PC-based control promotes innovation in paper converting
When developing a system for producing sustainable padded envelopes, the Spanish Lemu Group relied on PC- and EtherCAT-based control technology from Beckhoff. This facilitated the implementation of the entire production process starting from the roll material through to the envelope ready for dispatch. A particular challenge was making padding only from paper.
More than just a passing trend, the increasing e-commerce has become ingrained in our daily lives. In the face of this global development, the need for sustainable solutions is more urgent than ever, and businesses must adapt. If they want to remain competitive, they have to manage the balancing act between satisfying changing consumer demand and using sustainable shipping packaging, according to the experts of Lemu Group.
Lemu Group has taken a bold step towards sustainability with the production of equipment for manufacturing envelopes and bags entirely made from paper. One of these systems was custom-designed for the manufacturing of 100% paper padded envelopes. Not only does the e-Comm3 line improve production efficiency by fully automatic operation, it also embraces sustainability by eliminating the use of plastic in the padding layer. Within the production line, several stations are coupled for converting paper from roll material into padded envelopes ready for dispatch. The system can be optionally equipped with end-of-line modules for automatic carton packaging and palletizing. To ensure that the industry's high quality standards can be met, artificial intelligence is integrated into the process for error detection and quality assurance.
Powerful control technology and expert partners
Lemu Group has wide expertise in manufacturing machinery designed for paper conversion and has corresponding research and development capacities. However, when it comes to bringing in expertise on industrial automation, Beckhoff is the primary choice as a partner, they say. For the equipment manufacturer, one of the greatest advantages of the PC-based control philosophy lies in the fact that TwinCAT automation software can transform any Windows-based PC into a real-time controller. This enabled Lemu Group engineers to execute and refine the PLC code for the new system conveniently on a laptop. This is because the TwinCAT engineering platform offers unique possibilities for simulation that differ greatly from those of conventional simulators. In addition, Lemu Group was able to benefit from the expertise of Beckhoff employees through direct support, with the trusting collaboration facilitating the demanding innovation process.
In the conception of their equipment, Lemu Group focuses on OEE (Overall Equipment Efficiency), prioritizing efficiency and productivity without compromising the quality of the final product. This enables the machine builder to achieve maximum customer satisfaction and helps companies stand out in a changing market.
The control platform from Beckhoff makes significant contributions to the high production efficiency ensuring low program execution times. The powerful CX2033 Embedded PC achieves cycle times of 62.5 µs in EtherCAT real-time communication with the servo drives of the AX5000 series. With fast control of position, speed and force for all drive axes, EtherCAT ensures precise synchronization of all processes in the system – from feeding, folding and separating through to packaging. In addition, there are no restrictions on the number of axes supported by the fieldbus, as the EtherCAT process image is 4 GBytes.
The collaboration between Beckhoff and LemuGroup emerges as a role model in the industry, effectively combining their expertise in industrial automation and machinery manufacturing. The collaboration is not limited to a specific project but is projected as a lasting alliance focused on innovation, efficiency and customer satisfaction.