Circular Data Card Production Plant with Closed Transport Route
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Solution Overview
Problem
Existing production systems for data cards from laminate composites are inflexible and inefficient, with long cycle times and non-compact designs due to linear arrangements of processing stations, limiting productivity and flexibility.
Innovation Solution
A production system with a closed, circular or oval transport route allows for a one-piece flow of workpieces, enabling direct movement between stations without return routes, and includes a heating station for dimensional accuracy, a feed station for additional layers, and a buffer section for decoupling production and personalization lines, ensuring high productivity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual layers are fed sequentially from rolls in a linear arrangement, then lamination can be achieved, but the production line becomes long and non-compact
Solution Approach 1:
The patent transforms the linear one-dimensional arrangement of processing stations into a two-dimensional compact layout with a closed transport route. The workpiece carrier moves through processing stations in a compact spatial configuration rather than along a long linear path, achieving both lamination capability and compact design.
Solution Approach 2:
The patent combines multiple processing functions (feeding, printing, laminating, cutting) into a single integrated workpiece carrier system that moves through a closed route. This merging of functions into one cohesive unit allows compact arrangement while maintaining all necessary manufacturing capabilities.
2Productivity
If processing stations are arranged in a row along a straight transport route, then sequential processing is achieved, but cycle time increases
Solution Approach 1:
The patent implements a closed transport route that enables continuous one-piece flow of workpieces through all processing stations. The workpiece carrier continuously moves through the system without stopping or returning, eliminating idle time and achieving continuous productive action throughout the entire manufacturing cycle.
Solution Approach 2:
The patent introduces dynamic movement of the workpiece carrier along a closed route, allowing the system to adapt to different processing requirements while maintaining continuous flow. The carrier can be dynamically positioned and moved through different stations in an optimized sequence, reducing cycle time compared to static linear arrangements.
3Manufacturing precision
If raw cards are fed already cut to final dimensions, then dimensional accuracy during processing is improved, but flexibility in handling different card sizes is reduced
Solution Approach 1:
The workpiece carrier is designed as a universal platform that can accommodate raw cards of different sizes and types. The carrier system provides multi-functional capability to handle various card formats while maintaining precise positioning and dimensional accuracy during all processing operations through its standardized interface and positioning mechanisms.
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
This configuration results in significantly reduced cycle times, increased flexibility in production line design, and high-dimensional accuracy, achieving production times of less than 10 seconds per card while maintaining high productivity and allowing for easy addition or removal of stations.
Implementation Method 1
The production system preferably has a heating station for the raw card between the magazine for issuing raw cards and printing stations. This allows this raw card to be prepared for subsequent printing.
Data Source
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AI summary
Production plant for manufacturing data cards for security documents. The invention relates to a production plant for manufacturing data cards (53) for security documents from a laminate composite consisting of at least two laminated layers, comprising at least one production line (14): a transport device (23) comprising several workpiece carriers (25) that are movable along a transport path (24) of the transport device (23), a loading station (26) comprising a magazine (27) in which raw cards (28) cut to a final dimension are stored, and a handling device (29) comprising a loading station (26) that loads the workpiece carrier (25) with a raw card (28) from the magazine (27), a printing station (33) in which the raw card (28) fed by the workpiece carrier (25) can be printed, and a subsequent output station (36).by which at least one cover layer (35) can be arranged on the printed raw card (28), with a laminating station (41) by which the printed raw card (28) is laminated with the at least one cover layer (35), with a processing station (46) in which the laminated raw card (28) is punched or cut to a final dimension of the data card (53), wherein the workpiece carrier (25) passes through all stations (26, 28, 33, 36, 41, 46) assigned to the transport line (24) along an endless transport path (24) individually controlled with respect to the dwell time in each station.