PACKAGING MACHINES

Application Notes: Shrink wrapping machine with rotary pallet

Machine purpose Critical points to be solved by the manufacturer / know-how
To wrap palletized loads in stretchable plastic film (polyethylene) by rotating the pallet. Mechanical: mechanical rigidity of the tower. Electrical: constant film tension, synchronization between rotating table and reel-holder carriage, safety of operation, pre-stretching of the film. After having fastened the film to the pallet, the rotation of the table wraps the film around the table. The reel-holder carriage moves regularly upwards so that the pallet is spirally wrapped. Depending on the selection of the operator, the wrapping can be carried out during the upward movement only or during upward and downward movement. A stabilizer plate maintains the loads during the rotation of the table. Wrapping proceeds with one, two, or three additional turns at the pallet bottom and top. Top cover is placed before wrapping, or in between the upward and the downward wrapping.

Theory of operation

Systems for prestretching film and/or for unreeling at variable speed (optional) Reelholder carriage Plastic film Rotating table and pallet

Stabilizer plate (optional)

Outlet conyeyor

Inlet conveyor

Automatic conveying (optional)

2003 Schneider Electric

All rights reserved. Doc. # 0105DB0305

PACKAGING MACHINES

Several examples of use Names used

Wrapping pallets consisting of several individual loads, external packaging of paper reels. Shrink wrapping machine with rotary pallet, pallet wrapping machine with rotating table, pallet wrapping machine, wrapping machine using stretchable film for loaded pallets, automatic pallet packaging line, automatic shrink wrapping line. Shrink wrapping machine with or without stabilizer plate, with or without pre-stretching of film, machines with semi-automatic cycles for low cycle rates, horizontal shrink wrapping machine for long products. Shrink wrapping machine with rotary arm, with central rotary conveyor, 5-side wrapping machine, wrapping machine with automotive carriage, automatic curtain-type wrapping machine, shrink wrapping machine-tunnel. Step 1: cycle start Fastening film to pallet or to rotating table. Start of table rotation for multi-turn wrapping from the pallet bottom. Step 2: Spiral application of film by upward or upward/downward movement of reel-holder carriage. Step 3: end of cycle Multi-layer wrapping from pallet top. Downward movement of carriage and film detachment.

Main types

Other typical machines

Operating cycle of a shrink wrapping machine with rotary pallet

Step 1

Step 2

Step 3

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Kinematics

Rotation of pallet-holder table: asynchronous motor up to 1.5 kW / 2 hp (7 to 20 turns/min). Lifting of reel-holder carriage: asynchronous motor up to 750 W / 1 hp. Stabilizer plate: asynchronous motor up to 750 W / 1 hp. Rotating table conveyor: asynchronous motor up to 750 W / 1 hp. Pre-stretching of film: asynchronous motor up to 750 W / 1 hp, or mechanical variable speed controller or magnetic brakes.

Associated systems

Stabilizer plate (also called pressing plate), pallet conveying with or without automation system, motorized pre-stretching of plastic film, film supply at variable speed, infrared remote control for cycle start, access ramp to rotating table, film sealing by ultrasonics, manual unwinder for top covers, pallet lifting system to facilitate the wrapping of the pallet bottom. Upstream machines Belt, conveyor, boxing machine, box weight control, palletizing machine, lifting truck. Downstream machine Belt, conveyor, lifting truck, shrinkage frame, tunnel or oven. Related professions Handling, palletizing, manufacturing of stretchable and/or shrink film, boxing.

Machine located in a process

Machine structure

The use of an ASI bus on this machine is more justified by simplification of initiation and maintenance (self-diagnostics) than by elimination of wiring difficulties. This compact, non modular and non extendable machine is equipped with an automation system that is controlled by micro or nano PLCs. The electrical equipment is incorporated in a cabinet. Some cabinets must meet NEMA1/NEMA12 requirements and feature tightness, internal ventilation, overpressure in dusty environments and, if necessary heating in humid or cold environments. The automation products connected to the mechanical equipment (detection, cylinders, motors) must comply with harsh environmental requirements. High pressure cleaning requires air and water tight enclosures and heat resistant products (pushbutton box, position switches, sensors). In the agro-food segment some products like lactic ferments call for the use of stainless steel. Use these wrapping machines at low temperatures (-30C).

