Revolutionary ACOPOStrak transport system
Digitalization alone is not plenty to attain true mass customization and batch-of-one product. Such IIoT milestones will rely equally on new approaches in mechanical blueprint and movement command hardware. Quantum innovations in these two areas form the heart of ACOPOStrak – an intelligent ship organisation whose revolutionary design enables adaptive manufacturing systems and promises a new era in flexible and efficient production.
Manufacturing companies are on constant lookout for solutions that get new products to market faster and make them more than competitive in global markets. The challenge is to maximize overall equipment effectiveness (OEE) and productivity; fifty-fifty when mass producing customized products in batches of one. "The much discussed topic of digitalization based on communication engineering science and software takes too narrow a focus," contends Robert Kickinger, mechatronic technologies manager at B&R. A new generation of requirements also calls for radical new thinking in the mode products are transported through machines and production systems – and B&R has stepped up to the challenge: "In developing the intelligent ACOPOStrak transport system," he says, "nosotros accept prepare the stage for revolutionary new motorcar concepts."
Diverter maximizes OEE
So, what is it that makes the intelligent transport system so uniquely suited for automating adaptive processes? "The diverter is – quite literally – a pivotal component of the system," explains Kickinger. "It is 100% electromagnetic and therefore entirely free of article of clothing." Like a highway junction, the ACOPOStrak diverter allows product flows to diverge and converge. "The diverter allows the shuttles to switch tracks at full speed with no compromise in productivity," he emphasizes.
Mass-produced items such as bottled beverages can be grouped on-the-fly into custom six-packs – 3 of one flavor, two of another and one of a third – without any changes to the hardware. The diverter likewise allows defective products to exist sorted out as soon every bit they are identified, rather than standing on to the stop of the line as they would in a conventional organization. This has a positive effect on overall productivity.
Parallel processing
ACOPOStrak and its diverters too add a new dimension of flexibility for implementing parallel processing. The product menses tin can be divided, pass through multiple processing stations and so merge further downwardly the line. This style, production speed is no longer throttled by the station with the slowest processing time. "The stop customer can increase productivity without a corresponding increase in machine footprint," Kickinger explains. In other words, ACOPOStrak boosts output per foursquare meter. "Ultimately, that means a college ROI," he adds. When yous build a machine or line using this intelligent transport organisation, you have the modularity and flexibility to add individual rails segments and processing stations in response to changes in demand. The truly adaptive, scalable machines envisioned for the Industrial IoT become reality.
ACOPOStrak-based manufacturing systems are too exceptionally fault tolerant. If at that place is a problem with one valve in a bottling line, the bottles are simply no longer sent to that valve. The lacking valve does not effect in waste, which makes a large difference in the OEE quality factor.
Zero-downtime changeover
The hot-swappable shuttles can be replaced tool-free and on-the-fly for unprecedented availability. When switching products, all the operator has to practice is place the wheels of the new shuttle on the guides. The shuttles are held on the track purely past permanent magnets. Changeover and service can be made fifty-fifty more than efficient by including a pit lane in the track layout. "One way of thinking of it is like the bench in ice hockey," says Kickinger. The new shuttles are mounted in the pit lane and then channeled to the track's actual product lines via a diverter. In the aforementioned manner, any shuttles that are no longer needed can just be rerouted to the pit lane. "All of this takes place at full production speed," he emphasizes.
ACOPOStrack's accented design flexibility allows it to morph into all types of open and closed layouts by arranging the segments in dissimilar combinations on a filigree. The core of the rail system is a linear motor assembled from four types of modular segments: a straight segment, a 45° segment and 2 22.five° segments – ane curved to the right, the other to the left. "ACOPOStrak adapts perfectly to any production site," explains Kickinger. "And at the same fourth dimension, information technology opens upwards completely new auto designs that accept never before been possible."
Highly dynamic and flexible
The intelligent send system offers more just flexibility, however: it is as well unmatched in performance. The arrangement is capable of 5 g acceleration and reaches height speeds in excess of 4 meters per 2d with a minimum production pitch of simply 50 millimeters. "When you combine these performance numbers with the benefits of the diverters and the farthermost design flexibility; it'southward a full packet the market has never seen before," he says.
Faster time to market
B&R provides an extensive range of software functionality to become ACOPOStrak upwards and running with minimal fourth dimension and effort. The aforementioned application lawmaking tin can be executed in simulation or on the bodily hardware with no limitations. "Developers can switch back and forth between simulation and real hardware as often as necessary," Kickinger explains. This shortens evolution and commissioning times considerably. "That's an unbelievable advantage in terms of time to market place."
Developers likewise do good from process-oriented programming. They just describe the rules that define the product menstruum on the rails, rather than having to program a multitude of axes and shuttles individually. Autonomous traffic control with integrated collision avoidance takes further work off the hands of developers.
Mass customization
With ACOPOStrak, B&R has designed a solution that makes flexible, modular manufacturing systems highly profitable to operate. "Our system enables high overall equipment effectiveness, loftier render on investment and curt fourth dimension to market," shares Kickinger. And with that, the industry is on the fast track to truthful mass customization.
Profitable production in batches of one
Need for personalized products continues to increase, and consumers are willing to pay higher prices for them. Mass customization thus offers enticing economic returns. Implementing the new approach in a cost-effective way, nevertheless, remains a major challenge for almost industry segments. That's considering any increase in system flexibility is usually accompanied by a reduction in overall equipment effectiveness (OEE).
The goal of mass customization is therefore to keep the iii factors of OEE – availability, performance and quality – at a level consistent with what can be achieved in mass product. In addition, manufacturers seek to maximize their return on investment (ROI) and to minimize their fourth dimension to market (TTM) for new and improved products. This is the just manner to make large-scale mass customization viable from an economic perspective.
B&R volition exist present in Hall ane, Stand S1 at Automation India Expo 2018, Mumbai from 29 August to one September 2018.
Source: https://packagingsouthasia.com/technology/automation/revolutionary-acopostrak-transport-system/
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