Lingchen PLC Powers Upgrade of Lid-and-Base Box Production Line
In the packaging industry, the "Lid-and-Base" box production line serves as the core equipment for manufacturing high-end products such as gift boxes, cosmetic packaging, and mobile phone boxes. Traditional production methods for these boxes often rely heavily on manual machinery or human-assisted processing—approaches plagued by significant drawbacks, including low efficiency, insufficient precision, and high labor costs. This project addresses the critical need for equipment upgrades within the packaging sector; its central objective is the R&D and enhancement of Lid-and-Base box production lines. The aim is to create an automated system characterized by exceptional efficiency and stability, thereby replacing traditional, inefficient, and imprecise manual machinery or human-assisted workflows. Leveraging industrial PLCs as the central control unit, Lingchen Technology provides a comprehensive electrical control solution for these Lid-and-Base production lines. This solution integrates three core standalone units—the Corner Taping Machine, the Gluing and Positioning Machine, and the Forming Machine—to achieve fully automated production across the entire line.
01 Introduction to Equipment, Processes, and Core Standalone Units
The lid-and-base box production line consists of four core standalone units: a paper feeder, a corner-pasting machine, a gluing and positioning machine, and a forming machine; material positioning and transfer are facilitated by robotic manipulators. These individual units work in concert to execute the complete production workflow for paper boxes—spanning the entire process from paper feeding and corner pasting to gluing and final forming.
Corner Taping Machine
The corner taping machine is responsible for applying tape to the four corners of paper boxes. Its core processes involve actions such as tape heating and feeding, main slider movement, and bottom box suction. Through servo control, the machine achieves precise positioning and tape cutting, ensuring accurate tape placement and secure adhesion. Following the optimization of this solution, the production efficiency of the corner taping machine has increased by 30%.
Gluing and Positioning Machine
The Gluing and Positioning Machine is responsible for applying adhesive to the surface of paper boxes and precisely positioning them. Through a sequence of processes—including feeder-based paper feeding, adhesive application via glue rollers, and robotic positioning—it achieves the precise lamination of the paper box onto the face paper. Following the optimization of this solution, the production efficiency of the Gluing and Positioning Machine has increased by 30%.
Forming Machine
The forming machine serves as the core standalone unit in the production of telescoping-lid boxes; it is responsible for the final shaping of the cartons. This process involves the coordinated multi-axis movement of components—including the main slider, bottom die, and pressure rollers—to execute operations such as edge folding and bubble pressing. Following the optimization implemented in this solution, the production efficiency of a single forming machine has increased by 40%.
02 Core Technical Challenges
The production line for two-piece lid boxes imposes extremely rigorous demands on the control system's performance:
• Multi-axis Coordination: The forming machine involves fully cam-linked operation across 24 axes, requiring ultra-fast, synchronized coordination between the main slider and the bottom film.
• Cam Profile Planning: At a production rate of 30 units per minute, the main slider and bottom film must complete a reciprocating stroke of 537 mm within just 2 seconds.
• Synchronization Cycle: A motion control synchronization cycle of 4 ms ensures precise coordination of cam movements involving staggered start and stop times.
• Process Flexibility: Supports the switching of various processing modes—including ear-pushing selection, secondary folding, and bubble pressing—to accommodate the processing of products with varying lengths, widths, and heights.
03 Lingchen Solutions & Highlights
Hardware Configuration
This solution utilizes a complete suite of motion control products from Lingchen Technology:
Main Controller: Lingchen PLC Series, supporting a 4ms motion synchronization cycle
Servo Drives: Lingchen Series Servo Drives, matched to the specific load characteristics of each machine
Expansion Modules: Flexibly configured based on the required number of axes
Electrical Control Scheme
Corner Taping Machine: 10 Servo Motors, 3 Expansion Modules
Gluing and Positioning Machine: 5 Servo Motors, 5 Expansion Modules
Forming Machine: 24 Servo Motors, 5 Expansion Modules
Core Function Development
① Cam Point and Curve Program Development: Development of configuration programs for cam point parameters—covering core components such as the main slider and pressure roller—enabling flexible adjustment of parameters, including set selection, start angles, end angles, and travel distances to achieve precise, synchronized linkage across all 24 cam-controlled axes. Users can freely configure axis relationships and modify cam profiles based on the specific dimensions of the workpiece, thereby meeting the diverse processing requirements of various products.
② Tappet Parameter Programming: Development of programs for defining tappet points, setting tappet parameters, and assigning Group IDs. This ensures the precise triggering of auxiliary actions—such as air-blowing, torque application, and side disengagement—and guarantees that the timing of these auxiliary movements is perfectly synchronized with the main motion sequence.
