A Lenze IPC and automation software has achieved a more effective operator interface on the Bosch GKF701 capsule filling machine. After research to define the optimum operator processes, Bosch chose the Lenze PCMatic automation solution as it provided the functionality required at a good price to performance ratio.
The GKF 701 is the smallest of a range of capsule fillers. Up to 700 hard gelatine or gelatine free capsules per minute can be produced, each filled with powders, pellets or tablets. The hardware supply by Lenze is based around an embedded IPC with a 6.4” resistive touch screen. The IPC runs Lenze’s PCMatic Automation suite which is real-time capable, robust because it avoids hard disk drives or cooling fans and uses powerful Intel Celeron processors.
The PCMatic Automation Solution is an open automation system based on a panel PC including visualisation, Soft PLC and motion controlled components. It operates on Windows–CE 4.2 software, whose hard real-time ability ensures an even, deterministic computational time distribution between visualisation and control. The pulse width between the two can be finely regulated in 1ms steps. The Soft PLC component of PCMatic is supplied in IEC-61131-3 and Bosch Packaging Technology use it with the CoDeSys runtime and development environment.
Using integrated drivers, Lenze VisiWinNET visualisation software, which is part of the PCMatic system, supports connections to every level of corporate IT using standardized network technology. Local or decentralised OPC servers provide the process link-up. The fact that the functions can be grouped in reusable components makes it easier and quicker to configure consistent user interfaces. Available graphic elements include numeric and graphic control and display elements like list and selection boxes, push buttons, switches, trend diagrams, fill indicators and colour changes. Just a single development environment (VisualStudio.NET) is required for all target platforms for configuring the visualisation interfaces using drag and drop, and establishing links to the process variables. In addition all applications can be simulated and tested in advance, cutting commissioning times.
The Lenze EL600 Automation panel is an IPC that is suitable for difficult environments. With an IP65 protected panel at the front and no need for cooling fans or hard disk drives which are prone to wear and failure. Lenze supply the panels branded for Bosch. Since the operating system is conceived in such a way all the drivers are incorporated in the ROM or Flash memory, the IPCs can be built into the machine without need for further installation work and are ready to use as soon as they are switched on.
“The automation system has enabled us to realise the user interfaces in the most optimum manner according to our style guide”, explains Wolfgang Martin of the Control Technology Centre at Bosch Packaging Technology. The openness of the system is an advantage when configuring the operating elements and coupling them with various Field Bus’ drives and I/O modules. Its compact, robust construction and the fact the entire automation system can run on a single panel, make the PCMatic an economical solution which can be employed in difficult environments.