Bookbinding Machine Clamp Drive Using Traveling Wave Motors
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Solution Overview
Problem
Existing bookbinding machines face high wear and vibration issues due to roller chains and chain guides, leading to non-uniform movement, jerky stops, and inability to optimize station speeds, resulting in reduced performance and increased waste.
Innovation Solution
A bookbinding machine with individually driven clamps and a control unit that allows each clamp to move at its own speed, enabling synchronized processing with adjustable speeds based on position and product requirements, and the ability to stop clamps for faulty products, reducing waste and optimizing processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If roller chains with individually movable interlocking links are used as conveying means, then the clamps can be advanced along the guideway, but high wear occurs on the chains and chain guides, requiring stable construction with high moving masses
Solution Approach 1:
The patent replaces the roller chain mechanical transmission system with a traveling wave motor system that uses sequential activation of magnetic fields to propel clamps along the guideway. This substitution eliminates the mechanical contact and friction between chains and guides, thereby eliminating wear while reducing the moving mass requirement.
Solution Approach 2:
The traveling wave motor utilizes electromagnetic fields (analogous to pneumatic/hydraulic fluid transmission in function) to transmit motion through the guideway without mechanical contact. The electromagnetic 'fluid' propagates along the guideway segments, pushing clamps forward without the need for physical chain links that wear against guides.
2Speed
If roller chains are used to drive clamps, then the clamps can be transported, but non-uniform movement profile and vibrations occur due to the polygon effect
Solution Approach 1:
The traveling wave motor employs periodic activation of electromagnetic fields in sequential segments along the guideway. This creates a smooth, continuous wave-like motion that propels clamps at uniform speeds, eliminating the polygon effect vibrations inherent in rigid chain mechanisms.
Solution Approach 2:
The system transitions from a rigid, fixed-pitch chain mechanism to a dynamic traveling wave that can adjust its velocity profile continuously. The electromagnetic fields are activated in a controlled sequence, allowing smooth acceleration and deceleration without the mechanical shocks and vibrations of chain links engaging and disengaging.
3Speed
If roller chains with clamps are used, then book blocks can be transported, but jerky stops occur during emergency stops
Solution Approach 1:
The traveling wave motor can be deactivated in a controlled sequential manner, allowing the electromagnetic 'wave' to dissipate gradually along the guideway segments. This provides smooth deceleration and stopping without the sudden mechanical arrests characteristic of chain-driven systems.
Solution Approach 2:
The system can be programmed to anticipate stopping requirements and gradually reduce the traveling wave amplitude or deactivate segments in advance, cushioning the deceleration process. This prevents jerky stops by preparing the system for controlled energy dissipation before the actual stop is needed.
4Productivity
If chain speed determines clamp speed, then clamps can be transported, but the speeds of work stations cannot be optimized individually and depend on chain speed
Solution Approach 1:
The guideway is divided into independently controllable segments, each with its own electromagnetic field activation control. This allows different sections of the guideway to operate at different speeds, enabling each work station to be optimized for its specific processing requirements while maintaining overall system coordination.
Solution Approach 2:
The system transitions from a fixed-chain-speed mechanism to a dynamically adjustable traveling wave system. The velocity of the traveling wave can be modified independently in different guideway segments, allowing work stations to operate at their optimal speeds without being constrained by a uniform chain speed.
5Stability of the object's composition
If clamps are guided on guideways firmly connected to the machine frame, then stable guidance is provided, but high wear occurs on chains and guides
Solution Approach 1:
The patent replaces the mechanical chain-on-guideway contact system with an electromagnetic traveling wave system. The clamps are guided by magnetic fields rather than physical contact with guideways, eliminating wear while maintaining stable guidance through the electromagnetic force field.
Solution Approach 2:
The electromagnetic field acts as an intermediary between the guideway structure and the clamps. Instead of direct mechanical contact causing wear, the electromagnetic field mediates the guidance and propulsion forces, allowing the physical guideway to remain stationary and unworn while still providing stable guidance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces wear and vibration, allows for optimal processing speeds, and minimizes waste by enabling precise control over clamp movement and product handling, enhancing the overall productivity and precision of the bookbinding process.
Implementation Method 1
The clamps are advantageously driven by traveling field motors, ie linear motors or servomotors
Data Source
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AI summary
The invention relates to a book-binding machine (100) for producing printed products such as books, periodicals and brochures, having individually driven processing stations, for example a book spine preparation station (20), a glue application station (30), a cover feeder (50) and a pressure-exerting station (60), these being connected by a transporting system (1) which has a multiplicity of clamps (2) in which book blocks (B) can be clamped. The clamps (2) are driven individually, in particular by travelling-wave motors or servomotors, and are guided over a guide path (4).