Blank Alignment Module Using Internal Segment Edges
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Solution Overview
Problem
Converting machines face difficulties in aligning blanks with irregular lateral edges, leading to potential rotation during transportation, which complicates the folding process.
Innovation Solution
An alignment module with a guide having a downwardly sloping inlet end and a groove to align blanks with irregular edges, utilizing gravity to direct internal segment edges under the guide, and allowing selection of alignment based on edge geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laser beam is used to remove material during laser additive manufacturing, then material can be selectively removed to create features, but the laser beam may inadvertently remove support structure material due to irregular edge alignment
Solution Approach 1:
The system performs preliminary alignment by detecting the irregular edge of the support structure before laser processing begins. The alignment module calculates a corrected position offset based on the detected edge geometry, and pre-adjusts the coordinate system transformation to compensate for the irregular edge, preventing support structure damage before it occurs
Solution Approach 2:
An alignment module acts as an intermediary between the laser processing system and the irregularly-shaped support structure. This module detects the actual edge position, calculates the deviation from the ideal rectangular boundary, and generates a position offset that mediates the coordinate transformation, ensuring the laser beam is correctly positioned relative to the actual support structure geometry
2Device complexity
If the build plate coordinate system is assumed to be perfectly rectangular, then processing is simplified, but the actual irregular shape of the build plate causes misalignment between the laser beam and the support structure
Solution Approach 1:
The system dynamically adapts the coordinate transformation based on the actual build plate geometry. Instead of using a fixed rectangular coordinate assumption, the alignment module detects the irregular edge in real-time and dynamically calculates a position offset that adjusts the coordinate system to match the actual build plate shape, maintaining precision without requiring complete redesign of the coordinate system
Solution Approach 2:
The system changes the positioning parameters by introducing a position offset that compensates for the irregular edge. The alignment module detects the actual edge position and modifies the coordinate transformation parameters (X and Y offsets) to account for the non-rectangular build plate geometry, allowing the laser beam to be accurately positioned despite the simplified rectangular coordinate system assumption
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The present invention relates to an alignment module (11) for a converting machine (1). The alignment module comprises an alignment device (30) having an upper pressing member (22), a lower conveyor (24) and a guide (26). The guide is further provided with a downwardly sloping inlet end (32), the inlet end being configured to direct a lateral portion of the blank under the guide, while contacting the lateral guiding surface (40) with an internal segment edge (S1, S2) of the blank, the internal segment edge being arranged closer to the central longitudinal axis of the blank than the lateral portion of the blank positioned under the guide.