cynapse^® is an installation space-integrated solution for the digital connection of gearboxes from WITTENSTEIN alpha. The directly integrated module contains a temperature sensor and a 3-axis acceleration sensor, a computing unit for data pre-processing, a memory module for approx. 20,000 operating hours and an IO-Link communication interface. This ensures that the gearboxes can communicate with machine controllers via fieldbus interfaces using a corresponding IO-Link master and at the same time transfer their data directly to the company IT system, cloud applications or their digital twin via OPC UA. On this basis, the Smart Service cynapse^® Monitor enables the simple visualization and evaluation of operating data - including automatic teach-in of limit values and the output of alarms if they are exceeded. This means that manufacturers and operators do not have to develop their own solutions, thus saving considerable programming effort.

In addition to high positioning accuracy, it impresses with its compact design form, which enables space-saving integration. In total, more than a dozen of these right-angle gearboxes are installed in the machine - in all the driven axles: in the floating infeed, in the cam gearbox for position-accurate feeding, in the chain conveyor belt and in the outfeed belt. In the cross-sealing station, where the foil is cut and sealed, the gearbox is equipped with the cynapse^® functionality. This allows the setting of cutting knives to be monitored digitally.

The process-stable adjustment of the film cutting knives in the cross-sealing station is a tricky matter. As the trade shows are integrated directly into the sealing jaws, which are around 95 to 110 °C hot, they heat up and expand accordingly. This causes the adjustment of the trade shows to change. As a result, the quality of the cutting process can decrease and the wafer-thin foil is either not completely cut through on the outside or inside. It is true that the entire subassembly can then be replaced in just one minute and the replaced module readjusted in the workshop. But it would be better if the maintenance requirement could be indicated in good time so that the subassembly can be replaced during a break or a batch change and not only when it causes an unplanned machine downtime. With cynapse^® – integrated into the gearbox – and the Smart Services cynapse^® Monitor, just such a solution is possible.

The cynapse^® module in the CPK gearbox can measure and evaluate vibrations and peak-to-peak acceleration values in addition to temperature values. These are key indicators for the adjustment of the trade show. Values that are too high indicate that too much force is being applied in the cutting process and that there is a danger of wear on the blades, sealing jaws and sensors. They are also associated with high operating noise. If the values are too low, this indicates that the foil may not be cut completely, pizzas may not be packaged and sealed correctly and film residue may be dragged through the machine. For this reason, Schreyer Sondermaschinen is working on using data logging to record the sensor data of the gearboxes in the cross-sealing station.

Smart Service can take over and evaluate the recorded operating data. The integrated teach-in function is able to record the vibration and acceleration behavior over a defined period of time, as is typical for an I/O cross-sealing group. The software can determine and monitor individual limit values for the operating behavior of the cross-sealing station and the blade setting. The visualization of the current measured values can then be integrated into the machine's user interface and thus made directly accessible to the machine operator or service personnel. It is also possible to prepare all data as histograms and store them in the gearbox history. Schreyer Sondermaschinen is well on the way to working with WITTENSTEIN alpha and an end customer to implement automated detection and forecasting of maintenance requirements for the film cutting knives in the cross-sealing station.