Glue Application Roller Gap Control for Corrugated Cardboard
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Solution Overview
Problem
Existing methods for producing laminated corrugated cardboard are prone to damage of the glue application roller when it is pressed directly against the corrugated roller without a web interposed, leading to inefficiencies and potential damage.
Innovation Solution
A method involving a control device with a gap control unit and a contact pressure force control unit to automatically adjust the gap width and pressure force between the corrugating roller and the glue application roller, allowing precise control of glue application and preventing direct contact that could damage the roller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the glue application roller is pressed manually against the corrugated roller for glue application, then the glue application can be controlled, but the glue application roller can be damaged if pressed directly against the roller without a web interposed
Solution Approach 1:
The patent replaces manual mechanical adjustment of the glue application roller with an automated control system that includes sensors for detecting web presence and thickness, and actuators for automatically adjusting the roller position and pressure. This eliminates the need for manual intervention while protecting the roller from damage by preventing direct contact without a web.
Solution Approach 2:
The patent implements a feedback control system where sensors continuously monitor the presence of the web and its thickness, and this information is fed back to the control unit which automatically adjusts the glue application roller's position and pressure. This ensures the roller only contacts the corrugated roller when appropriate and maintains optimal glue application parameters.
2Manufacturing precision
If the gap width and pressure are adjusted manually, then the setup is simple, but the glue application consistency varies under different process parameters
Solution Approach 1:
The control unit receives continuous feedback from sensors about web thickness and roller position, and automatically adjusts the glue application parameters to maintain consistency. This closed-loop control ensures optimal glue application regardless of variations in process parameters or environmental conditions.
Solution Approach 2:
The system automatically changes operational parameters such as the gap width between the glue application roller and corrugated roller, and the contact pressure, based on real-time sensor data about web thickness and production conditions. This dynamic parameter adjustment maintains consistent glue application quality across varying conditions.
3Manufacturing precision
If the glue application roller is positioned close to the corrugated roller for precise glue application, then the glue application precision is improved, but the risk of roller damage increases when no web is present
Solution Approach 1:
The control system takes preliminary protective action by detecting the absence of a web through sensors before the glue application roller can contact the corrugated roller. When no web is detected, the system automatically positions the roller away from the corrugated roller or reduces pressure, preventing damage before it can occur.
Solution Approach 2:
Sensors continuously monitor whether a web is present between the rollers and provide real-time feedback to the control unit. This feedback enables the system to dynamically adjust the glue application roller's position and pressure, maintaining close proximity for precise glue application when appropriate while preventing contact when no web is present.
Data Source
Figure 1
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Figure 4~5
AI summary
The invention relates to a device for producing a corrugated board web (2) with a first corrugating roller (7) for generating a corrugated web (5). The device also has a glue application roller (19) for applying glue to the corrugated web (5). The glue application roller (19) is associated with the first corrugating roller (7) forming a gap (24) and is displaceable relative to the first corrugating roller (7) to influence the amount of glue applied. Furthermore, the device includes a displacement device (34) for displacing the glue application roller (19) relative to the first corrugating roller (7) and a pressure device (25) for pressing a laminating web (4) onto the corrugated web (5).It also includes a control device (52) which is in signal communication with the relocation device (34), a gap control unit (53) for controlling a gap width of the gap (24) between the first corrugated roller (7) and the glue application roller (19) and a contact force control unit (54) for controlling a contact force of the glue application roller (19) against the first corrugated roller (7).