Situation in environment

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PACKAGING MACHINES

Electrical equipment associated with shrink wrapping machine with rotary pallet
Item 1+2 Functions Power control and protection Power control Machine energizing Movement supply and safety cut-off Rotation of pallet holder table Lifting of reel-holder carriage Lifting/lowering of stabilizer plate Drive of rotating table rollers Pre-stretching of film Energizing variable speed controller power Protection Protecting motors against short circuits Protecting motors against overloads Protecting control circuit Protecting control power supply transformer Cabinet lighting circuit, 220V outlet Protecting and monitoring network and motor Detection Top of pallet, limiting vertical travel of carriage Bottom position of reel-holder carriage Reference position of table, counting, stop Upper overtravel of reel-holder carriage Stabilizer plate in contact with pallet Top position of stabilizer plate Presence and position of pallet before conveying End of film reel or film breakage Processing Start order sequence Time delays Power adaptation Switching variable speed controller setpoints Production and stock management Isolated machine Machine integrated into a process Emerg. stop and protective cover pos. switch monitoring 5 Dialogue Signaling Voltage presence on machine Machine energizing Machine in operation Displaying coded messages, machine status Displaying plain messages Resetting machine Controlling Starting and stopping machine Emergency stop Selecting automatic or manual modes Manual rotation control (maintenance) Resetting machine after fault Adjusting variable speed controller setpoints Program adjustment and selection Machine setting and adjustment *refer to general catalog for complete details.
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Solutions*

Q.

M1 M2 M3 M4 M5

LS1D, GS1, Vario, NS, Compact FA, KA LC1, U-Line ATV28/11 LC2, LH4, ATS, ATV28/11 LC2, LH4, ATS, ATV28/11 LC2, LH4, ATS, ATV28/11 ATV28/11 LC1, LU

1 1 1 1 1 1 1 3

Mx Mx

LS1D, GS1, GV2, GV, LB1L, NS, LG. LR, LT3, GV2M-P, GV7, LB1L, ATV28/11, LG. DF6, C60, GV2 DF6, C60, GV. DF6, C60, GV2 RH328AP, SM21, EM9T

3 3 1 1 2 x

3 D1 D2 D3 D4 D5 D6 D7 D8 4

XUJ-K1401386 XC XS, XC XC XC XC XU XU

1 1 1 1 1 x 3 1

CAD, LA1, RU, RX, RH, TWIDO, microTSX RE4, RE5, LA2D, LA3D, LA4D, micro TSX RU, RX, RH CAD, LA1, RU, RX, RH, TWIDO TSX micro PC link boards micro TSX micro TSX or TBX in unit and TSX7 cabinet XPS

