Rotary Printing Carousel With Direct Electric Drive
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Solution Overview
Problem
Traditional printing machine carousels face issues with bulkiness, limited durability, and reliability due to mechanical drive transmission and control mechanisms, which are laborious, expensive, and struggle with high inertia and positioning precision, especially at high operational capacities.
Innovation Solution
A carousel design with a reduced number of components, featuring a stator coil and rotor assembly with integrated encoder control, supported by a large diameter electric motor rotor and permanent magnets, eliminating mechanical contact and wear, allowing for high rigidity and precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical drive transmission and control mechanisms are used, then the carousel can be controlled, but the system becomes bulkier, more complex, and less reliable
Solution Approach 1:
The patent replaces the traditional mechanical drive transmission and control mechanisms with an electric motor directly supporting the carousel. The motor is coupled to the carousel without intermediate mechanical transmission components, eliminating gears, belts, and other mechanical linkages that caused bulkiness and complexity. This direct electric drive system reduces the number of parts while improving reliability and control precision.
2Duration of action of stationary object
If traditional mechanical control systems are used, then the carousel can be positioned, but mechanical wear and limited durability occur
Solution Approach 1:
The patent eliminates mechanical contact and wear by using an electric motor with direct electromagnetic coupling to the carousel. The motor rotor interacts with the carousel through electromagnetic fields rather than mechanical contact, removing the source of mechanical wear. This non-contact drive mechanism significantly extends the operational lifespan of the carousel system.
3Productivity
If high rotational velocity is used to achieve high operational capacity, then productivity increases, but inertial forces become particularly high
Solution Approach 1:
The patent uses an electric motor with direct electromagnetic coupling to control the carousel, allowing for precise control of acceleration and velocity profiles. The electric drive system can smoothly control the rate of change of velocity, reducing peak inertial forces compared to mechanical systems. The motor's electromagnetic torque can be precisely controlled to minimize harmful inertial effects while maintaining high productivity.
4Device complexity
If the number of driven parts is reduced, then the system becomes simpler, but achieving high positioning precision becomes more difficult
Solution Approach 1:
The patent replaces mechanical positioning mechanisms with electronic control and feedback systems. The electric motor is controlled by a microprocessor that receives feedback from an encoder device, enabling precise positioning through software control rather than mechanical precision. This electronic feedback system achieves high positioning accuracy with fewer physical components, as the control system can compensate for positioning errors dynamically.
5Power
If mechanical transmission means are used, then the carousel can be driven, but the system becomes more expensive
Solution Approach 1:
The patent uses a direct electric motor drive system that eliminates the need for mechanical transmission components such as gears, belts, and shafts. The motor is directly coupled to the carousel, reducing the number of parts and simplifying the overall system. This direct drive approach reduces manufacturing costs and maintenance requirements while providing sufficient power for the carousel operation.
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 provides a more robust, reliable, and efficient carousel with improved rigidity and precision, capable of handling high operational cycles without mechanical wear, decoupling movement and stop stages for flexible operation.
Implementation Method 1
The carousel comprises a casing, enclosing an assembly of a stator coil and a rotor
Implementation Method 2
the motor rotor which faces onto the upper surface of the casing. The rotating plate of the carousel is fitted directly to the motor rotor which bears peripherally-distributed permanent magnets
Data Source
AI summary
A rotary printing machine for printing on containers, comprising a chuck-bearing carousel exhibiting an intermittent circular motion, being rotatably supported by a base element or casing, and being powered by an electric motor and integrated encoder, in which the electric motor comprises a stator coil supported by the casing and a rotor supported directly by the carousel.