Lingchen Servo Pressure-Free Lead-Edge Feeding Solution
In a corrugated cardboard printing production line, the lead-edge feeding unit serves as a critical component that determines the overall efficiency and precision of the entire line. Its operating principle involves utilizing vacuum suction to firmly secure the stacked cardboard against the feed wheels, while a servo control system governs the reciprocating motion of these wheels to precisely convey the cardboard to the subsequent printing units.
Centered around a Lingchen PLC acting as the core controller and integrated with a Lingchen servo drive system, this solution delivers a comprehensive, pressure-free servo lead-edge feeding package. It is specifically tailored to meet the operational requirements of Model 480 printing equipment—characterized by a running speed of approximately 200 meters per minute and a precision tolerance of ±0.75 mm. After undergoing phase alignment within the lead-edge feeding unit, the cardboard is fed into three distinct printing units to complete the multi-color printing process and is finally processed by a forming unit to produce the finished product.
The Pain Points of Traditional Paper Feeding Methods
Traditional mechanical or standard pneumatic lead-edge feeding systems have long suffered from the following persistent issues during high-speed printing production:
◆ Paper Slippage: Under high acceleration, relative slippage frequently occurs between the feed wheels and the cardboard surface, leading to deviations in transport positioning and compromising color registration accuracy. This slippage is particularly severe when handling cardboard with smooth surfaces or thick coating layers.
◆ Friction Marks: The rigid contact and sliding friction between the feed wheels and the cardboard surface often leave behind indentations or scuff marks, negatively impacting the aesthetic quality of the finished product—a flaw that is especially detrimental for high-end packaging applications.
◆ Static-Induced Sticking: Electrostatic charges or adhesive forces generated by friction between adjacent sheets of cardboard make sheet separation difficult; this frequently results in multiple sheets feeding through simultaneously, thereby driving up the reject rate.
◆ Inertial Impact: During sudden stops at high speeds, the cardboard continues to surge forward due to inertia, often resulting in misaligned stacking or physical damage to the sheets, which subsequently compromises positioning accuracy for the printing process.
◆ Accumulated Phase Deviation: Traditional systems lack real-time closed-loop correction capabilities; consequently, feeding errors increase linearly as operating speeds rise, making it difficult to maintain consistent precision across the entire speed range.
Lingchen Technology’s Servo-Driven, Pressure-Free Lead-Edge Feeding Solution is specifically designed to address these critical pain points. By employing innovative control strategies—such as synchronized startup, graduated deceleration, intelligent sheet retraction, and fully closed-loop dynamic phase alignment—this solution effectively and comprehensively resolves the inherent flaws associated with traditional feeding methods.
Client Requirements and Process Challenges
The core requirement of the client centers on the lead-edge feeding process, which utilizes vacuum suction to firmly secure stacked cardboard against the feed wheels. Through servo control, these wheels execute a reciprocating motion to precisely convey the cardboard to the printing section. The system comprises a vacuum suction unit, feed wheels, a servo drive mechanism, and a front baffle; these components must operate in perfect coordination to ensure the accuracy and stability of the cardboard conveyance.
Under high-speed operating conditions—where the client mandates an equipment speed of 200 meters per minute and a feeding precision maintained within ±0.75 mm—the system must simultaneously address several critical challenges: mechanical backlash issues during the synchronized startup of multiple axes, the inertial impact on the cardboard during high-speed stops, and the phenomenon of "double feeding" (multiple sheets sticking together) caused by inter-sheet adhesion or static electricity.
Technical Implementation Challenges: Traditional lead-edge feeding systems operating at high speeds frequently face three major technical challenges:
◆ Start-up Delay: Mechanical clearances result in unsynchronized multi-axis startup, compromising the alignment of the cardboard's leading edge.
◆ Inertial Impact: During high-speed emergency stops, the significant inertia of the cardboard often leads to multiple sheets being dragged along or overlapping.
◆ Static Adhesion: Adhesive forces or static electricity between sheets of cardboard hinder complete separation, thereby increasing the reject rate.
Lingchen Non-Crush Leading-Edge Feeding Solution
Hardware Configuration: This solution utilizes a comprehensive suite of motion control products from Lingchen Technology. The Lingchen PLC series serves as the main controller, paired with Lingchen series servo drives specifically matched to the load characteristics of the paper-feeding wheels. By employing an incremental encoder scheme, the system achieves high-speed and high-precision control.
Core Control Strategies
① Synchronous Start, Millisecond-Level Response: Four sets of paper-feeding shafts achieve absolute synchronous startup, eliminating startup delays caused by mechanical backlash. This ensures precise alignment of the cardboard's leading edge and significantly enhances initial feeding accuracy.
② Timed Stop, Graduated Deceleration: Each shaft decelerates and halts sequentially according to a preset timing sequence. This effectively mitigates the inertial impact of the cardboard, prevents multiple sheets from being dragged along or overlapping, and ensures a smooth transition through the paper path.
③ Intelligent Back-Stacking, Anti-Drag Reversal: An instantaneous, minute reversal is executed the moment the shafts stop. This completely severs any adhesive forces or electrostatic attraction between sheets—phenomena that can cause sheets to drag one another—thereby ensuring clean, crisp separation of individual sheets and effectively reducing the scrap rate.
Fully Closed-Loop Dynamic Phase Alignment: This solution employs fully closed-loop dynamic phase alignment technology to achieve precise, real-time control of the paper feeding position.
◇ High-Speed Capture: Utilizes servo frequency-division outputs to provide real-time feedback on the slave axis position, thereby establishing a high-frequency position feedback loop.
◇ Intelligent Alignment: Calculates the deviation between the actual position and the theoretical phase—accurate to the millisecond—and automatically computes the optimal compensation increment.
◇ Seamless Correction: Through phase-feed compensation, real-time deviation correction is executed during the motion process, ensuring absolute consistency in the paper feeding position.
Performance Metrics Verified via Field Testing: This solution demonstrates exceptional performance across all key metrics:
◆ Equipment Speed: Approximately 200 meters/minute, meeting the specified requirement of 200 meters/minute.
◆ Paper Feeding Accuracy: ±0.75 mm, fully satisfying client requirements.
◆ Control Response: Millisecond-level synchronized startup and staggered shutdown, effectively eliminating inertial shock.
◆ Anti-Drag Effect: The reverse-rotation anti-drag function effectively resolves issues related to static-induced paper dragging.
Summarize
Lead-edge feeding constitutes a core process link in printing equipment—where synchronized startup tests multi-axis coordination, high-speed stopping challenges inertial control, and electrostatic adhesion complicates single-sheet separation. Centering on its proprietary industrial PLCs and servo systems, Lingchen Technology has successfully resolved the technical hurdles inherent in traditional feeding solutions through a series of innovations. These include millisecond-level response for synchronized startup, staged deceleration for timed stopping, intelligent reverse-stacking to prevent sheet drag, and full-closed-loop dynamic phase alignment. This solution achieves absolute synchronization across four sets of feeding shafts, thereby eliminating startup delays caused by mechanical backlash; employs staged deceleration to mitigate the inertial impact of cardboard effectively; utilizes reverse-stacking to neutralize the effects of inter-sheet adhesion and static electricity completely; and implements full-closed-loop dynamic phase alignment to correct phase deviations in real-time, ensuring consistent and precise feeding positioning. Moving forward, Lingchen Technology will continue to deepen its expertise in motion control technology, leveraging a more comprehensive suite of integrated product systems to empower a wider range of industries—including printing, packaging, textiles, and 3C electronics—and to grow alongside China's intelligent manufacturing sector.
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.
