CONVEYING TECHNOLOGY LOADING ... - BEUMER Group

CONVEYING TECHNOLOGY
LOADING TECHNOLOGY
PALLETIZING TECHNOLOGY
PACKAGING TECHNOLOGY
SORTATION AND
DISTRIBUTION SYSTEMS
• Control systems for
machines and installations
• Software for the production
management
• Teleservice
1 U1

Owners gain maximum benefit from
their machines and installations if the
mechanical and process engineering
are completed by custom-tailored
automation technology. BEUMER
provides optimum, comprehensive
solutions for both, single machines,
and complex installations.
Our automation engineers have profound
knowledge of the requirements
of machines and processes and
can efficiently and reliably use their
experience to fulfil project-related
requirements.
Software for the production management
is the link between the production
unit and our customers’ ERP systems.
BEUMER provides individual solutions
for this software, as well, based on the
standards of software development.
BEUMER does not only offer standard
solutions, but also designs, constructs,
and erects installations customized in
detail to meet the individual customer’s
requirements.
Our customers appreciate both,
our convincing technology, and its
reliability.
3

Electrical equipment for machines
Guidelines
The high standard of quality applied
to BEUMER machines is also valid for
the corresponding electrical equipment
which is designed according to
the requirements on the world market.
Control cabinet design
• Control cabinet housing fabricated
from mild steel plate protection
class IP 55, if separately driven fans
are used protection class IP 54
• Power and control circuitry in one
cabinet, designed to be electromagnetically
compatible
• Electrical design without fuses
• International touch protection class
IP2X (safe from finger-touch)
• Colour coding of cores according
to IEC
• All external connections on termi nal
strips or plug-in connections
• Emergency stop function by means
of redundant switching device
assembly
• Test according to EN 60439
Standards and requirements
Standard equipment meets the requirements
of European norms and
regulations, especially the machine
regulation and the EN 60204, Electrical
equipment for machines. Thanks
to the international standardization
within the ICE, the standard equipment
largely conforms to regulations in
countries outside the EU. All country
specific requirements can be met.
4

Safety
The safety interlock concept consists
of the following modules:
• Lockable safety switch for the
entire machine
• Emergency stop pushbuttons at
possible danger zones
• Protective covering with a safety
fence; access possible through
monitored doors
• Monitoring of conveying routes
with safety photocells at the
material feeding and discharge
points, where necessary due to
the possibility of danger
For every machine or installation, there
is a thorough safety interlock system
which takes into consideration the
corresponding valid EU requirements
relating to the CE marking. The design
of these safety interlocks is individually
tailored to the customer's requirements.
The equipment in the control cabinet
is labelled on the equipment itself and
on the mounting plate.
Terminal strips are used to optimize
the machine installation. Labels are
permanently fixed on all clamps and
cables.
Cabling is done with flexible cables.
All cores are identified with colours or
numbers and their ends are provided
with connector sleeves.
5

Electrical equipment for machines
Operation
For the efficient use of a machine,
the interface to the operator is
designed to be optimally ergonomic.
The operation of the machines is
affected by means of graphical
control terminals, enabling as well
the simple handling of more complex
machines.
Overview of the most important information
In all images, the
headline at the top
edge of the display
shows the status
of the machine.
The information on
the display changes
according to the
selected function.
The F-keys
(function keys) have
different functions
depending on the
respective menu.
The last message
is always
displayed here.
Visible selection area for the control
and input fields. The selection is done
by means of self-explanatory icons.
The K-keys (constant) always have
the same function. They can be used
to activate often needed functions
with one push.
6

Manual functions
are provided for use during troubleshooting
and for maintenance
purposes.
By means of graphics, the needed
function can be selected.
The activating function key is shown
in the graphic.
Parameters
Machine parameters can be entered
with the keyboard field. They are
stored by product in the PLC.
All fault and operating messages are
stored with time stamp in a ring memory.
With each message, the
reference number of the concerned
equipment is indicated.
Password protection
The entry of machine parameters
is password protected.
7

