New ideas for improving the design method of packaging machinery in China

New ideas for improving the design method of packaging machinery in China

China's packaging machinery industry started in the 1970s and developed rapidly in the late 1980s and 1990s. It has become one of the top 10 industries in the machinery industry. Both in terms of output and variety, it has made remarkable achievements and provided a strong guarantee for the rapid development of China's packaging industry. At present, China has become one of the major producers and consumers of packaging machinery industry in the world.

Packaging machinery as a product, its meaning is not only the material meaning of the product itself, but the three-layer meaning of the form product, invisible product and extension product. The form product refers to the specific form and basic function of the packaging machine itself; the invisible product refers to the actual utility provided by the packaging machine to the user; the extended product refers to the quality assurance, use guidance and after-sales service of the packaging machine. Therefore, the design of the packaging machine should include: market research, schematic design, structural design, construction drawing design, instruction manual writing and after-sales service plan. ?

The status quo of packaging machinery design in China

The categories of packaging machinery design mainly include: surveying and mapping imitation design, development design, improved design, serial design. For example, the production capacity of the beer filling production line is 1.6 to 40,000 bottles/h, and the filling valve number of the filling machine is 48, 60, 90 to 120. ?

The design from the ordinary beer filling production line to the pure draft beer filling production line is an improved and developmental design. For the packaging machine running at low and medium speeds, we can basically design it independently. The high-speed operation of the packaging machine, especially some advanced models, are mostly surveying and mapping, copying similar models of foreign countries, and carry out localized design and serial design. The main reasons are: (1) Most designers have not really mastered advanced design methods, such as the dynamic design theory and method of high-speed packaging machinery, and can not simulate the dynamic accuracy analysis of the mechanism under high-speed conditions. (2) The combination of production, learning and research is not tight enough. Theoretical research results cannot be used in actual design in time, and designers lack timely technical training. (3) The whole industry lacks macro-control and the superior resources cannot Get reasonable configuration and adjustment. ?

In the field of packaging machinery design, most designers still use the previous design methods: (1) find similar models according to the design task book as a prototype; (2) formulate various technical performance indicators and scope of use; (3) Design working principle diagram, transmission system diagram; (4) Design key parts and components; (5) Design assembly drawing plan and action cycle diagram; (6) Design part drawing, assembly drawing and part drawing; (7) Main components The key parts are checked for strength and stiffness; (8) Design control schematics, construction drawings, etc. ?

Nowadays, the design software of some universities in China can carry out finite element analysis and optimization design for the common institutions in the packaging machine. The CAD/CAM software of the cam linkage mechanism developed by the company can meet the ability of the enterprise to design the cam linkage independently. The application in the design of actual packaging machinery is not universal. ?

New packaging machinery is often an integrated machine, electricity and gas. Making full use of the latest achievements of information products, using pneumatic actuators, servo motor drives and Other separate transmission technology, the drive chain of the whole machine can be greatly shortened, the structure is greatly simplified, and the work accuracy and speed are greatly improved. One of the key technologies is the use of synchronous control technology with multiple motor drag. In fact, mastering this technology is not difficult, but some designers do not understand this trend of packaging machinery. If the design of packaging machinery in China was a copying and learning stage, then we should have the awareness of innovative design. ?

What are the new trends in packaging machinery design in Germany?

Germany and the United States, Japan, and Italy are both world packaging machinery powers. Leading in the design, manufacture and technical performance of packaging machinery. The design of German packaging machinery is based on market research and market analysis results. The goal is to serve customers, especially large enterprises. In order to meet customer requirements, German packaging machinery manufacturers and design departments have taken many measures:

(1) Process automation is becoming more and more automated to increase productivity and flexibility and flexibility of equipment. Use robots to complete complex movements. During operation, under the information and monitoring of the camera controlled by the computer, the robot completes the prescribed actions according to the computer instructions to ensure the quality of the package. ?

(2) Improve production efficiency, reduce production costs, and maximize production requirements. German packaging machinery is known for its beverage, beer filling machinery and food packaging machinery. It has the characteristics of high speed, complete set, high degree of automation and good reliability. The beverage filling speed is as high as 120,000 bottles/h, and the packaging speed of the small bag packaging machine is as high as 900 bags/min. ?

(3) Integrate product machinery and packaging machinery. Many products require direct packaging after production to increase production efficiency. For example, chocolate production and packaging equipment produced in Germany is controlled by a system. The key to the integration of the two is to solve the problem of matching each other in production capacity. ?

(4) Adapt to changes in production products, with good flexibility and flexibility. Due to the fierce competition in the market, the cycle of product renewal is getting shorter and shorter. If the production of cosmetics changes in three years, even in a quarter, the production volume is very large, so the packaging machinery is required to have good flexibility and flexibility, so that the life of the packaging machinery is much longer than the life cycle of the product, so as to be economical. Requirements. ?

(5) Universal use of computer simulation design techniques. As the speed of new product development continues to accelerate, the design of German packaging machinery generally adopts computer simulation design technology, which greatly shortens the development and design cycle of packaging machinery. ?

