Automatic metal and non-metal embossing machine

Abstract

To make each nameplate prominently, a mandrel and a matrix are required, which is practically impossible without a nameplate production machine if there are many characters or names and the need to match the names in a short time. This machine is a type of four-axis CNC machine that can automatically produce nameplates in a short time with a set of letters, numbers, or meaningful symbols without human intervention. The machine consists of various electromechanical parts that are controlled by a processor and artificial intelligence. The method of producing the plaque is as follows: the plaque holder jaw takes a raw plaque from the feeder and takes it to the embossing section, then takes the embossed plaque to the ejector section, and the final plaque is placed in a box next to the machine. If more than one plaque needs to be engraved, the process is repeated. This machine has a movement mechanism equipped with a completely fixed drive system that does not have a moving motor feed cable and Y-axis sensor, which reduces the weight and energy consumption of the movement set and increases efficiency and reliability.

Description

Description of the invention Title of the invention Automatic embossed metal and non-metal plate making machine Automatic metal plate & tag embossing machine Technical background of the relevant invention The automatic metal and non-metal embossed plate machine is one of the tools and machines in the field of non-chemical and non-laser engraving and plate making machines that works mechanically and automatically. This machine is used to engrave specification plates including text, numbers and letters in embossed form on metal or non-metal sheets completely automatically and without user intervention at high speed, similar to the printing process in a desktop printer. Technical problem and stating the objectives of the invention In most industries, there is a need to avoid any doubt about the loss of the color of the license plate and the distortion of the registered identity, which is why the only solution is to use a raised license plate. In the beginning, the process of engraving license plates was done manually, with a waste of time and energy, and with human error. Gradually, machines came to the market that helped the user to carry out the process of engraving license plates more quickly, but still manually and non-automatically. However, with the advent of CNC machines, this changed and innovations were made in this field. CNC engraving machines often require high technology and a complex and precise electromechanical structure, which is a set of motors, sensors, and electronic processors responsible for controlling and utilizing mechanical modules so that they can perform the precise engraving process in a recessed and semi-automatic manner. Such machines have the ability to produce these plates on a large scale, but technical problems in the electronic design and mechanical departments have caused such equipment to not be stable, fast, and reasonably priced, and their use is difficult and difficult. A description of the state of the prior art and the history of developments related to the claimed invention. According to available information, only two companies in the world have produced automatic embossed engraving machines, one American and the other Italian, with the trade names CIM and MATICA. CIM is a manufacturer of plate engraving machines with a brake and clutch method, the advantages of which are good engraving power for thick and steel plates, and the disadvantages are frequent breakdown of the brake and clutch system and mechanical parts and low speed. MATICA is a manufacturer of plate engraving machines without a brake and clutch and with an analog start and stop system. https: / / www.maticacorp.com / https: / / www.cim-usa.com / Providing a solution to an existing technical problem along with an accurate, sufficient, and integrated description of the invention One of the major problems with the issue of embossed plate engraving is the mechanical movement system, which in both brands can be called the frequent disconnections of the Y axis motor cable. The reason for this is the similarity in the design of the X and Y axis movement mechanism and the placement of the Y axis motor on the X axis, which in both types causes the intermittent and constant movement of its cable to eventually cause the Y axis motor cable to be disconnected, and the cause is the constant movement of the cable and its fatigue. If the design of the alleged mechanism of the X axis movement axes of Map A-5-2 and the Y axis movement axis of Map A-5-1 is designed in such a way that both of its drive motors are fixed, in addition to solving this problem, modern and completely indigenous techniques and methods are used in all other parts, including mechanics and electronics, and the country achieves complete self-sufficiency in this field, this device is equipped with a type of movement system in which all the movement motors of its various