ITALY: Ave Technologies, part of the Omnia Technologies Group of companies and an Italian OEM in the food and beverage sector, faced a significant challenge due to a mechanical linkage between its filling and capping machines for vinegar production. This linkage meant that synchronization after format changes was a long and complex process for operators. To tackle this challenge, the Ave Technologies automation team, consisting of software and automation engineering specialists, introduced an electronic solution to replace the mechanical linkage. The new iC7-Automation-based electronic system is flexible, maintains high performance and drastically simplifies the changeover between different production format types.
The situation: Manual format changes were time-consuming and costly
Ave Technologies, located in Spinea near Venice, builds tailor-made bottling machines based on specific customer requirements. The company specializes in liquid filling machines and operates in the non-alcoholic beverage and milk markets, both in Italy and abroad.
In its vinegar bottling line, the machine performing the filling and capping processes for consists of several sections:
- 1 blowing carousel for cleaning the bottles
- 1 filling carousel
- 2 capping turrets to handle both aluminium and plastic caps
In the initial setup, changing the bottle format was a long and complex process because it used a mechanical-pneumatic system with a gear that had to be engaged each time.
This system had several disadvantages:
- Time factor: Several days were required to manage the installation of various components on the machine
- Adjustment of several management devices required: This resulted in more labor and increased complexity, linked to the desire to keep the clutch engaged even after the machine was turned off.
- Inadequate machine performance: For a production rate of 12,000 bottles/hour, the capacity was barely sufficient. If production were to increase, the system would not have been able to offer the necessary reliability.
One solution to overcome these challenges could have been the implementation of brushless motors and servo drives. However, this would have significantly increased costs and complexities related to commissioning, managing special cables along the machine, and future spare parts management.
The solution: Precision without complexity
To overcome this challenge, Ave Technologies has tested an electronic
solution based on the Danfoss iC7-Automation drive with a motion-control application, to replace the mechanical linkage. During the machine design phase, automation engineers realized that next generation technology was required, in order to meet the needs of Ave Technologies and its customer. The Danfoss iC7-Automation variable frequency drive (VFD) with integrated cybersecurity proved to be the right solution.
In the testing phase, the iC7-Automation features enabled a smooth transition to a flexible system, maintaining high performance and drastically simplifying the format changeovers between different production types with perfect synchronization.
The test results demonstrate that the system offers flexibility, simplicity, and cost reduction in many facets of the automated format changeovers:
- Synchronization is highly precise and simple to implement using VFDs, asynchronous motors and encoders
- No additional external components are required, thanks to the VFD equipped with integrated application management software
- The PLC is relieved from managing synchronization, and the software modifications compared to standard machines are minimal
- Full compatibility with Siemens PLC and different types of encoder feedback
- Significantly less complexity for both Ave Technologies and the end customer
- Ease of spare parts management, leading to greater end-customer satisfaction: no special components are required, and the spare parts already in stock are sufficient
- Flexibility to adapt to future requirements with no added complexity, such as PM motors, increased cybersecurity demands, or introduction of new PLC type. The only limitations are related to mechanical parts.
- Integrated cybersecurity: Through MyDrive® Insight, it is possible to intervene remotely, and monitor kinematics and motor status to understand the system’s operating status
- Ability to integrate with the standard architecture of Siemens PLCs without adding software-level complexity. This is a key advantage of the solution
What satisfied the automation team most about the iC7-Automation was the precision achieved in the synchronization tolerance with asynchronous motors. The resultant precision was an order of magnitude better than the tolerance target assumed in the design phase, at 0.3-0.4 mm.
What particularly struck me was that, even though it is a synchronization system, our operators were able to manage everything very easily, without pressure or stress. I load the recipe for the bottle I want, press the button, and like magic, everything positions itself as it should. An unexpected and much appreciated result.
The outcome: A safe and reliable solution which is easy to replicate
For Ave Technologies, this was a completely new application that seemed complex and difficult to implement. However, thanks to the flexibility and safety features of the iC7-Automation VFD, it proved to be easy to realize, with highly tangible advantages for both Ave Technologies and the end customer.
The next time a similar challenge arises, we will be ready and know how to tackle it. iC7-Automation is a VFD ready to meet future requirements, such as operation with permanent magnet (PM) motors and compliance with cybersecurity regulations, thus ensuring a long-term investment.
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