Variable Speed Squaring Plate for Counter Ejector Vibration Control
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Solution Overview
Problem
Existing box-manufacturing machines with counter ejectors face challenges in ensuring adequate squaring of cardboard boxes, particularly for larger boxes, due to fixed squaring speeds and retention intervals that can lead to insufficient squaring, and increased mechanical vibrations when trying to enhance productivity.
Innovation Solution
A box-manufacturing machine with a counter ejector featuring a reciprocation driving unit that allows for varying the speed ratio of the squaring speed to the feed speed, using an actuator and control unit to adjust the squaring speed independently of the feed speed, ensuring sufficient squaring of cardboard boxes regardless of feed speed or stack size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the squaring speed is increased to ensure adequate squaring of cardboard boxes, then the squaring quality is improved, but mechanical vibrations increase and productivity decreases
Solution Approach 1:
The patent applies dynamics by making the squaring speed variable rather than fixed. The reciprocation driving unit adjusts the squaring speed dynamically based on the feed speed and stack size, allowing the system to optimize between squaring quality and vibration control in real-time operation
Solution Approach 2:
The patent changes the parameter of squaring speed from a constant value to an adjustable parameter. By modifying the reciprocation frequency of the squaring plate according to operating conditions, the system achieves adequate squaring while controlling mechanical vibrations
2Productivity
If the feed speed is increased to enhance productivity, then the output is improved, but the retention interval for squaring is reduced leading to insufficient squaring
Solution Approach 1:
The system dynamically adjusts the squaring speed in response to changes in feed speed. When feed speed increases, the reciprocation driving unit increases the squaring speed proportionally, maintaining adequate squaring quality while supporting higher productivity
Solution Approach 2:
The control unit receives feedback about the feed speed and stack size, and uses this information to adjust the squaring speed accordingly. This feedback mechanism ensures that squaring quality is maintained regardless of feed speed variations
3Productivity
If the stack size is increased to improve productivity, then the batch output is improved, but the retention interval is reduced leading to insufficient squaring for boxes at the top of the stack
Solution Approach 1:
The reciprocation driving unit dynamically adjusts the squaring speed based on the detected stack size. When larger stacks are detected, the system increases the squaring speed to ensure adequate squaring for all boxes in the stack, including those at the top that would otherwise receive insufficient squaring
Solution Approach 2:
The system changes the squaring parameter (reciprocation frequency) based on the stack size parameter. This allows the system to maintain consistent squaring quality across different stack sizes while improving overall productivity
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 configuration ensures adequate squaring of cardboard boxes by allowing faster squaring speeds when needed, preventing insufficient squaring and reducing mechanical vibrations, thus enhancing productivity and box quality.
Implementation Method 1
cardboard boxes that are fed in the conveyance direction through a pair of upper and lower feed rolls, and advance into a hopper part (receiving space) are hit to a front stop (front stopper plate), and are allowed to fall by their self weights or a wind pressure provided by a blower
Implementation Method 2
a squaring plate (referred to as a rectification plate or a squaring bar, or sometimes referred to as a spanker since it spanks one end of a cardboard box) that is arranged facing the front stop and reciprocates in the directions approaching to or departing from the front stop. The squaring plate reciprocates at a predetermined cycle, and rectifies cardboard boxes fed and fallen to the stacking part, one by one while sandwiching them in conjunction with the front stop
Implementation Method 3
cardboard boxes that are fed in the conveyance direction through a pair of upper and lower feed rolls
Data Source
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AI summary
A squaring device is provided which enables appropriate squaring irrespective of the stack number. It is provided to a counter ejector part that stops flat cardboard boxes 10 fed from an upstream, using a front stop 28, in a downstream part of a box-manufacturing machine, receives and stacks the flat cardboard boxes in a stacking part in a hopper part 100, and ejects the stack as a batch. It includes a squaring plate 60P that, while the stacking part retains in a stack position during an retention interval, squares the cardboard boxes stacked on the stacking part, in conjunction with the front stop 28, the retention interval being set in accordance with a feed speed of the cardboard boxes 10 and a count setting for a stack 50 of the cardboard boxes. A reciprocation driving unit that drives the squaring plate 60P to reciprocate in directions approaching to or departing from the front stop, and the reciprocation driving unit is configured capable of varying a speed ratio of a squaring speed for reciprocating the squaring plate 60P, to the feed speed.