450 blisters per minute!

18/06/2014
PLC, motion control, drive as one unit: A complete solution for PG Express described by Alexander Hack, Market Development Manager,Kollmorgen, Ratingen (D). Bringing in latest technological innovations, Kollmorgen is participating in strengthening the packaging & metal forming market segment in a big way.
Alexander Hack

Alexander Hack

It is in this pursuit of excellence, Kollmorgen has supplied the complete automation solution to IMA PG for their PG Express machine. IMA-PG India Private Limited is a pioneer in the field of Thermoforming machines in India having introduced its first machine in 1978. It is today well-respected for its ability to innovate and engineer solutions to meet constantly changing demands. It offers a complete range of packaging solutions that includes machines for applications such as cartoning, rotary vacuum forming, rotary sealing, flat sealing and tube-filling besides of end-of-line packaging. Kollmorgen has been associated with IMA PG for the last two years where they have supplied Automation Solution products like Motion Controller, HMI, Servo drives, Servo Motors, I/Os, etc. Through world-class knowledge in motion, industry-leading quality, and deep expertise in linking and integrating standard and custom products, Kollmorgen provides OEMs with the competitive advantage they need to succeed.

AKD PDMM brings high performance PLC and Motion Control into technologically advanced machines.

AKD PDMM brings high performance PLC and Motion Control into technologically advanced machines.

It is in this pursuit of excellence, Kollmorgen has supplied the complete automation solution to IMA PG for their PG Express machine. IMA-PG India Private Limited is a pioneer in the field of Thermoforming machines in India having introduced its first machine in 1978. It is today well-respected for its ability to innovate and engineer solutions to meet constantly changing demands. It offers a complete range of packaging solutions that includes machines for applications such as cartoning, rotary vacuum forming, rotary sealing, flat sealing and tube-filling besides of end-of-line packaging. Kollmorgen has been associated with IMA PG for the last two years where they have supplied Automation Solution products like Motion Controller, HMI, Servo drives, Servo Motors, I/Os, etc. Through world-class knowledge in motion, industry-leading quality, and deep expertise in linking and integrating standard and custom products, Kollmorgen provides OEMs with the competitive advantage they need to succeed.

PG Express – a backgrounder

The machine can now produce upto 450 blisters per minute thus making production much faster. Currently the P G Express machine is installed at a leading pharmaceutical manufacturer in India and is running successfully from last eight months...

The machine can now produce upto 450 blisters per minute thus making production much faster. Currently the P G Express machine is installed at a leading pharmaceutical manufacturer in India and is running successfully from last eight months…

PG Express machine is a blister packaging machine which is used for forming blisters. Blister is a pack of some tablets (e.g. 10, 4, 5, 1 etc.) made as per design which is used to hold the tablet. This machine is manufactured by IMA PG from the last three to four years but this was the first machine where Kollmorgen supplied the entire automation solution. It is a 3 axis machine used for Indexing, feeding and punching the blister. Major flow of machine operation is formation of blister, dropping of the actual tablet, sealing of the blister and finally cutting of the blister. Kollmorgen has improved the machine speed through excellent system performance. The machine can now produce upto 450 blisters per minute thus making production much faster. However, the OEM started developing obstacles in controlling the temperature which is a critical aspect of this machine because sealing is dependent on the effective temperature control. If the temperature is not controlled properly then the quality of final blister would be bad & it won´t be sellable in market.

Reliability right from the start
When the OEM approached Kollmorgen with this problem, they were quick to respond. An inbuilt function for temperature control was installed which is around 15 times faster than the external controllers. This saves additional PID controller  costs and more importantly it results in better quality and less wastage.

The program is controlled using AKD PDMM controller. This is a drive based motion controller with integrated PLC functionality, which is specially designed for small and compact machines typically used in packaging machines. AKD PDMM brings high performance PLC and Motion Control into technologically advanced machines. The integrated Motion Controller can synchronize up to 8 axes with 250 µs cycle time. It supports various motion control functions from simple point to point positioning to linear and circular interpolation. PDMM can take care of PLC logic, temperature control, motion control, HMI control & drive control for entire packaging machine.

To allow the highest flexibility and freedom of programming, Kollmorgen Automation SuiteTM software has been used where PLC logic, HMI programming, Motion control & drive control are all integrated at one place. It complies with IEC 61131-3 standard for programming languages.

