Transport Tracks & Conveying Systems
Maximum Adaptivity and Speed for Machines and Production Lines
Independence of Motion for High Production Flexibility and Throughput
Wireless & contactless communication on conveying systems is crucial for creating fully automated, innovative, and competitive machine design not possible before, for packaging, assembly, logistics and material handling. CoreTigo’s IO-Link Wireless communication solution revolutionizes the industry by providing real-time, cable-grade wireless connectivity for sensors and actuators located on dynamically moving machine components. This enables devices such as grippers, pumps, and valves, which are mounted on movers or independent units within conveying systems, to perform actions seamlessly while in constant motion.
With this wireless control capability, the need for external equipment like robots and delta robots is eliminated. Consequently, a highly flexible processing system can handle diverse product and package types without interruptions, maintaining a continuous high-speed workflow. This wireless solution also reduces the requirements for changeovers, maintenance, and the physical footprint of the machinery.
By introducing this critical layer of independence, products can be processed with optimal agility and synchronization, eliminating the traditional tradeoff between capacity and flexibility in the manufacturing process.
Wireless Benefits for Transport Tracks
Adaptive, Efficient, Sustainable
Increased Capacity
Mass Customization
Footprint Reduction
Enhanced Maintenance
Increase ROI
Cost Savings
Rockwell Automation/PFM Case Study: Wireless Multi-Carrier Systems for Packaging Machines
IO-Link Wireless enhances Independent Cart Technology
The PFM Group is a world-class manufacturer of flexible packaging machinery for the food and non-food industry. PFM turned to CoreTigo and Vahle Group to enable new capabilities for a packaging machine line for a world-known food manufacturing company.
By implementing CoreTigo’s IO-Link Wireless connectivity along with Vahle’s contactless power, the three create an optimal packaging machine, with real-time control of actuators on the moving carts. Constructed on a Rockwell Automation iTRAK system, the vacuum pumps on the carts are wirelessly connected via CoreTigo’s IO-Link Wireless Bridge (TigoBridge) and controlled by the IO-Link Wireless Master (TigoMaster). The wireless bridge units and pumps are powered by Vahle’s contactless power supply. This allowed the design of an adaptable packaging machine with minimal changeover time, while increasing the speed and capacity of the machine.
The three Rockwell Automation partners participated in Rockwell Automation’s PartnerNetwork™ Conference EMEA 2024 to discuss this innovative approach. See the recording here.
The PFM Group is a world-class manufacturer of flexible packaging machinery for the food and non-food industry. PFM turned to CoreTigo and Vahle Group to enable new capabilities for a packaging machine line for a world-known food manufacturing company.
By implementing CoreTigo’s IO-Link Wireless connectivity along with Vahle’s contactless power, the three create an optimal packaging machine, with real-time control of actuators on the moving carts. Constructed on a Rockwell Automation iTRAK system, the vacuum pumps on the carts are wirelessly connected via CoreTigo’s IO-Link Wireless Bridge (TigoBridge) and controlled by the IO-Link Wireless Master (TigoMaster). The wireless bridge units and pumps are powered by Vahle’s contactless power supply. This allowed the design of an adaptable packaging machine with minimal changeover time, while increasing the speed and capacity of the machine.
The three Rockwell Automation partners participated in Rockwell Automation’s PartnerNetwork™ Conference EMEA 2024 to discuss this innovative approach. See the recording here.
Rotzinger Case Study: Wireless & Contactless Communication on Conveying Systems
Innovative & Adaptive Packaging Machinery
Rotzinger, a leading provider of packaging & cosmetics machinery, was asked by a leading food manufacturer to develop an adaptive secondary food packaging machine that meets high demands of throughput along with the ability to support multiple package and product variations, all on a single machine.
CoreTigo’s IO-Link Wireless products and technology were integrated into Rotzinger’s multi-carrier machinery, resulting in new and advanced capabilities – performing actions on products while in constant high-speed motion, driving maximum flexibility, throughput, and sustainability. The number of machines decreases as well since one machine handles various products and package designs.
An example of this machine in action and the benefits gained from it can be found in this video.
Rotzinger, a leading provider of packaging & cosmetics machinery, was asked by a leading food manufacturer to develop an adaptive secondary food packaging machine that meets high demands of throughput along with the ability to support multiple package and product variations, all on a single machine.
CoreTigo’s IO-Link Wireless products and technology were integrated into Rotzinger’s multi-carrier machinery, resulting in new and advanced capabilities – performing actions on products while in constant high-speed motion, driving maximum flexibility, throughput, and sustainability. The number of machines decreases as well since one machine handles various products and package designs.
An example of this machine in action and the benefits gained from it can be found in this video.
