Partially Embossed Blank Production with Sensor-Driven Die Cutting
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Solution Overview
Problem
The precise positioning of embossing in conjunction with exact die cutting of embossed blanks from a continuous web is difficult to achieve, leading to potential misalignment and mutilation of designs during the manufacturing process.
Innovation Solution
A method involving embossing cylinders with a readable marking, a first sensor to trigger a print mark on the web, and a second sensor to control the feeding distance or speed of the web to a stamping device for precise die cutting at a predefined position in register with the embossing, ensuring the embossed design remains fixed on the finished blank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If embossing is performed on continuous web material, then design patterns are created on the blanks, but the embossed design position shifts during die cutting resulting in mutilated designs
Solution Approach 1:
A marking is applied to one of the embossing cylinders before the embossing process. This marking serves as a reference point that is detected by a sensor to trigger the die cutting operation at the precise moment when the embossed design is in the correct position, preventing position shifts and design mutilation.
Solution Approach 2:
A sensor detects the position of the marking on the embossing cylinder and provides feedback signals to control the die cutting timing. This closed-loop feedback system ensures that the die cutting operation is synchronized with the embossing process, maintaining precise design position alignment throughout production.
2Manufacturing precision
If precise positioning of embossing with die cutting is implemented using complex sensing and control systems, then registration accuracy is improved, but device complexity increases
Solution Approach 1:
Instead of using complex sensors to directly measure the position of the embossed design, a simplified marking is copied onto the embossing cylinder. This marking serves as a surrogate reference that is easier to detect and process, reducing the complexity of the sensing and control system while maintaining registration accuracy.
3Manufacturing precision
If the web is fed at variable speeds to accommodate embossing positioning, then registration precision is improved, but production efficiency decreases
Solution Approach 1:
The marking on the embossing cylinder creates periodic reference signals that trigger die cutting operations at regular intervals. This periodic action allows the web to be fed at consistent speeds while maintaining precise positioning, as the timing of die cutting is synchronized with the rotational position of the marking rather than requiring continuous variable speed adjustment.
Data Source
Figure 1
Figure 2A~2C
AI summary
A method for producing partially embossed blanks (20) having an embossed and a non-embossed area is disclosed, said method comprising the steps, providing a continuous web (4) of an embossable material, guiding said web (4) between two embossing cylinders (2, 3), embossing the surface of the web (4) between the two embossing cylinders (2, 3), supplying the embossed web (4) to a stamping device (68) at which the blanks (20) are punched from the web (4), whereby one of the embossing cylinders (2, 3) comprises a marking (30), said marking (30) being readable by a first sensor (35), said first sensor (35) reading the position of the marking (30) and producing a signal, said signal triggers a printing device (40) producing a print mark (50) on the web (4) after the embossing process, identifying the position of the embossing, feeding the embossed and marked web (4), driven by feed rolls (14, 15), to a stamping device (68), said print mark (50) being read by a second sensor (55), said second sensor (55) producing a signal for controlling and adjusting a feeding distance D by which the feed rolls (14, 15) supply the embossed and marked web (4) to the stamping device (68) for punching the partially embossed blanks (20) from the web (4) at a predefined position in register with the partial embossing of the blank 20 A device for conducting said method is also disclosed.