WO2016185097A1

WO2016185097A1 - Method and apparatus for manufacturing a paperboard product

Info

Publication number: WO2016185097A1
Application number: PCT/FI2016/050338
Authority: WO
Inventors: Mika KAINUSALMI; Ville LEMINEN; Henry Lindell; Panu Tanninen; Juha Varis
Original assignee: Lappeenrannan Teknillinen Yliopisto
Priority date: 2015-05-21
Filing date: 2016-05-20
Publication date: 2016-11-24
Also published as: FI20155371A; FI127959B

Abstract

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

Description

METHOD AND APPARATUS FOR MANUFACTURING A PAPERBOARD PRODUCT

FIELD OF THE INVENTION

The invention relates to a method as defined in the preamble of claim 1 and to an apparatus as de^¬ fined in the preamble of claim 8 for manufacturing a paperboard product. BACKGROUND OF THE INVENTION

Different kinds of methods and shaping tools are known in the prior art for manufacturing paper- board products and for shaping paperboard products from paperboard.

OBJECTIVE OF THE INVENTION

The objective of the invention is to disclose a novel method for manufacturing a paperboard product. Another objective of the invention is to disclose a novel apparatus for manufacturing a paperboard product. Specifically, the objective of the invention is to disclose a method and an apparatus for controlling the manufacture of a paperboard product. Another ob^¬ jective of the invention is to disclose a quality con- trol method for controlling the quality of a paper- board product being formed. In addition, an objective of the invention is to disclose a method for adjusting the forming force in connection with the manufacture of a shaped paperboard product.

DESCRIPTION OF THE INVENTION

The method and the apparatus according to the invention are characterized by the features set out in the claims. The invention is based on a method for manu^¬ facturing a paperboard product, preferably a shaped paperboard product, wherein the paperboard product is formed from paperboard material by means of at least one tool. In the method, the manufacture of the paper- board product is controlled by determining, e.g. by measuring or detecting, at least one variable prefera^¬ bly selected from the group of a quality characteris^¬ tic of the product, a process variable, a process con^¬ dition and combinations thereof, and by adjusting a selected process parameter, e.g. the forming force, positioning of the paperboard material, heating or other process parameter, based on the determined vari^¬ able, preferably based on the measurement result or the detected characteristic, and by utilizing feedback in connection with the manufacture of the paperboard product .

In addition, the invention is based on an apparatus for controlling the manufacture of a paperboard product, the apparatus being arranged in connection with at least one paperboard product manufacturing tool for forming the paperboard product from paperboard material. In addition, the apparatus comprises at least one de^¬ termining device for determining at least one variable, and at least one control device for adjusting a selected process parameter based on the determined variable by utilizing feedback in connection with the manufacture of the paperboard product.

Preferably, the paperboard product is formed from paperboard material by means of at least one tool. The tool may have been selected from the group of a die cutting tool, a cutting tool, a creasing tool, a shaping tool, a finishing tool and their combinations. In one embodiment, the paperboard product is formed from paper- board material by means of more than one tool. The shap^¬ ing of paperboard material into a product is important m terms of forming of the paperboard product, and it is preferably done by means of a shaping tool.

In this connection, paperboard material means paperboard or a paperboard blank. In one embodiment, be^¬ fore the first tool it is referred to as paperboard, and after the tool it is referred to as a paperboard blank instead of paperboard.

In this connection, the paperboard may have been formed from any fibre-based source material, such as wood-based or plant-based source material or fibre- based composite source material or combinations thereof. The source material may be material formed from so- called fresh raw material, such as wood- or plant-based material, pulp, fibres or the like, or alternatively re^¬ cycled material, such as pulp, fibres or the like, or their combinations. In one embodiment, paperboard is a paper product formed from several fibre-based plies. In one embodiment, paperboard is a thick paper product formed from one fibre-based ply or sheet-type material. Paperboard may be any paperboard, cardboard or other such thick paper which may have a grammage of 170 to 600 g/m².

