In an era dominated by Industry 4.0, smart factories, and servo-driven automation, it would be easy to assume that traditional mechanical indexing systems have become obsolete. Especially with the advances of servo motor technology, which has transformed many areas of industrial automation.
However, the flexibility, programmability and rapid reconfiguration that servo motors can deliver have little impact on dedicated production lines manufacturing the same product day after day. Particularly within the can-making industry where mechanical indexing technology continues to offer compelling advantages that modern electronic systems often struggle to match.
For instance, when machines operate consistently around the clock producing thousands of identical components every hour with the process rarely changing, speed, accuracy, reliability and uptime become more important than machine flexibility. This is where mechanical indexing excels, as a HEINZ mechanical indexer converts continuous rotary input from an electric motor into precise intermittent motion. This allows products to move through a series of stepped manufacturing processes, positioning components accurately at each station before rapidly indexing to the next operation. The result is a highly repeatable and dependable motion profile that can operate continuously for years with minimal adjustment.
In applications such as FMCG packaging, where production processes remain unchanged throughout the machine’s life, servo systems can introduce unnecessary cost and complexity. Whereas many mechanical indexing installations can remain operational for decades, often requiring little more than routine lubrication and scheduled maintenance.
Enabling CMbE to deliver exceptional production rates, repeatability and long-term reliability
To achieve optimal performance of the CarnaudMetalbox machine, careful specification of the indexing system was required. Working closely with HEINZ we were able to ascertain information on key factors such as indexing angle, input speed and duty cycle. Understanding these considerations meant that the mechanical indexer would be correctly sized and configured to match the application’s performance requirements.
As a leading systems integrator, we often combine high precision indexers alongside geared motors to deliver an optimal solution and technological advantage for applications requiring high precision, uniform incremental movements. In this case, a key component was the worm gearbox. The electric motor typically operates at a speed that is unsuitable for direct connection to the indexer, therefore the worm gearbox provided the necessary speed reduction while simultaneously increasing output torque.
The gearbox delivered a stable drive to the mechanical indexer, ensuring accurate indexing performance and helping maintain production consistency across extended operating periods.
For CMbE’s can manufacturing machinery, where uptime and repeatability are critical, this combination of electric motor, worm gearbox, and mechanical indexer provided a robust and proven solution.
We work across the spectrum and deliver solutions that best fit the needs of our customers, so rather than seeing one technology win out against the other, it’s very much down to application and the future is likely to involve a blend of technologies, with servo systems providing flexibility where required and mechanical indexers dominating fixed-process, high-volume production environments.
For manufacturers producing millions of identical components every year, the advantages remain clear:
- Exceptional repeatability
- High-speed operation
- Long service life
- Reduced complexity
- Lower cost of ownership
When combined with correctly specified worm gearbox drives, HEINZ mechanical indexing equipment continues to offer a highly efficient and dependable solution for modern can manufacturing machinery.
As a specialist in powertrain systems and integration, we continue to support manufacturers with the expertise needed to specify, size, and supply the optimal gearbox and indexing solutions for demanding industrial automation applications. Delivering proven performance when productivity and reliability matter most.
This is an edited excerpt from the article: The enduring case for mechanical indexing. You can read the full article in the August edition of IPE.
And if you have a question on anything discussed here or would like to know more about our capabilities to support your next project, get in touch.