System for repetitive formation of objects from sheet material

Abstract

A system for repetitive formation of objects from sheet material, the system comprising a converting machine for execution of a formation process, said objects being at least partially formed from the sheet material, the converting machine including a tool for engaging with the sheet material to at least partially form said object during a formation process An electronic memory storing a database comprising, for a plurality of prior executed formation processes, empirical data relating a pressing parameter applied in a first phase of first usage of the tool that corresponds to a stabilising phase, to process parameters, which are associated with the formation process. The system electrical circuitry configured to acquire process parameters for a subsequent formation process; derive a pressing parameter for the subsequent formation process, which is for application in a first phase of first usage of the tool, based on the acquired process parameters and the database.

Description

[0001] SYSTEM FOR REPETITIVE FORMATION OF OBJECTS FROM SHEET MATERIAL

[0002] TECHNICAL FIELD

[0003] The present disclosure relates generally to operated systems for repetitive formation of objects from sheet material. Such systems can be implemented in a converting machine configured to produce packaging elements such as flat-packed or folding boxes or blanks therefor.

[0004] BACKGROUND

[0005] Converting machines are used in the formation of objects referred to herein as blanks and packaging elements, comprising paperboard and cardboard boxes. Some types of converting machines are configured to punch out shaped blanks from sheets of paperboard and cardboard, and other types of converting machines may subsequently fold and glue the shaped blanks to form folding boxes or other similar packaging containers. Other types of converting machines are configured to both cut out shaped blanks and also fold them.

[0006] Cardboard and paperboard blanks are provided with cut lines which define the overall shape of the blanks and crease lines which define the locations of folds. These converting machines comprise a plurality of modules which perform different mechanical processing steps onto a sheet substrate in order to produce a packaging element such as a box blank or a folding box.

[0007] Said converting machines are part of a system for repetitive formation of objects from sheet material. The system can implement only the converting machine, or additional machine modules which may form part of a manufacturing line, which can include one or more of a printing module; a folding module, and a conditioning module.

[0008] The converting machine executes a formation process, in which said objects are at least partially formed from the sheet material. The converting machine including a tool, which is manipulated for repetitive mechanical engagement with the sheet material to at least partially form said object during the formation process. The system includes machine control electrical circuity to control the converting machine to execute said formation process.

[0009] The tool may implement one or more of with the sheet material: a crease; a fold; a line of weakening (also referred to as a frangible line); full or partial perforation; emboss; engrave; ablation; punch; roll. Hence the tool may be exemplified as including a cutting edge or folding edge. These types of edges may be linear, or curved when applied around a circumference of a roller or disc. The object formed may be packaging elements such as flat-packed or folding boxes, pouches and pamphlets.

[0010] The converting machines are typically designed for producing different objects in terms of shape and size. This is achieved by implementing a different tool and / or formation process. The control electrical circuity controls the converting machine with process parameters, which are used as inputs or targets for the formation process. Hence each formation process has a set of process parameters. Consequently, for the formation of different objects, different tools and / or process parameters may be required. Moreover, as a tool is used the process parameters may require adaptation to account for tool wear.

[0011] SUMMARY

[0012] In view of the above, one object of the present disclosure is to provide an improved system and method for a more accurate selection of process parameters.

[0013] The present disclosure provides a system for determination of a pressing parameter for repetitive formation of objects from sheet material. The system comprises a converting machine for execution of a formation process, in which said objects are at least partially formed from the sheet material, the converting machine including a tool for mechanical engagement with the sheet material to at least partially form said object during the formation process. The system may comprise machine control electrical circuity to control the converting machine to execute said formation process. The system comprises system electrical circuitry for acquisition of one or more process parameters associated with the formation process(s).

[0014] In embodiments, the system comprises an identifier arranged to be physically associated with the tool. In embodiments, the system electrical circuitry is configured to associate the one or more process parameters with an electronic record of the identifier. By associating the process parameters with an identifier, it may be ensured that the process parameters (and / or a pressing parameter history relationship, as will be discussed) is stored in association with the tool. In this manner as the tool moves between converting machines and / or is substituted for other tools and reused, a database of said parameters may continue to be populated in spite of said interruption.

[0015] In embodiments, the system electrical circuitry is configured to determine based on the process parameters a pressing parameter history relationship for the tool, in which the pressing parameter varies with respect to a number of formation processes, and to determine from said relationship when a predetermined condition associated with the usage of the tool is met. Hence, within the context of the present disclosure, the pressing parameter history relationship for the tool can be defined a relationship between at least one pressing parameter and a number of formation processes.

[0016] By implementing the system to establish a relationship between pressing parameters, (e.g. a pressing force applied to the tool) and a usage history, (e.g. a graphical relationship between a variation in force applied vs the number of forming processes implemented by the tool) a position on a graphical plot of such a relationship can be established to determine a usage condition of the tool (e.g. a depletion condition, which may be a particular trigger point at which some action is required in the system).

[0017] As used herein the term “based on the process parameters” may refer to one or more process parameters being used directly (e.g. a direct relationship without processing) or indirectly (e.g. an indirect relationship, in which some numerical function or other processing is applied) to determine the pressing parameter.

[0018] As used herein the term “pressing parameter” may refer to one or more parameters which are controlled and / or selected as inputs for the formation process, examples of which include the following or replated quantities: pressing force, displacement or acceleration; distance between cooperating rotary tools. The pressing parameter may be visualised as the dependent variable on the graphical plot.

[0019] As used herein the term “usage condition” in respect of the tool may refer to a depletion condition or a condition that is outside normal usage. As used herein the term “depletion condition” in respect of the tool may refer to a physical state of the tool indicative of wear, which may signify an end of life or onset thereof for the tool.

[0020] As used herein the term “predetermined condition” in respect is the usage condition may refer to a point on the history relationship that is indicative of the usage condition.

[0021] As used herein the term “history relationship” in respect of a number of forming processes implemented by the tool, may refer to a relationship between a number of forming processes implemented by the tool, which may be visualised as the independent variable on the graphical plot, and a magnitude of the pressing parameters, which may be visualised as the dependent variable on the graphical plot. In embodiments, the pressing parameter history relationship comprises: a first phase, which is associated with a higher (including an average, which may be defined as an average for a linear line between the start and end of the phase) first order derivative of the pressing parameter history relationship compared to a second phase, the higher first order derivative due to a stabilizing phase of the tool; a second phase which is associated with a lower (including an average, which may be defined as an average for a linear line between the start and end of the phase) first order derivative of the pressing parameter history relationship compared to the first phase, the lower first order derivative corresponding to a normal usage phase of the tool.

[0022] In embodiments, the system electrical circuitry is configured to: determine at least the second phase (e.g. and optionally the first and / or other phases) in the pressing parameter history relationship, and; to determine the predetermined condition associated with the usage of the tool based on the phase(s).

[0023] By identifying key characteristic phases in the pressing parameter history, the stages in the life cycle that are associated with usage may be identified.

[0024] As used herein the term “normal usage phase” may refer to a phase of use of the tool in which the process parameters and / or pressing parameter is with a value range that is considered nominal for operation, e.g. the tool has settled and / or does not require said parameters substantially compensating, including for excessive wear. A quality of a process feature formed in the sheet material in this phase may be considered as optimal.

