Printing machine with dual ink applicators

Information

  • Patent Grant
  • 6557465
  • Patent Number
    6,557,465
  • Date Filed
    Friday, May 4, 2001
    23 years ago
  • Date Issued
    Tuesday, May 6, 2003
    21 years ago
Abstract
Two ink applicators, each with an ink roll and an ink chamber, for supplying ink to a print roll, and one or more applicator adjustment mechanisms for retracting one ink applicator away from the print roll while the other ink applicator contacts and supplies ink to the print roll. The applicator adjustment mechanisms has eccentric bearings and gears, a primary actuator operates each applicator adjustment mechanism, and a secondary actuator operates a travel limiting mechanism connected to the primary actuator. Alternatively, one or more actuators operate one or more pivot arms, with the ink applicators mounted thereon, for engaging or retracting the ink applicators. A main drive rotates the print roll and the ink rolls, a registration adjustment mechanism with differential gearing permits adjusting the print roll rate of rotation, and an idle drive mechanism with clutches and motors permits rotating the ink rolls independently of the main drive.
Description




TECHNICAL FIELD




The present invention relates to machines for printing and cutting blanks of corrugated paperboard for assembly into boxes or other structures and, more particularly, to a print-cutter machine with a modular print section having a plurality of ink applicators and a precision adjustment mechanism for the ink applicators.




BACKGROUND OF THE INVENTION




Corrugated paperboard boxes are commonly used by merchants and manufacturers for shipping and/or storing a wide range of products, from produce to electronics. These boxes are typically made from corrugated paperboard blanks that are cut and/or scored to permit folding into the shape of a box. Additionally, the blanks are usually printed with text and/or graphics relating to product identification, specifications, instructions for handling, storing, or assembly, and so forth. In order to efficiently print and cut a quantity of blanks, a printer-cutter machine is commonly utilized.




Conventional printer-cutter machines have feed rolls for drawing a blank from a stack of blanks and feeding it between an impression roll and a print roll. The print roll has a print plate with a reverse image of the desired text and/or graphics formed thereon. The position of the printing on the blank is set by the registration of the print roll, that is, by the position of a timing mark on the print roll relative to the leading edge of the blanks. An ink applicator with an ink chamber mechanism and an engraved roll applies ink to the print plate, and the ink-laden print plate prints the text and/or graphics onto the blank. Traditionally, rotary cylinder-type printing machines have employed only a single ink applicator for each print roll.




Subsequently, transfer rolls feed the blank between an anvil roll and a cutting roll with one or more cutting dies with edges extending from it for cutting the blank as desired. The feed rolls, impression roll, print roll, engraved roll, transfer rolls, anvil roll, and cutting roll are interconnected by gears or belts that are driven by a rotary power source such as an electric motor.




After processing a batch of blanks for one application, the printer-cutter machine must be reconfigured for the next printing and cutting job. With regards to cutting, normally only the cutting dies on the cutting roll need to be replaced when making different sized boxes. In that case, the cutting roll is reconfigured with different cutting dies and with a different registration in order to produce cuts of the desired length at the desired locations on the blanks. With regards to printing, there are three components of the machine that are commonly replaced or adjusted between jobs: the print plate, the print roll registration, and the ink rolls of the ink applicators.




The print plate is usually replaced in order to change the particular text and/or graphics printed onto the blanks. This involves removing the print plate from the print roll and installing a new print plate with the new text and/or graphics. Normally, this is a relatively quick and easy task.




The registration of the print roll is changed in order to print a different text and/or graphic at a different location on the blanks, when making different sized boxes. This involves changing the position of the print roll so that the timing mark is adjusted relative to the leading edge of the blanks. This is typically not an overly burdensome task but does take some time to accomplish.




Additionally, the ink rolls of the ink applicators are often reconfigured or replaced to change the color and/or grade of the printing. For some applications, particularly those including graphics, vignettes, process, and fine text and line printing (e.g. bar codes), the merchant or manufacturer wants high quality and resolution printing on the boxes. For this generally “fine” grade printing, a relatively thin layer of ink is applied to the print plate. Therefore, an engraved roll is used that has a textured surface with an ink-carrying matrix of a relatively large number of shallow cells. In other applications, heavy lines and solid figures are desired for ease of viewing the printing. For this generally “coarse” grade printing, a relatively thick layer of ink is applied to the print plate. Therefore, an engraved roll is used that has a textured surface with a matrix of a smaller number of deeper cells. Also, the printing grade can be influenced by the geometry of the cell matrix, so the engraved roll can be selected with a matrix having any of a variety of cell geometries, including hex patterns, diamond patterns, or other regular patterns or irregular textured matrices.




