Scribing device and method for setting axial position and gap size

Abstract

A method for setting a gap size and an axial position of a gap between one or more scribe blades and an anvil shaft of a rotary scribe device includes: providing a control system including a controller, at least one sensor, and at least one adjustment device actuated by the control system; and in response to the at least one sensor sensing a deviation from the desired state, actuating the at least one adjustment device to set an axial position or gap dimension between the one or more scoring blades and the anvil shaft. The method further comprises: effecting actuation of the at least one adjustment device as a function of a result of operation of the control system in the closed-loop feedback loop; and sensing by at least one sensor, which occurs with or without interruption of the operation of the rotary scoring device.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 375,483, filed on September 13, 2022, entitled “Scoring Device and Methods for Setting Axial Position and Gap Dimension,” the disclosure of which is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to a scoring apparatus and a method for controlling the same. More particularly, the present disclosure relates to a scoring apparatus and a method for setting a gap size and an axial position of a gap between one or more scoring blades and an anvil shaft of the scoring apparatus. Background Art

[0004] In manufacturing, operational control and quality control of the (back or top) scribing process is highly desirable. The control scheme for this process is largely manual in nature. Although control schemes involving the use of electric actuators have recently become popular, control schemes that use feedback to achieve fully automatic control have received little attention. In addition, different control schemes are required when switching between different materials or substrates for the scribing process. However, such control schemes require the operator to make process modification decisions, usually requiring the shutdown of the production line operation, which is inefficient, disruptive and expensive.

[0005] Therefore, there is a need in the art for a scoring apparatus and control scheme that does not suffer from the above-mentioned disadvantages. Summary of the invention

[0006] In an example embodiment, a method for setting a gap size and axial position of a gap between one or more scoring blades and an anvil shaft of a rotary scoring device includes: providing a control system including a controller, at least one sensor, and at least one adjustment device actuated by the control system; and actuating at least one adjustment device in response to at least one sensor sensing a deviation from a desired state, thereby setting an axial position or gap size between the one or more scoring blades and the anvil shaft. The method further includes actuating at least one adjustment device based on a result of the control system operating in a closed-loop feedback loop. The method further includes sensing by at least one sensor, which occurs with or without interruption of operation of the rotary scoring device.

[0007] In another example embodiment, a method for operating a rotary scoring device includes: feeding a web of material to be processed into a feed port of the rotary scoring device; sending data associated with at least one characteristic attribute of the web of material (measured by at least one sensor) to a control unit; operating an adjustment device to adjust an axial position between two scoring blades; operating a motor to adjust a gap size between the two scoring blades and an anvil shaft; and setting the axial position and gap size between the two scoring blades and the anvil shaft to a desired position to process the web of material. The motor includes an encoder to send a feedback signal to determine at least one of speed, RPM, count, distance, or direction.

[0008] In yet another example embodiment, a method for setting a gap in a rotary die cutting system includes: providing a control system including a controller, at least one sensor, a first adjustment device, and a second adjustment device, each of which is actuated by the control system; actuating the first adjustment device in response to at least one sensor sensing a deviation from a desired state, thereby setting the gap size between the rotary die cutting device and the back pressure roller of the rotary die cutting device; and actuating the second adjustment device in response to at least one sensor sensing a deviation from a desired state, thereby setting the axial position and gap size between one or more scoring blades and anvil shaft of a rotary scoring device. The method further includes a rotary scoring device positioned in series with respect to the rotary die cutting device. The method further includes actuating the second adjustment device based on the result of the control system operating in a closed-loop feedback loop. The method further includes sensing by at least one sensor, which occurs with or without interruption of operation of the rotary die cutting system.

[0009] In yet another example embodiment, a rotary scoring device comprises: a frame including at least one blade holder and an anvil shaft, at least one blade holder frame containing a scoring blade located therein, at least one blade being separated from the anvil shaft by a gap; and a control system including a controller, at least one sensor, and first and second adjustment devices actuated by the control system. The first and second adjustment devices are operably connected to at least one blade holder to adjust the axial position.

[0010] Other features and advantages of the present invention will become apparent from the following more detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a perspective view of an exemplary rotary scoring system according to an exemplary embodiment of the present disclosure.

[0012] Figure 2is a front perspective view of an exemplary rotary scoring device according to an exemplary embodiment of the present disclosure.

[0013] Figure 3 is a rear perspective view of an exemplary rotary scoring device according to an exemplary embodiment of the present disclosure.

[0014] Figure 4 is a perspective view of an exemplary blade holder according to an exemplary embodiment of the present disclosure.

[0015] Figure 5 is a partial perspective lower view of an exemplary blade holder according to an exemplary embodiment of the present disclosure.

