Corrugated Cardboard Splice Timing for Reliable Web Detection
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Solution Overview
Problem
During the manufacturing of corrugated cardboard, paper splice parts are difficult to detect due to adhesion failures between the medium and top liner, leading to improper waveform formation and potential defects, especially when different types of liners are spliced, obstructing the detection of paper splice parts on the downstream side of the bridge.
Innovation Solution
A device and method that includes a second paper splicing device and a third paper splicing device to splice sheets, with a control device adjusting splicing times to ensure the paper splice part of the third sheet is placed downstream of the second sheet's splice, allowing detection based on the thickness of the attached sheets, and using ultrasonic and laser sensors to detect splice parts and corrugation deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If paper splicing is performed to continuously supply sheets, then sheet supply continuity is improved, but paper splice parts become defective and cannot be used as products
Solution Approach 1:
The patent applies preliminary action by detecting the paper splice part before it reaches the product output stage. The detection unit identifies splice parts upstream, and the removal unit eliminates them before they become defective products, thus maintaining both continuity and quality
Solution Approach 2:
The patent extracts the harmful splice parts from the continuous sheet stream. The removal unit specifically targets and removes detected splice parts while preserving the rest of the continuous sheet supply, separating the defective portions from the usable product
2Difficulty of detecting and measuring
If metal sheets are attached to paper splice parts for detection, then splice detection capability is improved, but detection reliability decreases when sheets meander
Solution Approach 1:
The patent replaces the mechanical detection method (metal sensor detecting metal sheets) with a non-contact optical detection system. The detection unit uses optical properties to identify splice parts, eliminating the problem of mechanical sensor failure due to sheet meandering while maintaining detection capability
Solution Approach 2:
The patent introduces an optical field as an intermediary between the splice part and the detection system. Instead of direct mechanical contact between sensor and sheet, the optical field mediates the detection process, allowing accurate detection regardless of sheet position variations
3Ease of operation
If splicing times are not coordinated, then splicing operation simplicity is maintained, but adhesion failure occurs and waveform formation becomes improper
Solution Approach 1:
The patent implements feedback control by using the detection unit to monitor splice part positions and feeding this information back to the control unit. The control unit then adjusts the splicing timing of different sheets based on detected positions, ensuring proper coordination without complicating the splicing operation
Solution Approach 2:
The patent changes the timing parameter of splicing operations dynamically. The control unit adjusts splicing timing based on detected splice part positions, modifying the temporal parameters of the splicing process to prevent adhesion failures while maintaining operational simplicity
4Device complexity
If thickness-based detection is used for paper splice parts, then detection method simplicity is improved, but detection accuracy decreases when adhesion failures occur
Solution Approach 1:
The patent uses optical property changes (analogous to color changes) to detect splice parts. The detection unit identifies splice parts based on differences in optical characteristics rather than thickness, maintaining detection simplicity while achieving accurate detection even when adhesion failures alter the physical structure
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 effectively suppresses obstructed detection of paper splice parts, ensuring accurate detection and preventing defects in the corrugated cardboard production process.
Implementation Method 1
the paper splice part of the top liner is detected by a difference between the thickness of the single-faced web at a location where the paper splice part of the top liner is not present, and the thickness of the single-faced web at a location where the paper splice part of the top liner is present
Implementation Method 2
a device is disclosed in the following Patent Literatures 1 and 2. The device for manufacturing a corrugated cardboard disclosed in Patent Literatures 1 and 2 cuts and removes a paper splice part of a sheet, after detecting the position of the paper splice part from the thickness of the corrugated cardboard sheet
Data Source
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AI summary
A device and a method for manufacturing a corrugated cardboard include a second paper splicing device that splices a succeeding sheet to a preceding sheet, which are a second sheet; a third paper splicing device that splices a succeeding sheet to a preceding sheet, which are a third sheet; a single-faced web splice detection unit that detects a third paper splice part of the third sheet, based on a thickness of a single-faced web in which the second sheet and the third sheet are attached to each another; and a control device that controls at least one of the paper splicing times of the second paper splicing device and the third paper splicing device so that the third paper splice part is placed on a downstream side of a second paper splice part of the second sheet in a sheet conveyance direction, at an attachment position of the second sheet and the third sheet.