Embossing Device Synchronized Rolls Can Barrel Positioning
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Solution Overview
Problem
Existing embossing technologies face challenges in achieving precise positioning accuracy and productivity due to variations in embossing position during the engagement of can barrels with inner and outer rolls, limiting the ability to produce designs with non-shaped sections and multiple embossed areas, such as double-embossed surface cans.
Innovation Solution
An embossing device with an embossing turret equipped with synchronized inner and outer rolls, a holding mechanism for rotational control, a sensor for match mark detection, an encoder for rotational positioning, and a controller to maintain the can barrel's rotation at the same speed as the rolls, allowing for precise positioning and embossing without stopping the can barrel's rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the can barrel is stopped and then engaged with the inner and outer rolls for embossing, then the embossing process can be initiated, but large variations in embossing position occur due to the instant rotation of the stopped can barrel
Solution Approach 1:
The patent transitions from a static engagement method (stopped can barrel) to a dynamic engagement method where the can barrel rotates at the same circumferential speed as the inner and outer rolls. This dynamic synchronization eliminates the instant rotation problem and maintains consistent embossing position accuracy throughout the engagement process.
Solution Approach 2:
The patent employs sensors to detect the position of positioning marks on the can barrel and provides feedback to the control system. This feedback mechanism allows real-time monitoring and adjustment of the can barrel's rotational speed to match the rolls' speed, ensuring precise embossing position control during the embossing process.
2Manufacturing precision
If the can barrel rotation speed is manually adjusted for positioning accuracy, then embossing alignment with the design improves, but the adjustment time increases significantly
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect positioning marks and electronically controls the can barrel's rotational speed. This substitution eliminates time-consuming manual adjustments while maintaining or improving positioning accuracy through automated feedback control.
Solution Approach 2:
The system performs self-positioning by automatically detecting the positioning mark on the can barrel and adjusting the rotation speed to match the rolls' speed. This self-service mechanism eliminates the need for external manual intervention, reducing adjustment time while ensuring accurate embossing alignment.
3Productivity
If the can barrel is held rotatably during embossing engagement, then the embossing process can proceed, but the instant rotation causes significant deviation from the design position
Solution Approach 1:
The patent maintains the dynamic rotation of the can barrel during embossing engagement but controls it to rotate at the same circumferential speed as the inner and outer rolls. This controlled dynamic state allows continuous embossing processing while preventing position deviation, as the synchronized speeds ensure consistent relative positioning between the can barrel and embossing tools.
Solution Approach 2:
The sensor-based feedback system continuously monitors the can barrel's rotational position and speed, providing real-time data to the control system. This feedback enables automatic adjustments to maintain the can barrel's speed matching the rolls' speed, ensuring position consistency with the design throughout the continuous embossing process.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
To provide an embossing device, an embossing method and an embossed can which are capable of conducting embossing having a non-shaped section and an arbitral number of embossed areas, and are capable of improving quality or productivity. An embossed can 10 is a double-embossed surface can in which on a can barrel 101 a first pattern 104 is printed; a first concave part 105 is formed in the state that it is so positioned as to almost conform to the first pattern 104; a second pattern 106 is printed at a position which is distant in the circumferential direction with the non-shaped section therebetween; and a second concave portion 107 is formed in the state that it is so positioned as to almost conform to the second pattern 106.