1 Introduction
In modern society, bottle filling production lines are widely used in food, medicine, daily chemical and other industries, and the level of filling production lines is directly related to the quality of products and the efficiency of production. With the development of the economy and the rapid development of science and technology, especially the wide application of automation and intelligent technology, the bottle filling machine industry has benefited a lot. At present, the market demand for bottle filling machines is huge, and there are many manufacturers at home and abroad, and the competition is extremely fierce. In the face of fierce competition in the market, how to reduce costs and improve the technical level of production lines has become an urgent need for many enterprises.
In order to reduce costs and improve the technical level, it has become a trend to replace the use of mechanical cams with electronic cams. The use of electronic cams greatly reduces production costs. Generally speaking, one electronic cam corresponds to one bottle filling product, and for production lines that need to fill multiple specifications of bottles, the corresponding number of electronic cam curves need to be preset in the servo drive, but there is nothing that can be done for unplanned bottle filling. Lenze company launched 9400 servo PLC, using online electronic cam curve calculation to solve this problem, this paper takes the bottle filling machine for semi-solid matter as an example, and proposes a solution for online calculation of electronic cam CAM.
2. The main structure of the equipment
The main part of the equipment is mainly composed of mechanical parts such as transport chains, trays, trays and filling nozzles. Transport chain: when filling, the filling bottle is sent to the filling place; After filling, the bottles that have been filled are transported away; Large dish: the large disc rotates around to complete the filling of a station bottle, that is, after a bottle is filled, the large disc rotates around to move the bottle out of the filling position, and at the same time moves the next bottle to the filling position where the filling nozzle is located, and is ready to fill the next bottle; Tray: lifting bottles, driven and controlled by servo motors, which can carry out precise CAM position lifting movements; Filling nozzle: Shaped as a slender cylindrical nozzle. When filling the bottles at each station, a certain liquid flow is controlled by the nozzle through the equipment.
The main timing of filling is as follows: when the equipment is filling, the bottles are first transported to the filling place through the transport chain and automatically loaded to the tray; The position of the filling nozzle is kept still, and the tray is controlled by the servo motor to rise so that the bottom of the bottle is close to the nozzle position; When filling, the liquid flows out of the nozzle under fixed pressure, the position of the filling nozzle is fixed, and the servo motor controls the tray bottle to automatically descend according to the position of the CAM curve, so that the nozzle and the liquid level always maintain a fixed position; After filling, the tray rotates in a circle so that the filled bottle moves to the transfer chain and is sent away by the transfer chain, and at the same time moves the next empty bottle to the position of the nozzle for the next bottle filling.
In addition, there are other filling equipment that takes the position of the tray bottle to fix, and controls the bottle filling by controlling the rising and falling position and speed of the nozzle. Although the mechanical structure is different, the principle is much the same, and the position is controlled by a servo motor to keep the position of the nozzle and the liquid level in the bottle unchanged during filling.
3 main difficulties
In order to improve the diversity and competitiveness of products, most customers design or choose different shapes of bottles for product packaging, as an important measure to improve their market attractiveness and thus improve product competitiveness, but this also increases the difficulty of bottle filling.
Since most of the materials used in filling are liquid or semi-solid substances, and have different colors, in order to ensure the quality of the overall product, the position of the nozzle and the liquid level in the bottle must be kept constant during filling. If the nozzle is quickly separated from the liquid level in the bottle or in contact with the liquid level in the bottle during filling, it is easy to cause the filling substance to splash in the bottle or there will be bubbles inside the product in the bottle, which will affect the appearance and quality of the product. Therefore, how to establish equations or curves, realize the filling CAM curve through drive control, and ensure the filling quality is an important issue that needs to be considered for filling.
In addition, in general, one bottle shape corresponds to one filling CAM curve. In practice, customers often use bottles of different shapes, and as a general rule, different CAM curves need to be pre-stored in the drive, but this means that only bottles with pre-stored shapes in the drive can be filled, and once other shapes of bottles are encountered, unless the curve is modified, the filling quality will be affected. But at the end customer, this can be extremely cumbersome. Therefore, how to establish an equation to adapt to the vast majority of bottle shapes is also a major difficulty.
4 solutions
Lenze9400 servo PLC provides the main carrier to solve the problem, 9400 servo PLC has the function of PLC in addition to the function of the server, and can be freely programmed. In this way, as long as the appropriate equations are established, it can be implemented in CAM mode by 9400 servo PLC to solve the problems in filling.