To make the machine user friendly for the OEM, easy software development was done using the Pipe NetworkTM which is one of the key differentiators by Kollmorgen. The software development was done in just 10 days as compared to 45 days by competitors thus saving valuable time and money for the client. With the Pipe NetworkTM it is possible to get rid of mechanical components (e.g. gear, cam) in the machine by defining equivalent motion blocks in the software. This is extremely user friendly, easy to implement & easy to troubleshoot. The user simply needs to draw the scheme & ultimately connect to the machine axes as per requirements. All necessary interconnections are done automatically in the program. The biggest benefit for programmer & end user is the ease of programming & troubleshooting with clear visual understanding of the scheme.

After-Sales Service & Support
At Kollmorgen, the »after sales service and support» to the customer is of prime importance. In this case the first commissioning of the machine was done with the help of global expertise in this kind of application.

Major flow of machine operation is formation of blister, dropping of the actual tablet, sealing of the blister and finally cutting of the blister.

Major flow of machine operation is formation of blister, dropping of the actual tablet, sealing of the blister and finally cutting of the blister.

Senior application development engineers from Germany did the entire conceptualization & programming. It was because of the hard work and dedication of the Kollmorgen team that the actual time for conducting trials & finalizing the performance took just 10 days (against 45 days taken by competitor).

Currently the PG Express machine is installed at a leading pharmaceutical manufacturer in India and is running successfully from last eight months. From the beginning, Kollmorgen has kept a dedicated application & sales engineer for IMA PG.

After the successful implementation of this machine, Kollmorgen subsequently got two new prototypes- PG Super & C350 and successfully executed the same. It was a moment of pride when Kollmorgen recently got the serial production orders for PG Express.


Quieter, more efficient, and improved controllability!

02/06/2014
Dr. Petr Osipov, Product Management Motors, Kollmorgen (D) tells how Multivac relies on Kollmorgen for pneumatic to electric transition

An increasing number of companies in the packaging machine industry have chosen electrical servo technology – mainly to replace motion axes previously powered by pneumatic systems. “Servo technology increases controllability and reduces noise emission. These systems also help us to increase the number of production cycles”, Guido Spix, CTO Multivac, recently emphasized during a packaging show. The packaging machine company uses motion control solutions from Kollmorgen to reduce energy consumption, increase the overall machine effectiveness and improve safety of packaging processes.

Author: Dr. Petr Osipov, Product Manager Motors, Killmorgen.

Author: Dr. Petr Osipov, Product Manager Motors, Killmorgen.

Optimised motorgear box combination.

Optimised motorgear box combination.

From meat stock to finished packaging…and all processed electrically. Compared to traditional, mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilise a motor-gearbox combination to deep draw and seal the foils.

From meat stock to finished packaging…and all processed electrically. Compared to traditional, mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilise a motor-gearbox combination to deep draw & seal the foils.

A motor-gearbox combination achieves a bonding pressure of 20 tons in the high performance R535 packaging machine. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit of their AKM servo motor series and a cycloidal gear drive for the lifting axis. The high power density of this unit allows for compact dimensions.

A motor-gearbox combination achieves a bonding pressure of 20 tons in the high performance R535 packaging machine. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit of their AKM servo motor series and a cycloidal gear drive for the lifting axis. The high power density of this unit allows for compact dimensions.

Kollmorgen was able to cover most of the transportation and rotary applications in meat processing and subsequent packaging processes with two standardized solutions: The AKM servo motors with washdown and food grade option – available also with the innovative single-cable technology.

Kollmorgen was able to cover most of the transportation & rotary applications in meat processing and subsequent packaging processes with two standardized solutions: The AKM servo motors with washdown and food grade option – available also with the innovative single-cable technology.

The AKMH™ stainless steel motors (http://www.kollmorgen.com/en-gb/products/motors/servo/akmh-series/akmh-stainless-steel-series/) provide a scalable solutions portfolio for motion applications in the packaging, food processing & pharmaceutical industries.

The AKMH™ stainless steel motors provide a scalable solutions portfolio for motion applications in the packaging, food processing & pharmaceutical industries.

Secure packaging:
Besides machine and operator safety, for Multivac, this also includes safe packaging processes. The excellent traceability and controllability of Kollmorgen’s servo technology for example, helped Multivac to design a more efficient sealing process for deep drawn packages with the additional benefit of improved food safety. This solution is currently used on the high performance deep draw machines, designed for mid-size to large loads.

