Abstract:

• Automation of a window sill production facility (40 x 40 m), which transports the raw sills of various widths away from eight extruder lines logistically on the basis of order data, cuts the sills and packs the finished product on pallets with up to 80 stacking patterns
• JetSym ST programming implements a data structure for each product which runs and is updated along the entire manufacturing process
• Optimized times for transport or separation/stacking, each with a JC-647 controller
• Lengthways separation of the raw sills performed with four JM-215 and one JM-204 servo controllers
• 53 JX3 modules with 480 inputs and 352 outputs scan system information or react at the right time by means of the respective JC-647 controllers

Criteria in Favor of Jetter AG:

The dimensions of the system (40 x 40 m) meant a special challenge for the machine manufacturer, as the main part of the system was constructed at the customer's premises.
With the aid of versatile employees and the following Jetter technologies, the project was successfully finished on this global market:

• The modularity and scalability of the new Jetter JX3 generation can be easily extended and can be flexibly adapted to the new requirements of a growing plant
• JX3-DIO16 modules permit the integration of sensors which could not previously be planned into the system without rewiring, as the outputs of the module are recognized as inputs, depending on the circuits
• The automation specialist's dream of a "transparent factory" has come true thanks to seamless data integration offered by Jetter software The data structure runs alongside manufacturing and order processing simultaneously with the product or order
• The integration typical for Jetter products permits the implementation of a continuous extrusion process in the system into a logistic transport system, positioning of the suction pads for stacking and also palleting of the end product with up to 80 stacking patterns, and results in decisive time savings during programming
• The greatest technical advantage of Jetter products is the smooth database connection between the plant and order processing system for job preparation

Technical Description of the Production Plant:

Raw sill conveying:

Eight extruders including wrapping plants produce raw window sills of various widths
Complicated transport algorithms, elegantly written in the JetSym ST programming language, forward the continuous, uninterruptible injection molding process of the eight parallel extruder lines through eight transport units to a logistic, order-based raw sill transport system
Each individual product has a data structure which is updated throughout the manufacturing process with the end-to-end Jetter data structure ("transparent factory"), which contains all information such as the decoration, width, manufacturing status, test information, stacking pattern, position in the stack, positioning points for suction arms, specification of the width for lengthways separation etc.
Core know-how in this section of the plant is transport and stacking of the raw sills which are still malleable without negatively affecting the dimensional accuracy
The logistics timing is controlled by a Jetter JC-647 controller.

Lengthways separation/stacking:

After hardening of the manufactured sills for two days in an intermediate storage facility, the stacked sills are individually supplied to the lengthways separation system, which is implemented with a Jetter servo-system, and cut to the respective width for each order The core know-how in this section of the plant is the subsequent stacking process of the end products in up to 80 stacking patterns. The window sills are offset and placed in a nested arrangement due to an edge on the sills. Another JC-647 controller is responsible for control of this section Both system sections communicate via a WLAN connection. Global access is available by means of remote maintenance if servicing is required.

Components used:

Raw sill conveying:

• JC-647
• JM-215-480
• JX3-BN-CAN
• JX3-AI4
• JX3-DI16
• JX3-DIO16
• JX2-CNT1
• JX3-PS1

Lengthways separation/stacking:

• JM-204-480
• JM-215-480
• JX3-BN-CAN
• JX3-AI4
• JX3-DI16
• JX3-DIO16
• JX3-PS1