INVT Motion Control Solution for High-Speed Vial Filling Machine in India

Abstract: This document introduces INVT AX72 PLC, DA180 Servo, VS-Q HMI combination is a powerful, cost-effective automation solution for vial filling machines, enabling precise, high-speed, synchronized multi-axis control via Ether CAT bus communication, It solve the filling accuracy on high speed as its synchronized through E-Cam function and increase the productivity.

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

Project Background:

This OEM, based in Mumbai, India, is an old manufacturer and exporter of automatic feeding and mechanical feeding vial filling machinery for pharma industries. Their existing filling machines used solenoid valve for filling and operated at low filling accuracy, limiting the productivity. The customer was seeking a high-performance solution to achieve faster, more precise, and fully automated machine.

Customer Requirements

The customer’s existing machines used solenoid valve and mechanical cam with first-generation PLCs, which were low-speed, less accuracy and had fixed motion profiles due to mechanical cam. 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 with accuracy. INVT provided the AX72 PLC, efficient DA180 servo, and VS-Q HMI to meet these requirements.

INVT Solution

Solution Overview:

To achieve high-speed, high-precision, fully automated filling machine INVT has installed the new generation control product to achieve the application demand. These systems integrate advanced control technologies like Motion PLC, human-machine interfaces, and high response servo systems to guarantee high speed, reliability and accuracy of the system.

Solution advantages:

* AX72 is codesys based new gerenation PLC which gives features like Cam point calculation for different volume of filling material, which helps to get accuraty during callibration.

* AX72 PLC has inbuilt Ethercat communication Bus that supports EtherCAT motion communication to control DA180 servo with high precession. Based on the vial size the cam table update and gives fast and accurate volumatric filling.

* AX72 offers to run multiple cam table at same time so it can synchronize the vial carrier segment with respect to virtual axis accurately.

* No bottle no filling means no cam enable function can reduce the waste of filling material.

Solution Topology:

System commissioning

Control panel

Solution Value

1. The overlap wrap machine uses INVT Motion based PLC AX72, In which we have developed 7 cam table, E-Cam function is inbuilt, carrier(rotary) movement, filling cam for each filling station driven by INVT servo motor and all are synchronize with respect one virtual axis.

2. INVT DA180 Supports Ether CAT communication which can reduce the wiring, trouble shooting is easier, Synchronize is faster and accurate. Cam Curve automatically update in real time as per required matrix.

3. Low maintenance and high accuracy due to Electronic cam function.

4. As this machine is fully automatic from infeed conveyor to out conveyor so less human interference and less human errors.

5. Customization as per user demand like production data logic, batch data logging, time wise product recipe selection etc.

6. Production is increased by 10%.

Conclusion

INVT’s solution delivered significant performance improvements in terms of speed, efficiency and accuracy. we have upgraded the system with AX72 PLC and DA180 servo on Ether CAT. Customer is very much satisfy with our performance and feature and given repeated order to INVT India.