Can Decorator Plate Cylinder Adjustment for Image Registration

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Solution Overview

Problem

Can decorators face issues with image registration errors, ink temperature inconsistencies, and ink application inefficiencies, leading to high spoilage rates and operating costs due to frequent shutdowns and ink wastage.

Innovation Solution

A control system with a can inspection system, controller, and adjustment assemblies to adjust plate cylinder positions and ink temperature, using stepper motors for precise image alignment and temperature control, based on image analysis and sensor feedback.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high speed continuous motion machines are used for can decoration, then productivity is improved, but image registration errors and ink application inconsistencies increase

Engineering Contradiction:

Improvedecoration speedVSAvoidimage registration accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements a feedback control system where image inspection cameras capture the actual decorated cans and the controller compares these images against reference images to detect registration errors. The controller then adjusts the plate cylinder positions based on detected errors, creating a closed-loop feedback system that maintains precision at high speeds.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary inspection of the decorated cans using image capture devices before the cans leave the decoration line. This allows the system to detect and correct registration errors while they are still detectable, preventing defective cans from proceeding to the next stage and enabling real-time adjustments.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If frequent adjustments are made to correct image registration errors, then manufacturing precision is improved, but downtime and loss of productivity increase

Engineering Contradiction:

Improveimage alignment accuracyVSAvoidcontinuous operation capability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The continuous feedback loop allows for real-time detection and correction of registration errors without requiring manual intervention or shutdowns. The system automatically adjusts plate cylinder positions based on image analysis, maintaining continuous operation while correcting precision issues.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system is designed to self-correct registration errors through automated detection and adjustment mechanisms. The inspection system detects errors and the adjustment mechanisms automatically correct them, eliminating the need for operator intervention and minimizing downtime.

Inventive Principle:

Principle #25Self-service

3Device complexity

If ink temperature is not controlled, then device complexity is reduced, but ink application quality and consistency deteriorate

Engineering Contradiction:

Improvetemperature control systemVSAvoidink application consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent controls ink temperature as a critical parameter to ensure consistent ink application quality. By maintaining optimal temperature ranges, the system ensures proper ink flow, transfer, and registration without requiring overly complex control mechanisms, balancing simplicity with quality control.

Inventive Principle:

Principle #35Parameter changes

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

Improves image quality, reduces maintenance and downtime, and enhances efficiency by ensuring accurate image application and optimal ink usage.

Implementation Method 1

a can inspection system structured to capture images of a can

Methodology Applied

Scientific EffectImage capture: Photography

Implementation Method 2

a controller structured to receive the captured images and to analyze the captured images to determine a quality of the image applied to the can

Methodology Applied

Scientific EffectImage analysis: Image Processing

Implementation Method 3

the adjustment assembly including at least one stepper motor, wherein operation of the at least one stepper motor causes the circumferential or translational adjustment

Methodology Applied

Scientific EffectStepper motor actuation: Electromagnetic Induction

Data Source

PatentUS20250381772A1Can decorator inspection and control system and adjustment assemblies

Publication Date: 2025.12.18 STOLLE MACHINERY CO LLC

AI summary

A control system for a can decorator structured to apply images to cans includes a can inspection system structured to capture images of a can, a controller structured to receive the captured images and to analyze the captured images to determine a quality of the image applied to the can based on a comparison of the captured images and a reference image, and an adjustment assembly structured to adjust a circumferential or translational position of a plate cylinder attached to a plate cylinder shaft end of a plate cylinder shaft, the adjustment assembly including at least one stepper motor, wherein operation of the at least one stepper motor causes the circumferential or translational adjustment.