Cardboard Box Forming Machine Synchronization Control
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Solution Overview
Problem
Existing cardboard box-forming machines using gluing technology face limitations in increasing production speed due to unnecessary downtime between machine elements and inefficiencies in coordinating the movements of the pintle and sheet feeder, leading to reduced productivity across various box sizes.
Innovation Solution
A method and machine configuration that synchronizes the movements of the drag element, pintle, and supplying mechanism to eliminate downtime, allowing the pintle to press sheets at high speed and position them accurately for gluing, using a computer-programmable controller to manage the process and adjust for different box types and environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machine uses traditional coordination control for pintle and sheet feeder movements, then the machine can operate with simple control logic, but unnecessary downtime occurs between machine elements reducing production speed
Solution Approach 1:
The control system initiates the sheet feeder movement in advance before the pintle completes its previous cycle, so that the sheet is already in position when the pintle arrives. This preliminary action eliminates idle waiting time and allows continuous operation without downtime between cycles.
Solution Approach 2:
The control system dynamically adjusts the timing and speed of the sheet feeder based on the real-time position and speed of the pintle. By making the feed rate variable rather than constant, the system optimizes coordination to eliminate gaps and overlaps in the production cycle, maximizing productivity.
2Productivity
If the machine increases the speed of sheet feeding and glue application, then production output increases, but precision in positioning and gluing quality may deteriorate
Solution Approach 1:
The system uses periodic high-speed positioning pulses followed by holding phases, where the sheet feeder moves rapidly to the target position then maintains precise positioning during the glue application. This periodic pattern of rapid movement followed by stable holding allows both high speed and high precision.
Solution Approach 2:
The control system continuously monitors the actual position of the sheet and the timing of the pintle cycle, comparing it with the desired trajectory. Real-time feedback allows dynamic corrections to maintain positioning precision even at increased speeds, ensuring gluing quality is not compromised by higher production output.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases the speed of cardboard box formation by optimizing the coordination of machine elements, reducing downtime, and allowing for faster production of boxes of varying sizes without compromising precision or introducing additional time for glue cooling.
Implementation Method 1
a heating element arranged to heat the glue
Implementation Method 2
a stream of compressed air arranged to dry the glued parts
Data Source
AI summary
A method to form cardboard boxes by gluing into a box-forming machine from sheets, said machine, a computer program with instructions for said machine to execute said method, and a computer-readable device that has stored said computer program. In this method, a stage of the movement of inserting a pintle into a mold starts with a controlling element when the position of a drag element of sheet to a delivery position, where you place a sheet aligned between said pintle and mold, it corresponds to a second intermediate position between a source position and said delivery position; and a stage of activation of a supplying actuator starts with a controlling element to supply a sheet subsequent to the source position, when the position of said drag element corresponds to a third intermediate position between said source position and said second position.