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10 Cover story been TÜV tested. The safety devices are separate from the equipment itself. Pluggable modules equip the inverters with their safety functions in a single click. The integrated safety technology also increases productivity, since it enables the motor to be stopped more quickly. With the integrated safety technology, the rotary field of the threephase AC motor is immediately switched off, so that the motor can no longer produce any torque. A permanently loaded DC bus runs throughout, Robotic colleagues It was just a few decades ago that robots belonged to the world of science fiction. But today’s car factories would be unthinkable without them. They are used all over the world in the automotive industry: most of them work in Japan, followed by Germany and the USA. They are used primarily in the production of bodywork. George Devol registered a patent for an industrial robot in the USA in 1954. Two years later he founded the world’s first robotics company, Unimation, together with Joseph F. Engelberger, and developed a working industrial robot called the Unimate. It was originally used on the production line of car maker General Motors where it stacked hot metal parts. The microprocessor was invented in 1971, and the first pocket calculator, which mastered only the four fundamental types of arithmetical operation, was put on the market that year by Texas Instruments. It which also enables a quick start-up. For instance, if a person enters the working zone of the Turnflex, the system stops immediately because man and machine are not permitted to be active within the zone at the same time. Once the person has left the working zone the drives can start up again immediately, since the DC bus is still loaded. The Turnflex has passed its first test at the Bremen and Sindelfingen factories of DaimlerChrysler’s Mercedes Car Group, where the system performs welding tasks during the assembly of bodywork. was also in that year that the first KUKA robot took up its post in a Mercedes-Benz factory. It was a European premiere. But it was not until the 1980s that robotic workers really began to feature strongly in the car manufacturing industry. Electronic drive and control technology had developed rapidly, giving the automatons an ever higher degree of production intelligence. They made the most of their speed and accuracy, especially in precision welding processes. Today’s robots have even more sensors, even better drive and automation technology, and can even take Robots at work on the production of cars. It’s why the Stuttgart-based carmaker is once again at the forefront of the production industry. In 1971 it became the first European company to use robots for the production of cars. www.kuka.de care of entire work processes in teams. And they no longer stand isolated next to one another, but instead work in networks. Other branches of industry also discovered robots several years ago. Chemical companies, for instance, operate automated lines which conduct complex working process completely autonomously. Furthermore, these machines are not restricted to factory halls. They also explore distant planets, seek out mineral resources beneath the ocean, and, as in the case of the robotic dog Aibo, they serve as toys for children.
A real innovation: now there is no longer any need to flood your freezer when producing ice-cubes at home. Melitta subsidiary Cofresco Frischhalteprodukte GmbH & Co. KG has developed ice cube bags which seem to defy gravity. If you pour in water and then turn the bag upside down, it is immediately sealed without having to be tied shut. This is achieved by means of a valve made of plastic film. And, once frozen, the ice cubes are easier to remove than their predecessors. Cofresco is producing these magical little bags using a completely refitted and modernised ice-cube bag machine. The Minden-based company is now using Lenze drive-based automation. The machinery was designed and converted by engineering specialist Falk Steuerungssysteme GmbH in Stadthagen. The production of ice-cube bags involves two primary processes: welding and perforating. Both production steps are intermittent. The unwinding of the unprocessed film and the subsequent winding up of the completed ice-cube bags, on the other hand, are both continuous processes. The welding station and perforating device are driven eccentrically and work synchronously. The welding bar sets the frequency of the production; the machine can reach 50 cycles per minute. After perforation the film is divided into two strips and fed onto two buffers, from which it is wound onto standardsized rolls and packaged. The data for the process procedure (Logic Control) is sent to the 9300 series servo controller via a PROFIBUS-DP. The 8200 vector series frequency inverters receive their signals from the Lenze Drive PLC controller, which in turn is connected to the system controller via a Profibus. All of the controllers are networked to one another via the standard integrated CAN system bus, and they work using a shared DC bus. “Lenze dealt with our scenario very simply,” explains Michael Vogtherr, electrical engineer at Falk. “We were able to build the machine without any brake resistors at all.” The result is fewer components in the control cabinet, less heat generated, and lower supply power. The movements of the servo axis are controlled decentrally by the Lenze controllers, which takes the burden off the central control unit. “The machine uses cam technology and positioning,” says Vogtherr. To this end, Falk Steuerungssysteme used the 9300 Servo PLC which In action Titel Pack ice Melitta subsidiary Cofresco produces ice-cube bags using Lenze technology Progressive drinks: self-closing ice cube bags. is user-programmable in the languages of IEC 61131-3. The controllers have preprogrammed movement functions for cams, winding and positioning, which enable parameters to be set quickly. However, they are also flexible enough to be programmed by the user down to the very last bit. “That’s a real asset,” points out Vogtherr, who draws on the comprehensive library for standard functions, then adapts them to customers’ needs. It is Lenze MCS synchronous servo motors which provide the movement in the ice-cube bag machines. To Friedrich Niedernolte, Director of Electrical Maintenance at Cofresco, the major arguments for converting their existing machines were high availability levels in multi-shift operations, along with the new system’s high production speed. The aim of converting these machines was not only to adapt the processes to the new ice-cube bag design, but also to make them more user-friendly. “It is important that our staff can operate the machine quickly, safely and intuitively,” emphasises the electrical engineer. As Director of Electrical Maintenance he pays particular attention to ease of servicing and to how easily the system can be adapted to changes of product. “In fact it is very easy, since software is used to control the movements,” says Niedernolte. “The programs are really easy to modify, and the frequency and servo controllers are very simple to operate.” 11
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Trade fairs - Lenze

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