FI127959B - Method and apparatus for producing a board product - Google Patents

Abstract

The invention relates to a method and an apparatus for producing a carton product, wherein a carton product is formed from a cardboard material by means of at least one tool (13). According to the invention, the production of the carton product (1) is controlled by determining at least one variable by means of a determining device (5) and by controlling a selected process parameter by means of a control device (3) on the basis of the determined variable by utilizing feedback in connection with with the production of the cardboard product.

Description

METHOD AND APPARATUS FOR MANUFACTURE OF A PAPERBOARD PRODUCT

FIELD OF THE INVENTION

The invention relates to a method as defined in the preamble of claim 1 and to a device as defined in the preamble of claim 7 for producing a paperboard product.

BACKGROUND OF THE INVENTION

Various methods and design tools are known in the art for making carton products and for making carton products from carton.

CA 2409330 discloses a method and apparatus for manufacturing a packaging product by means of a tool 15. Further, WO 2009130393 and EP 1320456 disclose processes for making carton products.

PURPOSE OF THE INVENTION

It is an object of the invention to provide a new type of method for making a paperboard product. It is a further object of the invention to provide a new type of device for making a paperboard product. In particular, it is an object of the invention to provide a method and apparatus for controlling the manufacture of a paperboard product. It is a further object of the invention to provide a quality control method for controlling the quality of the board product being formed. It is a further object of the invention to provide a method for controlling the molding force in the manufacture of a molded board product.

20155371 prh 18 -03-20199

DESCRIPTION OF THE INVENTION

The method and apparatus of the invention are characterized by what is claimed.

The invention is based on a method of manufacturing a paperboard product, preferably a shaped paperboard product, wherein the paperboard product is formed from a paperboard material by at least one tool. The method controls the manufacture of a paperboard product by determining, e.g., measuring or detecting, at least one variable preferably selected from product quality property, process variable, process condition, and combinations thereof, and adjusting the selected process parameter, e.g., molding force, carton15 material positioning, heating, on the basis of a determined variable, preferably a measurement result or an observed property, and utilizing feedback in the manufacture of a paperboard product.

Further, the invention is based on an apparatus for controlling the manufacture of a carton product, wherein the apparatus is arranged in conjunction with at least one carton production tool for forming a carton product from a carton material. In addition, the device comprises at least one assay device for determining at least one variable and at least one control device for adjusting a selected process parameter based on the defined variable by utilizing feedback in the manufacture of a paperboard product.

Preferably, the board product is formed from the board material by at least one tool. The tool may be selected from a stamping tool, a cutting tool, a nailing tool, a styling tool, a finishing tool, and combinations thereof. In one embodiment, the kar35 toner product is formed from cardboard material using more than one tool. An important aspect of forming a board product is the design of the board material

20155371 prh 18 -03-20199 product, which is preferably done with a styling tool.

By cardboard material is meant herein cardboard or board blank. In one embodiment, before the first tool, talk about carton and after the tool talk about carton blank instead of carton.

In this context, the carton may be formed from any fiber-based feedstock, such as wood-based or plant-based feedstock or fiber-based composite feedstock, or combinations thereof. The starting material may be so-called. material made from fresh raw material, such as wood or plant based material, pulp, fibers or the like, or alternatively recycled material such as pulp, fibers or the like, or combinations thereof. In one embodiment, the paperboard is a paper product formed from a plurality of fiber-based layers. In one embodiment, the board is a thick paper product formed of a single fiber-based layer or sheet material. The paperboard may be of any paperboard, paperboard or other similar paper stock having a basis weight of between 170 and 600 g / m ² .

In this context, a carton blank is meant to be a piece of cardboard, e.g. a cardboard web, cut or removed, preferably of a suitable size, piece or similar, from which the carton product is formed. The cardboard blank is preferably a piece of cardboard cut to a suitable size for the product to be formed. In one embodiment, the cardboard blank is treated in the noodling step prior to forming. In one embodiment, the cardboard blank is cut from cardboard, e.g., web, prior to forming. The cardboard blank may include scratches, cuts, cuts, openings, or the like.