Electrical equipment for machines - Option
BEUMER Machine Terminal
BeMa
The BEUMER Machine Terminal
BeMa offers a more comfortable
operation and is thus the correct
choice for machines with various
special functions.
Advantages:
• 12“ TFT flat screen
• Robust hardware
for use at the machine
• Additional function keys
for a fast operation
• Graphically supported entry
of preselections and parameters
and fault analysis
Hierarchical structure
The main image shows an overview
of the entire installation. By activating
the corresponding key, the operator
opens the image of the selected
machine module. Fault messages of
the individual modules are displayed
by means of a colour change of the
corresponding key on the overview.
8

BEUMER Machine Terminal
BeMa
Parameter entry
To optimize packing patterns
for palletizers, the actuators
have to be adjusted to the
product related setpoint values.
This task can be easily carried
out by the operators thanks to
the position of the entry fields
on the machine overview.
Module overview
The detail overview of the individual
machine modules gives information
on the position and the status of
sensors and actuators.
The parameters of the modules are
displayed and can be modified here.
9

Electrical equipment for machines – Standard
Field busses
PLC
Field busses enable an economical
and low-maintenance machine and
installation configuration.
The Profibus DP is used for the
connection of complex automation
components like operator panels,
frequency converters and position
encoders to the central PLC.
Profibus DP
Operator panel
DP AS-i
Link
AS-i
In the palletizing and packing technology,
equipment such as photocells,
proximity switches, and pneumatic
actors are connected by means of
the AS Interface. The amount of work
required for cabling can be considerably
reduced with this connection
technology. Furthermore, this also
offers the following information in order
to increase machine’s availability:
• Warning signal if photocells
are dirty
• Message in case of defective
proximity switches
• Fault message in case of failure
of a sensor due to a broken cable
Decentralized input card for the
Profibus DP
Motor with
frequency converter
Position encoder
Control layout for a palletizing or
packing machine
Connection of an AS Interface
participant to the standardized
AS Interface cable with a piercing
connection in IP68
An AS Interface device is of course
included in the delivery.
10

Sensors/Actuators
As sensors and actuators are very
important for a machine’s reliability,
BEUMER only uses equipment of
well-known manufacturers.
High-quality photocells ensure
reliable signals even in difficult
environments e.g. with cement
dust.
Non-contact proximity switches
ensure reliable signals.
Pneumatic actuators are controlled
and monitored by means of AS-
Interface Air boxes.
For the actual value detection of
actuators, the motors’ revolutions
are counted by the PLC. For this
purpose, the standard drive unit is
equipped with a fast proximity switch.
Angle transmitters are used for the
exact detection of positions of travel
axes and axes of rotation, in all possible
operating situations.
Time consuming reference travels
are no longer necessary.
11

Electrical equipment for machines - Option
BEUMER also delivers:
• according to country-specific
regulations
• according to works standards
• designed for explosion
protection according to Atex
The design of the electrical equipment
is individually tailored to the
customer’s requirements.
03005
03005
The standard colour coding of wires
in the control cabinet is carried out
according to the voltage levels.
The colour selection follows the IEC
recommendations.
The number is generated from the
page number in the wiring diagram
and a consecutive number per page.
Some customers and markets
require a unique identification of all
wires with a potential number, in
accordance with the documentation.
Reference systems
For the item designation of electrical
equipment at machines and installations,
a reference system is used,
corresponding to the DIN system.
This system leaves additional
room for the definition of reference
numbers for the equipment.
BEUMER’s interpretation of the
DIN system ensures a technologically
appropriate identification of the
equipment, a logical adaptation
to the machine structure, and an
unambiguous reference to the
documentation.
The adaptation of the reference
system to other systems (e.g. to
works standards) is possible, but
always has to be agreed in detail
with BEUMER.
To increase the machine capacity and
to reduce wear and tear, motors are
equipped with frequency converters.
BEUMER prefers the integrated solution
of motor and converter with the
advantage that less space is necessary.
The control cabinets are equipped with
air conditioners where necessary due
to higher environmental temperatures.
The protection class is not affected.
12

