Laminating Film Remaining-Amount Control by Sheet Size
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Solution Overview
Problem
Existing laminating systems waste laminate film due to uniform detection of near-empty film rolls, leading to increased costs and potential damage from sudden conveyance stops when smaller sheets are processed.
Innovation Solution
A laminating system that adjusts film consumption based on specific sheet sizes and conditions, using a hardware processor to calculate and manage remaining film amount dynamically, preventing unnecessary film waste and conveyance interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform near-empty detection length is used for all sheet sizes, then the lamination process can be interrupted before film runs out, but film is wastefully discarded when processing smaller sheets
Solution Approach 1:
The patent applies dynamics by making the near-empty detection length variable rather than fixed. The detection length is dynamically adjusted based on the sheet size being processed - using a first detection length for first sheet sizes and a second detection length for second sheet sizes. This allows the system to adapt the film consumption threshold to match actual usage patterns, preventing both premature interruption and unnecessary film waste.
Solution Approach 2:
The patent implements parameter changes by modifying the detection length parameter according to sheet size categories. The hardware processor changes the detection length parameter from a uniform value to different values (first detection length vs. second detection length) based on the sheet size, thereby optimizing the balance between preventing conveyance stop damage and minimizing film waste.
2Object-affected harmful factors
If film conveyance is stopped when remaining film equals maximum sheet size length, then damage is prevented, but film is wasted when processing smaller sheets
Solution Approach 1:
The patent applies local quality by tailoring the near-empty detection criteria to specific local conditions (sheet sizes). Instead of using a single uniform detection length for all cases, the system uses different detection lengths appropriate for different sheet size categories, thereby optimizing film management for each specific local situation while preventing damage to drive mechanisms.
Data Source
AI summary
A laminating system includes a laminator that performs a lamination process of overlaying a laminate film on a sheet, a conveyor that conveys the sheet to the laminator, and a hardware processor that obtains remaining amount related information that is information corresponding to a laminate film remaining amount, and changes the laminate film remaining amount in accordance with the obtained remaining amount related information.