Off-the-chart speed with an off-the-shelf solution

Bottling processes are notoriously time critical. To maximize quality and throughput, valves and sensors must be tightly synchronized in real time. Similar requirements are encountered when applying adhesive dots to packaging, sorting items in a recycling plant or laser-cutting sheet metal. "Historically, the short response times needed in such applications have required the use of special hardware," reports Andreas Hager, B&R's product manager for control systems.

With reACTION Technology, B&R proves there is another way. Programs developed using the Function Block Diagram editor in the Automation Studio engineering environment are executed directly on I/O modules from B&R's X20 and X67 series. This transforms the I/O modules into "mini controllers" able to handle certain processes independently and distribute the computational load across multiple systems.

Like any other control program, a reACTION program can be created in Automation Studio using function blocks according to IEC 61131-3. It is saved centrally on the PLC, transferred to one or more I/O modules as required and then stored there. Of course, different products require different recipes, so it is also possible to load new programs onto the modules during operation, and saved programs can be copied to other modules at any time. The selection of reACTION function blocks is growing all the time, and new blocks can be added in the field simply by upgrading the firmware. Users can also create their own function blocks based on the ones provided, and use them to bring clarity to complex programs. Developers who already work with Automation Studio do not need any additional training.

B&R's intelligent I/O modules pay dividends in many applications. A particularly good example is offered by one B&R customer's printing machine for packaging materials. Andreas Hager explains: "It currently runs at a web speed of 600 m/min, but there are already plans for a faster new version. So they needed enough reserves in the automation solution to handle those higher speeds down the road."

Printing the packaging material is the first step in the process. Then, a serial number is laser marked onto a specific location on each package. A sensor detects the position where the serial number should be placed and generates a digital signal. An X20 reACTION module evaluates that signal and generates a digital output signal for the laser marker. To minimize errors when the machine is accelerating, the sensor and laser marker need to be positioned as closely together as possible. Due to the construction of the machine, the minimum distance between them is 55 mm. The sensor for detecting registration marks is connected to Channel 1 of the I/O module, the starting signal for the laser marker to Channel 3.