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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 40 reviews

  • Avatar Alex Charters ★★★★★ 3 weeks ago
    I contacted Meridian Laboratory to obtain a slip ring for my Undergraduate Senior Capstone project. The project required … More a slip ring capable of highspeed data transfer with very little noise to drive an LED bar on a fan to generate images. Sven Krause was very knowledgeable and responsive and helped me figure out what product I needed. He even managed to get the slip ring donated to our team and had great advice on how to integrate it into our project. The project was a huge success thanks to Meridian Laboratory.
  • Avatar Max Thorne ★★★★★ 4 months ago
    I had a great experience working with Vance Nelson on a batch of custom polyurethane wheels. He provided fantastic design … More and material property advice related to my application and was able to deliver high quality wheels in a fast time frame at a reasonable price. I'd highly recommend working with Vance and Meridian Lab in the future
  • Avatar Andrew Diles ★★★★★ 7 months ago
    I've had the pleasure of working with Meridian Laboratory for the past couple of years, and they have revolutionized … More our product with the parts they created for us. Not only did they create the part, they also gave us advice on which type of material to use, and the combination of those two things has helped us be more efficient and productive.
    Vance has been helpful at every turn, and I look forward to working with him and the team at Meridian Laboratory more in the future. They do superb work.

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