Brushless Motorized Chuck for Printing Machines
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Solution Overview
Problem
Existing printing machines for cylindrical objects using offset, screen, or flexographic systems face issues with mechanical link motion devices being laborious, complex, and costly, and suffer from high moments of inertia due to non-integral motor drives and axial bulk, leading to poor print quality and high inertial forces.
Innovation Solution
A motorized chuck group with a casing enclosing a stator coil and rotor, supported by roller bearings, featuring peripherally-distributed permanent magnets and a brushless motor with an encoder-controlled speed, which directly supports the chuck without additional support means, reducing axial bulk and increasing torsional rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical link motion devices are used to synchronize chuck and matrix movements, then synchronization is achieved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical link motion devices with a direct motor drive system. The motor assembly is integrated directly into the chuck support structure, eliminating the need for separate mechanical synchronization mechanisms. The motor controller directly adjusts motor speed to match matrix speed, achieving synchronization through electrical control rather than mechanical linkages.
Solution Approach 2:
The motor assembly serves multiple functions simultaneously: it drives the chuck rotation, provides synchronization with the matrix, and eliminates the need for separate mechanical link devices. This multi-functional approach reduces overall device complexity while maintaining synchronization reliability.
2Extent of automation
If non-integral motor drives are used, then motorization is achieved, but axial bulk increases
Solution Approach 1:
The motor assembly is nested within the existing chuck support structure. The motor housing is integrated into the support assembly, with the motor shaft co-axial with the chuck support shaft. This nesting arrangement allows the motorized drive to be incorporated without significantly increasing axial dimensions.
Solution Approach 2:
The patent repositions the motor drive from a traditional axial arrangement to a configuration where the motor shaft is co-axial with the support shaft but the motor housing extends radially rather than axially. This dimensional reorientation reduces axial bulk while maintaining motorization.
3Volume of moving object
If chucks of significant axial length are used, then space for drive mechanisms is accommodated, but moment of inertia increases
Solution Approach 1:
The drive mechanism is nested within the existing chuck support structure rather than requiring additional axial space. The motor assembly is integrated into the support assembly, allowing the drive mechanism to be accommodated within the existing volume rather than increasing axial length.
Solution Approach 2:
The patent extracts the motor drive mechanism from the traditional axial extension approach and repositions it within the radial plane. By taking out the motor housing from the axial direction and positioning it radially, the design eliminates the need for significant axial length while accommodating the drive mechanism.
4Productivity
If carousel is operated at high speed with frequent starts and stops, then productivity increases, but inertial forces increase
Solution Approach 1:
The motor controller receives feedback from the encoder device that monitors chuck rotation position and speed. This feedback enables precise control of motor acceleration and deceleration profiles, allowing the system to achieve high productivity while controlling inertial forces through optimized motion control rather than mechanical constraints.
Solution Approach 2:
The patent employs dynamic motor control with adjustable acceleration and deceleration rates. The motor controller dynamically adjusts the motor parameters based on the operational phase, enabling smooth transitions at high speeds while minimizing inertial shocks. This dynamic control allows the carousel to operate at high productivity levels without excessive inertial forces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a compact, high-rigidity motorized chuck system that maintains precise synchronization with the print matrix, reducing inertial forces and enabling efficient, high-capacity printing with improved print quality and reduced complexity and cost.
Implementation Method 1
a casing (20), enclosing a stator coil (25) and a rotor, controlled both in velocity and activation times by a control circuit (60) comprising an encoder device
Implementation Method 2
Seatings are afforded inside the casing (20) for two roller bearings, respectively denoted by (22) and (23). The bearings support, rotatingly but axially fixed, a single axially-hollow shaft (24)
Implementation Method 3
a control circuit (60) comprising an encoder device, in which casing a motor shaft is rotatably supported
Data Source
Figure 1
Figure 2~3
AI summary
A motorized chuck-bearing group (2) for a printing machine, powered by a brushless motor, comprises a casing (20) housing a stator coil (25) and a rotor, controlled both in velocity and activation times by a control circuit comprising an encoder device, in which a shaft (24) supports permanent magnets (26) in a peripheral arrangement, the shaft (24) being coupled, internally of the casing (20), to the encoder device and extending outside the casing (20) such as to support a chuck which rotates an object to be printed (3).