Fanfold Corrugated Web Stacking With Dynamic Cutting
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Solution Overview
Problem
Existing systems for stacking fanfolded continuous webs of sheet material, such as corrugated cardboard, suffer from the formation of press creases and require the folding device to slow down or stop during the cutting process, limiting the efficiency and adaptability to different widths.
Innovation Solution
A system comprising a creasing device forming transverse creases on both sides of the web, a folding device for alternate fanfolding, a collection device with a vertically-extending column, and a dynamic cutting unit that cuts on-the-fly, allowing continuous web stacking without slowing down or stopping the folding device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the conveyor belt supports the stack only along one side and along a single series of fold lines, then the device complexity is reduced, but the stack becomes deformed under its own weight and press creases are formed
Solution Approach 1:
The support function is segmented into multiple independent support elements (first and second support elements) positioned at different locations along the stack. Each support element can be independently controlled to provide localized support at critical fold lines, preventing deformation without requiring a complex continuous support structure throughout the entire stack length
Solution Approach 2:
Support is provided locally at specific critical locations (fold lines) rather than uniformly across the entire stack. The support elements are positioned precisely where needed to prevent press creases and deformation, optimizing the support structure by concentrating support efforts only where required rather than providing continuous support
2Ease of operation
If the support elements project in cantilever fashion and retract laterally to slide out of the fold lines, then the ease of operation is improved, but the feeding speed decreases and the working speed of the entire device is strongly affected
Solution Approach 1:
The support elements employ dynamic positioning with controlled lateral movement capability. They can project into the fold lines during folding operations to provide necessary support, then retract laterally when not needed. This dynamic adjustment optimizes both support functionality and processing speed by minimizing interference during high-speed operation
Solution Approach 2:
The support elements operate periodically, projecting into the fold lines only during specific phases of the folding cycle when support is required, and retracting during other phases to maintain high feeding speed. This periodic engagement ensures support is provided when necessary without continuously impeding the web feed
3Device complexity
If the latch members operate on the cardboard web on one side only at one every two fold lines, then the device complexity is reduced, but press creases are formed in the vicinity of the first latch member
Solution Approach 1:
The support function is divided into multiple independent latch members positioned at different locations and orientations. Instead of relying on a single latch member that operates on one side only, multiple latch members are distributed across different sides and fold line positions, with each providing localized support to prevent press creases at their respective locations
Solution Approach 2:
The latch members are asymmetrically positioned and oriented to match the asymmetric folding pattern. They are placed at specific fold lines where support is most needed, with different numbers and positions on each side of the web, providing targeted support precisely where press creases would form without requiring symmetric coverage
4Manufacturing precision
If the cutting operation requires the folding device to slow down or stop, then the manufacturing precision of the cut is improved, but the productivity is reduced
Solution Approach 1:
The cutting operation is performed in advance on individual partitions before they are fully stacked. The dynamic cutting unit acts on partitions as they emerge from the folding device, completing the cut while the partition is still in motion. This preliminary cutting action eliminates the need to slow down or stop the folding device for cutting operations
Solution Approach 2:
The cutting system is made dynamic with a movable cutting unit that can engage and disengage from the moving web. The cutting blade moves with the web during the cutting operation, maintaining relative position stability for precise cutting while allowing the overall system to continue running at high speed without interruption
Data Source
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AI summary
A system (1) for stacking a fanfolded continuous web (M) of sheet material of indefinite length, such as corrugated cardboard, said system (1) comprising a feeding device having means for guiding the continuous web (M) in a longitudinal direction (L), a creasing device (2) located downstream of the feeding device to form transverse creases (C) on the continuous web (M) spaced apart at a constant longitudinal pitch (K) to define a succession of adjacent partitions (P), a folding device (14) located downstream of the creasing device (2) for progressively and alternately fanfolding adjacent partitions (P) along the creases (C), a collection device (39) for collecting the web (M) folded into a stack of adjacent partitions (P), wherein the collection device (39) comprises a vertically-extending column (40) for retaining the stack of fanfolded adjacent partitions (P). A dynamic cutting unit (52) is mounted at the top of the column (40), to act on the fly on the top adjacent partition (P) of the stack while tracking stack-formation without stopping the folding device (14). A method of stacking a sheet material, such as a fanfolded continuous web (M) of corrugated cardboard of indefinite length.