Apparatus for monitoring and adjusting a decoration formed on the external surface of metal containers, method for optimizing a decoration formed by a decorator on a cylindrical external surface of a metal container, and non-transiential computer-readable medium

Abstract

The present invention relates to an apparatus and methods for monitoring and adjusting a decorator for metal containers. The present invention relates to an apparatus and methods used to provide a decoration on a predetermined portion of a metal container body. The decorator includes a sensor that detects decorations on metal containers. A control system receives information regarding the detected decorations from the sensor and then determines whether the decorations at least meet the quality targets. The control system may optionally automatically adjust the elements of the decorator to correct a deficient decoration.In one embodiment, the control system can automatically send a signal to the decorator to adjust the position of at least one of the decorator's components: an inkwell, an ink roller, a conductor roller, a transfer roller, a plate cylinder, a printing plate, a blanket cylinder, and a transfer blanket, in order to correct the cause of a faulty decoration.

Description

1 / 165 Descriptive Report of the Invention Patent for APPARATUS FOR MONITORING AND ADJUSTING A DECORATION FORMED ON AN EXTERNAL SURFACE OF METALLIC CONTAINERS, METHOD FOR OPTIMIZING A DECORATION FORMED BY A DECORATOR ON A CYLINDRICAL EXTERNAL SURFACE OF A METALLIC CONTAINER AND NON-TRANSIENT COMPUTER-READABLE MEANS. CROSS-REFERENCE TO RELATED REQUESTS

[0001] This application is a continuance application in part and claims the benefit and priority of U.S. Patent Application 15 / 875,968 filed January 19, 2018, entitled System and Method for Monitoring and Adjusting a Container Decorator, which is a continuance application in part and claims the benefit and priority of U.S. Patent Application 15 / 654,255 filed July 19, 2017, entitled System and Method for Aligning a Decorator Inkwell, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Serial Number 62 / 364,728 filed July 20, 2016, entitled System and Method for Aligning a Decorator Inkwell, both of which are incorporated herein in their entirety by reference. FIELD OF THE INVENTION

[0002] The present invention generally relates to decorating containers. More specifically, this invention provides an apparatus and method used to monitor and automatically control the position and application of paint to the external surface of metal containers. BACKGROUND

[0003] Metal beverage containers offer distributors and consumers many benefits. The metal body of Petition 870230045110, dated 05 / 29 / 2023, p. 8 / 186 2 / 165 A beverage container provides excellent protective properties for products. For example, the metal body prevents CO2 migration and UV radiation transmission, which can damage beverages, negatively influencing the product's taste, appearance, or color. Metal beverage containers also offer an impermeable barrier to light, water vapor, oils and fats, oxygen, and microorganisms, keeping the container's contents fresh and protected from external influences, thus ensuring a long shelf life. The surfaces of metal containers are also ideal for decorating with brand names, logos, designs, product information, and / or other preferred indices to identify, market, and distinguish the metal container and its contents from other products and competitors. Thus, metal containers offer bottlers, distributors, and retailers a distinct advantage at the point of sale.

[0004] The increased durability and aesthetic advantage of metal beverage containers compared to glass and plastic containers reduce the number of containers damaged during processing and transport, resulting in additional savings. Furthermore, metal beverage containers are lighter than glass containers of comparable size, reducing energy savings during transport. Additionally, metal beverage containers can be manufactured with high burst pressures, making them ideal and safe for use as containers holding products under pressure, such as containers for carbonated beverages.

[0005] Moreover, many consumers prefer metal containers compared to those made of glass or plastic. Metal containers are particularly attractive to consumers due to the convenience they offer. The light weight of metal containers makes them easier to carry than Petition 870230045110, dated 05 / 29 / 2023, page 9 / 186 3 / 165 glass containers. Metal containers are particularly suitable for use in public and outdoor locations because they are more durable than glass containers. However, some consumers avoid plastic containers due to concerns that plastic may leach chemicals into consumable products.

[0006] As a result of these benefits, metal container sales were valued at approximately US$53 billion globally in 2014. A large percentage of the metal container market is driven by beverage containers. According to one report, approximately 290 billion metal beverage containers were shipped globally in 2012. A US trade group reported that 126 billion metal containers were shipped in the US alone in 2014. To meet this demand, metal container manufacturing facilities operate some of the fastest, if not the fastest, production lines in the container industry. On some container production lines, such as those for metal containers formed by an impact extrusion process, decorators can process approximately 120 to approximately 240 metal containers per minute.In beverage container manufacturing lines, production equipment, including decorators, typically needs to operate at 500–2,200 metal containers per minute or more. More preferably, decorators may be required to operate at production speeds of at least one thousand, and even more preferably, several thousand cylindrical metal containers per minute. Due to the high speeds of container production lines, techniques or processes that may work in other industries or with containers formed from other materials may not necessarily be applicable. Petition 870230045110, dated 05 / 29 / 2023, page 10 / 186 4 / 165 operate at the high speeds required for metal container production lines. For example, the equipment and methods for decorating sheets or blankets of paper and cardboard materials are distinct from the decorators used for three-dimensional objects such as metal containers. Consequently, specialized equipment and techniques are often required for many of the operations used to form and decorate metal containers.

[0007] Metal containers are frequently decorated with an image or inscriptions, such as a brand name, logo, product information, or design, by a lithographic or offset printing process. Several examples of printing methods and apparatus are described in U.S. Patent Number 3,960,073; U.S. Patent Number 4,384,518; U.S. Patent Number 5,233,922; U.S. Patent Number 6,550,389; U.S. Patent Number 6,899,998; U.S. Patent Application Publication Number 2012 / 0272846; U.S. Patent Application Publication Number 2014 / 0360394; U.S. Patent Application Number 2015 / 0183211; U.S. Patent Application Publication Number 2015 / 0217559; WIPO Publication Number WO 2014 / 006517; WIPO Publication Number WO 2014 / 008544; WIPO Publication Number WO 2013 / 113616; WIPO Publication Number WO 2014 / 108489; and WIPO Publication Number WO 2014 / 128200, each of which is incorporated herein by reference in its entirety.

[0008] In offset printing, one or more printing plates with image regions are attached to a plate cylinder (or press cylinder) of a decorator. The image regions may include both ink-receiving and non-ink-receiving areas. Cartridge assemblies transfer ink to the printing plates over a plate cylinder. The ink adheres to the ink-receiving regions of each printing plate. A decorator may have a plurality of plate cylinders with ink cartridge assemblies to transfer different Petition 870230045110, dated 05 / 29 / 2023, p. 11 / 186 5 / 165 ink colors for the printing plates affixed to each plate cylinder. For example, decorators used to decorate metal containers often have four to nine plate cylinders, each with an associated set of ink.

[0009] Each cartridge assembly transfers a specific color of ink to a printing plate from a single associated plate cylinder. Cartridge assemblies typically include an ink reservoir and an ink blade positioned along an outer surface of an ink roller. The amount of ink transferred to the ink roller and subsequently to the printing plates is adjusted by altering a gap between an edge of the ink blade and an outer surface of the ink roller. The ink blade may be divided into a plurality of individual segments, known as blade segments.

[0010] The gap between the edge of an ink blade and the outer surface of the ink rollers can be adjusted along the length of the ink roller by moving interconnected ink keys on the ink blade. More specifically, an ink key can be advanced to move a portion of the ink blade edge closer to the outer surface of the ink roller to decrease the amount of ink transferred to a portion of the ink roller. Similarly, the ink key can be retracted to move the ink blade edge away from the outer surface of the ink roller to increase the amount of ink transferred to that portion of the ink roller. Some ink blade assemblies of the prior art are described in Patent US Number 4,000,695 Patent US Number 4,008,664 Patent US Number 5,025,676 Patent US Number 5,052,298 Patent US Number 5,967,049 Patent US Number 5,967,050 Patent US Number 6,318,260 Patent US Number 7,969,613 Publication of US Patent Application Number 2015 / 0128819, and Petition 870230045110, dated 05 / 29 / 2023, p. 12 / 186 6 / 165 Publication of US Patent Application Number 2015 / 0128821, each of which is incorporated herein by reference in its entirety. Another ink blade assembly is described in QuadTech® Digital Ink System, which is available at https: / / www.quadtechworld.com / downloads / brochures / Digital_Tinta_System_en.pdf, which is incorporated herein by reference in its entirety.

[0011] After receiving ink, the printing plates transfer at least some of their ink to a printing blanket (also referred to as a transfer blanket or a secondary transfer plate) attached to a blanket cylinder (also known as an offset cylinder, a printing cylinder, or a segment wheel) of the decorator. Decorators used in the metal container industry typically have 2 to 12 printing blankets on blanket cylinders. As the plate cylinder and blanket cylinder are rotated, each of the one or more printing plates contacts a printing blanket and transfers a specific ink color to a printing blanket. When the ink and image have been transferred from one printing plate of each plate cylinder to a printing blanket, the final lithographic image is formed on a printing blanket.For example, if the decorator includes five plate cylinders, one printing plate from each of the five plate cylinders will transfer inks and images to a single printing blanket to form the lithographic image on a printing blanket. A metal container is then brought into rotational contact with a printing blanket from the plate cylinder, and the lithographic image is transferred from one printing blanket to the outer surface of the metal container.

[0012] The production of acceptable decorations on metal containers with decorators of the prior art is dependent on Petition 870230045110, dated 05 / 29 / 2023, page 13 / 186 7 / 165 The skill and attention required by the operator is considerable in terms of labor and associated expenses. More specifically, for each production operation to decorate metal containers with a decoration using a decorator of the prior art, the ink keys of each inkwell assembly are adjusted to an initial position, which takes a significant amount of time. As some metal container production lines may print more than 15 different decorations each day, the decorator may be out of production for several hours each day during setup to prepare the decorator to print different decorations. Considering the high production speeds at which metal container production lines typically operate, this represents a considerable amount of downtime and lost productivity.

[0013] As will be appreciated by someone versed in the art, an initial ink key position can apply too much or too little ink to portions of the printing plates. When this occurs, the decoration transferred to the metal container may be deficient because one or more of the color, density, depth, alignment, and consistency of the decoration do not meet the objectives specified by a client. Consequently, the decorator must be taken out of production to adjust an ink key position, resulting in additional downtime and lost productivity.

[0014] The decorator operator may also periodically examine a decorated sample metal container during a production operation to determine if the sample decoration meets the objectives for color, density, depth, alignment, and / or consistency. If the operator determines that the sample is deficient, the operator must then determine why the decoration is deficient. For example, the operator may need to determine which of the plurality of ink keys for each of the inkwell sets requires adjustment, Petition 870230045110, dated 05 / 29 / 2023, page 14 / 186 8 / 165 and how to adjust the ink key to produce an acceptable decoration. Determining which ink keys to adjust to correct the deficiency can be difficult if the poor decoration includes inks from two or more different cartridge sets. For example, if a color is deficient in a portion of the decoration, the operator may need to increase the amount of a first ink transferred to an axial portion of a first ink roller from a first inkwell set and decrease the amount of a second ink transferred to a corresponding axial portion of a second ink roller from a second inkwell set. The operator may also need to adjust one or more other components of the decorator to correct a deficient decoration.

[0015] Furthermore, ink rollers, printing plates, and printing blankets can become worn and require adjustment or replacement during a production operation. Consequently, the amount of ink transferred during the decoration process to the outer surface of a metal container can change during the production operation, altering decoration parameters such as color, density, depth, alignment, and consistency. Thus, decorations formed by known decorators should be inspected frequently during the production operation, and ink keys are periodically adjusted to ensure the quality and consistency required by the customer.

[0016] Manually identifying a faulty decoration and then manually adjusting the decorator consumes a significant amount of time. Due to the high speeds of beverage container production lines, several hundred or even several thousand metal containers with faulty decorations may be produced before the operator identifies the problem and then appropriately adjusts the paint keys. Consequently, a Petition 870230045110, dated 05 / 29 / 2023, page 15 / 186 9 / 165 A large quantity of scrap metal containers with deficient decorations is frequently created by decorators of the prior art. Furthermore, after identifying a poor decoration, the operator may shut down the decorator while adjusting the paint keys or other elements of the decorator. This wastes a valuable amount of time and can delay the operation of downstream production equipment due to a lack of decorated metal containers.

[0017] Adjusting the paint keys on prior art decorators is difficult and can be dangerous. Some paint keys are difficult to access. Thus, an operator may be required to at least partially disassemble the decorator and use a tool to change the position of a paint key. The tools used to adjust the paint keys may not intentionally damage the decorator. Still, the tools used by the operator may be inadvertently misplaced or left inside the decorator assembly, requiring additional downtime and the associated cost of lost production. Furthermore, the operator may be injured while reaching inside the decorator to adjust the paint keys.

[0018] Due to the limitations associated with existing methods and apparatus used to decorate metal containers, there is an unmet need for an apparatus and method to automatically monitor and adjust the settings of a decorator to generate less waste, require less operator time, and be less susceptible to human error than known decorators without sacrificing production efficiency or image quality in a high-speed beverage container production system. SUMMARY OF THE INVENTION

[0019] The present invention provides various devices, instructions Petition 870230045110, dated 05 / 29 / 2023, p. 16 / 186 10 / 165 stored on a non-transient, computer-readable medium, and methods for decorating metal containers in an economical, fast, and reliable manner. One aspect of the present invention is a closed-loop decorator assembly and system that includes a control system that can detect a deficient decoration on a cylindrical metal container. When the control system detects a deficient decoration, the control system can determine the cause of the deficiency. The control system can then automatically correct the deficiency. In addition, or alternatively, the control system can alert an operator that specific adjustments are required.If the cause of the defect can be corrected by adjusting the amount of ink transferred to the metal container, in one embodiment the control system may send a signal to adjust at least one component of an inkwell assembly to adjust the amount of ink transferred to a printing plate. The signal may cause an actuator to adjust at least one ink blade to correct the defective decoration on subsequent metal containers. Additionally, or alternatively, the signal may alter the rotation rate of an ink roller or a transfer roller of an inkwell assembly. Furthermore, a signal may be sent to equipment on the production line to reject any container which has a defective decoration. Defective decorations may include, but are not limited to, variations in color, ink density, ink thickness, ink color, incorrect index positions, and decoration quality.In one mode, when the deficiency cannot be corrected by the control system, the control system can automatically stop the production line.

[0020] Another aspect of the present invention is a decorator that includes at least one sensor communicating with a control system. The sensor collects or obtains data relating to decorations on Petition 870230045110, dated 05 / 29 / 2023, page 17 / 186 11 / 165 metal containers. The control system determines if the decorations are poor using data received from the sensor. If the control system determines that a decoration, or a portion of a decoration, is deficient, the control system uses the data to adjust one or more components of the decorator. For example, the control system might adjust one or more ink blades to alter the amount of ink transferred to an ink roller in an ink cartridge assembly. Additionally, or alternatively, the control system might alter the rotation rate of an ink roller or a transfer roller in an ink cartridge assembly to alter the amount of ink transferred to a printing plate. At least one sensor can collect optical data and other types of data associated with the decoration on the metal container. The sensor is operable to collect data of sufficient resolution to identify a defect in the decoration.In one embodiment, the sensor is a camera. In another embodiment, the sensor is operable to collect three-dimensional data relating to decorations.

[0021] In one embodiment, the sensor collects data on the decoration formed on the cylindrical body of the metal container. The sensor can collect data as the metal container rotates around a longitudinal geometric axis so that the sensor collects data on the entire outer cylindrical surface of the metal container. In another embodiment, at least one sensor comprises three or more sensors to collect data on the cylindrical surface of the metal container. Optionally, the three or more sensors are spaced substantially uniformly around the longitudinal geometric axis of the metal container. The sensors can collect the data substantially simultaneously. In one embodiment, the decorator includes four sensors that each collect data relating to at least approximately 25 percent of the cylindrical surface. In another Petition 870230045110, dated 05 / 29 / 2023, page 18 / 186 In the 12 / 165 mode, each of the four sensors collects data on approximately 30 percent of the cylindrical surface. As one skilled in the art will appreciate, the apparatus and methods described herein can be used on any type of surface or container such as an end closure or closed end wall, and are not limited to cylindrical portions of metal containers.

[0022] Optionally, a light source may be associated with one or more of the sensors. The light source may produce light continuously. Alternatively, the light source may produce light periodically, such as a strobe light. In this mode, the light source may produce light at a time when an associated sensor is collecting data relating to a decoration on a metal container.

[0023] In one embodiment, at least one sensor collects data from target areas of the cylindrical surface. Optionally, a target area may be associated with each paint blade of the decorator. The decorator may include from 20 to 80 individual paint blades. For example, the decorator may include four to eight paint cartridge sets. Each cartridge set may include 5 to 10 paint blades to adjust the amount of paint supplied to 5 to 10 axial portions of a paint roller in the cartridge set. Consequently, at least one sensor may collect data from up to 20 to 80 different target areas of the cylindrical surface of a metal container. In this mode, at least one sensor may collect data relating to the paint regulated by each individual paint blade of the decorator. In one embodiment, the sensor may distinguish variations in paint density within a decoration on a metal container.

[0024] The control system can use sensor data to determine whether a decoration meets target values ​​or is deficient. The Petition 870230045110, dated 05 / 29 / 2023, page 19 / 186 13 / 165 The control system can use sensor data to determine one or more of the following: (a) the ink is too light or too dark; (b) the decoration includes a void; (c) the decoration includes a smudge; (d) the decoration is not properly aligned (is out of registration); (e) the decoration was formed by a printing plate or transfer blanket that is damaged (such as including a cut or tear); (f) the decoration includes a smudge; (g) a topcoat varnish on the metal container is deficient or missing; (h) the decoration includes a contaminant; (i) the metal container is damaged or out of specification; (j) color shift of a decoration; and (k) that the decoration includes incorrect color. The control system can determine the location of an ink density variation on the cylindrical container body.By determining an axial portion of the cylindrical container body associated with the location of an ink density variation, the control system can identify an ink blade from one of four to eight inkwell assemblies responsible for the ink density variation. The control system can then send a signal to an actuator associated with the ink blade to alter the ink blade's position to correct a faulty decoration caused by the ink density variation. The control system can also determine that a metal container has a damaged body caused by upstream equipment.

[0025] Another aspect of the present invention is an operable control system for controlling a decorator. The control system includes an instruction to determine how to adjust at least one component of the decorator to correct a defective decoration. The control system can receive data collected by a sensor on a decoration on a metal container. The control system can determine if the decoration is defective by comparing the sensor data with target information for one or more parameters of Petition 870230045110, dated 05 / 29 / 2023, page 20 / 186 14 / 165 printing. Printing parameters may include at least one of a single color, density, thickness, orientation, and consistency of the decoration. The control system may use sensor data to determine how to correct poor decoration by adjusting one or more components of the decorator. When the decoration is deficient, the control system is operable to send a signal to an actuator associated with at least one ink blade requiring adjustment. The signal causes the actuator to move the ink blade relative to an ink roller of an ink cartridge assembly. In one embodiment, the actuator may move at least a portion of the ink blade toward or away from the ink roller. In this mode, the control system adjusts a gap between the ink blade and the ink roller to alter an amount of ink applied to an associated axial portion of the ink roller.In addition, or alternatively, the control system can send a signal to an actuator to change the rotation rate of an ink roller or a transfer roller of an inkwell assembly. By changing the rotation rate of the ink roller or the transfer roller, the control system can increase or decrease the amount of ink supplied through an associated ink train to a printing plate affixed to a plate cylinder. The sensor can collect data on the entire outer surface of a cylindrical metal container body. In one embodiment, the sensor comprises 3 to 5 sensors positioned to interpret the decoration quality on the entire cylindrical metal container body. In one embodiment, the control system compares the sensor data to an image stored in a control system memory. In another embodiment, the image is of a decoration that is not defective.In one embodiment, the control system compares portions of the sensor data to a plurality of corresponding portions of acceptable images of decorations stored in memory. In one embodiment, the system... Petition 870230045110, dated 05 / 29 / 2023, page 21 / 186 15 / 165 control can also stop the decorator in response to determining that a decoration is defective. More specifically, in one embodiment, the control system includes an instruction to stop the decorator after determining that a predetermined number of metal containers contain defective decorations. In another embodiment, the control system includes an instruction to stop the decorator after identifying a predetermined cause of a defective decoration. For example, the control system may include an instruction to stop the decorator if a defective decoration is not associated with an improper amount of paint transferred to a metal container.In another example, the control system might include an instruction to stop the decorator after determining that a defective decoration is related to one or more of the following: defective ink, a printing plate, a transfer blanket, a damaged metal container, an undetermined cause, and an improper position or alignment of a portion of a decoration. Additionally, or alternatively, the control system might generate an alert with information regarding the defective decoration and its cause. The alert could be sent to a display screen or to an electronic device, such as a computer, laptop, tablet, or smartphone. The alert could include a text message.

[0026] Another aspect of the present invention is to provide a decorator with an ink cartridge assembly. Optionally, the decorator includes a plurality of ink cartridge assemblies. The ink cartridge assembly includes one or more ink blades that can be radially adjusted with respect to an ink roller. Consequently, at least a portion of each ink blade can be moved closer to, or further away from, the ink roller. In one embodiment, each of the ink blades can optionally be moved axially with respect to the ink roller. In this Petition 870230045110, dated 05 / 29 / 2023, p. 22 / 186 In mode 16 / 165, the amount (or density, thickness) of ink transferred from an ink reservoir to each axial portion of the ink roller is adjustable. In one embodiment, each ink blade can articulate with respect to the ink roller. Alternatively, in another embodiment, each ink blade can move linearly toward and away from the ink roller.

[0027] The movement of the ink blades can be selectively provided by a variety of mechanisms as appreciated by one skilled in the art. In one embodiment, the movement of the ink blades is generally controlled by a control system. The ink blades generally move in response to a force. In one embodiment, the force can be generated by one or more of electrical, pneumatic, hydraulic, and magnetic energy.

[0028] In one embodiment, movement of one or more ink blades is generally provided by an actuator. In another embodiment, an actuator is associated with each individual ink blade. In yet another embodiment, a plurality of actuators may be associated with an ink blade. In one embodiment, the actuator initiates a force transverse to a longitudinal geometric axis of an associated ink blade. In this mode, the ink blade, or a selected portion of the ink blade, articulates or bends relative to the ink roller. In another embodiment, the actuator initiates a force which is generally parallel to the longitudinal geometric axis of the associated ink blade. In this embodiment, the ink blade moves linearly and generally parallel to the blade geometric axis toward or away from the ink roller. The actuators may be controlled by a decorator control system.

[0029] In one embodiment, the movement of the ink blades is controlled by a control system. In one embodiment, the control system includes computer-readable, non-transient instructions. Petition 870230045110, dated 05 / 29 / 2023, page 23 / 186 17 / 165 stored in a memory that controls the movement of the paint blades. Optionally, the control system includes an instruction to receive data from a sensor relating to the decoration on a metal container. In one embodiment, the sensor includes a charge-coupled device (CCD) or complementary metal-oxide-semiconductor (CMOS) image sensor. In one embodiment, the sensor includes a plurality of individual sensing elements. Each sensing element collects data relating to a portion of the metal container. In one embodiment, each sensor element collects one pixel of data.

[0030] The control system includes an instruction to analyze sensor data related to the decoration. In one embodiment, the control system includes an instruction to compare the sensor data with stored data. In one embodiment, the stored data is associated with at least one acceptable decoration. The acceptable decoration may be scanned and stored in memory accessible by the control system. In one embodiment, the acceptable decoration is scanned at a resolution such that the stored data related to the acceptable decoration includes a number of pixels that may be based on the number of individual sensing elements of the sensor. More specifically, the acceptable decoration may be stored in memory at a resolution equal to the resolution of the data collected by the sensor. In another embodiment, the acceptable decoration is stored at a resolution different from the sensor resolution.Consequently, in another embodiment, the acceptable decoration is stored at a higher resolution, or a lower resolution, than the resolution of the data collected by the sensor. In one embodiment, the stored data is in a computer database. The database may be stored in the control system's memory. Optionally, the control system... Petition 870230045110, dated 05 / 29 / 2023, page 24 / 186 18 / 165 accesses the database via a network connection.

[0031] In one embodiment, the control system includes instructions to determine if the decoration is deficient when the sensor data differs by a predetermined amount from the stored data. In one embodiment, the control system compares a plurality of portions of the sensor data with corresponding portions of the stored data. If the control system determines that portions of the sensor data differ from portions of the stored data, the decoration is deficient. Optionally, when a predetermined percentage of portions of the sensor data differs from corresponding portions of the stored data, the control system will determine that the decoration is deficient.

[0032] In one embodiment, the control system includes instructions to automatically adjust at least one of the ink blades to correct faulty decoration. For example, in one embodiment, the control system includes an instruction to send a signal to an actuator. In one embodiment, the signal causes the actuator to move an ink blade in a specific direction to alter the amount of ink transferred to the ink roller. Thus, the control system can automatically adjust at least one ink blade without operator input. In another embodiment, the signal causes an actuator to move one or more of a driver roller, an ink roller, a plate cylinder, a printing plate, a blanket cylinder, a transfer blanket, and a support element in a specific direction to correct faulty decoration.Additionally, or alternatively, the control system can send a signal to alter the rotation rate of one or more ink rollers and a transfer roller in a cartridge assembly to increase or decrease the amount of ink transferred to a printing plate attached to an associated plate cylinder. Petition 870230045110, dated 05 / 29 / 2023, p. 25 / 186 19 / 165

[0033] In one embodiment, when the control system determines that a decoration is defective, the control system sends an alert to a decorator operator. In one embodiment, the control system displays the alert on a control system display. In another embodiment, the alert may include an audible portion, such as an alarm, siren, or voice message. In another embodiment, the alert may be transmitted to a user device via a network connection. Consequently, in one embodiment, the operator may receive the alert on a smartphone, tablet, laptop computer, or other portable device. The alert may include information about the defective decoration. Optionally, the alert may include information regarding an adjustment of at least one component of the decorator to correct the defective decoration.For example, the alert may provide information about an adjustment for one or more of a conductor roller, an ink blade, an ink roller, a transfer roller, a plate cylinder, a printing plate, a blanket cylinder, a transfer blanket, or a support element determined by the control system to correct faulty decoration. In one embodiment, the alert is presented to the operator on a display of the control system.

[0034] In one embodiment, the operator may use a control system input device to approve, disapprove, or modify an adjustment of at least one component of the decorator planned by the control system to correct a deficient decoration. More specifically, the operator may make an input to the control system to approve (or confirm) the planned adjustment, modify the planned adjustment, or disapprove the planned adjustment of at least one paint blade or other component of the decorator. In one embodiment, the operator may make the input by contacting the display. In another embodiment, the operator's input may be made with a mouse or Petition 870230045110, dated 05 / 29 / 2023, page 26 / 186 20 / 165 another pointer in the control system. In yet another mode, the input can be entered using a keyboard.

[0035] In one embodiment, the control system includes an instruction to automatically adjust at least one component of the decorator after a predetermined period of time if the operator does not disapprove or cancel a planned adjustment. In yet another embodiment, the control system includes instructions to automatically adjust at least one component of the decorator after the predetermined period of time if the operator does not approve the planned adjustment.

[0036] In one embodiment, each ink blade has a width between approximately 12.7 mm (0.5 inches) and approximately 38.1 mm (1.5 inches). Consequently, a decorator who has five or six ink blades per ink cartridge set can decorate the cylindrical body of a metal container with a height of up to approximately 177.8 mm (7 inches). However, the ink cartridge set of the present invention could be used to decorate much larger cylindrically formed objects or containers, as will be appreciated by a person skilled in the art. In one embodiment, the ink blades of each cartridge set have substantially uniform widths. Alternatively, the ink blades in each cartridge set may have different widths. In yet another embodiment, the decorator's ink cartridge sets have from 5 to 10 ink blades.

[0037] Yet another aspect of the present invention is a decorator that includes an ejector. The ejector removes metal containers identified by the control system as having defective decorations from a conveyor.

[0038] Yet another aspect of the present invention is a control system for a decorator that is capable of determining a decoration. Petition 870230045110, dated 05 / 29 / 2023, page 27 / 186 21 / 165 acceptable for a metal container and whether the decoration quality falls within predetermined quality standards. Once the control system establishes an acceptable decoration, the control system can detect a decoration that deviates from the acceptable decoration. In this mode, the control system can determine that a metal container includes unacceptable, or deficient, decoration.

[0039] It is an aspect of the present invention to provide an apparatus for decorating a metal container. The apparatus generally includes, but is not limited to: (1) a cartridge assembly comprising an ink roller, a plurality of ink blades, an ink reservoir for ink, and an actuator for moving each ink blade relative to the ink roller to adjust an amount of ink transferred from the ink reservoir to the ink roller; (2) a plate cylinder comprising a printing plate in a predetermined alignment relative to the ink roller so that a printing plate receives at least some ink from the ink roller; (3) a blanket cylinder comprising transfer blankets in a predetermined alignment relative to the plate cylinder so that the transfer blankets receive at least some ink from a printing plate;(4) a support element for receiving the metal container from a conveyor and moving the metal container into contact with a transfer blanket from the blanket cylinder to transfer at least some ink from a transfer blanket to the metal container to form a decoration on an external surface of the metal container; (5) at least one sensor for collecting or obtaining data on the decoration on the external surface of the metal container; and (6) a control system that receives the data from at least one sensor and determines whether a decoration includes a defect. If the control system determines that the decoration includes a defect, the control system is operable to send a signal to an actuator of the apparatus to correct the defect. Petition 870230045110, dated 05 / 29 / 2023, page 28 / 186 22 / 165 In one embodiment, an actuator is associated with each ink blade. In one embodiment, the signal causes the actuator to adjust the ink blade to change the amount of ink transferred to the ink roller. Additionally, or alternatively, the signal may cause a drive element to change the rotation rate of an ink roller to change the amount of ink transferred to a printing plate. In another embodiment, the supporting element includes a plurality of stations. Each of the stations is operable to receive a metal container. In another embodiment, the stations comprise mandrels. In one embodiment, the apparatus includes a plurality of ink cartridge assemblies. Each of the plurality of ink cartridge assemblies is operable to transfer ink to an associated printing plate.

[0040] Optionally, in one embodiment of the present invention, the apparatus further comprises an ejector communicating with the control system. The ejector removes metal containers with defective decorations from the conveyor in response to receiving a signal from the control system.

