Aluminium Laufen

Strand press operation on highest level with innovative material flow logistics

The Project

Since their foundation in the year 1927 the company Aluminium Laufen AG has developed to an important company in the metal branch of Switzerland. They built up a good reputation in the “production” sector.
The existing logistics concept for baskets was revised and extensively amplified by the companies Hermann + Hieber and Aberle Automation. Therefore a 16MN existing press was replaced by a new 27MN press. The first step was the planning phase of the new axis of logistics. The project included the complete basket transportation by a three axis basket manipulator as well as the corridor conveyor technique, the press connection, the new ageing plant, an area storage and two new multi packaging plants.
Strand press operation on highest level with innovative material flow logistics Aluminium Laufen AG Lisberg, Switzerland. The existing plants in the area of the 40MN presses have been
included into the concept for transformation of the technical set
up and for the material flow connection.
These existing plants include corridor conveyor technique, one basket manipulator, one basket stacker as well as one packing place. The control engineering of the existing plants has been overworked and adapted for the new transport conveying system.
Because of the linkage and integration to the new TLS system of both parts of the plant the material flow system is becoming extremely flexible on the most advanced technology level.

The Integrated components

First the control engineering of the existing plants have been adapted (retrofit). The Siemens S5-115U technique was replaced for a S7-400 control with connection to the TLS via Ethernet TCP/IP. The drive engineering at the basket manipulator was modified and an optical path measure system was integrated. The security installations were adapted as well. The new transport control system was integrated. It replaces the former partly automatically activated transports. It also generates and administrates an optimised material flow. The TLS is designed as redundant cluster computer system with host gateway and a monitor workstation (Client).
An extensive plant visualisation is possible via graphic surfaces and reports. It is serviceable by all clients and offers an optimal plant overview at any time. The five subordinated S7 controls (PLC) are connected to the TLS by Ethernet TCP/IP. The close-by plant operation results by portable multi panels and radio controls. The sensor system and the installed scanners are connected with the controls on field bus level (profi bus). The drive engineering of the basket manipulator provides path measure technology and intelligent convertors. The required safety engineering has been converted with the most advanced technology and according to the request profile.
The concept of the complete plant is designed to easily realise extensions and integrations of the sub systems.

The Solution

The control system engineering as well as the automation realised by Aberle Automation are based on approved standards and technologies. Customer requirements as well as the plant conditions can be adjusted exactly. The reasonable basic concept of the plant and of the control division as well as failsafe computer systems result very high plant availability.

Advantages for the customers

The complete solution of Aberle Automation contains all steps from the preparation of the fine requirements specification up to the definition of the communication interfaces, the control standards and the safety engineering. It allows the company Aluminium Laufen AG to provide standardised structures for the integrated subsystems. The continuous realised concept guarantees a permanent control and transparency of the complete production plant.