Automate modularly, reduce plastics

In addition to flexibility, a key customer requirement was the future-proofing of the series. "Packaging machines are long-term investments that have to function for twenty years and more," explains Markus Peter, Head of Electrical Development at ILLIG Maschinenbau. To ensure that the new machine concepts can follow the advancing digitalisation as required, ILLIG opted for the open automation solution ctrlX AUTOMATION from its long-standing technology partner Bosch Rexroth. "Our machines must be open on the software and hardware side for future applications and modifications," emphasises Markus Peter. "Bosch Rexroth offered us optimal conditions for this."

With ctrlX AUTOMATION, ILLIG has opted for a new generation of control and drive technology that is characterised by the greatest possible flexibility and openness to match the machine concept. "The modular solution approach forms a good platform for the development of future-proof machines," explains Markus Peter. "The open hardware and software modules ensure high process quality and enable data to be obtained for continuous improvement and increased efficiency in terms of productivity and energy efficiency."

For the automation of the modular machine series, ILLIG uses, in addition to the ctrlX CORE control platform, I/O modules, ctrlX I/O and the compact ctrlX DRIVE servo drives with precise MS2N servo motors for all process-relevant axes such as handling, film unwinding or product feeding via a turntable. Thanks to the combination of scalable drive technology and highly integrated dual-axis devices, inverters, inverters and I/Os, the control cabinet is significantly smaller. In the case of the XLU series, the space saving amounts to about 40 percent compared to the conventional design.

ctrlX AUTOMATION also offers machine builders a great deal of design freedom when it comes to internal and external networking. ILLIG chose the industry standard EtherCAT for bus communication at machine level, which allows customer-specific components from different manufacturers to be seamlessly integrated. "Bosch Rexroth had been set as an automation partner for a long time," reports Markus Peter. In addition to the technological openness, the industry expertise and excellent application support also spoke in favour of expanding the cooperation. "Bosch Rexroth supported us intensively and at eye level during the basic engineering of the new machine series," says the Head of Electrical Development. "The support in project planning and design of drives, I/Os and other modules, helped us a lot to keep to the tight schedule."

Bosch Rexroth's decades of experience in motion applications, among other things, flowed into the development of ctrlX AUTOMATION. This is also reflected in web-based development environments that meet the low-code requirement. The ctrlX CORE control can also be simulated virtually on a PC, which speeds up the programming of the system. "The code created with virtual axes was quickly ready and could be put into operation in advance," says Markus Peter. "We only had to convert the built machine to the real axes, which saved further time."