Carton forming machine – XC series PLC controller

Carton forming machine with Xinje XC series PLC controller – a semi-automatic cardboard box forming device designed and built by Automation Dariusz Kulik. The carton forming machine replaced manual box folding operations, reducing cycle time and increasing packaging line throughput. The Xinje XC series PLC controller serves as the reliable control centre for the entire carton forming process.

Carton Forming Machine – How It Works

The carton forming machine carries out the process of folding flat cardboard blanks into finished boxes. The Xinje XC series PLC controller manages the sequence: feeding the blank from the magazine, folding the bottom of the carton, gluing or stapling the base, and ejecting the finished carton to the packaging line. Full automation of the carton forming process enables uninterrupted operation without continuous operator involvement. The machine adapts to various box sizes through mechanical adjustment or PLC programme changes.

Xinje XC Series PLC Controller – Automation Application

The Xinje XC series PLC controller selected for the carton forming project met all design specifications at a highly competitive price-to-performance ratio. The XC series offers fast digital and analogue I/O, Modbus RTU communication, pulse axis support for stepper and servo motor control, and IEC 61131-3 programming (ladder, function block). The Xinje PLC excels in packaging, assembly and conveying equipment as a cost-effective alternative to more expensive European platforms.

Results – Carton Forming Automation with PLC

Automating the carton forming process with the Xinje PLC controller delivered to the client: a threefold increase in packaging output compared to manual methods, elimination of box folding defects, seamless integration with the packaging and labelling line, and low running and maintenance costs. The carton forming machine with PLC project is an example of effective and economical automation implementation for small and medium-sized manufacturing companies.

Project Details

Use of the XC series controller

An example of the application of the Xinje controller is a device for forming cardboard packaging. In this semi-automatic machine, we used the Xinje XC series controller, which provided sufficient functionality for the design specifications defined by the customer.

The device is used to assemble various types of rectangular packaging. It can be adapted to a new carton, e.g. with different dimensions, by installing the appropriate mounting block and changing the actuator settings.

Cardboard packaging forming device – design

Main features of the solution

• Assembly of rectangular cardboard packaging using actuators,
• Operator safety thanks to the use of two-handed operation,
• Actuator and safety circuit control using a Xinje XC series controller,
• Possibility of adapting the device to different types of packaging.

Device design

The device consists of actuators that are used to press (form) packaging. The operator’s work area consists of two buttons and two indicator lights. The operator uses the buttons to operate the device with both hands. A safety valve controlled by Xinje XC-24 ensures safe operation of the machine.

Control

The device control programme is divided into modules such as:

• safety,
• cycle, counters,
• cycle time, etc.

The modular structure of the programme affects the performance of the control system and keeps the programme code organised. A fragment of the programme from the carton forming device is shown below.

Excerpt from the programme for a carton forming machine

Why Automate Your Production Processes?

Industrial process automation is an investment that delivers measurable returns in a short timeframe. Companies that have implemented robotics and automated systems report: productivity increases of 30–300% depending on the process, reduced labour costs while maintaining product quality, process repeatability independent of human factors, the ability to run 24/7 production without breaks, better quality control through real-time parameter monitoring, and improved worker safety by eliminating hazardous manual operations.

Automation Dariusz Kulik – Our Approach to Projects

Automation Dariusz Kulik delivers industrial automation projects end-to-end – from client needs analysis, through technical design and component selection, to manufacturing, commissioning and ongoing service. We approach every project individually, selecting the most technically and economically optimal solutions. We specialise in Xinje PLC controllers, HMI panels, servo motors and inverters, as well as robotic systems, CNC machines and assembly lines. Our completed projects span the food, metalworking, timber, packaging and chemical industries. Contact us to discuss your automation project.