Card Manufacturing Pattern Alignment via Dynamic Speed Control
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Solution Overview
Problem
Existing card manufacturing methods face challenges in accurately adjusting patterns due to slight misalignments of printing plates, which affects the quality and speed of card production.
Innovation Solution
A method involving the use of a reference sheet and detection means to adjust the feeding speed of continuous sheets, ensuring patterns are aligned at predetermined positions, and allowing for high-speed card manufacturing by controlling the feeding speed based on pattern position detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If printing plates are attached to the roll body with slightly misaligned positions, then the manufacturing process is simple, but the printed patterns have unequal pitches and poor alignment precision
Solution Approach 1:
The patent applies preliminary action by detecting the positions of multiple patterns before lamination and calculating the average pitch in advance. This pre-detection and pre-calculation allows the system to compensate for the misalignment of printing plates beforehand, ensuring accurate pattern alignment during high-speed manufacturing without requiring precise manual plate attachment.
2Manufacturing precision
If positional adjustment is performed for each single pattern, then the alignment precision is improved, but the manufacturing speed decreases
Solution Approach 1:
The patent applies partial action by performing positional adjustment based on a sample of multiple patterns (e.g., every 10th pattern) rather than adjusting every single pattern. This partial detection and adjustment approach maintains high alignment precision while significantly reducing the time required for position correction, thereby preserving high manufacturing speed.
3Productivity
If the feeding speed of continuous sheets is not adjusted, then the manufacturing process is simple and fast, but the patterns cannot be aligned at predetermined positions
Solution Approach 1:
The patent applies dynamics by making the feeding speed of continuous sheets adjustable and controllable based on detected pattern positions. The system dynamically modifies the feeding speed to compensate for pitch variations in printed patterns, enabling both high-speed manufacturing and precise pattern alignment at predetermined positions through real-time speed adjustment.
4Manufacturing precision
If detection and adjustment is performed for every pattern, then the alignment precision is maximized, but the time consumption increases significantly
Solution Approach 1:
The patent applies partial action by selecting and detecting only certain patterns at predetermined intervals rather than detecting and adjusting every single pattern. This selective detection approach maintains sufficient alignment precision for quality production while dramatically reducing the time required for detection and adjustment operations.
Data Source
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AI summary
A card manufacturing method includes a step of feeding a reference sheet serving as a reference for alignment; a step of feeding a first continuous sheet having a plurality of patterns repeatedly printed as one cycle thereon; a step of producing a laminated sheet by laminating the first continuous sheet on the reference sheet; a step of successively detecting a position of each one of the repeatedly printed patterns by detection means; a first adjustment step of adjusting such that the patterns are at predetermined positions with respect to the reference sheet by controlling a feeding speed of the first continuous sheet according to a detection result on the positions of the patterns; and a step of producing a card by cutting the laminated sheet 4 for each of the patterns, the patterns being printed so that plural patterns are repeatedly printed as one cycle, the adjustment step being performed for each cycle made up of the plurality of patterns.