Simplifying packaging machinery was a critical need for Talon Manufacturing, Inc., Spring Park, Minn., which specializes in horizontal flexible pouch packaging as well as microwave popcorn packaging. In 2006 B&R’s distribution partner Elec-Trol Inc. presented Talon with a new control solution for one of its Intermittent Pouch Packaging machines. The new solution consisted of a 5.7-in. B&R Power Panel PP200 as the operator interface with integrated control functionality, a B&R ACOPOS Servo Drive for decentralized motion control tasks, remote X20 slice I/O, and Modbus RTU support for third party VFDs. The combination of motion, machine logic, and HMI functionality in an integrated package improved maintainability while fewer components resulted in a net cost savings over the life cycle of the machine.

During the production process of the Intermittent Pouch Packaging machine a roll of the flexible pouch-packaging material is unwound and fed horizontally into the machine where it is folded in half. Seal bars, which must be maintained at a precise temperature, clamp onto the material once it has been moved into place, form the bags, and seal them. The PID temperature control of the seal bars is very important in creating a quality product with reliable seals.Because the flexible pouch packaging material is usually preprinted, accuracy is very important. The two VFDs open and close the seal bars and assist unwinding the material. Encoder input and bag registration-mark input are brought directly into the ACOPOS servo to synchronize the machine.

The most significant benefit of the new control solution is the elimination of the external PID controller that was required for temperature regulation in the eight PID zones of the sealing system. The new B&R solution not only eliminates an external PID controller but also allows for handling of all machine functionality and temperature settings directly in the operator interface.

Too, the function block PID in the new integrated system has proven more accurate than the dedicated PID controller of the previous version. and with a single programming tool, code can simply be imported into a new project even if a different B&R control system is selected.