The Role Of Hall Switches in Paper Cup Machines

Hall switches play a crucial role in position detection and motion control in paper cup machines, enhancing the precision, reliability and production efficiency of the equipment through non-contact magnetic induction technology. The following are its specific functions and implementation methods in the paper cup machine:

I. Core Function and Implementation Principle

Hall switches in paper cup machines mainly undertake position detection and motion control tasks. They achieve the following functions through non-contact magnetic induction:

Precise positioning control

Real-time detection of the positions of moving parts (such as paper feeding rollers and heat sealing molds)

Advantages: No mechanical contact wear, with a service life of over 1 billion operations

Synchronous action trigger

The magnet triggers the Hall switch signal as it moves mechanically

Advantages: Microsecond-level response speed, eliminating mechanical delay

Safety protection

Monitor the opening and closing status of the protective door/cover plate

Advantage: IP67 packaging is waterproof and dustproof

Automated beat control

Generate the timing reference signal for the device cycle

Advantages: No signal jitter, ensuring production consistency

 

Ii. Typical Application Scenarios

Paper feeding length control

 

Installation position: End of the paper feeding roller shaft

Workflow:

①The magnet is fixed on the rotating part and triggers the Hall switch to generate pulses each time it rotates once

②The PLC precisely calculates the feeding length according to the formula: paper length = roller circumference × pulse number

Accuracy: The error is controlled within ±0.5mm

The heat sealing station at the bottom of the cup is synchronized

 

Installation position: At the end of the movement trajectory of the heat-sealing mold

Control logic:

①When the magnet of the mold push rod is in place, the Hall switch is triggered

②Immediately start the heat sealing and pressing action

Value: To prevent poor sealing or material burning through

Safety door status monitoring

 

Installation position: Protective door frame (the door frame is embedded with magnets, and the door body is equipped with Hall switches

Security mechanism:

①Close the door: Magnetic field triggers the switch → equipment operation enables

②Door opening: Signal disappears → Emergency stop

Compliance: Meets the ISO 13850 mechanical safety standard

Finished product stack counting

 

Installation position: Cup drop channel at the end of the conveyor belt

Counting principle:Each action of the stacking push rod triggers a signal → PLC automatically counts +1

Benefit: Achieve unmanned batch production management

Iii. Key Requirements for Selection

For special working conditions of paper cup machines:

Temperature tolerance: It needs to support a range of -40℃ to 150℃ (resistant to high temperatures in the heat-sealing zone)

Anti-interference design: Built-in Schmitt trigger to suppress motor electromagnetic noise

Packaging protection: SOT-89 metal packaging is preferred (to prevent paper scraps and oil stains from penetrating)

Hysteresis width: > 30Gauss (to prevent false triggering by equipment vibration)

Iv. Compare the core advantages of mechanical switches

Service life: The operating life of Hall switches is over 100 million times, while that of mechanical switches is only 100,000 to 1,000,000 times

Response speed: Hall switch 1 to 10μs, mechanical switch 5 to 20ms (2000 times slower)

Environmental adaptability: Resistant to oil stains, moisture and dust. Mechanical switch contacts are prone to oxidation and jamming

Maintenance cost: Hall switches are basically maintenance-free, while mechanical switches require regular replacement of contacts

V. Typical Fault Diagnosis Cases

Fault phenomenon: The paper feeding length is out of control

Troubleshooting steps:

①Test the power supply voltage: Ensure it is within the range of 12V±10%

②Measure the magnetic field of the magnet: The strength should be greater than 80Gauss (if insufficient, replace the magnet).

③Clean the Hall element: Oil stains may cause the detection distance to decline

④Calibration installation clearance: The distance between the magnet and the Hall plate should be strictly controlled within 1 to 3mm

Hall switches achieve core process control of paper cup machines through non-contact position feedback. Their anti-pollution feature reduces the failure rate, and their microsecond response supports high-speed production of over 200 cups per minute. Digital signals can also be directly connected to the Internet of Things system, providing a data foundation for predictive maintenance

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