③ Process Logic Program Development: Development of logic control programs for specific manufacturing processes, including ear-pushing selection, secondary folding, and bubble-pressing. This enables the flexible combination and switching of various multi-functional processes, while the integration of parameter threshold monitoring and compensation routines serves to significantly enhance the overall processing precision of the equipment.
④ The HMI interaction program facilitates real-time communication between the HMI and the PLC, enabling the development of functions such as production data acquisition, parameter configuration, equipment monitoring, and alarm notifications, thereby lowering the operational threshold for the equipment.
Significant Improvement in Production Efficiency
Following the optimization implemented in this solution, the production efficiency of each core standalone machine has exceeded the project's required performance metrics:
The production efficiency of the corner-pasting machine and the gluing & positioning machine has increased by 30%.
The production efficiency of the standalone forming machine has increased by 40%.
The overall production cycle time and operational stability of the line have been substantially enhanced, effectively resolving the low efficiency inherent in traditional equipment.
Substantial Optimization of Process and Equipment Performance
Resolution of Process Defects in Traditional Solutions: The feeding process of the corner-pasting machine has been optimized to prevent "dry-firing" cycles caused by inaccurate material feeding. Furthermore, the cam-driven folding stroke of the forming machine has been redesigned to eliminate redundancies associated with traditional 360° stroke planning, thereby significantly reducing equipment start-up and shut-down times.
Achievement of High-Precision Synchronous Control: Featuring a 4ms motion-control synchronization cycle and a 24-axis full-cam mode, the system achieves ultra-fast synchronization and precise positioning across all structural components of the forming unit, thereby resolving the issue of insufficient processing precision in traditional equipment.
Enhanced Equipment Versatility and Adaptability: The system integrates a combined forming and bubble-pressing function, supporting the switching between various processes—such as "ear-pushing" modes and multi-pass folding—to accommodate products of varying lengths, widths, and heights. This versatility effectively meets the diverse production requirements of our clients.
Creating Comprehensive Value for Clients
Cost Savings: Fully automated production replaces manual-assisted processing, significantly reducing labor costs. Integrated equipment design and high adaptability minimize the need for additional capital investment in new machinery, while simultaneously boosting production yields and reducing material waste.
Ease of Operation and Maintenance: An intuitive, visual HMI (Human-Machine Interface) lowers the operational barrier for the equipment, while a modular electrical control system facilitates easy maintenance and efficient troubleshooting.
Superior Cost-Effectiveness: While delivering comprehensive enhancements in both functionality and performance, this solution retains a distinct price advantage. Furthermore, we provide highly efficient after-sales support to ensure the stable and reliable operation of our clients' equipment.
04 Summary
The R&D and upgrade project for the "Lid-and-Base" box production line has completed its core development and enhancement phases as scheduled, resulting in the creation of a highly efficient, stable, and multi-functional automated production system. Centered around an industrial PLC core, Lingchen Technology achieved a comprehensive production efficiency increase of over 30% across the corner-pasting, gluing and positioning, and forming units. This was accomplished through a 4ms motion control synchronization cycle, full 24-axis cam-based linkage, and flexible parameter configuration and process switching capabilities—metrics that significantly exceeded the project's original requirements.
The successful implementation of this project marks a pivotal milestone in Lingchen Technology's R&D efforts regarding automated packaging equipment. It validates the practical value of Lingchen's PLC and motion control technologies within high-precision, multi-axis automated systems, while simultaneously establishing a customized solution for Lid-and-Base box manufacturing equipment—thereby laying a solid foundation for the company's future expansion within the automated packaging equipment market.
About Us
Established in 2006, Suzhou Lingchen Data Acquisition & Computer Co., Ltd. operates under a business philosophy centered on creating value for clients and fostering win-win partnerships. The company provides customers with core components and system solutions for a wide range of automation equipment, including industrial computers, motion control systems, test and measurement instruments, machine vision systems, and robotics. Currently, Lingchen oversees two wholly-owned subsidiaries: Suzhou Xun'ya Automation Technology Co., Ltd. and T.O.K. Robotics (Suzhou) Co., Ltd., which specialize in the sales of robotic systems and the R&D, manufacturing, and sales of linear motion products, respectively.
Product System Network
Within the hierarchical structure of automated control networks, Lingchen Technology offers a comprehensive range of products spanning the device, control, and information layers.
