When Curt JOA Inc. (JOA) began looking for a partner to help develop their new Dry Molded Fiber Machine Platform, they found the technological capability and know-how with Bosch Rexroth’s automation system, ctrlX AUTOMATION.
JOA, an industry leader in automated disposable hygiene product manufacturing, recently began a partnership with the global sustainable packaging company, PulPac. Inspired by principles of sustainability and innovation, PulPac invented proprietary dry molded fiber production technology and joined forces with JOA to produce a machine platform. This new Dry Molded Fiber Machine Platform would convert standard, globally available cellulose pulp into a variety of biodegradable items. These dry molded fiber products offer a cleaner, environmentally friendly alternative to single-use plastic items.
This new machine platform required controls infrastructure that would ensure consistent throughput and scale as consumer demands fluctuate. JOA required flexible and powerful automation solutions – a task ideally fulfilled by ctrlX AUTOMATION.
JOA, Bosch Rexroth and its channel partner, CMA/Flodyne/Hydradyne (CMAFH), collaborated throughout the entire build.
Nearly all required components for this project were sourced from the ctrlX AUTOMATION portfolio – from state-of-the-art hardware and software to apps and interfaces for optimal networking.
“Working on JOA’s Dry Molded Fiber Machine was definitely a team effort. Once JOA told us about this new market they were pursuing, we knew it was a forward-looking venture that we wanted to be a part of,” said Eric Roggeman from Bosch Rexroth.
The new machine platform revolutionizes dry molded fiber technology and exceeds requirements from both OEMs and end-users, while also serving as an excellent example of the breadth of the automation system ctrlX AUTOMATION.
Efficiency and sustainability were the guiding principles throughout development. At the core of the platform are 28 axes of ctrlX DRIVE, which are connected through two separate lines and powered by two high-amperage converters. These converters also act as power supplies for two banks of cost-efficient and space-saving dual-axis inverters. The power for these servo systems is distributed through a DC bus, which helps sustainably reduce energy consumption when axes aren’t running simultaneously. The result is massive efficiency gains in panel design, power, and time-to-market thanks to the compact and flexible design of ctrlX DRIVE.
All elements of the ctrlX AUTOMATION system communicate and synchronize via EtherCAT. With EtherCAT, engineers can identify, integrate, and start programming an entire network of ctrlX CORE (control), ctrlX I/O, ctrlX SAFETY, and ctrlX DRIVE devices in minutes.
The platform’s dedicated control, ctrlX CORE, utilizes the Linux-based ctrlX OS, which serves as the framework for its uniquely modular, app-based architecture. By using individual apps designed to address PLC, motion, networking, and more, the programming experience is not only simplified, but expedited. Further apps such as tools like data acquisition, organization, and visualization are available in the partner network ctrlX World.
Through a focus on simplicity throughout the design process, this machine platform includes no extraneous components. Its footprint, including cabinet space, is kept to a minimum, and only consumes power when processes are in motion. Beyond the reduced energy use, the finished machine also easily recycles its own waste – nearly all the scrap material produced in this process is recycled into fiber to be pressed again.
“The final machine platform has met every metric we’ve asked of it and that speaks to both the innovative efficiency of the ctrlX AUTOMATION portfolio and our extensive experience in developing high-performance, quality machinery,” said Phillip Kocken from Curt JOA Inc.
As industry trends and governmental regulations turn more to sustainable solutions in consumer verticals, there will be an increased need for products that are within compliance. Not only does JOA’s machine platform helps to accomplish that goal, but it serves as an important example of how Bosch Rexroth’s automation system ctrlX AUTOMATION can provide a comprehensive suite of energy efficient solutions for the most innovative of production machinery.
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