Embossing Roller Phase Control via Feedback Correction
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Solution Overview
Problem
The embossed sheet forming apparatus faces challenges in maintaining a stable rotary phase difference between embossing rollers, leading to cyclic embossing phase deviations on the front and rear surfaces of the embossed sheet, making it difficult to achieve high-precision embossing within tolerance.
Innovation Solution
The apparatus incorporates first and second embossing rollers with rotational origin position detecting means, rotary phase difference computing means, and correction-amount computing means to detect and correct the rotary phase difference, ensuring a stable rotary speed ratio between the rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the embossed sheet forming apparatus is continuously operated, then productivity is maintained, but the rotary phase difference between embossing rollers fluctuates causing embossing phase deviation
Solution Approach 1:
The patent implements a feedback control system that continuously monitors the rotary phase difference between embossing rollers and dynamically adjusts their rotational speeds. The control unit receives signals from rotational position detectors, computes phase differences, and modifies roller speeds to maintain precise embossing phase alignment throughout continuous operation, thereby resolving the contradiction between sustained productivity and embossing precision.
Solution Approach 2:
The patent introduces dynamic speed adjustment capability to the embossing rollers, allowing their rotational speeds to be continuously modified based on real-time phase difference measurements. This dynamic control enables the system to compensate for speed fluctuations and maintain optimal embossing phase relationships during continuous operation, transforming a static speed system into an adaptive one that preserves precision under varying operational conditions.
2Device complexity
If the rotary phase difference is not corrected, then device complexity is reduced, but cyclic embossing phase deviation occurs along the roller axis direction
Solution Approach 1:
The patent employs rotational position detectors to continuously monitor the phase difference between embossing rollers and feeds this information back to the control unit. The control unit processes this feedback signal, computes the necessary speed adjustments, and implements corrections to maintain zero phase deviation, thereby achieving high precision without requiring overly complex mechanical adjustment mechanisms.
Solution Approach 2:
The patent replaces complex mechanical phase alignment mechanisms with an electronic control system that uses rotational position detectors, microprocessors, and speed control circuits. This substitution of mechanical adjustment systems with electronic sensing and control enables precise phase difference correction while keeping the overall device structure relatively simple and maintainable.
Data Source
AI summary
An embossed sheet forming apparatus has phase controlling means (33, 34) axially shifting a second embossing roller 11, a front embossed profile detector 74 for detecting an embossed profile on a front surface of a both-sided embossed sheet 100, a rear embossed profile detector 75 for detecting an embossed profile on the rear surface, both surfaces phase difference computing means 80 comparing a detection signal from the front embossed profile detector 74 and a detection signal from the rear embossed profile detector 75 for calculating an embossing phase difference in a sheet width direction between the embossed profiles on the both surfaces, and phase adjustment control processing means 77 inputting a phase difference signal representing the embossing phase difference from the both surfaces phase difference computing means 80 for outputting a command to the phase controlling means (33, 34) to cancel a deviation of the phase difference.