Rotary Indexer for Packaging Machines

A rotary indexer for packaging machines is a precision motion-control component used to move products, containers, pouches, bottles, caps, or other packaging components from one processing station to another with accurate and repeatable intermittent motion. Rotary indexing systems are widely used in automatic packaging machinery where multiple operations must be performed at fixed positions.

In modern packaging automation, operations such as filling, sealing, capping, labeling, inspection, coding, assembly, and unloading often need to be completed at different stations. A rotary indexer enables the rotary table to move the product accurately between these stations and stop at the required position for each operation.

What Is a Rotary Indexer?

A rotary Indexer is a mechanical drive designed to convert continuous input rotation into precise intermittent rotary motion. Instead of rotating continuously, the output table rotates through a predetermined angle and then remains stationary for a specific dwell period.

Rotary Indexer Applications in Packaging Machines

Rotary indexers can be integrated into many types of packaging and processing equipment. Typical applications include:

• Automatic filling machines

• Pouch packaging machines

• Bottle filling and capping machines

• Labelling machines

• Carton and box packaging machines

• Food packaging machines

• Pharmaceutical packaging machines

• Sachet and pouch handling systems

• Container assembly machines

• Cap feeding and assembly machines

• Inspection and vision systems

• Sealing and pressing machines

Sankyo's indexing technology is used in applications including food filling and wrapping machines, electronic-component assembly, inspection equipment, and other automated machinery.

How Does a Rotary Indexer Work?

A typical packaging machine rotary indexing system consists of a rotary indexing drive, gearmotor, dial plate, tooling or fixtures, and control/sensor components.

The motor continuously drives the input shaft of the indexer. The internal cam mechanism converts this continuous rotation into intermittent output movement.

The basic operating sequence is:

Input rotation → Cam movement → Controlled acceleration → Rotary indexing → Deceleration → Dwell → Next indexing cycle

During the dwell period, the rotary table remains stationary. Packaging operations can then be performed accurately before the table moves to the next station.

This allows several operations to be arranged around a single rotary table, creating a compact and highly automated production system.

Rotary Indexing drive for Packaging Machines

A rotary indexing drive is normally mounted on the output of the indexer. Fixtures are installed around the table to hold the product or package during each operation.

After each indexing movement, the product reaches the next processing station.

This arrangement allows multiple operations to be integrated into one automated packaging machine.

Choosing the Right Sankyo Rotary Indexer AD series for Packaging Applications

Selecting the correct rotary indexer requires careful consideration of the complete application.

Important parameters include:

1.Number of Stations

Determine how many processing stations are required. Common configurations include 4, 6, 8, 10, 12, 16, and more stations depending on the machine design.

2.Indexing Angle

The indexing angle can be calculated as:

Indexing Angle = 360° ÷ Number of Stations

For example:

·        6 stations = 60°

·        8 stations = 45°

·        10 stations = 36°

·        12 stations = 30°

·        16 stations = 22.5°

3.Indexing Time

Determine how quickly the rotary table must move from one station to the next. The index time directly influences machine cycle time and production output.

4. Dwell Time

The dwell period must be sufficient for filling, sealing, inspection, labelling, or other processes to be completed safely and accurately.

5.Load and Inertia

The indexer should be selected according to the total load, rotary table weight, tooling weight, workpiece weight, and the distance of the load from the center of rotation.

6.External Moment Loads

Packaging machinery may have cylinders, filling heads, sealing mechanisms, pressing units, or other equipment acting on the rotary table. These external forces and moments must be considered during indexer sizing.

7. Required Speed

The required input RPM and machine cycle rate should be evaluated to ensure that the selected indexer can operate reliably at the desired production speed.

Sankyo AD Rotary Indexers for Packaging Machines:

Sankyo offers a range of cam-based indexing solutions for industrial automation. Its products use roller gear cam technology designed for precise, rigid, and smooth rotary positioning.

The Sankyo AD Series is a compact fixed-stop cam indexing drive featuring a flange output, hollow output bore, high torque capacity, and multiple indexing-stop configurations.

Features of Sankyo AD Series:

Flange Output:The flange output allows dials, gears, sprockets, and other components to be mounted directly to the output arrangement.

WideProduct Lineup:Different sizes and indexing configurations are available to suit various machine requirements.

High Rigidity:The flange output arrangement provides rigidity in multiple directions, which can be beneficial in rotary-table applications.

