Demands on automation systems for packaging machinery automation technology

1. What will never change is change

Packaging machinery is the most extensive and full of changes in the market, because the production of the objects targeted by packaging machinery changes from time to time, such as the material (plastic, glass, metal, paper) and capacity (100ml, 100mg , 1l, 1kg), shape (round, square, special-shaped), packaging combination (such as internal bottle of medicine, external box, etc., and the box is bigger) There are so many changes. In addition, many packaging fields are divided according to the packaging objects and materials.

1. Food and Beverage-This includes daily food packaging such as beer, cola, liquor, milk, chocolate, coffee, eggs, candy, mineral water, etc .;
2. Corrugated paper packaging-including corrugated paper equipment, cutting equipment, folding boxes, boxes and other equipment;
3. Pharmaceutical packaging-for example, blister-packed tablets, injections, boxed, bagged, bottled, etc.
4. Tobacco packaging-this includes changes in soft boxes, hard boxes, strips, boxes, etc.
5. Fresh-keeping packaging-milk, yogurt, fruit, eggs, etc.

All these packaging changes pose challenges to machinery and control systems. How to adapt to so many changes?

Second, the development trend of packaging technology and the demand for automation systems

1. Demand for online production

On-line production is to combine the original discrete units into a continuous production process, eliminating the material handling and online storage in the production process, reducing online logistics and eliminating intermediate logistics links to greatly improve efficiency.

At Chinabrew in 2010, KRONES, the world's most well-known provider of overall filling line solutions, exhibited their all-in-one machine, which will blow bottles, clean, online inspection, filling, capping, labeling, hot film Packaging, stacking, and boxing all constitute a production line, so that beverage manufacturers can produce at the highest speed, because the turnaround time of the intermediate links of the entire production is eliminated, which greatly improves the efficiency of the whole plant. In addition, the entire production process is monitored by a strict management system, and the data can be integrated under a large factory structure, so that real-time analysis and process improvement of quality data and energy consumption data during the entire production process can be achieved And quality traceability, all of which can greatly improve the efficiency of the entire production system.

At the corrugated paper exhibition, we also saw domestic manufacturers develop integrated machines for slotting, die cutting, gluing, and palletizing of corrugated cardboard. These have greatly improved the efficiency of the entire production process, including The pre-printed flexo technology can also integrate the facial paper with the corrugated line, so that the corrugated cardboard can be cut and used directly without the need for subsequent printing, which not only improves the efficiency, but also improves the quality. , Because the pre-printing technology can better maintain the strength of the corrugated surface.

In the production line of baby diapers, various materials are unrolled, cut, pressed, sliced, palletized, packaged, heat sealed, and boxed, which can quickly produce a variety of different products.

The requirements of on-line production for automation are in the following aspects:

1). Open and flexible interface design: Only an open system can be connected to various sensors, instruments, and security systems, which not only includes the interconnection between devices, but also includes systems such as ERP / MES, CIMS, etc. The interconnection capabilities, including open interfaces such as OPC Server, connection to the database, etc.

2.) Flexible hardware design-First of all, there must be a complete product line to meet the products of various control systems. For example, B & R's GMC includes control for synchronous servo, asynchronous servo, DC, stepping, hydraulic, etc. Contains support capabilities for robots and CNC libraries.

2. More flexible production: rapid process switching

Due to the huge changeability of packaging objects, it poses a huge challenge to the flexibility of the production system. On the one hand, the process needs to be switched quickly, on the other hand, there is no need to design a new machine for a new production, which is reflected in the adaptation of the production system In terms of scope, the flexibility of the production system is not only reflected in the optimization of the organization and process of the production plant. On the execution side, the automation system provides rapid process switching and expansion of the production range. In this respect, the contribution of motion control technology is quite huge. How does motion control change the flexibility of the production system? We can see from a few examples:

2.1 Cutting: The most common packaging action is the heat sealing action. This unit exists in both horizontal and vertical food packaging machinery, and the cutting action changes the size and pressure, and these are most easily controlled by motion. To achieve this, because only a change in the torque output value of the cutting size and pressure is needed to achieve this, and the original system needs to be mechanically adjusted according to the change in parameters.

2.2 Filling: The system can automatically adjust the filling process according to the capacity requirements of the bottles, and modify the action logic of each valve according to different beverages such as carbonated drinks, beer, and water. These are very simple for automated systems.

For control technology, for example, B & R's motion control ACOPOS can realize online switching of electronic cams, which can be "side motion, side calculation"-it relies on real-time communication technology to ensure the rapid switching of the relationship between the various motion axes Online process switching capability.

3. Security Technology

With the end users and the government attaching importance to personal safety, the safety of the system must be taken seriously, which is mandatory, especially if Chinese packaging machinery manufacturers want to enter the European market, this must be considered.

According to IEC61508, the safety technology in the entire product life cycle is defined, and the corresponding methods and standards are defined from the entire process of system safety identification, evaluation, system design, testing, operation, maintenance and removal, including the definition of EN 62601, 61784, etc. The entire safety design and the safety standards of the adjustable speed system defined by EN61800-5-2, namely the definitions of Safe Motion SLS, SS1, SS2, SBC, etc.

To this end, various automation manufacturers have launched SafeLOGIC, Safe Motion and Safety Fieldbus technologies that meet SIL3 and PL e levels, and it is worth mentioning the openSAFETY technology introduced by B & R, which can run on different fieldbus and Ethernet technologies. Above, it can be used by end users and machine manufacturers, and it is an open source technology (Open Source Technology)

4.OMAC / PackML

The OMAC organization is an international organization jointly established by world-renowned packaging users such as P & G, Netstle, Coca Cola, and well-known automation manufacturers Rockwell AB, SIEMENS, B & R, etc., and has been committed to making packaging machinery have a consistent operation interface and have a procedural The common modular design allows terminal producers such as P & G, Coca Cola, Netstle, etc. to be able to operate freely when installing the mechanical system and electrical system of any manufacturer, because all the operation interfaces are designed to be unified, anyone Both can quickly realize the operation of the machine, and even for maintenance personnel, the modularity and openness of the software also allow them to quickly modify the program and adjust the program for process adjustment.

PackML defines the different states of the machine such as Starting, Suspended, stopping, aborted, etc. The operation process of the machine is the switching and combination between these processes, no matter how complicated the operation of the machine is, and what is shown to the operator is simple and easy to learn Screen.

At the same time, OMAC also defines the unified architecture of the hardware design of the machine system, including various system designs based on PC, PLC and drive as the control center.

The unified and standard operation is the future development requirement of packaging machinery, and the joining of large-scale end users will inevitably make this trend realized.

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