[0016] Figure 6 is a schematic block diagram of a rotational scribing system according to an example embodiment of the present disclosure.

[0017] Fig. 7A is an exemplary scribing-indentation image guide according to an example embodiment of the present disclosure.

[0018] Figure 7B is an exemplary scribed indentation image according to an example embodiment of the present disclosure.

[0019] Figure 7C According to an exemplary embodiment of the present disclosure Figure 7B Example max pooling of an image of .

[0020] Fig.7D is a schematic diagram of how an exemplary deep learning method according to an example embodiment of the present disclosure classifies rotary scribing device indentations by feeding image grayscale intensity values ​​into a convolutional neural network using a convolution filter.

[0021] Figure 8-Figure 13 is a display diagram illustrating an exemplary display of a rotational scribing system according to an exemplary embodiment of the present disclosure.

[0022] Fig.14 is a perspective view of an exemplary final material according to an example embodiment of the present disclosure.

[0023] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same parts. DETAILED DESCRIPTION

[0024] The present invention solves the above-mentioned problems by providing a scoring process that is less prone to human error and reduces downtime / costs associated with setup, improves safety by reducing operator work inside the scoring machine during operation, eliminates blade damage (during the setup process), reduces material scrap, extends blade life, produces a higher quality and consistent product, and / or increases production throughput by eliminating downtime. In addition, by utilizing a saved material library and job profiles, the lateral positioning and scoring depth of the cut formed in the material between one or more blades and an anvil roll of a rotating scoring device are automatically controlled. Thus, repeatable and accurate results for the cutting depth and lateral positioning of the blades are obtained from the saved material library and saved job profiles.

[0025] As used herein, "scoring" is a process known in the industry that partially cuts into a sheet or material to allow subsequent bending, folding, flexing, tearing, or peeling of the sheet or material. That is, the score does not completely cut through the sheet or material, but leaves a blade impression, indentation, or partial cut at a single stress point. The resulting score typically only partially penetrates or cuts through the material, which reduces the thickness at the stress point, or the resulting score completely penetrates or cuts through one or more layers of a multi-layer material while leaving one or more layers intact.

[0026] In some embodiments, the exemplary rotary scoring system performs a kiss cut so that the cut material remains bonded to the support material. That is, the kiss cut only cuts one layer of material, leaving the support material intact, wherein the end user can remove the cut material from the support material. The cut is just deep enough to penetrate the top surface, leaving the backing support material intact. Coupons, stickers, or pull-back displays are good examples of using the kiss cut technique.

[0027] The exemplary rotary scoring systems described herein perform either top (cutting completely through the material face, leaving the liner intact) or back (cutting completely through the material liner, leaving the material face intact) scoring.

[0028] Figure 1 An exemplary rotary scoring system 1 is shown, which includes a rotary scoring device 10, which includes two blade holders 12 and a through gap 16 ( Figure 2 ) is separated from the back pressure roller 14 (or anvil shaft) of the two blade holders 12. In other words, the gap 16 is the scoring blade 83 ( Figure 5) and the distance between the anvil shaft 14. The rotary scoring system 1 further comprises a control unit 32, which comprises a controller 36, which is functionally coupled to a plurality of sensors 21, 22, 23, 24, for determining at least one characteristic attribute of the scoring device 10 or of the material 30 to be processed. Such a characteristic attribute may be the type of material 30 being processed, the thickness of a specific material 30 or a specific portion of a material 30. In such a manner, the sensors 21, 22, 23, 24 may determine the thickness profile of each material 30 and transmit such data to the control unit 32, which uses the information provided by the sensors 21, 22, 23, 24 to operate the blade holder 12. Thus, materials having a single and / or different thicknesses in the direction of the scoring device 10 may be processed. Then, the gap 16 between the blade 83 and the anvil roller 14 may be adjusted so as to always ensure the correct contact pressure for the scoring operation. In some embodiments, the sensors 21, 22, 23, 24 may also be used to determine the exact position of the leading end 33 or the trailing end 34 of the material 30 fed to the rotary scoring system 1. For example, sensor 24 can sense the leading end 33 of material 30, and sensor 21 can sense the trailing end 34 of material 30. In some embodiments, sensors 21, 22, 23, 24 include a linear array camera system. For example, sensor 23 can capture an image of the leading end 33 of material 30, and sensor 22 can capture an image of the trailing end 34 of material 30. In other embodiments, sensors 21, 22, 23, 24 can also be used to determine at least one characteristic attribute of the rotary scoring system 1 when material 30 is currently being processed. In other embodiments, sensors 21, 22, 23, 24 can be gap sensors or load cells to sense misalignment or tolerance stack-ups that can cause positional changes between the scoring blade 83 and the anvil shaft 14 depending on the position of the scoring blade 83 along the anvil shaft 14.