[0041] In one embodiment, the sensor includes a charge-coupled device (CCD) or complementary metal-oxide-semiconductor (CMOS) image sensor. In another embodiment, at least one sensor is operable to obtain data on one or more of: (A) a decoration color; (B) a decoration density; (C) a decoration depth or thickness; (D) a decoration alignment; and (F) a decoration consistency. In one embodiment, the sensor is a camera. Optionally, the apparatus may include from one to six sensors. In one embodiment, the one to six sensors are positioned around a circumference of the cylindrical body of the metal container. In one embodiment, each sensor may be adapted to obtain a type of data, such as color, density, Petition 870230045110, dated 05 / 29 / 2023, p. 29 / 186 23 / 165 depth or thickness, alignment, and consistency, with respect to decoration. In another embodiment, the apparatus includes three to six sensors to obtain data on the cylindrical body of the metal container. In one embodiment, at least one sensor obtains data from a plurality of target areas on the outer surface of the metal container. In another embodiment, each of the plurality of target areas corresponds to any area on the outer surface of the metal container associated with one of the ink sheets. In one embodiment, at least one target area is associated with an ink from an inkwell set.

[0042] In another embodiment, the control system is operable to determine a deficiency that includes an error in at least one of: (i) a decoration color; (ii) a decoration density; (iii) a decoration thickness; (iv) a decoration alignment; and (v) a decoration consistency. In response to detecting a decoration deficiency, the control system is operable to change the position of at least one component of the apparatus while the apparatus is in operation decorating the metal containers. In one embodiment, the control system sends a signal to change the position of one of the plurality of ink blades. The control system may send a signal to an actuator associated with that ink blade to selectively move the ink blade to a predetermined position relative to the ink roller. In another embodiment, a distance between the ink blade and an axial portion of the ink roller is changed.In another embodiment, the control system can send a signal to a drive element to change the rotation rate of an ink roller or a transfer roller in an ink assembly.

[0043] Another aspect of the present invention is to provide a method of detecting and correcting an abnormality in a decoration applied to a Petition 870230045110, dated 05 / 29 / 2023, p. 30 / 186 24 / 165 external surface of a container. The method includes, but is not limited to: (1) providing a container; (2) decorating the container with a decorator; (3) obtaining data on the decoration on the external surface of the container by at least one sensor; (4) determining, by a control system, whether the decoration includes an abnormality; and (5) if the decoration includes an abnormality, sending, by the control system, a signal to the decorator to change at least one of a color and density of subsequent decorations. In one embodiment, the container is a metallic container that includes a closed end wall and a body portion extending from the closed end wall. In one embodiment, the body portion is substantially cylindrical. Optionally, the method may further comprise sending an alert to an operator. In one embodiment, the alert is presented on a display of the control system. In another embodiment, the alert includes information about the abnormality.In one mode, the information about the anomaly includes an image of the container's external surface obtained by at least one sensor. In another mode, the alert includes information about the signal sent to the decorator by the control system.

[0044] In one embodiment of the present invention, the decorator includes: (a) an inkwell assembly comprising an ink roller, a plurality of ink blades, an ink reservoir for ink, and an actuator for moving the ink blades relative to the ink roller to adjust the amount of ink transferred from the ink reservoir to the ink roller; (b) a plate cylinder comprising a printing plate in a predetermined alignment relative to the ink roller such that a printing plate receives at least some ink from the ink roller; (c) a blanket cylinder comprising transfer blankets in a predetermined alignment relative to the plate cylinder such that each transfer blanket receives at least some ink from the ink roller. Petition 870230045110, dated 05 / 29 / 2023, p. 31 / 186 25 / 165 less some ink from a printing plate of the plate cylinder; and (d) a support device for receiving a container from a conveyor and moving the container into contact with a transfer blanket of the plate cylinder to transfer at least some ink from a transfer blanket to the container so that the decoration is formed on an outer surface of the container. In one embodiment, an actuator is associated with components of the decorator. Optionally, an actuator is associated with each ink blade. In another embodiment, the support device includes a plurality of stations that are each operable to receive a container. In yet another embodiment, the decorator includes from two to twelve sets of ink cartridges. Each of the sets of ink cartridges is operable to transfer ink to a printing plate of a plate cylinder.

[0045] In one embodiment, the ink roller includes a plurality of axial portions, each axial portion defined by an ink blade. In one embodiment, each axial portion of the ink roller comprises a cylindrical portion of the curved surface of the ink roller. Optionally, the signal from the control system causes the drive element to change the rotation rate of the ink roller.

[0046] In one embodiment, the signal causes an actuator associated with an ink blade to move the ink blade in a specific direction to alter an amount of ink transferred from the ink reservoir to an axial portion of the ink roller. In another embodiment, the signal causes the actuator to rotate in a first predetermined direction to move the ink blade of the inkwell assembly to a position which either increases or decreases the amount of ink transferred to the axial portion of the ink roller. In yet another embodiment, the signal causes the decorator to alter at least one of a color, a density, a thickness, an alignment, and a Petition 870230045110, dated 05 / 29 / 2023, p. 32 / 186 26 / 165 consistency of subsequent decorations.

[0047] In another embodiment, the signal causes at least one of the inkwell, ink roller, plate cylinder, and blanket cylinder assemblies to move in a specific direction. In yet another embodiment, the control system may send a signal to an actuator to change the position of at least one of a printing plate on the plate cylinder and a transfer blanket on the blanket cylinder. In another embodiment, the control system may send a signal to an actuator of a drive roller associated with an inkwell assembly. The signal may alter the rate of movement of the drive roller. In this mode, the control system may adjust the amount of ink transferred to a printing plate associated with an inkwell assembly. More specifically, the control system may send a signal to decrease or increase the rate of movement of the drive roller.Optionally, in one embodiment, the method further comprises sending, via the control system, a signal to an ejector to remove the container with the abnormal decoration from the conveyor associated with the decorator.

[0048] In one embodiment, the at least one sensor comprises one to six sensors. In another embodiment, the one to six sensors are arranged to obtain data on the cylindrical body substantially simultaneously. Optionally, the one to six sensors are arranged around the cylindrical body of the metal container. In one embodiment, the at least one sensor comprises two to six sensors substantially uniformly arranged around a longitudinal geometric axis of the metal container. In one embodiment, each of the one to six sensors can obtain the same type of data. In another embodiment, the one to six sensors can obtain different types of data. For example, in one embodiment, the at least one sensor comprises one or more of: (i) a first sensor Petition 870230045110, dated 05 / 29 / 2023, p. 33 / 186 27 / 165 to obtain data on a decoration color; (ii) a second sensor to obtain data on a decoration density; (iii) a third sensor to obtain data on a decoration depth; (iv) a fourth sensor to obtain data on a decoration alignment; and (v) a fifth sensor to obtain data on a decoration consistency.

[0049] In one embodiment, the method also includes one or more of: (6) change the position of at least one paint sheet in response to receiving the signal from the control system; (7) provide a second container; (8) decorate the second container with the decorator; (9) wait a predetermined amount of time for the second container to reach at least one sensor; (10) obtain data about a decoration on the outer surface of the second container; and (11) determine, by the control system, whether the decoration on the second container includes an abnormality.

[0050] Another aspect of the present invention is a control system for monitoring and identifying decoration abnormalities and executing an action to correct the abnormalities. The control system includes instructions stored in a non-transient, computer-readable medium which, when executed by a processor of the control system, cause the control system to modify and change physical parameters and equipment to perform the methods described herein.

[0051] Yet another aspect is a non-transient computer-readable medium that has stored within it computer-executable instructions that cause a processor of a control system to execute a method of automatically correcting an abnormality in a decoration formed on a cylindrical surface of a metal container by a decorator. The instructions include one or more of, but are not limited to: (1) an instruction Petition 870230045110, dated 05 / 29 / 2023, page 34 / 186 28 / 165 to receive data relating to the decoration formed on the cylindrical surface of the metal container by the decorator; (2) an instruction to determine if the decoration includes an abnormality; and (3) if the decoration includes an abnormality, an instruction to determine an adjustment by the decorator to correct the abnormality. In one embodiment, the abnormality may relate to at least one of the color, density, thickness, alignment, and consistency of the decoration. Optionally, in another embodiment, the instructions may further comprise an instruction to determine a cause of the abnormal decoration.More specifically, in one embodiment, the instructions include an instruction to determine whether an abnormal decoration is related to one or more of: (i) an improper amount of ink; (ii) defective ink; (iii) a printing plate or a decorator transfer blanket; (iv) improper alignment or adjustment of a decorator component; and (v) a damaged or defective metal container. In one embodiment, the control system may determine that an abnormal decoration is related to a printing plate or a transfer blanket that is defective, worn, or improperly aligned based on the data received.

[0052] In one embodiment, the instructions still include an instruction to send a signal to the decorator to correct the abnormal decoration. In another embodiment, the signal may cause the decorator to alter at least one of a color, density, thickness, alignment, and consistency of subsequent decorations formed by the decorator. More specifically, in one embodiment, the signal may activate an actuator to move a component of the decorator in a specific direction. In another embodiment, the signal causes an actuator to move so that a quantity of paint transferred to a paint roller of the decorator is altered. Furthermore, Petition 870230045110, dated 05 / 29 / 2023, p. 35 / 186 29 / 165 or alternatively, the signal may cause a drive element to change the rotation rate of at least one of an ink roller and a transfer roller of an ink cartridge assembly.

[0053] In one embodiment, the instructions further include an instruction to send a signal to an actuator to adjust an ink blade. In one embodiment, the signal causes the actuator to move the ink blade in a specified direction relative to a decorator ink roller to alter the amount of ink applied to a portion of the ink roller. In another embodiment, the signal causes the actuator to move at least one decorator ink blade to a position which either increases or decreases the amount of ink transferred to a portion of the ink roller.

[0054] In another embodiment, the instructions may further include an instruction to send a signal to a decorator actuator to move at least one of an inkwell assembly, an ink roller, a conductor roller, a plate cylinder, a printing plate over the plate cylinder, a blanket cylinder, and a decorator transfer blanket in a specific direction. Optionally, the signal may alter the rotation rate of one or more of an ink roller, a transfer roller, a plate cylinder, and the blanket cylinder or alter the movement rate of a conductor roller.

[0055] In one embodiment, data are obtained by at least one sensor. Optionally, the at least one sensor comprises three to six sensors spaced substantially uniformly around a circumference of the metal container.

[0056] In one embodiment, the instruction to determine whether the decoration includes an abnormality still comprises an instruction to compare the received data with stored data associated with an acceptable decoration. The method may optionally include an instruction to determine that the decoration Petition 870230045110, dated 05 / 29 / 2023, page 36 / 186 30 / 165 includes an anomaly when the received data differs from the stored data by a predetermined amount. In one embodiment, the instructions further include an instruction to compare a plurality of portions of the received data with a corresponding plurality of portions of the stored data. Optionally, the instructions may include an instruction to determine that the decoration includes an anomaly when a predetermined percentage of the portions of the received data differs from the corresponding portions of the stored data.

[0057] In one embodiment, the stored data is stored in a database. The database may include a plurality of fields associated with acceptable decoration. In one embodiment, each field is associated with a paint blade of the decorator. In another embodiment, at least one field in the database includes information relating to acceptable decoration targets. The targets may comprise one or more of paint color, paint consistency, paint density, paint thickness, decoration orientation, and decoration alignment.

[0058] Optionally, the stored data may include sensor data obtained from a plurality of metal containers that include acceptable decorations. More specifically, in one embodiment, the control system includes instructions to receive data obtained by a sensor relating to a plurality of metal containers with acceptable decorations. The instructions may include an instruction for the control system to analyze the sensor data and an instruction to store the sensor data in database fields.

[0059] Yet another aspect of the present invention is a non-transient computer-readable means provided in a storage medium and having instructions that, when executed by a processor of a Petition 870230045110, dated 05 / 29 / 2023, page 37 / 186 31 / 165 control system instructions cause the processor to execute a method of detecting and correcting an abnormality in a decoration formed on a cylindrical surface of a container by a decorator. The instructions include one or more of, but are not limited to: (1) an instruction to receive data relating to the decoration formed on the cylindrical surface of the container; (2) an instruction to determine if the decoration includes an abnormality; and (3) an instruction to send a signal to the decorator to alter subsequent decorations formed by the decorator. In one embodiment, the data is received from a sensor. In another embodiment, the abnormality relates to at least one of the decoration's color, density, thickness, alignment, and consistency.In yet another modality, the signal causes the decorator to alter at least one of: (i) a color, (ii) a density, (iii) a thickness, (iv) an alignment, and (v) a consistency of subsequent decorations formed by the decorator.

[0060] Optionally, the instructions may also include an instruction to compare the data received from the sensor with data from an acceptable decoration. In one embodiment, the instructions may also include an instruction to determine whether the abnormal decoration is related to one or more of: (A) an improper amount of ink; (B) defective ink; (C) a defective printing plate or transfer blanket of the decorator; (D) improper alignment of a decorator component; and (E) a defective or damaged container. In one embodiment, the instructions may also include an instruction to determine whether the abnormal decoration is related to an unknown cause.

[0061] In one embodiment, the signal causes at least one of an inkwell assembly, an ink roller, a conductor roller, a transfer roller, a plate cylinder, a printing plate on the Petition 870230045110, dated 05 / 29 / 2023, page 38 / 186 32 / 165 plate cylinder, a blanket cylinder, and a decorator transfer blanket move in a specific direction or rotate at a different rate. For example, the signal may cause a drive element to rotate the ink roller or the transfer roller at a different rate to alter the amount of ink transferred to the printing plate. In another embodiment, the signal causes an actuator to move a decorator ink blade to a position which either increases or decreases the amount of ink transferred to a portion of an ink roller. In yet another embodiment, the signal causes an actuator associated with one or more of an inkwell assembly, an ink roller, a conductor roller, a plate cylinder, a printing plate on the plate cylinder, a blanket cylinder, and a decorator transfer blanket move in the specific direction. Optionally, the signal may alter the rate or timing of movement of a conductor roller.In this mode, the amount of ink transferred to a printing plate can be changed.

[0062] Another aspect of the present invention is to provide an ink cartridge assembly for a decorator. The ink cartridge assembly generally includes, but is not limited to, one or more of: (1) an ink roller; (2) an ink reservoir; (3) a plurality of ink blades positioned close to the ink roller, each ink blade defining an axial portion of the ink roller; and (4) an actuator associated with the ink blades, wherein, in response to a signal received from a control system, the actuator is operable to alter a position of an ink blade relative to the ink roller to adjust an amount of ink transferred to the ink roller. In one embodiment, a portion of each ink blade closest to the ink roller includes a longitudinal portion and an end portion extending from the longitudinal portion. In one embodiment, the longitudinal portion and the end portion have shapes that are substantially flat. Optionally, the portion of Petition 870230045110, dated 05 / 29 / 2023, p. 39 / 186 33 / 165 end extends from the longitudinal portion at an angle between approximately 80° and approximately 100°.

[0063] In one embodiment, an actuator is associated with each of the ink blades. In another embodiment, each actuator includes a shaft interconnected to an associated ink blade. Optionally, the shaft is threaded interconnected to an associated ink blade so that rotation of the shaft in a predetermined direction moves the associated ink blade either closer to or further away from the ink roller. In one embodiment, the actuator is a solenoid.

[0064] Optionally, the inkwell assembly may also include a potentiometer associated with each of the plurality of ink blades. In one embodiment, the potentiometer is operable to measure the movement of the ink blades relative to the ink roller. In another embodiment, the potentiometer may detect the rotation of the shaft. In one embodiment, the potentiometer includes a first gear that engages a second gear associated with an actuator.

[0065] Another aspect of the present invention is to provide a decorator with a conveyor roller that can be adjusted while the decorator is in operation decorating the metal containers. An actuator is associated with the conveyor roller. The actuator is operable to alter a rate of movement of the conveyor roller. In this mode, a quantity of ink transferred from a cartridge set to a printing plate can be altered. In one embodiment, the actuator can alter one or more of the timing of the conveyor roller's movement. In another embodiment, the actuator is operable to receive a signal from a control system.

[0066] Another aspect of the present invention is a control system for a decorator. The control system communicates with a sensor positioned downstream of the decorator. The sensor is operable to collect data on a cylindrical surface of a metal container decorated by the decorator. Optionally, the Petition 870230045110, dated 05 / 29 / 2023, p. 40 / 186The 34 / 165 sensor may comprise three to six sensors arranged around the metal container so that data are collected on all, or a substantial portion, of the cylindrical surface. In one embodiment, the three to six sensors are image detection devices such as cameras. The control system includes an instruction to compare the sensor data with a master image. The control system includes an instruction to determine if the decoration on the metal container is deficient compared to the master image. In one embodiment, the decoration is deficient if one or more of a decoration color, a decoration density, a decoration depth or thickness, a decoration alignment, a decoration consistency, and a decoration position vary by more than a predetermined amount from the master image.Optionally, the control system can determine that the decoration is defective if a color in the decoration in one or more target areas differs from a color in a corresponding target area of ​​the master image. In one embodiment, the decoration is defective if a color differs (has a ΔE) greater than a predetermined amount.

[0067] In one embodiment, the control system includes an instruction to determine a cause of the deficient decoration. Specifically, the control system can determine whether the deficient decoration is caused by the decorator or equipment located upstream of the decorator.

[0068] In one embodiment, the control system includes an instruction to determine that the deficient decoration is caused by one or more of: an incorrect adjustment of an inkwell assembly; an incorrect rotation rate of an ink roller or a transfer roller; an incorrect dwell time of a conductor roller; improper alignment of a printing plate; and improper alignment of a transfer blanket. The control system may optionally include a Petition 870230045110, dated 05 / 29 / 2023, page 41 / 186 35 / 165 instruction to send a signal to one or more decorator actuators to correct one or more of the following: incorrect adjustment of an inkwell assembly; incorrect rotation rate of an ink roller or transfer roller; incorrect dwell time of a conductor roller; improper alignment of a printing plate; and improper alignment of a transfer blanket.

[0069] In another embodiment, the control system includes an instruction to determine that the deficient decoration is caused by a problem that cannot be corrected by the control system. A problem that cannot be corrected includes one or more of, but is not limited to: a damaged printing plate; a damaged transfer blanket; a problem with the ink in an inkwell; and a damaged container. In response to determining that the problem cannot be corrected by the control system, the control system may include instructions to generate an alert. Optionally, the control system may include an instruction to stop the decorator when the deficient decoration is caused by a problem with the decorator that cannot be corrected. Additionally, or alternatively, the control system may include an instruction to upstream equipment of the decorator when the cause of the deficient decoration is a damaged container.

[0070] One aspect of the present invention is an apparatus for monitoring and adjusting a decoration formed on an outer surface of metal containers. The apparatus includes, but is not limited to, one or more of: (1) a decorator comprising an inkwell assembly, a printing plate, a transfer blanket, and a support element for receiving the metal container and moving the metal container in contact with the transfer blanket to transfer a decoration to a cylindrical outer surface of the metal container; (2) a sensor positioned downstream of the decorator. Petition 870230045110, dated 05 / 29 / 2023, p. 42 / 186 36 / 165 to obtain data from predetermined targets within the decoration on the cylindrical outer surface of the metal container relating to the quality of the decoration; and (3) a control system that receives the sensor data, the operable control system to compare the data with stored data to determine if the decoration is defective. If the decoration is defective, the control system can send an initial signal to adjust at least one of the inkwell assembly, a rotation rate of an ink roller of the inkwell assembly, a rotation rate of a transfer roller of the inkwell assembly, the printing plate, and the transfer blanket to correct the cause of the defective decoration. In addition, or alternatively, the control system can also determine if the structure of the metal container is defective.If the metal container structure is defective, the control system can send a second signal to at least one upstream display screen and equipment. Optionally, the stored data is stored in a database accessible by the control system.

[0071] In one embodiment, the sensor comprises three to six image detection devices arranged in a predetermined orientation to detect portions of the cylindrical outer surface of the metal container. In another embodiment, the control system can determine whether the defective decoration is associated with at least one of a decoration color, a decoration density, a decoration depth, a decoration alignment, a decoration consistency, and a decoration position.

[0072] In one embodiment, the sensor is operable to collect data on one or more of the decoration color, decoration density, decoration depth or thickness, decoration alignment, decoration consistency, decoration position, and metal container shape. Petition 870230045110, dated 05 / 29 / 2023, page 43 / 186 37 / 165

[0073] In another embodiment, the first signal is sent to an operable actuator to alter an amount of ink transferred to the transfer blanket while the decorator is in operation. Optionally, the actuator is operable to adjust a position of an ink key or an ink blade of the ink cartridge assembly. The ink cartridge assembly may include a plurality of ink blades, each of the plurality of ink blades including a longitudinal geometric axis. In one embodiment, each of the ink blades is configured to move generally parallel to the longitudinal geometric axis in response to a force received from an actuator. The actuator may move the ink blade generally linearly with respect to the ink roller to alter an amount of ink transferred to a printing plate. For example, the first signal may cause the actuator to rotate a threaded shaft coupled to the ink blade.By rotating the shaft in a first direction, the actuator can bring the ink blade closer to the ink roller, thereby decreasing the amount of ink transferred to the transfer blanket. In one embodiment, a potentiometer is associated with each of the plurality of ink blades. Each potentiometer is operable to determine the movement of an associated ink blade relative to the outer perimeter of the ink roller. Additionally, the actuator is operable to change the rate of movement of a drive roller positioned between the ink cartridge assembly and the printing plate. In one embodiment, the first signal is operable to move one or more of the printing plate and the transfer blanket while the decorator is in operation. Optionally, the first signal can also cause a drive element to change the rate of rotation of the ink roller and / or the transfer roller to change the amount of ink transferred to the printing plate.The drive element may comprise a motor. Petition 870230045110, dated 05 / 29 / 2023, page 44 / 186 38 / 165

[0074] Another aspect of the present invention is to provide a method for optimizing a decoration formed by a decorator on the outer surface of a metal container. The method includes one or more of, but is not limited to: (1) providing the metal container; (2) feeding the metal container into the decorator at a predetermined speed rate; (3) decorating the metal container with the decorator which includes an inkwell assembly, a printing plate, a transfer blanket, and a support element for moving the metal container in contact with the transfer blanket; (4) obtaining a captured image of the decoration on the outer surface of the metal container with an image capture device; (5) comparing, by a control system, the captured image with a stored image of a metal container with an acceptable decoration;(6) determine, by the control system, whether the captured image meets density quality parameters that correspond to one or more criteria; and (7) send, by the control system, a signal to the decorator to change at least one of a color, density, thickness, alignment, and consistency of ink transferred to the transfer blanket. In addition, or alternatively, the control system may send a signal to a display device in communication with the control system.

[0075] In one embodiment, the signal is operable to cause at least one of an ink blade of the inkwell assembly, the printing plate, and the transfer blanket to move in a specific direction while the decorator is in operation. The signal can cause an actuator to move the ink blade generally linearly relative to an ink roller of the decorator. In this mode, the signal can alter the amount of ink transferred to a portion of the transfer blanket. In another embodiment, the signal alters the rate of movement of a driver roller positioned upstream of the printing plate. Petition 870230045110, dated 05 / 29 / 2023, p. 45 / 186 39 / 165 printing while the decorator is in operation. Additionally, or alternatively, the signal can change the rotation rate of an ink roller or a transfer roller in the ink cartridge assembly. In this mode, the signal can alter the amount of ink transferred to the transfer blanket.

[0076] Optionally, the method may also include: To determine, through the control system, that the metal container is defective; and to send, through the control system, a signal from at least one display device and equipment located upstream of the decorator. In another embodiment, the method also includes: when the captured image does not meet the quality parameters, to determine, through the control system, that the decoration is defective due to one or more of an improper quantity of ink, a defective ink, a defective printing plate, a defective transfer blanket, and an improper alignment of a component of the decorator.

[0077] In one embodiment, the method includes forming the stored image by collecting images by the image capture device from a plurality of metal containers with acceptable decorations; and storing the stored image in a database accessible by the control system.

[0078] Yet another aspect of the present invention is a non-transient computer-readable means comprising a set of instructions stored therein which, when executed by a processor of a control system, causes the processor to adjust a component of a container decorator while the container decorator is in operation, by one or more of: (1) receiving data from a sensor, the capture data relating to a decoration formed by the container decorator on a cylindrical outer surface of a metal container; (2) comparing the Petition 870230045110, dated 05 / 29 / 2023, page 46 / 186 40 / 165 data with an image of an acceptable decoration; (3) determine if the decoration on the outer cylindrical surface of the metal container includes an abnormality relating to at least one of the decoration's color, density, thickness, alignment, and consistency; (4) prepare an instruction for the container decorator to address the cause of the abnormality; and (5) send the instruction to the container decorator to adjust the container decorator component to correct the abnormality. The instruction may be configured to cause the container decorator to adjust at least one of the following: a paint blade position, a paint roller rotation rate, and a transfer roller rotation rate.Optionally, the instructions may also include determining whether the abnormal decoration is related to one or more of the following: improper ink quantity, defective ink, a defective printing plate or transfer blanket of the container decorator, and improper alignment of a component of the container decorator.

[0079] In one embodiment, sending the instruction causes the container decorator to change at least one of a color, density, thickness, alignment, and consistency of subsequent decorations. In another embodiment, the instruction directs the container decorator to change an adjustment or position of at least one of the container decorator's inkwell assembly, ink roller, conductor roller, transfer roller, plate cylinder, printing plate on the plate cylinder, blanket cylinder, and transfer blanket.

[0080] In one embodiment, sending the instruction causes a container decorator actuator to move at least one of an ink blade from an inkwell assembly, a conductor roller, a printing plate, and a transfer blanket in a specific direction. A Petition 870230045110, dated 05 / 29 / 2023, p. 47 / 186 The 41 / 165 ink blade includes a longitudinal geometric axis. The instruction can cause the actuator to move the ink blade generally parallel to the longitudinal geometric axis relative to an ink roller. In this mode, the instruction causes the ink blade to increase or decrease the amount of ink transferred to a printing plate. Optionally, the instruction can cause the actuator to rotate a threaded shaft coupled to the ink blade. When the actuator rotates the shaft in a first direction, the ink blade moves toward the ink roller, thereby decreasing the amount of ink transferred to a portion of a printing plate. Alternatively, the actuator can rotate the shaft in a second direction to move the ink blade away from the ink roller to increase the amount of ink transferred to that portion of the printing plate.In addition, or alternatively, the instruction may cause a drive element to change the rotation rate of an ink roller or a decorator transfer roller. Increasing the rotation rate of the ink roller may increase the amount of ink transferred to the printing plate. Alternatively, decreasing the rotation rate of the ink roller may decrease the amount of ink transferred to the printing plate. In one embodiment, the drive element is a motor, such as an electric motor.

[0081] In one embodiment, the sensor is a plurality of cameras positioned downstream of the container decorator in a predetermined orientation. Optionally, at least one camera comprises three to six cameras positioned around a circumference of the cylindrical outer surface of the metal container. The plurality of cameras is configured to collect data from predetermined targets within the decorator.

[0082] In another embodiment, the container decorator comprises an inkwell assembly that includes at least one ink blade, a Petition 870230045110, dated 05 / 29 / 2023, page 48 / 186 42 / 165 printing plate, a transfer blanket, and a support element for moving the metal container in contact with the transfer blanket. The control system may include, but is not limited to, one or more of a memory, an input device, an output device, and the processor which is in communication with the memory, the input device, and the output device.

[0083] In one embodiment, the computer-readable means further comprises: forming the image of acceptable decoration by collecting images with the sensor of a plurality of metal containers with acceptable decorations; and storing the image in a database accessible by the control system.

[0084] Although generally referred to herein as metal container, beverage container, can, and container, it should be appreciated that the present invention can be used to decorate containers of any size or shape including, without limitation, beverage cans, beverage bottles, and aerosol containers. Consequently, the term container is intended to cover containers of any type or shape for any product and is not specifically limited to a beverage container, such as a soda or beer can. The containers can also be in any state of manufacture and can be formed by a deep drawing and smoothing process or by an impact extrusion process. Thus, the present invention can be used to decorate a cup that is subsequently formed into a finished container, a pre-formed bottle that is subsequently formed into a metal bottle, or a tube that is formed into an aerosol container body.

[0085] The terms metal or metallic, as used herein, refer to any metallic material that can be used to form a container, including without limitation, aluminum, steel, tin, and any combination thereof. However, it will be appreciated that the apparatus and Petition 870230045110, dated 05 / 29 / 2023, p. 49 / 186 43 / 165 The method of the present invention can be used in various forms and embodiments to decorate containers made of any material, including paper, plastic and glass.

[0086] The methods and apparatus of the present invention can be used with inks of any type or variety. For example, one or more special inks, including pigmented ink, thermochromic ink, photochromic ink, scented thermochromic ink, fluorescent ink, UV ink, black light ink, infrared ink, phosphorescent ink, pressure-sensitive ink, tactile ink, thermotactile ink, leuco dye, matte ink, and any other type of ink, dye, or varnish that changes appearance, color, phase, and / or texture in response to changes in temperature or exposure to light or pressure, can be used with a decorator of the present invention.

[0087] The sentences at least one, one or more, and / or, as used here, are open expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions at least one of A, B and C, at least one of A, B or C, one or more of A, B and C, one or more of A, B, or C, and A, B, and / or C means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

[0088] Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and embodiments are to be understood as being modified in all cases by the term approximately. Consequently, unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, ratios, ranges, and so forth used in the specification and embodiments may be increased or decreased by approximately 5% to achieve satisfactory results. Furthermore, all ranges described herein may be reduced to any Petition 870230045110, dated 05 / 29 / 2023, page 50 / 186 44 / 165 subrange or portion of the range, or for any value within the range without deviating from the invention.

[0089] The term "one" or "an entity," as used herein, refers to one or more of that entity. As such, the terms "one," "one or more," and "at least one" may be used interchangeably herein.

[0090] The use of including, comprising, or having and their variations here is intended to encompass the items listed below and their equivalents, as well as additional items. Consequently, the terms including, comprising, or having and their variations may be used interchangeably here.

[0091] It should be understood that the term means, as used herein, shall be given its broadest possible interpretation in accordance with 35 USC, Section 112(f). Consequently, an embodiment incorporating the term means shall cover all structures, materials, or acts presented herein, and all their equivalents. Furthermore, the structures, materials, or acts and their equivalents shall include all those described in the Summary of the invention, Brief description of the drawings, Detailed description, Abstract, and embodiments themselves.

