咖啡粉枕式包裝機總體設計及計量裝置設計
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包裝機械創(chuàng)新源自控制系統(tǒng)摘要: 一套豐富而先進的自動化產品體系為Hensen包裝技術設備公司所用,制造出最現代化的飲料包裝機械。位于德國不萊梅市的Hensen包裝技術設備有限責任公司(HPC)在制造先進的包裝機械領域已有25年的經驗。它所采用的由羅克韋爾自(www.rockwell.com)集成體系構建的先進并且易于操作的控制系統(tǒng)使包裝機械設計獲得了持續(xù)的創(chuàng)新能力。 正文:包裝機械呼喚自動控制 HPC公司因其制造的裝填和密封等機械而蜚聲世界,其產品包括一系列的標準機械和特種機械,可滿足不同的市場需求和應用。HPC公司是提供用于立式紙盒、軟袋的裝填和密封機械的專業(yè)制造廠家,其產品所對應的領域正在從可重復填充的包裝袋向不斷更新的快速消費品過渡。HPC公司同時也進行紙盒加工、機械組配,具備整條包裝系統(tǒng)生產線的制造能力。Hensen機械的使用功能可靈活調整,而且此型設備易于維護,在高速運轉時仍可保持穩(wěn)定的性能,并且可以快速轉換產品的種類和型號。HPC的客戶多是生產、包裝諸如飲料等快速消費品的廠商,他們面臨激烈的市場競爭,因此需要不斷開發(fā)新產品來吸引消費者的注意力。在德國,立式紙盒和軟袋被用作主要的可重復填充的包裝物,但是在北美和遠東,可再封口立式軟袋目前是諸如能源、運動飲料、洗衣液和個人護理液等液體的主要包裝形式。用于運動飲料外包裝的此類立式軟袋,因其外觀具有柔美的曲線和便于手握的模紋,使其在貨架上顯得十分醒目,運動過后口渴的人們也能更方便順暢地飲用飲料。今天高速的和全自動化的包裝機械需要具備最現代化的硬件和軟件控制系統(tǒng),此類控制系統(tǒng)包括精確運動控制系統(tǒng)、方便使用的人機界面和功能強大的邏輯控制系統(tǒng)。選擇集成供應商作為一家客戶遍布全球的供應商,HPC需要一家運轉良好的自動化設備生產廠家為其提供一流的、涵蓋全球范圍的技術支持和零部件供應。HPC同時也希望和在高端自動化領域有所建樹的專家合作,借助專業(yè)知識和豐富經驗來開發(fā)新一代包裝機械的先進的控制系統(tǒng)。在認真調查過一些自動化設備供應商后,HPC最終選擇了Rockwell自動化公司作為其供應商,并將Allen-Bradley Logix自動控制平臺作為其最新包裝機械的標準配件。Logix 是可編程邏輯控制器(PLC)系列的品牌,包括從功能強大的ControlLogix到緊湊的FlexLogix等一系列的品牌。因為Logix系列提供了多種的具體型號的控制器PLC以供選擇,HPC總能從中選出適合的控制器,應用到從小型機械到大型生產系統(tǒng)等不同場合。因為所有的Allen-Bradley PLC都使用相同的Logix控制核心,所以它們都使用相同的容易使用的RSLogix5000 軟件語言來編程。HPC的工程師只需熟悉這一種開發(fā)工具即可勝任工作。一套編碼可在這一系列中不同型號的PLC之間相互通用。 方便靈活 如虎添翼ControlLogix將邏輯和運動控制集成到了一個控制體系之中,并且可以對此兩種控制使用相同的一套開發(fā)工具,即RSLogix5000語言來方便地編程。除了這一通用的開發(fā)環(huán)境,Logix系列PLC還使用NetLinx獨特的、帶有開放式軟件界面的Allen-Bradley網絡協(xié)議來保證數據的有效流通。利用NetLinx協(xié)議,如同利用DeviceNet、ControlNet、EtherNet/IP等協(xié)議一樣,可以方便地傳輸數據;而且因為這些網絡使用開放的CIP因特網協(xié)議,因此可以直接和制造商的ERP(企業(yè)資源管理)以及其他商務IT系統(tǒng)相連。因為使用完全開放的傳輸協(xié)議,NetLinx確保了可以實現從機器的任一個輸入端口對機器進行設置的功能。工程師通過網絡,不必和控制器進行直接的物理連線,即可實現對設備的編程,從而設備調試、試車時間大為縮短。同樣,維護工程師在控制室,而不必走到機器旁,即可診斷、調試和修改程序。通過采用因特網技術,此理念得到了進一步的發(fā)展。用戶安裝一個Allen-Bradley 9300-Rades調制解調器,即可從世界上任何一個可以撥號上網的地方撥號連接整個基于NetLinx協(xié)議的控制網絡。NetLinx協(xié)議是Rockwell自動控制集成體系的關鍵,它保證了此體系中的硬件和軟件在出廠時即能完美結合在一起,相互配合,聯(lián)手工作。集成體系對例如象HPC這樣的機器制造商提供了諸多益處,例如它大幅縮短了設計和構建控制系統(tǒng)的時間,而且它提升了整臺機器的運行性能,使機器更易于維修,也更可靠,同時提高了生產商的生產效率和獲利能力。使用Allen-Bradley平臺DeviceNet的另一個益處是可以實現全自動化的設備置換(ADR)。ADR功能實現了在不用關停網絡的情況下即可置換Allen-Bradley PowerFlex驅動器這樣的設備,在系統(tǒng)萬一出現崩潰時,可將停機時間壓縮到最短。ControlLogix使用SERCOS數字界面和高速光纖網絡來實現控制器和伺服驅動器之間的數據傳輸。光纖網絡取代了大捆的電線,而且它還可以發(fā)送和接收驅動器的狀態(tài)信息。使用SERCOS的益處還包括使得機器調試更便捷、運行的精確性更高、系統(tǒng)運行性能更穩(wěn)定。HPC同時也采用Rockwell自動化公司的Allen-Bradley Guardmaster機器安全系統(tǒng)作為標準配件。此安全系統(tǒng)提供了一套完備的安全產品,從簡單的聯(lián)鎖裝置到使用激光掃描儀和光幕的屏蔽系統(tǒng)。Guardmaster系統(tǒng)達到了HPC的所有安全要求,同時也保證了和Allen-Bradley控制體系的可兼容性。Rockwell自動化公司集成體系的優(yōu)點在HPC的最新包裝機 HO-Auto上得到了集中體現。這款包裝機采用集成的運動和邏輯控制系統(tǒng),實現下述功能:即將一個噴口插入到一個紙盒中,并將接縫處密封好。