Synchronous Drive for Container Processing Wheel Synchronization
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Solution Overview
Problem
Existing container processing systems face challenges with system instability, position synchronization issues, and maintenance difficulties due to the use of asynchronous motors and complex transmission ratios, which affect production efficiency and flexibility across different machine configurations.
Innovation Solution
A drive device for container processing wheels featuring a synchronous motor with an encoder and intermediate pinions, allowing for precise angular position control and a range of reduction ratios, which enhances mechanical strength, maintenance accessibility, and synchronization between processing and transfer wheels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If asynchronous motors with speed control are used to drive processing wheels, then speed regulation capability is improved, but position synchronization accuracy deteriorates due to position variations
Solution Approach 1:
The patent replaces asynchronous motors with synchronous motors that have encoder feedback systems. This substitution eliminates position variations by using precise angular position encoding, allowing the system to maintain both speed regulation and position synchronization accuracy simultaneously.
Solution Approach 2:
The patent introduces encoder feedback systems that continuously monitor the angular position of drive pinions and provide real-time position information. This feedback mechanism enables the control system to compensate for any position deviations, resolving the contradiction between speed control and position accuracy.
2Measurement precision
If complex transmission ratios are used to achieve precise positioning, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent introduces an intermediate pinion as a mediator between the drive pinion and the processing wheel. This intermediate element simplifies the overall transmission ratio calculation while maintaining precise positioning capability through the encoder feedback system, reducing the complexity of the transmission system.
Solution Approach 2:
The patent changes the approach from using complex mechanical transmission ratios to using encoder-based digital position measurement. This parameter change allows for precise positioning control through electronic means rather than complex mechanical gearing, significantly reducing device complexity.
3Area of stationary object
If drive motor is positioned close to the processing wheel for compact design, then space utilization is improved, but maintenance accessibility deteriorates
Solution Approach 1:
The patent segments the drive system by separating the synchronous motor from the processing wheel, positioning the motor at a distance connected through the intermediate pinion. This segmentation allows the motor to be accessed independently for maintenance while the processing wheel continues to operate, resolving the contradiction between compact design and maintenance accessibility.
4Ease of operation
If simple transmission ratios are used for easy reset after power interruption, then ease of operation is improved, but adaptability to different machine configurations deteriorates
Solution Approach 1:
The patent changes from fixed mechanical transmission ratios to programmable encoder-based positioning systems. This allows the system to adapt to different machine configurations through software programming rather than mechanical reconfiguration, while maintaining easy reset capability through digital position memory and reproduction features.
Solution Approach 2:
The patent creates a universal drive system using synchronous motors with encoders that can be programmed to work with various machine configurations. The intermediate pinion and encoder combination provides a standardized interface that maintains ease of operation across different applications while adapting to specific machine requirements through control programming.
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 improves system stability, reduces position variations, facilitates maintenance, and increases production efficiency by enabling precise synchronization and adaptable transmission ratios, thus optimizing container processing operations across various machine configurations.
Implementation Method 1
a synchronous motor (84), in particular a synchronous electric motor
Implementation Method 2
an encoder for the current angular position of the drive pinion
Implementation Method 3
at least one intermediate pinion, not coaxial with the drive pinion, fixed in rotation with the drive pinion and disposed between the drive pinion and the drive element
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
Container processing device (70), comprising: - a container processing wheel (21) circumferentially provided with a plurality of container processing stations (M), the container processing wheel (21) being rotatable about an axis (O), and comprising a drive element (72) integrated into or fixed to the container processing wheel (21), and - a drive device (80) for rotating the container processing wheel (21), cooperating with the drive element (72), the drive device (80) comprising a drive motor (84) equipped with a pinion (86) driven and rotationally fixed to a rotor of the synchronous drive motor (84), characterized in that the drive device (80) further comprises: - an encoder (87) for the current angular position of the pinion (86) driven, and - at least one intermediate pinion (88), not coaxial with the pinion (86) engine,fixed in rotation with the motor pinion (86) and disposed between the motor pinion (86) and the drive element (72), so that the rotation of the drive motor (84) drives that of the container processing wheel (21) via the motor pinion (86) and the intermediate pinion (88).