[0092] The term automatic and its variations, as used herein, refers to any process or operation performed without material human input when the process or operation is executed. However, a process or operation may be automatic even if the performance of the process or operation utilizes material or immaterial human input, if the input is received prior to the performance of the process or operation. Human input is considered material if such input influences how the process or operation will be executed. Human input that consents to the performance of the process or operation is not considered material. Petition 870230045110, dated 05 / 29 / 2023, page 51 / 186 45 / 165

[0093] The term bus and its variations, as used herein, can refer to a subsystem that transfers information and / or data between various components. A bus generally refers to the hardware communication interface, interconnects, bus architecture, standard, and / or protocol that defines the communication scheme for a communication system and / or communication network. A bus can also refer to a part of a communication hardware that interfaces the communication hardware with other components of the corresponding communication network. The bus can be for a wired network, such as a physical bus, or a wireless network, such as part of an antenna or hardware that couples the communication hardware with the antenna. A bus architecture supports a defined format in which information and / or data are arranged when sent and received across a communication network.A protocol can define the format and communication rules of a bus architecture.

[0094] A communication mode may refer to any defined protocol or standard or specific communication sections or interactions, such as Voice over Internet Protocol (VoIP) bus architecture, cellular communication (e.g., IS-95, 1G, 2G, 3G, 3.5G, 4G, 4G / IMT Enhanced, 3GPP, WiMAX™, GSM, CDMA, CDMA2000, EDGE, 1xEVDO, iDEN, GPRS, HSPDA, TDMA, UMA, UMTS, ITU-R, and 5G standards), Bluetooth™, text or instant messaging (e.g., AIM, Blauk, eBuddy, Gadu-Gadu, IBM Lotus Sametime, ICQ, iMessage, IMVU, Lync, MXit, Paltalk, Skype, Tencent QQ, Windows Live Messenger™ or Microsoft Network (MSN) Messenger™, Wireclub, Xfire, and Yahoo! Messenger™), email, Twitter (e.g., tweeting), Digital Service Protocol (DSP), and similar.

[0095] The term communication system or network of Petition 870230045110, dated 05 / 29 / 2023, page 52 / 186 46 / 165 Communication and its variations, as used herein, may refer to a collection of communication components capable of transmitting, transferring, interconnecting, controlling, or otherwise manipulating information or data from at least one transmitter to at least one receiver. As such, communication may include a range of systems that support point-to-point or data transmission. A communication system may refer to the individual communication hardware as well as the interconnections associated with and interconnecting the individual communication hardware. Communication hardware may refer to dedicated communication hardware or may refer to a processor coupled with a communication medium (i.e., an antenna) and executing software capable of using the communication medium to send and / or receive a signal within the communication system.Interconnection refers to some type of wired or wireless communication connection that connects various components, such as communication hardware, within a communication system. A communication network may also refer to a specific configuration of a communication system with the collection of individual communication hardware and interconnection that have some definable network topography. A communication network may include a wired and / or wireless network that has a pre-setup for an ad hoc network structure.

[0096] The term computer-readable medium, as used herein, refers to any tangible storage and / or transmission medium that participates in providing instructions to a processor for execution. Such a medium may take many forms, including, but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, non-volatile random access memory (NVRAM) or magnetic or optical disks.Volatile memory includes dynamic memory, such as core memory. Common forms of readable media... Petition 870230045110, dated 05 / 29 / 2023, page 53 / 186 47 / 165 computer devices include, for example, a floppy disk, a floppy disk, a hard disk, magnetic tape or any other magnetic medium, magneto-optical medium, read-only memory (ROM), a compact disc read-only memory (CD-ROM), any other optical medium, punched cards, paper tape, any other physical medium with hole patterns, a random access memory (RAM), a programmable read-only memory (PROM), and an erasable programmable read-only memory EPROM, a FLASH-EPROM, a solid-state medium such as a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read. A digital file attachment to an email or other file or set of self-contained information files is considered a distribution medium equivalent to a tangible storage medium.When the computer-readable medium is configured as a database, it should be understood that the database can be any type of database, such as relational, hierarchical, object-oriented, and / or similar. Consequently, the description is considered to include a tangible storage medium or distribution medium and recognized equivalents of the prior art and successor media, in which the software implementations of the present description are stored. It should be noted that any computer-readable medium that is not a signal transmission can be considered non-transient.

[0097] The terms display and their variations, as used herein, may be used interchangeably and may be any panel and / or area of ​​an output device that can display information for an operator or use. Displays may include, but are not limited to, one or more control panel(s), instrument housing(s), gauge(s), meter(s), light(s), computer(s), Petition 870230045110, dated 05 / 29 / 2023, page 54 / 186 48 / 165 display(s), heads-up display (HUD) unit(s), and graphical user interface(s).

[0098] The term module, as used herein, refers to any known or subsequently developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software capable of performing the functionality associated with that element.

[0099] The term desktop refers to a metaphor used to depict systems. A desktop is generally considered a surface that may include images, called icons, widgets, folders, etc., that can activate and / or display applications, windows, cabinets, files, folders, documents, and other graphical items. Icons are generally selectable to initiate a task through user interface interaction to allow a user to run applications and / or conduct other operations.

[0100] The term display refers to a portion of a physical screen used to display a computer's output to a user.

[0101] The term displayed image refers to an image produced on the display. A typical displayed image is a window or desktop. The displayed image may occupy all or a portion of the display.

[0102] The term electronic address may refer to any contactable address, including a telephone number, instant messaging address, email address, Uniform Resource Locator (URL), Globally Universal Identifier (GUID), Universal Resource Identifier (URI), Address of Record (AOR), electronic alias in a database, etc., and combinations thereof.

[0103] The term screen, touch screen, touch-sensitive screen or touch-sensitive display refers to a physical structure that allows the user to interact with the computer by touching areas of the screen and provides information to a user through a display. The touch screen Petition 870230045110, dated 05 / 29 / 2023, page 55 / 186 49 / 165 can detect user contact in a number of different ways, such as by a change in an electrical parameter (e.g., resistance or capacitance), variations in acoustic waves, proximity detection of infrared radiation, light variation detection, and the like. In a resistive touchscreen, for example, conductive and resistive metal layers, normally separated in the screen, carry an electric current. When a user touches the screen, the two layers make contact at the contacted location, thereby a change in the electric field is noticed and the coordinates of the contacted location are calculated. In a capacitive touchscreen, a capacitive layer stores an electrical charge, which is discharged to the user upon contact with the touchscreen, causing a decrease in the charge of the capacitive layer. The decrease is measured and the coordinates of the contacted location are determined.In a surface acoustic wave touchscreen, an acoustic wave is transmitted through the screen, and the acoustic wave is disturbed by user contact. A receiving transducer detects the instance of user contact and determines the contacted location coordinates.

[0104] The term window refers to a displayed image, typically rectangular, over at least part of a display that contains or provides content different from the rest of the screen. The window may obscure the desktop. The dimensions and orientation of the window may be configurable either by another module or by a user. When the window is expanded, it may occupy substantially all the display space on a screen or screens.

[0105] The terms determine, calculate and compute, and their variations, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation, or technique.

[0106] The Summary of the Invention is not intended to, nor should it be Petition 870230045110, dated 05 / 29 / 2023, page 56 / 186 50 / 165 is considered representative of the full extent and scope of the present invention. Furthermore, references made herein to the present invention or to aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be considered as limiting all embodiments to a specific description. As will be appreciated, other embodiments are possible using, alone or in combination, one or more of the features presented above or described below. For example, it is contemplated that several features and devices shown and / or described with respect to one embodiment may be combined with or substituted for features or devices of other embodiments regardless of whether or not such combination or substitution is specifically shown or described herein.The present invention is presented in various levels of detail in the Summary of the Invention, as well as in the accompanying drawings and the Detailed Description, and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements or components. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken in conjunction with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0107] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate embodiments of the invention and, together with the Summary of the Invention provided above and the Detailed Description provided below, serve to explain the principles of these embodiments. In certain cases, details that are not necessary for an understanding of the description or that make other details difficult to perceive may be omitted. It should be understood, of course, that the present invention is not necessarily limited to the specific embodiments illustrated herein. Petition 870230045110, dated 05 / 29 / 2023, page 57 / 186 51 / 165 Furthermore, it should be understood that the drawings are not necessarily to scale.

[0108] Figure 1 is a schematic flowchart of a decorator that presents an embodiment of the present invention and also illustrating a metal container decorated by the decorator of the present invention;

[0109] Figure 1A is another schematic flowchart of another embodiment of a decorator of the present invention;

[0110] Figure 2A is a top plan view of various components of an ink cartridge assembly of an embodiment of the present invention;

[0111] Figure 2B is a top plan view of an ink sheet of an embodiment of the present invention;

[0112] Figure 2C is a top plan view of another embodiment of an ink sheet of the present invention which includes transverse grooves that define portions of the ink sheet;

[0113] Figure 2D is yet another top plan view of an ink sheet of the present invention which comprises a plurality of individual sheet segments;

[0114] Figure 2E is another top plan view of an ink sheet of an embodiment of the present invention with a plurality of ink channels;

[0115] Figure 3A is a side elevation cross-sectional view of the cartridge assembly taken along line 3A-3A in Figure 2A and showing a first gap between a blade segment and an ink roller of the cartridge assembly;

[0116] Figure 3B is another side elevation cross-sectional view of the ink cartridge assembly taken along line 3B-3B of Figure 2A and showing a second gap between another blade segment and the ink roller of the cartridge assembly wherein the second gap has a greater length than the first gap;

[0117] Figures 3C, 3D are top-down plan views of a set of Petition 870230045110, dated 05 / 29 / 2023, p. 58 / 186 Figure 52 / 165 of the ink cartridge of the present invention generally illustrates the axial movement of an ink blade relative to an ink roller;

[0118] Figure 4 is a front elevation view in cross section of a cartridge assembly of another embodiment of the present invention;

[0119] Figure 5 is a top perspective view of the inkwell assembly of Figure 4;

[0120] Figure 6 is a top perspective view of the inkwell assembly of Figure 5 with some components removed for clarity;

[0121] Figure 7 is a front elevation cross-sectional view of the inkwell assembly of Figure 4 taken along line 77 of Figure 5;

[0122] Figure 8 is a perspective view in right side cross-section of the inkwell assembly of Figure 4 taken along line 8-8 of Figure 7;

[0123] Figure 9 is a top perspective view of the ink blades and actuators of the inkwell assembly of Figure 4;

[0124] Figures 10A, 10B are side elevation views in cross section of ink blades relative to the ink roller of the inkwell assembly in Figure 4;

[0125] Figure 11 is a flowchart illustrating the transfer of ink from axial portions of ink rollers to corresponding cylindrical portions of a metal container;

[0126] Figures 12A - 12C are top plan views of sensors positioned around a longitudinal geometric axis of a metal container to detect the cylindrical surface of the metal container at predetermined locations according to various embodiments of the present invention;

[0127] Figure 13 is a block diagram of an embodiment of a control system of the present invention; Petition 870230045110, dated 05 / 29 / 2023, page 59 / 186 53 / 165

[0128] Figure 14 is a block diagram of one embodiment of a data structure for storing sensor data;

[0129] Figure 15 is a flowchart of a method used with a control system to recognize an acceptable decoration according to an embodiment of the present invention;

[0130] Figure 16 is a process flowchart of a method for identifying a cause of a deficient decoration;

[0131] Figure 17 is a flowchart that presents a process for automatically adjusting a decorator to correct a deficiency in a decoration on a metal container according to an embodiment of the present invention;

[0132] Figure 18 is a flowchart that presents a process for operating a decorator according to a modality; and

[0133] Figure 19 is another flowchart of another modality of a process for operating a decorator.

[0134] Similar components and / or features may have the same reference number. Components of the same type may be distinguished by a letter following the reference number. If only the reference number is used, the description is applicable to any of the similar components that have the same reference number. To aid in understanding an embodiment of the present invention, the following list of components and associated numbering found in the drawings is provided here: Component Number Decorator First cylinder of plates Printing plate of the first cylinder of plates First set of ink cartridges Ink roller from the first set of ink cartridges. Ink train Petition 870230045110, dated 05 / 29 / 2023, p. 60 / 186 54 / 165 Second cylinder of plates Conductor roller Printing plate of the second cylinder of plates Second set of inkwells Ink roller for the second set of inkwells Ink train Axial portion of the paint roller Ink blade Ink blade Segments or portions of a blade Grooves Ink Longitudinal edge of blade segments Ink key Ink channel Actuator Axle Gap between ink blade segment and ink roller Threads Ink reservoir Ink blade edge Blanket cylinder Transfer blankets (or printing blankets) Outer surface portion of the transfer blanket Supporting element Station on the support element for the metal container. Control system Transporter Sensor Sensor Petition 870230045110, dated 05 / 29 / 2023, page 61 / 186 55 / 165 Light Undecorated metal container Decorated metal container External surface of a metal container. Cylindrical container portions Decoration Target Metal container with poor decoration. Ejector Upstream equipment Downstream equipment Foundry Mounting plate Articulating blocks Side walls Top plate Ink bar Rear plate Potentiometer Busbar CPU Input devices Output devices Storage devices Computer-readable storage media reader Communication system Working memory Processing acceleration unit Database Network Petition 870230045110, dated 05 / 29 / 2023, page 62 / 186 56 / 165 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 140 142 144 146 148 150 152 154 156 158 160 166 disabled 168 Remote storage device / database Operating system Another code Data structure Ellipses Ellipses First data object Identifier Color Density Thickness Position / Alignment Consistency Others Records Second data object Method of programming the control system Start Provide a metal container with decoration. Detecting the decoration Control system analyzes sensor data. The control system stores sensor data. Repeat To provide a metal container with poor decoration. Defective decoration sensor Control system identifies deficient decoration. End A method for determining the cause of a decoration. Start Petition 870230045110, dated 05 / 29 / 2023, page 63 / 186 57 / 165 170 Receiving data from the sensor 172 Determine if the decoration is satisfactory. 174 Determine if an improper quantity of ink is transferred. 176 Determine if a defective ink is present. 178 Determine if a defective printing plate or transfer blanket is present. 180 Determine if the position or alignment of the decoration is improper. 181 Determine if the metal container is damaged. 182 Undetermined disability 184 Optionally remove defective metal container 186 Optionally send an alert 188 End 200 Method of automatically adjusting a decorator to correct a faulty decoration 202 Home 204 Move ink keys to initial position 206 Transferring ink to axial portions of ink rollers 208 Transferring ink to printing plates 210 Transferring ink from printing plates to transfer blankets 212 Transferring ink from transfer blankets to metal containers 214 Wait a predetermined period of time 216 Detect decorations on metal containers using at least one sensor 218 Determine if the decoration is satisfactory. 220 Optionally remove metal containers with faulty decorations. Petition 870230045110, dated 05 / 29 / 2023, p. 64 / 186 58 / 165 222 Send alert 224 Determine whether to continue decoration operation 226 Adjust at least one element of the decorator 228 Drive decorated metal containers to downstream equipment 230 Determine whether the decoration production operation should continue 232 End 238 Method of operating a decorator 240 Start 242 Decorating a metal container 244 Receiving data from a sensor 246 Determining if the decoration is satisfactory 248 Determining if poor decoration is caused by decorator 250 Send signal to adjust decorator 252 Determine if poor decoration is caused by upstream equipment 254 Undetermined deficiency 256 Send an alert 258 Determine if production operation should continue 260 End 262 Method of operating a decorator 264 Start 266 Decorate a metal container 268 Receive data from a sensor 270 Determine if the decoration is satisfactory 272 Determine if the cause is correctable by the control system 274 Send a signal to make the correction 276 Send an alert Petition 870230045110, dated 05 / 29 / 2023, page 65 / 186 59 / 165 278 Determine whether the production operation should continue. 280 End DETAILED DESCRIPTION

[0135] The present invention has significant benefits through a wide spectrum of endeavors. It is the Applicant's intention that this specification and the embodiments attached hereto be agreed upon as comprehensive as possible in maintaining the scope and spirit of the invention being described, notwithstanding what might appear to be limiting language imposed by the requirements of reference to the specific examples described. To familiarize persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment illustrating the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the accompanying drawings which form a part of the specification. Exemplary embodiments are described in detail without attempting to describe all the various forms and modifications in which the invention could be embodied.As such, the embodiments described herein are illustrative, and as will be apparent to those skilled in the art, can be modified in numerous ways within the scope and spirit of the invention.

[0136] Referring now to Figure 1, a schematic flowchart of a decorator 2 of the present invention is illustrated. The decorator 2 generally comprises at least one plate cylinder 4, 12, at least one printing plate 6, 14 interconnected to each of the plate cylinders 4, 12, at least one inkwell assembly 8, 16 which includes an ink roller 10, 18 associated with each plate cylinder 4, 12, a blanket cylinder 36, transfer blankets 38 interconnected to the blanket cylinder 36, a support element 42, a control system 46, a sensor 50, and optionally, one or more of a light 51 and an ejector 62. Petition 870230045110, dated 05 / 29 / 2023, page 66 / 186 60 / 165

[0137] The ink roller 10, 18 of each inkwell set 8, 16 is in a predetermined alignment with the plate cylinder 4, 12 with which it is associated. The ink rollers 10, 18 of each inkwell assembly 8, 16 transfer one color of ink to the printing plates 6, 14 of each plate cylinder 4, 12. The first inkwell assembly 8 transfers the first color or type of ink to one or more printing plates 6 of the first plate cylinder 4. Similarly, the second inkwell assembly 16 transfers a second color or type of ink to one or more printing plates 14 of the second plate cylinder 12. It will be appreciated that the decorator 2 may include any number of inkwell and plate cylinder assemblies to transfer a plurality of inks to the transfer blankets 38 of the blanket cylinder 36. In one embodiment, the decorator 2 includes from two to eleven associated inkwell and plate cylinder assemblies.In one embodiment, each cylinder of plates 4, 12 has only one printing plate 6, 14.

[0138] In one embodiment, the ink rollers 10, 18 contact a portion of the outer surface of the printing plates 6, 14. Optionally, in another embodiment, the ink rollers 10, 18 do not contact the printing plates 6, 14. More specifically, the ink rollers 10, 18 transfer the ink 26 to one or more intermediate transfer rollers of an ink train 11, 19. The intermediate transfer rollers form a path through which the ink is transferred from the ink rollers 10, 18 to the intermediate transfer rollers of the ink train 11, 19, and then to the printing plates 6, 14. Each ink roller 10, 18 may have an associated ink train 11, 19. The ink rollers 10, 18 contact a first transfer roller in each ink train 11, 19. The printing plates 6, 14 contact the final transfer roller of each ink train 11, 19. One of the rollers of each ink train ink train 11, 19 could be a conductor roller 13. In one embodiment, the ink rollers 10, 18 periodically contact a Petition 870230045110, dated 05 / 29 / 2023, p. 67 / 186 61 / 165 drive roller 13. An actuator or drive element may be associated with the ink rollers 10, 18 as well as one or more of the transfer rollers of the ink train 11, 19. In one embodiment, the ink rollers 10, 18 rotate at a different rate than the transfer rollers of the ink train 11, 19. Optionally, the control system 46 may send a signal to a drive element to change the rotation rate of at least one of an ink roller 10, 18 and a transfer roller of an ink train 11, 19 to change the amount of ink transferred to a printing plate 6, 14.

[0139] Any suitable ink train 11, 19 may be used with the decorator 2 of the present invention. The intermediate transfer rollers of the ink trains 11, 19 may have a variety of different diameters.Although only three intermediate transfer rollers are illustrated in the ink trains 11, 19, one skilled in the art will appreciate that any number of intermediate transfer rollers may be included in the ink trains 11, 19. An example of an ink train that may be used with the decorator of the present invention is described in US Patent Application Publication 2017 / 0008270, which is incorporated herein by reference in its entirety. In one embodiment, the ink rollers 10, 18 rotate in a first direction as the plate cylinders 4, 12 rotate in a second, opposite direction.

[0140] Referring now to Figure 2A, a portion of an ink cartridge assembly 8A or 16A of an embodiment of the present invention is illustrated. The amount of ink 26 transferred by the ink cartridge assembly 8A, 16A to the one or more printing plates 6, 14 associated with each plate cylinder 4, 12 can be individually adjusted along a plurality of axial portions 20A - 20L of each ink roller 10, 18. More specifically, each ink cartridge assembly 8A, 16A includes an ink blade 22 that meters the ink 26 over the ink roller. Petition 870230045110, dated 05 / 29 / 2023, p. 68 / 186 62 / 165 10, 18. In one embodiment, the ink blade 22 is continuous along the length of the ink roller 10, 18. Segments 24 of the ink blade 22 correspond to one of the axial portions 20.

[0141] Referring now to Figure 2B, in one embodiment, the ink blade 22A has a generally flat shape. Portions 24A - 24L of the ink blade 22A can move relative to the corresponding axial portions 20A - 20L of the ink roller 10, 18. In one embodiment, portions 24 of the ink blade 22A can bend in response to a force to move closer to, or away from, an ink roller 10, 18.

[0142] Alternatively, and now referring to Figure 2C, the ink blade 22B includes blade segments 24 formed by transverse cuts or grooves 25 through the ink blade 22B. The grooves 25 extend along at least a portion of the width of the ink blade 22B. The blade segments 24 are individually adjustable with respect to the ink roller 10, 18. Each of the blade segments 24A - 24L defines a corresponding axial portion 20A - 20L of the ink roller 10, 18. In one embodiment, the grooves 25 extend through a longitudinal edge of the ink blade 22B that will be positioned closest to the ink roller 10, 18.

[0143] Referring now to Figure 2D, in another embodiment, the ink blade 22C comprises a plurality of individual blade segments 24A - 24L. Each blade segment 24A - 24L is formed separately from other blade segments 24A - 24L. In one embodiment, a longitudinal edge 27 of each blade segment 24 is disposed closer to a longitudinal edge 27 of at least one adjacent blade segment 24. In one embodiment, each blade segment 24A - 24L defines an axial portion 20 of the ink roller 10, 18. Each blade segment 24A - 24L is individually movable with respect to the ink roller 10, 18 and an axial portion. Petition 870230045110, dated 05 / 29 / 2023, page 69 / 186 63 / 165 corresponding to 20A - 20L.

[0144] Optionally, in another embodiment generally illustrated in Figure 2E, the ink blade 22D may comprise a plurality of channels 29A - 29L that guide the ink 26 to a corresponding axial portion 20 of the ink roller 10, 18. In contrast to other ink blades described herein, in one embodiment, the ink blade 22D is not movable relative to the ink roller 10, 18. In another embodiment, a pump directs the ink 26 to the channels 29. In one embodiment, the pump may individually control the amount of ink flowing to each of the channels 29. Optionally, each channel 29A - 29L may be associated with an individual pump.

[0145] Referring again to Figure 2A, in one embodiment, a 28A - 28L ink key is associated with each of the blade segments 24. Each ink key 28 can be individually advanced and retracted relative to the ink blade 22 and a corresponding blade segment 24. In one embodiment, the position of each 28A - 28L ink key can be adjusted by an actuator 30A - 30L. In one embodiment, the ink blade 22 is flexible. In another embodiment, each individual blade segment 24A - 24L is flexible. Consequently, portions 24A - 24L of the ink blade 22 can be positioned in close proximity to the outer surface of the ink roller 10, 18 or, alternatively, further away from the ink roller 10, 18 in response to the movement of the ink keys 28. In one embodiment, the ink blade 22 is tensioned away from the ink roller 10, 18.In this embodiment, the movement of an ink key 28 away from the ink roller 10, 18 allows at least a portion of the ink blade 22 closest to the ink key 28 to move away from the ink roller 10, 18. Optionally, the ink blade 22 is positioned articulated with respect to the longitudinal geometric axis of the ink roller 10, 18. In this mode, the blade segments 24A - 24L. Petition 870230045110, dated 05 / 29 / 2023, p. 70 / 186 64 / 165 can articulate with respect to the outer surface of the ink roller 10, 18. Optionally, a cycle rate of a conveyor roller 13 of the decorator 2 can be adjusted to change the amount of ink on the ink roller 10, 18 after the ink is applied by the segments 24 of the ink blade 22. In this mode, the control system 46 can change the amount of ink transferred to a printing plate 6, 14.

[0146] Referring now to Figure 3A, in one embodiment, by advancing the ink key 28A, a portion 24A of the ink blade 22 is pushed towards the ink roller 10, 18. In this mode, a gap 32A between the blade portion 24A and the axial portion 20A of the ink roller 10, 18 is reduced in length. This reduces the amount of ink 26 transferred to the axial portion 20A of the ink roller 10, 18 and subsequently to the printing plates 6, 14. As presented, the gap 32A generally defines the density or thickness of ink 26 which is transferred to the ink roller 10, 18 and subsequently to a metal container 52. The ink density generally refers to the amount of ink used to form the decoration. When the ink density is incorrect, the color of the decoration may be incorrect. For example, background colors may be at least partially visible through the paint used for decoration.In one embodiment, the gap 32 between a portion of the ink blade 24 and an axial portion 20 of the ink roller 10, 18 can vary from approximately 0 mm (0 inches) to approximately 0.38 mm (0.015 inches). In another embodiment, the gap 32 can be up to approximately 0.50 mm (0.02 inches). In another embodiment, the gap can be between approximately 0.025 mm (0.001 inches) and approximately 0.50 mm (0.02 inches). In one embodiment, the movement of the ink switch 28A is initiated by the actuator 30A. The actuator 30A can receive a signal from the control system 46 to change the position of the ink switch 28A to change the size of the gap 32. Petition 870230045110, dated 05 / 29 / 2023, page 71 / 186 65 / 165

[0147] Alternatively, and referring now to Figure 3B, by retracting the ink key 28B, blade portion 24B moves away from the axial portion 20B of the ink roller 10, 18. In this mode, the gap 32B is increased in length, increasing the amount of ink 26 transferred to the axial portion 20B of the ink roller 10, 18 and subsequently to the printing plates 6, 14.

[0148] Referring now to Figures 3C, 3D, in an optional embodiment of the present invention, the individual segments 24 of the ink blade 22C can be moved axially with respect to a geometric axis of rotation of the ink roller 10, 18. For example, in one embodiment, the blade segment 24F can be moved axially with respect to the blade segments 24E, 24G. Optionally, at least a portion of blade segment 24F can overlap one of the blade segments 24E, 24G, as generally illustrated in Figure 3D. It will be appreciated by one skilled in the art that all blade segments 24 can be repositioned axially in the same or similar manner. Furthermore, each of the blade segments 24 can be moved radially with respect to the ink roller 10, 18 as previously described.

[0149] Referring now to Figures 4-10, an 8B inkwell assembly, 16B according to another embodiment of the present invention is generally illustrated. The inkwell assembly 8B, 16B is similar to the inkwell assembly 8A, 16A described in conjunction with Figures 2-3 and operates in a similar mode. Notably, the inkwell assembly 8B, 16B includes individual ink blades 21 that generally move linearly with respect to the ink roller 10, 18. Each of the ink blades 21 is individually positionable with respect to the ink roller 10, 18. Although six ink blades 21A - 21F are illustrated, the inkwell assembly may have any number of individual ink blades 21. In one embodiment, the ink cartridge assembly 8B, 16B includes Petition 870230045110, dated 05 / 29 / 2023, p. 72 / 186 66 / 165 from two to twelve ink blades 21. In another embodiment, the inkwell assembly includes four to eight ink blades. In one embodiment, each ink blade 21 has a width of up to approximately 12.7 mm (0.5 inches). In another embodiment, each ink blade 21 has a width of up to approximately 38.1 mm (1.5 inches). However, other dimensions are contemplated. Consequently, in one embodiment, each ink blade regulates the ink flow to a corresponding axial portion 20 of the ink roller 10, 18 which has a width of up to approximately 12.7 mm (0.5 inches), or, in another embodiment, up to approximately 38.1 mm (1.5 inches).

[0150] The 8B, 16B inkwell set usually includes a casting 68, a mounting plate 70, articulation blocks 72A, 72B supporting the ink roller 10, 18, side walls 74A, 74B, a top plate 76, an ink bar 78, a back plate 79, the ink blades 21, and actuators 30. The ink bar 78, top plate 76, side walls 74, ink blades 21, and ink roller 10, 18 define a reservoir 34 for the ink that will be transferred to the ink roller 10, 18. In one embodiment, a portion of the side walls 74 nearest to the ink roller 10, 18 is formed to mount at least partially around the ink roller.

[0151] The actuator 30 is mounted on the inkwell assembly 8B, 16B at a predetermined distance from the ink roller 10, 18. In one embodiment, the actuator 30 is mounted on the inkwell assembly 8B, 16B on the back plate 79. However, other arrangements of the actuator 30 are contemplated. The actuator 30 can adjust the position of the ink blade 21 relative to the ink roller 10, 18. In one embodiment, each actuator 30 is interconnected to an ink blade 21 by a shaft 31. In another embodiment, the actuator 30 is in communication with the control system 46. Consequently, in response to a signal from the control system 46, the actuator 30 converts electrical energy into a Petition 870230045110, dated 05 / 29 / 2023, page 73 / 186 67 / 165 mechanical force to adjust the position of an associated ink blade 21. The actuator 30 may comprise a solenoid or other similar devices known to those skilled in the art.

[0152] In one embodiment, each shaft 31 is selectively receiveable by an associated ink blade 21. Consequently, the distance between the ink blade 21 and the actuator 30 is adjustable by the actuator. Optionally, the shaft 31 includes threads 33 which are received by one end of the ink blade 21 nearest to the actuator 30. In one embodiment, each ink blade 21 includes a hole with internal threads to engage the shaft threads 33.

[0153] In one embodiment, an edge portion 35 of each ink blade 21 nearest to the ink roller 10, 18 is substantially parallel to a longitudinal geometric axis of the ink roller 10, 18. The edge portion 35 is defined by a longitudinal portion, or top surface, and an end portion extending from the longitudinal portion. In one embodiment, the longitudinal portion defines a plane that is generally parallel to the longitudinal geometric axis of the ink blade. In another embodiment, the end portion is generally perpendicular to the axis 31. In one embodiment, the longitudinal portion and the end portion have substantially planar shapes. Optionally, the end portion extends from the longitudinal portion at an angle between approximately 80° and approximately 100°. In one embodiment, the end portion is substantially orthogonal to the longitudinal portion.Optionally, in another embodiment, the end portion is interconnected in the longitudinal portion at an angle that is not orthogonal.

