Decorator Inker Alignment With Closed-Loop Print Quality Control

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Solution Overview

Problem

Existing decorators for metallic containers require significant manual intervention and are prone to human error, leading to inefficiencies and high waste rates due to the need for frequent adjustments and inspections at high-speed production lines, resulting in inconsistent decorations and downtime.

Innovation Solution

A closed-loop decorator system with sensors and a control system that automatically detects deficiencies in decorations on metallic containers, adjusts ink blade positions, and alerts operators to ensure consistent ink application, reducing waste and operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual inspection and adjustment methods are used in high-speed production lines, then production speed can be maintained, but decoration consistency deteriorates and waste increases

Engineering Contradiction:

Improveproduction speedVSAvoiddecoration consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements a closed-loop feedback system where sensors continuously monitor decoration quality parameters (ink density, alignment, coverage) and automatically adjust inker positioning and ink flow rates. This real-time feedback mechanism maintains decoration consistency at high production speeds by dynamically compensating for variations without requiring manual intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual mechanical inspection and adjustment operations with an automated control system comprising sensors, processors, and actuators. The system uses optical sensors to detect decoration deficiencies and automatically actuates adjustment mechanisms to correct alignment and ink application issues, eliminating human error and maintaining precision at high speeds.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If frequent manual adjustments are made to maintain decoration quality, then decoration consistency can be preserved, but production downtime increases

Engineering Contradiction:

Improvedecoration qualityVSAvoidproduction downtime

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent ensures continuous operation by implementing real-time automatic adjustment capabilities that eliminate the need for production stoppages. The control system continuously monitors decoration quality and makes instantaneous adjustments to inker positioning and ink flow, maintaining uninterrupted production flow while preserving decoration quality standards.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system performs self-adjustment through automated control algorithms that detect decoration deficiencies and automatically correct them without external intervention. The control system autonomously modifies inker positions and ink application parameters based on sensor feedback, enabling the system to maintain quality standards independently without requiring operator downtime for adjustments.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If manual monitoring and adjustment processes are used, then operator control is maintained, but labor time and human error increase

Engineering Contradiction:

Improveoperator controlVSAvoidoperator time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent replaces manual monitoring and adjustment operations with an automated control system that performs detection and correction functions. Sensors continuously monitor decoration quality parameters and the control system automatically adjusts inker positioning and ink flow rates, eliminating operator labor time while reducing human error in high-speed production environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system autonomously performs monitoring and adjustment tasks through integrated sensors and control algorithms. The control system self-regulates ink application parameters and inker alignment based on real-time feedback, freeing operators from repetitive manual tasks while maintaining precise control over decoration quality without increasing labor time.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10976263B2System and method for aligning an inker of a decorator

Publication Date: 2021.04.13 BALL CORP

AI summary

An apparatus and methods of decorating a metallic container are provided. More specifically, the present invention relates to apparatus and methods used to provide a decoration on a predetermined portion of a metallic container body. The decorator includes a sensor that senses decorations on metallic containers. A control system receives information related to the sensed decorations from the sensor and then determines if the decorations at least meet predetermined color, density, thickness, orientation, and consistency targets. The control system can automatically adjust elements of the decorator to correct a deficient decoration. In one embodiment, the control system can automatically adjust ink blades associated with a plurality of inking assemblies of the decorator to adjust the color, density, orientation, positioning, and consistency of decorations transferred to the metallic containers. In another embodiment, the control system can adjust a position of an inking assembly, an ink roller, a plate cylinder, a printing plate, a blanket cylinder, and a transfer blanket of the decorator.