The development of machines at
reasonable prices, with high demand
on capacity, operator convenience,
and availability, is only possible by
creating standards for the machine
and installation controls.
For regional markets or works standards,
other standards can be the
better solution. BEUMER also offers
configurations for this purpose.
For customers preferring control
systems from company Rockwell,
BEUMER provides appropriate
solutions.
The system MODICON QUANTUM
from company Schneider is a high
capacity process control. With the
corresponding configuration, it can
also be used for machine control.
The system SIMATIC by the global
player Siemens is the BEUMER
standard as it offers a good price
performance ratio.
Rockwell
ControlLogix / CompactLogix
Installation network based on Ethernet
Palletizing and packing
machines are part of a
production chain.
Main control system
For optimum production
control, it is necessary to
connect the machines with
the production management
systems.
For this purpose, BEUMER
offers interfaces designed to
the customer’s requirements.
The preferred interfaces are
based on Ethernet.
Machine 1 Machine 2
Implementation
into the customer’s
production management
For an easy and low-cost
implementation, standards
like OPC are used.
13

Electrical equipment for machines
The optimum solution for all requirements
Cost-effective solutions according
to the requirements are available for
controlling belt conveyor systems or
roller conveyors. A central control
cabinet with directly connected motors
is the most cost-effective solution if
no control devices or safety switches
are necessary directly at the motor.
In other cases, the decentralized
version is the better solution, consisting
of a central power distribution
unit and a PLC. The motor starters
are directly installed at the motor.
From the central unit, the power is
looped from starter to starter.
Bus systems are used for the signal
exchange to the PLC.
Transport control for roller conveyors with central control cabinet
Central control
cabinet
Decentralized
motor starters
Factory-built motor starter
Motor starter adjusted to the project
14

Electrical equipment for large-scale belt conveyor systems
Belt conveyor systems, especially
curved belt conveyor systems,
demand a lot from the drive unit
system. The main target is to keep
the tensile load on the belt in all
operation situations as small as
possible. A long service life and a
reliable guiding of the belt in curves
can thus be achieved.
The requirements can be fulfilled by
using modern motion control systems
and application software especially
designed for this purpose.
3 x 132 kW
3 x 132 kW
Winch
Control of a down-hill belt conveyor system, 4.5 km long. Under rated load,
an electrical energy of approx. 600 kW is transferred into the supply network.
The use of AFE (Active Front End) units
is recommended for systems that
transfer energy back into the supply
network. Thus, a high functional
reliability can be achieved, even in
case of weak networks.
Block diagram of the drive unit system. At the rear and at the head, 3 frequency
controlled motors are installed that are coordinated by means of PROFIBUS.
15

BeMES – BEUMER Manufacturing Execution System
Software for production management
offers a great potential for increasing
productivity, both in the automated
production, and in the distribution of
goods (logistic chain). BEUMER has
developed a software product for this
area of product automation called
BeMES.
When designing software packages
for this sector, BEUMER sticks to the
definitions of the MESA (Manufacturing
Enterprise Solution Association)
with regard to functions, interfaces
and IT standards.
Enterprise
Resource
Planning
ERP
Advantages:
• Fast realisation of new projects
• Clear and thereby fast definition
of interfaces
• Data exchange based on
standards like XML
• Easy distribution of information
via Internet
• Standardised interfaces to the
production machines via OPC
• Inexpensive software products
• World-wide market of providers
SCM
Supply Chain
Management
Manuf acturing
Execution
Sy stem
Machine
Control
CRM
Customer
Relationship
Management
MES
SCADA
PLC
Sensors
Hierarchy of production automation
ERP
Enterprise
Resource
Planning
Ethernet
Fieldbus
HMI
Actors
BeMES – Classification into the IT environment
P/PE
T/L
Transport
and
Logistics
BeMES
e.g. Product Data Management
Collaborative Manufacturing
Commerce
16
Control systems
Machine
control systems
CNC, PLC

