Trim Press Ejector Linear Drive Mechanism
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Solution Overview
Problem
Existing article ejector mechanisms in thermoforming machines are cumbersome, require complex mechanical linkages, and often result in contamination due to lubricant dispersion, limiting cycle efficiency and cleanliness, especially in food industry applications.
Innovation Solution
A linear drive mechanism using a servo motor and computer-controlled linear actuator with rack and pinion assemblies, eliminating the need for lubrication and allowing independent control of the article ejector relative to the trim press, reducing component weight and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flywheel-driven rocker arm assembly is used to move the article ejector, then the ejector can be mechanically driven, but the weight of moving components substantially increases
Solution Approach 1:
The patent replaces the traditional mechanical flywheel-driven rocker arm assembly with an electric motor and linear actuator system. The motor (108) drives a lead screw (104) that converts rotational motion into linear motion of the ejector platen (102), eliminating the need for heavy mechanical linkages, flywheels, and connecting rods while maintaining reliable drive functionality.
Solution Approach 2:
The ejector system is divided into independent functional modules: the motor (108) as a separate drive unit, the lead screw (104) as a transmission element, and the ejector platen (102) as the execution component. This modular segmentation allows each component to be optimized independently and reduces the overall weight compared to an integrated mechanical linkage system.
2Device complexity
If the same flywheel drive mechanism is used to drive both the die platens and the article ejector, then the system is simplified, but the time available to activate the article ejector during a cyclical trim operation is very limited
Solution Approach 1:
The drive system is segmented into two independent control systems: the flywheel mechanism drives the die platens for trimming, while a separate electric motor (108) with controller (112) independently controls the article ejector timing. This allows the ejector to be activated at any point in the trim cycle without being constrained by the flywheel's mechanical synchronization, maximizing the available time window for ejection.
Solution Approach 2:
The controller (112) dynamically adjusts the timing and duration of ejector activation based on the specific operational requirements. The motor-driven system can rapidly start and stop the ejector platen (102) within the available time window, providing dynamic control that optimizes ejection timing regardless of the trim press cycle phase.
3Ease of operation
If mechanical components are frequently lubricated to reduce friction, then the components can move smoothly, but lubricating grease and oil can become airborne and contaminate articles
Solution Approach 1:
The patent replaces heavily lubricated mechanical linkages (rocker arms, connecting rods, flywheel bearings) with an electric motor and lead screw system. The lead screw (104) requires minimal lubrication compared to complex mechanical linkages, and any lubrication used is contained within the closed motor housing and lead screw mechanism, preventing lubricant from becoming airborne and contaminating food industry articles.
Solution Approach 2:
The motor-driven linear actuator system is designed to operate with minimal maintenance and lubrication. The sealed motor (108) and lead screw assembly (104) are self-contained units that do not require frequent external lubrication, eliminating the source of lubricant contamination that plagues traditional open mechanical linkage systems.
4Adaptability or versatility
If a linear actuator with rack and pinion assemblies is used, then the article ejector can be independently controlled, but the device complexity increases
Solution Approach 1:
The motor (108) serves multiple functions: it drives the lead screw (104) for linear motion, provides precise positioning control through the controller (112), and can be easily reprogrammed for different ejection timing and force requirements. This multi-functionality reduces the need for separate specialized components, balancing independent control capability with manageable system complexity.
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 enables efficient, contamination-free ejection of articles with increased cycle efficiency and reduced risk of lubricant contamination, allowing for more cycles per operation and improved cleanliness, particularly suitable for the food industry.
Implementation Method 1
A linear drive mechanism using a servo motor and computer-controlled linear actuator
Implementation Method 2
the linear actuator comprises a pair of interacting rack and pinion assemblies
Data Source
AI summary
A trim press article ejector is provided having a support base, a linear actuator, at least one article ejector and a drive mechanism. The linear actuator is carried by the base. The at least one article ejector is carried by the linear actuator for axial movement to-and-fro. The drive mechanism is configured to reciprocate the linear actuator in order to move the at least one article ejector to-and-fro. A method is also provided.