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CASE STUDY

ROTOCON Slip Rings Increase RPM and Output Capacity By 150% for Automated Packaging Machinery

Custom slip ring alternatives

A worldwide manufacturer and leader in paper cup forming machinery was able to achieve unsurpassed production output and efficiency by utilizing ROTOCON slip rings for high power and signal communication in their next generation of paper and plastic thermal forming machinery. Working closely with Meridian Laboratory engineers they were able to get single piece prototypes, prior to their annual trade show launch, which drew interest in their newest models.  Following the event, they were able to offer industry-leading output and production capacities, while eliminating all prior slip ring related maintenance downtime.

Challenge

A worldwide manufacturer and leader in paper cup forming machinery was able to achieve unsurpassed production output and efficiency by utilizing ROTOCON slip rings for high power and signal communication in their next generation of paper and plastic thermal forming machinery. Working closely with Meridian Laboratory engineers they were able to get single piece prototypes, prior to their annual trade show launch, which drew interest in their newest models.  Following the event, they were able to offer industry-leading output and production capacities, while eliminating all prior slip ring related maintenance downtime.

Setting out with the goal of designing the most productive paper and plastic cup production equipment, a major worldwide manufacturer soon realized the variety challenges which had prohibited them from achieving this in the past.  While building out the means of handling extra output and capacity, they soon agreed one of the easiest ways to improve output was to increase the operation speed (RPM).  The downside to this was the greatly accelerated wear and maintenance to their conventional, brushed slip rings above their prior 350 revolutions per minute speed.  After trying different slip ring brush materials and compounds offered by the manufacturer, they were unable to find a solution which would accommodate both the power demands they needed for heated mandrels, while still providing the accurate signals they needed to ensure proper cycling.  After exhausting their prior slip ring providers products they temporarily placed the slip ring issue on hold and focused on completing their next generation of machines for an upcoming packaging expo.

Solution

A few months later, an engineer received a referral to Meridian Lab from a colleague.  With less than 30 days until their trade show debut for their newest line, timeliness was critical.  Working closely with Meridian Laboratory’s engineers they were able to develop a series of solutions that integrated with their existing machine designs, requiring very little modifications to accommodate for ROTOCON brushless slip ring rotary electrical connectors.  Meridian Labs was able to get first pieces in hand, for assembly and final testing, within two weeks of the initial request.  After fine-tuning the three machines they planned on debuting, they were able to output 75-150% more than ever before.  This impressive jump in output capacity gave them a key advantage over the competition at the industry’s largest tradeshow.  Three years later they have sold over a hundred machines to satisfied manufacturers of paper and plastic cups worldwide.

Key Statistics

  • 35 amp power, thermocouple, and high speed data signals combined within the same assembly
  • Increased RPM and output capacity of machines by up to 150%
  • Quickly received first parts in time for critical trade show debut of next generation of machinery

The ROTOCON platform utilizes a sealed contact system that is brushless and provides the cleanest electrical signal available in any rotary electrical contact solution, for both power and data signals, you can count on no measurable noise from our rotary electrical union.

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Google Rating

5.0 35 reviews

  • Avatar Krystian Bajek ★★★★★ a month ago
    I have nothing but good things to say about working with Meridian Laboratory. The quality of their product and service is … More top notch. It's always a pleasure to work with Vance.
    Highly recommend!
  • Avatar Kyle Paris ★★★★★ a month ago
    Extremely helpful customer service! Any time I reach out I can consistently expect a reply within the day and my questions … More are always answered. Not to mention that the product works very well. The whole process of working with Meridian has been a pleasure!
  • Avatar Boris Shneyder ★★★★★ in the last week
    I am a plant support welding engineer and found these guys through a google search. I reached out and quickly received technical … More support with specking out the proper rotary ground and direction on making modifications on my automated rotating welding application. We were burning up bearings and replacing them every 3 months. After installing the rotary grounds, lathes have been running for close to a year with no need for calibration or bearing replacement. The payback is less than 8 months and will annually save $35K in bearings, downtime for lathe calibration and bearing greasing.
    Again, the technical support was critical and the guys are easy to work with.
    Boris

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