Modular Flexibility and Safety in Filter Production

Turck's decentralized I/O solution networks compact systems safely and efficiently – without a central PLC and even under extreme conditions

An automotive supplier of filters is planning to use an automatic production machine that can be used to manufacture different filter variants using interchangeable machine parts. This modularity enables reduced changeover times and increased productivity, as the system can be flexibly converted to different filter variants with minimal effort. A decentralized safety and control solution is required as the compact machine platform does not offer the space for a conventional control cabinet and traditional control systems are too inflexible for making fast adjustments. All safety requirements, such as emergency stop circuits and monitoring systems, must be fully met, even without the presence of a central PLC.

Your Benefits

Flexible adaption to new production requirements.
Maximum safety without central control unit.
Fast troubleshooting and shorter maintenance times
Cost efficient and future-proof solution

Modular production cells offer maximum flexibility for different requirements
Decentralized TBEN-LL-4FDI-4FDX modules efficiently network machine parts without a central controller
The compact production machine enables flexible conversion to different filter types

Safe networking without central control

Turck's TBEN-LL-4FDI-4FDX Ethernet I/O module and Turck Safe Link protocol offer a customized solution for the flexible and safe networking of machine components – without the need for a central controller. The modules can be installed remotely at the automated machinery and use existing network cables, thus considerably reducing the amount of cabling required.

The TBEN modules communicate safely with each other via Turck Safe Link and react to safety-critical events in real time. An emergency stop signal is immediately forwarded to all modules to stop the machinery safely. This ensures the protection of employees and prevents damage.

Flexible modularity and seamless integration

Installation at critical points on the production machine, such as safety doors, flaps and emergency stop areas, ensures comprehensive safety. As there is no need for central control cabinets, the machine can be flexibly adapted to new configurations. The modular design allows up to 31 modules to be networked in order to produce different filter variants on a single machine – without any major retooling required.

The TBEN modules support standard protocols such as Ethernet/IP, Profinet and Modbus TCP, as well as the safety protocols CIP Safety and Profisafe. This multiprotocol capability enables seamless integration into existing networks and saves time and costs.

Minimum changeover times, maximum flexibility

The high modularity of the TBEN modules makes it possible to integrate new machine operations quickly and easily. Thanks to direct networking, changes are easy to implement without having to adapt the existing control system. This keeps downtimes to a minimum and enables production adaptions to be made more quickly.

Future-proof solution with cost benefit

Turck's TBEN-LL-4FDI-4FDX modules and the Turck Safe Link protocol offer a solution that adapts automated production to new requirements flexibly and maximizes safety at the same time – entirely without the need for central control cabinets or complex PLC systems. The protocol ensures a coordinated response to safety-critical events, which protects employees and protects the machine from damage. Extensive diagnostic options also ensure rapid fault detection, reduce maintenance times and increase operational reliability. This means that users benefit from a future-proof and cost-efficient solution that minimizes downtimes and increases productivity.

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