Packaging machinery design must not only pay attention to its ability and efficiency, but also pay attention to its economy. The so-called economic incompleteness is the cost of the mechanical equipment itself, and more importantly, the operating cost, because the equipment depreciation expense only accounts for 6% to 8% of the cost, and the other is the operating cost. ?

Improvement ideas for packaging machinery design methods

First of all, in the design concept, we should learn from the experience of advanced countries, aim at the needs of users, and combine the concepts of flexible design and modular design. Multiple machines can be used, or a small number of parts and components can be replaced to complete different functions. Or to meet different product needs. ?
With the development of science and technology and the intensification of market competition, the needs of customers are also getting higher and higher. This demand is reflected in the following aspects: First, to improve production efficiency, to meet the delivery time and reduce the cost of production, for some products, also requires packaging machinery and production machinery to connect; Second, to adapt to product changes and changes Need, packaging machinery should have high flexibility and flexibility; third, when equipment failure, it is required to carry out remote diagnosis service; fourth, it is conducive to environmental protection, noise, dust and waste; fifth, equipment purchase investment is as small as possible The price should be as low as possible. Therefore, on the basis of market research, we must fully understand and carefully analyze the needs of users, determine the functions and technical indicators that the packaging machine should complete, and formulate preliminary principle design plans. ?

The design process of modern packaging machine should include: market research, user demand analysis, packaging machine function determination, feasibility demonstration, design design, user benefit analysis, program feasibility demonstration, schematic design, structural design, construction drawing design Prototype production (virtual manufacturing), technical verification and construction drawing modification, development of after-sales service plans and remote diagnosis programs, improved design, serial design, etc. ?

Market research is the basic work of all packaging machine design. Without market research, all the design work we do can be equal to zero. Market research, according to policy guidance, industry supply and demand information, expert analysis, industry exhibitions, technical exchanges and other clues, find the user's demand information, and after sorting and analysis, determine the function that the packaging machine should complete. ?

In the design of the principle scheme, we must first fully understand the functions of related information products and electronic products, understand the performance of pneumatic components, and simplify the mechanical transmission system, and also use multi-motor drag to shorten the mechanical transmission chain. For the indispensable mechanical transmission system, modern design methods should be utilized as much as possible, and the optimal design scheme can be obtained through innovative concept, system modeling, dynamic analysis and dynamic optimization on the basis of product function analysis. ?

The technical design is to structure the principle design, determine the quantity, shape, size, material, etc. of the parts, and perform dynamic calculation, power calculation, strength calculation and stiffness calculation on the key parts of the main parts. ?

In the overall design, it is necessary to fully consider the layout of the entire packaging machine system, motion coordination, modeling design, human-machine environment, and packing and transportation. Modular design is an advanced design method. Its core idea is to divide the system into several modules according to functions, and design the units of the same function in the packaging machine into modules with different performance and interchangeability, through different combinations of modules. To make the packaging machine multifunctional and serial. The advantages of using this method are: (1) to speed up the packaging machine replacement. Because of the replacement of new models, it is often a partial improvement. It is easier to achieve partial improvement by introducing advanced technology into the corresponding modules; (2) shortening the design cycle. When the user requests, just replace the module, or design and manufacture some modules, you can get new models to meet user needs; (3) reduce costs and facilitate maintenance; (4) stable and reliable performance. Because the module is designed, the function division and module design of the packaging machine are carefully studied to ensure the performance of the module, such as: cam mechanism, servo mechanism, detection system, transmission system, control system, measuring mechanism, cutting mechanism Wait. ?

In addition, the industry standard of packaging machinery serialization and modularization has also become one of the top ten machinery industries in China at the time of formulation. The formulation of serialized and modular industry standards will certainly promote the cross-country of China's packaging machinery industry. Take a new step. ?

With the introduction of virtual concepts, the simultaneous development of electronic technology, computer-aided design (CAD), three-dimensional graphic design (3D) and computer simulation design, a new technology is adopted in the design - virtual design, virtual manufacturing, and soon The machine element data is stored in the computer. After digitizing the drawing and inputting it into the computer, the computer can automatically become a three-dimensional model. Then input the data and indicators in actual production, and input all kinds of possible faults. The computer 3D model can be operated according to the real working conditions, demonstrating the production capacity that can be achieved, the quantity of waste, and the matching of various links in the production line. Situation, production bottlenecks, etc., and can modify the model according to the customer's opinion, and operate quickly until the customer and the designer are satisfied. ?

Modern packaging machine design should meet the "green design", that is, the requirements of humanized design. It is a comprehensive design for quality design, assembly design, manufacturing design, maintenance design, and reliability design. China has a large population, the per capita consumption level is lower than that of developed countries, and the urban-rural difference is large. The design of packaging system should be based on low price and good quality, and cannot be blindly pursued. Take into account various factors such as reliability, safety, environmental protection, and low noise. Fully embody principle optimization, structural optimization, manufacturing optimization, and styling optimization.