OCME's new generation of Vega shrink wrappers was designed with energy and material savings in mind, an exercise in ‘green' engineering that simultaneously delivers sustainability and productivity.
Major features include a low-consumption shrink tunnel, wide use of high efficiency servo motors, the ability to run film as thin as 30 microns, size changes with no change parts required, easy access for operators and technicians, simple maintenance, plug-and-play controls and an improved operator interface.
Advanced hardware, software and mechanical design
A complete machine control solution from B&R Industrial Automation plays a pivotal role in achieving this new level of performance. The Vega begins with a modular machine design, constructed of two basic frames that are readily built up with different solutions and options according to application requirements.
Wide use of servo motion
The PACK EXPO machine used17 B&R servo motors. Chain transmissions are replaced by direct drive B&R servos, and chains in the collating section are run by servos for fast changeovers. For models up to 60 cpm, no change parts are required. The infeed and collating section have been completely redesigned so that two operators can complete a format change in 5 minutes.
Standard infeed lanes are individually motorized and adjusted using a handwheel and channelizing blades in the infeed and pusher sections. Automated changeover and chain drive servos are optional to reduce changeover times and labor requirements.
Photoeyes detect the exact position of each bottle in every lane in between the chain lanes and the pusher and adjust the belt feed rates into the pusher. An upper group of belts adds stability and helps transfer the container between the two sections. The system provides zero pressure accumulation.
The film feeding and cutting ramp module is mounted on rails for easy access to replace film cutting blades, roller cleaning and changing film feed belts. Film unwind is gently controlled by B&R servo motors to minimize film stress, and an automated splicing unit performs head-to-head sealing and checks for proper welding. The film wrapping module has also been designed for fast belt replacement.
Energy efficient shrink tunnel design
The energy efficient shrink tunnel features infeed and outfeed doors that close to retain heat when the machine is not running product. Channelizing pipes provide efficient air flow and cooling fans are run by B&R servo motors. The mesh conveyor has a temperature detector, and thermal power and mesh conveyor speed are adjustable in real time according to the production rate.
Plug-and-play, ergonomic design
The operator side of the machine is free from obstructions and the B&R control panel is rail mounted to move with the operator. Full vision safety guards are provided. A pan-tilt video camera is optional to assist with remote diagnostics. Cables are pre-installed inside machine frame and the electrical cabinet is pre-mounted and connected on top of the machine using no floor space.
Powerful touch panel simplifies operation, maintenance data acquisition
In another emerging trend, OCME's Albatros 5 HMI (human machine interface) software is designed for ease of use by non-skilled operators. The new graphic menu allows operator to browse through different parts of the machine by simply touching them on the B&R touchscreen. Information for each module – production rates, commands, alarms and data acquisition – is highlighted and access limited according to authorization level.
Alarms also provide possible causes and corrective actions. Programmed preventive maintenance tasks are periodically highlighted on the screen. Both scheduled and non-scheduled maintenance activities can be recorded.
Major features include a low-consumption shrink tunnel, wide use of high efficiency servo motors, the ability to run film as thin as 30 microns, size changes with no change parts required, easy access for operators and technicians, simple maintenance, plug-and-play controls and an improved operator interface.
Advanced hardware, software and mechanical design
A complete machine control solution from B&R Industrial Automation plays a pivotal role in achieving this new level of performance. The Vega begins with a modular machine design, constructed of two basic frames that are readily built up with different solutions and options according to application requirements.
Wide use of servo motion
The PACK EXPO machine used17 B&R servo motors. Chain transmissions are replaced by direct drive B&R servos, and chains in the collating section are run by servos for fast changeovers. For models up to 60 cpm, no change parts are required. The infeed and collating section have been completely redesigned so that two operators can complete a format change in 5 minutes.
Standard infeed lanes are individually motorized and adjusted using a handwheel and channelizing blades in the infeed and pusher sections. Automated changeover and chain drive servos are optional to reduce changeover times and labor requirements.
Photoeyes detect the exact position of each bottle in every lane in between the chain lanes and the pusher and adjust the belt feed rates into the pusher. An upper group of belts adds stability and helps transfer the container between the two sections. The system provides zero pressure accumulation.
The film feeding and cutting ramp module is mounted on rails for easy access to replace film cutting blades, roller cleaning and changing film feed belts. Film unwind is gently controlled by B&R servo motors to minimize film stress, and an automated splicing unit performs head-to-head sealing and checks for proper welding. The film wrapping module has also been designed for fast belt replacement.
Energy efficient shrink tunnel design
The energy efficient shrink tunnel features infeed and outfeed doors that close to retain heat when the machine is not running product. Channelizing pipes provide efficient air flow and cooling fans are run by B&R servo motors. The mesh conveyor has a temperature detector, and thermal power and mesh conveyor speed are adjustable in real time according to the production rate.
Plug-and-play, ergonomic design
The operator side of the machine is free from obstructions and the B&R control panel is rail mounted to move with the operator. Full vision safety guards are provided. A pan-tilt video camera is optional to assist with remote diagnostics. Cables are pre-installed inside machine frame and the electrical cabinet is pre-mounted and connected on top of the machine using no floor space.
Powerful touch panel simplifies operation, maintenance data acquisition
In another emerging trend, OCME's Albatros 5 HMI (human machine interface) software is designed for ease of use by non-skilled operators. The new graphic menu allows operator to browse through different parts of the machine by simply touching them on the B&R touchscreen. Information for each module – production rates, commands, alarms and data acquisition – is highlighted and access limited according to authorization level.
Alarms also provide possible causes and corrective actions. Programmed preventive maintenance tasks are periodically highlighted on the screen. Both scheduled and non-scheduled maintenance activities can be recorded.
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