Digital Printing System Linear Indexing for Container Speed
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Solution Overview
Problem
Current digital printing systems for containers, especially plastic and glass, face challenges in achieving high-speed, flexible, and high-throughput printing while optimizing print head utilization and reducing energy consumption.
Innovation Solution
A digital printing system with independently controlled lightweight container carriers that can index sets of containers through a modular and flexible track, allowing for simultaneous processing at multiple locations and reducing the mass and energy required for movement, thereby enhancing print head utilization and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional rotary print systems are used to achieve high-speed container printing, then printing speed is improved, but energy consumption and mass required for movement increase significantly
Solution Approach 1:
The system divides the printing process into multiple independent print heads (e.g., four print heads) that operate simultaneously on different containers or different surfaces. This segmentation allows the system to maintain high printing speed while each individual print head uses less energy, as they work in parallel rather than one large rotary system consuming all the energy sequentially.
Solution Approach 2:
The system transitions from a static rotary indexing mechanism to a dynamic linear indexing system where containers are moved continuously through the printing zone. This dynamic approach allows for more efficient energy utilization as the system can adjust movement speed and positioning dynamically, reducing the peak power requirements compared to accelerating and decelerating heavy rotary mechanisms.
2Productivity
If traditional rotary print systems are used for container indexing, then printing throughput is achieved, but indexing time and device complexity increase
Solution Approach 1:
The indexing system is segmented into multiple independent linear actuators that can move containers through the printing zone simultaneously. This allows multiple containers to be indexed in parallel, reducing the total indexing time required to maintain high printing throughput without the mechanical complexity of a single large rotary indexer.
Solution Approach 2:
The system replaces traditional heavy mechanical rotary indexing mechanisms with lighter linear positioning systems that use fewer moving parts and require less time to index containers. This substitution reduces both the mechanical complexity and the time required for the indexing operation while maintaining productivity.
3Adaptability or versatility
If conventional printing systems are used, then basic printing functionality is provided, but print head utilization and flexibility are limited
Solution Approach 1:
The system employs dynamically controllable print heads that can be independently activated or deactivated based on the printing requirements. This allows the system to adapt to different container types, sizes, and printing patterns by selectively engaging only the necessary print heads, increasing flexibility without proportionally increasing overall system complexity.
Solution Approach 2:
The printing system is designed with universal print heads that can handle multiple container types and configurations. The same print head assembly can print on different container surfaces (sides, bottoms, necks) by adjusting positioning and orientation, providing multi-functionality that increases adaptability without requiring separate specialized equipment for each function.
Data Source
AI summary
A digital printing system includes a track and a plurality of print heads, wherein the system is configured to index a plurality of containers to or through a plurality of process locations. In embodiments, the track is configured to convey a plurality of containers to or through the plurality of process locations, and the plurality of print heads are configured for digital printing on the plurality of containers.