Necking Machine Non-Circular Gear Drive
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Solution Overview
Problem
Current necking machines face limitations in increasing cycle rates without compromising processing time and quality, due to constraints in crank drive design and energy efficiency, leading to suboptimal acceleration profiles and potential quality reduction.
Innovation Solution
A non-constant transmission ratio between the drive motor and crankshaft, combined with a flywheel mass as an energy accumulator, allows for extended processing time and optimized motion profiles, enabling a 15% increase in processing time with a 25% higher cycle rate while maintaining low energy expenditure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cycle rate is increased by 25%, then productivity is improved, but processing time is reduced leading to quality deterioration
Solution Approach 1:
The patent applies dynamics by implementing a variable transmission ratio mechanism through non-circular gears. The transmission ratio changes continuously during the cycle, allowing the machine to spend more time at critical processing positions (front dead center) while maintaining higher overall cycle rates. This dynamic adjustment of motion characteristics enables both increased productivity and preserved processing quality.
Solution Approach 2:
The patent changes the motion parameters by using non-circular gear profiles that modify the transmission ratio throughout the cycle. This parameter change allows the advancing movement to be optimized: the tool carrier remains at the work position longer during critical processing phases, thereby maintaining processing time and quality even when the overall cycle rate increases by 25%.
2Manufacturing precision
If the transmission ratio is made non-constant to extend processing time, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces a complex electronically controlled variable speed drive with a purely mechanical non-circular gear transmission system. The variable transmission ratio is achieved through the geometric design of the gear profiles rather than through electronic control systems, sensors, or actuators. This substitution maintains manufacturing precision while avoiding the complexity of electronic control systems.
Solution Approach 2:
The non-circular gear mechanism is self-regulating and automatically provides the required variable transmission ratio through its geometric design. The mechanism serves itself by using the inherent properties of the non-circular gear profiles to control the motion timing, eliminating the need for external control systems, sensors, or complex mechanical linkages.
3Ease of operation
If a servomotor is used for direct drive, then ease of operation is improved, but energy consumption increases due to large masses being moved
Solution Approach 1:
The patent employs periodic action through the reciprocating motion of the crank drive mechanism. The flywheel stores kinetic energy during the power stroke and releases it during the return stroke, creating a periodic energy exchange that reduces the peak power requirements. This allows the system to move large masses (over 1000 kg) efficiently without requiring high continuous energy input from the drive motor.
Solution Approach 2:
The flywheel mechanism recovers and stores kinetic energy during phases when the tool carrier is moving or when the load is lower, then discards (releases) this stored energy when additional power is needed. This energy recovery and reuse mechanism significantly reduces the overall energy consumption compared to direct servomotor drive, while maintaining ease of motion control through the mechanical advantage of the crank 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
This solution enhances processing efficiency by increasing processing time by 15% and maximizing acceleration utilization across motion phases, ensuring consistent quality even at higher cycle rates.
Implementation Method 1
Through its function as an energy accumulator, the machine can still be operated with a comparatively low energy expense despite higher output
Data Source
AI summary
A necking machine (1) having a plurality of processing stations on a rotating tool carrier (7). The motion of the tool carrier (7) with respect to the work pieces is carried out by a crankshaft (25). This is carried out by a non-constant gear. The gear includes two non-round gearwheels (21, 23) that improve a rotational-speed profile of the crankshaft (25) and thus a velocity profile, in particular, in an area of the dead center.