[0025] As used herein the term “stabilizing phase” may refer to a phase where the tool is new and is subject to settling in the formation processes. The pressing parameter may gradually be increased in value in this phase.

[0026] As used herein the term “first order derivative” may refer to a derivative of the value of the pressing parameter for which the history relationship is determined. Typically, the derivative is in respect of the number of uses (e.g. the independent variable) but other representative quantities may be used, e.g. time.

[0027] As used herein the term “based on the phase(s)” may refer to the usage condition being determined when part of a phase is exceeded, including at a transition between phases.

[0028] In embodiments, the pressing parameter history relationship comprises: a third phase, which is associated with a higher (including an average, which may be defined as an average for a linear line between the start and end of the phase) first order derivative of the pressing force compared to the second phase, the higher first order derivative corresponding to an end of the normal usage phase of the tool, wherein the system electrical circuitry is configured to: determine the third phase in the pressing parameter history relationship. In embodiments, system electrical circuitry is configured to: determine the predetermined condition associated with the usage of the tool based on a transition from the second to the third phase or a portion of the third phase.

[0029] By identifying key characteristic phases in the pressing parameter history, the stages in the life cycle that are associated with usage may be identified. In particular, the third phase may define the final phase where the tool is acceptable for use. Hence its identification may be associated with the usage condition of ordering a replacement tool, accounting for lead time for the replacement tool etc.

[0030] As used herein the term “end of normal usage phase” may refer to a phase subsequent to the normal usage phase, in which the process parameters and / or pressing parameter is markedly compensated in value from the value range in the normal use phase to account for wear (e.g. blunting) of the tool. The tool may be acceptably used in formation processes during this phase but with said compensation of the parameters, such that a quality of a process feature formed in the sheet material is maintained as optimal.

[0031] In embodiments, the pressing parameter history relationship comprises: a fourth phase, which is associated with a higher first order derivative of the pressing force compared to the third phase, the higher first order derivative corresponding to an end of the life phase of the tool; wherein the system electrical circuitry is configured to: determine the third phase in the pressing parameter history relationship. In embodiments, system electrical circuitry is configured to: determine the predetermined condition associated with the usage of the tool based on a transition from the third to the fourth phase.

[0032] By identifying key characteristic phases in the pressing parameter history, the stages in the life cycle that are associated with usage may be identified. In particular, the fourth phase may define when the tool is not acceptable for use and requires substitution.

[0033] As used herein the term “end of the life phase” may refer to a phase subsequent to the end of normal usage phase, in which the process parameters and / or pressing parameter can no longer be compensated in value to account for wear (e.g. blunting) of the tool. The tool may be sub- optimally used in formation processes during this phase, such that a quality of a process feature formed in the sheet material is sub-optimal.

[0034] In embodiments, a duration of the second phase is greater than the other phases. In embodiments, a duration of the fourth phase is less than the third phase.

[0035] In embodiments, one or more of the phases comprise an envelope of pressing parameter value that defines an upper and lower bound for the phase. In embodiments, the envelop defines a linear region for each phase, which the pressing parameter is bounded by. In embodiments, the predetermined condition associated with usage comprises a pressing parameter exceeding said envelope.

[0036] By defining an envelope, e.g. an upper and lower bound for each point in the independent variable, for the value of the pressing parameter, one or more of the following may be determined of the envelope is exceeded: the crossing of the pressing parameter history relationship between phases; an operator error, e.g. in a process parameter input; tool failure / damage.

[0037] In embodiments, the predetermined condition associated with usage comprises comparing the determined pressing parameter history relationship to a predetermined (e.g. an empirical or numerically calculated) pressing parameter history relationship. By comparing the determined pressing parameter history relationship to a predicted pressing parameter history relationship, it may be determined how the tool performs to an ideal tool. This predicted pressing parameter history is a known pressing parameter history, which can be based on data acquired for the same tool in the same machine and for the same blanks.

[0038] In embodiments, the system electrical circuitry is configured to determine a performance value for the tool based on said comparison. By determined a single numerical value, e.g. a performance index, tool performance maybe comparatively quantified.

[0039] In embodiments, the system electrical circuitry, based on the determination of said predetermined condition, is configured to implement a response comprising one or more of: providing a notification to a user interface; initiating an ordering process of a replacement tool; initiating a replacement tool installation process; initiating a refurbishing process of the tool; determining a number of formation processes prior to replacement of the tool.

[0040] By implementing said responses it may be ensured that the tool is replaced at a correct time in the tool life cycle and / or that a replacement tool is immediately available for replacement. One of more of said response may include determining an identifier associated with the replacement tool and implementing a subsequent pressing parameter history relationship for the tool.

[0041] In embodiments, the response is based on a current stock of replacement tools. For example, if several tools are determined as in stock / at a location of the converting machine / a machine user location, a tool may only be reordered once said stock is below a predetermined amount.

[0042] In embodiments, the system comprises one or more replacement tools.

[0043] In embodiments, the method comprises associating said parameters with an electronic record of an identifier associated with the tool.

[0044] In embodiments, the method comprises determining based on the process parameters a pressing parameter history relationship for the tool, and to determine from said relationship when a predetermined condition associated with the usage of the tool is met.

[0045] The present disclosure provides electrical circuitry to implement the method of the preceding embodiments or another embodiment disclosed herein.

[0046] The present disclosure provides a computer readable medium comprising program code, which may be executable on one or more processors (e.g. of the system / electrical circuitry), to implement the method of the preceding embodiments or another embodiment disclosed herein.

[0047] The preceding summary is provided for purposes of summarizing some embodiments to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the abovedescribed features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding embodiments may be combined in any suitable combination to provide further embodiments. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description of Embodiments, Brief Description of Figures, and Claims.

[0048] BRIEF DESCRIPTION OF FIGURES

[0049] Aspects, features and advantages of embodiments of the present disclosure will become apparent from the following detailed description of embodiments in reference to the appended drawings in which like numerals denote like elements. Figure 1 is a block system diagram showing an embodiment system repetitive formation of objects from sheet material.

[0050] Figure 2 is a block system diagram showing embodiment electrical circuitry of the system of figure 1 as a disturbed computer system.

[0051] Figure 3 is a schematic cross-sectional view of a converting machine in the form of a flatbed diecutter.

[0052] Figure 4 is a schematic side view of showing an embodiment system for repetitive formation of objects from sheet material.

[0053] Figure 5 is a top view of a blank produced in a converting machine.

[0054] Figure 6 is a schematic perspective view of a tool for a converting machine.

[0055] Figure 7 is a schematic perspective view another type of converting machine in the form of a rotary die-cutter.

[0056] Figures 8a and 8b are detailed views of a die-cutting module in the converting machine of figure 5.

[0057] Figure 9 is flow diagram showing an embodiment process of determining a depletion condition of a tool of the converting machine of the system of figure 1.

[0058] Figure 10 is an illustrative diagram showing an embodiment pressing parameter history relationship for a plurality for formation processes of the converting machine of the system of figure 1 .

