In my recent travels of the east coast from Boston to Tampa, customers have been looking for quality solutions to be able to run:
and multiple sizes,
and multiple form-factors,
all on one production line.
Two things about this seem to be in every application:
- Change-over needs to be simple for the operators.
- Management needs to see the cost/time savings, be it planned or unplanned downtime.
But how can I do multiple recipes or multiple jobs on one machine? I have to reprogram/reposition sensors, move guide rails, swap out components, etc…
Install smart sensors and devices with communication built into them (like IO-Link). Smart devices are the future of quick recipe changes. Using the parameterization functionality of IO-Link devices allows you to pre-program standard recipes into the device and then store them in the controller for later. Yes, you can store sensor programming in your controller!
For Example: Say you are interested in making sure your package is color matched for the product you are filling with. A color sensor with IO-Link technology can be programmed to detect a certain color as “good” So everything works great with “Product A” but then you need to run “Product B”. All the operator needs to do is select the pre-programmed recipe from the HMI and the controller automatically resets the color sensor for “Product B.” If the sensor is damaged, the maintenance crew just installs a new one and tells it, “Product B.” No other setup is required!
This parameterization function in IO-Link devices solves our application needs:
1. It makes recipe changeover for the operator an easy one touch of the HMI.
2. Planned & unplanned downtime are reduced using parameters & diagnostics.