TBS Engineering offers its customers enhanced production agility thanks to Rockwell Automation
28/10/2013 Rockwell Automation
TBS Engineering Ltd., part of the Berkshire Hathaway Corporation, was founded in 1967 by Thomas B. Stamp in Cheltenham, England. The company, a world leader in the production of automatic assembly machinery for the battery industry, operates across three sites: Cheltenham, UK; Albany, Oregon, USA; and Qingdao, China.With over 90% of its equipment being exported overseas, TBS was awarded the Queen's Award for Industry in 1990. Indeed, TBS can proudly boast that most of the World's OEM battery suppliers to the major car producers produce their batteries on one or more of TBS' machines. In addition to the car industry, most medium-to-large UPS systems in operation around the world have SLA and VRLA cells in them that have been produced on TBS machinery.
Even with such a large presence in the market, TBS does not stand still. It is committed to innovation - especially when it comes to enhancing its existing technology. The recent addition of a servo-driven option for its Unloader module, using an Allen-Bradley Kinetix-based servo solution, supplied by Rockwell Automation, promises to give its customers even greater levels of flexibility and time saving.
The Unloader module is part of a much bigger machine known as a COS 10 (Cast On Strap). Resembling a production line made up of a number of separate sections, it undertakes all the steps necessary to assemble valveregulated lead-acid batteries for UPS and standalone power systems.
The issue that TBS faces is that its customers demand high levels of flexibility, allowing them to vary the type and model of the batteries being produced.
This variety of end product types means that the Unloader module must be capable of performing an incredibly diverse - almost inï¬Ânite - range of motion and positioning tasks in order to cater for the unique design of each of the battery variants.
This operational variability is normally achieved mechanically using pneumatic cylinders. Although effective, it does present a number of issues when it comes to modifying the motion parameters; namely operators working at height, overly long adjustment times, tooling issues and the possibility of introducing operator errors.
It was for these reasons that TBS approached Rockwell Automation - who already supply a great deal of the company's automation infrastructure - to help develop a servo-based option for the Unloader based on Allen Bradley technology.
The new Unloader servo option employs a mechatronic solution controlled by an Allen-Bradley SLC 500 PLC. It utilises Allen-Bradley Ultra Servos, an Allen-Bradley PanelView Plus 1250 HMI, Allen-Bradley PowerFlex drives and a number of Allen-Bradley low-voltage components. In addition, safety equipment, comprising Allen-Bradley GuardMaster safety control relays and interlocking switches, is also part of the package, which, thanks to the Integrated Architecture solution, integrates seamlessly with the overall 'parent' machine safety system.
The Unloader is connected via Ethernet to the Gripper Assembly, which is controlled by an Allen-Bradley CompactLogix Programmable Automation Controller (PAC). The motion tasks are undertaken by 12 AllenBradley MPL Servo Motors - one for each of the 12 grippers (two banks of six). These motors are controlled by 12 Allen-Bradley Kinetix 300 Servo Drives, which are, in turn, connected to the PAC via EtherNet/IP, a feature believed to be unique in the market.
The Unloader is not the only module to beneï¬Ât from an Allen-Bradley infrastructure. The overall machine control for the COS 10 is also achieved using an Allen-Bradley SLC 500 PLC alongside various other Allen-Bradley Servos, HMIs, Drives, low voltage and safety components. The same goes for other modules, including the Auto Loader and the Group Transfer Unit (GTU).
Early on in the design process, engineers from TBS Engineering and Rockwell Automation quickly realised the potential that an Allen-Bradley Kinetix-based system would have over the existing pneumatic infrastructure. Indeed, over 50% of the pneumatic system and its supply could be removed, offering signiï¬Âcant energy savings. Machine set up is now completely automated and can be achieved in a fraction of the time.
The Kinetix 300-based solution also offers easier commissioning, conï¬Âguration and start up, and with EtherNet/IP deployed across the entire machine, TBS Engineering is utilising what is widely believed to be one of the most powerful and flexible industrial communications systems currently available on the market.
"From a technology standpoint we had a tremendous amount of help on the servo systems. I believe that where it matters Rockwell Automation has the right people. We also appreciate the service levels from Rockwell Automation and Routeco, the distributor we use, who has set up a stock system for parts."
"We have always found Allen-Bradley products to be excellent and very reliable," explains Chris Barge, Technical Director at TBS Engineering. "We really try to standardise on Rockwell Automation as we can sell this technology very easily into both established and emerging markets.
For more information, please contact:
Rockwell Automation Ltd
UK Marketing Communications Specialist
Pitfield, Kiln Farm
Milton Keynes K11 3DR
Tel: 0870 242 5004
Fax: 01908 839696
Email: ukmarketing@ra.rockwell.com
Web: www.rockwell.com
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