容器几乎无声地滑入到位，平稳地接近目的地：CleanDock。精致的不锈钢材质。整洁、从容且可靠。然后到站了。主动部分的气动抓取系统从上方推进，抓住被动部分的容器盖子并提起盖子。两到三次的泄气声表明计量元件和目标容器已无缝连接。主动部分的柔性补偿器能够精确为容器下方的称重计去皮，与容器已容纳的产品数量无关。然后开始灌装散装物料。该过程结束后，主动和被动部分会优雅而彻底地相互分离，然后容器将移至下一个灌装站。从外面无法看到的情况是，几乎整个灌装过程都是由 CleanDock 本身分散控制的。
开拓性的一步
“我们的系统可以运输和分配您能想象到的所有散装物料类型”，奥斯特尔布尔肯的 AZO GmbH + Co. KG 的开发主管 Frank Pahl 说。“物料的范围从婴儿食品的奶粉和配料到药品和清洁剂以及各种塑料和颜料，例如湿涂料生产。谈到我们在食品、生命、化学和聚乙烯四个业务领域中已实现的各种应用，几天也说不完”。AZO 在散装物料搬运领域拥有 70 多年的历史，在全球拥有 1,000 多名员工。目前最具开拓性的创新是最新一代 CleanDock。借助这一系统，AZO 及其长期合作伙伴和自动化专家 Festo 朝着快速调试、减少错误和提高散装物料灌装的安全性方面迈出了重要的一步。为此，CleanDock 采用了分散控制器形式的智能，因此在过程中具有自主性。虽然过程控制系统在控制技术角度来看是掌控大局，但带有集成控制器 CEC 和 Festo 阀岛 MPA 的模块化电气终端 CPX 承担了驳接和拆接程序的详细过程。
安全是重中之重
“散装物料搬运本身就是一门艺术，需要很多经验”，Frank Pahl 说。“一把面粉比一辆装满碎石的卡车含有更多的颗粒。搬运塑料时会形成臭名昭著的天使头发，而化妆品和药品中较高的研磨度和较小的细粉则每天给我们带来新的挑战。散装物料和散装物料技术还在发展之中。我们的系统必须毫无问题地处理这些任务，而且确实也做到了。我们为此感到自豪”。散装物料行业的两个最大挑战是如何防止交叉污染和不必要的粉尘释放。一方面，目标是产品纯度，另一方面是员工保护。在过去的几年中，AZO 越来越专注于制药和食品行业，尤其是化学行业。搬运散装物料时，可能会导致操作人员的健康问题，例如过敏性食品中的灰尘。此外，防爆和防护起着重要作用。运输和搬运原材料以及中间产品和成品需要使用大量不同的容器，这对于散装物料系统的设计人员来说并不容易。其中包括集装袋、桶、麻袋和便携式容器。与其他行业一样，灵活性正成为散装物料搬运中越来越重要的因素。
No dust in the ambient air
“For the product to stay where it belongs, in target containers and the dosing device, both must be closed before docking takes place,” emphasises Pahl. This sounds simple, but isn’t. As is often the case, the devil lies in the details. “We definitely don’t want any of the product adhering to the inside of the dosing device’s downpipe to fall out before coupling and after decoupling and soil the floor or release dust into the ambient air.” AZO achieves this objective using the CleanDock. The dosing device and container remain hermetically sealed before and after filling. “While some double-cone systems available on the market do not consistently ensure freedom from carry-over effects, the CleanDock always guarantees this through the line contact of the components involved in the sealing process,” says Pahl. By using this technology in the CleanDock, AZO is very deliberately positioning itself between classic docking systems and the containment systems familiar from pharmaceuticals, such as split valves.
Decentralised control, reduced complexity
The passive section is docked to the active section using pneumatic linear actuators from Festo. They are also used for opening and closing the cone seal in the active section for filling the target container as well as locking and tightening the active and passive sections. A pneumatic knocker is used to loosen any bulk material residues stuck in the dosing device. The pneumatic actuators are controlled by the modular electrical terminal CPX with integrated controller CEC and valve terminal MPA. While in the predecessor version of the CleanDock the valve terminal CPV was centrally controlled by the process control system, the decentralised controller of the CPX-CEC now implements the control sequences directly on the dock. This especially reduces commissioning time. “Some bulk material plants store more than 80 raw materials in silos,” explains Frank Pahl. “The largest number of CleanDocks we have installed in a plant so far is around 60.” With so many filling stations, the programming and commissioning effort has been relatively high until now. The probability of errors also goes up as the number of units controlled via the process control system increases. “Controlling the CleanDock decentrally speeds up the commissioning of a plant and reduces the risk of errors,” says Pahl. “All the process control system does is give the command for docking and undocking. The CleanDock looks after all the detailed operations itself. Programmers no longer need to worry about these detailed processes on-site during commissioning.”
The CleanDock system in action. Docking and undocking is controlled decentrally and autonomously by the CPX-CEC from Festo.
Modular, flexible, pioneering
The modular electrical terminal CPX from Festo with integrated controller CEC and valve terminal MPA provides a uniform interface for the decentralised intelligence and enables the complete control of machines or more complex subsystems. As an automation platform for electric and pneumatic components, it connects pneumatic and electric control chains to different automation systems and company-specific standards simply, quickly and flexibly. The entire system is programmed simply using CODESYS. Interfaces are reduced, engineering and handling processes are simplified and the reliability of machines and plants is increased.
Added to this is an essential aspect that is gaining significance worldwide for the future of plants: modularity. Automation functions are increasingly distributed across individual modules. The process management level merely sets the pace. The key to greater flexibility and simplified handling lies in the integrated, decentralised intelligence. While the process control system calls up a function, it doesn’t need to have a detailed knowledge of the stored process steps. This is taken care of by intelligent modules such as the CPX-CEC with valve terminal MPA at AZO.
Together towards a modular future
What AZO and Festo have already successfully implemented here corresponds with the objective currently being discussed in detail and worked out between NAMUR/ZVEI (Association of German Electrical and Electronic Manufacturers), machine builders and operators and research facilities for the automation of modular production plants. The decentralised and complete automation of the individual modules reduces complexity and shortens time-to-market for system operators.
Individual modules can also be produced for stock and adapted without a great deal of effort. Systems can be easily expanded with additional modules. In this way, system builders can react even more flexibly to the changing requirements of worldwide markets. As an automation expert, Festo is actively involved in the design of concepts and standards that drive and simplify the automation of modular plants now and in future.
AZO GmbH & Co. KG
Rosenberger Strasse 28
74706 Osterburken
Germany