x x x x x 1 x 1

XB4B, XB5B XB4B, XB5B XVB, DBM ZA2V, XBLA XBT XB2B, XA2B, Domino, XB4B, XB5B

1 1 x x 1 1

LG., XAD, XB4, XB5 Vario, LG., XAL, XAD, XB4, XB5 XB4, XB5 XB2M, XAD, XBT, XB4, XB5 SZ1RV, XBT, XB4, XB5 XBT XAC

1,2 1 1 x 1 1,2 1 1

PACKAGING MACHINES

Electrical equipment associated with shrink wrapping machine with rotary pallet (continued)
Item 6 Functions Communication Status of machine or certain elements Fault of machine or certain elements Machine parametering Slave definition Management of production data Management of administration data 7 Supervision Controlling the process: parameters ..... Preventive maintenance 8 Mounting and wiring: see special sheet chapter xx. Mechanical protection of equipment and control Attaching electrical equipment Routing cables Distributing power Connecting cables 9 Distribution General electrical distribution Mobile electrical distribution Mechanical protection of distribution Transformer Power supply NS, MasterpactTM, GS1 KN, KS AA, AM, ACM , Prisma 9070T/TF Phaseo, ABL7 1 x 1 x x AA, AM, ACM, ACP, LG., XAP, DE8-B AM3, AM1, DZ6, LG. AK2-G, AK2-L, LG. AB3, AK5 AB1, DB6, DZ5, AB5, ABE, 9080G 1 x x x XBT N/G XBT N/G x x TSX TSX XBT, ATS, TSX, ATV28/11 XBT, XAL, XVB, motor starter, soft starter TSX, Transparent Factory TSX, Transparent Factory x x x x x x Solutions* Q.

*refer to general catalog for complete details.

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PACKAGING MACHINES

Selection criteria for users of shrink wrapping machines with rotary pallet
Machine performances: - cycle rate: up to 70 pallets per hour. - range of pallets to be wrapped - maximum height: 8' - width x length: 5' x 5', table diameter 6' - maximum weight: 4,400 lbs. - centering fault admissible by the machine: 5 to 10cm - ranges of film that can be operated by the machine: - type: polyethylene, polypropylene and heat-shrink films, - film thickness: 15 to 50 microns, - top cover thickness: 60 to 100 microns - pre-stretching range of film: 0 to 300% - adjustable covering rate - number of required packaging ing components - wrapping on the5sides or making up a top cover - load maintained by stabilizer plate - automatic fastening of film to pallet - automatic sealing and cutting of film at the end of wrapping action - printing or labeling of pallets - automated pallet transfer - real and perceived quality of the finished product. Reducing the operating costs Optimum use of the ground surface: machine size. Quick change of production runs: - automatic adjustment: pallet height, cycle, pre-stretching of film, - memorization of wrapping programs, - rapid machine cleaning - automatic change of film reel Controlling the machine: - synoptical control, production supervision, - man/machine interface by means of plain - grouped commands, - adjustable production cycle rates. Economical utilization: - reduction of adjustment and parametering times, - economical consumption of materials (containers and contents), Respect of environment: emitted EMC. Reduction of machine stop times; minimization of disturbances: - limiting the mechanical wear and tear by movement controls: - amplitude control (detection), - speed and acceleration control (variable speed controllers and motor starters), - automatic operation should be preferred (automation system). - selecting electrical components meeting the environmental requirements - ambiance: received EMC, temperature, humidity, vibrations. Reducing the maintenance costs Using preventive or prediction maintenance. - programmed maintenance table. Centralizing the maintenance actions - automatic and/or centralized lubrication. Quick trouble-shooting of the machine - graded access, - spare part availability, - accessibility of machine elements, - standardizing used products, - self-diagnostics, - plug-type products, - products that can be configured by uploading, - using products that require just few adjustments. Cost of a shrink wrapping machine with rotary pallet $6,700 to $116,000 Standards and homologations of the user country Safety of persons This machine is covered by machine directive No. 89/392/CEE, amended. Casings or covers protect the operator. Their correct closing is checked by safety position switches. These position switches and the emergency stop devices are monitored by a Preventa safety module. Illuminated signalling units indicate the machine operation. Leaders in Europe Germany: Dentz, Cyclop Austria: Belgium: Denmark: Soco Sytem, Kurt Lachenmeier Spain: Agfer, Saba Finland: France: Sfeima, Newtec, DEM, Thimon, Atecmaa, Agrafvit, Pack Alpha, Sogeplast.Cegepac, Linpac Greece: Hungary: Italy: Sotema Pack, Robopac, AF, Comarne Marchetti Norway: Netherlands: Poland: Portugal: Sweden: Switzerland: Form Czech Rep.: Turkey: UK: Leaders in Asia China: Korea: Japan: Taiwan: Thailand: Indonesia: Singapore Leaders in America Canada; Mexico: US: Argentina: Brazil:

