Web Substrate Buffer for Asynchronous Tandem Print Engine Synchronization
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Solution Overview
Problem
Existing web press systems require synchronous feeding of substrates through multiple print engines, which reduces efficiency and necessitates significant effort to synchronize print operations, limiting the modularity and independence of print engines.
Innovation Solution
A buffer device is introduced between print engines to store and feed a variable amount of web substrate, allowing each engine to operate independently of the other's speed and phase, with rollers and actuators maintaining constant tension and optimizing substrate flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If synchronous feeding is used to maintain alignment between print engines, then printing precision is improved, but device complexity and synchronization effort increase
Solution Approach 1:
A buffer device is introduced as an intermediary between the first and second print engines. The buffer stores portions of the web substrate and feeds them to the second print engine as needed, decoupling the synchronous feeding requirement while maintaining alignment through controlled substrate delivery
Solution Approach 2:
The substrate feeding process is segmented into independent stages: the first print engine feeds substrate to the buffer, and the buffer independently manages substrate delivery to the second print engine. This segmentation allows each print engine to operate independently while maintaining overall coordination
2Manufacturing precision
If synchronous feeding is used to maintain alignment between print engines, then printing precision is improved, but productivity decreases
Solution Approach 1:
The buffer device dynamically adjusts substrate storage and feeding based on the operational needs of each print engine. This dynamic operation allows the system to maintain precision alignment while optimizing throughput, as the buffer can accumulate substrate during high-speed printing and release it when needed
Solution Approach 2:
The buffer acts as a mediator that absorbs timing variations between print engines, allowing each engine to operate at optimal speeds without being constrained by synchronous feeding requirements, thereby improving overall productivity while maintaining alignment
3Manufacturing precision
If synchronous feeding is used between print engines, then alignment is maintained, but ease of operation decreases
Solution Approach 1:
The operation of each print engine is segmented into independent control units. The first print engine operates independently to print on one side of the substrate, while the buffer independently manages substrate storage and feeding to the second print engine, which also operates independently. This segmentation greatly simplifies operation and maintenance
Solution Approach 2:
The buffer device serves as an intermediary that decouples the operational dependencies between print engines. Each engine can be operated, maintained, or adjusted independently while the buffer ensures proper substrate delivery and alignment is maintained
Data Source
AI summary
A printing device (100,101) has a first print engine (103, 303, 603, 703), a second print engine (105, 305, 605, 705), and a buffer device (107, 307, 609, 709, 711) disposed between the first (103, 303, 603, 703) and second print engines (105, 305, 605, 705). The buffer (107, 307, 609, 709, 711) is configured to store a variable amount of web substrate (106, 301, 713) received from the first print engine (103, 303, 603, 703) and feed the substrate (106, 301, 713) to the second print engine (105, 305, 605, 705).