Corrugator Web Coupling for Fast Order Changeovers
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Solution Overview
Problem
Existing corrugated board production lines are inflexible, requiring long changeover times to process different orders, which affects their efficiency.
Innovation Solution
A coupling/decoupling arrangement that allows the printing web to be used as a laminating web or decoupled from the corrugated board manufacturing arrangement, enabling separate production and handling of printing and laminating webs, with adhesive connections and devices for splicing and joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the printing device is permanently integrated into the corrugated board production line, then the production process is simplified, but the flexibility and adaptability to process different orders is reduced
Solution Approach 1:
The system enables dynamic coupling and decoupling of the printing device from the corrugated board production line through a coupling device that can connect or disconnect the printing web path from the laminating web path. This dynamic reconfiguration allows the production line to adapt between different operational modes (integrated printing vs. separate printing) based on order requirements, resolving the contradiction between operational simplicity and flexibility.
2Productivity
If the printing web is always used as the laminating web, then the production line operates continuously, but the ability to produce separate printing webs and laminating webs independently is lost
Solution Approach 1:
The system segments the web handling into separate printing web path and laminating web path, with the coupling device controlling their integration. When decoupled, each web type can be produced and handled independently by its respective subsystem, enabling separate production capabilities while maintaining the option for integrated continuous production when coupled.
Solution Approach 2:
The coupling device serves multiple functions: it can connect the printing web to the laminating web path for integrated production, disconnect them for separate production, and enable independent operation of either subsystem. This multi-functionality allows the system to adapt between continuous production mode and independent production mode based on operational requirements.
3Productivity
If the production line is configured for high-speed continuous operation, then productivity increases, but the changeover time for different orders increases
Solution Approach 1:
The dynamic coupling/decoupling mechanism allows rapid reconfiguration of the production line between different operational modes without requiring complete shutdown or complex retooling. The coupling device can be activated or deactivated quickly, enabling fast changeover between integrated and separate production modes to accommodate different order requirements while maintaining high-speed 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
Enables flexible operation of corrugated board production, allowing simultaneous production of corrugated boards and printed/laminated webs without stopping the line, enhancing efficiency and flexibility.
Implementation Method 1
The laminating web and printing web are, in particular, adhesively connectable to each other, in particular splicable, preferably using at least one adhesive strip.
Data Source
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AI summary
The invention relates to a corrugator which has a corrugated-fiberboard production assembly (1) having at least one device (5) for producing at least one corrugated fiberboard web (6) laminated on one side and having a joining device for producing a corrugated fiberboard web laminated on both sides, which comprises the at least one corrugated fiberboard web (6) laminated on one side. The corrugator also has a print-web/laminating-web production assembly (2), which comprises: a printing device (58) for printing on a print web (4); a print-web storage device (66); and a laminating-web unrolling device (70) for unrolling a laminating web (40). Furthermore, the corrugator has a coupling/uncoupling assembly (76) having a coupling device for coupling the printing device (58) to the corrugated-fiberboard production assembly (1), while the print web (4) is used as a laminating web in the corrugated-fiberboard production assembly (1), and/or having an uncoupling device for uncoupling the printing device (58) from the corrugated-fiberboard production assembly (1), while the laminating web (40) is used in the corrugated-fiberboard production assembly (1).