Training Videos

During equipment changeovers there are usually pneumatic, vacuum, sensor electrical and other connections to be made up. In too many cases, these connections require tools rather than quick connections. Some plants do not permit operators to use tools forcing a mechanic to be used. Where quick connectors are used, they often, especially for tubing and piping, need to be made up one by one.

This is time consuming and introduces the possibility of error. Error will cause loss of time correcting it but more importantly, it can cause damage to a machine if an air cylinder goes in when it is supposed to go out.
There are several alternatives available. Cole-Parmer offers their Twin-Tube and Ten-Tube connector to allow quick connection of two tubes or up to ten tubes. Both are quick connectors with a button to unlock.

For larger or more diverse needs there are systems from companies like Staubli that connect multiple hoses up to an inch or so and contain electrical connectors in the same connection.
One application is in the Krones labeler dock. These labelers use umbilicals with all electrical, sensor and pneumatic services in a single plug .The labeling head is unplugged and wheeled away for cleaning and changeover. A previously set up head is wheeled up to the machine, latched in place and the umbilical connected.

Wherever fittings need to be made up, use quick connectors. When appropriate, use multi-connectors. You’ll save time and mistakes.

NOTE: In some cases there may be safety reasons for not using quick connectors. Safety must never be slighted.

Quick setting nozzle rack

Setting nozzle spacing on a liquid filler is not hard but it can be time consuming. An idea I originally saw on a Douglas case packer gave me the idea to design a better nozzle rack for a client having some troubles.

The nozzles are mounted on plastic blocks that slide on a pair of rods. Each mounting block has a fork affixed. On the same mounting bracket, in front of the nozzles an aluminum strut is mounted. Both Douglas and my design use 3″ square 80/20 extruded aluminum. The strut is prevented from rotating by a locking pin. On each face of the strut a ferrule, the same size as the nozzle forks is mounted so that the top ferrule aligns with the fork. This locates and holds the nozzle in place.

If more than 4 nozzle positions are required, hexagonal or octagonal strut may be used or it may be possible to mount multiple sets of ferrules on the same face.

To change from one nozzle spacing to another:

1) Release the locking pin (On the left in the sketch)
2) Rotate the strut about 45 degrees to allow movement of the nozzles
3) Position the nozzles approximately
4) Rotate the strut until the ferrules engage the nozzle forks
5) Engage the locking pin to lock the strut in place.

Simple, elegant and foolproof

Set up for nozzle fillers can be tedious and tricky to nail by hand. Using a single point adjuster helps the machine to adjust to bottles of different sizes, freeing up mechanics for other tasks.

Magnets can be a useful means of eliminating tools during changeover. In some cases, the magnet can provide 100% of the holding force. A common holder for surface grinding uses only a magnet to hold the workpiece.

These may have some applications in packaging, though I’ve not run across any yet. A more common application is to mount the changepart mechanically using slots and keyholes. Once in place, the configuration prevents it coming loose.

The problem is that, absent some sort of fastener, the changepart can vibrate out of position. Here is where magnets come into play. The video, and the picture below, show a pusher mounted to a conveyor chain. The pusher base drops into the matching hole on the lug. When the pusher is slid back about 1/4″, tabs engage locking it in place vertically. The normal pushing load holds the pusher in place.

When not under load, the pusher could vibrate forward and up causing a jam or damage. twelve small but powerful magnets prevent this. When the pusher is in its correct position, the magnets align and prevent it from moving forward accidentally.

This tool-less mounting allows operators to change the pushers rather than requiring a mechanic as in some companies. More importantly, if there are 20 pushers and it takes 1 additional minute to replace each by unbolting and rebolting, this eliminates 20 minutes of downtime.
If the cost of downtime is $10,000/hour, this represents a saving of over $3,000 per changeover.

Hard to believe that a tiny magnet can save that much money.

But it can.

My goal in changeover reduction is elimination of all tool usage. There may be a few exceptions, particularly when required for safety. With a bit of ingenuity, though, most, if not all tools can be eliminated.

One obvious aid is handknobs and handlevers. Handknobs are available in a wide variety of sizes and styles but are all characterized by being symmetrical around the thread. Handlevers are asymmetrical. Many handlevers have ratcheted handles for ease of positioning.

TIP: Spend the extra money and buy handlevers with stainless steel ratchets. Plastic, brass and aluminum may be cheaper but will strip.

I make a rule of using handknobs when complete removal is required. Handlevers should be used when only loosening is required. This is partly for ergonomics but also for also as a memory aide to prevent removal of fasteners that do not need removal.

When Handknobs need to be fully removed, take a tip from NASCAR and relieve the last 1/4 to 3/8″ of the threads. This prevents cross threading when replacing.

Several styles of quick acting knobs and levers are commercially available. These can be useful but do not provide the same mechanical security as regular, fully threaded, fasteners. they should be used with caution and only on non-trivial applications such as adjusting guides rails.

Knobs and levers should only be used on those fasteners that are touched during routine changeovers. they should not be used elsewhere. This serves as a memory aide. If a tool is required, it is not to be adjusted.

Knobs and levers are so simple and common that we take them for granted. We shouldn’t.

Those who know me know that my goal in any changeover is to eliminate tools. Toggle clamps are a useful way to do this. They come in a variety of styles and sizes. Most are familiar with manual toggle clamps but they also come with pneumatic and hydraulic actuators.

Common uses include:

Latches used to secure tank lids, doors, machine docking stations.

Push pull clamps can be used to pull two components together or to push them apart. They can be used equipment as to lift portable equipment slightly off the floor to lock it in place.

Hold down clamps are ubiquitous in some changeovers. Change parts, such as a guide plate or wrap belt have locating holes to match pins on the machine. The part is placed over the pins and the toggle clamp snaps in place to hold it down.

Most toggle clamps are single lever. Most clamps are also available with a locking trigger. This requires the trigger to be pulled before the main lever can be released. I highly recommend these on most machine applications for safety against accidental release.

Toggle clamps: One of the most useful tools in my changeover toolbox.