Schirmer Reframes Machine Design with Cabinet-Free Automation

Beckhoff’s fully machine mountable MX-System helps window profile processing machine OEM eliminate control cabinets and change the game in their industry 

While you might initially think about the construction labor behind their installation in homes and offices, the processes required to manufacture windows and doors is a seriously high-tech business. This much is evident right from the first manufacturing step, with fully automatic processing of raw bars on a profile processing machine built by Schirmer Maschinen GmbH.  

Schirmer was founded in 1979 in Verl, Germany and was Beckhoff’s first customer. The company has relied on PC-based control technology from Beckhoff for over 40 years now, from the first positioning controller to the new cabinet-free automation hardware platform, the MX-System. This fully machine mountable solution features pluggable hardware and connectorized cables, which aligns particularly with Schirmer’s machine concept: the development of custom machines based on largely standardized process modules. This helps the nimble machine builder to create customer-specific solutions with high output and flexibility in terms of profiles and processes. Schirmer has been part of Beckhoff Automation Group of companies since 2016 and currently employs around 250 people. 

Many tough jobs, one profile processing machine

In this 14-meter-long Schirmer machine for PVC window profile processing, all previously required control cabinets were replaced with the MX-System for the first time. 

Schirmer machines can be used for a variety of different processes: The individual parts for window frames and sashes are produced from approximately 6-meter long profile bars in a continuous process. As much as possible, all drilling, milling, and punching operations are carried out on raw bars, followed by cutting and processing at the ends. While the profile bars are being processed, the reinforcement profiles are cut to size on a separate line with the option to automatically insert and position them in the PVC profile. This is followed by further processes such as screwing in the profile and reinforcement, steel processing (drilling, milling), and inserting and screwing in the locking mechanisms. 

As Schirmer machines are tasked with handling a wide variety of frequently changing profile geometries, the conversion process takes place automatically. “Manual set-up is definitely out of the question for us,” says Ludger Martinschledde, Managing Director of Schirmer Maschinen GmbH. With this being the case, many stops and brackets have to be positioned on a fully automatic basis. “Last year, for example, we implemented a line with a total of 210 axes,” recalls Martinschledde, outlining the requirements profile for the control platform. 

Traditional control cabinets hamper production processes

The electrical equipment used in Schirmer machines to date reflects the current standards. Drive amplifiers, power supplies, power distribution, and PC-based control technology are all installed in control cabinets. On Schirmer machines, there are typically several of these stations set up along the machine, where cables from usually 2 to 3 process modules of the machine are routed and connected. EtherCAT I/Os are also used in junction boxes. These are used to collect actuator and sensor signals from each of the individual process modules; however, combining several process functions in a single control cabinet and using junction boxes to which the signal lines are connected rather than plugged in represents a compromise for modular machine building. 

The complete machine is set up and operated via a customer-specific Beckhoff Control Panel display. 

Martinschledde describes the disadvantages of this solution as follows, “This means that most of the electrical installation and commissioning will only take place during final assembly, which is precisely when we are trying to commission the system as quickly as possible before taking it apart again for delivery.” The discrepancy between the modular machine concept and the central control cabinets has long been identified by Schirmer as an obstacle to achieving a more efficient project workflow. 

When Martinschledde and the design engineers at Schirmer heard about the possibilities of completely control cabinet-free automation with the Beckhoff MX-System in 2021, they were intrigued. “The design engineers and Ludger immediately recognized the potential of the MX-System for their modular machine building projects,” recalls Daniel Siegenbrink, MX-System Product Manager at Beckhoff. 

The window opens to cabinet-free machine design

The back of the system is particularly interesting for automation engineers, as each machine module has its own MX-System baseplate where the various function modules are plugged in and set with screws.

Schirmer is pioneering the use of the MX-System on one of its machines for the first time, marking a new direction with the primary aim of optimizing the lead times and processes involved in machine building. “The MX-System is changing the face of design and installation in the world of machine building,” explains Martinschledde. In place of the traditional control cabinets that used to stand next to the machines, MX-System baseplates can now be seen directly on the steel frames of the different process modules. As for the junction boxes, their tasks have either also been accommodated in the MX-System or else been replaced by decentralized I/O modules (EtherCAT Box modules) from Beckhoff. This combination of MX-System and EP box modules enables efficient, pluggable connection of  all cables to the motors, sensors, and valve terminals.  

Double-row baseplate of the MX-System: The open installation on the base frames simplifies machine wiring and diagnostics. 

