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包装机械创新源自控制系统摘要： 一套丰富而先进的自动化产品体系为Hensen包装技术设备公司所用，制造出最现代化的饮料包装机械。位于德国不莱梅市的Hensen包装技术设备有限责任公司(HPC)在制造先进的包装机械领域已有25年的经验。它所采用的由罗克韦尔自()集成体系构建的先进并且易于操作的控制系统使包装机械设计获得了持续的创新能力。 正文：包装机械呼唤自动控制 HPC公司因其制造的装填和密封等机械而蜚声世界，其产品包括一系列的标准机械和特种机械，可满足不同的市场需求和应用。HPC公司是提供用于立式纸盒、软袋的装填和密封机械的专业制造厂家，其产品所对应的领域正在从可重复填充的包装袋向不断更新的快速消费品过渡。HPC公司同时也进行纸盒加工、机械组配，具备整条包装系统生产线的制造能力。Hensen机械的使用功能可灵活调整，而且此型设备易于维护，在高速运转时仍可保持稳定的性能，并且可以快速转换产品的种类和型号。HPC的客户多是生产、包装诸如饮料等快速消费品的厂商，他们面临激烈的市场竞争，因此需要不断开发新产品来吸引消费者的注意力。在德国，立式纸盒和软袋被用作主要的可重复填充的包装物，但是在北美和远东，可再封口立式软袋目前是诸如能源、运动饮料、洗衣液和个人护理液等液体的主要包装形式。用于运动饮料外包装的此类立式软袋，因其外观具有柔美的曲线和便于手握的模纹，使其在货架上显得十分醒目，运动过后口渴的人们也能更方便顺畅地饮用饮料。今天高速的和全自动化的包装机械需要具备最现代化的硬件和软件控制系统，此类控制系统包括精确运动控制系统、方便使用的人机界面和功能强大的逻辑控制系统。选择集成供应商作为一家客户遍布全球的供应商，HPC需要一家运转良好的自动化设备生产厂家为其提供一流的、涵盖全球范围的技术支持和零部件供应。HPC同时也希望和在高端自动化领域有所建树的专家合作，借助专业知识和丰富经验来开发新一代包装机械的先进的控制系统。在认真调查过一些自动化设备供应商后，HPC最终选择了Rockwell自动化公司作为其供应商，并将Allen-Bradley Logix自动控制平台作为其最新包装机械的标准配件。Logix 是可编程逻辑控制器（PLC）系列的品牌，包括从功能强大的ControlLogix到紧凑的FlexLogix等一系列的品牌。因为Logix系列提供了多种的具体型号的控制器PLC以供选择，HPC总能从中选出适合的控制器，应用到从小型机械到大型生产系统等不同场合。因为所有的Allen-Bradley PLC都使用相同的Logix控制核心，所以它们都使用相同的容易使用的RSLogix5000 软件语言来编程。HPC的工程师只需熟悉这一种开发工具即可胜任工作。一套编码可在这一系列中不同型号的PLC之间相互通用。 方便灵活 如虎添翼ControlLogix将逻辑和运动控制集成到了一个控制体系之中，并且可以对此两种控制使用相同的一套开发工具，即RSLogix5000语言来方便地编程。除了这一通用的开发环境，Logix系列PLC还使用NetLinx独特的、带有开放式软件界面的Allen-Bradley网络协议来保证数据的有效流通。利用NetLinx协议，如同利用DeviceNet、ControlNet、EtherNet/IP等协议一样，可以方便地传输数据；而且因为这些网络使用开放的CIP因特网协议，因此可以直接和制造商的ERP(企业资源管理)以及其他商务IT系统相连。因为使用完全开放的传输协议，NetLinx确保了可以实现从机器的任一个输入端口对机器进行设置的功能。工程师通过网络，不必和控制器进行直接的物理连线，即可实现对设备的编程，从而设备调试、试车时间大为缩短。同样，维护工程师在控制室，而不必走到机器旁，即可诊断、调试和修改程序。通过采用因特网技术，此理念得到了进一步的发展。用户安装一个Allen-Bradley 9300-Rades调制解调器，即可从世界上任何一个可以拨号上网的地方拨号连接整个基于NetLinx协议的控制网络。NetLinx协议是Rockwell自动控制集成体系的关键，它保证了此体系中的硬件和软件在出厂时即能完美结合在一起，相互配合，联手工作。集成体系对例如象HPC这样的机器制造商提供了诸多益处，例如它大幅缩短了设计和构建控制系统的时间，而且它提升了整台机器的运行性能，使机器更易于维修，也更可靠，同时提高了生产商的生产效率和获利能力。使用Allen-Bradley平台DeviceNet的另一个益处是可以实现全自动化的设备置换(ADR)。ADR功能实现了在不用关停网络的情况下即可置换Allen-Bradley PowerFlex驱动器这样的设备，在系统万一出现崩溃时，可将停机时间压缩到最短。ControlLogix使用SERCOS数字界面和高速光纤网络来实现控制器和伺服驱动器之间的数据传输。光纤网络取代了大捆的电线，而且它还可以发送和接收驱动器的状态信息。使用SERCOS的益处还包括使得机器调试更便捷、运行的精确性更高、系统运行性能更稳定。HPC同时也采用Rockwell自动化公司的Allen-Bradley Guardmaster机器安全系统作为标准配件。此安全系统提供了一套完备的安全产品，从简单的联锁装置到使用激光扫描仪和光幕的屏蔽系统。Guardmaster系统达到了HPC的所有安全要求，同时也保证了和Allen-Bradley控制体系的可兼容性。Rockwell自动化公司集成体系的优点在HPC的最新包装机 HO-Auto上得到了集中体现。