Independent Servo Turrets for Backlash-Free Machine Line Recovery
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Solution Overview
Problem
Conventional machine lines for forming containers suffer from backlash due to gear slippage, inability to rotate individual turrets independently, and limited jam detection capabilities.
Innovation Solution
A servo-controlled machine line where each module is equipped with a separate servo motor that rotates a corresponding turret, allowing for synchronous operation and independent control of each turret, with error detection and manual intervention capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a motor drives a series of gears connecting turrets throughout the machine line, then the turrets can be rotated together, but backlash occurs as slack within the gears is taken up during starting or stopping
Solution Approach 1:
The patent divides the machine line into multiple independent modules, each with its own servo motor and turret. This segmentation eliminates the gear connections between modules, thereby eliminating backlash caused by gear slack. Each module operates independently with its own motor, preventing the propagation of mechanical errors throughout the entire system.
2Adaptability or versatility
If each turret is connected through a series of gears, then the turrets can be driven together, but the ability to rotate only one turret is lost
Solution Approach 1:
The machine line is divided into independent modules where each module contains its own servo motor and turret. This segmentation allows any single turret to be rotated independently by its dedicated servo motor without affecting other turrets, providing full adaptability while eliminating the complex gear connection system.
3Measurement precision
If a series of gears connects turrets throughout the machine line, then power can be transmitted to all turrets, but the ability to detect jams or issues and their general location is limited
Solution Approach 1:
The system is divided into independent modules, each with its own servo motor and control system. This segmentation enables precise jam detection at the module level, as each servo motor's controller can independently monitor its own operational status, torque, and position. When a jam occurs, the exact module location is immediately identified by its controller, providing both high measurement precision and complete location information without loss.
4Speed
If conventional gears are used to connect turrets, then the structure is simpler, but the starting and stopping of turrets is slower due to gear inertia
Solution Approach 1:
Each module is equipped with its own servo motor, allowing independent and rapid acceleration and deceleration of each turret. The servo control systems provide precise speed and position control with fast response times, eliminating the inertia issues associated with large gear systems. While this increases control system complexity, it dramatically improves turret responsiveness and overall system speed.
Data Source
AI summary
Systems and methods are disclosed for controlling the rotation of turrets with servo motors within a machine line used in the shaping of articles. Error conditions can be detected using the servo motors for resolving issues with the machine line. Control of the turrets by the servo motors allows for each turret to be rotated relative to the other turrets independently for resolving the issues. Absolute encoders are used to return the servo motors and their respective turrets back to being aligned with a virtual axis for synchronous rotation of the turrets within the machine line, despite the turrets not being mechanically coupled together by a series of gears.