使用ControlLogix控制器的機器可以快捷方便處理不同尺寸或規(guī)格的紙盒。當需要改變插入紙盒的噴口的尺寸時,需要變換機器的關鍵部件;在對機器的關鍵部件重新布位時,和傳統(tǒng)的機器相比,新型機器的控制部件PLC采用DeviceNet協(xié)議,來對伺服驅動器發(fā)出指令,大幅縮短了完成這一過程所需的時間。 Logix系列有多種具體型號的PLC控制器供選擇,HPC總能從中選出適合的控制器,應用到從小型機械到大型生產系統(tǒng)等不同場合。 操作人員可以通過Allen-Bradley PanelView人機界面來選擇所需的機器設置,然后通過ControlLogix來完成剩余的工作。Allen-Bradley Flex I/O模塊分布于機器的不同部位,通過此模塊,可實現對水壓閥的控制,并可將傳感器的信號反饋回來;它利用DeviceNet實現與PLC的數據交換,以往將信號傳會控制臺需要使用相當數量的電線,現在所需的電線數大為減少。 這一工序完成以后,紙盒可以通過傳送帶或軌道傳送到下一生產環(huán)節(jié)。HPC同時將Rockwell自動化公司的運動控制系統(tǒng)應用到了其CMF型裝填和密封機器設備中。此款連續(xù)作業(yè)的機器每分鐘可處理多達250個紙盒,這些紙盒可以由軌道系統(tǒng)提供,也可由HO-Auto紙盒成型機器直接提供。紙盒由一個注冊過專利的索引系統(tǒng)送入CMF中,導引到裝填器旁。在這里紙盒被引導到一個具有12個裝填和密封工位的旋轉傳輸帶上。這道工序也可實現加強型的密封。每一個CMF旋轉傳輸帶上的填充位都安裝有一個Allen-Bradley MP系列低慣性伺服馬達,此馬達由一個Allen-Bradley Ultra3000數字伺服驅動器控制。由于MP系列馬達具有較高的力矩/尺寸比,因而它在傳輸帶上只占用非常小的空間,而且便于安裝。Ultra3000驅動器也安裝在傳輸帶上,并通過SERCOS界面與ControlLogix PLC相連。傳輸帶通過滑環(huán)與機器的其它部位相連,這樣DeviceNet和SERCOS網絡即可通過旋轉節(jié)點無縫運行。經由PowerFlex可調速驅動器控制的傳輸帶傳輸,被填充和密封后的紙盒被送到最后一道包裝工序。“通過Logix實現的網絡和伺服技術之間完美的集成大幅縮短了工程時間”HPC的編程人員Jorg von Mallotkie表示:“這是因為利用一段程序,從機器的某一個單點即可對機器進行設置。在調試、試車階段也可以通過單點界面進行故障診斷,從而使得機器的安裝、調試時間較以前大為縮短?!?5Control architecture enhances machine innovationKe-Zhang Chen,Xin-An Feng,Lan DingAbstract :A broad family of advanced automation products enables Hensen Packaging Concept GmbH to continue developing and manufacturing state-of-the-art packaging machinery for leading drinks manufacturers and packers around the world. Hensen Packaging Concept GmbH (HPC) (www.hpc-machines.com), Bremen, Germany, has more than 25 years of experience building advanced packaging machinery. Advanced, yet easy-to-use control systems made possible by Rockwell Automations (www.rockwell.com) Integrated Architecture approach have been key in developing the advanced packaging machinery that keeps these innovations coming. Text: HPC is best known for its filling and sealing machinery, offering a range of standard and specialty machines to suit a wide range of applications. It specializes in machines designed to fill and seal standup cartons and pouches, a sector that is moving from the humble role of refill packs to highly innovative consumer goods. The company also builds machines to form cartons and assemble finished products in their final packaging, enabling it to offer complete end-to-end packaging systems. Hensen machines are designed to be flexible and easy to maintain, to operate reliably at high throughputs and to enable rapid product changeovers. Rockwell Automation has supplied automation and controls to many companies featured in Packaging Digest stories. For a list of these stories, go to the Packaging Digest website at www.packagingdigest.comHPCs customers in the highly competitive world of