[0154] Referring now to Figure 10A, in one embodiment, the actuator 30A can rotate the shaft 31A in a first direction. As the actuator 30A and the shaft 31A are mounted at a fixed distance from the roller Petition 870230045110, dated 05 / 29 / 2023, p. 74 / 186 68 / 165 of ink 10, 18, rotating the shaft 31A in the first direction causes the ink blade 21A to move in the direction of the ink roller 10, 18. The ink blade 21A can generally move parallel to a longitudinal geometric axis of the ink blade as indicated by the arrow in Figure 10A. In this mode, a gap 32A between the edge portion 35 of the ink blade 21A and the axial portion 20A of the ink roller 10, 18 is reduced in length. This reduces the amount of ink 26 transferred to the axial portion 20A of the ink roller 10, 18 and to the printing plates 6, 14. More specifically, the gap 32A generally defines the density or thickness of the ink 26 which is transferred to the ink roller 10, 18 and subsequently to an undecorated metal container 52. In one embodiment, the blade edge portion 35 can be moved into contact with the axial portion 20A of the ink roller 10, 18 so that the gap 32A is closed.Thus, the ink blade 21A can impede the flow of ink to the axial portion 20A. In one embodiment, the gap 32 between an ink blade 21 and an axial portion 20 of the ink roller can vary from approximately 0 mm (0 inches) to approximately 0.38 mm (0.015 inches). In another embodiment, the gap 32 can be up to approximately 0.50 mm (0.02 inches). In another embodiment, the gap can be between approximately 0.025 mm (0.001 inches) and approximately 0.50 mm (0.02 inches). In one embodiment, the movement of the ink blade 21A is initiated by the actuator 30A. The actuator 30A can receive a signal from the control system 46 to change a position of the ink blade 21A to change the size of the gap 32.

[0155] Similarly, and referring now to Figure 10B, rotating the axis 31B in a second direction, the actuator 30B causes the shaft 31B to move the ink blade 21B away from the ink roller 10, 18. The ink blade 21B can generally move parallel to the longitudinal geometric axis of the ink blade as indicated by the arrow in Figure 10B. Petition 870230045110, dated 05 / 29 / 2023, p. 75 / 186 69 / 165 This increases the length of the gap 32B between the ink roller 10, 18 and the edge portion 35 of the ink blade 21B. This movement of the ink blade 21B correspondingly increases the amount of ink transferred to the axial portion 20B as well as the density (or thickness) of ink transferred to the metal container 52.

[0156] Referring now to Figure 9, an angle and / or rotation detection sensor may be used. For example, in one embodiment, a potentiometer 80 may optionally be associated with each actuator 30 or paint blade 21. The potentiometer 80 is operable to determine the movement of the paint blade 21. In another embodiment, the potentiometer 80 is operable to detect the movement of the shaft 31. The potentiometer 80 may transmit the amount and direction of shaft movement to the control system 46. For example, the potentiometer 80 may transmit a signal, such as a voltage, indicating an amount and direction of movement of the shaft 31 to the control system 46. The control system 46 may use the information received from the potentiometer 80 to determine the position of the paint blade 21 relative to the paint roller 10, 18.In one embodiment, potentiometer 80 is operable to detect the rotational movement of shaft 31 and differentiate between rotation in the first and second directions. In one embodiment, potentiometer 80 is interconnected to shaft 31. Optionally, potentiometer 80 and shaft 21 may include interlocking gears. Alternatively, or in addition, other sensors may be used to detect the movement of shaft 31. That is, one or more rotation and / or angle sensors 80 may utilize or otherwise include a Hall effect sensor, one or more rotary encoders including, but not limited to, mechanical, conductive, and optical rotary encoders, contactless imaging systems, and the like.

[0157] Referring again to Figure 1, more than two colors or Petition 870230045110, dated 05 / 29 / 2023, page 76 / 186 70 / 165 types of ink 26 can be used with the decorator 2 if additional plate cylinders are provided. For example, although only two plate cylinders 4, 12 are illustrated, it will be appreciated by one skilled in the art that the decorator 2 can include any number of plate cylinders 4, 12. In one embodiment, the decorator 2 includes from two to eight plate cylinders 4, 12, each receiving a different color, or a different type, of ink from an associated inkwell set 8, 16.

[0158] Optionally, one or more of the printing plates 6, 14 may have an image formed on the outer surface. Furthermore, although individual printing plates 6, 14 are illustrated interconnected on the plate cylinders 4, 12, a single sleeve or cylinder that wraps around a circumference of each plate cylinder 4, 12 may also be used with the decorator 2 of the present invention.

[0159] Each plate cylinder 4, 12 is in a predetermined alignment with respect to the blanket cylinder 36 and the transfer blankets 38 interconnected to it. Consequently, as the blanket cylinder 36 rotates, a transfer blanket 38 is rotated in contact with a first printing plate 6 of the first plate cylinder 4. The first printing plate 6 transfers at least some of the first ink 26A to an outer surface portion 40 of the transfer blanket 38.As the blanket cylinder 36 continues to rotate, the transfer blanket 38 is rotated in contact with a second printing plate 14 of the second plate cylinder 12. The second printing plate 14 transfers at least some of the second ink 26B to the outer surface portion 40 of the transfer blanket 38. Optionally, a single continuous transfer blanket may be positioned around the circumference of the blanket cylinder 36. In one embodiment, the blanket cylinder 36 rotates in the first direction. Petition 870230045110, dated 05 / 29 / 2023, page 77 / 186 71 / 165

[0160] After the transfer blanket 38 has received the first and second inks 26A, 26B from a printing plate 6, 14 of each plate cylinder 4, 12, the outer surface portion 40 of the transfer blanket 38 is rotated in contact with an outer surface 56 of an undecorated metal container 52. The transfer blanket 38 transfers at least some of the first and second inks to the outer surface 56 of the metal container 52. In this way, a decoration 58 is formed on the outer surface of the container 56. It will be appreciated that the decoration may comprise any combination of images, text, numbers and symbols.

[0161] Referring now to Figure 11, the outer cylindrical surface of the metal container 54 includes cylindrical portions 57 which correspond to the axial portions 20 of the paint rollers 10, 18 of the paint sets 8, 16. Consequently, for a decorator 2 which includes paint rollers 10, 18 with six axial portions 20A - 20F defined by six portions 24A - 24F paint blade 22 (illustrated in Figure 2) or by six individual paint blades 21A - 21F (as illustrated in Figure 9), the metal container 54 includes six corresponding cylindrical portions 57A - 57F. The amount of first ink 26A transferred to the cylindrical portions 57A - 57F by the printing plates 6 affixed to the first plate cylinder 4 can be controlled by adjusting the ink blades 21 or portions 24 of ink blade 22 relative to the axial portions 20A - 20F of the first ink roller 10.Similarly, the amount of second ink 26B transferred to the metal container 54 by the printing plates 14 of the second plate cylinder 12 can be adjusted by altering the gaps 32 (illustrated in Figures 3, 10) between the ink blades 21 or ink blade portions 24 and the axial portions 20A - 20F of the second ink roller 18.

[0162] As generally illustrated in Figure 11, the metal container 54 may have two or more different decorations 58A, 58B. Petition 870230045110, dated 05 / 29 / 2023, page 78 / 186 72 / 165 As will be appreciated by a person skilled in the art, decorations 58A, 58B may include different types or colors of ink. For example, in one embodiment, decoration 58A is formed by the first ink 26A of the first inkwell set 8. Similarly, decoration 58B may be formed by the second ink 26B of the second inkwell set 16. Furthermore, each decoration 58A, 58B may include portions of other inks. Consequently, in one embodiment, decoration 58C numbers 58B may be formed from a different ink than the second ink 26B. For example, in one embodiment, the decoration portion 58C is formed from the first ink 26A of the first inkwell set 8. Alternatively, the decoration portion 58C may be formed from a different third ink from another inkwell set of decorator 2.

[0163] In one embodiment, a support element 42 receives an undecorated metal container 52 from the upstream equipment 64. The metal container 52 may be a beverage container, such as a beverage can, a beverage bottle, an aerosol can, or a container for any other type of product. In one embodiment, the metal container 52 includes a base coating, such as, but not limited to, a white base coating. Alternatively, the metal container does not have a base coating.

[0164] Upstream equipment 64 may comprise a deep drawing and flattening production line or an impact extrusion production line. An example of a deep drawing and flattening metal container production line is generally illustrated and described in Inside a Ball Beverage Can Plant, available at http: / / www.ball.com / Ball / media / Ball / Global / Downloads / How_a_Ball_Metal_Beverage_Can_Is_Made.pdf?ext=.pdf (last accessed 30 April 2016), which is incorporated herein by reference in its entirety. Upstream equipment 64 may generally include a Petition 870230045110, dated 05 / 29 / 2023, page 79 / 186 73 / 165 cup former, one or more body makers for forming cups in containers, trimmers which cut the containers to a uniform height, washers which clean the containers, and ovens which dry the containers. The metal containers 56 are transported from the upstream equipment 64 to the decorator 2 in random order. Methods and apparatus for forming metal containers in an impact extrusion production line are described in U.S. Patent Application Publication Number 2013 / 0068352 and U.S. Patent Application Publication Number 2014 / 0298641, each of which is incorporated herein by reference in its entirety.

[0165] Optionally, an undecorated metal container 52 may be received from a pallet. For example, in one embodiment, a metal container 52 is manufactured at a location separate from the decorator 2 and transported to the decorator.In another option, the 52-piece metal container is received from storage regardless of the manufacturing location.

[0166] In one embodiment, the upstream equipment 64 includes at least one sensor. The sensor may be the same as, or similar to, sensor 50. Consequently, in one embodiment the control system 46 may receive data collected or obtained by a sensor of the upstream equipment 64 in relation to the external surface 56 of metal containers 52 before the metal containers 52 reach the support element 42.

[0167] The support element 42 moves the metal container 52 in contact with a transfer blanket 38. In one embodiment, the support element 42 includes a plurality of stations 44 for receiving and supporting the metal containers 52 in a predetermined position relative to the blanket cylinder 36. Optionally, a sensor 50 may be associated with a support element 42. The sensor may obtain data on the position or orientation of a Petition 870230045110, dated 05 / 29 / 2023, page 80 / 186 74 / 165 metal container 52 supported by a station 44. The sensor 50 can provide data to the control system 46. In this mode, the control system 46 can determine if the metal container 52 is in a predetermined orientation or alignment with respect to a transfer blanket 38 of the transfer cylinder 36. In one embodiment, the stations 44 comprise recesses to receive a portion of a metal container. Alternatively, in another embodiment, the stations may comprise mandrels projecting from the support element 42. A portion of each mandrel is configured to project at least partially through an open end into a hollow interior of a metal container 52. An example of a support element 42 that can be used with the decorator 2 of the present invention is described in US Patent Number 9,452,600, which is incorporated herein by reference in its entirety.

[0168] Returning again to Figure 1, in one embodiment of the present invention, one or more inkwell assemblies 8, 16 may move in response to a signal received from the control system 46. More specifically, in one embodiment, the inkwell assemblies 8, 16, or at least the ink roller 10, 18, may move to alter the alignment of the inkwell assemblies 8, 16 and / or the ink rollers 10, 18 with respect to the plate cylinders 4, 12. In one embodiment, the inkwell assemblies 8, 16 and the ink rollers 10, 18 may move in a plurality of directions. Optionally, the cartridge assemblies 8, 16 and / or ink roller 10, 18 may move in one or more of: (1) a z or axial direction (substantially perpendicular to the plane of Figure 1); (2) a lateral x direction (substantially perpendicular to the axial direction); and (3) a y or vertical direction (substantially perpendicular to each of the axial and lateral directions).In one or more embodiments, each of the inkwell assemblies 8, 16 and / or the ink roller 10, 18 can move, or otherwise articulate, around. Petition 870230045110, dated 05 / 29 / 2023, p. 81 / 186 75 / 165 a rotational geometric axis. In one embodiment, one or more actuators are associated with each of the inkwell assemblies 8, 16 and / or ink rollers 10, 18. Each of the actuators is operable to move an associated inkwell or ink roller assembly in one or more of the x, y, and z directions in response to a signal from the control system 46. In this mode, the control system 46 can send a signal to an actuator associated with the inkwell assemblies 8, 16 and / or ink rollers 10, 18 to alter one or more positions and alignments of ink transferred from the ink rollers to the printing plates 6.

[0169] In another embodiment, one or more of the 4-plate cylinders, 12, the blanket cylinder 36, and the support element 42 can move in response to a signal from the control system 46. For example, in one embodiment, one or more of the plate cylinders 4, 12, the blanket cylinder 36, and the support element 42 can be interconnected to actuators. In response to a signal from the control system 46, the actuators can move at least one of the plate cylinders 4, 12, the blanket cylinder 36, and the support element 42 in a plurality of directions. In one embodiment, one or more of the plate cylinders 4, 12, the blanket cylinder 36, and the support element 42 can move in at least one of the x direction, the y direction, and the z direction in response to a force received from an actuator.Consequently, when the control system 46 determines that a decoration's position or alignment is deficient, the control system 46 can adjust the position of one or more of the plate cylinders 4, 12, the blanket cylinder 36, and the support element 42 in a plurality of specific directions. Furthermore, or alternatively, the control system 46 can send a signal to an actuator to alter the movement of the drive roller 13. Specifically, the dwell time of the drive roller 13 can be... Petition 870230045110, dated 05 / 29 / 2023, page 82 / 186 76 / 165 altered by the control system. The waiting time is the period of time the conveyor roller contacts an associated ink roller 10, 18. Optionally, the control system 46 can send a signal to a drive element associated with one or more ink rollers 10, 18 and a transfer roller of an ink train 11, 19. The signal can cause the drive element to change the rotation rate of the ink roller or the transfer roller. In this mode, the control system 46 can change the amount of ink transferred by a cartridge set 8, 16 to a printing plate 6, 14.

[0170] The actuators associated with the inkwell assemblies 8, 16, the ink rollers 10, 18, the conductor rollers 13, the plate cylinders 4, 12, the blanket cylinder 36, and the support element 42 (which are not illustrated in Figure 1 for clarity) may be the same as, or similar to, the actuators 30. Furthermore, one or more potentiometers may be associated with each of the actuators. The potentiometers, or rotation sensors, may send data to the control system 46 so that the control system 46 can determine the relative positions of the inkwell assemblies 8, 16, the ink rollers 10, 18, the plate cylinders 4, 12, the blanket cylinder 36, and the support element 42.

[0171] After the metal containers 54 are decorated by the decorator 2, the sensor 50 collects data on the decoration 58. The sensor 50 is positioned to detect the entire cylindrical surface 56 of the metal container 54. In one embodiment, the sensor 50 detects the decorated metal containers 54 while the containers are associated with a support element 42. Alternatively, the decorated metal containers 54 are transported, for example, by a conveyor 48, to the sensor 50. Any suitable conveyor 48 can be used with the decorator 2 of the present invention. In one embodiment, the conveyor 48 comprises a Petition 870230045110, dated 05 / 29 / 2023, p. 83 / 186 77 / 165 belt. In another embodiment, the conveyor 48 is a pin chain. Examples of pin chains that can be used with the decorator are described in U.S. Patent Application Publication 2012 / 0216689 and U.S. Patent Application Publication 2017 / 0334659, each of which is incorporated herein by reference in its entirety. The cycle rates of the support element 42 and the conveyor 48 can be controlled by the control system 46.

[0172] Optionally, in one embodiment, the metal containers 54 are sequentially transported by the conveyor 48 to the sensor 50. For example, when the conveyor 48 is a pin chain, the metal containers 54 are transported to the sensor 50 in the order in which they were decorated. In one embodiment, each metal container 54 that exits the decorator is counted. Furthermore, in one embodiment, a pin or fastener of the pin chain conveyor 48 may be associated with a specific transfer blanket 38. In one embodiment, the number of pins or fasteners on the conveyor is a multiple of the number of blankets on the blanket cylinder 36. In this mode, the decoration 58 on a metal container 54 can be traced to a specific transfer blanket 38 of the decorator.After the metal containers 54 are transported downstream of sensor 58 (or sensor 58A), the metal containers 54 are placed on a master conveyor when the order in which they were decorated becomes mixed up.

[0173] Optionally, chain conveyor pins 48 and / or transfer mats 38 may include beacons or sensors. For example, each conveyor pin 48 may include an RFID or similar beacon. In addition, each transfer mat 38 may also include a beacon, such as an RFID. In this mode, a specific conveyor pin 48 may be associated with a mat. Petition 870230045110, dated 05 / 29 / 2023, p. 84 / 186 78 / 165 transfer 38 which decorated a metal container 54 when the pin receives the metal container 54 from the support element 42. When the pin transports the metal container 54 to the sensor 49, 50, it can read the RFID of the pin to identify which transfer blanket 38 contacted the metal container 54.

[0174] In one embodiment, the sensor 50 is positioned so that the sensor 50 collects data on the metal container 54 while the paint 26 that forms the decoration 58 is wet. Specifically, in one embodiment, the sensor is positioned upstream of equipment 66 such as a pin oven which subsequently cures the paint.

[0175] Optionally, one or more operations may be performed on the metal containers 54 after the metal containers 54 receive the decoration 58 and before the metal containers 54 are detected by the sensor 50. More specifically, the metal containers 54 may be cured by a pin furnace, illustrated as downstream equipment 66. Consequently, there may be a predetermined delay time from when the decoration 58 is formed on a container 54 until the metal container 54 is detected by the sensor 50. Thus, although the sensor 50 is generally illustrated upstream of the downstream equipment 66 in Figure 1, the sensor 50A may be positioned downstream of at least some of the equipment 66. For example, in one embodiment, after leaving the support element 42, the metal containers 54 are transported to one or more of a tester, a cleaner, and a furnace.Sensor 50A collects data about the metal container 54 once the paint 26 that forms the decoration 58 is dry, or cured.

[0176] A predetermined period of time may elapse after a metal container 54 receives a decoration 58 before sensor 50A detects the cylindrical surface of the container 56. Thus, sensor 50A Petition 870230045110, dated 05 / 29 / 2023, p. 85 / 186 79 / 165 and the control system 46 must take into account and adjust for the delay time which occurs after making adjustments to the decorator 2 before a metal container with a decoration formed after the adjustments reaches the sensor 50A. In one embodiment, between approximately 100 decorated metal containers 54 and approximately 500 decorated metal containers 54 are arranged on the conveyor 48 between the support element 42 and the sensor 50A depending on the length of the conveyor. In another embodiment, between approximately 350 and approximately 500 containers are between the support element and the sensor 50A. In yet another embodiment, approximately 400 metal containers are being transported by the conveyor 48 between the support element 42 and the sensor 50A. Regardless, the number of containers between the support element 42 and the sensor 50A is known and can be taken into account by the control system 46.

[0177] Sensor 50 is positioned to detect the outer surface 56 of the metal container 54. Sensor 50 sends data relating to the decoration 58 of each metal container 54 to the control system 46. More specifically, sensor 50 gathers data about the decoration 58 on the metal container 54. The control system 46 uses data gathered by sensor 50 to determine if any defects are present in the decoration 58. For example, sensor 50 can collect or obtain data relating to a color, density, depth, consistency, or alignment of the decoration 58. Optionally, the metal container 54 can be substantially stationary when sensor 50 collects data about the decoration 58.

[0178] The 50 sensor, in one embodiment, is different from the sensors used to evaluate images formed on flat substrates, such as paper or a continuous sheet. Specifically, the 50 sensor must collect data on approximately 1,800 Petition 870230045110, dated 05 / 29 / 2023, page 86 / 186 80 / 165 containers per minute. Furthermore, the shape of the metal containers requires a sensor 50 which is different compared to known sensors associated with continuous sheet decorators. The sensor 50 must be able to quickly collect data on a curved, cylindrical surface 56 of a metal container. Consequently, the sensor 50 must obtain data through the arched surface. Due to the arched or cylindrical surface 56 of the container, portions of the container are at different distances from the sensor 50.

[0179] Some decorations 58 do not completely cover the cylindrical surface 56, leaving bare metal of the metal container visible. The bare metal complicates data collection by the sensor 50 since the bare metal can be reflective or shiny. The ink 26 is not absorbed by the metal container 54, which is also different from paper product decorators, such as a continuous sheet of paper. Some inks (or ink colors) do not completely cover the metal of the metal container 54, so the metallic material of the cylindrical surface 56 shines through the ink, adding to the difficulty of collecting data on the decoration by the sensors 49, 50. In one embodiment, the sensors emit energy and collect data relating to reflections of the energy received from the metal container. For example, in one embodiment, the sensors emit sound or light and record reflections of sound or light received from the cylindrical surface 56. In one embodiment, the sensor 50 is a laser.Optionally, ultrasonic or infrared sensors can be used to collect data on the decorations 58.

[0180] In one embodiment, the sensor 50 comprises an optical or visual sensor. In another embodiment of the present invention, the sensor 50 comprises a camera. The camera may be a high-speed camera. In yet another embodiment, the sensor 50 comprises a laser. In yet another embodiment, the sensor 50 comprises a Petition 870230045110, dated 05 / 29 / 2023, page 87 / 186 81 / 165 hyperspectral imager. In one embodiment, the sensor 50 can collect data in three dimensions. In one embodiment, one or more of the camera's optics, resolution, magnification, and shutter are controlled by the control system 46. In one embodiment, the sensor 50 is operable to detect up to approximately 700 metal containers per minute. In another embodiment, the sensor 50 is operable to detect up to approximately 2,000 metal containers per minute.

[0181] The sensor is operable to detect and measure one or more characteristics of a metallic container 54 and a decoration 58. In one embodiment, the sensor 50 is operable to measure one or more colors of the paints 26 that form a decoration 58. The sensor 50 or the control system 46 can subsequently describe the color as a number according to one or more color space standards. Color space standards provide different means of measuring or characterizing colors. The color space standard can be that described by the International Commission on Illumination (CIE). Optionally, sensor 50 can characterize decoration 58 in one or more of an L* a* b* (or CIELAB) color space, an L* u* v* (or CIELUV) color space, an RGB (or CIE RGB) color space, an XYZ (or CIE XYZ) color space, a CMYK (or CMY) color model, an HSI color model, an LCh (or CIELCh) color space, and a user-specified color space.In one embodiment, the sensor 50 can measure the density of a decoration 58. In another embodiment, the sensor 50 can measure a variation or distance between a target color of a decoration (such as a target value for a color in one of the color spaces) and a color of a paint of a decoration on a metallic container 54. Optionally, the color variation can be expressed in CIE ΔE (or Delta E) by the sensor.

[0182] In one mode, one or more targets 59 on the surface Petition 870230045110, dated 05 / 29 / 2023, p. 88 / 186 82 / 165 external container 56 are selected for detection by sensor 50. Targets 59 can be selected by control system 46. Alternatively, targets 59 can be adjusted by a decorator operator 2. In one embodiment, targets 59 are determined at least in part by the decoration 58 to be applied to the metal container 54. More specifically, targets 59 can be selected based on locations where one or more paints 26 are to be positioned on the external surface 56. Additionally, targets 59 can also be selected for locations where no paint is to be applied to the external surface 56. Consequently, a target 59 can vary from a first decoration operation to a second decoration operation.

[0183] Referring again to Figure 11, one or more targets 59 may be located in a variety of predetermined locations on the outer surface of container 56. In this mode, sensor 50 will collect data relating to the ink 26 applied by each inkwell set 8, 16. In one embodiment, at least one target 59 is associated with an ink 26 from each inkwell set 8, 16. In one embodiment, a target 59 is associated with each of the ink blades 21 or ink blade segments 22 for each ink cartridge set. In this mode, a target 59 will be associated with each ink blade 21 or blade segment 24 of the decorator. Consequently, there will be one target 59 for each ink blade or blade segment for each ink 26 used by the decorator 2.

[0184] For example, for a decorator 2 with between four and eight sets of inkwells, each of which has five to ten ink blades 21 or ink blade segments 24, the sensor 50 can collect data on approximately 20 to 80 targets 59. Specifically, if the decorator has four sets of inkwells, each of which has five ink blades, at least 20 targets will be selected on the Petition 870230045110, dated 05 / 29 / 2023, p. 89 / 186 83 / 165 outer surface of container. In this mode, the control system 46 will almost continuously receive data relating to the quality, thickness, and positioning of the ink 26 applied by each ink blade 21 and each segment 24 of an ink blade 22 of each inkwell assembly 8, 16.

[0185] Optionally, at least one light source or illumination source may be associated with the sensor 50. In one embodiment, the light 51 is operable to provide stroboscopic illumination so that an associated sensor 50 can obtain data from moving metal containers 54. The operation of the light 51 can be controlled by the control system 46. In this mode, the illumination generated by the light 51 is timed with the data collection of the sensor 50. In one embodiment, the light 51 comprises at least one of an incandescent lamp, an LED, a high-intensity light, a laser, a fluorescent light, a xenon flash tube, and an arc discharge lamp. The light 51 is selected to generate illumination of a predetermined wavelength based on the requirements of the sensor 50.

[0186] In one embodiment, the light 51 is generally aligned parallel to a sensor sight, as generally illustrated in Figure 1. In one embodiment, one or more diffusers and lenses are associated with a light 51. In one embodiment, the diffusers and lenses are aligned so that the illumination generated by the light 51 is generally parallel to (or aligned with) a longitudinal geometric axis of the metal containers 54. In one embodiment, the diffuser has a width which is approximately equal to the height of the metal containers. Consequently, the light 51 can illuminate one or more portions of the outer surface 56 of the metal containers 54.

[0187] Optionally, one or more lighting angles may be provided by at least one light. In another embodiment, light 51 includes two or more lights arranged at different angles with respect to Petition 870230045110, dated 05 / 29 / 2023, p. 90 / 186 84 / 165 to the metal container 54. For example, in one embodiment, a first light 51 may be positioned at an angle of approximately 90° above a portion of the metal container 54 to be detected by the sensor 50. In another embodiment, a second light 51 is positioned at an angle between approximately 10° and approximately 90° or between approximately 1° and approximately 10° with respect to the portion of the metal container 54 to be detected. Consequently, the angle of the light 51 with respect to the metal container 54 may be selected so that the decoration 58, which may include a variety of surfaces or paints extending to different heights from the cylindrical surface 56 of the metal container 54, reflects light differently than other portions of the outer surface 56 of the metal container 54.

[0188] In one embodiment, the sensor 50 can detect the entire outer surface 56 of the metal container. In contrast, some prior art decorators for decorating continuous sheets or substrates include a sensor that can only detect a portion of the width (known as a strip) of the continuous sheet between a first longitudinal edge and a second longitudinal edge of the sheet. The prior art sensor can periodically move from the first longitudinal edge to the second longitudinal edge of the sheet. However, at any given time, the sensor can only detect a portion of the width of the sheet. Consequently, when detecting a first strip, the prior art sensor may not detect a printing error or deficiency in a second strip.

[0189] Image processing and correction techniques may be required due to the curved or arched shape of the cylindrical outer surface 56 of the metal container. More specifically, sensor 50 is required to collect data (or create an image) of a curved outer surface. After sensor 50 collects data on each container Petition 870230045110, dated 05 / 29 / 2023, page 91 / 186 85 / 165 metallic, the data is sent to the control system. The control system 46 stitches together multiple images of each metallic container to form a composite image of the cylindrical outer surface 56 and the decoration 58 of each metallic container 54.

[0190] In another embodiment, the sensor 50 remains substantially stationary during detection of the metal container 54. Consequently, data (such as images) collected by the sensor 50 may not include distortions caused by sensor movement. Optionally, the metal container 54 rotates around the longitudinal geometric axis of the metal container during detection by the sensor 50. Consequently, additional processing techniques may be required to correct distortion in images obtained by a sensor 50 due in part to rotation or movement of the metal container 54. In contrast, some continuous sheet decorator sensors or cameras of the prior art move laterally across a width of the sheet. Camera movements may decrease the accuracy of images captured by the camera. Still, in some sheet decorators of the prior art, the camera and the sheet are both moving during image collection by the camera.This simultaneous movement can cause additional distortions in images collected by the camera. Simultaneous movement also adds complexity to controlling the camera and identifying the causes of decoration flaws, as well as the corrections required to address those flaws.

[0191] Optionally, the metal containers 54 move substantially continuously with respect to the sensor 50. More specifically, in one embodiment, the metal containers 54 move laterally perpendicular to a longitudinal geometric axis of the metal containers as the sensor 50 detects the outer surface 56 of the metal containers. Alternatively, in another Petition 870230045110, dated 05 / 29 / 2023, page 92 / 186 In mode 86 / 165, the metal containers 54 are substantially stationary with respect to sensor 50 during metal container detection.

[0192] Although only one sensor 50 is illustrated in Figure 1, it will be appreciated by one skilled in the art that any number of sensors 50 can be used with the decorator 2 of the present invention. Consequently, and referring now to Figure 1A, another decorator 2A of the present invention is generally illustrated. The decorator 2A includes one or more plate cylinders 4, 12, inkwell assemblies 8, 16, ink rollers 10, 18, ink trains 11, 19, a blanket cylinder 36, a support cylinder 42, a sensor 50, and an ejector 62 which are the same as, or similar to, those of decorator 2. Notably, decorator 2A includes a plurality of optional sensors 49. The sensors 49 may be the same as, or similar to, sensor 50. In addition, the sensors 49 may provide data to the control system 46. A light 51 may be associated with one or more of the sensors 49.

[0193] In one embodiment, a sensor 49A is positioned to collect data on an external surface 56 of an undecorated container before the undecorated container is received by the support element 42. The control system 46 can use data from sensor 49A to determine if the external surface 56 of the container 52 includes any defects or abnormalities. For example, the control system 46 can determine that a container 52 is damaged (e.g., scratched, dented, bent, and the like) or has a shape that is out of specification (such as an improper height or diameter).

[0194] Another sensor 49B may be arranged to collect data, and / or images, on the printing plates 6 of the first cylinder of plates 4. Similarly, an optional sensor 49C may be positioned to collect data on the printing plates 14 of the second cylinder. Petition 870230045110, dated 05 / 29 / 2023, page 93 / 186 87 / 165 of plates 12. In one embodiment, sensors 49B, 49C collect data relating to the inks transferred to the printing plates 6, 14 by their respective inkwell assemblies 8, 16. In this mode, the control system 46 can determine that the ink is improperly transferred to the printing plates 6, 14. For example, in one embodiment, the control system 46 can determine that an inappropriate amount of ink is being transferred to printing plates 6, 14 or to a portion of the printing plates. In another, the control system 46 can use the data from sensors 49B, 49C to determine that the ink is being applied to inappropriate portions of the printing plates. In yet another embodiment, the sensor data from sensors 49B, 49C can indicate that an inappropriate type or color of ink is being applied by one or more of the inkwell assemblies 8, 16.The control system 46 can also determine that the ink 26 applied by one of the inkwell assemblies 8, 16 is defective based on data received from one or more of the sensors 49B, 49C. In yet another embodiment, the control system 46 can determine, using data from sensors 49B, 49C, that one or more of the printing plates 6, 14 is not properly aligned on a respective plate cylinder 4, 12.