As used herein, the design of carton material refers to any design, modification, molding or extrusion, or any combination thereof

20155371 prh 18 -03-20199 to obtain the shape of a paperboard product, preferably by means of a forming tool. In one embodiment, the forming step of the carton material is carried out such that the opening of the carton product to be formed opens downwards. In one embodiment, the forming step of the carton material is implemented such that the opening of the carton product to be formed opens upwards.

In one embodiment, the process variable and the process parameter are the same quantity. In one embodiment, the process variable and the process parameter are the molding force. In one embodiment, the process variable and the process parameter are different quantities.

In one application, the variable is defined online. In one embodiment, 15 process parameters are adjusted in real time.

In this context, the control means any control device, control means or the like. The control device is preferably a control device known per se, which is suitable for process control in connection with the manufacture of carton products.

In one embodiment, the control device is part of a control system for a board product production line. In one embodiment, the control device is part of a control system for a tool, e.g., a shaping tool or a die tool. In one embodiment, the control device includes a variable analyzer result analyzer and a process parameter control device. In a preferred embodiment, the device for determining the selected variable, preferably the online device, is coupled to the control device. In one embodiment, the control device adjusts the molding force, e.g., by controlling the amount of compression in the molding. In one embodiment, the control device also adjusts process parameters other than an adjustable, selected process parameter based on the results of the determination. In one embodiment 35, a molding force-generating power source is provided which may be electrically adjustable.

20155371 prh 18 -03-20199

In one embodiment, the quality characteristics of the paperboard product are controlled by a control device by adjusting the desired process parameter during the production of the paperboard product. In one embodiment, the quality of the cardboard product to be formed is monitored by at least one quality feature, preferably after the cardboard article is shaped. Preferably, the board product is evaluated by determining at least one board product quality property by at least one assay method, preferably an online method. In one embodiment, the process parameter is adjusted based on the result of the determination in real time. Preferably, the adjustment of the quality characteristics is based on the principle of feedback. In one embodiment, the cardboard product 15 formed is determined to have at least one quality property, e.g., external dimension or manufacturing defect, such as rupture, improper blank placement, printing surface damage, or the like, or combinations thereof. In one embodiment, the determination is made by pattern recognition 20, machine vision, thermal imaging, or molding force measurement, or a combination thereof. In one embodiment, the board product moves on a conveyor belt or the like where the quality property determination is made. In one embodiment, the pro25 process parameter, e.g., the run parameter, is adjusted based on the detected property by feedback. In one embodiment, a paperboard product whose defined property does not meet the quality criterion of a paperboard product is recycled. By controlling the quality characteristics of the board product 30, good quality and consistent board products can be formed. Thanks to a good quality board product, the conditions for gas tight sealing of the board product can be achieved.

In one embodiment, the molding force of the carton product 35 is controlled in connection with the manufacture of the carton product. In one embodiment, the molding force is controlled by force measurement, e.g., a shaping tool

20155371 prh 18 -03-20199 or with the die cutting tool. Molding force, as used herein, refers to the force required to form carton material, which may be provided by a power source, e.g., an engine such as a stepper motor, an actuator or other suitable power source.

Preferably, the control of the molding force is based on the principle of feedback.

In one embodiment, the molding force exerted on the board material to be shaped is measured by at least one sensor. In one embodiment, the force measurement of the molding force is made by means of a force measuring instrument comprising at least one sensor. In one embodiment, the sensor is disposed with a shaping tool or die tool. In one of the 15 applications, the control device includes a device for analyzing the measurement results of the force measurement and a control device for the forming force. Preferably, in the embodiment, the force measurement measuring device or sensor is connected to the control device, and in one embodiment, to the analyzing device. In a preferred embodiment, the control device adjusts the molding force, and in one embodiment, also other process parameters, based on the measurement results. In one embodiment, a molding force generating power source is provided which may be electrically adjustable.

In one embodiment, the design and design force are controlled by a manufacturing control system. In one embodiment, the design run parameters can be controlled by a control system.

In one embodiment, at least one of the 30 process parameters is controlled based on the configuration results.

In one embodiment, at least two process parameters are controlled based on the configuration results. In one embodiment, at least two process parameters are independently controlled based on the configuration results. In one embodiment, the process parameters are controlled as a whole.