In this connection, a paperboard blank means a preferably suitable-size portion, piece or the like, cut or removed from paperboard, e.g. a paperboard web, for forming the paperboard product. Preferably, the paperboard blank is a portion of paperboard cut to a size suitable in terms of the product being formed. In one embodiment, the paperboard blank has been treated in a creasing step before shaping. In one embodiment, the paperboard blank has been cut from paperboard, e.g. a web, before shaping. The paperboard blank may contain creases, incisions, cuts, openings or the like .

In this connection, shaping of the paperboard material means any shaping, processing, forming or pressing to shape or their combinations for providing the shape of the paperboard product, preferably by means of a shaping tool. In one embodiment, the paper- board material shaping step is carried out in a way that the mouth of the paperboard product being formed opens down. In one embodiment, the paperboard material shaping step is carried out in a way that the mouth of the paperboard product being formed opens up.

In one embodiment, the process variable and the process parameter are the same property. In one embodiment, the process variable and the process pa^¬ rameter are the forming force. In one embodiment, the process variable and the process parameter are differ^¬ ent properties.

In one embodiment, the variable is determined on an online basis. In one embodiment, the process pa^¬ rameter is adjusted in real time.

In this connection, a control device means any control device, control means or the like. The control device is preferably a control device known per se and suitable for process control in connection with the manufacture of a paperboard product.

In one embodiment, the control device is part of the control system of the paperboard product manu- facturing line. In one embodiment, the control device is part of the control system of a tool, e.g. a shap^¬ ing tool or a die cutting tool. In one embodiment, the control device comprises a device for analysing the results of determining the variable and a device for adjusting the process parameter. In a preferred embod^¬ iment, the device for determining the selected varia^¬ ble, preferably an online determining device, is con^¬ nected to the control device. In one embodiment, the control device adjusts the forming force, e.g. by con- trolling the amount of pressure in the shaping. In one embodiment, the control device also adjusts other pro- cess parameters, in addition to the selected process parameter being adjusted, based on the determination results. In one embodiment, the power source producing the forming force is adjusted, which power source may be electrically adjustable.

In one embodiment, the quality characteris^¬ tics of the paperboard product are controlled by means of the control device by adjusting the selected pro^¬ cess parameter in connection with the manufacture of the paperboard product. In one embodiment, the quality of the paperboard product being formed is controlled by means of at least one quality characteristic, pref^¬ erably after the shaping of the paperboard product. Preferably, the paperboard product is evaluated by de- termining at least one quality characteristic of the paperboard product by at least one determining method, preferably an online method. In one embodiment, the process parameter is adjusted based on the determina^¬ tion result in real time. Preferably, the adjustment of the quality characteristics is based on the princi^¬ ple of feedback. In one embodiment, at least one qual^¬ ity characteristic is determined in the formed paper- board product, e.g. an outer dimension or a manufac^¬ turing defect, such as a tear, wrong blank position- ing, damage in the printing surface or the like, or combinations thereof. In one embodiment, the determi^¬ nation is done by means of pattern recognition, by means of machine vision, by means of a thermographic camera or by means of measurement of the forming force or by means of a combination thereof. In one embodi^¬ ment, the paperboard product moves on a conveyor belt or the like on which the determination of the quality characteristic is conducted. In one embodiment, the process parameter, e.g. an operating parameter, is ad- justed based on the detected characteristic by means of feedback. In one embodiment, a paperboard product having a determined characteristic not meeting a pa^¬ perboard product quality criterion is conveyed for waste. By controlling the quality characteristics of the paperboard product it is possible to form good- quality and consistent-quality paperboard products. By means of a good-quality paperboard product, conditions for gas-tight closure of the paperboard product can be achieved .

