Closed-Loop Decorator System for Metallic Containers

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Solution Overview

Problem

Existing decorating technologies for metallic containers are labor-intensive, prone to human error, and result in significant downtime and waste due to the need for manual adjustment of ink keys, which is difficult and can be dangerous, especially at high production speeds.

Innovation Solution

A closed-loop decorator system with sensors and a control system that automatically detects and corrects deficiencies in decorations on metallic containers, adjusting ink blades and potentially rejecting flawed containers, to ensure consistent quality without operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual adjustment of ink keys is used, then decoration quality can be corrected, but operator safety deteriorates and adjustment difficulty increases due to high production speeds

Engineering Contradiction:

Improvedecoration qualityVSAvoidadjustment difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The system uses sensors to detect decoration deficiencies on containers and feeds this information back to automatically adjust ink blade positions, eliminating the need for manual intervention while maintaining decoration quality at high production speeds

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The decorator system performs self-adjustment of ink blades based on sensor feedback, allowing the system to correct its own decoration deficiencies without operator intervention, thereby improving safety and ease of operation

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If manual adjustment of ink keys is used, then decoration quality can be corrected, but production downtime increases due to the time required for manual adjustment

Engineering Contradiction:

Improvedecoration qualityVSAvoidproduction downtime

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The automatic adjustment system operates continuously during production without requiring stoppages, allowing the decorator to maintain decoration quality while eliminating the downtime associated with manual adjustments

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Real-time sensor detection and automatic feedback control enable continuous correction of decoration deficiencies during high-speed production, eliminating the need to stop the line for manual adjustments

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If manual adjustment of ink keys is used, then decoration quality can be corrected, but labor intensity and human error increase

Engineering Contradiction:

Improvedecoration qualityVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system replaces manual mechanical adjustment of ink keys with an automated control system that uses sensors and actuators to adjust ink blade positions, eliminating labor-intensive operations and reducing human error

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The decorator system automatically monitors and adjusts its own operation through integrated sensors and control mechanisms, eliminating the need for operator intervention and associated labor complexities

Inventive Principle:

Principle #25Self-service

4Productivity

If high production speeds are used, then productivity increases, but the ability to manually adjust and correct decorations deteriorates

Engineering Contradiction:

Improveproduction speedVSAvoiddecoration correction capability

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system uses real-time sensor feedback to detect and correct decoration deficiencies during high-speed production, maintaining manufacturing precision without sacrificing productivity

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Manual adjustment mechanisms are replaced with automated systems that can operate at high speeds, allowing the decorator to maintain both high productivity and precise decoration correction capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11034145B2System and method for monitoring and adjusting a decorator for containers

Publication Date: 2021.06.15 BALL CORP

AI summary

An apparatus and methods of monitoring and adjusting a decorator for metallic containers 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 optionally automatically adjust elements of the decorator to correct a deficient decoration. In one embodiment, the control system can automatically send a signal to 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 send a signal to adjust a position of an inking assembly, an ink roller, a ductor roller a plate cylinder, a printing plate, a blanket cylinder, and a transfer blanket of the decorator.