Patent Application
20250065645
The disclosed concept relates generally to an apparatus and method for decorating cans using a can decorator and, more particularly, to an automatic label creator and method for can decorating.
High speed continuous motion machines for decorating cans, commonly referred to as “can decorator machines” or simply “can decorators,” are generally well known.
While mounted on a mandrel, each can 16 is decorated by being brought into engagement with a blanket (e.g., without limitation, a replaceable adhesive-backed piece of rubber) disposed on a blanket wheel of the multicolor printing unit indicated generally by reference numeral 22. Thereafter, and while still mounted on the mandrels, the outside of each decorated can 16 is coated with a protective film of varnish applied by engagement with the periphery of a varnish applicator roll (not shown) rotating on a shaft 23 in the overvarnish unit indicated generally by reference numeral 24. Cans 16 with decorations and protective coatings thereon are then transferred from the mandrels to suction cups (not shown) mounted adjacent the periphery of a transfer wheel (not shown) rotating on a shaft 28 of a transfer unit 27. From the transfer unit 27 the cans 16 are deposited on generally horizontal pins 29 carried by a chain-type output conveyor 30, which carries the cans 16 through a curing oven (not shown).
While moving toward engagement with an undecorated can 16, the blanket wheel engages a plurality of plate cylinders 31, each of which is associated with an individual inking station 32 (an exemplary eight inking stations 32 are shown in
Each inking station 32 includes a plurality of rollers, or as used herein, “rolls,” that are structured to transfer a quantity of ink from a reservoir, or as used herein an “ink fountain,” to the blanket. The path that the ink travels is, as used herein, identified as the “ink train.” That is, the rolls over which the ink travels define the “ink train.” Further, as used herein, the “ink train” has a direction with the ink fountain being at the “upstream” end of the ink train and a plate cylinder 31 at the “downstream” end of the ink train.
The ink train extends over a number of rolls each of which has a purpose. As shown, the ink train starts at the ink fountain and is initially applied as a film to a fountain roll. The fountain roll is intermittently engaged by a ductor roll. When the ductor roll engages the fountain roll, a quantity of ink is transferred to the ductor roll. The ductor roll also intermittently engages a downstream roll and transfers ink thereto. The ductor roll has a “duty cycle” which, as used herein, means the ratio of the duration of the ductor roller being in contact with the fountain roller divided by the duration of a complete cycle (ductor roller in contact with the fountain roller, move to the first downstream roller, contact with first steel roller, move back to fountain roller).
The other rolls include, but are not limited to, distribution roll(s), oscillator roll(s), and transfer roll(s). Generally, these rolls are structured to distribute the ink so that a proper amount of ink is generally evenly applied to the plate cylinder 31. For example, the oscillator rolls are structured to reciprocate longitudinally about their axis of rotation so as to spread the ink as it is applied to the next downstream roll. The final roll is the plate cylinder 31 which applies the ink to the blanket. It is understood that each inking station 32 applies an “ink image” of a single selected color to the blanket and that each inking station 32 must apply the ink image in a proper position relative to the other ink images so that the main image does not have offset ink images.
Thus, as used herein, an “ink image” means the image of a single ink color which is part of a “main image.” As used herein, a “main image” means an image created from a number of ink images and which is the image that is applied to a can body as the “can body applied image.” It is understood that a “main image” includes a number, and typically a plurality, of ink images. For example, if the main image was the French flag (which is a tricolor flag featuring three vertical bands colored blue (hoist side), white, and red), an inking station 32 with blue ink would provide an ink image that is a blue rectangle, an inking station 32 with white ink would provide an ink image that is a white rectangle and an inking station 32 with red ink would provide an ink image that is a red rectangle. Further, presuming that the main image was of a French flag with the hoist side on the left, the inking station 32 with blue ink would provide the blue rectangle ink image on the left side of the blanket, the inking station 32 with white ink would provide the white rectangle ink image on the center of the blanket immediately adjacent the blue rectangle ink image, and the inking station 32 with red ink would provide the red rectangle ink image on the right side of the blanket immediately adjacent the white rectangle ink image. Once all the ink images are applied to the blanket, the main image is formed and then applied to a can body.
