29 www.drivesncontrols.com October 2024 MACHINE BUILDING n box modules allows all cables to the motors, sensors and valve terminals to be pluggable. The crucial advantage of the new approach for Schirmer lies in restructuring its internal processes. The pluggable system allows the machine-builder to install all of a machine module’s electrical components during preassembly and to connect them using preassembled cables. Another crucial aspect is that, during pre-assembly, the machine modules are accessible from all sides, making it easier to lay out and connect the cables. “This saves a lot of time and significantly increases the efficiency of our workflows,” explains Martinschledde. “This not only applies to assembly, but already begins with planning, preparatory work, and material provision in the production phase.” The system’s function modules also eliminate the need for complex wiring of numerous sub-components that is typical of conventional control cabinet designs. This avoids wiring errors and streamlines the number of parts needed. As a result, the required components – baseplates, modules and pre-assembled cabling – can be picked from a warehouse for pre-assembly after the electrical planning stage. The aim, according to Martinschledde, is “to achieve an order-independent warehouse that we can manage with minimum stock levels, requirements, and replenishment times”. Schirmer’s initial development project revealed two further insights: last-minute change requests are much easier to implement and need less effort (even at a late stage); and with modular commissioning, any functional errors can be detected early and rectified without time pressure. In the final assembly phase, the machines take up a large area of Schirmer’s floorspace, so processes have to run quickly to make room for the next systems. Martinschledde notes that the upstream processes – particularly electrical installation and partial commissioning – significantly reduce downtime and increase space efficiency. This allows Schirmer to assemble, inspect, and deliver more systems in the same area. As a machine-builder which exports 75% of its output, a universal automation system is another important aspect for Schirmer. Previously, it had to consider the installation location during electrical planning and material procurement, but the new machines can be used worldwide without needing time-consuming modifications because the MX System is IEC-, UL- and CSAcompliant. This is unlike conventional control cabinets, and is helping Schirmer to increase its levels of standardisation. User benefits The cabinet-free automation technology also offers potential benefits for end-users, including improved accessibility to their machine structures, and space-saving due to the elimination of the cabinets. Production facilities can be located closer together on the shop floor, optimising space without, for example, violating escape route requirements. A ten-fold reduction in the number of components needed also reduces the size of spare parts stores. Beckhoff is launching a diagnostics app for the MX-System that will make it easier for maintenance personnel to find and rectify faults. “The end-to-end pluggability and the use of the diagnostic app as a replacement for the multimeter means that specially trained electricians are not required to connect or replace the MX System modules,” explains Beckhoff product manager, Daniel Siegenbrink. Schirmer’s adoption of the cabinet-free system has resulted in significant advantages and optimisations across its process chain. For example, the electrical planning workload has been cut by around 50%, with the usual two to three weeks of assembly time being cut to just a few hours. Ludger Martinschledde also expects a significant reduction in downtime at the final assembly stage. The new machine was presented for the first time earlier this year at the window industry’s Fensterbau Frontale trade fair. Martinschledde believes that the technology will lead to a new era of control cabinet-free automation. The cabinet-free approach “is changing the face of design and installation in the world of machinebuilding,” he argues. “We are fully on-board with transitioning our machines to control cabinet-free automation with the MXSystem, and this will also apply to the product lines for aluminium and steel profiles in the future.” n The machine components Schirmer’s 14m-long profileprocessing machine includes: n 11 process modules n 67 axes n 23 AM8000 synchronous servomotors n 4 AL8000 linear servomotors n 28 AM8100 synchronous servomotors n 12 three-phase asynchronous motors n 18 valve terminals n 11 MX System baseplates n 118 MX System function modules n 1 IPC module n 39 system modules n 34 I/O modules (including 28 for compact drive technology) n 7 relay modules n 37 drive modules n 64 EtherCat box modules n 1 customised control panel The MX System’s double-row baseplate is installed on the machine’s base frame, simplifying wiring and facilitating diagnostics. Each machine module has its own baseplate onto which the various function modules are attached. The loading magazine needs only two 48V servodrives and a few digital signals, and uses a compact singlerow baseplate with 12 slots for MX modules with 24/48V DC supplies Images: Beckhoff
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