Automotion Spec. Issue Packaging MM-E01409.115

Ultrafast Automation
reACTION Technology
The B&R Technology Magazine
05.14
Industrial PC Panel PC 900 Multitouch
X20 assembly line Installed, switched-on and ready
Image processing An eye for detail
ISO 50001/EN 16001 Energy Management
Focus your energy
on new growth
ISO 50001/EN 16001 Energy Management
Focus your energy
on new growth
` APROL EnMon Out-of-the-box solution for
ISO 50001 or EN 16001 energy management
` Improved energy efficiency shows up on the
bottom line
` Maximum flexibility with very little engineering
` Ultimate scalability the system grows with you
Perfection in Automation
www.br-automation.com
editorial
01 05.14
Dear Reader,
Automation technology certainly has its work cut out for
it. On top of ecological concerns, plants and production
lines are under increasing pressure to make more effi-
cient use of their resources. Automation technology
providers are called upon to help machine builders re-
spond more flexibly to a wide variety of customer re-
quests and efficiently produce each machine variant in
smaller quantities. The result is a continuously expand-
ing range of products.
B&R offers the key to mastering all of these demanding
challenges: Scalability+. The complete integration of all
software and hardware components opens the door for sustained, measurable results
and streamlines development down to an absolute minimum. At the same time, mechan-
ical cam systems are being replaced by more intelligent and flexible electronic solutions.
Scalability+ allows machine builders to choose whatever hardware and software best
meets their current needs. When the needs change, the solution can simply be scaled
along with them while taking full advantage of previously completed development work.
In a growing market like Turkey, our goals are to play an active role in the advancement
of machine manufacturing standards and to introduce machine builders to the many
advantages of Scalability+ and fully integrated automation. One thing is for sure: We
will continue to be a driving force that shapes the future of the Turkish automation
market delivering our customers world-class solutions with no compromises. That is
the not-so-secret key to our success.
Happy reading!
Adnan Gla
General Manager, B&R Turkey
Publishing information
automotion:
The B&R technology magazine, Volume 13
Online version:
www.br-automation.com/automotion
Media owner and publisher:
Bernecker + Rainer Industrie-Elektronik Ges.m.b.H.
B&R Strasse 1, 5142 Eggelsberg, Austria
t +43 7748 6586-0
automotion@br-automation.com
Managing Director: Hans Wimmer
Editor: Alexandra Fabitsch
Authors in this issue:
Emelie Bockasten, Peter Kemptner,
Stphane Potier, Franz Joachim Romann,
Raimund Ruf, Wolfgang Seiss
Graphic design, layout & typesetting:
Linie 3, www.linie3.com
Printing: VVA Vorarlberger Verlags-
anstalt GmbH, Dornbirn
Published at: B&R Strasse 1
5142 Eggelsberg, Austria
Cover photo U1: B&R
All articles published in this magazine are protected
by copyright. Translation, reproduction and
duplication are prohibited without the expressed
permission of the publisher. B&R assumes no
liability for any errors they may contain.
13
08 03
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contents
cover story
03 Ultrafast automation
Performance boost without additional costs
reACTION Technology reduces response times
to 1 s using standard hardware
news
07 Fast, fanless and flexible
State-of-the-art processors give new Panel PC 900
maximum performance, multi-touch displays and new
sizes make flagship system more versatile than ever
13 Span up to 100 meters with Smart Display Link 3
Operating an HMI panel up to 100 meters away from
a PC is no longer a problem thanks to Smart Display
Link 3 from B&R
18 openSAFETY for embedded systems
Add integrated safety technology to any embedded control
solution with openSAFETY and POWERLINK
19 Record: 23,000 downloads of POWERLINK stack
Open source strategy thrives in industrial environments
23 Automation Studio 4 integrated with Team Foundation Server
B&R integrates Team Foundation Server in Automation Studio
to provide source control essential to team development
27 B&R Germany under new leadership
Markus Sandhfner takes over as general manager
report
08 Intelligent cameras with an eye for detail
LIBA skillfully overcomes textile industry challenges with
Cognex cameras featuring an integrated POWERLINK interface
14 Technology to protect the worlds oceans
Ship control systems ensure efficient, safe and environ-
mentally friendly operation, S-two relies on robust B&R
automation to build them
20 Installed, switched on and ready to go
B&R continues its revolution of I/O control and safety
systems with state-of-the-art X20 assembly line built in
cooperation with Stranger
24 Lower TCO for more competitive machines
perfact::mpa provides machine builders and operators
secure and reliable remote access for centralized monitoring
and maintenance
28 Good things come in right-sized packages
Using B&R technology, Packsize provides custom-fit
packaging potentially saving hundreds of squares miles of
forest each year.
Ultrafast
automation
Control technology
cover story news technology report 03 05.14 03
reACTION Technology reduces response times in industrial automation applications down to
1 s. B&R has designed this new ultrafast control technology using standard hardware that
can be programmed in accordance with IEC 61131 standards. The result is an immense increase
in performance without the downside of additional costs.
In many applications, control speed has a direct impact on prod-
uct quality. When forming PET bottles, for example, pressure must
be controlled very precisely, explains Anton Meindl, manager of
B&Rs Controls business unit. The greater the control precision,
the thinner you can make the wall of the bottle. Other examples
include the high-precision speed and position control required in
injection molding applications. The printing industry is another
area where high-speed control functions are essential. When pa-
per is fed into a machine, the edge needs to be detected at a very
fast speed, says Meindl. The list of applications that could poten-
tially benefit from ultrafast response times is virtually endless.
Conventional I/O technology operates with a minimum response
time of around 1 ms. A millisecond is no longer fast enough for
some applications, notes Meindl. In filling stations for bottled
beverages, the control technology needs to process the signal
from the fill level sensor faster in order to achieve optimal results.
Response times in a conventional solution are influenced by a
number of factors such as network performance, or the number of
nodes on the network, as well as network traffic and controller
performance. With conventional signal processing, the input driv-
er in an I/O module reads the input signal and converts it into a
logic signal. This signal is then sent over the network to the cen-
tral PLC. The PLC processes the signal and sends it back to the
module. The output driver once again converts it and sends it to
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Anton Meindl
Manager of B&Rs Controls business unit
Distributed automation systems using reACTION Technology are advancing into a whole new
dimension of high-speed control.
cover story news technology report 04
where it is needed. With this approach, there is no way to achieve
response times much below the millisecond range.
1 s response time
When we developed reACTION Technology, our goal was to accel-
erate signal processing by integrating as much of it as possible
directly into the I/O modules themselves, says Meindl. At the
same time, we wanted to do so without sacrificing the benefits of
centralized software management. This new B&R solution cuts
the delay between the time the input signal is received and the
time the control signal is sent down to 1 s. The technology itself
is based on I/O modules with integrated FPGA chips. We used
FPGA chips because of their ability to process signals quickly in
parallel, explains Meindl. With around 10 connected function
blocks, the processing time in the FPGA is around 0.8 s.
FPGAs programmed quickly and easily
One challenge B&Rs developers faced was the difficulty typically
associated with programming FPGAs. We found a very good solu-
tion to this problem, says Meindl. Machine builders can now man-
age and program FPGAs in the familiar Automation Studio develop-
ment environment. They do so by developing programs and
parameters in the form of IEC 61131 function blocks; communica-
tion between I/O and CPU tasks is handled conventionally through
the exchange of process variables. Logical operators like AND, OR,
XOR and NOT can be used, as can arithmetic operators such as
ADD, SUB, MUL and DIV as well as flip-flops, PWM, comparator func-
tions and counters. The connections created with function blocks
can be tested just like regular control code. Simulation is possible
by executing the modules on the controller. If everything works as
planned, the software function is then assigned to the respective
hardware component in the Automation Studio hardware configura-
tion. Using the same easy approach to software development that
B&R customers are accustomed to, reACTION Technology opens up
a whole new dimension of speed, says Meindl. In the interest of
making applications as universal as possible, function blocks can
be loaded to the modules at any time for local execution. P
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cover story news technology report 05 05.14
The advantages
> Response time of 1 s
> Massive reduction of PLC load
> IEC 61131 programming
> Centralized program management
> Integrated parameter management
The FPGAs are programmed using the function block
editor in B&Rs Automation Studio engineering platform
using corresponding reACTION libraries.
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Flexibly faster with reACTION Technology
reACTION Technology integrates signal processing directly in the
module, taking the system bus and central controller out of the
response time equation. reACTION Technology always offers the
same ultrafast performance, says Meindl. Other solutions on the
market either dont offer the same speed or impose unnecessary
restrictions on the machine builder with regard to flexibility and
programming. With signal processing using reACTION Technology,
the input driver samples the input signal with a resolution of 20 ns
and converts it to a logic signal. The FPGA then processes the
signal with a cycle time of up to 1 s. The result is sent back to the
I/O modules output driver. The module converts it and generates
a physical signal. In other words, the FPGA assumes responsibility
for certain control functions and reduces the load on the PLC.
Since reACTION Technology takes on a significant portion of the
processing load, a smaller PLC can be used, says Meindl. This
means that machine builders can achieve microsecond control
responses using a controller that operates in the millisecond
range. The user now decides the size of processor to be used
based on the average load of the application rather than the peak
speeds required by a few specific functions, adds Meindl.
Ultrafast modules, ultrafast control
reACTION Technology is available on both X20 and X67 I/O modules,
as well as on the new X20 compact controllers. Three modules with
different I/O configurations are available, including two X20 mod-
ules (X20RT8001 and X20RT8201) and one X67 module (X67BC81RT).
IP20-rated X20 modules each have four digital inputs with variable
input filters and another four configurable digital I/O points with a
physical conversion time under 2 s. The X20RT8201 module has
two additional analog inputs (+/-10 V) with 12-bit resolution and a
5 s conversion time. The X67 module features IP67 protection and
offers two 24 VDC digital inputs, three 5 VDC inputs and four con-
figurable I/O points. In addition to the two analog inputs, an analog
output (+/-10 V) with 12-bit resolution has also been integrated.
B&R offers reACTION Technology on two compact controller mod-
els, the X20CP1381-RT and X20CP1382-RT. These compact con-
trollers are available with 200 MHz or 400 MHz processors. Depend-
ing on the variant, up to 256 MB RAM and 16 kB nonvolatile RAM is
available. A built-in flash drive is available to provide up to 4 GB of
application and data storage. The controllers come equipped with
Ethernet, USB and RS232 interfaces. In both performance classes,
integrated POWERLINK and CAN interfaces are also available.
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Video:
Apple under fire
B&R offers reACTION Technology for the I/O modules in both its X20 and X67
series (photo), as well as the compact controllers in the X20 system.
Fast, fanless and flexible
Panel PC 900 with multi-touch:
The new flagship system from B&R
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By taking advantage of state-of-the-art
processors up to and including Intel
Core i7 technology the new Panel PC
900 with multi-touch functionality offers
the absolute highest level of total comput-
ing power. Combining new display sizes
with multi-touch operation, B&Rs new
flagship system is more versatile than ever,
even offering full compatibility with the
previous device generation. The Panel PC
900 takes full advantage of the state-of-
the-art projected capacitive touch screen
also used in the Automation Panel wides-
creen display series. With an edge-to-edge,
anti-glare glass surface and high-resolution
monitors, maximum functionality and an ad-
vanced design have been integrated into a
single operator panel. Displays ranging from
15.6 to 24 with Full HD resolution ensure
that every possible requirement is covered.
Safe with multi-touch
These multi-touch displays allow new and
innovative user interactions, such as zoom-
ing with two fingers or quickly paging for-
ward with swipe gestures. In addition, two-
hand gestures for critical or potentially dan-
gerous operations provide an effective way
of preventing unintentional operator errors.
Compatible
Systems in the Panel PC 900 series are
available as widescreen displays in addi-
tion to the traditional 4:3 format. Equipped
with an analog resistive touch screen and
display sizes ranging from 12.1 to 19,
Panel PC 900 single-touch systems provide
full compatibility with the previous device
generation with respect to screen resolu-
tion and dimensions.
Fanless
Many Panel PC 900 variants can be operated
without fans. Used together with SSD drives
and/or CFast cards, these systems com-
pletely eliminate rotating components, mak-
ing maintenance work such as regularly re-
placing the air filter a thing of the past.
The Panel PC 900 is available in a wide range of sizes and configurations.
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Image processing
Current trends in the textile industry present three key challenges, which LIBA has skillfully
overcome using the latest technology. The machine builder has further improved process
reliability, while also optimizing raw material consumption and simplifying quality control. This
success is owed in large part to LIBAs implementation of Cognex cameras featuring an integrated
POWERLINK interface as demonstrated by three of the companys latest developments.
Intelligent
cameras
with an eye
for detail
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Todays image processing systems are able
even without an image processing PC to
recognize complex errors that could previ-
ously only be discerned by the human eye.
They also provide data that makes it easier
to document and analyze production pro-
cesses. A high level of integration makes
the cameras used in these systems very
easy to adapt to new requirements for
measurement and inspection. It is there-
fore not at all surprising that more and
more of the worlds most innovative ma-
chine manufacturers are using integrated
image processing systems to gain a clear
advantage over their competition.
More than meets the eye
Real-time integrated vision
Incorporating intelligent cameras into a
machines architecture has recently be-
come a whole lot easier. Thanks to the part-
nership between B&R and image process-
ing specialist Cognex, intelligent Cognex
In-Sight 7000 cameras are now available
with a POWERLINK interface. The integration
of the POWERLINK standard into the Cognex
Connect communication package and of
the cameras into the Automation Studio
development environment makes it pos-
sible to incorporate image processing sys-
tems into POWERLINK networks and con-
nect them to B&R controllers. Equipped
with POWERLINK interfaces, Cognex cameras
are a seamlessly connected element of the
overall B&R system. This integration reaches
so deep that the user sees no difference be-
tween B&R components and the Cognex vi-
sion system. The cameras firmware and
parameters, for example, come directly
from the controller. Since standard Ether-
net protocols can also just as easily be
transferred via POWERLINK without impact-
ing cyclic data traffic and real-time behav-
ior, an extra Ethernet interface is not
needed to configure the cameras (this is
done with the Cognexs In-Sight Explorer
configuration tool) or to call up images for
documentation and analytical purposes.
Image processing and automation
systems converge
For us, the clear advantage of this inte-
gration is that, since our machines are al-
ready fully equipped with B&R controllers,
POWERLINK is the only communication bus
we need, which allows us to keep wiring to
a minimum, says Wolfgang Jahn, manager
of control technology at LIBA. Combined
with the fact that the bus is deterministic,
this is one of the main reasons we opted to
base our image processing system on In-
Sight cameras with a POWERLINK interface.
Customer recommendations further solidi-
fied this decision.
