Registered Shaping of Printed Preforms for Precise Embossing Alignment
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Solution Overview
Problem
Existing registered shaping machines for deforming thin-walled tubular bodies, such as aluminum alloy preforms for containers, face limitations in alignment accuracy, flexibility in deformation location and size, and the ability to apply deformations over the entire length of the preform, particularly when detailed printing and embossing are required.
Innovation Solution
A registered shaping machine with a conveyor system, a tool table with reciprocating tool stations, a registered shaping tool, sensors for angular orientation determination, and reorientation actuators to achieve precise alignment and deformation over the entire length of the preform, allowing for accurate and versatile out-of-round shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional necking machines are used for registered embossing, then production rates are maintained, but alignment accuracy between printing and embossing is limited to within +/â4 degrees
Solution Approach 1:
The patent applies preliminary action by detecting the angular position of the preform using a sensor (such as a coded mark sensor or optical sensor) before the embossing operation. This allows the control system to calculate the required rotation angle in advance and position the embossing tool or preform accurately before deformation begins, achieving alignment accuracy of 3 degrees or better while maintaining production rates.
Solution Approach 2:
The patent implements feedback control by using sensors to detect the actual angular position of the preform, comparing it with the desired position, and automatically adjusting the rotation of the preform or embossing tool. This closed-loop feedback system ensures precise alignment between the printed design and embossing features, resolving the contradiction between high precision and acceptable device complexity.
2Ease of operation
If the embossing tool is positioned upstream of necking tools, then access to container interior is improved, but the axial length of forming tool parts is reduced limiting deformation coverage
Solution Approach 1:
The patent applies dynamics by making the embossing tool axially adjustable along the preform. The tool can be moved to different axial positions to emboss various regions of the preform, including areas far from the open end. This dynamic positioning capability allows the tool to access the container interior effectively while maintaining sufficient axial length coverage for different deformation requirements.
Solution Approach 2:
The patent implements multi-functionality by designing the embossing tool with both rotational adjustment (for angular alignment) and axial adjustment (for position along the preform). This universal tool can perform registered embossing at multiple locations and orientations on the preform, accommodating various design requirements while maintaining good access to the container interior.
3Manufacturing precision
If single-step embossing is used, then process simplicity is maintained, but registration accuracy cannot achieve 3 degrees or better
Solution Approach 1:
The patent applies preliminary action through a two-step embossing process: first, the preform is rotated to the correct angular position using sensor detection and control; second, the embossing operation is performed with high precision. This preliminary positioning step enables registration accuracy of 3 degrees or better while keeping the overall process manageable through automation.
Solution Approach 2:
The patent implements feedback control in the two-step process by continuously monitoring the angular position of the preform during rotation and making real-time adjustments to achieve precise alignment before embossing. This feedback mechanism ensures high registration accuracy while the automated control system manages the increased process complexity efficiently.
4Productivity
If the tool table reciprocates quickly for high production rates, then productivity is improved, but the time available for reorientation and alignment is reduced
Solution Approach 1:
The patent maintains continuity of useful action by integrating the sensor detection, calculation, and reorientation functions into a seamless automated process that occurs during the brief intervals between reciprocations. The control system continuously processes angular position data and adjusts the preform or tool rotation without interrupting the production flow, enabling high production rates with maintained alignment accuracy.
Solution Approach 2:
The patent replaces manual or mechanical alignment methods with an automated control system that uses sensors, calculators, and actuators. This substitution allows rapid reorientation and precise alignment to be achieved in the short time available between reciprocations, maintaining both high productivity and manufacturing precision through electronic control rather than mechanical adjustment.
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 achieves alignment accuracy of 3 degrees or better with a high probability, enabling consistent production of container bodies with registered shaping within lower error tolerances, and allows for a wider range of deformation positions and sizes, improving product quality and manufacturing efficiency.
Implementation Method 1
The orientation of the printing is determined by a sensor which detects at least one mark which is in predetermined register with the printing. The mark may be any mark capable of being sensed automatically by an appropriate sensor. Conveniently, it may be a printed or painted mark applied as part of the printing and therefore inherently consistently in register with it. Such a printed mark is optically sensed, and its position determined and used to control rotation of the or each embossing tool or the corresponding preform
Data Source
AI summary
A machine for shaping an initially tubular cylindrical preform to form a non-round shape in registration with printed or similarly applied surface decoration or the like on the preform, comprises: a conveyor for carrying a series of the preforms; a tool table having a plurality of tool stations 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 at the tool stations into and out of operative engagement with the preforms; a registered shaping tool at at least one of the tool stations operatively arranged to deform the preforms to an out-of-round shape; at least one sensor operatively arranged to determine the angular orientation of each preform in a plane normal to the reciprocation axis; at least one reorientation actuator 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.