Ferromagnetic Counter Die Ring for Fast Embossing Alignment
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Solution Overview
Problem
Current methods for positioning Counter dies in embossing processes require manual handling of positioning pins and grippers, leading to increased handling time and potential damage to graphic designs due to pin dislodgment during machine operation.
Innovation Solution
A ferromagnetic ring with a crown-shaped arm design is used, which is embedded in the Counter die mold, ensuring precise positioning through magnetic attachment, eliminating the need for manual pin insertion and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual positioning pins and grippers are used for Counter die positioning, then positioning can be achieved, but handling time increases and potential damage to graphic designs occurs
Solution Approach 1:
The patent replaces manual mechanical positioning pins and grippers with a magnetic positioning system. The Counter die contains ferromagnetic material that is attracted to a magnet in the die, providing automatic positioning without manual intervention. This substitution eliminates the time-consuming manual handling while maintaining positioning accuracy, and prevents damage to graphic designs by removing the need for physical pins that could dislodge during operation.
Solution Approach 2:
The magnetic positioning system enables self-service positioning where the ferromagnetic material in the Counter die automatically aligns and attaches to the magnet in the die without external assistance. The system self-regulates the positioning process through magnetic attraction, eliminating the need for operators to manually insert and secure positioning pins, thereby reducing handling time while ensuring consistent positioning accuracy.
2Adaptability or versatility
If manual pin insertion and removal is required, then positioning can be adjusted, but the process becomes complex and time-consuming
Solution Approach 1:
The patent replaces the complex mechanical system of manual pin insertion and removal with a simple magnetic attraction system. The ferromagnetic material and magnet create an automatic positioning mechanism that eliminates the need for operators to manually handle positioning pins. This substitution maintains positioning adaptability through magnetic strength adjustment while dramatically simplifying the overall mechanism, reducing both device complexity and operational complexity.
Solution Approach 2:
The patent utilizes parameter changes in the magnetic field strength to achieve positioning adjustment without mechanical intervention. By varying the magnetic attraction force, the system can accommodate different positioning requirements while maintaining a simple fixed structure. This parameter-based control eliminates the need for complex mechanical adjustment mechanisms, reducing device complexity while preserving adaptability.
3Reliability
If positioning pins are used during machine operation, then positioning can be maintained, but pin dislodgment can damage graphic designs
Solution Approach 1:
The patent replaces mechanical positioning pins that can dislodge and cause damage with a magnetic positioning system. The magnetic attraction force continuously holds the Counter die in position without physical contact points that could fail. This substitution eliminates the harmful factor of pin dislodgment while maintaining positioning stability throughout machine operation, protecting graphic designs from damage.
Solution Approach 2:
The magnetic positioning system provides beforehand cushioning by creating a continuous magnetic field that prevents positioning failure before it can occur. The magnetic attraction acts as a protective force that maintains positioning stability under various operating conditions, preventing the kind of positioning failure that would lead to pin dislodgment and graphic design damage.
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 method significantly reduces setup time by up to 80% and prevents deformation or displacement of the Counter die during the injection process, ensuring accurate graphic mark formation.
Implementation Method 1
A ferromagnetic ring with a crown-shaped arm design is used, which is embedded in the Counter die mold, ensuring precise positioning through magnetic attachment
Data Source
AI summary
A positioning element for a counter die for making graphic marks on flat sheets for packaging is shown. It includes at least a ring 0.2 to 0.8 mm thick, shaped on both sides, and made of ferromagnetic material. The ring has a hole that fits into a mold cavity of the counter die. A mold for making a counter die containing a positioning element for a counter die for making graphic marks on flat sheets for packaging is also described. The mold is provided with sockets for fixing the position of rings, wherein each socket is a cylinder facing with its apex, a surface of the mold together with a milled base to a minimum depth equal to a thickness of the rings, a number of sockets being equal to number of rings.