Cooling Roller Layout for Sheet Inspection After UV Curing
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Solution Overview
Problem
Existing sheet processing machines face challenges in efficiently cooling and inspecting sheets after curing, leading to potential deformation and soiling of components, which affects print quality and requires frequent maintenance.
Innovation Solution
A sheet processing machine with a cooling roller and inspection device, featuring a simultaneous double printing unit and curing device, where the cooling process is separated into passive and active phases to prevent deformation and soiling, allowing for rapid cooling and precise inspection of both sides of the sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If sheets are cooled immediately after curing using a cooling cylinder, then cooling efficiency is improved, but sheets may deform due to temperature stress and adhesive layers may soil the cooling surface
Solution Approach 1:
The cooling process is divided into two distinct phases: passive cooling zone where sheets cool without contact to prevent deformation, and active cooling zone where sheets contact the cooling cylinder for rapid heat removal. This segmentation allows each zone to perform its specific function optimally without compromising the other.
Solution Approach 2:
The passive cooling zone is positioned before the active cooling zone, allowing sheets to undergo preliminary cooling without contact. This preliminary action reduces the temperature differential that would cause deformation during subsequent active cooling, preparing the sheets for the more intensive cooling phase.
2Speed
If sheets are cooled using a cooling cylinder, then cooling speed is improved, but adhesive layers soil the cooling surface requiring frequent maintenance
Solution Approach 1:
The cooling system is segmented into passive and active zones, where only the active cooling zone involves contact with the cooling cylinder. This reduces the overall exposure of the cooling surface to soiling materials compared to continuous contact cooling, thereby reducing maintenance frequency.
Solution Approach 2:
The passive cooling zone acts as an intermediary between the curing zone and the active cooling zone, allowing sheets to be pre-cooled before contact with the cooling cylinder. This reduces the temperature and viscosity of adhesive layers at the point of contact, minimizing soiling of the cooling surface.
3Measurement precision
If inspection devices are positioned before cooling, then inspection accuracy is improved, but hot sheets cause thermal stress and deformation
Solution Approach 1:
The passive cooling zone is positioned before the inspection devices, allowing sheets to undergo preliminary cooling to reduce thermal stress. This preliminary cooling action brings sheets to a more stable temperature state, preventing deformation during inspection while still allowing accurate inspection to occur.
4Manufacturing precision
If passive cooling zone is extended to prevent deformation, then sheet quality is improved, but machine length increases
Solution Approach 1:
Different zones of the cooling system have different qualities: the passive cooling zone provides gentle, contactless cooling for quality preservation, while the active cooling zone provides intensive, contact-based cooling for speed. This local differentiation of cooling intensity and method allows the system to achieve both sheet quality and compact design.
Solution Approach 2:
The system changes the cooling parameter from contactless (passive) to contact-based (active) along the transport path. This parameter change allows the machine to provide sufficient cooling length for quality while maintaining a compact overall design by concentrating intensive cooling in a smaller active zone.
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 ensures rapid cooling and inspection of sheets, reducing deformation and soiling, enhancing print quality, and minimizing maintenance needs, while enabling high-speed printing and efficient energy use.
Implementation Method 1
at least one cooling device (301), comprising at least one cooling element (303), which more preferably comprises a line system through which cooling liquid can flow for the transport thereof
Implementation Method 2
a curing device (300), which more preferably comprises at least one UV radiation source (302), which more preferably is designed as an LED UV radiation source (302)
Implementation Method 3
The first inspection unit (401) comprises at least one sensor device for detecting electromagnetic radiation in the visible range of the spectrum and at least one sensor device for detecting electromagnetic radiation in a first portion of the infrared region of the spectrum
Data Source
AI summary
Examples include a sheet processing machine to which a transport path is assigned for transporting sheets. The sheet processing machine includes an application device with an application point for applying material to the sheets. A cooling device including a cooling cylinder is arranged along the transport path, downstream from the application point. An inspection transport body is arranged along the transport path, downstream from the cooling cylinder, and has a sensor device of an inspection unit aligned therewith. Examples further include a sheet-fed printing machine with a simultaneous double printing unit and an application point. A curing device with an LED UV radiation source is arranged downstream from the application point and includes two curing units for drying two opposite sides of sheets. A cooling device of the curing device includes a cooling element with a line system, and the cooling section is arranged downstream from the curing section.