Printing Roller Replacement Device for Flexographic Presses

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Solution Overview

Problem

The existing printing processes for in-line flexographic rotary machines face inefficiencies due to lengthy 'job-change' times and significant material waste during the replacement of printing rollers, which interrupts the printing process and results in waste of the print medium.

Innovation Solution

A device comprising a working station, a holding station, and a removal station with movement means, such as pivoted rods and sliding tracks, allows for the seamless replacement of printing rollers without stopping the machine, enabling continuous operation and minimizing material waste by facilitating the gravity-assisted movement of rollers between stations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If printing rollers are replaced manually by stopping the machine, then the replacement process is simple and reliable, but the job-change time increases and material waste occurs

Engineering Contradiction:

Improvereliability of roller replacementVSAvoidjob-change time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The printing unit is divided into multiple independent printing stations, each with its own roller replacement capability. This segmentation allows one station to undergo roller replacement while other stations continue printing, thereby reducing overall job-change time without compromising the reliability of the replacement process at each individual station.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A new printing roller is pre-positioned in a ready position adjacent to the working printing roller before replacement is needed. When replacement is required, the new roller is already in place and can be swapped immediately, eliminating the time-consuming process of fetching and preparing a new roller, thus reducing job-change time while maintaining reliable replacement through proper positioning.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If printing rollers are replaced by stopping the machine, then the replacement process is straightforward, but material waste increases due to interrupted printing

Engineering Contradiction:

Improveease of roller replacementVSAvoidmaterial waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The printing process maintains continuity by allowing other printing stations to continue operating while one station undergoes roller replacement. The movable support structure enables the replacement operation to be performed without stopping the entire printing press, thereby eliminating material waste associated with interrupted printing while keeping the replacement process simple and straightforward.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

A movable support structure acts as an intermediary mechanism between the old and new printing rollers. This intermediary structure facilitates the transfer and replacement of rollers without requiring the machine to stop, thus preventing material waste while maintaining the ease of replacement through a simple mechanical interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a fixed roller replacement system is used, then the system is simple and reliable, but it cannot be applied to different printing methods

Engineering Contradiction:

Improvereliability of replacement systemVSAvoidapplicability to different printing methods

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The support structure is designed to be movable rather than fixed, allowing it to adapt to different printing methods and roller configurations. The movable support can be repositioned and adjusted to accommodate various printing station layouts and roller types, thereby maintaining system reliability through consistent replacement mechanics while achieving versatility across different printing methods.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The roller replacement system is designed with universal characteristics that allow it to be applied to different printing methods and machine configurations. The movable support structure and replacement mechanism can accommodate various roller sizes, shapes, and mounting methods, making the system versatile while maintaining reliable operation across different printing applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces 'job-change' times and material waste, allowing for efficient roller replacement without disrupting the printing process, maintaining print register and enabling flexible, reliable, and cost-effective operation across different printing methods.

Implementation Method 1

facilitating the gravity-assisted movement of rollers between stations

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentEP3010717B1Device and method for replacing the printing rollers of a printing unit, particularly for in-line flexographic rotary machines

Publication Date: 2017.02.22 BOBST FIRENZE

AI summary

A device (1) for replacing the printing rollers of a printing unit (2), particularly for in-line flexographic rotary machines, which comprises: - a work station (5) for a first, working printing roller (13), - a holding station (3, 7) for a second printing roller (11), - a removal station (7, 3) for a printing roller (11, 13) to be removed, - movement means (9), for the movement of the first printing roller (13) from the work station (5) to the removal station (7, 3) and for the movement of the second printing roller (11) from the holding station (3, 7) to the work station (5).