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Filling with µs synchronization

The B&R automation platform can control both gravimetric (level-based) and volumetric (flow-based) filling processes with real-time synchronization of the valves and sensors involved. POWERLINK and NetTime provide µs synchronization that meets even the most demanding market requirements.

Maximum motion control performance

With the real-time Ethernet POWERLINK protocol and B&R's comprehensive range of motion control solutions, production lines can move up to 2,000 products per minute. B&R allows you to simultaneously boost both quality and productivity.

With a communication cycle of 400 µs and a current control loop of 50 µs, the ACOPOS series provides the extremely fast, event-based cam profile transitions that today's high-speed packaging machines need. With no programming whatsoever, the drive compensates for cam profile deviations every 400 µs. This outstanding performance is completely independent of how powerful the controller is or how many real or virtual axes are used in the application.

The touch probe inputs on the ACOPOS series are processed in the sub-microsecond range and are perfectly suited for applications such as registration mark control, belt synchronization, rotary or fly cutting and quality control. This speed makes it possible to react in real time and perform smoother transitions between motion profiles without any impact on development of the application software.

Gluing, marking and waste detection with 1 µs precision

B&R NetTime provides high-performance synchronization in real time via POWERLINK. Multiple encoder positions (real or virtual) and distributed I/O channels (analog or digital) are synchronized with 1 µs precision.

This eliminates the need for external devices for digital cam switching required by high-speed packaging machines for applications such as shooting glue, marking products and rejecting waste.

NetTime digital output patterns can be controlled with extremely short high/low times for a resolution of 125 ns. In the same way, fast input edges such as registration marks or product detection marks are recorded with a time stamp of 1 µs.

The comprehensive technology library provides a simple user interface to configure interactions between position sensors and actuators – with automatic time/position conversion and dead time compensation.

Automatic identification of the adhesive unit

End users want maximum flexibility in production, which is why they continue to invest in modular, mechatronic labeling machines. The adhesive components must be transferred from machine to machine very quickly, a requirement for which POWERLINK was specifically developed. With automatic node detection and support for hot plugging as standard functions, POWERLINK allows fast and reliable changes without production stops for increased uptime and OEE.

Controlling motion with complete flexibility

When electronic cam profiles are used in packaging machines, it is often necessary to change motion profiles on a running machine. Some examples include product or packaging changeover, registration mark correction, simultaneous cut-and-seal functions, belt tracking and product handling. The B&R Cam Profile Automat allows machine operators to change motion profiles dynamically without requiring any new calculations on the controller. Application development becomes easier, faster and more robust since performance is guaranteed independently of the controller's processing power, network connectivity and the number of axes being controlled.

The Cam Profile Automat allows new profiles to be generated and stored directly on the servo drive every 400 µs. The programmer can define a variety of boundary conditions and limits such as profile type, position, speed, acceleration and rotation. The optimal transition profile is calculated in real time, taking into consideration external events such as hardware and software states.

B&R's Cam Profile Automat combines the advantages of centralized programming, distributed performance and highly flexible profile changes – all at the top speeds achieved by the fastest machines on the market. Cam profiles are programmed and configured in B&R's Automation Studio engineering environment. The B&R Cam Profile Automat is a 100% software solution provided as a standard feature on all ACOPOS servo drives.

Controlling motion with optimal performance

B&R motion control has the performance you need to get the best seal quality at the highest production speeds. Using the MC_MoveAdditive and MC_BR_TorqueControl function blocks for PLCopen, you can switch between position control and high-precision torque control within 400 µs.

Rotary plate control

B&R offers highly flexible motion control solutions that are completely independent of the type of motor technology used – whether it's servo, torque or stepper motors. Thanks to Generic Motion Control (GMC), the OEM has the freedom to select the most appropriate actuator for each project. This ensures the best price/performance ratio every time, without requiring any changes to previously developed software. Compact servo or stepper motors, together with the ACOPOSmicro, cover the entire performance range required for controlling the rotary plate on a labeling machine.

