Open Core Engineering

Time is money: snappy automation of testing machines

Guest contributor: Andreas Sokoll, Bosch Rexroth

Usefully combining automation and IT is not only typical of Industry 4.0. In the engineering of measuring and testing machines, open interfaces also unleash great potential for efficiency. With the aid of National Instruments’ LabVIEW graphic programming environment and Open Core Engineering, they can now be modelled and automated in an integrated manner without creating a separate PLC code. The effect: a significantly quicker time to market!

Why complicate things if they can be actually be done simply

The idea of precisely modeling customer-specific measuring and testing machines without having to acquire and coordinate an additional PLC programmer is very attractive to many manufacturers. That’s because, until now, they had to program I/O queries and axis motions separately and transfer them into a joint machine program throughout all the development phases. An irksome and time-consuming task, which introduces additional sources of errors. However, this cost and quality-related factor can be minimized if the development environment communicates directly with the control core.

Modeling measuring and testing machines without additional PLC programming: in National Instruments’ LabVIEW programming environment, manufacturers can execute the motion sequences as well as measuring and testing tasks. The Open Core Interface acts as an open interface between the control system and the PC.

Parameterizing instead of programming

National Instruments’ LabVIEW graphic programming environment, which is widely used in the measuring and testing machines field, satisfies this requirement by supporting Bosch Rexroth’s Open Core Interface. Development engineers therefore get direct access to the control functions via their usual interface. Device drivers and functions can consequently be quickly and simply selected as graphic modules (Virtual Instruments) and then only need to be parameterized. This also speeds up commissioning. This is because, in addition to the measuring and testing applications, the full machine workflow can now be mapped in LabVIEW, and consequently in a joint project. There’s no need for the PLC code to be written in parallel and continually coordinated.

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Reduced engineering workload: Since LabVIEW supports Bosch Rexroth’s Open Core Interface, machine developers no longer have to work in two environments. The axis motions can also now be produced directly in LabVIEW.

Over 550 VIs to be parameterized

With its Open Core Interface, Bosch Rexroth has established the basis for not only the graphic LabVIEW language but also other modern high-level languages, software solutions from the simulation and model-based engineering fields, and open i4.0 standards such as OPC-UA being able to access control functions directly. The seamless integration in the respective programming environment is achieved by using a software development kit (SDK). In the case of LabVIEW, it contains more than 550 Virtual Instruments (VIs). They control the connection set up (ApiLib), access to direct motion commands (MotionLib), and access to the control system (SytemLib) or the drive and control parameters (ParameterLib) among other things. They are clearly structured in function libraries and they can be simply dragged & dropped into the project and then parameterized.

Motion PLC, drive and control functions: The LabVIEW SDK contains eight libraries with over 550 additional Virtual Instruments.

Fully fledged HMI for M2M communication

Both the “front panel” and “block diagram” programming windows that are typical of LabIEW now form a fully fledged user interface for man-machine communication. The block diagram shows the flow logic in the form of VIs and links, and all the control and display elements appear in the front panel, e.g. buttons, switches or graphical displays. So direct operation of the machine is also possible. For instance, in order to move an axis, the programmer simply activates the corresponding VI. The SDK provides numerous example projects illustrating the initial steps. The HMI templates that they contain can be quickly adapted to the respective requirements.

Simple block diagram: In this example, the logically linked Virtual Instruments read a value from the control unit.

Force measurement practical example

Force measurements are by far the most common form of test task. Including handling tasks, an estimated 90 to 95 percent of all measuring and testing tasks can in practice be carried out just by using LabVIEW. Here’s an example of the monitoring of a joining process:

A DIN 625 industrial bearing is to be pressed into a tolerance ring in a controlled manner. In order to control the linear axis motion, measure the pressing force and compare it with the tolerance range, the programmer divides the project into five steps: Connect, move (axes into position), start force control and measuring, measurement completed, and retract axis. The programming takes place purely in LabVIEW with the aid of self-explanatory VIs such as “Standstill”, “MoveVelocity”, “Continuous Motion” or “Stop”. The VIs are linked by connections in the graphical user interface and are activated and deactivated via target and transfer values such as “TRUE” and “FALSE”.

Quick access to the desired operating interfaces: The SDK for LabVIEW comes with lots of example projects in which the HMI can be quickly and easily adjusted.

Complete control set from a single source

In addition to pure modeling and programming in LabVIEW, as a system manufacturer Bosch Rexroth provides even more ways of increasing engineering efficiency. In the practical example shown for instance, the press-fit procedure is carried out via an energy-efficient electromechanical cylinder (EMC) with an integrated force sensor and drive. In combination with an IndraControl XM control this produces a fast, higher-level control loop in which the mechanical and electrical components work together optimally with short cycle times of 250 µs. The test system is quick to set up so it can precisely control the force moments which arise, run at constant speeds and position the work piece in a highly dynamic, flexible and precise manner depending on the requirements. A Bosch Rexroth linear motion technology tolerance ring is used as a frictionally engaged connection element for the insertion of the bearing.