这款包装机采用集成的运动和逻辑控制系统，实现下述功能：即将一个喷口插入到一个纸盒中，并将接缝处密封好。使用ControlLogix控制器的机器可以快捷方便处理不同尺寸或规格的纸盒。当需要改变插入纸盒的喷口的尺寸时，需要变换机器的关键部件；在对机器的关键部件重新布位时，和传统的机器相比，新型机器的控制部件PLC采用DeviceNet协议，来对伺服驱动器发出指令，大幅缩短了完成这一过程所需的时间。 Logix系列有多种具体型号的PLC控制器供选择，HPC总能从中选出适合的控制器，应用到从小型机械到大型生产系统等不同场合。 操作人员可以通过Allen-Bradley PanelView人机界面来选择所需的机器设置，然后通过ControlLogix来完成剩余的工作。Allen-Bradley Flex I/O模块分布于机器的不同部位，通过此模块，可实现对水压阀的控制，并可将传感器的信号反馈回来；它利用DeviceNet实现与PLC的数据交换，以往将信号传会控制台需要使用相当数量的电线，现在所需的电线数大为减少。 这一工序完成以后，纸盒可以通过传送带或轨道传送到下一生产环节。HPC同时将Rockwell自动化公司的运动控制系统应用到了其CMF型装填和密封机器设备中。此款连续作业的机器每分钟可处理多达250个纸盒，这些纸盒可以由轨道系统提供，也可由HO-Auto纸盒成型机器直接提供。纸盒由一个注册过专利的索引系统送入CMF中，导引到装填器旁。在这里纸盒被引导到一个具有12个装填和密封工位的旋转传输带上。这道工序也可实现加强型的密封。每一个CMF旋转传输带上的填充位都安装有一个Allen-Bradley MP系列低惯性伺服马达，此马达由一个Allen-Bradley Ultra3000数字伺服驱动器控制。由于MP系列马达具有较高的力矩/尺寸比，因而它在传输带上只占用非常小的空间，而且便于安装。Ultra3000驱动器也安装在传输带上，并通过SERCOS界面与ControlLogix PLC相连。传输带通过滑环与机器的其它部位相连，这样DeviceNet和SERCOS网络即可通过旋转节点无缝运行。经由PowerFlex可调速驱动器控制的传输带传输，被填充和密封后的纸盒被送到最后一道包装工序。“通过Logix实现的网络和伺服技术之间完美的集成大幅缩短了工程时间”HPC的编程人员Jorg von Mallotkie表示：“这是因为利用一段程序，从机器的某一个单点即可对机器进行设置。在调试、试车阶段也可以通过单点界面进行故障诊断，从而使得机器的安装、调试时间较以前大为缩短。”45Control 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) (), 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 () 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 HPCs 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 毕 业 设 计横封装置三维图集专 业 机械设计制造及其自动化 学生姓名 唐 佳 红 班 级 BD机制031 学 号 0320110135 指导教师 陈 树 祥 完成日期 2007年6月13日 图1三维图正面图2三维图侧面图3三维爆炸图正面图4三维爆炸图侧面图5销轴图6铜套图7隔套图8导杆轴头图9连接套图10导杆图11螺栓图12螺母图13切刀底板图14螺母图15弹簧图16弹簧图17推板图18压块图19螺栓图20切刀图21螺栓图22连接杆图23螺栓图24联结盘图25螺栓图26垫刀板27螺母图28刀架图29热封块图30机架图31凸轮图32轴承 毕业设计任务书课题： 咖啡粉枕式包装机总体设计及计量装置设计专 业 机械设计制造及其自动化 学 生 姓 名 唐 佳 红 班 级 BD机制031 学 号 0320110135 指 导 教 师 陈 树 祥 专 业 系 主 任 王 宗 荣 发 放 日 期 2007年3月16日 一、设计内容设计一台咖啡粉枕式包装机，具体进行总体设计、横封切断装置设计及计量装置设计。主要内容有：1总体设计(1)制定总体方案；(2)完成动力设计、运动设计、结构设计；(3)绘制总装配图。2计量装置设计(1) 计量装置装配图；(2)零件图；(3)有关计算、校核等。3横封切断装置设计横封切断装置三维爆炸图二、设计依据1课题来源：盐城市盛和轻工机械厂2产品名称：咖啡粉枕式包装机3包装物品：咖啡粉4包装速度：30袋/min5. 包装膜：PP卷、最大宽度50mm、长度50m三、设计要求1设备应能满足咖啡粉包装要求。2. 设备应保证包装膜对正，便于调整。3设备应结构简单、运转平稳，工作可靠。4设备应便于维修。5设计图样总量：折合成A0幅面在3张以上；工具要求：应用计算机软件绘图。过程要求：装配图需提供手工草图。6毕业设计说明书按照学校规定的格式规范统一编排、打印，字数不少于1万字。7查阅文献资料10篇以上，并有不少于3000汉字的外文资料翻译。8到相关单位进行毕业实习，撰写不少于3000字实习报告。9撰写开题报告。四、毕业设计物化成果的具体内容及要求1、设计成果要求 （1）毕业设计说明书 1 份（2）咖啡粉枕式包装机装配图 1 张（3）计量装置装配图 1 张（4）计量装置零件图 1 张（5）横封切断装置三维爆炸图 1 张（6）其它零件图 不少于7张2、外文资料翻译（英译中）要求：（1）外文翻译材料中文字不少于3000字。（2）内容必须与毕业设计课题相关；（3）所选外文资料应是近10年的文章，并标明文章出处。 五、