Capsule Housing Gear Drive for Labeling Machine Noise Reduction
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Solution Overview
Problem
Conventional labeling machines require complex and maintenance-intensive sealing systems, are prone to premature oil degradation due to condensation, and have limited transmission ratios, leading to increased load on the cam system and roller lever, resulting in high operational noise and maintenance needs.
Innovation Solution
The implementation of a toothed wheel drive contained within a capsule housing, which eliminates the need for an oil bath, allows for a compact axial design, and uses a planetary or bevel gear system with lubrication for maintenance-free operation, enabling higher transmission ratios and reduced moving masses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a common gear housing with oil bath is used to contain the shaft control, then the gear train is lubricated, but the overall height increases and complex sealing devices are required
Solution Approach 1:
The patent divides the common gear housing into separate capsule housings, each containing its own gear train and lubricant. This segmentation eliminates the need for a large common oil bath and complex sealing systems, while reducing the overall height by distributing the lubrication function across multiple compact, independent units.
Solution Approach 2:
The patent extracts the lubricant from a common oil bath and places it directly into individual capsule housings. This extraction eliminates the harmful factor of condensation in a large oil reservoir and removes the need for complex sealing devices, while maintaining reliable lubrication of the gear train.
2Reliability
If a common gear housing with oil bath is used, then the gear train is contained, but complex and maintenance-intensive sealing systems are required
Solution Approach 1:
By segmenting the gear housing into separate capsules, each with its own lubricant reservoir, the patent eliminates the need for complex sealing systems that would be required in a common oil bath. Each capsule is a self-contained unit with minimal sealing requirements, dramatically reducing system complexity and maintenance needs.
Solution Approach 2:
The patent removes the harmful factor of condensation by taking out the lubricant from a large common reservoir and placing it in small, sealed capsules. This extraction eliminates the environment that promotes condensation and removes the need for complex, maintenance-intensive sealing systems.
3Device complexity
If toothed gears with maximum transmission ratio of 1:2.5 are used, then the gear drive is simple, but large loads occur on the cam system and roller lever
Solution Approach 1:
The patent introduces a planetary gear mechanism that dynamically multiplies the transmission ratio beyond the standard 1:2.5 limit of simple toothed gears. This dynamic gear system allows the cam system and roller lever to operate with significantly reduced loads while maintaining the ability to generate large deflections and rapid direction changes.
Solution Approach 2:
The planetary gear mechanism acts as an intermediary between the roller lever and the drive shaft, providing additional mechanical advantage. This intermediary gear system amplifies the force transmission capability without requiring larger or more complex cam tracks, thereby reducing the load on the cam system and roller lever.
4Length of stationary object
If the capsule housing is fixed in the carousel, then the gear drive is compact axially, but the lubricant supply must be matched to lifetime lubrication
Solution Approach 1:
The capsule housing is designed as a self-service lubrication system where the lubricant is pre-filled and sealed for lifetime operation. The fixed capsule housing contains all necessary lubrication components, eliminating the need for periodic maintenance and allowing the system to service itself without external intervention throughout its operational life.
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 results in a labeling machine with reduced overall height, minimized maintenance, and improved smoothness and quiet operation, as well as the ability to handle larger translation ratios without complex sealing systems, reducing loads on the cam system and allowing dry running of rollers.
Implementation Method 1
The capsule housing (22) contains a gear train (G), in particular a planetary gear train (P), with at least one stage consisting of a planetary gear carrier (33), at least one planetary gear (34) on the planetary gear carrier, at least one ring gear (36) with internal teeth, and at least one sun gear (37)
Implementation Method 2
The capsule housing (22) contains a supply of lubricant (V), in particular lifetime lubrication for the gear train (G)
Implementation Method 3
at least one pinion gear (23) in the capsule housing (22), which is coupled to an input of the gear train (G), and at least one output gear (23) in the capsule housing, coupled to an output of the gear train and coaxial to the drive shaft (31)
Data Source
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AI summary
In a labeling machine (E) with a rotary-driven carousel (2) in which drive shafts (31) parallel to the axis of rotation (1) are rotatable for pallet shafts (7), and which has a shaft control for oscillating rotation of the drive shafts (31) via multi-ratio gear drives (G) which can be driven by roller levers (24) cooperating with a stationary control cam system (20), each gear drive (G) is completely enclosed in a closed capsule housing (22) with a lubricant reservoir (V) and the capsule housing (22) is fixed in the carousel (2).