For Schirmer, the crucial advantage of the MX-System lies in restructuring internal design and installation processes. After all, this pluggable solution allows the machine builder to install all the electrical components of a machine module during pre-assembly and connect them to pre-assembled cables with ease. Another key aspect is that, during pre-assembly, the machine modules are freely accessible from all sides, which makes it much easier to lay and connect the cables. As Daniel Siegenbrink explains, “This saves a lot of time and significantly increases the efficiency of our workflows.” This not only applies to assembly, but also extends to planning, prep work, and material sourcing in the production phase. 

The MX-System function modules also eliminate the need for the complex individual wiring of numerous sub-components that is still all too common in conventional control cabinet design. This new approach prevents wiring errors and streamlines parts management. As a result, the required components – MX-System baseplates, modules, and pre-assembled cables – can be picked from the warehouse for pre-assembly directly after the electrical planning. “The aim here is to achieve an order-independent warehouse that we can manage with minimum stock levels and replenishment times,” explains Martinschledde. 

For Schirmer, this initial development project has also provided two further insights: Last-minute change requests are much easier to implement and require less effort – even in a late project phase. And with modular partial commissioning, any functional errors can be detected at an early stage and rectified without time pressure. 

RELATED: Recording of the MX-System Webinar: The era of cabinet-free automation has arrived

Speedy and efficient deliveries to end users

In the final assembly phase, the machines take up a large area, so processes have to run quickly at Schirmer to make room for the next systems in the queue. Martinschledde notes that the upstream processes – particularly electrical installation and partial commissioning – significantly reduce downtime and support efficient use of space in the process. This allows Schirmer to assemble, inspect, and deliver more systems in the same hall.  

As a machine builder that exports 75% of their systems, the universal use of the automation solution is another crucial aspect for Schirmer. While previously the future installation location had to be taken into account during electrical planning and material procurement, the machine can now be used worldwide without requiring any time-consuming modifications since the MX-System is designed to be IEC-, UL- and CSA-compliant. This stands in stark contrast to the localization work required for conventional control cabinets, and further increases the degree of global standardization at Schirmer. 

The Schirmer loading magazine only requires two 48 V servo drives and a few digital signals, for which the compact single-row MX-System baseplate with 12 data slots for MX modules with 24/48 V DC supply voltage is ideally suited. 

But it’s not just Schirmer that benefits from control cabinet-free automation, as the MX-System also offers substantial benefits for end users. These notably include far better accessibility inside and outside of the machine, and the reduced space requirements due to a smaller machine footprint from the elimination of control cabinets. This means that the production lines can be positioned closer together on the factory floor, optimizing the valuable space without, for example, violating emergency exit route requirements.  

The 10-fold reduction in the number of components also reduces the size of the spare parts warehouse. The Beckhoff Diagnostics App, which is being launched on the market together with the MX-System hardware, is a tool that makes it easier for maintenance personnel to localize and rectify faults. “The easy-to-use diagnostic app ensures end-to-end pluggability as a convenient replacement for a multimeter, emphasizes Daniel Siegenbrink. “This means that no specially trained electricians are required to inspect, connect, or replace the MX-System modules.” 

The era of cabinet-free automation begins now

“The MX-System allows us to add value throughout our manufacturing processes and achieve highly efficient production,” explains Ludger Martinschledde, Schirmer Maschinen GmbH (right), pictured alongside Daniel Siegenbrink, MX-System Product Manager at Beckhoff. 

The use of the Beckhoff MX-System has resulted in significant advantages and optimizations throughout the entire process chain at Schirmer. This includes a reduction in the previous workload for electrical planning by around 50%, as the usual two to three weeks of assembly time for conventional control cabinet design was cut down to just a few hours of system assembly. Martinschledde also expects a significant reduction in downtime during the final assembly stage.  

The new machine was presented for the first time at Fensterbau Frontale 2024, the world’s leading international trade show for windows, doors, and facades. The demonstration of the machine was a huge success and Martinschledde believes that this will certainly not be the last system of its kind in a new era of control cabinet-free automation: “Schirmer will continue to rely on this innovative solution from Beckhoff. We are fully on-board with transitioning our machines to control cabinet-free automation with the MX-System, and this will also apply to the machines for aluminum and steel profiles in the future.” 

Ready to start your journey to cabinet-free automation? Reach out to your local Beckhoff sales engineer today.

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Brandon Snell is the MX-System Product Manager at Beckhoff Automation LLC.