The move has strengthened LIBAs already
excellent position among warp knitting
machine builders around the world. The
companys leadership was recently recog-
nized when its new self-healing Multi Com-
pact woven fabric was awarded the Tech-
textil Innovation Prize in the category New
technologies. This success did not hap-
pen by chance. After all, LIBAs declared
goal is to identify industry trends at their
earliest stages and offer the advanced
solutions necessary to prepare their cus-
tomers for tomorrows requirements today.
Earlier detection and prevention
of production errors
With the development of three new image
processing solutions based on In-Sight 7000
cameras with a POWERLINK interface, LIBA
has remained true to its successful strategy.
The cameras ensure that production errors
are detected earlier, which minimizes their
negative effects. At the same time, they
also make documentation faster and easier
than ever before. One of the first to profit
Thanks to the partnership between B&R and image processing specialist Cognex, intelligent Cognex
In-Sight 7000 cameras are now available with a POWERLINK interface.
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Wolfgang Jahn
Control Technology Manager, LIBA Maschinenfabrik GmbH
When it comes to the communication bus, we rely
exclusively on POWERLINK for deterministic real-time
communication with minimal wiring effort. Positive
customer feedback gives us confidence in our decision.
from this new technology is a well-known
automobile manufacturer, who uses an en-
hanced warp knitting machine with multiaxial
weft insertion to produce fabric that goes on
to be processed into car body panels.
This machine cuts sections of carbon fiber
tape from rolls and stacks them with the
fibers in each layer aligned in a different
direction. Two chains lined with pins hold
the ends of the tape sections in place as
they transport the 50 to 150-inch wide fab-
ric through the approximately 35-meter
long production line. The layers are then
stitch-bonded together. Then the edge of
the fabric is trimmed off. The final product
is wound on a roll, while the waste that re-
mains on the pins is vacuumed away.
Minimized waste for reduced
production costs
Each of these transport chains is moni-
tored by an image processing system at
the front of the machine that detects not
only bent, broken or missing pins, but also
contamination. An In-Sight 7200 camera
handles all image processing and evalua-
tion tasks. When it detects an error, the
machines central controller is notified and
the machine is stopped.
In the past, machine operators or quality
control personnel would find damaged pins
more or less by chance, says Rainer
Seuss, the engineer in charge of multiaxial
technology at LIBA. By that point, many
meters of defective fabric had already
been produced.
Vision system increases availability
Now, the image processing system reliably
identifies damaged or contaminated pins
after no more than a single cycle. This does
more than simply reduce waste; it also
generates added value. When an error oc-
curs, the operator no longer has to tedi-
ously search 80 meters of chain for the pin
that is responsible, explains Jan Mrtin,
head of design and development at LIBA.
Since a bent or broken pin is often an indi-
cation of a more general problem with the
machine, reacting to them faster helps
prevent subsequent damage or machine
downtime. The bottom line is that the im-
age processing system brings increased
machine availability and process reliability.
Further improvements to process reliability
For LIBAs second image processing sys-
tem, now found on every continuous weft
insertion system, process reliability was
more than a welcome side effect it was
the top priority. The particular challenge
here was that the sum of tolerance values
over a very long chain made it difficult to
predict the exact position of a particular
pin. The image processing system would
have to ensure that a thread is inserted in
each of the gaps between pins. An intelli-
gent In-Sight 7200 camera measures the
entry point of the thread in each gap.
The results are sent via POWERLINK to the
machines central controller. This allows
the weft insertion system to correct its po-
sitioning in the next cycle to keep the
thread within a 10 percent deviation of the
center of the gap. POWERLINKs real-time
capabilities were absolutely essential for
this type of positioning, says Jahn.
The new image processing system replaces
the light sensor measurement system LIBA
previously used for the continuous weft in-
sertion systems. The biggest problem with
the old solution was that the contact-de-
pendent light sensor had to sweep be-
tween the pins, making accidental colli-
sions virtually inevitable. A collision would
destroy the measurement system and re-
sult in machine downtime. Thanks to the
The flexibility and performance of Cognex cameras with a POWERLINK interface provide plenty of room for improved functionality and new features. Tapping into this
potential, LIBA has already upgraded the image processing system that monitors the tape infeed with an additional function that allows machine operators to create
a log file containing the sizes and positions of gaps in the tape.
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no-contact solution based on cameras,
these problems are now a thing of the
past, explains Mrtin, clearly pleased.
Higher availability = Higher productivity
The third image processing system was de-
veloped to monitor the carbon fiber tape as
it is fed into the machine. Depending on the
width of the tape being used, one or more
cameras are used to record the length and
width of any gaps that appear in the tape.
They also use the edges of the tape to cal-
culate its width. If any of the measurements
deviate from their specified values, an error
message is sent and the machine is stopped.
The operator then decides based on the se-
verity of the deviation whether to allow the
machine to continue running or to have the
tape automatically removed. smartvision
GmbH, commissioned by LIBA to develop the
camera software for the three image pro-
cessing systems, design the lighting and
optics and commission these systems on
the machine, selected In-Sight 7402 camer-
as for the task. These cameras can process
images with a resolution of 1280x1024 pixels
in just 30 milliseconds,says Jahn. Thats
sufficient to provide the necessary meas-
urement performance.
Sights set on future developments
LIBA has already made great leaps forward
with regard to process reliability, waste re-
duction and machine availability. Yet the
textile innovator sees no reason to rest on
its laurels. The flexibility and performance
of these cameras gives us plenty of room
for improved functionality and new fea-
tures, says Seuss.
Recognizing this potential, LIBA has already
upgraded the image processing system
that monitors the tape infeed with an addi-
tional function that allows machine opera-
tors to create a log file containing the sizes
and positions of gaps in the tape. This data
can then be used to create error maps for
further analysis by quality control person-
nel. And were not going to stop there,
promises Mrtin. We have a lot of very in-
teresting ideas in store for the future.
On a warp knitting machine with multiaxial weft insertion provided by the Copcentra MAX 5 CNC, an optional image processing system based on In-Sight 7402
cameras ensures fabric quality by monitoring the carbon fiber tape for gaps before it is fed into the machine.
Offering minimum jitter and maximum performance, POWERLINK is the perfect choice for Ethernet-based industrial applications
with hard real-time requirements. The POWERLINK approach to communication management prevents collisions and provides
uncompromising determinism. This is what has helped establish POWERLINK as the go-to solution for the most demanding
applications in a wide range of industries.
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B&R is excited to introduce Smart Display
Link 3, the newest generation of its proven
technology for digital display data transmis-
sion. This new version allows a maximum
distance of 100 meters between the PC and
panel, providing clear benefits for modular
machine and system manufacturing in par-
ticular. Smart Display Link technology was
first introduced in 2004 and made it possi-
ble for B&R customers to operate HMI devic-
es at distances up to 40 meters.
Decentralization made easy
With Smart Display Link 3, all communica-
tion channels are transferred over a stand-
ard Ethernet cable. In addition to reducing
cable costs, the thin cable and RJ45 con-
nector are a perfect fit in tight spaces such
as feed-through openings and support arm
systems. Smart Display Link 3 offers high-
end graphics performance as well. Graph-
ics data is transferred directly from the PC
system to the panel without having to be
processed by additional PC architecture in
the panel. This technology can also be
used regardless of operating system.
With its modular design, Smart Display
Link 3 can be used on all Automation Pan-
els not only new product generations,
but all previous generations as well. As a
result, Smart Display Link 3 is compatible
with all Automation Panels currently in
the field.
Smart Display Link 3 allows Automation PCs
and panels to be placed at optimal locations
along the machine even in extensive sys-
tems spanning up to 100 meters.
B&R presents the new generation of display data transmission
Span up to 100 meters
with Smart Display Link 3
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Marine automation
The scalable, multifunctional POSEIDON control system can be implemented at any level of complexity. The actuators can be connected in a ring, star or hybrid topology.
Technology to protect
the worlds oceans
The multifunctional control systems used
on modern ships help ensure efficient, safe
and environmentally friendly operation. They
monitor tanks containing ballast water and
various types of fuel and redistribute the
liquids for stabilization. They control auxiliary
equipment such as wastewater treatment
systems, collect data and communicate
with the ships higher level control systems.
The POSEIDON ship control system from
S-two is built from extraordinarily robust,
reliable and redundant hardware. The
solution features I/O systems, controllers
and HMI stations from B&R.
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The hulls of large cargo ships and specialty vessels such as
semi-submersible heavy lifters often contain as many as fifty
tanks that hold drinking water, various types of fuel and ballast
water. In order to maintain stability and ensure safe operation under
all circumstances, the distribution of these liquids must be con-
stantly monitored and adjusted during loading and unloading, as
well as during transport. S-two GmbH & Co. KG is a leading manu-
facturer of control systems for ballast water, fuel and bilge water
management. The POSEIDON control system from S-two provides
efficient monitoring and control of a ships fuel and water distribu-
tion. In addition to interfacing with the ships other systems, PO-
SEIDON also collects data from fill level, temperature and pressure
sensors and alerts the crew if any defined limits are violated.
Absolute safety, availability and ease of maintenance
Particularly when it comes to specialty transport and lifting ships
for offshore equipment, the increasing integration of automatic
features demands a much greater degree of interaction between
systems performing different tasks, explains S-twos technical
manager, Christoph Ihnen. This means that todays ship control
systems must offer much more flexibility without compromising
vital aspects such as safety compliance, system availability, ease
of use or efficient installation and maintenance. Already standard
fare in the mainstream machine and systems manufacturing in-
dustry, bus systems, PLCs and servo drives are beginning to gain
a foothold in the considerably more conservative maritime sector.
S-two has been one of the pioneers of this development. A perfect
example is the companys Smart ShipBus, which combines two
separate bus systems in a single cable. This dual-redundant, bidi-
rectional bus uses the common RS422 standard as its physical
medium and is operated in a ring topology. S-two experts devel-
oped the data protocol for the Smart ShipBus specifically for ship-
building applications. This meant making transmission reliability
the clear priority, whereas transfer rates took a back seat due to
the relatively slow processes involved. Smart ShipBus doesnt re-
quire a particularly fast physical medium, emphasizes Ihnen. The
cable doesnt even need to be shielded. In principle, even a simple
bell wire would be sufficient.

Distributed intelligence with sensor connections
The electro-hydraulic actuators for the butterfly valves use Smart
ShipBus to communicate with the controller. Each actuator is
equipped with an LPU whose high-performance RISC processor
handles both bus communication and control of the valve motors.
It is also capable of supplying the controller with data from up to
four freely configurable analog or digital inputs with high precision.
With an average of sixty to one hundred valve actuators and often
an even larger number of sensors for temperature, pressure, flow
and fill level, the traditional star topology is no longer feasible,ex-
plains Ihnen. By allowing decentralized connections, Smart ShipBus
greatly simplifies cabling and commissioning and saves considera-
ble costs at the shipyard. This is a particularly significant advan-
tage for shipbuilding, where the cost and effort involved in cabling is
compounded by requirements such as cable armor and strain relief
devices as well as the long distances and inaccessible conduits.
This technology also results in a substantially smaller control cabi-
net and space on board a ship is a valuable commodity.
Redundant bidirectional bus for communication and power
Cabling and commissioning is even easier still for those who use
the Smart ShipPowerBus. On top of the functionality provided by
Smart ShipBus, this patented S-two technology also integrates P
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Christoph Ihnen
Technical Manager, S-two
We value the fantastic support provided by B&Rs local
tech nical offices, the companys strong international
presence and the outstanding quality of its products. To date,
more than 130 POSEIDON systems have been equipped with
B&R controllers.
When dealing with sixty to one hundred valve actuators, traditional star topolo-
gies are no longer feasible. By allowing decentralized connections, Smart Ship-
Bus simplifies cabling and commissioning considerably while also shrinking the
size of the control cabinet.
S-two operates its own assembly line for hydraulic and electro-hydraulic drives.
the power supply for the valve actuators. Short circuits in the
communication or power supply network caused by water pene-
tration are identified immediately, and the controller alerts the
crew of the cause and location of the error with an alarm on the
operator station via Ethernet. If a defective actuator is detected, it
is electrically isolated in both directions when the system is re-
started and its power supply is cut off. Thanks to the ring topology,
the remaining actuators continue to function normally.
Safe emergency operation after total power failure
Any POSEIDON system can be optionally equipped with a UPS unit,
which ensures that essential ballast valves are automatically
closed to maintain the ships stability in the event that both gen-
erators fail simultaneously. This added security is especially im-
portant for heavy lift ships that carry extremely valuable freight
and gives the ships owner a decisive competitive advantage.
GL-certified HMI with integrated PLC
S-two offers two levels of control redundancy to accommodate the
requirements of both the ships operator and the classification so-
ciety. In addition to the primary PLC with its array of analog and
digital I/O modules for bus communication and integration of sen-
sors and actuators, the basic level of redundancy involves a sec-
ond, unpowered PLC with identical software. If the primary control-
ler fails, the reserve controller takes over. For maximum system
availability, an even higher level of redundancy can be achieved
using a "hot-standby" PLC. This solution involves two identical B&R
controllers running the same software and operating the respec-
tive input and output modules in parallel. The PLCs are completely
synchronized and monitor each others activities. In the event of a
disruption on the primary PLC, the hot-standby PLC and I/O layer
are activated to ensure seamless system availability. Weve been
using B&R in shipbuilding applications for many years. There are a
number of good reasons for this longstanding relationship, says
S-twos technical manager. For one thing, B&R obtained GL certi-
fication for the X20 system two years ago at our request. This
gives us an absolutely cutting-edge control platform that is ex-
tremely scalable and allows us to continue using the software
from the previous version. Another reason has to do with the high
demands that our Smart ShipBus places on the serial interface
module. A comprehensive market analysis and extensive testing
showed that B&Rs X20 system is the only solution that is up to the
task. The decisive factor here is the modules local intelligence,
which can be used to preprocess protocol data so we dont have
to send everything to the PLC over the internal bus.
Other things we value from B&R are the fantastic support provid-
ed from its local technical offices, the companys strong interna-
tional presence and the outstanding quality of its products, says
Ihnen. To date, more than 130 POSEIDON systems have been
equipped with B&R controllers. So we were naturally very pleased
to hear that B&Rs latest HMI systems, like the Power Panel 500,
are also GL-certified. This allows us to use them in applications
where such classification is an absolute requirement. In the fu-
ture, S-two expects not only more widespread use of its POSEIDON
system in ships, oil platforms and other offshore equipment, but
also that its unique performance characteristics will prove benefi-
cial in onshore processing applications as well. P
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POSEIDON offers electrical, hydraulic, pneumatic and electro-hydraulic actua-
tors for valve operation.
S-two uses GL-certified HMI panels with integrated controllers from B&Rs Power
Panel 500 series.
