Sheet Stacking Device with Distance Detection for Corrugated Box Jamming
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Solution Overview
Problem
The existing box making machines face production losses due to sheet jamming caused by corrugated cardboard boxes coming into contact with each other during the stacking process, requiring skilled operator adjustments to transport speed, interval, or air supply, which is burdensome and inefficient.
Innovation Solution
A sheet stacking device with a hopper unit, feeding unit, distance detection unit, and output unit that detects the inter-sheet distance between the rear and tip ends of the boxes and outputs a behavior stabilization command to prevent contact, adjusting the sheet feeding speed or air flow to maintain a safe distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the transport speed of corrugated cardboard boxes is increased to improve productivity, then the production efficiency increases, but the risk of sheet jamming due to contact between boxes increases
Solution Approach 1:
The system uses a distance detection unit to continuously monitor the inter-sheet distance between consecutive corrugated cardboard boxes and provides feedback to the control unit. The control unit automatically adjusts the transport speed based on this feedback, increasing speed when distance is sufficient and decreasing speed when distance becomes too small, thus preventing sheet jamming while maximizing productivity
Solution Approach 2:
The transport speed is made dynamic rather than fixed. The feeding unit automatically varies the transport speed according to real-time inter-sheet distance conditions, allowing the system to operate at high speeds when safe and slow down when necessary to prevent contact between boxes
2Reliability
If manual adjustment of transport parameters is performed to prevent sheet jamming, then the reliability of stacking improves, but the operational complexity and skill requirement increase
Solution Approach 1:
The system performs self-adjustment of transport parameters automatically. The control unit uses distance detection feedback to autonomously regulate the feeding speed without requiring operator intervention. This eliminates the need for skilled manual adjustment while maintaining high stacking reliability
Solution Approach 2:
Manual mechanical adjustment by operators is replaced with an automated control system that uses electronic distance detection and automatic speed regulation. This substitution eliminates the need for operator skill in adjusting transport parameters while achieving more consistent and reliable results
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
This solution effectively suppresses production losses from sheet jamming, improves the workability of the stacking operation, and enhances the productivity of the box making machine by ensuring stable and efficient stacking of corrugated cardboard boxes.
Implementation Method 1
an air blower device that blows air, from above, toward the corrugated cardboard box fed out by the feeding rolls to a space above the hopper unit
Implementation Method 2
the corrugated cardboard box falls due to air blown from the air blower device and its own weight
Data Source
AI summary
A sheet stacking device is provided with a hopper unit configured to stack a sheet, a feeding unit configured to feed out the sheet to the hopper unit, a distance detection unit configured to detect an inter-sheet distance, in the vertical direction, between a rear end portion of the sheet that is preceding and a tip end portion of the sheet that is subsequent, and an output unit configured to output a behavior stabilization command for the sheet based on the inter-sheet distance.