Omron MagazineUnique application stories

New trends and developments in the market continue to have a major impact on the requirements of machine builders all over the world. In this issue, we show how we are addressing all these challenges. In this magazine you can read how Omron Partners: Machine Builders and Integrators do it.

3Nr

Good morning, It is already the third edition of Omron Magazine,

which shows the collection of description of the most

interesting implementations which have been realized in

collaboration with Omron. What makes this edition special

is its international character: it includes not only Polish

description but also Hungarian ones in order to inspire

innovative solutions our existing and potential customers.

If only your business involves machines, thats where

our solutions will help. Because we can help make your

machines become smarter, faster, more efficient, better

value, more flexible, more reliable in short, we can help

give you a serious advantage over your competitors.

These solutions are based on specialized expertise in

sensing and control automation. And more. They are

based on a heritage of working closely with our customers.

A heritage that has given us an intimate understanding of

our customers needs in a variety of distinct industries. Each

of which includes their own particular challenges, and by

working with our customers we have developed their own

particular solutions.

Nobody knows your business better than you do. In each

industry we face different challenges taking it learns us

everyday a lot. Take a look at how we can work with you.

Best Regards,

Omron Team

3 OMRON MAGAZINE

Spis Treci:

ARET - Production lines for sticking candle lids with a sticky tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ARUM The rolomat is designed to manufacture flexible tapes in automatic mode . . . . . . . . . . . . . . . . . . . . 6AUTO-BAST - V1000 inverters for car lamp assembly lines and programmable G9SP

safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8EGIS - Marking station with a laser printer and Omron-camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 HITMARK - Hitachi Industrial printers - reliable system for product labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14KAPOSVAR - Wastewater treatment with Omron SX frequency inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16KART - Cigarette filter cutter line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18GAWLIKOWSKI - Small Water-Power Stations control system with Archimedes turbines . . . . . . . . . . . 20NEOTECH - Single spindle winding machines .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22PABLO - Battery sorter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24PRO-AUTOMATION - Automation of integrated transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26REMTER - HD1500 cutting-off machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28RIAS - Efficient, flexible and multiformat typesetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30TMA - Multiaxes miling machine - TMA millingLine as a response for modern

industry needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32TOOLS FACTORY - Innovation in Vacuum Thermoforming Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34U-R-B-A-N Milling machine DFM-200/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4

5 OMRON MAGAZINE - ARET

Production lines for sticking candle lids with a sticky tape

ARET has been established by Andrzej Roszkiewicz - the current owner - in January 1980. Since the early beginning, the company has been involved in the maintenance and repair of every kind of electric motors as well as in the production of rectifiers for battery charging and welding machines. In 2004, the company created a separate division forautomation, robotics and machine construction, run by a young dynamic team of experts.

ARET has completed many projects, among others, producti-

on lines for corrugated board pallets. In 2014, ARET received

the Omron Solution Partner certificate that proves the com-

panys quality of projects performed with the use of Omron

systems and components. ARET employees are highly satisfied

with the ability to design and construct unusual machines

and other devices. The company ensures complete support

of industrial investments. A wide variety of solutions allows us

to deliver turnkey solutions, starting from an idea, through a

project, full integration, to implementation and support.

A line for candle packing, designed by ARET in 2014, handles

two types of conic glass. The line capacity is 7 000 items per

hour. Before the line was mounted, the process was done ma-

nually with much lower efficiency and precision. The clients

increasing demands and needs forced the company to intro-

duce inovative changes. Automation of this process allowed

ARET to assign its employees to other, no longer monotonous

tasks. A glass candle is closed in a two-phase process with the

use of pneumatic elements and servo motors. First, a plastic lid

is put on the glass, then a tape is applied by pneumatic actu-

ators. The key to success is to synchronize each process phase

on the turntable. This is achieved by SYSMAC automation

platform. All process is controlled by a motion controller with

PLC NJ301 that supports 2 axes of servo drives, which drive

two separate packing sections equipped with a distributed I/O

system. Machine safety is managed by a safety system that is

based on SL3300 controller, non-contact Omron door switch

as well as STO function (safe drive stop) in MX2 inverters and

Accurax G5 servo drives. The system uses EtherCAT network,

which in the real time connects crucial machine elements

such as: servo drives, three slave terminals NX with distributed

I/Os and integrate safety functions. Such a network structure

with G6 servo system ensures high efficiency and small signal

delays. For the communication with a user a HMI NB is used. It

allows for complete machine configuration and diagnosis.

The device uses complex Omron automation components

( inductive and photoelectric sensors, supply cables). Short

process time is achieved thanks to Sysmac Studio integrated

platform. The platform enables complex machine develop-

ment from the automation point of view. Sysmac Studio also

makes the maintenace easy for the client. The line is also

equipped with labeling machines. At the end of the line,

there is a bar code control system installed. It consists of an

independent compact PLC controller Omron CP1L and HMI

6NB 3,5 panel. It is crucial to use cheap and flexible handling of

RS 232C protocol for a bar code reader.

Thanks to the professionalism of ARET employees, and their

broad attitude towards project management, the company

quickly got new orders, and was asked to deliver the same

packing line together with two visualization HMI systems for

glass quality control.

Dane kontaktowe:Firma ARET Andrzej Roszkiewicz

ul. Rana 12

63-004 Tulce k/Poznania

tel.: (+48) 61 879 85 09

aret@aret.com.pl

www.aret.com.pl

7 OMRON MAGAZINE - ARUM

The device is used for manufacturing short winders that are

difficult to process on standard winding machines that involve

human operation. By collecting winders 10-150 m long, of

which the maximum speed is 300 m/min, we can reduce time

needed to perform winding in comparison to manual work by

200%. The machine has got a color 8 touch NS panel.

Touch control, clear high quality graphics, image processing,

TouchFinder maintenance are only some advantages of NS

models, and give possibility to use Smart Active Parts (SAP)

solution, which saves time of machine configuration, start-

up and maintenance. SAP stands for preset and tested visual

objects with built-in communication code. Thanks to this

we can use swipe and drop technology provided by HMI

terminal. These modern communication solutions between

the machine and operator definitely save time of the operator

work and increase efficiency.

Rolomat uses Sigma servomotors, in which there is no

space for any compromise in the scope of quality. The drive

size is 100 W 2000 W, rated speed of 1500 and 3000 r/

min with automatic motor recognition by servo drive. High

resolution encoders guarantee high flexibility and precise

synchronization of all drive axes in the machine. These energy

saving solutions compared to capacity tend to reach energy

balance, and in connection to easy handling guarantee long,

failure-free operation with positive economic balance.

The body is made of steal of laser burnt segments with 0,1

mm precision. It allows for parallelism of all co-working

machine moving parts in a way that ensures machine work

without any problems, even with very difficult manufactured

carriers/materials???. Pneumatic interlocks for winder roll

The rolomat is designed to manufacture flexible tapes in automatic mode

Rolomat TYP - AEx R/O/NP/1100 is a semi automatic winding machine for film tape, BOPP, Cast PP, LDPE, HDPE, unwoven fabrics PES, and paper. Our rolomat is designed to manufacture flexible tapes in automatic mode, in a closed cycle. It uses a system of three revolver winders, and this solution increases machine efficiency depending on the winder length, for example, for a 20 m winder it is 3 rolls/min. Automatic cut-off and protection of winded roll by using a labeling machine integrated into rolomat. It freely defines labels (width, length) with the produers logo and bar code; it saves time for packing and eliminates the necessity to use an additional package with the producer info.