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openSAFETY and POWERLINK make it possi-
ble to add integrated safety technology to
any embedded control solution without
having to migrate from the existing platform.
This avoids the time-consuming develop-
ment of new systems that meet the latest
safety standards while also completely pro-
tecting investments already made. In this
way, POWERLINK and openSAFETY provide an
efficient way to implement advanced safety
concepts and high-performance industrial
Ethernet applications. Because standard
Ethernet technologies and open architec-
tures are used, it is possible to use any
hardware platform.
openSAFETY for
embedded systems
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<
Virtual wiring
<
Freely programmable
<
Configuration and parameter
management
<
Machine options
<
CAT 4/Pl e/SIL 3
<
Unlimited expansion possibilities
<
Robotics, CNC, motion control
<
Vision systems
<
Complete portfolio of
automation components
<
IP20 and IP67 protection
<
digital and analog modules
<
Configurable pulse signals
<
Integrated two-channel processing
<
Any embedded platform with
ARM, x86 or FPGA processor
<
Available for LINUX kernel 2.x or 3.x
<
Real-time solution through direct RT
Preempt support
<
Other operating systems available
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Five years after the open source POWER-
LINK stack was first published on Source-
Forge.net as openPOWERLINK, the down-
load count now lies at 23,000 and thus has
set a new download record for an industrial
communication stack.
The decision to make openPOWERLINK
available as a free download has brought
sustained growth in the number of system
integrators using this advanced commu-
nication standard, says Stefan Schneg-
ger, managing director of the Ethernet
POWERLINK Standardization Group. In addi-
tion to being free, POWERLINK is also the
first and only industrial real-time Ethernet
standard to fulfill every aspect of open
source software all of which have con-
tributed to its success.
Open source in every aspect
openPOWERLINK, the open source software
stack used to implement the POWERLINK
real-time Ethernet communication standard,
meets every criteria for open source soft-
ware. Equipped for both master and slave
implementations, it is available for a wide
range of operating systems, including Win-
dows, Linux (including real-time variants
using the RT-preempt patch) and VxWorks,
and has been designed for easy portability
to any hardware platform and operating
system. Most significantly, openPOWERLINK
is available under a BSD license, which
grants system designers full rights to the
software and makes POWERLINK the only
truly vendor-independent Ethernet-based
industrial communication standard around.
It therefore comes as no surprise that more
and more leading device and systems
manufacturers are integrating POWERLINK
into their products. openPOWERLINK down-
load numbers are soaring with no sign of
slowing anytime soon.
Open source strategy a huge
success in industrial environments
POWERLINK stack achieves
record 23,000 downloads
The POWERLINK software stack for master and slave nodes has been downloaded 23,000 times
since it was first published as open source software.
openSAFETY for
embedded systems
<
IP20 and IP67 protection
<
digital and analog modules
<
Configurable pulse signals
<
Integrated two-channel processing
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Installed,
switched-on
and ready
New X20 assembly line
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In 2004, the compact X20 series revolution-
ized the design of I/O control and safety
systems for industrial automation. But B&R
is not one to rest on its laurels: Together with
specialty machine builder Stranger, the
company has now developed a state-of-the-
art X20 assembly line with clear advantages.
The line produces complete, ready-to-run
devices that give customers increased
process reliability at reduced cost.
The degree of automation featured in industrial machinery and
production lines continues to grow rapidly. Nevertheless, the ap-
proach typically followed by machine builders in practice is to wait
until the control cabinet is being set up to take the control and I/O
components from their packaging and install each one separately.
This complex manual process slows down construction and pro-
vides plenty of opportunities for costly errors. The new X20 assem-
bly line offers a much more sophisticated alternative.
Faster and more cost-effective
B&R now supplies compact, individually-configured X20 systems
as complete, preassembled units. These are typically provided
with modules and terminals already labeled and ready to be at-
tached to the mounting rail and wired. Upon request, they can also
be equipped with terminal and module locking mechanisms and
preinstalled application software. This prevents assembly errors
and accelerates the commissioning process. Logistics across the
board are streamlined from order placement to receipt and inter-
nal transport while also reducing packaging and waste. Users
also benefit from a guarantee that covers not only the individual
components but their correct assembly as well.
We had to find a way to make assembly more efficient, or we
would lose the ability to offer the customer a cost benefit. After
all, our goal is to offer our customers guaranteed high quality for
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When the pirate ship reaches the assembly station, the manual
task of putting together the three elements of the I/O modules
begins with lining up the bus modules on an assigned workpiece
holder. Once this backplane of bus modules is complete, the
electronic modules are added, followed by the terminal modules.
Throughout assembly the barcode of each item is scanned and
compared against the parts list to prevent errors and ensure the
traceability of each individual module based on its serial number.
Assembly personnel are guided by a "Pick-by-Light" system, a
concept borrowed from high-tech circuit board assembly stations.
After each completed action is confirmed, the screen shows which
component needs to be picked next, while lights indicate where it
needs to be placed. Sensors monitor the entire process and alert
the personnel of any errors.
As it continues on, the pirate ship can optionally take the partially
assembled unit to the labeling station in the interior of the line.
Here, the labels for the modules and terminal plates are printed
with the required background color and applied in the correct loca-
tions. After laser labeling, the X20 rack then passes through to the
completion workstation. This is where module and terminal locking
mechanisms are added to prevent unwanted disconnections.
Before it continues on to the packaging station, the rack is once
again checked by an image processing system to verify correct
placement of all components, labels and locking mechanisms. If
everything is where it belongs, the finished racks are packaged in
specially developed adjustable-width boxes. The parts list and all
other documentation are printed at the time of packaging to ensure
that only accurate and up-to-date documents are included.
Andreas Karrer
Project Manager for Global Industrial Management at B&R
B&R delivers its customers precisely the I/O control systems
they need, when they need them assembled to their
specifications with a processing time of only two days. By
doing away with inconvenient assembly work performed in the
confines of the control cabinet, frequently in the field during
an already stressful commissioning process, machine and
systems manufacturers can ensure considerably higher
process reliability.
less than it would cost with their own personnel, says Andreas
Karrer, project manager for global industrial management at B&R.
In order to achieve this, B&R would have to make intelligent use of
automation technology to provide optimal support for its assembly
personnel. The result is a whole new production line, developed
and built in cooperation between B&R and the specialist machine
manufacturer Stranger KG. The customer-specific X20 racks are
assembled here in a fully integrated, semi-automated sequence,
from the collection of materials to packaging and labeling.
How does the X20 assembly line work?
First the required items are collected in a container known as the
pirate ship, which is equipped with a RFID chip identifying the
customer and order. The SAP parts list has a complete picture of
the future unit from the very beginning.
Controllers are assembled on demand, supported by a Pick-by-Light system. The X20 system can be ordered as a fully assembled unit for convenient one-step
rail mounting. Significantly increased process reliability is the result.
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The integration of the Team Foundation
Server platform into B&R's Automation Stu-
dio software development environment
makes it easier than ever to versionize in-
dividual software components and ensure
adherence to defined sequences. Essen-
tial for structured development within a
team, a source control system is the only
way to guarantee clearly defined develop-
ment versions while helping to prevent er-
rors such as unintended overwriting or the
use of outdated modules.
Uniform workflows
Manually saving different versions and
writing up change logs for each is an ex-
tremely time-consuming and error-prone
process. The TFS adapter for Automation
Studio provides software developers a way
of leaving tedious version management
tasks up to the system with synchroniza-
tion a breeze thanks to the software's inte-
grated comparison mechanisms. Uniform,
user-defined workflows also ensure that
real-time information is available for every-
one involved and prevent the distribution
of unreleased versions.
The development process itself can be
traced through history logs, helping devel-
opers retain an overview of their current
tasks. In addition to TFS, Automation Stu-
dio can also be integrated with the open-
source Subversion versioning and revision
control system.
Always a step ahead
Along with the integration of version man-
agement software, the openness of Automa-
tion Studio also means that it supports con-
tinuous integration a process that com-
piles the application, performs unit testing
and creates reports each time a check-in
procedure takes place. This not only allows
potential errors to be identified and correct-
ed immediately, but also guarantees the
highest level of software quality beginning
directly in the development process itself.
Software development in teams
has become considerably easier
with automated source code
management provided by Team
Foundation Server.
Automation Studio 4 integrated with Team Foundation Server
Structured work within a team
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The perfact::mpa software architecture allows machine builders and owners to monitor production equipment
from anywhere in the world and initiate targeted remote access whenever it is needed.
Lower TCO for
more competitive
machines
Service & remote maintenance
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For OEMs operating in high-wage countries like Germany, constant
innovation is the go-to weapon in the battle for global market
share. Differentiation through technical features alone is not
enough, however. Customers purchasing machines and equip-
ment are looking for suppliers who are willing to assume a greater
portion of the investment and production risk. Not infrequently,
the decision hinges on a total cost of ownership calculation that
takes into consideration the cost of maintenance, repairs and un-
planned downtime. In order to calculate these risks, it must be
possible to identify, categorize and manage the respective costs.
This means deploying service personnel more efficiently, prevent-
ing errors altogether or detecting them early and correcting them
via remote maintenance.
Proactive, not reactive
Service calls, replacement parts and remote maintenance are
part of the daily routine when youre building or operating machin-
ery, says Dr. Robert Rae, co-founder and CEO of PerFact GbR. Yet,
were always surprised to see how many companies are content
with handling these issues reactively rather than proactively.
Since 1998, Raes team of IT experts has been helping machine
builders and owners implement remote maintenance solutions
and optimize overall operating procedures. The multitude of dif-
ferent systems and lack of transparency that these companies
deal with are indeed quite daunting.
One of the most common obstacles is often presented by the
communication media used. Traditional remote maintenance
systems connect to machines via modems, explains Rae. The
problem is that connection technology and transfer rates vary so
greatly from country to country that these systems cant easily be
implemented on a global scale.
A machete for the legacy system jungle
The tangled mass of isolated solutions that tends to accumu-
late over the years presents an overwhelming challenge for ma-
chine builders and owners looking to streamline their opera-
tions. Its not uncommon for us to arrive at a company to find
multiple VPN solutions and several different types of modems
being used in parallel, reports PerFacts customer relations
manager, Bernd Khler. Both untapped potential and serious
dangers lurk in this jungle of partial solutions. Operators desen-
sitized by excessive error messages ignore important warnings,
machine controllers generate helpful data that is never utilized
and service requests are misdirected, processed multiple times
or simply go unanswered. In many cases, potential solutions are
further hindered by concerns regarding the security of remote
communication and access.
This is where the perfact::mpa software architecture comes into
play. It allows machine builders and owners to manage all of their
processes on a single platform. It lets them monitor production
equipment from anywhere in the world and initiate targeted re-
mote access whenever it is needed. Machine data, error messages
and maintenance tasks are all managed and documented in a
central location.
The heart of the perfact::mpa solution is the Meeting Point server.
Its database stores comprehensive data about each machine
from blueprints, parts catalogs and users manuals to photo-
graphs documenting the machines original condition. A ticket
system allows maintenance tasks to be prioritized, processed
and archived.
More secure than online banking
When an error occurs, an on-site technician can simply log in to
the Meeting Point server from a standard browser, create a ticket
The PerFact Meeting Point Architecture
perfact::mpa provides machine manufac-
turers and operators secure and reliable
remote access to their machines for
conveniently centralized monitoring and
maintenance with the aid of B&R technol-
ogy. By uniting previously isolated processes
and hardware platforms, perfact::mpa
helps bring the frequency and severity of
production down time to a minimum.
Bernd Khler
Customer Relations Manager, PerFact GbR
"One of the many strengths of B&Rs solution is that it comes
from a company with an exceptional level of Linux expertise
and a rare depth of understanding for the needs of machine
and systems manufacturers.
that describes the problem and then hand the matter over to the
manufacturers service team. The responsible support personnel
is informed immediately of the pending request via email or text
message. If the issue requires access to the machine or control
system, the on-site technician can allow remote access via the
Meeting Point server. No communication occurs until confirmation
is received from the on-site technician. Once established, the se-
cure tunnel connection can be terminated by either party at any
time. Another advantage of our system is that the user can define
rights to control what parts of the machine service personnel can
access, says Rae. This is a very effective way to keep sensitive
information isolated.
SSH tunneling and HTTPS authentication using x509 certificates
ensure maximum security while transferring data. These measures
allow secure Internet connections without requiring the user to
modify their firewall or open up ports for remote access. At the
end of the day, perfact::mpa is more secure than online banking,
says PerFacts CEO.
Encrypted transmission of all types of data
The specific data that is transmitted over the encrypted network
cable depends on the users requirements as well as the data and
functions offered by the respective machine controllers. The
range of diagnostic options varies greatly from provider to provid-
er, says Rae. Not everyone does this at B&Rs level. Features like
the System Diagnostics Manager integrated in every B&R control-
ler which provides automatic access to hardware and software
status information and the ability to modify the control application
via remote maintenance are something you wont find in the
portfolio of many suppliers.
The Meeting Point server is complemented in the field by the re-
mote Meeting Point router, whose two Ethernet ports allow it to
serve as a hub for communication between the Internet or in-
tranet and the machine network, while integrated firewalls pre-
vent unauthorized access. Wireless connections are also possi-
ble, letting users access the machine network directly from their
phone or tablet without having to go through the Internet or in-
tranet. The routers Linux software does not require a license,
which means adding new machine networks is a straightforward
matter of hardware costs alone. Even though we dont sell the
hardware ourselves, our customers are always asking us which
device we recommend using as a router, says Khler. Finding
the right device turned out to be tougher than we thought. The
first one we selected ultimately proved unsuitable for industrial
environments. For one, it wasnt readily available to all of our cus-
tomers around the world, and after a few months it ended up be-
ing discontinued altogether.
B&R delivers system availability
In 2011, PerFact took a new look at the market and found what
it was looking for at B&R. Industrial PCs from B&Rs Automation
PC 500 series and HMI systems from the Power Panel 500 series
possessed exactly the qualities needed by the company. The
first great advantage was clear from the start, recalls Rae.
These systems all use the same standard hardware platform,
so we only have to develop and maintain a single Linux image,
regardless of whether or not a display is needed. And since the
devices are standard equipment and not specific to any par-
ticular customer or application, the user isnt caught in a tech-
nology trap.
With the software installed on a B&R CompactFlash card, replac-
ing devices is quick and easy. It is also possible to update and
modify the software centrally via the Meeting Point server. B&Rs
rugged devices without fans or conventional hard drives are im-
pervious to adverse industrial environments.