axes are fixed and there is no moving cable connected to the motor in this device. The aforementioned manufacturers have avoided modern electronic and software technologies, and their manufactured devices still use old communication ports, and when it comes to operating systems, they are very limited and exclusive to Windows. In the construction of this internal device, the widely used industrial ports RS232 and RS485, and office USB and WIFI have been used to connect to Windows and Android computers. Map A-8-6 from 1 to 4 Other problems with the foreign brand CIM include the use of mechanical brakes and clutches to control the embossing system, which leads to frequent failures and a lot of energy loss. The Matica brand uses an analog electronic control system, but this system, due to its analog, bulky, and complex nature, limits the possibility of control and performs it offline. In the claimed device, the complete control of this part is controlled by artificial intelligence and allows for movement correction with the PID controller. The PID Controller consists of three proportional, integrator, and derivative parts, each of which takes the error signal as an input and performs an operation on it, and finally their output is added together. The output of this set, which is the output of the PID controller, is sent to the system processor for error correction. The processor, using artificial intelligence and real-time programming, has greatly reduced the complexity of the system and the volume of consumable parts, and the DC embossing motor of the A-9-5 diagram, part 1, and the drive set are controlled without errors. Among the significant shortcomings and frequent failures of similar old systems, we can mention the offline nature and lack of health feedback during operation for the drum, embosser and stepper motors compared to the central processor section. In the drum section, if the movement time of the drum set is disrupted for any reason, due to the high power of the embosser hammer, many losses are incurred to the drum, mandrel and matrix set, and it causes long stops and huge costs in the production lines. In the embosser press motor announcement system, it is monitored in real time and online by the sensor of map A-7-6, section 1 and the encoder of map A-7-7, section 1, and an independent microcontroller is used as a slave for this set, which is connected online and instantaneously with the micro-master and immediately reports to the micro-master in the event of an error or failure, preventing the set from continuing to work and further failures. In the drum section, the position sensor for each mandrel is also used during engraving of map A-7-8, section 2. It is taken advantage of so that if for any reason the timing of the drum assembly is disrupted, the embossing assembly will not strike the mandrels and the message will not be displayed.The drum position error is displayed to the user. Additionally, each driver has the ability to report ISD (overcurrent) and TSD (high temperature) errors so that if an error occurs, the device stops before the problem escalates and displays each motor error independently to the user for faster troubleshooting. Due to the complexity of this system and the need for repairs and troubleshooting for technicians, this device has an internal troubleshooting system that, if any sensor or motor fails, a current or temperature error occurs, the system stops immediately and reports the system error to the user through the display and the relevant application. Other features of this device in terms of troubleshooting include that it tests all modules once at the beginning of operation and then proceeds to work. There is also a section in the application panel for the repair technician, through which he can manually test the health of each module of the device. In order to increase the speed of this device, the mechanical assemblies have been lightened, while new methods and techniques for manufacturing and selecting appropriate materials have been used. In the electronics section, the use of the Ramp Up acceleration system has greatly reduced the effects of system inertia on speed reduction and vibration in the system, allowing the system to operate at a higher speed and more stably than similar models. Explanation of shapes, maps and diagrams Feeder module MapA-1: It is responsible for storing and sending the plates one by one to the gripper. A-2 Map Plate Gripper Module It is responsible for receiving the plate from the feeder module and holding it during the embossing process and determining the engraving position of each punch on the plate until it is unloaded and delivered to the ejector. Map Embosser Module A-3-3 It is responsible for hammering the punch and matrices onto the plate. Ejector module Map A-4 It is responsible for transferring the engraved plates out of the machine and into the sorter box. X-axis or longitudinal axis motion support module Map A-5-2 It is responsible for moving the gripper module and the Y-axis motion support in the longitudinal direction