Rotary Embossing Device Segmented Patrix Synchronization
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Solution Overview
Problem
Existing rotary embossing devices face challenges in achieving precise synchronization and adaptability to product size for embossing Braille on folding box blanks, leading to reduced production output and embossing quality.
Innovation Solution
A rotary embossing device with two rotating embossing tools, where the embossing segment is designed to match the product's dimensions, allowing for precise synchronization and easy adaptation, using a patrix and stencil with interchangeable segments and a common drive system for efficient embossing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rotary embossing tools are synchronized using a common drive system, then production output is improved, but synchronization precision deteriorates due to mass moment of inertia
Solution Approach 1:
The patrix is divided into multiple independent embossing segments that can be selectively positioned. Each segment can be independently adjusted along the circumferential direction, allowing precise synchronization with the folding box blank without requiring the entire patrix to be perfectly synchronized. This segmentation enables the system to maintain high production output while achieving the required embossing precision.
2Manufacturing precision
If rotary embossing devices operate in start/stop mode for synchronization, then embossing precision is improved, but production output deteriorates
Solution Approach 1:
The embossing segments are designed to be dynamically adjustable along the circumferential direction of the patrix. This dynamic positioning capability allows the segments to be precisely aligned with the folding box blank during continuous operation, eliminating the need for start/stop cycles while maintaining embossing precision.
3Device complexity
If rotary embossing devices use fixed embossing tools, then device complexity is reduced, but adaptability to different product sizes deteriorates
Solution Approach 1:
The patrix is segmented into multiple independent embossing segments that can be selectively positioned and adjusted. This segmentation allows the same device to accommodate different product sizes and distances between products by repositioning only the necessary segments, rather than requiring complete tool changes or complex adjustments of the entire embossing system.
Solution Approach 2:
The embossing segments are designed with adjustable positioning capabilities along the circumferential direction. This dynamic adjustability enables the device to adapt to different product dimensions and spacing requirements while maintaining a relatively simple overall device structure.
4Productivity
If multiple punched sheets are produced with Braille embossing, then production output is improved, but manufacturing cost and complexity increase due to multiple tool sets
Solution Approach 1:
The segmented patrix design enables a single embossing device to function universally for producing Braille on multiple different folding box blanks. By selectively positioning and adjusting the embossing segments, one tool set can accommodate various product types and sizes, eliminating the need for separate tool sets for each punched sheet configuration.
Data Source
Figure 1
Figure 2a~2b
Figure 2c
AI summary
The device (10) has an embossing segment (30) that is raised opposite to a lateral surface of an embossing roller of a male part (11) i.e. roller, where length (X) of the segment along a circumferential direction of the roller corresponds to the extension along a transporting direction (T) of a surface of a printing substrate (2). The embossing segment is provided with an embossed stamp, where the distance between the surface of the embossing segment and a lateral surface of a female part (12) i.e. roller, corresponds approximately to thickness of the substrate during the embossing process.