Mr Grünberger, what is fascinating and exciting about your field of electronics?
Electronics in special machine construction is very exciting for several reasons.For one, electronics technology is constantly evolving. There are constantly new techniques, components and innovations that drive progress in this field.
It is also exciting that special machine construction, and thus we at AKE, inevitably have to keep up with the constant renewal and rapid development of electronics. While in other industries it often takes years to update and maintain equipment, in special machine construction it is essential to adapt quickly to the latest technology. This requires constant exposure to the latest electronic developments and a high degree of flexibility.
In addition, the industry is increasingly relying on "smart" devices. The emergence of Industry 4.0 and the introduction of communication protocols such as IO-Link are good examples of this. Electronics plays a crucial role in the realisation of these intelligent systems, which enable greater networking, data analysis and automation.
Another aspect that makes electronics interesting for special machine construction is the progressive electrification of mechanical movements. In the past, for example, pneumatic or hydraulic cylinders were used for certain movements. Nowadays, these are increasingly being replaced by electric drives. This allows for more precise control, better adaptability and higher efficiency.
That sounds really exciting. What challenges can arise in the process?
There are a few challenges that can arise. First of all, given the rapid developments in electronics mentioned above, our internal AKE standards need to be maintained and kept up to date to ensure the quality and performance of the special machines.
This includes, for example, correct dimensioning. It is important to properly size the motor sizes and drive parameters to ensure optimal performance and reliability. Incorrect sizing can lead to inefficient operation or even failures.
This is where cycle time sizing comes into play. If a special machine is designed for a specific cycle time, all electronic components and systems must be correctly dimensioned accordingly. This is the only way to achieve the required production speed.
Last but not least, I would like to mention occupational safety: When working with electronics, certain safety precautions may be required, especially if high voltage is involved. Compliance with occupational health and safety guidelines is of great importance to ensure the safety of employees.
These challenges require expertise, careful planning and close cooperation between electronics engineers, design engineers and other relevant disciplines to achieve optimal results in special machine construction.
How can one ensure that the electrical equipment of a special machine is protected from electromagnetic interference?
There are some relevant measures that can be implemented. Basically, the LFS standard is to ensure that electromagnetic interference is avoided.
One effective method is to lay the control and load circuits separately. By spatially separating the lines, interference can be minimised. Already in the planning phase, care should be taken not to plan for excessive cable reserves. The cables can simply be laid separately from each other. During e-planning, only components that have suitable electromagnetic compatibility should be used. In addition, every electrical installer is trained in the use of appropriate installation methods and protective measures. This ensures that the electromagnetic compatibility (EMC) of the electrical installation is guaranteed.
So how can electrical systems in special machines be designed to be safe and reliable?
Well, there are some crucial aspects here. Electrical systems must be designed to work efficiently in continuous operation and not be overloaded. It is important to assess the performance of the components and systems in advance and ensure that they can withstand the required demands.A comprehensive safety concept is developed in advance by the e-planning department. Clear guidelines and procedures must be established for the safe operation of the electrical systems. Each electrical and pneumatic movement is calculated and a performance level is set to ensure that the systems meet the required safety standards. If the performance level is too low, new components may need to be installed to achieve a higher safety level. An example of this is the use of safe brakes that prevent uncontrolled movements during emergency braking.
In addition, it is important to regularly assess and check the electrical equipment and its components to ensure that they comply with current standards and requirements. This may include, for example, regular inspections, maintenance and functional tests.
Okay, what norms and standards are we talking about here?
There are several norms and standards that need to be considered here. Some examples areVDE-0113-1 (Verband der Elektrotechnik Elektronik und Informationstechnik e.V.):
This standard specifies the requirements for the electrical and electronic design of machines. It contains guidelines for the safety, design and testing of electronic components and systems.
EN60204-1:
This standard specifies the safety requirements for the electrical equipment of machinery. It covers the electrical structure, wiring, protection against electrical hazards and testing of electrical systems.
ESD coordination:
ESD (Electrostatic Discharge) is an important aspect of protecting electronic components. Careful planning from the outset protects the components and determines which distances must be maintained. Components that come into contact with ESD components can be painted with special ESD paint, for example.
Training according to EN61350:
This standard deals with the protection of electronic components against electrostatic discharge. Training according to this standard is important to raise awareness of the correct procedures and measures to protect against ESD damage.
In addition, we always keep abreast of current developments and updates to norms and standards in order to always meet the latest requirements.
Which control systems are best suited for use in special machines and how can they be optimally adapted?
Well, we use both Siemens and Beckhoff, for example.Siemens is a well-known supplier of controllers and offers a wide range of products for mechanical engineering. The controllers offer flexible configuration options, high reliability and a powerful programming environment. For optimum performance, Siemens controllers should be configured and programmed according to the specific requirements of the special machine. It is important to correctly set up and develop the required inputs and outputs, communication interfaces and functions.
Beckhoff also offers high-performance control systems for machine construction. The Beckhoff TwinCAT system, which is based on the PC-based control concept, enables flexible programming and extensive functions. In order to set up this system optimally, the required software modules should be selected and set. This includes setting up the digital and analogue inputs and outputs, configuring the communication interfaces and programming the desired functions.
Wow, thank you very much for this insight. How can AKE be as energy efficient as possible to minimise the impact on the environment?
We have installed a photovoltaic system on our hall roofs. With a capacity of about 300 kWp, we can ensure that we generate our own electricity from solar energy during the day when we are at capacity and can be self-sufficient. This reduces our dependence on conventional energy sources and reduces the environmental footprint of our production.We have also converted a large part of our vehicle fleet to electric and hybrid cars. Charging facilities will soon be available on our company premises so that our vehicles can be charged with our own electricity. By using electric vehicles, we reduce emissions in the transport sector and contribute to improving air quality.
At AKE, we place great emphasis on the conscious use of energy. We actively work to increase our energy efficiency and minimise our environmental impact.
What other advantages do customers have with AKE?
AKE has a dynamic, young and professional team. My colleagues and I are experts in our field and the needs of our customers are close to our hearts. We listen carefully, analyse needs and work closely with our customers to meet their expectations. In doing so, we place great emphasis on considering and adhering to the client's own standards and requirements. With our dynamism and competence, we can develop innovative solutions and overcome challenges. The Lower Bavarian hands-on mentality also prevails at AKE. This means: we are pragmatic, solution-oriented and flexible. We are known for our fast response time and our commitment to meeting our customers' needs promptly.
Through these advantages, AKE's customers benefit from tailor-made solutions, high competence, customer-oriented service and close cooperation. We are committed to building long-term partnerships.
There you have the feeling that you are in good hands. What tip would you give to current and potential customers?
One important tip is to always stay up to date with the latest technology. The world of technology is constantly evolving and it is important to keep up with the latest developments.By keeping up to date with current technologies and trends, our current and potential clients can keep their businesses competitive and reap the benefits of modern solutions. This can help them work more efficiently, increase productivity and potentially open up new business opportunities.
At AKE, we have the privilege of staying on the cutting edge of technology by working closely with our customers. Through these partnerships, we are constantly challenged to develop innovative solutions and tackle new tasks.