Keeping it clean

Solukon GmbH, based in Stadtbergen in the German state of Bavaria, uses the LOGO! controller for the safe and efficient automation of cleaning booths for laser-melted metal components.
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Challenge

Technology in demand

3D printing is becoming increasingly more important in both the ­consumer and industrial sectors. While hobbyists and DIY enthusiasts make items from melted plastic, large companies use metal powder or other substances.

These materials are melted into workpieces using methods such as selective laser sintering. However, "After the production process, the cooling ducts, cavities and support structures of the metal components are still full of fine powder," reports Andreas Hartmann, an engineer and one of the directors of Solukon Maschinenbau GmbH. ­Previously, this powder needed to be manually blown away with air or shaken off. "For more complex components, that might take as long as seventeen hours," says Hartmann.


In 2015, at the request of a leading car manufacturer, the company developed and built the first automated line of cleaning booths for large, laser-melted metal components. Two years and 12 models later, in 2017, came the simpler and less expensive ­SFM-AT300 variant – for use with smaller and lighter steel, aluminum and titanium alloy components. These easy-to-use machines really hit the mark with ­Solukon's customers and they are highly sought after in the automotive sector and in the energy technology and aerospace industries.

Customer

Innovation from Bavaria

Solukon develops and designs systems for specialist machinery and plant construction. The company’s portfolio includes the custom manufacturing and serial production of equipment to remove powder from laser-melted metal and plastic parts.

Solukon Maschinenbau GmbH was founded in 2013 by engineers Andreas Hartmann and Dominik Schmid in the Bavarian town of Stadtbergen, near Augsburg. The two had previously gained experience as lead design engineers for a major manufacturer of 3D printing systems. Initially established as an engineering consulting company – for the development and design of specialist machinery such as packaging machines, freezers and 3D printing systems – its operations now include the planning, design, manufacture and installation of cleaning booths and unloading stations for laser-sintered components

We use LOGO! 8 to control our machines because it offers lots of functionality at low cost.
Andreas Hartmann, engineer and one of the directors of Solukon Maschinenbau GmbH
Solution

Closed system

In order to achieve such flexible, user-friendly and low-maintenance cleaning booth operation, Solukon relies on the Siemens LOGO! 8 controller.

Cleaning booths remove loose metal powder from the laser-melted metal components using targeted oscillation inside a sealed process chamber. The component and its mounting platform are clamped onto a turntable for this procedure. The turntable swivels around one or two axes for a preset amount of time. "This fluidizes the powder so that it can drain off," Hartmann explains. It is then collected in a hopper and discharged into special containers through a gate. After the automated cleaning, an operator can then reach in through glove ports to post-clean any complex cavities or ducts as needed, using compressed air or an inert gas.

Safety is the top priority in these ­procedures. If a component is made from any reactive, explosive material such as an aluminum or titanium alloy, the process chamber can be made inert using a protective gas. This also protects the material as the dust is no longer prone to oxidation and thus reusable. Thanks to the closed cleaning circuit, it is all retained and can be recycled.

"We use LOGO! 8 to control our machines because it offers lots of functionality at low cost," says ­Hartmann. The logic module is ­supplemented by two digital ex­­pansion modules – the DM16 24R and the DM8 24R – along with a SITOP PSU100S power supply unit. With the exception of safety monitoring of the inerting process, Solukon can now automate all the essential functions of the cleaning booth.


These include controlling the motor as LOGO! 8 permits easy ­timer-controlled operation of the swivel arm to limit switches. At a preset cleaning time, the swivel arm stops vibrating and moves back to its home position. ­Hartmann says the time savings is ­substantial. "This ­automation enables time savings of about seventy percent on post-­processing compared to cleaning by hand," he reports.

The controller also communicates with the safety PLC during inerting, and only activates automatic swiveling after the chamber has been filled with protective gas. A traffic light signal switched by LOGO! 8 indicates to the user whether the system is ready to operate, or whether clean­ing is complete. The logic module also sends digital status signals that control external peripherals, such as a material conditioner which vacuums the floor of the booth to empty it after cleaning.

Benefits

Equipped for further growth

The logic controller's text display indicates the remaining cleaning time and signals any errors during operation.

