Corrugator Control via Colored Marking Detection
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Solution Overview
Problem
In corrugated sheet and box manufacturing, existing systems face challenges in efficiently managing order changes and reducing waste due to manual adjustments and difficulties in printing on multi-layered corrugated structures, leading to inaccuracies and increased product waste.
Innovation Solution
The implementation of colored markings on the corrugated board web to indicate order changes, detected by sensors, which trigger automated adjustments in the corrugator's cutting and scoring processes, allowing for quick and accurate changes without the need for manual checking of the corrugator plan, and the use of computer-readable markers to confirm the board web's position and enable automated control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual checking and adjustment of corrugator plan is used, then flexibility in order changes is maintained, but time consumption and product waste increase
Solution Approach 1:
The patent replaces manual mechanical checking and adjustment of corrugator plans with an automated optical detection system. Sensors detect colored markings on the board web, automatically trigger order change procedures, and adjust cutting parameters without manual intervention, thereby reducing adjustment time while maintaining flexibility
Solution Approach 2:
The system enables self-service automation where the corrugator automatically detects order changes through colored markings, retrieves new order instructions from storage, and adjusts its own operating parameters without requiring manual operator intervention for each order change
2Manufacturing precision
If manual checking and adjustment of corrugator plan is used, then order accuracy can be verified, but product waste increases
Solution Approach 1:
The system performs preliminary detection of colored markings that indicate upcoming order changes. By detecting these markings in advance, the system can prepare and load the appropriate order instructions and cutting parameters before the actual order change point is reached, ensuring accurate cuts are made at the correct positions while minimizing waste material
Solution Approach 2:
The sensor system provides continuous feedback by detecting colored markings on the board web. This feedback triggers automatic retrieval of correct order instructions and adjustment of cutting parameters, ensuring that cuts are made at the precise required positions and reducing erroneous cuts that would create waste
3Productivity
If automated control with colored markings is implemented, then productivity increases, but system complexity increases
Solution Approach 1:
The patent uses colored markings printed on the board web as visual signals for order changes. This simple color-based signaling system integrates with the existing corrugator control system through sensors, enabling automated detection and response without requiring complex communication protocols or sophisticated control architecture
Solution Approach 2:
The colored markings serve as an intermediary carrier of order change information. Instead of requiring direct complex communication between detection sensors and control systems, the colored markings provide a simple, standardized interface that bridges the physical board web and the digital control system, simplifying the overall automation architecture
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 solution enables efficient and automated control of the corrugator, reducing waste and improving accuracy in cutting and forming sheet or box structures by allowing for seamless order changes and precise positioning, thereby enhancing manufacturing efficiency and productivity.
Implementation Method 1
one or more sensors may be used to detect a colored marking
Data Source
AI summary
Systems for providing efficient manufacturing of sheet or box structures, corrugate sheets, or other products of varying size and structure often with pre-applied print (“pre-print”) are provided herein. The systems include various features and modules that enable automated control of the corrugator, including the knives, slitters, scorers and cut-to-mark detection system(s), are contemplated. Colored markings may be used to indicate an order change section between two order sections of a roll plan for the manufacturing process. The colored markings are detected as the corrugator runs and, once detected, a controller determines a next set of order instructions—e.g., to match the upcoming order. Thus, an order change may occur, thereby enabling automated control of the corrugator based on the new order instructions. Computer readable markings may enable checking of the actual position in the roll plan to an intended position, enabling stopping or changing of the corrugator operation if needed.