Compared to traditional mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilize a motor-gearbox combination to deep draw and seal the foil. These units utilise a knee lever mechanism to lift the molding tools – some weighing several hundred kilograms. They withstand the high bonding pressure of up to 20 tons, ensuring the two foils seal securely. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit consisting of an AKM® servo motor  and a cycloidal gear drive for the lifting axis. Kollmorgen calculated and selected the optimal motor size and gear drive type in close cooperation with Multivac’s engineering development teams.

Two important aspects for the drive train selection were the overall unit length and overload capacity. The model HKS03 six-point lift unit features a servo gear motor with brake having a total length of 307mm and an acceleration torque of 1400 Nm. These results are possible thanks to the high power density of the AKM servo motors, the ideal overall length of the cycloidal gear drive and the fact that the unit comes without end bells and clutches. Piston rods convert the rotary to linear lifting motion. This solution has three significant advantages. Firstly, the energy efficiency of the machine increases because the pneumatic system was replaced as the power source to create the required pressure for the deep draw and sealing operation. Secondly, the geometry of the piston rods creates an extreme closing force at the end of travel which improves food safety. Finally, the high sealing force results in a more secure and thus reliable sealing process.

“Perfectly Clean” inside and out
The two-component epoxy coat used for the hygienic design conforms with FDA 21 CFR 175.300 and is resistant against acids, bases and established cleaning agents with a pH range of 2 to 12. In a long term test performed by the company EcoLab, this coat withstood exposure to an equivalent of more than 2000 washdown cycles including disinfecting treatments. Kollmorgen’s washdown gear motor comes standard with a white coating, significantly improving the machine operators’ ability to detect dirt and biofilms on the surface during cleaning operations.

A stainless steel-like coating is offered as an option. The surface of both coats is water repellent (hydrophobic) and aqueous liquids will run off more easily, which leads to decreased formation of residue on the surface. Hence, Kollmorgen’s standard of a “perfectly clean” gear motor can seamlessly be incorporated in the MULTIVAC Hygienic Design™ concept that is rigorously applied to all deep draw packaging machines.

From Co-Engineering to Production
Multivac has a global distribution network with about 60 subsidiaries and offers a variety of different machine models with different features. Managing this variety with extensive standardization requires strategic partners that are able to cover a large range of machine applications with their technologies. The Kollmorgen washdown gear motor solution is a perfect example for how a project based custom-designed and custom-built product becomes a standardized, ready-to-install module. The concept of the current motion and automation technology used on the deep draw machine follows the requirements of the new Multivac solution: more flexibility by being able to combine several axes interchangeably and at the same time, smaller control units, plus an increase in dynamic performance for better productivity. In summary, thanks to Multivac’s and Kollmorgen’s close cooperation in this project, the entire pneumatic system was replaced by a highly efficient electrical solution. After the first successful practice runs, Multivac determined a reduction in energy consumption for the R 095 e-concept of at least 20 percent compared to similar models.


Driving the lightweight helpers of Universal Robots!

29/03/2014
Kollmorgen drives the lightweight helpers of two models with which Universal Robots aim to establish the flexibility of articulated-arm robots in industrial production. 

UR 5 and UR 10 are the names of the two models with which Universal Robots aim to establish the flexibility of articulated-arm robots in industrial production. The focus is on work areas in which conventional robots have thus far been too big, too expensive, and too loud. Due to their low weight they can be used wherever they are needed. A large part of the power density of the six-axis articulated robots comes from specially adapted KBM direct drive motors from Kollmorgen. Universal Robots was able to embed the motors directly into the articulation axes without need for additional housings.

Author: Ian Young, Key Account Manager, Kollmorgen, Ratingen (D)

Author: Ian Young, Key Account Manager, Kollmorgen, Ratingen (D)

The six-axis robots are being used in processing and production facilities for example. The robots are easily programmed to accomplish repetitive tasks

The six-axis robots are being used in processing and production facilities for example. The robots are easily programmed to accomplish repetitive tasks

The KBM motors offer a great deal of freedom to configure the servo axes in a space-optimized way due to their variable, modular design.

The KBM motors offer a great deal of freedom to configure the servo axes in a space-optimized way due to their variable, modular design.