Conserving energy with regenerative power supply

In virtually every production cycle, machines are required to continuously accelerate and decelerate heavy loads. B&R's ACOPOSmulti drive system converts the kinetic energy generated during braking movements into power and then feeds it back into the mains supply. Up to 30% of overall energy consumption can be regenerated – for considerable cost savings.

Power regeneration prevents additional heat from being generated by braking resistors, making it no longer necessary to install and maintain expensive cooling systems. The integrated power regeneration system is not only highly efficient, but also environmentally-friendly.

Aligning bottles and labels without a camera

B&R has developed a powerful image processing algorithm that determines bottle orientation without using a camera. Instead, a standard sensor is used to detect the bottle embossing. A standard X20 analog input module reads the analog data with a sample rate of 100 µs and saves the data in a buffer directly on the module. The algorithm then analyses the buffered data and calculates the required positioning movement for the rotary plate.

The entire alignment process takes less than 400 ms, including:

  • Embossing / Image acquisition
  • Data transfer and processing of the image algorithm
  • Generation of the movement profile
  • Rotary plate movement
  • Labeling
Film control – B&R's specialty

All types of rolled packaging material, including ultra-thin and elastic films, can be processed perfectly with B&R's technology library. Automatic speed control adjustments as well as feed forward control for speed and acceleration maintain the necessary tension during the acceleration and deceleration phases of high-speed packaging machines.

  • Winding/Unwinding with open-loop torque-based tension control
  • Winding/Unwinding with closed-loop tension control, analog dancer feedback
  • Winding/Unwinding with closed-loop tension control, digital encoder feedback
  • Automatic roll change with high-precision sensorless diameter calculation
  • Intelligent, predictive registration mark correction with the MC_BR_RegMarkCapture library
  • Precise temperature control during heating and cooling with integrated autotuning algorithm
Compliance with FDA 21 CFR Part 11

All hardware and software from B&R is fully compliant with FDA 21 CFR Part 11 regulations. B&R provides customers an add-on package of technology libraries that support all FDA criteria for electronic records and signatures.

Perfect integration of high-precision multihead scales

B&R's complete range of food and liquid dosing solutions deliver outstanding speed along with exceptional precision. Multihead scales can be integrated seamlessly into a VFFS control system to bring added flexibility, productivity and ease of maintenance.

  • Direct control of vibratory feeders
  • Full-bridge strain gauge inputs with 24-bit converter resolution at 7.5 kHz, directly connected to B&R X20 or X67 I/O modules
  • Stepper or brushless motor control for hoppers
  • Software algorithm for optimal net weight calculation
Quality assurance with an integrated vision system

B&R offers an intelligent and flexible vision portfolio consisting of cameras, lenses, lighting equipment and software. Seamless integration in the B&R control system enables synchronous data exchange throughout the entire system. The image processing functions are easy to configure and applications can be created without much programming effort.

Controlled axis-synchronized stopping

The intelligent B&R ACOPOSmulti motion control system automatically detects dips in the primary power supply and initiates an emergency shutdown. The kinetic energy that remains in the motors is used to maintain automation functionality until the system reaches a complete stop. The ACOPOSmulti's active power supply module generates 24 VDC for the controllers, I/O modules and drives – eliminating the need for a UPS. The intelligent solutions from B&R prevent production wastage and eliminate the time-consuming process of getting the plant up and running again after a power failure.

Powerful image processing with the Automation PC 910

Equipped with the best technology on the market, including the latest generation of Intel® Core™ i-series processors, the Automation PC 910 is the perfect choice for your most ambitious applications. USB 3.0 ports provide a perfect connection for integrating vision systems. Its modular design allows the Automation PC 910 to be customized perfectly to the demands of any application.

Machine modularity

B&R offers hardware and software solutions for fast and easy development of mechatronic machines with options that can easily satisfy the requirements of the end user.

