Tobacco Packaging Production Line

Industry Case Background

On a high-speed cigarette production line, approximately 18,000 cigarettes per minute need to undergo packaging, inspection, and sorting. At such high speeds, production enterprises have long been troubled by a key problem: when there is an abnormality in packaging, the rejection mechanism will also remove the normal cigarettes before and after the defective products, resulting in a large number of intact products being incorrectly discarded. To avoid the waste of these normal cigarettes, on-site operators must reinsert them into the production line. This reinsertion operation under high-speed production conditions is not only difficult to perform but also significantly increases labor costs and the risk of errors. Recently, Sinsegye has designed an automated transformation solution to address this pain point in the cigarette packaging production line. The solution increases the production line transmission speed from 1.5m/s to 2m/s, and while improving performance, it reduces the overall solution cost by 50%.

Industry Requirements

• Improve production takt: The production line transmission speed needs to be increased from 1.5m/s to 1.8m/s, while ensuring accurate insertion of cigarette packs.
• Reduce solution cost: The original vision solution paired with a certain imported brand of PLC has high costs, requiring a more cost-effective localized alternative solution.
• High control complexity: Visual recognition, motion control calculation, and manipulator grabbing and placing actions need to be completed within 1 second.
• High requirements for precision and stability: A 5mm gap must be maintained between the insertion position and the previous cigarette pack, with a vertical fluctuation of no more than 2mm.

Scene Architecture Diagram

Advantages of Sinsegye's Solution

1.Index Breakthrough:

On the premise of ensuring stable insertion of cigarette packs, the production line transmission speed is increased from 1.5m/s to 2m/s, exceeding customer expectations, and the overall efficiency is improved by 33%.

2.Integrated Control and Computation:

Replace imported PLCs and vision controllers with industrial intelligent computers, and combine self-developed software function blocks to replace imported motion control boards. While improving performance, the cost is reduced by 50%.

3.High Precision and Stability:

The fluctuation of the insertion position is controlled within 2mm, meeting the 5mm interval requirement and ensuring continuous and stable operation of the production line.

4.Localization and Independent Control:

Realize the localized replacement of core control components, reduce supply chain risks, and improve the flexibility of system maintenance and expansion.