Optical Alignment of Ejection Rubber Elements on Die-Cutters

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The manual application of ejection rubber elements on die-cutters is time-consuming, prone to errors, and results in significant material waste due to the difficulty in distinguishing small, differently shaped elements, which affects the efficiency and cost of the die-cutting process.

Innovation Solution

An apparatus with a needle gripper and optical recognition system automatically applies ejection rubber elements by aligning and positioning them using retractable needles and a manipulator, ensuring precise placement on the die-cutter based on optical recognition and correction algorithms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual application of rubber elements is used, then flexibility and adaptability are maintained, but productivity is low and loss of time is high

Engineering Contradiction:

Improveapplication speedVSAvoidautomation level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The system uses optical recognition to automatically identify and locate rubber elements and die-cutter features, enabling the application process to guide itself without manual intervention for positioning and alignment

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical application with an automated system combining optical recognition, computational algorithms, and precision positioning mechanisms to apply rubber elements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If manual application is used, then adaptability to different shapes is maintained, but manufacturing precision deteriorates due to difficulty in distinguishing small elements

Engineering Contradiction:

Improveplacement accuracyVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The optical recognition system captures images of the die-cutter and rubber elements, processes them through algorithms to identify precise locations and orientations, and uses this feedback information to guide the positioning and application of each rubber element with high accuracy

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes the state of information about rubber elements from visual perception to digital data through optical recognition, allowing precise measurement and positioning parameters to be determined and applied automatically

Inventive Principle:

Principle #35Parameter changes

3Loss of time

If manual application is used, then device complexity is low, but loss of time increases due to time-consuming processes

Engineering Contradiction:

Improveapplication timeVSAvoidsystem complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The optical recognition system serves multiple functions: identifying rubber element positions, determining die-cutter features, guiding positioning, and verifying application, thereby reducing total process time despite increased device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12521904B2Apparatus and method for applying in an automatic way foam elements on a die cutter

Publication Date: 2026.01.13 PROFORM

AI summary

An apparatus and a method for automatically applying, without the intervention of an operator, rubber elements on a die-cutter during the manufacturing step thereof. The apparatus comprises a manipulator, preferably a robotic arm, and a needle gripper. The gripper withdraws the water jet pre-cut rubber elements from a sheet with double-sided adhesive tape, and places them one by one at the point provided for by the working program.