[0195] In one embodiment, another sensor 49D may be positioned to collect data from the transfer blankets 38 on the blanket cylinder 36. Using the data from sensor 49D, the control system 46 can determine that one or more of the inks 26 transferred to the transfer blankets 38 by the printing plates 6, 14 are not properly aligned. The control system 46 can also determine that a decoration formed on the transfer blankets 38 by the inks is defective. For example, the control system can determine that one or more target parameters associated with a decoration are deficient while the ink is on a Petition 870230045110, dated 05 / 29 / 2023, page 94 / 186 88 / 165 transfer blanket 38. In one embodiment, using the data received from sensor 49D, the control system 46 can determine that one or more color, density, depth, alignment, and consistency of ink on a transfer blanket 38 does not conform to the decoration parameters.

[0196] In another embodiment, the decorator may also include a sensor 49E positioned downstream of the ejector 62. In one embodiment, the control system 46 can compare the data received from sensor 49E with data received from sensor 50. In this mode, the control system 46 can determine if a decoration on a metal container 54 has moved after the metal container has been detected by sensor 50. In another embodiment, the control system 46 can determine if a decoration formed on a metal container 54 was damaged during transport by the conveyor 48. For example, a decoration may be scratched or otherwise damaged during transport after moving downstream of sensor 50.

[0197] In one embodiment, the decorator 2 includes three to six sensors 50 arranged around the longitudinal geometric axis of the metal containers 54. In this mode, the cylindrical body 56 of the metal container 54 can be detected in one operation. Put differently, the three to six sensors 54 are positioned to detect the cylindrical body 56 substantially simultaneously. Data or images for each metal container 54 collected by the three to six sensors 54 can be stitched together to form a composite image of the cylindrical outer surface 56 and the decoration 58.

[0198] Referring now to Figure 12A, in one embodiment, the decorator 2 includes three sensors 50A, 50B, 50C, each of which detects at least approximately one-third of the cylindrical body 56. The sensors 50A - 50C are substantially uniformly spaced. Petition 870230045110, dated 05 / 29 / 2023, page 95 / 186 89 / 165 around a longitudinal geometric axis of the metal container 54. Three images of each metal container taken by sensors 50A and 50C are subsequently stitched together to form a single composite image of each metal container. The longitudinal geometric axis of the container is substantially perpendicular to the plane of Figure 12A. In another embodiment, generally illustrated in Figure 12B, the decorator 2 includes four sensors 50A, 50B, 50C, and 50D, each of which detects at least approximately one-quarter of the cylindrical body 56. Similar to Figure 12A, sensors 50A and 50D are substantially uniformly arranged around a longitudinal geometric axis of the metal container 54.Optionally, and referring now to Figure 12C, in one embodiment, five sensors 50A - 50E of the decorator 2 each detect at least approximately one fifth of the cylindrical body 56, with the five sensors being substantially uniformly positioned around a longitudinal geometric axis of the metallic container 54. Data from the three to five sensors 50A - 50E can be stitched together to form a composite image of the cylindrical body 56. In one embodiment, the composite image may include a predetermined portion, or the entire circumference, of the cylindrical body 56.

[0199] In one embodiment, the three to five sensors 50A - 50E are positioned to detect the metal containers upstream of the equipment 66 so that the paint 26 is wet. Alternatively, the sensors 50A - 50E can be positioned downstream of an oven or curing chamber (such as downstream of the equipment 66) and the paint 26 forming the decoration 58 will be dry.

[0200] The three to five 50A - 50C sensors are also at a predetermined distance from the metal container. In one embodiment, the metal container 54 is positioned on a pin of a 48-pin chain carrier. Consequently, the sensors Petition 870230045110, dated 05 / 29 / 2023, p. 96 / 186 90 / 165 50A - 50C can be positioned so that they do not impede the movement of conveyor 48 or contact the metal container.

[0201] The one to six sensors 50 can each collect or obtain the same types of information. Such information obtained from the sensors can be in the form of an image; consequently, the images can be processed and analyzed in order to obtain color, ink density, alignment, depth, and / or consistency of a decoration. According to at least one embodiment, at least one sensor 50 detects a different type of information than another of the one to six sensors. For example, in one embodiment, a first sensor can collect a first type of data relating to the decoration 58 and a second sensor of a different type can collect a second type of data relating to the decoration 58.Optionally, in one embodiment of the present invention, a first sensor collects data on the color of the decoration, a second sensor collects data on the density of the decoration, a third sensor collects data on the alignment of the decoration, a fourth sensor collects data on the depth of the decoration, and a fifth sensor collects data on the consistency (or uniformity) of the decoration. In another embodiment, each sensor 50 is operable to detect colors including at least red, green, and blue. In yet another embodiment, each sensor 50 is operable to detect variations or gradations in colors within each cylindrical portion 57 of a metallic container. In yet another embodiment, the sensors 50 are operable to distinguish a paint density or paint color in a first cylindrical portion 57 from a paint density or color in a second cylindrical portion 57.

[0202] Referring now to Figure 13, a control system 46 of an embodiment of the present invention is generally illustrated. More specifically, Figure 13 illustrates an embodiment of a system of Petition 870230045110, dated 05 / 29 / 2023, page 97 / 186 91 / 165 control 46 of the present invention operable for determining and correcting an abnormality in a decoration applied to an external surface of a metal container by a decorator 2. The control system 46 is generally illustrated with hardware elements that can be electrically coupled via a bus 82. The hardware elements may include one or more central processing units (CPUs) 84; one or more input devices 86 (e.g., a mouse, a keyboard, etc.); and one or more output devices 88 (e.g., a display device, a printer, etc.). The control system 46 may also include one or more storage devices 90.In one embodiment, the storage device(s) 90 may be disk drives, optical storage devices, solid-state storage devices, such as random access memory (RAM) and / or read-only memory (ROM), which may be programmable, instant-updatable and / or similar.

[0203] The control system 46 may further include one or more computer-readable storage media readers 92; a communications system 94 (e.g., a modem, a network card (wireless or wired), an infrared communication device, etc.); and a working memory 96, which may include RAM and ROM devices, as described above. In some embodiments, the control system 46 may also include a processing acceleration unit 98, which may include a DSP, a special-purpose processor and / or the like. Optionally, the control system 46 also includes a database 100.

[0204] The computer-readable storage medium reader may also be connected to a computer-readable storage medium, together with (and optionally in combination with storage device(s) 90) comprehensively representing Petition 870230045110, dated 05 / 29 / 2023, page 98 / 186 92 / 165 remote, local, fixed and / or removable devices plus a storage medium for temporarily and / or more permanently containing computer-readable information. The communications system 94 may allow data to be exchanged with a network 102 and / or any other data processing. Optionally, the control unit 46 may access data stored on a remote storage device, such as a database 104, by connecting to the network 102. In one embodiment, the network 102 may be the Internet.

[0205] The control system 46 may also comprise software elements, shown as currently located within the working memory 96. The software elements may include an operating system 106 and / or other code 108, such as implementing program code that implements one or more methods and aspects of the present invention.

[0206] Someone skilled in the art will appreciate that alternative embodiments of the control system 46 may have numerous variations from that described above. For example, customized hardware could also be used and / or specific elements could be implemented in hardware, software (including portable software, such as applets), or both. Furthermore, connection to other computing devices, such as network input / output devices, may be employed.

[0207] In one embodiment, control system 46 is a personal computer, such as, but not limited to, a personal computer running the MS Windows operating system. Optionally, control system 46 may be a smartphone, a tablet computer, a laptop computer, and similar computing devices. In one embodiment, control system 46 is a data processing system which includes one or more of, but is not Petition 870230045110, dated 05 / 29 / 2023, page 99 / 186 93 / 165 limited to: at least one input device (e.g., a keyboard, mouse, or touch screen); one output device (e.g., a display, a speaker); a graphics card; a communication device (e.g., an Ethernet card or wireless communication device); permanent memory (such as a hard disk); temporary memory (e.g., random access memory); computer instructions stored in permanent and / or temporary memory; and a processor. The control system 46 can be any programmable logic controller (PLC). An example of a suitable PLC is a Controllogix PLC produced by Rockwell Automation, Inc., although other PLCs are contemplated for use with embodiments of the present invention.

[0208] In one embodiment, the control system 46 is in communication with one or more of the inkwell assemblies 8, 16, conductor rollers 13, plate cylinders 4, 12, actuators 30, potentiometers 80, blanket cylinder 36, support element 42, sensors 49, 50, light 51, conveyor 48, ejector 62, upstream equipment 64 and downstream equipment 66. Consequently, the control system 46 receives data from sensors 49, 50 relating to undecorated metal containers 52, decorated metal containers 54, printing plates, and transfer blankets 40. Using the data, the control system 46 can determine whether the decoration 58 is deficient or satisfactory. More specifically, the control system 46 can determine whether the decoration 58 at least meets the targets that correspond to one or more parameters, such as color, density, depth, alignment, and consistency. The targets can be adjusted by a customer or a decorator operator 2. One or more of the parameters may include a target range. If the sensor data relating to a parameter falls within the lower and upper limits of the range, at least this parameter Petition 870230045110, dated 05 / 29 / 2023, pp. 100 / 186 94 / 165 of the decoration is acceptable. In one modality, when a decoration 58 does not meet one or more of the targets, the decoration is deficient.

[0209] Control system 46 compares sensor data 50 with targets for indices / decoration 58. In one embodiment, control system 46 compares data associated with a plurality of portions of a decoration / indice image received from sensor 50 with the target level for corresponding portions of the decoration. In this mode, control system 46 can determine if one or more of the color, density, depth (or thickness), alignment, and consistency for each portion of the decoration differs from the target values ​​or position for each portion of the decoration. If the sensor data for a portion of the decoration differs from one or more of the target values, control system 46 can determine that the decoration is deficient.

[0210] In one embodiment, the control system 46 recognizes a deficient decoration by inspecting at least one metal container with an acceptable decoration 58. For example, metal containers 54 with acceptable decorations 58 can be detected by sensor 50. The control system 46 receives data from the sensor regarding the acceptable decorations 58. With this information, the control system 46 can create a database 100, 104. The database 100 can be stored in a memory of the control system 46 such as memory 96. Optionally, the database 104 can be accessible via network connection 102. The database can include a plurality of fields that describe the characteristics of the acceptable decoration. The characteristics can include one or more of the color, density, depth (or thickness), position (or alignment), and consistency of the decoration. Each of the characteristics can be assigned a value based on the sensor data.In one mode, each portion of the decoration 58 (or target 57) detected by sensor 49, 50. Petition 870230045110, dated 05 / 29 / 2023, p. 101 / 186 95 / 165 is associated with a field from the plurality of fields. Thus, the data associated with each detected portion of a decoration can be stored in the database and accessed by the control system 46.

[0211] Referring now to Figure 14, one embodiment of a data structure 110, such as a database, is generally illustrated. The data structure may include one or more data files or data objects 116, 134. Thus, the data structure 110 may represent different types of databases or data storage, for example, object-oriented databases, flat file data structures, relational databases, or other types of data storage arrangements. The embodiments of the data structure 110 described here may be separate, combined and / or distributed. As indicated in Figure 14, there may be more or fewer portions in the data structure 110, as represented by ellipses 112. Also, there may be more or fewer files or records 132 in the data structure 110, as represented by ellipses 114.In one embodiment, the data structure 110 is stored in a memory of the control system 46, such as the database 100. Furthermore, or alternatively, the data structure 110 can be accessed by the control system 46 using the network 102. Consequently, in another embodiment, the data structure 110 is stored in a remote location, such as a database 104.

[0212] A first data object 116 may refer to data collected from at least one acceptable decoration known to sensor 50. In one embodiment, the data for the first data object 116 is collected while the control system 46 is being programmed to recognize an acceptable decoration before a production operation. The data object 116 may include several Petition 870230045110, dated 05 / 29 / 2023, page 102 / 186 96 / 165 portions 118 - 130 representing different data types. Each of these data types can be associated with a decoration 58 detected by sensor 50. There may be one or more records 132 and associated data stored within the first data object 116.

[0213] In one embodiment, each record 132 includes an identifier 118. For example, identifier 118 may be associated with each container detected by sensor 50. Other fields include different data collected by sensors 49, 50 for each decoration. The fields may include, but are not limited to, field 120 relating to color(s), portion 122 relating to density, portion 124 associated with thickness or depth, field 126 relating to decoration position and / or alignment, field 128 for decoration consistency, and field 130 for other data. In one embodiment, field 120 may include information associating an ink color with an inkwell set 8, 16. More specifically, field 120 may include information identifying a color of the first ink 26 of the first inkwell set 8. Field 120 may also include information identifying a color of the second ink 26 of the second inkwell set 16.In this mode, the control system 46 can determine which inkwell set 8, 16 is associated with an ink deficiency 26 of a decoration 58. The control system 46 can also identify which ink blade 21, 22 is associated with the ink deficiency based on one or more cylindrical portions 57 that contain the ink deficiency. In one embodiment, an image of each decoration detected by the sensors 49E, 50 is saved in each register 132. In another embodiment, an image is stored in portion 130.

[0214] The settings for ink blades 21, 22 can be stored in data structure 110. In one embodiment, the Petition 870230045110, dated 05 / 29 / 2023, p. 103 / 186 97 / 165 ink blade settings can be stored in portion 130. Optionally, the ink blade settings can be entered into the control system 46 by an operation. In another embodiment, the ink blade settings can be determined by the control system. In one embodiment, before a production operation begins, an image of a decoration to be formed by decorator 2 is received by the control system 46. The control system 46 can analyze the image and automatically determine the settings for the ink blades 21, 22. In another embodiment, the control system 46 saves the ink blade settings 21, 22 associated with each metal container detected by sensor 50. In this mode, when a decoration includes a defect, the ink blade settings and other decorator 2 settings that existed when the defective decoration was formed can be revised.

[0215] Optionally, data structure 110 may include a second data object 134. Data object 134 may include the same or similar fields 118-130 as the first data object 116. In one embodiment, control system 46 may store data received from sensors 49, 50 during a production operation in the second data object 134. Consequently, the second data object 134 may include a plurality of records 132 relating to metal containers decorated by the decorator during the production operation. In contrast, in one embodiment, data object 116 may optionally include data collected by sensors 49, 50 before the production operation begins.

[0216] Referring now to Figure 15, a modality of a method The order of operations for method 140, used with control system 46, is generally illustrated. Although a general order of operations for method 140 is shown in Figure 15, method 140 may include more or fewer operations, or may arrange the order of operations differently from that shown. Petition 870230045110, dated 05 / 29 / 2023, page 104 / 186 98 / 165 shown in Figure 15. Furthermore, although the operations of method 140 can be described sequentially, many of the operations can in fact be executed in parallel or concurrently. Generally, method 140 begins with a start operation 142 and ends with an end operation 160. Portions of method 140 can be executed as a set of computer-executable instructions executed by a computer system and encoded or stored in a computer-readable medium. An example of a computer system might include, for example, control system 46. An example of a computer-readable medium might include, but is not limited to, a memory of control system 46. Hereafter, method 140 will be explained with reference to control system 46, decorator 2, and components described in conjunction with Figures 1-14.

[0217] In operation 144, a metal container 54 with a decoration 58 is provided. Optionally, the decoration 58 is formed by the decorator 2. Data relating to the decoration 58 of the metal container 54 are collected by at least one sensor 49, 50 in operation 146. The control system 46 then receives the data collected from at least one sensor 49, 50. The sensor 49, 50 may be positioned upstream of a furnace or downstream of the furnace.

[0218] In operation 148, the control system analyzes the collected data received from the sensor. In one embodiment, the control system considers the data associated with a plurality of targets 59 on the outer surface of container 56. In another embodiment, the control system 46 analyzes the data collected from one or more cylindrical portions 57 of the metal container 54. The control system 46 can identify decoration characteristics 58 such as, but not limited to, color, thickness, density, consistency, and alignment.

[0219] In operation 150 the control system 46 optionally Petition 870230045110, dated 05 / 29 / 2023, pp. 105 / 186 99 / 165 stores the collected data in memory. Specifically, the control system 46 can store the data collected from one or more of the detected metal containers 54. Optionally, the control system 46 can store the data collected from each metal container 54 that is detected. In one embodiment, the control system stores the collected data in a record 132 of the database 110. Optionally, the collected data can be stored in the first data object 116 of the database 110.

[0220] In one embodiment, method 140 returns a predetermined number of times in operation 152. For example, method 140 might include detecting a predetermined number of metal containers 54 with acceptable decorations. In one embodiment, method 140 returns from 50 to 500 times. Specifically, method 140 might repeat until the control system 46 has received sensor data on approximately 50 to 500 metal containers with acceptable decorations. In this mode, the control system 46 learns, or is trained, to recognize deficient decorations.

[0221] In one embodiment, data, such as images, from each metal container 54 with an acceptable decoration are stitched together to form a master image. In this mode, the master image is created using metal containers 54 decorated by decorator 2 with sensors 49, 50 associated with the decorator. Specifically, in one mode, the master image is specific to decorator 2. Furthermore, a master image can be created for each production operation.

[0222] Once a sufficient number of decorations 58 are detected by sensors 49, 50, the master image is stored in memory. Subsequently, the master image can be used to determine if subsequent decorations 58 formed by decorator 2 are acceptable. Creating a master image from data collected by Petition 870230045110, dated 05 / 29 / 2023, pp. 106 / 186 100 / 165 sensor 49, 50 associated with decorator 2, the decorations 58 of subsequent metal containers 54 are evaluated using similarly created decorations collected by at least sensors 49, 50. In this mode, the comparison of decorations with the master image formed in the same decorator 2 can correctly identify acceptable and deficient decorations.

[0223] In contrast, if the decorations 58 were evaluated against a master image formed by a different decorator using data collected by different sensors, there would be more variables relating to the formation of the decoration and the data collection by the sensors 49, 50 which would have to be taken into account. For example, a light 51 associated with a sensor 49, 50 could generate a different wavelength or intensity of light compared to a similar light associated with a different decorator. A lens from a sensor 49, 50 might also transmit light differently than a similar sensor from a different decorator. Consequently, a master image formed by a different decorator would likely include variables that would be difficult to take into account when evaluating decorations.

[0224] Optionally, in one embodiment, method 140 may include detecting at least one metal container 60 that includes a known deficient decoration. The decoration may be deficient with respect to one or more parameters that vary from target to target. The parameters may include, but are not limited to, at least one of the color, density, thickness (or depth), position and / or alignment, and consistency of the decoration. Optionally, a plurality of metal containers 60 with deficient decorations may be detected by the sensor 50. In one embodiment, at least one of the deficient decorations is associated with an improper amount of paint. Another of the poor decorations is due to paint. Petition 870230045110, dated 05 / 29 / 2023, pp. 107 / 186 101 / 165 defective. Yet another of the bad decorations is caused by a defective (or misaligned) printing plate. Another bad decoration may be related to a defective (or misaligned) transfer blanket. Still another deficient decoration may be associated with an improperly aligned (or positioned) decoration. Specifically, the deficient decoration may include a first ink 26 of a first inkwell set 8 that is improperly aligned (or registered) with respect to a second ink 26 of a second inkwell set 16.

[0225] For each detected metal container 60 which includes a known defective decoration, the control system 46 can store the sensor data in a register 132 which includes a field with data identifying the reason for the defective decoration. In one embodiment, the field may include data indicating an action that the control system 46 should take if a similar defective decoration is detected by at least one of the sensors 49, 50 during a production operation of the decorator 2. For example, the database 110 may include an action in the other field 130 to provide an alert to the operator when a defective decoration is detected. In another embodiment, when a defective decoration relating to an improper amount of paint is detected, the other field 130 may include instructions to adjust the position of one or more paint blades 21 or portions 24 of paint blade 22.In this mode, the control system 46 can alter the amount of ink 26 transferred to an ink roller 10, 18 and subsequently to a metal container. Furthermore, or alternatively, if an improper amount of ink is detected in one or more cylindrical portions 57 of a container, the control system 46 can send a signal to an actuator associated with a drive roller 13 or a drive element of an ink roller 10, 18 or a transfer roller of an ink train. Petition 870230045110, dated 05 / 29 / 2023, pp. 108 / 186 102 / 165 11, 19 to change a quantity of ink 26 transferred from an ink roller 10, 18 to an associated printing plate 6, 14. Specifically, the control system 46 can alter the movement of the drive roller 13 to adjust the dwell time of the drive roller. Additionally, or alternatively, the control system can adjust a drive element to change the rotation rate of one or more ink rollers and a transfer roller to change the amount of ink transferred to a printing plate 6, 14. In yet another embodiment, if a decoration is defective due to improper alignment or position, the control system can include instructions to change the position of one or more elements of the decorator 2. For example, the control system 46 can include instructions to move at least one of an inkwell assembly 8, 16, an ink roller 10, 18, a plate cylinder 4, 12, a blanket cylinder 36, and a support element 42.In this mode, in one embodiment, the control system 46 can correct a deficiency caused by an improper alignment or position of a decoration formed on a metal container.

[0226] If the predetermined number of metal containers was not detected by sensor 50, control system 46 may determine in operation 152 that operations 144 - 150 should be repeated. Consequently, method 140 will return YES for operation 144. Alternatively, control system 46 may determine that a sufficient (or predetermined) number of metal containers with decorations was detected so that operations 144 - 150 should not be repeated. In this case, method 140 remains NO for operation 154.

[0227] Method 140 can then optionally test the ability of control system 46 to recognize a deficient decoration in operations 154-158. More specifically, in operation Petition 870230045110, dated 05 / 29 / 2023, page 109 / 186 103 / 165 154 a metal container 60 with a known defective decoration is provided. At least one sensor 49, 50 collects data on the defective decoration during operation 156.

[0228] In operation 158, control system 46 evaluates the collected data similarly to operation 148. Control system 46 will then determine whether or not the decoration is deficient. In one embodiment, control system 46 compares the collected data with the master image. If control system 46 does not identify the deficient decoration, method 140 returns NO for operation 144, and additional metal containers with decorations are detected and analyzed by the control system. More specifically, control system 46 will analyze sensor data relating to one or more decorations, including acceptable or deficient decorations.

[0229] Alternatively, if control system 46 correctly identifies the defective decoration, method 140 continues YES to complete operation 160. In one embodiment, correctly identifying the defective decoration includes control system 46 correctly identifying why the decoration is defective. For example, the decoration may be defective due to one or more of the paint color, paint density, paint thickness, paint quantity, paint consistency, and decoration location or alignment.

[0230] In one embodiment, correctly identifying the defective decoration still includes the control system correctly identifying an action required to correct the defective decoration. For example, if the decoration is defective due to an incorrect amount of paint, the control system may indicate one or more paint blades or paint blade segments that must be adjusted to correct the deficiency. In addition, or alternatively, the control system may identify a paint roller, a conductor roller, or a transfer roller for which a rate of movement or rotation is required. Petition 870230045110, dated 05 / 29 / 2023, page 110 / 186 104 / 165 must be changed to adjust the amount of ink transferred to a printing plate 6, 14. Similarly, if the decoration location or alignment is deficient, the control system 46 can identify at least one set of inkwell, ink roller, plate cylinder, blanket cylinder, and support element that must be adjusted to correct the deficient decoration.

[0231] Once control system 46 is trained to recognize an acceptable decoration, control system 46 can detect a decoration 58 that differs from the acceptable decoration. Specifically, once control system 46 has detected a sufficient number of decorations 58 to create a master image, the master image can be used to determine whether subsequently formed decorations 58 are acceptable or deficient. In this mode, the control system can determine that the metal container includes an unacceptable, or deficient, decoration. In one embodiment, control system 46 can be trained to recognize an acceptable decoration when fewer than 100 metal containers with acceptable decorations are detected by sensor 50 and stitched together into a master image.Alternatively, in another embodiment, the control system 46 is trained to recognize an acceptable decoration after receiving sensor data from approximately 100 to approximately 200 metal containers with acceptable decorations and creating a master image with the sensor data. In one embodiment, data from approximately 200 to approximately 600 metal containers with acceptable decorations are collected by the sensors and subsequently stitched together to form a master image. Optionally, the master image will be created after 500 metal containers with acceptable decorations have been detected by sensors 49, 50. According to the embodiments of the present invention, the system of... Petition 870230045110, dated 05 / 29 / 2023, page 111 / 186 105 / 165 control 46 can use supervised and / or unsupervised machine learning techniques such as, but not limited to, support vector machines, powered decision trees, and / or one or more neural networks, in order to recognize an acceptable decoration.

[0232] In one embodiment, the control system 46 compares sensor data received from one or more of the sensors 49, 50 with a known reference stored in memory. For example, the control system 46 may compare sensor data, or a portion of an image obtained, with a master image. The master image, in one embodiment, is stitched together from data collected on a plurality of metal containers 54 with acceptable decorations 58. In another embodiment, the master image is created from an image of a metal container with an acceptable decoration and stored in memory. Alternatively, the master image is created by the control system and stored in memory. In yet another embodiment, the master image is created by an operator or a client and loaded into the control system's memory.

[0233] The master image of the metal container can be stored in a memory 90, 92 of the control system 46. In another embodiment, the master image can be stored in a database 110 with which the control system 46 is in communication, such as by a connection on the network 102.

[0234] The decoration may be defective if one of the inkwell assemblies 8, 16 transfers an excessive or insufficient amount of ink 26 to a portion of the printing plates 6, 14. In another embodiment, a decoration may be defective if the inkwell assemblies 8, 16 transfer the ink 26 to an improper portion of the printing plates 6, 14. A decoration may also be defective if a conveyor roller 13 is not transferring a correct amount. Petition 870230045110, dated 05 / 29 / 2023, p. 112 / 186 106 / 165 of ink from an associated ink roller 10, 18 for a printing plate 6, 14.

[0235] If control system 46 determines that decoration 58 is deficient, control system 46 is operable to determine whether a component of decorator 2 should be adjusted to produce an acceptable decoration 58. More specifically, in one embodiment, control system 46 can determine which inkwell set 8, 16 is associated with a deficient decoration based at least in part on an ink color 26 of the deficient decoration. In one embodiment, control system 46 can retrieve data from field 120 of data structure 110 to determine which of the inkwell sets 8, 16 is associated with the ink color. Control system 46 can determine at least one ink blade 21, 22 of the inkwell assembly 8, 16 which is associated with the defect based on a location of the defective decoration in one or more cylindrical portions 57. For example, in one embodiment, the inkwell assembly 8 includes a first ink 26A of a first color.Database 110 includes information in field 120 that associates the first ink 26A with the first cartridge assembly 8. One or more sensors 49, 50 obtain data relating to a metal container 54 (illustrated in Figure 11) that includes the decoration 58B. The control system 46 can determine that a portion of the decoration 58B formed from the first ink 26A is deficient. The deficiency may be in the cylindrical portion 57E. Consequently, the control system 46 can determine that the ink blade 21E or 22E of the inkwell assembly 8 is in an improper position relative to the axial portion 20E of the first ink roller 10. If too little or too much ink is the cause of a deficient decoration, the control system 46 can determine that the movement of a drive roller 13 should be adjusted. Alternatively, the control system 46 can determine that a rotation rate of one or more of... Petition 870230045110, dated 05 / 29 / 2023, p. 113 / 186 107 / 165 an ink roller 10, 18 or a transfer roller of an ink train 11, 19 must be changed to change the amount of ink transferred to a printing plate.

[0236] The control system 46 can cause one or more corresponding actuators 30 to change the alignment of the ink blades 21 or ink blade 22 to increase or decrease the gap 32. In one embodiment, the control system 46 can automatically send a signal to one or more corresponding actuators 30 to change the alignment of the ink blades 21 or ink blade 22 to increase or decrease the gap 32. In this mode, the control system 46 can adjust the amount of ink 26 transferred to the printing plates 6, 14 from one or more of the plate cylinders 4, 12 without the insertion of a decorator operator 2.

[0237] In addition, the control system 46 can optionally send a signal to the actuators 30 to adjust an axial position of an associated blade segment 24 with respect to the paint rollers 10, 18. More specifically, in one embodiment, the signal from the control system 46 can cause the actuator 30F to move at least a portion of the associated blade segment 24F in the direction of one of the blade segments 24E or 24G, as generally illustrated in Figure 3D.

[0238] In another embodiment, the control system 46 can send a signal to an actuator associated with at least one element of the decorator 2, such as the inkwell assemblies 8, 16, the ink rollers 10, 18, the plate cylinders 4, 12, the blanket cylinder 36, and the support element 42. The signal can cause an actuator to move an associated element to automatically correct a deficient decoration relative to a position or alignment of the decoration. The actuator can move the associated element in one or more specific directions, which includes along one or more x directions, a Petition 870230045110, dated 05 / 29 / 2023, pp. 114 / 186 108 / 165 y direction, and a z direction. In another embodiment, the control system 46 can send a signal to an actuator associated with a drive roller 13. The signal can cause the actuator to change a rate at which the drive roller 13 moves to adjust the amount of ink 26 transferred from an ink train 11, 19 to a printing plate 6, 14.

[0239] In another embodiment, the control system 46 can report changes in decorator elements 2 made to correct a deficient decoration to an operator. In one embodiment, the report may include changes in the radial or axial position of one or more of the paint blades 21 or paint blade segments 22 required to correct a deficient decoration. In addition, or alternatively, the report may include changes in other decorator elements 2 required to correct the deficient decoration, such as changes in the operation of a guide roller 13.

[0240] The report may be presented on an output device of the control system 46, such as a display. In this mode, the operator may at least review the changes, such as changes in the ink blades 21 or segments 24 of ink blade 22 prepared by the control system 46. In one embodiment, the operator must approve the planned changes before the control system 46 sends a signal to the actuators 30 to change positions. In another embodiment, the operator may use an input device 86, such as a pointer (including a mouse, touch panel, or trackball), a keyboard, or a touch screen of the control system 46, to approve, disapprove, or modify the changes planned by the control system.

[0241] In one embodiment, after reporting the planned changes to the decorator 2 elements to the operator, the control system 46 waits for a predetermined period of time. Petition 870230045110, dated 05 / 29 / 2023, pages 115 / 186 109 / 165 Optionally, if the operator does not reject the planned changes within the time period, the control system 46 sends a signal to the actuators 30 to implement the planned changes. In another embodiment, if the operator does not approve the planned changes within the time period, the control system 46 will not send the signal to the actuators 30 and the paint blades 21 or paint blade segments 24 and other decorator elements will remain in their current position.

