Synchronization/Registration Controller with PLC

The CX-1200 is a Synchronizing Controller. It controls the Follower machine in a Lead-Follow machine coordination process. It will command the Follower to match both speed and phase as it tracks the Lead machine, to achieve automatic synchronization between the machines.

Typical applications include:

• Packaging
• Filling
• Transfer conveyors
• Wicket ovens
• Flighted conveyors with cleats or pockets
• Overhead chains with hooks or grippers

The Lead and Follow machines may be of similar construction, or may be completely different designs, with different motor drives, gear ratios, or process functions.

The CX-1200 uses four 4 basic signals. An encoder device on each machine gives high resolution speed information, and also provides a tracking signal to assist the position control. Two marker pulses (photo eyes, or prox switches) give precise positional information. These synchronization pulses, also called job-space markers, permit automatic alignment of the correct machine phase or position lock. The follower machine can start/stop with the lead machine, or it can be started at random into a "running lead" and still achieve synchronization.

• Synchronization or Registration Control.
• Lead/Follow machines can be similar or very different designs or functions.
• Electronic Phase Shifting and Line Shafting functions.
• Learn and Trend Modes for web stretch or variable configurations.
• Pre-Programmed... no code to write.
• Menu Driven Operator Interface for Setup & Monitoring.
• Integrated PLC Control.
• On-the Fly Reconfiguration Parameter Blocks.
• Fully Isolated Analog and Digital I/O.
• Optional DeviceNet® Network Card.

The CX-1200 is a Universal Controller that can operate through a DC, DC Regen, AC Inverter, AC Vector Drive, or Servo controller. It can be used to retrofit old drives, or work with the latest digital drive products of any brand.

The built-in operator's interface, with keypad, multi-line display, and help screens make set-up and operation simple. A PLC function can help customize the application or coordinate with other machine control devices. Automatic Learn Mode, Trending Mode, or Fixed Ratio Modes allow it to adapt to any machine configuration. Multiple configurations or Set points can be pre-programmed, and changed on-the-fly.

Advance /Retard functions permit operator supervision when desired.

Serial link, or optional remote analog signal, or optional DeviceNet card further enhance integration with host control schemes.

The CX-1200 control is housed in a ½ DIN vertical instrument enclosure with embedded LCD multi-line operator interface. The integrated display and keypad panel gains access to numerous control and monitor parameters through a menu driven screen format. Individual application requirements are met by simply accessing the relevant screen and code parameter, and then entering the appropriate numerical value. Because the CX-1200 control is pre-programmed, applications can be commissioned in a matter of minutes once the control has been installed. A full compliment of monitor parameters are available to verify operation and assist with diagnostics.

The CX-1200 control has a serial port for RS485 communication. ContrexHost software, when installed on a Windows PC or laptop, allows you to initiate commands, change or monitor the complete set of CX-1200 parameters, and load/save setup values.

• Features:
  Pre-programmed control algorithms for Fixed machine designs, or Learn variable configurations, or Trend to adjust for web stretch or shrink.
• Up to eight user defined parameter configuration blocks with on-the-fly digital input for easy reconfiguration.
• Analog card accommodates remote input signals for some phase adjustment features.
• The precision Speed/Position frequency inputs utilize many types of encoder signals including quadrature, open-collector and differential line drivers.
• Phase sensors (Job Space Marker Pulses) can be photo-eyes, prox switches, etc. detecting a machine element (flag) or the target product itself.
• Eight programmable digital outputs are provided for drive control and alarm functions.

About Contrex

CONTREX has been providing precision speed controls to the industrial market for over thirty years. With over 100,000 controls placed into operation, CONTREX has maintained its position as a leader in precision speed control technology. CONTREX control products provide solutions for many applications including web wind/unwind, web tension, wire twisting, diameter control, continuous blending, wicket oven loading, rotary print/cut, pouch packaging, extrusion pullers and cut-to-length.

Contact Us Today

PHONE:
763.424.7800
800.342.4411

E-MAIL:
sales@contrexinc.com

• Intermittent and Continuous Motion, Modular, Rotary Dial and In-Line Assembly Systems (including sorting and feeding, filling, capping, labeling, coding, gluing, pressing, welding, screwing, soldering, forming, tray loading/unloading, and vision inspection).
• Sorting/feeding/inserting/loading components into intermittent or continuous motion cartoning, wrapping, pouching, bagging or blistering machines.
• Products collated and placed into trays or product removed from trays and placed on a conveyor or into another package or into a machine.
• Orienting, Collating and Stacking Systems.
• Material handling systems coupled with other types of packaging machinery (i.e. label applicators, non-contact coders/printers/lasers, and vision inspection systems.

TGW manufactures packaging knives from high-performance tool steels with accurate flatness standards and exceptional tooth profile consistency for precise cutting performance that produces an extraordinary package appearance.

Cutting edges available include serrated, perfed and beveled edges, EZ Open and cross cut tooth forms and optional tear notches. Blade configurations include straight, circular and formed tray punches for vertical form fill and seal baggers, pouch, sachet and portion packaging, shrink wrappers, overwrappers, rollstock and vacuum packaging and automatic tapers.

Tool steels available include standard carbon, high carbon, high chrome for wear applications, high speed steel for long life and stainless for corrosive resistance properties. Special coatings are available for increased wear resistance and non-stick properties.

At TGW International, they provide quality diagonal or inclined-cut top knives, zig-zag knives and anvils for horizontal flow wrappers. Top knives, both diagonal and zig-zag cut, are precision ground to a sharp cutting edge for precise cutting performance that produces an extraordinary package appearance. Anvils are manufactured to exact dimensional and hardness tolerances to assure superior cutting performance and long life.

They also manufacture and supply:

• Half star and full star punches for vacuum packaging and rollstock machines and semi-rigid packaging machines.
  

