Knife-Type Folding Machine Dynamic Sheet Feed Interval Control
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Solution Overview
Problem
Conventional knife-type folding machines face challenges in setting an optimal sheet feed interval, leading to sheet jams due to manual adjustments based on intuition, which are time-consuming and inefficient, and automated settings that do not account for sheet characteristics, resulting in reduced productivity.
Innovation Solution
A knife-type folding machine equipped with sensors to measure the sheet feed interval, a timer to record and calculate adjustments, and a mechanism to dynamically change the interval based on measured values, allowing for step-by-step reduction of the sheet feed interval while considering variations in delay time and knife blade motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sheet feed interval is set manually based on worker experience and visual checking, then the machine can operate without sheet jams, but the setting process takes time and effort and the interval cannot be sufficiently shortened
Solution Approach 1:
The system uses sensors to detect sheet presence and automatically measures the actual time interval between sheets. This feedback mechanism replaces manual visual checking with automated detection, allowing the system to learn optimal intervals and adjust settings dynamically to prevent sheet jams while maximizing productivity.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors, timers, and a microcomputer to determine and adjust the sheet feed interval. This substitution eliminates the need for workers to manually set intervals based on experience, automating the process to improve both reliability and productivity.
2Extent of automation
If the sheet feed interval is set automatically based on theoretical values, then the setting process is automated, but sheet characteristics such as friction and stiffness are not taken into account causing sheet jams
Solution Approach 1:
The system incorporates sensors that detect actual sheet characteristics and behavior during operation. This feedback allows the automated system to adapt to real-world variations in sheet properties like friction and stiffness, adjusting the feed interval dynamically to prevent sheet jams while maintaining automation.
Solution Approach 2:
The patent implements a dynamic adjustment mechanism where the sheet feed interval is not fixed but can be modified in real-time based on measured performance and sheet characteristics. This dynamic approach allows the automated system to respond to changing conditions and prevent sheet jams that would occur with static theoretical settings.
3Reliability
If a large sheet feed interval is used to prevent sheet jams, then sheet jam occurrence is reduced, but productivity is reduced due to excessive leeway in the interval
Solution Approach 1:
The system continuously monitors actual sheet processing times and uses this feedback to optimize the feed interval. By learning from actual performance data, the system determines the minimum safe interval needed to prevent sheet jams, eliminating excessive leeway and maximizing productivity while maintaining reliability.
Solution Approach 2:
The patent implements automatic adjustment of the sheet feed interval parameter based on measured conditions. The system dynamically changes this parameter to find the optimal balance between preventing sheet jams and maximizing productivity, rather than using a fixed conservative interval.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A sheet supplying unit (1) supplies sheets (S) one by one. A knife-type folding unit (5) folds the sheet. A first sensor (28 detects the sheet entering the folding position. A second sensor (30a, 30b) detects the sheet passing through the opening (14). A timer (31 measures a time interval from end of sheet detection by the second sensor to start of sheet detection by the first sensor. A sheet feed interval change unit (33) calculates a reduction amount of the sheet feed interval (A) using the measured values of the timer and changes the sheet feed interval based on the reduction amount each time a predetermined number of the sheets are folded.