Quicker to market due to large time savings

With the aid of LabVIEW and the Open Core Interface technology, together with Bosch Rexroth’s modern automation solutions, precise movements can be carried out in measuring and testing machines even without any PLC programming – including interfaces, handshakes and synchronization. For users this results in an enormous saving of time, especially since troubleshooting can also concentrate on one instead of two programming environments. This considerable time saving enables manufacturers of measuring and testing machines to bring innovative and complex products to market much more quickly and also inexpensively than before – but without compromising on quality.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

The 5 automation trends in the packaging industry

Guest contributor: Hans Michael Krause, Bosch Rexroth

i4.0 in practice: the 5 automation trends in the packaging industry

Next-generation packaging machines are being designed without control cabinets and are increasingly vertically and horizontally connected. Big data analyses, smart maintenance and model-based engineering have unleashed tremendous potential. But even conventional automation tasks can be handled more easily with open interfaces and integrated functions. What are the five major automation trends in detail?

What the packaging lines of tomorrow will be able to do

When I look at the highly dynamic packaging industry, I see four major challenges faced by machine builders: more individuality when it comes to packaging, more flexibility in terms of formats, higher availability and less space required for machines and lines. These challenges lead to five major trends in automation:

(1) Connected – the connectivity trend

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As a user, I need transparency, whether I want to improve system availability through smart maintenance, make my line more flexible, or optimize complex packaging processes. Without knowledge of subprocesses and plant conditions, I can’t analyze anything – neither on premise nor via the cloud. Modern automation technology and sensor systems now provide all the necessary data. I have to retrofit existing systems, but preferably without the need for programming or intervention in the automation. The IoT gateway fulfills this requirement extremely elegantly and can be set up in just five minutes. Machine builders can also opt for Starter Kit, which includes the Software Production Performance Manager (PPM), for a complete analysis platform from a single source.

The sweet side of Industry 4.0

There is also enormous potential in cross-vendor and system-wide networking via IIoT protocols such as MQTT or the open i4.0 standard OPC UA. At interpack, four machine builders and Bosch Rexroth will showcase the “ChoConnect” project as an exciting example of authentic M2M communication: Four locally distributed exhibition machines from LÖSCH Verpackungstechnik, SOLLICH, THEEGARTEN-PACTEC and WINKLER and DÜNNEBIER Süsswaren exchange information as a virtual production line for chocolate products using OPC UA in accordance with the Weihenstephan standard and create an end-to-end transparent value chain at the shopfloor level – without the need for an MES or control system. The individual steps of mass processing, molding, primary and secondary packaging automatically adjust performance according to individual capacities. The production process becomes more flexible; system efficiency increases.

Merging of automation, IT and IIoT

The fact that inflexible line PLCs will soon be obsolete is also a consequence of a merging of automation, IT and IIoT. With open interfaces such as Open Core Interface, ERP systems can be directly linked to machine automation, simplifying inventory management for machine components. Obviously, there must be also be a security strategy for regulating access to the control system.

(2) Simple – Make it simple!

The current trend towards fewer personnel per line has increased the need for intuitive control units such as HMI with multi-touch. Transparent and seamless visualization solutions are required – on the production line itself and at other locations in the company – in order to continuously improve processes and respond quickly when necessary. The ActiveCockpit interactive communication platform shows that such solutions are already available today.

Companies often need the ability to easily integrate new machines or lines into existing systems – this can already be done mechanically using standardized chain conveyor systems such as VarioFlow plus in combination with the MTpro planning tool. In the future, open M2M interfaces will allow for easy electrical integration.

With the growing need to simplify diagnostics and maintenance, we will see even more web-based service tools and innovative LED concepts at machines in the future. Augmented and virtual reality are sure to play a part here, too. It has been repeatedly demonstrated at trade shows how the digital twin integrates itself into the real picture using open interfaces so that complex technical relationships can be visualized and understood more quickly. A product orientation module for beverage packages by WestRock will be showcased at interpack.

(3) Efficient – end-to-end digital engineering

Ever more complex design needs and shorter time-to-market requirements are fueling the demand for model-based engineering with simulations and virtual commissioning. As a technology partner with industry expertise, Open Core Engineering not only ensures seamless integration of the machine control with simulation platforms such as MATLAB/Simulink or 3DEXPERIENCE by Dassault Systèmes. For immediate creation of a digital twin that can be simultaneously used by mechanics, electricians and software programmers, Bosch Rexroth delivers digital behavior models of its automation products as standard.

Bosch Rexroth also provides a comprehensive library of prepared technology functions along with the machine control. By emphasizing parameterizing instead of programming, flow wrappers, secondary packaging systems, fillers or sealing machines can be commissioned more quickly. Integrated standard kinematics and functions for delta, parallel and palletizing robots are also available. Object-oriented PLC programming and high-level languages, such as Java and C++, facilitate creation of the machine control software. The controllers feature a web server for easy integration of Internet technologies such as visualization using HTML5. Of course, standardized programming templates support the creation of machine programs following OMAC/PackML standards as well as the Weihenstephan standard and PLCopen.

