Posted to News on 22nd Jul 2024, 09:03
Customised, modular machine building with Module Connect
igus Module Connect is helping machine builder Zemat to produce customised 'plug and play' modules for its Boxmat HD cardboard packaging machine, allowing the quick and smooth coupling of table modules for different sized boxes.
(See igus at MachineBuilding.Live, 2 October 2024, on stand 56)
In the super-competitive machine building industry, companies are looking for a manufacturing advantage so machines can be assembled more quickly and easily. Zemat Technology Group, a leading manufacturer of packaging machinery, has designed a modular system using the igus Module Connect system to help customers add modular stations to upgrade base machines quickly.
Module Connect from igus is a modular plug-in connector for connecting several services in one coupling, such as electric cables, fibre optic and encoder cables, and pneumatic hoses. The space-saving industrial connector is designed for plug-and-play use. Zemat designs and manufactures a range of machines such as sealing machines, cutting plotters,and industrial automation production lines. One of its biggest product lines is a cardboard packaging machine. The Boxmat HD is the most advanced and versatile in the range, allowing the customer to make short and medium production runs of different corrugated boxes by changing the table module.
A Boxmat HD customer needed a system for easy coupling and decoupling of additional modules - a feeder table. The solution needed to integrate control, communication, pneumatic, and sensor cables in a single multi-connector, that was able to mechanically connect connectors to sockets, in a modular design, allowing one of three variants to be connected to each base machine. It should be small and allow for future expansion.
Perfect outcome with Module Connect and Harting Han inserts
Zemat designed, manufactured and commissioned a bespoke solution that met all customer requirements, that combines HARTING Han inserts with the igus Module Connect. Zemat worked together with igus to develop the optimal interface: three Module Connect modules permanently mounted to the machine housing. igus selected suitable control cables (CF130.05.12.UL, CF130.05.18.UL series), communication cables in CAT5e standard (CFBUS.PVC.045 series) and pneumatic cables (CAPU.A.06.0 series) and delivered the whole system as a prefabricated cable harness.
Zemat also developed a system for precisely guiding the machine's modules so that the electrical connectors are not damaged during assembly.
The entire Module Connect system can be expanded with additional machine modules, allowing customisation of future machine versions - for example, adding an additional printer behind the feed table.
Zemat customer Klaus Rumpp was pleased with the modular solution. "Zemat supplies intelligent, reliable machines. Communication is pleasant and staff can answer all questions quickly. The goal is not short-term sales, but rather long-term customer loyalty for mutual benefit. Their obligations for this project have been fulfilled without exception. Thank you Zemat, for your support and we look forward to further cooperation."
igus UK Managing Director Matthew Aldridge says: "Module Connect was developed from direct customer feedback, that customers wanted a single, plug-and-play master connector for all services from energy to data and fibre optics, that docks to the machine with ease. It's great to see that Zemat has built a perfect working example of this. We are developing similar solutions for customers in the UK - please get in touch for more details."
Zemat is the first serial machine manufacturer in Poland to build a range of industrial machines with the Module Connect; the winner of the Red Dot Design Award in 2018.
