Can Necker Positioning With Encoder Feedback for Maintenance
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Solution Overview
Problem
Manual hand-winding of can necking machines for positioning during maintenance is laborious and requires significant effort and time, with operators unable to visually confirm the machine's position, necessitating a second person for verification.
Innovation Solution
A positioning system comprising a drive motor with an encoder for monitoring rotational displacement and a controller that receives user input to achieve desired movement of the processing arrangement, including a human machine interface and remote input device for precise control, allowing automatic or manual electronic positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual hand-winding mechanism is used for positioning, then the machine can be positioned during maintenance, but the process is laborious and requires significant effort and time
Solution Approach 1:
The patent replaces the manual mechanical hand-winding mechanism with an automated motor-driven positioning system. The motorized drive unit with encoder feedback eliminates manual effort while reducing positioning time through automated control, directly resolving the contradiction between ease of operation and time consumption.
Solution Approach 2:
The positioning system incorporates self-service capabilities through automated motor control and encoder feedback, allowing the system to position itself without manual intervention. This eliminates the laborious hand-winding process while maintaining precise positioning control.
2Ease of operation
If manual hand-winding mechanism is used for positioning, then the machine can be positioned, but the operator cannot see the position of the machine and requires a second operator for verification
Solution Approach 1:
The patent implements feedback through an encoder associated with the drive motor that monitors rotational displacement and provides real-time position information to the controller. This feedback mechanism allows the operator to see and verify the machine position through the HMI, eliminating the need for a second operator and resolving the information loss problem.
Solution Approach 2:
The controller acts as an intermediary between the motor drive and the HMI, processing encoder feedback and presenting position information to the operator. This intermediary system bridges the gap between the mechanical positioning and the operator's need for visual confirmation.
3Productivity
If automated motorized positioning system is implemented, then positioning speed and accuracy are improved, but the device complexity increases
Solution Approach 1:
The patent employs a universal controller that handles multiple functions including motor control, encoder feedback processing, and HMI communication. This multi-functional approach consolidates complexity into a single component rather than distributing it across multiple specialized devices, partially mitigating the complexity increase.
Solution Approach 2:
The controller serves as an intermediary that manages the complexity of coordinating the motor, encoder, and HMI. By centralizing control logic in a single device, the system manages complexity rather than allowing it to proliferate across multiple components.
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 efficient and accurate positioning of the necking machine components, reducing labor and improving safety by allowing operators to control the machine's movement from a preferred vantage point, thus enhancing maintenance efficiency and reducing downtime.
Implementation Method 1
an encoder associated with the drive motor for monitoring a rotational displacement of the shaft
Data Source
AI summary
A system for performing necking operations on a can body includes a necker machine and a positioning system. The necker machine includes a frame; a processing arrangement having a plurality of components movable relative to the frame for performing the necking operations on the can body, and a drive motor having a shaft operatively coupled to the processing arrangement for moving the processing arrangement relative to the frame. The positioning system includes: an encoder associated with the drive motor for monitoring a rotational displacement of the shaft and a controller in communication with the encoder and the drive motor. The controller is structured and programmed to: receive an input from a user, the input being indicative of a desired movement of the processing arrangement relative to the frame, and to operate the drive motor using feedback from the encoder such that the desired movement of the processing arrangement is achieved.