Pad Printing Machine Automatic Registration via CCD Imaging
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Solution Overview
Problem
Pad printing machines require complex and time-consuming manual adjustments to ensure precise registration of multiple printing stages, necessitating skilled operators for accurate positional alignment during multi-stage printing processes.
Innovation Solution
A pad printing machine with a printing unit carrier and x-y platforms for each printing stage, equipped with image recording and comparison technology using CCD cameras, allows for automatic alignment of printing plates and object carriers relative to fixed reference marks, simplifying the adjustment process and ensuring precise registration of print positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of printing plate zones is used for each printing stage, then positional registration accuracy can be achieved, but the adjustment process becomes complex and time-consuming requiring skilled operators
Solution Approach 1:
The patent applies preliminary action by pre-defining reference marks on the printing plate zones and object carrier that establish predetermined geometric relationships. These reference marks are positioned in advance during plate mounting, eliminating the need for complex real-time manual adjustments. The control unit automatically detects these pre-positioned marks and calculates alignment corrections, thereby simplifying the adjustment process while maintaining high registration accuracy.
2Manufacturing precision
If manual adjustment of printing plate zones is used for each printing stage, then positional registration accuracy can be achieved, but the printing process becomes time-consuming
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated optical-mechanical system. CCD cameras detect the positions of reference marks, and a control unit automatically calculates and executes positioning corrections. This substitution of manual mechanical adjustment with automated detection and control dramatically reduces adjustment time while maintaining or improving registration accuracy, as the system can quickly detect and correct positional deviations without requiring skilled operators to perform time-consuming manual alignments.
3Manufacturing precision
If skilled operators perform manual alignment, then accurate print positioning is achieved, but operator expertise is required increasing operational complexity
Solution Approach 1:
The patent implements self-service by enabling the printing system to automatically perform the alignment function that previously required skilled human operators. The control unit autonomously detects reference marks using CCD cameras, calculates positional deviations, and executes correction movements of the printing plate zones and object carrier. This automation transfers the alignment intelligence from human operators to the machine system itself, eliminating the need for specialized operator skills while maintaining high positioning accuracy, thereby significantly improving ease of operation.
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 quick and accurate alignment of multiple printing stages, reducing the need for manual expertise and streamlining the printing process, allowing for efficient polychrome printing with perfect register alignment.
Implementation Method 1
After an image has been produced at least of parts of the printing plate zone (10) of a second printing stage, said image is compared with reference data. This comparison determines the position of the printing plate zone (10) relative to a setpoint position given by the reference data.
Data Source
AI summary
A pad printing machine (1) to print an object (8) in at least two stages, said machine comprising at least one printing pad (6) to print said object and at least two printing plate zones (10) within each of which a printing plate (14) may be moved into the desired position, the pad printing machine furthermore comprising an image recorder (44) generating an image of at least a partial area of at least one printing plate zone (10), and a comparator (46) to compare the image generated by said recorder (44) with reference data.