The disclosed concept relates generally to can decorators and, in particular, to can decorator inspection and control systems. The disclosed concept also relates to adjustment assemblies for can decorators.
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 its ink image in a proper position relative to the other ink images so that the main image does not have offset ink images.
The position of an image can be skewed, misprinted, or inefficient levels of ink for a specified optimal temperature required to apply an image on a container. In some instances, there is overlay of print layers which results in ink contamination and undesired colors being printed on the can. In this circumstance, hundreds or thousands of cans need to be discarded and the decorator shut down which leads to the can line as a whole being shut down and typically produce between 400 and 6000 cans per minute. This stoppage results in higher operating costs and large amounts of spoilage. In other instances, where the ambient air surrounding the decorator is unstable or difficult to control, the application of the ink may also become inconsistent due to the material properties being effected by the environmental temperature and the ability of the ink substrate being able to adhere to the can surface in addition to maintaining the thinnest film weight of the ink as possible. The tinctorial strength of the ink directly relates to the film thickness of the ink. The higher the tinctorial strength, the thinner the film thickness can be. If the tinctorial strength of the ink is not optimized, the film weight will need to be quicker and the decorator run slower. The typical temperature range suggested by ink manufacturers is between 95° and 105° F. If the ink is too cold, it will appear pin-holed on the container. If the ink temperature is too high, the ink can start to mist or apply to thinly which will also cause the image to not be shown as intended leading to higher spoilage rates. In both cases, the inability to adjust the temperature can lead to excessive ink application as an operator may increase ink flow to increase ink coverage in this circumstance. A typical decorator fountain can hold 50 ounces of ink and can be replenished on an hourly basis. In cases where the operator is compensating for poor ink density or temperature, the ink usage can easily double. There is thus room for improvement in can decorators and their components.
According to an aspect of the disclosed concept, a control system for a can decorator structured to apply images to cans comprises: a can inspection system structured to capture images of a can; a controller structured to receive the captured images and to analyze the captured images to determine a quality of the image applied to the can based on a comparison of the captured images and a reference image; and an adjustment assembly structured to adjust a circumferential or translational position of a plate cylinder attached to a plate cylinder shaft end of a plate cylinder shaft, the adjustment assembly including at least one stepper motor, wherein operation of the at least one stepper motor causes the circumferential or translational adjustment, wherein in response to determining an image registration error based on a comparison of the captured images and the reference image, the controller is structured to determine an excitation period and frequency based on the image registration error and to control the at least one stepper motor according to the determined excitation period and frequency.
According to an aspect of the disclosed concept, an adjustment assembly for a plate cylinder and a plate cylinder shaft of a can decorator comprises: a translation ring coupled to the plate cylinder shaft such that rotation of the translation ring causes a circumferential adjustment of the plate cylinder shaft and the plate cylinder attached to a plate cylinder shaft end; a guide structure disposed proximate the translation ring; cam followers attached to the guide structure and operatively coupled to the translation ring such that rotation of the cam followers causes rotation of the translation ring; and a stepper motor operatively coupled to the cam followers such that operation of the at least one stepper motor causes rotation of the cam followers.
According to an aspect of the disclosed concept, an adjustment assembly for a plate cylinder and a plate cylinder shaft of a can decorator comprises: a shaft housing coupled to the plate cylinder shaft and a plate cylinder shaft end such that axial movement of the shaft housing causes a translational adjustment of the plate cylinder shaft end and the plate cylinder attached to the plate cylinder shaft end; a translation coupling member having a first end coupled to the shaft housing such that the shaft housing and the translation coupling member move in conjunction; a translation guide coupled to a second end of the translation coupling member such that the translation guide and the translation coupling member move in conjunction; and a stepper motor operatively coupled to the translation guide such that operation of the at least one stepper motor causes linear movement of the translation guide and the plate cylinder shaft end.
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:
The circumferential adjustment assembly 200 includes the stepper motor 202, a guide structure 204, cam followers 206, cam follower springs 208, and a translation ring 210. The cam follower springs 208 are structured to pre-load the cam followers 206 against the translation ring 210. The cam followers 206 are attached to the guide structure 204 and are spaced apart from each other. The stepper motor 202 is operatively coupled to the cam followers 206 and is structured to control rotation of the cam followers 206. A translation ring 210 is coupled to a plate cylinder shaft 104 of the plate cylinder shaft assembly 100 such that rotation of the translation ring 210 adjusts the circumferential position of the plate cylinder shaft 104. An outer portion of the translation ring 210 is disposed between the cam followers 206 such that rotation of the cam followers 206 causes rotation of the translation ring 210. By driving the step motor 202 to rotate the cam followers 206 in a controlled manner, rotation of the translation ring 210 and circumferential adjustment of the plate cylinder shaft assembly 100 can be controlled.
