Converting Machine Calibration for Printed Image Die-Cut Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Converting machines struggle to accurately align pre-printed images on sheets with die-cutting tools due to unknown printed pattern locations, leading to inconsistent image placement on finished boxes.
Innovation Solution
A calibration system with an image sensor, control unit, and memory to detect and correct deviations in the position of pre-printed images, using transfer drives to adjust the sheet's position along the conveyance path, ensuring consistent image placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a register control system using optical detectors and front leading edge reference is used, then the alignment of sheets is improved, but the position control of printed patterns deteriorates
Solution Approach 1:
The patent replaces the mechanical/optical register control system that uses front leading edge reference with an image recognition system using cameras and software to detect printed pattern positions. This substitution enables direct measurement and control of printed pattern locations rather than relying on mechanical sheet alignment references.
Solution Approach 2:
The patent introduces an intermediary image recognition system that detects the actual position of printed patterns and provides feedback to the control system. This intermediary layer bridges the gap between sheet feeding and printed pattern positioning, enabling precise control of pattern locations despite variations in sheet delivery.
2Stability of the object's composition
If the position of sheets is controlled rather than the position of printed patterns, then the sheet alignment is improved, but the consistency of image placement deteriorates
Solution Approach 1:
The patent implements a feedback control system where cameras capture images of printed patterns, the control unit determines actual positions, calculates deviations from target positions, and adjusts transfer drive speeds accordingly. This closed-loop feedback enables consistent image placement by continuously correcting position errors.
Solution Approach 2:
The patent makes the transfer drives dynamically adjustable by controlling their speeds individually based on real-time image analysis. This dynamic control allows the system to adapt to variations in sheet delivery and actively maintain consistent printed pattern positioning throughout the converting process.
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
Ensures that the printed image is placed at the same position on all boxes by detecting and correcting deviations in real-time, improving the accuracy and consistency of the final product.
Implementation Method 1
an image sensor configured to capture an actual image of an indicia on a sheet passing through the converting machine
Data Source
Figure 1a~1d
Figure 2
Figure 3
AI summary
The present invention relates to a calibration system (30) and a calibration method for a converting machine (20) provided with a die-cutting tool (18') and at least one transfer unit (25) for transporting a sheet (1) along a travel path in a direction of conveyance (D) through the converting machine. The calibration system comprising a first image sensor (33), a memory (36) and a control unit (34). The calibration system is configured to detect an actual position of an indicia (42) on the sheet (1) and compare with a reference position of the indicia (42) stored in the memory (36). A correction program stored in the memory is executed when at least one of the longitudinal displacement (Δxi) and the lateral displacement (Δyi) of the indicia exceeds a predetermined tolerance threshold (Txi, Tyi).