Folding Helix and Guide Rail Alignment for Box Gap Control
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Solution Overview
Problem
Existing methods for folding boxes struggle to minimize gap deviations and prevent fishtailing, resulting in inconsistent box shapes and dimensions.
Innovation Solution
The method involves a folder-gluer machine with specific folding and alignment processes, including the use of folding helices and guide rails to ensure precise folding around longitudinal grooves, and a calibration module to adjust the width of the folded boxes, while offsetting the blank's position relative to the direction of advance to align the bending axis with the folding axis, thereby minimizing gap deviations and preventing fishtailing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If simultaneous folding of end flanks through 180° is performed, then folding speed is improved, but gap deviation increases and fishtailing occurs
Solution Approach 1:
The patent divides the simultaneous folding process into two sequential folding operations. The first folding operation folds one end flank through 180°, followed by a second folding operation that folds the other end flank through 180°. This segmentation allows each folding operation to be controlled and measured independently, reducing cumulative errors and preventing fishtailing while maintaining production efficiency.
2Manufacturing precision
If successive folding of right and left sides through 180° is performed, then gap control is improved, but folding time increases and productivity decreases
Solution Approach 1:
The patent segments the folding process into two distinct folding operations performed in sequence. The first operation folds one side through 180°, and the second operation folds the other side through 180°. This segmentation enables precise control of each folding action while maintaining a compact machine structure, achieving both good gap control and reasonable productivity.
3Device complexity
If blank position is not offset relative to direction of advance, then machine structure is simpler, but bending axis does not align with folding axis causing fishtailing
Solution Approach 1:
The patent introduces an asymmetric offset of the blank position relative to the direction of advance. The blank is positioned such that its longitudinal axis forms a non-zero angle with the direction of advance, creating a deliberate asymmetric configuration. This asymmetry ensures that the bending axis aligns with the folding axis during the folding operations, preventing fishtailing and producing rectangular folded boxes with equal gaps at front and back.
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 approach effectively minimizes gap deviations and eliminates fishtailing, ensuring that the gap at the front and back of the folded boxes are equal, resulting in consistently shaped rectangular boxes that meet dimensional specifications.
Implementation Method 1
a first folding operation consisting in bending through 180° a first side of the blank around a first longitudinal groove
Implementation Method 2
a first alignment operation consisting in bringing the first bent side of the blank into linear contact with a first guide rail, along the latter
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The folding method involves folding a panel (1a-1d) at 180 degrees around the longitudinal grooves (2a-2d) into a first folding device (30), and forms a longitudinal fold along the groove. A blank (1) is conveyed by a conveyor (11) from a feeder (10) and aligned along the longitudinal fold into a main aligning device (40), and folding blank at 180 degrees around the groove into a second folding device (50). An independent claim is also included for a folder-gluer.