Electricity and Control September 2021

DRIVES, MOTORS + SWITCHGEAR

Trust reduces complexity The collaboration between BT-Watzke and Beckhoff was intensive from the outset and built on trust. “Because my colleague Gerhard Schuller and I have to cover a broad range of activities as industrial electricians – from lamp replacement, maintenance and repair to drawing plans and (re)programming – we clearly needed more support with this first project with a technology provider who was new to us than someone who already has more experience of such matters. In this regard, proximity to the Styrian sales office was a great benefit to us, especially with two of our main contacts – Bernhard Fischer and Thomas Maierhofer – living not far away. They were on hand immediately if needed,” says Wolf, recognising the quick response times of the Beckhoff team. Some joint activities are planned for 2021. Discussions are under way in relation to an extension of the twist cap side face painting unit with the addition of energy measurement, the connection to the ERP system, and numerous other conversion or upgrade activities. “Our engineering department always has its hands full because there is always something new to design or construct, and existing equipment to maintain or, if necessary, modernise with the latest electronics,” says Christian Stanzel, confirming more orders soon to be placed with Beckhoff. “Perhaps in future we will want to process data in real time or incorporate image processing,” says Wolf, looking ahead. With Beckhoff the Pinggau-based manufacturer has an implementation partner at its side with numerous “facilitator” qualities, like BT-Watzke itself: on one hand, PC-based control technology is, by nature, finely scalable – in terms of both hardware and software; and on the other, because the Beckhoff team invests all its know-how in exceeding and not just meeting the expectations of the customer. For BT-Watzke, it was primarily the interaction between the “small and large drive technology” in synchronisation with production cycles, which at first glance for Reifbäck and Wolf did not seem so easy to control. However, with the cam disc functionality recommended by Fischer, even this highly complex task could be solved easily with one software switch for everything. All actual and target positions are transmitted via EtherCAT to the EL72xx servo motor terminals and AX5000 servo amplifiers involved, thus allowing an electronic cam disc to be implemented on the AM8000 servo motors. “We watched closely how several motion sequences are synchronised in TwinCAT 3. Next time we will be able to do it ourselves,” say Wolf and Schuller, pleased with how much they learned through the collaboration with Beckhoff. □

[Picture: © Beckhoff]

I gave him the weights and diameters relevant at certain points and the associated speeds and, as I looked on, he worked out which components could be considered,” says Reifbäck. The corresponding CAD data was sent directly to his computer. “The design process couldn’t have gone more smoothly. I didn’t have to call anywhere or send further information; everything was done here on site. It was complete within just a few hours,” he adds. In addition to numerous EtherCAT input and output terminals, the EL5151 incremental encoder interface, EL72xx servo motor terminals, and an EL9576 brake chopper terminal, the lateral surface painting process at BT-Watzke is now also supported by a CX5130 embedded PC with an Intel® Atom™ multicore processor and four servo motors from the AM8000 series. The latter ensure attachment or detachment of capsule blanks at the revolver that is synchronised with production cycles. In addition, they manage the movements of this turntable. “The probability that the attachment would immediately work as we had envisaged was almost 100%, but the removal from the turntable was the greatest unknown. Would everything really work as calculated beforehand? Would the mechanics and electrical drive technology interact properly? As we had not done anything similar in this way before, there was some trepidation before the first real test run,” Wolf confesses, adding: “Simulations are one thing, but everyday production has proven us wrong on many occasions. A few snags can arise very quickly here and there.” “Capsules are not all alike,” says Reifbäck. “Depending on whether a matt or gloss paint is applied, or the products being transported are black or green, they behave slightly differently. And the drive technology has to respond to these small, subtle differences,” he says, highlighting that the Beckhoff solution used has to offer maximum adaptability and flexibility. In addition to the servo drive technology, the lateral surface painting process at BT-Watzke is supported by numerous EtherCAT input and output terminals as well as a CX5130 Embedded PC with an Intel ® Atom™ multicore processor.

For more information visit: www.beckhoff.co.za

12 Electricity + Control SEPTEMBER 2021