Folder-Gluer Flap Position Correction Using Vacuum Suction
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Solution Overview
Problem
Existing folder-gluer machines face challenges in accurately positioning and correcting folded cardboard flaps due to position deviations caused by mechanical inaccuracies and variations in cardboard geometry, leading to material wastage as flawed blanks are discarded.
Innovation Solution
A method and device that uses optical detection to assess flap positions, applies glue, folds the flaps, blocks the central flap with vacuum nozzles, and corrects flap positions using suction cups with partial vacuum to ensure accurate alignment and adhesion, allowing for real-time adjustment and correction of flap positions during the folding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional folder-gluer machines are used to fold and glue flaps, then the basic folding-gluing operation is performed, but position deviations occur due to mechanical inaccuracies and cardboard geometry variations
Solution Approach 1:
The patent replaces traditional mechanical positioning systems with an optical measurement system. Optical sensors detect the actual positions of flaps and cutouts, providing precise feedback about position deviations without the mechanical contact and inaccuracies inherent in traditional systems. This substitution enables non-contact, high-precision measurement of flap positions during the folding process.
Solution Approach 2:
The patent implements a closed-loop feedback system where optical sensors continuously monitor flap positions, compare them against target positions, and provide real-time feedback for correction. The system measures actual positions, calculates deviations, and uses this information to adjust positioning in real-time, ensuring consistent accuracy despite variations in cardboard geometry or mechanical tolerances.
2Productivity
If position deviations are not corrected, then the processing speed is maintained, but material wastage increases as flawed blanks are discarded
Solution Approach 1:
The patent performs position detection and correction actions before the gluing operation is complete. By detecting position deviations early in the process and applying corrections while the blank is still being processed, the system prevents flawed products from being finalized, thereby reducing material wastage without requiring slower post-processing inspection and sorting.
Solution Approach 2:
The system enables the folder-gluer to automatically detect and correct its own positioning errors through integrated optical sensors and active correction mechanisms. This self-correction capability allows the machine to maintain high productivity by automatically compensating for deviations without requiring external intervention or manual inspection, while simultaneously reducing material wastage through real-time correction.
3Ease of manufacture
If mechanical moving parts are used for folding, then the folding operation is performed, but position deviations occur due to mechanical inaccuracies
Solution Approach 1:
The patent introduces optical measurement systems that replace reliance on purely mechanical positioning. Instead of depending solely on the precision of mechanical moving parts, the system uses optical sensors to detect actual positions and provides feedback for correction, thereby compensating for mechanical inaccuracies while maintaining the simplicity of mechanical folding operations.
4Ease of operation
If all blanks are processed with the same machine settings, then the operation is simple, but blanks with different geometric characteristics produce position deviations
Solution Approach 1:
The patent implements real-time optical detection that measures the actual geometric characteristics of each blank and provides feedback for individualized correction. This allows the system to maintain simple, consistent machine operations while automatically adapting to variations in blank geometry through feedback-driven position adjustments, thereby preserving operational simplicity without sacrificing precision.
Solution Approach 2:
The system dynamically adjusts positioning parameters based on detected geometric characteristics of each blank. By changing correction parameters in real-time according to the specific geometry of each cutout, the system maintains high precision across diverse blanks without requiring complex manual reconfiguration, thus preserving ease of operation while achieving accurate results.
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
This solution enables precise correction of flap positions, reducing material wastage by allowing only necessary corrections based on individual cardboard geometries, thereby maximizing usable blanks and ensuring reliable blocking and adhesion of the central flap.
Implementation Method 1
blocking means operating with a depression by vacuum of the lower face
Implementation Method 2
seizure of the upper face of the folded right flap and of the folded left flap
Data Source
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AI summary
The invention relates to a method for checking and correcting the position of a blank (10), comprising the following steps: closing left-hand and right-hand flaps (17, 18) one on top of the other in at least one overlap portion, checking the position of the right-hand edge (13) and the left-hand edge (14) and comparing this with a predetermined position such as to determine a position deviation; when the position deviation exceeds a permissible deviation value, before the glue sets: immobilising the central flap (19) by the underside thereof using immobilising means (71) which operate with a negative pressure by means of a vacuum, then gripping the top surface of both the right-hand flap and left-hand flap by means of at least one vacuum suction grip (21, 23, 24, 26) respectively, and correcting the position of the left-hand flap (18) and/or of the right-hand flap (17).