{"id":2998,"date":"2021-11-24T09:19:10","date_gmt":"2021-11-24T09:19:10","guid":{"rendered":"https:\/\/www.publiteconline.it\/controlloemisura\/?p=2998"},"modified":"2025-06-24T15:35:15","modified_gmt":"2025-06-24T15:35:15","slug":"motion-control-for-aseptic-filling","status":"publish","type":"post","link":"https:\/\/www.publiteconline.it\/controlloemisura\/motion-control-for-aseptic-filling\/","title":{"rendered":"Motion Control for Aseptic Filling"},"content":{"rendered":"\n<h2 class=\"wp-block-heading\">Motion control specialist Yaskawa supported a client in the restyling of a multi-format rotary washing machine, for vials and bottles for aseptic production. The hallenge was to move from\u00a0a mechanical to an electronic concept<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Located right at the heart of the Packaging Valley, the cluster of advanced mechanics and industrial automation in Emilia Romagna, IMA has been designing and manufacturing hi-tech automatic machines for the processing and packaging of pharmaceuticals, cosmetics, food, tea and coffee for almost sixty years. The company philosophy, based on research and innovation, considers the constant technological upgrading of machines and plants to be of primary importance, in order to pursue a continuous evolution of efficiency and sustainability of its production lines. Recently IMA Life has dedicated itself to the innovation of the standard module of its VEGA Series multi-format rotary washing machines, part of the aseptic filling line for vials and bottles for sterile environments. The restyling has involved the entire series, which has gone from a mechanical concept to a fully electronic one, with the adoption of a hybrid system of engines.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Advanced motion control solutions<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">IMA wanted to increase the flexibility and scalability of the hardware and software of the machines, thereby reducing their footprint and costs. \u201cSince in the past we had experienced some problems with the mechatronic solutions of a labelling machine, a tray filler with advanced collision detection and a module for loading bottles into a tunnel in quincunx layout, we decided to install advanced motion control solutions for the multi-format rotary washing machines in the IMA Life line\u201d, Maurizio Lodato, HW &amp; SW Technical Dept. Manager at IMA Life, at the Calenzano site, near Florence, explained.&nbsp;<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For the ideal solution, the company turned to Yaskawa. For the machine\u2019s basic functionality of transporting bottles and managing the washing trolley, the mechatronic axis control subsystem consists of an MP3300iec machine controller with Sigma-7 motors and drives.<\/p>\n\n\n\n<figure class=\"wp-block-gallery columns-3 is-cropped wp-block-gallery-1 is-layout-flex wp-block-gallery-is-layout-flex\"><ul class=\"blocks-gallery-grid\"><li class=\"blocks-gallery-item\"><figure><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"600\" src=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/1-6.jpg\" alt=\"The washing machine\u2019s control panel.\" data-id=\"2999\" data-full-url=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/1-6.jpg\" data-link=\"https:\/\/www.publiteconline.it\/controlloemisura\/?attachment_id=2999\" class=\"wp-image-2999\" srcset=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/1-6.jpg 800w, https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/1-6-300x225.jpg 300w, https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/1-6-768x576.jpg 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><figcaption class=\"blocks-gallery-item__caption\">The washing machine\u2019s control panel.<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"599\" src=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/2-6.jpg\" alt=\"The restyling involved moving from a mechanical to an electronic solution.\" data-id=\"3000\" data-full-url=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/2-6.jpg\" data-link=\"https:\/\/www.publiteconline.it\/controlloemisura\/?attachment_id=3000\" class=\"wp-image-3000\" srcset=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/2-6.jpg 800w, https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/2-6-300x225.jpg 300w, https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/2-6-768x575.jpg 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><figcaption class=\"blocks-gallery-item__caption\">The restyling involved moving from a mechanical to an electronic solution.\n<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"656\" src=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/3-5.jpg\" alt=\"A hybrid system of engines has been adopted.\" data-id=\"3001\" data-full-url=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/3-5.jpg\" data-link=\"https:\/\/www.publiteconline.it\/controlloemisura\/?attachment_id=3001\" class=\"wp-image-3001\" srcset=\"https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/3-5.jpg 800w, https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/3-5-300x246.jpg 300w, https:\/\/www.publiteconline.it\/controlloemisura\/wp-content\/uploads\/2021\/11\/3-5-768x630.jpg 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><figcaption class=\"blocks-gallery-item__caption\">A hybrid system of engines has been adopted.