Counter Ejector Servo Control for Carton Former Cycle Time
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Solution Overview
Problem
The existing counter ejectors in carton former machines face challenges in achieving high-speed and stable operation to shorten the cycle time required for processing corrugated board boxes, as the moving parts such as the elevator, ledge, and press bar operate at limited speeds and responsiveness.
Innovation Solution
The counter ejector incorporates a hopper, a lower conveyor, a ledge, an elevator, and a press bar driven by servo motors, with a controlling unit that manages the relative movement of the press bar and conveyor to ensure precise and rapid operation, utilizing a rack and pinion mechanism for improved responsiveness and synchronization of horizontal movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the speed of moving parts (elevator, ledge, press bar) is increased to shorten cycle time, then productivity improves, but operational stability deteriorates
Solution Approach 1:
The patent replaces pneumatic actuators with servo motors to drive the press bar, ledge, and elevator. This substitution enables precise control of moving parts at high speeds while maintaining operational stability through closed-loop feedback control, resolving the contradiction between increased productivity and maintained reliability.
Solution Approach 2:
The patent implements dynamic control of the press bar's vertical movement relative to the ledge using servo motors. The system adjusts speed and position dynamically during operation, allowing high-speed operation while maintaining stability through real-time feedback adjustment of motor parameters.
2Speed
If servo motors are used to drive the press bar vertically relative to the ledge, then operational responsiveness improves, but device complexity increases
Solution Approach 1:
The patent uses a single servo motor system to control multiple functions: the press bar's vertical movement, the ledge's horizontal movement, and their synchronized coordination. This multi-functional approach reduces overall system complexity compared to using separate actuators for each function while maintaining high operational responsiveness.
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 configuration allows for stable high-speed operation of the press bar, rapid pressing of batches, and synchronized horizontal conveyance, significantly reducing the cycle time by enhancing the operational responsiveness and precision of the moving parts compared to pneumatic actuators.
Implementation Method 1
one of the ledge and the press bar has a rack, and the other has a pinion meshed with the rack, and the relative movement servo motor rotates the pinion
Data Source
AI summary
A counter ejector has: a ledge that moves toward an inner side of a hopper to receive boxes S in the hopper when the boxes accumulated in the hopper reach the predetermined number; a press bar that is disposed so as to move vertically relative to the ledge, and presses the batch on the elevator by moving vertically downward relative to the ledge; and a relative movement servo motor that moves the press bar vertically relative to the ledge. The press bar is driven by the relative movement servo motor to vertically move relative to the ledge.