• Action:

    The first step was to integrate the load of the roll containers in the logistics centre with two process control systems. Every state and every function of the roll container system is shared with the two process control systems – the resulting amount of data is enormous. An additional challenge has arisen as the roll containers have structural tolerances and moreover some of them are deformed due to transport damages. Therefore the system has to be particularly robust and the software has to run smoothly, to compensate unexpected incidents.

    Beyond that we integrated the labeller together with the scanner and the wrapper into the entire process. In addition we configured the communication between the automatic feeder for the empty roll containers and the pick-up for the loaded ones with an automatic unmanned lifting truck system. As a whole there were 26 roll container systems in the logistics centre that had to be integrated this way. A special feature of this project was the international cooperation with project teams from seven countries.

    Industry:

    Logistics in the food industry

    Achievement:

    As a result of the project our customer now disposes of a fully automatic logistics centre. The roll containers are loaded order-related at 26 systems. All processes, starting with the incoming order from the branches via the loading of the roll containers up to the handing over to the forwarding agent, now run independently.

    Technologies:

    • S7-300 Saftey-CPU
    • HMI-BasicPanel
    • TIA V13
    • SEW Movi Drive
    • SEW Movi Trac
    • ProfiNet + ProfiSafe
  • Action:

    The first of two dried sewage sludge silos, that charge an incinerator in collaboration, was extensively modernized. The silo was out of order for approximately one year to realize the considerable conversion measures. During the modernization not only parts of the hardware were renewed but also the existing S7 control unit including InTouch®-visualization was switched to a Simatic-PCS7-control system.

    Now it was our task to integrate the silo into the processes. The tight schedule was our biggest challenge: We only had four hours of downtime at our disposal as the incinerator was integrated into the running production process. We integrated the available control units into an existing PCS7-environment and embedded the new hardware components. Afterwards we put the old control unit out of operation and changed the control units of the old system step by step to the new PCS7-control system.

    Moreover we integrated a MultiFlex-weighing system into the machine. This means a screw weigh feeder for the continuous dosage according to weight units. Besides we brought the whole system up to date of the latest guidelines according to the requirements for explosion-proof zones to receive the necessary certification of the Technical Inspection Agency.

    To realize such complex works in limited time an optimal planning is of the utmost importance. Therefore we had constructed the whole system in EPLAN P8 and inserted a new customized designation code.

    Industry:

    Construction, stone and soil

    Achievement:

    With the new control unit the combustion process runs more constantly in collaboration with the second silo than before. Therefore it is possible to burn more dried sewage sludge thanks to an improved redundancy. The new system also prevents down times during maintenance work.

    Moreover the system was updated with the latest safety technology according to the latest guidelines.

    It makes us a little proud that we kept the tight schedule for the conversion of the system: The topical realization of the works went completely according to plan.

    Besides it was the first project with a PCS7 control unit. Therefore we now have another system for our customers in our competence portfolio.

    Technologies:

    • Simatic PCS7
    • Simatic ET 200SP
    • ABB frequency converter, model ACS355, ACS880
    • MultiFlex-screw weigh feeder
    • Profinet / Profibus
  • Action:

    We, the commercial clerks, are the interface of erler: On the one side we deal with our customers’ and on the other side with our own teams’ requests.

    We make sure that everything runs smoothly.

    Inside erler we connect the different areas of our ERP-system. Modern EDP supports us in doing our work effectively. We advise our customers on the phone, make appointments and deal with the monitoring of offers. From the enquiry over the purchasing to the project completion and after-sales service: For all of our customers’ interests we are friendly and competent contacts.

    Here we are always on standby and highly flexible. If something urgent has to be done we are spontaneous and react immediately. We help our colleagues as good as we can and keep their options open. To be always up-to-date we regularly improve our knowledge and take part in information meetings.

    Achievement:

    At the linking point between our customers and our technical colleagues we take care of an all round good collaboration. Our customers profit from our good collaboration: When they are satisfied, so are we.

