Registered Shaping of Thin-Walled Preforms for Print Alignment
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Solution Overview
Problem
Existing registered shaping machines for deforming thin-walled tubular bodies, such as aluminum alloy preforms, face limitations in alignment accuracy and the extent of deformation, particularly in achieving precise registration of embossed or debossed regions with printed designs, and are restricted by the size and location of the shaping tools.
Innovation Solution
A registered shaping machine with a conveyor system and a tool table that includes a registered shaping tool, sensors for angular orientation determination, and reorientation actuators to achieve precise alignment of the shaping tool with the preforms, allowing for more accurate and extensive deformation over the length of the preform, using interconnected dies for embossing/debossing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional necking machines are used for registered embossing, then production rates are maintained, but alignment accuracy between printing and embossing is poor (within +/- 4 degrees)
Solution Approach 1:
The preform is rotated to a predetermined angular position before the embossing operation, and the embossing tool is pre-aligned at a stationary tool station. This preliminary positioning ensures that when the preform passes through the tool station, the embossing pattern is already in correct registration with the printed design, achieving high alignment accuracy without complex real-time adjustment mechanisms during the embossing process
Solution Approach 2:
The patent replaces the complex mechanical system of rotating the embossing tool with a simpler system that rotates the preform itself. The preform rotation is achieved through the existing conveyor and holder mechanism, while the embossing tool remains stationary. This substitution reduces device complexity by eliminating the need for complex tool rotation mechanisms while maintaining high alignment accuracy
2Ease of operation
If the embossing tool station is positioned upstream of necking tools, then access to container interior is improved, but the extent and location of deformation is limited
Solution Approach 1:
The embossing tool station is designed with universal applicability to perform multiple functions: it can emboss preforms at various positions along the preform length, accommodate different embossing patterns, and work with preforms of different sizes. The stationary tool station configuration allows the same tool to service multiple deformation locations by adjusting the preform position rather than requiring multiple specialized tool stations
3Measurement precision
If controlled rotation of preform is implemented for alignment, then registration accuracy is improved, but production time increases
Solution Approach 1:
The preform rotation to the predetermined angular position is performed in advance, during the conveyor transport phase, before the preform reaches the embossing tool station. This preliminary rotation utilizes the existing conveyor timing and holder rotation mechanisms, so the alignment preparation occurs during normal production flow without adding dedicated alignment time to the embossing cycle
Solution Approach 2:
The system uses the preform's own rotation capability, already present in the necking machine's holder design, to achieve alignment. The holder rotates the preform to the required angular position using the existing rotation mechanism, eliminating the need for separate alignment devices or additional time-consuming alignment operations. The preform essentially aligns itself through the controlled rotation of its holder
Data Source
AI summary
A machine for shaping an initially tubular cylindrical preform 1 to form a non-round shape in registration with printed or similarly applied surface decoration or the like on the preform, comprises: a conveyor (3, FIG. 3) for carrying a series of the preforms; a tool table 6 having a plurality of tool stations 7, 9 between which the preforms are conveyed by indexed motion of the conveyor, the tool table being reciprocable along an axis towards and away from the conveyor, to bring forming tools 11 at the tool stations into and out of operative engagement with the preforms; a registered shaping tool 11 at at least one of the tool stations operatively arranged to deform the preforms to an out-of-round shape; at least one sensor 118, 124, (128, 126, 130, 132) operatively arranged to determine the angular orientation of each preform in a plane normal to the reciprocation axis; at least one reorientation actuator (A1, A2, B1, B2, C, D, E), F1, F2, G operatively arranged to cause relative rotation between each preform and the registered shaping tool, whereby the registered shaping tool and the preforms are brought into a predetermined relative angular orientation about an axis of the preform at the registered shaping tool station; the relative rotation with respect to a given preform taking place during a plurality of reciprocations of the tool table and/or indexing movements of the conveyor. Improved embossing/debossing tools are also disclosed (FIGS. 8a-23).