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HOW IO LINK IS REVOLUTIONIZING OEE, CHANGE OVER AND PREDICTIVE MAINTENANCE
HOW IO LINK IS REVOLUTIONIZING OEE, CHANGE OVER AND PREDICTIVE MAINTENANCE
Introduction
Greg Molinaro Industry Manager with Balluff USA 25 years in Manufacturing and Automation Electrical Engineer Controls Automation Vendor Machine Builder
What is Overall Equipment Efficiency?
OEE: The percentage of manufacturing time that is truly productive.
Three Components of OEE1. Availability Loss
a. Unplanned Stops/Downtime – Machine Failureb. Planned Downtime – Set up and Adjustments
2. Performance Lossa. Small Stops – Idling and Minor Stopsb. Slow Cycles – Reduced Speed
3. Quality Lossa. Production Rejects – Process Defectsb. Start up Rejects – Reduced Yield
What is IO-Link?
• IO Link is Universal• IO Link is Smart (Intelligent)• IO Link is Easy (Straight Forward)• Simplifies Controls Architecture• Provides Visibility Down to the Sensor and Device• Backbone of the Smart Factory
What is IO-Link?IO-Link is a point-to-point or peer-to-peer communications between a master and a device utilizing the 4-wire unshielded sensor cable
Same cable used today for prox switches or photo-eyes.
Device can be up to 20m away from the master.
master
device
What is IO-Link?
• Capable of building STAR topology
• Extend the Master Block
• Extend the Hub
• Use with existing infrastructure
• Simplifies Retro Fit Projects
What is IO-Link?What does IO-Link communicate?
• Process data (Control) Cyclical communication of process status
• Parameter data (Configuration) Messaging data with configuration information
• Event data (Diagnostics) Communication from device to master
(diagnostics/errors )
Data communicated in engineering units (millimeters, psi/bars, degrees)
1101
1000
0110
0101
00011010
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Vendor Neutral & Open Standard (IEC 61131-9)
Similar to USB's "plug & play" feature
IO-Link is Universal
IO-Link is NOT a NetworkIO-Link is NOT a Network
For Computer Technology
=For Automation
Technology
IO-Link is NOT a Network
For Computer Technology
=For Automation
Technology
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Use Existing Infrastructure & Network ArchitectureDeviceNet & EtherNet/IPCC-Link & CC-LinkIE FieldProfinet & ProfibusEtherCAT & TCP/IP
Controller AgnosticSiemens or Allen BradleyMitsubishi or Omron
Robot AgnosticYaskawa or MotomanKuka or Fanuc
IO-Link is Universal
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Reduce Planned and Unplanned Downtime
Offers full Remote Configuration
Provides Enhanced Diagnostics
Reports Event Warnings
Store settings in the control or master and swap as needed on the fly
Swap smart sensors w/o programming (Fast Change out)
IO-Link is SMART
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Eliminates need for Manual Configuration
No errors on setup of new device
Find & Replaceo Sensor Parameters are
downloaded automaticallyo Saving precious time and
production
Enables Faster Troubleshooting
IO-Link is EASY
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Reduce Analog costs by 15%-20%
Reduce risk of electrical noise disrupting the process
Reduce terminations and turn them into connections
Easily retrofit measurements & analog devices
Simplify Analog & Measurements
IO-Link is EASY – Eliminate Analog Headaches
IO-Link Simplifies the Controls Architecture
One Standard Interface
Use the same standard sensor cable across the board for integrating Discrete I/O Analog I/O Smart Devices and sensors Specialty devices (RFID, Vision)
IO-Link Simplifies the Controls Architecture
What is Predictive Maintenance?
Predictive Maintenance helps determine the condition of in-service manufacturing equipment in order to predict when maintenance should be performed.
The desire is to prevent the occurrence of a failure by performing planned maintenance. Predict when a failure might occur Prevent unplanned downtime Increase OEE Reduce Equip Failure Reduce Small Stops Reduce Slow Cycles
Preventative Maintenance only captures 18% of the machine failures
Example: Car taken to the shop and put on computer
IO-Link and Predictive MaintenanceIO Link Smart Sensors Makes Data Available
Process Data Counting/Sorting
Parameter Data (Device Configuration) Rate/Gain/Distance
Diagnostic/Event data (Condition Monitoring) Temp/Vibration/freq/resist/pressure/current/volts
Increase OEE Reduce Planned Stops Reduce Small Stops Reduce Slow Cycles Production Rejects
Example – CP PackagingEnhanced Diagnostics
• Standard sensors connected to IO Link Hubs
• Visibility by IO Link Master and Hub port
• Reduced Service Timeo HMI button – send configuration to
device
• Increased Available Run Time and Reduced Downtime
Example – CP Packaging
Simplifies Retro Fit of earlier model machine
• Able to keep existing standard sensors
• Reduced analog wiring
• IO Link Master Block provides short circuit protectiono 277 VAC Heaters
• Reduced PLC program changes
What is Change Over?
Format Change – adjusting or changing out parts on a machine to run a new product(Bag Size, Carton Size, Case Size, Bottle Size)
Semi Automatic and Automatic Verifying Correct Position
Guided format change (Height, Length) Magazine Guide Rails Lug Adjustment Flap Plow Adjustment Glue Nozzle Adjustment
Change part detection Fixture Forming Tube Jaws Timing Wheels
Examples of Change/Swap out• Bag size• Carton Size• Case Size• Bottle Size• Bottle Color• Container Size
Verify Position• Consistent every time• Faster• No tweaking
Change Over – Guided Format ChangeLinear Positioning over IO Link
Examples of Change/Swap outo Bag sizeo Carton Sizeo Case Sizeo Bottle Sizeo Container Size
Identify correct change/swap out of equipmento Fixture Changeso Chocolate Moldso Forming Tubeso Jawso Spout
Change Over – Change Part DetectionRFID Over IO-Link
Change Over Demonstration Video
IO-Link and Change Over
Advantages of IO-Link and Linear Positioning for Change Over Reduced change over time More accurate positioning Much Less Tweaking after change over Reduced product waste from new production run Easier for operator Minimal cost to upgrade existing equipment Eliminates Analog wiring
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“With these technologies, customers are able to reduce their changeover time from over 30 minutes down to five while eliminating potential human errors.” Edson Packaging
Increase Machine Throughput: Faster Changeover – Tools & Guides
IO-Link and Change Over
Balluff Inc | Marketing Management Director, Will Healy III @WillAutomate
IO-Link Equals Increased OEE
IO-Link Enables Smart Factory Concepts Today
Intelligent Devices More information Accurate information Enhanced Diagnostics Simplifies Retrofit Utilize existing devices
How IO-Link is RevolutionizingOEE, Predictive Maintenance and Change OverAvailability Loss (Planned and Unplanned Downtime) Reduces unplanned downtime Helps pin point trouble areas and bottle necks Reduces machine tweaking and cleaning
Performance Loss (Stops and Slows) Reduces obstructed product flow Prevents incorrect settings Prevents misaligned or blocked sensors
Quality Loss (Bad and Reduced Product) Reduces incorrect settings
THANK YOU FOR YOUR ATTENTION!
© All rights reserved: Balluff GmbH, Neuhausen. Transmission of this text in original or copy form as well as sharing with third parties is prohibited.
Phone:e-mail:
If there are any questions, please feel free to contact me.
Greg MolinaroIndustry Manager
