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Creasing-unit Transmission Study Part I

Espínola Lozano, Alberto (2008) MMK920
Product Development
Abstract
The goal of this Master Thesis is to help Tetra Pak with the current problems related with the creasing units. The creasing unit is set with different configurations depending on which package is wanted to be manufactured. The unit is provided with different modules and each module is moved by means a gear transmission. The different packages require different gears setups that could affect the quality of the final product. The precision of the transmission is quantified by means the gears backlash that is indispensable to keep in the right rage of values in order to get the expected accuracy level. A big gears backlash leads big misalignments of the creasing tools and consequently
the quality of the final product could be lower than... (More)
The goal of this Master Thesis is to help Tetra Pak with the current problems related with the creasing units. The creasing unit is set with different configurations depending on which package is wanted to be manufactured. The unit is provided with different modules and each module is moved by means a gear transmission. The different packages require different gears setups that could affect the quality of the final product. The precision of the transmission is quantified by means the gears backlash that is indispensable to keep in the right rage of values in order to get the expected accuracy level. A big gears backlash leads big misalignments of the creasing tools and consequently
the quality of the final product could be lower than expected. Tetra Pak has noticed some problems to adjust the gears backlash within the allowed range that ensures the desired final product quality. Moreover some unexpected gear failures has detected in the gear transmission. These failures decrease the reliability of the creasing units and affect the production.
The gears failures has motivated to make a thoroughly study of the gears in order to reveal how convenient the current gears design is in this application. The geometrical analysis has been done by means a Matlab program developed in this thesis. This program is designed to calculate the main parameters that characterize the gears. This calculation has been done over the whole range of sizes used in production. Thereby suitableness of the design has been evaluated by means how the gears meshing is. The results of the Matlab program are used to find out if the current design provokes any interference. Also if gears design provides a big enough contact ratio value to ensures a well load distribution on the teeth and a smooth transmission movement. Since the goal is to improve the gears performance some solutions has been evaluated and described. The solutions are developed in order to solve the existing geometrical problems and increase the reliability of the transmission. The difficulties to adjust the gear backlash and the unacceptable results, in terms of accuracy, have motivated the development of a measuring methodology to define how good the gears are. This procedure reflects the potential the gears have to fulfil the company accuracy ambitions. A measurement protocol has been development and some sample has been taken and analyzed to be aware about the gears quality. Furthermore the methodology describes the fundamental parameters that have to be checked to know which accuracy the gears are able to get and how their tolerance affect the final product. (Less)
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author
Espínola Lozano, Alberto
supervisor
organization
course
MMK920
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Intermediate gear, Measurement, Divided gear, Backlash, Module, Creasing Unit, Misalignment, Gear geometry
language
English
id
1494952
date added to LUP
2009-10-21 11:02:47
date last changed
2010-02-01 14:40:04
@misc{1494952,
  abstract     = {The goal of this Master Thesis is to help Tetra Pak with the current problems related with the creasing units. The creasing unit is set with different configurations depending on which package is wanted to be manufactured. The unit is provided with different modules and each module is moved by means a gear transmission. The different packages require different gears setups that could affect the quality of the final product. The precision of the transmission is quantified by means the gears backlash that is indispensable to keep in the right rage of values in order to get the expected accuracy level. A big gears backlash leads big misalignments of the creasing tools and consequently
the quality of the final product could be lower than expected. Tetra Pak has noticed some problems to adjust the gears backlash within the allowed range that ensures the desired final product quality. Moreover some unexpected gear failures has detected in the gear transmission. These failures decrease the reliability of the creasing units and affect the production.
The gears failures has motivated to make a thoroughly study of the gears in order to reveal how convenient the current gears design is in this application. The geometrical analysis has been done by means a Matlab program developed in this thesis. This program is designed to calculate the main parameters that characterize the gears. This calculation has been done over the whole range of sizes used in production. Thereby suitableness of the design has been evaluated by means how the gears meshing is. The results of the Matlab program are used to find out if the current design provokes any interference. Also if gears design provides a big enough contact ratio value to ensures a well load distribution on the teeth and a smooth transmission movement. Since the goal is to improve the gears performance some solutions has been evaluated and described. The solutions are developed in order to solve the existing geometrical problems and increase the reliability of the transmission. The difficulties to adjust the gear backlash and the unacceptable results, in terms of accuracy, have motivated the development of a measuring methodology to define how good the gears are. This procedure reflects the potential the gears have to fulfil the company accuracy ambitions. A measurement protocol has been development and some sample has been taken and analyzed to be aware about the gears quality. Furthermore the methodology describes the fundamental parameters that have to be checked to know which accuracy the gears are able to get and how their tolerance affect the final product.},
  author       = {Espínola Lozano, Alberto},
  keyword      = {Intermediate gear,Measurement,Divided gear,Backlash,Module,Creasing Unit,Misalignment,Gear geometry},
  language     = {eng},
  note         = {Student Paper},
  title        = {Creasing-unit Transmission Study Part I},
  year         = {2008},
}