Beckmann Automation, based in Ochtrup, Münsterland, develops and builds automatic machines for the production of mattresses as well as for the manufacture of conveyor belts and car seat belts. The family business with its 25 permanent employees supplies mattress and webbing manufacturers all over the world. But with the coronavirus crisis, sales slumped here too, machines were not accepted and new orders failed to materialize. To avoid having to put its employees on short-time working, the company decided to use its expertise in textile manufacturing processes and start producing the urgently needed face masks.

With the XV300 and the Xsoft-Codesys programming software, changes could be made to the control system. © Eaton

The fact that Beckmann's machines are modular in design was an advantage - this meant that the system for mask production could be implemented relatively quickly by combining existing sub-processes. The XV300 operating and control unit and the XN300 I/O system from Eaton played a central role here: the HMI/PLC combination device controls the entire system, collects and processes the information from the sensors and sends the travel commands to the servo controllers of the stepper motors. The embedded technology of the XV300 enables high cycle rates in the sub-processes of Beckmann's systems. With the XV300 and the Xsoft-Codesys programming software, changes to the control system could be implemented quickly and easily.

Beckmann has connected the ultra-compact XN300 I/O system to the multi-touch panel via Can bus, whose fast backplane communication enables response times of less than a millisecond. In addition, the I/O system's wide range of functions and variants reduces device costs and enables a system solution in the smallest of spaces. The XN300-Assist software tool allows the system to be configured quickly and tested in advance during commissioning. The mounting concept in combination with the push-in connection technology also makes wiring and commissioning easier.

"Speed was of the essence in this project. With the automation devices and the direct line to Eaton, an idea became a new mainstay for our company within a very short time," says Kevin Beckmann, Sales and Junior Managing Director at Beckmann Automation. Today, the prototype produces 20,000 masks per shift; in the next expansion stage, this figure will rise to 40,000. Each mask is certified and has special approval from the Federal Institute for Drugs and Medical Devices. The price is also internationally competitive, at least under the current conditions. As things stand today, Beckmann has managed to keep total sales roughly the same compared to otherwise good years despite corona. as