Hot Glass Packaging Extractor Mechanical Stop Referencing
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Solution Overview
Problem
Current packaging extractors for hot glass handling machines face issues with high maintenance needs, precision, and reliability due to complex mechanisms, exposure to aggressive environments, and frequent sensor failures, leading to increased maintenance costs and occupational risks.
Innovation Solution
The extractor employs independent motors with a mechanical stop referencing method, eliminates belt or chain transmission systems, uses a commercial reduction gear with parallel shafts, and servomotors with low-backlash reducers, reducing maintenance and ensuring high precision and reliability in extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are used to reference the extractor position, then positioning accuracy is improved, but reliability deteriorates due to high failure rate in high-temperature and high-vibration environments
Solution Approach 1:
The patent replaces electronic sensors with a mechanical referencing system using a mechanical stop and software control. The mechanical stop provides a physical reference point that is immune to high-temperature and vibration-induced failures, while software controls the motor to slowly rotate and detect the stop position, eliminating sensor dependency in harsh environments.
Solution Approach 2:
The patent introduces a mechanical stop as an intermediary element between the motor and the control system. This mechanical stop serves as a reliable physical mediator that translates motor position into a reference point without requiring electronic sensors, thereby improving reliability while maintaining positioning accuracy.
2Device complexity
If belt or chain transmission systems are used to transmit motion from motors to extractor arm, then device complexity is reduced, but manufacturing precision deteriorates due to deformation and play over time
Solution Approach 1:
The patent replaces belt or chain transmission systems with a direct mechanical connection using a connecting rod. This eliminates the deformation and play issues inherent in belt/chain systems while maintaining mechanical simplicity. The connecting rod provides rigid, accurate motion transmission without the periodic maintenance required for belt/chain systems.
Solution Approach 2:
The patent segments the transmission function into distinct rigid components (connecting rod, motor shaft, extractor arm) rather than using a continuous flexible transmission medium. This segmentation allows each component to be precisely manufactured and maintained, improving overall positioning precision while keeping the system mechanically simple.
3Manufacturing precision
If frequent maintenance is performed to prevent deformation and play in transmission systems, then manufacturing precision is maintained, but productivity deteriorates due to production stoppages and labor requirements
Solution Approach 1:
The patent employs self-lubricating and sealed components that maintain their functional properties without requiring external intervention for lubrication or maintenance. The sealed bearings and gearbox retain their lubrication internally, eliminating the need for periodic disassembly and lubrication that would cause production stoppages, thereby maintaining both precision and productivity.
Solution Approach 2:
The patent uses excessive sealing and lubrication protection (sealed bearings, oil-immersed gearbox) to prevent degradation before it occurs, rather than performing periodic maintenance to correct degradation. This preventive over-protection eliminates the need for production-stopping maintenance while ensuring continuous precision.
4Reliability
If lubrication is applied frequently to transmission systems in high-temperature environments, then reliability is improved, but loss of substance increases due to expensive grease consumption and environmental impact
Solution Approach 1:
The patent uses sealed bearings and a sealed gearbox that act as protective shells, trapping lubrication inside and preventing its escape to the environment. This sealing approach eliminates the need for frequent grease application while maintaining reliable lubrication, thereby reducing both grease consumption and environmental impact.
Solution Approach 2:
The sealed transmission components are self-contained systems that retain their lubrication internally without requiring external replenishment. The system serves itself by preventing lubrication loss through sealing, eliminating the need for frequent grease application and reducing substance loss.
5Ease of repair
If workers access the machine for maintenance work, then ease of repair is improved, but object-affected harmful factors increase due to exposure to high temperatures and hazardous environment
Solution Approach 1:
The extractor system is designed with self-lubricating and sealed components that require minimal maintenance intervention. The reduced maintenance frequency and complexity allow workers to perform necessary tasks from a safer distance or with reduced exposure time, thereby reducing occupational hazards while maintaining ease of repair for essential tasks.
Solution Approach 2:
The patent uses excessive sealing and protective design to prevent degradation, reducing the frequency and intensity of maintenance required. This over-protection minimizes the occasions when workers must access hazardous areas, thereby reducing exposure to harmful factors while preserving the ability to perform necessary repairs.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
Packaging extractor, for hot glass handling installations which includes a packaging handling scoop (P) with two degrees of freedom provided by two independent motors (M1), (M2) controlled by means of appropriate software, and mounted on a main arm (C) using, at a minimum: - a first transmission associated with the motor (M1) which rotates it in both directions by a determined angle (α); with a first shaft (11) which, associated with the output shaft of the motor (M1) and mounted on a mortise (C1) of the main arm (C), controls the rotation of a primary arm (12); and - a second transmission associated with the motor (M2) which rotates it in both directions by a determined angle (β); with a second shaft (21) which, associated with the output shaft of the motor (M2) and mounted on a mortise (C2) of the main arm (C), controls the rotation of a secondary arm (22).