Omron Magazine

Nr

Unique application
stories

New trends and developments in the market continue to have a major

impact on the requirements of machine builders all over the world. In
this issue, we show how we are addressing all these challenges. In this
magazine you can read how Omron Partners: Machine Builders and
Integrators do it.

OMRON MAGAZINE

Good morning,
It is already the third edition of Omron Magazine,
which shows the collection of description of the most
interesting implementations which have been realized in
collaboration with Omron. What makes this edition special
is its international character: it includes not only Polish
description but also Hungarian ones in order to inspire
innovative solutions our existing and potential customers.
If only your business involves machines, thats where
our solutions will help. Because we can help make your
machines become smarter, faster, more efficient, better
value, more flexible, more reliable in short, we can help
give you a serious advantage over your competitors.
These solutions are based on specialized expertise in
sensing and control automation. And more. They are
based on a heritage of working closely with our customers.
A heritage that has given us an intimate understanding of
our customers needs in a variety of distinct industries. Each
of which includes their own particular challenges, and by
working with our customers we have developed their own
particular solutions.
Nobody knows your business better than you do. In each
industry we face different challenges taking it learns us
everyday a lot. Take a look at how we can work with you.
Best Regards,
Omron Team

Spis Treci:
ARET - Production lines for sticking candle lids with a sticky tape .. ....................................................................
ARUM The rolomat is designed to manufacture flexible tapes in automatic mode .. ...................
AUTO-BAST - V1000 inverters for car lamp assembly lines and programmable G9SP
safety relay ...................................................................................................................................................................................................................
EGIS - Marking station with a laser printer and Omron-camera ............................................................................
HITMARK - Hitachi Industrial printers - reliable system for product labeling ............................................
KAPOSVAR - Wastewater treatment with Omron SX frequency inverter ......................................................
KART - Cigarette filter cutter line ...........................................................................................................................................................
GAWLIKOWSKI - Small Water-Power Stations control system with Archimedes turbines .. ..........
NEOTECH - Single spindle winding machines .......................................................................................................................
PABLO - Battery sorter .. .....................................................................................................................................................................................
PRO-AUTOMATION - Automation of integrated transport system .. ....................................................................
REMTER - HD1500 cutting-off machines .......................................................................................................................................
RIAS - Efficient, flexible and multiformat typesetting .......................................................................................................
TMA - Multiaxes miling machine - TMA millingLine as a response for modern
industry needs .........................................................................................................................................................................................................
TOOLS FACTORY - Innovation in Vacuum Thermoforming Technology ........................................................
U-R-B-A-N Milling machine DFM-200/4 ....................................................................................................................................

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OMRON MAGAZINE - ARE T

Production lines for sticking candle lids with a sticky tape

ARET has been established by Andrzej Roszkiewicz - the current owner - in January 1980. Since the early beginning, the
company has been involved in the maintenance and repair of every kind of electric motors as well as in the production of
rectifiers for battery charging and welding machines. In 2004, the company created a separate division for
automation, robotics and machine construction, run by a young dynamic team of experts.

ARET has completed many projects, among others, production lines for corrugated board pallets. In 2014, ARET received
the Omron Solution Partner certificate that proves the companys quality of projects performed with the use of Omron
systems and components. ARET employees are highly satisfied
with the ability to design and construct unusual machines
and other devices. The company ensures complete support
of industrial investments. A wide variety of solutions allows us
to deliver turnkey solutions, starting from an idea, through a
project, full integration, to implementation and support.
A line for candle packing, designed by ARET in 2014, handles
two types of conic glass. The line capacity is 7 000 items per
hour. Before the line was mounted, the process was done manually with much lower efficiency and precision. The clients
increasing demands and needs forced the company to introduce inovative changes. Automation of this process allowed
ARET to assign its employees to other, no longer monotonous
tasks. A glass candle is closed in a two-phase process with the
use of pneumatic elements and servo motors. First, a plastic lid
is put on the glass, then a tape is applied by pneumatic actuators. The key to success is to synchronize each process phase
on the turntable. This is achieved by SYSMAC automation

platform. All process is controlled by a motion controller with

PLC NJ301 that supports 2 axes of servo drives, which drive
two separate packing sections equipped with a distributed I/O
system. Machine safety is managed by a safety system that is
based on SL3300 controller, non-contact Omron door switch
as well as STO function (safe drive stop) in MX2 inverters and
Accurax G5 servo drives. The system uses EtherCAT network,
which in the real time connects crucial machine elements
such as: servo drives, three slave terminals NX with distributed
I/Os and integrate safety functions. Such a network structure
with G6 servo system ensures high efficiency and small signal
delays. For the communication with a user a HMI NB is used. It
allows for complete machine configuration and diagnosis.
The device uses complex Omron automation components
( inductive and photoelectric sensors, supply cables). Short
process time is achieved thanks to Sysmac Studio integrated
platform. The platform enables complex machine development from the automation point of view. Sysmac Studio also
makes the maintenace easy for the client. The line is also
equipped with labeling machines. At the end of the line,
there is a bar code control system installed. It consists of an
independent compact PLC controller Omron CP1L and HMI

NB 3,5 panel. It is crucial to use cheap and flexible handling of

RS 232C protocol for a bar code reader.
Thanks to the professionalism of ARET employees, and their
broad attitude towards project management, the company
quickly got new orders, and was asked to deliver the same
packing line together with two visualization HMI systems for
glass quality control.

Dane kontaktowe:
Firma ARET Andrzej Roszkiewicz
ul. Rana 12
63-004 Tulce k/Poznania
tel.: (+48) 61 879 85 09
aret@aret.com.pl
www.aret.com.pl

OMRON MAGAZINE - ARUM

The rolomat is designed to manufacture flexible tapes in

automatic mode
Rolomat TYP - AEx R/O/NP/1100 is a semi automatic winding machine for film tape, BOPP, Cast PP, LDPE, HDPE, unwoven
fabrics PES, and paper. Our rolomat is designed to manufacture flexible tapes in automatic mode, in a closed cycle. It uses
a system of three revolver winders, and this solution increases machine efficiency depending on the winder length, for
example, for a 20 m winder it is 3 rolls/min. Automatic cut-off and protection of winded roll by using a labeling machine
integrated into rolomat. It freely defines labels (width, length) with the produers logo and bar code; it saves time for
packing and eliminates the necessity to use an additional package with the producer info.

The device is used for manufacturing short winders that are

difficult to process on standard winding machines that involve
human operation. By collecting winders 10-150 m long, of
which the maximum speed is 300 m/min, we can reduce time
needed to perform winding in comparison to manual work by
200%. The machine has got a color 8 touch NS panel.
Touch control, clear high quality graphics, image processing,
TouchFinder maintenance are only some advantages of NS
models, and give possibility to use Smart Active Parts (SAP)
solution, which saves time of machine configuration, startup and maintenance. SAP stands for preset and tested visual
objects with built-in communication code. Thanks to this
we can use swipe and drop technology provided by HMI
terminal. These modern communication solutions between
the machine and operator definitely save time of the operator
work and increase efficiency.
Rolomat uses Sigma servomotors, in which there is no
space for any compromise in the scope of quality. The drive
size is 100 W 2000 W, rated speed of 1500 and 3000 r/
min with automatic motor recognition by servo drive. High
resolution encoders guarantee high flexibility and precise
synchronization of all drive axes in the machine. These energy
saving solutions compared to capacity tend to reach energy
balance, and in connection to easy handling guarantee long,
failure-free operation with positive economic balance.
The body is made of steal of laser burnt segments with 0,1
mm precision. It allows for parallelism of all co-working
machine moving parts in a way that ensures machine work
without any problems, even with very difficult manufactured
carriers/materials???. Pneumatic interlocks for winder roll

sleeves, batch roll and a cutting knife make day-to-day

operation easier and save time. Small energy consumption,
about 2,5 kW for a machine of such capacity is a solution
worth paying attention. All machine elements can be recycled.

