Highly flexible transport systems such as the multi-carrier system offer maximum flexibility with maximum productivity. Such an automated transport system helps to optimize production processes. In cooperation with system manufacturer Rotzinger Pharmapack, the Zimmer Group has equipped a multi-carrier infeed with 32 two-jaw parallel grippers from the GEP2000 series. Specifically, this involved handling cookie packs weighing 300 grams. This complex process could be improved and made more flexible thanks to intelligent handling components.

Freely positionable and wireless

Rotzinger Pharmapack needed a gripper system that meets the requirements of linear drives for a multi-carrier system for handling individual cookie packs. The cabling in a circulation system in particular is usually a major challenge. Several grippers are installed one behind the other on the movers and move with the conveyor belt. Conventional cabling can quickly lead to a disruptive contour in the process sequence - especially when many end effectors are used, as in this case. In addition, a circulation system - like all modern automation solutions - requires a high degree of flexibility. Statically mounted communication modules for the moving end effectors prevent a smooth process flow, as the workpieces to be gripped must be in the correct position at a specific time. To maximize productivity, the system must be flexible and allow querying via the end effector in order to grip workpieces variably.

The challenge was therefore to position the grippers so that they could move freely and not hinder the smooth handling process on the system with additional cables. Zimmer achieved such flexibility of the grippers with the IO-Link wireless gripper technology; the manufacturer was thus able to ensure wireless real-time communication between the sensors and actuators of the gripper and the PLC controller. IO-Link capability was therefore another important basic requirement for the selection of the grippers. Added to this were the limited dimensions of the carrier, which specified a maximum width of just 50 millimetres.

Small installation space, large stroke

Zimmer solved the task with the GEP2010. The gripper is IO-Link-capable, can be set up quickly and easily and can be controlled wirelessly using a supplementary component. The combination of Bridge Communication Module (BCM), which is attached to the end effector, and Master Communication Module (MCM) on the PLC module ensures effective and secure communication between the partners. Data is exchanged within a few milliseconds. This fast data transfer makes it possible to achieve the cycle time required by the customer without any problems. The 32 individual GEP2010 grippers are easily supplied with energy via a non-contact power supply.