Automated Sheet Folding Apparatus with Creasing and Gripping
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Solution Overview
Problem
The manual folding of large stacks of sheets is inefficient, time-consuming, and ergonomically challenging, leading to inconsistent results and increased risk of musculoskeletal disorders.
Innovation Solution
An automated folding system comprising a conveyor system, gripping elements, a creasing element, and control sensors that facilitate the efficient and consistent folding of stacks of sheets by forming creases and gripping the stack to ensure stability during the folding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual folding is used to prevent sheets from sliding and ensure stable folded stacks, then folding quality and stability are improved, but productivity is reduced and ergonomic difficulties increase
Solution Approach 1:
The patent replaces the manual mechanical folding system with an automated mechanical folding system. The automated folding apparatus uses mechanical conveyors, gripping elements, and creasing mechanisms to perform folding operations that were previously done manually, thereby increasing productivity while maintaining folding quality through consistent mechanical execution.
Solution Approach 2:
The folding system is designed to be self-regulating through feedback from sensors that detect sheet position, fold completion, and stack stability. The system automatically adjusts its operations to maintain folding quality without human intervention, achieving both high productivity and consistent results through automated control.
2Reliability
If manual folding is used to ensure stable folded stacks, then folding quality is improved, but ergonomic difficulties and health risks increase
Solution Approach 1:
The patent replaces manual folding operations with an automated mechanical system that handles heavy stacks of sheets. The automated apparatus performs all folding, gripping, and creasing operations mechanically, eliminating the need for operators to physically handle large stacks and perform repetitive manual folding, thereby resolving ergonomic difficulties and health risks.
3Productivity
If automated folding is implemented to improve productivity, then folding speed increases, but device complexity increases
Solution Approach 1:
The automated folding system is divided into distinct functional modules: conveyor systems for material transport, gripping elements for holding stacks, creasing mechanisms for creating fold lines, and control systems for coordination. This segmentation allows each component to be optimized independently and simplifies maintenance and operation while achieving high productivity.
4Volume of moving object
If sheets are stacked in high piles for transport, then space utilization is improved, but folding difficulty increases due to sheet sliding
Solution Approach 1:
The automated folding system applies preliminary creasing to sheets before the actual folding operation. This pre-creasing creates defined fold lines that guide the folding process and prevent sheets from sliding during manipulation, making it easier to handle high stacks of sheets and improve folding reliability.
Data Source
AI summary
According to an example aspect of the present invention, there is provided a method and apparatus for folding a stack of superposed sheets. The method comprises transferring the stack to a folding station, gripping a first part of the stack with a first grip and forming a crease on the stack to facilitate the folding. Then the at least a part of the stack is folded over the first part of the stack that has been gripped by utilizing the crease, the folded stack is gripped with a second grip and the folded stack is transferred from the folding station to a next handling stage and releasing the first grip.