Control and sorting: good news

FLEXIBILITY With the aid of Beckhoff electronics, FBA Srl has developed an automatic system able to perform the identification and sorting of parcels of different shapes and sizes, according to parameters that the user defines and modifies to suit specific requirements.

The goal was to create a line to detect weight, volume and barcodes of individual packages with subsequent sorting, capable of operating automatically with the greatest accuracy and flexibility, and integrating seamlessly into the user’s handling and tracking system. Beneficiaries: carriers, forwarding agents and any organization that has to manage a multitude of objects on a daily basis that differ in configuration and weight and that must be traceable.

The fact that the challenge was demanding can be judged by the characteristics of the machine developed by FBA, a specialized manufacturer of internal goods handling systems based at Torre d'Isola (PV). The new system is called Packmaster Light and performs all the operations conforming to the parameters set by the user to suit each single occasion.
The functions are highly sophisticated but the way the machine operates is simple: to ensure the promised performance, FBA has integrated all the electronics into a single modular architecture which manages and optimises communication between the various Packmaster components and between the machine and user’s management software.

The development of the machine was partnered by Beckhoff Automation, a company of German origin that develops and implements open automation and control system, present in Italy with its direct branch in Nova Milanese and two other area offices. The result of the collaboration is an original and powerful system that offers a series of interesting features. Fabio Sacchi, FBA Sales Manager, explains the logic and characteristics of the same.
 
What market demands led to the drawing up of the Packmaster project? What results did you aim to achieve?
Major hubs as well as small branch offices need to optimize productivity, automate processes and minimize errors in data collection. Our Packmaster automatic pack weight volume and barcode identification system has been especially designed to do just that.
The latest and most recent development of this system is called Packmaster Light, which we launched at Ipack-Ima 2012 in two versions, with an output of 1200 and 1800 packages/h, which responds to the need to automate production lines with minimal impact. Consider that in just 6 meters with Packmaster Light you can get a line that performs full automatic loading, measuring and sorting of packages.
Furthermore, all machines in the Packmaster series provide real time information on shipments, also capturing and storing pictures of the selfsame parcels.
The Light line in particular features a very simple structure and is minimally invasive, particularly quick to install and can also be easily integrated with the carrier or a smaller subsidiary branch.
 
What problems if any cropped up during its development? How did you solve these?
Switching from traditional to integrated data management demands a change of mentality of the operator that also involves the system supplier. It was the only "problem" we had to face, and honestly, it wasn’t that difficult to solve.
 
Electronics plays a key role in the machine’s general economising. Why did you choose Beckhoff as a technology partner? For which solutions?
FBA wanted to acquire an all-in-one technology that would allow the customer to eliminate the problems caused by the use of the classic PC, for example due to bulk, or the dust and the consequent need to put on gloves to use the mouse and keyboard...
Beckhoff’s skills and knowhow led them to provide solutions at one and the same time effective and relatively simple; what is more, their integrated technology leads to a much more functional usage of the scanning and capture system, enabling a clearly coherent, direct management of information without any danger of data dispersal.

Do you have any new projects in the pipeline?
We are constantly committed to creating increasingly advanced machines, capable of generating added value for the various types of user. The integration between these systems and automatic labeling and sorting solutions, together with the adoption of new all-in-one technologies, makes us competitive and capable of implementing closely customised solutions, improving individual functions and the overall product-service package.               

Automatisms: at the heart of technology
The CX5020 by Beckhoff has proven to be the ideal solution in terms of the logic control system thanks to TwinCAT PLC and its interconnection with the applications in Microsoft® required for the correctly running the supply chain, exchanging data in real-time on the network and eliminating any latent periods. TwinCAT PLC enables exchange of data with Microsoft® applications directly using PLC functions whatever programming environment they have been created in, without additional procedures. The EtherCAT protocol, directly available on the CX5020, was chosen for its straightforward hardware configuration upgrade facility as well as for the potential implementation of any additional devices with the possibility of remoting Ethernet ports available for Win XP, thus improving PC communicability. The very structure of the CX5020 has, with minimal investment, has enabled customer problems and needs to be solved using a single platform. Success comes easily with the CX5020.

Modular, powerful, "easy"
Packmaster Light constitutes the latest and most updated FBA system for package weight, volume and barcode identification. It features simple architecture, easy installation, rapid return on investment and limited size: an automatic line of only 6 m satisfies the most varied demands. Made in two versions with a throughput of 1200 and 1800 packages/h, both with integrated Beckhoff technology, 100% monitoring of goods and real time rendering of shipping information.
Among its distinctive features, the extreme modularity, all-in-one control with friendly touchscreen interface, the possibility of use in degrade mode as well as important optionals such as automatic processed package picture capture and storage. Packmaster Light comes with metrological certification and fully complies with MID 2004/22/EC standards.
FBA Srl (Torre d'Isola, PV) manufactures and installs material handling systems and automation technologies on a global scale - primarily in Europe, India and Russia - providing a round-the-clock after-sales service seven days a week.
FBA’s solutions include all the elements necessary to perform the weighing, sorting, inspection, handling, labeling, and whatever else takes place at end of the line and during storage. There are three major system families, respectively dedicated to express carriers (sorting offices, major hubs for land or air transport...); internal logistics (software, facilities and equipment); manufacturing processes (internal handling of finished and semi-finished goods).