• Automated molding

    Action:

    In future a wide variety of parts will be molded using a KUKA robot and an index table station. The contract included:

    • Planning of hardware and safety systems
    • Electrotechnical design of the metering system and the robot cell with index table station
    • The software development for the HMI and robot

    At the same time we helped the customer, who was responsible for building the control cabinet and programming the PLC, to perform electrical and control system-related tasks.

    Industry:

    Plastics technology

    Achievement:

    With additional option packages for the KUKA robot, a flexible system for metering and sealant application was created, which is perfectly adapted to suit the small batches to be produced and the special applications. As per the customer's wishes, the metering system and the robot can be operated using a single visual display. This allows quick and simple recipe management when changing production process. Due to the open program structure, the end user can add program expansions for the robot at any time. The erler team meticulously accompanied the commissioning of all the system components whose working and safety zones are safeguarded by the robot option package SafeOperation.

    Technology used:

    • SIMATIC S7 300, Profinet
    • SIMATIC HMI Touchpanel TP1200 Comfort
    • KUKA 6-axis robot KR30HA
    • KUKA KR C4 controller
    • KUKA option SafeOperation
    • Pilz PNOZmulti
  • Award as Preferred System Integrator

    Action:

    Together with Stäubli, we have been developing innovative automation solutions for customers in a wide variety of industries for many years now. To ensure smooth commissioning of robotic systems, the highest level of flexibility and experience is required, as every application is different and individual framework conditions must be taken into account in the automation concept.

    Success:

    The award confirms the quality of our excellent integration services. According to Stäubli, in all the years spent working together successfully we have never disappointed them when they have recommended us as a partner. The award, which was handed over by the managing director, fills us with pride, as it is proof of our performance and our commitment to optimum customer solutions.

    Technology used:

    • Stäubli 6-axis system
    • Stäubli Scara system
    • CS8 and CS7 controllers
  • Action:

    The assignment comprised the electrical design and the software development for the robot, including the integration of the new safety systems. Before connecting the Kuka KR150L110 robot system to the existing grinding machine, we carried out a feasibility study of the planned application using simulations. An automatic stacking height management system, including the option to manually correct the stacking height, was planned as a special feature.

    Industry:

    Furniture industry / parquet flooring industry

    Achievement:

    The customer can now optimally use the second-hand robot system bought on the open market and thus compensate for the current lack of operating personnel through automation. This also allows the grinding machine to be operated over several shifts. The system's concept is so flexible that it is possible to feed different parquet tiles, with regard to both size and quantity. A highlight during this project was the successful allocation of the tasks between erler and the customer. Our customer was responsible for installing the entire gripper system and the safety enclosure and also for setting up the robot system; we undertook the entire planning, organization and coordination of the project and performed all electrical and control tasks.

    Technologies used:

    KUKA KR150L110 robot system
    KUKA KRC2 robot controller

  • Award as Preferred System Integrator

    Action:

    Together with Stäubli, we have been developing innovative automation solutions for customers in a wide variety of industries for many years now. To ensure smooth commissioning of robotic systems, the highest level of flexibility and experience is required, as every application is different and individual framework conditions must be taken into account in the automation concept.

    Success:

    The award confirms the quality of our excellent integration services. According to Stäubli, in all the years spent working together successfully we have never disappointed them when they have recommended us as a partner. The award, which was handed over by the managing director, fills us with pride, as it is proof of our performance and our commitment to optimum customer solutions.

    Technology used:

    • Stäubli 6-axis system
    • Stäubli Scara system
    • CS8 and CS7 controllers
  • Action:

    As a plant manufacture, our customer realises customer-specific automation solutions from a single source for the semiconductor and electronics manufacturing sector. To this end, 20 individual automation cells had to be linked up to form a final-assembly line. We were responsible for the entire PLC and HMI software development for individual cells. This was based on the software standard used by the customer. We were also responsible for the technical clarification and planning of the interface connection to the MES level at the operating company.

    Industry:

    Special machinery for the semiconductor and electronics manufacturing sector

    Achievement:

    With this project, we were able apply our know-how of the TIA Portal and the SIMATIC S7-1500 controller series from Siemens, as the customer had not previously used these technologies. The changeover was achieved through excellent teamwork involving five PLC programmers, of which three were members of the customer's staff, working together closely. Due to this rewarding partnership, further projects are in the pipeline. In particular, our quality awareness and the reliability and commitment of our staff were held in high regard.
    The I/O test and functional commissioning at the operating company of the final-assembly line went off smoothly. It is now possible to perform a fully automatic product changeover from the MES level.

    Technologies used:

    Siemens TIA Portal V13 SP1 with Add-On Safety Advanced
    Siemens Sinamics S120
    Siemens S7-1515F/S7-1516F

  • Action:

    To label autoinjectors, a TP80 robot with a CS8C controller from Stäubli was programmed and commissioned. A cycle time analysis was performed with SRS2013 in order to define the optimum paths. A customer-specific standard interface programmed by erler, which can also be used for future projects, connects the robot controller with the Elau PLC via Profibus DP. This was achieved in close cooperation with the machinery manufacturer's software developers. In addition, a teach-in menu for intuitive operation developed by erler was integrated into the Stäubli SP1 hand-held unit.

