Carton Aligner Using Caster Effect and Vacuum Belts
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Solution Overview
Problem
Existing carton folder/gluer systems require high operator skill to align carton blanks correctly due to asymmetry and varying machine parameters, leading to inconsistent blank orientation and position, which affects subsequent operations like gluing and windowing.
Innovation Solution
A carton aligner system using castered wheel assemblies and a driven side guide belt to firmly grip and align carton blanks, allowing for precise alignment without the need for servo programming or extensive operator intervention, ensuring accurate speed and position sensing during the alignment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If prior art aligning section with loose contact between belts and rollers is used, then sheet can shift to become aligned with guide, but sheet speed and position are not well defined, repeatable, or predictable
Solution Approach 1:
The patent replaces the traditional mechanical aligning system with loose contact between belts and rollers with a vacuum-based system. Vacuum belts firmly grip the sheet through vacuum suction, eliminating slippage while maintaining alignment capability. The vacuum force provides consistent, predictable control of sheet speed and position throughout the aligning section, making the system both precise and reliable.
2Productivity
If carrier belts run faster than feeder belts to create spacing, then desired spacing between cartons is achieved, but carton blank twists out of desired orientation
Solution Approach 1:
The patent replaces the friction-based carrier belt system with vacuum belts that firmly grip the carton. This firm grip prevents twisting during the speed transition from feeder to carrier belts, maintaining orientation alignment even when creating spacing between cartons through differential speeds.
Solution Approach 2:
The patent changes the gripping mechanism from friction-based mechanical contact to vacuum-based adhesion. This parameter change allows for firm, controlled gripping that prevents twisting while still enabling the speed differential needed for carton spacing.
3Manufacturing precision
If numerous components and variables in aligning section are adjusted, then alignment can be achieved, but operator skill requirement increases
Solution Approach 1:
The vacuum belt system is self-aligning through the firm grip it maintains on the sheet. The vacuum force automatically keeps the sheet firmly attached and aligned without requiring numerous manual adjustments of components and variables, significantly reducing operator skill requirements.
4Measurement precision
If scanning occurs later in process after aligning, then accurate position sensing is possible, but window application position becomes inaccurate or impractical
Solution Approach 1:
The patent replaces the slippage-prone mechanical belt system with vacuum belts that firmly grip the blank. This firm grip eliminates slippage during alignment, allowing position sensing to occur earlier in the process while maintaining accurate correlation between sensed position and final window application position.
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
The system reduces operator skill requirements, improves alignment accuracy, and allows for earlier position sensing, enhancing productivity and reliability in subsequent operations by maintaining consistent speed and position of carton blanks.
Implementation Method 1
Carton blanks or sheets are conveyed on vacuum belt cartridges as is known
Implementation Method 2
a series of upper and lower castered or bias-angled rollers or wheels are positioned adjacent the vacuum belts
Data Source
AI summary
An improved apparatus and method for properly orienting and aligning flat sheets or strip material, such as in the form of folding carton blanks, on a conveying system such as used in carton folders/gluers is disclosed. A moving sheet is engaged on at least one surface by plural non-driven movable casters oriented at an angle relative to the sheet's intended direction of travel, or target direction. The casters apply a lateral force to the sheet so that a linear lateral edge of the sheet is brought into contact with an adjacent guide member aligned with the target direction, with the sheet assuming a predetermined orientation relative to the target direction. Each caster is resiliently biased such as by a spring at a predetermined angle relative to the target direction. With the sheet's lateral edge in intimate contact with the guide member, the moving sheet is in the aforementioned predetermined orientation relative to, and is displaced in, the target direction.