GapChek: Manufacturer’s Gap Measurement from the Bundle

Measurement of manufacturer’s joint gaps has traditionally only been possible from inside the flexo-folder-gluer prior to the box being completely folded and straightened. This results in distorted and sometimes inaccurate gap measurements as well as exaggerated skew analysis. As customers with automated packaging equipment demand more consistent and correctly-sized folding gaps from their box suppliers, the pressure to accurately measure gaps and remove boxes with out-of-spec gaps is increasing. GapChek™, the latest corrugated vision system from Valco Melton’s ClearVision division, moves the measurement point to the bundle so that the lead and trail gaps are measured on finished boxes. As finished bundles travel along the conveyor, they are imaged from the front and the rear by two cameras mounted above the conveyor. These images are used to locate and measure the manufacturer’s gaps and provide on-screen analysis of gaps that are too small or large as well as boxes they may be skewed, where the leading and trailing edge gaps have a large difference. Installed prior to a ClearVision BundleChek system, bundles with gaps that are out of the plant tolerance specification can be ejected and the ClearVision screen used to locate the position of the out-of-spec box in the stack. GapChek provides a screen at the folding section as well as at the bundle ejector in order to facilitate folding rail adjustments. GapChek displays both per-bundle averages as well as statistical process control charts on-screen that assist the user in modifying folding rail settings based on how much gap variation is occurring and the average gap size that is being produced. As with all ClearVision systems, GapChek data are available remotely via the MeasurementChek access over the internet. Users can look at per-job and per-box gap data and analyze historical trends for certain box designs or customers. Special cases such as square boxes and trimmed flaps as well as unstrapped bundles where the top boxes are partially open are all handled by GapChek. GapChek requires bundles to be spaced apart and stacked straight from front-to-back. Sideways skew or box offsets do not effect accuracy. GapChek is capable of keeping up with the fastest dual-out machines on the market today. Valco Melton is a leading supplier of gluing and inspection systems in the corrugated industry. Since 1952, Valco Melton has been selling and servicing equipment and providing robust solutions for the industry. ClearVision® products are dedicated to using vision for inspecting corrugated production and making removal of defects from the production stream possible.

For more information on GapChek: Manufacturer’s Gap Measurement from the Bundle talk to Valco Melton UK