[0059] Figure 11 is flow diagram showing an embodiment process of the system of figure 1 .

[0060] Figure 12 is flow diagram showing an embodiment process of the system of figure 1.

[0061] DETAILED DESCRIPTION OF EMBODIMENTS

[0062] Before describing several embodiments of the system, it is to be understood that the system is not limited to the details of construction or process steps set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the system is capable of other embodiments and of being practiced or being carried out in various ways. The present disclosure may be better understood in view of the following explanations:

[0063] As used herein the term “system for repetitive formation of objects from sheet material” may refer to an arrangement that includes hardware comprising a converting machine for repetitively executing a formation process in a predefined manner for the formation of an objects from sheet material. The system may implement only the converting machine, or additional machines, which may form part of a manufacturing line, which can include one or more of a printing machine; gluing machine; filling machine, and; a assembling machine. The converting machine may also implement any of the aforesaid machine processes.

[0064] As used herein the term “converting machine” may refer to hardware for executing a formation process for full or partial formation of an object. The hardware may be arranged as modules, e.g. in distributed in series or as a single unit. The converting machine may be configured to at least partially form the object from sheet material. The converting machine includes a tool which is manipulated / driven for repetitive mechanical engagement with the sheet material to at least partially form said object during the formation process.

[0065] As used herein the term “formation process” may refer to a process executed by the converting machine on the sheet material to at least partially form the object.

[0066] As used herein the term “sheet material” may refer to a material arrangement with a comparatively thin thickness and a large in-plane length and width. The sheet material may be supplied as individual sheets or as a continuous web. From each individual sheet and each impression one or a plurality of objects can be at least partially formed. Examples include: cardboard; plastic; metal base foil; laminates of the aforesaid. The sheet material may refer to a blank, wherein the formation process either forms the blank in the sheet material as the object (e.g. by cutting), or the formation processes the blank to the object and typically by folding.

[0067] As used herein the term “object” may refer to the item formed by the formation process. In the example of the sheet material processed to a blank the object can refer to the blank. In the example of the blank being processed the object can refer to packaging element or other like arrangement.

[0068] As used herein the term “paperboard” or “cardboard” may refer to paper pulp-based board. A thickness of the material may be greater than 0.30 mm and / or a grammage of a grammage above 250 g / m2, hence to distinguish the material from paper. Paperboard maybe single-ply or multi-ply. As used herein the term “fibreboard” may refer to wood product that is made out of wood fibres or a kraft-based paperboard. It may include a kraft-based paperboard or corrugated fiberboard.

[0069] As used herein the term “direction of transportation” in respect of the sheet material may refer to a direction that extends from an inlet to an outlet of the converting machine. This may correspond to a direction from a feeder device of the sheets to a delivery module of the final blanks.

[0070] As used herein the term “tool” may refer to an implement for physical engagement with the sheet material to form the object. The tool may be configured to repetitively implement a processing feature in the sheet material that may comprise one or more of the following: a crease; a fold; a line of weakening; a full or partial perforation; an embossing; an engraving; an ablation; a punch; a roll. Hence the tool may be exemplified as including one or more of: a cutting edge; a folding edge, and; a roller.

[0071] As used herein the term “impression” may refer to the engagement the tool makes with the sheet material.

[0072] As used herein, the term “identifier” may refer to a formation that enables unique identification of the tool from other like tools. An identifier may include one or more of: a code, including an optically readable or a magnetic code or an electronically readable code; a chemical tracker; a mechanical formation; a chip, including an RFID. In embodiments, the tool may include electronic memory for the storage of the database of one or more of: process parameters; pressing parameter(s); pressing parameters force history relationship, as will be discussed.

[0073] As used herein the term “physically associate” in respect of the identifier may refer to one or more of: the formation of the identifier on or in the tool; on a member to be physically associated with the tool, e.g. a strip or ribbon.

[0074] As used herein the term “associate” in respect of the process parameters and an electronic record of an identifier, may refer to an electronic indexing, e.g. by a look-up table / key value database paradigm, in which the electronic record of an identifier is used to look-up / store the process parameters.

[0075] As used herein the term “process parameters” may refer to parameters for one or more of: parameters used as inputs for control of the converting machine to execute a formation process; parameters that are measured during a formation process; parameters that are set as a target for the converting machine to execute the formation process, and; any parameters that have an influence on the formation process. Examples include one or more of: displacement applied to the tool; force applied to the tool; distance between cooperating tools, velocity applied to the tool; acceleration applied to the tool; transportation speed of the sheet through the converting machine, a time history relationship of any of the aforesaid during a formation process; machine calibration parameters; any parameter based on the aforesaid.

[0076] As used herein the term “recipe” may refer to a group of parameters, which may comprise a full or partial set of inputs to the control of the formation process.

[0077] As used herein the term “system electrical circuitry” may refer to electrical circuitry for process parameter acquisition, database and optional analysis functions. The system electrical circuitry can be distributed on one or more components of the system.

[0078] As used herein the term “machine control electrical circuitry” may refer to electrical circuitry for control of the converting machine to execute the formation process. The machine control electrical circuitry may fully or partially control the converting machine, e.g. with partial manual control. The machine control electrical circuity can be arranged as part of the converting machine or distributed on one or more components of the system.

[0079] As used herein, the term "electrical circuitry" or "circuitry" may refer to one or more hardware and / or software components, examples of which may include: an Application Specific Integrated Circuit (ASIC); electronic / electrical componentry (which may include combinations of transistors, resistors, capacitors, inductors etc); one or more processors; a non-transitory memory (e.g. implemented by one or more memory devices), that may store one or more software or firmware programs; a combinational logic circuit; interconnection of the aforesaid. The electrical circuitry may be located entirely at one component of the system, or distributed between a plurality of components of the system which are in communication with each other over a computer network via communication resources.

[0080] As used herein, the term "processor" or "processing resource" may refer to one or more units for processing, examples of which include an ASIC, microcontroller, FPGA, microprocessor, digital signal processor (DSP), state machine or other suitable component. A processor may be configured to execute a computer program, e.g. which may take the form of machine readable instructions, which may be stored on a non-transitory memory and / or programmable logic. The processor may have various arrangements corresponding to those discussed for the circuitry, e.g. on-board or distributed as part of the system. As used herein, any machine executable instructions, or computer readable media, may be configured to cause a disclosed method to be carried out, e.g. by the system or components thereof as disclosed herein, and may therefore be used synonymously with the term method, or each other.

[0081] As used herein, the term "computer readable medium / media" or "data storage" may include any medium capable of storing a computer program, and may take the form of any conventional non-transitory memory, for example one or more of: random access memory (RAM); a CD; a hard drive; a solid state drive; a memory card; a DVD. The memory may have various arrangements corresponding to those discussed for the circuitry.

[0082] As used herein, the term "communication resources" or "communication interface" may refer to hardware and / or firmware for electronic information transfer. The communication resources / interface may be configured for wired communication (“wired communication resources / interface”) or wireless communication (“wireless communication resources / interface”). Wireless communication resources may include hardware to transmit and receive signals by radio and may include various protocol implementations e.g. the 802.11 standard described in the Institute of Electronics Engineers (IEEE) and Bluetooth™ from the Bluetooth Special Interest Group of Kirkland Wash. Wired communication resources may include; Universal Serial Bus (USB); High-Definition Multimedia Interface (HDMI) or other protocol implementations. The converting machine may include communication resources for wired or wireless communication with an external device and / or server system.