01 Industrial Computers
Lingchen Industrial Chassis provides comprehensive physical protection for critical computing cores through its industrial-grade robust structure, exceptional thermal management, and dust-proof design, ensuring enduring and stable operation even in harsh industrial environments characterized by vibration, dust, and extreme temperatures.
02 Embedded Industrial PC
Lingchen Embedded Industrial PCs feature a compact and rugged industrial design, integrating high-performance computing, extensive I/O interfaces, and broad tolerance for wide temperature and voltage ranges. Specifically engineered for embedded applications—such as machine vision, edge computing, and automation equipment—these systems provide a stable and reliable intelligent core within limited spaces, empowering smart manufacturing and IoT applications.
03 Motion Control Card
The Lingchen motion control card is capable of controlling up to 32 motion axes and simultaneously supports the control of up to 512 DI points and 512 DO points, with a maximum bus communication cycle of 250 µs. In terms of motion control, it supports functions such as single-axis relative motion, absolute motion, jogging, and drive-based homing; multi-axis interpolation; multi-axis point table motion; and electronic gearing.
04 LMC Series Motion Controllers
The Lingchen LMC series motion controllers are designed around an open, hard real-time kernel (with jitter < ±0.3 µs). This design thoroughly resolves the non-real-time limitations inherent in traditional Windows-based platforms, ensuring both determinism and instantaneous response for multi-axis commands. Installation is remarkably simple, requiring only a single Ethernet cable for connection; furthermore, utilizing highly efficient asynchronous communication technology, the system enables the synchronized issuance and control of motion commands for up to 12 axes within just 1 millisecond.
05 NAC Series High-Performance Motion Controllers
At the core of the Lingchen NAC controller lies a powerful bus expansion capability, supporting four EtherCAT masters to enable the precise control of 256 axes per station—totaling 4,096 I/O channels. Its motion control capabilities are both comprehensive and robust: beyond standard point-to-point, linear, and circular interpolation, it features advanced functions such as 5-axis interpolation, spline-based trajectory smoothing, and dynamic coordinate systems. Furthermore, it integrates vibration suppression, "soft landing" capabilities, and high-precision position comparison outputs; combined with eight independent interpolation groups and continuous interpolation functionality, it effectively meets the demands of complex trajectories and high-speed synchronization. The development environment is open and flexible, supporting multiple programming languages—including C++, C#, and Python—and allows for direct programming within the real-time operating system, thereby significantly enhancing integration and debugging efficiency.
06 PLC Motion Controller
Lingchen PLC controllers strictly adhere to PLCopen specifications and the IEC 61131-3 international standard, combining high performance, a compact footprint, and a modular design to facilitate easy development and flexible deployment. Widely applicable to automation equipment and production line systems across sectors such as 3C electronics, lithium-ion batteries, packaging, and printing, these controllers can also be extended to serve as network communication nodes within integrated production lines for logistics, automotive, and consumer goods industries. By meeting requirements for internal/external network isolation, high-speed bus communication, and real-time data processing, they provide a stable and reliable control core for a diverse range of industrial environments.
07 Industrial Network Cards
Lingchen industrial network cards are specifically engineered for harsh industrial environments, featuring 10/100/1000Mbps auto-negotiation capabilities to deliver stable and reliable high-speed network connectivity. Characterized by robust anti-interference, surge protection, and wide-temperature operation, these cards are widely deployed in critical applications such as motion control, machine vision, and automation systems. The products feature a flexible installation design—including a standard full-height bracket and an optional half-height bracket—enabling seamless integration into a wide range of smart manufacturing equipment and industrial networks.
08 IO Module
Lingchen Technology offers a comprehensive range of I/O module solutions, designed to meet the diverse requirements of industrial automation flexibly.
LC/LD Series Expandable I/O Modules: Supporting multiple protocols—including EtherCAT, Profinet, Ethernet/IP, and Modbus TCP—these modules allow for the flexible expansion of data acquisition capabilities covering digital signals, analog signals, temperature, pressure, and pulses. They are widely applied across sectors such as 3C electronics, lithium-ion batteries, semiconductors, automotive manufacturing, and medical equipment.
MINI Series I/O Modules: Characterized by their compact size and high real-time performance, this series encompasses digital I/O, analog I/O, temperature modules, and communication modules. They are ideally suited for control and data acquisition scenarios where space constraints and real-time responsiveness are critical requirements.
GWS Series Cabinet-Free I/O Modules: Featuring exceptional stability and convenient network cabling capabilities, these modules are designed for distributed system layouts, enabling significant reductions in both system integration time and costs.
Our entire product portfolio is dedicated to providing users with reliable, easy-to-integrate, and adaptable I/O module support for a wide variety of application scenarios.
