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| Paper cup machine manufacturer improves changeover time and production flexibility with servo drive technology |
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Packaging: Paper Machinery Corporation
Challenge:
Create industry’s first all-servo driven paper cup forming machine to enable faster tooling changeovers at a lower cost.
Solution:
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Rexroth Results:
- Produce up to 200 cups per minute consistently, with highest quality
- Faster changeovers for different size cups, within one shift
- Faster machine assembly and shorter delivery time
- Electronic cam profiles provide platform for easier machine changes and updates
- Remote diagnostics capability supports drive-level troubleshooting, eliminating need for technician travel
Download the complete PMC case study. (PDF 208 KB)
More Food & Packaging Case Studies
PMC 2000S: The “S” stands for servo drives
Industry leader Paper Machinery Corporation recently launched the PMC 2000S: the first-of-its-kind servo-driven paper container forming machine, using Rexroth digital servo drives and high-performance direct drive motors to deliver a machine engineered for faster changeovers and higher output in paper container production.
Paper Machinery Corporation (Milwaukee, WI www.papermc.com) is the world's leading source of high-performance forming machines for paper cups, paperboard canisters and custom paperboard packages.
The company designed the PMC 2000S in response to customers seeking machines that were more economical, provided faster, easier tooling changeovers and were able to support a wider range of container sizes and dimensions. |
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Tooling changeovers can be accomplished within one shift.
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The 18-axis machine is driven and controlled by Rexroth’s IndraMotion MLC platform.
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For their first all-servo machine, PMC chose a complete Rexroth drive and control platform: The IndraMotion MLC (Motion Logic in Controller) motion, logic and drive system that controls the machine, combined with advanced Rexroth IndraDyn T direct drive motors and compact IndraDrive Cs servo drives.
The PMC 2000S is an 18-axis machine capable of producing up to 200 cups per minute with three main sections: a feed turret that feeds the blank container sidewalls into the machine, a large mandrel turret that indexes the sidewalls through multiple wrapping, gluing, seaming and bottom application stations, and a rimming turret for curling the top rim of the container.
The Rexroth IndraMotion MLC platform replaces mechanical cams with digital electronic cams for each of the 18 machine axes. It creates an operating framework that will support changeover from one complete tool set to another in a single shift, much faster than cam-driven machines.
With the Rexroth servo technology, each station on the machine runs its own unique electronic cam profile -- one that has been optimized to that station’s motion, and is integrated and synchronized with the entire machine.
Along with programming the servo controls and motion-logic, one of the other engineering challenges presented by the PMC 2000S was selecting and sizing the motors for each axis — in particular, the direct drive motors to turn the mandrel turret, transfer turret and gripper turret. Given the weight of this equipment and the precision required for each index, the motors for these turrets needed to move profiles that were very demanding.
Rexroth’s IndraDyn T torque direct drive motors are optimized for high torques of up to 13,800 Nm. This enabled PMC to satisfy another key machine requirement: stopping the machine motion within one index when needed (i.e. if a container fails to be ejected on the cup diverter) without harming either the machine’s mechanical systems or the drive itself.
Download the complete PMC case study. (PDF 208 KB)
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