An alliance at the service of packaging

Cooperation and innovation go hand-in-hand in bringing good results. Ronchi & Bosch Rexroth have pooled their core knowhow, the first as a filling and capping machine builder, the latter as a supplier of automation systems. This has allowed them to grow, leading to the joint creation of an innovatory electronic cam capping machine, previewed at this year’s interpack.

Ronchi Mario SpA’s experience, built up in nearly 50 years working on all the main world markets, forms an almost unique knowledge and knowhow base, producing one-off solutions to satisfy their customers’ every needs.
The fields of application are extensive, going from personal care to the food industry including chemistry, pharmaceuticals and household products.

Focus on capping machines
Ronchi Mario SpA’s wide range of cappers that come under the name “Sirio”, enable an extensive handling   not only ofcaps and plugs of every shape, style and color, but also spray-, dispenser and trigger pumps, with solutions that ensure the best quality for this type of application.
The Sirio cappers are available in both a mechanical and a servo-controlled  brushless motor version for the rotation of the capping heads.
The latest capper from Ronchi has the electronic cam capper full electronic control of the vertical movement of every capping head and ensures  a series of benefits such as practicality, flexibility, optimisation and speed of production.
And it is precisely here, when it decided to exploit this new technological evolution made available by modern electronics, that Ronchi began its “alliance” with Bosch Rexroth, international leader in the production of sophisticated, super-hitech automation tools.

Mechanical and electronic decisions
Ronchi and Rexroth’s R&D sections have been working together right from the “concept” phase, sharing their respective experience and clear project objectives from the moment the agreement was made, establishing the ideal conditions for the creation of an innovative, unique machine featuring both mechanical and electronic innovations.
With the clear aim of producing an application with the maximum modularity, it was decided to replace conventional mechanics with a linear module for each single capping unit. The studies, sizing and simulations guided the choice towards the MKK 20-80 - a compact linear module with ball screws that ensures quick installation and optimum sturdiness, and is able to perform the stressful cycles and profiles produced by Ronchi in years of experience, modifications and fine-tuning.
In terms of electronics, the architecture puts the MLC (Motion Logic Controller) at the heart of the machine, connecting it to the various peripheral devices in Modbus TCP/IP, EthernetIP/Profinet and Sercos III in real time for all motion aspects.
The application was developed with an entirely “cabinet-free” concept, using motors with built-in drive (second generation IndraDrive Mi) for both the capping heads and the electronic up-down cams.
The “daisy chain” linking structure and the use of a single hybrid cable proved to be especially appropriate for this type of application, where space is at a premium and the power and control signals must be conveyed via a rotating manifold fixed to the carousel.
Key feature in Rexroth’s system is the intelligence of the drive: thanks to the synchronism and the interpolation functions (linear, cubic and spline) performed directly by the drive, and
in virtue of specific firmware functions such as cogging torque compensation and analysis of position, speed and torque in frequency and during operation (with quick mode change), the pre-fixed goals regarding speed, accuracy and repeatability were not only reached but superceded.
The architecture with decentralised servo motors was also implemented with Safety integrate (STO, Cat 4 PL acc. to EN ISO 13849-1 & SIL3 acc. EN 62061), and with the possibility to create and activate/deactivate independent safety areas.

Interaction with smart devices
Lastly, innovatory too the ability to interact with the machine via the use of smart devices (smartphones or tablets) - presented at Interpack 2014. All this is made possible thanks to the Open Core Interface, that enables the linking of a typical PLC-based automation world with the wider IT automation world via exchange libraries.
Open Core Interface is a programming interface that enables the creation of a  direct link between the Rexroth MLC controller and external devices like smart devices, Windows applications and quick simulation/prototype tools such as LabView, Matlab and Simulink. The interface also enables direct acess to the heart of the controller, at exactly the same firmware level, enabling the user to develop and integrate customized control functions even on a real time basis (Wind River Workbench on VxVowrks).
The electronic technology (already tested and in use for some years now) used by Ronchi Mario SpA on its machines has  been even further strengthened by the addition of Bosch Rexroth’s electronic and mechanical systems. The collaboration between the two companies continues with mutual satisfaction, continuous dialogue and a constant exchange of ideas and communication, ever on the look-out for ground-breaking solutions to meet the ever increasing demands of today’s market.