[0029] In other embodiments, the sensors 21, 22, 23, 24, when controlled by the controller 36, measure the thickness of the material 30, including the front web material 31a and the backing web material 31b, after being introduced between the blade holder 12 and the anvil shaft 14, and the thickness measurement can be performed after or before the front web material 31a is removed. Subsequently, a historical operating database corresponding to the same or similar materials 30 and thicknesses (stored in the memory 39, such as Figure 6 ) to find out what gaps 16 were used in the past to produce the desired results. In addition, the controller 36 is adapted or configured to provide reminder / logging information and receive historical operating data or updates to software or firmware from a storage 39 or storage device (such as cloud storage or the Internet of Things ("IoT")), which is well known and not further discussed herein.

[0030] It should be understood that deviations from the desired state due to changes in the thickness of at least one of the backing web 31b and the overlying web 31a may also be due to thermal expansion of the web material or equipment, changes in humidity in the environment surrounding the rotating scoring device 10, changes in the tension gradient of at least one of the backing web 31b and the overlying web 31a, the cutting depth of the material 30 and the scoring blade 83, and the indentation quality of the material 30 and the scoring blade 83 or other reasons.

[0031] Each of the sensors 21, 22, 23, 24 is connected to the controller 36 via respective conduits 71, 72, 73, 74, and the controller and the sensor may be in hardwired or wireless communication. For example, the controller 36 may communicate with the sensors 21, 22, 23, 24 via a serial connection, or the controller 36 may communicate with the sensors 21, 22, 23, 24 wirelessly, such as Bluetooth, Wi-Fi, RF transmission, GPS, etc.

[0032] The sensors 21, 22, 23, 24 are used to provide a closed feedback loop utilizing the sensors to permit continuous or uninterrupted operation of the scoring process.

[0033] In some implementations, information from one or all sensors of one or all embodiments is transmitted to or from the controller 36 , including an IoT framework, an on-site network infrastructure, or a local medium located in the controller 36 .

[0034] refer to Figure 2 and Figure 3 , the blade holder 12 and the anvil shaft 14 are supported and surrounded by a frame 15 made of, for example, stainless steel. The frame 15 is designed as a flush side frame mounting member so that it can be directly mounted to the side frame of the machine, without the need for additional cutouts for installation. The frame 15 includes a top portion 51 connected between two side portions 52a, 52b, which is used to support an electromagnetic transducer 61 for measuring the lateral position of the blade holder 12 and a drive system 65 for translating (moving) the blade holder 12 in the lateral direction. In one embodiment, the drive system 65 is a belt drive 66 driven by an electric motor 67, such as a stepper motor, a hydraulic motor, or other suitable power sources operably connected to the belt drive 66 for moving the blade holder 12 to the desired position. In other embodiments, the drive system 65 can be a rack and pinion system, which includes at least a circular gear engaging a linear gear for linear actuation. It should be understood that other drive systems not described herein can be adopted.

[0035] refer to Figure 4(only one blade holder is shown), the blade holder 12 includes a top housing portion 54 and a bottom housing portion 56. The top housing portion 54 is configured to receive a belt drive 66 via an opening 68 and a pair of attachment members 69 for connecting the blade holder 12 to the frame 15, more specifically, to the bottom surface of the top portion 51 of the frame 15. An electromagnet 71 associated with the electromagnetic transducer 61 is included near the top housing portion 54 for operation.

[0036] The bottom housing portion 56 houses a motor encoder 72 (or rotary encoder) mounted to an electric motor 74, which is controlled by the controller 36 to provide a closed loop feedback signal by tracking the position of a motor shaft 79. The encoder 72 is used to provide high speed and high accuracy for the blade holder 12. In other embodiments, the encoder 72 may send feedback signals to determine speed, RPM, counts, distance, and / or direction in addition to positioning.

[0037] In one embodiment, the accuracy of the scoring can be about 0.0004 inches, depending on the material used. For example, for vinyl face stock, a test accuracy of 0.004 inches can be achieved, and, for polypropylene face stock, a test accuracy of 0.0002 inches can be achieved. In other embodiments, the scoring can be independent of the material used. For example, when using a motor with an integrated gearbox and encoder, an accuracy of up to 4 x 10-6 inches can be achieved.

[0038] Near the lower portion of the bottom housing portion 56, a blade housing 81 is attached thereto. The blade housing 81 holds a scoring blade 83 ( Figure 5 ) for scoring (or stamping) the material 30. The blade housing 81 includes a first housing 82a and a second housing 82 to cover and protect a blade 83. The scoring blade 83 extends or retracts between an opening 84 formed between the first housing 82a and the second housing 82. The scoring blade 83 includes a metal shield bearing (not shown) to ensure precision and accuracy. The scoring blade 83 can be replaced by unlocking the fastening device 86 for replacement.

