Variable Die Cutter With Acceleration Gap
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Solution Overview
Problem
Existing punching technologies require a new punch cylinder or bed with a tailored punch length for each change in product length, leading to high costs and extended setup times due to the need for multiple cylinders or beds.
Innovation Solution
A device and procedure where the punch length is set larger than the arch length, allowing for variable punching of different lengths without exchanging the punch cylinder, by using an acceleration device to create a gap between arches, enabling continuous operation and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a punching cylinder with a fixed punching length is used, then the punching precision is maintained, but the adaptability to different product lengths deteriorates
Solution Approach 1:
The invention makes the previously static punching length dynamic by introducing an acceleration device that can vary the gap between sheets. The punching cylinder maintains its fixed circumference, but the effective punching length becomes adaptable through dynamic sheet acceleration, allowing the same cylinder to handle different product lengths while maintaining punching precision.
Solution Approach 2:
The invention changes the parameter of sheet gap (LL) through acceleration, allowing the effective punching length to vary without changing the punching cylinder circumference. By controlling the acceleration parameter, the system adapts to different product lengths while the punching cylinder remains fixed.
2Adaptability or versatility
If multiple punching cylinders with different circumferences are maintained for different product lengths, then the adaptability is improved, but the device complexity and maintenance costs increase
Solution Approach 1:
The invention makes a single punching cylinder universal by combining it with an acceleration device. The same punching cylinder can process different product lengths by adjusting the sheet acceleration, eliminating the need for multiple specialized cylinders and reducing device complexity while maintaining adaptability.
Solution Approach 2:
The acceleration device acts as an intermediary between the fixed punching cylinder and the variable product lengths. It mediates the mismatch by adjusting the sheet gap dynamically, allowing one cylinder to serve multiple product length requirements without direct modification to the cylinder itself.
3Manufacturing precision
If the punching cylinder circumference is precisely adjusted to match the product length, then the punching precision is improved, but the setup time and production downtime increase
Solution Approach 1:
The acceleration device is pre-configured with adjustable settings for different product lengths. Instead of physically adjusting the punching cylinder circumference during setup, the system prepares acceleration parameters in advance that can be quickly switched, maintaining punching precision while dramatically reducing setup time.
Data Source
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AI summary
The invention relates to a device for format-variable die-cutting a plurality of sheets to be die-cut, wherein each sheet has a length Lb, comprising a feeding device for sheets to be die-cut, a die-cutting unit with a die-cutting length Ls, and a die-cutting tool with an effective die-cutting tool length Lw. The object of the present invention is to provide a device and a method with which sheets of different lengths can be processed with a die-cutting length Ls, such as a die-cutting cylinder with a defined effective diameter and consequently with a defined die-cutting length Ls, without changing the cylinder. The device according to the invention is characterized in that the device includes an acceleration device for creating a gap of length LL between the fed sheets.The method according to the invention is characterized in that a sheet fed to each die-cutting device is accelerated by means of an acceleration device to create a gap with a gap length LL. Such a device and such a method have the advantage that a die-cutting bed or a die-cutting cylinder of a specific die-cutting length Ls can be used for different lengths of die-cutting patterns and thus for a plurality of product lengths, which minimizes the effort required for the acquisition, storage, and maintenance of corresponding die-cutting cylinders or die-cutting beds. Furthermore, it is not necessary to change the die-cutting cylinder or the die-cutting bed when the product length changes, which significantly reduces setup times.