容器幾乎無聲地滑入到位，平穩地接近目的地：CleanDock。精緻的不鏽鋼材質。整潔、從容且可靠。然後到站了。主動部分的氣動抓取系統從上方推進，抓住被動部分的容器蓋子並提起蓋子。兩到三次的洩氣聲，表明計量元件和目標容器已無縫連接。被動部分的彈性補償器能夠精確量測容器下方的稱重計皮重，與容器中已容納的產品數量無關，然後開始填充散裝物料。此過程結束後，主動和被動部分會優雅而徹底地相互分離，然後容器將移至下一個填充站。從外面無法看到的情況是，幾乎整個填充過程都是由 CleanDock 本身分散控制的。
「我們的系統可以運輸和分配您能想像到的所有散裝物料類型，」位於德國 Osterburken 的 AZO GmbH + Co. KG 的研發主管 Frank Pahl 說。「物料的範圍從嬰兒食品的奶粉和配料、到藥品和清潔劑以及各種塑膠和顏料，例如濕塗料生產。談到我們在食品、生命、化學和聚乙烯四個業務領域中已實施的各種應用，幾天也說不完。」AZO 在散裝物料搬運領域擁有 70 多年的歷史，在全球擁有 1,000 多名員工。目前最具開拓性的創新是最新一代 CleanDock。藉由這一系統，AZO 及其長期合作夥伴和自動化專家 Festo，朝著快速調試、減少錯誤和提高散裝物料填充的安全性方面邁出了重要的一步。為此，CleanDock 採用了分散控制器形式的智能，因此在過程中具有自主性。雖然過程控制系統從控制技術角度來看是掌控大局，但具有整合控制器 CEC 和 Festo 閥島 MPA 的模組化電氣終端 CPX，承擔了接駁和拆接程序的詳細過程。
“Bulk material handling is an art in itself that requires a lot of experience,” says Frank Pahl. “A handful of flour contains more particles than an entire truck full of gravel. The infamous angel hair can form when handling plastics, while higher degrees of grinding and finer powders with smaller particles in cosmetics and pharmaceuticals present us with new challenges every day. Bulk materials and bulk material technology are in motion. Our systems must handle these tasks without a problem – and they do. We are proud of that.” Two of the greatest challenges of the bulk materials industry are the prevention of cross-contamination and the unwanted release of dust. On the one hand, the objective is product purity and, on the other, employee protection. In the past few years, AZO has increasingly focused on the pharmaceutical and food industries in particular, but also the chemical industry. When handling bulk materials, dust from allergenic foods, for example, can lead to health problems for operating staff. In addition, explosion prevention and protection play a large role. The high number of different containers needed for transporting and handling raw materials, as well as the intermediate and finished products, don’t make things any easier for the designers of bulk material systems. This includes, amongst other things, FIBCs, drums, sacks and portable containers. As in other industry sectors, flexibility is becoming an increasingly important factor in bulk material handling.
The CleanDock system in action. Docking and undocking is controlled decentrally and autonomously by the CPX-CEC from Festo.
The modular electrical terminal CPX from Festo with integrated controller CEC and valve terminal MPA provides a uniform interface for the decentralised intelligence and enables the complete control of machines or more complex subsystems. As an automation platform for electric and pneumatic components, it connects pneumatic and electric control chains to different automation systems and company-specific standards simply, quickly and flexibly. The entire system is programmed simply using CODESYS. Interfaces are reduced, engineering and handling processes are simplified and the reliability of machines and plants is increased.
Added to this is an essential aspect that is gaining significance worldwide for the future of plants: modularity. Automation functions are increasingly distributed across individual modules. The process management level merely sets the pace. The key to greater flexibility and simplified handling lies in the integrated, decentralised intelligence. While the process control system calls up a function, it doesn’t need to have a detailed knowledge of the stored process steps. This is taken care of by intelligent modules such as the CPX-CEC with valve terminal MPA at AZO.
What AZO and Festo have already successfully implemented here corresponds with the objective currently being discussed in detail and worked out between NAMUR/ZVEI (Association of German Electrical and Electronic Manufacturers), machine builders and operators and research facilities for the automation of modular production plants. The decentralised and complete automation of the individual modules reduces complexity and shortens time-to-market for system operators.
Individual modules can also be produced for stock and adapted without a great deal of effort. Systems can be easily expanded with additional modules. In this way, system builders can react even more flexibly to the changing requirements of worldwide markets. As an automation expert, Festo is actively involved in the design of concepts and standards that drive and simplify the automation of modular plants now and in future.
AZO GmbH & Co. KG
Rosenberger Strasse 28
74706 Osterburken
Germany