Currently, operators of a can decorator 10 need to manually adjust mechanical components (e.g., without limitation, plate cylinders 31 and inking stations 32) of the can decorator 10 in order to determine values (e.g., setpoints, ink recipes including color parameters, etc.) for image registration for printing a label. Often, the operators must make small movements or adjustments to the mechanical components, and then check to see if a can 16 includes the label as set forth by a label specification received from a vendor. The operators repeat the manual adjustments until the label appears correctly on a can 16. Such manual adjustments require guesswork on the part of the operators until the label appears correctly on a can 16. Further, at times, what appeared to be correct may not be exactly in accordance with the label specification, resulting in wasted time and cans.
There is room for improvement in creating labels for cans during can manufacturing.
These needs, and others, are met by a can decorating system. The can decorating system includes a can decorator including at least a plurality of cylinder plates and a plurality of inking stations, each plate cylinder being associated with an individual inking station; and a control station communicatively coupled to the can decorator, the control station comprising: an input apparatus structured to receive an input including at least the label specification; a display structured to display real time information including at least the label specification; a control system structured to monitor and control operations of the can decorator; and an automatic label creator comprising a memory, the automatic label creator being structured to receive an input including at least the label specification, create a label, determine values for image registration based at least in part on the label specification and data associated with previously applied labels, and transmit at least the label and the values of image registration to the control station, where the control system causes at least the plurality of plate cylinders and the plurality of inking stations to be adjusted based at least in part on the label and the values of image registration, and where upon being adjusted, the plurality of plate cylinders and the plurality of inking stations print the label on undecorated cans based at least in part on the label and the values.
Another example embodiment of the disclosed concept provides an automatic label creator for use in can decorating by a can decorator. The can decorator has at least a plurality of plate cylinders and a plurality of inking stations, each plate cylinder associated with an individual inking station, the can decorator being communicatively coupled to a control station including a control system structured to control operations of the can decorator communicatively coupled to the control station. The automatic label creator includes an input apparatus structured to receive an input including at least a label specification obtained from a vendor; a display structured to display real time information including at least the label specification; and an automatic label creator controller comprising a memory, the automatic label creator being structured to receive an input including at least the label specification, create a label, determine values for image registration based at least in part on the label specification and data associated with previously applied labels, and transmit at least the label and the values of image registration to the control station, where the control system causes at least the plurality of plate cylinders and the plurality of inking stations to be adjusted based at least in part on the label and the values of image registration, and where, upon being adjusted, the plurality of plate cylinders and inking stations print the label on undecorated cans based at least in part on the label and the values.
Yet another example embodiment of the disclosed concept provides a method of automatically creating a label. The method includes receiving, by an automatic label creator, an input including at least a label specification; creating a label by the automatic label creator; determining, by the automatic label creator, values for image registration based at least in part on the label specification and data associated with previously applied labels; transmitting, by the automatic label creator, at least the label and the values of image registration to a control system of a control station communicatively coupled to a can decorator and structured to control operations of the can decorator, the can decorator comprising at least a plurality of plate cylinders and a plurality of inking stations; causing, by the control system, at least the plurality of plate cylinders and the inking stations to be adjusted based at least in part on the label and the values of image registration; and printing, by the plurality of plate cylinders and inking stations, the label on undecorated cans based at least in part on the label and the values.
A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
It will be appreciated that the specific elements illustrated in the figures herein and described in the following specification are simply exemplary embodiments of the disclosed concept, which are provided as non-limiting examples solely for the purpose of illustration. Therefore, specific dimensions, orientations, assembly, number of components used, embodiment configurations and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concept.
Directional phrases used herein, such as, for example, clockwise, counterclockwise, left, right, top, bottom, upwards, downwards and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.
As used herein, the singular form of “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
As used herein, “structured to [verb]” means that the identified element or assembly has a structure that is shaped, sized, disposed, coupled and/or configured to perform the identified verb. For example, a member that is “structured to move” is movably coupled to another element and includes elements that cause the member to move or the member is otherwise configured to move in response to other elements or assemblies. As such, as used herein, “structured to [verb]” recites structure and not function. Further, as used herein, “structured to [verb]” means that the identified element or assembly is intended to, and is designed to, perform the identified verb. Thus, an element that is merely capable of performing the identified verb but which is not intended to, and is not designed to, perform the identified verb is not “structured to [verb].”
As used herein, “associated” means that the elements are part of the same assembly and/or operate together or act upon/with each other in some manner. For example, an automobile has four tires and four hub caps. While all the elements are coupled as part of the automobile, it is understood that each hubcap is “associated” with a specific tire.
