Lingchen Technology PLC Powers Upgrades for Flatbed Die-Cutting Machines
Flatbed die-cutting machines are core equipment for material forming and processing in industries such as packaging, electronics, printing, and self-adhesive labeling. Traditional die-cutting solutions often rely on low-speed machines; these systems suffer from issues such as low overall efficiency despite high servo speeds and excessive time spent on acceleration and deceleration. Consequently, the equipment cannot sustain high-speed operation for extended periods, directly limiting production output and the enterprise's market responsiveness.
This project addresses the need to upgrade core die-cutting equipment. Its primary objective is to develop a high-performance, automated flatbed die-cutting machine characterized by high precision, efficiency, and stability, designed to replace traditional, inefficient, and less precise equipment or manual die-cutting processes.
Leveraging industrial PLCs as the core controllers, Lingchen Technology provides an integrated "all-servo drive and motion control" solution, enabling customers to achieve significant improvements in cycle speeds.
Customer Needs and Core Technical Challenges
Core Customer Requirements
Production Efficiency: Target cycle time of 400 pcs/min
Control Precision: High-speed synchronization and precise positioning between the material feeding axis and the die-cutting axis
Operational Stability: Minimized idle travel and start/stop times to ensure reliable, high-speed operation over extended periods
Process Flexibility: Support for the free configuration of parameters such as material feed lengths and pusher points
Technical Implementation Challenges
In the flat-bed die-cutting process, the stamping shaft (master axis) and the material-feeding shaft (slave axis) must be strictly synchronized via electronic camming. The material-feeding action is executed when the master axis is at approximately 220 degrees (as the stamping head lifts); upon completion of the feed, a trigger signal is sent to the ram to execute the stepping cut. Since the cutter requires a start-up interval, the trigger signal must be issued in advance at the 350-degree mark, ensuring the cutting action completes after the sensor signal is received.
This process places extremely high demands on the control system regarding synchronization cycles, cam curve planning, and signal response speed.
Lingchen Technology Solutions
Hardware Configuration
This solution utilizes a complete suite of motion control products from Lingchen Technology:
Main Controller: Lingchen PLC series, supporting a 1ms motion control synchronization cycle.
Servo Drives: Lingchen series servo drives, matched to loads such as the stamping axis, material feeding axis, and cutter.
HMI: Lingchen HMI, enabling parameter settings, cam curve monitoring, and alarm notifications.
Core Technical Implementation
① 1ms Motion Control Synchronization Cycle
Achieves ultra-fast synchronization and precise positioning between the material-feeding axis and the die-cutting axis; significantly reduces idle travel and start/stop times, ensuring stable, high-speed operation over extended periods.
② Electronic Cam Curve Planning
Allows users to flexibly set the material-feeding length for the slave axis and automatically adjust cam relationships; supports free modification of parameters such as follower points and cutter trigger angles. The cam operation logic is clear: material feeding occurs at approximately 220° of the main axis rotation; the cutter is triggered in advance at 350° (after feeding is complete), and the cutting cycle concludes upon receiving the sensor signal.
③ Probe Function and High-Speed I/O Response
Utilizes a probe routine to precisely capture external sensor signals, ensuring the cutter action strictly aligns with the main axis phase to prevent misalignment or missed cuts.
④ HMI Visual Interaction
Provides intuitive interfaces for cam curve monitoring, parameter configuration, and alarm diagnostics, lowering the operational barrier and facilitating on-site commissioning and maintenance.
Achievement of Performance Metrics
On-site testing and verification demonstrate that this solution excels across all performance metrics:
Production Efficiency: Increased from 21,000 (original solution) to 24,000—a 14.28% improvement.
Synchronization Cycle: 1 ms, ensuring precise high-speed cam tracking.
Cycle Time Target: Meets the design requirement of 400 pcs/min.
Operational Stability: Full servo drive eliminates mechanical backlash; no performance degradation during prolonged high-speed operation.
Solution Highlights and Customer Value
Key Technical Innovations
Full Servo-Driven Architecture: Replaces the semi-mechanical drive systems found in traditional low-speed die-cutting machines, eliminating time losses associated with acceleration and deceleration.
Ultra-Fast 1ms Synchronization Cycle: Ensures seamless coordination between material feeding and die-cutting actions, significantly reducing the single-cycle time.
Flexible Parameter Configuration: Parameters such as feed length, ram position, and cutter trigger angle can be freely configured via the HMI to accommodate diverse material and process requirements.
Precision Probe Detection: Integrated with high-speed I/O to ensure millisecond-level response for the cutting action, preventing misaligned or missed cuts.
Value Created for Customers
Efficiency Boost: Single-cycle output increased from 21,000 to 24,000, directly driving a significant rise in daily production capacity.
Cost Savings: Full automation replaces manual assistance, reducing labor costs; Lingchen’s solution offers a distinct price advantage and highly responsive service.
Ease of Operation: A visual HMI lowers the operational threshold, while real-time cam curve monitoring facilitates process optimization.
Stability and Reliability: A 1ms synchronization cycle ensures stable, high-speed operation over extended periods, minimizing downtime for maintenance.
Summarize
Flatbed die-cutting machines are core equipment in the die-cutting sector; their efficiency and precision directly determine production line capacity and product quality. Centered on industrial PLC technology, Lingchen Technology has achieved a 14.28% increase in efficiency—raising single-cycle output from 21,000 to 24,000 units and fully meeting the target throughput of 400 pieces per minute—through a suite of innovations including full servo drive systems, a 1ms motion control synchronization cycle, electronic cam curve planning, and precision probe capture.
This solution addresses the limitations of traditional low-speed die-cutting machines—specifically excessive acceleration/deceleration times and the inability to sustain high-speed operation—while offering customers a cost-effective, user-friendly path to automation upgrades through flexible parameter configuration and a visual HMI.
Looking ahead, Lingchen Technology will continue to deepen its expertise in motion control technology. By delivering enhanced PLC solutions, the company aims to empower industries such as packaging, electronics, printing, and self-adhesive labeling, thereby driving quality improvements and efficiency gains for "Intelligent Manufacturing" in China.
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.