(4) Adaptive – the adaptivity trend

What if the packaging line automatically adjusted the product stream in the event of a fault, instead of jamming and displaying a lot of error messages? Prefabricated software functions such as intelligent infeeds or product grouping are already available, even for these trend-setting M2M scenarios. For the use of robots and flexible transport system a separate controller is not needed anymore. These are managed by the standard machine controller, and the number of interfaces and the effort required to use transport systems or robotics are reduced.

In view of increasingly complex packaging processes, there is also a need for machines to automatically adjust to their environment. Machines require Smart Sensor Nodes with MEM technology like XDK in order to “learn” from their current state. Virtual sensors like servo motors and drives, including the intelligent MS2N servo motor, provide useful information.

Last but not least, next-generation packaging machines automatically adjust to the current format and regulate process speed as well as product handling. Adaptive software functions have also been developed for this scenario of the future. The spectrum ranges from flexible electronic cams in the machine control (FlexProfile), drive functions such as auto-tuning and anti-vibration to frequency response measurements and innovative filter functions for minimizing resonance frequencies in mechanical parts.

(5) Cabinet-free – much more than just space saving

This trend in packaging is not just about saving space in the automation technology, machine footprint and control cabinet space. Instead, it’s about a modular machine configuration that allows machine operators and customers to respond flexibly to different requirements. The individual modules are connected to one another only by a single hybrid cable and can be easily integrated into the machine or retrofitted later. This reduces the installation area and increases servo density in favor of greater flexibility. Installation space, cabling and maintenance costs are also reduced. Such modular approaches are especially useful for secondary packaging and rotary machines such as filling and capping machines as well as retrofit projects.

Solutions for these packaging trends are already available. Use them now!

Manufacturers and users of packaging machines already have numerous options for boosting their competitiveness through intelligent and connected automation solutions. But to achieve this, they need an industry-oriented, expert partner with a broad ecosystem of solutions. At interpack 2017, Bosch Rexroth will give visitors the opportunity to experience the trade show theme of “Connected Automation i4.0 now“ live in all of its facets – including modern networking, simple design, model-based engineering and groundbreaking service. The future of automation has already begun and is ready for “installation” in the latest generation of packaging machines. Now!

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

Virtual commissioning saves precious time

Guest contributor: Steffen Winkler, Vice President Sales Factory Automation, Bosch Rexroth

Ever shorter product life cycles and the desire for smaller batch sizes constantly present designers and programmers of production machines and lines with new challenges. To save time and costs, machine builders increasingly rely on model-based engineering, which creates unimagined potential for efficiency enhancement and cost reduction especially during commissioning – thanks to Bosch Rexroth.

The commissioning of machines is a very elaborate process so far. The reason for this is, among others, that programmers can test and optimize their machine program only on the real machine. Thus, 70% of the time that is needed for the commissioning of the control technology is mainly used for time-consuming and therefore cost-intensive optimization measures of the program. This occupies machine space in the assembly hall and causes considerable additional expenses at approaching delivery dates, like additional night shifts.

However, a majority of this optimization tasks can be virtually performed before through model-based engineering. The advantages are obvious: Starting with the first CAD click, all design data could be created in a PLM system. On this basis, a behavior model of the machine is created. Bosch Rexroth therefore provides 3D models and behavior models of its components. In the simulation software, PLC programmers can then test new control functionalities directly at the behavior model of the virtual machine, without the machine must be set up in the assembly hall.

Controller waits for simulation results

Therefore, a simplified machine model additionally had to be used in the simulation environment so far. The computing power of current PC technology is usually insufficient to simulate the complete machine model synchronously to the real-time behavior of the PLC and motion control.

But this deficit is a thing of the past thanks to the Open Core Engineering from Bosch Rexroth. The controller adapts itself to the timing of the simulation and waits for its results before the next motion cycle is executed. Thus, a real behavior of the simulation of the complete machine model is guaranteed.

When the machine is put into operation at the customer’s site, the engineers only need to start it in the ideal case – more extensive optimizations are thus needless. Open Core Engineering supports all established system simulation platforms like MATLAB Simulink and environments on the basis of the open modelling language Modelica, like the 3DEXPERIENCE platform from Dassault Systèmes or SimulationX.

Consistently digital engineering in practice

The example of the American packaging manufacturer WestRock shows how huge the potential savings are in practice. For the model-based development of their machines, the company relies on the 3DEXPERIENCE platform from Dassault Systèmes, which also supports Open Core Engineering. Directly in the simulation environment, the engineers can thus check and optimize all machine movements and put the control virtually into operation. Subsequently, the knowledge gained here is directly incorporated in the engineering environment IndraWorks from Rexroth. In this way, WestRock could shorten the entire development time from design to commissioning drastically.

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