Wireless and flexible thanks to IO-Link connection

Customer report on the Rotzinger PharmaPack GmbH packaging line

Highly flexible transport systems, such as the Multi-Carrier System, offer maximum flexibility with high productivity, thus enabling the optimization of manufacturing processes through automated systems. In cooperation with plant manufacturer Rotzinger Pharma Packaging , we equipped a Multi-Carrier feed with 32 grippers from the GEP2000 series. The focus was specifically on handling 300g biscuit packages. The solution provided by Zimmer Group and CoreTigo - Industrial Wireless Automation demonstrates how the complexity and flexibility of this process were improved through intelligent handling components such as IO-Link grippers and wireless communication modules from CoreTigo.

Freely positionable and wireless

ROTZINGER PharmaPack GmbH required a gripping system for a Multi-Carrier system handling individual biscuit packages, which should meet the requirements of linear actuators. Particularly, wiring in a circulating system often poses a significant challenge. Several grippers are installed one after the other on the movers and move with the circulating belt. Conventional wiring can quickly become a disturbance contour in the process flow, especially when, as in this case, a large number of end effectors are used.

Furthermore, as with all modern automation solutions, a high degree of flexibility is demanded in circulating systems. Statically mounted communication modules for moving end effectors hinder smooth process flow since the workpieces to be gripped must be in the correct position at a certain time. For maximum productivity, the system must be flexible and allow querying via the end effector to grip workpieces variably. The challenge was, therefore, to place the grippers on freely movable movers without impeding the smooth operation of the system with additional cables.

But how can this flexibility of the grippers be ensured? The solution lies in the IO-Link Wireless Gripper technology, which ensures wireless real-time communication between the gripper's sensors/actuators and the PLC control. Thus, IO-Link capability was another important prerequisite for selecting the grippers. In addition, the limited dimensions of the carrier, which specified a maximum width of 50 mm, had to be considered.

Wireless & contactless communication on conveying systems is crucial for creating fully automated, innovative, and competitive machine design not possible before, for packaging, assembly, logistics and material handling. CoreTigo - Industrial Wireless Automation ’s IO-Link Wireless communication solution revolutionizes the industry by providing real-time, cable-grade wireless connectivity for sensors and actuators located on dynamically moving machine components. This enables our GEP2000 grippers, which are mounted on movers, to perform actions seamlessly while in constant motion.

Small installation space, large stroke: the GEP2010 as a solution

We solved these challenges with the GEP2010. The gripper is IO-Link capable, making it easy to set up and can be wirelessly controlled with the help of a complementary component. The combination of the Bridge Communication Module (BCM), which is attached to the end effector, and the Master Communication Module (MCM) on the PLC module ensures effective and secure communication between the partners. Data exchange takes place within a few milliseconds. This fast data transmission enables achieving the customer's required cycle time effortlessly. The 32 individual grippers are easily supplied with power through contactless power supply. In the Multi-Carrier system of ROTZINGER PharmaPack GmbH, additional advantages of the GEP2000 series are evident: The GEP2010 impresses with a compact design while providing a large stroke. Moreover, the electric gripper series boasts a longevity of up to 10 million maintenance-free cycles.

The IO-Link connection of the end effectors ensures not only flexible positioning but also enables easy parameterization of the system, permanent position detection of the gripper jaws, and the straightforward addition of further grippers as needed. In addition, potential sources of error due to cable breakage and the necessary replacement of wear parts are minimized through wireless information transmission. Furthermore, the existing interface between the modules offers maximum flexibility, allowing for many other applications, for example, in the pharmaceutical industry, consumer goods, or intralogistics.

Communicate wirelessly

With the wireless communication between end effector and BCM/MCM, we address the requirements of production plants such as those of ROTZINGER PharmaPack GmbH. Besides cost-effectiveness and flexibility, providing reliable, straightforward process and status information is a central demand. We provide the basis for networked production with an extensive portfolio of IO-Link end effectors that can also be wirelessly controlled thanks to BCM. As an experienced partner, we support our customers worldwide from all industries with comprehensive on-site consulting and service. We accompany our customers from the development of intelligent, networked automation solutions to implementation and beyond.

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Special thanks to Rotzinger Pharma Packaging and CoreTigo - Industrial Wireless Automation .

This article originally appeared here.