It is no secret that machine builders today are under significant pressure to deliver equipment that can meet the demands of flexible manufacturing. In today’s made-to-order world, consumers are challenging the status quo by demanding a multitude of variety in the flavors, packaging sizes, and multi-pack offerings of their favorite packaged goods.
Consumer packaged goods (CPG) manufacturers are challenged to deliver future-proof designs that optimize changeover today – and ramp up rapidly for new SKUs not yet imagined.
Until recently, machine builders had little choice regarding how they delivered equipment to the factory floor. Typically, any CPG manufacturing or packaging application comprised of a series of standalone machines that were integrated to complete the line. That legacy remains on many plant floors today.
These lines are characterized by static mechanical parts, friction-based conveyance, and a plethora of disparate, ancillary equipment. Therefore, while they may achieve impressive throughput running uniform product based on fixed variables, machine flexibility is often compromised. Complex mechanical adjustments and equipment synchronization takes time and time is at a premium on any plant floor – especially when a product launch is at stake.
Advancing technologies
Thankfully, there is a better way. With advances in technology, OEMs now have a better way to meet the demands of manufacturers for more flexibility. Specifically, three key mechatronics technologies are changing the equation for OEMs and the customers they serve.
Firstly, robotics is finding its way into more CPG applications than ever before. Robots are intrinsically flexible, thanks to their ability to operate fully in three dimensions, determine appropriate paths without mechanical rerouting – and address infinitely variable product shapes and sizes.
Secondly, linear motor technology – and notably, Independent Cart Technology (ICT) – boost machine response to a diverse product mix. Unlike conventional conveyance that advances product on a preconfigured path at fixed speed, ICT intelligently moves products as operations are completed.
And finally, automated changeover – which minimizes the need for manual intervention and facilitates machine setup for a new product or packaging configuration from the operator interface. New servo drive functionality is making this option even more cost-effective.
Advances in motion control technologies can help manufacturers meet consumer demand for more product variety and packaging sizes. Rockwell Automation recently introduced a new Kinetix 5100 servo drive, Kinetix TLP motor and cable that can function as a system without a controller – a more cost-effective option for OEMs building smaller machines.
The new Allen-Bradley Kinetix 5100 servo drive can be used with a Micro800 controller, a Logix controller or even by itself, allowing OEMs to choose how the product best functions in their applications.
This drive system can also help OEMs make customers more productive. With the explosion of SKUs, manufacturers are faced with multiple changeovers, which are often a manual process. Using the Kinetix 5100 servo drive, OEMs can create a motorized, or automated, system that can help speed up changeovers.
Featuring built-in Safe Torque Off, users can remove motor torque without removing power from an entire machine, allowing a machine to restart faster after it has reached a safe state. Dual-port EtherNet/IP also supports Device Level Ring topologies.
In addition to enabling more machine flexibility, advanced technologies also allow OEMs to do more with less equipment and less space. In fact, more machine builders are delivering compact solutions that combine once distinct operations, like filling and cartoning, into a unified offering.
Integrated robotics
Integrated robotics is more than just the latest buzzword – it is defined as the single line or cell controller controlling the robot, which can reduce the need for the dedicated robot controller and associated hardware components such as servo motors, drives, teach pendant and I/O. In this way, a single controller can be used to control multiple robots and it can be simplifying integration and increasing operational efficiency.
A recent study by Mordor Intelligence has shown that the industrial robots market has witnessed a huge demand over the past decade, owing to the rising adoption of smart factory systems, of which robots play a vital part. It estimates that the global smart factory market is expected to reach USD 388.68 billion by 2024, which provides insights on the scope of the adoption of industrial robots for automation across end-user industries.
