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While developing a machine to cut corrugated, testing by Hipsher Tool & Die, a custom fabricator in Wabash, Indiana, revealed that the finished sheet length was inconsistent. The encoder providing length data to the cutting mechanism sometimes missed counts, which resulted in finished length variations that were out-of-spec. The machine’s existing encoder and wheel system worked perfectly with other applications, but this particular material presented a challenge.
Further investigation revealed the cause. Seams in the corrugated passing under the encoder wheel would cause it to jump and lose contact with the surface. The right encoder would need to be heavy enough to provide increased down-pressure to maintain contact with the corrugated being fed through, yet constructed with a material that would not damage the corrugated it touched. The new encoder also needed to match the old encoder’s CPR and counts per inch.
The encoder chosen had to meet the following requirements:
- Quadrature output
- High resolution
- Sealed bearings
- Ultra heavy-duty housing
- Wheels that would not damage material.
Hipsher Tool & Die contacted C&E Advanced Technologies, an Ohio distributor for Encoder Products (Booth SL-6440). After consulting with Encoder Products, C&E’s Sales Engineer Jeff Ligon recommended the Model TR3 Heavy Duty Tru-Trac™ encoder, a compact, easy-to-use unit that integrates the encoder with a spring-loaded, heavy-duty measuring wheel assembly.
Key features of the Model TR3 include:
- Integrated heavy-duty, all-metal encoder and measuring wheel in one unit.
- Spring-loaded torsion arm for quick wheel pressure adjustments.
- Easily installed in a vertical, horizontal or upside-down orientation.
- Operates reliably on a variety of surfaces at speeds up to 3,000 ft./min.
- Available in a single- or dual-wheel format.
- Three-year warranty.
Available in a single- or optional dual-wheel format, the Model TR3 Heavy Duty Tru-Trac encoder is a versatile tool for tracking velocity, position or distance. Its spring-loaded torsion arm provides a simple-to-adjust torsion load, allowing the unit to be mounted in any orientation, even upside-down.
The Model TR3 housing is an all-metal workhorse, specifically designed to withstand the toughest environments at operating speeds up to 3,000 ft./min. The Model TR3’s sturdy all-metal housing and integrated spring-loaded pivot arm were key features that appealed to Eric Flory, the Hipsher Tool engineering manager tasked with solving the problem.
The heavier housing and stiff internal spring provided down-pressure that is more than adequate to offset the “jolt” caused by the corrugated seams passing beneath the wheel. To avoid any damage to the corrugated, 12-in. dual-urethane wheels were specified.
Thee encoders also were configured with a line drive output and CPR resolution that matched the previous encoder counts per inch.
After the Model TR3 was installed and testing completed, Hipsher’s customer reported that cut length was spot-on and production was up and running.
Starting as a one-man tool and die shop in 1946, Hipsher Tool & Die has expanded beyond tools, dies, jigs and molds to the design and fabrication of custom machinery. Customers range from walk-ins with small requests, to companies needing larger manufacturing systems.
For more info, visit www.encoder.com.