Eaton supports mask production in response to crisis of COVID-19 global pandemic
The XV300 combined HMI/PLC devices and the XN300 I/O system enable the easy planning and commissioning of a system to enable production of thousands of medical masks
“This project was all about speed. With the help of the automation devices from Eaton and the direct line to the company, we were able to turn an idea into a new business within a very short time.”
Background
Sewing, cutting, handling – all textile manufacturing processes are based on these three processes.
Beckmann Automation GmbH, based in Ochtrup in the Münsterland region of Germany, has mastered these three key manufacturing processes over the course of 30 years. The company develops and builds automatic machines for the production of mattresses, belts and car seat belts. This family-run business has established itself as a leader in its field, and its customers include major mattress and belt manufacturers from around the world and is currently supported by 22 service partners globally.
Yet Beckmann Automation GmbH felt the impact of the Coronavirus crisis: “In March 2020, the first mattress manufacturer decided to close due to the pandemic,” recalls Kevin Beckmann, junior managing director at Beckmann Automation GmbH. “Manufacturing machines that we had already completed on were no longer being accepted simply because many of our customers’ plants had been forced to shut down.” Beckmann Automation GmbH was also threatened with closure and the company had to decide the future of both its business and employees. “However, that's something I wanted to avoid at all costs – our employees are truly excellent, and I didn't want to subject them to the burden of short-time work if furloughed.”
Challenge
Reconfiguring established processes in the shortest possible time
Beckmann Automation GmbH teams got together to review available alternatives. “At the time, the shortage of protective masks was already being widely reported in the media, so it made sense to take a closer look at the required production processes,” recalls Kevin Beckmann. The sewing machine experts quickly realized that the process involved in mask production is virtually the same as the manufacturing process of mattresses. Consequently, the company decided to compensate for at least some of the shortfall in the sales of its mattress production machines by producing protective face masks. Beckmann Automation GmbH was able to efficiently design and build the necessary production line required so they could produce up to 100 mask’s per minute – all in house.
Solution
XV300 and XN300 enable rapid adaptation
As Beckmann Automation GmbH already had extensive experience with modular machine designs, it meant that the individual processes did not have to be newly designed or engineered, as Kevin Beckmann explains: “Processes such as ultrasonic welding, belt dispensing, or embossing are nothing new for us – we just had to combine them in a different way.”
The Eaton XV300 HMI/PLC and the XN300 I/O system play a crucial role in this process: The combined HMI/PLC controls the entire system, collects and processes the information from the various sensors and activates the servo controllers of the stepper motors. The XV300's powerful technology also enables fast cycle times in the sub-processes of Beckmann’s systems. “Compared to the specialized stepper motor controllers that we’ve used in the past, which required taking apart the entire program when making adjustments, the combination of XV300 and the XSOFT-CODESYS programming software allows us to implement controller changes quickly and easily,” added Kevin Beckmann.
Beckmann Automation GmbH uses a CAN bus to connect the ultra-compact XN300 I/O system to the multitouch panel, whose fast backplane communication enables response times of less than 1 ms. In addition, the I/O system’s wide range of available functions and models reduces equipment costs and enables the creation of system solutions while keeping the footprint to a minimum.
Thanks to the XN300-Assist tool, the system can be quickly configured and tested in advance, while the combination of mounting system and push-in connection technology simplifies wiring and commissioning. “In total, the system controls two servos, processes signals from at least 12 inputs and issues commands to 18 outputs,” summarizes Beckmann. “And this number will rise significantly with the safety technology that we are planning to integrate in the future.”
Thanks to this control engineering solution, Beckmann Automation GmbH was able to easily reconfigure its various sub-processes for fully automated production of three-layer masks. In a first step, the system combines the upper and lower layers of a standard non-woven fabric and inserts a so-called melt-blown fabric as a filter in between. Next, the bottom material is folded so that it securely encloses the filter material, and a nose wire is inserted. The resulting flat mask is welded together by means of ultrasonic welding and then passes through a folding device that creates the three horizontal folds that are characteristic of protective face masks. In a separate ultrasonic welding process, the folds are fixed in place, which in turn determines the length of the masks. At the end of the process, a roll cutter separates the masks before a pre-cut strap is welded on and the masks are dispensed via a stacking device.
Result
Beckmann Automation GmbH is not only selling the masks, but also its new machinery
“We were able to get the machine up and running within just six weeks,” says Mr. Beckmann. “Currently, we produce 20,000 masks per shift, which will rise to 40,000 in the next expansion phase.” Each mask is certified and approved for use in hospitals by the German Institute for Drugs and Medical Devices.
Beckmann Automation GmbH has now produced a total of around 800,000 masks, at a price that is competitive on the international market, at least under the current conditions. But that's not all: “We have received numerous inquiries about our new machine, from all over the world,” reports Kevin Beckmann. Since then, Beckmann Automation GmbH has sold seven of the new machines, each of which can be adapted to individual customer requirements thanks to its modular design and flexible automation technology – for example, it is possible to integrate stations for embossing the masks with a customized logo. “Originally, we only wanted to produce the masks to compensate for our deteriorating sales prospects. The fact that the mask production machine itself is now selling so well is a welcomed bonus,” says Kevin Beckmann. As of today, Beckmann Automation GmbH has managed to keep its overall sales at about the same level as during previous years, despite the Coronavirus crisis.
