Under the influence of China's "Made in China 2025" plan, and with the continuous improvement of technological capabilities, more and more Chinese companies have successfully gained international market recognition with their high-quality and highly reliable equipment.
Hengchang Machinery Manufacturing Co., Ltd. is such a company. Founded in 1998, it is a Chinese company that manufactures machines and equipment for disposable hygiene products, employing approximately 400 people. The company's superior quality, high productivity, and stringent safety standards have helped it gain a foothold in the international market.
High-quality partners
To succeed in the international market, domestic equipment manufacturers, such as Hengchang Machinery Manufacturing Co., Ltd. (HCH) mentioned above, must comply with European standards and regulations. However, this requires highly specialized knowledge and extensive experience to accomplish successfully. Therefore, Hengchang Machinery Manufacturing Co., Ltd. (HCH) chose automation expert Pilz as a partner to provide assistance.
Having been immersed in the manufacturing industry for many years, HCH understands that safety and productivity should not be seen as opposing forces. Pilz China was established in Shanghai in 2006, and from the outset of its partnership with HCH, both parties reached a consensus that productivity and safety must go hand in hand. During the year-plus of cooperation with Pilz, HCH has consistently placed great trust in the flexible and easy-to-use PSS4000 automation system provided by Pilz, praising the added value the system offers in terms of operation, diagnostics, and performance.
Internationally recognized manufacturing strength
When a renowned international end-user of hygiene products lists a domestic equipment manufacturer as one of the best global suppliers, it signifies that the company possesses strong expertise and can provide the highest quality products to satisfy the brand owner. HCH has twice received the Kimberly-Clark Global Supplier of the Year award in recent years. Its diaper production equipment consists of a series of processing stations equipped with multiple feeding and processing units. The base material is pulp, made from so-called fibers, which is prepared for processing. After several processing steps and approximately 30 meters of production line, diapers emerge from the conveyor belt at an astonishing speed. After folding, the same number of diapers are packaged into units, boxed, and shipped.
Reduce complexity
Based on customer requirements, HCH initially hoped to use the PSS3000 programmable control system with SafetyBUSp to implement the functionality. However, at Pilz's suggestion, this was ultimately not adopted.
The PSS3000 programmable control system is not prone to serious errors, but it is not the most advanced system either. The complex modular structure and wide range of branches with various safety functions necessitate a well-structured, easy-to-program, and easy-to-operate safety control system.
Pilz's PSS4000 automation system is essentially an upgrade from the PSS3000, integrating control, sensors, operation, and monitoring into a single solution. It is highly effective in distributing control functions to peripheral devices using a mechatronics approach. The system can easily and flexibly meet demanding requirements. Safety and productivity are never mutually exclusive.
Real-time data exchange
In highly automated diaper production equipment, numerous safety-related signals need to be monitored: safety doors and top covers alone account for approximately 50, and the drive unwinding shaft presents a potential risk. In addition to further protection mechanisms, emergency stop buttons are distributed throughout the system. The actual safety tasks are performed by a central control system consisting of two PSSuniversal PLCs in the control cabinet, working in conjunction with 18 modules of the PSSuniversal distributed I/O system in the peripheral devices. The PSS4000 connects to the machine control system via Ethernet/IP protocol. Unlike the PSS3000 programmable control system, the PSS4000 automation system uses real-time Ethernet SafetyNETp for communication. It is based on standard Ethernet, which has been the performance standard for office communications for many years. However, this communication standard offers more functionality and meets all the requirements of routine industrial operations.
Furthermore, from the project planning stage to the operation stage, the PSS4000 automation system is more flexible and easier to operate.
Central Overview
The PAS4000 software platform enables quick and intuitive configuration and programming. Configuration, programming, debugging, and operation tools are all closely coordinated. Furthermore, charges are only for the functions actually used; there are no software licensing fees. The PAS4000 software platform provides operators with a centralized overview of distributed user programs at all times. Within PAS4000, all control systems in the network can be configured, programmed, and diagnosed. The simplified and unified approach to the entire project significantly reduces engineering, commissioning, and maintenance costs. Process or control data, fail-safe data, and diagnostic information are exchanged and synchronized between various automation components via Ethernet.
Hygiene advantages
However, the performance of hardware and software components alone may not be the key to Pilz winning HCH's trust. What impressed HCH more was its professional service.
From basic concepts to factory testing, Pilz assists its clients through consulting and technical support. This includes risk analysis, module selection, and software programming.
The PAScal safety calculator has proven to be an indispensable and easy-to-understand tool. It calculates the PL (Performance Level) and SIL (Security Integrity Level) achievable for safety functions on devices and machines based on the components used.
“HCH repeatedly mentioned that we earned their trust. Their recognition stemmed from our comprehensive consulting approach, the application of the PSS4000 automation system, and the advantages it brings,” said Yin Zhiyao, Senior Application Engineer at Pilz Shanghai, reflecting on the project. HCH highly valued Pilz's continued service to the customer after delivering the hardware and software, far exceeding the delivery date.
HCH was ultimately equipped with state-of-the-art diaper manufacturing equipment, receiving high praise for its improved quality and productivity. Pilz China understands the significant advantages users enjoy in integrating the PSS4000 automation system, including safety and convenience. In short, all these advantages enhance users' competitiveness, particularly in the North American and European markets. This is why Pilz and its automation solutions and services will continue to be an important partner for HCH in the future.
