Glue Applicator Roll Gap Control via Drive Current Feedback
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Solution Overview
Problem
Existing corrugated board manufacturing processes face challenges in automatically adjusting the rider roll to glue applicator roll gap, leading to inconsistent adhesive application and potential damage to the singleface web, requiring complex mechanical mechanisms and frequent calibration.
Innovation Solution
A method that utilizes regenerative glue applicator roll drive current feedback to adjust the rider roll gap, achieving precise compression of the singleface web without additional mechanical hardware or calibration, ensuring proper adhesive transfer and preventing flute tip deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the rider roll gap is set manually by operator, then the gap can be adjusted, but the adjustment is inconsistent and requires frequent calibration
Solution Approach 1:
The patent replaces manual mechanical gap adjustment with an automated feedback control system. The rider roll gap is automatically adjusted based on real-time adhesive application monitoring, eliminating the need for complex mechanical adjustment mechanisms and frequent manual calibration while improving gap setting precision and consistency.
2Manufacturing precision
If the rider roll to glue applicator roll gap is set too tight, then adhesive application is improved, but the singleface web is deformed and damaged
Solution Approach 1:
The patent employs a feedback control system that monitors adhesive application quality in real-time and automatically adjusts the rider roll gap accordingly. This closed-loop control ensures the gap is maintained at the optimal setting that achieves consistent adhesive application without excessive compression that would deform or damage the singleface web.
3Object-affected harmful factors
If the rider roll to glue applicator roll gap is set too loose, then web damage is prevented, but adhesive application becomes insufficient
Solution Approach 1:
The feedback control system continuously monitors adhesive pickup quality and automatically adjusts the rider roll gap to maintain optimal compression. This ensures sufficient adhesive application is achieved without excessive gap settings that would prevent proper adhesive transfer to the flute tips.
4Manufacturing precision
If frequent adjustment of glue machine is made, then quality production is maintained, but productivity decreases
Solution Approach 1:
The patent implements a self-adjusting system where the glue machine automatically maintains optimal rider roll gap settings through real-time monitoring and feedback control. This eliminates the need for frequent manual adjustments by operators, thereby maintaining production quality while significantly improving productivity and reducing downtime.
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 allows for automatic and precise adjustment of the rider roll gap, reducing maintenance needs and ensuring consistent adhesive application without damaging the singleface web, thereby improving the quality and efficiency of corrugated board production.
Implementation Method 1
A method for automatic setting of the rider roll/glue applicator roll gap on a glue machine utilizes regenerative glue applicator roll drive current feedback to adjust the rider roll gap
Data Source
AI summary
A method for automatically setting the rider roll/glue applicator roll gap for the single face web on a glue machine senses a forward drag that the single face web, operating at corrugator speed, exerts on the glue applicator roll, driven at an underspeed, after bringing the flute tips of the single face web into contact with the glue applicator roll by adjusting the position of the rider roll. Changes in forward drag exerted on the glue applicator roll are monitored and related directly to glue applicator roll drive current to provide a slight compression of the single face web between the rider roll and the glue applicator roll. Preferably, the glue applicator roll uses a regenerative drive and the target drive current command in a feedback control system to cause the gap to be adjusted to achieve the desired slight compression of the web flutes and to maintain the glue applicator roll under speed.