Sheet Panel Alignment Device for Print Pattern Registration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bag making apparatuses face challenges in preventing misalignment among the first continuous sheet panel, the second continuous sheet panel, and additional components like side gussets, which affects the alignment of print patterns and the overall appearance of the bags.
Innovation Solution
An alignment device is introduced that includes feed devices for intermittent feeding of the sheet panels, guide rollers for superposition, and fixing devices for aligning and fixing the additional components. Sensors detect detection points on the sheet panels to adjust the feed and tension, ensuring alignment at predetermined design positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple continuous sheet panels are supplied from respective different rolls, then the bag making process can proceed continuously, but misalignment of print patterns occurs due to displacement and print pitch differences
Solution Approach 1:
The patent applies preliminary action by predetermining design positions on sheet panels at the print pitch before the actual bag making process. These predetermined positions serve as reference markers that guide subsequent alignment operations, ensuring that print patterns from multiple rolls can be accurately matched during continuous production without requiring real-time adjustment.
Solution Approach 2:
The patent implements feedback mechanisms through detection points positioned on the sheet panels that monitor the actual positions of print patterns during production. This feedback information is used to detect deviations from the predetermined design positions and trigger corrective actions, such as adjusting feed amounts or tension, to maintain print pattern alignment throughout continuous operation.
2Ease of manufacture
If sheet panels are fed intermittently to allow fixing operations, then additional components can be properly incorporated, but misalignment may occur during feed transitions
Solution Approach 1:
The patent applies periodic action by implementing intermittent feeding cycles that alternate between feeding phases and pause phases. During each cycle, the feed devices intermittently advance the sheet panels to predetermined positions, then pause to allow fixing operations for incorporating additional components like side gussets. This periodic rhythm ensures that alignment is maintained during transitions while enabling necessary manufacturing operations.
3Manufacturing precision
If tension is applied to sheet panels to prevent sagging and maintain position, then alignment is improved, but excessive tension can cause displacement or damage
Solution Approach 1:
The patent applies dynamics by making the tension applied to sheet panels adjustable rather than fixed. The tension can be dynamically modified based on real-time detection of sheet panel positions and alignment status. This allows the system to apply sufficient tension to prevent sagging and maintain alignment during feeding, while reducing tension when not needed to prevent displacement or damage to the sheet panels and printed patterns.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
Misalignment among a first sheet panel, a second sheet panel, and an additional component is prevented. Both of the first and second sheet panels 1 and 2 have print patterns that repeat at a print pitch and each include a detection point therein. Design positions are predetermined on each of the first and second panels 1 and 2 and repeat at the print pitch. A first feed device 10 adjusts an intermittent feed amount thereof based on output of a first sensor 31 such that a design position of the first panel 1 is aligned with a first fixing position 28 during every pause phase of an intermittent feed cycle. A second feed device 13 adjusts tension of the second panel 2 and an intermittent feed amount of a feed unit 14 based on output of at least one second sensor 33 such that a design position of the second panel 2 is aligned with a second fixing position 30 during every pause phase of an intermittent feed cycle. A third feed device 24 adjusts an intermittent feed amount thereof based on output of a third sensor 34 such that the design position of the first panel 1 is aligned with the second fixing position 30 during every pause phase of an intermittent feed cycle.