Perfect Binder Cycle Time Division for Continuous Format Change
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Solution Overview
Problem
Existing perfect binders require time-consuming setup processes for changing printed product formats, especially for smaller print runs, as they need to be stopped and reset, which is economically disproportionate to processing time.
Innovation Solution
The cycle time of processing stations is divided into an adjusting segment for resetting and a processing segment, allowing continuous production with adjustable pitch spacing and variable motion profiles, enabling real-time adjustments during production without stopping the machine, and using sensors and control systems for precise adjustments based on product characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the perfect binder is stopped and reset for changing printed product formats, then the processing stations can be adjusted to new dimensions, but the setup time increases and productivity decreases
Solution Approach 1:
The control device determines the required format change in advance and initiates the adjustment of processing stations before the book block conveying device stops. This preliminary action allows the system to prepare for format changes proactively, minimizing the actual downtime during product transitions.
Solution Approach 2:
The system dynamically adjusts processing station configurations during operation. The control device coordinates adjustments of multiple processing stations sequentially, allowing the book block conveying device to continue operating while adjustments are made, thereby maintaining productivity while enabling format changes.
2Manufacturing precision
If the book block conveying device is stopped for resetting, then adjustments can be made accurately, but energy consumption increases and production continuity is interrupted
Solution Approach 1:
The control device determines the required format change in advance and initiates adjustments before complete stopping. This allows the system to maintain partial operation and reduce energy consumption while still achieving accurate adjustments through coordinated control of processing stations.
Solution Approach 2:
The book block conveying device continues to operate continuously during the adjustment process. The control device coordinates adjustments of processing stations sequentially while the conveying device maintains motion, ensuring uninterrupted production flow and optimal energy utilization.
3Productivity
If the pitch spacing is minimized for high-volume production, then manufacturing efficiency increases, but the ability to accommodate format changes is reduced
Solution Approach 1:
The system maintains a dynamic relationship between pitch spacing and processing station adjustments. The control device coordinates adjustments of processing stations to accommodate format changes even when pitch spacing is minimized, allowing the system to adapt to different book block dimensions while maintaining high manufacturing efficiency.
Solution Approach 2:
The control device modifies operational parameters including pitch spacing and processing station configurations based on the specific format change requirements. This allows the system to optimize for either high-volume production or format flexibility depending on the production needs.
Data Source
AI summary
In a machine (1) for manufacturing perfect-bound brochures (2) that includes a book block conveying device (10) with an endless conveying means (11), a plurality of clamps (14) that are arranged on the conveying means at a fixed pitch spacing (T) and serve for clamping book blocks (3, 3.1 . . . 3.8), and of at least one processing station (25, 18, 19, 20, 21, 22, 30) that can be adjusted in a motor-driven fashion, the cycle time (t0) referred to the conveyance of the clamps (14) by the pitch spacing (T) defined in the at least one processing station is divided into an adjusting segment (tV1, tV2) for resetting and/or adjusting the at least one processing station (25, 18, 19, 20, 21, 22, 30) in accordance with changing printed product characteristics and a processing segment (tB1, tB2) for processing the book blocks (3, 3.1 . . . 3.8) and/or covers (4, 4.1 . . . 4.4). The resetting of the at least one processing station to another printed product can take place within one work cycle (t0) of the respective processing station while the conveyance of the book blocks (3, 3.1 . . . 3.8) continues.