Modular solution for complex processes with high precisionEvery 4.8 seconds, the system produces a smoke detector in its final configuration: The new modular production process is a real challenge for automation. The sensitive electronic board must be broken out of a carrier and mounted. The handling of the LEDs is just as demanding.
Modular system concept to combine precision and expandability
At the various stations of the new assembly system, it is possible to observe how smoke detectors are created. The base carrier is manually fed into the system - after which the automatic system takes over. The electronic board is used at the beginning of the assembly system.
The carrier is turned over and placed on the rotary table, where eight stations assemble the other components: 1-2 light-emitting diodes, a photodiode, the shield plate and the lens.
Speed and reliability are central to the manufacture of the smoke detectors: in order to make the system faster, more flexible and cheaper, only electric axes were used, and pneumatic components were dispensed. This also reduces energy consumption. The automation stations for lid assembly and packaging are added later.
Thanks to the modular design of the system, the manual feeding of the base carrier can also be automated. The requirements for the operating solution for the system were correspondingly high: The HMI should optimally support the personnel in the control, optimization and maintenance of the system and at the same time be flexibly adaptable to new tasks.
Smart solutions for complex and cross-linked automationInsys Industriesysteme AG (member of Smart Automation Group) realizes special machines for medical and electrical engineering, the luxury industry and the automotive sector. The 70 employees in the Bernese town of Muensingen develop grinding, polishing and testing systems and in particular complex assembly systems - such as the new system for the production of smoke detectors.
We have implemented a more extensive system, which can be further expanded modularly.Marc Luginbühl, CSO, Insys Industriesysteme AG
Complete automation solution from the same source
The Teamcenter Lifecycle Management (PLM) platform is used for optimal data management. The powerful Scalance Ethernet Switches enable a quick and easy setup of networks. The high-end motion control system SIMOTION convinces through its performance and enables a high flexibility of the assembly system, and SITOP components ensure a reliable power supply of the system. The system is operated via a 4-inch mobile panel from Siemens. The SIMATIC HMI mobile panels communicate via Profinet and are fully IP65 protected. Safety Integrated guarantees the safety of the system and employees. Together with the connection box, it forms a space- and cost-saving solution for tasks with safety-relevant operating functions that do not require complex graphical representation. 4 function keys support touch functionality for combined touch and key operation.
BenefitsThe mobile panel from SIMATIC HMI impresses with its high functionality, compactness and flexibility. Marc Luginbuehl is enthusiastic: "The handy panel has all the necessary functions, is attractive, compact and easy to operate".
Regarding the engineering, Insys benefited in particular from the seamless integration of all automation components in a common framework: The TIA Portal provides corresponding software modules that greatly simplify programming. Using the Teamcenter Product Lifecycle Management (PLM) platform, design data can be optimally managed. An efficient development across company boundaries becomes possible. Of course, the project data from the TIA portal can also be integrated into Teamcenter. In the future, the system will be connected to the IT system from Siemens Building Technologies. The continuously exchanged data can be used for quality assurance or order planning. As a result, Marc Luginbuehl draws a positive conclusion from his experience with the integrated solution from Siemens: "It is quite possible that we will be using the panel and other Siemens components more frequently in the future".