    Naturally we also enhance the good working atmosphere at erler. With our organization we make sure that job-sharing is practiced and that this also works: This is one example how we manage to harmonize our experience with innovations.

    We, the commercial clerks, are a team we could not wish for better. Mutual helpfulness is self-evident for us. We live according to The Three Musketeers’ motto: „All for one and one for all!” Even in our leisure time we often spend time together and we also like to organize extraordinary events for the company.

  • Action:

    For more than 50 machines that produce dialysis filters in different variations, erler developed the software according to the customer´s requirements. This software can be used as a basis for several types of machines. Here we could fall back on solid experience from previous projects and use our know-how specifically, for example for the connection to the process control system and the installation of new industrial robots.

    The systems are produced in Germany every three or four months and are also commissioned here. After the dismantling and shipping to the US the systems are assembled there with our support.

    Industry:

    Medical equipment

    Achievement:

    The procedure with proven technology guarantees short commissioning times both in Germany and the US. Here we profit significantly from the experience of previous projects.

    As the systems with the electrical installation were assembled and tested at our premises, the erler team is able to support the customer specifically with the assembling and commissioning in the US. Therefore the system´s functional safety is guaranteed in every respect.

    Technologies:

    • S7 controller
    • Industrial robots
  • Action:

    We implemented an efficient software that is able to enter and analyze an extensive amount of information for the maximum decrease of energy costs. Therefore all energy data – for electricity, hot water, water, vapour, compressed air, nitrogen and fuel oil – can now be recorded and analyzed with the greatest precision. The energy consumption is automatically allocated to the four production areas, the warehouse and laboratory as well as the administration. With this investment the foundation stone for the ISO 50001 certification was laid. Moreover our customer is now able to use the energy potential much better.

    Industry:

    Chemicals

    Achievement:

    The entry of the energy consumption is now done automatically and without gaps and replaces the weekly entry by hand and the monthly analysis. Through individualized valuations, analysis and reports the energy consumption is allocated to the individual production and working areas. Therefore our customer is now able to enter the energy costs for individual production orders and has the opportunity to realize an allocation of costs that is based on the actual energy consumption. At the same time it was possible to take specific measures for a reduced consumption due to the collected data.

    The automatically generated energy reports are sent to the energy manager, as well as the production, sales, plant and general management. The reports especially inform about the production´s energy costs and give an overview of the individual energy costs. The data provide clues to reduce the energy consumption further and therefore correspond with the ISO certification that stipulates regular energy savings regarding to the quantity that was produced.

    Due to the now received ISO 50001 certification our customer is exempted from EEG apportionment and has been able to organize itself for the stricter conditions in the future.

    Technologies:

    • B&R APROL V4.0-8
    • B&R X20CP3585
    • B&R X20AP3121
    • B&R Business-Intelligence-Suite
    • Jasper Soft
  • XTS

    Action:

    To replace the old Reis robot with a Kuka of the latest generation, we redesigned the system at our customer´s premises in two shifts. The seven-day rebuilding phase with several erler employees in two-shift operations was meticulously prepared and coordinated.

    Parts of the project were the dismantling of the old robot as well as the assembly of the new robot including the gripper. The new robot´s control system was integrated into an existing PLC control system via Profibus. As there was elaborated a new safety concept this had to be considered for the planning and the assembly.

    Industry:

    Construction, Stone, Soil

    Achievement:

    Our customer recognized the downtime of only seven days as an extraordinary achievement as the dismantling and the assembly of the robot took place in tight spaces. The existing workstations didn´t have to be dismantled during this time.

    The 400 previous robot jobs could be reduced to 70. The system now again works completely automatic after the retrofit. A secure restriction of the robot´s working area is assured through KUKA.SafeOperation.

    The laboratory robot system runs 365 days round the clock and is one of the most important systems of our customer. The system is used for quality tests and assurance of rock samples.

    Technologies:

    • KUKA KRC4
    • KUKA.SafeOperation
    • Orange HMI
    • Simatic S7
    • Profibus
  • XTS

    Action:

    Beckhoff Extended Transport System consists only of a small number of components and offers an extremely flexible automation concept. The movers operate independently from each other and can be programmed due to customers´ demands and automation requests.

