Embossing Tool Synchronization via Piezo Actuator
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Solution Overview
Problem
Existing embossing devices fail to reliably prevent component damage due to deviations in synchronous operation between male and female molds, leading to potential tool damage during the embossing process.
Innovation Solution
The method involves electronically synchronizing the motors driving the male and female molds and using angular position sensors to monitor deviations, with an actuator automatically moving one tool away from the other to prevent damage when impermissible deviations occur, utilizing a piezo actuator for rapid reaction and ensuring the male mold disengages from the female mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electronic synchronization of motors is used, then operational flexibility is improved, but reliability deteriorates due to undetected deviations causing component damage
Solution Approach 1:
The patent implements a feedback mechanism by monitoring the angular positions of both motors continuously and comparing them to detect synchronous deviations. When a deviation exceeds a predetermined threshold, the system automatically triggers a protective response to disengage the tools, thereby preventing component damage while maintaining electronic synchronization flexibility.
2Reliability
If mechanical synchronization via gear connection is used, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent replaces the mechanical gear connection synchronization system with an electronic synchronization system using independently controlled motors. This substitution reduces mechanical complexity while maintaining synchronization reliability through electronic control and monitoring mechanisms that detect and respond to deviations.
3Device complexity
If no monitoring system is used, then device complexity is reduced, but harmful factors increase due to undetected deviations
Solution Approach 1:
The patent implements preliminary protective action by continuously monitoring motor synchronization before damage can occur. The system is prepared in advance with predetermined deviation thresholds and automatic disengagement mechanisms, so when a deviation is detected, the protective action is immediately triggered to prevent component damage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reliably detects deviations and initiates protective measures to prevent component damage, ensuring continuous operation and extending the lifespan of embossing tools by quickly disengaging the molds when excessive asynchronicity is detected.
Implementation Method 1
the actuator is a piezo actuator. This is advantageous with regard to a quasi-sudden reaction to the occurrence of the impermissibly large deviation. Using the piezo actuator, one tool can be moved away from the other tool with extremely high reaction speed
Implementation Method 2
synchronous operation of the motors is monitored with regard to deviations that occur by means of at least one angular position sensor
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The method involves providing an embossing tool in form of a male mold (1), where the tool cooperates with another embossing tool in form of a die (3). The tools are rotatively driven by two motors (6, 8), respectively. The motors electronically synchronized to each other, where synchronous running of the motors is monitored with respect to arising deviations by angle position generators (9, 10). One of the tools is automatically adjusted by an actuator (11) i.e. piezo-actuator, during occurrence of an unallowable large deviation in synchronous running of the motors. Independent claims are also included for the following: (1) an embossing machine (2) a folding box sticking machine.