With the innovation of technology, the molding equipment is constantly updated, the traditional hydraulic blister machine has been unable to meet the needs of the market, the servo system with a higher degree of automation is gradually taking over, the continuous development of thermoforming technology makes its application field more and more extensive, and various equipment suppliers continue to launch new products for customers with multi-purpose and high flexibility. Under the fierce market competition, in order to help users make more effective use of resources to reduce costs and improve efficiency, we must continuously improve the control system, so that it can excellently complete the needs of users, by improving the degree of automation of machinery and equipment, making full use of raw materials, reducing production costs, reducing maintenance time, and then helping users to enhance market competitiveness and jointly win long-term and stable customer groups. Lenze products meet the requirements of these machines with outstanding performance, high precision, high operational reliability and even customer-specific designation.
The structure of the transfer molding machine
At present, the control system of the thermoforming machine generally adopts Japanese and European brands. The manufacturing process of thermoforming equipment is constantly improving, and the production speed of mechanical equipment is gradually accelerating; In the sheet heating temperature, mold specifications, pressing time and other conventional conditions of balanced comparison, domestic production of equipment its stable working speed does not exceed 40 molds / min, Taiwan equipment basically exceeds the domestic, European imported equipment up to 60 molds / min or even higher, how to improve equipment production capacity has become a necessary means to win the competition, the current use of Lenze control system of the thermoforming machine has reached the production speed of imported equipment, its stable work, stable operation characteristics successfully helped customers open the overseas market. As technology continues to advance, the functions will be improved day by day.
Production process:
Lenze Product Introduction
Lenze is one of the most innovative companies in the industry, with drive and automation as its core competitiveness, the equipment adopts 3200C motion controller configuration i700 series servo drive to build a multi-axis system, standard EtherCAT motion bus, and uses regenerative energy unit or power module to connect the braking resistor to process energy feedback, ensuring the safety and reliability of the equipment. The positioning function of the mold table adopts Lenze 8400motec inverter all-in-one machine, which establishes communication through the CANOpen interface of the host computer to control the working operation of each station, and the heating system adopts PROFIBUS interface communication to control the temperature controller of Siemens HCS716I, and the optimized program algorithm makes the temperature control system faster and more accurate.
Lenzei700 multi-axis system solution
Lenze can provide a complete system solution, taking the four-station high-speed molding machine as an example, the system takes the 3200C motion controller as the core, and configures 8 i700 servo controllers to drive the MCA motor to complete the functions of sheet feeding, forming, punching, cutting and stacking. The Lenze standard motion control function is used to complete the brake holding, zeroing, positioning and motion curve control functions of each axis, which reduces the development cycle of the system and improves the reuse rate.
The parameters of the control program and the equipment are all stored in the memory card of the 3200C standard, even if the fault occurs, only the data in the card needs to be backed up, and the card is powered on after the new controller is replaced, the controller will automatically load the data and run the program, and the running status of the PLC can be judged by the status indicator, which greatly improves the upgrade and maintenance efficiency of the equipment. The highly integrated programming software PLC Designer can complete the configuration and debugging of the entire project, so that the operation and operation data of each axis become clear at a glance, and the controller also has the function of Web remote protocol, which only needs to build an Internet remote access terminal to realize real-time monitoring of the equipment, which is convenient for equipment manufacturers to grasp the operation of the equipment at any time.
The system architecture of the molding machine is shown in the following figure:
Technical key points
1. Motion controller 3200C, equipped with Intel® Atom™ 1.6G high-speed processor, integrated logic, motion control functions, hierarchical storage area is used to load man-machine interface programs, abandoning the traditional bus communication mode, speeding up the interactive processing speed, and reducing the response time of the man-machine interface.
2. The incoming power supply is filtered to ensure its stability, the symmetrical installation of the i700 shaft module ensures that the bus voltage can be used more effectively, and the power unit is equipped with braking resistor, which effectively converts the remaining energy in the frequent reciprocating operation of the load, thereby eliminating the feedback impact on the equipment and improving the service life; The load carrying capacity is significantly increased by increasing the torque limiting and maximizing the performance of the drive unit. Optimized system design maximizes the use of system resources.
3. By analyzing the mechanical structure, the geometric model of the crank rocker load structure is established, the correspondence between the running angle of the shaft and the position of the mold platform is obtained, the mathematical model is established to generate the running curve, and the optimal value of the parameters of the mechanical operation is obtained, which gives full play to the performance of the servo.
4. In the front interface of the man-machine interface, the system data can be backed up by using a common USB flash drive, which makes maintenance extremely simple.
Trends
With the improvement of people's awareness of environmental protection, degradable sheets will gradually replace traditional resin materials, then we must comprehensively improve the equipment to adapt to the characteristics of new materials, while enhancing the competitiveness of users in the market, but also improve our living environment, at present, degradable materials have been successfully introduced to the packaging market, and will soon be widely used, in the foreseeable future nanosheets or will be widely used in the field of packaging.
The Lenze 3200C controller configures the Siemens HCS716I slave through the DP master interface, sets the temperature control standard time base value, optimizes the algorithm to improve the feedforward link of the heating system, and can heat to the predetermined temperature within 15 minutes, and the temperature fluctuation after stabilization is within ±0.5 degrees, which meets the needs of users and is at the leading level in similar equipment. In the subsequent upgrade process, users can use infrared heating, the heating of the sheet will be more uniform, and the product quality will be improved. With the upgrade of the system, Lenze is also actively developing new engineering application systems, which will be implemented by the new motion control PackML function in the subsequent commissioning, which can greatly shorten the development cycle of the motion control part of the new equipment and significantly improve the work efficiency of designers.
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