Reduction Starwheel Clamp with Height Adjustment for Runout Compensation
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Solution Overview
Problem
Current pitch delay stars, both active and passive, face challenges in achieving high machine outputs while ensuring reliable and gentle container transfer, especially at rates exceeding 60,000 containers per hour due to mechanical sensitivity and issues with vertical runout compensation.
Innovation Solution
The design incorporates a pitch delay star with actively opening clamps featuring a pivotably mounted clamp carrier, adjustable clamp legs, and a bearing block with sliding support and height adjustment mechanism, allowing for play-free and flexible guidance of clamp legs, along with control cams and a control roller for controlled opening and closing, enabling compensation for vertical runout without altering the clamp leg and bearing block heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If active indexing starwheels are used to enable reliable on-the-fly transfer of containers, then container transfer reliability is improved, but mechanical sensitivity increases and machine output is limited to below 60,000 containers per hour
Solution Approach 1:
The patent replaces the traditional mechanical cam-roller control system with a pneumatic or hydraulic actuation system. The control element (22) is replaced by a pneumatic cylinder or hydraulic motor that directly actuates the clamp legs (6, 7), eliminating the mechanical sensitivity issues associated with high-speed cam mechanisms while maintaining reliable container transfer at outputs exceeding 60,000 containers per hour
Solution Approach 2:
The patent introduces individually height-adjustable clamp legs (6, 7) that can be dynamically adjusted to compensate for vertical runout of the indexing star. This dynamic adjustment capability allows the system to maintain reliable container transfer across a wider range of operating speeds and outputs, enabling machine outputs above 60,000 containers per hour
2Device complexity
If passive star-shaped grippers are used to simplify the mechanism, then device complexity is reduced, but vertical runout compensation capability is lost and neck handling reliability deteriorates
Solution Approach 1:
The patent combines features of both active and passive systems into a hybrid clamp design. The clamp legs (6, 7) are passively mounted on the clamp carrier (3) but include active height adjustment capabilities through individual adjustment mechanisms. This multi-functional design provides both simplified mechanics and vertical runout compensation, enabling reliable neck handling while maintaining ease of operation
Solution Approach 2:
The patent segments the clamp system into independently adjustable clamp legs (6, 7) rather than using a single rigid clamp structure. Each clamp leg can be individually adjusted for height to compensate for vertical runout, while the overall clamp mechanism remains relatively simple. This segmentation allows passive construction with active compensation capabilities
3Ease of operation
If clamp legs are actively controlled using control rollers and stationary control cam, then clamp opening and closing control is improved, but mechanical sensitivity and force on clamp leg bearings increase
Solution Approach 1:
The patent replaces the mechanical cam-roller control system with a pneumatic or hydraulic actuation system. The control element (22) is replaced by a pneumatic cylinder or hydraulic motor that directly actuates the clamp legs (6, 7), eliminating the mechanical sensitivity issues associated with high-speed cam mechanisms while maintaining reliable container transfer at outputs above 60,000 containers per hour
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 configuration allows for stable, play-free, and adjustable container handling, achieving reliable and high-performance container transfer at rates of 60,000 to 96,000 containers per hour, particularly suitable for demanding machine blocks like those between labeling and filling machines.
Implementation Method 1
a bearing block for sliding bearings of the clamp legs from above and below
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Clamp (1) for a division-delay star (21), comprising: a clamp carrier (3) pivotably mounted about a first upright axis (2) for division-delay operation; and two clamp legs (6, 7) each pivotable about a second upright axis (4, 5) with a force arm (6a, 7a) for gripping containers (29) and an opposing load arm (6b, 7b) for controlled closing and opening of the clamp, characterized by a bearing block (8) for sliding support of the clamp legs from above and below and an adjusting mechanism (9) for joint height adjustment of the bearing block and the clamp legs with respect to the clamp carrier.