[0242] Referring again to Figure 11, the control system 46 can determine that one or more of decorations 58A, 58B (or a portion of one of the decorations 58) is deficient. For example, part of the decoration 58B on the cylindrical portion 57E may be deficient. One or more of the sensors 49, 50 may have a target 59E associated with the cylindrical portion 57E. In one embodiment, the control system 46 can use the data from sensors 49, 50 to determine that the deficiency is due to an improper amount of one or more of the first and second paints 26A, 26B transferred to the cylindrical portion 57E.Using the sensor data, the control system 46 can determine that the amount of improper ink is caused by one or more of: (1) too much first ink 26A from the axial portion 20E of the first ink roller 10; (2) too little first ink 26A from the axial portion 20E of the first ink roller 10; (3) too much second ink 26B from the axial portion 20E of the second ink roller 18; and (4) too little second ink 26B from the axial portion 20E of the second ink roller 18.

[0243] After determining the cause of the deficiency for the decoration part 58B in the cylindrical portion 57E, the control system 46 can send a signal to the actuator 30E associated with the axial portion 20E of the first paint roller 10 to change the gap 32 between the axial portion 20E of the first paint roller 10 and the associated paint blade 21 or the segment 24E of the paint blade 22. The signal can result in a Petition 870230045110, dated 05 / 29 / 2023, pp. 116 / 186 110 / 165 an increase, or a decrease, in the quantity of the first ink 26A transferred to the axial portion 20E of the first ink roller 10. If the deficiency is due to an incorrect quantity of the second ink 26B transferred to the cylindrical portion 57E, the control system 46 can send a similar signal to the actuator 30E associated with the axial portion 20E of the second ink roller 18 to adjust the quantity of second ink 26B transferred to the cylindrical portion 57E. Optionally, in another embodiment, the control system 46 can send a signal to a pump to change the quantity of ink supplied to the ink channel 29E of the ink blade 22D of the first or second ink roller 10, 18.

[0244] Alternatively, the control system 46 may determine that the deficiency is not related to an improper amount of ink 26A, 26B transferred to the metal container 54. As one skilled in the art will appreciate, the deficiency may be due to other problems, such as, but not limited to: a problem with the printing plates 6, 14, a problem with a transfer blanket 38, defective ink 26, and a problem with the support element 42. Problems with the printing plates 6, 14 and the transfer blankets 38 include, among others: damaged, defective, and misaligned printing plates 6, 14 or transfer blankets 38.

[0245] Printing plates 6, 14 and transfer blankets 38 gradually wear out during a production operation. For example, frequent contact of printing plates 6, 14 with ink rollers 10, 18 (or transfer rollers of ink trains) and transfer blankets 38 causes the surface of printing plates 6, 14 to wear out. Transfer blankets 38 are also subject to wear due to contact with printing plates 6, 14 and metal containers 54. The control system 46 can Petition 870230045110, dated 05 / 29 / 2023, pp. 117 / 186 111 / 165 compensate for wear by substantially and continuously adjusting the amount of inks 26A, 26B transferred to the metal containers 54 as described above. In one embodiment, wear may cause a decoration to be defective, such as being out of alignment or in an improper position. In response to determining from sensor data that the deficiency is due to improper alignment or position of one or more of the decorations 58, the control system 46 may send a signal to move one or more of the inkwell assemblies 8, 16, ink rollers 10, 18, plate cylinders 4, 12, blanket cylinder 36, and support element 42 in a specific direction. In this mode, the control system 46 may automatically correct a defective decoration caused by improper alignment or position of a decoration.

[0246] Occasionally a printing plate 6, 14 or transfer blanket 38 is damaged. The damage may occur either before the start of a production operation or during the production operation. A printing plate 6, 14 or transfer blanket 38 may also include a defect that affects the decoration quality. Furthermore, one of the printing plates 6, 14 or transfer blankets 38 may not be properly aligned with an associated plate cylinder 4, 12 or blanket cylinder 36. The alignment problem may occur during the production operation. For example, the high rotation rate of the plate cylinders 4, 12 or blanket cylinder 36 may cause the printing plates 6, 14 or transfer blankets 38 to move out of proper alignment, negatively affecting the decorations formed on the metal containers 54.

[0247] The control system 46 can determine that a defective decoration 58 is due to a problem with a printing plate 6, 14, or a transfer blanket 38, because the Petition 870230045110, dated 05 / 29 / 2023, pp. 118 / 186 112 / 165 faulty decoration 58 will periodically repeat on other metal containers 54. More specifically, a metal container 54 with faulty decoration caused by a problem with a printing plate 6, 14 or a transfer blanket 38 may be positioned between metal containers with satisfactory decorations.

[0248] Control system 46 can associate the defective decoration caused by either printing plates 6, 14 or transfer blanket 38 based on how frequently the defective decoration is repeated on the metal containers. More specifically, in one embodiment, the number of printing plates 6, 14 on plate cylinders 4, 12 is different from the number of transfer blankets 38 on blanket cylinder 36. Consequently, a defective decoration caused by a problem with a transfer blanket 38 will repeat at a different rate than a defective decoration resulting from a problem with a printing plate 6, 14. If the defective decoration repeats at a rate equal to the number of transfer blankets 38, control system 46 can determine that the defective decoration is caused by a problem with one of the transfer blankets 38.Otherwise, if the defective decoration is repeated on each metal container and is located in the same position as each defective decoration, the control system 46 can determine that a printing plate 6, 14 with a problem is the cause of the defective decoration. In an embodiment in which each plate cylinder 4, 12 includes only one printing plate 6, 14, a problem with one of the printing plates 6, 14 will cause each metal container to have a defective decoration.

[0249] The defective decoration can be traced, by the control system 46, either to the printing plates 6 of the first plate cylinder 4 or to the printing plates 14 of the second plate cylinder. Petition 870230045110, dated 05 / 29 / 2023, pp. 119 / 186 113 / 165 based on which of the first and second inks 26A, 26B is associated with the periodically deficient decoration. For example, if deficient decorations are observed and the deficiency relates to a problem with only the first ink 26A, then the control system 46 can determine that the first printing plate 6 has a problem. Alternatively, if the decoration deficiency occurs in each metal container and is only associated with the second ink 26B, the problem is related to the second printing plate 14. In one embodiment, the control system 46 can send a signal to one or more of the plate cylinders 4, 12 to change a position of a printing plate 6, 14 to correct the alignment of the printing plate on the plate cylinder. In this mode, the control system 46 can correct a deficient decoration due to an improper alignment or position of a printing plate 6, 14.In another embodiment, the control system 46 may send a signal to a blanket cylinder actuator 36. The signal may direct the actuator to move a transfer blanket 40 in a specific direction to correct an improperly aligned transfer blanket 40.

[0250] A problem with the support element 42 may be identified by the control system when a decoration is improperly aligned or positioned on the metal container 54. For example, the support element 42 may be improperly aligned with the blanket cylinder 36. When this occurs, a decoration transferred to a metal container 54 may be improperly positioned on the metal container. For example, the decoration may be too high or too low on the metal container. Alternatively, the decoration may not be aligned with a geometric axis of the metal container.Poor decoration can also be caused when the metal container 54 is not properly aligned on a support element station. Petition 870230045110, dated 05 / 29 / 2023, pp. 120 / 186 114 / 165 44. For example, a station 44 may be damaged or worn so that a metal container 54 is not properly aligned with a transfer blanket 38. In one embodiment, the support element 42 includes a plurality of mandrels 44. A mandrel 44 may be damaged so that a metal container 54 on it is improperly aligned with a transfer blanket 38. The control system 46 may determine that the support element 42, or a station 44 of the support element, is associated with the faulty decoration at least in part based on a frequency at which the faulty decoration occurs. In one embodiment, the control system 42 may send a signal to an actuator associated with a support element 42 to move the support element 42, or a mandrel 44 of the support element, in a specific direction to correct the faulty decoration.In another embodiment, control system 42 can send an alert to an operator indicating that a faulty decoration is associated with support element 42.

[0251] A defective ink 26 may include one or more of: ink of an improper color, incorrect ink viscosity, impurities in the ink, and ink that is at an incorrect temperature. The control system 46 may determine that a deficient decoration is related to a defective ink if similar deficiencies are observed on a number of metal containers and adjusting the amount of ink transferred to the metal containers does not eliminate the deficiency. In one example, the control system 46 may identify a deficient decoration and determine that an improper amount of ink is the cause. The control system 46 may adjust the position of one or more ink blades 21 or portions of ink blades 24 associated with at least one of the first ink roller 10 and the second ink roller 18. In addition, or alternatively, the system Petition 870230045110, dated 05 / 29 / 2023, pp. 121 / 186 Control system 46 can alter the movement rate (or movement time) of a conductor roller 13 to change the amount of ink transferred to one or more printing plates 6, 14. More specifically, the dwell time of the conductor roller 13 with an associated ink roller 10, 18 can be increased or decreased. If similar deficient decorations are identified by control system 46 after adjusting the ink blades 21 or ink blade portions 24 or the movement of the conductor roller 13, the control system can determine that the cause of the deficient decoration is defective ink.

[0252] In another embodiment, control system 46 can determine that defective ink is causing deficient decorations when the deficiency is observed on two or more cylindrical portions 57 of the cylindrical body 56 of the metal container.More specifically, an improperly fitted ink blade 21 or ink blade segment 24 should only affect one cylindrical portion 57 of the metal container. In contrast, when defective ink is supplied to the inkwell assemblies 8, 16, the defective ink will be transferred through all axial portions 20 of the ink rollers 10, 18. Consequently, at least two cylindrical portions 57 of the metal container 54 will include decoration defects.

[0253] Control system 46 can assign an error value to each defective decoration. In one embodiment, the error value may be stored in portion 130 of database 110. In one embodiment, control system 46 may perform different actions based on a level of the error value. For example, in one embodiment, control system 46 may perform a first action for a first error value and a second action for a second error value. In another embodiment, the first action may include sending a signal to an actuator to adjust an element of a decorator. Petition 870230045110, dated 05 / 29 / 2023, pp. 122 / 186 116 / 165 2. The signal can activate the actuator to move an associated ink blade 21, 22, inkwell assembly 8, 16, ink roller 10, 18, plate cylinder 4, 12, blanket cylinder 36, or support element 42 in a specific direction. Alternatively, the signal can cause the actuator to change the movement rate of a drive roller 13. The first action can also include sending an alert to an operator. The second action can include sending a signal to the ejector 62 to remove a metal container with a deficient decoration from the conveyor 48. In one embodiment, the second action can also include sending a signal to the decorator 2 to stop the decorator. In one embodiment, the first error value is a warning level and the second error value is a rejection level. In another embodiment, the first error value is associated with a deficiency associated with a first density of a decoration.The first density can be obtained by one or more sensors 49, 50 and transmitted to the control system 46. The second error value may be associated with a second density of a defective decoration. In one embodiment, by assigning an alert level before assigning a rejection level, the control system 46 is given a period of time to adjust a decorator 2 to correct defective decorations before stopping the decorator.

[0254] In another embodiment, the error value will increase as the magnitude of the defect increases. The error value may be related to one or more of the color, density, alignment, depth, and consistency of the defective decoration. In one example, the error value is proportional to the surface area of ​​the outer surface of container 56 covered by the defective decoration. Additionally, or alternatively, the error value may be below a predetermined value if the defect is not visible to the human eye. Similarly, the error value may be above the predetermined value. Petition 870230045110, dated 05 / 29 / 2023, pp. 123 / 186 117 / 165 if the disability is visible to a human.

[0255] The error value may also be associated with a periodic frequency of defective decoration. For example, an error value associated with a problem of a printing plate 6, 14 or a transfer blanket 38 (which, in some cases, cannot be corrected by the control system 46) may be higher than an error value for a decoration defect associated with the amount of ink transferred to the metal container (which can be corrected by the control system 46). In one embodiment, a defective decoration caused by a printing plate 6, 14 will be given a higher error value by the control system 46 than for a defective decoration caused by a transfer blanket 38.The error value associated with a decoration deficiency caused by a 6,14 printing plate is greater than an error value associated with deficiencies caused by a 38 transfer blanket because the printing plate deficiency will occur more frequently than the transfer blanket deficiency because each cylinder of plates 4,12 includes only one 6,14 printing plate. Consequently, a defective 6,14 printing plate will cause a decoration deficiency on each metal container decorated by decorator 2.

[0256] In one embodiment, the error value may increase based on the number of metal containers observed with deficient decoration. More specifically, deficient decoration may be associated with a first error value. The first error value may be a warning level. If additional metal containers are identified within a predetermined time period with deficient decorations, control system 46 may increase the error value to a second error value. Control system 46 may then send a signal to decorator 2 which causes the decorator Petition 870230045110, dated 05 / 29 / 2023, pp. 124 / 186 118 / 165 stop. In one mode, when control system 46 identifies a predetermined number of metal containers 60 with defective decorations, control system 46 will send the signal which causes decorator 2 to stop.

[0257] Optionally, the control system 46 can assign an error value based on the ΔE of a difference between the target value of a color and the color value measured by sensor 49, 50. For example, if the ΔE is within a predetermined percentage of the target value, the control system can assign a first error value for the deficient decoration. In response, the control system 46 can determine a cause of the deficient decoration. In one embodiment, the control system 46 can send a signal to an actuator associated with a component of the decorator 2 which can be adjusted to correct the deficiency. In one embodiment, when the ΔE is within approximately 5% of the target value for a color, the control system will assign the first error value.

[0258] When ΔE is within a second predetermined percentage of the target value, the control system can assign a second error value to the decoration. The second error value can cause the control system 46 to activate the ejector 62 to remove the metal container 60 with the defective decoration from the conveyor 48. Similar to the first error value, the control system 46 can determine a cause of the defective decoration and, if adjusting a component of the decorator 2 will correct the cause of the defective decoration, the control system 46 can optionally send a signal to one or more actuators 30 of the decorator. Optionally, the control system 46 can generate an alert after assigning the second error value. In one embodiment, the second error value is assigned for a defective decoration for which the ΔE is within approximately 15% of the target value if it is a color. Petition 870230045110, dated 05 / 29 / 2023, pp. 125 / 186 119 / 165

[0259] When ΔE exceeds a predetermined amount, control system 46 may assign a third error value to the defective decoration. In one embodiment, the third error value is assigned to decorations which have a ΔE greater than approximately 15% of a target value for a color. In one embodiment, control system 46 may send a signal to stop decorator 2 after assigning the third error value to a defective decoration. Additionally, or alternatively, control system 46 may send an alert associated with the third error value to an operator.

[0260] In another embodiment, for a deficient decoration that the control system 46 determines is due to defective ink 26, the control system 46 may assign an error value that is higher than the error values ​​relating to problems with printing plates 6, 14 and the transfer blanket 38. The higher error value for defective inks is warranted because a defective ink can cause deficient decorations at a higher frequency than the rate of deficient decorations caused by problems with printing plates 6, 14 and transfer blankets 38.

[0261] Control system 46 can generate an error or alarm code related to defective decorations. In one embodiment, the error or alarm code is stored in field 130 of database 110. The alarm code can include information about the cause of the defective decoration as determined by control system 46. The error value assigned to defective decoration by control system 46 can be included in the alarm code. In one embodiment, control system 46 can generate the alarm code when a defective decoration is related to an improper amount of ink transferred to the metal container, a problem with a printing plate 6, 14 or a transfer blanket 38, or a Petition 870230045110, dated 05 / 29 / 2023, pp. 126 / 186 120 / 165 defective ink. In another embodiment, the alarm code is generated when the error value assigned to the defective decoration exceeds a predetermined value. In yet another embodiment, the alarm code may be generated for each defective decoration identified by the control system 46. In one embodiment, the alarm code may be generated for defective decorations which the control system cannot correct or which are not eliminated. For example, a defective decoration which the control system cannot correct by sending signals to the actuators 30 to adjust the amount of ink transferred to the metal containers 54 or by adjusting the position of one or more of the inkwell assemblies, ink rollers, plate cylinders, blanket cylinder, and support element may cause the control system 46 to generate an alarm code.In another mode, the 46 control system can generate an alarm code for faulty decorations for which the control system cannot identify a cause.

[0262] In addition, or alternatively, the control system 46 may stop the decorator 2 after detecting a defective decoration based on rules stored in a memory 96 of the control system 46. In one example, the rules may direct the control system 46 to stop the decorator 2 when the error value is above a certain amount. In this mode, the control system 46 may stop the decorator when one or more of the following: (1) a defective decoration occurs at or above a predetermined frequency; (2) a defective decoration has a surface area greater than a predetermined amount; (3) more than a predetermined number of defective decorations are detected; (4) similar defective decorations are detected after the position of at least one paint blade 21 or portion of paint blade 24 is adjusted by a signal from the control system 46 to an actuator 30; and (5) decorations Petition 870230045110, dated 05 / 29 / 2023, pp. 127 / 186 121 / 165 similar defects are detected after a rotation rate of one or more of an ink roller 10, 18 and a transfer roller of an ink train 11, 19 is changed by a signal from the control system 46 to a drive element.

[0263] Optionally, when control system 46 determines that a metal container 60 has a defective decoration 58, control system 46 is operable to send a signal to activate the ejector 62. The ejector 62 is operable to remove the metal container 60 from the conveyor 48, as illustrated by the ejection of metal container 60 in Figure 1. In this mode, metal containers 60 with defective decorations are not transported to the downstream equipment 66.

[0264] In one embodiment, the control system 46 sends a signal to the ejector 62 to remove metal containers 54 which include a deficient decoration with an error value above a predetermined level. Some deficient decorations may be subtle. Although the deficient decoration does not meet decoration standards, the deficiency may not be apparent to the human eye. Consequently, the control system 46 may adjust the paint sheets 21 or portions of a paint sheet 22 to correct the deficiency; however, if the deficiency is not detectable by a human eye, the control system 46 may allow the metal container 54 to continue to the downstream equipment 66. For example, if the decoration with a deficient color is evaluated in the L*a*be color space to include a ΔE less than approximately 1, the deficient color is likely not perceptible to a human observer.In one embodiment, when a decoration has a ΔE less than approximately 1, the metal container 54 is not ejected. Other defective decorations may be apparent to the human eye. In another embodiment, decorations with a ΔE greater than approximately 1.1 will be ejected. Decorations visible to... Petition 870230045110, dated 05 / 29 / 2023, pp. 128 / 186 122 / 165 humans may be assigned a higher error value so that metal containers 60 with visibly defective decorations require ejection. Consequently, the control system 46 may send a signal to the ejector 62 to prevent the flow of metal containers 60 with visible defects above a predetermined error value to the downstream equipment 66.

[0265] In one embodiment, the ejector 62 uses a burst of compressed gas, such as air, to remove metal containers 60 with defective decorations from the conveyor 48. In another embodiment, the ejector 62 contacts and applies mechanical force to the defective metal containers 60. The force moves the metal containers 60 from the conveyor 48.

[0266] Metal containers 54 with acceptable decorations 58 are conveyed past the ejector 62 to the downstream equipment 66. In one embodiment, the downstream equipment 66 includes one or more of a coater, an oven, a waxer, a die narrower, a tester, an inspection station, a sensor, and a palletizer. The coater applies a varnish (or other material) to the inside of the metal container 54. In one embodiment, the coater is positioned upstream of the sensor 50. Consequently, in one embodiment, the metal containers 54 may receive a varnish coating before being detected by a sensor 49, 50. The oven cures the varnish. A thin layer of lubricant may be applied by a waxer to a portion of the container body nearest to an open end of the metal container 54. The die narrower reduces the diameter of a portion of the metal container body and applies a ferrule to aerosol containers.The tester checks the container for unwanted openings or leaks. The inspection station can check the shape or other characteristics of the metal container 54. Optionally, the downstream equipment 66 includes at least one. Petition 870230045110, dated 05 / 29 / 2023, pp. 129 / 186 123 / 165 sensor. The sensor may be the same as, or similar to, sensors 49, 50. Consequently, in one embodiment the control system 46 may receive data collected by a sensor from the downstream flow equipment 64 relating to the external surface 56 of metal containers 54. The palletizer may group the finished metal containers 54 for transport or storage.

[0267] Referring now to Figure 16, a modality of a method 166 of the present invention for determining a cause of a deficient decoration on a metal container 54 is generally illustrated. Although a general order of operations of method 166 is shown in Figure 16, method 166 may include more or fewer operations, or may be operated in a different sequence than that shown in Figure 16. Furthermore, although the operations of method 166 can be described sequentially, many of the operations may in fact be performed in parallel or concurrently. Generally, method 166 begins with a start operation 168 and ends with an end operation 188. At least a portion of method 166 may be performed as a set of computer-executable instructions executed by a computer system and encoded or stored on a computer-readable medium. An example of a computer system might include, for example, the control system 46.An example of the computer-readable medium may include, but is not limited to, a control system memory 46. Hereafter, method 166 will be explained with reference to control system 46, decorator 2, and components described together with Figures 1-15.

[0268] In operation 170, control system 46 receives data from a sensor 49, 50. Control system 46 can then determine if the decoration is satisfactory in operation 172. In one embodiment, control system 46 compares the sensor data with data Petition 870230045110, dated 05 / 29 / 2023, pp. 130 / 186 124 / 165 stored data of an acceptable decoration. Optionally, the stored data relates to a master image comprising data collected from a plurality of metal containers with acceptable decorations. Alternatively, the stored data of an acceptable decoration is provided by an operator or a client. In one embodiment, the stored data of an acceptable decoration is formed from an image of a metal container.

[0269] When sensor data differs from stored data by a predetermined amount, control system 46 can determine that the decoration on the metal container 60 is defective. Specifically, if the sensor data for a decoration differs by more than a predetermined amount from the master image, the decoration is defective. In one embodiment, any variance between the sensor data and the master image results in control system 46 marking decoration 58 as defective. Consequently, control system 46 can determine a cause and action to correct the defective decoration.

[0270] Optionally, control system 46 can establish an error value for deficient decoration. As described previously, the error value can be related to one or more of, but not limited to, the type of deficient decoration, the frequency of occurrence of the deficient decoration, whether the deficient decoration is visible to a human, and the magnitude of variation of a decoration color from a target value for the color (such as ΔE).

[0271] In one embodiment, the error value is one of a warning level and one rejection level. Control system 46 can determine that a decoration is defective for one or more reasons. For example, control system 46 can determine that a decoration is defective due to one or more of a quantity of paint. Petition 870230045110, dated 05 / 29 / 2023, pp. 131 / 186 125 / 165 improper, defective ink, a defective printing plate or transfer blanket, an improper decoration position, an improper decoration alignment, and others. In one embodiment, the control system determines whether a decoration is satisfactory or deficient as described in conjunction with operation 158 of Figure 15. If the decoration is not satisfactory, method 166 continues NO to operation 174. When the decoration is satisfactory, method 166 skips YES to the final operation 188.

[0272] In operation 174, the control system 46 can determine whether the deficient decoration is caused by an improper amount of ink 26 transferred to the metal container 60. The improper amount of ink may include too much or too little ink transferred to one or more axial portions 20 and subsequently to the metal container 60. The improper amount of ink may result in a deficient decoration which has an improper color, improper ink density, or improper thickness. The control system 46 can determine that a deficient decoration is due to an improper amount of ink from the data received from sensor 50.

[0273] In one embodiment, when decoration 58 is deficient in only one cylindrical portion 57 of a metal container 60 and the deficiency is repeated in a plurality of metal containers 60, the control system 46 can determine that the deficient decoration is associated with an improper amount of ink 26 transferred to an axial portion 20 of one of the ink rollers 10, 18. Furthermore, or alternatively, the control system 46 can determine that the deficient decoration is due to an improper amount of ink if at least one of the color, density, and thickness of at least one portion of a decoration 58 is different from the color, density, and thickness of a corresponding portion of an acceptable decoration, such as an acceptable decoration stored in data object 116 Petition 870230045110, dated 05 / 29 / 2023, pp. 132 / 186 126 / 165 of database 110.

[0274] Furthermore, in operation 174, the control system 26 can determine which paint blade 21 or paint blade portion 22 is associated with the cylindrical portion 57 that includes an improper amount of paint 26. When an improper amount of paint is the cause of a deficient decoration, the improper amount of paint will be of a substantially uniform density or thickness along a single cylindrical portion 57 of the metal container 60. Consequently, the improperly fitted paint blade 21 or paint blade portion 24 will generally correspond to the cylindrical portion 57 with the improper amount of paint.

[0275] For example, if cylindrical portion 57B of container 54 illustrated in Figure 11 includes a decoration 58A formed with an improper amount of ink, then ink blade 21B or blade segment 24B of ink blade 22 is improperly fitted with respect to one of the ink rollers 10, 18. The control system 46 can also determine whether inkwell assembly 8, 16 includes an improperly fitted ink blade 21B or blade segment 24B based at least in part on the type or color of ink 26 associated with the deficiency identified in cylindrical portion 57B. More specifically, if ink blade 21B or blade segment 24B of the first inkwell assembly 8 is improperly fitted, the defective decoration will be associated with the first ink 26A.Control system 46 can also consider data received from a potentiometer 80B associated with ink blade 21B or blade segment 24B to determine a current position of the ink blade or blade segment. The data received from the potentiometer may indicate that ink blade 21B or blade segment 24B has inadvertently or unexpectedly moved from an initial position.

[0276] In one embodiment, the control system 46 can Petition 870230045110, dated 05 / 29 / 2023, pp. 133 / 186 127 / 165 also consider data received from one or more of the sensors 49B, 49C relating to the ink on the printing plates. The data from sensors 49B, 49C may indicate that an ink blade 21 or blade segment 24 of one of the inkwell assemblies 8, 16 is transferring an incorrect amount of ink 26. Consequently, the control system 46 may consider data from a plurality of sensors 49, 50, and potentiometers 80 to determine which ink blade 21 or blade segment 24 is improperly adjusted.

[0277] The control system 46 may also determine that an improper quantity of a type or color of ink 26 has been applied to more than one of the cylindrical portions 57 of the container 54. Specifically, the density of an ink 26 may be incorrect across the entire outer surface 56 of the container. In response, the control system 46 may determine that adjusting the rate or time of movement of a conveyor roller 13 of an ink train 11, 19 associated with the ink 26 will correct the deficiency. Alternatively, the control system 46 may determine that the improper quantity of ink transferred may be corrected by altering the rotation rate of an ink roller 10, 18 and a transfer roller of an ink train 11, 19. The ink rollers 10, 18 and the transfer rollers may be driven by drive elements that are in communication with the control system 46.The control system can send signals to one or more drive elements associated with an ink roller 10, 18 and a transfer roller to adjust the amount of ink transferred by an inkwell assembly 8, 16 to an associated printing plate 6, 14. Optionally, the ink rollers 10, 18 can rotate at a rate that is different from that of at least one transfer roller in an associated ink train. In one embodiment, increasing the rotation rate of the ink rollers 10, 18 can increase the amount of ink transferred to a transfer roller. Petition 870230045110, dated 05 / 29 / 2023, pp. 134 / 186 128 / 165 subsequently for a printing plate.

[0278] If the deficiency is not due to an improper quantity of ink, method 166 proceeds NO to operation 176. If the deficiency is due to an improper quantity of ink, method 166 proceeds YES to operation 184.

[0279] In operation 176, control system 46 can determine that a deficient decoration is related to a defective paint 26. More specifically, if the deficient decoration is observed on each of a plurality of metal containers 60, and the deficient decoration extends to more than one cylindrical portion 57 of the metal container 60, control system 46 can determine that the deficiency is due to defective paint or other criteria.

[0280] In one embodiment, the control system 46 can determine that a defective ink 26 is the cause of the deficient decoration when adjusting the position of an ink blade 21 or a portion of an ink blade 22 and / or altering the operation of a conveyor roller 13 to change the amount of ink transferred to the metal containers does not eliminate the deficiency. Optionally, the rate or time of movement of the conveyor roller 13 can be altered. In another embodiment, the control system 46 can determine that the defective ink 26 is causing deficient decorations when the deficiency is observed in sensor data associated with two or more cylindrical portions 57 of the cylindrical body 56 of the metal container. More specifically, an improperly adjusted ink blade 21 or blade segment 24 should only affect one cylindrical portion 57 of the metal container 60.However, when defective ink is supplied to cartridge assemblies 8, 16, the defective ink will be transferred through all axial portions 20 of the ink rollers 10, 18. Consequently, at least two cylindrical portions 57 of the metal container 60 will include defects. Petition 870230045110, dated 05 / 29 / 2023, pp. 135 / 186 129 / 165 decoration.

[0281] Furthermore, or alternatively, the control system 46 can determine that a defective ink 26 is the cause of a deficient decoration when data received from one or more of the sensors 49, 50 indicate variations in the color, density, or thickness of the ink within a cylindrical portion 57 of the container 60. More specifically, non-defective ink 26 should have uniform color, density, and thickness when transferred from an axial portion 20 of an ink roller 10, 18 to a cylindrical portion 57 of a container. However, if the ink 26 is defective, the sensor 50 data associated with a cylindrical portion of the container may include variations. Ink may be defective if it is contaminated (such as with particles, other inks, etc.), is at an improper temperature, is improperly mixed, or is at an incorrect viscosity.

[0282] When an ink is contaminated with particles, one of the sensors 49E, 50 can detect the particles in one or more cylindrical portions 57 of the container. In one embodiment, one of the sensors 49B, 49C, 49D can detect particles in the ink 26 on a printing plate 6, 14 or a transfer blanket 38. In another embodiment, ink contaminated with particles can be detected when a particle in the ink prevents or interrupts the transfer of ink to the ink roller 10, 18. For example, a particle trapped in the gap 32 between the ink roller 10, 18 and an ink blade 21 or portion of an ink blade 24 can result in a lack of ink being transferred to a circumferential portion of the ink roller 10, 18. The circumferential lack of ink on the ink roller 10, 18 can result in a disconnected band on a printing plate, a transfer blanket, or on a metal container 60.Consequently, when the control system 46 detects an unconnected band nearby. Petition 870230045110, dated 05 / 29 / 2023, pp. 136 / 186 130 / 165 of the metal container, control system 46 can determine if the ink is contaminated with particles.

