Buckle Plate Device Using Suction Sheet Stopping
Solution Overview
Problem
Existing buckle plate devices in folding machines are cumbersome, noisy, and prone to causing damage to sheets due to high-speed sheet transport, and they often require mechanical stops that lead to variations in print image positioning and increased noise levels.
Innovation Solution
A buckle plate device with clamping means that stops sheets without a mechanical stop, allowing for lightweight, easier-to-handle buckle plates and reduced noise by using clamping elements that act transversely to the sheet transport direction, controlled by sensors for precise sheet or print image alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical stop is used to stop sheets in the buckle plate, then the sheet stopping function is reliable, but the noise level increases and sheets may be damaged at high speeds
Solution Approach 1:
The patent replaces the traditional mechanical stop (solid rail) with a suction-based stopping mechanism. The suction means creates a vacuum field that holds the sheet in place without physical contact, eliminating the impact and noise associated with mechanical stops while maintaining reliable sheet stopping function even at high transport speeds.
2Adaptability or versatility
If buckle plates are made large to accommodate increased sheet formats, then larger sheets can be processed, but the buckle plates become heavy and difficult to handle
Solution Approach 1:
The patent replaces heavy mechanical stop components with lightweight suction means (such as suction cups or vacuum fields). This substitution significantly reduces the weight of the buckle plate while maintaining the ability to stop large format sheets, making the buckle plates easier to handle and install.
3Productivity
If sheet transport speed is increased to improve productivity, then more sheets can be processed per unit time, but noise pulses from sheet impact increase and sheets may be damaged
Solution Approach 1:
The patent uses a suction-based stopping mechanism that maintains effective sheet holding even at high transport speeds. The vacuum field adapts to the increased speed by maintaining sufficient suction force, allowing high productivity without the noise and damage problems associated with mechanical stops at high speeds.
4Reliability
If continuous stop rails are used to replace divided stop rails, then sheet stopping is more effective, but manufacturing costs increase
Solution Approach 1:
The patent replaces the continuous mechanical stop rail with distributed suction means that can be implemented as discrete elements. This substitution maintains effective sheet stopping while reducing manufacturing complexity and cost, as the suction means can be manufactured as separate, standardized components rather than requiring precision-machined continuous rails.
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
Enables high-speed sheet processing without damage or noise pulses, maintaining print image integrity and reducing the need for large, costly noise protection hoods, while allowing for flexible folding lengths and easier handling of buckle plates.
Implementation Method 1
suction means for stopping the leading edge of a sheet by a vacuum field
Data Source
AI summary
A buckle plate device for a folding machine comprises a buckle plate (10) and a sheet stopping means for stopping a sheet (24) running into the buckle plate (10) in the intake direction, wherein the sheet stopping means is formed by a clamping means (26) which clamps the incoming sheet (24) in order to stop it and preferably automatically releases the clamping at the onset of tractive forces of the subsequent rollers. Hereby a buckle plate device is provided which requires little space and makes it possible to fold sheets with comparably low noise development without a mechanical stop in a sheet-edge controlled manner or in a print-image controlled manner at a high sheet transport speed.