fast-moving consumer goods are constantly looking to develop new products to catch the jaded eyes of shoppers in supermarkets the world over. In Germany, standup cartons and pouches are mainly used as refill packs, but in North America and the Far East, manufacturers are now using standup pouches with resealable tops to package liquids such as energy and sport drinks, laundry detergents and personal-care products. In the sports-drink sector, these workparticularly well as alternatives to plastic bottles or cans, as the curvaceous pouch, with its molded hand grips, looks different on the shelf and enables thirsty sportsmen and women to gulp down the refreshing liquid faster. Todays high-speed, fully automated packaging machines require state-of-the-art control hardware and software, including accurate motion control, easy-to-use human machine interfaces (HMIs) and powerful logic control. As a major exporter to customers around the globe, HPC needed a well-recognized automation supplier able to provide first-class, global, technical support and parts backup. The company also wanted to work with proven experts in advanced automation, able to bring their knowledge and experience to help develop sophisticated controls for HPCs next-generation packaging systems. After carefully considering a number of automation vendors, HPC selected Rockwell Automation and has standardized on the Allen-Bradley Logix automation platform for its latest packaging machines. Logix is a family of PLCs, ranging from the powerful ControlLogix to the compact FlexLogix distributed controller. With such a wide selection available in the Logix range, HPC always has the right controller to match the application, from the smallest machine to the largest production system. Because all Allen-Bradley PLCs share the same Logix control engine, they are programmed using the same easy-to-use RSLogix5000 software, so HPCs engineers only need to be familiar with one development tool. Code can be reused across the range of controllers. ControlLogix brings together logic and motion control in a single, integrated architecture, and both can be programmed easily via RSLogix5000 using a common set of tools. In addition to this common development environment, the Logix family also takes advantage of NetLinx, a unique Allen-Bradley network protocol with open software interfaces that ensures the efficient flow of data. With NetLinx, data can be sent justas easily over DeviceNet, ControlNet or EtherNet/IP and, because these networks use the open CIP Internet protocol, they also link directly to a manufacturers enterprise resource planning or other business IT systems. By ensuring completely transparent communications, NetLinx