Cloostermans Case Study: Achieving Independence of Packaging Machines
IO-Link Wireless Empowers Independent Cart Systems
Flexible manufacturing requires on-the-move control and automation. Machine Builder Cloostermans integrated CoreTigo’s IO-Link Wireless TigoHub and TigoMaster to extend automation and flexibility offered by a Rockwell Automation iTRAK® based packaging machine.
The solution includes:
Deployment of wirelessly controlled vacuum pumps, compressed air systems, and motors on top of each shuttle
Real-time monitoring and data flow from shuttle onboard sensors to the main Logix Controller through the TigoMaster IO-Link Wireless Master.
The entire packaging machine is fully adaptive for customized production, supporting hundreds of SKUs on the fly with minimal changeover time and no size parts.
The solution utilizes Vahle Group’s contactless power system and is applicable to any independent transport track system.
Flexible manufacturing requires on-the-move control and automation. Machine Builder Cloostermans integrated CoreTigo’s IO-Link Wireless TigoHub and TigoMaster to extend automation and flexibility offered by a Rockwell Automation iTRAK® based packaging machine.
The solution includes:
Deployment of wirelessly controlled vacuum pumps, compressed air systems, and motors on top of each shuttle
Real-time monitoring and data flow from shuttle onboard sensors to the main Logix Controller through the TigoMaster IO-Link Wireless Master.
The entire packaging machine is fully adaptive for customized production, supporting hundreds of SKUs on the fly with minimal changeover time and no size parts.
The solution utilizes Vahle Group’s contactless power system and is applicable to any independent transport track system.
"Changeover is key, in the past we had machines running 24/7 for months and months, doing one SKU. Today a lot of customized products need to be handled as a variety of the machine, meaning that the changeover challenge is growing. Our clients sometimes want to change several times a day from one SKU to another, which was in the past difficult for some machines since it needs a lot of additional tweaks, but now eliminating those cables gives us the capability of doing this while the machine is at a stop or even while the machine is in motion. So it can be done very easily."
Manu Peelman
Principal Technical Program Manager
"The combination of the flexible electromagnetic product transport module we used in the customer machine and the CoreTigo technology, results in a minimal footprint and makes the line much more flexible. I’m sure, we will have many more opportunities to expand our collaboration in the future."
Andreas Graf
CEO
How Does it Work
Integration of the IO-Link Wireless System
CoreTigo’s solution provides real-time data connectivity for sensors and actuators on independent movers with no need for additional external robotics or equipment. Each mover is equipped with an IO-Link Wireless Multiport Hub (TigoHub) or IO-Link Wireless Bridge (TigoBridge) which provides multiple sensors and actuators with connectivity on the mover itself. The IO-Link Wireless Master (TigoMaster) communicates wirelessly with all the devices on the movers, and is connected to the PLC for automation control and to IoT and enterprise IT-level servers for data monitoring. CoreTigo’s unique antenna solution enables a highly reliable, scalable, and secure solution that can support communication to hundreds of movers and devices wirelessly.
With this solution, products can be processed while in constant motion in an agile and synchronized manner. Changeover and tooling setup time is minimized, enabling a single machine to handle a broad range of product types and reducing the cost and time to market of applying new types and designs. Machine footprint and maintenance overhead are reduced due to the reduction of cables, chains, belts, mechanical components, and additional external automation equipment. Communication with the movers also enables condition-monitoring capabilities and predictive maintenance.
CoreTigo’s solution provides real-time data connectivity for sensors and actuators on independent movers with no need for additional external robotics or equipment. Each mover is equipped with an IO-Link Wireless Multiport Hub (TigoHub) or IO-Link Wireless Bridge (TigoBridge) which provides multiple sensors and actuators with connectivity on the mover itself. The IO-Link Wireless Master (TigoMaster) communicates wirelessly with all the devices on the movers, and is connected to the PLC for automation control and to IoT and enterprise IT-level servers for data monitoring. CoreTigo’s unique antenna solution enables a highly reliable, scalable, and secure solution that can support communication to hundreds of movers and devices wirelessly.
With this solution, products can be processed while in constant motion in an agile and synchronized manner. Changeover and tooling setup time is minimized, enabling a single machine to handle a broad range of product types and reducing the cost and time to market of applying new types and designs. Machine footprint and maintenance overhead are reduced due to the reduction of cables, chains, belts, mechanical components, and additional external automation equipment. Communication with the movers also enables condition-monitoring capabilities and predictive maintenance.
Related Items
Wireless Connectivity & Contactless Power for Packaging Machines: Rockwell Automation Case Study
Adaptive Packaging Machine’s Multi-Carrier Track Gets Wireless Boost
AB InBev Integrates CoreTigo’s Solutions
Unbound Flexibility for Transport Tracks
Wireless Network for Manufacturing
TigoHub i4 IO-Link Wireless Multiport Hub
