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Reciprocating Insert Applicator Machine and Gear Tooth Heating Application

Reciprocating Insert Applicator Machine

Reciprocating Insert Applicator Machine
Machine: Reciprocating applicator dispenses inserts to a conveyor fed product

Application Description: A conveyor is feeding randomly spaced product to a reciprocating inserting station. Upstream, a motor is driving the conveyor carrying the product. The conveyor travels at various speeds depending on the product being transported. The insert must be properly placed and aligned on the product. In order to achieve this exact placement, the independently driven insert applicator must be synchronized to the conveyor.

Application Solution: The EMAX 1-1/2 axis controller is chosen for this master/slave electronic cam application. A line encoder (master) is connected to the conveyor and is used for position and speed data. Product changeover is simple and easy using the touch-screen display operator interface. High-speed sensors are mounted in two strategic places: above the conveyor to detect the presence of product, and next to the insert cartridges to verify that an insert has been dispensed. A simple motion control program developed with the Emerald Motion Language (EML) PC software coordinates the insert applicator, encoder, and I/O in the following sequence:

  1. Upstream, randomly placed product is fed onto a conveyor in preparation for the insert applicator. The products are not equidistant from each other but are aligned and in position.
  2. The fingers vacuum an insert from the insert cartridge and accelerate to conveyor speed, where the insert will be placed on the product. After the insert has been applied, the servomotor will unlock from the master axis and stop. The motor will then move the fingers back to their home position and prepare to vacuum the next insert.

Additional Application Features:

  • Sensor initiates a 'skip cycle' for a lack of insert
  • Skip cycles reduce insert waste, and increase throughput
  • Simple touch-screen input for product changeover

Other Industry Applications:

  • Folding/Gluing
  • Printing
  • Perforating Press
  • Rotary Cutter
  • Registration Synchronization

Gear Tooth Heating Application

Gear Tooth Heating Application
Machine: A rotary table machine uses an induction heater and servo system with electronic divider stops to precisely harden each gear tooth surface

Application Description: Large gears require heating of the finished gear tooth to harden the metal surfaces. Hardened gear tooth surfaces are required to extend the life of the gear. The machine is for general use with custom gears of various numbers of teeth. The whole gear cannot be heated nor can consecutive teeth be heated without warping the gear.

Application Solution: The EMAX 1-1/2 axis controller provides the servo motion, operator interface functions and heater control for this application.

An application program for the EMAX controller is developed using the Emerald Motion Language (EML) PC software to create the following sequence:

  1. The operator loads the gear to be heat treated onto the servo driven turntable and jogs the gear to align the first tooth with the induction heater.
  2. The operator then enters the number of teeth on the gear and how many teeth to skip between heating cycles. Skipping teeth evenly distributes the heat and prevents warping of the gear.
  3. The EMAX calculates the incremental motion needed between each heating cycle and how many turns the gear must make on the table to complete each and every tooth.
  4. The air cylinder is extended to place the induction heater between the gear teeth. Then the induction heater is turned on.
  5. The heater is left on for programmable period of time and then retracted.
  6. The gear is indexed to skip the programmed number of teeth and induction heater is extended and turned on.
  7. This process is repeated until all the teeth are heated.

Additional Application Features:

  • Touch-screen operator interface for parameter entry, diagnostics and error messages
  • Control of the induction heater extend and retract
  • Control of induction heater temperature, duration and timing
  • Precision divider software guarantees accurate position of the heater between the gear teeth

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