Semi-automate format changeovers with Balluff's Guided Changeover Solution

The following is an example application of the semi-automated format changeover used on a filling line.

From filling the bottles, screwing on the lids, and applying the labels, to packing them in beverage crates, find out how the Guided Changeover Solution supports format changeover at every step.

• Low changeover and ramp-up times

• Error prevention and minimization of waste

• Easy creation and management of changeover instructions

• Intuitive step-by-step operator guidance

• Retrofit solution independent of company network or machine control system

Balluff's Guided Changeover Solution enables safe semi-automated format changeover through intuitive and simple configuration of different formats, creation and management of work steps, and detailed operator guidance.

Our software guides the operator step by step through the format changeover process when configuring different formats. This means that even employees with little experience can carry out format adjustments more quickly, and downtimes are reduced to a minimum. There is no need for time-consuming readjustment. Manuals and high training costs are a thing of the past. The instructions can be displayed both on permanently installed screens and on mobile tablets. In this way, the operator is optimally supported at every changeover point.

Every machine is different. From our broad IO-Link portfolio, we find the right sensor for the correct setting of lengths, widths and heights for every application. When changing parts, our identification systems also provide support. In this way, we cover the most diverse types of changeover processes. The sensors provide immediate feedback as to whether, for example, lengths and widths have been set correctly, and that the correct interchangeable parts have been installed.

Our digital position indicator is suitable for setting lengths, widths and heights with a handwheel.

For each different product size, the correct distance of the guide rails for each format is stored in the Guided Changeover Solution software. The display then shows the new target sensor value in addition to the actual position. This makes it possible to set precise positions with the handwheel without error. Thanks to the real-time position feedback in the Guided Changeover Solution, the correct setting can also be seen in the software overview.

Like the master blocks, this position sensor also has IP69k class protection, making it suitable for installation in washdown environments.

• Faster adjustment of lengths, widths and heights

• Intuitive operator guidance with the aid of the display

• Precise and error-free adjustment of dimensions

As formats change, the size of objects and their packaging changes. To set the correct gripper position, our BTL length measuring system is used.

The accepted threshold values as well as the target and actual values are displayed in the software. This makes it easier for the operator to make the correct setting.

• Facilitates the setting of correct length dimensions

• Software enables verification of correct settings

Reliably position objects, regardless of their surface material. Optical distance sensors can be used to set distances in format adjustment. In this example, different format sizes require height adjustment of the tunnel.

A display of threshold values and the optimum distance set in the software provides the operator with guidance and real-time feedback on the current settings of the optical sensors and the tunnel height.

• Facilitates setting the correct height

• Software allows verification of correct settings

Automatic detection of interchangeable parts ensures that the correct format part is inserted during changeover. This is achieved with our identification technologies. At all changeover points, RFID read/write heads check the exchangeable parts, which are equipped with RFID data carriers.

Depending on requirements, the change part can be identified once by the RFID read/write head or monitored continuously.

This example shows a one-time identification of the exchangeable part. The data carrier is located on a label roll, e.g. for the 1-liter bottle size. When the format is changed, the new label roll is identified once with an RFID read/write head before insertion.

• Ensures that the correct format part has been inserted

• Detection of different change parts at one point

To permanently ensure that the correct exchangeable part is present, the exchangeable part can be monitored at the exchange point using an RFID read/write head.

This example shows permanent monitoring of the guide rail for a specific bottle size.

• Ensures that the correct format part has been inserted

• Permanent monitoring of the format parts

With our SmartLight, you know what the status of the format parts is at all times. It reliably monitors the status of the system and visualizes the progress of the format change to guide the operator through the process.

During production, the correct positions and settings of the format parts are monitored.

• Real-time feedback of format part settings

• Faster error detection and correction

With the SmartLight Indicator, the correct setting at individual setup points on the machine can be verified.

By changing the color of the SmartLight, the use of the correct exchange part or the setting of the appropriate length is visualized directly at the changeover point. This saves walking back and forth to check the settings on the HMI.

• Real-time feedback on the status of the format part setting.

• Provides direct feedback when the setup point is set correctly

Our central network block collects data from all of the connected sensors and communicates with the Guided Changeover software. In addition, all settings and parameterizations of the sensors are made via the network block.

With different housing designs, the master block can be matched to the environmental conditions. Especially for the food and beverage industry we offer blocks with a protection class up to IP69k which are suitable for mounting in washdown environments.

• Fast integration and easy configuration

• Consistent diagnostics

• IP69k protection class for washdown environments

• Powerful end-to-end network