Innovating Controls Architecture with IO-Link
All-in-One IO and safety solution boosts OEE
Industry:Food & Packaging IndustryCustomer:CP Packaging
CP Packaging, in Appleton, Wisconsin produces Horizontal Form Fill and Seal machines primarily in the Food Industry. They incorporated IO-Link controls architecture from Balluff on their VisionPak™ vacuum pack machines and realized added benefits from Balluff's safety system solution and the efficient handling and configuring of analog and digital devices into the system.
As manufacturers strive to implement smart factory concepts such as Industrial Internet of Things (IIoT) technologies to drive efficiency and growth, it is vital that they keep safety solutions front of mind. Safety over IO-Link solutions combine automation and safety to deliver more efficient production while protecting staff and equipment.
When Ryan Hartter, engineering manager for CP Packaging, an OEM manufacturer of innovative horizontal vacuum packaging equipment in Appleton, Wisconsin, was researching solutions to handle the safety system of their VisionPak machines, he knew he needed tools that would allow him to configure, control, and monitor the safety system.
Hartter began his search for a safety system solution after he learned that his previous safety solution was no longer going to be supported, but in Balluff he found a more robust and valuable safety solution. Balluff specializes in delivering dependable, rugged products for industrial sensing, networking, and industrial identification to help prevent downtime, eliminate errors, and innovate the way their customers automate. In Balluff's IO-Link safety hub module, CP Packaging found a beneficial and valuable safety system solution. For the VisionPak machines, Balluff's IO-Link controls architecture provided improved functionality and flexibility.
Balluff delivered digital and analog IO, as well as safety solutions, on the existing safety-capable Profibus network architecture CP Packaging had already designed - a major benefit for CP Packaging. It reduces wiring, is easier to configure, and provides real-time feedback of all safety-related data. This gives CP Packaging the ability to better notify the user of the root cause and exact reason for a safety fault.
Once CP Packaging saw the value of the safety features and capability, it was easy to see the overall benefit of incorporating Balluff products into the machines. Using the Balluff IO-Link solution and device interface tools on the VisionPak machine reduces costs, decreases labor hours, and provides improved diagnostics - a necessary component for Industry 4.0. And its capabilities can easily be expanded to the entire warehouse.
On the VisionPak machine, remote IO is routed through Balluff IO-Link modules - which are configurable 16 digital in/digital out modules. Additionally, they use the configurable analog input module for the RTD (Resistance Temperature Device) and thermocouple inputs. These modules give CP Packaging the ability to configure each of the 8 ports.
They currently use 3 types: 0-10 VDC input; 4-20 mA input; and PT100 RTD input all on the same 8-port module. The analog input module delivers great flexibility, valuable information on run time data, and straightforward information CP Packaging engineers can use for other parts of the application-and they don't have to add multiple devices to process three different types of data.
According to Hartter, another advantage of connecting analog devices through Balluff IO-Link is the benefit of circuit and device isolation, especially for the RTDs used for 277 V heaters. In an environment that is conducive to high moisture being able to minimize the points of failure or localizing the failure point is a huge advantage of the system. Moving the RTDs to the IO Link analog module has eliminated the need for the analog module in the PLC chassis. In CP Packaging's previous network architecture, when a short-circuit occurred it would require an expensive, newly programmed analog IO module replaced in the PLC backplane. Once replaced, the module would then need to be reconfigured with third-party software. In more serious cases, a short circuit would find its way onto the PLC backplane and cause additional downtime due to parts needing to be replaced, more programming requirements, or a host of other issues that could be wrong.
Today, with the Balluff configurable IO Link analog modules, RTD devices can be connected at the IO block mounted on the machine instead of in the panel. This provides CP Packaging with short circuit protection at the device, and also at every port. This protection is valuable, in that if a short circuit happens it only affects that port. A short will not disable the master block or any other devices on the backplane. This protects the entire network and reduces unplanned downtime. And the configuration of the block and device is taught from the PLC.
This new configuration has made connecting devices easier from an analog perspective. CP Packaging now uses all standard 4-wire device cables that go directly from the IO-Link analog module to the devices, which minimizes wiring time, costs, and mistakes. From a PLC perspective, having a standard 4-wire cable for the analog devices means scaling - translating amperage to temperature values - is not necessarily required.
IO-Link monitors the values and displays them in the browser interface page. Having the IODD (IO Device Description) file loaded on the master enables process data to be readable; otherwise, it would be displayed in hexadecimal format. The VisionPak machine receives the 0-10 VDC reference voltage, as opposed to an arbitrary count value, as a parameter configured in the web page. The system provides temperature data in Celsius, while milliamps voltage is used to display the data in proper human-readable units.
For servicing and diagnosing the VisionPak machine, having analog feedback in meaningful units makes it easy for maintenance people to understand. Another benefit is that the service personnel can connect to the network to access the information that is being provided by the modules themselves. Access to the IO-Link master browser interface page gives them all the information, as well as what is external to the PLC, without having to disrupt the PLC program or load the HMI software. They can just view it on the HMI. This allows them to be more prepared and shorten their service times.
Startup times have been reduced from days to hours because of this new seamless IO configuration - for both analog and digital devices. For CP Packaging's analog devices, the operator can go directly to the HMI, and when a device is replaced the operator can push a button and the configuration is loaded directly onto the device.
On CP Packaging's digital devices, that configuration is all sent down through the IO-Link masters. Hartter can easily add and remove standard plug-and-play digital devices without the need for major rewiring and have port level diagnostics for these standard devices. A new plug-and-play device automatically registers when it is plugged in. Balluff was able to help CP Packaging save space and make machine areas less cluttered and easier to access.
Balluff solutions clearly provided a dramatic positive effect for CP Packaging. The company was originally only looking to control, configure, and monitor their safety system in their VisionPak machines, but in partnering with Balluff was able to simplify their controls architecture and more efficiently handle and configure analog and digital devices into the VisionPak machines.
Furthermore, CP Packaging realized additional benefits:
- increased production volumes with the same resources and without having to expand the store floor
- increase overall equipment efficiency by reducing planned and unplanned downtime
- reduce the cost of servicing the machines for the end users.
VisionPak machine