As used herein, the statement that two or more parts or components are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs. As used herein, “directly coupled” means that two elements are directly in contact with each other. As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other. As used herein, “adjustably fixed” means that two components are coupled so as to move as one while maintaining a constant general orientation or position relative to each other while being able to move in a limited range or about a single axis. For example, a doorknob is “adjustably fixed” to a door in that the doorknob is rotatable, but generally the doorknob remains in a single position relative to the door. Further, a cartridge (nib and ink reservoir) in a retractable pen is “adjustably fixed” relative to the housing in that the cartridge moves between a retracted and extended position, but generally maintains its orientation relative to the housing. Accordingly, when two elements are coupled, all portions of those elements are coupled. A description, however, of a specific portion of a first element being coupled to a second element, e.g., an axle first end being coupled to a first wheel, means that the specific portion of the first element is disposed closer to the second element than the other portions thereof. Further, an object resting on another object held in place only by gravity is not “coupled” to the lower object unless the upper object is otherwise maintained substantially in place. That is, for example, a book on a table is not coupled thereto, but a book glued to a table is coupled thereto.
As used herein, the statement that two or more parts or components “engage” one another means that the elements exert a force or bias against one another either directly or through one or more intermediate elements or components. Further, as used herein with regard to moving parts, a moving part may “engage” another element during the motion from one position to another and/or may “engage” another element once in the described position. Thus, it is understood that the statements, “when element A moves to element A first position, element A engages element B,” and “when element A is in element A first position, element A engages element B” are equivalent statements and mean that element A either engages element B while moving to element A first position and/or element A either engages element B while in element A first position.
As used herein, “correspond” indicates that two structural components are sized and shaped to be similar to each other and may be coupled with a minimum amount of friction. Thus, an opening which “corresponds” to a member is sized slightly larger than the member so that the member may pass through the opening with a minimum amount of friction. This definition is modified if the two components are to fit “snugly” together. In that situation, the difference between the size of the components is even smaller whereby the amount of friction increases. If the element defining the opening and/or the component inserted into the opening are made from a deformable or compressible material, the opening may even be slightly smaller than the component being inserted into the opening. With regard to surfaces, shapes, and lines, two, or more, “corresponding” surfaces, shapes, or lines have generally the same size, shape, and contours.
As used herein, the term “number” shall mean one or an integer greater than one (i.e., a plurality). That is, for example, the phrase “a number of elements” means one element or a plurality of elements. It is specifically noted that the term “a ‘number’ of [X]” includes a single [X].
As used herein, “about” in a phrase such as “disposed about [an element, point or axis]” or “extend about [an element, point or axis]” or “[X] degrees about an [an element, point or axis],” means encircle, extend around, or measured around. When used in reference to a measurement or in a similar manner, “about” means “approximately,” i.e., in an approximate range relevant to the measurement as would be understood by one of ordinary skill in the art.
As used herein, an “elongated” element inherently includes a longitudinal axis and/or longitudinal line extending in the direction of the elongation.
As used herein, “generally” means “in a general manner” relevant to the term being modified as would be understood by one of ordinary skill in the art.
As used herein, “substantially” means “for the most part” relevant to the term being modified as would be understood by one of ordinary skill in the art.
As used herein, “at” means on and/or near relevant to the term being modified as would be understood by one of ordinary skill in the art.
Example embodiments of the disclosed concept provide an automatic label creator and method for use in can manufacturing. Upon receiving an input including a label specification obtained from a customer (e.g., without limitation, a vendor), the automatic label creator automatically creates a label. Upon creating the label, the automatic label creator determines values for image registration based at least in part on the label specification and data associated with previous labels applied by the can decorator and/or other can decorators. Then, the automatic label creator automatically transmits the label and the values for image registration to a control station communicatively coupled to the can decorator, the control station including a control system structured to monitor and control operations of the can decorator. Upon receiving the label and the values, the control system causes one or more can decorator components to be adjusted based at least in part on the label and the values for image registration. The can decorator (e.g., without limitation, a plurality of plate cylinders and a plurality of inking stations) print the label on undecorated cans 16. By automatically creating a label and adjusting the can decorator based on the label and the values for image registration, the automatic label creator eliminates repeated manual adjustments and the guesswork required by the conventional label creation systems and methods, thereby greatly expediting the label creation and changing process. By utilizing machine learning based on a large amount of data associated with the previously applied labels, the automatic label creator further increases the accuracy of the label and allows the can decorator to adjust the components thereof to correct locations and parameters at a first attempt.
