Electronic Tool Alignment for Packaging Devices
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Solution Overview
Problem
Existing devices for processing workpiece sheets, such as paper, cardboard, or plastic, require time-consuming and labor-intensive manual alignment of changeable tools, leading to significant production losses due to the need for precise adjustment and reconfiguration for different sheet formats.
Innovation Solution
A device equipped with a central electronic control unit, electronic digital sensors, and digital display devices that store and display specific setting position data for each changeable tool, allowing for automatic alignment and reducing the need for mechanical position indicators, enabling faster and more accurate tool alignment without wear-related inaccuracies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment and adjustment of changeable tools is used, then the tools can be precisely aligned with the edges of cut and adapted to different sheet formats, but the setup time increases significantly to roughly 20 minutes per tool change
Solution Approach 1:
The patent applies preliminary action by pre-defining and storing optimal holder positions in a database before actual tool changes. The system recalls these pre-stored position data when a specific changeable tool is installed, eliminating the need for time-consuming manual measurement and adjustment during each setup. This allows the operator to quickly set the holder to the predetermined position without performing alignment operations from scratch.
Solution Approach 2:
The patent uses copying by creating and storing digital copies of optimal alignment positions in a database. Instead of physically measuring and recording positions manually each time, the system creates a digital replica of the correct holder position data, which can be rapidly retrieved and applied during tool changes. This digital copying process replaces the time-intensive physical alignment process while maintaining precision.
2Measurement precision
If mechanical position indicators and manual adjustment means are used, then the holder positions can be ascertained and permanently measured, but the process requires multiple trial runs and intuitive readjustment by the operator
Solution Approach 1:
The patent implements feedback by providing a display device that shows the current holder position and the target position from the database. This visual feedback allows the operator to immediately see whether the holder is correctly positioned without requiring trial runs or intuitive judgment. The system compares the actual position with the stored optimal position and guides the operator to the correct setting, eliminating the trial-and-error process.
Solution Approach 2:
The patent replaces the mechanical measurement and adjustment system with an electronic information system. Instead of relying on mechanical position indicators and manual trial adjustments, the system uses electronic storage and display of position data to guide the adjustment process. This substitution transforms a mechanical, experience-dependent process into an electronic, data-driven process that is both more accurate and more efficient.
3Adaptability or versatility
If multiple different sheets are processed in one day, then the device must be set up several times each day, but this results in considerable production loss due to repeated alignment processes
Solution Approach 1:
The patent applies universality by creating a database that stores optimal holder positions for multiple different sheet formats and changeable tools. This universal database serves all tool change scenarios, allowing the system to quickly retrieve the appropriate position data regardless of which specific tool or sheet format is being used. The single database structure supports multiple functions and formats without requiring separate adjustment procedures for each case.
Solution Approach 2:
The patent uses preliminary action by pre-calculating and storing the optimal holder positions for all anticipated sheet formats and tool combinations in the database. When processing different sheets throughout the day, the operator simply recalls the pre-prepared position data corresponding to the current production requirements, eliminating the need to perform alignment operations from scratch for each format change.
4Loss of time
If the holder is set to previously determined positions using sticky labels and coordinate systems, then substantial time gain is achieved during reinstallation, but the process still requires manual intervention and is less accurate than automated systems
Solution Approach 1:
The patent replaces the manual sticky label and coordinate system method with an electronic database and display system. Instead of physically attaching labels and manually interpreting coordinates, the system electronically stores and retrieves position data, then displays it clearly on a screen. This electronic substitution eliminates the limitations of manual methods while maintaining the benefit of quick reinstallation.
Solution Approach 2:
The patent uses copying by creating accurate digital replicas of the holder positions in the database. These digital copies are more precise and reliable than physical sticky labels, as they can be stored without degradation and retrieved with exact accuracy. The digital copying process ensures that the position data remains consistent and error-free across multiple tool changes.
Data Source
AI summary
A device for processing workpiece sheets for packaging, includes a processing station through which the workpiece sheets are transported in succession, at least one changeable tool (2, 10, 18) that is specific to the processing and is moved against the sheet introduced in the processing station to process the sheet, at least one holder (11) on the device side for the changeable tool (2, 10, 18), the holder being adjustable for aligning the changeable tool (2, 10, 18), a central electronic control unit (37) for controlling the device, the control unit (37) having a memory for storing specific setting position data for each individual specific changeable tool (2, 10, 18), electronic digital sensors (36) for determining the current position of the holder (11), which sensors are coupled to the control unit (37), and digital display devices (38) that are coupled to the control unit (37) and display the target position and the actual position of the holder (11) or of parts coupled thereto, or display the relation of the target position and the actual position for the individual specific changeable tool (2, 10, 18).