Variable Size Die Cutter Web Speed Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing punching machines require multiple cylinders with varying circumferences to accommodate different product lengths, leading to high production costs and maintenance efforts due to the need for frequent adjustments and replacements.
Innovation Solution
A device with a deflection mechanism that adjusts web speed cyclically, allowing a single punching cylinder with a defined diameter to handle products of different lengths by compensating for length differences between the punching length and pattern length, reducing the need for multiple cylinders and minimizing setup times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple punching cylinders with different circumferences are used to accommodate different product lengths, then the adaptability to different product lengths is improved, but the device complexity and production costs increase
Solution Approach 1:
The patent employs a variable speed drive system that dynamically adjusts the web speed during the punching cycle. The web speed is increased during the punching phase to match the pattern length, and decreased during the return phase to match the longer punching cylinder circumference. This dynamic speed adjustment allows a single punching cylinder to handle multiple pattern lengths without physical replacement.
Solution Approach 2:
The invention changes the operational parameter of web speed to resolve the contradiction. By varying the web speed parameter in synchronization with the punching cycle, the system enables one punching cylinder to effectively accommodate different pattern lengths. The web speed is modulated between a first speed during punching and a second speed during the return phase, allowing adaptability without adding multiple cylinders.
2Adaptability or versatility
If multiple punching cylinders with different circumferences are used to accommodate different product lengths, then the adaptability to different product lengths is improved, but the loss of time for replacements and adjustments increases
Solution Approach 1:
The variable speed drive system dynamically adjusts web speed in real-time during the punching cycle, eliminating the need for physical cylinder replacements. The system transitions smoothly between different operational speeds based on the punching phase, maintaining continuous production without downtime for cylinder changes.
Solution Approach 2:
The system pre-synchronizes the web speed adjustments with the punching cycle phases. Before the punching operation begins, the web speed is adjusted to the appropriate first speed, and before the return phase, it transitions to the second speed. This preliminary coordination eliminates idle time and ensures seamless operation when changing pattern lengths.
3Device complexity
If a single punching cylinder is used for different pattern lengths by adjusting web speed, then the device complexity is reduced, but the manufacturing precision of pattern registration may be affected
Solution Approach 1:
The patent incorporates a control system that monitors and coordinates the web speed adjustments with the punching cycle phase. The variable speed drive receives feedback about the punching state and automatically adjusts the web speed to maintain proper synchronization. This feedback mechanism ensures that pattern registration precision is maintained even though the web speed varies during the cycle.
Solution Approach 2:
The web speed is adjusted periodically in synchronization with the punching cycle. During each punching phase, the web speed follows a predetermined pattern of acceleration and deceleration that ensures the pattern is registered correctly on the web. This periodic speed modulation, coordinated with the punching operation, maintains manufacturing precision while using a single punching cylinder.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a device and a method for printing and die-cutting a web, wherein the device comprises at least one printing device, wherein in the printing device the web is printed with a recurring print image with a print length Lb, and wherein the web has a substantially uniform printing web speed v20 in the area of the at least one printing device, and wherein the device comprises a die-cutting unit, wherein the die-cutting unit has a die-cutting length Ls, and wherein a pattern with a pattern length Lm can be die-cut or embossed by means of the die-cutting unit, wherein the pattern length Lm is less than or equal to the print length Lb.The object of the present invention is to provide a device and a method with which products of different lengths to be punched out, or stamping patterns of different lengths, or pattern lengths Lm of different lengths can be processed without changing the cylinder, using a punching length Ls with a defined effective diameter and consequently with a defined punching length Ls. The device according to the invention is characterized in that the punching length Ls of the die is greater than the pattern length Lm, and wherein the device comprises at least one deflection device for cyclically changing the web speed v.