of the machine. Y-axis or transverse axis motion support module Map A-5-1 It is responsible for moving the gripper module in the transverse direction of the machine. Drum module or spindle and matrix map A-10 This section holds the punch and die and its function is to place the desired punch and die in the channel of the embossing process. Control unit module or control board Map A-6 It is the electronic part of the device and is responsible for controlling all motors and sensors and communicating with the computer. Measuring modules including sensors and encoders or sensors Item 7 of embossing machine drawing 1: These modules are responsible for receiving mechanical data, including position, from various parts of the device and transmitting data to the control unit. Motors and actuators module item 9 embossing machine map 1: The motors in this device are responsible for moving the mechanical parts with high precision. Sensors and encoders are used to detect the position of the motors in different parts. Cover or body module item 8 embossing machine map 1: It plays the role of protecting the user's life and protecting the equipment inside the device from dust and foreign object penetration, as well as reducing the noise produced by the device. A clear and precise statement of the advantages of the claimed invention over prior inventions. A. New all-fixed drive motion system Dual fixed drive motors Due to the use of the new Ball SPLine drive mechanism, part 1 of diagram A-5-4, both the X and Y axis drive motors of this device, part 1 of diagram A-9-2 and diagram A-9-3, are fixed on the chassis of the device, and the weight of the X axis support, part 1 of diagram A-5-2, has been greatly reduced, and the speed, life, and accuracy of the assembly have been greatly increased compared to similar mechanisms, and energy and heat losses have been reduced and the efficiency of the system has increased significantly. Also, due to the absence of a movable cable connected to the Y axis motor and sensor, the issue of disconnection of the controller with the Y axis drive motor and the corresponding sensor has been completely eliminated. B. In addition to having the old RS232 ports found in similar devices, this device is equipped with advanced input and functional ports such as RS485 and USB ports, a WIFI wireless network, and it is possible to connect directly wirelessly to a Windows computer or Android phone. Map A-8-6 from 1 to 4. C. In addition to the Windows version of the device program, the device program is also written in the Android environment, which allows the device to be connected wirelessly and via Wi-Fi to an Android phone or tablet and a Windows computer or laptop. With this feature and the direct installation of an Android tablet on the device, this device becomes a fully functional device without the need for a computer outside the device. Stand alone system software. E. The embossing module uses a timing belt system to transmit power, which reduces system failure and provides smooth operation, shock resistance, and higher speed. Section 1 Map A-3-2 F. In this machine, the location of the mandrel assembly and the engraving matrix or drum wheel has been optimized and redesigned in a way that reduces failure and increases accuracy. For the first time, a mandrel position sensor has been used to always report the feedback of the drum position to the controller, and if the mandrel is not under the embosser, the controller prevents the machine from operating. Part 1 of Figure A-10-3 shows the encoder plate of this system and Part 2 of Figure A-7-8 shows the corresponding sensor. G. Also, in the design of the punches of this set, a cylindrical design has been used and an independent spring matrix & Punch self spring return has been used for each punch so that in the event of failure of any punch or spring, that part can be replaced independently. Sections 1 and 2 of the A-10-5 drawing, in addition to the complexity of these devices compared to most similar CNC devices, both in terms of mechanical structure and in terms of electronics and software, unique techniques and innovations have been used in it so that it can be considered as a valuable CNC device. Description of at least one implementation method for implementing the inventionThe task of this machine is to engrave embossed plaques automatically, and its general working process is as follows: the user places a number of raw plaques in the raw plaque tank or feeder of the machine, Part 1 of Figure 1-1-A, and then sends one or more lines of writing to the machine according to his needs using the program in the computer that is connected to the machine by a data cable. Similar to the process of printing text with a printer, upon receiving a command from the user by the electronic control unit, Part 1 of Figure A-6, this unit issues a signal to the feeder module, and subsequently the feeder outputs a number of plaques, Part 1 of Figure A-1-2. To output each plaque, the stepper motor of the feeder module, Part 1 of Figure A-9-1, which is connected to