Girbau optimises the energy efficiency of its automated ironing line in collaboration with SMC. Sustainability and reduction of energy consumption have been key values for Girbau for many years. The company has recently launched a new ironing unit that is part of a complete automated line. Close collaboration between Girbau and SMC has made it possible to improve ironing quality and achieve an energy saving of 30%, a reduction of 25% in compressed air consumption and a 25% increase in the useful life of textile coatings.   Girbau, whose headquarters are in Vic (Barcelona), is the world's fifth-largest manufacturer of industrial laundry solutions: washing, ironing and drying systems. The company operates in more than 100 countries and has 15 subsidiaries in Europe, the Americas, Oceania and Asia. Throughout its 60 years of history, it has maintained the values of a family company since its beginnings, placing people and closeness to its customers at the core of its activities. Its firm commitment to innovation, energy efficiency and sustainability make Girbau a leading company in its sector. As part of its product range, Girbau develops and manufactures ironing lines. These lines are made up of 4 units: a front feeder that leads to the ironing unit, which we will talk about below, followed by the folder and stacker. These lines, which may measure as much as 15 metres long and 4 metres wide, iron and fold up to 1,200 articles per hour. Optimisation of the ironing line was carried out in two countries: the ironing unit was optimised by Girbau Spain and optimisation of the other 3 units was performed in France. In both cases, Girbau could rely on the unconditional support of SMC. Optimisation of the ironing unit "Our modular ironing machines for drying and ironing (heaters) handle fabrics of many different kinds, from napkins to tablecloths and duvet covers". "The wide variety of these fabrics made it necessary to redesign the heater to ensure the best result with any type of item. We wanted this improvement in quality to go hand-in-hand with an increase in energy efficiency, which always guides our designs", according to Quim Riera, the product manager for ironing equipment at Girbau. Quim Riera, product manager for ironing equipment at Girbau The ironing unit is based on a rigid steel bed, which is heated internally, on which a perforated roller with a textile coating turns. The turning of the roller slides the item being ironed over the interior face of the bed. Drying and ironing of the item takes place due to evaporation of the water in the item because of the temperature of the bed and the pressure that the roller exerts on it. "Process optimisation was based on introducing 6 pressure levels in the ironing rollers. Application of the correct pressure on each fabric guarantees customers that the various items will suffer less, thus increasing the quality of their finish. In energy terms, it translates into a reduction in consumption of up to 30%," Quim Riera added. Customised solutions and complete "plug and play" modules Large pneumatic actuators were installed in each heater, capable of handling heavy loads up to as much as 2,400 kg and ensuring correct movement of the item through the different modules as the residual humidity is eliminated until it is perfectly ironed. "The heater produces a lot of heat and humidity during the process; so we have designed special cylinders that withstand temperatures of up to 90°C and ensure the resistance the ironing machine requires", commented Albert Albó, SMC's technical advisor for Girbau in Spain. "At SMC we are able to design, produce and assemble the cylinders in Europe; that is a great advantage, since we can supply Girbau with a tailored solution with a short delivery time. That is part of our ongoing commitment to being close to and supporting customers," Albert concluded. The installation of proportional valves in the ITV series guarantees control of the force exerted. The proportional valves are part of a customised electro-pneumatic module that was developed and assembled by SIMA (an SMC distributor and integrator). Together with the ITVs, 5-way solenoid valves, a digital pressure switch and a 3-way solenoid valve are assembled in accordance with ISO13849-1. The basic function of this set is to automatically control the pressure that the roller exerts on the item, depending on the type and thickness of the item to be ironed; the proportional valve regulates the pressure, depending on whether greater or lesser resistance is exerted when the item passes through. It also includes a safety system so that roller maintenance stoppages can be performed safely. Improvement in the ironing machine's energy efficiency "The most important thing for Girbau is customer satisfaction and this new solution has been extremely well received by the market", said Quim. "The results obtained have been palpable to our customers right from the start. The most visible aspect is the better treatment of the textile and the increase in ironing processing cycles. However, optimising the pressure produced another set of benefits such as cost reduction arising from electricity savings of up to 30% and a reduction of up to 25% in air consumption." Finally, Quim argues that "we have made an improvement to maintenance tasks for our customers due to decreased wear of parts; for example, we