Technical specification:
1. Max width of main wound
1400 mm
2. Max diameter of main wound
1000 mm
3. Max diameter of winding roll
400 mm
4. Max running speed
300 m/min.
5. Diameter of internal main roll sleeve
76 mm
6. Diameter of internal winding
roll sleeve
3 pcs, 49,5 mm
7. Material type
LDPE, OPP, paper
8. Material thickness
18 m 200 m
9. Power consumption
max ~ 2,5 kW
10. Power supply
400 V / 50 Hz
11. Touch terminal
NS (color 8 Omron)
automatic stop after the work is done
lateral shift regulation of the main roll with 1 mm
precision
main roll positioning
sound and visual indication
automatic control and speed readings of the tape shift
possibility to create setting libraries for processed
materials (tension power, number of meters)
co-operation with thermotransfer printer (label printing
with bar code)
co-operation with production planning system (order
acceptation, co-operation with weighting system)
12. Automatic control of belt tension
13. Automatic bonding of winding roll (material-sleeve)
14. Automatic cut-off after winding cycle
15. Winder component made in the revolver system with
tree expander shafts
16. Automatic interlock and release of sleeves of pneumatic
winder expanding shafs

Dane kontaktowe:
Arum Z.Michlewski, J.Radomski Spka jawna
95-200 Pabianice
ul.L.Okulickiego 4
tel.: (+48) 42 215 14 81
fax: (+48) 42 2031270
biuro@arum-maszyny.p
www.arum-maszyny.pl

OMRON MAGAZINE - AUTO-BAST

V1000 inverters for car lamp assembly lines and programmable

G9SP safety relay
The line is used to assembly front car lamps. V1000 inverters are used to drive four chains, and two elevators which
transport lamp assembly pallets.

Thanks to V1000 inverters with built-in safety inputs it is easier to perform electric
installation. There is no need to use additional contactors. In comparison to its older
versions, V1000 inverter is up to 40% smaller. Inverter small size allowed us to save
space in the switchbox. Omron inverter configuration is easier than ever since the
implementation of new broad CX-Drive package for drive configuration. All new
functions safe time and automatically identifies series and drive type.
This line has a lot of safety functions: safety buttons, mechanic limit switch, magnetic
limit switch and safety curtain. The installation is very complicated, this is why we
decided to use programmable safety relay G9SP-N20S. Easy programming means fast
start and easy modification. All relay inputs and outputs have built-in signal LEDs for
very fast system diagnosis.

10

Application of the fiber and colour sensors for recognition

the electric beams.
Lines carousel type is used to assembly and test electric
beams. Thanks to Omron sensors, we were able to eliminate a
very complicated mechanical solution for detecting miniature
fastenings in connectors.
Application of the fiber sensors E3X-HD series together with
precise fiber unit E32-EC31 series on the assembling and
testing line for groups of wires. With this sensors presence of
fastening in the electrical connection was tested.
E3X-HD sensor main features: Last and easy learning thanks
to Smart Tuning function. Dynamic power control function
provides highest work reliability in changeable objects and
working conditions. Signal high resolution - 2,5 higher that
standard models.
We have also used color sensors for detecting connector
body color. Sensors E3X-DAC-S series with the corresponding
fiber units detects 2 colors according to programmable logic.
Color sensors main features: White LED diode ensures the
sensor universality for each color. Short response time 60 s.
Timer function with the ability to turn output on/off with 5 s
delay. Remote learning function or learning function with one
button action.

The companys main activity is the development of

automated assembly stations and production lines
for car, electrical and food industry. We offer also a
manufacture station for assembly and test wiring
harnesses, check gauges, and tools according to the
clients needs and specification.
Our company stands for a team of high class experts on
mechanics, automation, and processing technology. This
provides us with a variety of abilities/capability.
We have our own modern machinery for even most
complicated projects. That helps us meet clients
expectations.
Our goal is to offer high quality products and services,
as well as meet the delivery deadline. We have clients
among domestic and foreign companies.
Dane kontaktowe:
Auto Bast Sp. z o.o.
ul. Wolnoci 69a
34-220 Makw Podhalaski
tel.: (+48) 33 875 75 21
fax: (+48) 33 875 75 31
kontakt@auto-bast.com
www.auto-bast.com

SOLUTION PARTNER

11

OMRON MAGAZINE - EGIS

Marking station with a laser printer and Omron-camera

Verification of printed information on pharmaceutical paper boxes using touch-screen operator interface

A sophisticated technology such as the printing of texts

and 2D codes as part of pharmaceutical packaging processes
will also require a well arranged group of easy-to-use HMI
devices in addition to the reliable technological hardware
elements (mechanical equipment, electric drive, printer,
sensors and control elements, etc.). As a solution, a large-sized
touch-screen monitor can be applied to provide an operator
interface divided into sections through which the entire
technological process can be controlled and checked.
The printing of texts (alphanumeric characters) and 2D codes
on paper boxes and the verification thereof are considered as
an essential station within the automatic packaging process
of pharmaceutical products. In this stage of the technological
process a conveyor is taking the medicinal products packed
in paper boxes to the data marking device where printing
is done by a special laser printer, the correctness of printing
is verified and assessed by a camera and at the end of the
process faulty boxes are removed from the conveyor by
means of compressed air. Finished products with faultless

printing on the boxes are packaged ready for delivery at the

end of the technological process.
Units of the data marking device
In order to control the marking phase of the packaging
process a PLC was required for operating the conveyor and
controlling the printer and the verification camera. In the
original solution a separate HMI was necessary for setting
the operation parameters of the conveyor and checking
the conveyors operation and another HMI for entering the
text and code to be printed and correcting their position. A
third HMI was also needed to check the measurement and
assessment results of the cameras shape recognition and
control system.
The units used to set up this system were a PLC of type CP1L
and of Omron-make, an FZ sensor system with camera, which
was also of Omron-make, and a special laser printer of type
D550+ manufactured by the company Domino based in
England. Due to its complicated handling and checking owing

12

mainly to the three-screen design, the relatively small system

was a bit difficult to operate.
Advantages of the touch-screen operator interface
The request of the buyer EGIS Pharmaceutical PLCs
production site (located) in Krmend, where medicines are
both produced and packaged was to simplify the operation
of the above described system. This simplification had been
performed by the staff of Omron Electronics Kft of Budapest,
Hungary, as subcontractor by using a TFT LCD touch-screen
monitor of type ELO1515L manufactured by TYCO Electronics
and designing appropriate software required for its operation.
The advantage of the solution is that all details of the box
printing technological phases are integrated into a common
screen, while all the details of the previously elaborated
operational process have been maintained. Thus, this solution
represents a very economical development on the system,
with the main advantages being the considerably simpler and
more flexible arrangement and ease of handling in addition to
the high degree of integration.
Functions of the automatic marking station
All the functions of the marking station can be seen on the
main screen which consists of six clearly separated panels. The
arrangement of the panels also follows the logical sequence
of the administrative and technical preparation, execution and
assessment of the technological process.
The first step is to log in as this will decide the intervention
possibilities available to a given user. In case of the
operators, technicians, engineers or administrative
authorisation levels certain functions are enabled or
disabled depending on the extent of accessibility allowed.
In the second step the layout form, content, position and
angle of rotation of the text to be printed can be given in
the production menu; here also the modification of all these
and the content of logging can also be given.
The third panel serves to set the production parameters
(box dimensions, dimensional tolerance, viewing the print
image).

13

OMRON MAGAZINE - EGIS

T he next panel will show in a form identical with that

worked out for the previous solution the messages related
to the stations operating condition and mode of operation
and to the manufacturing process that are continuously
being updated on the screen by the PLC unit.
The display will also show the camera images and thus
provides a colour marked visual checking possibility to verify
the quality of printing; however, upon request it will also
display all the printing-related information (e.g. position,
place and number of characters of the 2D matrix code and
text, etc.).
Finally, the system will display in a logged form all the
operator interventions, production messages and wording
information concerning the condition of the system. It is
also possible to save the logbook messages and to retrieve
earlier logged information.

is an unavoidable requirement) that are made possible by

the excellently designed cost-effective shape and character
recognition systems as a result of their extremely flexible and
versatile features.
The touch-screen operator interface has been designed as
a new and innovative development for Omrons PLC and
industrial camera products that have so far proved their
suitability excellently and been widely used; this also proves
that these products are of internationally acknowledged
quality not only in terms of control engineering, but also in
terms of visual sensing and processing.

