MATERIALS AND PACKAGING INDUSTRY · PLC, MOTION AND SAFETY
One machine, many operating modes: KM-Automation has developed the control system for a multi-purpose machine that winds, cuts and packs material in a wide range of configurations – thereby replacing several separate processes with a single integrated unit.
The customer
The end customer is a Danish manufacturer specialising in materials and packaging processing, producing both sheets and rolls for industrial customers.
The task
The customer wanted to combine several production formats into a single machine without compromising on speed or operator safety. This required a flexible control system capable of handling three different types of shafts, automatic sealing with packaging film and welding, as well as safe manual threading at the start of each new roll. At the same time, operation had to be intuitive – the operator had to be able to start and run the machine without having to memorise a complex procedure.
The technique
KM-Automation programmed the control system on a Siemens PLC, providing a clear overview of the many sub-sequences in automatic operation. Motion control with torque control ensures that the pull rollers and winder adapt to the material and do not run away should the web break. Safety is integrated into a dedicated safety programme featuring Sick laser scanners, physical limit switches and a global reset function. The HMI panel controls the entire machine – from selecting sheet functions and jogging the material to clean cutting and automatic welding of the final packaging film.
The dividend
The multi-machine replaces several previous processes and enables the customer to produce the type of roll specified in the order without lengthy changeovers. The operator is guided through a logical workflow via the HMI, can handle both sheet production and the finishing of finished rolls, and the safety system ensures that an inexperienced operator cannot go wrong. The result is reduced downtime, fewer machines in production and a more flexible production schedule.