Fanfolded Web Stacking with On-the-Fly Cutting and Crease Control
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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 efficiency and adaptability to different widths.
Innovation Solution
A system comprising a feeding device, creasing device, folding device, collection device, and dynamic cutting unit that allows for high-speed stacking by forming transverse creases, alternately folding partitions, and cutting on-the-fly without altering the horizontal plane, using vertically-extending columns and movable supporting racks to maintain continuous web alignment.
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 structure is segmented into multiple independent support elements (first support element, second support element, third support element, fourth support element) that can be independently positioned and adjusted. Each support element corresponds to different fold lines (first fold line, second fold line, third fold line, fourth fold line) and can provide localized support to prevent stack deformation and press crease formation while maintaining operational simplicity.
2Ease of operation
If the support elements project in cantilever fashion and laterally retract 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 are designed with dynamic positioning capabilities, allowing them to move between different positions (projecting and retracted states) during operation. The system includes actuation mechanisms (such as motors or actuators) that enable the support elements to dynamically adjust their positions to accommodate the continuous web movement and cutting operations without compromising feeding speed.
Solution Approach 2:
The support elements are positioned in advance at predetermined locations corresponding to the fold lines before the web arrives. This preliminary positioning ensures that when the web is being processed and cut, the support elements are already in the correct positions to provide immediate support without requiring lateral retraction during critical operations, thereby maintaining feeding speed.
3Productivity
If the continuous web is cut to form stacks, then the productivity is improved, but the folding device must slow down or stop, causing press creases to form
Solution Approach 1:
The system enables continuous cutting operations without stopping or slowing down the folding device. The support elements remain in position throughout the cutting process, providing continuous support to the web and stack. The cutting unit operates in synchronization with the continuous web flow, allowing stacks to be formed and separated while the folding and support operations continue uninterrupted, preventing press crease formation while maintaining high productivity.
Data Source
AI summary
A system for stacking a fanfolded continuous web of sheet material of indefinite length, such as corrugated cardboard, includes a feeding device that guides the continuous web longitudinally, a creasing device downstream of the feeding device to form transverse creases on the continuous web with a constant longitudinal pitch to define a succession of adjacent partitions, a folding device downstream of the creasing device for progressively and alternately fanfolding adjacent partitions along the creases, and a collection device for collecting the folded web. The collection device includes a vertical column for retaining the stack of fanfolded adjacent partitions, and a cutting unit is mounted at the top of the column to act on the fly on the top adjacent partition of the stack while tracking stack-formation without stopping the folding device. A method of stacking a sheet material, such as a fanfolded continuous web of corrugated cardboard of indefinite length.