Gauge Roller Recess Design for Accurate Corrugated Board Bending
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Solution Overview
Problem
The existing sheet folding devices for corrugated boards suffer from inaccurate bending due to insufficient support from gauge rollers, leading to asymmetrical shapes and varying gaps between bent portions, which decreases the quality of the corrugated boxes.
Innovation Solution
A sheet folding device with forming belts that press the corrugated board's end portions inward and gauge rollers with recessed portions on their outer surfaces, positioned to support the bent portions effectively, ensuring accurate bending and symmetrical shapes by adjusting the inclination and depth of the recessed surfaces to maintain the bent portions at appropriate positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the gauge roller has a recessed portion with width larger than the bent portion thickness, then the bent portion can be accommodated, but the bent portion is not sufficiently supported and flutters causing quality decrease
Solution Approach 1:
The gauge roller is designed with a recessed portion that has different width characteristics at different locations: the upper width is smaller than the bent portion thickness to provide support, while the lower width is larger to accommodate the bent portion. This local variation in dimensions allows the roller to simultaneously support and accommodate the bent portion, preventing flutter while maintaining bending accuracy.
2Adaptability or versatility
If the recessed portion width is increased to accommodate bent portions, then more bent portions can be supported, but the support effectiveness decreases causing asymmetrical shapes
Solution Approach 1:
The recessed portion is designed with differentiated width characteristics: the upper width is controlled to be smaller than the bent portion thickness to maintain support effectiveness and symmetry, while the lower width is larger to provide accommodation capacity. This local quality variation resolves the contradiction between support capacity and symmetry maintenance.
3Stability of the object's composition
If the gauge roller supports the bent portion at multiple points, then stability increases, but the bent portion position varies causing gap inconsistency
Solution Approach 1:
The recessed portion design creates a stable single-point support condition by having the upper width smaller than the bent portion thickness. This ensures the bent portion contacts the gauge roller at a consistent location (the deepest position), maintaining both stability and gap consistency without the problems of multi-point support.
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 improves the bending accuracy of corrugated boards by maintaining the bent portions at intermediate positions in the thickness direction, resulting in higher quality corrugated boxes with consistent gaps and improved structural integrity.
Implementation Method 1
forming belts which are disposed on both sides in a transfer direction of a corrugated board and move to a center side in a width direction of the corrugated board toward a downstream side in the transfer direction of the corrugated board to press both end portions in the width direction of the corrugated board from an outside so as to bend both the end portions
Implementation Method 2
gauge rollers which are disposed along the transfer direction of the corrugated board and come into contact with outer sides of both bent portions in the width direction of the corrugated board bent by the forming belts
Implementation Method 3
the positions of the recessed portions in a direction of the rotation axis at deepest positions are disposed to be offset downward in a vertical direction toward a downstream side in the transfer direction of the corrugated board
Data Source
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AI summary
This sheet folding device and carton folder comprises: a shaping belt (107) that is disposed on both sides of a corrugated cardboard sheet (S) in a conveyance direction (D) of the corrugated cardboard sheet (S) and that presses and folds, from the outside, both ends of the corrugated cardboard sheet (S) in the width direction of the corrugated cardboard sheet (S) by moving further toward the center in the width direction of the corrugated cardboard sheet (S) the further the corrugated cardboard sheet (S) is toward the downstream side in the conveyance direction (D) of the corrugated cardboard sheet (S); and gauge roller groups (105, 106) composed of a plurality of gauge rollers (114, 115) that are disposed along the conveyance direction (D) of the corrugated cardboard sheet (S) and contact the outer sides of folded parts (341, 342) disposed on both sides, in the width direction, of the corrugated cardboard sheet (S) that have been folded by shaping belt (107). A plurality of second gauge rollers (115) each have a recess (151) in the outer circumferential surface thereof, which is radially recessed toward a rotational axis center, and extend in the circumferential direction. The recess (151) is disposed such that the point on the rotational axis center (O) that corresponds to the deepest point (P) of the recess is at a position that is offset downward in a vertical direction, toward the downstream side in the conveyance direction (D) of the corrugated cardboard sheet (S).