The automatic label creator 1 is structured to receive a label specification, create a label, determine values for image registration based at least in part on the label specification and data associated with previously applied labels, and transmit at least the label and the values to the control station 200. Upon receiving at least the label and the values, the control station 200 (i.e., a control system 215 as shown in
Upon receiving the label specification, the automatic label creator 1 is structured to create a label to be printed on undecorated cans 16. An example label is illustrated in
Upon creating a label, the automatic label creator 1 is structured to determine values for image registration based on the label. Image registration includes, e.g., without limitation, plate cylinders and ink registration. Plate cylinders registration includes, e.g., without limitation, vertical registration that registers vertical (i.e., up or down) setpoints, circumferential registration that registers circumferential (i.e., right or left) setpoints, and plate pressure registration that registers plate pressure points. The plate cylinders registration is performed for each cylinder plate 31. For plate cylinders registration, the automatic label creator 1 is further structured to determine setpoints including vertical setpoints, circumferential setpoints and plate pressure points for each plate cylinder. Ink registration includes ink recipes that indicate, e.g., without limitation, how much base and pigment should be mixed to obtain a desired color, and include color registration parameters, e.g., without limitation, ink level, densities, tints, shade gradients, etc. For ink registration, the automatic label creator 1 is further structured to generate an ink recipe including at least color parameters for each inking station 32 and set ink key setpoints for respective inking stations 32.
The data associated with previously applied labels include at least respective registration information and corresponding can decorator information. Respective registration information includes, e.g., without limitation, previous setpoints and ink recipes that were optimized for the previously applied labels. Corresponding can decoration information includes at least can decorator conditions (e.g., without limitation, use, age, operational history, etc.) and environment information thereof (e.g., without limitation, ambient temperature, ambient moisture, etc.). For example, the automatic label creator 1 automatically and continuously collects data. The data may include at least data of the can decorator 10 and a plurality (e.g., without limitation, thousands) of cans 16 printed by the can decorator 10, can decorator conditions and ambient information thereof. Further, the automatic label creator 1 continuously updates the data and trains based at least in part on the updated data via the machine learning algorithm therein. In some examples, the data may also include data associated with previously applied labels, respective registration information and corresponding can decorator information of can decorators that have the same or different specifications as the can decorator 10, and operate at different locations (domestic and/or abroad). In those examples, the automatic label creator 1 can train based on a large amount of the globally collected data and optimize the values for image registration based on the large amount of the data, thereby significantly increasing the accuracy of at least the values determined as compared to when the automatic label creator 1 is training based on local data only or when the conventional label creation systems and methods requiring manual adjustments based on guesswork are being used.
Upon determining values for image registration, the automatic label creator 1 transmits at least the label and the values to the control station 200. In the examples using a can decorator having a controller therein, the automatic label creator 1 transmits the signal to the controller. The control system 215 then causes the can decorator 10, or printing components thereof to be adjusted based at least in part on the label and the values. The printing components may include, e.g., without limitation, a plurality of plate cylinders 31 and a plurality of inking stations 32, each plate cylinder 31 being associated with an individual inking station 32. Upon receiving the label and the values for image registration, the control system 215 causes at least the plate cylinders 31 and the inking stations 32 to be adjusted based at least in part on the label and the values. That is, the control system 215 causes the plate cylinders 31 to be moved to setpoints specified by the values and causes the inking stations 32 to set the ink fountain components based on the ink recipes. Upon being adjusted, the plurality of plate cylinders 31 and a plurality of inking stations 32 print the label on undecorated cans 16. In some examples, the control system 215 may include an automatic registration device (not shown) and/or an automated color registration device (e.g., without limitation, an automated ink fountain). In those examples, the automatic label creator 1 together with the automatic registration device and/or the automated ink fountain can significantly expedite the label creation and change process as compared to when the conventional label creation and change system and method are being used.