Users can rest assured that these devices will be available for
many years to come, and with B&Rs global support and distribu-
tion network they are easily accessible to customers anywhere in
the world, says Khler. Another strength of the B&R solution is
that it comes from a company with an exceptional level of Linux
expertise and a rare depth of understanding for the needs of ma-
chine and systems manufacturers. B&R stands head and shoul-
ders above other suppliers, which is why it gets our unconditional
recommendation. P
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perfact::mpa gives plant operators such as Mediseal GmbH highly secure and
reliable access to a unified maintenance and documentation solution.
The cockpit of the perfact::mpa system. From a standard browser and without any
special software, the on-site technician can log in to the Meeting Point server,
create a ticket that describes the problem and then hand the matter over to the
manufacturers service team.
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Markus Sandhfner became the new general
manager of B&R Germany at the beginning of
this year. Sandhfner a specialist in the
field of automation engineering took over
from Frank Winter, who led the company in
Germany with great success since its found-
ing in 1983. Winter will continue to assist the
company in an advisory capacity. Sandhf-
ner has held various positions at B&R over
the past 13 years and been part of the B&R
Germany management team since 2010. He
is a native of Baden-Wrttemberg and has
20 years of experience in the area of ma-
chine manufacturing. After studying ma-
chine manufacturing and mechanical engi-
neering, he began his career at B&R head-
quarters in Eggelsberg and played an
important role in establishing the subsidiary
company in the USA. B&R USA now has 25 of-
fices and has become very successful in the
American market.
Focusing on customers
Together with our customers, we want to
further increase our strength in the mar-
ket, says Sandhfner, defining B&R Ger-
many's primary goal for the coming years.
Working closely with customers and offer-
ing an extensive range of services will also
remain central elements. With many new
products and innovations, we will be able
to further increase our customers' com-
petitive edge.
Markus Sandhfner takes over as general manager
B&R Germany under
new leadership
Markus Sandhfner has been in charge of B&R Germany since January 2014.
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Truckloads of savings through On Demand Packaging
The potential environmental benefits are impressive: 17.4 billion
kilograms of carbon dioxide emissions and 36.91 million barrels of
oil could be saved each year by eliminating the empty space in over-
sized packages. Through its innovative approach to right-sized
packaging, Packsize has already prevented over 35.6 million kilo-
grams of carbon dioxide emissions through 24.3 million avoided
truckloads. The environmental aspect was one of our main motiva-
tions for developing this solution, says Niklas Pettersson, global
vice president of technical innovation at Packsize, but one should
not forget the huge savings it promises for companies who imple-
ment it. Shipping logistics is a universal challenge faced in every
industry. The traditional approach maintaining a stock of boxes in
a limited variety of sizes racks up costs for strategic planning,
inventory maintenance and warehouse management systems.
Companies end up paying for excessive corrugated cardboard, fill-
ing material, warehouse space and transportation just to move
around large quantities of air. Not to mention that products shipped
in oversized boxes are also much more prone to damage. Deter-
mined to create a win-win solution to these problems not only for
the companies involved, but for the planet as well Packsize intro-
duced the concept of On Demand Packaging. Their customers and
partners can now enjoy cost savings and optimized supply chain
logistics while contributing to a healthier planet.
The right partner for the right strategy
One might easily assume that Packsize has paved its way to suc-
cess with On Demand Packaging, but the road has not been with-
out its share of bumps. Early on, Packsize had difficulty convincing
manufacturers particularly those for whom packaging was not a
core business to invest in its new machines. Thanks to the re-
sourcefulness of current CEO Hanko Kiessner, however, Packsize
was able to turn this obstacle into a stepping stone. Rather than
selling its machines, Packsize chose to lend them to its custom-
ers and charge instead for the supply of corrugated cardboard. In
order for this new business model to work, Packsize knew it would
have to produce its machines more cost-effectively without inter-
fering with their performance. Looking for an automation partner
with the technology and know-how to make this happen, Packsize
found B&R to be the clear choice. Well-known for its portfolio of
The average package shipped today contains 40 percent empty space, contributing to the
unnecessary destruction of more than 342 square miles of forest every year. Both environmen-
tally and economically, this is an immense problem requiring urgent attention. Rather than just
thinking outside of the box, Packsize went ahead and reinvented it. With superior automation
performance from B&R, Packsize now allows manufacturers to produce custom packages on
demand to perfectly fit their content.
Good things
come in
right-sized
packages
Packaging technology
Packsize iQ Fusion is a slimmed, multi-patented automatic packaging machine, designed
to enable On Demands Packaging. The machine is especially made for the fast growing
e-commerce/fulfillment industry, but also for industries such as manufacturing, furni-
ture, plastic and metal and many more. It uses minimal warehouse space and still con-
tributes to remarkable environmental and financial savings.
With Automation Studio, Packsize
has developed their motion applica-
tion hardware independently. Without
changing the Programming Code,
Packsize were able to shift over from
a Servo Controlled application using
PLCopen Motion Control blocks with
microsecond precision, to a more
cost-effective Stepper Motor solution
- keeping the same functionality and
real-time precision. In Automation
Studio, both topologies are kept
in the same project, with a single
source for program development
and diagnostics.
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easily integrated and highly scalable solutions spanning the en-
tire bandwidth of automation technology, B&R was able to help
optimize both performance and cost.
Right-sized automation for the new iQ Fusion
To better serve an e-commerce market that is growing faster than
ever, Packsize and B&R have developed a new, even smaller ma-
chine the Packsize iQ Fusion. With its small footprint and versatile
carton-making ability, this machine has the agility needed for the
fast-paced e-commerce fulfillment industry. The Packsize iQ Fu-
sion can create an infinite number of box styles, and WMS integra-
tion allows it to seamlessly connect with any warehouse manage-
ment system for automatic transmission of product dimensions.
Packsizes sustained position as an innovative leader in its field is
owed in part to B&Rs outstanding product portfolio. B&Rs Automa-
tion Studio development environment provides a seamless link be-
tween programming, diagnostics, I/O and motion control, ensuring
the high-performance positioning and speed control that is vital
for Packsize. The flexibility and openness of B&Rs fully integrated
components makes them perfect for creating right-sized solutions
that harmonize nicely with Packsizes own philosophy. On Demand
Packaging allows vendors to give their customers environmentally
friendly packaging while still increasing their own margin. With the
fast growing e-commerce industry and a major contract with Sta-
ples, Packsize looks forward to a bright future where it will continue
to rethink the packaging industry together with B&R.
Niklas Pettersson
Global Vice President of
Technical Innovation, Packsize
The environmental aspect was one of our
main motivations for developing superior
automation performance from B&R but one
should not forget the huge savings it
promises for companies who implement it.
The B&R Technology Magazine
Software Customize machines without redeveloping software
Motion control Modular machinery gaining momentum
Packaging industry Warning: Paradigms may shift in transit
Change
Packaging
S
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01 05.14
editorial
Publishing information
automotion:
The B&R technology magazine, Volume 13
Online version:
www.br-automation.com/automotion
Media owner and publisher:
Bernecker + Rainer Industrie-Elektronik Ges.m.b.H.
B&R Strasse 1, 5142 Eggelsberg, Austria
t +43 7748 6586-0
automotion@br-automation.com
Managing Director: Hans Wimmer
Editor: Alexandra Fabitsch
Authors in this issue: Craig Potter,
Walter Burgstaller, Yvonne Eich,
Olivier Rambaldelli, Franz Joachim Romann
Graphic design, layout & typesetting:
Linie 3, www.linie3.com
Printing: VVA Vorarlberger Verlags-
anstalt GmbH, Dornbirn
Published at: B&R Strasse 1
5142 Eggelsberg, Austria
Cover photo U1: B&R
All articles published in this magazine are protected
by copyright. Translation, reproduction and
duplication are prohibited without the expressed
permission of the publisher. B&R assumes no
liability for any errors they may contain.
The packaging world is evolving
Are you fit enough to survive?
Individually and as a society, we are increasingly con-
cerned about the future of our natural environment, ask-
ing ourselves what changes we need to make in order for
that future to be one where we and our children can
thrive. The CPG industry faces a climate shift of its own,
as a number of trends promise to dramatically reshape
the market landscape. Manufacturers of packaging
equipment are asking themselves how best to adapt in
order to thrive under these new conditions.
By 2025, the continuous growth of the world's consumer
class will bring about a tremendous shortage of natural resources. The resulting rise
in cost of living, together with green consumption trends, will force packaging strate-
gies to take large steps in the direction of sustainability and affordability. These steps
will follow a path that leads us to fundamentally rethink the role of packaging. Yet as
we redesign and simplify production methods, we will also have to keep pace with new
demands such as product individualization and increased human safety.
As a leading global provider of packaging solutions, B&R is ready to advance side-by-
side with its partners to meet these challenges head-on. We're constantly investing in
new automation technology that makes our customers more energy efficient while
helping them achieve whole new dimensions of productivity and flexibility.
In this special edition of automotion, you'll learn about companies who are innovating
their way to the top of their segments. You'll read about how B&R's integrated approach
to automation incorporates advanced technologies like safe robotics, vision inspec-
tion, in-line digital printing and IT systems to deliver solutions that are far greater
than the sum of their parts.
We look forward to seeing you at Interpack 2014 in Dsseldorf.
Happy reading!
Maurizio Tarozzi
Global Technology Manager, Packaging Solutions
02
contents
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technology
03 If you can't stand the heat, get out of the motor
B&R's ACOPOSmotor is the only servo drive on the market
that doesn't require derating and can handle an entire
machine module on its own
23 A turn for the better
POWERLINK is particularly immune to electromagnetic
interference typically encountered when transmitting large
volumes of data via slip rings
interview
12 Do you speak PackML?
Standardized machine language allows machines,
operators and higher-level systems to communicate with
unprecedented clarity
26 Pushing packaging to new levels
Fundamental challenges compounded by emerging trends
are prompting a paradigm shift in packaging automation
report
08 Far greater than the sum of its parts
Integrated software modules and fully scalable hardware
from B&R help Mediseal build custom machines without
unnecessary redevelopment
15 Speed baking with POWERLINK
Fully automated De La Ballina baking line processes
18,000 baguettes per hour
17 Salad made simple
Pro Pack Systems takes unique robotics approach with
RoboLoader, made possible by B&R's fully scalable portfolio
20 Modular efficiency Integrated performance
GEA builds exceptionally efficient machines with minimal
development overhead thanks to B&R's fully scalable portfolio
30 Modularity: The lead time killer
Virtually zero time is spent on programming during
construction and commissioning of a Seidenader CS-series
inspection machine
news
07 New generation of robotic hand
Research team Poitiers University develops new robotic
hand with 16 joints and 16 motors able to perform complex
human-like movements
34 Real solutions in action
Automation up close: 1,000 bottles per minute and
other records
26 03
17 08
Motion control
If you cant stand
the heat, get out
of the motor
news technology report interview 03 05.14
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The ACOPOSmotor unites all of the key components, including the motor, encoder,
high-precision gearbox and servo drive, into one extremely compact unit.
news technology report interview 04
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The automation experts at B&R have developed an exceptionally
compact motor-drive combination the ACOPOSmotor that is
able to provide the same dynamic performance as a standard drive
and adds the convenience of a single supply cable. This latest
step in the company's continued expansion of an already impres-
sive motion portfolio seeks to address the evolving needs of to-
days modular machinery.
Another B&R innovation, the longstanding ACOPOSremote, was
also geared towards this growing market segment. Nevertheless,
certain applications require an even more compact solution. Fill-
ers with actuators mounted directly on the rotary plate highlight
the challenge of making the most of extremely limited space. In
addition, an ultra-compact motor-drive solution is just as impor-
tant in many other applications that require integrated safety
functions and a local POWERLINK hub for additional I/O compo-
nents. In the Italian city of Parma, the ACOPOSmotor turned out to
be just the answer that a customer was looking for.
The Parma region is known by gourmets the world over for its del-
icacies. For nearly 60 years, it has also been home to OCME, one of
the largest manufacturers of packaging and filling systems.
OCME machines are exceptionally versatile and exhibit a high de-
gree of technological sophistication, with more than 25 patents
testifying to the company's innovative prowess. With its new end-
of-line system, it is therefore no surprise that OCME was looking to
push the envelope particularly in terms of machine footprint and
energy consumption. As a result, a key requirement of the Dry-
Block system became clear early in development.
Customer requirements The only true measure
For its new DryBlock system, OCME needed a more compact drive
unit than any available on the market at the time. OCME's electrical
department manager, Antonio Mosca, brought the situation to the
attention of Davide Beviglieri, key account manager at B&R. "We're
looking for a way to combine the motor and the servo drive into a
single compact unit, explained Mosca.
After all, OCME had ambitions of revolutionizing the way a packag-
ing line is developed, built and managed. This would include new
technology to make product handling more flexible, allow handling
of individual bottles and prevent contact between products. The
individual modules the labeler, shrinkwrapper and palletizer
would be operated from a single multi-touch panel and would take
advantage of OMAC's PackML standard to optimize machine con-
The DryBlock system has revolutionized the way a packaging line is developed,
built and managed.
The larger a machine, and the more flexible options it offers, the more it stands to benefit from
hardware and software composed of modular, mechatronic units. The complexity that arises
from incorporating large numbers of axes and safety technology further intensifies the demands
on the automation solution. B&R has added the ACOPOSmotor to its portfolio to handle precisely
these types of applications. This system is the only motor-mounted servo drive on the market
that doesn't require derating and can handle an entire machine module on its own.
Well-known Italian beverage producer San Benedetto puts its trust in OCME pa-
ckaging systems.
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trol, communication and synchronization. This approach would
rely on full modularization with distributed I/O and motion control.
Beviglieri contacted Alois Holzleitner, manager of B&R's Motion
business unit, and described the application requirements. "We've
been working on a solution for just such an application," Holzleit-
ner replied, outlining the project and the current status of product
development.
Keeping the proven, innovating the rest
The goal was to leverage as much of the existing ACOPOSremote
concept as possible. Through conceptual design, simulation and
experimentation, it was soon evident which components could
fundamentally remain the same. Managing the temperature in such
a confined space, on the other hand, proved to be quite a chal-
lenge. The electronics would be mounted on a housing that reach-
es 110C during normal operation. No conventional component
would last long under these conditions without additional meas-
ures. After all, the rule of thumb says that every 10C increase in
temperature doubles the rate of failure.
With less surface area to dissipate the thermal energy there would
be an increased load on the motor as well. Various conventional
approaches to resolving this conflict were considered. When wa-
ter coolers, Peltier coolers and additional fans proved costly and
unsuitable, however, B&R's developers initiated a more extensive
series of trials in search of the optimal solution.
Extreme demands on motor and electronics
A test motor prepared to emulate the thermal characteristics of
the final product was subjected to extreme operating loads. The
temperature distribution in the windings, bearings and especially
the encoder were analyzed in detail. The outcome? Without modi-
fications, existing motors would not produce acceptable results.
