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With the intensification of the overseas epidemic and the arrival of a comprehensive return to work in the domestic environment, the demand for masks is immense. To ensure the efficient operation of mask enterprises, countless automation manufacturers have plunged into this smoke-free “epidemic counterattack” to help create efficient mask machine production lines.
Siemens Responds Immediately, Providing Automation Solutions
After the outbreak of the epidemic, Siemens responded immediately on January 21, providing ultrasound equipment for severe care to local hospitals in Wuhan.
Upon receiving nearly a thousand requests for automation solutions for mask machine equipment,they immediately prepared customized electrical configuration plans, coordinated supply channels, placed orders for production in factories, and ultimately delivered thousands of Siemens devices on time, arranging debugging personnel for on-site coordination.
Siemens uses the V90PN servo drive system, with V90 servo drives available in pulse sequence versions (PTI) and PROFINET versions (PN), supporting various motion modes including external pulse position control mode, internal set value position control mode, speed mode, torque mode, etc.
The SMART series PLC and human-machine interface ensure high dynamic response and precise positioning, guaranteeing the stable and efficient operation of the mask machine.
Siemens’ solutions are supporting the rapid upgrade and transformation of China’s manufacturing industry in this epidemic, integrating the powers of electrification, automation, and digitalization into this epidemic counterattack, achieving unprecedented heights, speeds, precision, and depth, allowing most traditional manufacturing industries to glimpse a corner of automation.
Schneider Improves Technology, Combining Remote Operation and Automatic Control
Schneider Electric’s automation and servo products have been widely used in the manufacture of epidemic prevention materials,and Schneider’s self-developed automatic mask machine control system can cover flat masks and N95 mask equipment, providing strong technical support for epidemic prevention material security.
Schneider has made technical improvements to the conventional configuration of one-to-two or one-to-three flat mask machines in the market, launching a control solution centered on the more intelligent and compact Modicon M221 programmable controllerand utilizing EcoStruxure machine advisor to closely integrate local automatic control of machines with remote operation and maintenance, thereby increasing production capacity.
In this urgent battle, Schneider Electric opened a green channel, providing a full set of solutions and high-performance products such as Modicon M241 PLC, GXU touch screens, and LXM28 servo drives to multiple automation equipment companies.
Mitsubishi’s High-Performance Automation Products Support Mask Machine Production
Mitsubishi Electric PLCs, inverters, servo systems, HMIs, CC-Link networks, and other automation products have superior performance and are widely used in mask machines, creating ultra-high-speed automated mask production lines..
The fully automatic high-speed production line is formed from fabric integration, closed manufacturing, to finished product segments, operated by only 5-6 workers. It can produce 1000 masks per minute, with a maximum daily output of 1.44 million masks.
The first batch of equipment for the high-speed flat mask machine JT-KZ500 and the high-speed JT-DH60-X automatic spot welding machine independently developed by Jiatai CNC uses a control system that employs Mitsubishi FX5U-64M + FX5-80SSC-S, with servo motors using the Mitsubishi FX5U-64M + FX5-80SSC-S series, and the drivers and inverters being Mitsubishi MR-JE and E700 series, respectively. Mitsubishi uses PLC microcomputer control, full servo motors, adaptive tension control, and automatic correction systems to ensure high stability of the equipment.
The entire machine operates automatically from feeding to finished product, requiring only one person to operate, is simple to operate, and produces at high speed and efficiency, with the mask flat speed reaching over 500 pieces per minute.
Delta Tackles Technical Challenges, Providing Multiple Solutions
As an important enterprise in the field of industrial automation and smart manufacturing, Delta quickly responded to the demand for epidemic protection, rapidly developed, and tackled technical challenges of mask machines, helping multiple mask equipment manufacturing companies successfully produce. The production process of fully automated mask machines is mainly affected by the appearance shape of the masks, and Delta provides different solutions based on the characteristics of flat masks and three-dimensional masks.
The flat mask machine process is relatively simple, focusing on process control, with the main efficiency impact occurring at the backend ear strap welding station.Delta provides the PLCAS300 series and ASDA-A2 series servo drives to help a slitting device carry multiple ear strap welding devices at the same time, increasing production capacity.
The ASDA-A2-M series is a CANopen high-speed communication type servo drive system that includes an electronic cam function, smoothly producing equipment travel, planning reasonable cutting curves to meet the process requirements of fully automated mask machine equipment for transportation and cutting.
Additionally, this system is also very efficient in the hot pressing process of the mask ear straps, usually used in conjunction with 2-3 ear strap welding machines, achieving a high hot sealing accuracy of ±0.5mm, with ear strap accuracy reaching ±1mm. Tests show that the production speed of the fully automated flat mask machine using Delta’s solutions can reach 150 pieces per minute.
For folding mask machines, Delta provides the CANopen bus-type motion controller DVP15MC11T. Seamlessly connecting Delta’s ASDA-A2-M series servo drive system, it uses a trailing cutting and retrieval curve to process the three-dimensional shape of the masks.
Estun Builds Robot Mask Production Line, Making Unmanned Factories a Reality
Estun has built a universally applicable automated robot mask production line, centered around TRIO high-end motion control + Estun high-performance servo systems + Estun robots, to realize rapid production and increased efficiency, providing unmanned mask production lines for mask manufacturing factories..
In the flat mask machine process, Estun adopts the EtherCAT bus solution, with precise position control, which is more efficient and precise than traditional PLC pulses. The hot sealing precision error is 0.5mm, and the ear strap precision error is 1mm.
