using servos for changeover adjustments
Problem
End users often have issues center-lining changeovers as operators sometimes have to “tweak” changeover points when unnecessary. Furthermore, mechanical changeovers often require a skilled technician/s to complete, which reduces production time and efficiency. Sometimes, servo-driven changeover makes sense when production lines have multiple SKUs and change over often.
Servo Changeover Benefits
Servo-driven changeover is a great feature that allows end users to change over from one SKU to another rapidly. By using a servo motor, the adjustment of the changeover point is completed accurately and within seconds. Furthermore, servo changeovers are typically found on screw-type adjustment points on end-of-line packaging machinery. Some systems, like a case packer or carton former, can have a fully automatic changeover where you can complete a changeover in less than five (5) minutes. Additional benefits are below.
- Reduces the dependence on having a skilled technician complete changeovers
- It can be flexible, meaning you can leave some adjustment points manual and have other high volume adjustment points servo change over
- Can significantly improve downtime and production efficiency
- Eliminates the possibility of operators making “tweaks” or changes to standard changeovers
- You can easily make adjustments or set up new sizes all through the HMI
Cartoner Servo Changeover
Case Packer Servo Changeover
Carton Former Servo Changeover
Servo Changeover Drawbacks
The main drawback with servo-driven changeover is cost. Since you require a servo drive and motor along with a gearbox, servo-driven changeover is a more expensive option. Furthermore, if you are only running one or two sizes on your packaging line, then servo-driven changeover is typically optional. Also, with servo-driven changeover, you will have more failure points on the machine due to having electronic components involved with the changeover. Other drawbacks are below.
- Potentially can increase project lead time due to sourcing additional components
- Additional programming time during the project testing and debugging phase
- It has limitations as some changeover points cannot be servo adjusted, i.e., a carton magazine on a cartoner
Summary
Servo-driven changeover can bring exceptional value to any packaging line that typically completes daily changeovers. Even though the cost is high, end-users can realize a quick return on investment as their lines will operate more efficiently and have a higher overall uptime. Furthermore, servo-driven changeovers are a great way to lock in adjustment points without fearing operators/technicians making changes that could hurt efficiency.
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