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Siemens Offers The North American Markets Conveyor Technology For Material Handling

Siemens brings a full complement of solutions and services with its value proposition to the North American conveyor sector of the material handling industry

Siemens brings a full complement of solutions and services with its value proposition to the North American conveyor sector of the material handling industry

Siemens is offering conveyor technology for material handling, to all builder, system integrator and end-users of both discrete and process manufacturing markets.  An integrated drive system with Siemens motion control and drives products, along with communication protocols, is available.  It spans the range of drives, motors, gear motors and automation technology, plus machine safety, power supply and circuit protection.

As a longtime supplier to the global conveyor and material handling industry, Siemens brings this offering to the North American market with the full support of its global network of engineering, sales, service and technical support.

Advantages for machine builders

Siemens brings a flexible and field-tested portfolio of products and software services to the builders of material handling equipment in all industries.  Free design tools allow a more efficient process in customer design, configuration and product selection, plus communication and energy calculation.

When a large or multi-unit system is needed, the advantages of Siemens distributed control and common DC bus afford many with an economical solution to material handling.  This translates to a lower installation and commissioning cost.

Through the OEM Partner Program, machine and equipment builders benefit from the global experience of Siemens.  Machine conversion services, design tool-kits, global coordination for companies seeking more international business including full standards compliance, co-marketing opportunities and assistance in emerging markets are among the many services provided by the global team of Siemens.

Advantages for system integrators and end-users

Whether a greenfield project or brownfield expansion of an existing material handling machine or full production line, Siemens integrated drive systems bring a full portfolio of products and automation solutions to the task.  In the field, fast commissioning is provided by a team of qualified personnel, resulting in quicker start-up and less downtime.

The preventive maintenance and remote diagnostics software combine to keep equipment running more productively.   The recent expansion of our popular drives platform to include PROFINET, PROFIBUS, EtherNet / IP and AS-interface allow Siemens drives to communicate with other brands of existing products or new components on the customer’s line, resulting in cost savings and greater efficiencies.

Siemens can satisfy an array of typical material handling scenarios, as it supplies a full range of products and services to create the ideal solution for the customer.

Siemens products for material handling applications include:

Gear motors

Recently established in Greenville, S.C. to better serve the North American market, the Simogear gear motor facility assembles energy-efficient gear motor units commonly found in material handling.  Simogear can be combined with Sinamics drives to suit a broad range of applications — from the low-speed uses (0.1–1000 rpm) to the most challenging, high-torque demands.

Siemens is in the forefront of the evolution from worm to helical bevel gear motor utilization in the material handling world, as this technology means less motor power is needed to produce the same output torque and speed. This translates to smaller units with higher efficiency and overall lower cost.

Drives

The complete family of Siemens Sinamics drives means a single source for a broad assortment of product solutions, globally recognized and capable of controlling virtually every application in material handling, from basic roller tracks to multi-axis, high-bay racking units, all with high-dynamic performance.

Central and decentralized drives are highlighted by the Sinamics V20, G120C and G120D.  All are space-saving and offer a variety of communication, programming and control capabilities.  In addition, the decentralized Sinamics G120D can be machine-mounted and is suitable for tough environments.

Controllers, I/O and Software

Simatic S7 PLCs offer both PAC and PLC reliability in their performance with modular and PC-based options.

Distributed I/O from Siemens is useful in all conveyor, sorting and assembly operations, plus is offered in space-saving compact or modular form factors.

Simatic software includes operator control and monitoring systems with a single software environment for every automation task.  Totally Integrated Automation (TIA) means over 100,000 Siemens products share a core intelligence.

 

Additional products available in the Siemens suite include RFID code systems, industrial PC’s, various HMI options for panel mount and portable use, full wireless automation and motion control communications hardware, safety devices and power management switchgear, measuring and monitoring.

For more information, videos and to download the relevant brochure, please visit:  www.usa.siemens.com/conveyor-pr

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

 

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Rattunde Utilizes Precision Motion Control For Tube and Bar Production System; Up To 11,000 Parts Per Hour Reported with Zero Rejects

Through the use of Siemens SINUMERIK CNC technology, plus PLC and HMI, on a combination servo-controlled cold saw cut-to-length and brush deburring system, Rattunde customer achieves triple the output on small engine exhaust components

Rattunde ACS + BDM tube and bar production system at Cosmos.

Rattunde Corporation of Grand Rapids, Michigan is the five-year-old subsidiary of Germany’s Rattunde & Co. GmbH, a machine tool builder of tube, pipe and bar processing equipment.  The company is already making its mark in the American manufacturing industry, as demonstrated by a recent success it had at Cosmos Manufacturing of South Chicago Heights, Illinois, a major supplier of small engine exhaust tubes to the leading outdoor power equipment manufacturers in the country.

The Rattunde system, incorporating a servo-controlled cutoff saw and brush deburring mechanism, is consistently producing up to 11,000 parts per hour at Cosmos, according to Mike Jemilo, the end user’s general manager.  “This number represents triple the output production for Cosmos.” He continues, “Better still, it’s been in operation more than a year and we have not reported a single reject, with only routine maintenance and zero downtime due to machine problems.  This is truly a win-win scenario for the machine tool builder and us alike.”