\n<\/figcaption><\/figure><\/li><\/ul><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\">Two important challenges lie ahead<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Yaskawa was immediately faced with major challenges. First of all, it had to incorporate a non-digital, non-real-time sub-system into a digital, real-time control system. The restyling of the VEGA series required the use of two special motors for lifting the carousel, which were neither produced by Yaskawa nor equipped with a Yaskawa digital interface, and therefore could not be managed directly by the chosen controller.&nbsp;<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Two possible solutions were identified. The first proposed to use a Yaskawa drive \u201cin simulation\u201d mode (that is, without a motor connected to it) to generate the analogue trajectory of the non-Yaskawa external axes. The second solution would have controlled the external system using deterministic trajectory \u201cstreaming data\u201d generated by a virtual axis in the Yaskawa controller. IMA opted for the latter option, which offered several advantages: in addition to being strong and reliable, it also reduced components (space in the cabinet) and wiring, while offering a significant cost saving.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A further challenge was that the external two-motor system was equipped with an incremental encoder. As this is a \u201cvertical gantry\u201d mechanical configuration, it was necessary to manage the Homing procedure at the machine start-up, the management and correction of any mechanical mismatch during the normal cycle and in the event of an emergency stop. During the tests to explore the tollerance of the Streaming solution, we tried to overload the CPU of the Yaskawa controller, burdening it with about ten additional virtual axes in electronic cams, some FOR_TO cycles and several additional subroutines. As a result, the CPU did not exceed 60% of its computing capacity, confirming that the CPU\u2019s real-time management and multitasking behaved exactly as expected.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Standard components available worldwide<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cYaskawa helped us to evaluate the most suitable motion control solution for our requirements, supporting us in making the most suitable choice from a hardware, software and functional standpoint, demonstrating great competence and helpfulness,\u201d Maurizio Lodato said. \u201cIMA Life was thus able to analyse and evaluate a series of possible alternatives, and then choose the most efficient and performing one\u201d.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The use of standard components, both hardware and software, with worldwide availability, was another essential factor in the customer\u2019s choice of the Yaskawa solution. \u201cYaskawa\u2019s motion control system was not only efficient in terms of both hardware and software, but was also designed to ensure the longevity and resilience of the final product due to the predominant use of standard components. In addition, the solution is environmentally sustainable, thanks to its high performance which allows a lower energy impact\u201d Maurizio Lodato concluded. <\/p>\n","protected":false},"excerpt":{"rendered":"<p>Motion control specialist Yaskawa supported a client in the restyling of a multi-format rotary washing machine, for vials and bottles for aseptic production. The hallenge was to move from\u00a0a mechanical to an electronic concept Located right at the heart of the Packaging Valley, the cluster of advanced mechanics and industrial automation in Emilia Romagna, IMA &hellip;<\/p>\n","protected":false},"author":4,"featured_media":2996,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":"","_seopublitec_title":"","_seopublitec_meta_desc":"Yaskawa, specialista nel motion control, ha supportato un cliente nel restyling di una lavatrice rotativa multi-formato destinata\u00a0a fiale e flaconi per la produzione asettica. La sfida era quella\u00a0di passare da un concept meccanico a uno elettronico","_seopublitec_keyphrases":"motion control","_seopublitec_canonical":"","_seopublitec_noindex":false,"_seopublitec_nofollow":false,"_seopublitec_og_title":"","_seopublitec_og_desc":"","_seopublitec_twitter_title":"","_seopublitec_twitter_desc":"","_seopublitec_twitter_image":"","_seopublitec_og_image":"","_seopublitec_twitter_card":"","_seopublitec_cornerstone":false,"_seopublitec_score":"{\"overall\":\"good\",\"keyphrases\":{\"motion control\":\"good\"},\"readability\":\"ok\"}"},"categories":[17],"tags":[586],"class_list":["post-2998","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-applicazioni","tag-yaskawa"],"openstation_lock":null,"openstation_contributors":[],"openstation_attached_media":[2996,2999,3000,3001],"_links":{"self":[{"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/posts\/2998","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/users\/4"}],"replies":[{"embeddable":true,"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/comments?post=2998"}],"version-history":[{"count":1,"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/posts\/2998\/revisions"}],"predecessor-version":[{"id":3002,"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/posts\/2998\/revisions\/3002"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/media\/2996"}],"wp:attachment":[{"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/media?parent=2998"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/categories?post=2998"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.publiteconline.it\/controlloemisura\/wp-json\/wp\/v2\/tags?post=2998"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}