Overlapping Sheet Folding Machine with Dynamic Pockets
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Solution Overview
Problem
Existing folding machines face challenges in increasing productivity without deforming or damaging sheets, as higher throughput speeds lead to quality issues, and previous methods to enhance productivity are complex and prone to mechanical complications and electrostatic disruptions.
Innovation Solution
A method and folding machine design that allows overlapping feeding of sheets with a fold length overlap, enabling sheets to be folded transversely and then further processed without structural modifications, using a transport device to manage speed differences between folding stations, and incorporating adhesive, trimming, and pressing devices for producing booklets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the throughput speed of sheets through the folding machine is increased to increase productivity, then the output of the folding machine is improved, but the sheets are deformed and damaged leading to quality losses
Solution Approach 1:
The continuous stream of sheets is divided into discrete groups called signatures, where each signature contains a specific number of sheets (e.g., 8 sheets) folded together. This segmentation allows the folding process to handle sheets in manageable batches, enabling higher throughput speeds without deforming individual sheets, as the folding action is distributed across multiple sheets simultaneously rather than processing each sheet individually at high speed
2Productivity
If the folding gap widths are adjusted to increase productivity without increasing throughput speed, then the output is improved, but complicated mechanical bearings and complex control systems are required
Solution Approach 1:
The folding machine employs dynamically adjustable folding pockets with variable inlet lengths that can be changed during operation. Instead of complex mechanical bearings and control systems, the invention uses simple mechanical adjustments of pocket stops that define the inlet length of each folding pocket. This allows the folding gap to be optimized for different signature sizes while maintaining a relatively simple mechanical structure with movable folding pockets that adapt to different folding requirements
3Productivity
If successive sheets are moved at relative speeds to increase productivity, then the output is improved, but sheets are damaged and markings occur
Solution Approach 1:
The folding machine maintains all sheets within a signature at the same transport speed throughout the folding process. By keeping successive sheets at equal speed (equipotential state) as they enter and pass through the folding pockets, the invention eliminates relative movement between sheets that would cause damage and markings. The synchronized motion ensures that sheets fold together as a unified group without rubbing or friction against each other
4Productivity
If the distance between sheets is reduced to increase productivity, then the output is improved, but electrostatic charging and disruptions in the pocket inlet area occur
Solution Approach 1:
The folding machine uses folding pockets as intermediary structures that receive and guide multiple sheets simultaneously. These pockets act as mediators between the sheet feed and the folding action, providing a controlled environment where sheets are gently guided into position. The pocket structure prevents direct contact and friction between sheets that would generate electrostatic charging, while the smooth surfaces and proper geometry of the pockets eliminate disruptions in the inlet area by providing a continuous, uninterrupted path for sheet entry
Data Source
Figure 1a~1b
Figure 2a
Figure 2b
AI summary
The invention relates to a folding machine (1) and a method for overlapping the folding of sheets (7) of paper, cardboard, and the like, in a folding machine with at least one first (3) and one second (4) folding station, each having driven folding rollers (15), and a transport device (9) arranged between the first (3) and second (4) folding stations, with a drive, wherein the drives are connected to a common control unit. The products are transported in an overlapping manner between the first (3) and second (4) folding stations.