Application status of servo control system in the field of pharmaceutical packaging

Servo systems are automatic control mechanisms that adjust the output of an object—such as its position, orientation, or state—in response to an input command. These systems play a critical role in industrial automation, with the controller being one of the most influential components. Common motion controllers include PLCs, PC-based motion cards, dedicated systems, and integrated driver solutions. These controllers translate predefined commands into precise mechanical movements through servo drives. In 2004, China’s servo market was dominated by specialized controllers, which accounted for nearly 60% of the market share. PCs followed closely, making up around 20%, while PLCs were also widely used in equipment. However, only a small number of European manufacturers offered integrated motion controllers with drivers, mainly for applications requiring compact designs. When applied to packaging production lines, servo systems can bring significant improvements in performance, flexibility, and efficiency. To explore these benefits, three industry experts shared their insights on the use of servo control in the packaging sector, offering perspectives on current trends and future developments. First, packaging technology is driving the evolution of servo systems. Despite the quietness surrounding new pharmaceutical equipment, servo-driven packaging systems remain essential in many factories. As flexible production becomes more common in consumer goods manufacturing, the need for adaptable systems has increased. Servo systems allow for quick changes in production methods, reducing downtime and cleaning time, which makes short-run, small-volume production more cost-effective. Bosch Packaging, for example, has developed various servo-controlled machines for pharmaceutical clients. According to David Blau, Bosch's Director of Electronic Engineering, the benefits of servos are clear: reprogramming takes just minutes, eliminating the need for lengthy cleaning and manual adjustments. Servo systems are cleaner, simpler, and less prone to failure compared to traditional mechanical setups. Compared to traditional shaft-driven systems controlled by PLCs, servo systems rely on PC-based controls, which offer greater flexibility. Many pharmaceutical companies prefer using servo devices, especially when dealing with multiple packaging types. The ability to quickly change configurations is a key advantage. Second, the advantages of servo systems are numerous. Mike Wagner from Rockwell Automation highlighted that servo-based equipment outperforms traditional mechanical systems in terms of speed, precision, and adaptability. Without mechanical connections, each servo unit operates independently, allowing for faster and more accurate adjustments. Previously, changing configurations could take hours; now, it takes just a few minutes. Bob Hatavigo of Pitt emphasized that servo systems enable independent adjustment during the packaging process, improving data collection and problem-solving. John Kwa from ELAU noted that servo systems have significantly boosted speed and accuracy, with over 70% of pharmaceutical packaging equipment using them. Another key feature of servo systems is their closed-loop feedback, which ensures high precision—up to ±0.02%—compared to standard clutch-driven systems, which are much less accurate. This precision allows for targeted recalls and better maintenance planning. Third, despite their advantages, servo systems face challenges related to control complexity. While they offer superior performance, the reliance on software and PC-based processors introduces new risks. Unlike traditional PLC-based systems, which follow predictable logic, computers can perform multiple tasks simultaneously, making system verification more complex. Pharmaceutical equipment requires consistent, reliable operation. Any deviation could lead to product failures. Companies are concerned about potential computer crashes, such as blue screens, which could halt production. Some manufacturers still prefer using PLCs to control servo systems, ensuring stability at the expense of some advanced features. Fourth, the reliability of servo systems remains a concern. Some companies isolate the computer for compliance with regulations like 21 CFR Part 11, but this can reduce the system’s flexibility. Others opt for hybrid systems that combine the strengths of both PC and PLC control, minimizing errors and improving overall stability. To ensure reliability, some systems initialize control structures before the Windows OS takes over, allowing the machine to continue operating even if the OS freezes. Others use human-machine interfaces (HMIs) to switch between control modes, providing a balance between flexibility and stability. In conclusion, while servo systems offer significant benefits in speed, accuracy, and flexibility, their implementation requires careful consideration of control strategies and system reliability. As the technology continues to evolve, the integration of smart, efficient, and stable servo solutions will be key to unlocking their full potential in the packaging industry.

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