Series Print Engines with Optical Alignment for Web Substrate
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Solution Overview
Problem
Synchronous operation of multiple print engines in web presses reduces efficiency due to hardware and software synchronization requirements, leading to inefficiencies in advancing and aligning the web substrate for simultaneous printing.
Innovation Solution
A printing device with two print engines operating in series, where the first engine prints an image and leaves a blank area, and the second engine prints on that area in simplex, using an optical sensor for alignment and a buffer to maintain constant tension, allowing each engine to operate independently of the other's speed and phase, with control circuitry for stall and null printing cycles to synchronize operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple print engines operate synchronously in web presses, then printing capacity is increased, but hardware and software synchronization requirements reduce efficiency
Solution Approach 1:
The printing system is divided into multiple independent print engines that operate separately on different portions of the web substrate. Each engine handles its own printing operations without requiring complex synchronization with others, as they work on segregated areas of the continuous substrate.
Solution Approach 2:
A buffer system is introduced as an intermediary between print engines to decouple their operations. The buffer stores intermediate printed material, allowing engines to operate at different speeds and phases without direct synchronization requirements, while maintaining overall system productivity.
2Speed
If web substrate is continuously fed through print engines, then printing speed is increased, but alignment and tension control become more difficult
Solution Approach 1:
Optical sensors are implemented to continuously detect alignment indicators on the web substrate and provide feedback to the control system. This enables real-time monitoring and adjustment of substrate position, maintaining precise alignment despite high-speed continuous feeding through the print engines.
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
This configuration enables increased productivity by allowing each print engine to print independently, maintaining alignment and tension, resulting in faster and more reliable printing with reduced waste, capable of printing at least double the rate of a single engine system.
Implementation Method 1
an optical sensor to identify a number of alignment indicators on the web substrate
Data Source
AI summary
A printing device may include a first print engine to print a first image in a first area of a web substrate and leave blank a second area of the web substrate, a second print engine in series with the first print engine to print a second image on the second area of the web substrate in simplex. The printing device may also include an optical sensor to identify a number of alignment indicators on the web substrate, and a controller to engage the second print engine with the web substrate based on the identification of the alignment indicators by the optical sensor.