[0083] As used herein, the term "network" or "computer network" may refer to a system for electronic information transfer between a plurality of apparatuses / devices. The network may, for example, include one or more networks of any type, which may include: a Public Land Mobile Network (PLMN); a telephone network (e.g. a Public Switched Telephone Network (PSTN) and / or a wireless network); a local area network (LAN); a metropolitan area network (MAN); a wide area network (WAN); an Internet Protocol Multimedia Subsystem (IMS) network; a private network; the Internet; an intranet; personal area networks (PANs), including with Bluetooth a short-range wireless technology standard.

[0084] As used herein, the term “external device” or "external electronic device" or “peripheral device” may include electronic components external to the converting machine, e.g. arranged at a same location or remote therefrom, which communicate therewith over a computer network. The external device may comprise a communication interface for communication with the machine and / or a server system. The external device may comprise devices including: a smartphone; a PDA; a video game controller; a tablet; a laptop; or other like device.

[0085] As used herein, the term “server system” may refer to electronic components external to converting machine, e.g. arranged at a same location or remote therefrom, which communicate therewith over a computer network. The server system may comprise a communication interface for communication with the converting machine or the external device. The server system can include: a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

[0086] As used herein the term “database” may refer to a data storage configuration which may be implemented as a key-value paradigm, in which an electronic record of an identifier acts as a key and is associated with a value as one or more process parameters, including sets of process parameters.

[0087] [General system description]

[0088] Referring to figure 1 a system 2 comprises: a converting machine 4; sheet material 6 and object 8, and electrical circuitry 10. The converting machine 4 implements a formation process under the control of the electrical circuitry 10 to form the object 8, from the sheet material 6 as will be discussed.

[0089] The electrical circuitry 10 may be idealised as: system electrical circuitry 12 for process parameter acquisition, database and analysis functions as will be discussed; machine electrical circuitry 14 to control the converting machine 4 to execute said packaging formation process.

[0090] Referring to figure 2, the electrical circuitry 10 is distributed over the converting machine 4; a server system 3, and one or more peripheral devices 5. The electrical circuitry 10 implements a communication interface (not illustrated) on said components of the system for electronic communication over a computer network as defined herein. Hence the components of the system may communicate directly with each other or via an intermediary component, e.g. the converting machine 4. Since the electrical circuitry 10 may be distributed over components of the system 2, any one of the electrical circuitries 12, 14 maybe referred to more generally as the electrical circuitry 10. In variant embodiments, which are not illustrated: the peripheral device and / or server system is omitted; the electrical circuitry is distributed over any one or more of the above components of the system.

[0091] [Converting machine]

[0092] Referring to figures 3 and 4, a converting machine 4 in the form of a platen-press machine is illustrated, the converting machine 4 comprises: a processing unit 16 for processing of the sheet material 6; a processing zone 18, in which the processing unit 16 engages with the sheet material 6; and a conveying system 20 to deliver the sheet material 6 to the processing zone 18 and optionally eject the sheet material 6 and / or object 8 from the processing zone 18. This type of configuration may be part of a flatbed die-cutter converting machine.

[0093] The processing zone 18 may include a register control system configured to locate the arrival and potential skewness of the sheet material 6 before it enters into the processing position.

[0094] The conveying system 20 is configured to drive the sheet forward in the direction of transportation. The conveying system 20 may be exemplified as one or more of: a conveyor system comprising belt conveyors onto which the sheet material 6 is fed; a feeding system into which a stack of sheet material 6 is loaded, with individual sheet material 6 portions being extracted and processed from the stack; a roller arrangement, in which sheet material 6 is supplied in a roll, hence the sheet material 6 can be a continuous sheet / roll.

[0095] The processing unit 16 includes a tool 22 and a driving mechanism 24 configured to drive the tool 22 in a predefined manner. The machine electrical circuitry 14 controls the processing unit 16 to execute the formation process.

[0096] The converting machine 4 can be controlled to produce different objects 8 from the same or different configurations of sheet material 6. This can be achieved by specifying different process parameters and / or tools 16. For instance, the different objects 8 may be packaging elements of different shape, size and material characteristics. An example of a packaging element 8 for a folding box is illustrated in figure 5. The object 8 is provided with cut lines 11 defining the overall shape of the object 8, and crease lines 13 defining the location of folds.

[0097] In variant embodiments, which are not illustrated: the delivery system and / or processing zone may be omitted, e.g. the sheet material is manually fed to the processing unit. The conveying system 20 conveys the sheet material 6 in a longitudinal direction 100, with the plane of the sheet material 6 to extend in the longitudinal direction 100 and a lateral direction 102, and the tool 22 to engage the sheet material 6 in a depth direction 104.

[0098] In variant embodiments, which are not illustrated: other orientations are implemented.

[0099] Since the sheet material 6 may refer to a blank which is processed by the formation process or may refer to sheet from which a blank is formed by the formation process, it will be understood that the disclosed examples optionally implement either arrangement.

[0100] Within the context of this application, the term “converting machine 4” is not limited to a specific type. For instance, as illustrated in figures 7, 8a and 8b the converting machine 4 may be configured as a rotary die-cutting machine 4. The rotary die-cutting machine 4 comprises a feeder module 19 and a processing unit 16. Preferably, the rotary die-cutting machine 4 comprises a printing module 17 such as a digital printing module or a module comprising a plurality of flexographic printing units.

[0101] The processing unit 16 of the herein illustrated rotary die-cutting machine comprises a tool-holder cylinder 21 and a counter cylinder 23. Around its circumference, the tool-holder cylinder is provided with a tool 22. The tool 22 comprises creasing rules 27 and cutting rules 29. The counter cylinder 23 and the tool-holder cylinder are spaced apart at a distance d1. The distance d1 is can be varied in order to modify the force with which the processing unit nips the sheet 6. The smaller the distance d1 is, the higher the cutting force becomes.

[0102] [Example 1 - Folding and embossing]

[0103] Referring back to figures 3 and 4, in a first example the tool 22 is implemented as a flat creasing die 22. The creasing die 22 is driven by the driving mechanism 24 to apply a fold to the sheet material 6 at a predefined position, e.g. for formation of an object 8 including as a rectangular packaging container. The driving mechanism 24 drives the creasing die 22 into the sheet material 6, which is interposed between the tool and a support member 25.

[0104] The tool 22 is attached to a tool-holder 26 which is movable in the vertical position between a pressing position and a clearing position., in the tool-holder further comprises an engagement portion 27 for engagement with the driving mechanism 24.

[0105] In the first example, and as further illustrated in figure 6, the tool 22 includes a base 28 and a projection 30. The projection 30 projects outwardly from the base 28 to implement said creases by being driven into the sheet material 6 under axial load along the depth axis 104 applied by the driving mechanism 24. The projection 30 comprises creasing rules 30b.The projection 30 may be formed of a suitable material, such as metal. The base 28 is preferably a compressible material to allow the ejection of waste parts. The base 28 commonly comprises foam ejectors.