have increased the usage time of textile coatings in the heater by 25%". Ongoing improvement of the complete line Developing a line with 4 units involves a large number of automation tasks and it is essential to simplify the development and installation processes. These improvements were mainly carried out in France. As Patrice Subra, director of operations at Girbau Robotics in France, explains, "SMC is differentiated by its high-quality service, its fast reaction speed at all times and the high reliability of its solutions. They have supported us from the initial stages of our developments. When we define an electro-pneumatic module, SMC analyses the components that have the best size and simulates energy consumption. Through this 'fit for purpose' focus, SMC improves overall energy efficiency and reduces the cost to the end customer. We have also managed to reduce returns of defective products." SMC thus designed 20 different modules to cover all line needs. These control panels, designed to Girbau's specifications, simply need to be configured and then they are ready to be connected to the ironing unit. Delivery of customised models that are ready to connect greatly simplifies their installation, reduces assembly costs (by minimising the risk of failure during assembly, since SMC tests all of the modules before delivery) and aids purchasing processes since each module has a unique reference number. "Stock management is enormously simplified. In addition, SMC is able to supply the modules by the required deadlines," Patrice Subra added. Later, when the first prototypes are already in operation, SMC analyses consumption and helps optimise some pneumatic functions, if necessary. SMC also collaborated on improving existing lines to reduce energy consumption. "Sensors were fitted that detected the lines with the greatest consumption, resulting in an improvement in the folding process. The system that used air blades to fold sheets was replaced with a mechanised system", Patrice Subra added. "With its wide range of reliable solutions and service focus, SMC will undoubtedly be our partner in tackling future development challenges," Patrice Subra concluded.

A rebirth in the name of innovation. SMC, the world leader in pneumatic automation, and DMC Automation of Turin, which has created a robotic island equipped with SMC components, including an innovative wireless control transmission system, is a solid and stimulating technological partnership oriented towards the search for cutting-edge solutions. By Simona Recanatini   In Grugliasco, in the province of Turin, exactly in the same places where the automotive district that made the Piedmontese city famous throughout the world took shape a few decades ago, is based a company strongly projected on innovation. A challenging company that loves to try new ways and find new technological solutions to stand out and emerge in a highly competitive and complicated world like that of industrial automation today. DMC Automation, a small-to-medium-sized company that nevertheless boasts solid roots and a natural openness towards innovation, has recently moved to a new and modern location, which also marks the beginning of a new course. Let's take a step back: the history of the company began in 1972 with DNC, founded by Domenico De Caroli. In 1992 it began producing machines for the assembly of the metal structure that is in fact the 'skeleton' of car seats: it was a turning point as it marked the entry into a fundamental sector that is still one of the company's core businesses today. All the biggest car seat manufacturers, in fact, use machines supplied by the Turin-based company to make the internal structure of the seat. "We are specialized in the realization of machines for the assembly of this 'skeleton' starting from elements that are composed together and assembled to realize the supporting structure of the seat, an important piece because it allows to satisfy the main safety criteria" explains Carlo Amicilia, sales director of DMC Automation. In 2018, the owner of DNC decides to retire and is succeeded by two young entrepreneurs, Mauro Esposito and Daniele Signoretta, who take over the company and relaunch it, based on a more structured and modern organization. With the change of ownership also comes the transfer to the new headquarters in Grugliasco, a moment that for DMC takes on the symbolic role of the beginning of a new era. As a result of the new, more organised approach, ISO certification also arrives: being able to rely on procedures that follow precise standards is an important business card for DMC to show its customers. Simplify production Accelerating and simplifying the production process of different sectors using intelligent technologies is the philosophy with which DMC Automation approaches the market. "We want to work in the field of robotics and automation and we have an in-house design and manufacturing office for the machines and lines we produce. Everything we design is always pre-assembled and tested in-house and then delivered to the end customer," explains Amicilia. "Our production program is quite articulated: machines and assembly lines for the realization of metal structures of car seats but also robotized assembly and welding lines. Then there are machines and lines for assembly (with processes and technologies that allow to put the