The customer described in this Application Story is a manufacturer of food handling equipment.  They design and manufacture special conveying equipment that allows for cooling and heating to take place over a longer period of time while maintaining product throughput.

Application:

Knowing the types of machines the customer builds, Steve Harrold, one of Knotts Co's Strategic Account Managers, made contact with the customer to introduce them to Omron's newest MX2 AC Drive.  The initial interest from the customer was solid. He mentioned that he may have an application in mind where something like the MX2 might make things work a little smoother.  He wouldn't give up much information, but we decided to get the Omron factory specialist in for a face-to-face with the customer to iron out the details.  What we didn't realize is that we were walking in to a perfect fit application for the Omron MX2 AC Drive.

Overview:

This application story is about a company that produces a wide variety of packaging materials including bubble wrap and packaging peanuts.  In addition to making the packaging material, they also sell a small machine that creates air packs.  Along with the machines for the air packs, they include add-ons including a stand for the machine and basket for filled air packs.

Problem/Application:

The process of creating the air packs, a length of empty packs are processed through the machine where they are filled with air and sealed.  As the packs pass through the machine, they are still attached to each other and needed to be gathered as not to end up on the floor and possibly damaged.  It is important to keep them contained and where they would not possibly be broken or accumulate dirt as they were being used for packaging.

Additionally, the stands for the air packs were made of steel and cost to make a sturdy stand that would not take up much floor space was substantial.  With a fully constructed stand, it proved costly to ship and did have a tendency to be top heavy.    

Solution:

Taking a look at the design of the steel stand, a similar structure was made from 80/20 aluminum extrusion.  The stand was ~35” in height with a single centered pole.  Using 3030 as the support and 1515 making up the base, along with key joining plats, a lower cost sturdy frame was provided.  The customer would include an aluminum plate on the top to hold the machine.  

To eliminate the issues with the air packs flowing everywhere, a small basket made of 1010, measuring ~38”x39”x36” was constructed.  With netting clipped on to the sides, the customer was able to provide to their customers a light weight, easy to assemble basket to collect the air packs during each run.  This allowed them to store the air packs safely until they were used.  

This design, in addition to resolving the issue with the cost, eliminated the issues with the stand being top heavy and significantly reduced the weight of the stand.  This, with the ability to build the stand in the field, allowed their sales men to carry a unit they could sell on the spot to their customers.  Sales of this add on increase ~20% compared to the previous stand.

Have an Application Question?

Whether your application is using  timing belt technology for a component of a larger system or a complete solution, the 3200 Precision Move provides the flexibility needed. Dorner offers a simple yet versatile pallet attachment system, the widest width possible with one belt, the complete integration with servo motors and drives, and package performance specifications.

MX2 Features and Functionality

• Dual motor configuration – You can configure drive parameters for 2 separate motors.(MX2) and 3 motors for RX.
• Motor Cable Length voltage suppression function Parameter
• Reduces noise associated with long distance motor cables.
• 4 Banks of parameter data on parameter unit. – Allows you to store up to 4 sets of parameters (systems) with easy upload and download
• High Speed Mode 1000Hz (B171) – Spindle applications
• DC Injection Braking/Dynamic Braking (Resistors available) – For fast braking applications.
• Frequency Matching (Speed Search)
• 200% Torque at .5Hz (MX2) & 200% Torque at .3Hz (RX)
• PTC Motor Thermistor Input. (Standard on all drives built it) – For monitoring motor temperature
• Support Permanent Magnet Motors (Servo Motors 200W and above)
• 1 Parameter auto tuning
• PLC Logic programming no additional cost.
• Positioning – 8 pre-set positions with Homing and speed Synchronization
• EtherCAT, Ethernet/IP, DeviceNET, Built in Modbus, Profibus, MLII and more.
• Torque control in open loop mode. This allows the 3G3MX2 to be used in applications where closed loop AC
• Vector drives were previously used.
• 10bit and 12bit Analog input resolution
• External 24 VDC for continuous operation
• Safety embedded; SO 13849-1, cat 3 – EDM monitoring output and direct integration into the safety circuit
• Built-in application functionality (i.e., Brake control)
• USB port for PC programming (Free Programming Software CX-Drive)

A customer in the contract packaging business needed to make changes to a machine in a timely manner. The equipment is a used to handle a roll of material and convert it to a packable product (commonly referred to as Converting Equipment). The material may be coated, heated, die cut and final cut into its final size. Some or all of these operations may be done depending on the product.

If the die cutting is not required, then the dies must be removed. Likewise if the coating is not required, the coating machine must be removed.

The problem is that each time a unit is removed; it must be lined up perfectly with the other stations in the machine. This is where 80/20 solved the problem.  First the entire machine frame was made out of 80/20. Then each section Coating, Heating, Die Cutting and The Final Cutter were made into stand alone frames made of the same 80/20 extrusion size. Each modular section was then fitted with 80/20’s UHMW linear bearing. The entire section could then be loaded from the end of the machine and slid to its correct position. Since the machine frame is one continuous length of 80/20, the linear bearings keep each section perfectly in line with the rest of the equipment.

The changeover is now done in half the time. The changeover can also be done by the line workers. There is no need to bring in the maintenance staff and spend hours of making mechanical adjustments.

Have an Application Question?

Cam systems are used by machine builders and machine integrators for very complex operations during machine operations. Cam systems are necessary in order to make the process run consistently and smoothly – but the programming and configuration requirements for cam systems can be very complex, time consuming, and require a high degree of experience and skill.

Cam editors are helpful in setting up complex motions for industrial systems. However, cam editors can be cumbersome in and of themselves. Cam editors also only perform one function – what if there are other systems and operations involved that require additional set up or configuration?

The Omron NJ Motion Controller’s cam editor is the newest generation of machine controllers. The exciting feature of the Omron NJ Motion Controller is how this system integrates vision, cam editor, motion, sequencing, RFID, and logic into a singular controller. In addition to this centralized programming capabilities is how Omron NJ Motion Controller still performs very efficiently without the typical slow down seen with other systems.

The cam editor in the Omron NJ Motion Controller has extremely easy programming for even the most complex motion operations, with profiles stored and available for edit or reuse at any time. Cam tables are easily modified whenever necessary and also PLCopen function blocks are available for any general purpose motional control requirements. The graphical screen for the cam editor makes navigation and programming changes much simpler to utilize so that with minimal experience your machine builders and integrators can use the Omron NJ Motion Controller.

With electronic gear and cam synchronization, imbedded EtherNet/IP and EtherCAT ports, certified PLCopen function blocks, and synchronous control of all machine network devices, it is easy to see how the Omron NJ Motion Controller can be a benefit to any industrial operation as well as machine builders and machine integrators who need easier ways to get their job done.

For additional information on the Omron NJ Motion Controller and how the cam editor as well as other features can benefit your operation, contact the professionals at The Knotts Company. The experience and focus on customer service at The Knotts Company will provide you with automation and motion control solutions that will fit your business and help you to achieve efficient operations and quality results while staying within your operating budget.

Contact Mark Guida, our Product Manager, if you have any questions.