[0106] In another embodiment, the tool 22 can be an embossing tool 22. The tool 22 can be a braille embossing tool 22. In an advantageous variant, the braille embossing tool 22 may comprise a pair of embossing cylinders, where a first cylinder is a tool-holder cylinder configured to carry a first embossing tool provided with embossing protrusions and the second cylinder is a counter cylinder configured to carry a second embossing tool provided with cavities configured to receive the embossing protrusions. Such a tool 22 is disclosed in document EP2844462.

[0107] In another variant, the braille embossing tool 22 may be flat die or form part of a flat die such 22 as the one illustrated in figure 6.

[0108] In other variant embodiments, which are not illustrated: other formations of one or more projections can be implemented, e.g. to form complex shapes in the sheet material / blank.

[0109] The tool 22 preferably comprises an identifier 40 attached to the tool 22. Optionally, and as in the illustrated example, the identifier 40 may be removably attached to the tool 22. The identifier 40 may be an RFID, an optically readable code, or any other machine-readable identifier 40.

[0110] As numerous formation processes are executed by the creasing and cutting tool 22, it will be understood that the tool 22, particularly the projection 30, is subject to wear, due to which the tool has a limited life cycle.

[0111] Specific process parameters for the first example may include one or more of: axial displacement applied to the tool; axial force applied to the tool; other machine calibration parameters.

[0112] [Example 2 - Cutting]

[0113] In a second example (not illustrated) a full or partial cut is formed in the sheet material 8. In the second example, the first example is adapted with the tool projection 30 to include a cutting blade. Hence the second example implements the compatible features of the first example, together with the discussed variants, which for brevity are not repeated.

[0114] In the second example, the sheet material 6 is fully or partial cut, e.g. to form a blank or to process the blank. [Process parameter acquisition and processing]

[0115] We advantageously perform a couple of steps (referred hereinafter to as “blocks”) to acquire process parameters and determine a process parameter tool history associated with a specific tool 22, or with a plurality of specific tools 22. The process parameter can for instance be a pressing force (in Newton), a distance in the form of an axial displacement ora clearance between a tool-holding cylinder and a counter cylinder.

[0116] Referring to figure 9, the system electrical circuitry 12 is configured to implement the following process: at block 120, acquire one or more process parameters associated with the formation process. at block 122 associate said process parameters with an electronic record of an identifier (not illustrated), which is physically associated with a tool 22; at block 124 determine based on the process parameters a pressing parameter history relationship for the tool; at block 126 determine from said relationship when a predetermined condition associated with the depletion of the tool is met.

[0117] In variant embodiments, which are not illustrated, variant processes are implemented, for example: block 122 can be omitted, e.g. in a system in which the same tool is used in one converting machine until it is fully depleted and as such the identifier may not be needed for tracking of the parameters of the tool between different machines and / or replacement and reinstallation on the same machine; block 126 can be omitted, e.g. the system is configured to determine the pressing parameter history relationship for the tool, which may be utilised in other ways to block 126; blocks 124 and 126 can be omitted, e.g. the system is configured to acquire process parameters, which may be utilised in other ways to blocks 124 and 126.

[0118] In more detail, at block 120 the system electrical circuitry 12 may acquire the process parameters by one or more of the following: an input via a user interface (not illustrated), which may be incorporated on any component of the system, e.g. the peripheral device or the server system or of the converting machine 4 itself; automatic acquisition, e.g. during a formation process, in which the machine electrical circuitry 14 transfers the implemented process parameters to the system electrical circuitry 12, and; other implementations, e.g. a monitoring system implemented by the system electrical circuitry 10.

[0119] In more detail, at block 122, the tool is physically associated with the identifier 40., as discussed in the preceding examples.

[0120] The system electrical circuitry 12 implements electronic memory (not illustrated) as a database for storage of said one or more process parameters with an associated electronic record of the identifier. The database is arranged as a key-value paradigm, in which an electronic record of an identifier acts as a key and is associated with a value as one or more process parameters, including sets of process parameters.

[0121] Hence this block may include reading the identifier of the tool 22 and associating the process parameters with the electronic identifier of the read identifier and storing them in the database. The process parameters may be acquired for each formation process, or updated each time there is a change in the value of the process parameters. Likewise, the identifier may be read for each formation process or periodically, including each time there is a change in the value of the process parameters. For instance, the identifier may be read when new process parameters are uploaded into the machine, for example in the form of a recipe.

[0122] Moreover, since the database is associated with the tool identifier, the database may continue to be populated with the acquisition of more process parameters as the tool 22 is moved between different converting machines 4. Moreover, each converting machine 4 which has used the tool can be logged in the database. For example, a machine identifier may be stored for tractability.

[0123] In more detail, at block 124 the pressing parameter history relationship for the tool can comprise the derivation of the or each pressing parameter from the process parameters.

[0124] For example, any of the following may be implemented where a pressing parameter is force applied to the tool: one or more process parameters, e.g. those related to acceleration and mass, may be used to determine a pressing force; a pressing force may be determined based on a known relationship between tool displacement and force; the process parameter may be a force (e.g. by means of a loadcell positions on the tool of base element) in which case no processing is required since the process parameter is the pressing parameter. The pressing parameter can also be a distance d1 between cooperating rollers in a rotary die-cutter machine. The history relationship comprises the acquisition of the pressing parameter over multiple formation processes so that key stages of tool wear may be identified, examples of which will be provided.

[0125] In more detail, at block 126 the predetermined condition associated with tool 22 depletion comprises determining said key stages of the history relationship for which appropriate action is implemented, e.g. for maintaining the converting machine 4 operable to execute formation processes, examples of which are provided following.

[0126] [Pressing parameter history relationship over formation processes]

[0127] Referring to figure 10, an example pressing parameter history relationship 110 determined at block 124 for the tool 22 is illustrated, in which the dependent variable is the number of formation process executed (e.g. number of impressions) and the independent variable is the pressing parameter, which in this example is a pressing force applied to the tool 22. The pressing force is preferably measured in Newton. In particular, it is the pressing force needed to ensure adequate formation of the processing feature in the sheet material 6, which as the tool 22 experiences wear through usage, it will be understood requires more force to achieve.

[0128] The plotted curve of the pressing parameter history relationship 110 illustrates a plurality of different phases. The pressing parameter history relationship 110 comprises a first phase 112. The first phase 112 is associated with a higher first order derivative of the pressing parameter history relationship 110 compared to a second phase 114. The higher first order derivative is due to a stabilizing phase of the tool 22, in which the force applied by the tool 22 is notably increased. The higher first order derivative may be defined as the average, or e.g. for a linear line extending between the pressing parameter history relationship 110 at a start and end of the phase 112.

[0129] The pressing parameter history relationship 110 comprises a second phase 114. The second phase 114 is associated with a lower first order derivative of the pressing parameter history relationship 110 compared to the first phase 112. In this phase, the first order derivative is the smallest during the life of the tool. This means that the second phase 114 represents a stable usage of the tool. The lower first order derivative corresponds to a normal usage phase of the tool. The lower first order derivative may be defined as the average, e.g. for a linear line extending between the pressing parameter history relationship 110 at a start and end of the phase 114.

