Necker Machine Drive Layout for Synchronized Modules Without Gear Trains
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Solution Overview
Problem
Existing necker machines require a large number of necking modules with uneven gear wear and high expense due to a gear train driven at one end, leading to oversized gears and unnecessary costs.
Innovation Solution
A drive arrangement for necker machines featuring a frame assembly with modules, control motors, power buses, voltage sensors, and a control unit that monitors and synchronizes the operation of drive shafts, allowing for synchronized or independent operation based on power bus voltage, and includes a shutdown sequence to prevent uneven wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a gear train is used to connect and drive all modules in a necker machine, then the rotational position of each module can be kept in sync with adjacent modules, but the gear tooth load at the driven end becomes very high causing uneven gear wear and requiring oversized gears which incurs additional expense
Solution Approach 1:
The patent divides the drive system into multiple independent drive units, each responsible for driving a specific module. This segmentation eliminates the single gear train configuration and distributes the drive function across multiple points, thereby reducing the load on any single gear and preventing uneven wear while maintaining synchronization through independent control of each drive unit.
Solution Approach 2:
The patent replaces the mechanical gear train system with an electronically controlled drive system. Each module is driven by its own drive unit that can be independently controlled to maintain rotational synchronization with adjacent modules. This substitution eliminates the mechanical constraints of gear tooth loading and allows for more efficient power distribution across the necker machine.
2Device complexity
If a gear train driven at one end is used to drive all modules, then the structure is simplified, but the load distribution becomes uneven causing high gear wear and unnecessary expense
Solution Approach 1:
The drive system is segmented into multiple independent drive units distributed along the necker machine, with each unit responsible for driving a specific module. This segmentation creates a more complex structure compared to a single gear train, but it ensures uniform load distribution and prevents the uneven gear wear that would occur with a single-driven configuration.
Solution Approach 2:
The patent replaces the centralized mechanical gear train with distributed electronic drive units. This substitution allows for better reliability through uniform load distribution while accepting increased structural complexity, as each drive unit can be independently monitored and controlled to maintain optimal operating conditions.
3Strength
If oversized gears are used to handle high load at the driven end, then the gear train can function, but additional and unnecessary expense is incurred
Solution Approach 1:
By segmenting the drive system into multiple independent drive units, each unit handles a portion of the total load rather than one gear handling all the load. This allows the use of smaller, more cost-effective drive components while maintaining the required strength and load capacity across the entire system.
Solution Approach 2:
The patent replaces the need for oversized gears with multiple smaller drive units that collectively provide the required load capacity. This substitution reduces manufacturing costs by eliminating the need for large, expensive gears while maintaining or improving the overall strength and reliability of the drive system through distributed loading.
Data Source
AI summary
A drive arrangement for a necker machine having a frame assembly and a plurality of modules, each having a number of drive shafts. The arrangement includes a plurality of control motors, each structured to be operatively engaged with a drive shaft of the number of drive shafts of each of the modules and to be electrically connected to a power bus of a number of power buses. The arrangement also includes a control unit in communication with each control motor of the plurality of control motors for controlling operation of each control motor and a number of voltage sensors in communication with the control unit for detecting voltage in a corresponding power bus of the number of power buses. The control unit is programmed to monitor, via the number of voltage sensors, the voltage in each power bus of the number of power buses during operation of the necker machine.