"LOGO! 8 offers us lots of possibilities to meet customers' needs and wishes," says Hartmann, with an eye toward the future. "They extend from control and monitoring, through web servers, to messaging on cell phones with the LOGO! CMR module." Other benefits of the controller are its compact design and user-friendly operation. "I'm ­certainly no programmer," ­Hartmann asserts, "but with LOGO! I can easily change, test or simulate functions myself."

This is opening up new opportunities for Solukon. "The machines for 3D printing are now going into production," Hartmann reveals. "We are also looking to integrate them into the automated factory. That also means automating booth loading by robots, for example." The company intends to continue using Siemens controllers in the future. Hartmann concludes: "As makers of specialist machinery in a highly critical, high-end sector, we have to be able to rely on the manufacturer and its products one hundred percent."

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Portfolio

Products in use

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IO-Link allows the easy integration of sensors and actuators from different manufacturers. The IO-Link Master modules enable data exchange with the IO Link devices. Due to the compatibility of IO-Link to standard sensors, commercially available sensors can be operated in accordance with IEC 61131 Type 1 on the IO-Link master. 
ET 200pro supports IO-Link communication via a 4-port electronic module and a corresponding connection module:

Electronic module 4 IO-Link HF

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  • Port Class B

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Connection module CM IO-Link 4 X M12 P

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SIMATIC RF170C for ET 200pro

The SIMATIC RF170C is a communication module for connecting the SIMATIC identification systems to the ET 200pro I/O system. 
The readers (SLGs) of all RFID systems as well as the MV400 optical reader devices and MV300 optical handheld readers can be operated on the RF170C. In addition, the RF170C provides a universal RS232/ RS422 interface for connecting devices using the Freeport protocol.
 

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Highlights:

  • Two parallel reader channels ensure real-time mode at dynamic read points.
  • Through selection of the corresponding head module, a connection of the RFID systems via PROFIBUS or PROFINET is possible
  • Reader connection using an 8-pin M12 connector for quick mounting of all components.
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  • Very easy downloading of firmware via the SIMATIC Manager for function expansions and error rectification ensure high availability of the identification system.
  • Adjustable and parameterizable identification-system-specific diagnostics facilitate easy commissioning and troubleshooting.
  • A wide selection of pre-assembled connecting cables can be ordered for ET 200pro and RF170C. This saves time and money during installation and assures

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SIMATIC ET 200pro frequency converter is suitable for the open-loop and closed-loop control of induction motors over a wide range of industrial applications. It is predestined for applications in conveyor technology where the drives are networked via PROFIBUS and PROFINET; and especially where it makes sense to combine several drives in a distributed configuration without requiring electrical cabinets. Examples include machining cells in the automotive sector or ninety degree routers in logistical systems.

Compact, intelligent motor starters

The intelligent ET 200pro motor starters are used for starting and protecting motors and loads of up to 5.5 kW. They are available as Standard and High Feature electromechanical motor starter and High Feature electronic motorstarter versions.

The electromechanical motor starter is switched with conventional contactors and is offered as direct or reversing starter with optional 400 V brake control. The electronic motor starter is equipped with semiconductor switching elements and is therefore especially suited for applications with high switching frequencies. This high feature device not only handles the direct on/off switching of motors with high switching frequency, but also fulfills the additional function of a full-fledged soft starter for a soft start-up and stoppage. The conversion from motor starter to soft starter is achieved using simple re-parameterization in SIMATIC Manager.

 

ET 200pro High Feature motor starters

The High Feature motor starters differ from the Standard motor starters in that they have more parameters and feature four parameterizable digital inputs. Parameterization is easy and convenient to carry out using the SIMATIC Manager.

The motor starters ET 200pro feature high functionality with a small footprint, as well as simple and fast configuration and installation – and they increase the availability of production plants.

 

ET 200pro safety motor starters

ET 200pro safety motor starters, which are specially developed for applications without control cabinets, provide a very economical safety concept solution. Depending on your requirements, we offer: Local safety motor starter solutions for local safety-oriented solutions with a standard PLC. And: Safety motor starter solution PROFIsafe for use with safety-oriented control using PROFIBUS or PROFINET.

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References

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