[0039] The electromagnetic transducer 61 measures the linear displacement or movement of the blade holder 12 when controlled by the controller 36 via the conduit 78 or via wireless communication between the controller and the electromagnetic transducer. Subsequently, the controller 36 operates the electric motor 67 via the conduit 77 or via wireless communication between the controller and the electric motor to drive the belt drive 66 and move the blade holder 12 to the desired lateral position. Similarly, the controller 36 operates the motor encoder 72 via the conduits 75, 76 or via wireless communication between the controller and the motor encoder to move the corresponding scoring blade 83 to the desired cutting depth for scoring. In some embodiments, a historical operation database (stored in the storage 39) corresponding to the same or similar material 30 is used, for example, to find what gap 16 was used in the past to produce a desired result. The algorithm in the controller 36 determines the signal sent to the motor encoder 72 via the conduits 75, 76 or via wireless communication between the controller and the blade holder 12 so as to achieve the same gap 16 returned from the database in the storage 39. It should be understood that the database may include parameters such as material name, material type, material serial number or identifier, material caliper measurement, material basis weight, material tensile strength, material elasticity, machine measurements, individual scoring blade diameters, machine settings or conditions when parameters were saved.

[0040] Figure 6is a schematic diagram of an exemplary rotary scoring system 1 according to an example embodiment. In the schematic diagram, the controller 36 can be communicatively coupled to each sensor 21, 22, 23, 24, the storage device 10, the blade holder 12 and / or the input device 50. In one embodiment, the controller 36 can be a computing system including a processor 38 and a storage system 39. The storage system 39 includes software, including stored data, which includes data in a database structure. In one embodiment, the stored data can be a previously used material library, including its configuration or parameters, for example, a saved combination of settings for the axial position or gap size between the scoring blade and the anvil shaft based on the saved parameters and / or configuration. The processor 38 loads and executes the software, which is a software application stored in the storage system 39. The processor 38 can also access the data stored in the database to perform the methods and control instructions described herein. Although the controller 36 is depicted as a single system encapsulating a processor 38 and a storage system 39, it should be understood that one or more storage systems 39 and one or more processors 38 can include the controller 36, which can be a cloud computing application and system. The processor 38 includes a processor that can be a microprocessor, a general-purpose central processing unit, a special-purpose processor, a microcontroller, or any type of logic device. The processor 38 may also include circuits for retrieving and executing software. It should be understood that the processor 38 can be implemented with a single processing device, but can also be distributed across multiple processing devices or subsystems that cooperate to execute software instructions.

[0041] The storage system 39 includes any storage medium or storage medium group that can be read by the processor 38 and can store software and data. The storage system 39 can include volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing information (such as computer readable instructions, data structures, program modules or other data). The storage system 39 can store a set of processor instructions or algorithms that enable the rotary scoring system 1 to operate automatically when executed by the controller 36. Examples of non-volatile memory can include, but are not limited to, flash memory, read-only memory (ROM), programmable ROM (PROM), erasable PROM (EPROM), and electrically EPROM (EEPROM) memory. Examples of volatile memory can include, but are not limited to, dynamic random access memory (DRAM) and static random access memory (SRAM).

[0042] In one embodiment, the controller 36 provides control instructions to the scoring device 10 via the conduits 77, 78 or wireless communication between the controller and the scoring device 10, and the control instructions are executed by the belt drive motor controller that controls the movement of the belt drive 61. For example, the control instructions can move the two blade holders 12 laterally to their respective desired positions via the belt drive 61. The control instructions can further provide instructions to the motor encoder 72 to control the blade 83 to move to the desired cutting depth position. More specifically, the controller 36 provides instructions to the motor encoder 72 to control the motor 74 to move the shaft 79, which then controls the blade 83 in a linear movement (i.e., up and down).

[0043] In some embodiments, the controller 36 may receive control instructions from an input device 50, which may include a display 51 to display information that may be executed by the controller 36, as will be described in detail later. The display 51 is a graphical user interface (i.e., a touch screen display) that may be displayed on a device such as a computer, laptop, television, smartphone, etc. In one embodiment, the controller 36 is adapted or configured to receive historical operating data or updates to the selected material to operate the scoring function.

[0044] In other embodiments, the controller 36 processes the neural network 100 ( Fig.7D ). For example, the neural network 100 classifies the scores or indentations of the corresponding materials according to predefined categories. The classified scores from the neural network are compared to the desired results and an error is determined. The algorithm in the controller 36 uses the error to determine the signal to be sent to the scoring device 10 and / or the blade holder 12 to achieve the desired result.

