In order to meet the market on the major categories of rigid boxes and mobile phone boxes, as well as rapid production, one machine with universal functions. Zk-660FCS fully automatic rigid box making machine with multiple functions of 660A(N) and 660C(N) was born. It can switch freely between the boutique box and ordinary box, and freely adjust the inner folding depth. The equipment is used to produce high-end cardboard boxes such as phone box packaging, gift packaging, cosmetics packaging,industrial standard part packaging, food packaging, digital appliance packaging, stationery packaging and pharmaceutical supply packaging of various major types and styles. The equipment can make box with smoothing surface, no paper folding and printing marks, adopts the cardboard joining and gluing method(optional) and the full ear folding mechanism to overcome the drawbacks of the ordinary rigid box forming machine and thereby meet the market demand for various major types of rigid boxes and iPhone packaging boxes.
The equipment adopts Delta servo control system, visual manipulator system and touch screen HMI to realize automatic paper feeding, gluing, cardboard joining, positioning, automatic fetching, box pasting, edge covering, full ear folding and folding & forming all at one time. The equipment overcomes the drawback of “irregular products with no guarantee of quality”, thus significantly increasing work efficiency.
The use of virtual cam drive and mechanical cam to play their respective advantages, so that the action is more stable and more flexible. It is convenient for customers to make multiple samples of the box and improve efficiency.
The online glue viscosity testing system tests the glue viscosity in a real-time manner so as to ensure proper gluing in an inclement environment.
Visual manipulator system are adopted to make correct deviation, making pasting and positioning more accurate and making exquisite boxes look neater.
The automatic fetching system enables rapid transfer of cardboard boxes at the height range of 2-13cm, making the paper not susceptible to turning, curling and deformation and thus completing the forming process in an easy and perfect manner.
The cardboard box pasting and forming section carries out box feeding, edge covering, full ear folding and folding-in operation in a continuous manner to ensure standardized and exquisite cardboard boxes. The full ear folding mechanism pastes the four ears at both sides of the box to the box width upright plane and you can neither see or feel the folding lines of the four ears, thus rendering the unique value of the exquisite boxes.
Features

1.Suitable for all kinds of automatic rigid box production line
2.Machine adopts Delta's motion controller 15MC as the core control system
3.Automatic suction of paper and cardboard
4.Four-corner angle heating, single man-machine interface control or cardboard stitching bonding (optional)
5.Visual positioning system and SCARA manipulator grabbing (positioning error ±0.05mm)
6.24-hour control glue preheating function
7.Automatic glue viscosity control system (optional)
8.Full computer function parameter setting
9.Built-in product data matching mode
10.Fault diagnosis function
Main technical parameters



ZK-660FCS Main Specification

Function mode selection

Ⅰstandard

Ⅱ half ear fold

 full ear fold

Box Size

Length

L

max

400mm

400mm

400mm

Length

L

min

85mm

85mm

85mm

Width

W

max

300mm

200mm

100mm

Width

W

min

60mm

60mm

60mm

Height

H

max

125mm

120mm

120mm

Height

H

min

12mm

45mm

45mm

Turn In Depth

Turn in

R

max

70mm

Turn in

R

min

15mm

Paper wrap size

Length

B

max

660mm

Length

B

min

190mm

Width

A

max

560mm

Width

A

min

155mm

Thickness

g/m2

max

100

Thickness

g/m2

min

350

Cardboard

Thickness

mm

max

3

Thickness

mm

min

0.8

Speed

pcs/min

15-35

15-30

15-25

Ear folding

mm

15

15-100

15-100

Precision Error

±0.05mm

Grabbing Accuracy

±0.2mm

Paper pile height

260mm

cardboard pile height

1000mm

Electrical power

24KW

Glue tank capacity

45L

Air supply

12L/min

Net weight

8100KG

Overall dimension

6800mm×4300mm×3000mm


Note: the minimum box length is 85mm.


Introduction to ZK-660FCS box making process
I. Function of the four corners of blank box
    
1. Cardboard feeding mechanism with double swing arm supporting beam: it is convenient to adjust the size of cardboard, sensitive in action, compact in structure and stable in operation.
2. Micro-motor numerical control feeding tape: precise length control and flexible setting.
3. Hot-melt cutting four-corner device: Synchronous work, so that the four corners of the blank box are regular, firm, and not loose.
4. Outlet of blank box device: make the finished blank out of neat, standardized, orderly, not rolling, not spinning.
II. Function of surface paper gluing and conveyor belt

1. Electronic feeder mechanism: the paper is sucked after air nozzle, and the paper is fed by the front suction wind wheel, which is suitable for the size and specification of paper. The response is sensitive and fast.
2. The corridor of the surface paper can effectively eliminate the problem of bent and warped surface paper, as well as the control alarm of multiple sheets after glue.
3. Hot-melt glue device:simple and convenient structure for cleaning and uniform gluing.
4. Two-color conveyor belt system: The black-and-white conveyor belt can distinguish paper of various colors with different shades of color; the two-color conveyor belt is covered with thin holes, and through vacuum adsorption to ensure smooth, non-warped and non-askew delivery of surface paper.
5. The two-color conveyor belt is driven by a servo motor and automatically controls the step position.
III. Function of visual manipulator positioning
    
1.Blank box fixed platform: adopts L-shaped bilateral positioning, the subsequent delivery conveyor belt does not rebound continuously, the side cylinder soft contact anti-lock, the center of the bottom of the blank box is used as the reference to eliminate the four sides of the blank box to ensure the blank box positional accuracy.
2. Manipulator: the suction nozzle of the multi-nozzle sucks the bottom surface of the blank box, with strong adsorption, stable, non-rotating and non-sideslip, and no accumulated error of mechanical positioning structure, so as to ensure the positioning accuracy of the blank box is within± 0.05mm.
3. Visual automatic calibration system: the relationship between the center of blank box, the center of manipulator, the center of camera, the center of surface paper and the image feature of paper is difficult to find the data of mutual connection. The automatic calibration system of this product uses the suction cup to automatically absorb the visual automatic calibration rod to run various data collection, saving busy operation steps and time.
    
