Thermoforming Packaging Machine Print Mark Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thermoforming packaging machines face challenges in precisely aligning the formation of lower and lid film webs during the sealing process, especially when producing geometric shapes like spheres or egg-shaped packaging, where congruent positioning of sealing edges is crucial.
Innovation Solution
A thermoforming packaging machine equipped with detection devices that monitor print marks on both films, allowing the controller to adjust the film feed and forming stations to ensure precise alignment and positioning of the lower and lid film webs in the sealing station, using cameras and actuators to regulate the film transport and stretching for accurate placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thermoforming packaging machine forms both lower and lid film webs with printing and print marks, then the packaging can be produced with decorative printing, but it becomes particularly difficult to align the forming of both film webs precisely in the sealing station
Solution Approach 1:
The patent employs detection devices (print mark sensors) that detect the position of print marks on both lower and lid film webs. The controller receives signals from these sensors and uses feedback to dynamically adjust the positioning of forming stations and sealing station, ensuring precise alignment despite variations in film transport. This closed-loop control system continuously monitors and corrects alignment, resolving the contradiction between achieving high precision and managing system complexity.
Solution Approach 2:
The patent replaces purely mechanical alignment systems with an automated control system that uses optical detection (print mark sensors) and electronic control. Instead of relying solely on mechanical precision of fixed stations, the system uses sensors to detect print mark positions and electronically controls the positioning of forming and sealing stations, substituting mechanical rigidity with flexible electronic adjustment capability.
2Measurement precision
If the position of print marks is checked after each feed step and the roller guide is changed using a dancer, then the print mark position can be corrected, but this adds complexity to the film transport system
Solution Approach 1:
The patent uses print mark sensors positioned to detect print marks at critical locations (before forming stations and at the sealing station). The controller receives feedback from these sensors about actual print mark positions and automatically adjusts the positioning of forming and sealing stations accordingly. This feedback mechanism enables precise print mark positioning without requiring complex mechanical transport adjustments.
Solution Approach 2:
The patent makes the forming stations and sealing station motor-adjustable, allowing their positions to be dynamically changed based on detected print mark positions. This dynamic positioning capability replaces static mechanical alignment with flexible, controllable adjustment, enabling the system to adapt to variations in film transport while maintaining precision.
3Manufacturing precision
If the forming stations are motor-adjustable to position according to print marks, then alignment precision is improved, but the device complexity increases due to additional motors and control mechanisms
Solution Approach 1:
The patent replaces complex mechanical linkage systems with motorized adjustment mechanisms controlled by an electronic controller. The forming stations and sealing station are equipped with motors that can be precisely controlled based on feedback from print mark sensors, substituting mechanical complexity with electronic control precision.
Solution Approach 2:
The motor-adjustable stations are controlled based on feedback from print mark detection devices. The controller receives position information from sensors and automatically adjusts the motor positions to achieve precise alignment, creating a closed-loop system that maintains precision while using manageable complexity through intelligent control.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a thermoforming packaging machine (1) with a control unit (22), a first forming station (5) for forming a recess (8) in a bottom film (4), and a second motor-adjustable forming station (18) for forming a lid (24) in a top film (10). A first detection device (16) detects the marking (4a) of the bottom film (4) in order to control a film feed step of the recess (8) associated with this marking (4a) into the sealing station (9).