The UR 5 and UR 10 designs use KBM motors from Kollmorgen. They are integrated directly into the axis joint without a housing.

The UR 5 and UR 10 designs use KBM motors from Kollmorgen. They are integrated directly into the axis joint without a housing.

Esben H. Östergaard, technical business manager of Universal Robots, values Kollmorgen's high availability of supply in a constantly growing market.

Esben H. Östergaard, technical business manager of Universal Robots, values Kollmorgen’s high availability of supply in a constantly growing market.

Close partnership with people: the robots from Denmark have been designed for collaborative work in production.

Close partnership with people: the robots from Denmark have been designed for collaborative work in production.

They developed the UR5 and UR10 models for small and medium-sized enterprises in particular. The handling units lift a payload of five and ten kilograms, but only weigh 18 and 25 kilograms themselves respectively. This low weight makes it possible to move the units easily without complex subcomponents. The multi-functional robots are just as flexible in operation given their user-friendly software. This multi functionality supports the Danish company with a user-friendly piece of software. Using this, the six-axis lightweight robots are ready for new tasks in no time. No special knowledge of robotics is necessary for the programming.

Modular Design
The exceptional ratio of dead weight to loading capacity is the result of a sophisticated lightweight construction that does not contain anything it does not need. With the drive technology, this minimalist strategy means integrating Kollmorgen’s frameless kit motors directly into the articulation axes. In so doing the robot takes on the function of the motor housing, while the gear unit simultaneously serves as the primary bearing of the rotor. Viewed as a whole, the components used by UR frequently take on multiple functions, and this ultimately reduces the number of mechanical components such as ball bearings, couplings, or shafts considerably, thus decreasing overall system weight and form factor. In addition, with their high power density, the Kollmorgen motors increase the lifting capacity of the UR5 and UR10 platforms. With their high power density, the KBM motors increase the lifting capacity of the UR 5 and UR 10 at the same time.

The KBM motor series offers advanced electromagnetic designs for optimized torque and minimal cogging and harmonic distortion. These benefits are offered over a large operating speed range. The electromagnetic technology with a high packing density in the stator increases torque and keeps thermal losses low. High strength rare earth magnets are used in the rotor, which allow a continuous torque of 1.45 to 3,445 newton meters along with a peak torque of 4.91 to 12,812 newton meters. “The high quality of these motors was a reason why we opted for Kollmorgen,” explains Esben H. Östergaard, technical business manager of Universal Robots.

Given that the KBM motors are embedded in the robot housing and directly drive the load, the robots are able to achieve high level of precision in movement and force control. Targeted force control is critical in this regard, because the robots constantly have to move different workpieces perfectly with high variability. In practice they recognize the size and elasticity of the objects and adjust the force to be applied accordingly. This force must be stronger than just 25 newtons to do this. With a precision of ± 10 newtons and an accuracy of ± 5 millimeters, the required force and desired position can be programmed and executed for each of the six joints.

Operation without noise but high energy efficiency
Another advantage of the robots is its low-noise and energy-saving operation. From a total-cost-of-ownership perspective, the economical use of resources directly increases the efficiency of the robots overall. The competitiveness of this technology thus increases as a result. An additional benefit of high energy efficiency is closely linked to reduced losses in the motors. As efficiency is high, less heat is produced. This means the motors stay cooler, operate below their maximum ratings, and consequently achieve a longer service life. The improved temperature behavior also prevents the entire construction from heating up. “The motors we used in the past became pretty hot when in continuous operation. Because of the lower losses, the KBM motors from Kollmorgen simply stay colder. We can therefore run our robots in continuous operation without derating,” states Östergaard, and he refers to test procedures with long operation periods and comparatively high loads.

The KBM series is an innovative direct drive frameless motor technology provided by Kollmorgen. The frameless kit motors offer mechanical and plant engineering a wide range of solutions for creating applications with a maximum degree of flexibility, power density, dynamics, and durability. In addition to the technical advantages provided by this product, the KBM platform includes 14 frame designs and many pre-engineered standard options with competitive lead times. “We can basically order as many motors as we want, when and how we want,” emphasizes Östergaard. This aspect is of particular importance because Universal Robots is growing strongly. “We therefore need a partner in drive technology who is a good fit for us.” In this regard, Kollmorgen was able to impress the Danish robot specialists with delivery reliability and has since established a UR-specific production line at the Czech location in Brno.