It should also be mentioned as a further advantage of the

touch-screen operator surface developed that in addition to
its actual use in pharmaceutical factories the above solution
can also be applied in the packaging processes of food
products and drinks (practically in all technological processes
where the marking of production information and conditions

operator interface designed by Omrons staff members meets

customer expectations in all aspects. The primary reason
for that is that through its highly automated operation the
system makes the job of the people working on the medicine
packaging line considerably easier, as the operation of the
system is simple and can be easily followed thanks to the

Operational experiences
In connection with the assessment of the newly designed
marking system, Rbert Nmeth, the plant engineer of the
pharmaceutical factory had explained that The touch-screen

14

solution that integrates the adjustment, operation and control

of the functional units belonging to the marking and printing
equipment into a single screen.
The favourable experiences of the EGIS Pharmaceutical
Factory in connection with the Omron products are proven
clearly by the fact says Rbert Nmeth that out of our
6 packaging equipment used for similar purposes 4 are
equipped with cameras of Omron make, the procurement
of which had been carried out on the basis of previous
favourable experiences. This is why Omrons products were
again ordered during the design of the marking system, but
the factorys staff had not been left alone during the further
development stage, either, as the staff of the companys
representation in Hungary had also been involved in the
development work successfully.
In respect of the project concerning the marking equipment
it is worth mentioning that from the technical point of view
the implementation of the project took place in a very short
time, which, in addition to the use of the reliable products
of excellent quality could also be thanked to the high
standard of expertise and successful contribution of the staff
members working in Omrons branch facility in Budapest.
This cooperation had also proved that Omron is a reliable and
highly competent business partner in the development and
application of products and it should be emphasised that
the solution developed fully meets and in certain cases even
exceeds the customers initial requirements.
In respect of the wide use of Omron products within the
pharmaceutical industry it is very typical as plant engineer
Rbert Nmeth puts it referring to the pharmaceutical
factorys investments that the manufacturing company
offers a complete production equipment to the
pharmaceutical factory in such a manner that at the outset
of the project no information is available as to what sorts
of equipment would be used by the supplier to meet the
specified technical, economic and operational conditions.
The equipment and product mix will only be known after the
technical discussions. The situation was similar in connection
with the original design of the marking equipment, and it was
only at the end of the investment project when it could be
seen that the equipment consisted mainly of Omron products.
In the further development stage it was obvious that the
factory should seek Omrons assistance.

Dane kontaktowe:
Egis Pharmaceuticals PLC
H-9900 Krmend, Mtys kirly u. 65.
E-mail: mailbox@egis.hu
www.egis.hu

During the time since the development and putting into

operation the close connection between the pharmaceutical
factory as buyer and Omrons Budapest branch facility had
been maintained and thus modifications and other further
developments could be realised easily.

15

OMRON MAGAZINE - HITMARK

Hitachi Industrial printers - reliable system for product labeling

Failure-free verification
Modern factories put emphasis on three main factors:
quality, efficiency and the lowest percentage of rejected end
products.
A recognizable brand and aesthetic packaging is not enough
for effective sale in front of tough competition on the market.
A modern customer needs something more to make him
buy specific products. One can influence customers decisions
by modern marketing practices that rely on building mutual
relations, which support two-sided activities. Apart from
standard advertising campaigns that promote unique
product features, it may be effective to organize a lottery, a
competition or loyalty programs with attractive rewards.
As a response for these necessities we created a system
enabling all these promotional activities. Two companies
took part in this undertaing. Hitmark Sp. z o.o., a distributor of
Hitachi printers for product marking and Omron Electronics
Sp. z o.o., a producer of visual systems. Their cooperation
resulted in an innovative solution that generates alpha
numeric codes on products with high speed, which later is
verified in detail. Not only its presence is verified, but also its
readability. Incorrect or unreadable products are rejected from
production lines, and corresponding lottery codes marked in
the imprint library.
As a result, a customer receives correctly indicated products
with unrepeatable codes. In addition, it has a complete
verified library of printed and used codes. Part of them
guarantees winnings.

Visual system specification

Technical information
Production line
capacity

about 30 000/h = about. 8,3/sec

Line speed

about 100 m. /min.

the number of information marked

10 alphanumeric characters.
imprints sent systematically from imprint library on
a PC.

Application

Printing of changeable codes on the products with

an ink-jet printer and control over them with OCR
system.

Hitachi

Hardware: HITACHI RX-S printer co-working with a

PC. the printer works with an encoder and standard
optic Omron product detector. Task: Printing of
changeable information send systematically from a
remote PC.

Omron

Hardware: FH-1050 controller, FH-SC color camera

with 3Z4S-LE SV-1214V lens and IP65 body Task:
quality control and imprint corrected with the use of
OCR function. toss control of defective product

Hitmark

Integration, hardware installation and system startup. Original software for project realization

End effect

OCR time recognition for 40x15 mm area containing

10 alphanumeric characters 10-15 msec. OCR work
efficiency 99,9%

What distinguishes Hitmark Sp. o.o. from competition:

5 year guaranty
the highest reliability ratio
low operation costs
24 h technical support

16

Hitachi RX-SD160W printer specification

Parameter

RX-SD160W

Line maximum
length

to 3 lines (option: to 5 lines)

print height

2-10 mm (option 16 mm)

User interface

Screen: TFT LCD (10.4 color), podwietlany, WYSWIG

Data entering: touch screen with sound acknowledgment

Maximum printing
time (m/min) (char/s) (font 5x5,
space 1, 1 line)

188 m/min - 1256 char/s (option: 230 m/min - 2513

char/s)

Standard characters

Alphanumeric (A-Z, a-z, 0-9), symbols (27), space:

total 90

Print functions

Calendar, counter, various font types, storage capacity: 48 inscriptions (option: to 2000 - depending on
the content), etc

Bar code printing

EAN-13, Code39, ITF, NW-7, EAN-8, UPC-A, UPC-E,

code-128/EAN-128.

Communication

RS-232C to 115 200 bps (option: Ethernet)

Body

Stainless steal / IP 55

head terminal length 4 m (straight/90)

Dimensions (width x 400 x 340 x 480 mm
depth x height)
approximate weight

25 kg / 55 lbs

Options

bar code scanner connection

special communication functions, additional external
indication

individual approach to the customer needs

preferential cooperation conditions
Hitachi Online 24 remote system
free printer test on the customer line

Hitmark is an exclusive distributor of Hitachi printers

in Poland. Discover printers, which you can rely on.
Since 1975. Printers Ink - Jet type have originated from
Hitachi testing laboratory. In 1971, the first brochure was
published that described a process of creating drops from
continuous water stream with the help of vibrations and
their electric charging and deflection. First printer model
built in Continuous Ink-Jet technology was installed in
Japanese coca-cola factory.
Since then, 40 years have passed of dynamic
development and adjusting the level of our devices to
the growing industrial needs. The speed of production
lines becomes higher and higher, increased the diversity
of base for marking and care for environment determined
the way our printers had to change. Our current model Hitachi RXS - is a result of experience coming from over
80 000 successful installations all over the world. Hitachi
activities are oriented on the quality of products, which
is known all over the world, and involve discipline and
precise procedures. Hitachi companies are obliged to
manufacture goods in according to the highest Japanese
standards, and this contributes to creating the most
reliable printers on the market.
We care about our clients satisfaction, thus we offer a
chain of 110 distributors worldwide. Careful selection
of our partners provides the highest level of sale and
maintenance services. We offer solutions for even most
demanding customers and industries.
Dane kontaktowe:
Hitmark Sp. z o.o.
Industrial ink printers Hitachi Ink-Jet
ul. wietlicowa 7/9, 05-520 Konstancin Jeziorna
tel.: (+48) 22 754 10 13
fax: (+48) 22 754 10 14
serwis 24h: (0) 604 26 22 00
hitmark@hitmark.pl
www.hitmark.pl

17

OMRON MAGAZINE - K APOSVAR

Wastewater treatment with Omron SX frequency inverter

In the course of the wastewater treatment plant modernization in Kaposvar, the drive of several, already employed or
newly integrated three-phase electric motors was completed with a frequency inverter, which enables the user to change
the speed of the motor continuously. Given that the motor speed may have a direct impact on the effectiveness of the
technology driven and the quantity of energy consumed, this method made it possible to ensure the optimal operating
conditions easily and conveniently.

