Analysis of The Power System of The Transparent Film Three-dimensional Packaging Machine

The power system of the transparent film three-dimensional packaging machine is the core support for achieving efficient and automated packaging. Its design needs to take into account stability, response speed and energy consumption control. The following analysis is carried out from three dimensions: power source configuration, transmission mechanism optimization, and dynamic performance guarantee:

First, power source configuration: Mechatronic drive architecture

Modern equipment generally uses three-phase asynchronous motors as the main driving units, with a power range typically between 3 and 5kW, and is compatible with 380V/50Hz industrial power supplies. Its advantages lie in:

High load adaptability: The output torque of the motor, after being amplified by the reducer, can drive the actuating mechanisms such as film feeding, forming, and heat sealing to complete complex actions.

Variable frequency speed regulation technology: Through the collaborative control of PLC and frequency converter, it achieves stepless speed regulation from 0 to 120r/min, meeting the packaging rhythm requirements of products of different specifications.

Redundant design: Servo motors are configured at key transmission nodes as auxiliary power sources. For instance, in the film feeding system, independent servo drives are adopted to ensure that the tension fluctuation of the film material is ≤±2%.

Second, optimization of transmission mechanism: multimodal energy transmission path

The power transmission system adopts a modular design and includes the following core components:

Gear-chain compound transmission: The main transmission shaft distributes power through a straight cylindrical gear set, and the end is connected to the actuator by a double-row roller chain. The transmission efficiency can reach more than 92%.

Gas-hydraulic linkage technology: The feeding push plate is driven by a cylinder, with a working pressure of 0.4-0.6MPa and a response time of ≤0.3 seconds. The heat sealing module is equipped with a hydraulic buffer device, and the pressure fluctuation of the sealing is ≤±5%.

Application of flexible couplings: A plum blossom-shaped elastic coupling is set between the motor and the reducer to effectively absorb installation errors and vibration shocks, thereby extending the service life of the equipment.

Third, dynamic performance guarantee: Closed-loop control system

To achieve high-precision packaging, the power system has constructed a three-level control architecture:

Basic control layer: The frequency converter receives instructions from the PLC and regulates the motor speed through vector control algorithms, with a speed stability accuracy of ±0.1%.

Process monitoring layer: Three sets of photoelectric sensors are deployed along the film feeding path to collect the position signal of the film material in real time. PID regulation is triggered when the deviation exceeds ±1mm.

Fault diagnosis layer: The current transformer monitors the motor load and automatically shuts down when the overload factor exceeds 150%. The temperature sensor monitors the temperature rise of the bearing. When abnormal, the cooling fan is activated.

Fourth, energy efficiency optimization strategies

Energy recovery system: Under braking conditions, the motor converts kinetic energy into electrical energy and feeds it back to the DC bus, achieving an energy-saving rate of up to 18%.

Lightweight design: The drive shaft adopts a hollow structure, combined with an aluminum alloy swing arm, reducing the overall machine weight by 25% and minimizing inertial load.

Intelligent sleep mode: When there is no operation for 10 consecutive minutes, the main motor enters standby mode, and the standby power consumption is ≤50W.

Fifth, verification of typical application scenarios

In the test of a certain production line in the tobacco industry, the power system achieved:

Maximum packaging speed: 120 boxes per minute

Sealing qualification rate: ≥99.8%

Noise level: ≤75dB(A)

Continuous operation time: > 720 hours without failure

Through the integration of the above-mentioned technologies, the power system of the transparent film three-dimensional packaging machine has achieved a dual improvement in energy efficiency and reliability while ensuring packaging quality, providing a solid foundation for high-speed automated production.