Thermoforming Workstation Cam Tilting for Low-Friction Tool Changes
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Solution Overview
Problem
Existing thermoforming packaging machines face challenges in efficiently and cost-effectively changing heavy tool bases due to complex tilting mechanisms, space constraints, and excessive friction with seals, which complicates the removal process and increases maintenance complexity.
Innovation Solution
A workstation with a changing device that uses a simple cam mechanism to tilt the lower tool part away from seals, allowing easy removal by rotating a cam about a separate axis, and incorporates a support element with a guide rail for smooth movement, eliminating the need for additional locking units and reducing friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a tilting mechanism with multiple components is used to tilt the tool base, then the tool base can be changed position, but the device complexity increases and removal becomes complex and costly
Solution Approach 1:
The tilting mechanism is segmented into two independent functional parts: a cam mechanism for generating the tilting motion and a separate rail device for guiding and supporting the tool base during removal. This segmentation allows each component to be optimized independently and simplifies the overall structure compared to integrated complex mechanisms.
Solution Approach 2:
The rail device acts as an intermediary element between the tilting mechanism and the tool base removal process. It provides a guided path that accommodates both the tilted position and the lateral removal motion, mediating the transition between different operational states without requiring complex coordination mechanisms.
2Adaptability or versatility
If the rail device is mounted separately from the tilting mechanism, then the tilting function is independent, but the rail device protrudes from the packaging machine and takes up a lot of space
Solution Approach 1:
The rail device is nested within or integrated with the machine frame structure rather than being mounted as a separate external component. The rail is positioned to extend along the side of the machine frame, utilizing the existing structural space and minimizing protrusion into the surrounding environment.
3Reliability
If the tool lower part rests on a seal, then sealing function is maintained, but friction becomes so great that the tool lower part cannot be moved sideways for removal
Solution Approach 1:
The cam mechanism performs a preliminary tilting action that lifts the tool base away from the seal before lateral removal is attempted. This preliminary elevation reduces the friction contact between the tool base and seal, enabling smooth lateral extraction without damaging the seal or requiring excessive force.
Solution Approach 2:
The system transitions from a static resting position on the seal to a dynamic tilted position during the removal process. The cam mechanism continuously adjusts the angle of the tool base, maintaining optimal separation from the seal surface throughout the removal trajectory, thereby minimizing friction throughout the entire operation.
4Ease of operation
If lifting devices with pneumatic cylinders are used to lift the tool lower part, then the tool can be detached from the seal, but the devices comprise complex components and require control devices making them expensive
Solution Approach 1:
The complex pneumatic cylinder system is replaced with a simpler cam-based mechanical lifting mechanism. The cam converts rotational motion into the required tilting and lifting motion through its geometric profile, eliminating the need for pneumatic actuators, control valves, and associated control electronics while achieving the same functional result of elevating the tool base for removal.
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
Enables easy, cost-effective, and space-efficient tool base changes by minimizing friction and simplifying the removal process, while providing stable construction and improved seal protection.
Implementation Method 1
The changing device has a first cam and is configured to tilt the first support element about the first tilting axis by rotating the first cam about a first rotational axis arranged separately from the first tilting axis
Data Source
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AI summary
The invention relates to a workstation (19) for a thermoforming packaging machine (1), comprising a tool upper part (21), a tool lower part (22) removable from the workstation (19) in a change direction (28), a changing device (29) for tilting the tool lower part (22) from an operating position (30) to a change position (28), wherein the tool lower part (22) is mounted on a first support element (31) of the changing device (29), wherein the first support element (31) is rotatably mounted on the workstation (19) about a first tilting axis (32), wherein the changing device (29) has a first cam (33), wherein the changing device (29) is configured to tilt the first support element (31) about the first tilting axis (32) by rotating the first cam (33) about a first axis of rotation (34) arranged separately from the first tilting axis (32).