An important part of modern treatment technologies is to

control the dissolved oxygen level of the sewage. During the
intervention the necessary oxygen supply is ensured by means
of blowers rotated by powerful electric motors. The newly
integrated units are driven through the Omron SX type inverters
in Kaposvar.
The entire system which includes the blowers already
commissioned earlier in addition to the new ones is controlled
by the Omron CJ1 type PLC, complete with a computer display
and a user interface. The PLC is connected to the already
existing inverters and soft starters via a serial communication
according to Modbus RTU protocol, so when the new inverters
were selected, the primary concern was to ensure that they
could be matched to this network. In case of the SX series, it was
not a particular problem, since several other communication
cards are also available in addition to the Modbus RTU.
The IP54 degree of protection was also another important
expectation to ensure the protection against the unpleasant
circumstances which can be faced at waste water treatment
plants. In fact, this was the main reason why the SX model
group was selected, because the IP54 protection is standard
for each member of this group. The optionally available special
lacquering of the components and circuitry elements, which
is designed to reduce the effects of aggressive gases, provides
a further protection against external influences. The purpose
of the built-in input noise filter, which is also standard, is to
suppress the electrical network problems emerging due to the
operating principle of the
frequency inverter. An additional advantage was the surprisingly
small size of the version having the proper performance, which

made fitting the new device into the really tight space designed
for it easily, as opposed to its former counterparts which were
larger, despite their lower protection level.
The first step in the installation is matching the inverter to
the motor. This actually meant entering and setting the
necessary motor data. Our work was greatly supported by
the special auto-tuning function, in the course of which only
the characteristics listed on the nameplate of the motor had
to be entered manually the inverter measured the others
automatically. Owing to the auto-tuning function it was not
only entering the individual values absolutely indispensable for
the precise control of the motor that became easier, but the
winding was also checked. In addition, knowing the data which
are difficult to access or measure otherwise may further increase
the rate of energy saving which is definitely experienced with
frequency inverters.
Still before the first test run we entered the basic operating
characteristics the minimum and maximum speed, the
acceleration and deceleration values and characteristics and
matched the various integrated protections to the motor
and the application. This was followed by the manual first
start independently of the PLC in the course of which
we checked the rotation direction of the motor and found
that the connection of the motor and the frequency inverter
was faultless and the operational values (motor current, etc.)
were appropriate. After all this we established and tested
the connection between the PLC and the frequency inverter
and configured the inputs and outputs of the inverter. We
also developed a local control mode, which allows the user
to set the speed directly beside the machine by means of a
potentiometer. Finally, we programmed such oddments as the

18

definition of the monitors and feedback signals appearing on

the freely configurable displays according to the user needs.
Even according to the experience gained during the relatively
short period since the commissioning, the decision on the
modernization and expansion of the wastewater treatment
plant in Kaposvar seems to be justified. We do hope that the
Omron SX frequency inverters integrated will also support the
investment to promote the preservation of the immediate
neighbourhood in a quickly remunerative manner.

19

OMRON MAGAZINE - K ART

Cigarette filter cutter line

KarT sp. z o.o. is an experienced and reputable manufacturer of technological machines and devices. It also provides tool
services and complex machining of metals and other materials. Throughout 30 years of their market activities, the company
became specialised in designing and constructing complete production lines, assembly and testing equipment, control
stations and machines and devices of special purpose, dedicated for food, automotive and tobacco industry, as well as
household appliances, etc. KarT sp. z o.o. provides a complex customer care, from the design stage to the ready machine, as
regarding its assembly as well as warranty and post-warranty repairs.
One of the examples of a project executed by KarT sp. z.o.o. is
a customised cigarette filter cutter line for a tobacco industry
factory. The goal for the design and construction of the line was
to automatize the process of retrieving tobacco from defective
batches, which did not pass the intramural quality control.
This process had been manual until then, which required an
unacceptable labour and time input. The usage of cigarette
filter cutter line in the process line allowed our client to
significantly improve the effectiveness of the tobacco retrieving
process and cost reduction of the whole process.
The device has been constructed and launched in its entirety by
KarT sp. z o.o., including the design of the mechanical structure,
drawing up the controlling conception, designing and installing
of the electrical system, construction of the mechanical parts, as
well as assembly and on-site start-up.
Cigarette filter cutter line consists of a series of machines
connected into one line. The goal of the process is to retrieve
tobacco from cigarette packets. It consists of cutting through
the cigarette pack at the point of contact between the tobacco
and the filter, and then separating the part with filters from the
part with tobacco, shaking out the content of the packaging
onto the conveyor and dividing them into three separate
containers for tobacco, filters and packets. The retrieved
tobacco, wrapped in paper, is conveyed for subsequent
processing in the factory. The KarT sp. z o.o cigarette filter cutter
line consists of: side pusher with vision system, belt conveyor,
vertical band saw, turnover device, vibrating conveyor, belt
conveyor, final sieving machine.
The machine has a skid frame design. Respective modules are
built upon a steel supporting frame with adjustable covers
of the working parts. It is equipped with 3x400 V AC mains
powered electrical installation and pneumatic installation
powered with compressed air of 6 bar pressure. The line has one
integrated control system based on the Omrons components.
The operation of the line boils down to loading in a cassette
filled with packets arranged in rows. The whole row of packets
is pushed cyclically to the working area with the side pusher.

The key element of the process is to check if all the packets

are arranged in the same way, that is with filters facing the
same direction to prevent the filters from getting into the final
tobacco container. The system checking the packet orientation
is based on two Omron FQ2 vision sensors. Detection of the
incorrectly arranged packets leads to the pusher ceasing to
operate and pushing the packet out with a moving shaft
powered with a linear pneumatic servo-motor. After removing
the incorrectly oriented packet, the side pusher continues its
operation, pushing the whole row further back to the buffer
zone, from where they are moved to the belt conveyor, which
moves the product to the cutting chamber in a uniform motion.
There, the packets are cut on a vertical band saw. The part of the
packet that contains filters is moved further to a proper discards
container, while the part with the tobacco is flipped hole
downwards and its content shaken out from the packets in the
vibrating conveyor onto the belt conveyor. Tobacco wrapped
in paper, intended for subsequent processing, is transported
to the container, while the empty packets end up in another
container, in order to be discarded.
The control system has been created basing on the PLC CP1LEM30DT1-D controller in cooperation with 7-inch HMI NB7WTW01B panel by Omron. The communication between the
controller, HMI panel and FQ2 vision sensors is done through
Ethernet network with the usage of the TCP/IP protocol, which
guarantees adequate speed and reliability of data transfer, as
well as resistance to EMI and RFI distortions.
The device is universal adapted to work with packets of
different types and sizes. Machine can work with a different
packet by adjusting the moving bars and selecting an
appropriate pattern for the machine vision. Selection of the
appropriate pattern is done through the HMI panel with a
database of patterns, together with photographs of every
packet, programmed in the FQ2 sensors. The usage of two
FQ2 vision sensors allows for saving twenty-four patterns of
packets and taking photographs from two different angles, with
different lighting and different filter settings according to the

20

requirements for each packet.

