"Who would have dared to think five years ago? This biscuit packaging line originally required 6 people to watch the assembly line, and now 1 technician has doubled the output while drinking tea." In the debugging workshop of the ply-pack factory, Master Li, who has worked for 28 years, took a picture of the newly launched fully automatic packaging machine, and smiled so much that the wrinkles at the corners of his eyes were squeezed into wavy lines.
1. Mechanical structure: "welding" the craftsmanship of the master into steel
The fully automatic packaging machine is not a new term, but it is the solid structural innovation that can truly string together the five major processes of feeding, metering, bagging, sealing, and testing into a "continuous production line".
"In the past, the most headache was the packaging of puffed food. Manual bagging either leaked or had unstable weight." Director Wang, who is responsible for the transformation of the puffed food production line, has a deep understanding of this. "Now the double-helix metering bin of this fully automatic packaging machine imitates the action of the master's shaking spoon - first fill quickly, and automatically switch to slow feeding when approaching the target value, and the error can be controlled within 3 corn kernels."
What makes the workshop directors applaud is the self-developed "peak feeding" system. Traditional equipment is prone to jamming when encountering irregular materials. Our fully automatic packaging machine has an infrared array sensor installed under the vibrating screen to adjust the material falling rhythm in real time. In the words of a Northeast customer: "This machine can read your eyes better than an old friend, and it can even neatly arrange frozen sticky bean buns for you."
2. Control system: Let PLC understand "Chinese needs"
When you walk into the electrical debugging room of ply-pack, you can always see Xiao Zhang, a technician born in the 1990s, programming the PLC. "The German logic is not suitable for us here. They pay attention to absolute precision, but Chinese factories want "almost fast." "He pointed to the parameters jumping on the screen and explained: "For example, the tracking algorithm of this fully automatic packaging machine allows dynamic speed adjustment within the error range of ±2%, so that the rhythm will not be delayed due to waiting for correction, and the batch qualification rate can be guaranteed. "
A spicy strip production company has tasted the sweetness. "The moisture content of their products fluctuates greatly, and traditional equipment either slows down to stabilize or produces waste products crazily." Xiao Zhang said while calling up historical data, "Now the fully automatic packaging machine will automatically learn the best sealing temperature curve, and the waste rate in the first half hour of starting the machine has dropped from 15% to 3%. The money saved on spicy oil alone is enough to buy another device. ”
3. Operation and maintenance revolution: self-checking faults is more sensitive than the old master's nose
"Listen to the sound to identify the fault? That's the old calendar from 20 years ago!" Chen Gong, who is responsible for after-sales service, took out his mobile phone and showed the "health file" system of the fully automatic packaging machine. The vibration and temperature data of the key parts of the equipment are uploaded to the cloud in real time, and can also be combined with the 100,000-hour fault database for early warning.
Last month, a seafood processing plant in Guangdong escaped a disaster. At three o'clock in the morning, the fully automatic packaging machine suddenly popped up a prompt: "The torque fluctuation of servo motor No. 4 is abnormal. It is recommended to replace the carbon brush within 72 hours." During the inspection, it was discovered that the heat dissipation holes of the motor were mostly blocked by squid debris. "If it weren't for the early warning, the entire salmon production line would have to stop." The equipment section chief of the factory is still in shock.
4. The future has come: unmanned is not the end, but the starting point
Standing in front of the observation window on the second floor of the general assembly workshop, the technical director of ply-pack looked at the seventh-generation fully automatic packaging machine being tested thoughtfully: "The industry is always discussing replacing manual labor, but we want to solve those jobs that "people can't do well". ”
He gave a vivid example: a Chinese medicine pill factory used to bottle by hand, and sweat stains would be mixed in when wax sealing. After switching to a fully automatic packaging machine, not only can nitrogen replacement packaging be achieved, but also pills with diameter deviation exceeding 0.1mm can be removed through visual inspection. "The craftsmanship of the master plus the sharp eyes of the machine, this is what an intelligent packaging production line should look like."
Looking at the fully automatic packaging machine with the indicator light flashing regularly, Master Li unscrewed the thermos cup and sipped the tea: "My apprentice thought this business had no future and switched to delivering food. Now? Humph! He can't afford a servo axis on this machine even after delivering food for five years!"
