automation control for bag making machine...automation control for bag making machine solutions to...

Automation Control For Bag Making Machine

Solutions to Help You to Design, Develop, and Deliver Innovative Machines

• Feeding : Smoothest indexing CAM profile with print mark correction, adjustable feeding angle• Sealing : Constant seal time control by advance CAM calculation• Line Speed : Production speed is changeable under running• Registration : Combine phase and length correction

Cutting feeder roll, handled by Servo

Cross sealing and chiling zone

Length sealingand chiling zone

3-Sided Seal & Central Feeder RollCentral feeder roll,

handled by servo

Dancer and bu�erMaterial unwind, handled by powder brake

Unwind feeder roll, handled by Variable Frequency Drive (VFD)

Stacking Conveyor

Machine Basics and Challenges• Multiple sealing zones with very critical temperature accuracy that affect the quality of end product

• Material length may elongate after sealing process, but the print mark accuracy still needs to be maintained

• The web-indexing movement poses challenges where the tension needs to be maintained

• To maintain the consistency of sealing quality, no changes are normally allowed during the production process; thus room for adjustment is very rigid and difficult

• Material can only be adjusted under running condition (production speed) which causes high wastage before condition turns stable

Machine Builder Efficiency• Configure motion, temperature, tension, and other factors with the easy-to-use Studio 5000 Logix Designer® software

• Standardize with S88 modular programming for reusable code that transfers into smooth and consistent data flow resulting in easy recipe management

• Minimize downtime by leveraging global, round-the-clock support from Rockwell Automation

• Reduce operational risk and improve productivity by adopting a comprehensive and integrated safety approach

Studio 5000 Logix Designer provides power programming based on the PackML State Model, offering modular code for easier programming, saving significant engineering, startup, and commissioning time.

Advanced Electronic CAM profiles help to provide “Equal-Time Sealing” feature. It also enables change in Sealing Time/Machine Speed during production.

Built-In Temperature Proportional Integral Derivative (PID) Loop helps to reduce panel space and also provide temperature accuracy.

Human Machine Interface (HMI) includes diagnostic information.

Feed-Forwarding Registration Compensation helps to deliver accurate feeding length.

Virtual Machine Master helps to synchronize each motion axis and punching/cutting movement, improving production quality and stability.

Advanced Machine Typical Architecture

• Architecture fully supported by EtherNet/IP™, improving machine efficiency and enabling information

• Advanced motion control improves production quality and flexibility

• Secure remote access providing real-time data collection, alarming, analytics, and troubleshooting

Machine Speed Typically 250 Cuts Per Min.

Network EtherNet/IP

Variable AC Drive PowerFlex 525

Servo Drives Kinetix 5500

Synchronized Motion Up to 4 Axes

*Standard bag length is 200mm, so average feeding speed is 200mm x 250cuts/min = 50meters/min

Midrange Architectural System

PanelView™ Plus 7 Graphic Terminal

PowerFlex 525 Drive

PowerFlex 525 Drive

Kinetix 5500 Servo Drive

MPM Servo Motor

MPM Servo Motor

MP-Series™ Medium Inertia (MPM) Servo MotorAC Motor AC Motor AC Motor

PowerFlex® 525 Drive

Stratix® 2000 Switch

CompactLogix™ Controller

Conveyor SealerUnwind

FeederCentral FeederCut Feeder

Custom MachineTypical Architecture

• Architecture fully supported by EtherNet/IP, improving machine efficiency and enabling information

• Advanced motion control improves production quality and flexibility

• Integrated Safety solution improves machine safety• Common Direct Current (DC) Bus motion solution helps to

save energy• Secure remote access providing real-time data collection,

alarming, analytics, and troubleshooting

Studio 5000 Logix Designer provides power programming based on the PackML State Model, offering modular code for easier programming, saving significant engineering, startup, and commissioning time.

Advanced Electronic CAM profiles help to provide “Equal-Time Sealing” feature. It also enables change in Sealing Time/Machine Speed during production.

Built-In Temperature PID Loop helps to reduce panel space and also provide temperature accuracy.

HMI includes servo diagnostic information.

Feed-Forwarding Registration Compensation helps to deliver accurate feeding length. It also helps to improve Multiple Print-Mark alignment for complex bag production.

Virtual Machine Master helps to synchronize each motion axis and punching/cutting movement, improving production quality and stability.


