Special metal bellows couplings
No broken glass brings good luck
Competitive production is hardly possible without automated production systems. Disruptions in the production flow or even machine downtime can quickly lead to high financial losses. Operators must therefore be able to rely on the process reliability and performance of their systems. This requires drive components that are suitable for the sometimes very specific application requirements. This also includes couplings, which can offer valuable advantages in many respects if designed to meet the requirements.
R+W Antriebselemente offers a wide range of precision and industrial couplings for various applications. In addition, individual customer solutions are also part of our daily business. A special coupling was also required in the following case, for example, in which a customer turned to R+W to increase efficiency and safety in its production process.
A transition without an edge
The client from the pharmaceutical industry is faced with an ever-increasing demand for flexibility in the manufacturing process for its products. He often has to change products or even processes. The entire production system therefore has a mobile design so that the process sequence, among other things, can be varied as required. An adjustable, mobile table also plays an important role in the further processing of the manufactured pharmaceuticals. This consists of a movable table top that is attached to a rotary axis. After a process step, a total of 500 to 1,000 filled vials are transported onto the table top and temporarily stored there. A pusher then feeds them to the next process.
This important interface also represents a major challenge. In order to be able to react flexibly to different bottle shapes and fillings, the company has deliberately dispensed with an inflexible bottle guide. However, depending on the load, the table top can tilt by up to 0.3 mm around a pivot point. This would cause all the bottles to fall over due to the resulting impact edge between the push-off levels. Therefore, the company needed a solution that would provide flatness and accuracy between the interface of the adjustable table and the upstream and downstream equipment.
Previously, the customer used a servomotor to rotate and adjust the table, which he operated as a closed control loop in conjunction with the sensors. In this previous drive concept, damping elastomer couplings between the gearbox and rotary axis transmit the torque and also compensate for shaft misalignments. The servomotor moves the mechanism and thus ensures that the table is aligned. This readjustment with the aid of the control loop therefore prevented tilting under load. However, this was associated with considerable effort, as the setting parameters often change during the course of flexible production. Accordingly, the intermediate storage of the vials, which is intended to ensure fast and precise further processing, was quite complex and difficult.
Simple solution with metal bellows couplings
To solve the problem, the experts at R+W developed a metal bellows coupling model that is optimally designed for the required torsion spring stiffness, the maximum permitted torsion angle and the required torque for this application. By replacing the flexible elastomer couplings with torsionally rigid metal bellows couplings in the axis of rotation, the table top will in future have a very high level of rigidity and therefore positioning accuracy - regardless of the total weight of the vials on it. These can then be pushed safely on one level for further processing. Thanks to the special coupling and the corresponding functional concept, the cost-intensive sensor system and the electrical control circuit could be dispensed with. Time-consuming readjustment is also no longer necessary.
As some of the vials are worth more than 250 euros each, it was important for the client to have additional protection for the table top. R+W was also able to help here and designed a bellows breakage protection system that is integrated into the special coupling. The external dimensions of the coupling remain the same. In the worst-case scenario of a bellows breakage, for example due to a torque overload, the hubs of the metal bellows coupling interlock positively and thus guarantee the emergency running properties. If the bellows were to break, the table top would therefore not tip or fall.
For the customer, the advantages of the new concept are obvious. The simplified drive train eliminates the need for complex sensor and control systems and readjustment of the table. At the same time, the special solution enables better adaptability to the respective products and changed processes. This reduces costs and time expenditure while increasing productivity. Furthermore, the integrated bellows breakage protection provides additional protection and supports the operational reliability and process stability of the system. All of this helps the customer to flexibly adapt their production to customer requirements and market trends.
You might also be interested in
Plagiarius 2024 negative prize
On January 26, 2024, the Plagiarius campaign awarded its dreaded "Plagiarius" negative prize for the 48th time to manufacturers and retailers of particularly brazen counterfeits and fakes.
read more...Ivalua honors winners of the Generative AI...
AI-supported "add-ons" for buyers within 48 hours
Ivalua, provider of cloud-based spend management solutions, announced the winners and innovations of the first Generative AI Innovation Cup. The competition took place in December 2023. It was open to all Ivalua partners and employees - more than...
read more...Efaflex celebrates 50 years of high-speed...
The emphasis is on "fast"
Since day one, Efaflex has wanted to use new technologies as early as possible and drive progress in the industry. This year, the family business is celebrating its 50th anniversary under the motto "Fast Forward".
read more...Security of supply even during power outages
In the winter of 2022, Germany was worried about energy shortages. The drugstore retailer dm did not paint any horror scenarios, but nevertheless saw the possibility of controlled, temporary, regional power cuts (brownouts).
read more...Safety technology in mechanical engineering
Modules with new functions
Euchner's product highlights at EMO 2023 include the communication-capable solenoid interlocks.
read more...Transforming the paper industry towards climate neutrality
Together with partners from industry and research, Voith is developing a project for the optimization of energy and material flows in paper production. The aim of the research project is to develop a digital framework that enables effective process...
read more...Up to 95 percent less flue gas thanks to direct extraction
The requirements for occupational safety measures and safety technology are also constantly increasing in welding technology. The Technical Rules for Hazardous Substances (TRGS) stipulate that welding fumes and harmful substances must be extracted...
read more...Competitive advantages with large machines
Whether 3D-printed components for machines and systems, prototypes or aids for design: additive manufacturing is almost indispensable for modern companies in mechanical and plant engineering and automation if they want to play in the premier league.
read more...Transport technology from the modular system
Many transport tasks can be realized with the help of linear technology. Pre-configured solutions are available to simplify the interaction between the linear unit, motor, gearbox and controller. This minimizes the effort required for research and...
read more...