Distributed servo drive and EtherCAT P save valuable space in the machine

The new machine concept from Borghi S.p.A. based on EtherCAT P and Beckhoff´s distributed servo drive system allows the company to make a significant leap in terms of productivity for the production of brooms and brushes.

When it comes to manufacturing a broom, the brush is the most important element. Brushes consist of several rows of fibers that are threaded into what is known as a ‘lath’. Not only can these have completely different geometries, but they can also be made of different materials. “For example, the ability to process synthetic, natural, and metallic fibers all in a single plant calls for extremely high flexibility,” notes Paolo Roversi, chairman of the Italian machine manufacturer Borghi S.p.A..

“With our new generation of machines, we wanted to break with the classic pattern of phase change cycles and develop a machine concept that can operate continuously,” Paolo Roversi notes, pointing out the optimized approach to brush production. This requires a completely different machine design and an automation supplier who can handle this high level of complexity with a safe, reliable, and deterministic approach.

After evaluating various automation concepts, the decision was made in favor of Beckhoff, whose automation solutions, which include the AMP8000 distributed servo drive system and EtherCAT P, made implementation of the concept possible in the first place, recalls Paolo Roversi.

The core element is formed by four small, independent machining turrets that transfer the plates seamlessly from one machining phase to the next. Each machining turret can be flexibly positioned via five servo drives to suit the formats of the plates being processed. This concept requires compact and powerful drive technology in the form of AMP8000 distributed servo drives with integrated power electronics. A single EtherCAT P line is used to connect power and communication, including safety, which not only saves space on the turrets, but also cuts down weight.

The consistently distributed approach, with around 50% of the power electronics located directly on the machine, also has a positive effect on the footprint: despite having a total of 45 axes, the machine control cabinet is highly compact and offers sufficient space for the CX2040, the EtherCAT Terminals, and additional servo drives from the AX8000 series. Paolo Roversi enthuses, “This concept has resulted in significant savings in terms of cost, materials, space, and installation effort.”

More Informations