Efficient communication and automation of deep-hole drilling machines
Eaton’s XV300 multi-touch panel and SmartWire-DT communication system delivers a modern, efficient communication system
The mrm² solution not only enables us to offer our customers shorter lead times, but also faster commissioning and easier maintenance.
Faster machine design processes thanks to modular software and hardware.
By combining intelligent I/O mapping with a modern communication system, it becomes possible to implement flexible machine designs, quickly and in line with specific application requirements. A modular system enables Tibo to tailor its deep-hole drilling machines to the precise needs of its customers. Meanwhile, mrm² has developed the perfect control concept for this purpose, based on Eaton’s powerful XV300 multi-touch panel and SmartWire-DT communication system. The solution also includes standard software that integrates all possible machine types. By simply selecting or de-selecting the required components, the application software can be adapted to the respective machine type.
Background
Customized machinery thanks to a modular system
mrm² automatisierungstechnik gmbh is a certified expert in the automation of ideas and products. It equips machines with intelligent automation technology and offers consulting, software development, electrical design, electrical assembly, mechanical design as well as special machine construction - all individual solutions for highly complex projects.
Camshafts, injectors, drill pipes, hydraulic cylinders – producing any of components requires deep-hole drilling. Deep-holedrilling involves drilling holes with a depth that is many times greater than their diameter, namely by a factor of 10 or more. This process is used in almost all sectors of manufacturing – on a small scale, for example in medical or space technology, but also in the oil and gas industry or in shipbuilding, where huge drill diameters and drilling depths of up to 12,000 millimetres and more widely are required.
What all these applications have in common is that they are highly specialized and rely on deep-hole drilling machines that have been custom-designed for the specific purpose and TIBO Tiefbohrtechnik GmbH specializes in exactly this kind of machinery. The company has developed a modular system that allows the machines to be specifically adapted to the needs of professional users based on tried and tested system components. This way, the need for an individual machine can be realized quickly – usually resulting in delivery within four to six months from placing the order, depending on the machine type.
Challenge
Reducing engineering costs while enabling updates
“The modularity of the system should not only be reflected in the hardware, i.e. the machine components, but also in the control concept,” explains Jost Eppinger, Managing Director at Tibo. Until now, the control software had to be redesigned for each machine type, whether it’s gun drills, BTA drills, milling tables or special deep-hole drilling machines. Depending on the configuration, this meant either creating new program lines or deleting unnecessary ones each time.Basic modifications in the software had to be implemented separately for each control program, i.e. for each machine. A new, modern control concept was needed that would not only reduce the engineering costs, but also accelerate the installation and commissioning of the machines and simplify operation.Tibo placed the order with mrm² automatisierungstechnik gmbh from Bad Ditzenbach, Germany. The company specializes in equipping machines with intelligent automation systems – from the consultation phase through software development to the design and construction of the control panels.
Solution
Modular application software in combination with SmartWire-DT
mrm² developed a control concept in which the application software and the hardware are designed in such a way that all machine types and options are based on the same program and a single circuit diagram.
mrm² implemented the concept using automation components from Eaton: not only because mrm² is an Eaton Solution Partner, but above all because the various Eaton systems are the perfect match for a modular, flexible design concept. The solution is built around the 15” XV touch panel: “Tibo wanted its deep-hole drilling machines to be as intuitive and simple to operate as possible” says Martin Rieg, Managing Director of mrm². This is made possible by Eaton’s XV300 panel with multi-touch technology.
Important features for using the XV300 HMI/PLC:
- The powerful graphics processor support the design of user interfaces with high-resolution graphics and fast image changes.
- numerous interfaces, such as Modbus TCP for communication with the safety controller.
- It can also be used as a Profibus master.
- The programming of the integrated PLC function is based on a recent version of CODESYS (IEC 61131 standard.)
SmartWire-DT replaces the conventional control wiring of all components inside and ooutside the control cabinet (IP67). The communication system connects all the Eaton automation components inside the deep-hole drilling machine, such as the pilot devices of the RMQ family and the PKE motor-protective circuit breakers and motor-protection/contactor combinations with XV300 HMI/PLC and communicates their data – depending on the type, the machines each contain between seven and more than 30 of these devices. The positioning of the control terminal is flexible.
Results
Lower engineering costs, faster commissioning
“With SmartWire-DT, we can easily visualize the modularity of the system at the input and output level,” notes Marius Hetmank, Application Project Manager at mrm².
“The system automatically searches for the connected components, and during installation, all that needs to be done is to assign a corresponding input or output to each component, simply by selecting it in the software. This I/O mapping method, which was specially developed by mrm², is much more elegant than using placeholders inside the control panel that are not actually needed.
“This modular concept is not only evident in the application software, but extends right through to the control panel design,” says Marius Hetmank. “The components required for tailor-made machines can be easily selected and automatically integrated in the circuit diagram. This way, each control panel is made to measure.”
This modular standard application software now forms the basis for all possible machine types, each with over 20 different options. “Updates or new options automatically become available for all different machine types,” explains Marius Hetmank.
By using the XV300 in combination with the modular software and SmartWire-DT, it was possible to considerably reduce the engineering and maintenance costs, the latter by around two thirds. And the combination of PKE motor-protective circuit breakers with SmartWire-DT also supports energy measurement.
“This was another request from Tibo, because it allows customers to see how much energy they can save with the EcoDrill setting on its machines,” says Martin Rieg.
For the time being, these data are displayed via the control terminal and are only being used for reporting purposes. However, plans are underway to use the data for predictive maintenance as well – the XV300 is equipped with the necessary Ethernet interface to transfer the data from the machine to a cloud or edge computing system for evaluation.
Given its high degree of flexibility, the multi-touch panel can also be used as a Profibus master, thereby facilitating the seamless integration of devices from other manufacturers via a peripheral module. For both Tibo and mrm², the technology also offers another important advantage: SmartWire-DT significantly speeds up the wiring of the system.
“Compared to standard wiring, SmartWire-DT offers time savings of around 35 percent.” This pays off in more ways than one: during the initial wiring carried out by mrm² in the control panel itself; then again when Tibo assembles the system for customer acceptance at its facility; and finally, when the new deep-hole drilling machine is dismantled and then installed and commissioned on the customer’s premises.