  • Servo motors with an integrated drive: ACOPOSmotor
  • Servo motors with a decentrally mounted IP67 drive: ACOPOSremote
  • IP67 and IP20 I/O, optional safety modules: X20, X67 I/O modules
  • Stepper motors: 80MP and ACOPOSmicro

B&R offers machine builders a comprehensive selection of motor types. The Generic Motion Control (GMC) concept allows the software to be developed independently of the motor type. For each mechatronic module in a machine, the OEM can select whatever solution offers the greatest amount of freedom, which in turn saves time, resources and money.

Sorting with ease using B&R SmartBelt technology

B&R's SmartBelt technology library controls all the movements involved in aligning unsorted products on a conveyor belt. In primary and secondary packaging machines, products are aligned at regular intervals. This requires one or more conveyor belts depending on the belt speed and the length and weight of the products themselves.

Integrating robotics effectively

With POWERLINK and B&R's Generic Motion Control (GMC), it is exceptionally easy to integrate and synchronize robots with your automation architecture. High-speed packaging machines can easily synchronize standard motion control systems and all types of kinematics – portal, delta, SCARA, articulated arm and even specialty kinematics – in a single, complete control platform.

B&R robotics make it possible to perform maintenance tasks with direct human-robot interaction, such as removing blockages, without stopping operation. B&R offers TÜV-certified function blocks for the required safety applications, integrated via the open and bus independent openSAFETY protocol.

Stäubli robots can be accessed directly by B&R automation technology. This is possible thanks to the POWERLINK interface on the uniVAL drives from Stäubli, which allows GMC programs from the B&R controller to be transferred and executed seamlessly.

Safe motion control

Ensuring maximum safety during maintenance requires safety functions that are implemented directly on the drive, including Safely Limited Speed (SLS), Safe Direction (SDI), Safe Operating Stop (SOS) and Safe Torque Off (STO). openSAFETY guarantees safe motion control up to SIL 3 in accordance with IEC EN 62061 or PLe, Category 4 in accordance with EN ISO 13849-1.

Additional information about the extensive range of B&R safety functions:

Working safely with robots

In order for industrial robots to work together with human operators, the speed at the tool center point must be safely monitored. The area surrounding a palletizer is typically inaccessible to humans. Some situations, however, require hands-on interaction to put the final touches on setup or maintenance work. Many other processes demand that humans and machines work hand-in-hand.

B&R laid the first stone on the path to advanced robot safety with the "SLS at TCP" function (Safely Limited Speed at the Tool Center Point). In order to limit the speed at the tool center point to the 250 mm/s maximum required by regulations for collaborative operation, B&R safely monitors kinematic transformations. This eliminates the need for additional sensors.

A library of TÜV-certified function blocks is available for developing the necessary safety-related control programs. Simple parameter tuning provides unrestricted kinematic design. Safe robots are up and running quickly and easily.

Controlling adhesive film labelers

B&R's high-performance stepper motor control can achieve a linear speed of up to 100 m/min. Puller, winder and unwinder motors can easily be synchronized with electronic cam profiles, even in an open control loop.

B&R's packaging library includes functions for automatic roll changes with sensorless diameter calculation as well as predictive registration mark correction.

Running both power and data through a slip ring

Distributed control and drive components are often mounted on a part of the machine that rotates. These machines rely on a slip ring to connect the power supply and control voltage. POWERLINK and openSAFETY guarantee connectivity, not only of the control data at a certified rate of 100 Mbit/s, but also of the 24 V power supply and 750 VDC bus for distributed servo drives.

Controlling capping heads with complete flexibility

B&R offers a wide range of solutions for controlling capping heads:

  • Servo motors with an integrated drive: ACOPOSmotor
  • Ultra-compact and highly dynamic servo motors and drives: 8LV and ACOPOSmicro
  • Stepper motors: 8OMP and ACOPOSmicro
  • Linear rotary motors from LinMot and ACOPOSmicro

With B&R, the machine builder has the freedom to choose any type of motor, guaranteeing the most ideal solution for the requirements at hand. The drive technology used has no impact on the corresponding software. For more information, check out Generic Motion Control (GMC).

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