New development of the hottest digital packaging m

2022-08-18
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New development of digital packaging machinery

digital packaging machinery can not only provide greater output and stronger equipment flexibility, but also add many new features, such as remote maintenance, integration with the company's ERP system, evaluation of production data, etc

only a few years ago, no one expected the rapid speed of packaging machinery moving towards digitalization. With the increasing speed of the electronic process, it was once necessary to increase the distribution box. However, when the number of cables required by the bus system can be greatly reduced, coupled with the emergence of decentralized computers, it means that there is no need to increase the volume of the distribution box. Nowadays, independent distribution boxes are no longer necessary in the packaging industry, and digital packaging machines occupy less space than previous mechanical or electromechanical packaging machines

automation brings changes to packaging

the era of automation in the packaging industry began about 20 years ago. At that time, all mechanical equipment was equipped with a programmable logic controller (PLC) to control the logical functions and the mechanical power shaft of the driver. However, the flexibility of this first generation of automation equipment is not satisfactory. The life cycle of consumer products, especially food, is shortened, and products tend to be diversified, stimulating greater demand for equipment flexibility. In the second generation of automation equipment developed later, more and more functions are transferred from the mechanical power shaft to the electronic drive system, and the logic functions are still controlled by the PLC system

control and drive technology has been proved to be a key technology in the field of packaging machinery structure. Today, the fully electronic third-generation machine has all the advantages of servo technology, while setting up a new industry standard. Digital packaging machinery can not only provide greater output and stronger equipment flexibility, but also add many new features, such as remote maintenance, integration with the company's ERP system, evaluation of production data, etc

the logic function originally performed by PLC is losing its importance, and now the electronic motion function is dominant. With the improvement of equipment flexibility requirements, the number of servo motors is also increasing. This means that physical and logical interfaces are no longer required due to different programming languages and systems. Since the mid-1990s, some companies have driven the trend of integrated motion control and logic control solutions in the field of packaging machinery

top loading equipment is becoming more and more popular in carton packaging. Flexible cartoning machine loads goods from above, which is more flexible than horizontal machine. The robot arm can be equipped with different vacuum fixtures to adapt to different products. This solution is also very effective for composite packaging. For example, in medicine, blister packaging, ampoules, medicine bottles, medicine instructions and medicine spoons can be packaged with top loading equipment. In the field of confectionery, the top loading device is used to put all kinds of chocolates of different shapes into deep plates. The flexibility of top loading equipment operation is also effective for larger packages. The machine can adapt to different container shapes with only minor adjustments. This means that new product types can meet future requirements

data sharing and remote maintenance

the oil source control part is on the left. Now, in order to meet the customized needs of different customers, suppliers design controllers differently. Therefore, standardization not only enables different manufacturers to exchange key components with each other, but also frees users from relying on proprietary technology of manufacturers with a manufacturing gap impact ≥ 10kj/m2. The so-called open control structure will undoubtedly have greater flexibility

the automation concept jointly coordinated internationally is elaborated by OMAC (open modular structure controller) packaging machinery working group. The working group was initiated by machine users from the trademark product industry. They cooperated with machine manufacturers and technology suppliers within the framework of OMAC, with the goal of making the hardware of the automation system interchangeable within a period of time. The next step should be to coordinate different systems, achieve information transmission between machines, and standardize the operating principle

another trend is to establish system solutions for communication between automation technology (at) and information technology (it), as well as standards for data networks. This means that the company's information network and vertical data integration are feasible from the trial, control stage to the production stage. The joint communication standard makes the whole process from diagnosis, remote maintenance to interconnection and logistics (purchasing spare parts) smooth. This means that the information flow from digital packaging machinery can be used for more efficient production, including upstream and downstream business processes

with the birth of remote maintenance, rapid information exchange saves working time and travel costs, mechanical failures can be solved, and downtime can be reduced. For example, Bosch's remote diagnosis enables errors to be detected inside the computer through the operation interface of the servo drive system. The equipment adjustment required for replacing products or packaging materials also needs to be adjusted by software through remote servicing. Ideally, digital packaging machinery is equipped with a wireless system, which can be connected with external transmission media to control the supply of automatic packaging materials. So far, this is only a beautiful ideal

strengthen the quality assurance system

with the deepening of market globalization, the specific policies and regulations of each country need to be observed, and the quality requirements of the food and pharmaceutical industry also increase, which means that the requirements for quality assurance systems (such as automatic image processing) are also rising. Optical sensors can capture the details of high-speed mass production process, which can not be achieved by manual detection

all this means that the quality assurance system will be greatly improved, because the production process is fully monitored and the peak time is not automatically set: users can freely set the time from 1 second to 99 seconds according to the peak demand under the automatic peak measurement state, and then need to conduct random sampling. The importance of continuous inspection can be clearly reflected in the production of glass bottles and containers. Because the cap of reusable bottles sometimes has fragments, which makes it difficult to open the cap, not to mention that glass fragments may enter the bottle, so unqualified products must be reliably identified and removed from the production line. The optical system with flexible structure and operation interface can meet the needs of detection

the controller of packaging machinery depends on the accurate information sent by the sensor. For example, the special light barrier in the field of film packaging can obtain decisive rationalization results. If the light barrier is placed in an oval shape, it can be comparable to the appearance of a 1600t shuttle two station press in bentler Sigri's R & D center in ried im innkreis, and the film consumption can be reduced. This requires quite high requirements for the sensor, because the sensor must recognize the product through the film, which may cause trouble to the multi-layer film, melting seam or fold. The highly adaptable receiver has been proved to be able to successfully meet the requirements in this case, and can also adapt to different products and film types

reprinted from: Zhonghua printing and packaging

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