Design of online compression force measurement for the paper cup manufacturing system
Wanigarathne, Tharindu (2025)
Diplomityö
2025
School of Energy Systems, Konetekniikka
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Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi-fe2025061770750
https://urn.fi/URN:NBN:fi-fe2025061770750
Tiivistelmä
In paper cup manufacturing, the side sealing process is a critical stage that determines both the quality and mechanical strength of the paper cup. Achieving consistent seal quality in ultrasonic sealing systems requires precise control of the compression force applied during the sealing cycle. Most of the existing machines lack integrated force monitoring and is relying only on empirical settings and visual inspection for quality control.
This study presents the design and analysis of a mechanically integrated force measurement system for a high-speed paper cup manufacturing machine. The system employs low profile load cells in combination with custom designed bridging arms and a guided actuator platform to accurately capture the applied sealing forces without modifying the ultrasonic sonotrode structure. A CAD-based mechanical integration was developed and validated using Finite Element Analysis (FEA) to assess stress distribution, deformation and overall mechanical feasibility.
Simulation results demonstrate that the proposed system achieves successful integration while establishing a foundation for real-time force monitoring in high-speed paper cup manufacturing. The design is fully manufacturable using CNC machining and readymade components, allowing for practical retrofitting into existing production equipment. Future work will focus on prototype testing and dynamic force data acquisition to further validate the system in production environments.
This study presents the design and analysis of a mechanically integrated force measurement system for a high-speed paper cup manufacturing machine. The system employs low profile load cells in combination with custom designed bridging arms and a guided actuator platform to accurately capture the applied sealing forces without modifying the ultrasonic sonotrode structure. A CAD-based mechanical integration was developed and validated using Finite Element Analysis (FEA) to assess stress distribution, deformation and overall mechanical feasibility.
Simulation results demonstrate that the proposed system achieves successful integration while establishing a foundation for real-time force monitoring in high-speed paper cup manufacturing. The design is fully manufacturable using CNC machining and readymade components, allowing for practical retrofitting into existing production equipment. Future work will focus on prototype testing and dynamic force data acquisition to further validate the system in production environments.