Sensor-Integrated Printing Cylinder for Real-Time Error Detection
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Solution Overview
Problem
Existing printing technologies lack a structure for detecting errors during printing, leading to increased production costs and time due to the need for sending printing cylinders to manufacturers for diagnosis when quality issues arise.
Innovation Solution
A printing cylinder assembly equipped with sensors for measuring acceleration, speed, and temperature, a communication interface, a control unit, and a power supply, allowing for real-time error detection and analysis of balance disruptions without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a printing cylinder assembly is disassembled for cleaning or maintenance, then the internal components can be accessed, but ink or moisture remains trapped in the internal components causing contamination and damage
Solution Approach 1:
The patent extracts the internal components (printing plate, blanket, ink rollers) from the printing cylinder assembly by providing removable access paths. These components can be taken out for cleaning and maintenance, and the extraction is designed to allow complete removal rather than partial access, thereby preventing trapped ink contamination while maintaining component availability for repair.
2Reliability
If seals are used to prevent ink leakage, then ink containment is improved, but moisture trapped during assembly causes swelling and seal failure
Solution Approach 1:
The patent applies preliminary action by providing dedicated drainage channels and ventilation pathways that are pre-configured to allow moisture escape before sealing is finalized. The assembly process is designed to enable complete drying of internal components before final seal engagement, preventing moisture-trapping that would cause swelling and subsequent seal failure.
Solution Approach 2:
The patent introduces intermediary structures such as drainage channels, ventilation pathways, and removable access components that mediate between the internal cavity and external environment. These intermediaries allow controlled moisture evacuation and air circulation during assembly, preventing moisture accumulation that would compromise seal integrity while maintaining ink containment during operation.
3Reliability
If the printing cylinder assembly is sealed to prevent ink leakage, then ink containment is improved, but cleaning and maintenance become difficult
Solution Approach 1:
The patent segments the printing cylinder assembly into distinct modular components (printing plate, blanket, ink rollers, support structure) that can be independently accessed and removed. This segmentation allows the assembly to maintain sealed integrity during operation for ink containment, while enabling complete disassembly for cleaning and maintenance by removing individual components through provided access paths.
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
Enables on-site detection and analysis of printing errors, reducing downtime and costs by providing real-time data for balance adjustments and predictive maintenance.
Implementation Method 1
at least one sensor (3) which is suitable for being placed in the said cavity (22)... adapted to detect existing and/or developing errors during printing
Implementation Method 2
The printing cylinder rotates around an axis, and as a result of this rotational movement, receives ink from a reservoir
Implementation Method 3
parameters such as changes in ambient temperature... may cause the balance to be disrupted
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a printing cylinder assembly (1) for detecting existing and/or developing errors during printing comprising at least one printing cylinder (2) which is suitable for printing on a material, and has at least one cylindrical body (21), at least one shaft (23) forming a rotational axis for the body (21), and characterized by the printing cylinder (2) which has at least one cavity (22) extending from the surface of the body (21) towards its interior volume, at least one sensor (3) which is suitable for being placed in the said cavity (22), at least one communication interface (4) which is suitable for communicating with an external device, at least one control unit (5) which is adapted to receive data from the sensor (3), and transfer these data to an external device via the communication interface directly and/or by processing them, and at least one power supply (6) which is for supplying the power needed by the sensor (3), the communication interface (4) and/or the control unit (5).