4.1. Product Introduction
The 9400 Servo PLC is a servo controller from Lenze and one of Lenze's highest-precision products, providing a revolutionary approach to system processing and process control. The main features are as follows:
1) High calculation speed and control accuracy
The controller uses a 32-bit processor, which greatly improves the calculation and control accuracy.
2) Compatible with PLC programming function
The 9400 servo PLC has PLC programming function, which can flexibly realize the different needs of customers. At the same time, the PLC runs extremely fast with a scanning time of up to 1 ms.
3) Communication compatibility
By selecting different communication modules, the 9400 servo PLC can quickly communicate with third-party PLCs or other servo drives, such as Profibus-DP, ProfiNet, EtherCAT and other modules.
4) Integrable security technology
Optional pluggable safety modules meet the requirements of IEC61508SIL3 safety standards. The modular solution also provides a reliable guarantee for meeting the safety requirements that may be further increased in the future.
4.2. System configuration
Figure 1 shows the system configuration. The 9400 servo PLC drive drives the synchronous servo motor to control the up and down movement of the pallet, and the electronic cam CAM curve is calculated online by the 9400 servo PLC and stored in the 9400 servo PLC. An SSI absolute value encoder is installed on the large disk, and the encoder signal is connected to the 9400 servo PLCX8 interface, which is used as the spindle signal of the CAM curve.
Due to the high dynamic response required of the system, Lenze high-performance MCS synchronous servo motors were selected for the execution motor. The motor generates power generation energy during operation, and the 9400 servo PLC drive is connected to an external braking resistor.
The 9400 servo PLC drive communicates with the touch screen via the integrated CAN interface, and the extended IO interface is connected to the 9400 servo PLC via the CAN bus.
4.3. Main Functions
1) Online calculation of CAM curve
Input the feature points about the bottle shape on the screen, and the 9400 servo PLC program can obtain the bottle shape volume model according to the bottle shape feature points, and then calculate the general curve equation according to the bottle volume, filling speed, and SSI encoder angle of the large plate, and obtain the calculation of the CAM curve discretically.
2) CAM curve calculation error protection
Since the motor is not allowed to reverse or rush during the filling process, the calculation results of the CAM curve need to be checked for fault tolerance.
a) Error check for input of feature point coordinate values;
b) Filling curve trend check;
c) Check whether the value skipping between adjacent points of the calculation result is too large to prevent the motor from bursting.
3) CAM curve online switching
In the overshoot of the filling of the production line, the CAM curve online switching function is used to realize the non-stop switching of filling different bottles.
4) LocktoCAM function
Before running the CAM curve, the motor may be in any position. In order to prevent the motor from rushing at the moment of putting into the CAM curve, the following methods can be adopted: after putting in the CAM curve running command, the motor position is automatically positioned to the position corresponding to the CAM calculation curve, and then the CAM curve is automatically run after the positioning is completed.
5) Torque compensation
When the external inertia is large, torque compensation can be used. Since the external load is fixed and the direction of the load is downward when the motor is running, it can be equated with a potential load. When the servo controller drives the motor to drive the rod up, the torque corresponding to this load needs to be added; When the motor drives the rod down, the torque corresponding to this load needs to be subtracted.
5Lenze highlights
1) High-precision servo PLC drive, 32-bit processor, with extremely high calculation and control accuracy, program scanning time up to 1ms;
2) In addition to the characteristics of 9400 servo drive, it is also compatible with PLC function. A 9400 servo PLC can replace the combination of PLC + servo drive, reducing cost and cost-effective;
3) The calculated CAM curve or fixed CAM curve generated by the executable formula can be switched online;
4) Compatible with third-party equipment such as ProfibusDP, ProfiNet, EtherCAT and other commonly used communications;
5) Peripheral expandable IO ports.
6 Conclusion
In addition to the characteristics of high-precision servo control, the 9400 servo PLC driver has the function of PLC, supports ST, FBD and other programming languages, and can also carry out peripheral IO expansion, which has a high cost performance. In addition, it can also realize a variety of functions such as online CAM curve calculation, fixed CAM curve and calculated CAM curve switching, which has important practical application significance for the improvement of the technical level of filling equipment.
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