ZRAY Announces Next-Gen Carton Erectors (40 CPM, AGV/AMR Ready, Modbus TCP / EtherNet-IP) for Autonomous Factory Integration | ZRAY
Manual feeding is the weakest link in a lights-out cell: one empty magazine stops the line every 6 minutes. ZRAY’s next-gen erectors — led by the ZR-40H at 40 cartons per minute — now ship AGV/AMR-ready with a 24 V DC handshake and fieldbus, so an autonomous vehicle can refill, confirm and resume without an operator.
Handshake Signals and Fieldbus
| Signal / Protocol | Type | Function |
|---|---|---|
| Line Ready | 24 V DC dry contact (out) | Erector armed and in auto |
| Machine Running | 24 V DC dry contact (out) | Cycle active |
| Fault | 24 V DC dry contact (out) | Any AL-x active |
| Material Request | 24 V DC dry contact (out) | Magazine below threshold |
| Buffer Full | 24 V DC dry contact (in) | AMR hold off refill |
| Modbus TCP | Option | MES/WMS dispatch link |
| EtherNet-IP | Option | Rockwell PLC cell |
| PROFINET | Option | Siemens PLC cell |
Mechanical Docking Conditions
| Condition | Value | Note |
|---|---|---|
| Infeed/outfeed height | 500–600 mm adjustable | Match AMR deck |
| Position repeatability | ±5 mm | Locator pins or QR |
| Floor | Trackless, flat | AMR free-path |
| AMR travel aisle | ≥1 200 mm clear | Both directions |
Throughput and Buffer Window
At 40 CPM the magazine holds 3–5 cartons. With a 5-carton buffer the refill window is 5 ÷ 40 = 7.5 s before starvation; ZRAY sets Material Request at 60% remaining, leaving a 12–15 s cycle. A Cat.3 / PLd safety PLC with interlocks and muting curtain lets the AMR enter without halting the guard.
Core Specifications
| Parameter | ZR-40H (AGV/AMR Ready) |
|---|---|
| Speed | up to 40 cartons/min |
| Carton L × W × H | 250–550 × 200–400 × 150–500 mm |
| Board | 3–9 mm, 3/5-layer, flute B/C/E/BC/EB |
| Power | 3.0 kW, 380 V/50 Hz 3-ph |
| Air | 0.5–0.6 MPa, ~150 NL/min |
| Sealing | 50 / 75 mm tape, hot-melt opt |
| Control | Mitsubishi FX5U + 7″ HMI |
| Safety | Safety PLC Cat.3 / PLd, muting curtain |
PLC Alarm Codes for Autonomous Cells
| Code | Description | Typical cause | Field action |
|---|---|---|---|
| AL-02 | Magazine empty | AMR late or dock fail | Verify handshake, re-dock |
| AL-03 | Pickup miss | Mis-aligned AMR deck | Re-home AMR, check ±5 mm |
| AL-07 | Safety circuit open | Muting fault | Reset, check light curtain zone |
| AL-08 | Conveyor overload | Downstream buffer full | Clear jam, check Buffer Full |
| AL-09 | Air pressure low | Supply dip during auto | Check FRL, drain trap |
| AL-10 | Encoder / comm fault | Fieldbus drop | Reseat connector, check switch |
Preventive Maintenance
| Interval | Tasks |
|---|---|
| Daily | Drain FRL bowl; verify 0.5–0.6 MPa; test E-stop; confirm handshake LEDs |
| Weekly | Clean sensors; check belt tension; verify AMR locator pins |
| Monthly | Replace vacuum filter; torque frame bolts; test muting logic |
| Quarterly | Replace suction cups; verify safety PLC I/O; grease gearbox |
| Annually | Change gearbox oil; insulation-test panel; re-level; speed re-cal |
Commissioning Checklist
Before an AMR enters, confirm four things: 24 V DC handshake polarity, Material Request at 60% magazine, the ±5 mm locator and the 1 200 mm aisle cleared — then validate Buffer Full latching. For multi-machine cells, the Double-Head High-Speed Case Former doubles buffer depth; see the Support page for the I/O map.
Get a Quotation for Your Packaging Line
Send us your carton size range, board grade and required CPM — our engineers will return a model recommendation, layout drawing and quotation within 24 hours.
Contact ZRAY: [email protected] · WhatsApp +86 13681839278
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