When French window and door manufacturer, Bieber, built a new production plant setting new standards in sophistication and flexibility, enhanced flexibility, speed and efficiency were the aims.
To this end Bieber commissioned Koch Maschinenfabrik based in Leopoldshöhe, Germany. With more than 50 years of experience, Koch is a leading supplier of high quality machines for sawing, milling, drilling, gluing and dowelling. Bieber’s goal was achieved using PC and EtherCAT based control technology from Beckhoff.
Koch‘s requirements for the new CNC machining centre were maintaining and even increasing the high product quality, with maximum flexibility right down to the smallest lot size. Both are key success factors in the market for wooden windows and doors. The result is a unique, modular woodworking machine which despite its size and complexity, only requires two operators. The new production plant meets Bieber’s special requirements through in-house developed software for the PC control master computer.
The plant consists of five modules – the intermediate parts store, the three processing modules arranged in a U-shaped configuration, and the tool changer – with a shuttle system located in between. Koch uses EtherCAT and TwinCAT NC I software for transferring and processing control data within the individual machine modules. This was a prerequisite for meeting the high requirements for axis synchronisation of the servo-controlled and independently operating tension jacks in the processing module.
Oliver Bexte, software development manager at Koch, explains: “Each of the two processing sections may contain up to six individual components. The high processing performance and short cycle times require very fast control technology. We therefore operate the NC with 2 ms speed and precision and the cam-plate axes at 1 ms.” Based on a proven track record over many years, Koch uses Beckhoff’s automation technology for all its NC-controlled machines.
The communication with the master computer – which is used for the calculation and allocation of the production data, parts tracking and tool management – is based on TwinCAT ADS.
The high complexity of the plant is reflected in the key data of the automation system: C6140 control cabinet industrial PCs with RAID system from Beckhoff are used as control computers in all modules and as master computer. They are operated via customised Beckhoff touch panels with push-button extension. Including the upstream planer, a total of 102 servo axes have to be controlled. In addition, the EtherCAT system has 1804 digital inputs and 1516 digital outputs, numerous analogue I/Os and TwinSAFE terminals – for realisation of a start-up lock and a global emergency stop – and several other terminals, such as the EL6001 for connecting RS-232 devices.
Oliver Bexte, Koch software expert adds: “The new plant accounts for 80% of Bieber’s production. A quick response in the event of a system shutdown is therefore crucial. This is one of the reasons why we use Beckhoff control technology throughout. The same PCs, EtherCAT couplers and I/Os are used anywhere in the system, so that in the event of a fault components can be replaced quickly and easily, quite often even without having to call in a service technician.”
Bieber plant designer, Yves Kuhl says: “The high requirements resulting from short production times are satisfied thanks to the high performance and positioning speed of the plant. On average we achieve a throughput of two workpieces per minute and therefore an output of around 800 window components per shift. The Koch plant has many innovative functions that were not possible with the previous individual systems.”
PC-based control technology from Beckhoff has already been tried and tested in everyday practice at Bieber for a long time, as Ralf Steube, chief designer for window and door production machines at Koch, explains. “Two of our machines that are controlled with Beckhoff technology were installed at Bieber over 10 years ago and are still operating extremely reliably. PLC-controlled machines therefore became a thing of the past quite some time ago. With the new plant, Bieber once again benefits from comprehensive PC control
expertise,” he says.
For more information contact Kenneth McPherson, Beckhoff Automation, +27 (0)11 795 2898, [email protected], www.beckhoff.co.za
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