SOLUTIONS - Moeller Electric Parts

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Safety PackageeasySafety inpackaging technologyIn order to transport products, theyare normally packed appropriatelyin accordance with regulations. In thefood and non-food sectors carton and/or bagsare used for this purpose. Packaging lines themselvesconsist of several subsections such as filling stations with dosingand weighing systems, cartoning machines, packing stationsand palletisers. Q-bag, a subsidiary of Optima PackagingGroup, offers tailored customer applications with its highperformancecartoning machines and tray packers. The entireautomation technology is provided by APA-Tec. The guaranteeof the machine‘s functional safety requires the compulsoryobservance of the Machinery Directive and the relevant safetystandards. Moeller‘s easySafety also provides outstanding,perfectly matched and cost-effective safety-related functions forpackaging machines.THE COMPANIESQ-bag packaging machinery GmbH& Co. KG has its headquarters inSchwaikheim, near Stuttgart and hasrecently become a subsidiary of theOptima Packaging Group. Q-bag isa household name in the sector asa manufacturer of future-orientedpackaging machines and systems.The company is ideally set up withinnovative, high quality products aswell as a worldwide service.(www.optima-packaging-group.de)APA-Tec GmbH is based in Böbingen,near Schwäbisch Gmünd, and wasfounded at the beginning of 2004.Its main activities focus on the designand implementation of automationsolutions for general machine buildingand packaging. Even modernisationtasks, i.e. the so-called retrofittingof packaging systems, has a separatecompetence area. APA-Tec suppliesmachine control units as well therelevant services from planning,commissioning up to after-salessupport. (www.apa-tec.de)16Products are packaged in many ways on theirway from the manufacturer to the user. Retailpackaging, for example, has to meet differentrequirements than transport packaging.Powdery, free flowing and chunky products areprimarily packed in bags and then placed incartons. Cartoning machines from Q-bag offer anoutstanding degree of flexibility as well as a largesize range with a high performance. A typicalexample is the packaging of wheat semolina.The filling of semolina in bags is controlledby dosing and weighing units. The cartoningmachine prepares the folding cartons. Thecartoning machine then places the filled bagsas bag-in-box items in the cartons provided andthe cartons are closed. Up to 220 cartons withfill weights of 250g are packed every minute.The individual packages are provided with thecurrent batch data in a printer station, are thenpassed to the tray packer where packaging unitsconsisting of 10 cartons each are made up. Thesepackages are conveyed to the palletiser with anintegrated wrapper, where they are stacked fortransport on pallets and then wrapped againand sealed in a stable protective film. The entireprocess runs fully automatically, and all processdata is recorded and archived.High speed and flexibilityThe servo-controlled application describedhere involves 19 servo axes in all, whichcontrol the required folding, dosing andtransport operations in the cartoningmachine and in the tray packer. Themachines are equipped with Elau MotionControl Systems with an integrated PLCfunctionality. The programming is carriedout on the largely known CoDeSys IEC61131-3-compliant programming platform.Touch panels installed close to the machineare used for the visualization of the system.They are used to operate and configurethe entire system (including processparameters, speeds, dosing quantities,format management for the packaging).In the event of a fault, a history memoryand extensive Help functions provide theoperator with the necessary information andensure a high level of plant availability.easySafety controllers can implement allsafety-related functions, such as Emergencystopcircuits or guard circuit monitoringwith a setting function. Together with thecontact-free disconnection of the outputstage of the Elau servo they achieve thehighest level of plant safety. The easySafetycontrollers are linked into the Profibusnetwork of the systems with the easy204-DP interface. This is used to transfer faultor status messages from the safety systemto the machine control where they areevaluated and displayed.easySafety for operating and plant safetyPackaging lines are normally large in areaand involve several potentially hazardouspositioning sequences which have to besafeguarded by technical means. A largenumber of Emergency-Stop actuators,guard doors and operating elements forsafe setting operation have to be controlledand monitored, whilst the plant has to beswitched to the safe operating state inthe event of an emergency. Traditionallythese functions are implemented with acomplex system of hardware components.easySafety reduces this hardware complexity,For Moeller Electric Sales and Support call KMparts.com (866) 595-9616
SOLUTIONS18easySafety monitors all door and emergency-stop circuits, and communicates with the motor control system via Profibus DP.which is restricted to the sensor / actuatorlevel. This device enables applications tobe implemented that comply with thehighest safety requirements: The safetyrelatedcontrol relay complies with category4 in accordance with EN 954-1, PL e inaccordance with EN ISO 13849-1, SILCL 3in accordance with EN IEC 62061 as well asSIL 3 in accordance with EN IEC 61508. Inthis respect the date 30.11.2009 is of specialsignificance for panel builders. After thisdate, only EN ISO 13849-1 and EN IEC 62061shall apply to new machines, and the “old”EN 954-1 shall no longer apply. easySafety istherefore designed to be future-proof andcan be optimally combined with Moeller DILand PKZ switching and protective devices aswell as RMQ control circuit devices.The devices of the easySafety series comeas standard with a host of conventionalsafety relays in the form of safety functionblocks, such as Emergency-stop, guard doormonitoring optionally with the monitoringof guard locking, light curtain with andwithout muting, two-hand control button,safety switch mat, enable switch, safety footswitch, operating mode selector switch, zerospeed and overspeed monitoring, externaldevice monitoring, safety timing relays andsafety markers. easySafety devices comewith 14 safety inputs and have either fourrelay outputs or one redundant relay plusfour redundant transistor outputs. Thesafety function blocks of easySafety caneither be configured from a PC or directly onthe device. Thanks to the easySoft-Safety PCconfiguration software with an integratedsimulation function, users can save the timerequired for project design and alreadyeliminate any faults before commissioning.easySafety offers more than a stand-alonesafety control relay. In addition to the safetycircuit diagram contained in the safetyconfiguration, the safety control relay alsoprocesses a standard circuit diagram. Thiscan be used for standard tasks such asthe processing of diagnostics messages orgeneral control tasks for a machine. If theinputs or outputs are insufficient for solvingthe standard task, standard expansionmodules of the easyRelay series can beconnected with the easySafety device.CONCLUSIONeasySafety supports machine and systembuilders in a wide range of safety-relatedtasks. Eberhard Vaas, owner of APA-Tecexplains: “easySafety provides us witha high level of flexibility during thedevelopment, design and commissioningphase and reduces the need forexpensive hardware. Added to this isthe fact that we can use easySafety forboth safety-related and also for standardtasks. The connection to a fieldbus orPLC is also ensured: Whether Profibus-DP,CANopen or DeviceNet – the easy familyalready offers coupling modules that canbe used by easySafety devices.”Quicklink ID:MS1813For Moeller Electric Sales and Support call KMparts.com (866) 595-961617
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SOLUTIONS - Moeller Electric Parts

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