Slave Machine Synchronization via Encoder Pulse and Escape Gripper
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Solution Overview
Problem
Conventional article processing systems fail to maintain synchronization between master and slave machines, leading to unintended processes such as excessive hot water injection during abnormalities, causing deformation in vessels.
Innovation Solution
An article processing system with a master machine and synchronized slave machines, equipped with an encoder for generating pulses, and a pulse generator to continue operation of slave machines during master machine abnormalities, along with star wheels featuring grippers with escape mechanisms to prevent interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control means stops both motors of the master machine and slave machine when synchronization cannot be maintained, then the synchronized state is restored, but the slave machine continues processing for excessive time causing deformation of vessels
Solution Approach 1:
The control means determines whether to stop the slave machine before excessive processing occurs by detecting abnormalities in the master machine and calculating the time until the slave machine completes current article processing. This preliminary decision prevents vessel deformation by avoiding unnecessary continued operation.
Solution Approach 2:
The control means continuously monitors the operational status of both master and slave machines, receiving signals about abnormalities and using this feedback to dynamically adjust whether to stop or continue slave machine operation, preventing both synchronization loss and vessel deformation.
2Reliability
If the slave machine stops when an abnormality occurs in the master machine, then synchronization is maintained, but processing time is extended causing deformation
Solution Approach 1:
The control means calculates in advance whether stopping the slave machine will cause deformation by determining if the current article is already being processed or will complete before the stop command takes effect. This preliminary calculation optimizes the stop timing to maintain synchronization without extending processing time unnecessarily.
3Manufacturing precision
If the slave machine continues operation after master machine abnormality, then processing completion is ensured, but synchronization with master machine is lost
Solution Approach 1:
The control means determines in advance whether to continue or stop slave machine operation by checking if the master machine abnormality occurred during article processing. If processing is ongoing, the slave machine continues to complete the article, ensuring non-defective products while temporarily accepting synchronization loss.
Solution Approach 2:
The control means uses feedback about the slave machine's processing state to decide whether to maintain operation or stop, ensuring that articles already in process are completed without deformation while restoring synchronization once processing finishes.
4Productivity
If star wheel grippers are positioned to deliver articles between master and slave machines, then article transfer is enabled, but interference occurs when master machine stops during slave machine operation
Solution Approach 1:
The escape mechanism is activated in advance when master machine abnormality is detected, causing the star wheel gripper to release or move away from articles before interference can occur. This preliminary anti-action prevents harmful interference while maintaining article transfer capability during normal 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
Ensures continuous operation of slave machines until processing is completed, preventing damage and ensuring non-defective products by maintaining synchronization and activating escape mechanisms during master machine failures.
Implementation Method 1
an encoder for generating a pulse depending on rotation of the revolving body of the master machine
Implementation Method 2
the control means is provided with a pulse generator for generating a predetermined pulse
Data Source
Figure 1
Figure 2(a)~2(b)
AI summary
A star wheel H of a blow molding machine 13 constituting a blow molding line 2 as a master machine driven by a motor M is provided with an encoder E for generating a pulse depending on rotation of the star wheel H, and a filling line 3 as a slave machine driven by first to fifth servomotors SM1 to SM5 is controlled by second control means 5 based on a pulse from the encoder E. In the event of an abnormality in the blow molding line 2, the second control means 5 controls the filling line 3 based on a pulse from a pulse generator 5a instead of a pulse from an encoder E, and thus performs processing of a vessel retained by the filling line 3. Even in the event of an abnormality in the master machine, the slave machine can be continuously operated.