Application of INVT Non-woven Flat Mask Machine Control System

Abstract: This article focuses on the application of INVT non-woven flat mask machine control system, includes system requirement and process introduction.

Keywords: AX70, DA200, GD350, Flat mask machine

1.Preface
The most needed automation equipment in 2020 is the flat mask machine. Since the beginning of 2020, the epidemic of coronavirus has become more and more serious, this has led to a surge in the demand for masks. From China to dozens of countries such as South Korea, Japan, Iran, Europe, and the United States, more than three billion people. People must wear a mask and take the necessary protection to prevent the spread of the virus. The surge in the demand for masks naturally leads to an increase in the demand for mask machines, because masks need to be produced by automated equipment.

Facing the huge gap between supply and demand, INVT has combined its own advantages and organized experts to launch a new application plan for the control system of non-woven flat mask machines. The solution includes a series of products such as controllers, inverters, touch screens, servos, etc., which can not only meet the needs of customers, but also help enterprises to greatly increase production capacity and ease the supply of masks to a certain extent.

2.Equipment (control system) process and requirements
Non-woven flat mask machine process：

The flat mask is a combination of a mask body and an ear band. Traditional mask  equipment refers to the body machine that is responsible for forming and playing the mask body and the ear band machine that is responsible for welding the ear band. The efficiency of the body machine is high (120-150 Pieces/min), and the ear band welding machine is relatively low (40-60 pieces/min). In order to achieve the perfect combination of the output of the main body and the ear band welding machine, it needs the main body machine with 2 to 3 ear band welding machines In the fully-automatic integrated equipment, generally, a mask body machine is also connected to 2 to 3 ear band welding machines.

Figure 1: Non-woven flat mask machine process diagram

Non-woven flat mask machine control requirements:
The application solutions mainly include AX70 series programmable controllers, HMI, DA200 high-performance universal AC servo series, which can meet the needs of machine process.

The raw materials are passively pulled and unwinded, and the inverter realizes a relatively constant tension supply; The mask is shaped by a special mechanical mold, and the corresponding pattern is printed with the ultrasonic mold; The ear band welding station is divided into left and right positions, and the ear band is welded to the mask by controlling the on/off clip of the ear band, cutting the ear band, and lifting the platform. The two sides are folded and shaped, and the horizontal axis extends the structure of the model to fold the mask in half and fold together; The welding station and the folding and setting station need to keep the platform and the raw materials synchronized for welding. The servo system uses the electronic cam follow-up function to realize the round-trip operation.

Figure 2: Electrical system application diagram

Figure 2 is a schematic diagram of the electrical system application of a non-woven flat mask machine; the system is a PLC and servo drive to implement multi-axis control through the EtherCAT communication bus and communicate with the touch screen via Modbus TCP;

It has the characteristics of reliable stability, fast speed, and high compatibility; the main conveyor uses an inverter to adjust the motor conveying and the stepping motor is turned over. During the welding and folding process, there are two axes that need to follow the main axis to and fro and need to support more complex synchronization command.

3.Advantages and control system design
•Convenient wiring: This solution adopts the EtherCAT bus, the controller and the servo are connected through a network cable, which saves a lot of wiring time and improves production speed;
•Simple troubleshooting: bus mode communication feeds back fault conditions of each axis, saving trouble and time for troubleshooting;
•Improve accuracy: EtherCAT bus has high response speed and synchronous control to improve cutting and welding ear positioning accuracy;
•Increase productivity: Servo has a higher response and operating speed than cylinders, increasing production speed.

a.Electrical selection list:

Sideband press servo is 0.4kw, Blanking servo is 0.75kw, ear band press servo is 1.5kw, conveyor Servo is 0.75kw, and Transmission belt synchronous servo is 0.4kw.

Picture of non-woven flat mask machine:

Figure 3: Overall appearance of non-woven flat mask machine

Figure 4: Front part of non-woven flat mask machine

Figure 5: Side section of non-woven flat mask machine

4.Summary
The successful application of the INVT non-woven flat mask machine solution provides a more cost-effective non-woven flat mask machine system solution. It effectively solves the problems of complicated electrical wiring, low efficiency and high failure rate of traditional control, and realizes many functions that traditional control cannot achieve, and makes the mask machine debugging and maintenance easy and fast. It also shows that the application scheme of the mask machine control system is very suitable for this industry.

Reference:
1.AX70 Series PLC Hardware Manual. Shenzhen INVT Electric Co., Ltd.
2.DA200 servo operation manual. Shenzhen INVT Electric Co., Ltd.
3.Goodrive350 high performance VFD operation manual. Shenzhen INVT Electric Co., Ltd.