also enables configuration of the complete machine from a single point of access. Because the engineer can program devices remotely over the network rather than having to physically connect to each one separately, commis sioning time is greatly reduced. Similarly, the maintenance engineer is able to diagnose and correct many problems from the control room without having to go to the machine. Internet technology takes this concept a step further and, by installing an Allen-Bradley 9300-Rades Ethernet modem, users can have remote dial-in access to an entire NetLinx-based control network from a PC anywhere in the world. NetLinx is one of the keys to Rockwell Automations Integrated Architecture approach, which means that all of its hardware and software work together seamlessly off-the-shelf. Integrated Architecture offers many benefits to machine builders like HPC, as it dramatically reduces the time taken to design and build control systems. It also improves the performance, maintainability and reliability of the complete machine, increasing the productivity and profitability of the manufacturer. Another benefit of using DeviceNet with the Allen-Bradley platform is Automatic Device Replacement (ADR). ADR enables devices such as Allen-Bradley PowerFlex drives to be replaced in minutes without shutting down the network, which minimizesing downtime in the rare case of a breakdown. To communicate information between the controller and servo drives, ControlLogix uses the SERCOS digital interface and high-speed fiber-optic network. The network replaces the complex bundle of wiring associated with traditional servo drives, and it is also used to send and receive information about the status ofthe drive. The benefits of using SERCOS include ease of commissioning, higher accuracy and improved system performance. HPC has also standardized on Rockwell Automations Allen-Bradley Guardmaster machine-safety systems. With a complete selection of safety products, ranging from simple interlocks to screening systems using laser scanners and light curtains, Guardmaster meets all of HPCs safety requirements, while guaranteeing compatibility with the Allen-Bradley control architecture. The benefits of Rockwell Automations Integrated Architecture are demonstrated in HPCs latest packaging machine, the HO-Auto. This fully automated machine uses an integrated system of motion and logic control to insert and seal a spout into a carton. The ControlLogix controller enables the machine to be rapidly changed from one carton size or format to another, increasing the flexibility and productivity of the machine. The time required to change tools to allow different size spouts to be