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Markets for fast-moving consumer goods (FMCG) like toothbrushes are fiercely competitive. Bright Machine Tools gives its customers an edge with sophisticated technology for maximum productivity and quality. For all their automation and digitalization needs, they put their trust in B&R.

Bright Machine Tools has been catering to the complex needs of the toothbrush and textile industries for more than two decades. High-end machines that produce high-quality products have helped the company make a name for itself among India's top manufacturing OEMs. Established in 2006 and located in Ghaziabad near the capital city New Delhi, their core focus has always been providing their customers technologically sophisticated machines featuring cutting-edge mechanical and electronic systems that deliver exceptional speed and productivity.

The BT1000 series of tufting machines from Bright Machine Tools are highly synchronized CNC machines. (Source: Bright Machines)

Technological differentiation

To serve increasingly demanding market requirements, Bright Machine Tools replaced mechanical cam-based solutions with automation years ago. Today, ongoing digital transformation has helped make their fully automated machines more ready for the future than ever, with integrated vertical and horizontal connectivity and remote access.

"We have always differentiated our machines through technology – which shows in the quality of the machines themselves and the products they produce," says S. M. Shah, managing director of Bright Machine Tools. "This has helped us become successful in the cost-sensitive Asian market while also competing with OEMs all around the world."

The BT1000 series of tufting machines from Bright Machine Tools are highly synchronized CNC machines. Incorporating CNC controls and logic in the machine have helped double their speed and productivity. "With multi-color bristles, our machines are able to reach speeds of 850 toothbrushes per minute," says Shah, "and with single-color bristles even 1,000 per minute."

High-performance motion control

A driver unit controlled by an ACOPOSinverter runs a complex mechanical assembly that collects a bundle of bristles from the vertical feeder unit, together with a bonding wire, and embeds them in the defined hole in the toothbrush, which has been precisely positioned by a rotating turret.

The turret also relies on ACOPOSmicro servo drives to position each hole in front of the driver. A Panel PC 2100 from B&R runs the complex CNC application as well as an intuitive GUI. When logged in, authorized operators are able to change the CNC parameters or adapt the G-code and M-code for different toothbrushes or bristle configurations.

The Panel PC is capable of running not only the CNC but also the I/O and motion control. (Source: Bright Machines)

Integrated automation

"We thought that to achieve the desired speed, accuracy and precision, our machines would need to run CNC control on dedicated hardware," recalls Shah. "Yet dedicated hardware and CNC control offered us neither the modularity nor the flexibility we were looking for."

Bright Machine Tools' engineers were impressed by the B&R solutions. "The Panel PC is capable of running not only the CNC but also the I/O and motion control," says Shah. "B&R's integrated approach also makes it easy to synchronize servos, steppers and VFDs on a single network." The backbone of the B&R system architecture is real-time POWERLINK, capable of running cycle times as fast as 400 microseconds that make it possible to achieve the response times, accuracy and precision Bright Machine Tools needed.

Together with OPC UA and MQTT, the machines are equipped for IT/MES/ERP connectivity – at no extra cost. B&R's secure remote maintenance solution allows Bright Machine Tools engineers to connect with the machines 24/7, helping them provide their customers best-in-class after sales service that substantially reduces downtime and costs.

B&R's integrated approach makes it easy to synchronize servos, steppers and VFDs on a single network. (Source: Bright Machines)

Universal tool for simulation, programming, diagnostics

As the universal engineering environment for all B&R hardware, Automation Studio made project development and version management very easy for Bright Machine Tools. "Our developers were very impressed by the concept of programming and diagnosing the controller, motion, drives, I/O and HMI – all using a single tool," says Shah.

B&R's mapp Technology significantly reduced the time it took to develop the new machine. "Rather than programming from scratch, we just had to configure the ready-made software components," notes Shah. The time savings was used to implement innovative new features and optimize performance.

"Thanks to the powerful simulation tools provided in Automation Studio, our engineers were able to start software development even before the hardware was available," says Shah. They also enjoyed the freedom of platform-independent software development. "At any point in development, they can switch between the simulation environment and the controller or an Automation PC," notes Shah. "B&R has exceeded even our highest expectations for what could be achieved with an integrated automation solution."

A bright future

"B&R solutions have helped us take our dream of 1,000 tufts per minute and make it a reality," praises Shah. "We are thoroughly impressed with not only the hardware and software but also the expertise and support they provide". Bright Machine Tools looks forward to future projects and a continued successful partnership with B&R.

S.M. Shah

Managing Director, Bright Machine Tools

"B&R's solutions helped us take our dream of 1,000 tufts per minute and make it a reality. We are thoroughly impressed with not only the hardware and software but also the expertise and support they provide."

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