BePro – BEUMER Process Control System
BePro
BEUMER Process Control System
The BEUMER BePro is the BEUMER
MES solution for the automated distribution
of bagged material. Thanks
to its modular design, it can be extended
according to the definitions
of MES.
Basic functions:
• Central system control
• Visualisation of the whole system
with detailed displays of the
individual machines
• Collection and processing of
production data
• Fault history with statistical
evaluations
• Data tracking within the production
chain
• Interfaces to the machines
with OPC
Optional
extensions:
• Management of batch orders
• Management of recipes
• Product tracking within the
whole production chain
• Connection to ERP, SCM and
WMS systems
• Quality management
• Maintenance management
• Document management
Example of an installation overview in BePro
Bagging machine
paletpac
stretch hood
DPS
Step 7
Messages
Journal
Faults
Palletizing system
Packaging system
Communication structure
of a dispatch area
Local network TCP/IP
Bulk
Material
Bagging
ERP
Company network TCP/IP
Palletizing
BePro
Machine Control systems
Film
application
Label
• Orders
• Identification
• Regulations
• Remote operation
• Material disposition
• Processing order
• Recipes
• Inventory
• Order Status
• Capacities
• Messages
• Material flow
• Operator inputs
• Machinestatus
17

BeSS – BEUMER System Server
BeSS
BEUMER System Server
The BEUMER BeSS is the BEUMER
MES software integrating the BEUMER
sorting and distributing systems
optimally into logistic processes. It
is designed in the modular way on
the basis of the MES definitions to
suit the varied requirements and can
therefore be easily adjusted to
different tasks.
Basic functions:
• Central system control
• Sortation according to local
sorting tables
• Real-time data exchange with
the sorting machines
• Fault history with statistical
evaluations
• Statistical evaluations of the
sortation
Optional extensions:
• Product tracking within the whole
production chain
• Quality management
• Maintenance management
• Document management
Modules for implementation of
customer-specific requirements:
• Taking over sorting data from
HOST systems (e.g. ERP, WMS)
• Preparing and carrying out sorting
processes as batch runs
• Handling commissioning orders
according to default data from the
ERP system
• Dynamic allocation of sorting
destinations with real-time data
from the sorting process
• Integration of automatic reading
systems or coding stations
Message history
BeSS for sortation and distribution
technology
PC network for a sorting process
Overview of entire system with BeSS
18

Teleservice
The efficiency of production systems
is mainly determined by their availability.
Occurring irregularities must
be remedied as quickly as possible.
If the systems are complicated, the
maintenance personnel might not
be able to solve the problem, or the
trained maintenance technician
might not be immediately available.
In these cases, the BEUMER specialists
are able to offer immediate help.
This service is available anywhere
in the world, thanks to the today’s
telecommunication technology.
Upon contractual agreement,
BEUMER offers the following
teleservice advantages:
• worldwide
• at any time of the day
• for all delivered machines.
The technical implementation
depends on the configuration of
the installation and of the available
local data and telephone networks.
Customer’s
PC systems
ERP, WMS, SCADA
Customer Intranet
BeSS
BEUMER
System
Server
BSC
BEUMER
Sorter
Control
Company network TCP/IP
Modem
S7-400
Teleservice
Internet WAN
VPN connection:
analog
ISDN
DSL
BEUMER Intranet
BEUMER
parent company
BEUMER Service Center
In bigger production plants, the
PLCs and the PC systems work in
a local communication network.
The teleservice can be implemented
by connecting the local network of
the plant with the BEUMER Intranet.
The network connection is either
established via ISDN or via the Internet
on the basis of VPN connections.
19

