Electric Cam Diverter for High-Speed Box Diversion
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Solution Overview
Problem
Current Rotary Die Cutting systems face limitations in diverting boxes from the production line efficiently due to high Diverting Time and Diverting Repeatability requirements, which are often costly and not repeatable, especially at modern production speeds.
Innovation Solution
The implementation of an Electric Cam Diverter Apparatus with an electric power source, amplifiers, and a Cam mechanism to control a diverting surface, allowing for fast Diverting Time and Repeatability, enabling reliable diversion within the Sheet Gap Time at reasonable costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional diverting systems are used at modern production speeds, then productivity increases, but diverting repeatability deteriorates and costs increase
Solution Approach 1:
The patent replaces traditional mechanical diverting systems with an electric motor-driven cam mechanism. The electric motor provides precise rotational control, while the cam profile translates rotational motion into the linear diverting surface movement. This substitution of pure mechanical systems with an electromechanical system enables repeatable positioning at high speeds through electronic control rather than mechanical wear-dependent mechanisms.
Solution Approach 2:
The patent changes the operational parameters by using an electric motor with controllable speed and position, replacing traditional pneumatic or mechanical actuators. The cam profile is designed with specific geometric parameters that determine the diverting surface trajectory. By precisely controlling the cam rotation speed and position parameters, the system achieves repeatable diverting action at high production speeds that were previously unattainable with traditional systems.
2Productivity
If faster diverting action is implemented to match production speeds, then productivity increases, but system complexity and cost increase
Solution Approach 1:
The patent employs a dynamic cam mechanism where the diverting surface follows a predetermined trajectory defined by the cam profile. The cam rotates at variable speed controlled by the electric motor, allowing the diverting action to occur at optimal moments in the cycle. This dynamic approach enables fast diverting speeds while maintaining simplicity because the complex motion profile is built into the cam geometry rather than requiring complex real-time control mechanisms.
Solution Approach 2:
The cam profile is pre-designed to provide the exact diverting surface trajectory needed for successful box diversion. The electric motor is controlled to rotate the cam at the precise speed and position required. By preliminarily designing the cam geometry and control parameters, the system achieves fast, repeatable diverting action without requiring complex real-time adjustment mechanisms, thus reducing overall system complexity.
3Device complexity
If conventional diverting mechanisms are used, then device simplicity is maintained, but diverting time exceeds the available Sheet Gap Time
Solution Approach 1:
The patent replaces slow, traditional mechanical or pneumatic diverting mechanisms with an electric motor-driven cam system. The electric motor provides rapid acceleration and precise positioning, while the cam mechanism translates this into fast linear motion of the diverting surface. This substitution reduces diverting time from potentially hundreds of milliseconds to under the available Sheet Gap Time, while maintaining relatively simple system architecture through the use of a single motor and cam mechanism.
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
The Electric Cam Diverter system achieves adequate Diverting Time and Repeatability, enabling reliable diversion of boxes from the normal production flow even at high speeds, improving operational efficiency and reducing costs compared to existing systems.
Implementation Method 1
an electric motor connected to the diverter cam shaft and configured to rotate the diverter cam shaft
Implementation Method 2
a diverter cam in contact with the diverter, the diverter cam having a diverter cam angle representing angle of rotation of the diverter cam, the diverter cam is configured to control position of the diverter as the diverter cam rotates
Data Source
AI summary
A diverting system is proposed for diverting boxes from normal production flow. One embodiment comprises a diverter with a diverter surface, a diverter cam in contact with the diverter, a diverter cam shaft connected to the top diverter cam such that rotation of the diverter cam shaft causes rotation of the diverter cam, and an electric motor connected to the diverter cam shaft and configured to rotate the diverter cam shaft. The diverter cam is configured to control position of the diverter as the diverter cam rotates such that rotation of the diverter cam causes the diverter surface to move from a position above normal production flow to a diverting position within the normal production flow.