Reduction in Costs by Decentralisation according to DESINA®

Reduction in Costs by Decentralisation according to DESINA®

The KAPP group, headquartered in Coburg, is a leading manufacturer of machine tools specialised on gear and profile grinding machines. KAPP is a leading manufacturer of machines for finish processing of gears and other forms and is as well specialized in supplying the necessary grinding tools.

Installation Concept

Installation Concept

Kapp follows the DESINA® concept when installing their machines. Due to the decentralized installation technique a lot of components from the central cabinet can be transferred to the field installation and decentralized terminal housings can be reduced to a minimum.

The installation technique for the communication was realized with selected components of Han-InduNet®.

Decentralized Components

Decentralized Components

The SIMATIC ET 200X DESINA® with Han-Brid® FO is used as a decentralized I/O. Fibre optic hybrid cables (violet cable) for the signals facilitates the installation. The data communication for the PROFIBUS® - DP is done via plastic fibre cables (POF), so that a interference-free signal transmission is guaranteed.The control voltage (24 V) is wired in two independent circuits, one is the power-supply for the electronics of the module and the sensor supply the other the supply for the actuators to be switched of in emergency cases. The connection of the decentralized peripherals is done through pre-harnessed cables with

Han-Brid® connectors. This leads to a reduction of the existing interfaces and a reduction of possible error sources.

If the cable length is more than 3 metres the connection of the sensor- and actuator cables to the IP 67 fieldbus components is made through M12 circular connectors with HARAX® rapid connection technique. With this solution a quick harnessing of the signal cables on side.

Optical Network Components

Optical Network Components

The HARTING Media Converter MCP12P is used for the set-up of the optical PROFIBUS® - DP network. The conversion of the electrical PROFIBUS® signal from the control unit into two optical data lines is carried out with Han-Brid® fibre optic interfaces inside the device. Additionally the Media Converter is used as panel feed-through. The installed 24 V power supply feeds the module electronic as well as the connected hybrid cables connected with other field bus units. An automatic data rate recognition up to 12 Mbit/s ensures a trouble-free operation of the PROFIBUS®.

Media Converter MCP12 as Panel-Feedthrough

The other terminal boxes with IP 20 fieldbus modules are integrated into the optical PROFIBUS® network as well by means of the media converter. The high degree of protection of the device (IP 65) offers a secure use in rough industrial environments.

Connected Drives and Pumps

Connected Drives and Pumps

The DESINA® conception plans for the machine installation and maintenance a plug-in connection for all components, also for motors according the industrial standard Han® 10E. The connector insert is assembled on the motor side in an angled housing, that was designed to replace the terminal box. Star and delta circuits can be realised in the female connector. In case of a defect, the motor can replace in a short time. So down times are reduced and therefore the losses due to production stop are considerably reduced. The picture besides shows the pumps of the facility for cooling lubrication.

Reflect on Costs

Reflect on Costs

One of fundamentals of DESINA® is the reduction of the total costs of a machine under consideration of material-, installation- and maintenance costs. For a gear grinding machine Kapp has drawn up the following economical calculation:

The material costs have increased by up to 15 % but the installation costs were reduced by 41 %. For the considered compact grinding machine there already is a saving potential of almost 10 % for the sum of material and installation costs. Additionally there were extended diagnosis functionalities of the decentralized field bus components realized without any extra costs. At the same time the space requirement for the installation has been reduced by 40 %. When looking at the costs, additional savings through the reduction of the component range, eased service due to the improved diagnosis and the avoidance of installation failures were not considered.

The result shows if considering the total costs, the DESINA® concept for the standardization and decentralization for installation of machines and systems the forecasted savings can be achieved.