the drive pulley, Part 1 of Figure A-1-4, by the timing belt and the relevant pulleys, Part 1 to 3 of Figure A-1-3, rotates to a certain amount, and the pinion or drive gear, Part 1 of Figure A-1-5, also moves the shoulder gear of the PUSHERs, Part 1 and 2 of Figure A-1-6. A plate is transferred to the feeder and the front sensor of feeder section 1 from map A-7-1, after seeing the amount of plate output, sends a command to stop this output to the stepper motor of feeder section 1.From the diagram A-9-1, it is obvious that the feeder motor immediately moves in the opposite direction, so that this time the end part of the pusher triggers the rear sensor of the feeder, section 1 of the diagram A-7-2, and the pusher stops moving and is ready to eject the next plate. Then the gripper module of diagram A-2 is mounted on the Y-axis movement assembly, section 1 of the diagram A-5-1, which are both located on the X-support movement mechanism, section 1 of the diagram A-5-2, by the stepper motor driving the X-axis, section 1 of the diagram A-9-2, which is connected to it through the X-axis timing belt, section 1 of the diagram A-5-3, and moves transversely towards the feeder in the direction of the X-axis, and when the lower index connected to the X-axis support, section 1 of the diagram A-7-3, approaches the sensor fixed on the bottom of the device body, section 1 of the diagram A-7-4 A, and after triggering it, it stops in front of the feeder module. Then, by the stepper motor driving the Y-axis, section 1 of the diagram A-9-3, and by the belt and pulleys The timing connected to the motor and the power transmission shaft BALL SPLINE shaft, section 1 of diagram A-5-4, rotates this shaft, and subsequently the pulleys and timing belt connected to the Y-axis motion module, sections 1 and 2 of diagram A-5-5, move the gripper module number 2 towards feeder number 1 fromMap A-5-6, as a result of the movement of the gripper Map A-2, the trigger tab of the gripper module, Section 1 of Map A-2-1, rotates by hitting the adjustable screw of the feeder, Section 1 of Map A-1-9, and the gripper jaw is suddenly locked by the spring, Section 1 of Map A-2-2, and receives a plate from the feeder, Section 1 of Map A-2-3. According to the previous timing, the gripper stops when the Y motion support returns back and after triggering the corresponding sensor, Section 1 of Map A-7-5, and waits for the next step command. Then, the X-axis stepper motor, Section 1 of Map A-9-2, moves the X-axis motion support and the gripper assembly towards the embosser and drum, and stops in front of these two sections according to the program, Map A-3-1. The drum assembly has a stepper motor underneath it (Part 1 of Figure A-9-4) which transmits power to the drum shaft via a pulley and belt (Part 1 of Figure A-10-1) (Part 1 of Figure A-10-2). Also, two sensors (Parts 1 and 2 of Figure A-7-8) and a rotating disk equipped with two rows of consecutive and individual grooves to count the rotation rate and position of the drum wheel (Part 1 of Figure A-10-3) are located above the drum, which are responsible for rotating and positioning.The precise positioning of each pair of punches and matrices in the embossing position by the embosser. According to the program, the drum drive motor is activated and the drum is positioned at the appropriate location of the character by the two sensors mentioned, parts 1 and 2 of diagram A-3. Then, according to the program, the stepper motors of the X and Y axes are both activated and move the plate into the groove of the drum containing the different character sets for engraving the first character, diagram A-10-4. The embossing module has a DC electromotor (Part 1 of Figure A-9-5) and a pulley connected to its shaft, which is connected by a timing belt to the pair of pulleys driving the upper and lower embossing cranks (Part 1 of Figure A-3-2). Also, a number of sensors, one for the sector-shaped grooved disk of the upper embossing crank (Part 1 of Figure A-7-6) and a potentiometer coupled to the same crank (Part 1 of Figure A-7-7) are responsible for controlling the rotation rate of the cranks that strike the mandrel and matrix. After the plate is placed in the appropriate place and the drum is placed in the right place by the program, the first mandrel and matrix press is performed on the plate, and subsequently, according to the program, with the rotation of the drum and the movement of the X, Y axes support and, as a result, the plate itself, other points of the plateIt is also highlighted by the embosser. Then, when the Y-axis motor stepper motor of section 1 of map A-9-3 is activated, the Y-axis support of section 1 of map A-5-1 moves back until it is stopped by the Y-axis sensor of section 1 of map-7-5 A. In the next step and according to the program, the X-axis support of section 1 of map A-5-2 moves towards the ejector module of map A-4 and after the indicator connected to the X-axis support of section 1 of map A-7-3 reaches the excitation sensor located on the chassis of the machine of section 1 of map A-7-9, the