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Production lines

Packaging

Keep stations phase-locked electronically instead of by a line shaft.

  • Typical axes4
  • NetworkEtherCAT
  • Control modeCSP
  • Recommended seriesSD24-LP · SMR · SM08 · SDU3
Start Product Selection See the solution
01
The sector at a glance

Packaging

High-cycle multi-station lines must stay locked to a common line reference.

Three things that decide it on the shop floor

  1. 01

    Phase error at changeover

    A line is judged at the moment it changes format; cam profile and following error are what you tune.

  2. 02

    Mark-reading latency

    Sensor response time is part of the loop; a slow reader misleads a fast drive.

  3. 03

    Determinism along the line

    On a bus twenty stations share, determinism matters more than bandwidth.

02
Our advantages

Why SMB TECHNICS?

One set, controller to cable

Controller, drive, motor, cable and connector arrive checked against each other; interface problems are solved at the desk, not on the shop floor.

Open standards

EtherCAT, CANopen, Modbus RTU, CODESYS and CiA 402: your machine is not tied to a closed ecosystem.

Engineer-to-engineer support

The same team from sizing to commissioning, on site and remotely.

Documented products

Manuals, CAD, ESI/EDS and firmware in the Document Centre; every product you choose comes with its documents.

Our application know-how for this sector
  • Virtual master and electronic cam profiles (PLCopen)
  • Register correction from the print mark
  • Phase transition at format changeover
03
How we build the system

From control chain to commissioning, which product goes where

3.1

The control chain and the recommended products

How the machine is driven and the SMB products we choose for it.

Packaging lines run at high cycle rates with multiple stations — filling, sealing, labeling, cartoning — that must stay phase-locked to a common line reference. Servo drives with fast current loops and deterministic fieldbus communication (EtherCAT, CANopen) keep these stations synchronized electronically instead of relying on mechanical line shafts.

With the engineering know-how of an industrial group that runs its own production lines, SMB TECHNICS binds packaging stations to one electronic reference instead of a mechanical line shaft.

The control chain

A packaging line is a line shaft that no longer exists. Every station that used to be geared to one mechanical shaft now has to be phase-locked to a virtual one, and that is a control job: a MAT-LC CPU holds the master position, each station runs a servo drive — SD-LP and SD24-LP for the small axes that make up most of a line, SDU3 where a station carries real load — on SM06 to SM10 motors. Registration marks and product presence come back through photoelectric sensors.

What decides the result

  • Phase error under changeover. The line is judged at the moment it changes format, not while it runs steady. Cam profiles and the drive's following error are what you actually tune.
  • Where the mark is read. A registration sensor's response time is part of the loop. A fast drive behind a slow mark reader gives you a fast wrong cut.
  • The bus one station shares with twenty. Determinism matters more than bandwidth here; our drives publish EtherCAT and CANopen (CiA 301 / CiA 402) so the line's existing controller decides.

Sizing it

Per station we need the moved mass, the index distance and the cycle rate — that is what turns into torque and, more often, into the intermittent duty that actually sets the drive. Start from the selection guide for the drive and the sizer for the mechanics, and tell us the fieldbus your line already speaks.

Select the products for this machine Enter power, torque and network; compare compatible drives and motors and add them to your basket. Selection guide
3.2

The architecture: which product goes where

The boxes show the real products; click one to open the series.

EtherCAT Operator panel HMI-R9 Controller · CODESYS MAT-LC CPU I/O and sensors MAT-LC I/O · PNP / NPN Safe stop STO · brake Supply protection EMI · braking resistor Line master Drive · SD24-LP CSP · EtherCAT Motor SMR Infeed / index Drive · SD24-LP CSP · EtherCAT Motor SM08 Rotary knife (flying cut) Drive · SDU3 CSP · EtherCAT Motor SMR Labelling Drive · SD24-LP CSP · EtherCAT Motor SM06
  • EtherCAT
  • Ethernet
  • Power and feedback
  • Safety
Where this machine sits on the full SMB system map
CPU / PLC & Motion Control 3 series Expansion Rack / IO 10 products Ethernet switch Ethernet Operator Panels 3 series Sensors 3 series EtherCAT Servo Drives 17 products CANopen Servo Drives 6 products Modbus RTU Servo Drives 4 products Servo Motors 6 series Power and Encoder Cables 2 series CODESYS IEC 61131-3 PLCopen Motion Control CiA 402 Drive profile
EtherCAT Ethernet CANopen Modbus RTU Digital I/O Power and feedback

CPU / PLC & Motion Control

Expansion Rack / IO

Ethernet switch

The industrial switch distributes Ethernet traffic between the controller, the operator panel and the engineering PC. It is part of the architecture, not part of the SMB catalogue.

Operator Panels

Sensors

EtherCAT Servo Drives

CANopen Servo Drives

Modbus RTU Servo Drives

Servo Motors

Power and Encoder Cables

CODESYS

SMB controllers are programmed in CODESYS: the IEC 61131-3 languages, integrated motion and a single project covering both machine logic and the axes.

PLCopen

PLCopen Motion Control function blocks give every axis the same standard interface, so proven machine code carries over from one project to the next.

CiA 402

SMB servo drives implement the CiA 402 drive profile: the same state machine and the same operating modes over EtherCAT and over CANopen.