[0283] If the defective ink is at an improper temperature, improperly mixed, or at an incorrect viscosity, the ink may not flow uniformly through the gap 32 between the ink roller 10, 18 and an ink blade 21 or portion of an ink blade 24. Consequently, the ink 26 may be unevenly distributed over at least one of the axial portions 20 of the ink roller 10, 18. For example, the sensor 50 may collect data from two targets 59A, 59B within the cylindrical portion 57B of the metal container as generally illustrated in Figure 11. The control system 46 receives the data relating to targets 59A, 59B and can determine that the ink associated with target 59A differs from the ink associated with target 59B. The sensor data may indicate that the paint on targets 59A and 59B is one or more of the following: different thicknesses, different densities, different colors, or non-uniform.

[0284] When control system 46 determines that a defective ink 26 is the cause of the deficiency in operation 176, method 166 proceeds YES to operation 184. When defective ink is not the cause of the deficiency, method 166 proceeds NO to operation 178.

[0285] In operation 178, control system 46 determines whether the defective decoration repeats. More specifically, a defective decoration relating to a defective printing plate 6, 14 or a defective transfer blanket 38 will periodically repeat on metal containers. Consequently, a defective transfer blanket or printing plate will result in the same, or similar, defective decoration on a plurality of metal containers 60. When the defective decoration 58 repeats on each of the metal containers 60, control system 46 can determine that the defective decoration 58 is due to a printing plate. Petition 870230045110, dated 05 / 29 / 2023, pp. 137 / 186 131 / 165 defective 6, 14. The defective printing plate 6, 14 may be improperly positioned on one of the plate cylinders 4, 12. Alternatively, the defective printing plate 6, 14 may be worn or damaged. In one embodiment, the control system 46 may receive data from at least one of the sensors 49B, 49C, 49D which indicate that a printing plate 6, 14 or a transfer blanket 38 is defective.

[0286] In one embodiment, the control system can determine that the plate cylinder 4, 12 to which the defective printing plate 6, 14 is interconnected is based on the ink 26 associated with the defective decoration. More specifically, the defective printing plate 6 on the first plate cylinder 4 will be associated with ink 26A from the first inkwell set 8. Similarly, the defective printing plate 14 on the second plate cylinder 12 will be associated with ink 26B from the second inkwell set 16.

[0287] Control system 46 can also determine that the defective decoration is associated with a transfer blanket 38 when the defective decoration 58 repeats in a period associated with the number of transfer blankets 38 on the blanket cylinder 36. When the deficiency is due to a defective printing plate or transfer blanket, method 166 proceeds YES to operation 184. If the deficiency is not associated with a printing plate or transfer blanket, method 166 proceeds NO to operation 180.

[0288] In one embodiment, the control system 46 can also determine in operation 180 that the decoration is improperly aligned or positioned on the metal container 60. More specifically, the control system 46 can compare the data received from the sensor 50 with data stored in the database 110 associated with an acceptable decoration. If the alignment or Petition 870230045110, dated 05 / 29 / 2023, pp. 138 / 186 132 / 165 If the position of decoration 58 on the metal container is different from the acceptable decoration stored in memory, the control system can determine that the decoration is not properly aligned.

[0289] In one embodiment, the control system 46 can determine that a decoration is not properly positioned or aligned on the metal container by comparing the positions of two portions of the decoration. More specifically, and referring again to Figure 11, the control system 46 can receive sensor data relating to the position of decoration 58A on the cylindrical portion 57B and decoration 58B on the cylindrical portions 57C-57F. If the positions of decorations 58A and 58B are separated by a distance different from a predetermined amount, the control system 46 can determine that the decoration is defective due to improperly aligned or positioned decorations 58A, 58B.Furthermore, decoration 58C, formed from a first ink 26A, may not be registered with respect to the jersey, decoration 58B, formed from a second ink 26B. In this mode, the control system 46 can determine that one or more of the printing plates 6, 14 is improperly aligned. Generally, different colors or types of inks 26A, 26B must be separated by a predetermined distance. In one embodiment, inks 26A, 26B must be separated by a distance of up to approximately 0.127 mm (0.005 inches). In one embodiment, the control system 46 can consider the data from at least one of the sensors 49B, 49C, 49D to determine which printing plate 6, 14 or transfer blanket 38 is improperly aligned. Additionally, in one embodiment, metal containers 54 are transported from decorator 2 to a sensor 49, 50 sequentially.In another embodiment, each metal container 54 is transported on a conveyor pin 48 which keeps the metal container in order while being transported. Petition 870230045110, dated 05 / 29 / 2023, pp. 139 / 186 133 / 165 for downstream equipment. Consequently, control system 46 can determine a transfer blanket 38 associated with a defective decoration based on one or more of the order of the metal containers and the pin that carries the metal container with the defective decoration.

[0290] When the defect is due to an improperly positioned or aligned decoration, method 166 proceeds YES to operation 184. If the defect is not associated with a printing plate or transfer blanket, method 166 proceeds NO to operation 181.

[0291] In operation 181, control system 46 can determine that a deficient decoration is related to a damaged metal container. The damage may be caused by upstream equipment 64. For example, a body maker may cause a dent, pull mark, scratch, or wrinkle in the cylindrical body 56 of the metal container 54. The damaged portion of the cylindrical body 56 may not properly contact a transfer blanket 38. Consequently, the damaged portion may not properly receive paint resulting in a void or undecorated portion of the outer surface of container 56 and a deficient decoration. The deficient decoration may be visible as a void or blank space in the decoration. Additionally, or alternatively, the damaged portion may receive an improper amount of paint from the blanket 38. Similarly, upstream equipment 64 may cause rub marks, pull marks, and scratches.Scuff marks, pull marks, and scratches can detract from a decoration.

[0292] If the damage caused by the upstream equipment 64 recurs periodically, a similar void, undecorated portion, or area of ​​an improper amount of paint on the outer surface 56 Petition 870230045110, dated 05 / 29 / 2023, pp. 140 / 186 134 / 165 will be detected by sensor 49, 50. Although damage may be repeated in similar areas of multiple metal containers (such as approximately the same distance from a closed end wall of the metal container), as the metal containers 54 arrive at the decorator in random order, the damaged portion of the metal container will be randomly aligned with respect to the transfer mats 38. Specifically, the damaged area of ​​a first metal container will contact a first portion of a first transfer mat and a second metal container with a similar damaged area will contact a different second portion of a second transfer mat. The damaged portion of the metal containers will consequently cause different portions of a decoration to be defective.In this mode, control system 46 can determine that the faulty decoration is the result of damage to a metal container caused by upstream equipment 64.

[0293] Washers upstream of decorator 2 may also cause blemishes on an external surface 56 of a metal container. Blemishes may include droplets, spots, and other marks left on the external surface by a washer. When a metal container with a blemish is decorated, the blemish will alter the color or appearance of the paint that forms a decoration 58. For example, the paint may not completely cover the blemish. The blemish may also repel the paint. The blemish may cause the decoration to be classified as deficient by the control system 46 when compared to a master image.

[0294] When control system 46 determines that a deficiency is due to a damaged metal container, method 166 proceeds YES to operation 184. If the deficiency is not associated with a damaged metal container, method 166 Petition 870230045110, dated 05 / 29 / 2023, pp. 141 / 186 135 / 165 proceeds NO to operation 182.

[0295] Control system 46 may not be able to classify a cause for each identified deficiency. Consequently, in operation 182, control system 46 may register a deficiency as being due to an undetermined cause. Characteristics of the deficient decoration, such as (but not limited to): (a) a reason why the decoration is deficient; (b) a ΔE of a color deficiency; and (c) a location of the deficiency will be saved in memory 90, 96 of control system 46. The characteristics of the deficient decoration may also be stored in a register 132 of data structure 110. In this mode, historical data of deficient decorations are available for further analysis. Some causes of deficient decorations may only be identified after the same or similar deficiency has been observed in a number of metal containers.Consequently, control system 46 can continue production operation and receive data from sensors 49, 50 relating to decorations that are defective for the same or similar reasons. If a location of a defective decoration is repeated on a plurality of metal containers, control system 46 can subsequently determine a cause for the previously undetermined cause. Method 166 then continues to operation 184.

[0296] In operation 184, the metal container 60 with a defective decoration is optionally removed from the conveyor 48. For example, in one embodiment, when an error value associated with a defective decoration is at a rejection level, control system 46 can send a signal to the ejector 62 to remove the metal container.

[0297] In operation 186, control system 46 can send an alert. The alert can include information about the type of deficiency identified by the control system. For example, the alert can indicate Petition 870230045110, dated 05 / 29 / 2023, pages 142 / 186 136 / 165 that the defective decoration is due to an improper amount of ink, defective ink, a defective printing plate or transfer blanket, improper position or alignment of the decoration, and damage to a metal container. In one embodiment, the alert may include sending an image of the defective decoration collected by sensor 50 to a display 88 of the control system 46. In another embodiment, the portion of the decoration that is defective may be highlighted and / or enlarged. Alternatively, if the control system 46 cannot determine the cause of the defective decoration so that method 166 proceeds NO in operation 180 to operation 182, the alert may indicate that the control system 46 could not determine the cause of the defective decoration. In one embodiment, the alert may also include information about actions recommended by the control system 46 to correct the defective decoration.Consequently, the alert may identify one or more ink blades 21 or portions of ink blade 22 that need to be adjusted to correct the deficiency. In another embodiment, the alert may identify one or more of the inkwell assemblies, ink rollers, transfer rollers, plate cylinders, blanket cylinder, and support element that need to be adjusted to correct the deficiency. In addition, or alternatively, the alert may indicate an adjustment to the operation of one or more conductor rollers 13.

[0298] In one embodiment, the control system 46 can automatically adjust one or more of the ink blades 21 or portions of ink blades 22, the inkwell assemblies 8, 16, the ink rollers 10, 18, the ink train transfer rollers 11, 19, plate cylinders 4, 12, the blanket cylinder 36, and the support element 42 to correct the deficiency. Specifically, the control system 46 can send a signal to one or more actuators to move an ink blade 21, ink blade 22, cartridge assembly 8, 16, ink roller Petition 870230045110, dated 05 / 29 / 2023, pp. 143 / 186 137 / 165 ink 10, 18, a plate cylinder 4, 12, and the blanket cylinder in a specific direction. In yet another embodiment, the control system 46 can send a signal to an actuator to move a printing plate 6, 14 or a blanket 38 in a specific direction to correct the deficiency. Furthermore, or alternatively, the control system 46 can send a signal to an actuator of a drive roller 13 or a drive element of an ink roller or a transfer roller to change the rate of movement of the drive roller, the ink roller, or the transfer roller. In this mode, the control system 46 can change the amount of ink 26 transferred by an associated ink train 11, 19 to a printing plate 6, 14.

[0299] In one embodiment, a visual alert or indication on a display screen may identify the cause of the defective decoration, which may or may not be correctable by the control system 46. For example, if the defective decoration is caused by defective ink, a defective printing plate or transfer blanket, or structural damage to a container caused by upstream equipment 64, adjusting elements of the decorator 2 will not correct the defective decoration. Instead, an operator of the decorator 2 may be required to correct the cause of the defective decoration, such as changing a defective ink or replacing a damaged printing plate or transfer blanket. Optionally, if the control system 46 cannot correct the defective decoration, the control system 46 may send a signal to stop the decorator operation or provide a visual indication or alert of the problem to an operator.In one embodiment, if the cause of a faulty decoration is damage caused by upstream equipment 64, the control system can send a signal to stop the operation of the upstream equipment. Optionally, the control system 46 can stop the operation of one or more of the decorator 2 and upstream equipment 64 if the damage occurs. Petition 870230045110, dated 05 / 29 / 2023, pp. 144 / 186 138 / 165 caused by upstream equipment are observed in more than a predetermined number of metal containers. For example, if more than 50 metal containers are identified using sensor data 49, 50 as including defective decorations caused by damage, the control system 64 can send a signal to stop one or more of the decorator and upstream equipment.

[0300] The alert generated by the control system 46 may also include recommended actions such as changing the ink in the inkwell assembly 8. In another embodiment, the alert may indicate which of the printing plates or transfer blankets is defective or improperly aligned. In yet another embodiment, the alert may indicate that the control system cannot correct the deficiency. In one embodiment, the alert may indicate that the cause of the deficiency is undetermined. After sending the optional alert, method 166 proceeds to the final operation 188.

[0301] Referring now to Figure 17, a modality of a method A method 200 for automatically adjusting a decorator 2 to correct a deficient decoration according to an embodiment of the present invention is illustrated. Although a general order of operations for method 200 is shown in Figure 17, method 200 may include more or fewer operations, or arrange the order of operations differently from that shown in Figure 17. Furthermore, although the operations of method 200 can be described sequentially, many of the operations may in fact be executed in parallel or concurrently. Generally, method 200 begins with a start operation 202 and ends with an end operation 232. At least a portion of method 200 may be executed as a set of computer-executable instructions executed by a computer system and encoded or stored in a medium. Petition 870230045110, dated 05 / 29 / 2023, pages 145 / 186 139 / 165 computer-readable. An example of the computer system might include, for example, control system 46. An example of the computer-readable medium might include, but is not limited to, a memory of control system 46. Hereafter, method 200 will be explained with reference to control system 46, decorator 2, and components described in conjunction with Figures 1-16.

[0302] In operation 204, the control system 46 sends a signal to the actuators 30 associated with the inkwell assemblies 8, 16 of the decorator 2. The signal causes the actuators 30 to move the ink blades 21 or ink blade segments 22 closer to, or further away from, the ink rollers 10, 18. In one embodiment of the present invention, the actuators 30 are low-voltage motors.

[0303] Optionally, the actuators 30 may include (or be associated with) potentiometers 80 that provide positional feedback to the control system 46. The control system 46 may use information received from one of the rotation or motion sensors, such as the potentiometers 80, to determine a position of the ink blades 21 or the ink blade 22 (or a blade segment) relative to an associated ink roller 10, 18. For example, in one embodiment of the present invention, each actuator 30 includes a low-voltage DC motor associated with a corresponding ink switch 28 or shaft 31. Optionally, in another embodiment, the actuators 30 include a solenoid interconnected to an ink switch 28. In this mode, the control system 46 adjusts the gap 32 between each ink blade 21 or segment 24 of the ink blade 22 and the ink rollers 10, 18 to an initial position.The gap size 32 allows a predetermined amount of ink 26 to be dispensed to each axial portion 20 of the ink rollers 10, 18 required to form a decoration 58. In one embodiment, the control system 46 automatically determines the initial position of each ink blade 21 or segment 24. Petition 870230045110, dated 05 / 29 / 2023, pages 146 / 186 140 / 165 of ink blade 22 analyzing a decoration 58 entered by an operator in a database 110 of the control system 46. In another embodiment, the operator enters the initial position of each ink blade 21 or segment 24 of blade 22 into the control system 46.

[0304] In operation 206, ink 26 is transferred to axial portions of ink rollers 10, 18. The amount of ink 26 transferred to the axial portions 20 is determined by the gap 32 between the ink blades 21 or ink blade segments 22 and the ink rollers 10, 18 based on the initial settings of the associated ink switches 28 or shafts 31. Ink 26 is successively transferred to the printing plates 6, 14 in operation 208, to the transfer blankets 38 in operation 210, and then, in operation 212, to the outer surface 56 of the undecorated metal containers 52. In one embodiment, one or more of the sensors 49B, 49C collects data on at least the amount of ink 26 transferred to the printing plates 6, 14. In another embodiment, sensor 49D collects data on the amount of ink on the outer surface 40 of the transfer blankets 38.

[0305] The decorated metal containers 54 are subsequently transported to the sensor 50. In one embodiment, method 200 optionally waits for a predetermined period of time in operation 214 during which a metal container 54 is transported from the support element 42 to one or more of the sensors 49E, 50. More specifically, depending on the position of the sensors 49E, 50 relative to the support element 42, it may take several seconds or a period of minutes for a metal container 54 decorated based on changed components of the decorator 2 (such as after adjusting a position of the paint blades 21 and paint blade segments 24) to reach the sensors 49E, 50. If the sensor 49E, 50 is positioned before the downstream equipment 66 (for example, when the sensor is positioned to Petition 870230045110, dated 05 / 29 / 2023, pages 147 / 186 141 / 165 detect wet ink 26 of the decoration 58), the delay may be less than approximately 1 minute. However, sensor 50A may be positioned after downstream equipment 66 and the delay will be longer than 1 minute. In one embodiment, when sensor 50A is positioned downstream of a pin furnace, approximately 350 to 500 metal containers must pass through sensor 50A before a metal container decorated with the new decoration component settings reaches sensor 50A. Regardless of the position of sensor 49, 50, the amount of time delay between the metal container 54 leaving the support element 42 reaching each of the sensors 49E, 50 is known. Consequently, by waiting for the time period in operation 214, the control system 46 can determine the position of the paint blades 21 and the paint blade segments 24 when the metal container has been decorated.In one embodiment, up to approximately 500 decorated metal containers 54 may be in transit between the discharge of the support element 42 and the sensor 50A positioned after a curing oven 66. Consequently, after changing a setting of a component of the decorator 2, up to approximately 500 metal containers 54 must pass through the sensor 50A before a metal container 54 decorated by the changed decorator settings is detected by the sensor 50. When the sensor 50 is positioned upstream of a curing oven 66, fewer metal containers are in transit between the decorator 2 and the sensor. Consequently, fewer than approximately 100 and as few as 20 metal containers may be in transit between the decorator 2 and the sensor 50. Because of this, the sensor 50 can react faster to faulty decorations compared to the sensor 50A positioned after a curing oven.

[0306] The decorations 58 on the metal containers 54 are detected by at least one of the sensors 49E, 50 in operation 216. Petition 870230045110, dated 05 / 29 / 2023, pp. 148 / 186 142 / 165 In one embodiment, the decorated metal containers 54 are transported by the conveyor 48 to the sensors 49E, 50. Alternatively, sensors 49E, 50 are positioned to detect the decorated metal containers 54 on the support element 42.

[0307] Sensors 49E, 50 are aligned to detect or image the decoration 58 on the decorated metal containers 54. Sensor 50 and, optionally, sensor 49E, collect data on a decoration 58 required to determine one or more of: the color of the decoration; the density of the decoration; the depth (or thickness) of the decoration; the alignment of the decoration; and the consistency (or uniformity) of the decoration. In one embodiment, sensors 49E, 50 are cameras. Optionally, the decorator 2 includes three to six sensors 50 or sensors 49E. The three to six sensors 49E, 50 can be arranged around a longitudinal geometric axis of the metal container 50 to substantially simultaneously detect the entire outer cylindrical surface 56 of the metal container.

[0308] In operation 218, control system 46 receives data about a decoration 58 collected by one or more of sensors 49E, 50. Control system 46 is operable to determine whether the decoration 58 is acceptable or deficient based on targets for one or more of color, density, depth, alignment, and consistency. The targets can be adjusted by a customer. In one embodiment, control system 46 compares the sensor data with an image of an acceptable decoration stored in memory 96, 100, 104. In one embodiment, the image can be a master image formed by detecting a plurality of metal containers with acceptable decorations. In one embodiment, images of a plurality of acceptable decorations are stored in memory, as described in conjunction with Figure 15. The master image can be Petition 870230045110, dated 05 / 29 / 2023, pages 149 / 186 143 / 165 stitched together from images of individual acceptable decorations. Alternatively, in another embodiment, a master image of a metal container with an acceptable image is provided to the control system 46 and stored in memory. The master image may be provided by an operator or a client. Consequently, the control system 46 can compare portions of the sensor data with corresponding portions of a plurality of images or a master image stored in memory. Optionally, the control system 46 is programmed to recognize an acceptable decoration. For example, the control system 46 may be programmed to receive data on a plurality of acceptable decorations as generally described in method 140 illustrated in Figure 15. The control system 46 may also determine a reason for a deficient decoration in operation 218.In one embodiment, the control system determines the reason for the deficient decoration as described in conjunction with Figure 16.

[0309] In one embodiment, control system 46 receives data for all metal containers decorated by decorator 2. Alternatively, control system 46 receives data for some of the decorated metal containers 54. In one embodiment, control system 46 determines that a decoration is deficient as described in conjunction with operation 172 of Figure 16. If decoration 58 is satisfactory, method 200 continues YES to operation 228. When decoration 58 is not satisfactory, method 200 proceeds NO to operation 220.

[0310] Optionally, in operation 220, the control system 46 can send a signal to the ejector 62. The signal causes the ejector 62 to remove the metal container 60 with the unsatisfactory decoration from the conveyor 48. In one embodiment, the control system 46 sends the signal to the ejector 62 when an error value associated with the Petition 870230045110, dated 05 / 29 / 2023, pages 150 / 186 144 / 165 unsatisfactory decoration exceeds a predetermined quantity. In another embodiment, the control system 46 can send the signal to the ejector 62 for each metal container 60 that has an unsatisfactory decoration. Alternatively, the control system 46 can determine if the unsatisfactory decoration is visible to the human eye. For example, the unsatisfactory decoration may not meet a target; however, the deficiency may be very small or otherwise not visible to the human eye. If the unsatisfactory decoration is visible to the human eye, the control system 46 can cause the ejector 62 to remove the metal container 60. If the unsatisfactory decoration is not visible to the human eye, the control system 46 can allow the metal container to continue to the downstream equipment 66.

[0311] In operation 222, the control system 46 can optionally send an alert. The alert can be displayed on an output device 88 of the control system 46, such as a display. In one embodiment, the alert is audible. Optionally, the control system 46 can send the alert to a smart device such as a smartphone, tablet, or laptop computer over a network connection. In one embodiment, the alert can comprise a text message.

[0312] The alert may provide information regarding the type of deficiency identified in the decoration 58. In one embodiment, the information may include the error value associated with the unsatisfactory decoration. The information may also include actions performed, or planned, by the control system 46 to correct the deficiency, such as a list of ink blades 21 or ink blade segments 24 associated with ink rollers 10, 18 that have been, or will be, adjusted. In one embodiment, the alert includes information about adjustments to the positions, or operation, of the inkwell assemblies, rollers, Petition 870230045110, dated 05 / 29 / 2023, pages 151 / 186 145 / 165 ink, conductor rollers, transfer rollers, plate cylinders, printing plates, blanket cylinder, transfer blankets, or the support element required to correct the defective decoration. Optionally, in one embodiment, the operator may use an input device 86 of the control system 46, such as a pointer, a keyboard, or a touch screen, to approve the corrective actions presented by the control system 46. In another embodiment, the operator may use the input device to make changes to the decorator 2 to correct the deficiency. In this mode, the operator may activate one or more actuators 30 to change the position of one or more ink blades 21 or ink blade segments 22. In addition, the operator may change an adjustment of an actuator associated with a conductor roller 13 to adjust the rate of movement of the conductor roller.Specifically, the rate or time of movement of a drive roller can be increased or decreased to alter the amount of ink transferred to a printing plate. Additionally, or alternatively, the operator can alter the operation of a drive element to change the rotation rate of an ink roller 10, 18 or a transfer roller in an ink train 11, 19. In yet another embodiment, the operator can alter the settings planned or implemented by the control system 46 to correct the deficiency.

[0313] In operation 224, control system 46 can determine to stop the production operation. More specifically, in one embodiment, control system 46 can determine that the production operation should stop based on a rule saved in memory 96 after determining in operation 100 that a decoration 58 on a metal container 54 is defective. In one embodiment, the rule is associated with the error value assigned by control system 46 to the defective decoration. If the error value is above a certain Petition 870230045110, dated 05 / 29 / 2023, pages 152 / 186 146 / 165 quantity, control system 46 can send a signal to stop decorator 2. In one embodiment, the rule is associated with the number of defective decorations detected within a period of time. More specifically, if control system 46 determines that more than a predetermined number of metal containers include defective decorations, the control system can send a signal to decorator 2 to stop the production operation. In another embodiment, the rule may be relative to the type of deficiency identified by control system 46. Consequently, if the deficiency is of a type correctable by control system 46 activating at least one actuator 30 to change a position of an ink blade 21 or portion of an ink blade 22 or changing a waiting time of a conductor roller 13, control system 46 can determine that the production operation will continue.Similarly, when the deficiency can be corrected by the control system 46 by sending a signal to an actuator to adjust a printing plate 6, 14 or a transfer blanket 38, the control system can continue the production operation. Alternatively, when the deficiency is not correctable by the control system 46, the control system 46 can stop the production operation. Specifically, if the deficiency is due to a defective metal container 54, the control system 46 can stop the decorator. In this mode, the upstream equipment 64 can be inspected and serviced, if necessary. In one embodiment, the control system 46 can stop the production operation in response to an input entered by an operator. If the control system 46 determines that the decorating operation should continue, method 200 returns YES for operation 226.Alternatively, when control system 46 determines that the decoration operation should stop, method 200 continues NO to final operation 232.

[0314] In operation 226, control system 46 identifies one or Petition 870230045110, dated 05 / 29 / 2023, pages 153 / 186 147 / 165 more decorator elements 2 to adjust to correct the deficiency in an identified decoration 58. In one embodiment, the control system 46 uses the data received from sensor 50 or sensor 49E to identify the decorator elements that need to be adjusted. For example, control system 48 can identify one or more paint blades 21 or segments 24 of a paint blade 22 that require adjustment to correct a decoration deficiency 58 using data received from one or more sensors 49B, 49C, 49D, 49E, and 50. Specifically, control system 46 can determine that one or more axial portions 20 of at least one paint roller 10, 18 should receive more (or less) paint 26. Consequently, control system 46 can send a signal to one or more actuators 30 to move a paint blade 21 or paint blade segment 22 closer to, or further away from, the paint rollers 10, 18.The movement of actuators 30 adjusts the gap 32 between an associated ink blade 21, 22 and the ink rollers 10, 18 to dose a corrected amount of ink 26 to an associated axial portion 20 of the ink rollers 10, 18 to form a satisfactory decoration 58. Furthermore, the control system 46 can send a signal to at least one actuator 30 to adjust an axial position of at least one of the ink blade segments 24. In this mode, the control system can, for example, alter the alignment of the decoration. Similarly, in one embodiment, the control system 46 can send a signal to an actuator associated with a drive roller 13. The signal can alter the operation of the drive roller 13 (such as changing the rate or frequency of movement of the drive roller) to change an amount of ink transferred to a printing plate 6, 14.In addition, the control system 46 can send a signal to a drive element to accelerate, or decelerate, one or more of the ink rollers and transfer rollers to change the amount of ink transferred to a printing plate. Petition 870230045110, dated 05 / 29 / 2023, pages 154 / 186 148 / 165

[0315] In another embodiment, the control system 46 can determine that an improperly aligned or positioned decoration can be corrected by changing the alignment of one or more elements of the decorator 2. Consequently, the control system 46 can send a signal to at least one actuator associated with an inkwell assembly 8, 16, an ink roller 10, 18, a plate cylinder 4, 12, a printing plate 6, 14, a blanket cylinder 36, a transfer blanket 38, and a support cylinder 42. The signal can activate the actuator to move in a specific direction. In this mode, the control system 46 can correct a deficiency caused by an improperly aligned or positioned decoration. In one embodiment, the control system 46 determines the reason for the deficiency by performing one or more of the operations of method 166 described in conjunction with Figure 16.

[0316] In one embodiment, the control system 46 automatically controls the actuators 30. In another embodiment, the operator must approve the activation of the actuators 30 before the control system 46 sends the signal to the actuator 30. In yet another embodiment, the control system 46 automatically sends the signal to the actuator 30 after a predetermined period of time has elapsed after sending the alert in operation 104. The operator can cancel the planned adjustment for the ink blades 21, 22 during the predetermined period of time. Consequently, in one embodiment, the operator must approve an adjustment for the ink blades 21, 22 planned by the control system 46.

[0317] Method 200 then returns to operation 206 and the ink is transferred to the axial portions of the ink roller 20 with the adjusted settings of at least one of the ink blades 21, 22 or with an altered alignment of another element of the decorator. Method 200 again executes operations 208 - 218. After a decoration 58 Petition 870230045110, dated 05 / 29 / 2023, pp. 155 / 186 149 / 165 formed with the adjusted settings is transferred to the metal container 54 in operation 212, method 200 again detects the decoration in operation 216 and determines if the decoration is satisfactory in operation 218. In one embodiment, method 200 will optionally wait a predetermined period of time before the metal container 54 with the decoration 58 formed by adjusted settings reaches one or more of the sensors 49E, 50. In one embodiment, the control system 46 does not send signals to the actuators 30 during the specific time interval period of operation 214. In this mode, the control system 46 does not send signals to the actuators 30 to correct deficiencies which may conflict with or cancel corrections in the paint sheets 21,22 sent by the control system 46 to correct the previously detected deficiency.

[0318] In operation 228, the decorated metal containers 54 with satisfactory decorations 58 are transported by conveyor 48 to the downstream equipment 66. The control system 46 determines in operation 230 whether the decoration production operation should continue. For example, the control system 46 may determine that the production operation should stop if there is an equipment defect, if there is a supply shortage (such as a shortage of paint or a shortage of undecorated metal containers 52), upon receiving a stop command from an operator, or when a predetermined number of metal containers 54 have been decorated. If the control system 46 determines that the production operation should continue, method 200 returns YES to operation 206. If the production operation should stop, method 200 continues NO to the end 232.

[0319] Referring now to Figure 18, an embodiment of a method 238 of operating a decorator 2 according to the present invention is illustrated. Although the general order of operations of method 238 is shown in Figure 18, method 238 may include more or less Petition 870230045110, dated 05 / 29 / 2023, pp. 156 / 186 150 / 165 operations, or the order of operations may be arranged differently from that shown in Figure 18. Furthermore, although the operations of method 238 can be described sequentially, many of the operations may in fact be executed in parallel or concurrently. Generally, method 238 begins with a start operation 240 and ends with a finish operation 260. At least a portion of method 238 may be executed as a set of computer-executable instructions executed by a computer system and encoded or stored in a computer-readable medium. An example of a computer system might include, for example, control system 46. An example of a computer-readable medium might include, but is not limited to, a memory of control system 46. Hereafter, method 238 will be explained with reference to control system 46, decorator 2, and components described in conjunction with Figures 1-17.

[0320] Method 238 begins with operation 240. In one embodiment, undecorated metal containers 52 are fed from upstream equipment 64 to a decorator 2. Alternatively, in another embodiment, the metal containers are retrieved from storage.

[0321] The metal containers 52 are decorated by the decorator in operation 242. A conveyor 48 transports the decorated metal containers 54 to a sensor 49, 50 which collects data on the decoration 58 formed by the decorator. In one embodiment, the conveyor 48 transports the decorated metal containers to the sensor 49, 50 sequentially in the order in which they were decorated. A control system 46 receives data from the sensor 49, 50 in operation 244.