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PACKAGING MACHINES

Shrink wrapping machine with rotary pallet

M3 M2

Motor Starter
main functions (...) optional

product that may be critical

M5

M4

M4

M1

Mark

Qty
1

Motor starter function

Rotation of pallet-holder table - acceleration and deceleration on the ramp in the S-curve to avoid gaps between the products on the pallet, - working speed adjustable depending on: - pallet weight and dimension, - the stretching of the film, - the unreeling speed of the film, - the cycle time, - two running directions for positioning the table, - braking of strong inertias, - precise stopping in position for pallet evacuation on the outlet conveyor. Lifting reel-holder carriage: - positioning the film with regard to the pallet, - assuring the covering of the pallet by a constant spiral pitch smaller than the film width.

Recommended product
ATV28 --ATV11 Motor control by type ATV standard variable speed controller. - If P < 0.75 kW / 1 hp, a standard ATV16 will be used - If P > 0.75 kW / 1 hp, a standard ATV16 with brake option and associated dissipation resistance will be used. - For stopping In correct position on the sensor (3), the automation system will control the speed drive at low speed.

Remarks
The variable speed controller setpoints will be carried out: - by use of potentiometer connected to the 0-10 V input of the speed controller, - or by programmed preselection (by software or calculator) controlled by inputs that are connected to a type XBC-D selector or type XC, XD, XU position sensors if wrapping speed changes during the cycle. @ 460 / 575 VAC ---------@ 115 / 230 VAC

M1

M2

LC2 --U-Line

Direct Starter with two running directions, P < 0.75 kW / 1 hp. If the wrapping speed is adjustable (depending on product type and weight) a type ATV variable speed controller should be used to assure a constant spiral pitch whatever is the wrapping speed. Direct starter with two running directions, P < 0.75 kW. Motor control by type ATV16 standard variable speed controller, P < 0.75 kW / 1 hp.

If a variable speed controller is used and if P > 0.75 kW, an ATV with brake option + resistance will be used. The mechanical brake will be controlled by the variable speed controller.

M3

(1)

Lifting and lowering the stabilizer plate.

LC2 --U-Line ATV28 --ATV11

M4

Drive of conveyor rollers of the rotating table: - synchronization between inlet and outlet conveyor speeds and the rotating table speed, - stopping of pallet in position, checked by a deceleration ramp. Pre-stretching of film by a motorized device.

This variable speed controller is mainly used to avoid that products move during the start and stopping in position before wrapping. @ 460 / 575 VAC ---------@ 115 / 230 VAC Available as mechanical variable speed controller. @ 460 / 575 VAC ---------@ 115 / 230 VAC

M5

(1)

ATV28 --ATV11

Motor control by type ATV standard variable speed controller, P< 0.75 kW / 1 hp.

Guiding roller, constant angular speed Constant linear speed Tension pendulum

Film reel Guiding roller, adjustable angular speed related to the wrapping speed

The difference in speed of the drive rollers allows to stretch the film (up to 300 %). An adjustment with regard to the wrapping speed is necessary to assure a constant stretching if the the wrapping speed Page 7

PACKAGING MACHINES

Shrink wrapping machine with rotary pallet

D4 D6 M3 D1 D5

Detection
main functions (...) optional

product that may be critical

D8 D2 D7 D7 D3 D7

Mark

Qty Detection needs

1 Detecting top of pallet in order to limit vertical travel of reel-holder carriage

Recommended product
XUJ-K 1401386 Diffuse photo-electric sensor with background suppression, specific to shrink wrapping machines: - operating zone from 0.05 to 1.7 m. XCK angular position switch with roller lever (adjustable). XS7 / XS8 plug-type inductive proximity sensor. XCK angular position switch with roller lever.

Remarks
Sensor mounted on carriage. Stable sensing even if film has light ripples.

D1

D2

Detecting bottom position of reel-holder carriage. Detecting reference position of rotary arm to: - count the number of turns, - stop the arm in correct position at the end of cycle. Detecting vertical movement overtravel (top) of reel-holder carriage.

