Application of Direct Drive Technology in Die Cutting Machine
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The traditional die-cutting cutting machine adopts a gear transmission method, which not only has a complicated structure and a high cost, but also has difficulty in meeting the customer's requirements in terms of stability and accuracy. More and more post-press processing companies have realized this, and have gradually redesigned their die cutting machines with direct drive technology. This not only reduces machine parts, reduces noise, but also greatly improves the accuracy of the machine. Improve the overall productivity of the mold cutting machine.
The so-called direct drive is the direct coupling of the direct drive rotary motor (DDR) or the direct drive linear motor (DDL) to the driven load, thus achieving a rigid coupling with the load. Due to the elimination of components such as transmission belts and gearboxes, the direct drive solution simplifies the machine design, eliminates the mechanical drive that is noisier and the performance limitations associated with this drive, and is maintenance-free, high-rigidity, without lubrication, and positioning accuracy. The advantages of high speed, stable speed, and quiet operation make it an ideal choice for applications in printing, packaging, etc., which greatly increase the productivity and reliability of the equipment. At the same time, because of its compact assembly, fewer parts, and ease of installation and use, it can also help OEMs quickly bring products to market.
Direct-drive rotary motors, sometimes called torque motors, connect the load directly to the motor, producing higher torque at relatively low speeds, and can be used in high-speed chip sorters. The benefits that DDR can bring to customers include: clean mechanical parts; improved servo performance; DDR can improve accuracy by 50 times; maintenance-free; DDR has no belts that need to be tightened and adjusted, and no leakage and lubrication are needed Gears; increased reproducibility; reduced machine downtime; low operating noise, noise reduction up to 20db.
The Cartridge DDR (CDDR) motor is Danaher Motion's latest patented product, the industry's first motor combining the space-saving and performance advantages of frameless motor technology with the ease of installation of full-frame motors. The CDDR motor consists of a rotor, stator, and work setting type high-resolution feedback device. It does not contain the bearing itself. When it is mounted on the machine, the rotor of the motor is supported by the existing bearing of the machine.
An innovative press-fit coupling engages the rotor to the load, integrating the two, eliminating the flexibility between the motor and the load. The frame of the CDDR motor is mounted on the machine with the same bolt circumference and guide hole diameter as the conventional servo motor, saving space and design time and simplifying the entire system.
CDDR is CE certified and meets UL's global application standards and can be used for 230V, 400V and 480V voltages to meet maximum design flexibility and robust operation. CDDR has five frame sizes, including 4.25, 5.4, 7.4, 9.8, and 13.7 in2 (1 in2 = 6.45 x 10-4 m2). CDDR uses the S300 and S600 standard drive systems, and C09 and C13 have through-hole options. CDDR continuous torque is 4.6~510 Nm, peak torque is 11.3~1017Nm, maximum speed is up to 2500r/min.
Compared with other direct drive motor configurations, CDDR motors have made significant advances in cost efficiency and ease of use. The installation and commissioning of the frame motor and the feedback device takes several months, while the CDDR simply aligns the shaft with the guide and takes only 5 minutes to take it out of the transfer box and start operation. The CDDR motor can be mounted in any direction including horizontal or vertical axis mounting.
One of the world's leading post-press processing companies initially adopted a gear-driven die-cutting machine. However, as the user's requirements for the accuracy and efficiency of the machine tool continue to increase, the original transmission method is far from the customer's needs. Later, the company learned about the benefits of direct drive technology, and obtained a patented CDDR motor, redesigning their entire die cutting machine. Newly designed machines include gears, timing belts, gearboxes, housings, mounting brackets, gear oil tanks, phasers, pneumatic clutches, pulleys, position motors and more than a hundred parts. This design brings significant benefits to the company. It not only reduces noise by 20+ dB, but also reduces the number of parts by more than 100 pieces, and the accuracy is enhanced by more than 10 times. The overall productivity of the machine tool is increased by 20%.
The company’s engineering manager stated that the die cutting machines using direct drive technology are the smoothest models they have ever seen. Their customers have shown great interest in this redesigned machine tool and their demand has gone far beyond their imagination. One of the German customers, after seeing the new machine tool, immediately cancelled the original order and said, "I'm going to change to such a machine."