I/O hubs save machine builder 60%: Balluff IO-Link

Ingersoll CM Systems Inc., in building its next generation deep fillet rolling machine, saved 60% in cost compared to previous I/O modules. Savings came from reducing the number of machine components by using economical Balluff IO-Link hubs.


When Ingersoll CM Systems Inc. of Midland, MI, decided to build its next generation deep fillet rolling machine, engineers sought to create a more modular and expandable machine that would allow customers to easily keep pace with evolving crankshaft sizes. A I/O-based network connection technology helped save 60% in cost.

New IO-Link system allows for more decentralization of I/O and reduced cabinet area, Balluff says.

New IO-Link system allows for more decentralization of I/O and reduced cabinet area, Balluff says.

Used in rough machining production as a process to strengthen and straighten journals, a deep fillet rolling machine increases the fatigue strength of a crankshaft by up to three times. After evaluating and testing several I/O networking options in the market, those at Ingersoll determined that Balluff's IO-Link solution would be the best option to decrease cost and the number of components per machine. Gary Munger, controls engineering manager for Ingersoll, said, "The IO-Link solution resulted in a 60% cost savings over our previous I/O modules. The savings came from reducing the number of components used in the machine and using the more economical IO-Link hubs. Reducing the number and complexity of the components also reduces the possibility of failures for our customers."

Old traditional I/O system consumes more cabinet space and requires longer I/O cable runs, Balluff says.

Old traditional I/O system consumes more cabinet space and requires longer I/O cable runs, Balluff says.

Balluff IO-Link is an open, economical technology that allows for the expansion of networked I/O devices. By using low cost, standard M12 cables, the point-to-point wiring is the most cost-effective available. Balluff's IO-Link hubs contain only the I/O circuits without the cost of the full network protocol.

Switching a machine's networking architecture can sometimes be a difficult and daunting task. Using IO-Link as an expansion, Ingersoll maintained its Profibus architecture. Munger added, "Balluff supplied evaluation units for benchmark testing and the entire transition process was a relatively smooth and easy one."

By building this new generation of deep fillet machines integrated with Balluff IO-Link technology, Ingersoll can pass on significant time and cost savings to customers.

Ingersoll CM System's next generation deep fillet rolling machine uses Balluff's IO-Link technology: a Profibus I/O module with three IO-Link expansion modules.


More about the companies

Balluff Inc. is the U.S. subsidiary of Balluff GmbH, Neuhausen, Germany. The company manufacturers inductive, photoelectric, capacitive and magnetic sensors as well as linear position transducers, RFID systems, and networking solutions. Balluff products for OEM and factory floor solutions are used to control, regulate, automate, assemble, position, and monitor manufacturing, assembly, and packaging sequences for industries including metalworking, automotive, plastics, material handling, wood processing, aerospace, electrical, and electronics. www.balluff.com

Ingersoll CM Systems designs and manufactures machinery and systems for crankshaft and camshaft processing for the automotive, truck, off-road, locomotive, and stationary engine/generator industries. www.teamicms.com

Also read from Control Engineering :

- Balluff IO-Link Profibus/Profinet modular expansion ; and

- RFID, machine vision sensors, I/ O network components help error proofing .

- Richard Bertolone is Balluff powertrain business development manager. Edited by Mark T. Hoske, editor in chief, Control Engineeering , www.controleng.com. See the industrial network channel .

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