INVT Solution for Automatic Cartoning Machine in India

Abstract:  Automatic cartoning Machine solution from INVT represents cutting-edge technology in cartoning. This innovative Continuous Motion horizontal cartoning System smoothly erects cartons from the magazine, precisely inserts products, and securely seals them with either tuck or glue options. Designed with interlock features ensuring a “no carton, no product” solution, it guarantees accuracy and efficiency. Each product undergoes thorough validation with counters and check weighers at the final stage, ensuring only verified items are packaged. Equipped with state-of-the-art control technology and a user-friendly HMI concept.

Keywords: DA200 Servo, AX PLC, Motion control, Ether CAT , VS-Q HMI,E-CAM, INVT, PACKAGING, PHARMA

1. Introduction

MACHINE PROCEDURE:-
An automatic cartoning machine works by feeding cartons, loading products, folding and sealing the cartons, and then printing and quality assurance:
* Feeding: First, the carton is fed from the blanking device to the conveyor belt, and the machine transmits the command to the folding machine and the suction box device.

* Loading: The machine loads products into the cartons using a Pneumatic system. The guide rail clamp fixes the carton, and the push plate pushes the carton open. The two plywood moving with the carton rises from both sides of the guide rail to clamp the sides of the carton from the front to back, so that the carton opens at a right angle and moves forward to the filling area.

* Folding: The machine folds the carton's ears using a rotary motion and push plates. The conveyor belt of the automatic cartoner pack machine transports the materials, and the push rod pushes the materials into the empty boxes in the loading area.

* Sealing: The machine closes the carton's tongue and fastens it to lock the carton. After the material is pushed into the box by the push rod, the carton will enter the closing station driven by the guide rail. Before closing the box cover, the mechanise will first bend the tongue of the box, and the push plate will push the box cover to bend so that the tongue can be inserted into the box

* Printing and quality assurance: The machine checks the integrity of the cartons and prints labels and dates on them.

* The Basic Principal of the machine to feed the product inside the cartons and close the cartons. Filled, sealed and labelled product are coming through the labelling machine conveyor to cartoning machine Infeed Conveyor. It has a provision of feed worm which convert the product from vertical position to horizontal position. Leaflet also move parallel with product .Cartons are coming from the carton Loader. Vacuum cup will pick the carton and placed it in the carton loading channel. Simultaneously cartons conveyor and product conveyor moving parallel. During this time period bottom side of cartons are closed and from front side bottle will pushed inside the carton. Then after Top flap of the carton is to be closed and transfer to the out feed conveyor. Here one encoder is placed at the product conveyor which is the master axis and leaflet dropper, leaflet loader ,carton loader and product pusher are DA200 servo and the slave axis with respect to main conveyor and all this synchronization can be possible with the help of E-Cam of AX PLC .

2. Project information and Solution

* Project information

Site information: Pharma/ Packaging

* INVT solution

* System Configuration: 

* System commissioning

Control panels

3. Advantages and benefits

1) Automatic cartoning machines are faster and more accurate than semi-automatic machines, which can save time due to DA180 servo motor and AX PLC advance E-Cam synchronization function.

2) DA180 servo has 17 bit encoder leads to get more accuracy especially in synchronization motion and it support Ether CAT communication so the synchronization time with AX PLC is 2ms. Which improve the response time of machine and increase the speed of production.

3) PLC and drives communication over communication so external wiring decrease and troubleshooting easily.

4)  As all parts driven by servo and synchronization using E-cam function so we can bypass and run the machine with leaflet and without leaflet and only carton mode as per the production requirements

5)  No product no leaflet then no carton logic has been implemented so reduce the material wastage. So this logic can be easily implemented on AX PLC up to 60 station.
6)  Due to advance features of AX PLC and rich Ether CAT communication, Machine can run 300 carton per minutes without shifting the position and proper dropping of carton at product conveyor.
7)  This solution is cost effective and easily we can implement where cost issue compares to Omron.

4. Conclusion

INVT’s solution delivered significant performance improvements in terms of speed, quality, and efficiency. Machine accuracy is better and speed is increased now, earlier it was in Omron, now with INVT DA180 servo and AX PLC, the speed is increased from 260 carton per minute to 300 carton per minute. Machine is Install is Pharma Industry. Here we have given solution against Omron and Customer is much more satisfied with performance.