In one embodiment, the forming force for the paperboard product is controlled in connection with the manufacture of the paperboard product. In one em^¬ bodiment, the forming force is adjusted by means of force measurement, e.g. in connection with a shaping tool or a die cutting tool. In this connection, the forming force means the force required in the shaping of paperboard material, which can be produced by means of a power source, e.g. by means of a motor, such as a stepper motor, an actuator or other suitable power source. Preferably, the adjustment of the forming force is based on the principle of feedback.

In one embodiment, the forming force applied to the paperboard material being shaped is measured by means of at least one sensor. In one embodiment, the force measurement of the forming force is done by means of a force measuring device which comprises at least one sensor. In one embodiment, the sensor is disposed in connection with a shaping tool or a die cutting tool. In one embodiment, the control device comprises a device for analysing the results of force measurement, and a device for adjusting the forming force. In the embodiment, the force measuring device or the sensor is preferably connected to the control device, and in one embodiment to the analysing device. The control device preferably adjusts the forming force, and in one embodiment also other process param^¬ eters, based on the measurement results. In one embod- iment, the power source producing the forming force is adjusted, which power source may be electrically ad- j ustable .

In one embodiment, the shaping and the shap- ing force are controlled by means of the manufacture control system. In one embodiment, the operating pa^¬ rameters for shaping can be adjusted by means of the control system.

In one embodiment, at least one process pa- rameter is controlled based on the determination results. In one embodiment, at least two process parame^¬ ters are controlled based on the determination re^¬ sults. In one embodiment, at least two process parame^¬ ters are controlled independently based on the deter- mination results. In one embodiment, the process pa^¬ rameters are controlled as a whole.

The method and the apparatus according to the invention allow adjustment of the process parameters according to the material characteristics of the pa- perboard material being shaped. By adjusting the form^¬ ing force, paperboard materials of different thick^¬ nesses can be shaped by the same tool, such as a shap^¬ ing tool or a die cutting tool. Thus, separate tool parts, such as dies, need not be manufactured for each thickness of paperboard material.

In one embodiment, the method and the appa^¬ ratus according to the invention can be used in connection with a modular paperboard product manufacturing line. A modular paperboard product manufacturing line comprises different tool modules which are con- nectable to the manufacturing line. Preferably, the modular manufacturing line comprises more than one tool module. Each work stage may have been arranged at a different module, or more than one work stages may have been combined at the same module. The work stages of the modules may have been selected from the group of die cutting, such as creasing or cutting, shaping, such as forming or form-pressing, or other suitable work stage or their combinations. In one embodiment, the modular manufacturing line comprises a tool module provided with a shaping tool. In one embodiment, the paperboard material is shaped by means of a shaping tool which comprises a female tool element and a male tool element, one of the tool elements being moved relative to the other tool element. The number of tool modules may vary depending on the paperboard product being manufactured. The tool modules are preferably arranged one behind another on the modular paperboard product manufacturing line. Preferably, different tool modules are arranged in a suitable order considering the manufacture of the paperboard product. In one em^¬ bodiment, the tool module is connected to the frame of the modular paperboard product manufacturing line, e.g. by means of guides or by means of tracks arranged in connection with the frame. In one embodiment, the tool module is moveable on the modular paperboard product manufacturing line. In one embodiment, the tool module is independently replaceable on the modu^¬ lar paperboard product manufacturing line. Preferably, the tool modules are arranged at such distance from each other as their function requires, and the distance between the tool modules can be changed. By changing the distances between the modules it is pos^¬ sible to minimize the amount of waste material. The paperboard material is preferably fed in the form of a web to the manufacturing line and through the tool modules connected thereto. Preferably, each tool mod^¬ ule can be operated independently, but the feeding of paperboard material through the manufacturing line is controlled as a whole. The paperboard material can be passed through the tool module without the module per^¬ forming its work stage. In one embodiment, the elec- trification of the modules is arranged in such a way that each module is provided with independent electri^¬ fication and, in addition, the current supply and the necessary bus system (ethercat) of the modular manu- facturing line are arranged in the common electrical system of the line. Preferably, the frame structure of the modular manufacturing line is arranged as a unit which can be moved as one piece, e.g. in a transporta^¬ tion container.

