FLEXIBLE EXHAUST SYSTEM PRODUCTION
The automation of a production line for exhaust systems enables Turck to demonstrate the flexibility of its BL20 multiprotocol gateway in conjunction with the IO-Link-capable TBIL hubs
Flexible Muffler Production
One of the leading manufacturers of exhaust systems chose Turck's BL20 modular I/O system in order to provide a highly flexible I/O solution. A special feature of the new production line is that fieldbus systems have to communicate with different controllers – an ideal application field for Turck's BL20 modular IP20 I/O system. The multiprotocol gateways, which feature the necessary I/O slices, speak PROFINET, EtherNet/IP, and Modbus TCP. This enables the BL20 system to bring different types of signal to the controller and also link different valve blocks on the production line. The system integrator, Teknodrom Robotik ve Otomasyon, was responsible for the installation and integration of the entire automation solution. Teknodrom spoke to Turck about the sensor and I/O requirements for the new production line already in the design phase.
IO-Link ensures efficient production
The user benefits enormously from the flexibility that IO-Link provides for the requirements of this system. Turck's BL20-4IOL gateways with IO-Link master modules and the IO-Link capable IP67-TBIL I/O hubs bring up to 16 switching signals from the field to the control cabinet via a single four-wire cable. The TBIL functions as an IO-Link slave, bringing 16 binary signals to the IO-Link master on the BL20 gateway. This considerably reduces wiring effort and wiring errors. The alternative passive junctions with large multipole cables are more expensive and time consuming.
Flexibility with IO-Link
Another benefit of IO-Link in the production line becomes apparent when different tools are changed. “The clamping devices for the products have to be changed frequently in the plant. The IO-Link modules for BL20 offer a high level of flexibility. "During the installation, we can easily adapt the BL20 system by adding or reducing the number of signals," says Selim Çağatay, the control technician responsible at the system integrator. "With every additional expansion or upgrade of the plant we benefit from this flexibility.”
Efficiency through decentralized IP67 I/Os
Even at the production lines for MIG (metal inert gas), the smart IO-Link solution is significantly simpler, faster, and more economical to implement than multipole cable systems. It also makes a major contribution to quality assurance. All signals are collected via Turck's TBIL IP67 I/O hubs and then forwarded to the BL20 system via a single four-wire line. The IO-Link master and multiprotocol gateway handle the additional communication with the controllers via Ethernet. Thanks to the digital IO-Link transmission, the user can save on the expense of shielded cables and other EMC measures.
- Automotive
- Body Detection in Automobile Production
- Reliable Skid Detection in Automotive Production
- RFID Bus Mode Ensures Quality of Lithium-Ion Batteries
- Level Measurement in Dip Coating Line
- Level Control in Central Lubrication System
- Quality Assurance on the Gluing Robot
- Tilt angle sensor accelerates platform alignment
- IP67 Hybrid Module Processes Safety Signals
- Decentralized monitoring of cooling stations
- Robot welding cells networked with Ethernet
- Monitoring the cooling circuit on welding clamps
- Flow monitoring in drum washers
- Press Shop
- Body Shop
- Paint Shop
- Final Assembly
- Powertrain
- Item-level Detection with UHF RFID
- Supply of cooling lubricant in machine tools
- Controlling hydraulic pressure in pressing plants
- Measuring process pressure on scissor lifts
- Success Stories - Automotive
- Laser Sensor Detects Black Bumpers in Assembly Cell
- Decentralized Safety Technology for Modular Production
- Modular Conveyor System
- RFID and I/O modules for Safe Tool Changes
- RFID in an Automated Guided Vehicle
- Silencer Production Wired with IO-Link Junction Boxes
- Workpiece Carrier Identification in Rear Vent Production
- Weld Nut Sensing
- RFID Traceability
- RFID in Engine Production
- Bumper Production with Identification
- Solutions for Paint Shops
- Welding and Assembly Sensors
- Angle Sensors for Assembly Systems
- Tool Identification
- Unique Products on the Conveyor Belt
- RFID in the Body Shop
- IO-Link Eases Differential Gear Production
- Chemical
- Decentralized Automation in Ex Areas
- RFID Control of Tube Connections in the Ex Area
- Ethernet Signal Connection in the I&C Room
- Ethernet-based Automation of Modular Skids
- Detection of Pigs
