Direct Printer Ink Refilling Station with Exchangeable Tanks
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Solution Overview
Problem
Existing direct printing machines for containers face inefficiencies in ink supply systems, requiring frequent manual refilling, leading to operator errors, plastic waste, and lack of quality control.
Innovation Solution
A direct printing machine with a centralized refilling station that uses exchangeable refill tanks for automatic ink distribution, allowing for mechanical quality checks and reducing operator intervention, along with a design that minimizes plastic waste through recyclable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual refilling of ink in storage tanks is performed frequently, then the ink supply system can be maintained, but operator time is consumed and operator errors may occur
Solution Approach 1:
The system enables self-service through automatic ink refilling. The pump unit automatically detects when storage tanks need refilling and transfers ink from reserve tanks without operator intervention, making the system serve itself rather than requiring manual refilling operations
Solution Approach 2:
The system performs preliminary action by maintaining reserve tanks that are pre-filled with ink. When storage tanks are depleted, the system automatically refills them from the pre-prepared reserve tanks, eliminating the need for operators to perform refilling actions at the moment of need
2Reliability
If manual refilling is performed frequently, then ink supply continuity is maintained, but plastic waste from plastic containers increases
Solution Approach 1:
The system implements discarding and recovering by using reusable reserve tanks instead of disposable plastic containers. The reserve tanks are refilled and reused multiple times, recovering the container resource and reducing plastic waste while maintaining continuous ink supply
Solution Approach 2:
The reserve tanks serve multiple functions: they store ink for multiple storage tanks, can be refilled from external sources, and automatically supply ink when needed. This multi-functionality reduces the need for multiple single-use plastic containers
3Quantity of substance
If operator refilling is performed, then ink can be supplied to storage tanks, but control over operating errors is lacking
Solution Approach 1:
The system implements feedback through sensors that monitor ink levels in storage tanks and automatically trigger refilling operations when thresholds are reached. This closed-loop feedback eliminates human error in determining when refilling is needed and ensures consistent operational reliability
Solution Approach 2:
The system replaces manual mechanical refilling operations with an automated pump-based system controlled by sensors and a control unit. This substitution eliminates human error in the refilling process while maintaining proper ink quantity in storage tanks
4Extent of automation
If centralized refilling station with exchangeable tanks is implemented, then refilling automation is achieved, but device complexity increases
Solution Approach 1:
The system applies segmentation by dividing the ink storage system into separate storage tanks and reserve tanks, with a modular pump unit that can service multiple tanks. This segmentation allows automation while keeping each component relatively simple and manageable
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
The solution enables efficient, error-free refilling of ink supplies, reducing operator time and plastic waste while ensuring high-quality printing with improved ink circulation and sedimentation prevention.
Implementation Method 1
an automatic pump unit for pumping the printing ink from one of the exchangeable refilling tanks (631) into one of the storage tanks (51)
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Direct printer (1) for printing containers with a multiple-colour direct print, with a transporter (3) for the transport of the containers (2), a plurality of stationary direct printing stations (5W, 5C, 5M, 5Y, 5S, 5K) which are joined to it, with direct printing heads (52) for printing the containers (2) with the multiple-colour direct print, and with an ink supply system for supplying the direct printing stations (5W, 5C, 5M, 5Y, 5S, 5K) with a plurality of printing inks, wherein the ink supply system comprises one supply tank (51) per printing ink, characterized in that the direct printer (1) comprises a refilling station (6) with a plurality of receiving spaces (630) for exchangeable refilling tanks (631), wherein the receiving spaces (630) are configured in each case for automatically transferring printing ink from one of the refilling tanks (631) into one of the supply tanks (51).