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 .
Annual Salary Survey
After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.
The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.