In one embodiment, the tool comprises at least one heating means for heating the tool or part of it .

As the shaping tool it is possible to use any shaping tool which may comprise a male tool element and a female tool element.

The method and the apparatus according to the invention may be used in the manufacture of any paper- board product. In one embodiment, the paperboard prod^¬ uct is selected from the group of trays, dishes, con- tainers, suchlike products and different combinations thereof. The apparatus according to the invention may be used with any paperboard product manufacturing line, manufacturing equipment or manufacturing process. In addition, the apparatus according to the in- vention may be used on a modular paperboard product manufacturing line.

By means of the invention it is possible to improve the quality of a paperboard product. Thus, it is also possible to improve the appearance of the pa- perboard product and seamability of a lid added to the paperboard product, and thereby the production of a gas-tight package. The control method according to the invention is not critical in terms of thickness of the paperboard material. Advantageously, the quality of the paperboard product can be evaluated on an online basis and its manufacture can be controlled in real time .

The apparatus according to the invention may be connected to industrial processes, such as to a pa- perboard product manufacturing line and to the control equipment thereof, in an easy and cost-effective way. Small batches of different paperboard products can al^¬ so be flexibly and cost-effectively manufactured by means of the invention.

LIST OF FIGURES

Fig. 1 illustrates one apparatus according to the invention in connection with a paperboard product manufacturing line,

Fig. 2 illustrates one apparatus according to the invention in connection with a paperboard product manufacturing line, and

Fig. 3 illustrates one paperboard product manufacturing line.

EXAMPLES

The invention will now be described by way of detailed examples of its embodiments with reference to the accompanying figures.

Example 1

Fig. 1 illustrates the apparatus according to the invention in connection with a modular manufacturing line on which tray-type paperboard products are manufactured. A modular manufacturing line is schemat^¬ ically illustrated in Fig. 3.

The modular paperboard product manufacturing line (10) of Fig. 3 comprises more than one tool mod^¬ ules (11,12,13) which comprise a tool for shaping the paperboard product from paperboard material. The manu^¬ facturing line comprises a creasing tool (11), a cut- ting tool (12) and a shaping tool (13) for shaping the paperboard product. The tool modules are arranged one behind another on the manufacturing line and attached to a frame (14) of the manufacturing line, and they are replaceable and moveable. In addition, the manu^¬ facturing line comprises a control system (15) for controlling the manufacture of the paperboard product on the manufacturing line. The manufacturing line (10) also comprises the apparatus according to the inven- tion for controlling the manufacture of the paperboard product .

The apparatus (2) according to the invention of Fig. 1 comprises a determining device (5) for determining at least one product quality characteristic which is selected from the group of an outer dimension, a manufacturing defect, such as a tear, wrong blank positioning, damage in the printing surface or the like, and their combinations after the shaping tool (13) on an online basis, and a control device (3) for adjusting a process parameter selected from the group of forming force, positioning of the paperboard material, heating, other process parameter and their combinations based on the determined quality charac^¬ teristic in real time. The determination is done by means of pattern recognition. The manufacture control utilizes feedback in connection with the manufacture of the paperboard product (1) . The control device compris^¬ es analysing means (6) for analysing the determined quality characteristic and adjusting means (4) for ad- justing the selected process parameter. The control device (3) of the apparatus according to the invention may be arranged as part of the control system (15) of the manufacturing line. On the modular manufacturing line, the feeding of paperboard material through the tool modules is controlled as a whole, and each tool module is controlled independently by means of the control system (15) . The mouth of the paperboard prod^¬ uct being formed on the manufacturing line of Fig. 1 opens up. Example 2

Fig. 2 illustrates the apparatus according to the invention in connection with a modular manufacturing line on which tray-type paperboard products are manufactured .

