Rockwell Automation created the 'Best Future Machine Award' to recognize outstanding performance, creativity and innovation in the packaging industry. At last year's Interpack, the Cama Group received the award for the high level of innovation of its new IF318 Robotized Monoblock top-loading case erector and filler. The machine's cabinet-free design was developed by Cama several years ago as part of the redesign of its machines. This resulted in today's BTG technology (Break-Through Generation). Today, all Cama machines are cabinet-free, thanks to onboard drivers, remote I/Os and electrical and pneumatic components that are integrated into the machine frame.

The main advantages of cabinet-free technology are reduced space requirements and simplified access to the machine thanks to the elimination of the remote panel. In addition, the electronic components are now built into the machine frame, which speeds up the wiring and installation process, results in a shorter distance between the drives and also makes it possible to integrate the safety PLC.

A positive economic effect is that reduced downtime for maintenance and cleaning, faster installation and the use of standard components mean that cost benefits can be achieved with the cabinet-free technology in terms of overall equipment effectiveness (OEE).

The electronic and mechanical design of the IF318 is based on an ergonomic approach. The interaction between functional design and human factors is also taken into account in order to optimize system performance and user comfort.

The role of ergonomics

The cabinet-free machine design: The electronic components are integrated into the machine frame. One advantage of this: The wiring process is accelerated.

© Rockwell

In addition to the cabinet-free technology, the machine frame design offers the following advantages:

- safe and easy access and therefore an increased level of safety for operators; a complete overview of machine operation and simple operation;
- improved access to all parts of the machine and the elimination of hard-to-reach areas to simplify cleaning and maintenance;
- transparent work processes to identify problems quickly;
- reduced noise pollution for workers around the machine;
- a clear design and high hygiene standards: vertical and flat surfaces ensure that high hygiene requirements are met and cleaning work can be carried out quickly.

Changed user guidance

Visual management: The system guides the operator step by step through the work processes.

© Rockwell

The operability of the IF318 machines has been enhanced with new functions and additional devices. Firstly, visual management: all new-generation Cama machines benefit from this machine management system, which guides the operator step by step through the work processes during each format change. HMI notifications are supported by light signals to make it easier to identify problems and reduce the time required for interventions. The IF318 also features variable carton handling. This enables cartons to be handled throughout the entire conveyor system, regardless of their shape or size. This means that format changes are no longer necessary in this part of the machine.

In addition, the design of the machine now allows the operator to change the format for robot heads and machine components without tools and with guaranteed repeat accuracy and safety. In addition, there is simple error detection with direct feedback, user-friendliness, fast and tool-free machine changeover, an identical process for every changeover and, as a result, a shorter start-up time after a changeover.

The cloud connection

The special feature of the machine is that it provides important KPI data for further use via the Microsoft Azure cloud thanks to the combination of FactoryTalk Analytics for Machines and an Allen-Bradley CompactLogix 5480 controller with Windows 10. This information gives the user real-time insight into production performance. Specifically, this includes production and device diagnostic data as well as performance monitoring data - energy, power, mains voltage and current. Last but not least, the user receives information about the maintenance status and the axis progression with relative parameters such as current feedback or speed. This provides the user with detailed displays of the machine status, alarms, diagnostics, downtimes and causes, as well as detailed production reports. The system integrates and monitors all operating parameters. The operator can simultaneously monitor all information related to the respective production process. He gains insight into the machine operation and can modify the data immediately.

The iTrak system

Compared to its predecessors, the modular and scalable iTRAK system linear motor system increases the machine's production output by 50 %.

© Rockwell

The Cama machine also uses the iTrak system from Rockwell Automation. OEMs benefit from a simplification of the design and construction of rail-based solutions. In other words, by combining linear and rotary motion, machine designers can improve both handling efficiency and throughput. A nice side effect of this approach is that development time can be reduced by around 40% as the system is variably configured. iTrak is a modular and scalable linear motor system that enables independent control of multiple movers on straight or curved paths. Chains, belts and gears driven by rotary mechanisms are a thing of the past. iTrak replaces hardware with software profiles that set new standards in terms of speed and flexibility in automation. For the end user, this results in the advantages of a realizable increase in production output of up to 50%, shorter downtimes during changeovers, a reduced machine size, shorter yet more profitable production runs, less effort for regular maintenance and lower maintenance costs.

Author: Paolo Mosca is Electronic Department Manager at the Cama Group.