1 Introduction
With the arrival of the peak of Chinese population aging, the improvement of people's consumption capacity and the introduction of the two-child policy, diapers will usher in an era of rapid and sustainable development. In 2015, the annual consumption of baby diapers in China has exceeded 24.8 billion pieces, and the overall consumption in the domestic market is more than 70 billion yuan, and by 2017, the scale of China's diaper market will expand to 120 billion yuan. As one of Lenze's key industries in the consumer goods industry, the team members closely followed the market situation and cooperated with domestic OEM companies to develop a 128-axis full-servo high-speed diaper production line, integrating production, stacking and packaging, with a production speed of up to 800 pieces/minute, marking a new industry milestone for Lenze.
2 Introduction to diaper production line equipment and process
The diaper production line is mainly divided into baby diaper and adult diaper production line, and the production process is mainly divided into production line unit, stacking and middle pack unit. Figure 1 is a schematic diagram of diaper production line equipment. The main function of the production line is to spray different materials such as waterproof non-woven fabrics, composite cotton cores, polymer materials, and diversion layer non-woven fabrics, and then become finished diapers through arc cutting, longitudinal folding, final cutting, triple folding and waste rejection after layer by layer compounding, and the finished products enter the stacker crane through the stacking over-unit for packaging to obtain diaper products packaged in groups. See Figure 2 for the detailed process flow.
3 Lenze Solution
The diaper production line adopts a complete set of Lenze solutions, which is mainly composed of a front-end production line, a stacking and a mid-pack unit, the production line part uses two 3231C motion controllers to control 110 sets of servos, and the monitoring part uses a 15" p500 panel controller; One 3231C motion controller is used for the stacking and middle package parts, which controls 18 sets of servos, and the 7" p300 panel controller is used for the monitoring part. The controllers communicate with each other through the CAN bus, and the controller and the servo driver use the EtherCAT bus for communication, and the whole system has the advantages of clear network structure, reasonable bus load and stability. The system topology diagram is shown in Figure 3.
The main functional requirements of the production line are rewinding and unwinding, synchronization, cam curve and deviation correction, etc., "rewinding and unwinding" FAST technology module is one of the highlights of this system, compared with other brands of "rewinding and unwinding function block", Lenze's rewinding and unwinding function block does not need to input the coil diameter of the material, and directly calculates the tension and speed, eliminating the input of the coil diameter while ensuring the stable operation of the replacement material; The "synchronization function" is used for various multi-conveyors in the production line; The "electronic axis" FAST technology module ensures high-precision phase synchronization, intelligent material stretch compensation function, and can freely set the material length, so that the same equipment can be applied to the production of multiple types of diapers; The "Cam Curve" FAST technology module is mainly used for cutting production line materials, which can freely switch curves and is suitable for different product lengths and shapes; The "Web Guide" FAST technology module enables fast correction via a color mark sensor and reduces scrap rates during changeovers.
One of the highlights of the stacking and middle package section is the special function block developed by Lenze specifically for the "transition pusher", the difficulty of this function is that the mechanical part is a SCARA manipulator-like model composed of two slide mechanisms customized by the user, which needs to be synchronized with the production line for smooth quadrangular trajectory movement. Lenze's proprietary "Pick & Place" FAST technology module and model conversion algorithm program enable the free setting of trajectories and the function of synchronous tracking of spindles.
3.1 Lenze's main products
1. P500/P300 Panel Controller: Lenze's panel controller has the functions of PLC control and screen monitoring, fanless design, no maintenance, and stable performance; The integrated UPS design ensures the safety and reliability of the data; Swappable memory cards make it quick and easy to replace devices. It can provide 7" to 15" display, Windows CE 6.0 operating system, support Ethternet, CANopen and other communication interfaces.
2. 3200C motion controller: CPU frequency up to 1.75GHz, minimum task cycle of 1m, with powerful logic operation and motion control functions. It supports a wide range of communication options and is equipped with 2 USB interfaces, 2 Ethernet interfaces (with integrated network switch functionality), 1 EtherCAT interface, and optionally 2 CANopen or PROFIBUS Master modules. The integrated UPS design ensures that the data is safe and reliable. Swappable memory cards allow devices to be replaced quickly and easily.
3. i700 servo drive: is the basic automation system servo drive, using the design concept of multi-axis application, supporting CIA 402 standard operation mode (position, speed, torque control), supporting dual-axis design, reducing the space occupied, using simple connection design, plug-in terminal block, easy to integrate the system, debugging and replacement.
4. MCS/MCA servo motor: MCS is a Lenze high-precision synchronous servo motor, which is used for phase synchronization, cam control, deviation correction control and other applications of the production line. The MCA is a Lenze asynchronous servo motor with large inertia for applications such as rewinding and unwinding control, speed synchronization, and more. Both motors can be optionally equipped with Lenze's resolver and multiturn absolute encoders to meet the user's high-precision servo control accuracy.
3.2 Main functions with FAST technology module
1. Material unwinding: The "rewinding and unwinding" FAST technology module is used to realize fast and stable automatic material exchange function and unwinding control.
2. Synchronous control: The "electronic axis" FAST technology module is used to realize acceleration and deceleration compensation and high-precision production line position synchronization.
3. Cam curve: The "electronic cam" FAST technology module is used to realize the free online switching of cam curve.
4. Deviation correction function: The "deviation correction" FAST technology module is used to realize the window function of the deviation correction function, the correction limiting and curve compensation.
5. Transition pusher: "Pick &Place" FAST technology module is used to realize coordinate system conversion, cam curve synchronization, etc.
3.3 Advantages of the Lenze solution
1. All-in-one solution: Lenze can provide a complete set of drive and automation solutions for diaper production line, and the complete product line provides you with one-stop purchasing.
2. Best cost performance: As one of the mid-to-high-end European brands, Lenze can provide you with a cost-effective solution to save costs and maximize the performance and quality of your equipment.
3. FAST Technology Module: The FAST Technology Module is a program process module with integrated motion functions developed by Lenze, which can improve the program quality, shorten the programming time, and effectively reduce the equipment commissioning cycle.
4. Professional team support: Lenze can provide professional technical and sales support for the industry, and has offices in China and overseas, which can provide a full range of one-stop services.
4 Outlook
With the continuous improvement of user demand, diaper equipment will develop in the direction of high-end and high-speed, automation and modularization. High-end and high-speed: The production speed of domestic diapers will develop from the current 500-600 pieces/minute to 1000-1200 pieces/minute, the stability of production quality will be significantly improved, and the scrap rate will be reduced to less than 3%. Automation and modularization: With the high-end development of diaper equipment, the equipment structure is becoming more and more complex, and the equipment with a higher degree of automation and less labor has become a development trend, so the diaper equipment will be widely used servo control system, intelligent monitoring system, automatic detection technology, automatic waste removal technology, automatic fault diagnosis technology, accelerate the pace of research and development of stacking and packaging equipment, realize seamless connection with the main production line, and then realize the automatic control of the whole process from raw material input to finished product output and packing.
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