Analysis Goal: Increase the production capacity by 25% without increasing overall costs and energy consumption.

Production capacity is one of the most important features of an automatic packaging machine. OPEM’s designers, in Parma, Italy, are constantly looking for new design solutions with increased capacity and reliability, attractive pricing, and small dimensions that will enhance their competitiveness. The main objective of this project was to increase the packaging capacity by 25% without affecting the general architecture, the size of parts and the energy efficiency of the machine. The objectives were achieved by optimizing the motion profiles of all of the actuators (cams and controlled electric drivers) because optimizing motion profiles is the way to achieve higher capacity without increasing the power demand and dynamic loads. At the same time the behavior of a complex chain mechanism had to be considered. A large number of RecurDyn multibody dynamics simulations were performed in order to check and verify the effects of the optimized motion profiles on the overall system behavior.

Development Process

1. Motion profiles are applied to all ideal motors equipping the machine. Motion profiles are designed and optimized to guarantee continuity and lowest possible accelerations, while achieving the desired displacements at the desired instants.
2. The rigid multi-body model of the entire machine verifies that the motion profiles are properly synchronized. The same model also measures the power requirements, which determines the selection of the proper motors. Rigid multibody simulation is the best approach to verify motion profiles because each simulation runs quickly. Running multiple iterations to optimize the profiles is easy and can be done automatically. The RecurDyn Chain Toolkit allows for the easy modeling of the chain mechanism and the large number of contacts can be calculated quickly.
3. This model includes a FullFlex representation of the thin film that is used to seal the capsules. Flexible multi-body (reduced ex and full ex) is necessary to check the effectiveness of the proposed design solutions. Although some components of the machine are largely flexible, the relative positioning of the capsule, film and tools must also be guaranteed in severe dynamic conditions.
4. The multi-flexible body model of the entire machine is used to verify that the positions of tools and capsules are guaranteed even when the structures deform in dynamic conditions.
5. This model also calculates the dynamic reaction forces at the constraints that connect each machine sub-system to the main frame.
6. The loads obtained from the multi flexible body model are used for structural assessment (strength and fatigue) using finite element analysis software.