8Technical specification:1. Max width of main wound 1400 mm

2. Max diameter of main wound 1000 mm

3. Max diameter of winding roll 400 mm

4. Max running speed 300 m/min.

5. Diameter of internal main roll sleeve 76 mm

6. Diameter of internal winding

roll sleeve 3 pcs, 49,5 mm

7. Material type LDPE, OPP, paper

8. Material thickness 18 m 200 m

9. Power consumption max ~ 2,5 kW

10. Power supply 400 V / 50 Hz

11. Touch terminal NS (color 8 Omron)

automatic stop after the work is done

lateral shift regulation of the main roll with 1 mm

precision

main roll positioning

sound and visual indication

automatic control and speed readings of the tape shift

possibility to create setting libraries for processed

materials (tension power, number of meters)

co-operation with thermotransfer printer (label printing

with bar code)

co-operation with production planning system (order

acceptation, co-operation with weighting system)

12. Automatic control of belt tension

13. Automatic bonding of winding roll (material-sleeve)

14. Automatic cut-off after winding cycle

15. Winder component made in the revolver system with

tree expander shafts

16. Automatic interlock and release of sleeves of pneumatic

winder expanding shafs

Dane kontaktowe:Arum Z.Michlewski, J.Radomski Spka jawna

95-200 Pabianice

ul.L.Okulickiego 4

tel.: (+48) 42 215 14 81

fax: (+48) 42 2031270

biuro@arum-maszyny.p

www.arum-maszyny.pl

sleeves, batch roll and a cutting knife make day-to-day

operation easier and save time. Small energy consumption,

about 2,5 kW for a machine of such capacity is a solution

worth paying attention. All machine elements can be recycled.

9Thanks to V1000 inverters with built-in safety inputs it is easier to perform electric

installation. There is no need to use additional contactors. In comparison to its older

versions, V1000 inverter is up to 40% smaller. Inverter small size allowed us to save

space in the switchbox. Omron inverter configuration is easier than ever since the

implementation of new broad CX-Drive package for drive configuration. All new

functions safe time and automatically identifies series and drive type.

This line has a lot of safety functions: safety buttons, mechanic limit switch, magnetic

limit switch and safety curtain. The installation is very complicated, this is why we

decided to use programmable safety relay G9SP-N20S. Easy programming means fast

start and easy modification. All relay inputs and outputs have built-in signal LEDs for

very fast system diagnosis.

V1000 inverters for car lamp assembly lines and programmable G9SP safety relay

The line is used to assembly front car lamps. V1000 inverters are used to drive four chains, and two elevators which transport lamp assembly pallets.

OMRON MAGAZINE - AUTO-BAST

10

Application of the fiber and colour sensors for recognition the electric beams.Lines carousel type is used to assembly and test electric

beams. Thanks to Omron sensors, we were able to eliminate a

very complicated mechanical solution for detecting miniature

fastenings in connectors.

Application of the fiber sensors E3X-HD series together with

precise fiber unit E32-EC31 series on the assembling and

testing line for groups of wires. With this sensors presence of

fastening in the electrical connection was tested.

E3X-HD sensor main features: Last and easy learning thanks

to Smart Tuning function. Dynamic power control function

provides highest work reliability in changeable objects and

working conditions. Signal high resolution - 2,5 higher that

standard models.

We have also used color sensors for detecting connector

body color. Sensors E3X-DAC-S series with the corresponding

fiber units detects 2 colors according to programmable logic.

Color sensors main features: White LED diode ensures the

sensor universality for each color. Short response time 60 s.

Timer function with the ability to turn output on/off with 5 s

delay. Remote learning function or learning function with one

button action.

The companys main activity is the development of

automated assembly stations and production lines

for car, electrical and food industry. We offer also a

manufacture station for assembly and test wiring

harnesses, check gauges, and tools according to the

clients needs and specification.

Our company stands for a team of high class experts on

mechanics, automation, and processing technology. This

provides us with a variety of abilities/capability.

We have our own modern machinery for even most

complicated projects. That helps us meet clients

expectations.

Our goal is to offer high quality products and services,

as well as meet the delivery deadline. We have clients

among domestic and foreign companies.

Dane kontaktowe:Auto Bast Sp. z o.o.

ul. Wolnoci 69a

34-220 Makw Podhalaski

tel.: (+48) 33 875 75 21

fax: (+48) 33 875 75 31

kontakt@auto-bast.com

www.auto-bast.com

SOLUTION PARTNER

11 OMRON MAGAZINE - EGIS

Marking station with a laser printer and Omron-camera

Verification of printed information on pharmaceutical paper boxes using touch-screen operator interface

A sophisticated technology such as the printing of texts

and 2D codes as part of pharmaceutical packaging processes

will also require a well arranged group of easy-to-use HMI

devices in addition to the reliable technological hardware

elements (mechanical equipment, electric drive, printer,

sensors and control elements, etc.). As a solution, a large-sized

touch-screen monitor can be applied to provide an operator

interface divided into sections through which the entire

technological process can be controlled and checked.

The printing of texts (alphanumeric characters) and 2D codes

on paper boxes and the verification thereof are considered as

an essential station within the automatic packaging process

of pharmaceutical products. In this stage of the technological

process a conveyor is taking the medicinal products packed

in paper boxes to the data marking device where printing

is done by a special laser printer, the correctness of printing

is verified and assessed by a camera and at the end of the

process faulty boxes are removed from the conveyor by

means of compressed air. Finished products with faultless

printing on the boxes are packaged ready for delivery at the

end of the technological process.

Units of the data marking device In order to control the marking phase of the packaging

process a PLC was required for operating the conveyor and

controlling the printer and the verification camera. In the

original solution a separate HMI was necessary for setting

the operation parameters of the conveyor and checking

the conveyors operation and another HMI for entering the

text and code to be printed and correcting their position. A

third HMI was also needed to check the measurement and

assessment results of the cameras shape recognition and

control system.

The units used to set up this system were a PLC of type CP1L

and of Omron-make, an FZ sensor system with camera, which

was also of Omron-make, and a special laser printer of type

D550+ manufactured by the company Domino based in

England. Due to its complicated handling and checking owing

12

mainly to the three-screen design, the relatively small system

was a bit difficult to operate.

Advantages of the touch-screen operator interface The request of the buyer EGIS Pharmaceutical PLCs

production site (located) in Krmend, where medicines are

both produced and packaged was to simplify the operation

of the above described system. This simplification had been

performed by the staff of Omron Electronics Kft of Budapest,

Hungary, as subcontractor by using a TFT LCD touch-screen

monitor of type ELO1515L manufactured by TYCO Electronics

and designing appropriate software required for its operation.

The advantage of the solution is that all details of the box

printing technological phases are integrated into a common

screen, while all the details of the previously elaborated

operational process have been maintained. Thus, this solution

represents a very economical development on the system,

with the main advantages being the considerably simpler and

more flexible arrangement and ease of handling in addition to

the high degree of integration.

Functions of the automatic marking station All the functions of the marking station can be seen on the

main screen which consists of six clearly separated panels. The

arrangement of the panels also follows the logical sequence

of the administrative and technical preparation, execution and

assessment of the technological process.

Thefirststepistologinasthiswilldecidetheintervention

possibilities available to a given user. In case of the

operators, technicians, engineers or administrative

authorisation levels certain functions are enabled or

disabled depending on the extent of accessibility allowed.

Inthesecondstepthelayoutform,content,positionand

angle of rotation of the text to be printed can be given in

the production menu; here also the modification of all these

and the content of logging can also be given.

Thethirdpanelservestosettheproductionparameters

(box dimensions, dimensional tolerance, viewing the print

image).

13 OMRON MAGAZINE - EGIS

Thenextpanelwillshowinaformidenticalwiththat

worked out for the previous solution the messages related

to the stations operating condition and mode of operation

and to the manufacturing process that are continuously

being updated on the screen by the PLC unit.

Thedisplaywillalsoshowthecameraimagesandthus

provides a colour marked visual checking possibility to verify

the quality of printing; however, upon request it will also

display all the printing-related information (e.g. position,

place and number of characters of the 2D matrix code and

text, etc.).

Finally,thesystemwilldisplayinaloggedformallthe

operator interventions, production messages and wording

information concerning the condition of the system. It is

also possible to save the logbook messages and to retrieve

earlier logged information.

