Troubleshooting Common Commissioning Errors of Automatic Case Packing Machine

1. Equipment Introduction

The Automatic Case Packing Machine (also called Automatic Carton Packing Machine) is an industrial packaging system designed to automatically complete product case packing operations. It integrates a conveyor system, robotic arm, vacuum suction gripper, carton erecting mechanism, and PLC control system to achieve fully automated product picking, positioning, case packing, and output.

This machine is widely used in industries such as food, daily chemicals, pharmaceuticals, electronics, and industrial goods. It can be integrated with case erectors, carton sealers, and labeling machines to form a fully automated end-of-line packaging system, significantly improving efficiency and reducing labor costs.

2. FAQ: Common Commissioning Errors and Solutions

Q1: The machine runs normally, but the robotic arm does not pick up products. Why?

Possible causes:

Material sensor signal is not triggered or delay time is incorrect
Vacuum suction is not established (insufficient air pressure or leakage)
Incorrect pick-up position (X/Y coordinates deviation)
Solenoid valve of suction system is not activated

Solutions:

Check “material sensing delay” parameter settings
Ensure air pressure is within 0.6–0.8 MPa
Adjust pick-up coordinates in manual mode
Check vacuum lines and IO status of solenoid valve

Q2: Carton cannot be properly erected or fails to open.

Possible causes:

Incorrect height adjustment of carton erecting mechanism
Mismatch between carton size and mechanical settings
Pneumatic cylinder not functioning properly
Carton positioning deviation on conveyor

Solutions:

Adjust erecting height using manual adjustment wheel
Reset carton size parameters on HMI
Check air leakage or cylinder sticking
Recalibrate carton positioning system

Q3: Products fall or position is unstable during packing.

Possible causes:

Weak vacuum suction
Incorrect blowing time setting
Improper lifting height (A lifting position Y)
Incorrect motion radius setting

Solutions:

Check vacuum generator and air tightness
Adjust “blowing time” parameter
Increase lifting height to avoid collision
Optimize motion radius parameter for smoother movement

Q4: Cartons jam or double-feed during conveyor operation.

Possible causes:

Delay in buffer cylinder operation
Incorrect “carton arrival sensor” position
Unstable carton feeding spacing
Conveyor speed too high

Solutions:

Adjust “buffer release delay” parameter
Reposition arrival detection sensor
Ensure cartons are evenly supplied
Reduce conveyor speed during testing

Q5: Robotic arm path is incorrect or collision occurs.

Possible causes:

Incorrect product parameter settings (X/Y axis)
Wrong product dimensions input
Incorrect stacking quantity settings
Machine not re-homed after product change

Solutions:

Recheck product configuration parameters
Verify product width and height settings
Correct X/Y stacking quantities
Perform “homing (zero return)” after product change

Q6: Frequent alarms or unable to reset system.

Possible causes:

IO signal abnormal or incorrectly masked
Reset performed without clearing fault
Unstable power supply or poor grounding
Servo drive alarm not resolved

Solutions:

Check IO status in “Input Monitoring” page
Identify and resolve real fault before reset
Verify stable power supply and grounding
Check servo alarm codes in monitoring system

Q7: Suction succeeds but carton loading fails.

Possible causes:

Carton not fully opened
Incorrect placement coordinates (B_X / B_Y deviation)
Insufficient waiting time before release
Delayed vacuum release

Solutions:

Check carton erecting stability
Recalibrate placement coordinates
Increase “B waiting time”
Adjust blow-off timing for vacuum release

Q8: Machine speed does not reach set value.

Possible causes:

Excessive waiting time in motion cycles
Conveyor speed limitation
Unstable product feeding
Frequent safety protection triggers

Solutions:

Optimize delay parameters (pick/place/conveyor)
Increase conveyor motor speed setting
Improve upstream feeding stability
Check sensor false triggering issues

3. Summary

During commissioning of an automatic case packing machine, most issues are typically related to three core areas:

Mechanical system (carton erecting, conveyor alignment, mechanical positioning)
Electrical system (sensors, IO signals, servo drives)
Parameter system (X/Y coordinates, timing delays, product configuration)

A structured troubleshooting approach is recommended:

Mechanical alignment → Signal verification → Parameter calibration

Following this sequence can resolve most commissioning issues efficiently and safely.