1 Introduction to the device
According to statistics from relevant agencies, the global demand for packaging machinery, including case packers, is growing at an annual rate of 5.3%. About one-third of the packaging machinery (including case packers) on the global market comes from Germany, which ranks first in the world, followed by United States, Japan and Italy. Most of the packing machines used by some multinational companies and foreign-funded enterprises in China are imported from abroad. Relevant information shows that the global demand for packaging equipment has increased from 24.1 billion US dollars in 2004 to 28.6 billion US dollars in 2009, and will reach 44.5 billion US dollars by 2019. Among them, the market demand potential of the packing machine is huge.
Automatic cartoning machine is a kind of automatic equipment that loads the messy and disorderly packaging on the conveyor belt into the box according to a certain arrangement. The function of the equipment in this project is to sort the infusion bags with disorderly spacing on the conveyor belt by the timing belt and pack them, then pack them through two sets of XY manipulators, and finally transfer the boxes to the subsequent palletizing equipment through the conveyor roller table. The equipment is mainly composed of four parts, namely: feeding, packing, packing, and outgoing. Feeding: The conveyor belt is driven by the inverter to fill the infusion bag into the box. Cartoning: Two sets of synchronous belts are driven by two servo motors, and the two sets of magazines are respectively installed on the two synchronous belts, and the two synchronous belts are loaded into the box through the functions of feeding, positioning and following, and sent to the grabbing position. Packing: Packing: Consists of two sets of XY manipulators, which are composed of four servo motors. The gripper adopts the interpolation function to smoothly put the infusion tape into the box, and the whole gripper has the functions of path planning, smooth bending radius and so on. Out of the box: The manipulator will pack the infusion bag according to the layer, and then transfer the finished product to the stacking equipment by the out of the box roller table, and the drive system will be controlled by the frequency converter, and at the same time, the proximity switch and pneumatic components will be used to complete the conveying work of the box. For the equipment, please refer to Figure 1 Automatic Case Packer.
The machine can reach a single gripping time of up to 1.85 seconds - - times, and each grab 4 bags, so it can reach 130 bags/min. The equipment control system is mainly composed of Lenze's new-generation motion controller and servo controller, and the motor adopts MCS high-performance synchronous servo
The motor and control network use the EtherCAT bus. The whole equipment has the advantages of high level of automation, fast packing speed and low equipment vibration.
2 Lenze Solution
2.1 Lenze Main Products
1. L-force Controller 3231C: The main frequency of the controller is 1.6GHz, the minimum task cycle is 1ms, and it has powerful logic operation and motion control functions, and its function and performance far exceed that of ordinary PLC. In terms of communication capability, it supports a variety of communication methods, and the control is equipped with 2 USB interfaces, 2 Ethernet interfaces (and integrated network switch functions), 1 EtherCAT interface, and 2 CANopen or PROFIBUS master modules as an option. The built-in Windows (8) CE operating system can be directly connected to peripheral displays through the DVI interface. The built-in monitoring software VisiWinNET 2005 can directly monitor the picture in the motion controller, through MP 1000DVI output, so that when the touch screen is damaged, there is no need to re-download the monitoring program, just replace the monitor MP1000 DVI.
2. MP1000 DVI: TFT 10.4" screen, 640 x 480 resolution, and equipped with DVI interface, which can be directly connected to Controller 3231C as a touch screen display.
3. I700: Servo Controller: Built-in position, speed and torque control mode, using multi-axis design and easy installation technology, servo adopts centralized power supply module for power supply, servo includes single axis and dual axis module, can be flexibly combined. The integrated EtherCAT bus network features three mounting options: cold plate mounting, push-out cooling, and cabinet mounting, with a power range of 0.75 to 15 kW.
4. MCS servo motor: Lenze servo motor is equipped with a resolver as standard and the accuracy can be approximate to a 1024-wire encoder. The MCS servo motor is a permanent magnet synchronous servo motor with a very high dynamic response and overload capacity.
