NORTH AMERICA / FELXIBLE MANUFACTURING: When Ingersoll CM Systems, Inc. of Midland, MI, USA decided to build their next generation deep fillet rolling machine, they were looking to create a more modular and expandable machine that would allow their customers to easily keep pace with evolving crankshaft sizes. Used in rough machining production to strengthen and straighten journals, a deep fillet rolling machine increases the fatigue strength of a crankshaft by up to 3 times.

Ingersoll's deep fillet rolling machines are recognized as a world leader in crankshaft manufacturing.  After evaluating and testing several I/O networking options in the market, Ingersoll determined that Balluff's new IO-Link solution would be the best option for decreasing costs and the number of components per machine.

Gary Munger, Controls Engineering Manager for Ingersoll, said "The IO-Link solution resulted in 60% cost savings compared with our previous I/O modules." The savings came from reducing the number of components used in the machine and by using the more economical IO-Link hubs. Gary added: "Reducing the number and complexity of the components also reduces the possibility of failure."

IO-Link is an open, economical technology that allows for the expansion of networked I/O devices. By using low cost, standard M12 cables, the point-to-point wiring is the most cost-effective available. Balluff's IO-Link hubs contain only the I/O circuits without the cost of the full network protocol.

The process of switching a machine's networking architecture can sometimes be a difficult and daunting task. By using IO-Link as an expansion network, Ingersoll's PROFIBUS architecture was maintained.

"Balluff supplied evaluation units for benchmark testing and the entire transition process was a relatively smooth and easy one," said Gary Munger. "By building this new generation of deep fillet machines using IO-Link technology, Ingersoll is able to pass on significant cost savings to its customers." BALLUFF