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The flexible machine packages cosmetic and perfume samples individually for promotional campaigns. © Esatec

The processes involved in handling and the actual packing process require many powerful servo axes, which often also have to work together smoothly with pick-and-place robotics. It is practical if the different components can be controlled via a common controller. The programmer can concentrate entirely on the application and does not have to deal with the underlying technology of the different systems.

Quickly loaded via pick-and-place

With its four precisely controlled axes, the Delta robot is predestined for fast pick-and-place applications, as it can place even the smallest products quickly and accurately in confined spaces. © Yaskawa

The D4 Delta robot from Codian Robotics used in the packaging machine, for example, with its four precisely controlled axes, is virtually predestined for such pick-and-place applications, as it can position even the smallest products quickly and accurately to the millimeter with a reproducibility of 0.1 mm in a confined space. While the second pick-and-place unit is more suitable for flat objects, the product shape is irrelevant for this robot. Equipped with a camera vision system, the Delta robot picks up elements of any shape that are delivered by the friction conveyor.

When developing the servo drives in the Sigma 7 series, the focus was on features such as fast commissioning, high production output and maximum operational reliability. © Yaskawa

All other drive tasks for loading and packaging the cosmetic and perfume samples are performed by servo drives from the Sigma 7 series. Two of these servo axes drive the main conveyor belt, two others ensure a precisely controllable product spacing on the friction conveyor, the five axes of the patented pick-and-place unit are also moved by these drives and a Sigma-7 servo axis is installed in the folding unit.

High power density and simple commissioning

There were many reasons for using these drive systems. When developing the servo drives of the Sigma 7 series, the focus was on features such as fast commissioning, high production output and maximum operational reliability, which benefited the packaging machine designers. Added to this was the large selection. The fast-reacting AC servomotors cover outputs from 50 W to 15 kW at supply voltages of 200 or 400 V and impress with their extremely compact dimensions and very smooth running.

The series includes narrow single and double-axis amplifier modules for 200 V or 400 V in a space-saving design, which can be arranged in a row without gaps in the control cabinet and optionally wired very easily via daisy chain. This reduces the installation effort. There is also a further space advantage: no additional cooling is required at ambient temperatures of -5 to 55 °C. The servos impress with their high resolution (integrated 24-bit absolute encoder), high dynamics and functions such as vibration suppression, suppression of machine resonance frequencies and tuning-less function for simple commissioning.

Compact controller for servo drives and robots

The servo axes and the delta robot can be controlled via a single controller. This is made possible by the MP3300iec RBT compact machine controller. © Yaskawa

The servo axes and the delta robot can be controlled via a single controller. This is made possible by the MP3300iec RBT compact machine controller used in Turbomailing. It was recommended to the French packaging machine specialists by Yaskawa, primarily because of the uniform application programming via a single software tool with standard PLCopen and Yaskawa-specific function blocks, which are available free of charge and make system programming much easier.

The range of functions also includes the integration of visualization, the integration of camera systems, conveyor tracking, a group toolbox to support G-code and many other features. Machine builders can even use this solution to implement robots without the need for a programming device (teach box) or a proprietary robot programming language. The motion sequence of the robot's individual axes is calculated in the controller's firmware and transferred to the robot controller. This allows the programmer to concentrate fully on the application without having to worry about the underlying complex technology.

The servo axes can also be programmed in the same software environment. With the Mechatrolink III real-time Ethernet bus, the compact controller ensures simple synchronization of robots and servo axes. The motion controller really comes into its own in conjunction with the Sigma 7 servo systems. Up to 62 real and 2 virtual axes can be controlled.

In addition to process data, the servo systems also provide the controller with status information, e.g. for a vibration analysis. The data allows conclusions to be drawn about the condition of the entire system and enables efficient maintenance planning. All in all, this provides the best conditions for high-performance motion applications such as the packaging machine described.