20155371 prh 18 -03-20199

The method and apparatus of the invention enable the process parameters to be adjusted according to the material properties of the cardboard material being shaped. The control of the molding force enables the shaping of carton 5 materials of different thicknesses with the same tool, such as a shaping tool or a die cutting tool. Thus, there is no need to produce separate tool parts, such as molds, for each thickness of the board material.

In one embodiment, the Melo method and apparatus of the invention may be used in conjunction with a modular board product production line. The modular board product line includes various tool modules that can be connected to that line. Preferably, the modular molding line comprises more than one tool module. Each work step may be organized in a different module or more than one work step may be combined in the same module. The working steps contained in the modules may have been selected from die cutting, such as nailing or cutting, shaping such as molding or molding, or other suitable working steps or combinations thereof. In one embodiment, the modular manufacturing line comprises a tool module which includes a design tool. In one embodiment, the carton material is shaped by a forming tool comprising a female tool part and a male tool part, one of which is moved relative to the other tool part. The number of tool modules may vary depending on the carton product being manufactured. Preferably, the tool modules are arranged sequentially in a modular board product manufacturing line. Preferably, the various tool modules are arranged in an appropriate order with respect to the manufacture of the carton product. In one embodiment, the tool module is connected to the body of a modular carton 35 production line, e.g.

by means of guides or rails arranged in connection with the frame. In one embodiment, the tool module

20155371 prh 18 -03-20199 is mobile in a modular board product line. In one embodiment, the tool module is interchangeable independently in a modular board product manufacturing line. Preferably, the tool modules are spaced apart for the intended use, and the distance between the tool modules can be changed. By changing the distances between modules, the amount of wasted material can be minimized. The carton material is preferably fed in the form of a web into the production line and through the associated tool modules. Preferably, each tool module can be used independently, but the supply of carton material through the production line is controlled as a whole. The carton material can be passed through the tool module without performing the intended work step in that module. In one embodiment, the electrification of the modules is arranged such that each module has its own electrification, and in addition, the power supply of the modular production line and the necessary bus system (ethercat) are arranged in a common electrical system of the line. Preferably, the body structure of the modular manufacturing line is arranged as an assembly that can be moved as a whole, e.g., in a shipping container.

In one embodiment, the tool comprises at least one heating means for heating the tool or a portion thereof.

Any styling tool can be used as a styling tool, which may include a male tool part and a female tool part.

The method and apparatus of the invention can be used in the manufacture of any board product. In one embodiment, the carton product is selected from the group consisting of pans, containers, cartons, like products and various combinations thereof. The device according to the invention can be used in any carton product production line, manufacturing equipment

20155371 prh 18 -03-20199 or in the manufacturing process. Further, the device of the invention can be used in a modular board product production line.

Thanks to the invention, the quality of the cartonboard product can be improved. It is also possible to improve the appearance of the board product and the sealability of the lid to be attached to the board product, thereby providing a gas-tight packaging. The control method of the invention is not critical to the thickness of the board material. Advantageously, the quality of the board product can be evaluated online and production can be controlled in real time.

The device according to the invention can be connected to industrial processes, such as the board production line of carton products and their control equipment, easily and cost-effectively. Thanks to the invention, small batches of various board products can also be manufactured in a flexible and cost-effective manner.

LIST OF FIGURES

Figure 1 illustrates an apparatus according to the invention in connection with a board product production line,

Figure 2 shows an apparatus according to the invention in connection with a carton product manufacturing line, and Figure 3 shows a carton product manufacturing line.

EXAMPLES

The invention will now be described, by way of more specific embodiments, with reference to the accompanying drawings.

Example 1

Figure 1 shows a device according to the invention in connection with a modular manufacturing line for manufacturing board-like board products. Figure 3 is a schematic diagram of a modular manufacturing line.

20155371 prh 18 -03-20199

The modular board product production line (10) of Figure 3 comprises more than one tool module (11,12,13) including a tool for shaping the board product from the board material. The line of manufacture5 includes a nailing tool (11), a cutting tool (12), and a forming tool (13) for shaping a paperboard product. The tool modules are arranged sequentially on the production line and mounted on the production line body (14) and are interchangeable and movable. The manufacturing line also includes a control system (15) for controlling the production of the carton product in the manufacturing line. Further, the production line (10) includes a device according to the invention for controlling the manufacture of a paperboard product.

