Automated Metal Profile Packaging Line with Dynamic Centering

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Solution Overview

Problem

The existing production and packaging lines for metal profiles used in plasterboard walls and ceilings are inflexible, leading to high downtimes and waste due to the complexity and cost associated with changing profile lengths, which makes customized production costly and inefficient.

Innovation Solution

A line comprising a profiling machine, cutting unit, extraction bench, coupling bench, strapping machine, and package forming bench, all controlled by a management and control unit that automates adjustments to centering and strapping systems, allowing for flexible and efficient production and packaging of metal profiles to varying lengths without increasing operational complexity or costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If mechanical stops and thrust paddles are used for centering and levelling profiles, then the production line can operate with simple mechanical components, but the line lacks flexibility when changing profile lengths, resulting in excessive downtime

Engineering Contradiction:

Improveflexibility in changing profile lengthsVSAvoiddowntime for repositioning mechanical stops

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical adjustment systems with an automated computer-controlled system. The management control unit automatically positions mechanical stops and thrust paddles based on digital input of desired profile lengths, eliminating the need for manual repositioning and reducing downtime during length changes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces movable and adjustable mechanical components that can be dynamically repositioned along the production line. The mechanical stops and thrust paddles are designed to be movable rather than fixed, allowing quick adjustment to different profile lengths without requiring complete line reconfiguration.

Inventive Principle:

Principle #15Dynamics

2Productivity

If customized production of metal profiles is implemented, then installation operations become more efficient with less waste, but the complexity of packing operations increases excessively

Engineering Contradiction:

Improveinstallation efficiency and waste reductionVSAvoidcomplexity of packing operations

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent designs a universal packaging system that can handle multiple profile lengths and configurations through a single integrated line. The same mechanical stops, thrust paddles, and packaging equipment used for standard lengths are automatically repositioned and reused for customized lengths, avoiding the need for separate specialized packaging lines.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent changes operational parameters (positions of mechanical stops, spacing of packaging equipment) rather than changing the physical equipment itself. By digitally controlling the positions and timing of existing components, the system adapts to different profile lengths without adding physical complexity.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If multiple mechanical stops and thrust paddles are used for centering operations at different stages, then precise profile positioning is achieved, but the number of components requiring repositioning increases, leading to more downtime

Engineering Contradiction:

Improveprofile centering precisionVSAvoidnumber of mechanical stops and thrust paddles

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent incorporates a management control unit that coordinates the positioning of multiple mechanical stops and thrust paddles based on feedback about profile length and position. The control unit receives information about the profiles being processed and automatically adjusts each stopping and thrusting point to maintain precision without requiring manual intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent combines the control functions for multiple mechanical stops and thrust paddles into a single integrated management control unit. Rather than having independent manual adjustment mechanisms for each component, they are merged into one coordinated system that manages all positioning operations through centralized digital control.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4357259B1Line and method for producing and packaging metal profiles

Publication Date: 2024.11.06 DALLAN S R L CASTELFRANCO VENETO

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AI summary

The present invention concerns a line (1) for producing and packaging metal profiles for plasterboard walls or ceilings comprising in sequence along a profile advance direction (X): - a profiling machine (10); - a cutting unit (20); - an extraction bench (30) comprising a first profile centering system (300); - a profile coupling bench (40); - a layer forming bench (50); - a strapping machine (60) comprising an equalizing system (600); - a layer centering bench (80) comprising a second layer centering system (800); - a package forming bench (90). Said line (1) comprises a management and control unit (100) provided with a control interface (110). The first centering system (300), the equalizing system (600) and the second centering system (800) are configured to be controlled by said management and control unit (100) so as to be automatically adjusted.