Cabinet-free automation The game changer in mechanical and plant engineering

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In an initial plant for processing profiles, the MX system for cabinet-free automation from Beckhoff was convincing in all project phases. Why Schirmer Maschinen GmbH continues to rely on the plug-in system solution.

Editorial Management PR, Beckhoff Automation

Window and door construction is high-tech. This becomes clear from the first process step, the fully automatic processing of so-called raw bars on a profile processing machine from Schirmer Maschinen GmbH. Schirmer was founded in 1979 and was Beckhoff's first customer. For over 40 years, the company has relied on Beckhoff's PC-based Control, starting from the first positioning control to the new MX system.

The aforementioned plug-in system solution for cabinet-free automation fits particularly well with Schirmer's machine concept: the development of individual machines based on largely standardized process modules into customer-specific solutions with high output and flexibility in terms of profiles and processes. The company has been a member of the Beckhoff Automation Group since 2016 and currently employs around 250 staff members.

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Schirmer machine for complete processing of profile bars

Schirmer's machines encompass a multitude of different processes: Individual parts for window frames and sashes are created from profile bars about 6 meters long using a continuous process. As far as possible, all drilling, milling, or punching operations are performed on the raw bar. This is followed by cutting and end processing. In parallel to the processing of the profile bars, the cutting of reinforcement profiles is carried out on a separate line, which can be automatically inserted and positioned into the PVC profile if desired. Subsequent processes include screwing the profile and reinforcement together, steel processing (drilling, milling), and inserting and screwing the locking parts.

Since Schirmer machines must handle a wide variety of profile geometries that frequently change, conversion is automated. "Manual setup is taboo with us," says Ludger Martinschledde, Managing Director of Schirmer Maschinen GmbH. Accordingly, many stops and brackets are positioned fully automatically. "Last year, for example, we implemented a line with a total of 210 axes," Martinschledde outlines the requirements for the control platform.

Control cabinets determine the production processes

The electrical equipment currently used in Schirmer machines meets the status quo: drive amplifiers, power supplies, power distribution, and PC-based control technology are installed in switch cabinets. There are several of these on Schirmer machines, arranged along the machine, to which cables from generally two to three process modules of the machine are laid and connected. Additionally, EtherCAT I/Os are used in sub-distributors to collect the actuators and sensors of the individual process modules.

Combining several process functions in one control cabinet and using sub-distributors where signal lines are clamped and not plugged in represents a compromise for modular machine construction.

Managing Director Martinschledde describes the disadvantages of this solution as follows: "Therefore, the electrical installation and commissioning mostly take place during the final assembly—at a time when we actually want to get the system up and running as quickly as possible and then dismantle and ship it." The discrepancy between the machine's modular concept and the central switch cabinets has long been identified by Schirmer as an obstacle to creating a more efficient project workflow.

Therefore, he and the designers from Schirmer became attentive when they heard about the possibilities of a completely cabinet-free automation with the MX system from Beckhoff in 2021. "The designers and Martinschledde immediately recognized the potential of the MX system for their modular machine construction," recalls Daniel Siegenbrink, Product Manager MX System at Beckhoff.

Machine completely redesigned and without control cabinets

At one machine, Schirmer is now using the MX system for the first time, marking a new direction. The primary goal is to optimize the throughput times and processes in the construction of the machines. Instead of the switch cabinets that previously stood next to the machines, MX System Baseplates are now directly visible on the steel frames of the process modules. The tasks of the sub-distributors have either also been accommodated in the MX system or have been replaced by decentralized I/O modules (EtherCAT Box Modules) from Beckhoff. This combination of the MX system and EtherCAT Box modules enables all lines to the motors, sensors, and valve islands to be plug-and-play.

The decisive advantage of the MX system for Schirmer lies in the restructuring of internal processes. With this plug-and-play system solution, the machine manufacturer can already mount all electrical components of a machine module during pre-assembly and easily connect them via pre-assembled lines. Another aspect adds to this: In pre-assembly, the machine modules are freely accessible from all sides, which significantly facilitates cable laying and connection. Product Manager Siegenbrink emphasizes: "This saves a lot of time and significantly increases the efficiency of workflows." This applies not only to assembly but also starts with planning, work preparation, and material provisioning in production.

With the functional modules of the MX system, the elaborate individual wiring of numerous subcomponents common in conventional switch cabinet construction is no longer necessary. This prevents wiring errors and reduces the variety of parts. As a result, the required components—MX System Baseplates and modules, as well as the pre-assembled system wiring—can be picked directly from the warehouse for pre-assembly after the electrical planning. "The goal is to have a stock that is independent of orders, which we want to manage based on minimum stock levels, demands, and replenishment times," explains Martinschledde.

For Schirmer, two more insights have emerged from this initial development project: Short-term change requests can be implemented much more easily and with less effort, even in a late phase of the project. And with a module-by-module commissioning, any functional errors are detected early and can be rectified without time pressure.

Fast and efficient to the end customer

In the final assembly, where the machines occupy a large area, things need to move quickly at Schirmer to make space for the next installations. According to Martinschledde, the processes moved forward, such as electrical installation and possibly partial commissioning, significantly reduce standing times and thus increase area efficiency: Schirmer can thus set up, approve, and deliver more installations in the same hall.

As a machine builder with an export share of 75 percent, the universal application of the automation solution is another important aspect for Schirmer. Whereas the future installation site had to be considered in the electrical planning and material procurement until now, the machine can now be used worldwide without elaborate adjustments thanks to the MX system, which complies with IEC, UL, and CSA standards in contrast to conventional switch cabinets. This further increases the level of standardization at Schirmer.

But it's not only Schirmer that benefits from cabinet-free automation. The MX system also offers tangible advantages for end users. These include improved accessibility to machine areas and reduced space requirements due to the elimination of switch cabinets. This allows production equipment to be placed closer together in the halls, optimizing the valuable floor space without violating regulations such as emergency exit routes. Additionally, the tenfold reduction in the number of components also reduces the size of the spare parts inventory.

The Beckhoff diagnostics app, introduced with the MX system, is a tool that makes it easier for maintenance personnel to locate and fix errors. "The consistent plug-and-play capability and the use of the diagnostics app as a replacement for the multimeter allow for the connection or replacement of MX system modules without the need for specially trained electrical professionals," emphasizes Siegenbrink.

Successful launch into cabinet-free automation

The implementation of Beckhoff's MX system at Schirmer has resulted in significant advantages and optimizations at many points along the entire process chain. The previous effort required for electrical planning was reduced by about 50 percent; the usual two to three weeks of assembly time for conventional switch cabinet construction was reduced to just a few hours of system assembly. Ludger Martinschledde also expects a significant reduction in standing times during final assembly.

"The MX system changes the way in which machine construction and installation are carried out," believes Managing Director Martinschledde. Accordingly, the new machine will not be the last installation on the path to a new era of cabinet-free automation: "Schirmer will continue to rely on this innovative solution from Beckhoff. It is clear for us that we are converting our machines to cabinet-free automation with the MX system. And this will also apply to future product lines for aluminum and steel profiles."