Abstract: Focus on the application of Delta's new ASDA-A2 high precision network type AC servo driver. By simplifying the PLC program, the overall response speed of the high speed labeling machine is achieved.
Keywords: trapping machine, servo control, labelling, labeling, debugging
1 Introduction
The trademark packaging of FMCG has the function of disseminating commodity information and is an important competitive weapon for consumer terminals to realize the value of commodities. Since the 1990s, China's fast-moving consumer goods packaging industry has developed rapidly. The concentration of production and automation of fast-moving consumer goods companies has continued to increase, and packaging equipment has grown in size, speed, efficiency, and automation.
The purpose of the labeling machine is to bottle color fast-moving consumer goods color trademark film. Typical bottled bottled goods include bottled beverages, cosmetics, pharmaceuticals, and health products. The labeling speed indicates the technical level of the labeling machine and the benefits of the packaging equipment. The speed of the domestic labeling machine mainstream labeling is concentrated in 100-400 bottles/min. 400-800 bottles/minute speed is a high-speed sleeve label, and all manufacturers are actively developing their own high-speed labeling machines. The speed of 800 bottles/minute is usually considered to be close to the operating limit of the mechanical system. The use of sleeve labeling machine greatly reduces the manpower and material resources of the sleeve labeling machine. For example, in the juice processing line, the sleeve marking machine is an indispensable device. At present, the domestic mainstream bottle labeling speed of 400 bottles/minute is difficult to meet the demand for production of fast-moving consumer goods such as juice drinks, beer, etc. The process of sleeve labeling has increasingly become the production bottleneck of high-end users. With the rapid development of the food packaging industry, more and more world-renowned brands of juice drink manufacturers hope to achieve high-speed production profits by increasing the speed of production of the entire line.
2 sets of labeling process
2.1 sets of standard routing
Color printing factory thermoplastic plastic trademark packaging materials in the form of coil material. The function of the labeling machine is to automatically unwind and cut the tube label, accurately insert the container to achieve the label packaging, transfer to the subsequent heat shrinking process, and fix the label to the proper position of the container, as shown in FIG. 1 .
2.2 Sleeve labeling process
(1) The principle and process of the sleeve labeling machine are as follows: Sensor 1:mark check; Sensor 2:cutter check; Sensor 3:bottle check; Servo 1:bend; Servo 2: cut mark.
(2) The process is described as follows: When sensor 3 senses the bottle, motor1 starts and starts to send the mark; when sensor1 senses the mark, motor1 stops sending the mark; motor2 starts cutting the mark. The bottle is not stopped during the delivery of the label. Set labeling automated process is shown in Figure 2.
3 Delta High Speed ​​Labeling Automation System
Application of Delta's ASDA-A2 high-performance servo controller's labeling and labeling system enables the labeling speed to reach 600-800 bottles/min. The scheme design is shown in Figure 3.
3.1 ASDA-A2 Servo Drive System
The new ASDA-A2 high-accuracy network-based AC servo drive launched by Delta since 2000 is a key motion control system that realizes high-speed and high-precision automated sleeve labeling. Its features are as follows:
(1) High-resolution encoder specifications: A 20-bit incremental encoder is provided; it meets the needs of mechanical devices that require fine-positioning control. In addition, ASDA-A2 also supports absolute encoders to meet the current position when the client station is powered off, and provides a wider range of applications for position control.
(2) Network-based control architecture: In response to the current global industrial control community's need for high-speed network control, ASDA-A2 supports both the CANopen (1M bps) and FlexRay (10M bps) communication standards in addition to the standard Modbus communication specifications. The hardware interface is a single-input single-output RJ45 interface, which can achieve multi-axis high speed control.
(3) Powerful internal position mode: ASDA-A2 enhances the internal position mode function of the standard ASDA-A series and provides a "position control editor"; the internal position register has been increased from 8 points to 64 points, and the number of digital input points (DI ) Increased to 14 points, the position control mode from a simple point-to-point movement mode, promoted to a parameter can be set in the speed conversion between two points, or even jump settings in different locations. Greatly meets the customer's functional requirements for "servo driver".
(4) Electronic cam editor: ASDA-A2 provides electronic cam stroke planning. The software part provides the schedule editor to allow the operator to plan the route by himself, and the parameter part can select the source of the master axis to meet the diversified functional requirements of the customer.
(5) ASDA-Soft monitoring software: Four channels of monitoring oscilloscopes, providing 16bit data volume data, through the USB1.1 hardware interface, can achieve timely monitoring capabilities. In the parameter editor, increase the amount of parameter data to 32 bits to provide more function settings.
3.2 Labeling and Marking
The servos that send the mark and cut the mark are separated from the PLC of the upper layer control system, and the movement of the servo is realized by the machine sensor through the internal program of the DI trigger servo controller. Reduce unnecessary loss of time to meet the requirements of high-speed sleeves. Servo control mode: Pr mode (internal register command mode)
(1) Submitting a bid: In the PR mode, the COMPARE and CAPTURE function blocks are opened. Feed start: When the bottle is sensed
When using the event-triggered EV1 (sensor3) to touch the sending standard servo action and start the delivery, the EV2 triggers the PR parameter to write the COMPARE and CAPTURE control parameters, and starts the CAPTURE function to grab the color mark. The target is controlled by the target sensor1. Send the label to stop: When sensor1 senses the mark, PR uses the CAP positioning command to interrupt the previous path.
(2) Cut mark: The PR command is used to trigger the event. When the labeling is completed, the target servo motor's target position arrival signal DO directly triggers the cut servo operation.
3.3 analysis of process difficulties
(1) The memory occupied by the PLC program lengthens the cycle scan time of the program, and delays the action time of the cut and subscript.
(2) Due to high-speed requirements, at least 0.1 s will be required to complete a set of standard operations, requiring the subscript and cut the standard motor must start and stop frequently, accurate positioning.
(3) The deformation of the label, the sensor malfunction, etc., caused the inaccuracy of the length of the label.
3.4 A2 servo sleeve performance advantage
(1) 1KHz bandwidth response.
(2) Mark crawl uses the servo internal compare + capture function module. In the capture function, the scratch mark DI signal (response time is only 1um) is directly connected with the servo controller hardware connection to increase the servo action time. The compare module can effectively avoid the malfunction of the target sensor.
(3) The control parameters are written without communication with the host computer. The A2 driver and pr program can be triggered by external events to write parameters and the response time is greatly improved.
Figure 4 wiring diagram
4.1 Servo speed
The feed servo uses two speeds: to shorten the deceleration time. The first segment = 1700 r/min; the second segment speed = 1000 r/min (width = 130, JL = 4). The pulse traveled in one cycle is approximately 10,000 (1 turn), assuming that the diameter of the feed roller D is 40 mm.
Corresponds to the actual standard length = 3.14 * 40 * 1 = 125mm (speed ratio 1:1), as shown in Figure 4.
4.2 Cutting speed
Speed=650r/min (Bandwidth=150, JL=4). The one-cycle distance is 1/4 turn (speed ratio 1:1) as shown in Figure 5.
4.3 Labeling System
Comprehensively send the standard and cut the waveform diagram of the servo, the send/cut standard system diagram is shown in Figure 6.
5 Concluding remarks
The program adopts Delta's high-performance A2 servo internal programming function and special intelligent module. The entire labeling and labeling process completely deviates from the control of the upper computer, simplifies the PLC program, and enables the servo to handle the signals of the target, the target and the target. More quickly, the response speed of the whole machine has been improved. After testing, the Delta A2 high-performance servo is applied. The entire period of the labeling and cutting is 80 ms, and the speed of the labeling can reach 750 bottles/min.