    For this revolutionary automation concept we have developed a software environment where XTS functions only have to be configured. In detail these are work and test stations, workspaces within a station, movers and course lengths.

    Industry:

    Cross-sector

    Achievement:

    Faster at the market with reduced lead times: With XTS and our software environment you can realize the boldest automation ideas as time-consuming programming disappears.

    The systems are space-saving and easy to handle. Each mover runs according to its task of automation. Fast production changeovers are no longer a problem. Each work station can be selected and dropped individually. In addition very low cycle times of <1 seconds can be realized.

    Besides the enormous flexibility XTS sets new standards: The magnetic system is hardly subject to attrition, the cabling effort is low and a switch cabinet is only necessary on a small scale.

    Technologies:

    • TwinCat NC PTP
    • TwinCAT XTS
    • TwinCat 3
    • Motion Control
  • 100 Robots

    Action:

    Beckhoff Extended Transport System consists only of a small number of components and offers an extremely flexible automation concept. The movers operate independently from each other and can be programmed due to customers´ demands and automation requests.

    Since the introduction of the latest generation of robots (e.g. Stäubli CS9) a safe controller has allowed the usual safeguards to be omitted if required, allowing closer interaction between man and machine.

    Industry:

    Automotive, building materials, electronics, plastics, medicine, metal, packaging, pharmaceutical, ...

    Achievement:

    Delicate contact pins, dialysis filters or two-meter-long parquet boards:
    Our robots carry out precisely defined operating sequences for a wide variety of requirements. The robots are controlled by a higher-level controller, generally a PLC. In addition, we developed the erler teach menu as a recognized standard for robots.

    We perform the application work for and the commission of the robots in a wide range of countries; the man-machine communication is provided by multilingual robot systems.

    The following feedback represents the many successful implementations at our customers. Michael Bubach from IfK Automation stressed the following: “The IfK systems can be used intuitively due to the erler control and operating concept and provides us with significant time and cost benefits.” And Steffen Fabing from Harro Höfliger Verpackungsmaschinen GmbH emphasized: “The teach menu shortens the commissioning times and also the downtimes during servicing, benefits that are indispensable for the economic processes in our company."

    Technologies:

    • Stäubli: CS7 and RX60 to RX160
    • Stäubli: CS8 and TX and TS Series, TP FAST picker
    • Stäubli: CS9 and the new TX2 generation as well as safety functions
    • Kuka: KRC 2 and KR6

    Team:

    aeh, gk, je, rr, rs, sb

  • Service campaign

    Action:

    erler restructured the service and standardized the organization as well as the processing of service requirements. A special focus was placed on the close integration of service projects into the company´s existing processes.

    The employees of the new service team use special equipment and have done a specific training for their area of responsibilities.

    Industry:

    All branches of industry that use automation systems

    Achievement:

    With the restructuring and implementation of the service section we are now able to respond efficiently to customers’ questions. Moreover there is always the same contact for our customers available. This creates confidence and provides a perfect coordination inside and outside the company.

    As this department deals with all service requirements the entire service experience can be found here – favourable to all our customers.

    Technologies:

    • Services for systems realized by erler
    • All other systems that are equipped with technologies we are familiar with.
  • management

    Action:

    With its establishment in 1995, Alois Erler laid the foundation for today's company, which is still growing continuously. In 2014 he brought his eldest son, Jochen Erler, into the management team, and now his youngest son has been appointed as the third managing director.

    Achievement:

    As a reliable partner for automation technology, we set great store by continuity and future viability. We advise personally, cultivate a policy of direct communication with our customers, and accompany every project with a comprehensive support service. Our wide range of services enables us to provide bespoke, state-of-the-art solutions. These values have been at the core of the family business for over 20 years. Holger Erler, who has been a project manager and software developer at erler gmbh for several years now, is now joining the management team. The cross-generational basis is now complete.