Flat Press Gap Control Using Ball Screw and Servomotor
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Solution Overview
Problem
Existing laminating apparatuses lack precise control over the thickness of laminated products, leading to variations that can result in defective products, especially when used for sealing resin films with LED elements, where differences in thickness affect color and temperature, thereby reducing yields.
Innovation Solution
A laminating apparatus incorporating a ball screw, servomotor, gap measuring device, and pressing gap control system in the flat press device to accurately control the stopping position and pressing force of the pressing elements, allowing for precise setting of the gap between pressing elements and adjusting the servomotor's RPM based on measured distances to achieve uniform thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydraulic cylinders or air cylinders are used to move the press block, then the device structure is simple, but the stopping position control precision is insufficient leading to thickness variations
Solution Approach 1:
The patent implements a feedback control system where a scale measures the actual position of the press block during movement, and this position information is fed back to the control unit. The control unit adjusts the servomotor's rotation based on the difference between the target position and actual position, ensuring precise stopping position control and uniform thickness of the laminated product.
Solution Approach 2:
The patent replaces the conventional hydraulic cylinder or air cylinder system with a servomotor-driven ball screw mechanism. This substitution enables precise position control through servo control technology while maintaining the mechanical pressing function, thereby improving thickness control precision without excessive complexity.
2Productivity
If the press block moves quickly to improve productivity, then production efficiency increases, but the thickness uniformity deteriorates due to insufficient control
Solution Approach 1:
The patent employs a servomotor that can dynamically adjust its rotation speed and position based on real-time feedback from the scale. This allows the press block to move quickly when needed while maintaining precise control during the pressing operation, thereby achieving both high productivity and uniform thickness without compromise.
3Adaptability or versatility
If the gap between pressing elements is fixed, then the device structure is simple, but the adaptability to different workpiece thicknesses is poor
Solution Approach 1:
The patent makes the gap between pressing elements dynamically adjustable through the servomotor and ball screw mechanism. The control unit can set different target positions for the press block based on the required workpiece thickness, enabling the system to adapt to various thickness requirements while maintaining precise control through feedback from the scale.
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 solution enables precise control of the thickness of laminated products, reducing variations and improving production efficiency by allowing finer settings of processing conditions, thereby increasing the reproducibility and reducing the number of defective products.
Implementation Method 1
the flat press device includes a ball screw 36 having a screw shaft 36a and supporting the first pressing element 31, a servomotor 35 connected to the screw shaft 36a of the ball screw 36
Implementation Method 2
a vacuum laminating device for applying pressure to the workpiece by sandwiching the workpiece between a pair of pressing elements under a reduced-pressure condition to bring the resin film into intimate contact with a surface of the circuit board
Data Source
AI summary
A laminating apparatus includes workpiece transport units, a vacuum laminating device and a flat press device. The flat press device includes a ball screw having a screw shaft and supporting a first one of a pair of pressing elements, a servomotor connected to the screw shaft of the ball screw, a gap measuring device (linear scale) for measuring a distance between the first pressing element and the second pressing element, and a pressing gap control system for moving the first pressing element to a position in which a predetermined gap is defined between the first pressing element and the second pressing element to stop the first pressing element at that position. The pressing gap control system changes the RPM of the servomotor, based on information on the distance between the first and second pressing elements which is provided from the gap measuring device.