[0130] The transition between the first and second phase can be observed by a marked change in the first order derivative, particularly in a moving average of the first order derivative. The second phase may be considered generally linear in comparison to the other phases (as will be discussed), and in particular in comparison to the first phase over which there is substantial rate change. A duration of the second phase is greater than the other phases.

[0131] The pressing parameter history relationship 110 comprises a third phase 116. The third phase is associated with a higher first order derivative of the pressing force compared to the second phase 114. The higher first order derivative corresponding to an end of the normal usage phase of the tool. The higher first order derivative may be defined as the average, or e.g. for a linear line extending between the pressing parameter history relationship 110 at a start and end of the phase 116.

[0132] The transition between the second and third phase can be observed by a marked change in the first order derivative, particularly in a moving average of the first order derivative, since the second phase may be considered generally linear in comparison to the third phase. A duration of the second phase is greater than the third phase.

[0133] In embodiments, the pressing parameter history relationship comprises a fourth phase 118. The fourth phase 118 is associated with a higher first order derivative of the pressing force compared to the third phase 116. The higher first order derivative corresponding to an end of the life phase of the tool. The higher first order derivative may be defined as a moving average, or e.g. for a linear line extending between the pressing parameter history relationship 110 at a start and end of the phase 118. The transition between the third and fourth phase can be observed by a marked change in the first order derivative, particularly in and average first order derivative, since the fourth phase may be considered generally to ramp up comparison to the third phase. A duration of the fourth phase is less than the third phase.

[0134] In variant embodiments, which are not illustrated, whilst generally the second phase has the greatest duration and has the closest approximation to a linear profile, other graphical profiles for the pressing parameter history relationship are to be contemplated, for example: the fourth phase may have a greater direction than the third phase; the fourth phase may be omitted, e.g. tool usage may be terminated at the end of the third phase; the first phase may be omitted, e.g. the tool is initially used under the loading conditions of the second phase.

[0135] Specifically at block 124, the system electrical circuitry 12 is configured to determine part or all of one or more of the phases, and at block 106 utilise the determination to identify the depletion condition. In particular, at least par of the second phase 114 and / or third phase 116 is determined. In a specific example, the depletion condition may be determined at one of more of the following: a transition between the third and fourth phase; a transition between the second and third phase; a condition proximal the aforesaid transitions, e.g. just before or just after, which may be quantified as a number of uses remaining or after said transition point.

[0136] The transition point in the graph is represented by an increase in the first order derivative of between 10 and 25%, preferably about 20%. As the cutting rules 30a become increasingly blunt, the friction force between the sheet and the cutting rules 30a increases with each impression and the required applied pressing force increases more rapidly in the third phase than in the second phase.

[0137] When a transition point between the third and fourth phase is detected, the electrical circuitry 10 may perform a calculation of an estimated number remaining objects 8 and an action can be triggered to order a replacement tool 22, schedule a tool repair or maintenance, or change the production to allocate future production to another converting machine 4, which may also be located at another manufacturing site.

[0138] Whilst the pressing force is provided in the above examples as the pressing parameter, it will be understood that similar relationships can be achieved for other parameters, e.g. displacement applied to the tool, hence the examples are not to be considered limited to the pressing force. As previously described, the distance d1 between cooperating cylindrical / roll shaped tools is a parameter that is indirectly linked to the pressing force due to the nipping of the sheet material is increased when the distance d1 between the cooperating tools is decreased.

[0139] Referring to figure 6, the phases 112 - 118 are exemplified as comprising an envelope 108 of pressing parameter value that defines an upper and lower bound for each phase. The envelope 108 for each phase is idealised as a linear upper and lower parallel lined region, which the value of the pressing parameter for that phase is bounded by.

[0140] The system electrical circuitry 12 is configured to determine a condition of the envelope 108 being crossed. In response to said determination the system electrical circuitry 12 is configured to determine one or more of: a transition between phases; an operator error, e.g. in a process parameter input, and; tool failure / damage. A notification may be sent to a user interface (not illustrated) or other action (e.g. as discussed under the depletion condition below) based on any of the above determinations.

[0141] In variant embodiments, which are not illustrated, the envelope may be alternatively derived, including as non-parallel upper and lower linear lines; curved rather than linear lines; the envelope may be omitted.

[0142] Reoccurring operator errors can be identified when the converting machine 4 is out of the range of the envelope 108 (i.e. the ideal pressure settings) during one or a plurality of production runs. This identification is possible when the converting machine 4 is configured to request an operator login during start-up. Based on the reoccurring operator errors, a need for corrective action or training can be identified. Alternatively, if the applied pressure is outside of the range, the converting machine may generate an error message, request a recalibration and / or shut down. Alternatively, the machine may perform an automatic calibration to determine an initial pressing parameter as will be described further below.

[0143] [Depletion condition]

[0144] In response to a block 106 determination of a depletion condition, the system electrical circuitry 12 is configured to implement a response, which may comprise one or more of:

[0145] 1). Providing a notification to a user interface (not illustrated). The notification may comprise one or more of: an indication that the tool is fully depleted or is approaching a fully depleted condition; the items under 5) below.

[0146] 2). Initiating an ordering process of a replacement tool. This may comprise the system electrical circuitry 12 implementing one or more of: sending a notification to the user of the converting machine 4 to complete a purchase request for a tool supplier; a direct notification to a tool supplier to manufacture and / or ship a replacement tool. Such a response may be initiated at or proximal a transition between the second and third or the third and fourth phases.

[0147] 3). Initiating a replacement tool installation process. For example, the formation processes may be halted and a step of preparing the converting machine 4 and / or system electrical circuitry 12 for a replacement tool can be implemented (e.g. system electrical circuitry 12 may identify a new identifier of the replacement tool 22 and start a new / or continue with a different pressing parameter history relationship). 4). Initiating a refurbishing process of the tool. This may comprise the responses of items 2) above, however the rather than a full tool replacement, the parts relevant for refurbishment may be sent etc.

[0148] 5). Determining a number of formation processes prior to replacement / refurbishment of the tool / remaining for the tool. This may comprise an indication of the number of uses remaining, including for a particular, e.g. the second, third or fourth phase, or a total number of uses remaining for all the remaining phases.

[0149] The responses, particularly at item 2) above may be based on a current stock of replacement tools. For example, if several tools are determined as in stock / at a location of the converting machine / a machine user location, a tool may only be reordered once said stock is below a predetermined amount.

[0150] [Pressing parameter adjustments prior to depletion condition]

[0151] For a continuous production of a plurality of objects 8 of the same physical characteristics, a calibrated pressing parameter may be automatically increased with a value Ap as a function of the number produced objects 8. The value Ap can be determined by a historical pressing parameter as a function of the phases 112, 114, 116, 188 of the tool 22. This historical pressing parameter can be curve as the one illustrated in figure 10 and can be retrieved for tools 22 having an available tool-history.