[0045] For example, refer to Figures 7A-7D , from the exemplary blade indentation image 91 ( Figure 7B ), exemplary maximum pooling 92 ( Figure 7C ) is convolved to extract the engraved witness mark 93 ( Figure 7C ), in the neural network 100( Fig.7D). That is, in the neural network 100, the information of the witness markers 93 from the max pooling 92 is transmitted and flattened into a one-dimensional array 101, which is set as a node of the input layer 102, which is assigned different values ​​(weights and biases) for calculation, sometimes called perceptrons in the hidden layer 103, so that the blade indentation predictors 104 are identified as a light indentation predictor 104A, a medium indentation predictor 104B, and a heavy indentation predictor 104C. The blade indentation predictors 104A, 104B, 104C of the hidden layer 103 correspond to an exemplary output layer 105, which is identified as, for example, an operator-side actuator voltage 105A, a rear-side actuator voltage 105B, a belt motor drive speed 105C, a predicted blade remaining life 105D, and a predicted bearing use date 105E (associated with one or both scoring blades 83). Thus, in response to providing the blade impression images 91 at predetermined time intervals or intervals of material passing therethrough, the neural network 100 operates using a closed feedback loop to permit continuous operation of the scoring device 10, i.e., with or without interruption of the rotary scoring system. In other words, in response to measuring deviations from a desired state, the controller 36 is adapted to operate in a closed feedback loop for setting the gap size of the gap 16 between the blade and the anvil roll. In other words, the blade cutting depth adjustment is determined by the neural network 100.

[0046] In some embodiments, the neural network 100 allows for different weights in the hidden layer 103 portion to accommodate different preferences of different operators. In other words, such preferences can be changed corresponding to the work hours of different operators, and can be performed manually or automatically, such as when an operator "punches in" for a work shift.

[0047] In some embodiments, the neural network operates using one or more sensors that sense parameters without or before the material 30, backing web 31b, and matrix web 31a are separated from each other, and wherein the sensing by the one or more sensors occurs with or without interruption of operation of the rotary blade scoring system 1.

[0048] Feedback to the automated control process may include specifications or measurements related to the scoring device 10, the material being cut (eg, webs 31a, 31b), or other process parameters that affect the quality of the score.

[0049] The example embodiments described herein provide a closed-loop feedback loop or automated control process that is a significant improvement over current manual processes in which the exemplary blade indentation image guide 74 ( Fig. 7AAn operator of the rotary scoring device (images 74A, 74B correspond to a range of light blade marks, images 74C, 74D correspond to a range of medium blade marks, and image 74E corresponds to a heavy blade mark) must first interrupt operation of the rotary scoring device, inspect a portion of the web, determine the deviation from the desired state, make manual adjustments, and then restart operation of the rotary scoring device, which may need to be repeated if the operator's deviation determination is incorrect. Thus, the exemplary automated control process described herein solves the above-mentioned problems of current manual processes.

[0050] In some embodiments, the controller 36 uses an AI method to control the rotary scoring device 10. In other embodiments, the controller 36 uses a machine learning method to control the rotary scoring device 10. In other embodiments, the controller 36 uses a deep learning method to control the rotary scoring device 10. Therefore, the exemplary machine learning described herein learns how to classify the scoring by using a convolution filter to feed the image grayscale intensity values ​​into a neural network. For example, the output of the neural network is assigned to an actuator that performs blade gap and parallelism adjustment. The machine learns the optimal settings by assigning appropriate weights and biases to all perceptrons in each hidden layer.

[0051] In some embodiments, the neural network is deployed with the ability to perform training as needed either at the deployment location or remotely from an off-site location, both during and outside of operations.

[0052] In some embodiments, a custom neural network is constructed for isolated or combined parameters present in the control unit 32 or process (i.e., a custom neural network for each different type of web material, each different scoring device, each different blade, each different depth of cut setting, each different line speed setting, etc.).

