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CASE STUDY

ROTOCON Slip Ring Increases RPM and Output Capacity By 150% for Packaging Machinery

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 speed the operation speed.  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

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