A high speed, straight line, automatic system to glue absorbent soaker pads into styrene foam packaging trays.
The PAD-O-MATIC 360W was designed to operate in line with the thermoforming process in the tray production plant. The machine is mounted on castors to allow easy movement of the padding machine to the thermoforming line running the tray size to be padded. The trays are taken from the trim press packaging table and fed into the PAD-O-MATIC 360W denester or placed on the optional Tray Loading Conveyor, which feeds the trays into the denester of the PAD-O-MATIC 360W.
The PAD-O-MATIC 360W consists of a denester station to denest vertical stacks of foam packaging trays and feed them onto a single row flight conveyor. The denesting system does not require stacking lugs on the trays or any modification to the thermoformer tooling.
The flight conveyor transports the trays to the pad application unit. At the pad application unit, rolls of padding material are unwound from dual unwind spindles. The pads are cut to a predetermined length, which is set on the touch screen operator interface, hot melt adhesive is applied to the tray by adhesive guns, and the pad is positioned in the tray on the flight conveyor.
The padded tray continues on the flight conveyor to the stacking conveyor. At the stacking conveyor, the padded trays are rotated to vertical position, counted, the count tray is marked by a mechanical striker, or optional fluorescent ink, and horizontally stacked on the packaging table.
The packaging table is equipped with a pneumatic bag opening device to open wicketed polyethylene bags, fast pak bags, or an unwind spindle can be provided to use rolled, perforated bags. There are guides to allow easy insertion of the stacked, counted, padded trays into the poly bags. The optional sleeving attachment replaces the packaging table. A servo driven attachment to the stacking conveyor advances the counted sleeve of trays into the sleeving machine.
The PAD-O-MATIC 360W has an on-board vacuum pump and an automatic pressure lube system with alarm to lubricate all chains and gears. All electrical meets NEMA, NEC, CSA, and CE standards.
The PAD-O-MATIC 360W features single point handwheel adjustment of the denester width, the machine direction position of the denester vertical guides, the flight conveyor width, flight conveyor hold down rail height, and stacking conveyor width. The pad transfer wheel position in relation to the tray on the flight conveyor, the position of the pad on the pad transfer wheel, and the pad cut position between pouches may all be adjusted with the machine in production. The pad length and stack count are entered through the touch screen operator interface.
The operator interface is a 15″ tempered glass touch screen, providing a large format color interface. The main screen gives the operator control of, and gives status of the following: Registered pad cut, registered pad cut offset, pad length, vacuum pump and blowers, glue gun, glue swirl air, machine speed, tray count marker, and machine clear mode. Also displayed are: time and date, glue system ready, guard doors open, and emergency stop engaged. There is an alarm for low machine air pressure, or low machine vacuum.
The recipe screen allows the operator to name, store, and recall recipes for different products.
There is a re-settable display of total pads cut, total trays and pads counted, and total trays rejected by camera system if ordered with machine.
There is a control and display screen for the optional tray labeler if ordered with machine.
There is a parameter entry screen for the camera pad verification system if ordered. The operator can call up the images the camera sees and set up new recipes from the touch screen.
The machine encoder timing can be set from the touch screen without moving the encoder.
There is an alarm screen that displays alarms, and an alarm log
There is a diagnostics screen that displays in real time the status of the inputs and outputs of the Acroloop machine control. Each output may be toggled on and off from the touch screen to assist in troubleshooting. Each servo axis has a display showing DAC value and following error, and fault codes from the servo drive.
There is a help screen with a hypertext indexed complete machine manual with troubleshooting, adjustments, and setup instructions and diagrams.
The machine control has a USB port to allow program loading and recipe export using the operator interface and USB “thumb drive” without a laptop computer.
The control provides for machine shutdown on failure to denest a preset number of trays, failure to feed a preset number of pads, and denester jam. The control features a “pad saver” function that prevents a pad from being cut if a denester jam occurs. This eliminates wasted pad material. The control will provide an alarm and/or shutdown on adhesive system failure and Tray Loading Conveyor jam.
A new design pad cut assembly utilizes inexpensive steel rule knives that are replaced, rather than resharpening tool steel knives.
A tool box is supplied with the machine containing all the tools needed for size changeover, with a torque wrench for knife adjustment. The tool box has storage for the tray locks, tray checks, extra fasteners, and set-up gauges.