Printing Machine Calibration Using Load Sensors
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Solution Overview
Problem
Current calibration systems for printing machines require lengthy and complex manual operations, involving multiple adjustments and significant manpower to ensure precise positioning of printing units relative to a central drum or roller, which is inefficient and time-consuming.
Innovation Solution
Incorporation of load sensors and position transducers interfaced with a control unit to automate the calibration process, allowing the printing unit to move to a zero position defined by load sensor signals and subsequently using position transducers for precise positioning, reducing manual intervention and simplifying the calibration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration using feeler gauges and multiple actuators is used, then positioning precision can be achieved, but the calibration process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces the manual mechanical calibration system (feeler gauges, manual actuator operation) with an automated sensor-based system. Load sensors detect the contact force between the cliché roller and central roller, while position transducers measure the roller positions. The control unit automatically processes these signals to determine and store calibration positions, eliminating manual intervention and significantly reducing calibration time while maintaining precision.
Solution Approach 2:
The calibration system performs self-measurement and self-adjustment. The load sensors automatically detect when the correct contact force is achieved, and the position transducers automatically record the positions. The control unit autonomously stores these calibration values and retrieves them during operation, allowing the system to calibrate itself without external manual intervention.
2Manufacturing precision
If multiple manual adjustments are performed for each roller, then positioning accuracy is improved, but the complexity and manpower requirements increase
Solution Approach 1:
The patent replaces complex manual adjustment operations with automated sensor detection and control. Load sensors automatically detect the correct contact condition, position transducers automatically measure roller positions, and the control unit automatically stores and retrieves calibration data. This substitution eliminates the need for manual feeler gauge placement and manual actuator operation, reducing both complexity and manpower requirements while maintaining high positioning accuracy.
Solution Approach 2:
The calibration system uses feedback from load sensors and position transducers to automatically determine correct positioning. The load sensor feedback indicates when the correct contact force is achieved, and the position transducer feedback provides the exact position data. The control unit uses this feedback to store calibration values and retrieve them during operation, eliminating the need for complex manual adjustment procedures.
3Ease of manufacture
If manual calibration procedures are used, then initial positioning can be established, but subsequent positioning operations become time-consuming
Solution Approach 1:
The system performs preliminary calibration actions automatically during initial setup. Load sensors and position transducers establish the correct positioning parameters once, and the control unit stores these calibration values. During subsequent operations, the system simply retrieves the pre-stored calibration data and automatically positions the rollers, eliminating the need for repeated manual calibration and significantly improving operation speed.
Solution Approach 2:
The patent replaces time-consuming manual positioning operations with automated retrieval and application of calibration data. The control unit automatically retrieves stored calibration positions and commands the actuators to position the rollers accordingly, eliminating manual feeler gauge placement and manual adjustment during subsequent operations, thereby improving productivity.
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
Enables simpler, more precise, and rapid calibration of printing machines, reducing operational time and manpower requirements while ensuring accurate positioning of printing units, even with varying sleeve thicknesses.
Implementation Method 1
at least one load sensor and at least one position transducer associated with the cliché roller, interfaced with the control unit. Moreover, the control unit can be programmed to perform a calibration of the printing unit with a first step to move the printing unit towards the central roller until reaching a zero position defined on the basis of a signal of said at least one load sensor
Implementation Method 2
at least one position transducer associated with the cliché roller, interfaced with the control unit
Data Source
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AI summary
The printing machine comprises a central roller (3); at least one printing unit (5) with a cliché roller (7) and means (9, 13) for applying ink to the cliché roller. A control unit (50) in also provided, interfaced with at least one actuator (19) to move the printing unit towards the central roller. The printing unit (5) comprises at least one load sensor (41) and at least one position transducer (43) associated with the cliché roller, interfaced with the control unit. This latter is programmed to perform a calibration of the printing unit with a first step to move the printing unit towards the central roller until reaching a zero position defined on the basis of a signal of said at least one load sensor.