Dynamic Breaking-Out Means for Sheet Waste Separation
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Solution Overview
Problem
Existing sheet punching and embossing machines face inefficiencies in separating blanks and waste, particularly when blanks undercut each other in the transport direction, leading to poor material economy and lengthy setup times due to the need for manual adaptation of stripping tools.
Innovation Solution
A device and method utilizing a system with a first and second transport belt, where the breaking-out means can be moved between a breaking-out position and a rest position, allowing for the separation of blanks and waste without requiring a continuous waste web, and using sensors to detect the sheet edge for timed movement of the breaking-out means, enabling efficient separation of blanks that undercut each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a movable roller presses down the leading edge of the sheet to separate waste, then waste can be drawn off, but the leading edge area must have a disproportionately wide strip of waste which affects material economy
Solution Approach 1:
The breaking-out means is designed to be movable between a breaking-out position and a rest position, allowing dynamic adjustment of the separation mechanism. This enables the system to adapt to different waste distribution patterns without requiring a continuously wide waste strip, as the breaker can be positioned only when needed for separation.
Solution Approach 2:
The waste separation function is segmented into discrete breaking-out actions rather than continuous pressing. The breaking-out means operates at specific positions and times to separate waste pieces individually, eliminating the need for a continuous wide waste strip that would be required for constant pressing contact.
2Ease of manufacture
If rigid rollers continuously deflect waste downwards, then waste can be separated, but blanks cannot undercut in the transport direction and material economy deteriorates
Solution Approach 1:
The breaking-out means transitions from a rigid continuous deflection system to a dynamic movable system. The breaker can be positioned at different locations along the transport path and activated selectively, allowing it to handle various blank distributions including undercut patterns without continuously deflecting waste that would interfere with blank transport.
Solution Approach 2:
The breaking-out means operates periodically rather than continuously, activating only when waste needs to be separated. This periodic operation allows blanks to pass through uninterrupted during their transport, enabling undercut blanks to be handled correctly while still achieving effective waste separation when required.
3Adaptability or versatility
If manual setup of stripping pins is performed, then the tool can be adapted to the sheet, but setup time increases significantly affecting productivity
Solution Approach 1:
The system uses sensors to automatically detect the leading edge and trigger the breaking-out means, eliminating the need for manual setup and adaptation. The breaking-out means self-adjusts to the sheet configuration through automated detection and positioning, significantly reducing setup time while maintaining adaptability to different sheet types.
Solution Approach 2:
Manual mechanical setup of stripping pins is replaced with an automated sensor-based detection and actuation system. The sensor detects sheet characteristics and automatically controls the breaking-out means positioning and operation, eliminating manual intervention and dramatically reducing setup time.
Data Source
AI summary
The invention relates to a device and a method, in particular a device and a method suitable for a sheet punching and embossing machine, for separating finished products and scrap material of a punched sheet while the sheet is moved in a transport direction, said finished products and scrap material adjoining one another at punching lines. The aim of the invention is to prevent the disadvantages known from the prior art, to improve the economical use of material, and to separate scrap material and finished products from such sheets, said finished products being undercut in the transport direction. This is achieved by a device with break-off means which can be moved intermittently away from the second plane and towards the second plane between a break-off position and a rest position. The invention further relates to a method which is characterized in that the application of force onto the scrap material ends before the trace of the applied force crosses an unevenly arranged punching line, and the application of force is resumed after the trace of the applied force has crossed an evenly arranged punching line.