A Chinese supplier of automotive components has used Pilz PSS 4000 systems to handle safety-related and automation control functions in fully automated robotic paint shops, thereby maximising productivity without compromising safety.
Yanfeng Plastic Omnium in Shanghai is one of China's largest suppliers of automotive components, specialising in the development and manufacture of bumpers, tailgates and mudguards. Painting the components is an important part of the overall manufacturing process, and today most paint lines for automotive components are fully automated. However, to maximise plant availability, automation and safety functions must be harmonised, which is why Pilz PSS 4000 systems have been implemented; at the heart of these control systems are PSSuniversal PLC-type automation controllers for handling both safety-related and automation control functions.
The Yanfeng Plastic Omnium automated paint shops utilise robots from Shanghai Fanuc Robot Co Ltd, together with Pilz PSSuniversal control systems, to achieve high productivity without compromising safety. The PLC control systems monitor all of the sensor technology within seven PSENslock safety gate systems. Additional PSENopt light beam devices inside the installations prevent the system from restarting if there is still an operator within the potentially dangerous area at the time.
Already the PSSuniversal PLC handles numerous safety and automation control functions, but the I/O can be readily expanded using add-on modules if required. Further benefits of the PSSuniversal enjoyed by the system builder included simple graphic programming as well as the option of more in-depth programming via the PAS4000 software platform.
In this automated paint shop application the PSSuniversal PLC is equipped with a Profibus-DP interface that transmits data such as plant diagnostics. The control system also communicates with the robot controller, so is continuously informed about the robot status. In addition to Profibus-DP, the PSS 4000 can also be integrated with other existing communication networks (such as Ethernet/IP, CANopen, EtherCAT and Modbus TCP). Following the success of the first robotic paint shops controlled by PSSuniversal PLCs, Yanfeng Plastic OmniumPlans is now planning to install five more paint lines.
Follow the link for more information about the PSS 4000 automation system.