It should also be mentioned as a further advantage of the

touch-screen operator surface developed that in addition to

its actual use in pharmaceutical factories the above solution

can also be applied in the packaging processes of food

products and drinks (practically in all technological processes

where the marking of production information and conditions

is an unavoidable requirement) that are made possible by

the excellently designed cost-effective shape and character

recognition systems as a result of their extremely flexible and

versatile features.

The touch-screen operator interface has been designed as

a new and innovative development for Omrons PLC and

industrial camera products that have so far proved their

suitability excellently and been widely used; this also proves

that these products are of internationally acknowledged

quality not only in terms of control engineering, but also in

terms of visual sensing and processing.

Operational experiences In connection with the assessment of the newly designed

marking system, Rbert Nmeth, the plant engineer of the

pharmaceutical factory had explained that The touch-screen

operator interface designed by Omrons staff members meets

customer expectations in all aspects. The primary reason

for that is that through its highly automated operation the

system makes the job of the people working on the medicine

packaging line considerably easier, as the operation of the

system is simple and can be easily followed thanks to the

14

Dane kontaktowe:Egis Pharmaceuticals PLC

H-9900 Krmend, Mtys kirly u. 65.

E-mail: mailbox@egis.hu

www.egis.hu

solution that integrates the adjustment, operation and control

of the functional units belonging to the marking and printing

equipment into a single screen.

The favourable experiences of the EGIS Pharmaceutical

Factory in connection with the Omron products are proven

clearly by the fact says Rbert Nmeth that out of our

6 packaging equipment used for similar purposes 4 are

equipped with cameras of Omron make, the procurement

of which had been carried out on the basis of previous

favourable experiences. This is why Omrons products were

again ordered during the design of the marking system, but

the factorys staff had not been left alone during the further

development stage, either, as the staff of the companys

representation in Hungary had also been involved in the

development work successfully.

In respect of the project concerning the marking equipment

it is worth mentioning that from the technical point of view

the implementation of the project took place in a very short

time, which, in addition to the use of the reliable products

of excellent quality could also be thanked to the high

standard of expertise and successful contribution of the staff

members working in Omrons branch facility in Budapest.

This cooperation had also proved that Omron is a reliable and

highly competent business partner in the development and

application of products and it should be emphasised that

the solution developed fully meets and in certain cases even

exceeds the customers initial requirements.

In respect of the wide use of Omron products within the

pharmaceutical industry it is very typical as plant engineer

Rbert Nmeth puts it referring to the pharmaceutical

factorys investments that the manufacturing company

offers a complete production equipment to the

pharmaceutical factory in such a manner that at the outset

of the project no information is available as to what sorts

of equipment would be used by the supplier to meet the

specified technical, economic and operational conditions.

The equipment and product mix will only be known after the

technical discussions. The situation was similar in connection

with the original design of the marking equipment, and it was

only at the end of the investment project when it could be

seen that the equipment consisted mainly of Omron products.

In the further development stage it was obvious that the

factory should seek Omrons assistance.

During the time since the development and putting into

operation the close connection between the pharmaceutical

factory as buyer and Omrons Budapest branch facility had

been maintained and thus modifications and other further

developments could be realised easily.

15 OMRON MAGAZINE - HITMARK

Failure-free verificationModern factories put emphasis on three main factors:

quality, efficiency and the lowest percentage of rejected end

products.

A recognizable brand and aesthetic packaging is not enough

for effective sale in front of tough competition on the market.

A modern customer needs something more to make him

buy specific products. One can influence customers decisions

by modern marketing practices that rely on building mutual

relations, which support two-sided activities. Apart from

standard advertising campaigns that promote unique

product features, it may be effective to organize a lottery, a

competition or loyalty programs with attractive rewards.

As a response for these necessities we created a system

enabling all these promotional activities. Two companies

took part in this undertaing. Hitmark Sp. z o.o., a distributor of

Hitachi printers for product marking and Omron Electronics

Sp. z o.o., a producer of visual systems. Their cooperation

resulted in an innovative solution that generates alpha

numeric codes on products with high speed, which later is

verified in detail. Not only its presence is verified, but also its

readability. Incorrect or unreadable products are rejected from

production lines, and corresponding lottery codes marked in

the imprint library.

As a result, a customer receives correctly indicated products

with unrepeatable codes. In addition, it has a complete

verified library of printed and used codes. Part of them

guarantees winnings.

Visual system specification

Hitachi Industrial printers - reliable system for product labeling

Technical information

Production line capacity

about 30 000/h = about. 8,3/sec

Line speed about 100 m. /min.

the number of infor-mation marked

10 alphanumeric characters.imprints sent systematically from imprint library on a PC.

Application Printing of changeable codes on the products with an ink-jet printer and control over them with OCR system.

Hitachi Hardware: HITACHI RX-S printer co-working with a PC. the printer works with an encoder and standard optic Omron product detector. Task: Printing of changeable information send systematically from a remote PC.

Omron Hardware: FH-1050 controller, FH-SC color camera with 3Z4S-LE SV-1214V lens and IP65 body Task: quality control and imprint corrected with the use of OCR function. toss control of defective product

Hitmark Integration, hardware installation and system start-up. Original software for project realization

End effect OCR time recognition for 40x15 mm area containing 10 alphanumeric characters 10-15 msec. OCR work efficiency 99,9%

What distinguishes Hitmark Sp. o.o. from competition:

5yearguaranty

thehighestreliabilityratio

lowoperationcosts

24htechnicalsupport

16

Hitachi RX-SD160W printer specification

Hitmark is an exclusive distributor of Hitachi printers

in Poland. Discover printers, which you can rely on.

Since 1975. Printers Ink - Jet type have originated from

Hitachi testing laboratory. In 1971, the first brochure was

published that described a process of creating drops from

continuous water stream with the help of vibrations and

their electric charging and deflection. First printer model

built in Continuous Ink-Jet technology was installed in

Japanese coca-cola factory.

Since then, 40 years have passed of dynamic

development and adjusting the level of our devices to

the growing industrial needs. The speed of production

lines becomes higher and higher, increased the diversity

of base for marking and care for environment determined

the way our printers had to change. Our current model -

Hitachi RXS - is a result of experience coming from over

80 000 successful installations all over the world. Hitachi

activities are oriented on the quality of products, which

is known all over the world, and involve discipline and

precise procedures. Hitachi companies are obliged to

manufacture goods in according to the highest Japanese

standards, and this contributes to creating the most

reliable printers on the market.

We care about our clients satisfaction, thus we offer a

chain of 110 distributors worldwide. Careful selection

of our partners provides the highest level of sale and

maintenance services. We offer solutions for even most

demanding customers and industries.

Dane kontaktowe:Hitmark Sp. z o.o.

Industrial ink printers Hitachi Ink-Jet

ul. wietlicowa 7/9, 05-520 Konstancin Jeziorna

tel.: (+48) 22 754 10 13

fax: (+48) 22 754 10 14

serwis 24h: (0) 604 26 22 00

hitmark@hitmark.pl

www.hitmark.pl

Parameter RX-SD160W

Line maximum length

to 3 lines (option: to 5 lines)

print height 2-10 mm (option 16 mm)

User interface Screen: TFT LCD (10.4 color), podwietlany, WYSWIG Data entering: touch screen with sound acknowled-gment

Maximum printing time (m/min) - (char/s) (font 5x5, space 1, 1 line)

188 m/min - 1256 char/s (option: 230 m/min - 2513 char/s)

Standard characters Alphanumeric (A-Z, a-z, 0-9), symbols (27), space: total 90

Print functions Calendar, counter, various font types, storage capa-city: 48 inscriptions (option: to 2000 - depending on the content), etc

Bar code printing EAN-13, Code39, ITF, NW-7, EAN-8, UPC-A, UPC-E, code-128/EAN-128.