The translational adjustment assembly 300 includes the stepper motor 302, a translation guide 304, a translation coupling member 306, and a shaft housing 308. The stepper motor 302 is operatively coupled to the translation guide 304 and is structured to control the translation guide 304 to advance and retract. The shaft housing 308 is coupled to the plate cylinder shaft 104 and plate cylinder shaft end 102 of the plate cylinder shaft assembly 100. The shaft housing 308 is coupled to the translation guide 304 via the translation coupling member 306 such that the translation guide 304, coupling member 306, and shaft housing 308 all move in conjunction. The shaft housing 308 is also coupled to the plate cylinder shaft end 102 such that movement of the shaft housing 308 causes translational adjustment of the plate cylinder shaft end 102. Driving the stepper motor 302 to advance or retract the translation guide 304 thus causes a controllable translational adjustment of the plate cylinder shaft end 102 and any plate cylinder attached to the plate cylinder shaft end 102.
The inker station 500 includes an ink temperature control element 600, for example, at the fountain 502. The ink temperature control element 600 may be, for example a heating element. The inker station 500 also includes one or more ink temperature sensors 602,604. The ink temperature sensors 602,604 may be, for example, a contact ink temperature sensor 602 that senses temperature via direct contact with the ink, or a non-contact ink temperature sensor 604 that senses temperature without direct contact. The ink temperature sensors 602,604 may be disposed at any suitable location in the inker station 500, for example at the plate cylinder 506, at the blanket wheel, at a mandrel, at various point on the roller assembly 504, in the fountain 502, or in any other suitable location. In some example embodiment, cooling ports 508 may be included on one or more of the rolls of the roller assembly 504 or the plate cylinder 506. The cooling ports 508 may also be considered ink temperature control elements.
In some example embodiments, the controller 700 may control various components such as, without limitation, the circumferential adjustment assembly 200 and the translational adjustment assembly 300 in a prescribed motion, which may be, for example, stored settings specific to the label, a general home position, or a position defined by the operator. When the controller 700 analyzes the captured images of cans and compares them to the “proof image,” the controller 700 may create a range of acceptable values or a bound. The bound may be determined dynamically. The bound is determined over many samples or no less than three to define a statistical capability curve of the can decorator itself using sample data collected over many runs. For each unique label or unique run of a label, an additional subset of bounds is applied to create an optimized range specific to each label and run. When the image data collected fall outside of the optimized bounds, the controller 700 then excites the stepper motors 202 and/or 302 to drive the circumferential adjustment assembly 200 and/or the translational adjustment assembly 300 to move correspondingly to be within the optimized bounds. It is important to understand how the behavior of each can decorator differs as the components comprising of the decorator as whole can wear and be of different ages or manufactured slightly different. If simple bounds were set without understanding the behavior of the can decorator or how it effects a specific label, the can decorator will be susceptible high energy usage and motor fatigue due to the continuous adjustment process. Additionally, it allows for the most accurate image application for each unique label.
In some example embodiments, the controller 700 is also structured to receive outputs of the ink temperature sensor 602 and/or 604. The controller 700 is structured to analyze the outputs to determine the temperature of the ink. The controller 700 is also structured to control the ink temperature control element 600 based on the determined temperature of the ink, for example to control the temperature of the ink to be an optimal ink temperature. This is important as the properties of the ink can be changed with temperature and allow for the most optimal and efficient ink application to the print blanket and can for each ink type. The optimal ink temperature is typically defined by the ink manufacturer.
In some example embodiments, the controller 700 may also determine the ink density for application of half tones and color shading where the can colors seen with the human eye are actually compromised of several small dots that do not overlap and create a lighter, darker, or appearance of a blended of color depending on the quantity of ink applied. It is important these small dots do not overlap as this can create contamination of the ink and cause un-intended colors to be applied to the can or result in too little or too much ink to be applied which an operator may mistakenly attempt to adjust at the ink fountain. The controller 700 may be structured to control various components of the can decorator such as, for example, plate pressure or pneumatic ductor interval to adjust ink density to a desired level.
The controller 700 may utilize an application programming interface (API) to communicate with various components of the can decorator or external components. The controller 700 may control adjustments to various components of the can decorator independently based on feedback from various sensors. The controller 700 may also control adjustments to various components of the can decorator based on user input such as, for example, settings provided by an operator.
Various example embodiments of the disclosed concept improve the operation of can decorators by for example, improving quality, reducing maintenance and downtime, and improving efficiency.
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.
This application claims priority to U.S. Patent Application Ser. No. 63/461,619, Apr. 25, 2023, entitled, Can Decorator Inspection And Control System And Adjustment Assemblies.
Number | Date | Country | |
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63461619 | Apr 2023 | US |