As the level of automation continues to increase in the manufacturing industry, automated operations in the packaging industry are changing the way in which packaging processes operate and the processing methods for packaging containers and materials. A packaging system that achieves automatic control can greatly improve production efficiency and product quality, significantly eliminate errors caused by packaging processes and printing labels, and reduce energy and resource consumption.
First, the role of automatic packaging
Revolutionary automation changes the way packaging is manufactured and how its products are transported. The design and installation of the automatic control packaging system has played a very significant role in improving product quality and production efficiency, and in eliminating machining errors and reducing labor intensity. Especially for the food, beverage, pharmaceutical, electronics and other industries, it is vital. The technology in automation and systems engineering is being further deepened and more widely used.
At present, the structure of the automatic device is various. For example, you can meet the needs of a specific operation. The structural characteristics of industrial robots are between single and six axes. Based on the performance of this shaft structure, the robot "arm" is designed to operate an end effector or arm end tool under a motion controllable program. The number of axes represents the "degree of freedom" of the robot arm. In addition, there are auxiliary arms. For example, the shafts of conveyor belts, etc., but they are usually not mechanically coupled to the main arm of the robot. For different manipulator forms, they are generally classified according to the coordinate system composed of three axes of "x", "y", and "z". Most machines fall into the following five basic types: Cartesian or Cartesian coordinates, cylindrical coordinates, rotary or hinged coordinate systems, spherical or polar coordinate systems, and flexible combination manipulators (SCARA).
Second, the automatic function of the external device
A complete automation structure consists of many components, of which end-arm operating tools, material handling devices and identification/verification systems are the main components.
1, arm end operating tools
A robot is a tool that moves from one position to another using a device coupled to its end. The arm end operating tool, the end manipulator, is a component used to grab product, directional movement and feel performance parameters.
2. Material conveying device
Material handling and handling equipment is some type of equipment that is required for automatic movement during transport, storage, and control of the product during transmission and manufacturing. These include power transmission belts, monorail cranes, automatic guided vehicles and robots. In the packaging process, the factors that need to be considered for material handling are: product shape, weight and material properties; speed, distance and direction of the product during transportation, parceling and loading; the level of control required to connect with other devices and if The maneuverability of the component is allowed to be reformed as needed.
3. Identification and verification system
The ability to identify, validate and accurately track products has become an integral part of the entire packaging system. The identification method can use traditional bar code to radio frequency (RF) sensors that can track the tray or all products. Online bar code printing and verification is also necessary. Vision technology, which provides effective and reliable means to ensure product quality, can be used in many applications of packaging, such as product inspection and orientation, filling level and counting, optical labeling, text recognition, labeling copy verification, labeling Record and verification of all text and graphics (away from the production line).
Third, the process of automatic packaging
The first and most important step in implementing packaging automation is to define the process. A quality work project is based on the characteristics of the process, rather than on the automation equipment to determine the final design. The three key factors to consider when defining this process are product and packaging structure, total production, and labor force factors.
1, product / packaging structure
The structural design of the product/package directly affects the form of automated manipulator and material handling required. The structural size, shape, material and weight of the product/package will determine the structural design of the end effector and the requirements of the autoloader payload. Package structural designs with complex shape features, such as oval packaging containers, have more difficult orientation problems than standard round or square packages. The directional requirements for increasing system complexity should be carefully studied and analyzed prior to processing implementation. In the case of a filling box, the robotic end effector generally provides a process of grasping a sufficient amount of product and filling a complete box at one time. In this way, the moving distance of the robot is minimized and the product on the conveyor or production line is continuously traveled.
2, product production throughput
The main driving force behind packaging automation design is the total throughput of the product. The faster the line is, the faster the application of automatic gripping and sorting devices can help reduce the workload of the robot, and the fewer standard autoversaries that follow the package. The line speed not only affects the automation of the product, but also affects the labeling operation and visual inspection. In order to achieve effective visual inspection techniques, several related issues must be indicated. These include: part graphic consistency, inspection repeatability, consistent transfer speed (such as fluctuations in the production line), the number of tests that need to be completed, and appropriate software programs. These factors significantly affect the form and cost of a visual system. According to the general rule, the more the number of detections, the faster the video will run, which will lead to more complicated and expensive structural solutions. When the video device is integrated with the automated mechanism, the entire robot can achieve the orientation and presentation of the package in a consistent and repeatable manner.
3. Labor or human factors
The operation of automated packaging equipment is the result of continuous and effective cooperation, communication and interaction between management, engineering and production departments. All relevant personnel and technical departments must be assembled in a tightly united group that collectively acts in accordance with the established work processes, motivated by the same goal, and strategically reflects a cohesive force.
Fourth, the automatic system project management
As mentioned earlier, the best automated structural solution is always based on a complete process of good design. This requires a project with a certain level of management that ensures that all relevant issues are in the final design. When developing an automation solution, you must first establish a good team. This team should include representatives of various departments in the packaging process – procurement, investment, quality assurance, engineering, production, logistics, health care, safety, management, and system coordination with the seller. Internal and external users must form a partnership.
The system specification provides a systematic framework for program development. The design of the scheme, or preliminary design or preparation, is used to illustrate how the packaging process or system will address the specific provisions and requirements of the project specification. The design of the scheme is often a joint work between the manufacturer and the automatic line seller. The content is multi-faceted and can range from simple two-dimensional graphics to three-dimensional graphics of the main body.
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