Linear Motor Shaping Roller for Glass Tube Reshaping
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Solution Overview
Problem
Existing glass product manufacturing technologies face challenges in reducing cycle times and achieving high dimensional accuracy, particularly for glass syringes, carpules, vials, and ampoules, due to complex drive systems and insufficient precision in reshaping glass intermediates.
Innovation Solution
A device comprising shaping rollers that are translationally displaceable and rotatable, driven by linear motors, allowing precise shaping and deformation of glass intermediates with enhanced dimensional accuracy, reducing cycle times and complexity by integrating radial and axial linear motors for precise positioning and glass mass compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a threaded rod driven by a rotating motor is used to move the shaping roller, then the shaping roller can be positioned and moved relative to the glass intermediate, but the cycle time cannot be reduced sufficiently and the device complexity increases
Solution Approach 1:
The patent replaces the traditional mechanical drive system (rotating motor + threaded rod + carriage + pneumatic cylinder) with a linear motor that directly drives the shaping roller. This substitution eliminates intermediate mechanical transmission components, reducing device complexity and enabling faster positioning and movement of the shaping roller, thus reducing cycle time.
Solution Approach 2:
The patent extracts and removes the threaded rod and pneumatic cylinder from the drive system, keeping only the essential linear motor and shaping roller. This simplification reduces the number of components, lowers device complexity, and improves the speed and precision of the shaping operation.
2Productivity
If traditional drive systems are used for the shaping roller, then the device construction can be maintained, but the cycle time cannot be reduced sufficiently to lower production costs
Solution Approach 1:
The linear motor replaces the traditional rotating motor and transmission mechanism, providing direct linear motion to the shaping roller. This eliminates mechanical transmission losses and enables faster acceleration and deceleration, significantly reducing cycle time and thereby lowering production costs.
Solution Approach 2:
The linear motor enables dynamic and precise control of the shaping roller's position and speed throughout the shaping process. This dynamic control allows for optimized motion profiles that minimize cycle time while maintaining dimensional accuracy, directly impacting production efficiency and cost reduction.
3Manufacturing precision
If the glass intermediate is reshaped by pressing a shaping roller against it, then the glass product can be formed, but achieving high dimensional accuracy of 0.03 mm is difficult
Solution Approach 1:
The linear motor provides precise, programmable motion control with high resolution positioning capability. This enables the shaping roller to be positioned with micrometer-level accuracy, ensuring that the glass intermediate is reshaped with the required dimensional accuracy of 0.03 mm while maintaining a simplified device structure.
Solution Approach 2:
The linear motor system incorporates feedback control mechanisms that continuously monitor the position and movement of the shaping roller, making real-time adjustments to maintain dimensional accuracy. This feedback loop ensures consistent precision in the reshaping process without requiring overly complex mechanical guidance systems.
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 solution significantly reduces cycle times and achieves high dimensional accuracy, enabling the production of glass products with precision up to 0.03 mm, simplifying the drive system and increasing the complexity of the device while maintaining or improving accuracy.
Implementation Method 1
The linear motor (41, 43) has a translator (45, 47) and a stator (49, 51). The shaping roller (25) is translationally displaceable into a shape-rolling contact with the glass intermediate (9) for shaping by the linear motor (41, 43).
Implementation Method 2
The shaping roller (25) is translationally displaceable into a shape-rolling contact with the glass intermediate (9) for shaping
Data Source
AI summary
The invention relates to a device for reshaping a rotating glass intermediate, in particular a glass tube, comprising at least one shaping roller, which is translationally displaceable into a shape-rolling contact with the glass intermediate for shaping, and comprising at least one linear motor for the translational positioning of the at least one shaping roller in such a way that the shaping roller directly follows a translational positioning movement of the translator of the linear motor.