2.2 Lenze Solution
Lenze has a complete range of automation solutions for fully automatic case packers. In terms of hardware configuration, firstly, the controller adopts the new-generation motion controller 3231C as the core element of system control, secondly, the MCS high-performance synchronous servo motor is used as the actuator of the equipment, and finally the EtherCAT bus is used as the communication network of the whole system. For details, see Figure 2 for details.
In terms of control programs, Lenze has successfully applied FAST technology to the field of motion control, launched various standard control program modules, integrated boring and complex control programs into functional blocks, and truly realized the conversion from writing complex motion control programs to simple and practical function blocks, greatly saving the workload of engineering personnel, and making programming work as simple and practical as building blocks.
There are two main FAST modules for the main applications of the equipment:
1.MagicTrack function block: This function block is specially developed for the use of synchronous belt for automatic splicing, its main function is to convey the infusion bag on the roller table, through the box installed on the two synchronous belts, to achieve automatic cycle sceiving, after the material is completed, the product will be quickly sent to the gripping position of the manipulator. Two timing belts, automatic cycle operation, ensure that the products on the conveyor belt can enter the box. At the same time, the function block also has the functions of synchronous belt anti-collision alarm, automatic zero finding and manual control.
2. PickAndPlace function block: This function block is a function block developed for all kinds of manipulator control, its main function is to realize the function of grasping and putting down the manipulator, this function block can realize the path planning of any 10 points in a running trajectory, and each point can independently set the function of speed, acceleration, bending radius and pause. The function blocks support interpolation of up to 4 axes and can be used in a wide range of robot formats such as portal robots, belt robots, Delta 3, Delta 2, Scara robots and articulated robots.
3 Main features implemented
1. Automatic cartoning: The infusion bag is conveyed on the conveyor belt, and a photoelectric switch is installed at the outlet of the conveyor belt to detect the incoming signal of the infusion belt, which is connected to the MagicTrack function block. This function block can realize the function of using two synchronous belts for cyclic automatic splicing.
2. Gripper control: When one of the timing belts is filled with infusion bags, it will be transported to the gripper position, and send a signal to allow the gripper to move to the PickAndPlace function block, and the XY manipulator will put the infusion bag into the box according to the set smooth curve, and the trajectory can be flexibly set or taught, and there are also functions such as layer control, temporary pause, and manipulator rotation.
3. Roller table control: The incoming and outgoing boxes are controlled by the roller table, and the positioning and flow control of the boxes are realized by multiple photoelectric switches installed on the roller table.
4 Lenze Highlights
1. Lenze provides users with a complete, mature and cost-effective electrical automation solution.
2. The FAST function block launched by Lenze provides a software system like hardware installation for the user's equipment, eliminating the need for complex programming links and greatly shortening the debugging time of engineers. At the same time, the FAST function block is not a process package that meets the needs of the equipment, but a minimum unit function block that conforms to the process of the equipment, which maximizes the performance and provides users with more personal play space.
3. The synchronous belt has the functions of stable operation, powerful anti-collision control and intelligent zero-finding control.
4. The manipulator has the functions of fast and accurate operation, smooth trajectory and humanized teaching.
5 Outlook
With the improvement of the modernization level of China's enterprises, the tedious and boring work of product packing has gradually changed from manual to the development of a high degree of automation packing machine, and the use of efficient and automatic packing methods has significantly improved production efficiency. The equipment is mainly used in beer, beverage, tobacco, pharmaceutical, grain and oil, food processing, daily chemical, machinery, electronics industry and other fields. With high-quality automation products and a professional technical team, Lenze creates high-performance, high-automation packing equipment for enterprise users. The program module design concept, cost-effective automation products, and intelligent and humanized control methods provided by us are also in line with the future development direction of automatic packaging machines.
Lenze is a long-term and simple service concept, and is willing to work together with customers to create a better future.
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