Smart Polymer Roller Adjusting Punching Force Uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sheet and web printing machines face challenges in achieving uniform punching force distribution due to uneven deformation of tables and wear of knives, leading to suboptimal cutting and embossing quality, requiring time-consuming adjustments and reducing productivity.
Innovation Solution
The use of functional polymers, such as magnetically or electrically active polymers, to adjust properties like elastic hardness, compressibility, or friction of components like printing press cylinders or punching tools, allowing for dynamic control of surface pressure and contact width without the need for multiple tool sets or extensive setup times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wedge-shaped steel plates are shifted to adjust punching force, then the punching force can be adjusted globally, but the punching force distribution becomes uneven across the platen surface
Solution Approach 1:
The platen surface is divided into multiple zones with individual adjustment capabilities. Each zone has its own wedge-shaped steel plate that can be independently shifted to control punching force locally, rather than applying a single global adjustment across the entire surface. This segmentation allows precise control of punching pressure distribution.
Solution Approach 2:
Different regions of the platen surface are given different adjustment properties through individually controllable wedge-shaped steel plates. Each local zone can be optimized for its specific requirements, allowing the punching force to be tailored to local variations in material thickness, blade wear, or tool requirements.
2Manufacturing precision
If individual shimming of cutting dies is performed to correct punching force deviations, then cutting accuracy improves, but setup time increases significantly
Solution Approach 1:
The wedge-shaped steel plates are designed to be dynamically adjustable during machine operation rather than requiring static shimming during setup. The individual zones can be adjusted in real-time based on actual punching force measurements, eliminating the need for time-consuming manual shimming procedures while maintaining cutting accuracy.
Solution Approach 2:
The system incorporates sensors and control mechanisms that automatically detect punching force deviations and adjust the wedge-shaped steel plates accordingly. This self-adjusting capability eliminates the need for manual intervention and expert setup time, allowing the machine to maintain optimal cutting accuracy autonomously.
3Manufacturing precision
If the platen stiffness is increased to reduce deformation, then punching pressure uniformity improves, but the overall machine complexity and cost increase
Solution Approach 1:
Instead of relying solely on mechanical stiffening of the platen structure, the invention uses individually adjustable wedge-shaped steel plates in each zone to actively compensate for deformations. This substitution of passive mechanical stiffness with active local adjustment mechanisms achieves pressure uniformity without requiring an overly complex or heavy platen structure.
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 precise and adaptive processing of various substrates with reduced setup times and increased productivity by dynamically adjusting the properties of components in real-time, improving the uniformity and quality of cutting and embossing operations.
Implementation Method 1
a functional polymer – a so-called smart polymer – for modifying a property of a component of the assembly
Implementation Method 2
The functional polymer is a magnetically active polymer, an electrically active polymer or a dielectric elastomer
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An assembly of a sheet- or web-based printing machine comprises a functional polymer (6) – a so-called smart polymer – for modifying a property of a component of the assembly. The assembly can be, for example, a roller (25). The component of the assembly can be a roller cover (26). The property being modified can be, for example, a diameter.