Planar systems like the Acopos-6D system from B&R enable contactless transport on freely floating shuttles that can move flexibly in all directions—including the so-called six dimensions (forward/backward, left/right, up/down, and rotation around the three axes). This freedom of movement allows for particularly dynamic and individual control of the production process.

Individual transport systems offer several advantages: They enable high flexibility, as shuttles can be independently controlled and grouped, allowing various products to be moved efficiently through the production line. The machine footprint is reduced through optimized space utilization, and the rapid and precise positioning of the shuttles increases production speed and prevents bottlenecks. Additionally, the system's flexibility allows for the economical manufacturing of personalized products without impacting overall production. The product-friendly transport allows for the use of sustainable packaging, while the optimized material flow uses space and resources more efficiently.

Electromagnetic switches smoothly redirect products

Electromagnetic switches play a vital role in this context. They enable precise control of product flow by swiftly and smoothly diverting products onto different tracks—without any mechanical interventions. This allows for seamless redirection of products, even at high speeds. Additionally, product streams can be separated or merged, processes can be parallelized to increase throughput, and products can be selectively diverted, providing maximum flexibility in production. A distinctive feature of B&R is the high adaptability and efficiency achieved through precise control of the switches.

Furthermore, the vision system from B&R also contributes to flexibility and efficiency by enabling visual inspection, monitoring, and control of the packaging process. It handles tasks related to quality assurance and the synchronization of lighting and image capture. However, the camera can do even more: it simultaneously performs tasks such as reading codes and, based on that, adjusting different threshold values for fill levels. A new deep learning feature also enables intelligent analyses and improves error detection by allowing the system to learn from the results of past data.

Robots and shuttles coordinate their movements with each other

Lastly, robots and shuttles enable precise and fast processing of products through their adaptable movements. They can be controlled independently and in real-time. Advanced algorithms additionally adjust the movements of the robots to meet the specific requirements of the packaging process. They work synchronously with the shuttles to perform handovers between stations without delay. A common coordinate system seamlessly integrates robots, shuttles, and the vision system together, allowing for easy and rapid integration of multiple mechatronic systems.

In the development of adaptive manufacturing systems, B&R relies on simulation-based design. Virtual testing allows for the evaluation of various scenarios and production processes before the deployment of real machines, enabling the early identification of errors and optimization opportunities. Simultaneously, simulation facilitates a precise analysis of processes to identify and eliminate potential bottlenecks or risks in advance. This significantly enhances the efficiency and flexibility of the systems, as they can be optimally configured and adjusted before being implemented in actual production.

The digital twin accompanies the machine up to operation

The digital twin plays a central role in this process. It accompanies the entire life cycle of a machine—from the planning and design phase through commissioning to operational optimization. During the design phase, it enables precise virtual development and simulation, allowing the machine concept to be tested and improved. During commissioning, the digital twin simulates the operation of the machine, enabling tests and adjustments to be made before the real hardware is used. In the operational phase, the digital twin provides real-time data for monitoring and analysis, supports predictive maintenance, and thus helps to reduce downtime. Additionally, it enables continuous optimizations and upgrades without impacting the physical operation of the machine.

Another advantage of the digital twin is the ability to optimize production processes offline. Virtual tests and the simulation of process flows in a safe environment allow for the identification of bottlenecks and the implementation of improvements before these changes are introduced in the actual production.

AI will accelerate decision-making and optimization

Artificial intelligence and connected systems unlock further potential.

Adaptive manufacturing will continue to evolve in the future. Increasing automation, integration of artificial intelligence (AI), and connected systems open up new potentials: AI will play a larger role in decision-making and optimization. Furthermore, self-learning systems will improve and adapt production processes in real-time.

Enhanced connectivity also promises benefits. IoT and edge computing technologies provide the opportunity to further interconnect production facilities, allowing data to be evaluated in real time and processes to be automatically adjusted. Flexibility and modularity will continue to increase as machines are built more frequently from standardized modules that can easily be adapted to various production requirements. This connectivity not only streamlines operations but also significantly boosts efficiency by enabling a more responsive and adaptive manufacturing environment.

B&R will play a key role by advancing future-proof solutions such as integrated control and automation systems, intelligent transport systems, and vision technologies. With a focus on real-time systems and digital twins, B&R will enable companies to respond more flexibly and efficiently to new requirements and advance adaptive manufacturing. This commitment to innovation ensures that B&R remains at the forefront of facilitating industrial transformations that meet the demands of modern production landscapes.

SPS 2024, Hall 7, Booth 206