[0152] The converting machine 4 may thus automatically adjust the pressing parameter during a continuous production session comprising a large quantity of objects 8. In such a way, the actual pressing parameter follows the changes in the historical pressing parameter (as defined in the phases 1 to 4. There can be a plurality of corrections, where each correction is effectuated when the actual pressing parameter is outside the envelope defined in the historical relationship.

[0153] [Forecasting and anticipated orders of essential parts and consumables]

[0154] The system electrical control circuitry 12 can store a planned production schedule. Hence, the type of objects 8 to be produced, the related quantity and the production and delivery times in a production planning module of the memory. For each planned job in the future production planning / worklog, the converting machine may indicate which creasing or cutting tool 22 to use, as well as which inks (e.g. by indicating a reference) and compensation sheet to use. The system electrical control circuitry may also indicate which tool 22 that is most suitable for the planned job and the physical location of the tool 22 in the factory where the converting machine is located.

[0155] The components needed to produce a specific type of packaging elements are tools 22, spareparts and consumables. To make the converting machine ready to produce the packaging elements 8, these components need to be available.

[0156] The tools are specific for each type of packaging elements 8 and include the cutting or creasing tool 22 as previously described. Another example of a specific tool is a flexographic printing plate.

[0157] The system electrical circuitry 12 can retrieve the planned production schedule from the memory and identify shortage of consumables, spare parts and tools 22.

[0158] The system electrical circuitry 12 may therefore detect the availability, and if needed, initiate an ordering process of these components. The spare parts may be provided with an identification element tracked in the system. The inventory levels of the consumables can be tracked in the memory of the system electrical circuitry 12.

[0159] [Tool-maker interaction]

[0160] The machine operator may order the tools 22 from a toolmaker, who is producing the tools 22. The system electrical control circuitry may allow an exchange of information between the machine operator and the toolmaker.

[0161] For instance, the machine operator may send feedback on the tool 22, such as the pressing parameter history relationship 110 to the toolmaker. Additionally, a comparison of life cycles for identical tools 22 from the same of different toolmakers can be performed. Tools which have a lower number of available formation processes before reaching the depletion condition than the average or predicted number may be identified. Optionally, the toolmaker who provided the tool 22 can be notified. The toolmaker may also provide information and data to the machine electrical control circuitry, such as an estimated number of impressions before reaching a depletion condition. In such a way, a quality problem of the tool 22 may be identified.

[0162] Depending on the type and the state of the tool 22, the tool 22 may be replaced or repaired. For a repaired tool 22, a maintenance log can be stored in the system electrical control circuitry (preferably on the remote server). Depending on the maintenance history, it may be determined that the tool 22 is no longer be reparable and a replacement is needed.

[0163] The identification element 40 of each tool 22 may also be linked to a tool category. The tool category can be linked to a group of toolmakers. This group of toolmakers have the technical capacity to manufacture one or a plurality of tool categories. Additionally, the system electrical circuitry 14 may propose one or a plurality of toolmakers depending on the toolmakers predicted tool availability at the end of life of the tool 22.

[0164] The system electrical circuitry 14 may further propose new toolmakers suitable for producing the related tool 22. The proposed toolmakers may be provided based on a validation of the type of tool 22 and converting machine location.

[0165] The system electrical control circuitry may be further configured to extract technical parameters required for producing the tool 22 and send them to the selected toolmaker. Additionally, the toolmaker may provide technical information of the tool and price over the network.

[0166] An order of the new tool 22 may also be directly entered into the system.

[0167] [Determination of pressing parameter starting point]

[0168] In the first phase 112, the stabilizing phase of the tool 22 may comprise an automatic calculation of the initial pressing parameter. This automatic calculation can be immediately performed after a new tool 22 is attached to the converting machine 4.

[0169] The automatic calculation provides an initial pressure parameter. The initial pressure parameter may be determined from historical data, data provided from the toolmaker, or a calculated based on the blank and material characteristics of the sheet 6, or a combination thereof.

[0170] For instance, the length of the creasing rules or cutting edges of the tool 22 can be calculated when deciding the calibrated pressing parameter. Preferably, the system electrical circuitry 12 is configured to calculate the length of the knives from a drawing file of the blank 8 uploaded into the memory of the system electrical circuitry 12.

[0171] The historical data includes pressing parameters of similar tools 22 for similar sheet materials. The historical data may be stored in the system electrical control circuitry 12. Data provided by the toolmaker may comprise calibrated test data. The test data may comprise a plurality of initial pressing parameter settings for a new tool 22, where each pressing parameter setting is linked to a specific or a range of material characteristics. Such data may be downloaded from a remote computing location in the computer network.

[0172] The initial pressing parameter may also be determined by performing a pre-calculation based on fibre structure, sheet layer thicknesses and grammage. Optionally, the sheet 6 may be provided with a printed and optically readable code comprising information about the sheet material characteristics. The converting machine may further comprise a hygrometric sensor . A correction factor to the calculated material resistance may be determined from the measured humidity. The converting machine 4 may further comprise an optical sensor configured to retrieve the sheet material information and at least partially perform a pre-calculation of the initial pressing parameter from the sheet material characteristics.

[0173] Alternatively, the sheet material characteristics is uploaded by the supplier of the paper and cardboard sheets into the remote server

[0174] With a starting point in the initial pressing parameter, the converting machine 4 may in the stabilizing phase 112 perform one or a plurality of test impressions with an increasing applied pressure starting from the initial pressing parameter.

[0175] The test impressions are iterative such that and ideal applied pressure setting can be determined based on the previous sensed pressure of each impression when taken as the starting point of the next iteration. The calibration procedure may thus be performed by a plurality of impressions performed with different pressing parameters.

[0176] Referring to figure 12, the system electrical circuitry 12 is configured to implement the following process: at block 150, implement on electronic memory (e.g. of the system electric circuitry 12) a database comprising, for a plurality of previously executed formation processes, empirical data relating a pressing parameter applied in the first phase 112 of first usage of the tool (which corresponds to a stabilising phase) to process parameters associated with the formation process; at block 152, acquiring process parameters, which are variables associated with a subsequent formation process, and; at block 154, deriving a pressing parameter for the subsequent formation process, which is for application in a first phase of first usage of the tool, based on the acquired process parameters of block 152 and the database of block 150.

[0177] In more detail, at block 150, the database comprises for empirical data of past formation processes, a key value paradigm that relates the process parameters (e.g. the values thereof for a set of process parameters,) to one or more determined pressing parameter(s).

[0178] Whilst block 150 is illustrated as a process step, it will be understood that formation of the database and its population may be included as a process step, but it is not essential.

[0179] Moreover, the process may include, subsequent to block 154, a step of implementing the determined process parameter during the subsequent formation process.

[0180] Moreover, the process may include a step of storing the acquired process parameters and the derived pressing parameter(s) of block 152 and block 154 to the database for use in subsequent executions of the process.

[0181] Moreover, the process may also include a step of evaluating the determined pressing parameter of block 154, e.g. by means of the previously discussed predetermined condition as discussed for the embodiment associated with process of figure 11 . An optional step of subsequently correcting the pressing parameter according to said predetermined condition (e.g. by a reduction or increase in peak magnitude) may also be implemented prior to storing on the database.