3.3

Product placement, axis by axis

Each axis, its task, its control mode and the drive–motor pair on it.

  1. 01
    Line master The virtual master every station is geared to
    CSP · EtherCAT
    SD24-LP Drive SD24-LP Series Flagship EtherCAT low-power servo drive line. SMR Motor SMR Series Low-inertia servo motors in 60–130 mm frames, single-phase 220 V AC and three-phase 380 V AC, 400 W–7.5 kW, with BiSS absolute encoders.
  2. 02
    Infeed / index Fast, positioned transfer into the station
    CSP · EtherCAT
    SD24-LP Drive SD24-LP Series Flagship EtherCAT low-power servo drive line. SM08 Motor SM08 Flange Family 80 mm-frame 220 V AC servo motors, 750 W–1 kW, with BiSS encoder options and an optional brake.
  3. 03
    Rotary knife (flying cut) Cutting moving film on a cam
    CSP · EtherCAT
    SDU3 Drive SDU3 Series Three-phase 380 V AC EtherCAT servo drives with power steps from 400 W to 7.5 kW. SMR Motor SMR Series Low-inertia servo motors in 60–130 mm frames, single-phase 220 V AC and three-phase 380 V AC, 400 W–7.5 kW, with BiSS absolute encoders.
  4. 04
    Labelling Positioning to the print mark
    CSP · EtherCAT
    SD24-LP Drive SD24-LP Series Flagship EtherCAT low-power servo drive line. SM06 Motor SM06 Flange Family 60 mm-frame 220 V AC servo motors, 200–400 W, with absolute, BiSS and incremental encoder options and an optional brake. Photoelectric Motor Photoelectric Sensors M8-body photoelectric sensors with 110 mm–1 m sensing range and PNP/NPN, NO/NC outputs.

CSP: cyclic synchronous position · CSV: cyclic synchronous velocity · CST: cyclic synchronous torque · PP: profile position. The series is confirmed by load and supply voltage.

3.4

The build, step by step

From requirement to support; the SMB products and tools each step uses.

  1. 1

    Requirements and sizing

    The motion profile, load and cycle time of every axis are collected; torque, speed and inertia ratio are calculated per axis.

    • Peak and RMS torque, top speed
    • Load-to-motor inertia ratio and gearing
    • Supply: 220 V AC, 380 V AC or 24–70 V DC
    Sizer Selection guide
  2. 2

    Architecture and product choice

    The network (EtherCAT, CANopen, Modbus RTU), the controller and the drive–motor pair per axis are chosen; the safety and power side is drawn at this step.

    • EtherCAT for synchronised axes, CANopen for independent ones
    • Drive current covers the motor peak current
    • STO and braked motors come from the risk assessment
    SD-LP-04-D1-M SM06-DIN13-020B0 MAT-LC-C06 MATSPS1M8-350P4NOC
  3. 3

    Cabinet, cabling and EMC

    Power and encoder cables run in separate ducts with their shields bonded 360°; an EMI filter goes at the drive input and a braking resistor where the load regenerates.

    • Flexible cable for the cable chain
    • Shields are earthed at both ends
    • The braking resistor is sized from the braking energy
    Power / Motor Cables Encoder Cables SMKP Power Connectors SMKE Encoder Connectors EMI Filters Braking Resistors
  4. 4

    Software and network

    In the CODESYS project the axes are defined with PLCopen blocks; the drives join the network through their ESI/EDS files and run the CiA 402 state machine.

    • IEC 61131-3 languages and PLCopen Motion Control
    • ESI (EtherCAT) and EDS (CANopen) in the Document Centre
    • EtherCAT coupler for remote I/O
    MAT-LC CodeSys CPU MAT-LC I/O Modules MAT-LC System Modules
    CODESYS FAQ Document centre
  5. 5

    Commissioning and tuning

    After wiring and direction checks the gains are tuned and the axes homed; the operator panel carries the machine recipes.

    • Direction, limit and emergency-stop tests
    • Speed and position loop gain tuning
    • Backing up the parameter sets
    HMI-R9 Series
    Commissioning FAQ Troubleshooting
  6. 6

    Support and lifecycle

    Alarm codes, spare parts, firmware and training, from the same engineering team.

    • Alarm-code and troubleshooting guides
    • Manual, CAD and firmware downloads
    • Remote and on-site support
    Technical support Document centre
3.5

The solution package: what comes with the product

Hardware, software, engineering and lifecycle.

02

Software and know-how

The CODESYS project, PLCopen motion blocks and know-how specific to this machine.

  • Virtual master and electronic cam profiles (PLCopen)
  • Register correction from the print mark
  • Phase transition at format changeover
03

Engineering support

Sizing, architecture, commissioning and tuning, on site and remotely.

  • Motor and drive sizing per axis
  • System architecture and network choice
  • Commissioning, gain tuning and homing
04

Lifecycle

Manuals, ESI/EDS files, spare parts and training.

  • Document Centre: manuals, CAD, firmware
  • ESI and EDS files, parameter backups
  • Spare parts and user training
Engineering knowledge base

Commissioning this application

The topics engineers in this industry ask about most, each with answers, checklists and troubleshooting steps.

EtherCAT CODESYS Servo commissioning & tuning System design

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