The functionality of the HMI panel software allows changing
the packet pattern in the machine vision, insight into error
messages, informing the operator about any irregularities in
operation, damages to sensors, exceeding the programmed
limitations, etc., controlling the pneumatic actuators and drives
in the manual mode (which allows for a significantly easier
calibration and servicing), and preview of the digital inputs and
outputs in the PLC controller. The registered data is saved on
an external USB memory device and can be used to prepare
shift reports and carrying out manufacturing and maintenance
analyses. Access to particular HMI panel functions is regulated
with password-protected access levels, which allows for
elimination of unauthorized changes in the line settings.
The safety system is based on a set of G9SA safety relays,
integrated into one security system for the whole machine.
The implemented safety functions, designed according to
the normative requirements and based on the prepared
risk assessment, include emergency shutdown, locking the
adjustable covers during work and drive activation control. The
whole machine is created according to the safety category 3
pursuant to PN-EN ISO 13849-1 2008. The emergency shutdown
is done by e-stop push buttons, placed on the machine in a
way that allows an easy access for the operator and connected
in series with the G9SA safety relay. Cover locking has been
done with Omron door switches with D4GL-4CFA-A lock and
contactless F3S-TGR-NLPC door switches in cooperation with
G9SA safety relays. Opening of the cover is possible only with
all of the drives brought to standstill, which minimises the
probability of an accident while the machine is being operated,
reducing the risk to the acceptable level according to the
abovementioned norm. Drive system of the saw is equipped
with a certified standstill monitors used to monitor the
revolutions through the measurement of the electromagnetic
power on the winding of the motor, which guarantees the
dependability of the safety functions. After unlocking and
opening the covers, all of the drives have their power supply
cut off according to the safety category 3 requirements
pursuant to PN-EN ISO 13849-1:2008. The vibrating conveyor
and the final sieving machine are driven by vibrating induction
motors powered by Yaskawa V1000 power inverters. The
use of the frequency converters to control the motors
guarantees flexibility in the adjustments of motor operation
parameters, which allows for easy control of the angular
velocity, momentum control and setting the acceleration and
deceleration times. This turned out to be the key parameter
for ensuring that the conveyors function properly. All of the
drives are manufactured with safety inputs which considerably
simplify the design and construction of the safety circuits for

Dane kontaktowe:
KarT Sp. z o.o.
ul. gen. W. Andersa 40d
15-113 Biaystok
tel.: (+48) 85 743 30 64
fax: (+48) 85 743 75 87
bok@kart.com.pl
www.kart.com.pl
the machine, eliminating the need for cutting the power supply
off from the power inverters, which could lead to the damage
or shortening of their lifespan if happening frequently. Both the
side pusher and the belt conveyor are driven by R88M servomotor powered by Accurax G5 driver by Omron with impulse
controlling and feedback based on the incremental encoder.
Such servo-motors are characterized by small size which
minimises the space required in the control box and the space
in the machine for motor installation.
Solutions offered by Omron meet the requirements of the
Machinery Directive within the scope of operation safety
and maintenance. All the safety-related elements have their
reliability data included in attached documentation, necessary
for the post-completion verification of the safety devices.
Certificates of conformity and CE marking are also attached. The
ease of communication, small size, clear and understandable
documentation of the automation machines and the
developed technical support of Omron company allows for
easy and quick design and start-up of the machine control
system both for the simple technological machines designed
and constructed by KarT sp. z o.o., such as the assembly and
testing equipment for the plastics industry, and more complex
applications for different industry branches.
Pawe Murawski
Automation Designer

21

OMRON MAGAZINE - MEW

Small Water-Power Stations control system with Archimedes

turbines
Gawlikowski company has long-lasting experience in automation of water-power stations. The company has carried out a
project for power station in Kolonowskie which has been equipped with three Archimedes turbines. The control system is
based on CJ2M series unit that cooperates with SCADA CX-Supervisor software package
MEW Kolonowskie is built on the stage of fall of Maa Panew
River in the Kolonowskie town. A power station has three
Archimedes turbines. Our company supplied this project with
electrical power system) and automation control systems.
Automation system for power station control has to maintain
a level of upper water according to an ordinate set by the
system operator. On account of the nature of this project
it has been assumed that the power station has to be a
maintenance free object with the possibility to its remote
monitoring and electrical energy production process
controlling online. We had to design an easy and intuitive
application for managing processes in the power station,
because our client does not plan to employ qualified staff.
In order to fulfill the projects requirements we decided to use
two turbine set running with constant rotational speed and

one with steady control of rotational speed. For automation

systems we used Omron CJ2M controller and an inverter
ASC 800 series from ABB. A controller is to control the status
of electrical systems in the power station and to manage the
inverter work. For process visualization we used CX-Supervisor
software package that allows for remote supervision.
Connecting controllers to SCADA software gives the
possibility to create not only an user friendly interface for easy
object management, but also it provides invaluable diagnostic
functions and easy system adjustment to hydrological
conditions on site.
During project planning and building of MEW Kolonowskie
power station it was important to act fast in case of failure
and reduce time for power station shutdowns. In order
to achieve this, the system has been equipped with an

22

automatic diagnostics device. Simple commands shown on

CX-Supervisor allow for fast restoration of object to work via
unqualified personnel, and consequently, maximize electric
energy production .
A part of automatic control of power station is a prototype,
and because of that we had to provide possibility to remote
develop the project and introduce changes in software
installed by a programmer. The main unit CJ2M-CPU31
passed exams as a remote programmable controller, and
undoubtedly implementation of this solution brought
financial benefits and reduced time needed for development
of a power station control program (no need to wait for a
technician).
To sum up, a solution offering remote access to the control
system turned out to be exactly what our customer wanted.
Increased implementation costs very quickly resulted in
problem-free maintenance of MEW Kolonowskie, which is
synonymous with reduction of shutdowns. Products supplied
by Omron are ideal for process automation in water-power
stations. They provide high configuration flexibility and
reliability.

Gawlikowski company has experience in water-power

plant automation since 1991. Since the beginning
we cooperate with Omron, constantly developing
our systems in accordance with our partners newest
technology in automation.
Dane kontaktowe:
Gawlikowski - Rafa Gawlikowski
97-500 Radomsko
ul. Fabianiego 5B
tel.: (+48) 44 789 06 33-34
tel.: (+48) 606 669 077
biuro@mew.net.pl
www.mew.net.pl

23

OMRON MAGAZINE - NEOTECH

Single spindle winding machines

Single spindle winding machine type NCJ are universal devices used for winding elements on single spindle. They may
be used as basic machines in production plants or in services. These devises are controlled by microprocessors, and are
equipped with color touch panel for user communication.

Easy operation mode makes the machine suitable for service

application. Advanced software version makes it possible to
program an optional sequence: spindle movements, stratified
winding, pilot movements, machine stop time. If you use
software accordingly, you can perform beginnings, endings
and tapping of coils. You can use a PC to program winding
machines.

Our main problem was to select appropriate drives and

sensors defining the base point of machines. Drives have to
fulfill strict requirements, such as:
no overshooting;
possibly the smallest overshooting of point set by a
controller and real position;
follow up movement;
Omron drives and induction sensors have met our

Multispindle winding machines

Multispindle winding machines type CNW are designed to
wind coils on carcasses or ferrite cores. It has three axes XYZ
manipulator that guides wires. On the manipulator a rotary
beam is installed with wire guides. This allows for rotation of
90. It enables terminal winding in 2 surfaces. In addition, the
winding machine has wire clamps and optional scissors. For
installation of carcass and cores we use replaceable grids that
are designed to order.

requirements and over years have been successfully used not

only in our winding machines, but in almost every machine
that we produce.

Both winding machines types are programmable, and have

possibility to save settings for each product. A system software
for winding machines allows for:
program change by a receiver.
creating new programs.
user programs protected by password. Only authorized
staff may perform changes.
program modification when it is running.
Step running ( performing subsequent program lines).
movement sequence learning.

24

Neotech Sp. z o.o. exists on the market since 1989. We

produce various types of winding machines, automatic
tinning machines, measurement and monitoring
devices, automatic packing machines and complex
production lines. We also design machines according to
individual orders, and we modernize old equipment. We
have cooperated with companies from various branches,
thus we gathered wide experience in mechanical
construction and automation, and construction and
implementation of devices on site.
Dane kontaktowe:
NEOTECH Sp. z o.o.
ul. Komunalna 5
15-197 Biaystok
tel.: (+48) 85 67 55 632
tel.: (+48) 85 66 23 022
maszyny@neotech.pl
www.neotech.pl

25

OMRON MAGAZINE - PABLO

Battery sorter
Main assumptions: Sorting of various
battery types, like R03(AA), R6(AAA),
R14(C), R20(D), R9(6F22) with the capacity
of 10 batteries per second
and effectiveness of 98%.

