Controlling Automated Processes, Driving Efficiency
Enhancing or replacing traditionally manual processes with automated solutions is at the heart of the smart factory and what Sonderhoff is providing to a variety of markets and applications including eMobility, solar, lighting and power. Foam sealing, gasketing and potting are used to seal housings, protect electronics and provide improved system reliability by prohibiting entry of environmental contaminants. However, the traditional manual application of protective materials can be costly, time-consuming, and produce unnecessary waste.
Sonderhoff’s Smart L dosing cell completely automates the application of these materials, tapping into the power of sophisticated controls and the ability to perform automated low-pressure mixing and dosing for two- or three-component formulations. The dosing cells process the customized materials with high manufacturing quality through repeatable consistency and dimensional accuracy. The use of cutting-edge sensors and actuators provides further reassurance of reliable system quality and process regulation.
Partnering with ABB’s B&R division, Sonderhoff equipment relies on Digital EnDat encoders of the servo motors from #ABB #B&R to enable outstanding path accuracy of the servo axes when moving the mixing head. The use of an electronic plate in the servo motor offers the advantage of automatic parameterization of the servo controller to the current parameters of the connected motor.
Not only is quality exponentially improved through this level of precision, but the cost-saving potential is immense. A case study analysis illustrates the bottom-line impact in a comparison of a manually-applied gasket versus a Sonderhoff-applied formed-in-place foam gasket (FIPFG):
CASE STUDY ANALYSIS
2,000,000 pieces per year
Sonderhoff vs. Manual Application
- Material cost per gasket reduced by up to 60%
- Labor cost per part reduced by up to 30%
- Potential total cost savings of over 60% annually through labor and material cost reductions and quality improvements
As in the above example, advanced B&R control solutions such as PLCs, CNCs and Servo Drives – all managed through a single software tool – help Sonderhoff secure automation value for its global customers.
