I/O hubs save machine builder 60%: Balluff IO-Link

Ingersoll CM Systems Inc., in building its next generation deep fillet rolling machine, saved 60% in cost compared to previous I/O modules. Savings came from reducing the number of machine components by using economical Balluff IO-Link hubs.

01/26/2010


When Ingersoll CM Systems Inc. of Midland, MI, decided to build its next generation deep fillet rolling machine, engineers sought to create a more modular and expandable machine that would allow customers to easily keep pace with evolving crankshaft sizes. A I/O-based network connection technology helped save 60% in cost.

New IO-Link system allows for more decentralization of I/O and reduced cabinet area, Balluff says.

New IO-Link system allows for more decentralization of I/O and reduced cabinet area, Balluff says.

Used in rough machining production as a process to strengthen and straighten journals, a deep fillet rolling machine increases the fatigue strength of a crankshaft by up to three times. After evaluating and testing several I/O networking options in the market, those at Ingersoll determined that Balluff's IO-Link solution would be the best option to decrease cost and the number of components per machine. Gary Munger, controls engineering manager for Ingersoll, said, "The IO-Link solution resulted in a 60% cost savings over our previous I/O modules. The savings came from reducing the number of components used in the machine and using the more economical IO-Link hubs. Reducing the number and complexity of the components also reduces the possibility of failures for our customers."

Old traditional I/O system consumes more cabinet space and requires longer I/O cable runs, Balluff says.

Old traditional I/O system consumes more cabinet space and requires longer I/O cable runs, Balluff says.

Balluff IO-Link is an open, economical technology that allows for the expansion of networked I/O devices. By using low cost, standard M12 cables, the point-to-point wiring is the most cost-effective available. Balluff's IO-Link hubs contain only the I/O circuits without the cost of the full network protocol.

Switching a machine's networking architecture can sometimes be a difficult and daunting task. Using IO-Link as an expansion, Ingersoll maintained its Profibus architecture. Munger added, "Balluff supplied evaluation units for benchmark testing and the entire transition process was a relatively smooth and easy one."

By building this new generation of deep fillet machines integrated with Balluff IO-Link technology, Ingersoll can pass on significant time and cost savings to customers.

Ingersoll CM System's next generation deep fillet rolling machine uses Balluff's IO-Link technology: a Profibus I/O module with three IO-Link expansion modules.

 

More about the companies

Balluff Inc. is the U.S. subsidiary of Balluff GmbH, Neuhausen, Germany. The company manufacturers inductive, photoelectric, capacitive and magnetic sensors as well as linear position transducers, RFID systems, and networking solutions. Balluff products for OEM and factory floor solutions are used to control, regulate, automate, assemble, position, and monitor manufacturing, assembly, and packaging sequences for industries including metalworking, automotive, plastics, material handling, wood processing, aerospace, electrical, and electronics. www.balluff.com

Ingersoll CM Systems designs and manufactures machinery and systems for crankshaft and camshaft processing for the automotive, truck, off-road, locomotive, and stationary engine/generator industries. www.teamicms.com

Also read from Control Engineering :

- Balluff IO-Link Profibus/Profinet modular expansion ; and

- RFID, machine vision sensors, I/ O network components help error proofing .

- Richard Bertolone is Balluff powertrain business development manager. Edited by Mark T. Hoske, editor in chief, Control Engineeering , www.controleng.com. See the industrial network channel .





No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Your leaks start here: Take a disciplined approach with your hydraulic system; U.S. presence at Hannover Messe a rousing success
Hannover Messe 2016: Taking hold of the future - Partner Country status spotlights U.S. manufacturing; Honoring manufacturing excellence: The 2015 Product of the Year Winners
Inside IIoT: How technology, strategy can improve your operation; Dry media or web scrubber?; Six steps to design a PM program
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming
Managing automation upgrades, retrofits; Making technical, business sense; Ensuring network cyber security
Designing generator systems; Using online commissioning tools; Selective coordination best practices

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me