The EM3A high-dynamic servo motor meets the speed requirements for mass production of masks. The fully automated N95 folding mask machine production line utilizes the optimized cam curve from Estun, optimizing the trailing cutting process algorithm, making motion parameter adjustments more convenient while improving speed and effectively reducing machine vibrations.
Inovance Develops Technical Electrical Solutions, Driving Industry Development through Innovation
Inovance urgently developed a series of technical electrical solutions to combat the epidemic,using Inovance Kylin IV700 vision system + medium PLCAM401 + 4PME EtherCAT communication with 3 SV660 series servos, with the CPU capable of driving stepper motors, using two winding stepper motors for left and right ear straps with 4PME expansion control methods.
The mask machine under this solution operates smoothly and efficiently, with microsecond-level position capturing capability and extremely high marking accuracy. The dedicated trailing cutting process function block can automatically plan process parameters and motion curves, achieving flexible switching of production lines with one-click mold change.Production efficiency for N95 folding three-dimensional masks can reach 60 pieces per minute, and for ordinary flat masks, it can reach 120 pieces per minute.
In terms of intelligence, it adopts the self-developed deep learning vision controller – Kylin IV700, combined with specific optical solutions to achieve high precision foreign object and size measurement, eliminating manual operation and avoiding false negatives caused by human factors. Inovance’s addition of visual inspection has certain advantages for high-demand scenarios and is also an innovation.
Hechuan’s Compact Design Structure Ensures Production Efficiency
After the outbreak of the epidemic, Hechuan actively participated in the fight against the epidemic, fully combining its own technological characteristics to develop and apply automation solutions for mask machine production equipment.In response to epidemic prevention and control, Hechuan proposed an EtherCAT high-speed Ethernet solution.
Using a medium motion controller, it meets 32-axis high-speed Ethernet EtherCAT synchronous control, supporting interpolation, trailing cutting, flying cutting, and other complete motion control functions. The response servo driver, with a 2.5KHz response frequency bandwidth, ensures that the equipment quickly follows system instructions, simplifying PI debugging and saving installation space for motor mechanisms.
Hechuan’s driver mechanism design is compact, with ultra-short motors that do not take up space, making installation convenient. The position control is stable and reliable, with low failure rates.High response positioning improves the welding accuracy of the mask ear straps.Utilizing EtherCAT multi-axis connections significantly saves wiring and troubleshooting time, ensuring production efficiency and saving labor hours.
Hexin Takes Responsibility, Providing Automation Solutions
As a representative of domestic automation manufacturers, Hexin takes responsibility, providing industrial automation solutions for mask machines, disinfectant filling machines, and capping machines, contributing to the effort.Hexin’s N95 fully automatic mask machine control system configuration plan adopts the CTH300 series medium and large PLC, with large program space and data space, strong expansion capability, and fast processor scanning speed.
The high-speed EtherCAT bus control solution features simple wiring, high control accuracy, fast rates, and real-time response.
Hexin effectively tracks corresponding variable change curves through CODESYS software, making adjustments more convenient; the use of electronic cams allows better control of the process. The A4 servo system ensures that the fully automatic mask machine operates faster, more steadily, and more precisely.
Xinjie Solutions Stable Application, Becoming a Core Supplier
For Xinjie Electric, the main products include several categories: PLCs, servos, human-machine interfaces, and a series of supporting solutions for various industries. As the COVID-19 pandemic spreads, it has become a core supplier for mask production.
Xinjie’s fully automatic mask machine solution uses the CAM4-60T10-E model PLC with 10-axis high-performance cam control, with convenient and simple programming, optimized control algorithms, and using trailing cutting functions to improve production speed, reaching up to 70 pieces per minute, while the consistency of mask production can reach 0.3mm, fully meeting the accuracy and speed requirements for fully automated production.
Xinjie Electric revealed through its official WeChat account that the mask machine solution has been applied in multiple enterprises and has been reported by CCTV news broadcasts.
Currently, Xinjie’s fully automatic mask machine solution has been stably applied in multiple mask production enterprises, and Xinjie products are working day and night on the front line of the “epidemic battle”, contributing in their own way to ensuring the supply of epidemic prevention materials.
Leisai Initiates Emergency Plan, Providing Motion Control Products
Leisai Intelligent, as an important provider of motion control products in the medical equipment industry, initiated an emergency plan at the first moment, implementing epidemic prevention measures, arranging personnel for 24-hour duty, providing stepper, closed-loop, and AC servo motion control products to related mask, protective clothing, and drug manufacturers, and coordinating national offices to provide remote and on-site services to customers.
Since the Spring Festival, it has provided motion control products required for over 2000 devices to customers.
Leisai has cooperated with mask machine manufacturers for many years and is familiar with the application processes and technical requirements of mask equipment,providing high cost-effective solutions for equipment manufacturers with stepper + closed-loop + AC servo, meeting customer requirements for high reliability, high responsiveness, and high precision in driving products, especially with unique technical solutions for addressing ultrasonic interference issues in mask equipment.
During the epidemic, Leisai also launched the EtherCAT bus “servo + stepper” driving solution for mask machines based on the original “servo + stepper” pulse solution, enhancing the production efficiency of mask machines and assisting mask manufacturers in expanding capacity.
Since the outbreak of the epidemic, most industrial automation manufacturers have quickly produced mature solutions and products to support mask machine production, also showing outstanding performance in delivery and usage. However, as the epidemic continues, the situation in the mask machine industry is rapidly changing, and the requirements for automation bus solutions and motion control will gradually increase. The automation battle against the epidemic is a long-term task.
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