Examples of our automation services
Our automation in combination with software development and design realizes your idea through to the finished solution. The areas of application for our projects are diverse: industrial electronics, automation, research, air conditioning or renewable energies. You can find examples below:
Digital flow of goods with RFID tags
Together with our customer, we have designed and built an automatic system for recording several hundred tags for the rental area. We use contactless RFID technology to record the goods. Using two movable near-field antennas for the RFID area, the contents of a transport box can be scanned fully automatically. All the user has to do is slide the Universal Tour Case (120 x 60 x 78 cm) into the specified area underneath the column for scanning and after a few seconds it is clear how many parts are stored in the box without having to check the contents again. This very reliable and quick method of checking guarantees an optimum flow of logistics in the incoming and outgoing areas.
This not only saves a lot of time but is also more reliable than counting by hand!
If you would like to find out more about the project or about our reference customers, please contact us.
Control of production systems in the food industry
Due to the expected failure of the existing control system and the lack of availability of spare parts, it was necessary to replace it. Together with the customer, our development team first analyzed the process in detail.
The task was to design and build a new control cabinet and program the necessary control software. The integration of the pneumatics into the control cabinet and the operation and quick and easy selection of the various production programs via a touch display were new. The entire hardware was simulated in our development department for testing and adaptation purposes in order to minimize the effort required for on-site integration and the resulting production downtime.
The project avoided the need to invest in a completely new system, significantly optimized existing processes and reduced set-up and machine downtimes. Spare parts for the new control system are quickly available and easier to replace.
DC motor control with 37kw for horizontal lathe
Due to frequent breakdowns and the poor or impossible procurement of spare parts, the customer decided to purchase a new control system. We were commissioned to completely replace the old control system with a modern system.
Our tasks included the design, construction of the control cabinet, creation of the software for controlling the safety circuit, motor parameterization and commissioning of the entire system up to acceptance.
The control cabinet contains the safety control and release of all signals of the existing old system. Complete fuse protection, power supply, mains choke and filter including air conditioning.
Customer: CNC contract manufacturing
Planning and realization of a control system for wear measurement
Planning and realization of a control system for a wear measurement system
The task comprises the planning and realization of a control system for a wear measurement system for plain bearings of wind turbines. The special feature of the system is the personal safety technology, which consists of a combination of PC measurement technology and power electronics. The system is controlled autonomously and data is recorded using a separate PC. Our solution includes a control cabinet with Simatic S7-300 to control the drive (approx. 50 kW) and the simulation of a tensile and compressive load of up to 250kN with a Zwick roller tension machine. The execution includes the specification, the design of the system, the software development with various interfaces (RS232, TCpI, Profinet, Profibus and system I/O values from encoders) and the appropriate software solution on the PC. The data is recorded and evaluated using a Labview program. Various scenarios can be created as a recipe and long automatic test series can be carried out.
Advantages for the customer:
Area: Regenerative energy
Transport pallets on roller conveyor
Pallet circulation for SCR catalytic converters (AdBlue) for a manufacturer of agricultural machinery. A special feature is the control of the conveyor belt by individual drives in order to avoid possible gaps during manual removal.
The advantage: thanks to the software support, there are no gaps despite manual product removal. The products are always available in sufficient quantities at the removal station. In the event of a system failure, the pallets can be pushed across the belt by hand, as all motors have clutches. With a simple lever function, the pallets can also be operated manually pneumatically via foot valves in the event of a changeover in emergency operation.
The motors are electronically controlled and are virtually maintenance-free.
We supplied the roller conveyor, control cabinet and connection to the existing production line/assembly line.
Application: Conveyor belt for Euro pallets, transport of Euro pallets
Motors test bench
Test bench for function, earthing and insulation testing of motors and drive controllers.
The motor test system tests the test specimens for insulation voltage up to 2.5KV and creates a load test for the drive controller with max. 600V DC / 2KW. The test specimens are transported using a special tool carrier system with automatic contacting. All relevant connections are automatically connected via the tool carrier to guarantee a smooth and fast process.
This system includes a modular, scalable load test unit for the motor with integrated monitoring of cooling and continuous operation.
Advantage: Compact design thanks to the entire electrical system being installed on two levels below the work platform without a separate control cabinet
Portal welding system
With a welding current output of up to 25000A over a span of almost 4 meters.
SEW linear drives and drive controls via Profibus with a positioning accuracy in the µm range. Control via industrial PC with S7 and WINCC-Flexible. Safety gates, E-STOP etc. via PNOZMulti with interlinking and connection to PLC via Profibus.
Plan machining for bearing seat
Expansion of crankshaft machining with new honing machines for car engines at GM/Opel in Hungary and Austria.
Operator interface with Siemens HMIpro with LassoPlus on OP12 hardware. S7 control with Profibus and Profinet and interlinking to the existing machines and the master computer Siemens Servodyn axes for the machining process.
Test system for heating elements of the urea supply system on diesel engines
The heating elements are inserted and fed to the individual stations via a turntable. At the first station, the heating elements are inserted by hand. At the next station, the connecting cables are cut to length and stripped, and a marking from the previous station is also checked here. One station further on, the heating elements are electrically tested using a test computer, which monitors and evaluates the current flow during heating. After the test, the heating element is printed with caustic ink. The print job is generated by the test computer and the PLC controls the printer during printing. The parameters for the appropriate synchronization are set via the control panel. The barcode of the printout is checked by a scanner and the connecting cables are now cut to their final length. The system is controlled by a Siemens Simatic S7-300 with touch control panel TP177. Festo CMMS axes with Profibus-DP are used for length adjustment and printer positioning.
Projects with a focus on software were:
Conversion of existing systems at home and abroad:
- Expansion of a coolant system and filter system to 1000L/min (USA)
- Electrical interfaces between various production facilities (South Korea/India)
- Construction and commissioning of a machining center (China)
- Electrical interfaces between various production facilities (Austria)
- Commissioning of a production facility with 27 stations (Spain)
Special software projects were:
- Conversion of the S5 run-up control with type management and a parameterizable sequence (object-oriented program structure for memory optimization)
- Exhaust gas temperature control system with an S7 controller (control functions with S7 with master computer connection)
- Cost-effective operating concept (diagnostics-capable control concept without display with only 3 operating and display elements)
- Several barcode scanners on a PLC interface with priority management, data assignment and error evaluation
- Extensive tool carrier circulation system (approx. 200 nodes) with type-dependent tool carriers (WT), WT changeover procedure and retooling concept, WT storage with two lifts, software implementation via parameterized modules and data management
Projects carried out with hardware and software extensions:
- Several stations of a damping leg production
- Several tightening stations with torque monitoring for drive components and steering systems for an automotive supplier and agricultural machinery manufacturer
- Machine control for surface finishing
- Packaging and palletizing of food for Wrigley
- Soldering and production equipment for spectacle frames
- Multi-station production equipment for electric motors, windshield wipers, spark plugs, electronics production, etc.
- Multilayer presses with memory management
- Feeding systems for individual mechanical parts
