Sheet Stacking Device Pneumatic Control for Box Stability
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Solution Overview
Problem
High-speed production of corrugated boxes in box making machines leads to unstable behavior and damage due to improper stacking, with existing solutions either causing complexity or increasing costs through the use of drive mechanisms for flexible cams.
Innovation Solution
A sheet stacking device with a hopper unit, ejection unit, first and second blowing devices, and a control device that presses the front and rear ends of the box making sheet material differently to maintain a horizontal posture, using air to prevent damage and avoid direct contact, and a counter ejector that sorts and discharges boxes in batches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the production rate is increased, then productivity is improved, but the behavior of corrugated boxes becomes unstable and stacking becomes difficult
Solution Approach 1:
The blowing devices operate periodically rather than continuously. The control device activates the blowing devices only during specific time periods when corrugated boxes are being ejected and stacked, and deactivates them during other periods. This periodic operation maintains stacking stability at high production rates while reducing unnecessary air consumption and device complexity
Solution Approach 2:
The control device monitors the stacking process and adjusts the operation of blowing devices based on detected conditions. When instability is detected during high-speed production, the control device activates the blowing devices to provide corrective air flow, and deactivates them when stable stacking is achieved, creating a feedback control loop that maintains reliability at high productivity
2Reliability
If air is constantly blown to the corrugated box to maintain stacking, then stacking stability is improved, but lightweight and large-sized corrugated boxes are damaged due to excessive air pressure
Solution Approach 1:
The blowing devices are activated only during specific periods when corrugated boxes are being positioned on the hopper unit, and deactivated during other periods. This periodic operation provides air support only when needed for stacking stability, avoiding continuous air pressure that would damage lightweight and large-sized boxes during transfer and other operations
Solution Approach 2:
The control device adjusts the operational parameters of the blowing devices, including activation timing, air pressure, and flow rate. By dynamically changing these parameters based on the specific stacking conditions and box characteristics, the system maintains stacking stability while preventing excessive air pressure from damaging vulnerable boxes
3Manufacturing precision
If a flexible cam is used to press the sheet in the stack direction, then stacking control is improved, but drive means must be provided which complicates the device and increases costs
Solution Approach 1:
The patent replaces the mechanical flexible cam pressing system with a pneumatic system consisting of blowing devices and a control device. Instead of using mechanical drive means to rotate the flexible cam, the invention uses controlled air flow to achieve the same pressing and positioning effect, thereby eliminating the complex drive mechanism and reducing device complexity and costs
Solution Approach 2:
The invention uses pneumatic pressure from the blowing devices to press and control the positioning of corrugated boxes in the stack direction. This pneumatic approach replaces the mechanical flexible cam system, providing precise stacking control through controlled air flow rather than mechanical contact and rotation, thus eliminating the need for complex drive means
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 effectively inhibits damage to box making sheet material during high-speed transfer and ensures appropriate stacking in a predetermined posture, maintaining horizontal alignment while avoiding collisions and reducing operational complexity and costs.
Implementation Method 1
a blowing device that blows air to the box making sheet material in a transfer direction
Implementation Method 2
a first blowing device that is disposed above the downstream side of the hopper unit in a transfer direction of the box making sheet material and that presses the box making sheet material downward by blowing air
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Provided are a sheet stacking device, a counter ejector, and a box making machine that are provided with: a hopper (21) in which flattened cardboard boxes (B) are stacked; feeding rolls (22) which feed the cardboard boxes (B) to the hopper (21); a first fan (52) which is disposed above the downstream side in the transfer direction of the cardboard boxes (B) in the hopper (21) and which presses the cardboard boxes (B) downward by blowing air thereto; a second fan (53) which is disposed above the upstream side in the transfer direction of the cardboard boxes (B) in the hopper (21) and which presses the cardboard boxes (B) downward by blowing air thereto; and a control device (24) which controls the operation of the first fan (52) so as to press the front end of each of the cardboard boxes (B) downward and which also controls the operation of the second fan (53) so as to press the rear end of each of the cardboard boxes (B) downward by a pressing force stronger than that exerted on the front end.