Technical specification:
Line characteristics
EtherCAT net topology, Ethernet
Control System Description...
As a response for recycling industry needs,
a project concept has risen for an efficient
sorter for various battery types available
on market. The main assumption was
to achieve capacity of the sorting system at the level of 10
batteries per second and effectiveness of 98%.
Such strict requirements needed control components that
not only cope with such work, but also are flexible enough to
create fully functional and productive application.
After extended analysis, conversations and tests, among a
couple of global suppliers of automation components we
decided to choose Omron (see Technical specification).
A leading role in the process control was given to NJ301-1100
controller working as PLC controller, a supporting role was
given to visualization system based on FH-3050 controller
and 2 Mega pixel color FH-SC camera supported by LED FLBR13120W-H illuminators.
MX2 inverters became Shaft horses for the application,
together with EtherCAT communication modules used to
control of conveyor drives.
For database management of visual system batteries we
used a database program located on a PC. All components
mentioned are organized in a network for an easy and fast
exchange of data within group (see EtherCAT net topology,
Ethernet).
General system operating principle
All components are connected to one another, so that they
can exchange data among them. Such connection provides
unlimited possibilities for control and communication. For
data exchange between PLC-Visual system we used very

fast real time EtherCAT protocol. It is now possible to send

information from the visual system to PLC in a short time,
which along with the capacity of 10 batteries per second has a
very crucial meaning. The remaining modules, distributed IOs
and MX2 inverters, also communicate with PLC via EtherCAT.
For communication, special data frames structures have been
introduced, which send information from visual system to
PLC, from SCADA system to PLC and vice versa, as well as to
the visual system. In terms of communication via Ethernet, we
implemented UDP (User Datagram Protocol ).
Visual system learns battery types in a couple of simple steps.
First, the user defines battery parameters: type, producer,
size; next, he issues a command to the system to change
the operating mode into learning mode. After each learning
cycle, a battery picture is send to the system data of visual
and SCADA systems. Next, the operator defines which battery
types should be sorted and to which container. From SCADA
side it works the following way: from data base of learned
batteries only those are chosen that have been defined by the
operator, and later on a special data structure is sent to the
PLC controller, which takes control over correct sorting.
After sorting process is started, visual system takes pictures
of incoming batteries and analyzes them according to the
algorithm. When it recognizes a battery, it sends a defined
data structure to PLC, which does queuing of the battery
on the table of batteries recognized till it does not reach an
appropriate container. When the battery is located in the

26

right place, it is pushed from a queue with the compressed

air. If the battery is not recognized, it is send back for another
analysis.
Problems we have encountered...
For an observer, the process does not seem to be complicated.
However, during the project we have faced many adversities
and problems that we had to solve in order to achieve our
aim.
One of main problems was a huge diversity of batteries
that resulted from multiplying battery types by number of
producers. To sum up, it is about 2000 different battery types!
Processing data of such quantity is a challenge. If we take into
consideration time restrictions and high sorting capacity, this
makes us feel proud .
Luckily, the capacity of Omron visual and control systems
helped us to achieve our goal and solve the problem.

Summary...
Albert Einstein once said:
Everybody knows that something cant be done and then
somebody turns up and he doesnt know it cant be done and he
does it.
This citation correctly reflects what we have achieved. I
know that at the beginning almost nobody believed in
success of this project; however, stubbornness, knowledge,
determination and passion led us to success. Again I reached a
conclusion that Omron was a good choice both in the scope
of hardware as well as price and professionalism of people
involved.
People involved in the project:
Rafa Chojnowski PABLO company
(Project manager, PLC, SCADA)
Daniel Splny OMRON (specialist a visionary)
Bartomiej Macioek OMRON (an NJ specialist)
Piotr Piwowarczyk Freelancer (data base specialist)
Example of SCADA system window
Control cabinet view

Dane kontaktowe:
Fabryka Maszyn Pakujcych PABLO Sp. z o.o.
ul. rdlana 27,
26-065 Piekoszw k. Kielc
tel.: (+48) 41 306 16 04
tel.: (+48) 41 306 21 80
biuro@maszynypablo.pl
www.maszynypablo.pl

27

OMRON MAGAZINE - PROAUTOMATION

Automation of integrated transport, distribution and buffering

system
ProAutomation Sp. z o.o. is a continuous vision of an efficient engineering team. Our aim is to provide the highest quality
and fast implementation of automation systems. Our clients for whom we have had the possibility to implement our
solutions since we set up, speak for us. We implement over 100 projects a year.
We design and assemble control cabinets, program PLC controllers, operator panels and SCADA systems. Our strong points
are reporting systems (production, media consumption) and batch systems. Our extensive experience in the food and
chemical industries allows us to help you choose appropriate process instrumentation.
Production conditions and project guidelines
A modern plant cannot function without a modern transport
system. Together with the growth of quantity and diversity of
products, standard transport methods based on fixed linked
conveyors proved to be insufficient. In such conditions, an
investor - a company from chemical industry has decided to
modernize its existing system.
The most important requirements for the new system are:
a capability to select routes between a production machine
and any packing terminal with only one click
a capability to route production of many machines
into one buffer
verification and registration of products conformity
in accordance with the route set
automatic route switching in case of failure or
buffer overflow (considering product conformity)
scalability - the ability to expand easily by
introducing new production and packing machines
communication with an existing database system
power consumption optimization
Additional challenge has been the necessity to maintain
production continuity. That required synchronization of
assembly, electric and programming work as well as good
preparation of each implementation phase. In effect we were
able to minimize time of unavoidable downtime up to several
minutes.

A transfer system delivers product to any available buffer. This

is done by longitudinal and transverse conveyors system and
actuators with paddles.
Buffering systems are linked with packing terminals. Its main
task is to sustain constant production and eliminate short and
mid-term downtimes related to production conditions.
Buffering systems are equipped with CP1L-E controllers
which ensure independent and failure-free operation. The
system uses MX2 inverters. High flexibility is achieved by
parameterization of drives through Modbus network. Another
advantage of the communication bus is a detailed diagnosis
that allows to monitor current drives state.
NJ controller is the main processing unit for transport system.
Process control has been divided into 2 cabinet sets as a
consequence of systems arrangement and widespread. Each
set has MX2 inverters and other instrumentation necessary
for transporters drive connection. The key element is a
modular, distributed NX I/O system that communicates with
a controller via EtherCAT protocol. The same protocol is used
to exchange information with valve terminals located on
site. We used GX-JC switch and mixed star-line topology with
daisy chain connections. This enabled us to reduce amount of
cables on site. To be able to acknowledge paddles positions
we need induction sensor with wide measurement range and
compact construction. This is why we have chosen E2B series.

Systems structure and functionality

The system we have implemented can be divided according
to its functionality:
transport system
buffering systems

Flexibility and ability to parameterize the entire system,

requires information exchange between individual controllers.
For this purpose we have used master-slave communication
model and FINS/TCP commands, where NJ controller is the
master, and CP1L-E controllers are the slaves.

Production
machines

Transport
System

Buffering
Systems

Packing
machines

28

The main advantage of such solution is a possibility to easily

add consecutive slaves (buffering systems), without any
interference to the existing system.
Components used:
Our aim was to maintain the highest quality and consistency
of the system made. That is why we have chosen Omron
Electronic components and technology. Among the most
important components used we can name:
NJ301-1100 programmable controller
Modular NX-ECC201 I/O systems
Switch EtherCAT GX-JC
CP1L-E controllers
MX2 inverters - over 70
E2B sensors - over 100
One has to notice that a feature that distinguishes Omron
Electronics from other manufactures, aside from innovative
products, is complex technical support. Both in component
selection and project implementation.

