Layer Positioning Module with Real-Time Deviation Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing value or security documents face challenges in achieving high positioning accuracy and reducing production time, particularly in ensuring individual layers are correctly positioned relative to each other when forming composite layers, leading to inefficiencies and increased waste.
Innovation Solution
A device and method that utilize a positioning module within a production plant, incorporating a transport device and position detection systems to accurately determine and correct the spatial position of individual layers during transport, enabling precise alignment and positioning of layers along a desired trajectory, with the ability to handle layers of different formats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional transport methods are used to move individual layers, then the production time is reduced, but the positioning accuracy deteriorates
Solution Approach 1:
The system employs position detection devices that continuously monitor the actual position of individual layers during transport and feed this information back to the control system. The control system then adjusts the transport device's motion in real-time to correct deviations from the target trajectory, achieving high positioning accuracy without sacrificing transport speed
Solution Approach 2:
The transport device is designed with dynamic control capabilities, allowing it to adjust its motion parameters (speed, position, trajectory) in real-time based on detected layer positions. This dynamic adaptation enables the system to maintain high positioning accuracy even during fast transport operations
2Manufacturing precision
If high positioning accuracy is achieved through conventional methods, then the positioning precision is improved, but the production time increases
Solution Approach 1:
The position detection and correction processes occur continuously during the transport of individual layers, rather than requiring separate positioning steps. This continuous action allows the system to achieve precise layer alignment while maintaining uninterrupted production flow, thus preserving high productivity
Solution Approach 2:
The system detects and begins correcting position deviations during the transport phase itself, rather than waiting until the layer reaches its destination. This preliminary correction action ensures high alignment precision is achieved proactively, preventing the need for time-consuming post-positioning adjustments
3Manufacturing precision
If the positioning system is simplified to reduce complexity, then the device complexity is reduced, but the positioning accuracy deteriorates
Solution Approach 1:
The transport device is designed to perform multiple functions: it transports individual layers, detects their positions, and executes correction movements all in one integrated system. This multi-functionality reduces the need for separate positioning apparatus, maintaining high positioning accuracy while avoiding excessive system complexity
Solution Approach 2:
The position detection devices and control systems are integrated directly into the transport device structure, combining what could be separate complex subsystems into a unified positioning system. This merging maintains the necessary positioning accuracy while reducing overall device complexity through integration
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 allows for rapid and spatially accurate positioning of individual layers, minimizing deviations to less than 1/10 mm, thereby reducing production time and waste while enabling the production of composite layers with different formats.
Implementation Method 1
a suction device for separating individual layers from a stack or roll
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method and a device for positioning at least one individual layer (3a, 3b) of a value or security document, wherein the device (10a, 10b) comprises at least one transport device (11a, 11b) for transporting the at least one individual layer (3a, 3b) out of a starting spatial position (16a, 16b, 18a, 18b) into a final spatial position (17a, 17b, 19a, 19b), wherein the device (10a, 10b) comprises at least one position detecting device (20a, 20b) for detecting the actual starting spatial position and/or at least one actual transport spatial position of the at least one individual layer (3a, 3b), wherein the device (10a, 10b) comprises at least one evaluation and control device (22a, 22b), wherein a deviation of the actual starting spatial position from a setpoint starting spatial position and/or a deviation of the at least one actual transport spatial position from a corresponding setpoint transport spatial position can be determined by means of the evaluation and control device (22a, 22b), and the at least one transport device (11a, 11b) can be controlled in such a way that the deviation of the actual starting spatial position from the setpoint starting spatial position and/or the deviation of the actual transport spatial position from the setpoint transport spatial position are/is reduced, and to a method and a device for providing an individual layer composite (2). A slide (13a) can move in translation x-y-z and in rotation, can have a vacuum gripper device (15a) and can comprise sensors (position detecting device (20a, 20b)).