[0322] The control system 46 then determines whether the decoration is satisfactory or deficient in operation 246. The control system Petition 870230045110, dated 05 / 29 / 2023, pages 157 / 186 151 / 165 can compare the data received from sensor 49, 50 with a master image stored in memory. Optionally, the control system 46 can determine whether the decoration is satisfactory or deficient as described in one or more of operation 158 of Figure 15, operation 172 of Figure 16, and operation 218 of Figure 17. If the decoration 58 is satisfactory, method 238 returns YES to operation 242. If the decoration is not satisfactory, method 238 continues NO to operation 248.

[0323] In operation 248, control system 46 can determine if the deficient decoration is caused by decorator 2. In one embodiment, the control system can determine that a deficient decoration is caused by the decorator when the data indicate that the decoration includes an abnormality relating to at least one of a color, density, thickness, alignment, and consistency of the decoration. Specifically, control system 46 can determine that the deficient decoration is caused by one or more of (but not limited to) an improper amount of ink, a defective ink, a defective printing plate or transfer blanket, and improper alignment of a printing plate, transfer blanket, or metal container. In one embodiment, control system 46 determines the cause of the deficient decoration as described in Figure 16. When the deficient decoration is caused by the decorator, method 238 proceeds YES to operation 250.Alternatively, when the poor decoration is not caused by decorator 2, method 238 proceeds NO to operation 252.

[0324] Control system 46 can optionally send a signal to decorator 2 to correct a faulty decoration in operation 250. The signal can cause decorator 2 to adjust one or more components of the decorator. In one embodiment, the signal is operable to cause at least one of a paint blade of the Petition 870230045110, dated 05 / 29 / 2023, pp. 158 / 186 The 152 / 165 inkwell, a printing plate, and a transfer blanket move in a specific direction while the decorator is in operation.

[0325] More specifically, the signal can cause an actuator 30 to adjust the position of an ink blade 21 or portion 24 of an ink blade 22 to change the amount of ink transferred to a printing plate 6, 14, adjust the movement of a drive roller 13, change the position of a printing plate 6, 14 on a plate cylinder 4, 12, move a plate cylinder 4, 12 relative to an ink train 11, 19 and / or the blanket cylinder 36, change the position of a transfer blanket 38 on the blanket cylinder 36, and change the position of a support element 42 relative to the blanket cylinder 36. In addition, or alternatively, the signal can cause a drive element to rotate at least one of an ink roller 10, 18 and a transfer roller of an ink train 11, 19 to rotate faster or slower.In this mode, the control system 46 is operable to cause the decorator 2 to change at least one of a color, density, thickness, alignment, and consistency of subsequent decorations 58.

[0326] If control system 46 determines that the defective decoration cannot be corrected without action by an operator, the control system will not send the signal in operation 250. For example, if the defective decoration is related to one or more defective inks, a defective printing plate, and a defective transfer blanket, control system 46 will not send the signal.

[0327] In operation 252, control system 46 can determine if the defective decoration is caused by upstream equipment 64. As described herein, some defective decorations are caused due to damage to an undecorated metal container 52 by upstream equipment. The damage may be a dent, mark Petition 870230045110, dated 05 / 29 / 2023, pp. 159 / 186 153 / 165 of pulling, or scratching caused by upstream equipment, such as a body maker. Other upstream equipment, such as washers and ovens, may also damage the cylindrical surface 56 of undecorated metal containers 52. A washer or oven may stain the cylindrical surface, such as stains, blemishes, or drop marks. The damaged metal container may result in poor decoration 58 due to uneven or incomplete ink transfer from a blanket 38 to the cylindrical surface 56. Similarly, a stain on the cylindrical surface may repel ink from the blanket 38 or show through the ink.

[0328] Control system 46 can determine that a deficient decoration is caused by upstream equipment 64 in a number of ways. One method of determining whether upstream equipment is the cause of a deficient decoration is described in conjunction with operation 182 of Figure 16. Furthermore, control system 46 can determine that upstream equipment is the cause of a deficient decoration based on the frequency at which the deficiency is observed. More specifically, if the deficient decoration does not occur in every metal container 54, the deficiency is not caused by a printing plate 6, 14. If the frequency is not related to the number of transfer blankets 38, the deficiency is not caused by a transfer blanket. Thus, the deficiency is likely to result from upstream equipment malfunctioning unrelated with decorator operation 2.

[0329] In another embodiment, control system 46 can determine which upstream equipment is the cause of a faulty decoration based on the location of the fault. More specifically, if a body maker is not operated properly and is damaging metal containers 52, damage can occur in similar locations over a number of Petition 870230045110, dated 05 / 29 / 2023, pages 160 / 186 154 / 165 metal containers. However, since the metal containers are not oriented with respect to a transfer blanket 38 when ink is transferred to the cylindrical surface 56, the damaged areas of the metal containers will align with different areas of the transfer blankets. Consequently, the damaged areas of the metal containers will be randomly aligned with respect to the decoration formed on the blankets 38. When sensors 49, 50 collect data on defective decorations caused by upstream damage, the defect will not occur in the same location. In contrast, the problem due to the decorator will occur in the same location on each defective decoration.

[0330] Optionally, in another embodiment, the control system may determine that the upstream equipment is the cause of a defective decoration after unsuccessfully attempting to correct a defective decoration by sending a signal to decorator 2 in operation 250. If sensors 49, 50 detect a defective decoration after adjusting the decorator, and the defective decoration is the same as (or similar to) a previously observed defective decoration, the control system 46 may determine that the upstream equipment is the cause.

[0331] In operation 254, the control system may determine that the cause of a deficient decoration cannot be attributed to either decorator 2 or upstream equipment 64. More data may be required to determine the cause of some deficient decorations.

[0332] In operation 256, control system 46 may send an alert to an operator. The alert may be as described herein. The alert may include information about a deficient decoration observed by control system 46. In addition, the alert may include information about the cause of a deficient decoration (such as due to decorator 2 or upstream equipment 64) and the action taken by control system 46 to correct the deficiency. Petition 870230045110, dated 05 / 29 / 2023, pp. 161 / 186 155 / 165 Alternatively, the alert may include a recommended action for the operator to take to correct the deficiency.

[0333] Control system 46 can determine whether the production operation should continue in operation 258. Control system 46 can determine that the production operation should continue as described in operations 224, 230 of method 200. The production operation may continue based at least in part on an error value assigned by the control system for the deficient decoration. In addition, or alternatively, control system 46 may consider the frequency of the deficient decoration when determining whether to continue the production operation. Still, in one embodiment, control system 46 may send a signal to stop the production operation if the cause of the deficient decoration cannot be corrected by a signal from control system 46 to either the decorator or the upstream equipment.More specifically, in one embodiment, if the cause of the deficient decoration is one or more of a defective ink, a defective printing plate, a defective transfer blanket, and a damaged metal container, control system 46 will send a signal to stop the production operation. In another embodiment, when the control system cannot determine a cause of a deficient decoration (in operation 254), the control system may determine that the production operation should continue to collect additional information.

[0334] In one embodiment, the control system 46 can send a signal to stop the upstream equipment 64 after determining that the upstream equipment is the cause of a defective decoration. In another embodiment, the control system can send the signal to stop the upstream equipment 64 after a predetermined number of metal containers with defective decorations caused by the upstream equipment 64 has been observed. Optionally, the number Petition 870230045110, dated 05 / 29 / 2023, pp. 162 / 186 The predetermined number of 156 / 165 can be adjusted by an operator. In one mode, the predetermined number can be from 25 to 50 metal containers within a predefined time period.

[0335] When control system 46 determines that the production operation should continue, method 238 returns YES for operation 242 and decorator 2 continues decorating the metal containers. Alternatively, method 238 continues NO for END 260.

[0336] Referring now to Figure 19, a modality of a method 262 of operating a decorator 2 according to the present invention is illustrated. Although a general order of operations of method 262 is shown in Figure 19, method 262 may include more or fewer operations, or may arrange the order of operations differently from that shown in Figure 19. Furthermore, although the operations of method 262 can be described sequentially, many of the operations may in fact be executed in parallel or concurrently. Generally, method 262 begins with a start operation 264 and ends with a finish operation 280. At least a portion of method 262 may be executed as a set of computer-executable instructions executed by a computer system and encoded or stored in a computer-readable medium. An example of a computer system might include, for example, the control system 46. An example of a computer-readable medium might include, but is not limited to, a memory of the control system 46.From here on, method 262 will be explained with reference to control system 46, decorator 2, and components described together in Figures 1-18.

[0337] In operation 266, the decorator receives an undecorated metal container 52 from upstream equipment 64. Decorator 2 then decorates the metal container 54 as described here in operation 266. The metal container 54 is transported by conveyor 48 to a Petition 870230045110, dated 05 / 29 / 2023, pages 163 / 186 157 / 165 sensor 50 is positioned before downstream equipment 66, such as a furnace. Alternatively, the metal container is transported by conveyor 48 to a sensor 50A positioned downstream of the furnace. In operation 268, a control system 46 receives data collected by sensor 50, 50A.

[0338] In operation 270, the control system determines whether decoration 58 is satisfactory as described herein. In one embodiment, the control system 46 compares sensor data with data stored in a database. Specifically, the control system 46 can compare the sensor data of the decoration with a master image. The master image can be provided by a user or a client. Alternatively, the control system can create a master image by detecting a predetermined number of decorations which have acceptable decorations. Consequently, the master image can be created by the control system 46 stitching together images of a plurality of acceptable decorations. If the decoration is satisfactory, method 262 returns YES for operation 266 and continues decorating the metal containers. If the decoration is not satisfactory, method 262 continues NO for operation 272.

[0339] In operation 272, control system 46 can determine if the cause of the deficient decoration is correctable by an action of the control system. Control system 46 can first determine a cause of the deficient decoration. For example, the decoration may be deficient due to one or more of: (1) a decoration color; (2) a decoration density; (3) a decoration depth; (4) a decoration alignment; (5) a decoration consistency; and (6) a decoration position. Each of the problems 1-6 above can be corrected by adjusting a component of the decorator. Consequently, if the control system determines that the cause of a deficient decoration is one of the six problems listed above, Petition 870230045110, dated 05 / 29 / 2023, pages 164 / 186 158 / 165 the problem can be corrected by the control system 46 sending a signal to the decorator 2. Method 262 will then continue YES to operation 274.

[0340] Alternatively, some causes of deficient decorations may not be correctable by the control system. More specifically, control system 46 may determine that the cause of the deficient decoration is one or more of: (a) a defective or contaminated ink; (b) a defective or damaged printing plate; (c) a defective or damaged transfer blanket; (d) a damaged outer surface of a metal container. If the cause of the deficient decoration is one of the problems ad above, control system 46 cannot correct the deficiency by sending a signal to decorator 2. Consequently, method 262 will continue NO for operation 276.

[0341] In operation 274, control system 46 may optionally send a signal to decorator 2. The signal may cause decorator 2 to adjust one or more components to correct the deficient decoration. More specifically, the signal may cause the decorator to alter at least one of a color, density, thickness, alignment, and consistency of subsequent decorations. In one embodiment, the signal may alter an adjustment or position of at least one of an inkwell assembly, an ink roller, a conductor roller, a plate cylinder, a printing plate on the plate cylinder, a blanket cylinder, and a transfer blanket of the container decorator. In another embodiment, the signal may alter the rotation rate or position of one or more of an ink roller, a transfer roller, a plate cylinder, a blanket cylinder, and a support element of decorator 2. In one embodiment, an operator must approve the change.Alternatively, in another mode, the control system can automatically. Petition 870230045110, dated 05 / 29 / 2023, pp. 165 / 186 159 / 165 send the signal to the decorator.

[0342] Control system 46 may optionally send an alert to an operator in operation 276. The alert may be provided on a display screen. In one embodiment, the alert may include a visual element and an audible element. In another embodiment, the alert is a text message. The alert may provide information regarding the reason why a decoration is defective. Information associated with a corrective action to address the defective decoration may also be included in the alert.

[0343] In operation 278, control system 46 can determine whether the production operation should continue. In one embodiment, if the cause of a defective decoration cannot be corrected by the control system, the control system will send a signal to stop the operation of one or more of the decorator 2 and upstream equipment 64. Other methods of determining whether to stop or continue the production operation are described herein and may be used by control system 46.

[0344] If control system 46 determines that the production operation should continue, method 262 returns YES for operation 266. Alternatively, if the production operation should end, method 262 continues NO for operation 280.

[0345] In order to provide additional background and context, and to further satisfy the written description requirements of 35 USC § 112, the following references are incorporated by reference in their entirety: US Patent 5,724,259; US Patent 5,992,318; US Patent 6,142,078; US Patent 6,178,254; US Patent 6,184,988; US Patent 6,543,350; US Patent 6,867,423; US Patent 7,013,803; US Patent 7,017,492; PCT Publication WO 2013 / 113616; and PCT Publication WO 2016 / 087876.

[0346] The description of the present invention was presented for Petition 870230045110, dated 05 / 29 / 2023, pp. 166 / 186 160 / 165 are for illustrative and descriptive purposes, but are not intended to be exhaustive or limiting of the invention in the form described. Many modifications and variations will be apparent to those skilled in the art. The embodiments described and shown in the figures have been chosen and described in order to best explain the principles of the invention, the practical application, and to enable those skilled in the art to understand the invention.

[0347] Although several embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of these embodiments will occur to those skilled in the art. Furthermore, references made herein to the present invention or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be considered as limiting all embodiments to a specific description. It should be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as presented in the following embodiments.

[0348] Although the exemplary aspects, modalities, options, and / or configurations illustrated here show the various system components co-located, certain system components may be located remotely, in distant portions of a distributed network, such as a local area network (LAN) and / or the Internet, or within a dedicated system. Thus, it should be appreciated that system components may be combined into one or more devices, such as a personal computer (PC), laptop, netbook, smartphone, personal digital assistant (PDA), tablet, etc., or co-located on a specific node of a distributed network, such as an analog and / or digital telecommunications network, a packet-switched network, or a circuit-switched network. This will be appreciated from the preceding description, and for reasons of efficiency. Petition 870230045110, dated 05 / 29 / 2023, pages 167 / 186 161 / 165 computational, that the system components can be arranged in any location within a distributed network of components without affecting the operation of the system. For example, the various components may be located in a switch such as a private switching exchange (PBX) and media server, port, in one or more communications devices, in the premises of one or more users, or in some combination thereof. Similarly, one or more functional portions of the system could be distributed among telecommunications device(s) and an associated computing device.

[0349] Furthermore, it should be appreciated that the various connections linking the elements may be wired or wireless connections, or any combination thereof, or any other known or subsequently developed element(s) capable of supplying and / or communicating data to and from the connected elements. These wired or wireless connections may also be secure connections and may be capable of communicating encrypted information. The transmission medium used as connections, for example, may be any suitable carrier for electrical signals, including coaxial cables, copper wire and optical fiber, and may take the form of acoustic or light waves, such as those generated during radio wave and infrared data communications.

[0350] Also, although the flowcharts have been discussed and illustrated in relation to a specific sequence of events, it should be appreciated that changes, additions, and omissions to this sequence may occur without materially affecting the operation of the modalities, configuration, and aspects described. Furthermore, a number of variations and modifications of the description may be used. It would be possible to provide some features of the description without providing others.

[0351] Optionally, the systems and methods of this description Petition 870230045110, dated 05 / 29 / 2023, pages 168 / 186 162 / 165 can be implemented in conjunction with a special-purpose computer, a programmed microprocessor or microcontroller and peripheral integrated circuit element(s), an ASIC or other integrated circuit, a digital signal processor, wired electronics or logic circuitry such as a discrete element circuit, a programmable logic device or gate network such as a PLD, PLA, FPGA, PAL, special-purpose computer, comparable means, or the like. In general, any device(s) or means capable of implementing the methodology illustrated herein may be used to implement the various aspects of this description. Exemplary hardware that can be used for the embodiments, configurations, and aspects described includes computers, portable devices, telephones (e.g., cellular, Internet-enabled, digital, analog, hybrid, and others), and other hardware known in the art.Some of these devices include processors (e.g., a single or multiple microprocessors), memory, non-volatile storage, input devices, and output devices. Furthermore, alternative software implementations that include, but are not limited to, distributed component / object processing, parallel processing, or virtual machine processing can also be constructed to implement the methods described herein.

[0352] In one embodiment, the methods described can be readily implemented in conjunction with software that utilizes object-oriented or object-programmed software development environments that provide portable source code that can be used on a variety of computers or workstation platforms. Alternatively, the system described can be implemented partially or entirely in hardware using standard logic circuits or very large-scale integration (VLSI) design. If Petition 870230045110, dated 05 / 29 / 2023, pp. 169 / 186 163 / 165 The software or hardware used to implement the systems according to this description is dependent on the speed and / or efficiency requirements of the system, the specific function, and the specific software or hardware systems or microprocessor or microcomputer systems being used.

[0353] In yet another embodiment, the methods described may be partially implemented in software that can be stored on a storage medium, executed on a general-purpose computer programmed with the cooperation of a controller and memory, a special-purpose computer, a microprocessor, or the like. In these cases, the systems and methods of this description may be implemented as a program embedded in a personal computer such as an applet, JAVA® or computer-generated imagery (CGI) script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated measurement system, system component, or the like. The system may also be implemented physically by embedding the system and / or method in a software and / or hardware system.

[0354] Although the present description describes components and functions implemented in aspects, modalities, and / or configurations with reference to specific standards and protocols, the aspects, modalities, and / or configurations are not limited to such standards and protocols. Other similar standards and protocols not mentioned here exist and are considered to be included in the present description. Furthermore, the standards and protocols mentioned here and other similar standards and protocols not mentioned here are periodically replaced by faster or more efficient equivalents that essentially have the same functions. Such replacement standards and protocols that have the same functions Petition 870230045110, dated 05 / 29 / 2023, pages 170 / 186 164 / 165 are considered equivalent and included in this description.

[0355] Examples of processors as described herein may include, but are not limited to, at least one of the Qualcomm® Snapdragon® 800 and 801, Qualcomm® Snapdragon® 610 and 615 with 4G LTE integration and 64-bit computing, Apple® A7 processor with 64-bit architecture, Apple® M7 motion coprocessors, Samsung® Exynos® series, the Intel® Core™ processor family, the Intel® Xeon® processor family, the Intel® Atom™ processor family, the Intel Itanium® processor family, Intel® Core® i5-4670K and i7-4770K 22nm Haswell, Intel® Core® i5-3570K 22nm Ivy Bridge, the AMD® FX™ processor family, AMD® FX-4300 processors, FX-6300 and FX-8350 32nm Vishera, AMD® Kaveri, Texas Instruments® Jacinto C6000™ automotive infotainment processors, Texas Instruments® OMAP™ automotive-grade mobile processors, ARM® Cortex™-M processors, ARM® Cortex-A and ARM926EJ-S™ processors, and other equivalent processors in the industry.and can perform computational functions using any known or future developed standard, instruction set, library, and / or architecture.

[0356] The present description, in various aspects, modalities and / or configurations, includes components, methods, processes, systems and / or apparatus substantially as presented and described herein, including various aspects, modalities, configuration modalities, sub-combinations and / or their subsets. Those skilled in the art will understand how to make and use the aspects, modalities, and / or configurations described after understanding the present description. The present description, in various aspects, modalities, and / or configurations, includes providing devices and processes in the absence of items not presented and / or described herein or in various aspects, modalities and / or their configurations, including in the absence of such Petition 870230045110, dated 05 / 29 / 2023, pages 171 / 186 165 / 165 items as they may have been used in previous devices or processes, for example, to improve performance, ease of use, and / or reduce implementation costs. Petition 870230045110, dated 05 / 29 / 2023, pages 172 / 186

Claims

1 / 9 CLAIMS 1. Apparatus for monitoring and adjusting a decoration formed on an external surface of metal containers, characterized in that it comprises a decorator (2) that includes an inkwell assembly (8, 16) with a plurality of ink blades (21, 22) and an ink roller (10, 18), a printing plate (6, 14), a transfer blanket (38) and a support element (42) for receiving a metal container (54) and moving the metal container (54) in contact with the transfer blanket (38) to transfer a decoration (58) to a cylindrical external surface (56) of the metal container (54), wherein each ink blade (21, 22) includes a body (56) extending from a first end wall to a second end wall, and wherein a shaft (31) extends from an actuator (30) associated with each ink blade (21, 22). 22) attaches to the first end wall;a sensor (49, 50) positioned downstream of the decorator (2) to obtain data from predetermined targets (59) within the decoration on the cylindrical outer surface (56) of the metal container (54) relating to the quality of the decoration; and a control system (46) that receives the data from the sensor (49, 50), the control system (46) being operable to compare the data with stored data to determine if the decoration is deficient, wherein the control system (46) evaluates a plurality of data points associated with the predetermined targets in the data received from the sensor (49, 50), and wherein, if the decoration is deficient, the control system (46) sends a first signal to adjust at least one of a position of a paint blade (21, 22) of the plurality of paint blades (21, 22) and a rotation rate of the paint roller (10, 18) to correct the cause of the deficient decoration. Petition 870230045110, dated 05 / 29 / 2023, pp. 173 / 186 2 / 9; 2. Apparatus according to claim 1, characterized in that it further comprises an oven (66) positioned downstream of the decorator (2) for curing paint used to form the decoration on the cylindrical outer surface (56) of the metal container (54); a pin chain (48) for transporting the metal container (54) from the support element (42), through the oven (66), and to the sensor (49, 50), wherein the sensor (49, 50) comprises three to six image detection devices arranged in a predetermined orientation to detect portions of the cylindrical outer surface (56) of the metal container (54), and wherein the image detection devices are positioned so that they do not impede the movement of the pin chain (48).

3. Apparatus according to claim 1, characterized in that the control system (46) is operable to determine an initial position for each of the plurality of ink blades (21, 22) based on an image of the decoration stored in a database; and send a signal to the actuator (30) associated with each of the plurality of ink blades (21, 22) to move each ink blade (21, 22) to its initial position before a production operation is initiated to decorate the metal containers (54).

4. Apparatus according to claim 1, characterized in that the first signal is sent to an actuator (30) associated with the ink blade (21, 22) to change an amount of ink transferred to the transfer blanket (38) while the decorator (2) is in operation, wherein the shaft (31) has a distal end retained in an inner hole that extends to the first end wall, the first signal causing the distal end to move further into the inner hole, and Petition 870230045110, dated 05 / 29 / 2023, page 174 / 186 3 / 9 wherein the inner hole does not cross the second end wall.

5. Apparatus according to claim 1, characterized in that the control system (46) can determine whether the deficient decoration is associated with at least one of a decoration color, a decoration density, a decoration depth, a decoration alignment, a decoration consistency and a decoration position, and wherein the sensor (49, 50) is operable to collect data on one or more of a decoration color, a decoration density, a decoration depth or thickness, a decoration alignment, a decoration consistency, a decoration position and a shape of the metal container (54).

6. Apparatus according to claim 1, characterized in that each ink blade (21,22) has a longitudinal geometric axis and the axis (31) of the actuator (30) associated with each ink blade (21, 22) is approximately concentrically aligned with the longitudinal geometric axis.

7. Method for optimizing a decoration (58) formed by a decorator (2) on a cylindrical outer surface (56) of a metal container (54), characterized in that it comprises providing the metal container (54); feeding the metal container (54) into the decorator (2) which includes: an ink cartridge assembly (8, 16) with an ink roller (10, 18) and a plurality of ink blades (21, 22), each ink blade (21, 22) including a body (56) extending between a first end wall and a second end wall, and an actuator (30) being interconnected to each ink blade (21, 22) by a shaft (31) extending from a first side of the actuator (30) which engages with the first end wall; Petition 870230045110, dated 29 / 05 / 2023, p. 175 / 186 4 / 9 a plate cylinder (4, 12) with a printing plate (6, 14); a blanket cylinder (36) with a transfer blanket (38);and a support element (42) for moving the cylindrical outer surface (56) of the metal container (54) in contact with the transfer blanket (38); determine, by a control system (46), initial positions for each of the plurality of ink sheets (21, 22); decorate the cylindrical outer surface (56) of the metal container (54) with the decorator (2); obtain a captured image of the decoration on the cylindrical outer surface (56) of the metal container (54) with an image capture device (50); compare, by the control system (46), the captured image with a stored image of an acceptable decoration, wherein the control system (46) evaluates a plurality of data points associated with multiple target areas of the cylindrical outer surface (56) in the captured image received from the image detection devices;determine, by the control system (46), whether the decoration in the captured image meets density quality parameters that correspond to one or more criteria, wherein the control system (46) determines a color variation between a target value of a decoration color and an actual decoration color in the captured image; and send, by the control system (46), a signal to adjust at least one of a position of an ink blade (21, 22) of the plurality of ink blades (21, 22) and a rotation rate of the ink roller (10, 18) of the inkwell assembly (8, 16) to change at least one of a color, a density, a thickness, an alignment and a Petition 870230045110, of 29 / 05 / 2023, p. 176 / 186 5 / 9 consistency of ink transferred to the transfer blanket (38) when the color variation is between about 5% of the target value and about 15% of the target value.; 8. Method according to claim 7, characterized in that the signal is operable to cause an actuator (30) with a shaft (31) received on the paint blade (21,22) to move the paint blade (21, 22) in a specific direction while the decorator (2) is in operation, wherein one end of the shaft (31) is positioned within an internal hole formed in a body (56) of the paint blade (21, 22) and which has an opening in the first end wall, wherein the first side of the actuator (30) is oriented towards the first end wall of the paint blade (21,22).

9. Method according to claim 7, characterized in that the signal alters the rotation rate of the ink roller (10, 18) positioned upstream of the printing plate (6, 14) while the decorator (2) is in operation, and the method further comprises positioning the metal container (54) on a pin chain (48); transporting the metal container (54) on the pin chain (48) through an oven (66) to cure the decoration ink; and transporting the metal container (54) on the pin chain (48) past the image detection device positioned downstream of the oven (66).

10. Method according to claim 7, characterized in that it also includes, when the captured image does not meet the density quality parameters, determining, by the control system (46), that the decoration is deficient due to one or more of an improper amount of ink, a defective ink, a defective printing plate (6, 14), a defective transfer blanket (38), an improper alignment of a component of the decorator (2) and damage to the metal container (54); and sending, by the control system (46), a signal to stop the decorator (2) after determining that the decoration is deficient due to at least one of a defective ink, a defective printing plate (6, 14) and a defective transfer blanket (38).

11. Method according to claim 7, characterized in that the signal from the control system (46) causes an actuator (30) to move the ink blade (21, 22) in a first direction, wherein the ink blade (21, 22) has a longitudinal geometric axis and the axis (31) of the actuator (30) is approximately concentrically aligned with the longitudinal axis.

12. Non-transient computer-readable medium, characterized by comprising a set of instructions stored therein, which, when executed by a processor (84) of a control system (46), cause the processor to adjust a component of a metal container decorator (2) (54) while the metal container decorator (2) (54) is in operation, by receiving an image of a decoration from a database; determination of initial positions for each of a plurality of paint blades (21, 22) of the metal container decorator (2) (54) based on the image; receiving data from a sensor (49, 50), the data relating to paint of a decoration formed by the metal container decorator (2) (54) on a cylindrical outer surface (56) of a first metal container (54); Petition 870230045110, dated 29 / 05 / 2023, p.178 / 186 7 / 9 comparison of the data with the image, wherein the control system (46) evaluates a plurality of data points associated with multiple target areas in the data received from the sensor (49, 50); determination of whether the decoration on the outer cylindrical surface (56) of the first metal container (54) includes an abnormality relating to at least one of a color, density, thickness, alignment and consistency of the decoration; preparation of an instruction for the metal container (54) decorator (2) to address the cause of the abnormality; and sending the instruction to the metal container (54) decorator (2) to adjust a position of a paint sheet (21, 22) of the plurality of paint sheets (21, 22) to correct the abnormality; and determination of a delay time that occurs after sending the instruction to address the cause of the abnormality until a second metal container (54) with a corrected decoration reaches the sensor (49, 50).

13. Computer-readable means according to claim 12, characterized in that sending the instruction causes the metal container decorator (2) (54) to change at least one of a color, density, thickness, alignment and consistency of subsequent decorations, wherein the sensor (49, 50) is positioned downstream of an oven (66) so that the decoration paint is dry when the sensor (49, 50) collects the data, and wherein the first metal container (54) is positioned on a pin chain (48) when the sensor (49, 50) collects the data.

14. Computer-readable means according to claim 12, characterized in that it further comprises sending a signal to stop the metal container decorator (2) (54) after determining that the abnormal decoration is related to one or more of Petition 870230045110, dated 29 / 05 / 2023, page 179 / 186 8 / 9 a defective ink, a defective printing plate (6, 14) or a defective transfer blanket (38) of the metal container decorator (2) (54).

15. Computer-readable means according to claim 12, characterized in that the instruction causes an actuator (30) to move the ink blade (21, 22) generally parallel to a longitudinal geometric axis of the ink blade (21, 22) to increase or decrease an amount of ink transferred to a printing plate (6, 14) of the metal container decorator (2) (54).

16. Computer-readable means according to claim 12, characterized in that the instruction causes an actuator (30) to move a shaft (31) in a first direction so that the ink blade (21, 22) moves closer to an ink roller (10, 18), thereby decreasing the amount of ink transferred to a printing plate (6, 14), the shaft (31) generally extending linearly between the actuator (30) and the ink blade (21, 22).

17. Computer-readable means according to claim 16, characterized in that the actuator (30) includes a first side oriented towards a first end of the ink blade (21, 22), and a hole extending to the first end of the ink blade (21, 22) and a shaft (31) extending from the first side of the actuator (30) includes a distal end that is positioned within the hole.

18. Computer-readable means according to claim 12, characterized in that the control system (46) includes a memory (96); an input device (86); an output device (88); and Petition 870230045110, dated 05 / 29 / 2023, page 180 / 186 9 / 9 the processor in communication with the memory (96), the input device (86) and the output device (88).

19. Computer-readable means according to claim 12, characterized in that it further comprises determining a color variation between a target value of a decoration color and an actual decoration color as determined by the sensor (49, 50); and sending the instruction to the decorator (2) when the color variation is between about 5% of the target value and about 15% of the target value.

20. Computer-readable means according to claim 12, characterized in that it further comprises sending a signal to an actuator (30) associated with each of the plurality of ink blades (21, 22) to move each ink blade (21, 22) back to its initial position. Petition 870230045110, dated 05 / 29 / 2023, pp. 181 / 186

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