Cartons, packaging boxes, gift boxes and other paper made products have become essential to our daily lives. They are commonly used for a variety of shopping purposes, such as for groceries, clothes, and education or entertainment items. They are also applied to different occasions such as weddings, holidays, and others. Since the demand for box containers has increased alongside the demand for daily commodities, carton manufacturers must provide diverse products to meet customers' needs, while meeting the challenge of maintaining high manufacturing standards. Finished products require compactness, quality, and uniformed symmetry, as well as highly accurate assembly with minimal defect rates. Overall carton production line efficiency and precision is often affected by workers taking days off, suffering injuries, or switching shifts, causing low and inconsistent production quality. To solve this problem and exceed the limited production speeds and precision levels, traditional carton manufacturers are starting to upgrade their original manual production lines by applying automation equipment and solutions that enhance production flexibility and efficiency, as well as reduce labor and production costs.
To meet the fast and precise automatic forming requirements of carton manufacturing, Delta has recently provided a high-precision, highly efficient, and flexible cardboard lid forming solution to a factory in Mainland China. The automatic forming line guarantees the finished products with high-end quality and optimizes production management, while reducing labor and material cost and waste. The line includes five processes: paper feeding, gluing, assembling, pressing, and forming. Firstly, the solution employs Delta's 24-axis Motion Controller DVP15-MC Series to seamlessly control the conveyors and send the raw paper to the gluing station with the help of the Vector Control Drive C2000 Series and Delta AC Servo Drive ASDA-A2R Series. After the paper is glued and sent to the assembling station by the conveyor, the machine vision system positions the paper using captured images. At the same time, the modularized program of the Robot Controller with Servo Drive Integrated ASDA-MS Series controls the SCARA Robot DRS60L Series to pick up the semi-finished cardboard at the material tray and assemble the paper with the cardboard based on the positioning result and signal. In the end, the conveyor sends the assembled semi-finished product to the last two stations for high-precision pressing and forming in completing the whole paper and cardboard assembly process. Delta's automatic cardboard lid forming solution assists our customer with an efficient and flexible smart forming line that combines multiple smart products and modularized programs, enabling easy parameter setup and control and effectively enhancing production quality and speed.
Considering the customer's needs, Delta's automatic cardboard lid forming solution adopts Delta's 24-axis Motion Controller DVP15-MC Series for optimizing manufacturing quality and management effectiveness. With its strong industrial network, the DVP15-MC Series simultaneously connects numerous devices such as AC motor drives, servo drives, and motors to perform real-time and accurate control of the conveyors for the entire forming line and the motions of feeding, gluing, and pressing. Additionally, the Robot Controller with Servo Drive Integrated ASDA-MS Series combines a controller and servo drive into one control unit that boosts the control performance of the SCARA robot for picking up cardboard and attaching paper, achieving perfect motion and successfully reducing defect rates and waste costs.
In actual application, Delta's cardboard lid forming solution brings the following benefits to our customer:
· Real-time data monitoring for easy management and data analysis: Delta's cardboard lid forming solution uses the 24-axis Motion Controller DVP15-MC Series that is built-in with a variety of industrial network communication ports (e.g. Ethernet, RS-232, and RS-485). It can instantaneously connect and control 3 sets of the Vector Control Drive C2000 Series, 5 sets of the Delta AC Servo Drive ASDA-A2R Series, and the 7-inch Widescreen HMI DOP-B Series (via Ethernet), offering real-time adjustment of the conveyors' motor speed and achieving multifunctional control and high-precision performance. In addition, the DVP15-MC Series is able to store a variety of production data, including production and yield counts for reducing material waste and improving production management and analysis.
· High-precision smart equipment for optimizing production quality and efficiency: With Delta's SCARA Robot DRS60L Series' stable performance and the high-precision positioning algorithm of the Machine Vision System DMV 2000 Series, the solution speedily and specifically positions and calculates the special features of each semi-finished paper and cardboard for achieving high reproducibility and minimizing production error. The time-efficiency operation of the DRS60L Series and DMV 2000 Series also succeeds in solving the human error of the traditional manual forming line, reducing labor cost and optimizing production quality. The built-in easy calibration function speeds up overall processing effectiveness by allowing users to simply input parameters to complete the coordinate set up of the machine vision system and the SCARA robot.
· Flexible and fast production with simple setup and programming: The solution provides the modular programming software PVS100 Series with a built-in guided operation processes and easy system operation interfaces that facilitate setup and control of peripheral equipment such as the Robot Controller with Servo Drive Integrated ASDA-MS Series machine vision system and more, achieving fast and convenient operation. Users can simply input the box parameters for automatically switching the production mode, creating a highly flexible production line.
Delta's cardboard lid forming solution helps our customer build a high-speed and high-precision carton forming line with simple operation software, high-precision control and drive equipment, and high-end smart products for our customer. Our solution not only enhances their manufacturing quality and efficiency with real-time data analysis, but also creates a flexible and diversified production management system to ensure competitiveness and a brighter future.