INVT AX PLC and DA200 Servo Used for 3-Axis Horizontal Flowrap Machine in India

Abstract: In this flowrap machine we pack medical gloves with eyemark correction. Flowrap machine is used for packing of multiple items like tea pouch, pocket deodorant, shampoo sacket or packet coming from packaging machine or from production. In this application installed complete INVT solution of motion controller AX series PLC and DA200 series EtherCAT type servo to achieved the application requirements.
Keywords: AX72, DA200 servo drives, servo motors and VS series HMI.

1. Introduction

The major section of this machine is table, saddle, column, rotary table, motion controller, servo and drive, tool clamping etc.

The major process of 3-axis flowrap machine in manual & in auto process.

1) Cutter Servo :- It is used to rotate cutter shaft which is used to cutting of pouch. In this machine virtual axis defined for the master axis and gear-in/ECAM block executed to achieved the product requirements. The cutter axis rotates 360degree and in cutting angle work as synchronous speed.

2) Conveyor Servo :- It is used to take material from production to our flowrap named as material conveyor. It runs 1:1 ratio with respect the master axis.

3) Pulling Servo:  - It is used to pull paper from unwinder as per need of material it is also in cam profile with cutter but length is depends on data feed in HMI. This axis working as per the correction requirements in length.

Figure – 3-Axis horizontal flowrap machine with AX72 PLC

4) Eyemark correction: - It’s a process in which we have to cut the paper in between of given cutting zone on paper. So eyemark correction means pulling of paper need to be less or more done by it. For the correction function give tolerance and offset range for smooth operation.

5) Coding: By the help of this device we can write date , batch number on our pouch its command given by controller.

6) Auto Cycle: When auto cycle run that time all 3-axis servo working in synchronization mechanism as per the application requirements.

7) HMI: In HMI we have given all data and manual auto & Homing screen. Here HMI use for user friendly and data feeding as per the product types.

8) Process:  In this machine simple operation of flowrap, the product is completely cover through packing film. In first step gloves(products) feeding through conveyor belt axis and film material feed with puller axis(plastic film). In second step sealing mechanism is there for proper sealing of pouch. In third step role play by cutter, the cutter axis rotate as per the feeding length and product conveyor to cut the pouch with and without eyemark system as per selection in program. 

Figure – Horizontal flowrap machine mechanism

2. Project information and Solution

* Project information

1. In this application different types of products packing as per the selection
2. AX 72C-1608 PLC and DA200 servo drives used Codesys based programming
3. Total 3 axis installed, all three-axis work with etherCAT communication
4. Panel design as per the system requirements for the products
5. Here HMI given for data feeding and recipe selections of the product
6. In PLC operations different types of the logic executed and tested
7. In this application synchronization task achieved after the proper ECAM & Gear-In logic executed with the help of virtual as well as real axis of the servo
8.  Here HMI and PLC communication executed through RS485 Modbus communication and ethernet port of the PLC used for programming as well as remote support applications.

Figure - Machine process view

Figure - HMI auto cycle window

* INVT solution

* System commissioning

Figure – PLC and HMI control panel of the machine

Figure – Servo installation and machine front view

3. Advantages and benefits
•    High accuracy in case of eyemark correction.
•    All data received in one hmi and manual & auto process done.
•    Speed of 100+ PPM running in production with length of pouch 265 mm.
•    When testing the system that time trial up to 200SPM for 200mm length. 

4. Conclusion

As per study and application execution, these industries multiple axis type of machines for packing the products. We achieved result through implementation of simple cost-effective model of motion controller AX72 series PLC. These types of application very useful in many industrial products manufacturing and designing of textile products as well as pharmaceuticals. 
5.  Future Scope

In this application we execute our system with 3 Axis Codesys based system. These types of application are popular and we provide best solution with minimum price. This type of system we can implement in many industries.