Analysis and Redesign of the Brim Forming Manufacturing Process

Abstract

The principles of mechatronic design have been further applied to develop a robust brim curling system. The brim curling machine uses integration of mechanical, electrical, and computing systems to form a unique machine that is able to produce quality finished paperboard cups. This research involves the conversion from a PC controller to a stand-alone servo/stepper controller. The controller offers more programming flexibility with improved process control. This research also explores optimization of the brim curling machine to determine the maximum production rate. The rotary and linear servo actuators were tuned using a PID scheme. The machine processes for forming a brim were explored and time for the machine to complete these processes was evaluated. The process that took the most amount of time was the cup shell feeding mechanism. The feeding mechanism was reconfigured and the time required to feed a cup shell was reduced. Analysis was performed on a falling cup shell to determine a theoretical time estimate. This research also investigates the effects of machine turret deflection and the deflection's affect on cup brim thickness. Finite element analysis was used to determine the stresses present in a redesigned coupling. The coupling replaced a previously failed coupling. The brim curling machine was completely reconfigured and the result is an industry ready high speed brim curling machine.