Dane kontaktowe:
ProAutomation Sp. z o.o.
biuro / warsztat
ul. Annopol 4
03-236 Warszawa
tel.: (+48) 22 203 56 20
biuro@proautomation.pl
www.proautomation.pl

29

OMRON MAGAZINE - REMTER

HD1500 cutting-off machines

Thus it is not easy to find a product that guarantees reliable use and further development by its quality, components used
and applied software. Such solutions, however, are offered by REMTER company from Ktrzyn.

REMTER specializes in designing and constructing machines

that are numerically controlled. They are used to cut metal
sheets with the help of plasma stream. The company bases
its projects on proven solutions and cooperates with global
leaders, like OMRON. Since the early beginning, it has been a
priority for REMTER to design cut-off machines of the highest
quality along with reasonable prices. Starting from the
designing phase, the company takes into consideration the
needs, absorbing capacity and complexity of metal industry,
and dedicates its solutions to companies of many metal
branches. Our experience helped us to design and construct
machines that are diversified by parameters and quality,
so that we can find customers among steal construction
producers, light and medium metal industry, producers of
agricultural machines, ventilation installations and producers
of food industry devices. Such spectrum of buyers has
motivated us to diversify our offer and introduce three
different machine types: HD1000, HD1500 I HD 2000, and also
a special machine for pipe cutting GRH 23WH.
As a response for a need of high quality devices for plasma
cutting, REMTER uses advanced solutions and a possibility
to upgrade a standard machine if required. Technical
specification and materials used are very important, but also
their reaction to changes, multi functionality and simple
operation. This approach led REMTER to use advanced
solutions in plasma cut-off machines, in the scope of drive
control automation.
After extensive searchers REMTER decided for OMRON
components. The most important factors that influenced
our decision were: wide product range, components
accessibility, service quality and delivery time. OMRON has
met all requirements, and this is why our cooperation is so
productive.

REMTER HD1500 plasma cut-off machine is an interesting

device. Its electronics is almost entirely based on Omron
components. Thanks to its reliability, HD1500 is very universal,
and at the same time it cuts fast and precise. This machine can
have working place adjusted to the customers needs, from
1,5x3 m to this size repeatability. The machine working length
can be freely increased during operation, and additionally it
can have a table with mobile control station. A table with 6
sections has a system for pulling dust and fume back, and it
can be optionally equipped with filter ventilation. All machine
track have grease and maintenance-free linear slideywas,
and there is no need for the operator to clean them. Not to
mention it has an impact on the handling comfort. In this
machine series, tracks are outside table, and they are anchored
to the ground.
Long-term REMTER machine operation is owed to brush-andrifle free planetary gears. A drive is done by servo drives.
HD1500 is also universal because it can use aggregates of
different power, starting from supplies for cutting thin metals
to HD solutions for thick metals. The device can be optionally
equipped with a unit for edge scarfing or pipe turn-table.
Its multifunction is completed by simple and intuitive
maintenance. Any configuration changes can be performed
by the operator. The machine has a nesting software as
standard, which allows for simple and fast communication
between the designer and the device. As input files you can
use DFX files from any CAD software.
Electronics used in HD1500 is worth mentioning too. HD1500
cutting-off machines have a DAYLOX panel computer, motion
controller and PLC controller, and SmartStep2 digital drives.
This technology places REMTER among companies that use
the most advanced technologies for plasma stream burning.

30

The machine has a fan-free computer with integrated touch

panel Daylox for easy, effective and reliable communication
of the device with the operator. The control system thanks
to its parameters, semiconductor drive and passive cooling
is resistant to heavy conditions. Daylox uses a siliceous disc,
which is resistant to environmental conditions, especially
shock and vibrations, and in case of failure, it does spare
copies automatically on a second disc. In that way one can
easily go back to work, and exchange damaged disc for a new
one.
Excellent control of periphery systems, terminal sensors,
induction sensor and safety monitoring is ensured by Dyalox
computer together with PLC controller S1 series. This is what
has influence on the quality and reliability of the machine. The
producers warranty for this burning machine is 24 months.
We have used original Omron components for HD1500
device, they are: servo drives SmartStep2 and brush-free AC
motors. Wide parametrization range, vibration and resonance
suppression systems, electric gear and many other drive
features ensured REMTER that these are the most suitable
solutions for these machines.
It is worth mentioning that all OMRON products are handled
with one Cx-One software. Thus, system configuration, startup and maintenance have become completely problem-free.
The quality of OMRON technical support is worth mentioning.
Thanks to the cooperation with OMRON, REMTER company
manufactures reliable, failure-free and of reasonable prices
plasma cut machines.
Agnieszka Triebling-Matys

Dane kontaktowe:
REMTER CNC
ul. Budowlana 3D
11-400 Ktrzyn
Tel.: (+48) 724 341 378
www.remter.pl

31

Efficient, flexible and

multiformat typesetting
The company was established in 2006 in Swarzdz near
Pozna. At the beginning, RIAS was mainly involved in
preparing projects, technical consultancy, modernization
and implementation of industrial automation systems.

The company also designs and constructs untypical devices for various industrial
sectors. Our projects are carried out (from project, device selection and integration)
with the use of Omron components and automation systems. RIAS also offers
consultancy services with as-built documentation and maintenance trainings.
To meet the client requirements, RIAS created a division assigned to design and
develop serial machines. Since 2012, RIAS has produced, among others, RI-600
typesetting and joining press machine, RS-600 piling machines and internal
transport conveyors. These changes in production quantity forced us to expand our
machinery park. We had to buy machine tools like milling machines, turning lathes
and tool center from Bridgeport.
RI 600 is an efficient, flexible and multiformat typesetting and joining press machine
that is used to produce packages from corrugated board for many industrial
branches. Our main clients for such devises represent milk, meat, and fruit and
vegetables industry. Machine controlling and programing has been designed so
that an operator can handle the device intuitively. RI 600 is built on the basis of
components from the most recognizable brands like OMRON, SMC, Festo, Nordson,
RITTAL, IGUS, Elesa+Ganter. Omron automation components, which base on CP1L
compact control and SmartStep2 actuator system, allowed us to achieve higher
efficiency and repetition of package assembly process. A PLC controller is connected

OMRON MAGAZINE - RIAS

32

Dane kontaktowe:
RIAS-Systemy Informatyzacji Przemysu
Mariusz Pomorski
ul. Jasna Rola 34D/9
61-609 Pozna
tel.: (+48) 600 445 889
biuro@rias.pl
SOLUTION PARTNER

with HMI NS 5 panel with Ethernet network. It enables

remote access to visualization and support from anywhere in
the world. RI 600 has MX2 inventor that allows for easy tray
forming according to the quality of impression board.
The plant expansion and company development made
RIAS available to carry out more projects at the same time,
and as a result, we increased our productivity and ability to
introduce new projects.

33

OMRON MAGAZINE - TMA

Multiaxes miling machine - TMA millingLine as a response for

modern industry needs
You have to be very precise in order to manufacture products of the highest quality. The need for new solutions is caused
by the necessity of the highest production efficiency, failure-free work and process repeatability. An 8-axial miling machine
- TMA millingLine is designed as a response for clients representing wood industry.
TMA millingLine offers:
increased quality of products,
increased production efficiency
faster processing.
Modern machinery parks require constant development
so that they can meet requirements of industrial dynamic
conditions. Modern machining centers provide us with more
and more possibilities. How to increase the milling process
precision? How to make this process shorter? And finally, how
to increase the efficiency of the whole production process?
These questions were given by TMA from Gdynia, a company
from wood industry.
A company, which is one of European leaders in designing,
manufacturing and selling windows and doors, issued a huge
challenge to TMA engineers. It was to design a machine that
would integrate 8 linear drives driven by Omron servomotors.
The reason why the company decided to implement a project
for a new machine was the need to speed up the production
process and increase quality, as well as performing many tasks
on a profile at the same time. The client has been looking for
a solution designed for performing vents in profiles of mass
production. Before a TMA solution has been introduced,
vents were performed by a universal large-size CNC milling
machine. Its main disadvantage was the use of programmable
multiaxial CNC machine tool for unchangeable operations,
which resulted in small efficiency of the machine. As a
consequence, the processing took too much time.
The customer put strict requirements towards TMA project
team: shortening processing time by 50% ( from 3 min to 1.5
min) together with preserving the machine universality.
The task was not easy. It was a challenge for us to obtain
precision demanded by the client (+/- 0,2 mm) parallel to
milling of all vent pockets, and optimization of the whole
production process. Our result was the one expected by
our client - the requirements have been achieved. Tomasz

Zakrzewski, a TMA constructor.