gripper module stops in front of the ejector module. Next, according to the program, the Y-axis support of section 1 of map 5-1-A moves towards the ejector of map A-4, followed by the trigger arm of section 1 of map A-2-1 of the gripper module of map A-2, all of which are located on this support, moves towards the L-shaped bracket installed on the ejector of section 1 of map A-4-1, and when it hits it, it rotates, and the gripper jaw opens and the plate falls onto the ejector conveyor belt of map A-4-2. At the same time, the stepper motor of the ejector module of section 1 of map A-9-6 is activated, and as the conveyor belt moves outwards, the plate falls into the sorter box outside the machine.Map A-8-1. After this step, the operation is repeated, meaning that the gripper is automatically placed in front of the feeder and remains waiting for the plate to exit until the process is repeated. Three ventilation fans are installed on the body of the device to transfer the heat inside the device to the outside, parts 1 to 3 of Map A-8-2. A display is located on the transparent part of the device door to show the current operating status of the device, and the device identification code can also be extracted through this display, part 1 of Map A-8-3. The start and stop button is located on the front of the body so that in addition to the possibility of starting and stopping via the computer, this can be done manually, part 1 of Map A-8-4. In addition to the start and stop switches, there is an emergency button on top of the device so that in case of a problem, the device can be quickly disconnected from the circuit (section 1 of diagram A-8-5). The input power socket, as well as the USB and RS485 WIFI RS232 data connection ports, and the rocker switch for cutting off the input power of the device are located on the back of the device body (sections 1 to 5 of diagram A-8-6). Explicit mention of the industrial application of the invention In most industries, there is a need to avoid any doubt about the loss of the color of the license plate and the distortion of the registered identity, which is why the only solution is to use engraving numbers on metal plates, and such devices have the ability to produce these plates in large quantities. Among the uses of this device can be mentioned the automotive industry, which is used to produce specification plates installed inside the engine compartment or on the body pillars, and is considered one of the priorities and requirements of this industry. It is also a widely used and essential device in the military industry for military plates and other industries.

Claims

Claim What is claimed: Claim 1) Claim one: The claimed invention is a device for producing a nameplate in the form of embossing letters or numbers or symbols on metal or non-metal sheets, which is commonly called an automatic nameplate machine and includes a new movement system in the movable support of the Y axis of the device. The main parts of this device include the following parts: Part one - Feeder: or the raw plate tank, which contains a certain number of raw plates stacked on top of each other, and which outputs the raw plates individually and delivers them to the gripper. Part two - Gripper): or the raw plate receiving jaw, which is located on the movable X and Y axes and whose function is to receive a raw plate output from the feeder and take it to the embossing section and then transfer it to the ejector section. Part three - X-axis movable support: whose function is to move the Y-axis support mounted on it in the longitudinal direction of the device. Part Four - Y-axis movable support: Its function is to move the gripper mounted on it along the transverse axis of the machine.Section Five - Embossing: Or the part that highlights the characters, which includes an even number of male and female letters or signs or numbers (embossed and recessed) that are located inside a rotating circular grooved disk, with male letters in the bottom row and female letters in the top row and correspondingly, and a striker from both sides, when the feeder takes a raw plate into the groove of the rotating disk and hits the mandrels, and its effect on the raw plate is created in the form of a letter or number or sign. Section Six - Ejector: Or the ejector, whose task is to direct a number of plates executed by the embosser, which the movable gripper has delivered to it, out of the device and the tank for collecting the executed plates. Section Seven - Electronic controller unit: Which is responsible for the main control of all the above sections and also for communicating with the user and the computer. Claim 2) According to claim number one, this device uses a new system for a linear motion mechanism that is used in the Y-axis movable support section of this device. In this mechanism, there is a BALL SP LINE and the drive motor of the Y-axis movable support of this device is placed on the main chassis of the device and is fixed, like the drive motor of its X-axis.

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