Weidmüller Klippon® RailLaser – efficient digital engineering for a continuous value-added process

Engineering processes need to be increasingly fast, precise and efficient, therefore, a continuous value-added process is essential. At Hannover Messe 2018, Weidmüller demonstrated what a typical value-added process can look like using automatic terminal block assembly. At Hannover Messe 2019, Weidmüller is moving one step closer towards being “ready-to-robot” and presenting the Klippon^® Automated RailLaser system – a technology demonstrator for the fully-automated labeling of assembled terminal blocks. The continuous value-added process is based upon the intelligent and user-friendly "Weidmüller Configurator" (WMC) software that creates the terminal block’s digital twin. This data is used to create the individual labeling levels, and the generated data are sent directly to the Klippon^® Automated RailLaser system. All the operator needs to do beforehand is insert the assembled terminal block, which is then permanently labeled using laser technology.

Integrated approach for automated panel building

Weidmüller considers panel building to be an integrated process – from the planning stage through to installation and operation. The most recent example is the integration of a technology demonstrator for fully-automated labeling in a continuous value-added process. Particularly during times when the order books are full and there is a rising skills shortage, it is important that value-added processes are increasingly fast, precise and efficient, especially in panel building. New digitalisation and automation approaches play a fundamental role in this respect.

Weidmüller presented one such example at Hannover Messe 2018 – an automatic terminal block assembly that generates added value in the digital and automated process chain for machine and production facilities. In this demonstrator, the terminal block was supported from the configuration stage through fully-automated assembly to intra-logistics and completion. At Hannover Messe 2019, Weidmüller is going a crucial step further under the motto "Ready-to-robot", by integrating a technology demonstrator for fully-automated labeling into the existing process. The user-friendly "Weidmüller Configurator" (WMC) software ensures the consistency in the process and creates the terminal block’s digital twin. This data is used to create the individual labeling levels, which are sent directly to the Klippon^® Automated RailLaser. All the operating personnel need to do is insert the assembled terminal rail in the system and press the Start button. A data matrix code on the rear of the terminal rail ensures that the right program is called up. First of all, the Klippon^® Automated RailLaser checks the inserted terminal rail and then performs a comparison of the digital and real models. The terminal blocks, which are first assembled with markers, are then labeled directly. The colour of the markers used is of no importance; besides white and yellow, many other different coloured markers can be used for the fully-automated printing. Thanks to this option, industry-specific colour requirements and the customer’s individual colour scheme are easy to reproduce. Special markers are not required, as Weidmüller plastic markers are suitable for fully-automatic labeling.

Based on the digital twin, the Klippon^® Automated RailLaser detects the position of the marker as well as the material in each case and can therefore set the optimal labeling parameters automatically. Automated pre-assembly of the terminal rail is not essential. Manually assembled terminal rails can also be labeled without errors using the Klippon^® Automated RailLaser, due to the extensive measuring device. The benefits with regard to time, quality and costs are evident, especially for terminal rails with different terminal block contours or for several terminal blocks. Individual separation of the marker from a MultiCard mat, assignment of the marker to the correct component and snapping the marker onto the respective component are all things of the past. The Klippon^® Automated RailLaser enables time savings of up to 90%. Customers can focus their core value creation upon the areas of engineering and wiring.

Klippon^® Automated RailLaser is scheduled to go on sale at the end of 2019. The series solution allows the labeling of assembled terminal rails with a length of 100 mm to 1,200 mm.

Summary: Data consistency is an essential precondition for continuous automation in panel building. With its innovative hardware and software solutions, Weidmüller supports a continuous engineering and production workflow. And the customer gains competitive and production advantages during all phases of panel building.