BEUMER stretch hood ®
für die Verpackungsmittelindustrie
An der Aufrichtvorrichtung werden gekippte
Schalen wieder in ihre Grundstelkippte
Schalen wieder in ihre Grundstel-
An der Aufrichtvorrichtung
Leitlinien
prämien wider.
Folien-format
werden
ausgewählt.
ge-
Das Verpacken lung gebracht, von Kartonagen bevor sie und erneut belegt
lung gebracht, bevor
Beim Einsatz des BEUMER stretch Nicht
sie erneut
nur die
belegt
systembedingt deutlich
Kartonzuschnitten werden können. stellt besondere Aufrichtvorrichtungen
werden können. Aufrichtvorrichtungen
hood ® Verfahrens kann auf das höhere Durchsatzleistung der Anlage
Anforderungen können an bzw. die müssen Technik. vor Hier Einschleusungen,
BEUMER Horizontal- stretch und hood Vertikalkurven ® eingegen,
Horizontal- und
können bzw. müssen
Schrumpfen völlig verzichtet werden. gegenüber
vor Einschleusun-
dem Schrumpfverfahren
bietet das
Aus einem Seitenfaltenschlauch wird trägt
Vertikalkurven
zur Zufriedenheit
eingesetzt
werden.
der Anwender
Verfahren setzt eine werden. innovative Technologie
an, die Die wesentlich Aufrichtvorrichtung zur Verringe-
besteht aus
Die Aufrichtvorrichtung
BEUMER is an international leading eine der Höhe des Packstapels entsprechende
Haube geformt. Diese Hauben,
bei. Auch die exzellente Optik der
besteht
welche
aus
rung
manufacturer die Hochwertigkeit
der einer Brandgefahr
of
Stahlkonstruktion
intralogistic
beim
specialized
Verpacken
in the conveying, bei-trägt. len und loading, horizontalen palletizing Führungsschiene und len und horizontalen
mit einer vertika-
einer Stahlkonstruktion
besteht aus elastischem Material und der Kartonverpackungen
mit einer vertika-
erst richtig
kann vor dem Überziehen so weit gedehnt
werden, dass sie sich gut über hervorragende
zur
Führungsschiene
Geltung kommen
und
lässt und der
and packaging wird beidseitig technology auf as well dem as Sortergerüst angebracht.
and distribution eingesetzten Die horizontale systems. Führungsschiegebracht.
Die horizontale
wird beidseitig auf dem Sortergerüst
Schutz
an-
vor negativen
Bei in sortation der bisher
den Stapel ziehen lässt. Danach legt Umwelteinflüssen
Führungsschiene
ist mit einem auswechselbaren
auch bei längerer
Schrumpf-hauben-Technologie ne ist mit einem auswechselbaren werden
die über-gezogenen stoffbelag versehen, Hauben auf dem er-
der Stößel
stoffbelag versehen,
Kunst-
sie sich eng an das Paket an. Lagerung oder
Kunst-
Having approx. 700 employees and
beim Transport sind
ein
auf
wichtiges
dem der Stößel
a turnover of around 140 Mio. EUR,
Verkaufsargument beim
hitzt. Dadurch des gekippten schrumpfen sie und
des gekippten
Sowohl in der Umfangs- als auch in Endkunden.
legen BEUMER sich Kippelementes has, eng with an subsidiaries die Zuschnitte beim and Durchfahren an. angehoben
bei a und diesem worldwide entriegelt Ver-
presence wird. Im Anschluss
hoben und entriegelt
Kippelementes beim Durchfahren ange-
der Längsrichtung verbleibt eine
Leider representations, kann
Rest-dehnung in der Folie, die für eine
sichere Fixierung des Stapels auf stretch
Selbst
wird.
der
Im Anschluss
Preis einer BEUMER
packungsverfahren for various an industries. die Entriegelung das Brandrisiko drückt die vertikale
an die Entriegelung drückt die
hood
vertikale
® Verpackung ist günstiger
als der
nie ganz Schiene ausgeschlossen das Führungsstück werden, des Kippelementes
information
davon, die Grundposition ob die und richtet
mentes in die Grundposition
Schiene das Führungsstück
der Palette sorgt. Die Folie bleibt
des
einer
Kippele-
vergleichbaren
völlig For further unabhängig
dauerhaft elastisch. Dadurch entfällt Schrumpfverpackung.
und richtet
Hier kommen