At the heart of the Rattunde system, according to Richard Stadler, company president, is the computer numerical control (CNC) system used by this builder.  It consists of a Sinumerik 840D CNC, Simatic S7 PLC with various analog and Profibus modules, plus numerous Simotics servomotors, motor protection devices, circuit breakers and other components supplied by Siemens.

Machine performs all servo-controlled saw cut-to-length, washdown, brush deburring and packing operations on a single line, controlled by Siemens CNC and HMI.

At Cosmos, this Rattunde system is used to process mill-length tubes to customer-specified dimensions, using a fully NC-controlled cold saw.  Cut-to-length parts are then automatically measured for dimensional accuracy and brush deburred.  Production of these parts runs up to 11,000 units per hour, according to Cosmos’ Mike Jemilo.  Because of the overall improvements in automation, speed and parts handling, plus the precision of the Sinumerik CNC system, Cosmos is further experiencing significant reductions in parts handling, secondary operations and final assembly.

The primary products being produced on this equipment at Cosmos include mountings, connectors and sections for muffler tubes in dozens of lengths, typically in 3/8-inch, 7/16-inch, 12 millimeter and 1/2-inch sizes.  Products are routinely run in mild steel, aluminized steel and stainless steel on the same Rattunde system, with offline pre-programming done by the Cosmos engineering team.  The final products are sold by Cosmos to leading manufacturers of chain saws, leaf blowers, lawn mowers and other small engine-powered equipment.

All machine functions and 13 axes of movement are affected by the Siemens CNC, which also provides remote monitoring capability for the builder Rattunde.

Jemilo concluded by citing the Rattunde service advantages. “From the initial contacts with their application engineering, through the build process, commissioning and on-site training, we’ve been extremely impressed with their work — very professional and responsive.  Our previous system had nowhere near the production of the Rattunde solution and we are already working with this supplier on our next system.”

From the machine tool builder’s perspective, the same relationship is echoed about Siemens.  Alec Banish, vice-president at Rattunde, commented, “We were asking Siemens to do some fairly complex operations in motion control, including 13 total axes with an articulating gearbox, plus the conveyor and part articulations, spindles and servomotors.”  He further noted the scalloped motion of the ID/OD brushing with disc transfers all presented unique motion challenges for the control hardware and software alike.  “The Siemens servo technology automated our entire process in a totally controlled, high-precision manner, allowing customers such as Cosmos to process a wide variety of materials, dimensions, shapes and lengths with easy-to-manage presets.”  Banish concluded by saying, “The Siemens support is greatly enhanced by the remote monitoring capability of the Sinumerik CNC.  About 70 percent of our issues are resolved remotely, working between us and Siemens or directly with the customer’s plant personnel.”

Prior to the implementation of the Rattunde system, all the piece part work done at Cosmos required two or three saws, with the attendant fixturing, parts handling, logistics and labor costs.  These bottlenecks in production were eliminated by the fully automated and single operation processing of the tubes provided by the Rattunde system.  Four tubes are processed per cycle, with servo control of the entire bundle, as it moves through the saw, brush and loading zones on this fully integrated machine line.

Rattunde builds various production systems for tube and bar product manufacturers.

From a factory utilization perspective, the prior system at Cosmos ran in three shifts for six days, each week.  Today, with the Rattunde system on the floor, occupying a far smaller footprint, one shift per day working just five days produces the same output with far superior quality and virtually no rework, according to company sources.

Rattunde President Richard Stadler further comments on the power of the Siemens CNC and related motion control products.  “We’re using all ten channels and pushing the axis capability to some extreme limits, but have seen absolutely no problems in signal degradation or processing speeds.”  Stadler also observed the Sinumerik CNC program storage capabilities were quite impressive.  “All the operator needs to do is provide a size range indication onscreen and all the relevant programs appear for easy selection.  Repeatability is obviously critical for our customer, who often process dozens of shapes and sizes per shift.”

He recalled meeting the Cosmos team at FABTECH in 2009.  “They approached us with their scenario and it was right in our wheelhouse.  We did some test cuts and time/motion studies for them and the results were quite impressive, both to them and to us,” Stadler muses.

Rattunde operates facilities in Grand Rapids, Michigan as well as a service center in Burlington, Ontario to better serve their North American customer base.

Rattunde markets its tube and bar production systems to makers of precision parts.  Currently selling 60 percent automotive, the company’s systems produce airbag canisters, cam shaft cylinders, steering components, rack mounts, driveshafts, frame components, seating parts, headrests, shock absorber parts, door impact devices, luggage racks and a variety of axles.  In addition to the cut-off and brush deburring system detailed here, the company also supplies production systems to perform various types of secondary machining operations, including threading, facing, chamfering and ID turning.

For further information on this story, please contact:

RATTUNDE CORPORATION
4980 Kendrick St. SE
Grand Rapids, MI 49512
Phone:  616-940-3340
Web:  www.rattunde-corp.com
Email:  r.stadler@rattunde-corp.com
Attention:  Richard Stadler, president or Alec Banish, vice-president

OR

SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web:  www.usa.siemens.com/cnc
Email:  SiemensMTBUMarCom.sea@siemens.com
Attention:  John Meyer, Manager, Marketing Communication

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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.

The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.

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