Compact Construction:The thin-profile housing can help machine designers manage limited installation space.

Gearmotor Configuration:The Alpha Series is described as being equipped with a variable-frequency-drive gearmotor with a hollow output shaft.

Benefits of Rotary Indexers for Packaging Machines

Using a suitable rotary indexer can provide several machine-design benefits:

• Precise product positioning

• Repeatable indexing motion

• Smooth acceleration and deceleration

• High mechanical rigidity

• Compact machine construction

• Multiple operations on one rotary table

• Reduced mechanical complexity

• High production efficiency

  Reliable repetitive operation

• Easy integration with sensors and automation controls

ADVANTAGES OF SANKYO ROTARY CAM INDEXER

Sankyo Cam Indexers are precision mechanical indexing solutions designed for accurate, repeatable, and reliable rotary motion in industrial automation. Their cam-driven mechanism makes them suitable for applications where controlled indexing, smooth motion, high rigidity, and repeatable positioning are required.

1. High Positioning Accuracy

Sankyo's precision cam mechanism provides accurate positioning of the output shaft or rotary table at each indexing station.

2. Smooth Indexing Motion

The specially designed cam profile provides controlled acceleration and deceleration during indexing. This helps reduce shock, vibration, and mechanical stress, resulting in smoother rotary table movement and improved machine performance.

3. High Repeatability

The mechanical indexing mechanism provides consistent positioning from cycle to cycle. High repeatability is particularly important in assembly, inspection, packaging, machining, and material-handling applications.

4. High Mechanical Rigidity

Sankyo Cam Indexers are designed for demanding automation applications involving rotating loads, inertia, and external forces. When correctly selected according to the application load and operating conditions, the indexer can provide stable and reliable operation.

5. High-Speed Indexing

Depending on the selected series and model, Sankyo Cam Indexers can operate at high input speeds and support high-cycle automated production.

6. Multiple Indexing Positions

Sankyo offers indexing drives with different numbers of indexing stops. This allows the appropriate model to be selected according to the required number of stations and indexing angle.

For example, the required indexing angle can be determined from:

Indexing Angle = 360° ÷ Number of Stations

7. Compact Machine Design

Many Sankyo indexing-drive models feature compact construction, making them suitable for machines where installation space is limited.

8. Long Operating Life

When the indexer is correctly selected according to load, moment of inertia, indexing time, operating speed, duty cycle, and application conditions, it can provide reliable operation over a long service period.

Proper sizing and regular maintenance are important for achieving the expected service life.

9. Suitable for Continuous Automation

Sankyo Cam Indexers are well suited to repetitive industrial automation processes. Their repeatable indexing motion allows multiple operations to be arranged around a rotary table, supporting efficient and compact machine automation.

10. Wide Range of Indexing Models

Sankyo offers a wide range of indexing-drive configurations designed for different machine requirements. Depending on the application, engineers can select from various series and configurations based on factors such as load capacity, indexing angle, speed, inertia, external moment, table size, and required machine life.

This broad product range makes Sankyo Cam Indexers suitable for applications ranging from compact automation equipment to heavy-duty industrial machinery.

Conclusion:

A rotary indexer for packaging machines is an important motion-control solution for automated equipment requiring precise intermittent rotary movement. By accurately transferring products between loading, filling, sealing, inspection, labeling, coding, and unloading stations, a rotary indexing system can help packaging-machine builders develop compact, reliable, and productive automation equipment.

For machine builders, the key to achieving reliable performance is to treat rotary indexer selection as a complete application-engineering process rather than simply selecting a model based on load capacity. Evaluating the number of stations, indexing angle, index time, dwell time, total load, inertia, external moments, operating speed, table arrangement, and required machine life helps ensure that the selected indexer is appropriate for the actual operating conditions.

A properly sized Indexing drive can provide the required accuracy, rigidity, speed, and repeatability for demanding packaging applications. The selection should always consider the number of stations, indexing angle, index time, dwell time, table diameter, total load, inertia, external moments, operating speed, and required machine life.

For fixed-stop, high-cycle packaging applications, a precision cam indexer can be an effective alternative to more complex motion systems.

Overall, a rotary indexer for packaging machines provides an effective way to combine multiple automated operations around a single rotary table. By accurately transferring products between processing stations and providing controlled motion and dwell periods, the indexing system can support efficient and repeatable packaging processes.