inserted in the machine has been dramatically reduced compared with conventional machines. This has been achieved by using servo drives to reposition key components within the machine according to instructions sent by the PLC via DeviceNet. An Allen-Bradley PanelView HMI allows the operator to select the machine configuration required, and ControlLogix does the rest. Control of hydraulic valves and feedback from sensors is via Allen-Bradley Flex I/O modules distributed around the machine and linked to the PLC by DeviceNet, reducing the amount of wiring required to be brought back to the control panel. Once completed, the cartons can be delivered to the next stage of production either by conveyor belt or on rails.A wide selection of PLCs ensures that the controller always matches the application, from the smallest machine to the largest production system. HPC also relies on Rockwell Automation motion control for its CMF range of flexible filling and sealing machines. These continuous machines can handle up to 250 cartons/min, which are supplied via a system of rails or direct from an HO-Auto carton-forming machine. The cartons are fed into the CMF by a patented indexing system and are are guided to the filler. Here they are loaded onto a carousel, where 12 stations fill and seal the cartons. A security seal can also be applied at this stage if required. Each filling station on the CMFs carousel uses an Allen-Bradley MP Series low-inertia servo motor controlled by an Allen-Bradley Ultra3000 digital servo drive. Offering high torque-to-size ratios, the MP Series motors take up a minimum of space and are easy to install on the carousel. The Ultra3000 drives are also mounted on the carousel and are linked to the ControlLogix PLC via SERCOS interfaces. Slip rings connect the moving carousel to the rest of the machine, allowing DeviceNet and SERCOS networks to operate seamlessly across the rotating joint. The filled and sealed cartons are transported to thefinal packaging stage on a conveyor belt controlled by a PowerFlex variable-speed drive. The excellent levels of integration achieved between networks and the servo technology with Logix reduces engineering time considerably, says HPCs programmer, Jorg von Mallotkie. This is due to the ability to undertake all configurations of the machine from a single point using one piece of software. Diagnosis of problems during commissioning is also possible from the same single-point interface, enabling us to install and commission the machine far more quickly than before.55 畢 業(yè) 設 計橫封裝置三維圖集專 業(yè) 機械設計制造及其自動化 學生姓名 唐 佳 紅 班 級 BD機制031 學 號 0320110135 指導教師 陳 樹 祥 完成日期 2007年6月13日 圖1三維圖正面圖2三維圖側面圖3三維爆炸圖正面圖4三維爆炸圖側面圖5銷軸圖6銅套圖7隔套圖8導桿軸頭圖9連接套圖10導桿圖11螺栓圖12螺母圖13切刀底板圖14螺母圖15彈簧圖16彈簧圖17推板圖18壓塊圖19螺栓圖20切刀圖21螺栓圖22連接桿圖23螺栓圖24聯(lián)結盤圖25螺栓圖26墊刀板27螺母圖28刀架圖29熱封塊圖30機架圖31凸輪圖32軸承 畢業(yè)設計任務書課題: 咖啡粉枕式包裝機總體設計及計量裝置設計專 業(yè) 機械設計制造及其自動化 學 生 姓 名 唐 佳 紅 班 級 BD機制031 學 號 0320110135 指 導 教 師 陳 樹 祥 專 業(yè) 系 主 任 王 宗 榮 發(fā) 放 日 期 2007年3月16日 一、設計內容設計一臺咖啡粉枕式包裝機,具體進行總體設計、橫封切斷裝置設計及計量裝置設計。