INVT DA180 Servo and GD27 VFD for Biscuit Packaging Machine in India

Abstract: This article mainly introduced INVT AX PLC, Servo, VFD, and HMI solution for biscuit packaging machine. INVT solution achieved auto pack pre-wrapped or bulk biscuits into ready-made cartons, ensured product protection, efficient handling, and presentation for consumers.

Keywords: DA180 Servo, Packaging, Filling, AX72 PLC, Ether CAT, E-Cam, INVT, HMI, VS-Q, Motion Controller, VFD, Conveyor, GD27, Speed Control

Brief introduction

This OEM, based in Mumbai, India, is a long-standing manufacturer and exporter of automatic and semi-automatic packaging and wrapping machinery for various industries. Their existing biscuit packaging machines used stepper motors and operated at low speed, limiting flexibility and productivity. The customer was seeking a high-performance solution to achieve faster, more precise, and fully automated packaging.

Customer requirements

The customer’s existing machines used stepper motors and first-generation PLCs, which were low-speed and had fixed motion profiles. The customer wanted to upgrade the mechanical cams to electronic cams to achieve higher adaptability to different product sizes, faster changeovers, lower energy consumption, and increased productivity. INVT provided the AX72 PLC, efficient DA180 servo, and VS-Q HMI to meet these requirements.

INVT Solution

INVT provided a high-performance solution using AX72 PLC, DA180 servo, GD27, and flexible VS-Q HMI to meet the customer’s requirement for a high-precision, high-efficiency, fully automated Biscuit packaging machine. The system integrates advanced control technologies, including PLC, VFD, Servo, HMI, and automated synchronization, to ensure reliable, accurate, and fast operation.

INVT Solution:

These systems integrate advanced control technologies like PLC, human-machine interfaces, and automated rejection systems to guarantee high speed, reliability, and hygiene by minimizing human contact with the product.

In this application, wrapped biscuit packets are automatically transferred from main conveyor to stacked conveyor. Main conveyor motor is driven by INVT GD27 VFD and stack conveyor is driven by INVT DA180 servo for the position accuracy of material feeding. On the other end folded carton is opened and conveyed to the loading station by using pneumatic cylinder assembly. These process is programmed and control from AX72 PLC Then biscuits packs are loaded from stack conveyor into the cartons using DA180 servo and pneumatic cylinder assembly for accurate packing. The carton edges are finally closed, either tucked in or with glue.

Solution advantages:

* Superior Performance: These machines with INVT control product offer significantly greater speed, accuracy, and flexibility, enabling rapid product format changes and precise control over packaging processes. The high precision of servo motors minimizes errors and material waste.

* Simplified Troubleshooting: All sensors, solenoid valves, VFDs (Variable Frequency Drives), and servo drive signals provide feedback to the PLC, making fault detection and troubleshooting much easier compared to conventional machine systems. The use of bus communication like EtherCAT further reduces complex physical wiring.

* Advanced Homing Functionality: Servo motor homing positions can be determined without the need for external physical sensors by using the motor's built-in encoder index pulse (Z phase). This method helps maintain accurate home positions and a cleaner mechanical design.

* Flexibility and Adaptability: The system's advanced features, such as electronic cam functions and recipe management via the HMI, allow for easy adaptation to various product sizes and types with minimal downtime for changeovers.

System Topology

System commissioning

Control panels

Solution Value

Compare with competitor solutions

1. Integrated E-Cam Functionality: The system utilizes the PLC's inbuilt E-Cam function with two cam tables synchronized to a single virtual axis. [1] Feeder (rotary) and Pusher (linear) movements are precisely managed by INVT servo motors.

2. High-Speed EtherCAT Communication: INVT DA180 servos support the EtherCAT communication protocol, which significantly reduces wiring complexity and simplifies troubleshooting.This ensures rapid and accurate synchronization, with cycle times as fast as 1 ms.

3. Real-Time Cam Curve Updates: The electronic cam curves are automatically updated in real-time to adapt to required production parameters.

4.  Customizable Logic and Data Logging: The system has been modified to support extensive customization options, including production data logging, batch data recording, and time-based product recipe selection.

5. Reduced Downtime: Electronic systems are less prone to mechanical wear and tear than older, traditional systems, which minimizes downtime and maintenance frequency.

6.  Optimized Performance: The machine achieves a throughput of 20-40 cartons per minute, depending on the specific product matrix and configuration.

Conclusion

INVT’s solution delivered significant performance improvements in terms of speed, quality and efficiency. Machine performance is better and smooth now, earlier it was mechanical cam and stepper motor on pulse control, we have updated the system with AX72 PLC and DA180 servo on Ether CAT .Here we have given solution against traditional mechanical system and Customer is much more satisfied with performance.