Register Sensor Module for Plate Placement Error Correction
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Solution Overview
Problem
Current processing machines struggle to correct placement errors of plate-like elements exceeding +/-6 mm without causing machine stoppage, due to high accelerations required for precise alignment, which can lead to vibrations and damage.
Innovation Solution
A register for processing machines equipped with a gripping element, actuator module, front correction sensor module, and front pre-correction sensor module, which detects the passage of the plate-like element's front transverse edge upstream, allowing early activation of the gripping element to avoid excessive accelerations and vibrations, and subsequent correction of placement errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the gripping element is activated late to correct large placement errors (> +/-6 mm), then the alignment precision is improved, but the machine speed decreases due to high accelerations and vibrations
Solution Approach 1:
The patent applies preliminary action by using upstream sensors to detect the front transverse edge of plate-like elements before they reach the gripping element. This early detection allows the control system to pre-calculate and prepare the gripping element's trajectory, enabling smooth acceleration and positioning without excessive vibrations, thus maintaining both high precision and high speed production
2Productivity
If the gripping element is activated early to maintain high speed, then the productivity is improved, but the placement precision deteriorates for elements with large errors
Solution Approach 1:
The system performs preliminary detection of placement errors using upstream sensors before the gripping element activates. The control system calculates the corrected trajectory in advance, allowing the gripping element to be activated early at high speed while still achieving precise placement through pre-computed positioning adjustments
3Manufacturing precision
If additional upstream sensors are added to detect elements earlier, then the placement precision for large errors is improved, but the device complexity increases
Solution Approach 1:
The patent segments the detection function into multiple specialized sensor modules positioned at different upstream locations. Each sensor module has a specific detection zone, allowing the system to track elements at various stages of conveyance. This segmentation enables early detection of placement errors without requiring a single complex omnidirectional sensor system
Solution Approach 2:
The patent introduces intermediary sensor modules that detect the front transverse edge of plate-like elements at upstream positions. These intermediary sensors provide early warning of placement errors, allowing the control system to prepare correction trajectories before the gripping element activates, thus improving precision without directly complicating the gripping mechanism
Data Source
AI summary
A register (20; 60) for a processing machine (1) for processing plate-like elements (10) includes a gripping element (21; 22) for placing the plate-like elements (10) in a gripper bar (31) of a conveyor (30) of a processing machine (1) conveying the plate-like elements (10) in a longitudinal direction, an actuator module (201, 202) to drive the gripping element (21; 22), at least one front correction sensor module (7) configured to measure the front position of register marks (12a) printed on a front section of the plate-like element (10) grasped by the gripping element (21; 22). The register (20; 60) includes at least one front pre-correction sensor module (80), placed upstream of the front correction sensor module (7) in the longitudinal direction, the front pre-correction sensor module (80) is configured: to detect the passage of a front transversel edge of the plate-like element (10) in at least two longitudinally spaced lateral axis of detection (P1, P2), one located in front of the other, and to provide measurements to a computation and control unit (40) of the processing machine (1) that is configured: to control the actuator module (201, 202) in order to move the gripping element (21; 22) toward the gripper bar (31) and to activate the gripping element (21; 22) in order to grasp a plate-like element (10). Also a processing machine for processing plate-like elements includes the register. A method for placing plate-like elements within a processing machine is disclosed.