主要內容有:1總體設計(1)制定總體方案;(2)完成動力設計、運動設計、結構設計;(3)繪制總裝配圖。2計量裝置設計(1) 計量裝置裝配圖;(2)零件圖;(3)有關計算、校核等。3橫封切斷裝置設計橫封切斷裝置三維爆炸圖二、設計依據1課題來源:鹽城市盛和輕工機械廠2產品名稱:咖啡粉枕式包裝機3包裝物品:咖啡粉4包裝速度:30袋/min5. 包裝膜:PP卷、最大寬度50mm、長度50m三、設計要求1設備應能滿足咖啡粉包裝要求。2. 設備應保證包裝膜對正,便于調整。3設備應結構簡單、運轉平穩(wěn),工作可靠。4設備應便于維修。5設計圖樣總量:折合成A0幅面在3張以上;工具要求:應用計算機軟件繪圖。過程要求:裝配圖需提供手工草圖。6畢業(yè)設計說明書按照學校規(guī)定的格式規(guī)范統(tǒng)一編排、打印,字數不少于1萬字。7查閱文獻資料10篇以上,并有不少于3000漢字的外文資料翻譯。8到相關單位進行畢業(yè)實習,撰寫不少于3000字實習報告。9撰寫開題報告。四、畢業(yè)設計物化成果的具體內容及要求1、設計成果要求 (1)畢業(yè)設計說明書 1 份(2)咖啡粉枕式包裝機裝配圖 1 張(3)計量裝置裝配圖 1 張(4)計量裝置零件圖 1 張(5)橫封切斷裝置三維爆炸圖 1 張(6)其它零件圖 不少于7張2、外文資料翻譯(英譯中)要求:(1)外文翻譯材料中文字不少于3000字。(2)內容必須與畢業(yè)設計課題相關;(3)所選外文資料應是近10年的文章,并標明文章出處。 五、 畢業(yè)設計(論文)進度計劃起訖日期工作內容備 注3月17日3月18日布置任務 3月19日4月1日調查研究,畢業(yè)實習4月2日4月15日方案論證,總體設計4月16日4月30日技術設計(部件設計)5月8日5月23日工作設計(零件設計)5月24日6月7日撰寫畢業(yè)設計說明書6月8日6月10日畢業(yè)設計預答辯6月11日6月18日修改資料6月19日6月21日評閱材料6月22日6月24日畢業(yè)答辯6月25日6月28日材料整理裝袋六、 主要參考文獻:1 陸振曦、陸守道主編.食品機械原理與設計M.北京:中國輕工業(yè)出版社,1995.2 伍水順、張裕中主編.食品機械自動控制M. 北京:中國輕工業(yè)出版社,1994.3 宮相印主編.食品機械與設備M. 北京:中國商業(yè)出版社,1993.4 徐灝主編.新編機械設計師手冊M.北京:機械工業(yè)出版社,1995.5 葉偉昌主編.機械工程及自動化簡明設計手冊(上冊) M.北京:機械工業(yè)出版社,2001.6 葉偉昌主編.機械工程及自動化簡明設計手冊(下冊) M.北京:機械工業(yè)出版社,2001.7 M編寫組編.中國軸承新舊型號對照手冊.北京:兵器工業(yè)出版社,1995.8 周 暉,李興根.基于W77E58單片機的枕式包裝機控制系統(tǒng)的設計J. 輕工機械,2006,(03):97-99.9 陽斌.伺服技術在枕式包裝機中的應用J. 食品與機械,2005,(03):49-51.10 李曉偉.機電產品用于自動枕式包裝機J.現代制造,2006,(21):70-71.11 張延波,李曉偉.PLC在枕式包裝機控制系統(tǒng)中的應用J.山東科學,2006,(03):80-82.12 周駿.枕式包裝機熱封器與封口效果分析J.中國包裝,2004,(04):89-90.13 唐善華,仲淇生.枕式包裝機橫切機構的傳動問題分析及對策J.食品與機械,2003,(03):27-29.14 孫茂泉,嚴偉躍.信封式條狀包裝機的開發(fā)設計.輕工機械,2006,(03):127-129.15 呂月娥.枕式包裝機控制系統(tǒng)的設計與實現.機電一體化,2003,(03):32-36.七、其他八、專業(yè)系審查意見系主任: 年 月 日九、機械工程學院意見院長: 年 月 日5 畢業(yè)設計 文 獻 資 料專 業(yè) 機械設計制造及其自動化 學 生 姓 名 唐 佳 紅 班 級 B D機制031 學 號 0320110135 指 導 教 師 陳 樹 祥 文 獻 資 料1 周 暉,李興根.基于W77E58單片機的枕式包裝機控制系統(tǒng)的設計J. 輕工機械,2006,(03):97-99.2 陽斌.伺服技術在枕式包裝機中的應用J. 食品與機械,2005,(03):49-51.3 李曉偉.機電產品用于自動枕式包裝機J.現代制造,2006,(21):70-71.4 張延波,李曉偉.PLC在枕式包裝機控制系統(tǒng)中的應用J.山東科學,2006,(03):80-82.5 周駿,潘曉銘.枕式包裝機熱封器與封口效果分析J.中國包裝,2004,(04):89-90.6 唐善華,仲淇生.枕式包裝機橫切機構的傳動問題分析及對策J.食品與機械,2003,(03):27-29.7 呂月娥,李相偉.枕式包裝機控制系統(tǒng)的設計與實現.機電一體化, 2003,(03):32-36.8 梁燕飛.枕式包裝機橫封機構設計J.機械工程師,1999,(10):15-16.9孫茂泉,嚴偉躍.信封式條狀包裝機的開發(fā)設計.輕工機械,2006,(03):127-129.10劉云霞,周春國,楊軍良.多功能枕型包裝機光電自動定位系統(tǒng)分析J.包裝與食品機械,2000,(02):8-11.11項新建,鄭春水.多功能枕式包裝機自動定位控制系統(tǒng)的研究J.電工技術雜志,2001,(08):19-21.
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