Single Facer Corrugated Roll Unit Switching Mechanism
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Solution Overview
Problem
Existing single facers can only efficiently produce two types of single-faced cardboards, limiting their versatility and productivity in manufacturing different flute-shaped products.
Innovation Solution
A single facer equipped with a lifting/lowering device and horizontal movement device allows for the efficient switching and positioning of multiple corrugated roll units between use and standby positions, enabling the use of up to three different corrugated roll units based on production orders, with a control device managing the movement and support mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two corrugated roll units are provided in the single facer, then the single facer can manufacture two types of single-faced cardboards with high operation efficiency, but it cannot efficiently manufacture more than two types of single-faced cardboards
Solution Approach 1:
The patent introduces a vertical dimension by providing multiple levels (first level and second level) for accommodating corrugated roll units. Each level can hold multiple roll units, allowing the system to scale capacity without increasing horizontal footprint. This dimensional expansion enables manufacturing of more than two cardboard types while maintaining manageable device complexity.
Solution Approach 2:
The corrugated roll unit storage system is segmented into multiple independent levels and positions. Each level contains multiple designated positions for different corrugated roll units. This segmentation allows the system to accommodate and manage multiple roll units (more than two) in an organized manner, enabling production of various cardboard types without creating a monolithic complex structure.
2Productivity
If multiple corrugated roll units are provided to increase production versatility, then more types of single-faced cardboards can be manufactured, but the machine size and switching complexity increase
Solution Approach 1:
The system pre-arranges multiple corrugated roll units in designated positions on multiple levels before production begins. The first and second levels each have predetermined positions where different corrugated roll units are stored in advance. This preliminary arrangement enables quick switching during production without requiring complex real-time decision-making or rearrangement operations.
Solution Approach 2:
The patent implements a dynamic switching mechanism that can quickly relocate corrugated roll units between different levels and positions. The system includes movable components that can transfer roll units horizontally and vertically, enabling flexible reconfiguration. This dynamic capability allows the system to adapt to different production requirements by switching between pre-positioned roll units without excessive operational complexity.
Data Source
AI summary
A single facer equipped with a plurality of corrugated roll units each composed of a pair of corrugated rolls is provided with: a lifting/lowering device that causes each of the corrugated roll units to be lifted and lowered between a use position at which a core sheet is to be corrugated, a first position adjacent to and directly under the use position, and a second position adjacent to and directly under the first position; a horizontal movement device that causes each of the corrugated roll units to be moved horizontally between the first position, a third position adjacent to the first position on one side in a sheet transfer direction, and a fourth position adjacent to the first position on the other side in the sheet transfer direction; and a control device that controls the lifting/lowering device and the horizontal movement device to move the corrugated roll units.