I/O and safety modules increase throughput in intralogistics

Manufacturers of conveyor and sorting systems for large logistics centers face the challenge of designing systems that can operate at ever-higher speeds while maintaining maximum availability, as the central requirement of customers is optimal throughput. To guarantee this, items must be picked, sorted and arranged in the exact sequence as quickly as possible after receipt has been detected so that they can be shipped as quickly as possible.

Optimizing these processes is the core competence of EAE Solutions in Ahrensburg. The company develops innovative control solutions for various application scenarios in intralogistics. The modular software platform EAE Flow for controlling conveyor and sorting systems makes it possible to utilize the full potential of existing, new and retrofitted intralogistics systems. The system's design is based on the latest automation developments and the highest industry standards. 

EAE Flow consists of the EAE Flow.Master modules, which import sorting and transport parameters and optimally control the entire material flow. The EAE Flow.Control module provides real-time control of the electromechanical equipment. It transports goods efficiently and reliably based on WCS information, I/O signals and scan and image data. EAE Flow.Commander visualizes the operating status of the systems, statistics and reports. The SCADA-compatible user interface is web-based and can be accessed on multiple authorized (mobile) devices.

In addition to the engineering and development of software and hardware, EAE Solutions also handles installation and commissioning. To keep installation costs as low as possible while making the plants flexible and cost-efficient, the company relies on decentralized automation technology from TURCK, primarily Ethernet I/O and safety modules with decentralized control logic and IO-Link.

I/O modules with fast counter input ideal for logistics requirements

Depending on the sorting task, different sorting solutions are used, which EAE Solutions operates with specifically optimized control systems. In addition to the tray sorter, these include solutions for pocket sorters and crossbelt sorters, as well as for conveyor technology. In the pocket sorter, for example, precise detection of the sorted goods is a prerequisite for exactly timed processes. Progress along the transport route is detected via the teeth of the wheels that transport the bag holders. These teeth must be counted quickly in order to determine the exact positions for diverting transport bags, for example.

However, the high speed of the teeth makes it impossible to read in for standard control systems due to the cycle times. This is where TURCK's TBEN-S1 IP67 module comes into play: The compact multiprotocol I/O module for Ethernet has eight digital inputs. The first input is a fast counter – a real unique selling point, ideal for use in the pocket sorter. The rapidly rotating teeth are detected as pulses by a proximity switch and counted directly by TBEN-S decentrally; the control system then retrieves the determined values and can thus ensure exact position determination.

New development at the customer's request

The control technology for conveyor and sorting systems requires signals to be read quickly and at many points in the system. The large number of sensor signals requires a high number of block I/O modules to be used, so their price plays a greater role than in other industries and applications. In the specific application in the pocket sorter, this means that a module with eight inputs is not an economical solution in places where only three or four signals need to be read. Even modules with four inputs and four outputs cannot always meet the specific signal requirements.

At the suggestion of EAE Solutions, TURCK has therefore developed a module with four universal channels that can be used variably as inputs or outputs. A total of up to four 3-wire PNP sensors or four PNP DC actuators can be connected. "The new development from TURCK is very welcome," says Stefan Püttmann, Product and Project Manager at EAE, about the flexible module.  "It enables us to offer truly cost-effective solutions for the many hundreds of modules we use."

Safety control system without control cabinet in the immediate vicinity of the danger zone

EAE was also impressed by TURCK's decentralized IP67 safety solution: at its core is the TBPN hybrid safety I/O module, which allows safety functions to be controlled without a control cabinet and in close proximity to the danger zone. This decentralized signal processing allows for shorter cycle times, enabling the system to operate at a higher conveyor speed. In addition, this consistently decentralized solution ensures that safety functions are maintained in unaffected areas of the system in the event of an unplanned event such as a cable break. As the first Profinet/ProfiSafe block I/O module on the market, TURCK's TBPN combines safety and standard I/Os as well as IO-Link. "No one else offered a safety block I/O module that combined standard and safe inputs/outputs in one device," recalls Püttmann. "We realized that we could also use the module's standard inputs and IO-Link inputs for traffic lights, signals, or normal sensors. This allows us to utilize up to 90 percent of the module's capacity – with all of its features."

Joint development of individual solutions 

"At TURCK, we have access to ready-made components that are ideal for our applications," says project manager Püttmann, "starting with the small TBEN module with the fast counter at the first input, through to the safety module, the RFID readers and the pick-to-light components, right through to service."

TURCK's practical solutions, developed in collaboration with EAE Solutions, ensure the throughput and availability of modular customer systems. Particular emphasis is placed on consistently decentralized concepts that have been developed in partnership. "In addition to high product quality, good advice and reliable service are indispensable for us," emphasizes Stefan Püttmann. "I see TURCK as being way ahead in this respect. The great thing about our partnership is that we develop solutions together in workshops. We always have someone who listens and finds solutions to our concerns and customer requirements. A comprehensive service package – and that's important to us."

Customer | www.eaesolutions.com