A new device is adjusted to perform many tasks
simultaneously, and to shorten its time. To make the process
faster, one has to process an element with the use of
three tools at the same time, and reduce their processing
movements. To allow fur such ability we used OMRON
controllers NJ series, which enable controlling of a couple of
servo drives simultaneously. Thanks to that it is now possible
to process complicated forms.
Multiaxial TMA millingLine machine is a result of months of
work of TMA team. It is based on OMRON products. They are: 8
servo drives (3x0,75kW, 4x1kW, 1x0,75), NJ301-1200 controller,
a HMI panel, SmartStep2 R88M servo.
The main goal to implement this new machine was to
maximize production quantity at clients plant. This has
been achieved thanks to shorter processing time. Also, the
company now needs less time to complete orders and reduce
storage quantities. All these factors have influence on better
product quality.
Our mission is to create innovative solutions that help our
clients to increase their production efficiency. We deliver
solutions tailored to the clients needs. Each new project is
a challenge for us, and we do our best to face it. - says Piotr
Orlikowski, TMA Vice president.

34

Dane kontaktowe:
TMA Automation Sp. z o.o.
Al. Zwycistwa 96/98
81-451 Gdynia
info@tma-automation.com
www.tma-automation.com
SOLUTION PARTNER

35

OMRON MAGAZINE - TOOLS FAC TORY

Innovation in Vacuum Thermoforming Technology

Our machines are innovative and highly technologically advanced. This allows us for fast machine adjustment to
technological changes. Today, fast change from one product type to another is crucial, and very often required by clients.

Significant innovation of our machines lies in the ability to

adjust the heating rate of each heater individually using a
touch operator panel by Omron Electronics, where you can
adjust the percentage value of each heater individually, using
the PLC by Omron Electronics, and temperature figures of
material are obtained by means of a pyrometer. Another
solution that has been implemented into our thermoforming
machines using Omron Electronics applicable servo drivers,
enabling steady regulation of clamping frame dimensions.
We have used Omron products for many years, because they
are innovative, but also easy to use, they provide easy access
to machines for operators. What is more, our supplier is a
global company for us as an international company it has a
significant meaning.
Function and parameter selection is done via NB Omron
HMI operator panel with clear graphic menu, which gives
us easy access to its basic functions. HMI panel also gives us
a possibility to set a password and choose levels of access
authorizations.
Plastic industry is constantly changing. This forces our
company to constant modifications and being up to date with
the newest technological solutions. We link our experience
with technical knowledge of Omron engineers, thus we are
ready to meet even most difficult requirements of our clients.
This is our priority.

36

The company TOOLS FACTORY is a manufacturer of

plastic processing devices. We distinguish two main
types of machines we produce: vacuum thermoforming
machine SMARTLINE and CNC milling plotters MASTER
CUT, widely applied in the production of 3D shapes and
further processing, are modern machines, well-equipped
and constructed in accordance with the requirements of
the end user .
Dane kontaktowe:
TOOLS FACTORY sp.j.
Stefanwka ul. urawia 92
05-462 Wizowna
tel.:. (+48) 22 789 01 88
fax: (+48) 22 789 07 18
info@toolsfactory.pl
www.toolsfactory.pl

37

OMRON MAGAZINE - U-R-B-A-N

Milling machine
DFM-200/4
URBAN POLSKA
URBAN Polska, a company that constructed a milling machine
for CNC seals for 8 profiles, has now launched its version for
4 profiles. The machine is now more compact and easier to
maintain.
Production of windows mainly consist of plastic windows.
Window profiles are first cut under the 45 angle, and next
they are welded together. When PCV is melted and profiles
are joined together in the temperature of 240, the seals
become overheated, hardened, and deformed in the contact
area. As a result, draughtiness may occur in the window
corners. Performing suitable milling after the profiles are
cut eliminates negative influence of welding on the seal
shape, so that they remain elastic, and the windows keep
their insulating properties. For this purpose URBAN Polska
developed in 2013 a new CNC milling, a 3-axis device type
DFM 200 based on OMRON automation. The milling machine
is adjusted to mill up to 8 profiles. After launching its first
DMF-200 milling machine, we have waited for users opinions
about the product. After we analyzed gathered material, we
started working on second version of this device. This resulted
in launching of DFM-200/4 at the end of 2014. The milling
machine has been equipped with a drive based on linear
motors in X and Y axes, and actuators in the Y ax. The number
of profiles being processed has been reduced to 4, thus
reducing the size of machine. Additionally, stable/constant
cooperation with Omron experts made machine maintenance
easier. A milling machine processes 4 profiles from one side in
one cycle.
Its work table has been reduced, but is still suitable for
elements of maximum dimensions: 200 mm wide and 150
mm high.
The milling machine has 7 touch panel. It can visualize 20
intersections of standard profiles, based on sections received
from customers in dxf format. This makes the peration easy
and enables identification. Milling of profile ends takes place
with the help of VHM 80 mm mill cutter with fast exchange
of tools on a sleeve. Profiles are inserted in the horizontal
position, and after the milling process they are further
processed at the other side. The machine has got 8 pneumatic
clamps - two per each profile. A feed of the engine takes place

38

Dane kontaktowe:
URBAN Polska Sp. z o.o.
ul. Gospodarcza 7
68-200 ary
tel.: (+48) 68 478 78 00
fax. (+48) 68 478 78 01
office@u-r-b-a-n.pl
www.u-r-b-a-n.pl

on flat linear guides with automatic and smooth regulation of

the engine rotations in the scope of 6,000 - 18,000 rotations
per minute. The machine can operate both in the left- or rightside direction. Milling of 8 profiles at the same time results in
a bigger amount of chips, so in order to reduce maintenance
shutdowns, the milling machine can be connected to the chip
stay of 1,5 kW power and a 2200 m/h capacity. The milling
machine is now available in the U-R-B-A-N worldwide sales
chain.
We have had conversations with our end users, and as a result,
we have found a new application for the machine. In October
2014, one of our machines was sent to a company that welds
windows with profiles strengthened with glass fibers, which
have to be removed from the welding zone. Tests have shown
that our machine can be used also in such difficult conditions.
The only thing we had to change was the tool.

To the machine the work of the machine,

to man the thrill of further creation.
Kazuma Tateisi, founder of Omron

Omron at a glance
Listed in Top 2000 largest companies of the globe
Omron Corporation NASDAQ: OMRNY
Top ranking in Dow Jones Sustainability Index
Thomson Reuters Top 100 Global Innovators

200.000 products ranging

input, logic and output
Sensing, Control Systems, Visualization, Drives, Robots,
Safety, Quality Control & Inspection, Control and
Switching Components

7%
Investment in Research & Development

Innovation track
record of 80 years
Top 150 global patent assignee
1.200 employees dedicated to R&D
11.000 + issued and pending patents

36.500

Working for the

benefit of society

210

Industrial Automation

40%

Automotive

15%

Components

13%

Social Systems

11%

Healthcare

11%

Environmental

10%

Employees worldwide

Locations worldwide

22

Countries in EMEA

Close to your needs

The Perfect Match

Technical training & seminars, technical support,

Automation Technology Centers, online community

LITE

Cost effective for standard industrial environment

customer service & sales support, inter-operability labs

PRO

Extra performance and and extended product mix

(Tsunagi), safety services, repairs.

PROplus For advanced and unique applications

(MyOmron), online catalogues and technical documentation,

Jeli chcesz dowiedzie si wicej,

skontaktuj si z nami:
OMRON POLSKA

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