Can Decorator Automatic Registration and Color Adjustment

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Solution Overview

Problem

Existing can decorator machines face challenges with image registration and color adjustment, leading to defects such as skewed, misprinted, or inefficient ink application, resulting in significant can spoilage and increased operating costs.

Innovation Solution

An automatic registration and color adjustment system that includes sensors to monitor ambient and component temperatures, and an automatic adjustment device that controls the can decorator based on previous adjustment data to maintain optimal ink application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual inspection and adjustment methods are used for image registration, then device complexity is reduced, but manufacturing precision deteriorates due to delayed defect detection and trial-and-error adjustments

Engineering Contradiction:

Improveimage registration precisionVSAvoidautomation system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system employs sensors to continuously monitor image registration quality and provides feedback to the control device, which automatically adjusts component positions to maintain precision without manual intervention

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Manual mechanical adjustment by operators is replaced with an automated control system that uses sensors, processors, and actuators to perform registration adjustments, improving precision while managing complexity through automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If temperature changes are not monitored, then device complexity is reduced, but manufacturing precision deteriorates due to thermal expansion causing label drift and skewing

Engineering Contradiction:

Improvelabel registration accuracyVSAvoidtemperature monitoring complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Temperature sensors continuously monitor environmental conditions and the control device proactively adjusts component positions before thermal expansion causes registration defects, preventing rather than reacting to problems

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system monitors temperature as a critical parameter and adjusts mechanical positions of inking stations and plate cylinders in response to thermal changes, compensating for material expansion and maintaining registration accuracy

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If ink application is not optimized for temperature variations, then ease of operation is improved, but manufacturing precision deteriorates due to ink density and flow inconsistencies

Engineering Contradiction:

Improveink application consistencyVSAvoidoperational simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Sensors monitor ink temperature and flow characteristics, providing feedback to the control device which automatically adjusts ink delivery parameters to maintain consistent application quality without operator intervention

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts ink flow rate, pressure, and temperature parameters in response to environmental and operational changes, ensuring consistent ink application characteristics while simplifying operator tasks

Inventive Principle:

Principle #35Parameter changes

4Reliability

If continuous monitoring and automatic adjustment are implemented, then reliability is improved by preventing defects, but loss of time increases due to sensor data processing and adjustment cycles

Engineering Contradiction:

Improvedefect prevention capabilityVSAvoidadjustment response time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Sensors continuously monitor registration quality and temperature conditions without interruption, and the control device continuously makes minor adjustments to maintain optimal conditions, ensuring uninterrupted production with high reliability

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system detects and responds to temperature changes and registration drift before they cause defects, making proactive adjustments that prevent rather than react to problems, minimizing time loss through anticipatory control

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250065641A1Apparatus, system and method of automatic registration and color adjustment based upon machine elements and ambient parameters

Publication Date: 2025.02.27 STOLLE MACHINERY CO LLC

AI summary

An automatic registration and color adjustment system includes a can decorator including at least a plurality of plate cylinders and a plurality of inking station; a plurality of sensors; and an automatic registration and color adjustment device communicatively coupled to the can decorator, the plurality of sensors and the plurality of temperature control elements, the automatic registration and color adjustment device structured to: receive outputs from at least the plurality of sensors; determine that an adjustment to the can decorator is to be made based on the outputs and previous adjustment information; and control the can decorator to make the determined adjustment.