[0053] Reference now Figure 8-Figure 13 , which shows an example embodiment of a display on the display device 51, which is used to input control instructions to the controller 36 to operate the scoring device 10. In one embodiment, reference Figure 8, the display includes a graphical user interface configured as a tab layout 200, which includes five tabs, such as a main tab 202a, a mode tab 202b, an alarm tab 202c, a settings tab 202d, and a diagnostic tab 202e. In the main tab 202a, indicators 204a and 204b are shown to correspond to the actual position of the corresponding blade holder 12 measured in real time by the electromagnetic transducer 61. The main tab 202a further includes a mode selection block 206, an engagement / disengagement selection block 208, a cutting depth selection block 210, and a fine jog selection block 212. The mode selection block 206 allows the user to select which mode to select for operation. The mode can be selected from at least one of the next mode 206a, the new mode 206b, the modification mode 206c, or the manual mode 206d. The engagement / disengagement selection block 208 indicates the status of the scoring blade 83 on the anvil roller 14, where the button 210a (i.e., the down arrow button) indicates that the scoring blade 83 is engaged (contacting) with the anvil roller 14, and the button 210b (i.e., the up arrow button) indicates that the scoring blade 83 is disengaged (not in contact) with the anvil roller 14. The call interface 211a and the save interface 211b allow the user to select parameters for the saved material so that scoring can be performed based on the saved library (previously configured materials). The user can select from previously saved materials by selecting the call interface 211a, or select from existing materials by selecting the save interface 211a. Once the material is selected, the selected material will be displayed at the window 211c to indicate the selected material. In one embodiment, the window 211c indicates the type of material (i.e., PP40) and the cutting depth (e.g., 40mil). The cutting depth selection block 210 indicates the fine adjustment (i.e., small adjustment) of the corresponding blade 12. Each blade 12 can be adjusted (moved) independently of each other. In one embodiment, the up arrow moves the blades up for further disengagement, and the down arrow moves the blades down for further engagement. In other embodiments, the up arrow may have a first color (e.g., red) for disengagement, and the down arrow may have a second color (e.g., green) for engagement. The fine jog selection block 212 indicates moving the two blade holders 12 to the user side or the machine side to adjust for finer alignment of the web.

[0054] Fig.9AThe Mode tab 202b is shown as being selected. In this tab, the mode history for a particular job and the queue of materials may be accessed. In addition to the saved history, the Mode tab 202b also permits the user to save and edit the current job for future use. It should be understood that other parameters may be saved and retrieved, such as, but not limited to, material name, material type, material serial number or identifier, material caliper measurement, material basis weight, material tensile strength, material elasticity, machine measurements, individual scoring blade diameters, machine settings or conditions when parameters were saved, etc.

[0055] Fig. 9B The alarm tab 202c is shown when selected. In this tab, historical diagnostic alarms are displayed and saved to indicate previous faults, such as but not limited to blade collisions.

[0056] To illustrate an exemplary operation using an exemplary sample material (i.e., 6 inches wide), the user selects the modification interface 206c from the mode selection block 206 of the main tab 202a, as shown in FIG. Fig. 10A As shown, to modify the existing pattern of the selected material. Since the sample material is six inches wide, the user needs to change the width of the blade holder 12 to at least 5 inches to modify the existing pattern, that is, from 8 inches to 5 inches ( Fig. 10B Once the appropriate width (i.e., 5 inches) is entered, the start moving interface 213 is selected to set the blade holder 12 to its desired position. Fig.11A As shown, if the scoring blade 83 is in the engaged position, the scoring blade 83 will be retracted for a predetermined time (i.e., 10 seconds) until the blade 83 is completely disengaged, and then the blade holder 12 will move to its respective desired position (i.e., 5 inches), as shown in FIG. Fig. 11B shown.

[0057] Alternatively, if a new sample material is to be processed, the user selects the new interface 206b from the mode selection block 206 and enters parameters or configurations (i.e., type of material, thickness of material, blade holder position, cutting depth, etc.) for operation. The user can then save the parameters or configurations to a library for future use.

[0058] Next, refer to Fig.12, select the material selection to be run. For example, a selected material (e.g., 4 mil vinyl material) is called up from a saved library for selection. In this case, the saved material corresponding to the sample material is named "F40087". Once the saved material selection is selected from the saved library and the blade holder 12 is set in the appropriate position, the scoring blade 83 engages the sample material to perform the scoring operation. In one embodiment, the indicators 204a and 204b can turn into different colors (e.g., from red to green) to indicate that the scoring blade 83 is engaged for operation.

[0059] Fig.14 An exemplary final web material is shown with a scoring operation. In one embodiment, a top score 44 is employed on the web material 30, wherein the top layer 31a of the material is scored, while the support material 31b remains intact. As shown, the end user can remove the cut top layer material 31a from the support material 31b. The cut is just deep enough to penetrate the top surface, leaving the backing support material 31b intact.

[0060] Surprisingly, the results, including a deep learning approach for indentation characterization, treated transparent and opaque materials with equal effectiveness. Another result was that high accuracy was achieved with very little training.

[0061] In some embodiments, the present rotary scoring system can be incorporated into a rotary die cutting system including a rotary die cutting device including a die cutting cylinder and a back pressure cylinder separated from the die cutting cylinder by a gap, as described in U.S. Patent Application No. 17 / 217,226 and incorporated herein by reference. In addition to controlling the rotary scoring system, the control unit can also control the rotary die cutting device and the rotary scoring system separately, respectively or alternatively, to actuate the adjustment device to adjust the axial position and / or the gap size. In one embodiment, the rotary die cutting system is positioned in series with respect to the rotary scoring system.

