Smart retrofit increases safety, efficiency and user friendliness.

SMART RETROFIT STARTS WITH risk analysis 

“At Etex, we strive to minimize staff interaction with machines and, when interactions are necessary, we ensure they are as safe as possible.” says Francis Desmet, Etex Prevention Consultant. Many processes follow a similar structure: destacking panels, performing an action, and restacking them. Etex goal was to fully enclose the pick & place portals. It was the reason to adjust the line to meet both contemporary safety standards and Etex`s internal requirements.

This risk analysis was carried out by Avercon. Avercon has extensive expertise in machine safety, explains Dieter Foré, Avercon Automation Expert. After all, Avercon often builds customer-specific machines for the e-commerce industry, packaging industry, customized automation like handling products and fully automated production lines for various industries. We managed to deploy this broad experience well in the safety concept.

SAFETY CONCEPT

A safety concept was determined in close cooperation with Etex that classifies the line into strategic zones. The loading and unloading of the machine can, for example, now take place in a safe manner while the main production continues running. Every zone has strict access control. When someone accesses a zone, the machine places itself first in a safe position.
A robust fence was installed around the machine with access doors and light curtains equipped with Lockout/Tagout (LOTO) switches. The safety concept was aligned with the limited footprint and the many forklift truck movements. The hardware was kept, the software was upgraded.

User friendly control

The outdated distribution box was completely upgraded, with the old motor controls replaced by new SEW systems. The old PLC and safety relays were replaced by a Siemens PLC. The new control system is much more user-friendly, featuring a Siemens 19-inch touchscreen that displays machine components graphically. This setup allows operators to control the system from a single point intuitively without needing in-depth technical know-how. The learning curve is easy to navigate, enabling new operators get started right away.

Automatic product change

Previously, changing settings during a product or format changeover, had to be done manually. Now, format changeovers can be controlled from a single interface. The new touchscreen interface allows operators to select a new recipe after a few clicks. The PLC automatically updates all parameters for the motor controls. “For handling – picking up and putting down – the building panels, the thickness of the panels is also considered. The movement speed is adjusted according to the recipe’s capacity, ensuring an overall smoother operation,” says Dieter Simoens, External Technical Project Manager who works at Etex. “Improved control of handling the product contributes to a higher safety level because the risk of pallet- and board damage has been significantly reduced. Furthermore, operators now receive more detailed information on the touchscreen in case of a fault, which means the safety zone is accessed much less frequently. As a result, fewer interventions are needed, leading to an increase in Overall Equipment Effectiveness (OEE).”

Maximum safety

The new PLC program includes various functions to enhance machine safety and ensure a smooth restart after an intervention. In the previous setup, if an intervention occurred, the pick-and-place robot, for example, would remain in its current position. After the retrofit, the board – potentially weighing up to 130 kg – will first be placed down before access is allowed. This eliminates the risk of suspended loads when personnel are in the machine zone. While this may seem obvious now, it was not the case before.

Commitment of operators

Thanks to the thorough risk analysis conducted in close collaboration between the local Etex engineering team and Avercon, key preferences and requirements were identified. Tailored solutions were engineered. A special challenge was the limited footprint. Together, customized alternatives were developed to ensure the objectives of the safety standards could be achieved.

The operators and maintenance engineers at Etex were deeply involved in the project. “I spend a lot of time at the machine to ensure I listen carefully to the operators,” says Dieter Simoens. “By aligning the safety functions and the operator interface with their workflow, a more efficient system can be built.

One feature we suggested after consulting with the operators was to enable the pick-and-place portal – responsible for stacking pallets – to also remove a board from the depositing position and return it to the stacking position. This was a function that could be implemented relatively easily, but it greatly simplified the operators’ work during interventions.”