Cardboard is replacing plastic as a megatrend. To ensure that carton pallets can be supplied quickly and efficiently in industry, the French team of experts MATEK can help with its machines. The specialist for end-of-line machines relies on sensor solutions from SICK: The intelligent use of SLT signal lights, Dx35 mid-range distance sensors and the Sensor Integration Gateway SIG200 increases productivity and supports and relieves the burden on machine operators.

Since 2015, MATEK has been specializing in the trade of end-of-line machines and industrial equipment and offers a range of services: from spare parts supply to installation, troubleshooting and improvement of machine parks to maintenance. MATEK also supports the design of certain parts of the machines, especially in the packaging industry. A few years ago, the company also acquired a machine for folding carton pallets to meet the growing demand for this type of packaging. The main reason for this is that the new EU directive stipulates that plastic packaging should be reduced.

Optimizing machine productivity through ergonomics

The machine in question is a carton pallet forming machine: At its front, the machine takes the pre-cut cardboard from the loading container, prepares it for folding, applies adhesive and completes the forming process, thus producing a folded pallet. The operator needs to fill the material rack at the front and release the stack at the end of the machine. The two workstations are four meters apart. When the operator is at the end of the machine, he cannot see the filling container. If the filling container is empty, the machine stops and reports a fault, which significantly reduces productivity.

From this side of the machine, the operator cannot see the cardboard filling container.

To avoid this problem, Mathieu Hartmann, General Manager of MATEK, first considered a distance sensor that could trigger a machine stop at a certain threshold distance. SICK’s Dx35 mid-range distance sensor was perfectly suited to this task. However, since the theme of innovation is firmly rooted in MATEK’s DNA, as confirmed in a conversation with Emmanuel Renaud, Regional Sales Account Manager for France at SICK, the application could be further improved. Why not use a signal light or even a sound to warn the operator and avoid unnecessary machine stops?

Setup in just three minutes

The SLT signal light was thus integrated into the project. With 21 colored LEDs, it is now possible to transmit many different information via the same device and warn the operator when different thresholds are reached. The signal light is also equipped with IO-Link, as is the Dx35 mid-range distance sensor. Emmanuel Renaud therefore suggested connecting the sensor to the Sensor Integration Gateway SIG200 for easy configuration. The result was remarkable: Setting up the sensor took just three minutes. “Detection, safety blind zone, all parameters of the sensor connected to the gateway are accessible. It’s amazing how easy it is”, says Mathieu Hartmann from MATEK. After connecting the signal light, it took another ten minutes to parameterize the color change of the column.

How does it work exactly?

The Dx35 mid-range distance sensor is mounted on the top and detects the cardboard stacks in the loading tray at the front of the machine. The SLT signal light then returns information to the operator about the stack height:

Flashing blue: rack full / overflowing

Lights up green: rack at 100%

Change in color fraction, gradually switching to yellow between 100% and 50%

Yellow: rack at 50%

Change in color fraction, gradually switching to red between 50% and 20%

Adding an acoustic signal (using the buzzer module Smart Light Buzzer SLB) to red: between 20% and 18%

Flashes faster and faster between 18% and 1%

Below 1%, the machine stops cardboard pickup, but does not stop (no unnecessary machine restarts)

When this level is reached, simply fill the rack and restart the machine at the push of a button.

But the goal is of course to never reach the 1% level, so that productivity is not impaired.

5% increase in machine productivity

The power of the SIG200 allows this level of granularity in the machine parameter setting. Since the controller is also connected to the Sensor Integration Gateway, it is also possible to set conditions for stopping the machine. “The results exceeded my expectations”, explains Mathieu Hartmann. With this holistic solution, the production cycle is guaranteed and Hartmann estimates that the machine’s productivity has increased by 5%. The operator has better control over the filling and can anticipate what needs to be done. The comfort and ergonomics motivate the operator. Incidentally, the operator is actively involved in the parameter setting of the colors and therefore has confidence in the machine.

A good relationship of trust

The key to the success of this project was the good relationship of trust between Mathieu Hartmann and Emmanuel Renaud. This trust led to an open exchange of ideas and a mutual understanding of the respective requirements. During the demonstration, the simplicity and power of the SICK solution played a supporting role.
Related product recommendations:
GE IS420ESWBH3A
GE Fanuc IS420ESWBH1A
GE IS400JGPAG1A
Panasonic MSDA5A1A1A07
Panasonic MSD5AZA1Y
GE IC697CPX928
ABB NINT-512
ABB 3HAC023781-001
ABB SDCS-FEX-425
ABB ACS880-01-087A-3
ABB YT204001KB
ABB DSTD110A
ABB PM581-ETH C1
ABB XRM00-185-3P-EFM1SEP102240R3301
ABB DCS880/DCT880 3ADT220166R0002 SDCS-CON-H01
NORGREN AH385851U003
Bently Nevada 330101-36-80-10-02-00
HMS AB7006
ABB HIEE405246R0002
Omega DPF64-SQRT 110/220VAC Rate Meter
Yokogawa ADV151-E63
ABB DSAI133  57120001-PS
SIEMENS SINAMICS  6SL3000-0CE21-6AA0
2094BC02M02M
2711P-T6C20A8
More…