Industry applications | Packaging industry is facing new challenges, servo into efficient highlights!
Release time:
2022-12-01 16:49
Source:
New challenges facing the packaging industry
With the continuous improvement of social material civilization and spiritual civilization, the competition in the packaging machinery industry at home and abroad is becoming more and more fierce, and China's packaging machinery industry is facing new challenges. Multi-purpose, high-high quality, high-efficiency, and intelligent have become the future development direction of packaging machinery products.
At the same time, due to the increasingly fierce market competition in the downstream industry, large-scale and intensive production forms, rising human resource costs and other factors, packaging equipment manufacturers are facing increasingly fierce competition in the form of increased packaging capacity and lower unit prices.How to further improve the yield and production efficiency of packaging, while effectively controlling costs, has become a problem for the entire industry to think about.As the core of packaging equipment, motion control system is very important to reduce cost and increase efficiency in the packaging industry.
Servo products as an important part of the packaging machinery motion control system, in the packaging machinery towards multi-purpose, high quality, high efficiency, intelligent development process, what are the contributions?
1
Replace traditional machinery, help intelligent upgrade
Traditional packaging machinery, the use of machinery to carry out the division of labor, encounter different packaging, the need to replace the entire process on the production line, time-consuming, high cost.
Using PLC-controlled servo drive system, in addition to the superposition of sensors, cameras and other technologies, the whole process of packaging automation can not only realize the embedding of hundreds of packaging algorithms, but also improve efficiency.
Before the servo system, the packaging equipment had a large AC motor running at a fixed speed, and the mechanical connection away from the spindle controlled each packaging program, converting the shaft motion from one speed to another, or converting the rotary motion to linear motion. Every time the spindle rotates, a product is produced from the other end. When you want to replace small bottles with larger bottles or change the size or shape of the package, you must readjust the equipment.
The servo system changes this situation, there is no mechanical connection to the spindle,Each servo system operates independently.. The benefits of this are:Whether it is pressure, speed, position can be changed.Previously, it would take 7 hours to change these, which is difficult to change unless there is a large enough batch to ensure the effectiveness of the adjustment and the ideal production cycle. Now, it only takes 3 to 5 minutes to complete the adjustment, and the method is very simple.
For example, the introduction of servo system in pharmaceutical factories, the simple change of production methods makes short-term and small batch production more economical, no longer need to spend 4~6h to clean, autoclaving and change the cam and parts, only a few minutes can be reprogrammed, installed with different types or sizes of parts, so that the machine is running again. At the same time, the servo system is cleaner.
* Figure source network: four independent unit packaging machine drug packaging video screenshots
In addition, in the packaging production line, most users are familiar with the low-end servo drive system, that is, the "pure" single-axis servo drive, which is only used to complete the positioning control of a mechanical axis; some users have begun to master the terminal servo drive system, Usually it is also used to complete the positioning control of a single mechanical axis, but with programmable logic control function. The head of the packaging industry leader, the high-end servo drive system is more favored. Its main features:
1. Multi-axis system
2. For this axis motion control function
3. High-speed communication with upper motion controller and drive and drive
In other words, while the packaging production line with high-end servo system is fully automated, the devices are independent of each other, with timely feedback, self-adjustment and memory storage, making the entire production workshop digital and intelligent.
2
High reliability and high precision, help cost reduction
The application of servo system in the automatic packaging production line has undoubtedly greatly improved the efficiency of the automatic production of packaging. At the same time, because of the addition of the servo system, the precision of the packaging items on the packaging production line is improved, the rejection rate is reduced, the cost is reduced, and the production efficiency of the enterprise is improved.
One of the main features of the servo system is itsClosed loop feedback,That is, the encoder converts the angular displacement or linear displacement into an electrical signal, and the controller can reflect the current motor speed by calculating the number of pulses output by the photoelectric encoder per second. In addition, in order to determine the direction of rotation, the code disc can also provide two pulse signals with a phase difference of 90 °, so as to achieve the purpose of accurate positioning of the servo motor.
In recent years, the encoder domestic manufacturers to achieve a major breakthrough in performance, according to the detection principle, the encoder has optical, magnetic, inductive and capacitive. According to its calibration method and signal output form, it can be divided into three types: incremental, absolute and hybrid. Among them, the application of wide, high precision to the number of optical encoder, 25-bit optical encoder will achieve a resolution of 0.039 angular seconds, the accuracy of 10 angular seconds. In addition, the magnetic encoder has been developed to 19 bits, which has the advantages of vibration resistance, oil pollution resistance and dust resistance. In terms of precision design, both optical and magnetic weaving adopt a correction technology, which adds a correction amount in each certain interval to correct the cumulative precision, thus greatly improving the reliability and stability of the product.
For example, in the pharmaceutical industry, 70% to 80% of balers, outsourcing machines, container balers, and stackers use servo systems. The accuracy of the control torque of the sealing machine based on the servo system can reach +0.02, while the accuracy of the sealing machine driven by the standard clutch is only 20%. For example, after storing the torque value of each lid, if a recall is required, only 1000 bottles need to be recalled instead of 1 million bottles in the past.
* Source Network: Video Screenshot of Sterile Vial Production Line
There is also a food packaging line, the general requirements of packaging materials each feeding length is consistent, each feeding needs a certain pause time, and the number of feeding times per minute needs to be within a certain number of times. In addition, the film feeding and feeding of the packaging machine are carried out simultaneously, and the transverse sealing and cutting are transmitted immediately after the longitudinal heat sealing. These processes depend on the accuracy and stability of the servo system, as well as the strong dynamic response capability displayed during the overall speed-up or speed-down of the packaging machine.
* Source Network: Video Screenshot of Food Packaging Production Line
Once, due to the gradual decrease in the accuracy of synchronization between transmission speeds and the gradual increase in deviation, coupled with internal activities in the packaging process, the rejection rate of chocolate ice cream packaging line has been steadily increasing. A drive control scheme based on 6 servo improved lanes/curling has been upgraded, the rejection rate has been reduced by 90%, the yield rate has been improved, and the expenditure on buried scrap has been greatly reduced.
The application of servo system in the automatic packaging production line is more and more widely, and there are more and more application examples in our country. The continuous improvement of the automation degree of packaging production line will inevitably drive the market of servo system application. At the same time, the demand for high quality servo products is also an irreversible trend. At present, although international brand servo products are mostly used in China's packaging industry, domestic manufacturers are also accelerating the breakthrough of motion control technology and the upgrading of servo products, fully assisting the packaging industry to increase quality and efficiency, and contributing to the "Made in China 2025.
References:
[1] From the servo to see the packaging production line motion control-servo system to guide the development of packaging technology [J]. Modern Packaging, 2006(2)
[2] Drive to solve the packaging problem [J]. Plastics Manufacturing, 2010(9):33.
[3] China Self Media Market Research Department. Packaging machinery industry boom is still, servo into the biggest point of view [J]. Servo Control, 2012(4):18-20.
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