XC

Fulfills both lower-position and overtravel functions. Several sensors can be used to obtain a more precise identification of arm position (ex.: sensors for identification at 1/4 of turn).

D3

>1

XS or XC

D4

XC

XCK angular position switch with roller lever (adjustable).

In no case the position switch can be used as mechanical stop (pay attention to machine inertia). For machines with stabilizer plate only.

D5
!

(1)

Detecting contact position (pressure) between stabilizer plate an d pallet.

XC

XCK rectilinear or angular position switch actuated by a mechanical device built into the plate. XCK angular position switch with roller lever (adjustable). XU reflex photo-electric sensors at machine inlet or polarized reflex at machine outlet. XU diffuse photo-electric sensor, miniature range with sensitivity adjustment. Sensor is mounted on the carriage, perpendicular to the plane formed by the film (plane must remain fixed).

D6

(1)

Detecting top position (initial position) of stabilizer plate. Laterally detecting position and reference of pallet for conveying functions. Detecting end of film reel or film breakage.

XC

For machines with stabilizer plate only. Alternatives: XC, XS, XU.

D7

XU

(3)

D8
!

XU

(1)

If there is a background (mechanical parts) behind the film, use a XU diffuse photo-electric sensor with background suppression.

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PACKAGING MACHINES

Shrink wrapping machine with rotary pallet

F2 F3 F5

Programmed automation functions

main functions (...) optional

F4

product that may be critical

F$

F1

Mark Qty

Detection needs
Controlling the pallet-holder table: - taking up information for detecting the table reference, - counting the number turns carried out.

Recommended product
TSX DMZ ALL-OR-NOTHING input/output module: If the information presence is maintained less than 5 ms, an event-triggered input (parameter one of the 4 channels of the first module). The counting of the number of turns will be carried out by a counting input (parameter one of the 4 channels of the first module). Analog input/output integrated into the configuration of the base.

Remarks
The inputs of TSX DMZ module have a response time of 0.1 ms to 75 ms The information will processed in rapid task by the software. Other solutions: Counting by input integrated into TSX 3722 basic module (max. frequency 10 kHz). Counting by TSX CTZ counting module (max. frequency 40 kHz).

F1
!

2I

1+I Controlling the motor stopping 1 AO Changing the speed reference of the or 1 OS variable speed controller.

TSX3722

If an encoder for speed return is used, the analog input will be replaced by a counting input. Other solutions: - Use of integrated serial link, extension of terminal port ASCII or UNITELWAY. - Use of serial link by PCMCIA board (UNITELWAY or MODBUS) on TSX3721 PLCs or TSX 3722 only. If a variable speed controller is used for this movement, refer to function F1.

TSX3710 or TSX3721 or TSX3722

Analog input/output by specific module type TSX AEZ or TSX ASZ.

F2

2O 2I

Controlling the lifting of reel-holder carriage.

TSX DMZ

ALL-OR-NOTHING input/output module: direct control of type LC2 starter ALL-OR-NOTHING input/ output module: direct control of type LC2 starter Analog input/output by specific module type TSX AEZ or TSX ASZ.

F3

2O

Controlling the stabilizer plate.

TSX DMZ

F4

1 AI Controlling the conveyor: 1 AO - controlling the variable speed drive or that controls the conveyor rotation. 1 OS

TSX3710 or TSX3721 or TSX3722 TSX3710 or TSX3721 or TSX3722

(1AI) Pre-stretching of film: (1AO) - controlling the variable speed drive F5 or for stretching by creating a difference optional (1OS) in speed between drive roller and brake roller.

Analog input/output by specific module type TSX AEZ or TSX ASZ.

Other solutions: - Use of integrated serial link, extension of terminal port ASCII or UNITELWAY. - Use of serial link by PCMCIA board (UNITELWAY or MODBUS) on TSX 3721 PLCs, or TSX 3722 only.

I: Input

0: output

Al: analog input

AO: analog output

S: serial link

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