1 Introduction

Reducing energy consumption and improving production efficiency in the period of financial crisis has become an indispensable means for enterprises to reduce production costs. How to make production equipment more automated and more intelligent control becomes its key factor. Packing machine and unloading machine are food,Plastic Bottle palletizing MachineIt is considered that the pharmaceutical industry bottled automatic packaging line is an indispensable important equipment. The function of the unloading machine is to automatically remove the empty bottle from the box to realize the automatic production of bottle box separation the function of packing machine is to put the bottle filled with finished products into the automatic production equipment in the box. The working quality of packing machine and unloading machine directly affects the coordinated operation and production efficiency of the whole packing line. Improving the working quality and production efficiency of the loading and unloading machine to reduce the failure rate of equipment has become a very important link in production.

Technical structure and working principle of 2 loading and unloading machine

2.1 How the Unloading machine works

The unloading machine is mainly composed of five parts: the bottle suction frame, the conveyor chain, the bottle chain and the control circuit, and the S7-300 type programmable controller of Siemens company. Work Fashion full empty bottle box from the gearbox chain into the unloading machine inside the suction bottle rack drop suction empty bottle and then rise the empty bottle on the out of the bottle chain will be empty bottle sent to the bottle washer machine. Empty boxes are sent to the washing machine through the tank chain.

2.2 Working principle of packing machine

       Plastic Bottle production LineIt is understood that the mechanical structure of the packing machine is the same as that of the unloading machine. The same is true of the electrical control device. It is to put the bottle filled with the finished product into the empty box.

2.3 Loading and unloading machine control system hardware, software

S7-300 is a programmable controller produced by Siemens in Germany, which is widely used in small and medium-sized automation control systems. The native control system is a CPU loop to execute the user program. Automatic control is realized through continuous periodic access to input and output modules and program execution refresh output.

Program by OBPBSBFBDBDX and other software blocks to use Siemens S7 programming software can be very convenient to achieve online and offline programming, monitoring and other work. Loading and unloading machine control system as shown in Figure 1 a total of 65 output control points of the input detection point 22 in the input and output module has the corresponding LED signal indication.

Control system diagram of loading and unloading machine

Fig. 1 Control system diagram of loading and unloading machine

3 main factors affecting the efficiency of loading and unloading machine

At present, the domestic installation and unloading machine has the 80 's German design and production and the 90 's domestic model it has the advantages of simple operation, high degree of automation and so on. But there are also more obvious flaws. Its defects are mainly single function, easy to produce misoperation and so on, the specific performance is

(1) No Size box or glue box carton conversion program. Original, unloading machine procedures are not large, small box branch procedures are all in accordance with the signal generated by the sensor on the gearbox chain to calculate the entry of the rubber box and issue the release, Stop Box signal. The number of chain-bridge pulses required for different lengths of the size of the rubber box is also different in the production of the need to convert the rubber box varieties to adjust the pulse value set in the program. This for the vast majority of large and small box production tasks such as beer production line, soda beverage production line Large box carrying 24 bottles, small boxes or cartons of 12 bottles not only take up a lot of production time and need to be equipped with professionals to adjust the program.

2) Bottle-suction rack running speed is single, did not carry out intelligent treatment of the original suction rack operation control is only a single fast or slow speed can not be based on the operation of the bottle box automatically adjust the speed of the suction bottle rack program lack of intelligent management.

(3) The irregular clearance between the box and the box causes a false action. The position of the rubber box is calculated by using the sensor signal in the original program design but in the actual production because there are guardrails on both sides of the gearbox chain for some deformed box transport will be blocked so that the plastic box in the conveyor chain of the relative position changes caused by the packing machine, unloading machine to produce a part of the box may not be released in the machine. The program control cannot be adjusted on its own, thus reducing the machine's production capacity and increasing energy consumption.

4 Realization of technical transformation and intelligent optimization

The program transformation design has increased and modified 62 software blocks.

