Modular boom—modularity across the entire line

Modern industrial production systems require increasingly flexible solutions. Whether it is fluctuating production volumes, changing requirements for the shape and size of the parts being produced or the need for rapid changeover to a new product, manufacturers in many industries face the task of meeting these new challenges efficiently. These requirements are also driving a shift in thinking among machine builders. For a long time, hierarchically structured machines with centralized control were state of the art. Today, many tasks can usually be implemented far more efficiently with modular machine and system concepts whose modules are controlled in a decentralized manner.  

New valve cover production line  

As a specialist in industrial process automation, Polish system integrator Smart Automation has many years of experience in a range of industries including furniture, food, chemicals, pharmaceuticals and automotive. Headquartered in Olsztyn, Poland, the company uses innovative approaches for its custom solutions based on Industry 4.0 technologies. For a Tier 1 automotive supplier, Smart Automation developed a valve cover production line based on modular machines and decentralized control. This modular concept enables more flexible and efficient production and allows for faster responses to changing market conditions and customer needs.   

Modularity at multiple levels  

Developing the modular production line was a particular challenge, both in terms of the customer's flexibility requirements and its overall size. Smart Automation had never before designed and implemented a production line on this scale. The line combines modules for numerous tasks including UV laser marking of Data Matrix codes for traceability, induction heating, assembly and measurement of aluminum inserts as well as robot-based deionization and surface cleaning for the rubber seal. In addition, numerous measurements and leak tests had to be performed, from diameter and roundness to leak, flow and pressure drop tests. Each workstation consists of three submodules for transport, process and structure. With the modular structure of the workstations, Smart Automation was able to achieve standardization at the design, assembly and programming levels, which makes any changes later in the machine life cycle significantly easier.   

To implement this highly flexible line, the system integrator selected TURCK as its automation partner. "TURCK was involved as early as the concept phase of the project," recalls Cezary Zakrzewski, sales manager at Smart Automation. "That helped us discuss the optimal solution together with the customer and made the subsequent phases of project preparation easier."  

Future-proof thanks to standardized device integration   

A key requirement for the production line was support for different Ethernet protocols. With their Ethernet multiprotocol functionality, TURCK's BL67 and TBEN product series I/O modules were therefore the ideal solution for this project. They combine the three Ethernet protocols Modbus TCP, Ethernet/IP and PROFINET in a single device and can operate automatically in any of the three networks. This made it possible to significantly reduce the number of required device variants. In addition, identical planning of machine and system sections using different Ethernet protocols enables standardized device integration across different communication standards, allowing future system reconfiguration to be implemented with minimal effort.  

In addition, the TURCK I/O modules used in the line support the decentralized control concept with their on-board ARGEE logic. This "field logic controller" functionality can handle small to medium-sized control tasks without loading the central controller. As a result, changes to or replacement of I/O modules do not require modifications to the program in the central controller and the individual modules can be tested independently in advance. This strongly supports the modular machine design principle, as Zakrzewski confirms: "Working with TURCK enabled us to achieve a high degree of modularity across the entire production line. This allows us to easily reconfigure the process as needed."  

Flexible process monitoring with RFID  

For complete monitoring of the manufacturing process, Smart Automation implemented an RFID-based tracking system in which the TBEN-S RFID interface and TURCK HF read/write devices play a key role. All parameters and measurement values of the manufacturing process are recorded for each individual part and stored in a database on a server and in the cloud. This solution makes it possible to configure the manufacturing process flexibly, for example by skipping individual steps or reworking specific elements at any time.   

Factor 1 sensors with maximum switching distance for all metals   

In the field of inductive sensors, the company opted for TURCK's uprox product series. As factor 1 sensors, uprox devices reliably detect all metals with the same switching distance, enabling standardization in sensor selection—another advantage in machine design. The consistent use of these sensors simplifies system integration because different distances and target materials no longer have to be taken into account. Installation and maintenance are also less complex, making system construction more efficient.  

Keeping an eye on production with LED technology  

In a project of this scale, it is critical to display the current status at the various production stages. The company selected the programmable WLS27 LED strip lights from Banner Engineering, TURCK's optical sensor partner, to indicate each machine's status in the individual modules using different colors. K50 illuminated pushbuttons were used for intuitive communication with the user.  

Fast and error-proof: pre-assembled cables  

Another challenge given the complexity of this line was the connectivity. Here as well, Smart Automation found a solution in TURCK's extensive connectivity portfolio. During the planning phase, the team selected pre-assembled cables in various lengths and used passive hubs as needed. This approach not only eliminated connection errors from the outset, but also significantly sped up installation and commissioning of the individual modules.  

Summary  

With automotive production requirements continuing to increase, the combination of modular machine design and decentralized control offers numerous advantages. The solutions implemented made it possible to reduce the number of operators, cut wiring effort and speed up installation work, which would not have been possible with conventional centralized control technology. In addition, the modular concept increases system availability because if a module fails, only that module needs to be replaced. Ultimately, the modular design provides straightforward options for expanding the system to meet future requirements, increasing flexibility and ensuring long-term cost efficiency. "It was very important to us that manual operations can be easily automated if the customer requests this at a later point," says Zakrzewski. "TURCK's broad portfolio makes it easy to handle a wide variety of signals, from standard digital and analog signals to RFID, which was used for both operator logging and process traceability. Working with TURCK enabled us to achieve a high degree of modularity across the entire line."  

Customer | www.smartautomation.pl/en