pieces together and make a finished product, which are coordinated thanks to SMC components), vision systems, material handling, testing equipment and above all machines and lines made to measure for the individual needs of our customers" explains the manager. An important partnership In order to meet the needs of its customers in a precise and timely manner, DMC relies on the support of leading partners. In this path of change that has just begun, the historical collaboration with SMC, world leader in the pneumatic automation sector, is even more important. Thanks to its expertise and constant technological innovation, the Turin-based company is able to respond to customers' requests but also to expand its field of action and approach new market niches. "SMC is a must for us, a fundamental partner and we consider their components a real standard, which facilitates us in the design and allows us to have a continuity of service, spare parts, product updates and much more" underlines Amicilia. "On the one hand, there is the certainty of the quality of their components, but we are also very satisfied with the close collaboration with their team of technicians and salespeople, with whom a real technological partnership has developed over time in both pre and post sales, which has led us to the use of new and cutting-edge products in terms of technological innovation. And this is also an important plus for our customers..." he adds. An innovative robotic island Among the machines produced in the DMC plant in Grugliasco stands out a robotized island equipped with SMC components, characterized by a control transmission system realized through wi-fi, a decidedly avant-garde innovation for the sector. Intended for a Turkish customer, it is a jewel in terms of innovation. "It is an automatic machine for the assembly and testing of a car's rear backrest locking system. It features manual loading stations with presence controls via cameras while all the assembly stations are automatic. There is also a robot for the 'transfer' from a first table to the testing table. Parts are marked and values stored on a PC for traceability. On this machine we decided to use the wireless solenoid valve system that allows us to have the I/Os on board the table without the use of the classic air-electric joint, which is subject to wear and tear, is not easy to maintain and requires a dedicated electrical cabinet that involves additional costs," explains Carmelo Todaro, Technical Office Manager. The heart of the machine consists of a series of electrical connections that are in contact via wi-fi with the central detector, which is able to manage them without contact. From phase to phase the table rotates and consequently all the groups rotate while the central pin remains fixed: every single element is therefore managed in wi-fi through SMC's innovative EX600W. Effective solutions "Many of our machines, including this robotic island, are made with rotary tables with different positions that transfer groups, subgroups or components from one workstation to another. One of the problems is the need to maintain control during movement: when moving, the table should carry electrical wires and controls. The jump on wi-fi that SMC proposed to us was really enlightening and epoch-making and allowed us to solve this problem effectively," Carmelo Todaro points out. The technological collaboration with SMC is full of new and innovative solutions. "The SMC flow switch, which monitors air consumption during machine operation, is useful for troubleshooting and monitoring the air consumption in the plant and thus evaluating energy savings. In another application, we used the SMC CKZT series air closures, which allowed us to clamp the entire diameter of the tube so that we could work evenly. Another important product that we use here in DMC are the SMC electric axes, especially the Ley series, which allows us flexibility in positioning and setting up the machine both to us during the pointing phase and to the customer in the various phases of process and part modification" concludes Todaro. Integration 4.0 A final note: all DMC machines are already designed to meet the requirements of Industry 4.0, an important plus for companies that are already oriented to a production management with sophisticated systems. "For us it is fundamental to rethink and develop new production, organizational and management processes. This is why our machines are designed to be integrated into our customers' centralized management systems. On this, a bitter reflection: p er absurd we are finding more application, from the point of view of the 4.0 philosophy, in the foreign market: our machines have all the interface modules but it is the international customers who use for example the ethernet cable to connect and manage the machines remotely, the Italians decidedly less. We currently have three lines in Morocco, Romania and Turkey, all three of which have software and IT dialogue modules to demonstrate how much these markets have grown from a technological point of view..." stresses the DMC sales manager. Published in Technè (Open Factory) October 2019, Italia, written by Simona Recanatini

Oplossingen voor de industrie. Wat zijn de overeenkomsten tussen een auto en een chocoladereep?. Robotica Compacte, lichte en energie-efficiënte oplossingen die aan uw behoeften voldoen.