SERCOS News - Issue 1 - 2008

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10 Application The Real-Time Ethernet Magazine ROVEMA introduces packaging machine with SERCOS III communications At ROVEMA, intelligent packaging means the responsible, innovative design of individual components and entire process sequences. The company supplies complete solutions for sophisticated, complex packaging applications. Forming, filling, sealing, case packing and retail packaging for today‘s market require a holistic approach which goes beyond the individual component level to include the specific customer process. A very powerful and highly flexible control system is needed to support the broad product portfolio and the highly complex packaging operations. Rovema has been using its own proprietary PCbased P@ck-Control system for many years on its packaging machines. Motion control, PLC and visualization are the main features of ROVEMA control solutions. The motion control subsystem is based on centralized control architecture. P@ck-Control takes total control of axis coordination and position control. The interface to the speed-controlled drives has traditionally been a conven tional +/-10Volt interface with incremental encoder feedback. Interbus-S has provided the link between the integral software PLC in the P@ck-Control system and the outside world. The engineers at Rovema have designed the Ethernet-based SERCOS III real time communications system into the new P@ck-Control generation. A new VPL260 tubular bag machine with this communications interface will be on display for the first time at Interpack 2008. The machine also features continuous volumetric filling. Communications with the speed-controlled drives and digital I/Os flow through the SERCOS III interface. Two highspeed, high-precision linear motors, which drive the longitudinal sealing tools, put the real time performance of the bus system to the test. There has been general agreement for some time among the control system engineers at ROVEMA that the +/-10 Volt interface will have to be replaced by a future-proof Ethernet-based bus system. Given the large selection of systems on the market, it was no easy task for ROVEMA to make the right choice. One major criterion was of course the bus system's ability to support complex ROVEMA control technology. The availability of drives and I/Os and acceptance by ROVEMA customers worldwide were also important consi derations. However, support for ROVEMA - individual packaging solutions power ful and strictly standardized communications, I/O and drive profiles was the decisive factor. The +/-10 Volt interface was able to accommodate special customer configurations, and the new solution will have to offer the same flexibility in the future. To achieve this goal, the drives and I/Os have to speak the same language. Another goal of migration to a stateof-the-art bus system is to exploit highperformance, low-cost hardware components which reduce connectivity costs. Following an in-depth analysis of the competing bus systems, the decision in favor of SERCOS III was made at the beginning of 2007. With the aid
The Real-Time Ethernet Magazine Application 11 of defined profiles and open standards, the design team succeeded in integrating the real time Ethernet system into our machines within twelve months. The SERCOS III (Serial Real Time Communication System) is based on the proven real time mechanism of the SERCOS interface. It exploits the principle of cyclic data transfer in a precisely defined window. Hardware-based synchronization provides a solid basis for dependable implementation of sophisticated motion control functions, for example electronic drives and cams in packaging machines where up to 30 axes have to execute coordinated, high speed motion with highly accurate path control . In parallel with real time processing, SERCOS III can also handle standard IP data traffic (e.g. TCP/IP). ROVEMA P@ck- Control can exchange messages with open, standardized SERCOS III interface gives ROVEMA a universal drive and automation interface which is compatible with drives and devices from a whole range of manufacturers. This interface is based on the international standards IEC 61784/61158 (communication) and IEC 61800-7 (drive profile), and it offers the investment protection of standardized Ethernet to our customers. Susceptibility to electromagnetic interference is lower compared to analogue systems, and simplified wiring along with a reduc tion in component count enhance packing machine reliability. ROVEMA's has introduced third generation SERCOS to support the development of tomorrow's packaging machines, and the technology will be on display at Interpack 2008. Only one interface, namely a SERCOS III master The principle Product enters the system through the forming tube The forming collar shapes the flat film into a round film tube Low friction rollers guide the film to the forming area Vertical sealing bars seal the edges of the film tube together Film transport belts pull the film through the forming area Cross sealing jaws create top and bottom seals in the pouches other devices on the network. SERCOS III supports seamless, future-proof communications. In combination with the complex, centralized P@ck-Control automation system, ROVEMA's Ethernetbased solution expands existing diagnostic and remote maintenance capabilities down to the drive and I/O level. SERCOS III has replaced the traditional field bus for direct control of I/Os, monitoring subsystems and other field bus devices on ROVEMA packaging machines. This functionality along with the entire set of motion control functions will exploit the advantages of the real time Ethernet system. SERCOS III support for high-speed communications eliminates the need for additional hardware in the control computer. The card, needs to be installed on the PCbased control computer which is running P@ck-Control. Contact: ROVEMA Verpackungsmaschinen GmbH Reiner Zentgraf Industriestr. 1, D-35463 Fernwald Phone + 49 (0) 641/409-454 Fax + 49 (0) 641/409-397 e-mail: reiner.zentgraf@rovema.de www.rovema.de Quick-Info 1-0804 You expect more than just programming according to IEC 61131-3? CoDeSys: Integrated visualization to be displayed on different clients (local/target/web)! More information on our website: www.3s-software.com/index.shtml?en_Visualization_V3 CoDeSys Users’ Conference: www.users-conference.com HANOVER FAIR 2008 Hall 9 - Booth D47 3S-Smart Software Solutions GmbH Memminger Str. 151 · 87439 Kempten/Germany Tel. + 49-8 31-5 40 31-0 · www.3s-software.com We software Automation.
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