The operating and limit temperatures of every single electronic
Antonio Mosca
Electrical Department Manager, OCME
The motor-mounted drive system ACOPOSmotor is
a huge step forward for us. We're boosting productivity
and saving energy and money while we do it.
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component far over 1,000 in total were measured. It quickly
became clear which options were available. While the power elec-
tronics handled the higher temperatures well, the highly integrat-
ed digital components were much more sensitive. The same ap-
plied to many of the passive components, in particular the DC bus
capacitors, which would also need to be very small in order to
meet the dimensional requirements. The small size and corre-
sponding low capacitance meant additional risk of resonance in
the DC bus.
"One of our primary goals remains ensuring the interoperability of
all B&R components," explains Holzleitner. "This gives our custom-
ers the freedom to decide on a project-by-project basis whether
their application calls for an ACOPOSremote or ACOPOSmotor. Our
customers need to be able to scale their solutions at any time."
By skillfully arranging the components, partitioning the device into
various temperature zones and getting the manufacturers of crit-
ical components involved, the development team was finally re-
warded with a breakthrough.
Putting ACOPOSmotor to the test
The results blew all expectations out of the water. B&R was able to
ensure full compatibility with the rest of its ACOPOS drives and mo-
tors without any derating whatsoever. A single hybrid cable carries
both POWERLINK communication data and power from the ACOPOS-
multi DC bus directly to where it is needed. IP67 connections ac-
commodate modules from the X67 I/O series including the safe-
ty components while the SafeMOTION functions defined in IEC
61800-5-2 are available as an option. A remote axis can be brought
safely to a stop independently of the STO signal on the hybrid
cable or operated at a safe speed during setup or maintenance.
Standing with B&R's Davide Beviglieri in front of DryBlock, OCME's
head of development looks proudly on the fruits of their labor. The
ACOPOS devices are installed, and the system has been running at
top speed for days with ambient temperatures of nearly 50C. This
drive is a huge step forward for us. We're now well on our way to-
wards reaching our goal of boosting productivity while reducing
energy consumption by up to 36 percent, concludes Mosca.
The advantages
> Remote servo actuator available in three sizes
from 1.8 to 17 Nm
> Can be delivered with or without an add-on gearbox
> Seamlessly integrated into the ACOPOSmulti drive system
> Reduced wiring
OCME took advantage of OMAC's PackML standard to optimize machine control, communication and synchronization. The DryBlock system's HMI has also been
standardized with PackML and runs over a B&R Multi-Touch Automation Panel.
The Robioss robotics research team based
at Poitiers University has developed a new
generation of dexterous robotic hands with
16 joints and 16 actuators that reproduce
complex human movements such as grasp-
ing and fine manipulation. Mounted on a
Stubli robot arm and controlled by the B&R
Automation PC 910, this hand is capable of
performing a wide range of tasks, including
complex packaging tasks as the manipula-
tion of delicate food elements or flexible
sacks. Due to POWERLINK, both the hand
and the Stubli robot are controlled with
perfect synchronization. Moreover, the Au-
tomation Studio 4 software tool from B&R
allows researchers to handle the control
software as a bundle of reusable modules,
thus making cooperative development
easier within the team.
A strong partnership
In the 10 years of its existence, the part-
nership between Poitiers University and
B&R has grown stronger and stronger. The
mechatronics department and its students
benefit from the advantages of the educa-
tion support program B&R offers worldwide.
Beyond the B&R education support pro-
gram, this partnership has also contribut-
ed to highlighting the pioneering projects
of the Robioss robotics research team.
Based at Poitiers University, this team be-
longs to the P Prime Institute operated by
the French National Center for Scientific
Research (CNRS).
Robots and humans working hand in hand
One of the current areas being focused on
by Robioss researchers involves allowing
humans and robots to work hand in hand in
a safe way. Being able to integrate robots
that cooperate with human operators into
production lines has now become a key
factor for competitiveness for many con-
sumer goods companies. At the latest
event organized by Poitiers University and
B&R last November, over 150 participants
including many packaging machine build-
ers and users could see for themselves
that B&R systems and the bus-independ-
ent safety standard openSAFETY not only
allow easy and safe integration of robots
into production lines and medical applica-
tions, but also open up entirely new ways
for humans to work with robots.
Poitiers University and
B&R bring robots to life
New generation of robotic hand
Poitiers University automated the robotic hands
16 joints and 16 actuators with B&R technology.
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Packaging technology
Working with a single, all-inclusive project is not always the best way to
manage the monstrous task of engineering control software for machines
whose design requirements vary greatly from customer to customer.
According to Ulf Leineke, R&D manager at Mediseal GmbH, there is a better
solution. With a pool of thoroughly tested software modules and B&R as an
automation partner, the packaging machine manufacturer has greater
agility to deliver new solutions with minimal cost and risk.
Far greater than
the sum of its parts
For our customers in the pharmaceutical industry, product quality
and system reliability are absolute priorities, explains Mediseals
R&D manager, Ulf Leineke. Nevertheless, the substantial varia-
tions in requirements mean that up to thirty percent of each ma-
chine is either modified or newly developed.
Leineke argues that the approach frequently taken by manufac-
turers of series-produced machines maintaining a single soft-
ware project that incorporates multiple machine series and all of
their options would not have the same benefits for a company
like Mediseal. Considering the number of custom modifications
that we deal with, an all-inclusive project would quickly balloon to
unmanageable proportions. It would also result in us carrying a
unnecessary load of disabled modules in every project or having to
decouple parts of the main development line. Leineke also be-
lieves that customer acceptance would be problematic. Our users
in the pharmaceutical industry expect state-of-the-art custom
solutions and updates, but they dont want to have to test and
validate the entire project after every modification.
Pool of tested software modules
Mediseal draws from a pool of software modules with clearly de-
fined interfaces to create the bulk of each new machine. Since
this part is not modified in any way, only the newly added compo-
nents and any interdependencies require testing and validation.
This saves a great deal of time and effort for both us and our cus-
tomers, says Leineke.
Mediseals software modularization has been even easier since
switching to version 3 of B&Rs Automation Studio engineering en-
vironment five years ago. Encapsulating the software in reusable
modules accompanied by corresponding libraries is a very simple
matter, says Leineke. Plus the projects are available as ASCII text,
not just binary files. Leineke considers this to be one of the most
important factors, as it allows efficient use of a source control tool
to manage the various software modules. Once a version has been
tested and released, it can be frozen and reused over and over.
Not forced to change products
It was because of these clear advantages that Mediseal became
an early adopter of Automation Studio 3. Whenever we see a new
technology take a significant innovative leap, were quick to im-
plement it to our own advantage and to the advantage of our cus-
tomers. We expect our automation partner to incorporate our
feedback and inform us promptly of any issues and B&R does an
exemplary job of this," reports Leineke. It is important to him that
he is never forced to change products, but rather is free to choose
whichever time is most convenient. He appreciates that his devel-
opment team is able to continue using earlier versions of Automa-
tion Studio with B&R providing updates long into the future. "An-
other huge advantage is that we hardly ever have any issues with
firmware incompatibility," says Leineke, noting that Mediseal can
rest assured when it comes to product availability as well: "Even
B&Rs oldest products are generally still available." And he ought
to know after all, Mediseal has relied on B&R automation tech-
nology as standard equipment on all of its machines for over sev-
enteen years now.
An open solution, an open partnership
Mediseal originally switched to B&R in order to implement an inno-
vative machine architecture based on distributed drive technology
and flexible motion control. Even back then, B&R had a control
solution with integrated servo technology that allowed us to
change cam profiles at runtime as well as unifying PLC and motion
functionality in a single system, recalls Leineke. These factors,
plus the openness of the solution and B&Rs readiness to accom-
modate our special requests, were the foundation of our decision
to work with B&R as our automation partner.
This kicked off a long series of innovative machine developments,
as demonstrated by the CP600. This was the first Mediseal blister
packaging machine to be equipped with digital servo drives, and
with an output of 600 blisters per minute it is among the fastest
on the market.
Mediseal has more experience than any other company in the
world when it comes to the implementation of digital servo
technology. As a result, its users profit from an unparalleled lev-
el of flexibility and production efficiency. Direct drives replace
mechanical moving parts and reduce the time for format
changeovers between PVC/ALU and ALU/ALU blisters to under
35 minutes. The modular construction and clearly delineated
zones make it easy to implement optional function modules
with optimal support from open B&R technology. The full perfor-
mance of the CP600 can be best utilized by pairing it with a Me-
diseal cartoning machine. P
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High-performance blister packaging line from Mediseal GmbH. Encapsulated, reusable hardware and software modules minimize the cost and effort involved in the
customer-specific modifications frequently required in the pharmaceutical industry.
Development and commissioning in parallel
Each machine in a Mediseal line is controlled by a CPU module from
B&Rs X20 system. This decentralization makes it easier for us to
develop the software in parallel and commission a lines machines
independently, which is much more efficient than dealing with a
single centralized controller, says Leineke. Were currently eval-
uating Automation Studio 4, which would allow us to work concur-
rently on a single controller. If that pans out, its possible that we
may soon move to an architecture with a central controller." This
step would also eliminate the need for cross-communication be-
tween the lines controllers a welcome side effect.
Communication between the controllers and the distributed servo
drives, as well as networking of the local and remote I/O stations
from B&Rs X20 system, is all provided by POWERLINK. The B&R solu-
tion gives us virtually unlimited possibilities for integrating other
bus networks and 3rd-party systems, as well as complete freedom
for selecting the type of motor to use. With Automation Studio, we
can control linear, servo or stepper motors using the same software
interface, says Leineke. Yet even though we use B&R technology
across the board from control and I/O to HMI whats more impor-
tant to us is that B&R provides excellent single-source support to
accompany its products and solutions. This helps us minimize engi-
neering expenditures for our highly customized machines and still
be able to respond quickly to new trends. P
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As a manufacturer of packaging machines for the pharmaceutical industry, Mediseal develops or
modifies up to thirty percent of each machine to accommodate its customers needs. Thanks to
B&Rs Automation Studio engineering environment, Mediseal has been able to reduce the amount
of software engineering this requires to an absolute minimum. In particular, Mediseal values
Automation Studios ability to encapsulate software into reusable modules and add the corre-
sponding libraries.
Ulf Leineke
R&D Manager, Mediseal GmbH
B&R provides excellent single-source support to accompany
its products and solutions. This helps us minimize enginee-
ring expenditures for our highly customized machines and
still be able to respond quickly to new trends.
Fully equipped with POWERLINK and B&R servo technology, the CP600 produces
up to 600 blisters per minute
The operator console for the CP600 blister machine is based on a decentralized
Automation Panel, which B&R modified according to Mediseals design require-
ments to fit directly into the console housing.
The CP600 fulfills the most stringent demands on quality. Not a single defective
blister is permitted to leave the machine undetected. B&R technology makes it
easy to integrate external inspection equipment such as cameras and scales.
Do you
speak
PackML?
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Can you start by explaining the concept be-
hind PackML as an open stan dard?
In creating the standard, were defining a
consistent way of controlling discrete ma-
chinery. If we define things like the state
model, the modes of operation and the in-
formation that is exchanged between ma-
chines, then any two machines that apply
these definitions can communicate with
each other, regardless of who built them
and what control technology they used.
And as an open standard, PackML is not tied
to a particular technology or a particular
company. Its freely available to anyone in
the industry. Any machine that complies
can communicate with any other machine
that complies, and we no longer need large
systems in-between doing translation.
So are we just talking about communica-
tion at the machine-to-machine level or
also on a machine-to-MES or SCADA level?
Were looking in both directions. Let me be
clear that what were not talking about is
standardizing the network protocol used
internally in each machine. What we are
specifying is how those machines are go-
ing to talk to each other across a common
Ethernet-based network protocol. Which
specific protocol is used for any given line
is a decision that can be made by the end
user. The idea is that the machines can put
information out on that network in a format
that all the other machines can pick up.
The second step is then to get that infor-
mation up into an ERP system so we can
get recipe information down into the ma-
chines and reports from production back
up into the ERP layer based on events in
the line. This lets us record stoppages, for
example, and use that stoppage analysis
to determine whats causing the most
downtime over a specific period of time.
This new communication lets us target ef-
ficiency improvements not only at the ma-
chine level, but for the entire line as well.
So its not just the communication layer
that is standardized, but also the informa-
tion to be exchanged?
Yes, the information is contained in Pack-
Tags packets of information with a specif-
ic format and a specific function. So if we
take a speed tag for example, everybody
knows that its called CurMachSpeed. They
know it contains information in the format
primary units per minute of whatever it is
thats being made, and they know its going
to be a 32-bit number. Every machine in the
line knows these things, so when they get
something that says CurMachSpeed, they
dont have to figure out Now is that feet per
second or meters per minute? because
they know exactly what theyre dealing with.
Why are these standards so important for
an end user?
As an end user, the problem you have when
you build a line is that you buy a filler from
one company, a coupon inserter from some-
body else, a labeler, a caser, a palletizer and
theyre each made with a different engi-
neering methodology. So when everything
arrives at your factory, you face the task of
making the machines work together.
You spend a lot of money with a system in-
tegrator who has to go talk to each machine
builder and get into the inner workings of
each machine. It gets very expensive and
very difficult. And where do most of the
problems pop up during commissioning? Not
in any individual machine, but in making the
machines work together.
With a standard methodology in place, the
task of integrating the machines becomes
much easier. Rather than spending all this
time down in the guts of the PLC code
aligning bits and bytes, the system inte-
grator is focused on higher-level applica-
tions making the line more efficient and
providing tools that make the operator and
supervisor more effective.
The end user benefits from having the sys-
tem integrator and OEM each focusing on
what they do best. If you dictate to the ma-
chine builder what technology to use,
youre guaranteed a suboptimal machine.
Thats like going to Ford or Volkswagen and
telling them how to build an engine. You
dont do that. You specify the functionality
and performance, you specify PackML and
say, OK, give me your best machine that
complies. Then you get exactly what you
really want, which is a best-in-class ma-
chine with the best possible performance.
Are there already end users supporting
OMACs initiative and using PackML?
There are quite a number of end users who
are direct members of OMAC such as Nestl,
Procter & Gamble and PepsiCo. Then there
are other large end users who, while not
members of OMAC, are still specifying
PackML as a requirement for machines com-
ing into their factories, such as Arla Foods,
Mars and others.
So the end user saves on system integra-
tion, gets a smoother commissioning pro-
cess and sees overall improvements in line
performance. Whats in it for the OEM?
