With the development of the "Jumbo assembler" Premier Paper has responded to the demand for a flexible and efficient system for the production of partition walls of corrugated fiberboard and stripes. These partitions are used during shipment and storage, the protection of sensitive products from wine bottles to cryovials. The single, integrated automation and control system from Mitsubishi Electric fulfilled all the requirements of the new Jumbo assembler.
The American company Premier Paper Converting Inc., headquartered in New Berlin, Wisconsin, USA, is one of the market leaders for the production of paper processing machines. As a driver of innovation in its industry, the company continues to develop faster and more efficient machines, while aiming to integrate all innovations into simple and intuitive user interfaces. In the latest version of the Jumbo Assembler system, an intuitive user interface has been designed for easy handling. In addition, the new automation and control package should provide enough flexibility for future customizations and modifications. To meet changing needs and industry trends, Premier Paper's machines are regularly updated to the latest state-of-the-art.
Simple and flexible automation components
Premier Paper chose Mitsubishi Electric for a unified automation and control system. The automation components used include PLCs, variable frequency drives, servo controllers, simple motion modules, HMIs and a complete control software package. The modular PLC platform of the L series is a simple but flexible system. In addition, the control platform is extensible so that it can be adapted to complex customer requirements.
The system produces up to 16 separating strips simultaneously. It uses frequency inverters of the FR-E700 type, which are connected by a CC-Link network. Subsequently, the separating strips are conveyed to a second platform, on which another set of strips is placed vertically. This creates a perfect mesh pattern. The precise positioning of these strips is handled by an L Series Simple Motion Controller, which indexes the acquisition characteristics. In addition, MR-J3 servo drives are used over the SSCNET III fiber optic network.
Up to 100 recipes can be stored in the L Series PLC. They determine the dimensions of the separating strips and the respective transport mode, including continuous, interrupted or fully indexing feed, as well as the insertion of even and odd cells. The operator can easily select any of these recipes via a GT12 touch screen.
Smooth integration of all systems
With the flexible, modular PLC of the L series and the programming software GX Works2, Premier Paper has successfully integrated the new system. The complex feed modes are programmed using simple motion function blocks provided by Mitsubishi Electric. The program is easy to understand and easy to adapt to future requirements.
With the system, the user can flexibly create one unlimited number of configurations for different types of partitions with one machine. For the right recipe for a specific partition type and feed mode, the user simply enters the necessary parameters via the HMI GT12 touchscreen. The CC-Link and SSCNET III networks minimize wiring complexity, ensuring a clean, lean solution. The commissioning of the plant at Premier Paper went smoothly. The speed of the resulting system has been greatly increased. The new design, based on the integrated automation and control solution, has more than doubled the overall system efficiency of the Jumbo assembler.
Picture above: On the first feed platform, the separating strips are aligned precisely.