(1) Design two branch programs with ordinary button switch conversion large, small box or glue carton packaging production. Divide the original program segments into two to three branch programs you can use a conversion switch to convert two branch programs without interfering with production needs depending on the size of the box suction rack structure in different large box branch procedures using photoelectric switch to distinguish box number measuring box position and small box or carton branch program using encoder plus photoelectric switch to determine the location of the box. The parameter fixation of each program segment reduces the hassle of having to stop and adjust parameters in the past due to the size of the box size of different box sizes. The skill requirement of operation is greatly reduced.

(2) Preparation of the procedure. You can use the Siemens dedicated PG7XX series programmer to write online or offline programming using a PC plus SIMATICSTEP7 programming software. First create a function manual for each part of the process or device Write action description includes input and output I/O points, action function description, each actuator electromagnetic coil, motor, The state to be reached before the action condition action of the drive, etc. create a plc configuration diagram according to the requirements of the function specification the plc configuration diagram includes a list of locations related to the PLC and its I/O and process or device, a mechanical layout of the CPU and I/O modules, a CPU, and i/ The electrical connection diagram of the O module finally creates a symbol name table if you choose symbol name addressing to create a symbol name table for the absolute address used by the PLC system, including not only the physical value of the I/O signal but also other elements that will be used in the program. After the above work is completed, the basic work of programming is completed, you can use SIMATICSTEP7 programming software to start programming, debugging and online monitoring 2.

(3) Change the single slow or fast to determine the operating speed of the bottle holder according to the quantity on the pump chain. The original design of the suction bottle rack drop and rise are single slow or single fast. In order to improve the operation efficiency of packing machine and unloading machine and save energy, we changed it to when the bottle box was a long time. The speed of the bottle-suction rack and the rising speed are fast for the rapid bottle drop when the bottle drops at a slower rate. This not only improves the efficiency of bottling and unloading bottles, but also overcomes the defects of mechanical faults often caused by frequent braking mechanical shocks in the past due to single slow or fast suction of bottle-absorbing rack drive motor. The smooth operation of the suction bottle rack through intelligent treatment extends the service life of the equipment and saves energy by increasing productivity. The working principle of the improved bottle suction frame is shown in Figure 2.

Working schematic diagram of the improved bottle suction rack

Fig. 2 Working schematic diagram of the improved bottle suction rack

(4) The error of the gap between the box and the box is overcome. The new program for the gap between the box and the box between the cause of the error in the program to increase the chain bridge rotation pulse monitoring and photoelectric detection function when the number of chain bridge rotation pulse and photoelectric detection signal to achieve the setting when the value of the machine determines that the box has been out, let the next box into the machine if the chain Bridge rotation pulse recorded box in the exit has not been photoelectric detection of the machine, the identification box has not been completed to overcome The wrong action.

(5)Plastic Bottle Conveyor BeltThink of the problems that are noticed in the debugging process. A the location of the truncated device on the conveyor chain is determined not to change at will, especially in the case of small box production, once the position of the truncated box changes, the number of inlet box calculation error will be generated. b Photoelectric switch work should pay attention to wipe photoelectric switch and mirror check photoelectric switch sensitivity to avoid false action. c the synchronization of the suction bottle rack motor. Bottle Absorber spindle driven by two motors the synchronization of the motor is very important to check the motor braking device to avoid the spindle and transmission gear damage. The position of the encoder installed on the D transmitter bridge must be modified as soon as it is determined that the corresponding program part should be changed.

(6) Packing machine, unloading machine after this transformation should be the corresponding box, bottle conveyor system to make corresponding linkage adjustment to meet the requirements of the packing machine, unloading machine intelligent control, otherwise there will be such a bottle of the pause to affect the operating efficiency of the entire production line.

5 improvement and increase of conclusion procedure

Photoelectric detector and encoder make the system more perfect, flexible, stable and reliable the intelligent treatment of bottle-suction rack action not only improves the production efficiency, reduces the damage of the mechanical impact to the equipment, but also changes the rigid control mode of the general single speed. This retrofit project has been successfully made in the bottled automatic packaging line of Sheng Guangdong Beer Co., Ltd. to improve the production efficiency of single Machine by 15%, the energy consumption of single machine decreased by 2.1%, and the production efficiency of the whole production line was increased by 8%.