Communication RS-232C to 115 200 bps (option: Ethernet)

Body Stainless steal / IP 55

head terminal length 4 m (straight/90)

Dimensions (width x depth x height)

400 x 340 x 480 mm

approximate weight 25 kg / 55 lbs

Options bar code scanner connection special communication functions, additional external indication

individualapproachtothecustomerneeds

preferentialcooperationconditions

HitachiOnline24remotesystem

freeprintertestonthecustomerline

17 OMRON MAGAZINE - K APOSVAR

Wastewater treatment with Omron SX frequency inverter

In the course of the wastewater treatment plant modernization in Kaposvar, the drive of several, already employed or newly integrated three-phase electric motors was completed with a frequency inverter, which enables the user to change the speed of the motor continuously. Given that the motor speed may have a direct impact on the effectiveness of the technology driven and the quantity of energy consumed, this method made it possible to ensure the optimal operating conditions easily and conveniently.

An important part of modern treatment technologies is to

control the dissolved oxygen level of the sewage. During the

intervention the necessary oxygen supply is ensured by means

of blowers rotated by powerful electric motors. The newly

integrated units are driven through the Omron SX type inverters

in Kaposvar.

The entire system which includes the blowers already

commissioned earlier in addition to the new ones is controlled

by the Omron CJ1 type PLC, complete with a computer display

and a user interface. The PLC is connected to the already

existing inverters and soft starters via a serial communication

according to Modbus RTU protocol, so when the new inverters

were selected, the primary concern was to ensure that they

could be matched to this network. In case of the SX series, it was

not a particular problem, since several other communication

cards are also available in addition to the Modbus RTU.

The IP54 degree of protection was also another important

expectation to ensure the protection against the unpleasant

circumstances which can be faced at waste water treatment

plants. In fact, this was the main reason why the SX model

group was selected, because the IP54 protection is standard

for each member of this group. The optionally available special

lacquering of the components and circuitry elements, which

is designed to reduce the effects of aggressive gases, provides

a further protection against external influences. The purpose

of the built-in input noise filter, which is also standard, is to

suppress the electrical network problems emerging due to the

operating principle of the

frequency inverter. An additional advantage was the surprisingly

small size of the version having the proper performance, which

made fitting the new device into the really tight space designed

for it easily, as opposed to its former counterparts which were

larger, despite their lower protection level.

The first step in the installation is matching the inverter to

the motor. This actually meant entering and setting the

necessary motor data. Our work was greatly supported by

the special auto-tuning function, in the course of which only

the characteristics listed on the nameplate of the motor had

to be entered manually the inverter measured the others

automatically. Owing to the auto-tuning function it was not

only entering the individual values absolutely indispensable for

the precise control of the motor that became easier, but the

winding was also checked. In addition, knowing the data which

are difficult to access or measure otherwise may further increase

the rate of energy saving which is definitely experienced with

frequency inverters.

Still before the first test run we entered the basic operating

characteristics the minimum and maximum speed, the

acceleration and deceleration values and characteristics and

matched the various integrated protections to the motor

and the application. This was followed by the manual first

start independently of the PLC in the course of which

we checked the rotation direction of the motor and found

that the connection of the motor and the frequency inverter

was faultless and the operational values (motor current, etc.)

were appropriate. After all this we established and tested

the connection between the PLC and the frequency inverter

and configured the inputs and outputs of the inverter. We

also developed a local control mode, which allows the user

to set the speed directly beside the machine by means of a

potentiometer. Finally, we programmed such oddments as the

18

definition of the monitors and feedback signals appearing on

the freely configurable displays according to the user needs.

Even according to the experience gained during the relatively

short period since the commissioning, the decision on the

modernization and expansion of the wastewater treatment

plant in Kaposvar seems to be justified. We do hope that the

Omron SX frequency inverters integrated will also support the

investment to promote the preservation of the immediate

neighbourhood in a quickly remunerative manner.

19 OMRON MAGAZINE - K ART

One of the examples of a project executed by KarT sp. z.o.o. is a customised cigarette filter cutter line for a tobacco industry factory. The goal for the design and construction of the line was to automatize the process of retrieving tobacco from defective batches, which did not pass the intramural quality control. This process had been manual until then, which required an unacceptable labour and time input. The usage of cigarette filter cutter line in the process line allowed our client to significantly improve the effectiveness of the tobacco retrieving process and cost reduction of the whole process.The device has been constructed and launched in its entirety by KarT sp. z o.o., including the design of the mechanical structure, drawing up the controlling conception, designing and installing of the electrical system, construction of the mechanical parts, as well as assembly and on-site start-up.Cigarette filter cutter line consists of a series of machines connected into one line. The goal of the process is to retrieve tobacco from cigarette packets. It consists of cutting through the cigarette pack at the point of contact between the tobacco and the filter, and then separating the part with filters from the part with tobacco, shaking out the content of the packaging onto the conveyor and dividing them into three separate containers for tobacco, filters and packets. The retrieved tobacco, wrapped in paper, is conveyed for subsequent processing in the factory. The KarT sp. z o.o cigarette filter cutter line consists of: side pusher with vision system, belt conveyor, vertical band saw, turnover device, vibrating conveyor, belt conveyor, final sieving machine.The machine has a skid frame design. Respective modules are built upon a steel supporting frame with adjustable covers of the working parts. It is equipped with 3x400 V AC mains powered electrical installation and pneumatic installation powered with compressed air of 6 bar pressure. The line has one integrated control system based on the Omrons components.

The operation of the line boils down to loading in a cassette filled with packets arranged in rows. The whole row of packets is pushed cyclically to the working area with the side pusher.

The key element of the process is to check if all the packets are arranged in the same way, that is with filters facing the same direction to prevent the filters from getting into the final tobacco container. The system checking the packet orientation is based on two Omron FQ2 vision sensors. Detection of the incorrectly arranged packets leads to the pusher ceasing to operate and pushing the packet out with a moving shaft powered with a linear pneumatic servo-motor. After removing the incorrectly oriented packet, the side pusher continues its operation, pushing the whole row further back to the buffer zone, from where they are moved to the belt conveyor, which moves the product to the cutting chamber in a uniform motion. There, the packets are cut on a vertical band saw. The part of the packet that contains filters is moved further to a proper discards container, while the part with the tobacco is flipped hole downwards and its content shaken out from the packets in the vibrating conveyor onto the belt conveyor. Tobacco wrapped in paper, intended for subsequent processing, is transported to the container, while the empty packets end up in another container, in order to be discarded.

The control system has been created basing on the PLC CP1L-EM30DT1-D controller in cooperation with 7-inch HMI NB7W-TW01B panel by Omron. The communication between the controller, HMI panel and FQ2 vision sensors is done through Ethernet network with the usage of the TCP/IP protocol, which guarantees adequate speed and reliability of data transfer, as well as resistance to EMI and RFI distortions. The device is universal adapted to work with packets of different types and sizes. Machine can work with a different packet by adjusting the moving bars and selecting an appropriate pattern for the machine vision. Selection of the appropriate pattern is done through the HMI panel with a database of patterns, together with photographs of every packet, programmed in the FQ2 sensors. The usage of two FQ2 vision sensors allows for saving twenty-four patterns of packets and taking photographs from two different angles, with different lighting and different filter settings according to the

Cigarette filter cutter line

KarT sp. z o.o. is an experienced and reputable manufacturer of technological machines and devices. It also provides tool services and complex machining of metals and other materials. Throughout 30 years of their market activities, the company became specialised in designing and constructing complete production lines, assembly and testing equipment, control stations and machines and devices of special purpose, dedicated for food, automotive and tobacco industry, as well as household appliances, etc. KarT sp. z o.o. provides a complex customer care, from the design stage to the ready machine, as regarding its assembly as well as warranty and post-warranty repairs.