The apparatus according to the invention may be arranged in connection with the paperboard product manufacturing line illustrated in Fig. 3 for control^¬ ling the manufacture of the paperboard product.

The apparatus (2) according to the invention of Fig. 1 comprises a determining device (5) for determining the forming force in connection with the shaping tool (13) on an online basis, and a control device (3) for adjusting the forming force based on the determined forming force in real time. The forming force may be determined by means of force measurement. The manufacture control utilizes feedback in connection with the manufacture of the paperboard product (1) . The con^¬ trol device comprises analysing means (6) for analys^¬ ing the force measurement results and adjusting means (4) for adjusting the forming force. The control device (3) of the apparatus according to the invention is arranged as part of the control system (15) of the manufacturing line. The method and the apparatus according to the invention are suitable, as various embodiments, for use in providing the control of manufacturing devices for paperboard products of various types, and for use in connection with the manufacture of various paper- board products or the like. The invention is not exclusively limited to the above examples, but many variations are possible within the scope of the inventive idea defined by the claims .

Claims

1. A method for manufacturing a paperboard product, wherein the paperboard product is formed from paperboard material by means of at least one tool, and the manufacture of the paperboard product is controlled by determining at least one variable and by adjusting a selected process parameter based on the determined vari^¬ able by utilizing feedback in connection with the manu- facture of the paperboard product, c h a r a c t e r ^¬ i z e d in that the manufacture of the paperboard prod^¬ uct is controlled by determining the forming force and by adjusting the forming force based on the determined forming force in connection with shaping of the paper- board product.

2. The method according to claim 1, c h a r a c t e r i z e d in that the variable is selected from the group of a product quality characteristic, a process variable, a process condition and combinations thereof.

3. The method according to claim 1 or 2, c h a r a c t e r i z e d in that the process parameter is selected from the group of forming force, positioning of the paperboard material, heating, other process pa^¬ rameter and combinations thereof.

4. The method according to any one of claims 1 to 3, c h a r a c t e r i z e d in that the variable is determined on an online basis.

5. The method according to any one of claims 1 to 4, c h a r a c t e r i z e d in that the process param- eter is adjusted in real time.

6. The method according to any one of claims 1 - 5, c h a r a c t e r i z e d in that the manufacture of the paperboard product is controlled by determining at least one product quality characteristic and by adjust- ing a process parameter which is selected from the group of forming force, positioning of the paperboard materi- al, heating, other process parameter and their combinations based on the determined quality characteristic.

7. An apparatus for manufacturing a paperboard product, wherein the apparatus is arranged in connection with at least one tool for forming the paperboard prod^¬ uct from paperboard material, and the apparatus (2) com^¬ prises at least one determining device (5) for determining at least one variable, and at least one control device (3) for adjusting a selected process parameter based on the determined variable by utilizing feedback in connection with the manufacture of the paperboard product (1), c h a r a c t e r i z e d in that the de^¬ termining device (5) is arranged to determine the form^¬ ing force in connection with shaping of the paperboard product, and the control device (3) is arranged to ad^¬ just the forming force based on the determined forming force .

8. The apparatus according to claim 7, c h a r a c t e r i z e d in that the control device (3) comprises analysing means (6) for analysing the determined variable and adjusting means (4) for adjusting the selected process parameter.

9. The apparatus according to claim 7 or 8, c h a r a c t e r i z e d in that the determining device (5) comprises at least one sensor.

10. The apparatus according to any one of claims 7 - 9, c h a r a c t e r i z e d in that the de^¬ termining device (5) is based on the principle of pat^¬ tern recognition, machine vision, force measurement or thermographic camera or their combinations.

11. The apparatus according to any one of claims 7 - 10, c h a r a c t e r i z e d in that the ap^¬ paratus (2) is connectable to a modular paperboard product manufacturing line (10) .