From raw material pulp to papermaking, and then through packaging and logistics, the paper towel finally completes the "transformation" to meet customers. The impression of packaging and quality, coupled with the comprehensive effect of multiple specifications, traceability, high standards, authoritative certification and other factors, will finally win the hearts of customers, and then establish a trustworthy image. On the back, there is the full support of Mitsubishi Electric. Mitsubishi Electric has responded to a variety of issues related to the production of tissue production equipment, established a production system with different planning and control requirements, and provided a variety of treatment plans for the informatization, intelligence, and energy-saving upgrading of factories.
1. Tissue Occupation Factory Disposal Program
Mitsubishi Electric's e-F@ctory intelligent production and processing plan, which is based on 100 years of manufacturing experience, and the green production comprehensive processing plan composed of the E-JIT concept, help customers continuously improve production power, improve product quality, reduce energy consumption and cost, and promote the sustainable development of society through intelligent production.
e-F@ctory Intelligent Production Processing Plan
The core concept of e-F@ctory is to seamlessly connect FA and IT through accurate collection, marginal processing, efficient transmission and scientific analysis of on-site real-time data, and complete the visualization and continuous improvement of production management.
Mitsubishi Electric can provide a total processing plan from the sensor layer to the field layer, the control layer, and the information layer: CC-LINK IE network with a communication rate of 1G and a real-time communication capacity of up to 256k words, an open bus structure, high-performance control products, dedicated servers, and a visualization system to help enterprises reduce the cost of the entire system and improve the value of the enterprise.
E-JIT Energy Visualization Processing Plan
Combined with Mitsubishi Electric's MC Works software, it is possible to quickly implement a visualization system for energy management in tissue production plants, including air conditioning systems, lighting systems, receiving equipment, water supply systems, disinfection systems, and steam systems.
Mitsubishi Electric has changed the traditional idea of introducing energy-saving equipment or improving equipment in the past, and innovatively proposed the concept of E-JIT, using the energy-saving analysis system to find energy consumption problems on equipment, so as to achieve a benign combination of "operation improvement" and "equipment improvement" to achieve long-term energy saving.
2. Typical equipment treatment plan for tissue occupations
The efficient system is composed of a variety of high-performance equipment, such as dry papermaking equipment, rewinders, slitting machines, high-speed cutting machines, and large/super-large finished product complete sets of equipment, all of which have requirements for high speed, high precision, and control ability. Mitsubishi Electric has conducted in-depth research and innovated on the characteristics of typical equipment and key control points of each equipment, and has performed well in tension control, regenerative control, reciprocating cam control, synchronous speed control, etc., and has also been recognized by many customers.
Wet wipes production line
In the production process of wet wipes, Mitsubishi Electric's motion controller is selected, which has two synchronous forms: virtual form synchronization and advanced synchronization, which can easily complete the programming and establishment of multi-axis different control systems, and play an important role in the whole process of discharging, changing rolls, slitting, folding, stretching and liquid addition, cutting, stacking and packaging, and ensuring product quality.
(1) Build an error-free system based on R-series PLCs
Plan interpretation: The wet wipes production line can choose the high-performance R series PLC configuration (as shown in the figure above), relying on high-speed CPU and high-speed bus to handle many computing and data transmission topics, complete accurate synchronization, and improve the accuracy of the whole system. In this architecture, the motion controller is equipped with J4-B servo through the optical fiber bus to complete the processing of multiple stations and the synchronous control of various messy processes. The human-machine interface is selected from GOT2000 series products, and the equipment status monitoring can be easily completed through the Ethernet connection PLC; The high-speed analog module completes the function of inverter control and liquid level measurement.
(2) The TSN network is composed of a simple and efficient architecture
Plan interpretation: The architecture is connected to Mitsubishi Electric's touch screen, servo, inverter, long-distance I/O, long-distance analog and other products through the TSN network module, and only 3 modules are needed to complete all functions, and the power of the system is higher, the scalability is stronger, and the cost can be greatly reduced.
Wet paper capping machine
The effect of the wet wipes capping machine is to attach a plastic cover to the wrapped wet wipes bag, and the main processes include pushing the cap, labeling, grabbing the cap, gluing, gluing, gluing the cap, and controlling the conveyor belt, glue machine, robot, etc. together.
Plan interpretation: The PLC in the architecture uses FX5U (instruction speed up to 34ns, capacity 128K steps), which can be controlled by built-in analog to drive the conveyor belt to run, and then use the 40SSC simple motion module, through the SSCNET3/H bus connection, control labeling, push rod and recovery of three JE servos. In addition to the Ethernet connection with the PLC and GET, the robot is also visually connected to the position of the tissue bag on the conveyor belt during operation.
Problem response 1: Tension control of rewinding and unwinding
Rewinding and unwinding tension control is the most common topic in the tissue industry, and you can use torque control or speed control to complete precise control. Mitsubishi Electric not only has servo and inverter products for tension control, but also special products for tension control, such as magnetic particle brakes and tension controllers, so that the tension control of the rewinding and unwinding produced by paper towels is simpler.
Problem response 2: multi-axis synchronous control of more than 100 axes
If large equipment such as diapers and sanitary napkins need to complete multi-axis synchronous control of more than 100 axes, it is not enough to rely on the 64 servo axes controlled by the same motion controller on the left side to achieve multi-axis synchronization. Mitsubishi Electric R series PLC can be used, and more than three motion controllers can be installed to control 192 servo axes together to complete high-speed, high-precision synchronous control. In the super-large system, Mitsubishi Electric's new RD78 motion controller can also be used, which can achieve accurate and stable synchronous control of 768 axes (256*3).
Topic response 3: material correction
In synchronous control, due to various reasons such as mechanical errors, errors such as packaging, cutting, and positioning will be formed, and then it is necessary to compensate for the moving speed and moving distance through the motion controller, which is the function of color mark compensation and deviation correction.
Topic response 4: limit output function
In the high-speed glue spraying control, the limit output function can be used, after comparing the position data fed back by the encoder, when the specified position is reached, the glue gun can be opened to start spraying. The use of this function does not require programming, and can reduce the program size and then reduce the scanning time, improving the control accuracy.
Topic response 5: electronic cam function
In the paper towel occupation, the electronic cam function is very common, the cam curve can be actively generated and manually generated, and the rotary cam can generally be actively generated, and the more messy cam curve can not be used actively, so it needs to be generated by manual setting of angle, stroke and curve.
Topic 6: Synchronization between systems
In the production of paper towels, the synchronization function between devices is more important, which can be done simply among Mitsubishi Electric products. When synchronous control is required between different systems, the encoder can be used to transmit the movement status of the equipment and complete the synchronization function between multiple different devices.
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