There are typically three areas of benefit
that we see. The first is improved develop-
ment time. Say, for example, that two end
users are both buying a case packer from
the same company. One comes in and says
it must use Technology Provider A, and the
other says it must use Technology Provider
B, so the OEM has to develop the same ma-
chine with two different platforms just to
Bryan Griffen
OMAC Chairman
service multiple customers. They also need
technicians who understand both plat-
forms. This is not only expensive and diffi-
cult, it bogs down their capacity to innovate,
because theyre spending their time keep-
ing the technology platforms and techni-
cians at the same level instead of enhanc-
ing performance.
Theres also an improvement in terms of af-
ter-sales support. No longer do they send
out a technician who ends up sitting there
scratching his head because he knows
there was something different about this
machine but cant remember exactly what.
With standards in place, service calls be-
come much less of a headache. Yet it seems
to me that the biggest benefit is in the re-
tention of intellectual property. When the
end user buys a line that integrates equip-
ment from multiple OEMs, the system inte-
grator has to go down into the PLC code of
each machine to make them line up and
communicate. The OEM is forced to give
away intellectual property to a system inte-
grator, which of course nobody likes to do.
With PackML it can be a black box. The per-
missives are encapsulated in specifical-
ly-coded pieces of information, the Pack-
Tags. The system integrator knows what
the state model is, so he doesnt need to
know the inner workings; its practically
plug-and-play. Its a huge improvement for
a machine builder to keep that intellectual
property locked up.
So for the OEM, PackML brings improve-
ments in development, support and pro-
tection of their intellectual property. What
about the system integrators?
One of the things that a system integrator
struggles with is bidding on a project in-
volving a large number of machines. You
just never know how long it will take to get
it working. So if we can take that out of the
equation with a standard, the bidding pro-
cess becomes much easier and they can
focus on higher-level functions.
Also, instead of everything being one-off,
they can start making standard packages.
They can make a middleware package for
reporting line efficiency to a plant manager,
for example, and they know they can use it
in any factory because it is built on an ac-
cepted standard.
If were talking about line integration,
safety communication is going to come
into play. Are there any PackML develop-
ments that deal with the issue of safety?
There are several active subcommittees
within the OMAC packaging workgroup. One
of them is focused revising the standard
itself to make it more usable. Another is
PackSafety, who is working on providing the
same functionality as PackML at a safety
level to communicate information between
machines about safety events.
What is OMACs strategy for deploying these
standards on the market?
Right now, were in the final phases of a revi-
sion to the PackML standard aimed at im-
proving clarity and usability. Were working
with various technology providers to make
sure libraries are available for all the different
types of PLCs. At PACK EXPO 2013 we had a
PackML meeting with 8 different technology
providers showcasing PackML tools already
implemented in their programming software.
Beyond that, we have the push from OMAC
members such as Nestl, Procter & Gamble
and PepsiCo, who are establishing PackML
as one of their fixed requirements. Thats
certainly going to drive the industry, and
with technology providers also making it
easier to implement, the adoption will
move even more quickly.
Some of the larger OEMs like ProMach and
Bosch Packaging are also adopting PackML
as their standard.
How does a company become an OMAC
member, and what are the benefits?
One of the primary benefits is having input
on whats happening with the standard. Its
a very active community. Getting involved
now puts a company on the forefront of
that wave, allows them to help define the
future, gives them a first look at what is
going to be required to comply and helps
them get a step ahead of the competition.
Membership is pretty straightforward, rang-
ing from $1,000 to $3,000 per year depend-
ing on the size of the company. For us, the
most important thing is the participation.
Its the ideas that come out of the member
companies. This collaboration makes the
standard stronger and more applicable
across the board.
All of the details for joining can be found at
OMAC.org.
Sounds like you have an exciting future
ahead of you. We wish you all the best
thanks for your time!
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05.14 news technology report interview 15 05.14
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Speed baking
with POWERLINK
Image processing
The rising cost of raw materials is driving our customers to lower
their production costs, explains De La Ballina CEO Benjamin De
Chilly. Europes overall production volume is growing every year,
so they need to be able to accommodate higher production rates
while at the same time eliminating manual tasks. Under these
conditions, fully automatic lines like ours are no longer a luxury
theyre a necessity. In the future, we expect the market to require
even higher production rates as well as a continuously growing
variety of bread products. In preparation for these challenges, De
La Ballinas technical manager Thierry De Lazzari and his team re-
vamped the entire automation architecture of its quality control
system using B&R technology across the board. The goals were
to boost performance while making it easier to configure changes,
as well as reducing the cost of implementation and maintenance.
18,000 baguettes per hour
The result of the system revamp with B&R technology is a whole
new generation of machines that count, convey and monitor qual-
ity at a rate of 18,000 baguettes per hour. Products pass through
a 3D vision inspection system before being transported by an array
of suction cups to the packaging conveyor. The machines are
equipped with a complete automation solution from B&R consist-
ing of a PC-based Power Panel 500 that serves as the primary con-
trol and HMI platform, connected to a POWERLINK network of ACO-
Based in the Rouergue province in southern
France, De La Ballina develops, builds and
installs fully automated packaging lines for raw,
baked, fresh or deep frozen industrially produced
baked goods and pastries. Requirements for
performance and flexibility have risen sharply in
recent years, making computer-aided quality
assurance systems more important than ever.
POS servo drives for axis control and XV modules for valve control.
According to De Lazzari, the decision to switch to B&R was based
on some key advantages offered by its solution. These include the
high performance of the POWERLINK network as well as the distrib-
uted X20 I/O system, which allows distances of up to 100 meters
between stations. Other decisive factors were the ease of inte-
grating the valve terminals into the automation system using XV
modules, as well as B&Rs comprehensive range of products, in-
cluding mixed I/O modules. The countless integration features
offered by Automation Studio 4 and the variety of communication
protocols supported by the X20 system including TCP/IP and
Modbus make it easy to directly integrate multi-vendor systems.
POWERLINK Powerful network technology
The selection of POWERLINK-based B&R technology proved to be
just as advantageous for the 3D vision inspection system as it was
for the control system. The optical scanners and image process-
ing components used here demand absolute precision with very
fast response times. In the past, these requirements drove De La
Ballina to hardwiring and basic fieldbus solutions. Familiar with
POWERLINKs capabilities, vision systems manager Emmanuel Du-
mas was convinced that the real-time network would be perfectly
able to handle data transfer and synchronization for the 3D in-
spection system. The most important criteria for the network
technology were that it should be deterministic (precision <1 ms)
and especially powerful. With a precision of 10 ns, cycle times of
100 s and response times well under 1 ms, POWERLINK is more
than up to the task. When you design a new machine architec-
ture, selecting a network is an important strategic decision,
emphasizes Dumas. Our choice of POWERLINK harmonizes per-
fectly with our vision of an integrated automation solution.
Open-source technology eliminates the risk of hidden develop-
ment deficiencies you face with a proprietary solution. Thats the
great advantage of the white box principle behind open-source
products. Every machine that De La Ballina has installed all over
the world since 2010 has been based on POWERLINK technology.
POWERLINK easily handles even the most demanding require-
ments and has paved the way for the new machine generations
fully integrated and highly efficient automation architecture.
With the open POWERLINK solution, integrating the existing im-
age processing system was not only inexpensive, but also in-
creased its performance significantly. The next step for De La
Ballina will be so convert its image processing system to FPGA
technology. This is no problem for the compact POWERLINK solu-
tion and a single FPGA can handle both the image processing
algorithm and the POWERLINK connection. B&R technology and
the POWERLINK network help keep De La Ballina highly responsive
to its customers ever-changing requirements. The new machines
allow quicker configuration changes and increased production
volume. The new developments from De La Ballina will ensure that
its customers will move into the future ready to meet the compe-
tition head on.
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When it designs a new line, De La Ballina uses only the most advanced techno-
logy which explains its selection of B&R when it came time to implement an
integrated automation solution.
Emmanuel Dumas
Vision Systems Manager, De La Ballina
Our choice of POWERLINK harmonizes perfectly with our vision of an integrated automation solution.
Open-source technology eliminates the risk of hidden development deficiencies you face with a proprie-
tary solution. Thats the great advantage of the white box principle behind open-source products.
The high performance of the real-time POWERLINK network makes
it perfectly suited for providing data transfer and synchronization
for an image processing application. The most important criteria
for the network technology were that it should be deterministic
(precision <1 ms) and especially powerful. With a precision of
10 ns, cycle times of 100 s and response times well under 1 ms,
POWERLINK is more than up to the task.
Salad made simple
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Salad made simple
Cartoning machine
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California-based Pro Pack Systems used
this knowledge as an opportunity to offer a
more efficient case packing solution to
packaged salad producers. Pro Pack has
delivered advanced end-of-line packaging
machines since 1991, with current custom-
ers including Taylor Farms, Fresh Express,
Earthbound Farm and Dole Fresh Vegeta-
bles. Among its specialties are robotic case
packers that incorporate state-of-the-art
package handling technology.
Innovation with ease
Pro Pack knew that a new case packing
solution would have to provide the innova-
tive automation technology that customers
have grown to expect, including advanced
features for label inspection and package
orientation. Yet the machine would also
have to be especially flexible and intuitive to
operate while remaining price competitive.
And so the RoboLoader was born. The
RoboLoaders extremely robust frame and
conveyor are constructed from corrosion-
and stain-resistant powder-coated or elec-
tropolished stainless steel, offering trou-
ble-free operation and a sleek, hygienic
design. A delta robot from Codian Robotics
powered by a B&R control system runs the
case packer and is the key to the machines
flexibility. The robotics platform can handle a
wide variety of package styles, pack pat-
terns, payloads and speeds, reducing the
time and cost of production changeovers.
Whether the operator is running a bag line
or a clamshell line, the case packing equip-
ment is very similar in operation. Pack pat-
terns can simply be selected from a drop-
down recipe menu on the HMI. Changeovers
involve nothing more than switching out
guide rails and require no tools whatso-
ever. All of these features greatly ease the
training burden on machine operators and
maintenance staff.
Freedom of choice
The RoboLoader takes a unique approach
when it comes to robotics. The open archi-
tecture of the Codian robotic solution al-
lowed Pro Pack to choose control compo-
nents according to specific design needs
rather than being bound to proprietary
products as is the case with most off-
the-shelf robots. Based on its long track
record of innovative solutions, B&R was
selected to provide machine control for the
RoboLoader. In the four years that Pro
Pack has worked together with B&R," says
David Zurlinden, president of Pro Pack Sys-
tems, "we have built the full spectrum of
secondary packaging machines including
servo and pneumatic case erectors, con-
ventional and robotic case packers and
case sealers all using B&R technology.
When this project began it was clear that
the new machine would benefit greatly
from their expertise.
Pro Pack selected a B&R Power Panel to
unite PLC and HMI functionality in a single
device. The Power Panel allows integration
of the RoboLoaders motion control tech-
nology into the same system used for the
rest of the machine. Since Pro Pack uses
robotics to handle a range of tasks through-
out the line, this not only greatly simplified
the design but the troubleshooting process
as well. Compact, multi-axis servo drives
from B&R control the machines motion and
communicate via the real-time industrial
Ethernet POWERLINK protocol. RoboLoaders
architecture requires less wiring and cabi-
net space than traditional solutions, afford-
ing significant cost savings in hygienic en-
vironments such as salad processing.
Enhanced programming and diagnostics
Using B&Rs Automation Studio development
environment, Pro Pack creates highly modular
code that makes manufacturers in the food
industry even more efficient when using the
RoboLoader. This approach produces higher
quality software with vastly improved long-
term sustainability, thereby decreasing the
instances of programming errors, preventing
machine downtime and reducing the time
and expense of software development. Using
Automation Studio helps us substantially im-
prove integration of machine and robotic
control across the line, explains Zurlinden. It
makes life easier not only for Pro Pack engi-
neers but for the machine operator as well.
When a standalone robot is placed in a
work cell, the level of integration is often
very limited and may entail multiple electri-
cal cabinets with various electrical compo-
nents and a dedicated robot HMI. This limits
the developers ability to provide operators
with useful diagnostic information. With a
truly integrated approach, on the other
hand, alarms and errors associated with
the robot are handled in the same way as
any other axis for consistently simple diag-
nostics across the board. Our next venture
will be robotic palletizing for the salad in-
dustry. That market poses challenges for
conventional palletizers due to the spatial
limitations of their existing production
lines, but we are confident that, with B&R
as our partner, well soon be shaking things
up with an innovative solution, concludes
Zurlinden.
The allure of packaged salads remains strong. The convenience of this healthy food option
makes it accessible and attractive to many, but consumers are also price sensitive. Like others in
the food processing industry, packaged salad producers often devote a large portion of their time
and financial resources to packing their products by hand. While this may have worked in the
past, increasing pressure to maintain low prices and improve production efficiency is motivat-
ing packaged salad producers to embrace new technologies in order to remain competitive.
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David Zurlinden
President of Pro Pack Systems
Using Automation Studio helps us substantially improve
integration of machine and robotic control across the line.
It makes life easier not only for Pro Pack engineers but for
the machine operator as well.
The RoboLoaders extremely robust frame and conveyor are constructed from
corrosion- and stain-resistant powder-coated or electropolished stainless steel,
offering trouble-free operation and a sleek, hygienic design.
A delta robot from Codian Robotics powered by a B&R control system runs the case packer and is the key to the machines flexibility. The robotics platform can
handle a wide variety of package styles, pack patterns, payloads and speeds, reducing the time and cost of production changeovers.
Compact, multi-axis servo drives from B&R control the machines motion and com-
municate via the real-time industrial Ethernet POWERLINK protocol. RoboLoaders
architecture requires less wiring and cabinet space than traditional solutions.
Particularly when it comes to bringing ma-
chines together to form a line, our B&R
solutions are still bringing us significant
savings, says Stefan Krakow, head of prod-
uct management and sales support at GEA
Food Solutions Germany GmbH. Among its
many products, the company develops and
produces thermoformers for the food and
pharmaceutical industries. In one recent
example, our close cooperation with a well-
known sliced cheese producer from the
Netherlands yielded six-digit savings.
Process data pays dividends
These immense savings were preceded by a
detailed analysis of the timing of processes
in the production line responsible for slicing
and packaging the cheese. In addition to a
few mechanical modifications, the chal-
lenge here was a matter of shaving off a few
tenths of a second to achieve the desired
performance, explains Rolf Rein. Rein leads
the software and electrical development
teams at GEA's Biedenkopf location and was
around back when GEA (at the time called
CFS) switched to B&R control technology.
These differences aren't visible to the na-
ked eye, so we needed data to come direct-
ly from the machine with the necessary
temporal resolution. B&R controllers do just
that. They provide high-speed access to all
types of process data recorded at millisec-
ond intervals, which they are equipped to
handle internally.
The analysis of this data indicated that one
of the machines in the cheese production
line was waiting for the "Done" signal from
the preceding machine before it started.
