Puffer Pan Pneumatic Scrap Removal for Corrugated Stacking
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Solution Overview
Problem
The existing sheet stacking apparatuses for corrugated paper products do not efficiently separate scrap from boxes during the conversion process, leading to increased setup times, operational inefficiencies, and maintenance challenges, particularly when changing orders or accessing sample sheets for quality inspection.
Innovation Solution
A sheet stacking apparatus with a telescoping design that allows for adjustable Layboy Roll Out, Die Board Access, and Sample Sheet provision, enabling operators to increase the RDC-Layboy Gap without stopping production, and incorporates a Puffer Pan system to manage scrap using compressed air, reducing downtime and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If compressed air is continuously used to blow scrap off the pan, then scrap removal efficiency is improved, but energy consumption increases
Solution Approach 1:
The system uses periodic pneumatic pulses instead of continuous compressed air flow. A controller activates air nozzles in sequence at different locations on the pan surface, creating periodic action waves that progressively move scrap toward the discharge location. This periodic action achieves effective scrap removal while significantly reducing energy consumption compared to continuous air flow.
Solution Approach 2:
The pneumatic action waves utilize the scrap material itself as the medium for energy transfer. Once air is introduced at one location, the scrap moves and carries the air flow to subsequent locations, where it continues to propel other scrap pieces. The scrap essentially serves the system by transporting the pneumatic energy across the pan surface, reducing the need for additional energy input at multiple locations.
2Productivity
If the RDC-Layboy Gap is increased to improve scrap separation, then scrap removal efficiency is improved, but production must be stopped for adjustment
Solution Approach 1:
The system replaces static, fixed-gap mechanical separation with a dynamic pneumatic scrap removal system. The RDC-Layboy Gap remains fixed during production, maintaining continuous operation. Instead, pneumatic action waves are dynamically activated based on detected scrap locations, allowing the system to adapt to varying scrap conditions without mechanical adjustment or production interruption.
Solution Approach 2:
The patent replaces the traditional mechanical approach of adjusting physical gaps for scrap separation with a pneumatic field-based system. Air nozzles and pneumatic action waves substitute for mechanical gap adjustment, enabling scrap removal through fluid dynamics rather than mechanical reconfiguration. This substitution eliminates the need to stop production for adjustment while maintaining effective scrap separation.
3Object-generated harmful factors
If operators manually clean scrap from difficult-to-access areas, then scrap accumulation is reduced, but time and labor resources are consumed
Solution Approach 1:
The pneumatic system provides continuous automatic scrap removal without requiring manual intervention. The controller continuously monitors the pan surface and activates pneumatic action waves to propel scrap to the discharge location. This self-service mechanism eliminates the need for operators to manually clean difficult-to-access areas, freeing them to focus on higher-value tasks while maintaining a consistently clean pan surface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances scrap removal efficiency, reduces setup times, and minimizes operational disruptions by allowing continuous production while providing easy access for Die Board changes and sample sheet inspection, thereby improving overall production efficiency and reducing maintenance needs.
Implementation Method 1
one or more air chambers that include a plurality of groups of nozzles configured to blow scrap across the pan segments
Data Source
AI summary
A puffer pan comprises a plurality of pan segments and one or more air chambers that include a plurality of groups of nozzles. Each panel segment is associated with a group of nozzles configured to blow scrap across the panel segment to at least a next location. For a subset of panel segments, the next location is an adjacent panel segment. For an end panel segment, the next location is off the puffer pan.