the worldwide presence of the company and the support possibilities no matter where we are. Of particular importance is the fact that all of the FactoryTalk software platbs we are using have been specially developed for each of their individual purposes: FactoryTalk View for HMI development, FactoryTalk Metrics for OEE measurement, FactoryTalk VantagePoint for inbation delivery and reporting and FactoryTalk Transb Manager for transb integration and management.”

Pulsar also sees the benefits of hardware and software being tightly integrated.

“We have seen much easier integration of the supervision platb with the automation components from Rockwell Automation, with no need for conversion cards or translation software,” Bertini explains. “The ability to access the partnerships that Rockwell Automation has developed, with companies such as Cisco, for instance, is incredibly attractive when it comes to the configuration of communications systems and security protocols; or with its other partners for jobs such as the network realisation and implementation or service.”

Results

By developing and deploying a system based on the FactoryTalk suite from Rockwell Automation, Pulsar has created an extremely attractive platb for business improvement.

The use of FactoryTalk software and its very tight integration with Allen-Bradley control products means that the solution is easier to install and can start delivering data very quickly after deployment. The system is capable of interrogating hardware from other vendors, but this requires additional hardware and software for communication, which ultimaby increases complexity and costs.

“Within this development,” Bertini adds, “we have defined a strategy in the area of smart machines and tools and we have already seen dramatic developments occurring within the realms of the IIoT (Industrial Internet of Things). We strongly believe in this evolution, which is why we have developed this system.  With the help of Rockwell Automation and its commitment to the Connected Enterprise, we see the collection of data and subsequent interrogation and disbursement of inbation as the norm rather than a luxury.

“Another reason we went with Rockwell Automation,” Bertini concludes, “is that in Italy, we found a group of professionals with whom we subsequently became friends. We had complete support, including tools and technology ‘loans’ for application development. We get great support from Rockwell Automation in Italy and in the EU and now we are heading into the USA. Their approach differs compared to other suppliers, in that they are really willing to support development of projects. They don’t just make the tools available, they also offer significant levels of help, which is not something I can say for some of their competitors.”