- Remote Signal I/O
- Easy Connection of Field Devices
- Signal Processing with System I/O in the Control Cabinet
- Signal Separation with Interface Technology in the Control Cabinet
- Identification of Hose Connections
- Efficient Monitoring of Cabinets in the Field
- Monitoring of Quarter Turn Actuators
- Planning and Assembly of System Solutions
- Success Stories
- I/O System Excom Creates Space in the I&C Rooms
- Zone 2 and 22 RFID
- Efficient Testing Control
- Intrinsically Safe Field Communication
- Process Control System Partnership
- Hazardous Area Remote I/O
- Dual Valve Position Feedback
- Flexibility with Fieldbus
- Asset Management with Remote I/O
- Correct Positioning with RFID in Carbid Production
- Fast conversion in restricted space
- Energy
- Food and Beverage
- Dough Thickness Control in Rolling Machines
- Identification of Food Containers
- Detection of Valve Position
- Detection of Pipe Elbows
- Identification of Chocolate Molds
- Success Stories
- Grist for the Mill
- Decentralized Control Modules in Coldstore
- Track and Trace in Meat Production with RFID
- Contact-free Encoder in Potato Production
- UHF RFID in Food Distribution Center
- RFID for Chocolate Production
- Distributed I/O for Food Equipment
- Remote I/O for Distilleries
- RFID and Autoclaves
- Transparency in Chocolate Manufacturing
- IP67 Power Supplies for Conveyors
- Identification in Food Product Storage
- Logistics
- Tracking Big Bags with RFID
- Access Control for Protected Areas
- Decentralized Muting of Electro-sensitive Protectice Equipment
- Preventive Maintenance on Conveyor Belts
- Detection of Transport Containers
- Level Detection in Vessels
- Identification of Cryovessels
- Identification of Mobile Containers with Handheld Devices
- Identification of Food Containers
- Tier 1 – Bumper Identification
- Collision Protection on Reach Stackers
- Success Stories
- RFID Enables Unmanned Store at Major Building Site
- I/O and Safety Modules Increase Throughput in Intralogistics
- Shipment Tracking for Raw Materials
- RFID-based Shipment Control Minimizes Errors
- RFID-based Tracking of Inbound and Outbound Materials
- Decentralized UHF RFID Solution
- Contact-free Encoder in Potato Production
- Decentralized Control Modules in Coldstore
- IP67 Power Supplies for Conveyors
- Modular Conveyor System
- RFID Solution for Warehouse
- RFID Guides AGV in Suspension Production
- RFID Identifies Pharmaceuticals
- UHF RFID in Food Distribution Center
- Mobile Equipment
- Condition Monitoring Sensor Automates Climate Control
- Automatic Slope Compensation
- Distribution Lines for Field Sprayers
- Angle Measurement on a Field Sprayer
- Determining the Boom Angle Position
- Two-Axis Tilt Measurement on a Combine Harvester
- Collision Protection on Reach Stackers
- Success Stories
- RFID Solution with Smart Forklifts in Automobile Production
- Safe Remote Maintenance of Irrigation and Drainage Pumps
- Access Control with RFID System
- Selective Asparagus Harvester
- Position Measurement with RFID and Encoder
- RFID in an Automated Guided Vehicle
- Block I/O Modules on Super Yacht
- Wear-free encoder on hopper dredger
- I/O for Dust Suppression
- Cabinet Cooling
- Quick Disconnect Connectivity
- Automation Solutions for Extreme Cold
- Remote I/O for Cranes
- Rugged Heavy Metal Lifting
- Rollercoaster Positioning
- Mobile Machinery Solutions
- Exact Height Positioning
- Critical Angle Sensing
- Angle Indicator
- Oil and Gas
- Packaging
- Decentralized RFID Package Verification
- Identification of Printing Color Cartridges
- Reliable Operation of Machines
- Monitoring of Caps in Filling Lines
- Monitoring Changeover Processes
- Identification of Test Bottles
- Level Monitoring of Ground Coffee
- Level Detection in Vessels
- Detection of Transport Containers
- Success Stories
- Pharmaceutical
- End-to-End Sample Tracking with RFID
- Automate Modular Skids
- Pharmaceutical Skids with Decentralized I/O Technology
- Ex Isolation in Modular Process Plants
- Control of Valve Interfaces
- Monitoring of Quarter Turn Actuators
- Detection of Pipe Elbows
- Remote Signal I/O
- Planning and Construction of Super Skids
- Easy Connection of Field Devices
- Identification of Cryovessels
- Identification of Mobile Containers
- Identification of Mobile Containers with Handheld Devices
- Identification of Hose Connections for Precursors
- Identification of Hose Connections in Sterile Areas
- Identification of Hose Connections in Ex Zone 1
- Identification of Big Bags and Bioreactors
- Identification of Single-Use Applications
- Success Stories
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