Doing so resulted in an unnecessary delay
of several tenths of a second. The solution?
The timing of the signal is now advanced to
ensure a seamless transition between the
processes with no delay. What may seem at
first glance to be a mundane optimization
meant a four percent boost in output for
this cheese manufacturer, which adds up to
several hundred thousand euros per year.
On-the-fly optimization
Thanks to B&R's fully integrated automa-
tion solution, machines from GEA Food P
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GEA's PowerPak NT is a high capacity form-fill-seal machine
that delivers outstanding investment protection and process
reliability. Thanks to B&R technology, it is also exceptionally
easy to integrate in a line.
Software
Modular efficiency
Integrated performance
Solutions are capable of much more. Finely
tuned, intelligent communication between
machines allows operators to optimize the
system in real time for example, by switch-
ing out cam profiles on the fly. When re-
placing cheese blocks creates a gap in
production that can't be compensated by a
buffer, the packaging machine simply ad-
justs its speed accordingly. This prevents
empty packages, which in extreme cases
threaten to bring down the whole line.
With B&R's uniform HMI design, operators
can easily master a single, highly intuitive
operating philosophy and are able to react
more quickly to errors. From any given GEA
machine, operators are able to not only
monitor, but also operate, every GEA ma-
chine in the line.
To empower its customers with the means
to objectively measure and optimize the
productivity of their systems, GEA offers
various tools such as GEA CostFox built
around the wealth of data provided by its
B&R controllers. The operator uses this
software tool to perform an on-site perfor-
mance analysis in real time to obtain key
quality data. This is made possible by GEA's
across-the-board B&R solution from mo-
tion and I/O to control and HMI that en-
sures seamless communication without
the system disruptions that otherwise hin-
der comprehensive analysis.
In the cases where the user does require
outside assistance, B&R controllers offer
remote maintenance options that make
the process remarkably painless. Remote
machine communication has proven ex-
tremely helpful in practice, says Rein. Us-
ing the diagnostic options provided by B&R
controllers, our technicians are able to per-
form a detailed line analysis right from our
local offices.
Easy-to-use software for both
developers and users
Between the highly reliable hardware and
the easy-to-use software, however, outside
help is rarely required. Intuitive operation is
a key requirement not only for HMI design,
but for the engineering environment as
well, stresses Rein. After all, we don't just
use the tool to plan and develop the auto-
mation architecture, but also to commission
and service the machines and lines on-site,
so we need it to accommodate users with
very diverse backgrounds.
Rein values the careful attention to ergo-
nomic design that clearly went into the de-
velopment of B&R's Automation Studio en-
gineering environment. As a particularly key
benefit he points out the high degree of
integration: This makes a noticeable dif-
ference in the amount of time and effort
spent on engineering. Having a single envi-
ronment where you create the entire soft-
ware solution, including motion control and
HMI, makes things easier for both develop-
ers and users.
GEA has taken particular advantage of Au-
tomation Studio's ability to design control
software that mirrors the modular structure P
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GEA Food Solutions used Automation Studio to cre-
ate a uniform HMI application for all of its machines.
Modular efficiency
Integrated performance
Many machine builders share a common dream. They dream of a day when they can react to their customers'
requests with absolute flexibility, with a diverse range of machine solutions that is nevertheless built
from a consistent set of hardware and managed in a single software project. Not GEA Food Solutions.
For GEA, that day came more than ten years ago with an automation solution from B&R. Since then, this
supplier of secondary food processing and packaging equipment has been quick to market with efficient
solutions from standalone machines to complete processing lines all with minimal engineering effort.
Using Automation Studio, GEA Food Solutions established a standardized software solution for
all of its machines so that each customer's particular arrangement of machines requires nothing
more than simple configuration. Since then, the company has all but forgotten what it's like to
have to tediously rework the software for each new machine. B&R's engineering environment is
built around open standards and provides extensive software libraries allowing GEA to integrate
in-house and externally developed machines as though they were old friends.
of the machines themselves. This is par-
ticularly convenient for commissioning en-
gineers, helping them quickly find their way
around even complex systems such as
thermoformers, says Rein. The individual
modules are also highly encapsulated with
well-defined software interfaces, so it's
safe to change the code of one module
without worrying about any negative impact
on others.
A single software platform for all machines
The real secret of GEA's solution is that all of
the company's thermoformers share a com-
mon software platform. When they put to-
gether a new machine for a customer, all
that's left to do is adapt the configuration to
match the layout. For GEA, the tedious task of
reworking the software for each new machine
is nothing more than a faint memory. This is
one of the main ways that GEA is able to keep
such tight reins on its engineering costs.
This is especially important to us since ther-
moforming is a very price-sensitive market
with very stiff competition, says Krakow.
The customer not only profits considerably
from the performance of the B&R hardware,
but also from the sophisticated software
architecture that GEA developed in close
cooperation with B&R's expert developers.
All application data is stored on a standard
CompactFlash card. During commissioning
and maintenance, there's no need to load
the software onto the controller or any other
components since they all draw their data
from the central CompactFlash card. Hard-
ware is changed out quickly and easily with-
out having to call in an expert. The open-
ness of B&R hardware and software also
makes it extraordinarily easy to integrate
third-party equipment. B&R's commitment
to open standards for both hardware and
software, as well as the full-featured soft-
ware library, provides optimal support when
networking machines from different manu-
facturers, says Rein.
Simulation accelerates engineering
Further benefits of B&R's openness can be
found in other areas. Integrated interfaces
for MATLAB and Simulink allow complex mo-
tion algorithms to be easily developed and
simulated. GEA's future plans involve more
than simply increased use of this efficient
approach to engineering. We will also be
using the interfaces between Automation
Studio and E-Plan to prevent transcription
errors and eliminate the need to make re-
dundant entries in two different develop-
ment systems, concludes the GEA soft-
ware and control expert.
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An industrial PC from B&R's Automation PC 910 series
offers enough computational capacity to integrate
all of the software for machine and motion control in
a single device.
Stefan Krakow
Head of Product Management & Sales Support,
GEA Food Solutions Germany GmbH
Particularly when it comes to bringing machines together to form a line,
our B&R solutions are still bringing us significant savings.
When it comes to designing bottle fillers, PET blow molders, label applicators, machine tools,
printing presses and even wind turbines the best solution often involves a rotating carousel.
The stationary part of these machines serves as the frame, while the machines main components
are found on a rotating structure that must somehow be supplied with power and electrical
signals. This is achieved using slip rings.
A turn for the better
Industrial communication
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Transmission method affects immunity
Passing industrial Ethernet communication
through a slip ring is especially susceptible
to interference since each individual wire
in the cable must be transmitted via a sep-
arate brush track. Twisted pair cables pro-
vide protection against alternating mag-
netic fields and electrostatic interference.
Every time you open and untwist the cable
or add a connection, the system becomes
more vulnerable. Yet a systems immunity
to interference is determined not only by
the physical components, but also by the
communication protocol being used. The
main differentiation made here is between
single frame and summation frame meth-
ods. As defined in the standard Ethernet
protocol, single frame methods can offer
up to fifty times greater immunity to elec-
tromagnetic interference than summation
frame methods.
With a summation frame method, there is
also an exponential increase in suscepti-
bility to interference as you add nodes to
the network. The basic rule of thumb is that
the summation frame method is more sus-
ceptible to interference than the single
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Slip rings with brush contacts are a popu-
lar and well-proven technology. In motors
and generators, a brush provides a sliding
contact to carry electrical signals to the
commutator or slip ring on the rotating
part of the machine. Industrial machinery
generally requires a 24 VDC power supply
for the controller, I/O modules and sen-
sors, and in some cases an additional 400
VAC supply. Often, servo drives are provid-
ed with 560 to 750 volts of DC power
through the slip ring, rather than the 400
volts from the DC bus.
Industrial Ethernet with slip ring
technology
Communication has historically been pro-
vided using traditional bus systems such
as CAN, Profibus, DeviceNet or other tech-
nology from this generation. These sys-
tems generally operate at 125 kbit/s (CAN
and DeviceNet) and up to a maximum of
500 kbit/s (DeviceNet), 1 Mbit/s (CAN) or
12 Mbit/s (PROFIBUS). One of the challeng-
es is ensuring reliable contacts, which is
relatively easy to manage with the low
speed of 10 to 100 rpm at which the car-
ousel rotates. Another is meeting EMC re-
quirements. Todays machines rely on in-
dustrial Ethernet solutions to provide
communication at 100 Mbit/s. When you
put this next to a DC power line carrying
560 or 750 volts, electromagnetic interfer-
ence can produce errors within the data
frames. The protocol detects this with a
CRC, and the faulty frame is retransmitted.
Motion control applications will allow a sin-
gle retransmission without negatively af-
fecting the machine. If electromagnetic in-
terference causes a second invalid frame,
however, the machine will automatically
shut down and production will stop.
Maritial Favret
Technical and Quality Manager, COBHAM Sliprings
Our engineers were impressed by the robust-
ness and electromagnetic compatibility of the
POWERLINK protocol.
Slip ring demo with single frame method
Slip ring application with POWERLINK
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frame method by a factor of 1.25 times the
number of nodes. For a machine with 5
nodes, this equates to a factor of 6.25,
whereas a machine with 40 nodes is 50
times more susceptible.
One of the advantages of the single frame
method is that the frames are shorter and
only contain data for a single node. If a
frame is compromised, the machine as a
whole is not directly affected. With the sum-
mation frame method, however, a single
disturbance means the loss of an entire
network cycle and the data for all of the
nodes in the network.
Costly downtime
The errors produced by EMC interference
are sporadic in nature. As a result, the pos-
sibility of electromagnetic interference is
often overlooked at first, with investiga-
tions primarily centered around defective
hardware or an error in the software.
Engineers who have dealt with EMC errors
know how difficult it is to identify the
source. Poorly assembled contacts, im-
proper shielding or grounding or even mi-
nor wiring modifications made in the field
may be to blame. Testing equipment can
provide clues, but not an exact location.
Part of the problem is often that the error
cannot be reproduced in a clean develop-
ment lab, and the investigation must be
performed on-site at the end customers
location. Not only does the resulting pro-
duction downtime come at a high price, the
long drawn out search for an error can
mean cashing in reputation capital as well.
With or without a slip ring the selection of
a bus system plays a decisive role in the
robustness of a machine or system.
Certified solution, demonstrated at trade fairs by the EPSG (Ethernet POWERLINK Standardization Group),
transmits 24 VDC, 750 VDC, POWERLINK and openSAFETY through a slip ring.
Walter Burgstaller
International Sales Manager at B&R
Many large machine builders put their trust in the
reliable POWERLINK and openSAFETY protocols for
slip ring applications.
Holger Steffens
Data Transmission Team Leader, Data Transmission Schleifring
und Apparatebau GmbH
Intensive EMC testing has shown that single frame methods offer significantly
higher immunity to electromagnetic interference compared to summation
frame methods of Ethernet-based communication.
05.14
Recommended reading:
EMC and Errors Mathematical analysis of
data framing methods; Industrial Ethernet Book.
As a leading supplier of automation for the
packaging industry, B&R is clearly doing
something right. Whats the secret?
In todays consumer packaged goods indus-
try, a products packaging plays a crucial
role in its success and the success of a
packaging machine depends on how quickly
and easily it can adapt to new trends. B&R
has become a leading automation supplier
for its partners in the packaging industry
by following a concept of integrated auto-
mation that best answers the challenges
faced by the global market. B&R provides
solutions with the performance and scala-
bility to cover all the needs of the industry
and grow as these needs evolve. B&R
solutions push packaging machines to
new levels of performance, flexibility and
availability. This is the natural outcome of
B&Rs commitment to perfection in auto-
mation being applied with an in-depth un-
derstanding of the market which it has
earned through close cooperation with end
users around the globe.
Interview
Pushing packaging
to new levels
Machinery for the packaging industry faces four fundamental demands: it must deliver out-
standing performance and premium quality while also ensuring high availability and maximum
flexibility. As if this werent challenge enough, the advent of new requirements for individualiza-
tion and serialization is transforming the industry and prompting a paradigm shift in the
automation technology involved. Maurizio Tarozzi, Global Technology Manager for Packaging at
B&R, explains how B&R became a leading automation supplier in the packaging industry and
why B&Rs integrated automation is ready to take on future challenges.
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From primary and secondary packaging
through to end-of-line solutions, B&R con-
sistently leads the way with innovations
that shape the market. Only automated
packaging machines that synergize all the
benefits of state-of-the-art motion control,
robotics, safety, image processing and IT
connectivity can achieve a sustained edge
on the competition.
Whats the one thing an OEM needs in order
to get the most out of their equipment?
For todays packaging machinery a modular
mechatronic design is indispensable. Con-
sequently, the best performance can only
be achieved through perfect synchroniza-
tion of centralized and decentralized auto-
mation components all seamlessly or-
chestrated by comprehensive automation
software. POWERLINK and B&R Automation
Studio 4 were developed exactly for this
purpose; they are the backbone of our suc-
cess in the most advanced packaging ma-
chines. But this alone is not enough. There
is no "one thing".
Every core automation component the
control system, servo drives, I/O and HMI
units makes an essential contribution to
the overall performance. The B&R product
portfolio offers a wide range of integrated
and highly scalable solutions that perfectly
fit every requirement of the most advanced
packaging systems and push machine per-
formance to its physical limits.
What technologies does B&R offer that push
machine performance to its physical limits?
With B&Rs reACTION technology, programs
are executed directly on distributed I/O
modules eliminating internal data trans-
mission to achieve response times as low
as 1 s. This reduces the load on both the
network and controller and optimizes per-
formance to match demands. The result is
an immense increase in performance with-
out added costs.
Then theres NetTime, which provides re-
al-time clock synchronization over POWER-
LINK with an accuracy in the nanosecond
range, allowing you to synchronize multiple
encoder positions and distributed I/Os. To-
gether, reACTION and NetTime represent a
new paradigm in control performance.
Another essential aspect is motion control.
B&Rs intelligent ACOPOS servo drives work
with very short scan times and communi-
cation cycles of 400 s or only 50 s in
the control loop. This allows very fast,
event-driven cam transitions that satisfy
the requirements of the most advanced
packaging machines. Electronic cam pro-
file deviations are automatically calculated
every 400 s independently of the num-
ber of real and virtual axes used in the ap-
plication and unaffected by the network or
the control system.
What does this mean in terms of real-world
packaging applications?
Primary packaging is the most challenging.
On these machines the packaging material
meets the product at the highest possible
speed, so the level of precision directly in-
fluences both product quality and raw ma-
terial consumption. In filling machines, for
instance, both gravimetric and volumetric
filling processes can use reACTION tech-
nology to operate valves and sensors with
an unrivaled precision of 1 s.
