Plastic Flooring Registration Pattern Alignment via Servo Synchronization
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Solution Overview
Problem
Conventional plastic flooring technologies face challenges in synchronously conveying the substrate and printing film, leading to misalignment of pressing patterns, which affects the accuracy of formed three-dimensional patterns on the flooring.
Innovation Solution
A registration transferring system integrated with a rolling machine, utilizing sensors and servos to synchronize the delivery and pressing of the substrate, printing layer, and abrasion resistance layer, ensuring accurate alignment and synchronous conveyance to form registration patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional rolling machine with three or six press rollers is used to form three-dimensional patterns, then the substrate and printing film can be pressed to create patterns, but the substrate and printing film cannot be conveyed synchronously, causing misalignment of pressing patterns
Solution Approach 1:
The patent employs a feedback control system where sensors detect the position of the substrate and printing film during conveyance, and the control system adjusts the conveyance speed of each layer to maintain synchronous movement. This feedback mechanism ensures that the substrate, printing film, and abrasion resistance film are conveyed at the same speed, preventing misalignment of pressing patterns while maintaining manufacturing precision.
Solution Approach 2:
The patent replaces the conventional mechanical conveyance system with an independently controlled conveyance system for each layer. Each layer (substrate, printing film, abrasion resistance film) has its own conveyance mechanism with independent speed control, allowing precise synchronization without complex mechanical linkages between layers.
2Manufacturing precision
If synchronous conveyance of substrate and printing film is implemented using sensors and servos, then pattern alignment accuracy is improved, but the device complexity increases
Solution Approach 1:
The control system uses sensors to continuously monitor the position of each layer and employs servo motors to adjust conveyance speeds in real-time. This feedback loop ensures that even with the added complexity of multiple independent conveyance systems, the registration pattern alignment remains precise by automatically compensating for any speed variations.
Solution Approach 2:
The patent uses a unified control system that manages multiple conveyance mechanisms through a single controller. This multi-functional control approach allows the system to coordinate the substrate, printing film, and abrasion resistance film conveyance using the same control logic and interface, reducing operational complexity despite the multiple independent mechanisms.
3Manufacturing precision
If independent conveyance control for each layer is used, then synchronous conveyance and accurate pattern formation are achieved, but the system complexity and cost increase
Solution Approach 1:
The patent divides the conveyance system into separate independent modules for each layer (substrate, printing film, abrasion resistance film). Each module can be manufactured, tested, and maintained independently, which simplifies the overall manufacturing process despite the increased system complexity. The segmented approach allows for easier troubleshooting and replacement of individual components.
Solution Approach 2:
The patent replaces complex mechanical coupling between layers with independent electronic control systems. Each layer's conveyance is controlled by its own servo motor and sensor system, eliminating the need for complex mechanical linkages and reducing the difficulty of manufacturing and maintaining the overall system.
Data Source
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AI summary
Plastic flooring contains: a substrate (11), a printing layer, and an abrasion resistance layer (13) which are delivered into a rolling machine (20) so that the rolling machine (20) presses the substrate (11), the printing layer, and the abrasion resistance layer (13) together. The substrate (11) includes at least one soft film layer (111) and at least one hard film layer (112), the printing layer forms on the substrate (11) and has a convex portion (121) and a concave portion (122), and the abrasion resistance layer (13) forms on the printing layer. The rolling machine (20) includes two delivery rollers (22), a guiding roller (23), and a pattern roller (24). The pattern roller (24) has pressing patterns (241), and the pressing patterns (241) have a depressed part (241) and a raised part (243). When the substrate (11), the printing layer, and the abrasion resistance layer (13) are pressed together, the convex portion (121) corresponds to the depressed part (241) and the concave portion (122) corresponds to the raised part (243) by using the registration transferring system (30).