Compact Converting Machine Elevating Assembly and Pneumatic Elimination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing converting machines for sheet materials like paperboard and corrugated board are large, complex, and require significant space, power, and maintenance, with a need for compressed air, leading to inefficiencies and high costs.
Innovation Solution
A compact converting machine that elevates the converting assembly, uses deformable infeed wheels to minimize creases, and eliminates pneumatic components, reducing size, power consumption, and maintenance needs, while allowing for easy access and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional converting machines are used, then sheet material can be converted into box templates, but the machines occupy large floor space and are complex
Solution Approach 1:
The converting machine is divided into separate functional modules: a converting assembly that can be elevated and positioned independently, a support structure, and a base. This segmentation allows the converting assembly to be compact while maintaining full converting capability, reducing the overall footprint of the machine.
Solution Approach 2:
The converting assembly is elevated vertically above the base using the support structure with telescoping legs. By utilizing the vertical dimension, the machine achieves its converting function without requiring proportional horizontal space, effectively reducing the floor space occupied while maintaining operational capability.
2Ease of operation
If traditional converting machines are used, then converting functions are performed, but the machines require compressed air and high power sources
Solution Approach 1:
Pneumatic components and compressed air systems are replaced with electrically actuated mechanisms. The elevating support structure uses electric motors instead of pneumatic cylinders, and the converting assembly uses electric actuators for tool positioning and operation, eliminating the need for compressed air infrastructure and reducing overall power consumption.
3Productivity
If traditional converting machines are used, then box templates can be produced, but maintenance and repair are time-consuming and expensive
Solution Approach 1:
The converting assembly is designed as a self-contained modular unit that can be easily detached from the base and support structure. This segmentation allows the converting assembly to be transported to a service location for maintenance and repair, eliminating the need to move the entire machine or send the entire system for servicing, thereby reducing maintenance time and cost.
4Ease of operation
If infeed wheels are rigid, then material feeding is straightforward, but creases and deformations occur in the sheet material
Solution Approach 1:
The infeed wheels are designed with deformable properties, allowing them to change their physical state from rigid to compliant. This parameter change enables the wheels to conform to the sheet material during feeding, preventing creases and deformations while maintaining straightforward material feed operation.
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 compact design conserves space, reduces energy use, simplifies maintenance, and lowers operational costs by eliminating the need for compressed air, enhancing overall efficiency and usability.
Implementation Method 1
uses deformable infeed wheels to minimize creases
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A converting machine used to convert sheet material into packaging templates for assembly into boxes or other packaging, the converting machine comprising: a converting assembly configured to perform one or more transverse conversion functions and one or more longitudinal conversion functions on the sheet material, said converting assembly comprising: one or more longheads having one or more converting instruments that perform the one or more longitudinal conversion functions on the sheet material, wherein at least one of said one or more longheads is adapted to be selectively repositioned along a width of said converting assembly in order to make the one or more longitudinal conversion functions at different positions along the width of the sheet material; a crosshead having one or more converting instruments that perform the one or more transverse conversion functions on the sheet material, wherein said crosshead is selectively movable relative to the sheet material and along at least a portion of the width of said converting assembly in order to perform the one or more transverse conversion functions on the sheet material; and one or more guide channels through which the sheet material may be fed, the one or more guide channels comprising a fixed guide channel and a movable guide channel.