CAN MANUFACTURING is one of the most demanding production environments in modern industry. Machines routinely operate around the clock, producing thousands of identical components every hour. In these applications, the process rarely changes, product dimensions remain constant, and machine flexibility is often less important than speed, accuracy, reliability, and uptime.

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.

The choice of mechanical indexing over servo motors

Servo motor technology has transformed many areas of industrial automation, offering flexibility, programmability, and rapid reconfiguration. However, these advantages are not always necessary. For dedicated production lines manufacturing the same product day after day, mechanical indexing often delivers significant benefits.

• Superior repeatability: Mechanical indexers are designed around precision-engineered cam profiles that generate the same motion cycle every revolution. So, there is no dependence on software tuning, encoder feedback loops, or motion control programming. 
• High-speed operation: They can operate at very high cycle rates, making them particularly suitable for can manufacturing, packaging, assembly, and transfer applications.
• Reliability and long service life: They have a proven track record in demanding industrial environments. And with fewer components that can fail, maintenance teams benefit from simpler diagnostics and predictable servicing requirements.
• Lower total cost of ownership: They are designed to be simple, robust and have a fixed mechanical design which further ensures reduced programming effort. 

In applications such as FMCG packaging, where production processes remain unchanged throughout the machine's life, servo systems can introduce unnecessary cost and complexity. By contrast, many mechanical indexing installations can remain operational for decades, often requiring little more than routine lubrication and scheduled maintenance. 

Depending on the model and application, HEINZ indexing units support input speeds ranging from several hundred up to over 1,000 rpm, enabling extremely rapid indexing cycles while maintaining accurate positioning and smooth acceleration characteristics. This enables manufacturers to achieve high throughput without sacrificing product quality.

The importance of correct indexer selection

To achieve optimal performance of the CarnaudMetalbox machine, careful specification of the indexing system was required. Working with HEINZ, Lancereal was 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. 

However, once selected and installed, the motion profile becomes a permanent and highly reliable characteristic of the machine. Unlike programmable servo systems, there is generally no need for future motion adjustments because the process itself remains unchanged.

The role of the worm gearbox

As a systems integrator, Lancereal often combines 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 is the worm gearbox. The electric motor typically operates at a speed that is unsuitable for direct connection to the indexer. The worm gearbox provides the necessary speed reduction while simultaneously increasing output torque.

The gearbox delivers 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.

The rapidly evolving automation landscape  

Servo motors, electronic camming, and digital motion control systems will undoubtedly continue to expand their role, particularly in applications that require frequent product changeovers, digital integration and real-time optimisation, to name a few. 

However, this does not signal the end of mechanical indexing technology. In fact, as manufacturers such as CMbE focus increasingly on energy efficiency, reliability, and lifecycle costs, mechanical indexing remains attractive for dedicated high-volume production lines.

Instead, the future is likely to see a blend of technologies, with servo systems providing flexibility where required, while mechanical indexers continue to dominate fixed-process, high-volume production environments.

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.

Rob Yorke is MD – engineering and operations at Lancereal

For more information: 

www.lancereal.com

Tel: +44 (0)1484 606040