    Industry

    Medical equipment

    Achievement:

    The robot cell allows five different autoinjectors to be machined. To achieve this, the TP80 Fast Picker with five different grippers retrieves the parts out of a blister pack, places these on a feed unit of the rotary indexing table, retrieves the labelled and inspected part from another feed unit and sets it down in either the good or the reject parts trays. Thanks to the cycle time analysis performed at the start of the project, it was possible to meet the cycle time target of 30 parts per minute despite the limited space available and mechanical hindrances in the cell.
    Due to the teach-in menu specially developed by erler for Stäubli robots, it was possible to significantly reduce both the commissioning time and the service-related downtimes. Moreover, the operating company saves the cost of a Stäubli training course.
    The customer, who was thrilled by the result of the project, plans to implement further Stäubli systems together with erler using the standard interface and teach-in menu developed by us.

    Technologies used:

    TP80 Fast Picker from Stäubli with CS8C controller

  • The managing directors of the erler gmbh

    Action:

    Previously, erler's founder, Alois Erler, had sole responsibility for the management of the company. Now, however, his son, Jochen Erler, has been appointed as an additional managing director of the limited liability company. By taking this step, the family-run company is paving the way for a change of generations and is thus ensuring continuity in the management of the company.
    At the same time the company's name has been changed to suit the existing logo. Since 18/11/2014 the company has been registered under the name "erler gmbh automation . robotik" instead of "erler Dienstleistungen für SPS und Robotertechnik gmbh"

    Achievement:

    We are a reliable partner for our customers, providing bespoke automated production technology, and we will, of course, remain so in the future. With our personalised customer service, on-schedule project implementation, direct communication and flat hierarchal structures, we realise groundbreaking solutions with a comprehensive service portfolio. The company's founder Alois Erler has stood for this right from the beginning, as has his son, Jochen Erler, for over ten years now. With his appointment as the second managing director, the basis has been created for reliability through stability. And by renaming the company, we are paving the way for seamless communication at all levels: Legally binding corporate name and logo now speak the same language.

    Team:

    Alois Erler, Jochen Erler

  • Expansion of our services to include electrical and control cabinet design for machinery and plant equipment to be used in the USA and Canada

    Action:

    During an in-house training course on "Industrial Control Panels" lasting several days, six members of Erler's staff were taught the ropes by Underwriters Laboratories with regard to the UL standard UL 508A, which is mandatory in the USA and Canada. With the help of the certification company, they got to grips with the standard – which is written in English – and mastered its correct interpretation.

    Achievement:

    Now we are not only able to carry out electric and control cabinet design in accordance with UL 508A, but are also authorised to attach a UL label to the finished control cabinets.

    A first project covering six control cabinets was completed on schedule. The plant equipment, which is already in operation in France, successfully completed the field evaluation in July 2014. In February 2015 this plant equipment will be set up and commissioned at its final location in Rochester Hills, Michigan, USA.

    Further information:

    UL standard control cabinet design, News September 2014

  • Convinced and enthralled: Customers and interested members of the general public experience 'customer-orientated engineering' in the modern automated industrial sector at first hand

    Action:

    37 members of staff and the management team worked together to plan a multi-team project. On the 28th of September the great day arrived – with a varied program in and around the company's building, erler opened its doors to invited guests and interested members of the general public.

    Achievement:

    More than 800 visitors toured the premises in the Bubensulz industrial estate, in which the company has been located since 2010, and went home afterwards with lasting impressions.

    A comprehensive tour offered insights into the company and its range of products and services. And what was special? "The tour was designed to reflect the way we carry out our projects," explained Jochen Erler. "In other words: From the order intake to the finished automation solution". A total of ten teams presented their work using films and PowerPoint presentations, presented exhibits and explained the technologies used.
    It was also possible to admire the "fastest "four-axis robot in the world", the so-called "Fast Picker", which is designed to pick up and position as many objects as possible in the shortest possible time. The day's highlight included a 6-axis robot – which turned out to be a surprisingly difficult opponent in "Noughts and Crosses" – and a game of "Four in a Row" played with the Siemens Rack.

  • Automation of a manufacture process for injection-moulded components for various products by integrating a robot controller

    Action:

    As a full-range supplier, we were responsible for programming and commissioning the KUKU robot including the KRC2 controller as well as designing and installing the electrical system and the control cabinet. The ARBURG injection moulding machine was connected via the Euromap 67 interface.

    The system had to control a 6-cup suction gripper to remove the two-part injection-moulded components as well as a twin jaw gripper to remove the sprues. The parts are set down in four different storage positions, corresponding to the mould cavities, whereby the fill level of each parts container is controlled.
    The sprues are set down separately in order to separate the different types of plastic for recycling purposes. The run-in parts and rejects are sorted automatically and the SPC parts are sent to the quality-assurance department.

    Industry:

    Plastic gear engineering

    Achievement:

    Previously, Bauser implemented its automation solutions in-house. As the first external service provider engaged by Bauser as a full-range supplier, we were able to successfully implement the standards required. The limited space available combined with complex gripper mechanisms presented us with a unique challenge. This resulted in complicated movements to remove the parts. Moreover, as the system is used to manufacture various products, the result was a large number of awkward contours within the robot's working radius.

    The various plastic components can now be produced with a shorter set-up time, and the system can be used to its full capacity. Downtime is reduced to a minimum. The personal feedback from Michael Wahl, the head of automation at Bauser, is both an acknowledgement that we have done a good job and an incentive for the future. "The pleasant working relationship and the flexibility of everyone involved in the project was excellent throughout. Putting this task into practice has been a huge success for both sides."

    Technology used:

    • KUKA KRC-2 Controller
    • Coupling of Phoenix input/output modules via DeviceNet