GARFIELD, N.J. (Dec. 23, 2003) -- With help from the nationally recognized, NASA-funded Space Alliance Technology Outreach Program (SATOP) and a top-level engineer with Eastman Kodak Commercial and Government Systems, Algene Marking is adopting a new design tool that may help improve the company’s manufacturing efficiency.

Algene is a manufacturer of flexographic printing presses and coding machines used for printing on cardboard and corrugated boxes, sheets and cards. The company also supplies flexographic inks, removable rubber type and product support. Algene needed to generate a cost-effective motion profile that matched box speed with roller speed while at the same time prevented damage to the box. “Some modifications to the dimensions of our machine design were required,” said Algene president, Gary Mann.
At the Atlantic Design Show Expo in New York City, Mann learned about SATOP and the free technical advice the program offers to small businesses. Mann filled out a Request for Technical Assistance (RTA) and SATOP paired him with Michael O'Brien, the mechanisms group supervisor at Kodak, one of SATOP’S alliance partners. “I accepted this RTA because I felt it was well suited to our group's expertise in mechanism synthesis, kinematics, and dynamics,” said O’Brien. “We have solved similar problems in the past, and this gave me a refreshing break from the daily routine.”

O’Brien explained the challenge and solution: “Employing variable radius gears or cams were the obvious solutions, however, it is not possible to change velocity profiles or stroke once a machine is built, and the cost is excessive. We decided that while a simple four-bar mechanism did not match the requirements exactly, it can produce acceptable motions for this application. Additionally, it can be easily modified to suite a wide variety of performance requirements. Overall, this simple approach is very economical and is a highly reliable method of obtaining motion.”

One of Algene’s requirements was that they be able to calculate these motion profiles cost effectively. Understanding this requirement, O’Brien’s team developed a Microsoft EXCEL spreadsheet to calculate output link angle, velocity, and acceleration for a given speed. A second similar spreadsheet was then developed for an alternate feeder mechanism. “Between the two solutions, Algene now has tools to allow easy and quick optimization of linkages for new products in their line,” said O’Brien.

“Both the solutions offered are excellent,” said Mann. “The Kodak engineers were able to generate calculations that I didn't even know were possible with EXCEL.”  From his experience with SATOP, Mann has a new outlook regarding government-funded initiatives, “I wouldn't hesitate to contact them again because free advice was exactly what I needed. SATOP is one government program I fully support and feel good about my tax dollars funding.”