SERVO

The follow-up filling 

The follow-up filling machine is an automated equipment widely used in the packaging industry, mainly for automatically filling various liquids, pastes, and powders into

 predetermined containers (such as plastic bottles, metal cans, and glass bottles). Its core feature is that the filling head synchronously

 completes the filling action while moving with the conveyor belt. Compared with traditional intermittent filling, it has higher continuity and production efficiency.

Process & Workflow Diagram

• Missed Bottles and Detection Failure

If the bottle spacing is unstable during transmission or the detection switch fails, it can easily lead to "no filling when the bottle arrives" or accidental filling when there is no bottle, causing material waste and production line pollution.

• Inaccurate Timing Coordination (Bottle Clamping Issues)

During high-speed operation, if the filling valve and the bottle clamping mechanism are not tightly coordinated, it will cause "filling before clamping"; or if the piston starts pushing materials before the filling valve is fully opened, it can cause the material tube to burst off.

• Overload Shutdown Caused by High Viscosity

For high-viscosity liquids such as laundry detergent, if the material barrel is not cleaned in time or the resistance is too high, the piston servo is prone to overload, affecting the continuous operation stability of the equipment.

• Difficult Debugging for Multi-Specification Changeovers

When dealing with different capacities (large and small bottles) and different liquid formulas, traditional equipment requires cumbersome mechanical adjustments and parameter modifications, making it difficult to quickly adapt to flexible production needs.

Adopting a full EtherCAT bus solution, equipped with FLEXEM FV3S-R3 series servo drives (10 drives controlling the follow-up axis, belt axis, lifting axis, and piston axis respectively), FL8 series PLC, FE6400WE 10.1-inch HD HMI, and EAM series servo motors, to achieve minimalist wiring and high-speed synchronous filling.

1. E-Cam Flying Shear, High-Precision Synchronous Filling : Adopting the electronic cam (E-Cam) algorithm to build a flying shear curve, ensuring accurate speed matching between the filling head and the spindle conveyor belt. This achieves smooth synchronous filling, effectively solving leakage and misalignment issues.
2. Smart Algorithms and Recipe Management, Flexible Changeovers

The system has built-in large/small bottle sorting logic and intelligent tracking algorithms, supporting the storage of 100 sets of recipes. Customers can call up recipes with one click based on different bottle types and material needs, completing changeovers without complex programming, thereby significantly reducing manual debugging costs.

EtherCAT Bus Architecture, Stable & Anti-Interference

The entire system uses the EtherCAT bus solution. Compared to traditional pulse control, the wiring is simpler, the system has stronger anti-interference capability, and the communication is more stable. It not only improves the response speed but also facilitates later maintenance and troubleshooting.

High-Performance HMI, Enhanced O&M Experience

The FE6400 series touch screen is equipped with a high-performance CPU and large-capacity storage. It not only provides an excellent visual operation experience but also supports IoT functions, facilitating remote monitoring and data management, and enhancing the overall maintainability of the system.