Folding Unit Curvilinear Trajectory for Tray Corner Reinforcement
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Solution Overview
Problem
Existing forming machines for producing trays with reinforced corners are cumbersome to adjust for different formats and materials, requiring manual expertise and doubling of actuation devices for asymmetrical shapes, leading to inefficiencies and increased costs.
Innovation Solution
A folding unit with a frame supporting a first folding bar moved along a curvilinear trajectory by a combination of linear actuating devices, including a first and second actuating device with rotary motors and flexible members, allowing for remote control and adjustment of bar movements for optimized folding paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional linear actuating devices are used to move folding bars, then the folding operation can be performed, but the adjustment of actuator strokes requires manual expertise and repeating attempts, increasing setup time and complexity
Solution Approach 1:
The patent changes the control parameter from manual stroke adjustment to automated position control via computer. The system stores folding trajectories as digital data and automatically controls actuator movements, eliminating the need for manual adjustment and repeating attempts. This transforms the operation from skill-dependent to system-dependent, significantly reducing setup time.
Solution Approach 2:
The patent replaces the mechanical adjustment system (manual stroke setting) with an automated control system comprising computer, data storage, and digital actuators. The computer controls the position of folding bars along predetermined trajectories by digitally controlling actuator movements, substituting manual mechanical adjustment with automated digital control.
2Adaptability or versatility
If the folding unit is designed to handle asymmetrical trays, then all shapes can be produced, but the actuating devices must be doubled, complicating the machine structure and adjustment steps
Solution Approach 1:
The patent creates a universal folding unit that can handle both symmetrical and asymmetrical trays using the same actuating devices. The computer-controlled system stores different folding trajectories for different tray types and automatically selects the appropriate trajectory, making the system multi-functional without requiring duplicate hardware for different tray configurations.
Solution Approach 2:
The patent implements a dynamic control system where the folding trajectories are stored as digital data and can be changed instantly based on the tray type. The computer dynamically adjusts the actuator control parameters and movement paths according to the specific tray geometry, allowing the same physical hardware to adapt to various asymmetrical shapes without structural modification.
3Manufacturing precision
If expert operators manually adjust the actuator strokes, then folding precision can be achieved, but the process requires repeating attempts and cannot be easily repeated
Solution Approach 1:
The patent implements a feedback mechanism where the computer stores the actual folding trajectories as digital data and uses this information to precisely control subsequent folding operations. The system monitors and records the position of folding bars throughout the process, using this feedback to ensure repeatable precision without requiring manual re-adjustment for each production run.
Solution Approach 2:
The patent performs preliminary action by pre-calculating and storing the optimal folding trajectories as digital data in the computer before production begins. These pre-stored trajectories guide the actuators to achieve precise folding from the first attempt, eliminating the need for trial-and-error adjustment during actual production and ensuring consistent repeatability.
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
Enables easy adjustment and efficient folding of die-cut panels with reinforced corners, accommodating various formats and materials, reducing setup time and costs, and allowing for instantaneous format changes and handling of asymmetrical shapes with minimal equipment.
Implementation Method 1
a first actuating device (24) provided with a first transmission (240) actuated by means of a first rotary motor (244) to move this bar (22) with a rectilinear motion; said first transmission comprising a first flexible member (242) mechanically coupled to said first rotary motor (244) through a first pulley (246)
Data Source
Figure 1~3
Figure 4~5
Figure 6~7c
AI summary
Folding unit (1) comprising a frame (10) that extends along a given direction (D) and supports a first folding bar (22) directed according to the direction (D) through the interposition of an actuating unit (20) designed to move the first bar (22) along a curvilinear trajectory (T) transverse to the given direction (D) to fold flaps (L) of a die-cut panel (P); the actuating unit (20) comprising a first actuating device (24) and a second actuating device (26) carried by the frame (10) and associated with the first bar (22) to move this latter along the trajectory (T); the first actuating device (24) (26) being provided with a first transmission (240) (262) actuated by means of a first rotary motor (244) (260) mechanically coupled to the first bar (22) to move this latter with a rectilinear motion.