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.
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.
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."
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 :
- 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 .
- Events & Awards
- Magazine Archives
- Oil & Gas Engineering
- Salary Survey
- Digital Reports
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