Switchable Sheet Guidance Device for Parallel Folding
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Solution Overview
Problem
Current production systems for printed products face productivity limitations due to speed constraints in folding machines, leading to reduced quality and increased machine downtime when producing different types of printed products.
Innovation Solution
A production system incorporating a sheet guiding device with switchable transport paths allows for uninterrupted continuous flow of printed products, enabling them to be directed to either of two transport paths, thereby reducing the burden on folding stations and allowing for lower-speed operation while maintaining high productivity, and a method utilizing a digital printing press with an intermediate processing and transfer station for efficient production of multiple types of printed products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the speed of the folding machine is increased to increase productivity, then the production output increases, but the folding accuracy and quality deteriorate
Solution Approach 1:
The folding machine is divided into multiple independent folding units (first folding unit, second folding unit, third folding unit) that can operate in parallel. Each folding unit processes a portion of the sheets independently, allowing the system to handle increased volume without requiring each individual unit to operate at higher speeds, thus maintaining folding accuracy while increasing overall productivity.
2Productivity
If a single folding station processes all sheets, then the device complexity is low, but the productivity is limited by the folding machine speed
Solution Approach 1:
The system introduces a temporal dimension to the folding process by implementing alternating operation cycles. The sheet guiding device switches between directing sheets to the first folding unit and the second folding unit in alternating fashion, while the third folding unit handles cross folds. This dimensional approach to organizing folding operations allows multiple folding actions to occur effectively in parallel, increasing productivity without requiring all folding units to be simultaneously active, thus managing device complexity.
3Productivity
If the folding machine operates at high speed to match printing machine speed, then productivity increases, but machine downtime and setup costs increase when producing different product types
Solution Approach 1:
The sheet guiding device is designed with dynamic switching capability that can be easily reconfigured for different product types. The system can dynamically alternate between folding units based on the specific production requirements, allowing quick adaptation when switching between different brochure formats or book types. This dynamic flexibility reduces setup time and machine downtime when producing different product types, as the system can be reconfigured without requiring complete line shutdowns or complex adjustments.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The device (1) has a separating point (10) provided for separating a flow of sheet to two transporting devices, where the separating point is switchable between two positions. The transporting devices are arranged in a plane, where sheet transportation directions are aligned parallel to each other by the transporting devices. The sheet is guidable during switching of separating point between the two positions. A sensor detects running in or out of the sheet into the device. A drive (12) e.g. pneumatic cylinder, switches the point between the two positions. An independent claim is also included for a sheet folding machine comprising a feeder.