Multi-device interconnection: An analysis of the production plan for N95 masks by Zhongwei Xing N95.
2020-04-22
[STEP Group | Zhongweixing] To the rhythm of the machines, N95 masks are continuously produced through a series of processes—including feeding, punching, welding, cutting, and more. Recently, another equipment company in Jiangxi successfully completed the commissioning and delivered a batch of N95 mask production machines designed using Zhongweixing’s comprehensive motion control solution, marking another milestone in their collaboration.
Shooting a movie
Ear strap welding
Racing against time and vying with the virus. Since the outbreak of the pandemic, Zhongweixing’s mask machine project team has kept up the good work. Following the development of medical flat-face masks, they quickly formulated a production plan for N95 masks in the shortest possible time, helping to ramp up production of this vital “armor” for epidemic prevention.
The complete control solution for Zhongweixing’s N95 mask machine boasts mature technology and seamlessly integrates with Zhongweixing’s existing EtherCAT-based motion control and QX servo drive products, enabling “high-speed, high-precision, and highly flexible” production and processing. We can tailor fully automatic or semi-automatic solutions based on the customer’s site conditions and requirements.
The project undertaken by the Jiangxi equipment manufacturer mentioned above primarily focuses on semi-automatic production equipment for foldable masks. The production process can be divided into three main stages: a sheet-cutting machine, an earloop welding machine, and an ultrasonic edge-sealing and welding unit.
Based on the semi-automated characteristics of single-machine operations, we can achieve rational combinations and divide production into distinct stages, thereby maximizing stage-specific productivity and equipment utilization.
The Zhongweixing solution primarily involves two components: a punching machine and an earband welding machine, which respectively adopt bus-based and pulse-control schemes.
01. Electrical Configuration Diagram for the N95 Semi-Automatic Mask Machine Solution
02. Project Features
Single-machine production efficiency
The separation of the die-attach equipment from the welding equipment helps improve product production efficiency, with a die-attach rate of ≥200 pcs/min.
Flexible selection of bus + pulse
The pulse-plus-bus mode facilitates multi-axis control on the bus under conditions where the pulse axis is used.
Servo response
Utilizing the QXE high-response servo drive to elevate control performance and achieve precise, high-speed positioning.
Programming software features
The AMC1600E bus controller supports the IEC advanced development language and provides key production technology requirements such as cam and flying shear—essential for N95 manufacturing. Additionally, it comes with a powerful motion function library that fully meets programmers’ needs.
Hardware configuration
The AMC1600E board features 36 input points and 24 output points, eliminating the need for expansion modules; it comes with a built-in 6-channel pulse interface.
Single-machine design advantages
Single-machine workstation design can reduce equipment costs and offer greater versatility.
03. List of Proposed Products (*Provided by Zhongweixing)
04. Interpretation of Key Process Technologies
The manufacturing process involves manual material feeding and fully automatic material discharge; built-in nose bridge with automatic pressing and folding; multi-layer ultrasonic welding; automatic embossing and cutting—among other relatively complex procedures. In particular, this process makes extensive use of the electronic cam function provided by Zhongweixing.
Electronic Cam: An IEC programming language that directly calls the cam function library to achieve synchronized operation of multiple axes following the master axis—no debugging required—ensuring high-speed, high-precision, and consistent-length cutting of masks.
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