Heißluft please visit durch damit us on: Gasverbrennung die Schale wieder oder auf. Mit Erreichen
Heizelemente der Grundposition erzeugtendet die horizonchen
der Grundposition
damit die Schale wieder
auch das lästige Nachschrumpfen, Energieeinsparung,
auf. Mit Errei-
geringerer Folien-verbrauch
elektrische
welches bei den untersten Paletten
endet die
durch
horizontale
Führungsschiene,
den von BEUtale
mehrfach übereinander gestapelter
Pakete häufig erforderlich wie
MER
so
patentierten
dass die nun
Biaxialstretch
abfallende
Stößelrolle
so-
www.beumer.com
das
die
Kippelement
gegenüber
verriegelt.
den Wickelstretchfolien
deutlich preiswerteren Folien
ist. Die elastische Folie gleicht
Die Verriegelung der
im Gegensatz zur Schrumpf-folie zum
Stößelrolle
Tragen.
wird
durch eine weitere Führungsschiene, den
einen etwaigen Volumenverlust durch
wird. Auch Führungsschiene, entsprechende so Ab-dasdeckungelende helfen Stößelrolle nur begrenzt. das Kippelement verrie-
die nun abfal-
Niederhalter, sichergestellt.
das Zusammendrücken der Kartonagen
spielend aus. An der Aufrichtvorrichtung Sprechen sind Sie drei uns Licht-
an!
Haben Sie Fragen?
Gerade der gelt. unvermeidliche Staub,
schranken installiert: eine, bevor die
welcher bei Die der Verriegelung Erstellung der Stößelrolle Karton-zuschnitte
durch eine entsteht, weitere und Führungsschiene, das
den
wird
Mit dem Einsatz des Schalen 4-Format-Kopfes
wird das breite Spektrum den anderen, unter-nachdem die Schalen auf-
aufgerichtet werden und die bei-
leicht entflammbare Niederhalter, Produkt sichergestellt. erhöhen
schied-licher Palettenformate gerichtet und worden sind.
das Brandrisiko erheblich. Dieses
An der Aufrichtvorrichtung sind Zuschnitt-größen drei Lichtschranken
installiert: eine, bevor deckt. die Über entsprechende chanische Sensorik Position der Schale auf gekippt
komplett Die erste abge-
Lichtschranke überprüft die me-
spiegelt sich nicht zuletzt auch in
entsprechend hohen Versicherungs-
Schalen aufgerichtet werden und wird die die beiden
anderen, nachdem die Schalen letten auf-
und Kartonagen schranke zuverlässig überwacht er-
den Belegtzustand
Größe der einlaufenden oder nicht gekippt. Pa-
Die zweite Lichtgerichtet
worden sind. fasst und das für die der jeweilige Schale. Verpackungsaufgabe
die me-
optimal die Signale geeignete beider Lichtschranken mit dem
Die Sortersteuerung vergleicht
Die erste Lichtschranke überprüft
chanische Position der Schale auf gekippt logischen Status der Schale. Bei einer
oder nicht gekippt. Die zweite Lichtschranke
überwacht den Belegtzustand
eine Alarmmeldung mit Angabe der
Diskrepanz generiert die Sortersteuerung
jewei-
The information contained in this brochure merely serves as a non-binding description of our products and is without guarantee.
Binding information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete inquiries.
E002 0506
BEUMER Maschinenfabrik
GmbH & Co. KG
Postfach 12 54
D - 59267 Beckum/Germany
Tel.: +49 - (0) 25 21 - 24 0
Fax: +49 - (0) 25 21 - 24 280
E-Mail: BEUMER@BEUMER.com
Internet: www.BEUMER.com
BEUMER Corporation
Branchburg, NJ 08876/ USA
Tel.: +1 (732) 560-8222
Fax: +1 (732) 563-0905
BEUMER Ltda.
Campinas - SP/Brazil
Tel.: +55 (0) 19-3243-1700
Fax: +55 (0) 19-3242-1411
BEUMER S.a.r.l.
St. Ouen L’Aumone/France
Tel.: +33 (0) 1-3464-2520
Fax: +33 (0) 1-3037-6883
BEUMER Technology India
Private Limited • Mumbai /India
Tel.: +91 (0) 22-2577-2874
Fax: +91 (0) 22-2577-2876
Asia Representative Office
of BEUMER • Bangkok/Thailand
Ph.: +66 (0) 2731-7190
Fax: +66 (0) 2731-7194
+86 (0) 21-6921-3788
+86 (0) 21-6921-3628
Australian Representative Office
of BEUMER • North Ryde / Australia
Ph.: +61(0) 2-9889-5561
Fax: +61(0) 2-9889-5562