• Euroslots and hole punches for display packaging - "sombrero"and other custom shapes also available.

They also specialize in precision ground serrated formed tray punches for Modified Atmosphere Packaging (MAP) equipment, pre-formed tray and container sealing equipment and ready-to-eat (RTE) meal packaging equipment. Consistent tooth form and burr-free cutting edges assure longer knife life and accurate cutting performance.

Click here to view product data sheets.

About TGW International:

TGW International was established as a knife maker in 1908 and remains in family ownership today. Dedicated to quality, our modern factory is equipped with the best facilities available. Laser cutting, CNC machining, precision grinding, heat treatment, forming and polishing - all are carried out with the backing of a well-trained and committed work force.

Vacuum Pump Technology: Multi-Stage Air-Driven vs. Mechanical

In a high pressure manufacturing environment, where every second counts, it's ironic that the steady, unceasing flow of product would rely so heavily on a low pressure solution. Vacuum pressure, created by any pressure lower than atmospheric pressure, is the method of choice for keeping so many products moving and so many companies operating efficiently.

To keep your applications running at maximum velocity and efficiency, there's little question that vacuum pumps are the way to go. But within the vacuum pump arena, there are a number of different players, each creating vacuum by using greatly different methods.

Two ways to reduce the pressure
The two most popular vacuum pump contenders are compressed air-driven pumps, commonly referred to as generators, and electro-mechanical pumps. (There are two sub-categories within the compressed air-driven category: single-stage and multi-stage ejectors. All references within this article are to multi-stage ejectors).

Compressed-air driven vacuum pumps rely on Bernouli's Principal, which states that there is a consistent relation between pressure and velocity: high velocity of a fluid leads to low pressure, and vice-versa. Air-driven pumps force compressed air through an orifice or nozzle, increasing the velocity and creating low-pressure air. Atmospheric pressure outside the system flows in, trying to create equilibrium. This outside air mixes with the compressed air used to generate the low pressure, and the combination exits through the exhaust. With this method, the level of vacuum is dependent on the nozzle; in the narrowest part of the nozzle, the air stream reaches its greatest speed, therefore creating the deepest level of vacuum and suction at the system's openings.

Mechanical pumps usually have an electrical motor as a power source, but can alternatively rely on an internal combustion engine. A mechanical pump uses the same pumping mechanism as a compressor, except that the unit is installed so that air is drawn from a closed volume and exhausted to the atmosphere. There are three main types of mechanical vacuum pumps—regenerative and centrifugal blowers, rotary vane and piston.

Rotary vane pumps are the most commonly used mechanical pumps, and are most often found in the industrial range of vacuum applications. These pumps have individual rotors placed around a shaft and spun at high velocities. The rotary motion traps air entering the intake port and sweeps it through, creating a vacuum behind it. Most of these port vanes are made of carbon and operate within a housing that requires very exacting tolerances for proper performance.

Save your energy
When beginning a discussion comparing the two main vacuum generators, it's best to start by looking at the big picture – the very big picture. From a global environmental perspective, air-driven pumps, when used properly, can provide tremendous advantages. In fact, the U.S. Department of Energy has launched what it calls a "Compressed Air Challenge" to help lower the country's energy consumption and reduce greenhouse gases. This initiative is designed to build awareness of how users of compressed air improve and maintain efficiencies and lower output pressure.

One of the main recommendations from a major air compressor manufacturer is to regulate all point-of-use operations at the lowest possible pressure by using a quality regulator. These regulators can work to lower both leak rates and demand, making an environmentally-friendly pump system even safer and more efficient.

Airing out the differences In a side-by-side comparison of advantages and disadvantages, the multi-stage air-driven pump is a clear victor over the mechanical or rotary vane pump. Consider the following:

• Lubrication. Some rotary vane pumps require lubrication, and the precisely correct amount of lubrication at that. Too much lubrication can result in an oil feed rate that is too fast, or a heavy oil condensation. Insufficient lubrication can lead to too slow an oil feed rate, and eventually complete pump failure. Multi-stage air-driven pumps have no gears or moving parts that create friction, so they require no lubrication – another environmentally-friendly, maintenance reducing advantage.

Filling out applications
Multi-stage air-driven pumps fit the bill for a wide variety of different industries and applications. What follows are three applications for which these pumps are particularly well-suited.

No matter what the application, it's clear that multi-stage air-driven pumps offer a wide array of substantial advantages over alternative options.

Recent technology advances in multi-stage air-driven vacuum pumps.
Rising energy costs, coupled with increasingly strict environmental compliance regulations, have forced manufacturers to reevaluate the amount of energy they are consuming. Recently there has been a growing interest in a new ejector (nozzle) technology called COAX®, which is an improved design based on a multi-stage concept for creating vacuum with compressed air. COAX integrates the internal components of a multi-stage vacuum pump into a vacuum cartridge, resulting in a smaller, more efficient system. COAX vacuum cartridges are up to twice as fast as other cartridges and they provide 3 times more flow than a typical conventional ejector with the same air consumption. COAX is specifically designed for low and fluctuating feed pressures (25–90 psi) with sustained vacuum performance for maximum reliability. Additionally, COAX allows vacuum pumps to begin producing vacuum flow immediately when the pressure valve is turned on—making maximum use of the compressed air and consuming significantly less energy than traditional vacuum pumps.

In conclusion, when you compare the features and benefits of multi-stage (compressed) air-drive pumps versus those of the traditional mechanical pumps, one option is clearly superior. Low-pressure vacuum generators are cleaner, more durable, have a much longer life expectancy and suffer much less downtime, saving the operators countless man hours and dollars. So for your internal operation and the external environment, these multi-stage air-driven vacuum pumps are truly are a breath of fresh air.