20

requirements for each packet. The functionality of the HMI panel software allows changing the packet pattern in the machine vision, insight into error messages, informing the operator about any irregularities in operation, damages to sensors, exceeding the programmed limitations, etc., controlling the pneumatic actuators and drives in the manual mode (which allows for a significantly easier calibration and servicing), and preview of the digital inputs and outputs in the PLC controller. The registered data is saved on an external USB memory device and can be used to prepare shift reports and carrying out manufacturing and maintenance analyses. Access to particular HMI panel functions is regulated with password-protected access levels, which allows for elimination of unauthorized changes in the line settings. The safety system is based on a set of G9SA safety relays, integrated into one security system for the whole machine. The implemented safety functions, designed according to the normative requirements and based on the prepared risk assessment, include emergency shutdown, locking the adjustable covers during work and drive activation control. The whole machine is created according to the safety category 3 pursuant to PN-EN ISO 13849-1 2008. The emergency shutdown is done by e-stop push buttons, placed on the machine in a way that allows an easy access for the operator and connected in series with the G9SA safety relay. Cover locking has been done with Omron door switches with D4GL-4CFA-A lock and contactless F3S-TGR-NLPC door switches in cooperation with G9SA safety relays. Opening of the cover is possible only with all of the drives brought to standstill, which minimises the probability of an accident while the machine is being operated, reducing the risk to the acceptable level according to the abovementioned norm. Drive system of the saw is equipped with a certified standstill monitors used to monitor the revolutions through the measurement of the electromagnetic power on the winding of the motor, which guarantees the dependability of the safety functions. After unlocking and opening the covers, all of the drives have their power supply cut off according to the safety category 3 requirements pursuant to PN-EN ISO 13849-1:2008. The vibrating conveyor and the final sieving machine are driven by vibrating induction motors powered by Yaskawa V1000 power inverters. The use of the frequency converters to control the motors guarantees flexibility in the adjustments of motor operation parameters, which allows for easy control of the angular velocity, momentum control and setting the acceleration and deceleration times. This turned out to be the key parameter for ensuring that the conveyors function properly. All of the drives are manufactured with safety inputs which considerably simplify the design and construction of the safety circuits for

Dane kontaktowe:KarT Sp. z o.o.

ul. gen. W. Andersa 40d

15-113 Biaystok

tel.: (+48) 85 743 30 64

fax: (+48) 85 743 75 87

bok@kart.com.pl

www.kart.com.pl

the machine, eliminating the need for cutting the power supply off from the power inverters, which could lead to the damage or shortening of their lifespan if happening frequently. Both the side pusher and the belt conveyor are driven by R88M servo-motor powered by Accurax G5 driver by Omron with impulse controlling and feedback based on the incremental encoder. Such servo-motors are characterized by small size which minimises the space required in the control box and the space in the machine for motor installation.Solutions offered by Omron meet the requirements of the Machinery Directive within the scope of operation safety and maintenance. All the safety-related elements have their reliability data included in attached documentation, necessary for the post-completion verification of the safety devices. Certificates of conformity and CE marking are also attached. The ease of communication, small size, clear and understandable documentation of the automation machines and the developed technical support of Omron company allows for easy and quick design and start-up of the machine control system both for the simple technological machines designed and constructed by KarT sp. z o.o., such as the assembly and testing equipment for the plastics industry, and more complex applications for different industry branches.

Pawe MurawskiAutomation Designer

21 OMRON MAGAZINE - MEW

MEW Kolonowskie is built on the stage of fall of Maa Panew

River in the Kolonowskie town. A power station has three

Archimedes turbines. Our company supplied this project with

electrical power system) and automation control systems.

Automation system for power station control has to maintain

a level of upper water according to an ordinate set by the

system operator. On account of the nature of this project

it has been assumed that the power station has to be a

maintenance free object with the possibility to its remote

monitoring and electrical energy production process

controlling online. We had to design an easy and intuitive

application for managing processes in the power station,

because our client does not plan to employ qualified staff.

In order to fulfill the projects requirements we decided to use

two turbine set running with constant rotational speed and

one with steady control of rotational speed. For automation

systems we used Omron CJ2M controller and an inverter

ASC 800 series from ABB. A controller is to control the status

of electrical systems in the power station and to manage the

inverter work. For process visualization we used CX-Supervisor

software package that allows for remote supervision.

Connecting controllers to SCADA software gives the

possibility to create not only an user friendly interface for easy

object management, but also it provides invaluable diagnostic

functions and easy system adjustment to hydrological

conditions on site.

During project planning and building of MEW Kolonowskie

power station it was important to act fast in case of failure

and reduce time for power station shutdowns. In order

to achieve this, the system has been equipped with an

Small Water-Power Stations control system with Archimedes turbines

Gawlikowski company has long-lasting experience in automation of water-power stations. The company has carried out a project for power station in Kolonowskie which has been equipped with three Archimedes turbines. The control system is based on CJ2M series unit that cooperates with SCADA CX-Supervisor software package

22

Gawlikowski company has experience in water-power

plant automation since 1991. Since the beginning

we cooperate with Omron, constantly developing

our systems in accordance with our partners newest

technology in automation.

Dane kontaktowe:Gawlikowski - Rafa Gawlikowski

97-500 Radomsko

ul. Fabianiego 5B

tel.: (+48) 44 789 06 33-34

tel.: (+48) 606 669 077

biuro@mew.net.pl

www.mew.net.pl

automatic diagnostics device. Simple commands shown on

CX-Supervisor allow for fast restoration of object to work via

unqualified personnel, and consequently, maximize electric

energy production .

A part of automatic control of power station is a prototype,

and because of that we had to provide possibility to remote

develop the project and introduce changes in software

installed by a programmer. The main unit CJ2M-CPU31

passed exams as a remote programmable controller, and

undoubtedly implementation of this solution brought

financial benefits and reduced time needed for development

of a power station control program (no need to wait for a

technician).

To sum up, a solution offering remote access to the control

system turned out to be exactly what our customer wanted.

Increased implementation costs very quickly resulted in

problem-free maintenance of MEW Kolonowskie, which is

synonymous with reduction of shutdowns. Products supplied

by Omron are ideal for process automation in water-power

stations. They provide high configuration flexibility and

reliability.

23 OMRON MAGAZINE - NEOTECH

Easy operation mode makes the machine suitable for service

application. Advanced software version makes it possible to

program an optional sequence: spindle movements, stratified

winding, pilot movements, machine stop time. If you use

software accordingly, you can perform beginnings, endings

and tapping of coils. You can use a PC to program winding

machines.

Multispindle winding machines

Multispindle winding machines type CNW are designed to

wind coils on carcasses or ferrite cores. It has three axes XYZ

manipulator that guides wires. On the manipulator a rotary

beam is installed with wire guides. This allows for rotation of

90. It enables terminal winding in 2 surfaces. In addition, the

winding machine has wire clamps and optional scissors. For

installation of carcass and cores we use replaceable grids that

are designed to order.

Both winding machines types are programmable, and have

possibility to save settings for each product. A system software

for winding machines allows for:

programchangebyareceiver.

creatingnewprograms.

userprogramsprotectedbypassword.Onlyauthorized

staff may perform changes.

programmodificationwhenitisrunning.

Steprunning(performingsubsequentprogramlines).

movementsequencelearning.

Our main problem was to select appropriate drives and

sensors defining the base point of machines. Drives have to

fulfill strict requirements, such as:

noovershooting;

possiblythesmallestovershootingofpointsetbya

controller and real position;

followupmovement;

Omron drives and induction sensors have met our

requirements and over years have been successfully used not

only in our winding machines, but in almost every machine

that we produce.

Single spindle winding machines

Single spindle winding machine type NCJ are universal devices used for winding elements on single spindle. They may be used as basic machines in production plants or in services. These devises are controlled by microprocessors, and are equipped with color touch panel for user communication.

24

Neotech Sp. z o.o. exists on the market since 1989. We

produce various types of winding machines, automatic

tinning machines, measurement and monitoring

devices, automatic packing machines and complex

production lines. We also design machines according to

individual orders, and we modernize old equipment. We

have cooperated with companies from various branches,

thus we gathered wide experience in mechanical

construction and automation, and construction and

implementation of devices on site.