[0062] As used herein, the articles "a" and "an" refer to one or more when applied to any feature in the embodiments of the present disclosure described in the specification and claims. The use of "a" and "an" does not limit the meaning to a single feature unless such limitation is specifically stated. The article "the" preceding a singular or plural noun or noun phrase refers to one or more specifically specified features and can have a singular or plural meaning depending on the context in which it is used. The adjective "any" refers to one, some, or all, regardless of the number.

[0063] As used herein, "at least one" means one or more and thus includes individual ingredients as well as mixtures / combinations.

[0064] The transition terms "comprising," "consisting essentially of," and "consisting of," when used in the appended claims, define the scope of the claims in their original and amended forms with respect to which unrecited additional claimed elements or steps, if any, are excluded from the scope of the claims. The term "comprising" is intended to be inclusive or open-ended, and does not exclude any additional, uncited elements, methods, steps, or materials. The term "consisting of" excludes any elements, steps, and materials other than those specified in the claim, and, in the latter case, excludes impurities normally associated with the specified materials. The term "consisting essentially of" limits the scope of the claim to the specified elements, steps, or materials and those elements, steps, or materials that do not materially affect the basic and novel features of the claimed disclosure. In alternative embodiments, all materials and methods described herein that embody the present disclosure may be more specifically defined by any of the transition terms "comprising," "consisting essentially of," and "consisting of."

[0065] Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, without departing from the scope of the exemplary embodiment, the first element may be referred to as the second element, and, similarly, the second element may be referred to as the first element. As used herein, the term "and / or" includes any combination and all combinations of one or more of the associated listed items.

[0066] It should be understood that if an element is referred to as being "connected" or "coupled" to another element, it may be directly connected or coupled to the other element, or there may be intervening elements. Conversely, if an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.).

[0067] For ease of description, spatially relative terms (e.g., "below," "below," "lower," "above," and "upper," etc.) may be used herein to describe the relationship between one element or feature and another element or feature, as shown in the figure. It should be understood that in addition to the orientations depicted in the figures, spatially relative terms are also intended to cover different orientations of the device in use or operation. For example, if the device in the figure is turned over, the elements described as being "below" or "below" other elements or features will be oriented to be "above" other elements or features. Thus, for example, the term "below" can cover both an orientation located above and an orientation located below. The device can be oriented in other ways (rotated 90 degrees or viewed or referenced in other orientations), and the spatially relative descriptors used herein should be interpreted accordingly.

[0068] Example embodiments are described herein with reference to cross-sectional illustrations that are schematic representations of idealized embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and / or tolerances, are to be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

[0069] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as those commonly understood by those skilled in the art to which the example embodiments belong. It will be further understood that terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and will not be interpreted in an idealized or overly formal sense unless explicitly defined as such herein.

[0070] Although the present disclosure has been described with reference to preferred embodiments, it will be appreciated by those skilled in the art that various changes may be made and elements thereof may be replaced with equivalents without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt specific situations or materials to the teachings of the present disclosure without departing from the substantive scope of the present disclosure. Although various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for illustrative purposes and are not intended to be limiting, and the true scope and spirit are indicated by the appended claims.

Claims

1. A method for setting a gap size and an axial position of a gap between one or more scoring blades and an anvil shaft of a rotary scoring device, the method comprising: providing a control system comprising a controller, at least one sensor, and at least one regulating device actuated by the control system; as well as actuating the at least one adjustment device in response to the at least one sensor sensing a deviation from a desired state to set an axial position and a gap size between the one or more scoring blades and the anvil shaft, wherein actuating the at least one adjustment device is accomplished as a result of the control system operating in a closed feedback loop; Wherein, sensing by the at least one sensor occurs with or without interruption of operation of the rotary scoring device.

2. The method according to claim 1, wherein: Actuating the at least one adjustment device in response to the at least one sensor sensing a deviation from a desired state includes input from a user, the input being selected from a library of saved parameters.

3. The method according to claim 2, wherein: The parameters include at least one of: material name, material type, material serial number or identifier, material caliper measurement, material basis weight, material tensile strength, material elasticity, machine measurements, single scoring blade diameter, machine settings, ambient temperature, or conditions when the parameters were saved.

4. The method according to claim 1, wherein: Actuating the at least one adjustment device in response to the at least one sensor sensing a deviation from a desired state includes components with misaligned or tolerance stack-ups that cause positional changes between the one or more scoring blades and the anvil shaft, depending on the scoring blade diameter and positioning along the anvil shaft.