In some examples, the automatic label creator 1 is further structured to determine if the label is being printed on cans 16 as specified in at least one of the label and the label specification. For such determination, the automatic label creator 1 may obtain 3D images from, e.g., a camera or image sensor (not shown) disposed within, at, or in proximity to the can decorator 10, review the data for at one or more initially printed cans 16, and determine if the label on the one or more initially printed cans 16 appears as specified by at least one of the label or the label specification. In response to determining that the label has not been printed as specified, the automatic label creator 1 determines if the label and/or the values for image registrations need to be modified or the can decorator 10 needs to be adjusted further. For example, if the label included an error, e.g., an incorrect color density, the automatic label creator 1 determines that the label and/or the values for image registration need to be modified. In such example, the automatic label creator 1 is further structured to modify the label and/or the values for image registration, and transmit the modified label and/or the modified values to the control station 200. The control system 215 then causes one or more plate cylinders 31 and inking stations 32 to be adjusted based at least in part on the modified label and/or the modified values. If the automatic label creator 1 determines that the can decorator 10 needs to be adjusted further (e.g., without limitation, due to a damaged component in an inking station 32), but not the label, the automatic label creator 1 is further structured to cause the can decorator 10 to shut down and transmit an alert to at least one of the control station 200 or a can decorator operator. An alert may include an instruction (e.g., without limitation, replace the damaged component) for adjusting the can decorator 10. The control system 215 may adjust the can decorator 10 or the user may manually adjust the can decorator 10 based at least in part on the instruction. Upon adjusting the can decorator 10, the control system 215 turns on the can decorator 10 and the plurality of plate cylinders 31 and the plurality of inking stations 32 print the label on the undecorated cans 16 based at least in part on the label.
Therefore, the automatic label creator 1 according to the disclosed concept automatically creates a label and determines values for image registration without having to undertake the repeated manual adjustments based on the guesswork that are conventionally required for creating labels. Such automatic label creation eliminates human errors associated with the manual adjustments and the guesswork, significantly reduces can manufacturing time and costs, and increases accuracy in creating labels. Further, by utilizing the machine learning technologies based on a large amount of globally collected data and considering all relevant conditions, parameters, issues, and/or results pertaining to specific can decorators, the automatic label creator 1 further increases the accuracy in creating labels. In addition, by automatically modifying the label and/or the values for image registration based on instant data feedback from relevant sensors, the automatic label creator 1 increases the accuracy in creating labels even further. As a result of the increased accuracy, the automatic label creator 1 allows, e.g., without limitation, the plate cylinders 31 and the inking stations 32 to be adjusted and/or moved to correct locations at the first attempt.
The automatic label creator 1 may include its own processor 3 and memory 5. The processor may be, e.g., without limitation, a microprocessor, a microcontroller, or some other suitable processing device or circuitry. The memory 5 can be any of one or more of a variety of types of internal and/or external storage media such as, without limitation, RAM, ROM, EPROM(s), EEPROM(s), FLASH, and the like that provide a storage register, i.e., a machine readable medium, for data storage such as in the fashion of an internal storage area of a computer, and can be volatile memory or nonvolatile memory. The memory 5 may store instructions 6 for at least automatically creating labels. It may also store data 7 associated with previously applied labels. The data 7 may include respective registration information and corresponding can decorator information. For example, the data 7 may include at least data of the can decorator 10 and a plurality (e.g., without limitation, thousands) of printed cans 16 by the can decorator 10 based on previously applied labels, can decorator conditions and ambient information thereof. The data 7 may also include similar information associated with can decorators that have the same or different specifications as the can decorator 10, and operate at different locations (domestic and abroad). The automatic label creator 1 continuously and automatically updates the data 7. The memory 5 may also include a machine learning algorithm 8, which trains based on the data 7 and executes the instructions 6 based at least in part on the training. The automatic label creator 1 further outputs a signal to enable the display 210 to display real time information, e.g., without limitation, a label specification being input, a new label being created, values being determined, ink recipes being generated, data being captured including the cans being printed, etc. The automatic label creator 1 also transmits a signal including a label, values for image registration, and ink recipes to the control station 200. In some examples, the automatic label creator 1 may be included within the control system 215 of the control station 200.
At 6010, the automatic label creator receives an input including at least a label specification.
At 6020, the automatic label creator creates a label.
At 6030, the automatic label creator determines values for image registration based at least in part on the label specification and data associated with previously applied labels.
At 6040, the automatic label creator transmits at least the label and the values for image registration to a control station of the can decorator. The control station is communicatively coupled to the can decorator and receives at least the label and the values. The control station includes a control system structured to monitor and control operations of the can decorator.
At 6050, a control system of the control station causes at least the plurality of plate cylinders and the plurality of inking stations to be adjusted based at least in part on the label and the values for image registration. Upon adjusting, the control system causes the can decorator to be turned on. In some examples, based on the label and the values for the image registration from the automatic label creator, adjustment(s) to the can decorator components may be made manually.
At 6060, the plurality of plate cylinders and inking stations print the label on undecorated cans based at least in part on the label and the values.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof.
