Corrugated Board Process Control for Variable Raw Material Quality
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Solution Overview
Problem
The complexity of producing corrugated cardboard with consistent quality across batches is hindered by varying raw material properties and system conditions, making it challenging to achieve desired target qualities and properties, especially when dealing with different paper types and system configurations.
Innovation Solution
A computer-implemented method for dynamic process control in corrugated cardboard production, which involves characterizing end product and initial product configurations, system conditions, and adjusting process parameters using a mathematical model to simulate and optimize the production process, ensuring the corrugated cardboard meets the desired quality standards despite variations in raw materials and system parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different raw materials with varying properties are used to produce corrugated board, then the variety and flexibility of production options increase, but the consistency and uniformity of final product quality deteriorates
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting process parameters (temperature, pressure, speed, moisture content) based on the specific properties of raw materials used. The control system modifies operating parameters in real-time to compensate for variations in paper quality, moisture content, and other material properties, thereby maintaining consistent corrugated board output quality despite using different raw materials.
Solution Approach 2:
The patent implements feedback control by continuously monitoring process parameters and product quality characteristics, then using this information to adjust process settings. Sensors measure parameters such as board strength, moisture content, and dimensional stability, and the control system responds by modifying operational parameters to maintain quality specifications, creating a closed-loop control system that ensures consistency.
2Manufacturing precision
If multiple process parameters are adjusted to compensate for raw material variations, then the quality consistency improves, but the system complexity increases
Solution Approach 1:
The patent applies universality by implementing a centralized control system that manages multiple process parameters simultaneously. This single control system performs multiple functions: monitoring raw material properties, calculating required parameter adjustments, coordinating adjustments across different process stages, and verifying output quality. This multi-functional approach consolidates complexity into a unified system rather than requiring separate control mechanisms for each parameter.
Solution Approach 2:
The patent applies preliminary action by pre-programming the control system with the relationships between raw material properties and optimal process parameters. The system is pre-configured with knowledge of how different paper types, moisture contents, and material characteristics should be processed, allowing it to automatically determine the correct parameter adjustments without real-time complex calculations, thereby reducing operational complexity.
3Productivity
If tight tolerances are enforced throughout production batches, then the packaging efficiency and space utilization improve, but the production time and resource consumption increase
Solution Approach 1:
The patent applies continuity of useful action by implementing continuous process control that maintains quality parameters within specifications throughout the entire production batch without interruption. The control system operates continuously to adjust parameters, eliminating the need to stop production for quality checks or rework, thereby maintaining both tight tolerances and continuous production flow, which preserves packaging efficiency while meeting quality requirements.
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 method allows for the production of corrugated cardboard with consistent quality by dynamically adjusting process parameters, reducing waste and optimizing production time, while ensuring the desired target qualities are achieved within predetermined limits, even with varying raw material and system conditions.
Implementation Method 1
a heating element arranged to heat the coating material to a predetermined temperature
Implementation Method 2
a doctor blade arranged to remove excess coating material from the substrate
Data Source
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AI summary
The underlying invention relates in particular to a method for the dynamic process control of a corrugated board plant (1) for the production of corrugated board (2) of an end product configuration from several input products. The method comprises providing (202) several first parameter values (203) characterizing the end product configuration, acquiring (205) several second parameter values (205) characterizing an input product configuration of the input products (3, 4, 5), and acquiring (206) several plant parameter values (207) characterizing the state of the corrugated board plant (1). In the method, a process parameter data set (209) is determined based on a mathematical model (M) with the first and second parameter values (203, 205) and the plant parameter values (207) as input data.The procedure further comprises simulating (210) one or more quality images (211) characterizing the final product based on a mathematical manufacturing algorithm (H) in which process parameters from the process parameter data set (209) are used as input data. If a simulated quality image (211) meets the target quality requirements, the process parameter data set used in the simulation is provided or used for operating the corrugating machine (1) during the production of the corrugated board (2).