vffs application solution - rockwellautomation.com...such as cisco to leverage on their expertise....
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VFFS Application Solution
Vertical Form Fill And Seal MachineSolutions for Advanced, Customized And Stand-Alone Machines
Sensor DetectsEnd of Roll
Detecting Overtravel of Tension Arm
Detecting Jam at Outlet
Missing Lug Check
Detecting Registration Mark to Synchroniuze Sealing
and Cuting OperationsEdge Detection(centering of film)
Cross sealing jaws create top and bottom seals in the pouches, and cut the filled pouch from the empty pouch.
Product enters the system through the forming tube.
Vertical sealing bars seal the edges of the film tube together.
Low friction rollers guide the film to the forming area.
The forming collar shapes the flat film into a round film tube.
Film transport belts pull the film through the forming area.
Machine/OEM Challenges• Material splice and film roll placement.• Film tension and gripping control.• Unique mechanical designs for different products.• Adjustable sealing pressure for different films and product sizes.• Grip control / slippage.• Proper force applied to the seal without energy waste.
Development Tools• Design productivity tools –Standard and reusable software
modules, AOIs, Motion Analyzer, Safety Automation Builder.• Modular code and HMI screens compliant with industry
accepted standards.• Integrated Architecture® offers a scalable, multi-discipline Logix
platform in a single programming environment.• Standard, off-the-shelf components.• Engineering expertise and support to help decrease time-to-
market.
Advanced MachineTypical Architecture
• Modern Human Machine Interface – ability to access PDFs and videos.
• Servo for faster changeover. • Variable Frequency Drive on integrated architecture with
cost effectiveness. • Reduction of panel space – I/O outside panel.
Packaging Speed > 80 Packs Per Minute
Network EtherNet/IP™
Controller CompactLogix™ L2
Variable Frequency Drive PowerFlex® 525
Servo Drive Kinetix® 5500
Synchronous Motion Up to Four axes
Studio 5000 Logix Designer® Power programming which allows program designs to be modular for easier programming and higher equipment safety. It saves significant engineering time, enables faster startup, and commissioning.
Optimized electronic CAM profiles motion control systems may ensure smoother machine operation and enhance machine mechanical life.
Optimal machine speeds by using motion sizing tools - Motion Analyzer.
Diagnostic information regarding Servos available on Human Machine Interface.
Programmable for constant seal-time for any machine speed.
Dynamic change of machine speed and corresponding sections synchronize with Controller Master reference.
Application program based on Pack ML State Model.
Higher machine speeds by optimization of cycle.
Studio 5000 Logix Designer®
Stratix™ Switch EtherNet/IP
Kinetix®5500 Servo Drives
CompactLogix™ L2 Controller
Unwinder
Film Feed
Sealing Jaw
PowerFlex® Drive
Filler
Jaw Unit Up/Down
PanelView™ Plus 7Human Machine Interface
Customised Machine – Typical Architecture
• Food grade servos and wash-down I/O for better sanitation.
• Single network based control architecture.• Motion Analyzer – Advance Motion Design tools
that improve performance.• Faster development cycle reduces time to market.
Packaging Speed > 100 Packs Per Minute
Network EtherNet/IP
Controller CompactLogix L3
Variable Frequency Drive PowerFlex 525
Servo Drive Kinetix 5500
Synchronous Motion More than 16 axes
Scalable control with a single programming environment with integrated motion instructions.
Higher capability and scalability with up to 30 I/O modules and 16 motion axes.
Integrated recipe management recipe controls allow companies to sidestep the repetitive process of tuning machines during a line change by saving and managing multiple settings.
Common Human Interface platform and networking services.
Built-in security capabilities support security standards, particularly ISA SP99. Collaborate with IT security specialist company such as Cisco to leverage on their expertise.
Safety enabled throughout.
Studio 5000 Logix Designer
Stratix Switch EtherNet/IP
Kinetix 5500 Servo Drives
Compact logix L3 Controller
PanelView Plus 7Human Machine Interface
Film Feed
Sealing Jaw
Jaw Unit Up/Down
Rotary Disc Filler
Filler Nozzler
PowerFlex Drive
Unwinder
Common programming software Connected Components Workbench™ software for Micro800®, PowerFlex (AC Drives), PanelView™ 800.
Advanced Motion Control Supports up to 3 motion axes using Pulse Train Output.
Versatility of interfaces Up to 6 high speed counter inputs and up to 3 Pulse Train Outputs over embedded digital I/O. Up to 5 plug-ins and up to 4 expansion I/O modules.
High flexibility Plug-in and expansion modules allow you to optimize your machine cost by choosing performance and functionality specific to your machine needs.
Touch probe function Able to capture accurate registration position at high speeds with built-in hardware.
Stand-Alone Machine Typical Architecture
Connected Components - proven optimal configuration. Cost effective solutions. Reduced panel engineering enables a shorter time for wiring and thus improves machine assembly time. Availability of plug-in modules at the controller allow for expanded machine features and functions.
Packaging Speed < 80 Packs Per Minute
Network Modbus / Pulse Train Output
Controller Micro800® Family
Variable Frequency Drive PowerFlex® 523
Servo Drive Kinetix® 3 / Kinetix® 300
Motion Up to 3 axes
Micro850
IN
OUT
0 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27
18 19
0 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
POWER
RUN
FAULT
FORCE
COMM
Connected Components Workbench Software
Discrete/ Analog
PowerFlex 523 Drive
USB
EtherNet/IP
PanelView™ 800Human Machine Interface
Micro850® Controller
Film RegistrationSensor
Film Feed Encoder
Auger Feed
Film Pull
Cross Jaw
Film Unwind
PTO
PTO
PTO
Material Feeding
1
Filling of Materials
Vertical Sealing Web
Pulling
2
Sealing and Cutting
3
Supporting Your Business Every Step of the WayAt every stage in the life cycle of your machines, Rockwell Automation is your collaborator. From design to build to operation and maintenance, you can count on the continuum of Rockwell Automation resources.
By taking advantage of our products and services, you can lower your Total Cost to Design, Develop, and Deliver®, while improving your time to market. You will be better equipped to react quickly to change, increasing profits and attracting new customers with
high-performance and innovative machines. Whether providing you with single components, entire systems or specialized consultation or trying to achieve sustainable production initiatives, our goal is to offer solutions on a personalized level.
For More Information:Call a Rockwell Automation sales office or an authorized distributor today or visit us online at www.rockwellautomation.com
Publication OEM-BR044B-EN-P – September 2015 Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Allen-Bradley, Connected Components Workbench, Compact Logix, Compact I/O, Kinetix, LISTEN. THINK. SOLVE., Micro800, Micro850, PanelView, PowerFlex , Rockwell Automation, Rockwell Software, Stratix, Studio5000 Logix Designer, and Total Cost to Design, Develop and Deliver are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA. All other trademarks and registered trademarks are property of their respective companies.
For more information about our OEM Solutions, please visit: http://www.rockwellautomation.com/go/lit/oem