Network EtherNet/IP


Servo Drives Kinetix 5700

Synchronized Motion Up to 16 Axes


Large Advanced Architectural System

Stratix 5700™ExpressSetup

Setup EIPNet

EIPMod

AlarmIN1 IN2 OUT

2

4

41

85

6

8

1

3

5

7

Cons

ole

Com

1

2

1

2

N2

RefN1

DC +

DC -

Pwr B

DC +

DC -

Pwr B

Technology

Stratix 5700 Switch

Compact GuardLogix®


PowerFlex 525 Drive

PowerFlex 525 Drive

AC MotorMPM Servo Motor

MPM Servo Motor

MPM Servo Motor

MPM Servo Motor

MPM Servo Motor

MPM Servo Motor

MPM Servo Motor

MPM Servo Motor

AC Motor

AC Motor

PowerFlex 525 Drive

PanelView Plus 7 Graphic Terminal

Cut Feeder Central Feeder Front FeederUnwind

Unwind

Top Feeder

Main Sealer Bottom Feeder Side Feeder AConveyor


Network EtherNet/IP


Servo Drives Kinetix 3/300

PTO Motion Up to 3 Axes


Stand-Alone Machine Typical Architecture

• Leverage Connected Components for optimized configuration using a common software

• Simplify motion using indexing drives• Controller plug-in modules allow for

cost-effective expansion of machine features and functions

Common Programming Software using Connected Components Workbench® software for Micro800® controllers, PowerFlex AC drives, and PanelView 800 graphic terminals.

Kinetix 3/300 servo drives with embedded indexing simplifies motion control.

Versatility of Interfaces for up to six High Speed Counter (HSC) inputs and up to three ‘Pulse Train Output (PTO)’ over embedded digital I/O. Up to five plug-ins and up to four expansion I/O modules.

High Flexibility plug-in and expansion modules allow users to optimize machine cost by choosing performance and functionality specific to machine requirements.

Touch Probe Function in 2080-MOT-HSC plug-in captures accurate registration position.

Serial Port in 2080-SERIALISOL plug-in adds isolation for Modbus Remote Terminal Unit (RTU).

Component Bundle

PanelView 800 Graphic Terminal

Stratix 2000 Switch

AC Motor AC Motor AC Motor AC MotorTLY TL-Series™ Servo Motor

PowerFlex 525 Drive

PowerFlex 525 Drive

PowerFlex 525 Drive

PowerFlex 525 Drive

Micro850® Controller

Unwind (Powder Brake)


Table ConveyorConveyor

Sealer

Cut Feeder

Front Feeder

Unwind (Powder Brake)

Publication OEM-BR023A-EN-P - March 2017 Copyright ©2017 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Allen-Bradley, Connected Components Workbench, CompactLogix, GuardLogix, Kinetix, LISTEN. THINK. SOLVE., Micro800, Micro850, MP-Series, PanelView, PowerFlex, Rockwell Automation, Rockwell Software, Stratix, Studio 5000 Logix Designer, TL-Series, and Total Cost to Design, Develop and Deliver are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA. All other trademarks and registered trademarks are property of their respective companies.

For more information about our OEM Solutions, please visit: http://www.rockwellautomation.com/go/lit/oem

Start Building Smart Machines Today

Integrated Safety• Simplify machine design by utilizing safety

devices with minimal wiring • Shorten machine’s Time To Market (TTM) by

using a single software to easily program safety devices

Information Enabled• Provide insight into machine performance by

automatically collecting and analyzing critical data

• Increase productivity by leveraging the common network architecture to provide real time performance information

Simplified Integration• Save machine design time by integrating

multiple components into one infrastructure• Shorten commissioning and troubleshooting

time by utilizing modular programing techniques

Real-Time Diagnostics/Analytics• Reduce unplanned downtime by remotely

monitoring machine parameters on smart devices

• Achieve optimum operational performance and extend machine lifecycle with predictive maintenance

Operational Efficiency• Enhance productivity and reduce operating

costs by enabling machines to perform multiple functions

• Reduce engineering time spent on developing and rewriting machine code by using modular programming techniques incorporating Add On Instructions (AOI)

Partner with Rockwell Automation

Extensive Support• Enhance operational continuity with dedicated

pre- and post-sales support for machine design, programming, enhancements, and training

• Shorten TTM with global inventory and technical support regardless of your machine’s shipping destination

Safety & Compliance • Achieve global safety standards by leveraging on

an extensive portfolio of safety products • Improve productivity and machine safety while

reducing legal risks with help from TÜV-certified safety experts

Networks & Security Services• Link machines from various plant floors with

ease using solutions and productivity tools with minimal wiring

• Enhance machine’s protection from security breaches through collaboration with network experts

Global Brands Connection• Expand your product offerings or scale your

business by networking and connecting with global brands

• Enhance your business operations by gaining knowledge on best practices from fellow industry players

Co-Marketing• Strengthen your market presence by promoting

your machines at various global and local events• Collaborate with Rockwell Automation for

marketing collaterals for your machines

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