5. The method according to claim 1, wherein: Actuating the at least one adjustment device in response to the at least one sensor sensing a deviation from a desired state includes a change in the thickness of at least one of the backing web and the overlying second web.

6. The method according to claim 1, wherein: Actuating the at least one adjustment device in response to the at least one sensor sensing a deviation from a desired state includes at least one of the following: a change in material of at least one of the backing web and the overlying second web, thermal expansion of the material, a change in humidity of the environment surrounding the rotating scoring device, a change in the tension gradient of at least one of the backing web or the overlying second web, a cutting depth of the score line and the substrate web, an imprint quality of the score line and the substrate web, or a deflection of an undefined load.

7. The method according to claim 1, wherein: The control system adopts AI method to control the rotary scoring device.

8. The method according to claim 1, wherein: The control system uses a machine learning approach to control the rotary scoring device.

9. The method according to claim 1, wherein: The control system uses a deep learning method to control the rotary scoring device.

10. The method according to claim 1, wherein: The rotary scoring device operates top scoring or back scoring.

11. A method for operating a rotary scoring device, the method comprising: feeding a web of material to be processed into a feed opening of the rotary scoring device; sending data associated with at least one characteristic attribute of the web of material measured by at least one sensor to a control unit; operating an adjustment device to adjust an axial position of one or more scoring blades; operating a motor to adjust a gap size between the one or more scoring blades and the anvil shaft, the motor including an encoder to send a feedback signal to determine at least one of speed, RPM, counts, distance, or direction; and The axial position and gap size between the one or more scoring blades and the anvil shaft are set to a desired position for processing the web of material.

12. The method according to claim 11, wherein: Sending data associated with at least one characteristic attribute of the material web to the control unit includes measuring the thickness of the material, the material including the front web material and the backing web material present after being guided between the one or more scoring blades and the anvil shaft, wherein the measurement occurs after or before removal of the front web material.

13. The method according to claim 11, wherein: Sending data associated with at least one characteristic attribute of the web material to the control unit includes determining the exact position of the leading and trailing ends of the web material fed to the rotary scoring device.

14. The method according to claim 11, wherein: Setting the axial position and gap size between the one or more scoring blades and the anvil shaft to a desired position for processing the web of material includes input from a user selected from a library of saved parameters.

15. The method according to claim 14, wherein: The parameters include at least one of: material name, material type, material serial number or identifier, material caliper measurement, material basis weight, material tensile strength, material elasticity, machine measurements, single scoring blade diameter, machine settings, ambient temperature, or conditions when the parameters were saved.

16. The method according to claim 11, wherein: The rotary scoring device operates top scoring or back scoring.

17. A method for setting a gap in a rotary die cutting system, the method comprising: providing a control system, the control system comprising a controller, at least one sensor, a first regulating device and a second regulating device, the first regulating device and the second regulating device each being actuated by the control system; actuating the first adjustment device in response to the at least one sensor sensing a deviation from a desired state to thereby set a gap size between a rotary die cutting device and a backing cylinder of the rotary die cutting device; and actuating the second adjustment device in response to the at least one sensor sensing a deviation from a desired state to set an axial position and a gap size between one or more scoring blades and an anvil shaft of a rotary scoring device, wherein the rotary scoring device is positioned in series with respect to the rotary die cutting device, wherein actuating the second adjustment device is accomplished as a result of the control system operating in a closed feedback loop; Wherein, sensing by the at least one sensor occurs with or without interruption of operation of the rotary die-cutting system.

18. A rotary scoring device comprising: a frame comprising at least one blade holder containing a scoring blade therein and an anvil shaft, the at least one blade holder being separated from the anvil shaft by a gap; and a control system comprising a controller, at least one sensor, and a first regulating device and a second regulating device actuated by the control system; wherein the first adjustment device is operatively connected to the at least one blade holder to adjust the axial position, and Wherein, the second adjustment device is operatively connected to the at least one blade holder to adjust the gap size between the scoring blade and the anvil shaft.

19. The rotary scoring device according to claim 18, wherein: The first adjustment means is at least one of a belt drive system or a rack and pinion system to operatively control a motor to adjust the at least one blade holder to a desired position relative to the material to be processed.

20. The rotary scoring device according to claim 19, wherein: The first adjustment device adjusts the at least one blade holder along a lateral linear movement in the frame.

21. The rotary scoring device according to claim 18, wherein: The at least one blade holder includes two blade holders that are positioned spaced apart at desired locations based on the web material being used.

22. The rotary scoring device according to claim 18, wherein: The second adjustment device is a motor encoder to operatively control a motor to adjust the scoring blade to a desired depth relative to the material to be processed.

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