The figure above shows the schematic diagram of the overall work flow of full Automatic rigid box making machine. The core process is: how to achieve high-precision positioning and assembly?

High-speed, high-precision assembly operations
High-speed positioning assembly, speed up to 35Pcs/Min
Equipped with 5MP industrial camera positioning to achieve high precision positioning assembly: ±0.2mm

Integrated operation interface
Guided operation change line interface, easy to complete new product parameter settings, point teaching, one-key correction and other functions.

For the above core production, we use the DELTA system:

For high-precision positioning problems: provide Delta PVS visual positioning system;
For high-speed and high-stability problems: provide Delta high-speed, high-repetition accuracy SCARA;
For new product introduction problems: Provide one-key correction function, guided operation flow, import time is less than 15 minutes;
For the existing product line change problem: to provide database function, the machine parameters will automatically switch. Change time is less than 1 minute;
        
Function of forming part
    
1. Automatic drawing system: 15MC is used as the main controller, and the servo motor is connected to the synchronous operation through the CANOPEN bus. According to the change of the box specifications and speed, the production can be carried out smoothly and quickly.
2. The paper box forming unit can do consistent work including box feeding, ear folding, as well as rolling over and forming guarantees the paper carton standard finely,The 2 sets mould of the paper box forming parts running at the same time and also start a rhythm and a series of moves to complete the box feeding, ear folding, as well as rolling over and forming and other movements. 4 brush rollers with easy adjusting the pressure the glue surface paper even gable paper carton all around wall tightly; the high and low mold cushioning may realize both exerts pressure the exhaust and the protection cardboard function.
3. Turn in depth: through the CANOPEN bus control deep folding into the servo motor operation, so that the folding depth can be freely selected between 12mm-70mm, flexible and convenient, to meet the needs of a variety of box making, a multi-purpose machine, shorten the sample time, save the cost of boxing, and give you real profits.
4. Full ear folding device: multiple mode switching, free adjustment of folding distance in 15mm-100mm, to meet the market demand of high-end boxes,no folding mark boxes and various decorative boxes.
5. Finished product box-out device: the cylinder clamp removes the box mechanism so that the boutique box is not scratched.

Automatic fault diagnosis
The full automatic rigid box making machinery has Automatic fault diagnosis, Can safeguard the machinery momentarily self-examination, handling equipment revolution information in prompt accurately, also can be guaranteed the equipment at the good working status.
Machine with easy operation, the work setup time is short, and suits the long, medium and short version running flexible.The User-friendly design of the full automatic rigid paper box making machinery is low to the mechanical operator specification; the ordinary female worker can be operating machine. Equipment’s work setup time is short, generally the box changing time is about 1-2 hours, and suts the long medium and short version running flexible.
The equipment control simple, realizes the safe operation and the protection design.
The equipment has realized the safe operation and the protection design in each partial part's design and the generating process, for safeguard the user avoid safe hidden trouble in the high speed production process.

Environmental Requirement
(1)Temperature: normal ambient temperature of 20°C (In the summer should be install air conditioning system)
(2)Humidity: 50%-60%
(3)Keep the machine away from oil and gases, chemicals, acids, alkalis, explosive or flammable material
(4)Ambient lighting: more than 300LUX
(5)Avoid direct sunshine
(6)Avoid being close to those machines which can cause vibration
(7)Avoid direct cooling by fans

Material packaging requirement
(1)The surface paper, the cardboard are smooth
(2)The surface paper duplicate abdomen must be pass two-sided static electricity processing
If the colour of the surface paper (black) is similar with the conveyor belt, pls stick some other colour (like white) sticking tape, for distinction the colors.
Electrical power unit requirement
This machine uses the three-phase power source: 380V 50Hz, atmospheric pressure: 0.8Mpa
Personnel requirement
To ensure the safety of the operator, to maximize the performance of the machine, reduce faults and prolong its using life. Checking and repairing electrical control circuits must be carried out by electrically skilled persons ( about 1 person one machine)
Machine matching with auxiliary material:1.glue,2,tape
Glue features:
Unlimited usability of animal glue ensures perfect quality of products in terms of environmental friendliness and high accuracy
The glue of the full automatic rigid box making machinery using is animal glue. There has the following characteristics:1.dry fast, Under 20-25℃, usually drying time in 5-7 seconds, Even if under more than 30 degrees high temperatures, also can be dry in more than ten seconds, Thus, the cardboard will not drinking water and become deformed.. 2. Smoothly, after animal glue coating, will form mirror surface cellophane in the paper surface, the paper carton finished product looks flat and smoothly. 3. Environment-protective, which is the biggest feature Distinguishes in the traditional chemistry crepe glue, the animal glue is uses and boil with the animal fur and bone, therefore it may apply in food, drug sundries and daily clothing packing widely.
The heat change stick glue system of the full automatic rigid box making machinery has entrusted with the animal glue more widespread using space. The user can be control the thickness and viscosity of the glue easily, and produces a product from beginning to end.