Automate carton cutting - product protection included
From batch size 1 to series production: With the new carton folder from Wächter Packautomatik, the carton blanks have integrated product protection that is moulded during the folding process. The machine's complex motion sequences are controlled by components from SEW-Eurodrive's MOVI-C modular automation system.
1 November 2020
Components from the MOVI-C modular automation system from SEW-Eurodrive (left in the picture, picture: SEW-Eurodrive) control the motion sequences of a carton folder at Wächter Packautomatik (right in the picture, picture: Wächter Packautomatik).
When packaging is folded sensibly, the product is effectively protected. This is the basic idea behind Wächter Packautomatik's new carton folder. The complex motion sequences of this machine are controlled by components from the MOVI-C modular automation system from SEW-Eurodrive.
The new Packaging Ordinance of 1 January 2019 has increased the requirements for product packaging. Sustainable solutions and environmentally friendly technologies are in demand. Plastic packaging material should be avoided wherever possible. Parallel to this trend towards greater sustainability, a further change can be observed in the furniture industry in particular. Driven by rising labour costs and a lack of labour availability, the market is demanding concepts for Automated packaging solutions in general and with High product protection in particular.
The special machine manufacturer Wächter Packautomatik GmbH & Co. KG is a traditional, family-run company based in Bad Wünnenberg-Haaren near Paderborn. Founded in 1975 as a two-man operation, the company has developed over a few decades into a Specialists in the field of end-of-line packaging.
Among other things, Wächter Packautomatik has developed a complete solution for packing multi-part components. It can process a wide range of carton sizes. (Image: Wächter Packautomatik)
It mastered technical and economic challenges during this period with flexibility and confidence. This contributed just as much to the success story as the „Made in Germany“ quality standard that the internationally active company, which today has around 200 dedicated employees, stands for.
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From batch size 1 to series production
The fact that Wächter specialises in end-of-line packaging and builds complex packaging lines for a wide range of products and industries is well known among experts. A novelty, however, is that the company packs individual parts in the furniture sector. from batch size 1 to series production. With these concepts, the cardboard blanks have a Integrated product protection that is moulded during the folding process. This means that the product is protected from all sides and no additional packaging materials are required. This significantly reduces the ecological footprint of these products and at the same time promotes sustainable and efficient production.
A two-sided bumper is formed during the folding process. This integrated product protection means that no additional packaging materials need to be inserted. (Image: Wächter Packautomatik)
Wächter combines these new concepts with its scalable and sustainable solutions for a fully automated packaging process. Environmentally friendly packaging material is the basis of the special machine manufacturer's actions. The company is also focussing on Economic process optimisation during the packaging process.
Individual requirements
With take-away furniture, various components are packed in a cardboard box. They differ in shape, size, weight and material. Typical contents are individual furniture parts, fittings, screws, etc. According to Wächter, this packaging situation poses two difficulties and therefore necessitates process optimisation. Firstly, each individual component has its own characteristics due to its different nature. Individual handling requirements. Secondly, the merging of large and small format content often results in Unused empty space, which is lined with filling material.
Integrated product protection: Folding and subsequent gluing creates a guide or protective edge. This means that no additional packaging materials need to be inserted. (Image: Wächter Packautomatik)
Optimisation can be achieved through a Automate packing process and prepackaging take place. Erected cartons are transported along a line of robot cells. The individual cells are supplied with different components, and the robots in turn pack these components into the passing carton. Small parts such as hinges or individual parts with sensitive surfaces such as fronts are packed separately in advance. In addition, pre-packed parts can be taken directly to the supplier and only reassembled later with other components. This allows complex packaging processes and logistical procedures to be streamlined and logistics costs to be optimised.
Scalable performance
Another advantage of this concept from Wächter is the scalability of the fully automated packaging system. The modular design enables both a minimum and a maximum solution - and all expansion stages in between. The software components of the MOVI-C modular automation system from SEW-Eurodrive enables this modular structure to be continued in the controller as well.
The MOVI-C modular system from SEW-Eurodrive (Image: SEW-Eurodrive)
With customised MOVIKT software modules such as MultiMotion Camming (motion functionality plus electronic cam disc) or Auxiliary Positioning, drives can be easily expanded via the MOVISUITE engineering software and updated using automatic code generation. The programmer simply adds the appropriate logic modules at defined points in the prepared programme.
The entire motion control of the installed drive technology runs in the MOVI-C CONTROLLER Power UHX85A. The example of the turner, which can be used to turn products as required in the flowing process, demonstrates the Versatility of the MOVIKIT MultiMotion Camming. It offers overlay functions for all available travel profiles as standard ex works. The programmers at Wächter were therefore able to realise the solution very quickly by cleverly overlaying the travel profiles of the travel and rotary axes.
The control cabinet contains the MOVI-C CONTROLLER Power, a MOVIDRIVE MDP90A supply module and five MOVIDRIVE MDD90A double-axis modules. A mains choke, mains filter and braking resistor were also installed. (Photo: Wächter Packautomatik)
With the Camming driving profile, drives can not only be engaged and disengaged in various variations, but also The curve can also be adjusted „on the fly“. All of this can be addressed via structures already prepared by SEW in the PLC programme, which also made work easier for the programmers at Wächter.
(Image: SEW-Eurodrive)
„The use of the MOVI-C modular automation system showed that the Wächter employees were very quickly able to adapt the new functions and possibilities of the MOVISUITE engineering software and the MOVIKIT software modules used to their standardised program structures.“ Christian Pasing, Sales Engineer Automation Technology at SEW-Eurodrive
The simple and fast commissioning of the drivetrain, which makes the initial commissioning of drives considerably more efficient, was also particularly emphasised.
Productive collaboration
With Wächter, the special machine manufacturer's end customers have a single point of contact for the entire packaging process, from individual conveyor belts to fully automated packaging lines. The situation is similar with its automation partner, SEW-Eurodrive. Christian Pasing in the Dortmund technical office has been supporting Wächter for over 13 years.
During this time, new and interesting motion control solutions for the packaging systems were constantly being developed. He reports: „In regular meetings, we exchange information about new functions on the part of SEW-Eurodrive and new requirements on the part of Wächter. Over the years, this has created a familiar business atmosphere that makes our collaboration extremely pleasant, goal-orientated and productive.“ It is therefore no surprise that Pasing sums up: „I am already looking forward to the next systems that we will realise together.“
(Image: SEW-Eurodrive)
Guest article. The author of the article is Heiko Füller. He is Head of Market Management at SEW-Eurodrive in Bruchsal.