Dane kontaktowe:NEOTECH Sp. z o.o.

ul. Komunalna 5

15-197 Biaystok

tel.: (+48) 85 67 55 632

tel.: (+48) 85 66 23 022

maszyny@neotech.pl

www.neotech.pl

25 OMRON MAGAZINE - PABLO

Battery sorterMain assumptions: Sorting of various battery types, like R03(AA), R6(AAA), R14(C), R20(D), R9(6F22) with the capacity of 10 batteries per second and effectiveness of 98%.

Technical specification:

Line characteristics

EtherCAT net topology, Ethernet

Control System Description...As a response for recycling industry needs,

a project concept has risen for an efficient

sorter for various battery types available

on market. The main assumption was

to achieve capacity of the sorting system at the level of 10

batteries per second and effectiveness of 98%.

Such strict requirements needed control components that

not only cope with such work, but also are flexible enough to

create fully functional and productive application.

After extended analysis, conversations and tests, among a

couple of global suppliers of automation components we

decided to choose Omron (see Technical specification).

A leading role in the process control was given to NJ301-1100

controller working as PLC controller, a supporting role was

given to visualization system based on FH-3050 controller

and 2 Mega pixel color FH-SC camera supported by LED FL-

BR13120W-H illuminators.

MX2 inverters became Shaft horses for the application,

together with EtherCAT communication modules used to

control of conveyor drives.

For database management of visual system batteries we

used a database program located on a PC. All components

mentioned are organized in a network for an easy and fast

exchange of data within group (see EtherCAT net topology,

Ethernet).

General system operating principleAll components are connected to one another, so that they

can exchange data among them. Such connection provides

unlimited possibilities for control and communication. For

data exchange between PLC-Visual system we used very

fast real time EtherCAT protocol. It is now possible to send

information from the visual system to PLC in a short time,

which along with the capacity of 10 batteries per second has a

very crucial meaning. The remaining modules, distributed IOs

and MX2 inverters, also communicate with PLC via EtherCAT.

For communication, special data frames structures have been

introduced, which send information from visual system to

PLC, from SCADA system to PLC and vice versa, as well as to

the visual system. In terms of communication via Ethernet, we

implemented UDP (User Datagram Protocol ).

Visual system learns battery types in a couple of simple steps.

First, the user defines battery parameters: type, producer,

size; next, he issues a command to the system to change

the operating mode into learning mode. After each learning

cycle, a battery picture is send to the system data of visual

and SCADA systems. Next, the operator defines which battery

types should be sorted and to which container. From SCADA

side it works the following way: from data base of learned

batteries only those are chosen that have been defined by the

operator, and later on a special data structure is sent to the

PLC controller, which takes control over correct sorting.

After sorting process is started, visual system takes pictures

of incoming batteries and analyzes them according to the

algorithm. When it recognizes a battery, it sends a defined

data structure to PLC, which does queuing of the battery

on the table of batteries recognized till it does not reach an

appropriate container. When the battery is located in the

26

Dane kontaktowe:Fabryka Maszyn Pakujcych PABLO Sp. z o.o.

ul. rdlana 27,

26-065 Piekoszw k. Kielc

tel.: (+48) 41 306 16 04

tel.: (+48) 41 306 21 80

biuro@maszynypablo.pl

www.maszynypablo.pl

right place, it is pushed from a queue with the compressed

air. If the battery is not recognized, it is send back for another

analysis.

Problems we have encountered...For an observer, the process does not seem to be complicated.

However, during the project we have faced many adversities

and problems that we had to solve in order to achieve our

aim.

One of main problems was a huge diversity of batteries

that resulted from multiplying battery types by number of

producers. To sum up, it is about 2000 different battery types!

Processing data of such quantity is a challenge. If we take into

consideration time restrictions and high sorting capacity, this

makes us feel proud .

Luckily, the capacity of Omron visual and control systems

helped us to achieve our goal and solve the problem.

Summary...

Albert Einstein once said:

Everybody knows that something cant be done and then

somebody turns up and he doesnt know it cant be done and he

does it.

This citation correctly reflects what we have achieved. I

know that at the beginning almost nobody believed in

success of this project; however, stubbornness, knowledge,

determination and passion led us to success. Again I reached a

conclusion that Omron was a good choice both in the scope

of hardware as well as price and professionalism of people

involved.

People involved in the project:Rafa Chojnowski PABLO company

(Project manager, PLC, SCADA)

Daniel Splny OMRON (specialist a visionary)

Bartomiej Macioek OMRON (an NJ specialist)

Piotr Piwowarczyk Freelancer (data base specialist)

Example of SCADA system window

Control cabinet view

27 OMRON MAGAZINE - PROAUTOMATION

Automation of integrated transport, distribution and buffering system

ProAutomation Sp. z o.o. is a continuous vision of an efficient engineering team. Our aim is to provide the highest quality and fast implementation of automation systems. Our clients for whom we have had the possibility to implement our solutions since we set up, speak for us. We implement over 100 projects a year.We design and assemble control cabinets, program PLC controllers, operator panels and SCADA systems. Our strong points are reporting systems (production, media consumption) and batch systems. Our extensive experience in the food and chemical industries allows us to help you choose appropriate process instrumentation.

Production conditions and project guidelinesA modern plant cannot function without a modern transport

system. Together with the growth of quantity and diversity of

products, standard transport methods based on fixed linked

conveyors proved to be insufficient. In such conditions, an

investor - a company from chemical industry has decided to

modernize its existing system.

The most important requirements for the new system are:

acapabilitytoselectroutesbetweenaproductionmachine

and any packing terminal with only one click

acapabilitytorouteproductionofmanymachines

into one buffer

verificationandregistrationofproductsconformity

in accordance with the route set

automaticrouteswitchingincaseoffailureor

buffer overflow (considering product conformity)

scalability-theabilitytoexpandeasilyby

introducing new production and packing machines

communicationwithanexistingdatabasesystem

powerconsumptionoptimization

Additional challenge has been the necessity to maintain

production continuity. That required synchronization of

assembly, electric and programming work as well as good

preparation of each implementation phase. In effect we were

able to minimize time of unavoidable downtime up to several

minutes.

Systems structure and functionality The system we have implemented can be divided according

to its functionality:

transportsystem

bufferingsystems

A transfer system delivers product to any available buffer. This

is done by longitudinal and transverse conveyors system and

actuators with paddles.

Buffering systems are linked with packing terminals. Its main

task is to sustain constant production and eliminate short and

mid-term downtimes related to production conditions.

Buffering systems are equipped with CP1L-E controllers

which ensure independent and failure-free operation. The

system uses MX2 inverters. High flexibility is achieved by

parameterization of drives through Modbus network. Another

advantage of the communication bus is a detailed diagnosis

that allows to monitor current drives state.

NJ controller is the main processing unit for transport system.

Process control has been divided into 2 cabinet sets as a

consequence of systems arrangement and widespread. Each

set has MX2 inverters and other instrumentation necessary

for transporters drive connection. The key element is a

modular, distributed NX I/O system that communicates with

a controller via EtherCAT protocol. The same protocol is used

to exchange information with valve terminals located on

site. We used GX-JC switch and mixed star-line topology with

daisy chain connections. This enabled us to reduce amount of

cables on site. To be able to acknowledge paddles positions

we need induction sensor with wide measurement range and

compact construction. This is why we have chosen E2B series.

Flexibility and ability to parameterize the entire system,

requires information exchange between individual controllers.

For this purpose we have used master-slave communication

model and FINS/TCP commands, where NJ controller is the

master, and CP1L-E controllers are the slaves.

Production machines

Transport System

Buffering Systems

Packing machines

28

Dane kontaktowe:ProAutomation Sp. z o.o.

biuro / warsztat

ul. Annopol 4

03-236 Warszawa

tel.: (+48) 22 203 56 20

biuro@proautomation.pl

www.proautomation.pl

The main advantage of such solution is a possibility to easily

add consecutive slaves (buffering systems), without any

interference to the existing system.

