Continuous Web Inversion System with Lateral Registration Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing duplex printing systems for continuous web printers face challenges in maintaining consistent web registration and tension, leading to potential web breakage and reduced image quality due to manual adjustments and contamination from bias rollers.
Innovation Solution
An automated inversion and registration system using a series of turn bars and a control system with sensors and motors to adjust the position of the exit turn bar, maintaining consistent web path length and tension, and preventing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the exit turn bar is made adjustable to change lateral registration of the web, then the lateral registration accuracy is improved, but the web path length is altered which affects web tension and causes loss of web control, web damage, or breakage
Solution Approach 1:
The registration adjustment function is segmented from the turn bar positioning function. Instead of moving the entire turn bar assembly (which would change path length), only the turn bar itself is translated laterally while the support structure and mounting mechanism remain fixed, allowing registration adjustment without altering web path length or tension characteristics
Solution Approach 2:
A translation mechanism serves as an intermediary between the fixed frame and the turn bar. This intermediary allows the turn bar to move laterally for registration adjustment while maintaining a constant connection to the fixed structure, thereby preserving the web path length and tension characteristics
2Manufacturing precision
If a bias roller with manually adjusted edge guide is used to laterally register the return path web, then the lateral registration is improved, but loose paper dust and fibers are generated that may contaminate the printheads, reducing image quality and printhead life
Solution Approach 1:
The harmful bias roller and its associated dust-generating surface are completely removed from the system. Instead, a clean turn bar with a smooth surface is used to perform the same lateral registration function without generating loose particles that could contaminate the printheads
Solution Approach 2:
The invention replaces the complex bias roller mechanism with a simple, clean turn bar that can be easily maintained. The turn bar's smooth surface is designed to minimize particle generation, and its simple structure allows for easy cleaning and maintenance to prevent contamination
Data Source
AI summary
A continuous web inversion system for use in a continuous web imaging device includes a first turn bar positioned to receive a substantially continuous web moving in a first direction with a first surface facing in a printing direction and to flip the web and direct it in a second direction perpendicular to the first direction. A second turn bar is positioned to receive the continuous web from the first turn bar to flip the web and direct it in a third direction opposite the first direction. A third turn bar is positioned to receive the continuous web from the second turn bar to flip the web and direct it in the first direction with a second surface of the web facing in the printing direction. The second and the third turn bars are coupled together and supported for translation along an axis perpendicular to the first direction. A sensor is configured to generate a signal indicative of a lateral position of the continuous web exiting the third turn bar. A driver is operably coupled to at least one of the second and the third turn bars to adjust a position of the third turn bar along the axis based on the signal.