Drive systems

Compact, powerful and flexible for packaging machines

Compact, powerful and flexible for packaging machines

Compact, powerful and flexible for packaging machines

Compact, powerful and flexible for packaging machines

Speed, flexibility and high quality requirements are characteristics of modern logistics processes. Shipping packaging is also an important issue, because high-quality products can only reach their destination safely if they are protected in the best possible way. Electric drives are at the heart of this process: they transport packaging materials or drive the tools when forming and closing the packaging.

What is needed are cost-effective, precise and reliable drive systems that ensure reliable automation throughout the packaging process. At the same time, these often have to release considerable forces in very confined conditions, work reliably even in continuous or start-and-stop operation, and in some cases also position with high precision. Faulhaber drive systems have proven their performance in many applications. Regardless of whether high dynamics, precise positioning or particularly compact dimensions are required, there is always a suitable solution in the product portfolio with more than 25 million possible combinations of microdrives, optical, magnetic or absolute encoders as well as speed and motion controllers with a wide variety of interfaces.

Individual and safe packaging

A typical area of application for the versatile drive systems are packing stations, where the products are packed into suitable shipping boxes. Sensors record their dimensions for this purpose. Automatic packing stations then fold the appropriate cover individually from a cardboard web. This not only saves material, but also shipping costs, since logistics service providers base their prices on volume as well as weight. The actual folding work is done by small levers and flaps in the packaging machine. To move them, brushless DC servo drives with integrated motion controllers are well suited. They are compact and can therefore be easily integrated even in confined installation spaces.

For some handling tasks such as switches, flaps or sliders on conveyor belts or roller conveyors, graphite commutated DC micromotors of the CXR series have proven themselves in combination with matching gearboxes. Their commutation system is very robust and is particularly suitable for dynamic high-performance applications with fast start-stop operation, as is required in many packing stations. The DC motors are also easy to control due to their linear characteristics. Combined with high-resolution encoders, they are thus well suited for precise positioning tasks. High-quality neodymium magnets and the proven Faulhaber winding also ensure a high power density with a compact design. This allows them to be installed directly in the folding mechanisms of the packing stations. There, they can deliver considerable forces despite their small size.

Palletising and strapping

If the packages are then stacked on pallets for transport, they need to be fixed. Usually straps made of fibre-reinforced plastic are used for this. Strapping tools tension and weld the strap so that it fits tightly to the stack and secures it. Individual packages can also be additionally stabilised in this way. When these devices are held in the hand, the weight is particularly important here; every gram less is good for the health of the employees. Small, lightweight drives are therefore in demand, for example the brushless DC servo motor 3274...BP4. With a diameter of only 32 mm and a length of 74 mm, it achieves a peak torque of over 1 Nm. With this power, even belts for heavy loads can be tensioned safely. At just 320 g, the motor weighs less than half as much as comparable motors and is suitable for applications in which high performance and dynamic start-stop operation with the lowest possible total weight are important.

A lot of power in the smallest space

If the installation space in the axial direction is limited in packaging machines, the high-torque flat motors of the BXT series are often a good choice. Thanks to innovative winding technology and optimised design, the motors themselves are only 14, 16 and 21 mm long, but deliver torques of up to 134 mNm with diameters of 22, 32 or 42 mm. For precise speed control or in case of high demands on positioning accuracy, diameter-compliant magnetic encoders or speed controllers are now fully integrated into the housed motor variants, lengthening the drive by only 6.2 mm. Digital Hall sensors integrated in the motors are used for speed control. This provides a wide speed range from 200 up to 10,000 min-1. The compact drive combination is ideal for space-critical applications and offers easy installation and commissioning. The matching metal planetary gearheads of the GPT series are also characterised by short design, high torque and fine graduations of the numerous reduction ratios.

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