Oscillating Satellite Roller Feeding Device for Packaging Machines

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Solution Overview

Problem

Existing packaging production machines face issues with speed limitations, mechanical complexity, misalignment, and media jams due to the need for additional mechanisms and counterweights in feed stations, leading to register losses and rapid wear.

Innovation Solution

A device with a main drive roller and oscillating satellite roller, driven by secondary electric motors, replaces the complex connecting rod mechanism, reducing inertia and mechanical parts, allowing for precise longitudinal and lateral registration and increased speed, while maintaining constant tension.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a connecting rod mechanism with counterweight is used to link the satellite roller to the drive roller, then the satellite roller can oscillate cyclically, but the device complexity increases and the feeding speed decreases

Engineering Contradiction:
Improvecyclic oscillation of satellite rollerVSAvoidmechanical linkage mechanism
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the connecting rod mechanism and counterweight from the system. Instead of using mechanical linkages to achieve cyclic oscillation of the satellite roller, the invention uses a motor directly mounted on the drive roller axis that can be programmed to oscillate the satellite roller cyclically. This extraction of the complex mechanical linkage resolves the contradiction by maintaining the oscillation function while dramatically reducing device complexity.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical linkage system (connecting rod and counterweight) with an electrical control system. A motor with programmable control replaces the mechanical oscillation mechanism, allowing the satellite roller to oscillate cyclically without the complexity of mechanical linkages. This substitution resolves the contradiction by maintaining the desired oscillation motion while eliminating the complex mechanical structure.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If additional mechanisms and counterweights are added to the feed station, then the satellite roller can be controlled, but the inertia increases and maintenance needs increase

Engineering Contradiction:
Improvecontrol of satellite rollerVSAvoidinertia of feed station assembly
Core Design Contradiction:
Ease of operationVSWeight of moving object

Solution Approach 1:

The patent removes the counterweight and connecting rod mechanism from the system. By eliminating these heavy components, the overall inertia of the feed station assembly is significantly reduced. The satellite roller is controlled directly by a motor mounted on the drive roller axis, which provides control functionality without adding the excessive inertia associated with counterweights and mechanical linkages.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the heavy mechanical control system (counterweight and connecting rods) with a lightweight electrical control system. A motor with programmable control replaces the mechanical oscillation mechanism, providing the same control functionality for the satellite roller while dramatically reducing the weight and inertia of the moving parts. This substitution resolves the contradiction between control capability and inertia.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If multiple mechanical parts are used in the feed station, then the satellite roller can oscillate, but register losses occur and alignment precision decreases

Engineering Contradiction:
Improveoscillation of satellite rollerVSAvoidlongitudinal and lateral register
Core Design Contradiction:
Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the multi-component mechanical oscillation system with a direct motor-driven system. The motor is mounted on the drive roller axis and directly controls the satellite roller oscillation, eliminating intermediate mechanical connections. This reduction in mechanical interfaces minimizes cumulative alignment errors and register losses, thereby improving the longitudinal and lateral registration precision between the feed station and the subsequent chopping unit.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the connecting rod and counterweight mechanisms that introduce multiple mechanical interfaces. By eliminating these intermediate components, the system reduces the number of potential sources of misalignment and register loss. The direct motor-to-satellite-roller control path maintains oscillation functionality while improving registration precision.

Inventive Principle:
Principle #2Taking out (Extraction)

4Ease of operation

If a complex mechanical linkage is used, then the satellite roller can be controlled cyclically, but the components wear out quickly and media jams occur

Engineering Contradiction:
Improvecyclic control of satellite rollerVSAvoidmechanical component durability
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent replaces the complex mechanical linkage system with an electrical control system. A motor with programmable control directly actuates the satellite roller, eliminating the connecting rod, counterweight, and other intermediate mechanical components. This substitution dramatically reduces wear and failure points, as electrical motors have fewer moving parts subject to mechanical wear. The cyclic control functionality is maintained through programmable motor control, improving reliability while preserving the desired oscillation motion.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent removes the connecting rod mechanism and counterweight from the system. By extracting these mechanical linkage components, the system eliminates the sources of mechanical wear and potential media jams. The satellite roller oscillation is achieved through direct motor control, which has no mechanical linkages to wear out or fail. This extraction of problematic mechanical components resolves the contradiction between cyclic control capability and component durability.

Inventive Principle:
Principle #2Taking out (Extraction)

Data Source

PatentEP2356052B1Device for supplying a processing unit with a continuous-strip support for a supply station in a packaging production machine
Publication Date: 2015.04.08 BOBST MEX SA
  • EP2356052B1 patent drawingFigure 1~2
  • EP2356052B1 patent drawingFigure 3~5

AI summary

The present invention relates to a device for supplying power to a conversion unit with a continuous strip substrate, the conversion unit converting the substrate to the stop mechanism, including: - a main drive roller (12) that rotates (T) about a main shaft (13), - a main electric drive motor (14) that rotates (T) the main roller (12), - a satellite roller (16) capable of oscillating (O) around said main roller (12) from upstream to downstream and vice versa, and - two side levers (18) that support the satellite roller (16) and which are mounted onto said main shaft (13). The mounting is coupled with and supported between said main roller (12) and said satellite roller (16) and goes cyclically from a constant speed to zero speed at the output of the satellite roller (16) and vice versa. Both side levers (18) are rigidly connected to said main shaft (13). The device (9) includes at least one secondary electric drive motor (19) that is capable of oscillating (O) the main shaft (13), the two side levers (18), and the satellite roller (16).