[0182] In more detail, at block 152, for the subsequent formation process that is intended to be executed, the set of process parameters (e.g. any parameter relevant to the formation process) of the converting machine can be acquired by any suitable means (e.g. automated or manual or partially automated including by reading of a code), examples of which include: a user input (e.g. via a manufacturer of the tool 22 or sheet material 6 or by an end user of the converting machine 4 or by a converting machine manufacturer); a tool identifier (which may be physically associated with the tool, e.g. a code or an RFID); a sheet material identifier (which may be physically associated with the sheet material as defined in respect of the tool, e.g. a code or an RFID); a converting machine identifier, which may be stored in the machine electrical circuitry 14 or an identifier physically associated with the machine (as defined in respect of the tool), and; other electronic memory which may be part of or in communication with the system 2 e.g. an electronic device or a server system.

[0183] The process parameters may comprise any parameter, which may have an influence on the formation process, including one or more of: sheet material parameters; formation feature parameters; tool parameters, and; converting machine parameters; other process parameters as defined herein.

[0184] The sheet material parameters can comprise one or more of: fibre / flute parameters; material structure (e.g. corrugations of sheet); material type (e.g. paperboard or fibreboard); material thickness; material grammage; any of the aforesaid for one or more layers of a laminate.

[0185] The formation feature parameters can comprise one or more of: crease; perforation; embossing; debossing; braille; geometry of any of the aforesaid.

[0186] The tool parameter can comprise one or more of: tool formation parameters, e.g. material and / or geometry; tool identifier; tool manufacturer.

[0187] The converting machine parameter can comprise one or more of: machine identifier; machine manufacturer; calibration parameters.

[0188] In more detail, at block 154, the database is processed to determine functional links between the numerous process parameters (e.g. their values) and their effect / dependence on the pressing parameter. This can be refined by processing empirical data for numerous data sets. Whilst mathematical functions including interpolation can be implemented, particularly due to the large number of process parameters and their unknown influence on the pressing parameter such an approach is suited to machine learning.

[0189] Since the set of process parameters acquired at block 152 potentially includes a large set of parameters e.g. 10 - 50 parameters or more, it will be understood that a likelihood of an identical set of parameters occurring (e.g. in terms of their values) in the database is unlikely. However, at block 154 an optional step of determining if the acquired process parameters are identical in value to an existing set in the database can be executed, and if determined as identical, a step of looking-up the associated pressing parameter(s) for the existing set can be executed, and the looked-up pressing parameter returned. However, if the acquired process parameters have different values from any of the sets of process parameters stored in the database, then they may be determined by numerical processing of the database as discussed.

[0190] The pressing parameter determined at block 154 may comprise a single parameter value, e.g. a peak or other value of a history relationship. Alternatively, it may comprise a time or displacement history relationship.

[0191] Although the subsequent formation process for which the pressing parameter determined at block 154 is disclosed for execution as the first formation process of the in the first phase 112, in variant embodiments, it may be for execution in any stage of the first 112, second 114, third 116 or fourth 118 phases.

[0192] It will be appreciated that any of the disclosed methods (or corresponding apparatuses, programs, data carriers, etc.) may be carried out by either a host or client, depending on the specific implementation (i.e. the disclosed methods / apparatuses are a form of communication(s), and as such, may be carried out from either ‘point of view’, i.e. in corresponding to each other fashion). Furthermore, it will be understood that the terms “receiving” and “transmitting” encompass “inputting” and “outputting” and are not limited to an RF context of transmitting and receiving radio waves. Therefore, for example, a chip or other device or component for realizing embodiments could generate data for output to another chip, device or component, or have as an input data from another chip, device or component, and such an output or input could be referred to as “transmit” and “receive” including gerund forms, that is, “transmitting” and “receiving”, as well as such “transmitting” and “receiving” within an RF context.

Claims

CLAIMS1 . A system for determination of a pressing parameter for repetitive formation of objects from sheet material, the system comprising: a converting machine for execution of a formation process, in which said objects are at least partially formed from the sheet material, the converting machine including a tool for mechanical engagement with the sheet material to at least partially form said object during a formation process; electronic memory storing a database comprising, for a plurality of prior executed formation processes, empirical data relating a pressing parameter applied in a first phase of first usage of the tool that corresponds to a stabilising phase, to process parameters, which are associated with the formation process, and; system electrical circuitry configured to: acquire process parameters for a subsequent formation process; derive a pressing parameter for the subsequent formation process, which is for application in a first phase of first usage of the tool, based on the acquired process parameters and the database.

2. The system of claim 1 , wherein the system electrical circuitry is configured to: implement machine learning to determine for the database a relationship between the pressing parameter and the process parameters, and; derive a pressing parameter for the subsequent formation process using said relationship and the acquired process parameters.

3. The system of either of claims 1 or 2, wherein the acquired process parameters have different values from any of the process parameters stored in the database.

4. The system of any preceding claim, wherein the system electrical circuitry is configured to: determine if the acquired process parameters are identical in value to an entry of process parameters stored in the database, and;if determined as identical, then to obtain the pressing parameter associated with the identical entry of process parameters and implement as the pressing parameter for the subsequent formation process.

5. The system of any preceding claim, wherein the process parameters are acquired by / from one or more of: a user input; a tool identifier, an identifier read from the sheet material, and; electronic memory of or in communication with the system.

6. The system of any preceding claim, wherein the pressing parameter comprises a parameter value time or displacement history relationship or a peak value.

7. The system of any preceding claim, wherein the subsequent formation process is: any formation process executed by the tool in the first phase other than the first formation process, or; a first formation process executed by the tool in the first phase.

8. The system of any preceding claim, wherein the process parameters comprises one or more of: sheet material parameters; formation feature parameters, and; tool parameters; converting machine parameters.

9. The system of claim 8, wherein the sheet material parameters comprise one or more of: fibre / flute parameters; material structure; material type; material thickness; material grammage; any of the aforesaid for one or more layers of a laminate.

10. The system of claim 8, wherein the formation feature parameters comprises one or more of: crease; perforation; embossing; debossing; braille; geometry of any of the aforesaid.11 . The system of claim 8, wherein the tool parameters comprise one of more of: tool formation parameters; tool identifier; tool manufacturer.

12. The system of claim 8, wherein the converting machine parameters comprise one of more of: machine identifier; machine manufacturer; calibration parameters.

13. A method of determining a pressing parameter for repetitive formation of objects from sheet material to at least partially from said objects during the formation process with a converting machine including a tool for mechanical engagement with said sheet material, the method comprising: acquiring process parameters for a subsequent formation process, and; deriving a pressing parameter for the subsequent formation process, which is for application in a first phase of first usage of the tool, based on the acquired process parameters and a database comprising, for a plurality of prior executed formation processes, empirical data relating a pressing parameter applied in a first phase of first usage of the tool which corresponds to a stabilising phase to process parameters, which are associated with the formation process.

14. Electrical circuitry for a system for repetitive formation of objects or a computer program comprising program code executable on one or more processors, , to implement the method of claim 13.

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