The device (2) of the invention according to Figure 1 comprises at least one product quality property of the determining device (5) selected from the outer dimension, manufacturing defect such as rupture, improper blank placement, printing surface damage, and the like, and their combinations after the shaping tool (13). and adjusting the process parameter of the control device (3) selected from the molding force, carton material location, heating, other process parameter, and combinations thereof, in real-time based on the specified quality property.

Configuration is performed using pattern recognition. Feedback control is utilized in the manufacture of the board product (1). The control device includes analyzing means (6) for analyzing a determined laa30 characteristic and adjusting means (4) for adjusting a selected process parameter. The control device (3) of the device according to the invention can be arranged as part of the control system (15) of the production line. In the modular manufacturing line, the feed of carton material through the tool modules is controlled as a whole and each tool module is independently controlled by a control system (15). In the production line of Figure 1

20155371 prh 18 -03-20199 The opening of the board product to be formed opens upwards.

Example 2

Figure 2 shows a device according to the invention in connection with a modular manufacturing line for manufacturing board-like board products.

The device according to the invention can be arranged in connection with the carton product production line of Figure 3 to control the carton product manufacture.

The device (2) according to the invention of Figure 1 comprises a determining device (5) for determining the forming force online with the forming tool (13) and a control device (3) for adjusting the forming force based on the determined forming force 15. The molding force can be determined by force measurement. Feedback control is utilized in the manufacture of the board product (1). The control device comprises analyzing means (6) for analyzing force measurement results and adjusting means (4) for adjusting the molding force. The control device (3) of the device according to the invention is arranged as part of the control system (15) of the production line.

The method and apparatus according to the invention are suitable as various applications for use in controlling the equipment for manufacturing a wide variety of paperboard products and for use in the manufacture of a wide variety of paperboard products or the like.

The invention is not limited solely to the above examples, but many modifications are possible within the scope of the inventive idea defined by the claims.

Claims (11)

A process for making a carton product, wherein the carton product is formed from a carton. Material by means of at least one tool and the production of the carton product is controlled by determining an at least one variable and by controlling a selected process parameter on the basis of the determined variable by utilizing feedback in connection with the manufacture of the carton product, characterized in that the carton product is formed with shaping tools for effecting the shape of the board product and the manufacture of the board product are controlled by determining a molding force and by controlling the molding power on the basis of the defining molding power associated with the design of the board product. Process according to claim 1, characterized in that the variable is selected from the product quality characteristic, process variable, process ratio. 20 and combinations thereof. Process according to Claim 1 or 2, characterized in that the process parameter has been selected from the molding force, the positioning, heating, other process parameter and composition of the cardboard material. 25 combinations thereof. Method according to any one of claims 1 to 3, characterized in that the variable is determined online typically. The method according to any of claims 1 30 -4, characterized in that the process parameter is controlled in real time. The method according to any of claims 1 5, characterized in that the positioning of the carton product is controlled by the determination of at least a quality characteristic of the product and by controlling a process parameter selected from forming force, positioning, heating of the carton material, 20155371 prh 18/03 2019 other process parameters and combinations of these, on the basis of the determined quality property. 7. Apparatus for making a carton product, the apparatus being arranged in conjunction with At least one tool for forming a carton product of a carton material, and the device (2) comprises at least one determining device (5) for determining at least one variable and at least one control device (3) for controlling a selected process parameter on Based on the determined variable by utilizing feedback in connection with the manufacture of the carton product (1), characterized in that the device comprises at least one forming tool for shaping the carton product to achieve the shape of the carton product, and the determining device (5) is arranged to determine a molding force. in connection with the design of the cardboard product, and the control device (3) is arranged to regulate the forming force on the basis of the determined forming force. Device according to claim 7, characterized in that the control device (3) comprises analyzing means (6) for analyzing the determined variable and control means (4) for controlling the selected process parameter. Device according to claim 7 or 8, characterized in that the determining device (5) comprises at least one sensor. Device according to any of claims 7 - 9, characterized in that the determining device One (5) is based on the principle of pattern identification, artificial vision, power measurement or heat camera or combinations thereof. Device according to any of claims 7 - 10, characterized in that the device (2) can 35 is connected to a modular production line (10) for a cardboard product.