Components used: Our aim was to maintain the highest quality and consistency

of the system made. That is why we have chosen Omron

Electronic components and technology. Among the most

important components used we can name:

NJ301-1100programmablecontroller

ModularNX-ECC201I/Osystems

SwitchEtherCATGX-JC

CP1L-Econtrollers

MX2inverters-over70

E2Bsensors-over100

One has to notice that a feature that distinguishes Omron

Electronics from other manufactures, aside from innovative

products, is complex technical support. Both in component

selection and project implementation.

29 OMRON MAGAZINE - REMTER

REMTER specializes in designing and constructing machines

that are numerically controlled. They are used to cut metal

sheets with the help of plasma stream. The company bases

its projects on proven solutions and cooperates with global

leaders, like OMRON. Since the early beginning, it has been a

priority for REMTER to design cut-off machines of the highest

quality along with reasonable prices. Starting from the

designing phase, the company takes into consideration the

needs, absorbing capacity and complexity of metal industry,

and dedicates its solutions to companies of many metal

branches. Our experience helped us to design and construct

machines that are diversified by parameters and quality,

so that we can find customers among steal construction

producers, light and medium metal industry, producers of

agricultural machines, ventilation installations and producers

of food industry devices. Such spectrum of buyers has

motivated us to diversify our offer and introduce three

different machine types: HD1000, HD1500 I HD 2000, and also

a special machine for pipe cutting GRH 23WH.

As a response for a need of high quality devices for plasma

cutting, REMTER uses advanced solutions and a possibility

to upgrade a standard machine if required. Technical

specification and materials used are very important, but also

their reaction to changes, multi functionality and simple

operation. This approach led REMTER to use advanced

solutions in plasma cut-off machines, in the scope of drive

control automation.

After extensive searchers REMTER decided for OMRON

components. The most important factors that influenced

our decision were: wide product range, components

accessibility, service quality and delivery time. OMRON has

met all requirements, and this is why our cooperation is so

productive.

REMTER HD1500 plasma cut-off machine is an interesting

device. Its electronics is almost entirely based on Omron

components. Thanks to its reliability, HD1500 is very universal,

and at the same time it cuts fast and precise. This machine can

have working place adjusted to the customers needs, from

1,5x3 m to this size repeatability. The machine working length

can be freely increased during operation, and additionally it

can have a table with mobile control station. A table with 6

sections has a system for pulling dust and fume back, and it

can be optionally equipped with filter ventilation. All machine

track have grease and maintenance-free linear slideywas,

and there is no need for the operator to clean them. Not to

mention it has an impact on the handling comfort. In this

machine series, tracks are outside table, and they are anchored

to the ground.

Long-term REMTER machine operation is owed to brush-and-

rifle free planetary gears. A drive is done by servo drives.

HD1500 is also universal because it can use aggregates of

different power, starting from supplies for cutting thin metals

to HD solutions for thick metals. The device can be optionally

equipped with a unit for edge scarfing or pipe turn-table.

Its multifunction is completed by simple and intuitive

maintenance. Any configuration changes can be performed

by the operator. The machine has a nesting software as

standard, which allows for simple and fast communication

between the designer and the device. As input files you can

use DFX files from any CAD software.

Electronics used in HD1500 is worth mentioning too. HD1500

cutting-off machines have a DAYLOX panel computer, motion

controller and PLC controller, and SmartStep2 digital drives.

This technology places REMTER among companies that use

the most advanced technologies for plasma stream burning.

HD1500 cutting-off machines

Thus it is not easy to find a product that guarantees reliable use and further development by its quality, components used and applied software. Such solutions, however, are offered by REMTER company from Ktrzyn.

30

The machine has a fan-free computer with integrated touch

panel Daylox for easy, effective and reliable communication

of the device with the operator. The control system thanks

to its parameters, semiconductor drive and passive cooling

is resistant to heavy conditions. Daylox uses a siliceous disc,

which is resistant to environmental conditions, especially

shock and vibrations, and in case of failure, it does spare

copies automatically on a second disc. In that way one can

easily go back to work, and exchange damaged disc for a new

one.

Excellent control of periphery systems, terminal sensors,

induction sensor and safety monitoring is ensured by Dyalox

computer together with PLC controller S1 series. This is what

has influence on the quality and reliability of the machine. The

producers warranty for this burning machine is 24 months.

We have used original Omron components for HD1500

device, they are: servo drives SmartStep2 and brush-free AC

motors. Wide parametrization range, vibration and resonance

suppression systems, electric gear and many other drive

features ensured REMTER that these are the most suitable

solutions for these machines.

It is worth mentioning that all OMRON products are handled

with one Cx-One software. Thus, system configuration, start-

up and maintenance have become completely problem-free.

The quality of OMRON technical support is worth mentioning.

Thanks to the cooperation with OMRON, REMTER company

manufactures reliable, failure-free and of reasonable prices

plasma cut machines.

Agnieszka Triebling-Matys

Dane kontaktowe:REMTER CNC ul. Budowlana 3D 11-400 Ktrzyn Tel.: (+48) 724 341 378 www.remter.pl

31 OMRON MAGAZINE - RIAS

Efficient, flexible and multiformat typesetting

The company was established in 2006 in Swarzdz near Pozna. At the beginning, RIAS was mainly involved in preparing projects, technical consultancy, modernization and implementation of industrial automation systems.

The company also designs and constructs untypical devices for various industrial

sectors. Our projects are carried out (from project, device selection and integration)

with the use of Omron components and automation systems. RIAS also offers

consultancy services with as-built documentation and maintenance trainings.

To meet the client requirements, RIAS created a division assigned to design and

develop serial machines. Since 2012, RIAS has produced, among others, RI-600

typesetting and joining press machine, RS-600 piling machines and internal

transport conveyors. These changes in production quantity forced us to expand our

machinery park. We had to buy machine tools like milling machines, turning lathes

and tool center from Bridgeport.

RI 600 is an efficient, flexible and multiformat typesetting and joining press machine

that is used to produce packages from corrugated board for many industrial

branches. Our main clients for such devises represent milk, meat, and fruit and

vegetables industry. Machine controlling and programing has been designed so

that an operator can handle the device intuitively. RI 600 is built on the basis of

components from the most recognizable brands like OMRON, SMC, Festo, Nordson,

RITTAL, IGUS, Elesa+Ganter. Omron automation components, which base on CP1L

compact control and SmartStep2 actuator system, allowed us to achieve higher

efficiency and repetition of package assembly process. A PLC controller is connected

32

Dane kontaktowe:RIAS-Systemy Informatyzacji Przemysu Mariusz Pomorski ul. Jasna Rola 34D/9 61-609 Pozna tel.: (+48) 600 445 889biuro@rias.pl

SOLUTION PARTNER

with HMI NS 5 panel with Ethernet network. It enables

remote access to visualization and support from anywhere in

the world. RI 600 has MX2 inventor that allows for easy tray

forming according to the quality of impression board.

The plant expansion and company development made

RIAS available to carry out more projects at the same time,

and as a result, we increased our productivity and ability to

introduce new projects.

33 OMRON MAGAZINE - TMA

TMA millingLine offers:

increasedqualityofproducts,

increasedproductionefficiency

fasterprocessing.

Modern machinery parks require constant development

so that they can meet requirements of industrial dynamic

conditions. Modern machining centers provide us with more

and more possibilities. How to increase the milling process

precision? How to make this process shorter? And finally, how

to increase the efficiency of the whole production process?

These questions were given by TMA from Gdynia, a company

from wood industry.

A company, which is one of European leaders in designing,

manufacturing and selling windows and doors, issued a huge

challenge to TMA engineers. It was to design a machine that

would integrate 8 linear drives driven by Omron servomotors.

The reason why the company decided to implement a project

for a new machine was the need to speed up the production

process and increase quality, as well as performing many tasks

on a profile at the same time. The client has been looking for

a solution designed for performing vents in profiles of mass

production. Before a TMA solution has been introduced,

vents were performed by a universal large-size CNC milling

machine. Its main disadvantage was the use of programmable

multiaxial CNC machine tool for unchangeable operations,

which resulted in small efficiency of the machine. As a

consequence, the processing took too much time.