Other high-speed machine functions like
glue shooting, code stamping and bad
product rejection can combine B&Rs reAC-
TION and NetTime technology to synchro-
nize motion control with distributed I/O.
Digital output patterns can be controlled
with a resolution of 125 ns, and fast input
edges such as registration marks or prod-
uct detection are recorded with a times-
tamp of 1 s.
NetTime technology can also be used to
replace expensive intelligent sensors like
the ones found on rotary labelling ma-
chines to detect bottle orientation. Analog
input modules with a sample time of 50 s
can scan the bottles and provide the data
for precise bottle alignment at up to 80,000
bottles an hour.
Product and package changeovers, registra-
tion mark correction, cut-and-seal func-
tions, belt-tracking and product handling
are just few packaging tasks that require
on-the-fly motion profile changes. The B&R
Cam Profile Automat allows machine oper-
ators to change motion profiles dynamical-
ly without requiring any new calculations
on the controller. B&Rs Safe Motion Control
can drastically increase the uptime of any
packaging machine. You can remove a
product jam or make mechanical adjust-
ments while keeping the whole machine
under control. A safer machine results not
only in improved operator security but also
in higher productivity.
Why have POWERLINK, openSAFETY and the
open source approach been so successful
for B&R?
Aside from delivering remarkable perfor-
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sound investment. This is due to their open-
ness, as well as technical characteristics
such as hot plugging, easy diagnostics, free
choice of network topology, cross-traffic
and integration of CANopen mechanisms,
which give users considerable added value.
The system represents the only real-time
Ethernet standard on the market in the
true sense of the term an open source,
purely software solution that relies on
standard hardware components and fully
standard-compliant Ethernet frames.
Utilized and supported by a rapidly growing
community of leading packaging OEMs, tech-
nology providers and global end users, these
technologies are guaranteed an ongoing
process of standardization and broadening
acceptance keeping them future-proof
long down the road.
Packaging machine builders are clearly fa-
voring a modular mechatronic design strat-
egy. How does B&Rs integrated automotion
contribute to this approach?
The best way to accomplish mechatronic
design with true modularity is to have mod-
ular hardware working in perfect harmony
with modular software. From a hardware
point of view, youve got B&Rs motor-inte-
grated and machine-mounted ACOPOS drives,
which bring the power out of the cabinet
directly to where its needed. Distributed HMI
and I/O modules can be connected directly
to machine modules, giving you the added
speed and flexibility of decentralized intelli-
gence. And with a record 10 control systems
and 728 axes synchronized over POWERLNK
at 400 s, B&R has proven its knack for co-
ordinating multiple controllers and safety
systems an essential aspect of a modular
solution.
What benefits does Automation Studio 4
offer for packaging OEMs?
Automation Studio 4 provides all the team
development functions you need to develop
modular software that is completely inde-
pendent of the real hardware. Moreover, it
offers a complete suite for simulating the
tasks performed by every automation compo-
nent, including simulation of the motor load.
This means that machine builders can know
how the machines performance matches up
to the customers requirements before ever
beginning mechanical construction.
With B&Rs Generic Motion Control approach,
the motion control solution is developed in
complete independence of the actuators.
That means that, in the next step, the ma-
chine builder is free to select whatever
combination of synchronous motors, induc-
tion motors, stepper motors, DC motors and
hydraulics is needed to meet the machine
requirements without having to go back
and modify software that has already been
developed.
Why is robotics integration so important for
packaging machine builders, and what solu-
tion does B&R offer in line with this trend?
Being able to integrate all types of robot
kinematics into a machine is key to achiev-
ing maximum flexibility in production. SCARA
and delta robots embedded in machines for
sorting and placing need to be perfectly
synchronized with the machines I/O and
motion control in order to significantly im-
prove performance. Outside the machine,
youve got palletizers with anthropomorphic
or 4-axis kinematics. In this case the robot
is a complete machine, and the key to
boosting flexibility and performance is get-
ting it fully integrated with your secondary
packaging machine.
B&R has solutions for both types of require-
ments. By integrating a comprehensive set
of transformations for all the different types
of kinematics in Automation Studio, B&R has
made it easy to synchronize robotic and
motion control with IEC 61131 compliance
using PLCopen Part 4. This once again high-
lights B&Rs commitment to open standards
and the flexibility that comes with them.
Among automation suppliers, B&R has taken
a unique approach to vision system integra-
tion. Why is that?
Over the next few years, were going to be
seeing more and more cameras performing
various tasks on every packaging machine.
In order to guarantee total quality, maximize
OEE and satisfy market requirements such
as track-and-trace, serialization and food
safety, you need an automation solution
with eyes. Teaming up with Cognex allows us
to offer our customers added benefits, with
vision systems fully integrated and synchro-
nized in a unified machine architecture.
What will be the next big technology chal-
lenge for packaging end users and OEMs?
Individualization and serialization trends are
setting a clear path toward the conversion of
printing and packaging technology. Only by
enabling in-line digital printing can a ma-
chine builder push individualization to
batch-size-one production. Weve already
seen some experimentation here from Nute-
lla and Coca-Cola on their labels. These
were not batch size one, but were big steps
toward individualization. In the future, when
you go online to place an order, youll design
your own custom packaging along with it. At
Drinktec 2013 we saw the first machine
builders using in-line digital printing tech-
nology as a substitute for conventional bot-
tle labels. This is the kind of innovative com-
bination of printing and packaging that will
take over the field of packaging technology
in years to come. As a market leader in both
printing and packaging, B&R is perfectly sit-
uated to provide the integrated solutions to
accompany the convergence of these two
industries. P
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Until very recently, we faced the same mountain of programming
that many OEMs face when building and commissioning a new ma-
chine, says Herbert Grindinger, head of Seidenader's PLC program-
ming department. With our new series of CS inspection machines,
we've finally leveled this mountain. For Seidenader this means a
drastic reduction in lead times throughout production, commis-
sioning and maintenance of its inspection machines for liquid and
freeze-dried medication and nutrition provided in the form of infu-
sions or injections known as parenterals. For the programmers,
it means being able to focus on enhancing machine performance
and adding new features. Switching to integrated automation from
B&R was the first step toward these achievements. Seidenader now
works with a single software project that covers the entire inspec-
tion machine, including every piece of optional equipment. For us,
this turns the creation of custom control software into a simple
matter of configuration rather than tedious programming, explains
Seidenader's controls expert. And the best part is that, with B&R,
this also includes the safety solution. This elevated degree of
modularization and standardization allows Seidenader to produce
and test its machine modules in advance.
Modularity:
The lead time killer
Inspection machine
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A new level of functional safety
The end user has plenty to gain from this new machine design as
well. Since the software has already undergone thorough testing
on a fully operational machine and didn't have to be tweaked and
adapted throughout construction and commissioning, it provides
an unprecedented level of functional safety. When it comes time
to add or replace modules down the road, the comprehensive
standardization makes this much faster and easier as well. If the
requirements change and you need to swap out the infeed/out-
feed unit, it's no problem at all you just enable or disable the
respective software modules and the rest of the code remains un-
touched, explains Grindinger. This greatly simplifies the task of
system qualification for the end user. Machine operators are sup-
ported at every step along the way by B&R's commitment to com-
pletely integrated automation. The new solution makes it easy for
them to generate a complete list of components that can simply
be checked off during qualification. Grindinger's team found B&R's
engineering environment very helpful when it came time to create
the machine's control software. What we really like about Auto-
mation Studio is that it doesn't place any restrictions on the user
Virtually none. That's how much time is spent on programming during the construction and commis-
sioning of a CS-series inspection machine from Seidenader. The secret is the exceptional modularity of
both the machine and its automation architecture. For Seidenader's customers in the pharmaceutical
industry, this means spending more time in productive operation and less on qualification and
maintenance. Did we mention the machines are also more flexible? Behind all of these advancements,
you'll find a uniquely integrated automation solution from B&R that facilitates a modular machine
design along every step of the way.
The IP65 rating of decentralized ACOPOSremote
drive components allows them to be mounted
directly on the machine without an additional
control cabinet. Power runs through a single
hybrid cable carrying both the POWERLINK and
STO signals in addition to the 24 V supply.
By using this standardized technology as
the electrical interface between the various
modules that make up its new CS-series
inspection machines, Seidenader has taken
its modular solution to a whole new level.
with regard to selecting a programming language, explains PLC
developer Michael Grampp. We went with Structured Text, for
which B&R offers comprehensive and powerful libraries. The added
support for pointers helped us manage the large volumes of data
that come with modularization.
Transparency and user-friendliness thanks to PackML
B&R's support for PackML further added to the system's transpar-
ency. We've implemented PackML as an internal standard that
everyone must adhere to, says Grindinger. It's not something we
impose superficially just for the HMI benefits we've broken it
down to the level of each individual machine module. This makes
the software more transparent and easier to use and maintain.
Beyond that, it also simplifies the tasks of line integration and
communicating with higher level systems. Another significant
advantage of B&R's engineering environment is that it allows ma-
chine control and motion control to be handled on a single hard-
ware platform. The fact that we no longer need two separate plat-
forms substantially simplifies programming, adds Grindinger. A
powerful industrial PC from B&R's Automation PC 910 series handles
the control aspects of the new CS machine. It is mounted in the
main control cabinet on the central machine module along with up
to five image processing PCs, which ensure that the CS is able to
detect a wide array of contaminants and optical defects. The ma-
chine is suited for ampules, cartridges and vials up to 100 ml, cov-
ering a broad spectrum of product and container formats. To com-
plement visual inspection, it is also possible to integrate modules
for headspace gas analysis (HSA), near-infrared spectroscopy
(NIR), polarimetric inspection (GSI) and high-voltage leak detection
(HVLD).
Software cam switch for added triggering flexibility
When you use cameras for visual inspection, the way that they
are triggered has a direct impact on the quality of the results,
says Grindinger. In the past, the company had to use a separate
electronic cam sequencer, which only permitted position-based
triggering. This also meant that a new recipe had to be created in
advance for each new profile, or the cam switch software had to
be modified, retested and requalified. B&R offered a better solu-
tion, explains Grindinger. The X20DS4389 module from their X20
series provides digital outputs that use the AsMcDcs library to al-
low triggering based on timestamps. Used in conjunction with a
position-based trigger, this makes it possible to maintain consist-
ent timing and achieve optimal inspection results regardless of
how fast the inspection carousel passes the containers in front of
the camera and rotates them with the aid of small servo motors.
Not only does the CS no longer require a separate cam switch, it
also allows the same software to handle a whole range of speeds
simply by tuning recipe parameters so there is also no need for
requalification. Operators set these parameter values in the same
way they interact with every standard and optional module in the
machine using a custom Panel PC 820 HMI with an 18.5" display
in 16:9 format, which communicates with the Automation PC 910
control computer via Ethernet.
Seidenader uses PackML as an internal standard applied universally
by all programmers, which makes the software easier to understand,
diagnose and operate.
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Standardized electrical interface between modules
Seidenader selected POWERLINK to network the up to twenty ACO-
POS drives used in its new inspection machine. Between machine
modules, a single standardized hybrid cable provides the power
supply for the decentralized ACOPOSremote drives as well as two
lines for the STO signal and POWERLINK. The corresponding remote
connection boxes allow either a line or star topology. "The hybrid
cable lets us take modularization to a whole new level," says
Grindinger. We now spend considerably less time and effort in-
stalling, commissioning and servicing the modules.
Integrated diagnostics for service technicians
Thanks to B&R's integrated automation solution, commissioning
and maintenance were already pretty simple to begin with. With
the software for all of the automation components managed and
distributed from the central control computer, installing or replac-
ing a drive is child's play, confirms Grampp. With B&R, there's no
need to use a separate programming device or pre-install any
software. No extra equipment is needed to perform diagnostics
on the automation system, either. The diagnostic functions B&R
provides, such as System Diagnostics Manager, can be called up
directly on the HMI. Seidenader programmed all of the other tools
needed for analysis directly into its HMI application. Grindinger has
big plans for the system's yet untapped potential. B&R's solution
gives us so much capacity for growth, I expect we'll soon be able
to push the specified output for the new CS series even higher
than the current 400 containers per hour. We also designed the
machines and the automation architecture in a way that allows us
to easily scale the solution across our entire range of products,
including our most powerful inspection machine. With B&R, we're
confident that we have the right partner for the job.
The IP65 rating of decentralized ACOPOSremote drive components
allows them to be mounted directly on the machine with-out an
additional control cabinet. Power runs through a single hybrid ca-
ble carrying both the POWERLINK and STO signals in addition to the
24 V supply. By using this standardized technology as the electri-
cal interface between the various modules that make up its new
CS-series inspection machines, Seidenader has taken its modular
solution to a whole new level.
Herbert Grindinger
PLC Programming Manager, Seidenader Maschinenbau GmbH
We now work with a single software project, created
in Automation Studio, that covers the entire CS-series
inspection machine, including every piece of optional
equipment. A new machine is a simple matter of setting
parameters rather than tediously redeveloping code.
And the best part is that, with B&R, this also includes
the safety solution.
In developing its new CS series of inspection machines, Seidenader took advantage of B&R's commitment to fully integrated automation to drastically reduce lead
times for its custom-built machines through improved modularity.
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Real solutions in action
Applications
In the consumer packaged goods industry, a product's packaging plays a crucial
role in its success. As the intermediary between consumer and product, packaging
must strike a perfect balance between functionality and design, and it must do so
within the constraints of technical and economic feasibility. Below are five examples
of how industry leaders have tackled the requirements of the packaging industry in
real-world applications.
Dividella
Using one hundred servo
axes, the modular, re con-
figurable, GMP-designed
Dividella cartoner from Koerber
Medipak provides rapid changeover, recipe
management, data access, detailed diagnos-
tics, and simplified parameterization instead of
programming, all from a graphical HMI.
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Cermex
The VersaFilm shrink bundler
from Cermex reduces the
need for corrugated material
and achieves 1,000 bottle per
minute throughputs with over 98% efficiency,
using a new B&R automation platform.
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Krones
Krones presents its
award-winning EvoLite
packaging machine.
To provide safe, highly
repeatable and reliable machine automation,
B&R solutions are fully integrated with the
machine automation system.
TopTier
TopTier's new L7 All Electric
palletizer features PerfectPat-
tern technology, guarantee-
ing precise placement of
cases on the row-build section, as well as
confirming case rotation and size. The modular
B&R ACOPOSmulti drive system allows for easy
configuration and the option to control up to 30
drives on a single Ethernet IP connection.
Z-Italia
Z-Italia offers the only
labeling machine on the
market featuring safe motion,
a unique capability provided
by B&R networked safety technology.
F
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o
s

Y
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u
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Link:
B&R on Youtube

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