Corrugated Box Feeding Control for Batch Separation
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Solution Overview
Problem
In corrugated paperboard box making machines, the increased production rate leads to shorter time intervals between the feeding of box-structured sheets, causing the main ledge to fail in accurately entering between batches, resulting in jam-ups and improper stacking of sheets.
Innovation Solution
A corrugated paperboard box making machine equipped with a speed setting unit and control apparatus that controls the sheet feeding speed and operation to stop the sheet feeding process when the set speed exceeds an allowable speed, ensuring accurate separation of box-structured sheets as batches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the production rate is increased to shorten time intervals between feeding box-structured sheets, then productivity is improved, but the main ledge fails to accurately enter between batches causing jam-ups and improper stacking
Solution Approach 1:
The control apparatus performs preliminary actions by detecting when the main ledge is in the process of moving downward and proactively stopping the sheet feeding operation before the next batch is fed. This preemptive stop prevents the main ledge from failing to enter between batches, thereby maintaining reliable batch separation even at high production rates.
Solution Approach 2:
The control apparatus uses feedback from detecting the main ledge's downward movement state to dynamically control the sheet feeding operation. When downward movement is detected, the system feedbacks a stop signal to the sheet feeding apparatus, creating a closed-loop control that ensures the main ledge can accurately enter between batches regardless of production rate.
2Productivity
If the sheet feeding speed is increased to meet higher production demands, then productivity is improved, but jam-ups occur due to improper ledge positioning
Solution Approach 1:
The control apparatus implements periodic stopping of the sheet feeding operation based on the periodic downward movement of the main ledge. By rhythmically stopping feeding whenever the ledge moves downward, the system prevents jam-ups while maintaining high overall production throughput through efficient utilization of feeding intervals.
3Productivity
If the main ledge moves continuously without stopping to maintain high throughput, then productivity is improved, but the first sheet of the next batch may fall into the hopper without being loaded
Solution Approach 1:
The control apparatus performs a preliminary stop of sheet feeding when downward movement of the main ledge is detected, ensuring that the first sheet of the next batch will be properly positioned on the ledge before feeding resumes. This preliminary action prevents sheets from falling into the hopper while maintaining high throughput.
Data Source
AI summary
Disclosed is a corrugated paperboard box making machine which comprises a sheet feeding apparatus, a processing apparatus, a folder-gluer, a counter-ejector for stacking the box-structured corrugated paperboard sheets and separating them as a batch, a speed setting unit for setting a sheet feeding speed, and a control apparatus. The control apparatus is operable to execute a sheet feeding control processing of the sheet feeding apparatus such that a sheet feeding operation of feeding one corrugated paperboard sheet is successively repeated a number of times corresponding to the number of the given number of box-structured corrugated paperboard sheets in the batch, and a sheet feeding stop control processing of, when the sheet feeding speed is greater than an allowable speed, the sheet feeding apparatus such that the sheet feeding operation is stopped at least once after execution of the sheet feeding control processing.