Motion Control for Packaging Machines

In today's competitive atmosphere, shorter innovation cycles and flexibility are vital to packaging companies wanting to rise above the competition. We are continually hearing from machine builders and Original Equipment Manufacturers (OEMs) about these challenges and the complexities they bring to machine operator safety and the pressure to do this efficiently.


Further, this demand has resulted in the decrease of batch build and multi-pack runs and now requires machinery to produce multiple packaging variations from the same machine. Adapting to this means the ability to perform quick product changeovers while maintaining a high level of throughput productivity.

Ultimately this impacts the machine operator's ability to perform quickly and safely. This reality has driven the industry to look into alternative solutions. Automation, coupled with motion control is the key to accomplishing this. However, the increase in motion requires a robust safety system to monitor and control these added moving components. For safety processes to run quickly and smoothly systems require multiple axis controllers, additional motion control devices and they must meet industry standards.

When these modified systems are deployed properly you will achieve the required flexibility and observe an increase in the throughput of products. One last issue to accomplishing this is choosing the right safety products to fit system needs.

When looking for motion control products it is important to look at the overall picture. First of all, motion control is needed to manage the movement of any highly dynamic drives and camshafts, synchronization of a wide range of decentralized drives to keep manufacturing safe at a low cost and at a consistent quality. Second, quick setup and maximum flexibility, as well as the ability for automatic adjustment to product variances are essential. Finally, the handling and robotics of a packaging machine is as an integral part of a complete automation solution.

Any and all motion control products must include the following: PLC to control the machine, optimum movement management on decentralized drives for motion control and an individual safety solution customized with integrated software and tools that meet universal, local and federal legislations.

Packaging specific applications and motion control components should also be adaptable for individual requirements. The ability to join together safety and industrial standards is a crucial element in any motion application. Equally imperative, safety must be integrated within the drive to make sure that every law of motion is available, optional real or virtual master axes and all additional tools able to suit the task of a specific packaging machine.

It is important to note, that a control solution should also be platform-independent. Integrated soft PLC in accordance with IEC 61131-2, can fast scan time from < 50us for 1000 instructions and no adjustments are required to change platforms. Thus, all of the automation in one project with support for modular structures, large selection of field buses, extensive libraries, motion control, interpolation and OPC Server, can positively impact both safety and productivity.

In further examining comprehensive motion control functionality, always consider this indispensible checklist to discern the most important features within any motion control product:

• Virtual main shaft and cam synchronization

• Integral "flexible cam"

• Register control

• Web tension control

• Linear and circular interpolation

• Electronic camshaft and safe motion within the drive

When choosing safety products for your packaging machines choose a company that is aligned with your priorities and use the above checklist to ensure you're making the best choice possible.