Book Cover Machine Dynamic Format Adjustment

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Solution Overview

Problem

Existing book cover machines require time-consuming setup processes for format changes, making them economically inefficient for producing small runs of book covers with different dimensions.

Innovation Solution

The book cover machine is designed to adjust processing devices and stations during continuous production, allowing for the production of book covers in different dimensions without interrupting the process, using motorized adjustment systems and data from a control device to optimize setup times and reduce waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the book case machine is stopped for format changes, then the setup can be completed accurately, but the production time increases and productivity decreases

Engineering Contradiction:

Improveformat change accuracyVSAvoidproduction rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The machine transitions from static format changes (requiring complete stoppage) to dynamic format changes (adjustments made during continuous operation). The processing devices and stations are adjusted in time with the passage of book cases or components, allowing format changes without stopping production.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Adjustments are performed in advance during the passage of previous book cases or components. The control system coordinates adjustments so that by the time a specific book case reaches a processing station, the station is already configured for the required format.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the machine runs continuously without stopping for adjustments, then productivity is maintained, but the complexity of coordinating adjustments increases

Engineering Contradiction:

Improveproduction rateVSAvoidcontrol system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The control system continuously monitors the position and status of book cases and processing devices, and automatically coordinates adjustments based on real-time feedback. This automated feedback loop manages the complexity of coordinating multiple simultaneous adjustments during continuous operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control system serves multiple functions: it manages continuous production timing, coordinates format adjustments across multiple stations, and ensures synchronization between different processing devices. This universal control approach simplifies the management of system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of time

If setup time is reduced for small runs, then the economical production of small editions becomes possible, but the precision of format changes may be compromised

Engineering Contradiction:

Improvesetup timeVSAvoidformat change accuracy

Core Design Contradiction:

Loss of timeVSManufacturing precision

Solution Approach 1:

Manual or semi-automatic adjustment mechanisms are replaced with motorized adjustment systems controlled by a central control unit. This substitution enables rapid, precise, and repeatable format changes during continuous operation, achieving both speed and accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses parameter-based control where format specifications (dimensions, positions) are stored as data in the control system. Format changes are achieved by changing these parameters and automatically translating them into physical adjustments, ensuring precision regardless of change frequency.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If the machine is adjusted for each new format, then production flexibility is improved, but the time required for adjustments increases

Engineering Contradiction:

Improveproduction flexibilityVSAvoidadjustment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The machine maintains continuous production while adjustments are made. Instead of stopping to adjust and then producing, the system adjusts during the passage of existing book cases, ensuring that productive action continues uninterrupted throughout the format change process.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Adjustments are made periodically during the passage of book cases rather than all at once or continuously. The control system schedules adjustments to occur during natural cycles in the production process, optimizing the timing of format changes to minimize impact on overall production.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentEP2397339B2Method and device for producing book covers

Publication Date: 2024.01.24 KOLBUS GMBH & CO KG

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AI summary

The method involves supplying cover panel (4) and a rear insert (3) through a use cylinder (12) at an applicator roller (14). A book cover (8) is manufactured in different directions. An impact unit of a side impact station (43) is adjusted with the book cover. An independent claim is also included for a device for manufacturing book cover.