The customer put strict requirements towards TMA project

team: shortening processing time by 50% ( from 3 min to 1.5

min) together with preserving the machine universality.

The task was not easy. It was a challenge for us to obtain

precision demanded by the client (+/- 0,2 mm) parallel to

milling of all vent pockets, and optimization of the whole

production process. Our result was the one expected by

our client - the requirements have been achieved. Tomasz

Zakrzewski, a TMA constructor.

A new device is adjusted to perform many tasks

simultaneously, and to shorten its time. To make the process

faster, one has to process an element with the use of

three tools at the same time, and reduce their processing

movements. To allow fur such ability we used OMRON

controllers NJ series, which enable controlling of a couple of

servo drives simultaneously. Thanks to that it is now possible

to process complicated forms.

Multiaxial TMA millingLine machine is a result of months of

work of TMA team. It is based on OMRON products. They are: 8

servo drives (3x0,75kW, 4x1kW, 1x0,75), NJ301-1200 controller,

a HMI panel, SmartStep2 R88M servo.

The main goal to implement this new machine was to

maximize production quantity at clients plant. This has

been achieved thanks to shorter processing time. Also, the

company now needs less time to complete orders and reduce

storage quantities. All these factors have influence on better

product quality.

Our mission is to create innovative solutions that help our

clients to increase their production efficiency. We deliver

solutions tailored to the clients needs. Each new project is

a challenge for us, and we do our best to face it. - says Piotr

Orlikowski, TMA Vice president.

Multiaxes miling machine - TMA millingLine as a response for modern industry needs

You have to be very precise in order to manufacture products of the highest quality. The need for new solutions is caused by the necessity of the highest production efficiency, failure-free work and process repeatability. An 8-axial miling machine - TMA millingLine is designed as a response for clients representing wood industry.

34

SOLUTION PARTNER

Dane kontaktowe:TMA Automation Sp. z o.o. Al. Zwycistwa 96/98 81-451 Gdynia info@tma-automation.comwww.tma-automation.com

35 OMRON MAGAZINE - TOOLS FAC TORY

Significant innovation of our machines lies in the ability to

adjust the heating rate of each heater individually using a

touch operator panel by Omron Electronics, where you can

adjust the percentage value of each heater individually, using

the PLC by Omron Electronics, and temperature figures of

material are obtained by means of a pyrometer. Another

solution that has been implemented into our thermoforming

machines using Omron Electronics applicable servo drivers,

enabling steady regulation of clamping frame dimensions.

We have used Omron products for many years, because they

are innovative, but also easy to use, they provide easy access

to machines for operators. What is more, our supplier is a

global company for us as an international company it has a

significant meaning.

Function and parameter selection is done via NB Omron

HMI operator panel with clear graphic menu, which gives

us easy access to its basic functions. HMI panel also gives us

a possibility to set a password and choose levels of access

authorizations.

Plastic industry is constantly changing. This forces our

company to constant modifications and being up to date with

the newest technological solutions. We link our experience

with technical knowledge of Omron engineers, thus we are

ready to meet even most difficult requirements of our clients.

This is our priority.

Innovation in Vacuum Thermoforming Technology

Our machines are innovative and highly technologically advanced. This allows us for fast machine adjustment to technological changes. Today, fast change from one product type to another is crucial, and very often required by clients.

36

The company TOOLS FACTORY is a manufacturer of

plastic processing devices. We distinguish two main

types of machines we produce: vacuum thermoforming

machine SMARTLINE and CNC milling plotters MASTER

CUT, widely applied in the production of 3D shapes and

further processing, are modern machines, well-equipped

and constructed in accordance with the requirements of

the end user .

Dane kontaktowe:TOOLS FACTORY sp.j.

Stefanwka ul. urawia 92

05-462 Wizowna

tel.:. (+48) 22 789 01 88

fax: (+48) 22 789 07 18

info@toolsfactory.pl

www.toolsfactory.pl

37 OMRON MAGAZINE - U-R-B-A-N

URBAN Polska, a company that constructed a milling machine

for CNC seals for 8 profiles, has now launched its version for

4 profiles. The machine is now more compact and easier to

maintain.

Production of windows mainly consist of plastic windows.

Window profiles are first cut under the 45 angle, and next

they are welded together. When PCV is melted and profiles

are joined together in the temperature of 240, the seals

become overheated, hardened, and deformed in the contact

area. As a result, draughtiness may occur in the window

corners. Performing suitable milling after the profiles are

cut eliminates negative influence of welding on the seal

shape, so that they remain elastic, and the windows keep

their insulating properties. For this purpose URBAN Polska

developed in 2013 a new CNC milling, a 3-axis device type

DFM 200 based on OMRON automation. The milling machine

is adjusted to mill up to 8 profiles. After launching its first

DMF-200 milling machine, we have waited for users opinions

about the product. After we analyzed gathered material, we

started working on second version of this device. This resulted

in launching of DFM-200/4 at the end of 2014. The milling

machine has been equipped with a drive based on linear

motors in X and Y axes, and actuators in the Y ax. The number

of profiles being processed has been reduced to 4, thus

reducing the size of machine. Additionally, stable/constant

cooperation with Omron experts made machine maintenance

easier. A milling machine processes 4 profiles from one side in

one cycle.

Its work table has been reduced, but is still suitable for

elements of maximum dimensions: 200 mm wide and 150

mm high.

The milling machine has 7 touch panel. It can visualize 20

intersections of standard profiles, based on sections received

from customers in dxf format. This makes the peration easy

and enables identification. Milling of profile ends takes place

with the help of VHM 80 mm mill cutter with fast exchange

of tools on a sleeve. Profiles are inserted in the horizontal

position, and after the milling process they are further

processed at the other side. The machine has got 8 pneumatic

clamps - two per each profile. A feed of the engine takes place

Milling machine DFM-200/4 URBAN POLSKA

38

on flat linear guides with automatic and smooth regulation of

the engine rotations in the scope of 6,000 - 18,000 rotations

per minute. The machine can operate both in the left- or right-

side direction. Milling of 8 profiles at the same time results in

a bigger amount of chips, so in order to reduce maintenance

shutdowns, the milling machine can be connected to the chip

stay of 1,5 kW power and a 2200 m/h capacity. The milling

machine is now available in the U-R-B-A-N worldwide sales

chain.

We have had conversations with our end users, and as a result,

we have found a new application for the machine. In October

2014, one of our machines was sent to a company that welds

windows with profiles strengthened with glass fibers, which

have to be removed from the welding zone. Tests have shown

that our machine can be used also in such difficult conditions.

The only thing we had to change was the tool.

Dane kontaktowe:URBAN Polska Sp. z o.o. ul. Gospodarcza 7 68-200 ary tel.: (+48) 68 478 78 00 fax. (+48) 68 478 78 01 office@u-r-b-a-n.pl www.u-r-b-a-n.pl

To the machine the work of the machine, to man the thrill of further creation.

Kazuma Tateisi, founder of Omron

7%36.500

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40%

15%

13%

11%

11%

10%

Omron at a glance

Listed in Top 2000 largest companies of the globe

Omron Corporation NASDAQ: OMRNY

Top ranking in Dow Jones Sustainability Index

Thomson Reuters Top 100 Global Innovators

200.000 products ranging input, logic and outputSensing, Control Systems, Visualization, Drives, Robots,

Safety, Quality Control & Inspection, Control and

Switching Components

Investment in Research & Development

Innovation track record of 80 yearsTop 150 global patent assignee

1.200 employees dedicated to R&D

11.000 + issued and pending patents

Technical training & seminars, technical support,

Automation Technology Centers, online community

(MyOmron), online catalogues and technical documentation,

customer service & sales support, inter-operability labs

(Tsunagi), safety services, repairs.

Close to your needs The Perfect Match

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PRO

PROplus

Employees worldwide

Locations worldwide

Countries in EMEA

Cost effective for standard industrial environment

Extra performance and and extended product mix

For advanced and unique applications

Working for the benefit of societyIndustrial Automation

Automotive

Components

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