Thus, for each particular printing application with a desired print grade, an engraved roll with the appropriate surface matrix is installed in the machine. The appropriate surface matrix is a function of the line screen (number of cells per inch or other length), cell volume (in billions of cubic microns “BCM” or another volume unit), and cell geometry. Often, a combination of fine, coarse, or another grade of printing is provided in each print job.




In order to change out an engraved roll, the machine must be stopped and partially disassembled for access to the engraved roll. Then the engraved roll is removed and the engraved roll for the next print job installed. Finally, the machine must be reassembled and the machine restarted. This process is time consuming and typically is performed by highly trained maintenance personnel, not the machine operator.




Additionally, in order to change the ink color, the machines are typically provided with liquid lines and pumps for supplying water or another liquid to wash the ink chamber components prior to supplying a different color ink. Because only one ink applicator is provided, it cannot be used while the single ink chamber is being cleaned, so this is often done while the machine is idle between print jobs.




Thus, conventional printer-cutter machines suffer from a number of deficiencies when reconfiguring them between printing and cutting jobs:




(a) To change the print grade, the engraved roll must be changed out. For example, it is common to remove a coarse roll and install a fine roll, or vice versa, between print jobs, sometimes in order to manufacture a single batch of boxes. To access the engraved roll for change-out, the machine must be partially disassembled, the engraved roll replaced, and the machine reassembled, a process which takes a considerable amount of time.




(b) To adjust the machine for a different color printing, the engraved roll and ink chamber mechanism must be cleaned, then the different color ink supplied, sometimes adding significantly to downtime between print jobs.




(c) To change the position of the printing on the blank, the registration of the print roll must be adjusted.




The result is that between printing-cutting jobs, the printer-cutter machine operator typically stands by while maintenance personnel disassemble and reassemble the machine. With the machine disassembled, the operators replace or clean the engraved roll, clean and refill the ink chamber, and/or make any other needed adjustments. These are time-consuming, manual tasks that cannot be performed while the printer-cutter machine is in operation (without interfering with the job in progress). Therefore, the machine is often idle for a significant period of time between printing and cutting jobs while maintenance personnel and the operators make the changes necessary for the next job. For many printer-cutter machines, this downtime is on the order of about 8-10 minutes or so (for only cleaning the ink chamber) or about on hour or so (for changing out the ink roll). This downtime significantly reduces the machines effective efficiency and profitability. Additionally, having qualified personnel available to perform these involved tasks adds to labor costs.




Accordingly, there is a need for a printer-cutter machine for corrugated paperboard blanks that can be quickly and easily configured for printing the desired grades and colors at desired locations on the blanks, with little or no resulting downtime between printing and cutting jobs. Furthermore, there is a need for a machine that provides a wide variety of options in grades and colors of printing so that the engraved roll rarely if ever needs to be changed-out.




SUMMARY OF THE INVENTION




The present invention meets the aforementioned needs by providing a printer-cutter machine that can be refitted for a subsequent printing-cutting job with a downtime typically on the order of about 1-2 minutes or less. The machine has two (or more) ink applicators for each print roll, with each ink applicator having an engraved roll and an ink chamber mechanism. Each print roll can be provided with the associated ink applicators each having engraved rolls with different textured surface matrices and with ink chambers having different colors of ink, so that the ink applicators need to be refitted less often.




For example, one ink applicator can be fitted with an engraved roll having a fine textured surface for high quality graphics printing and the other ink applicator can be fitted with a coarse textured engraved roll for large, bold printing. As a further example, one of the ink applicators can supply black ink to the print roll and another ink applicator can supply red ink. Additional print rolls and ink applicators can be provided, for example, four print rolls each having two ink applicators, thereby providing eight colors of ink available for printing. The invention thus provides the advantage of a wide variety of readily available printing options, both in print quality and color, so that the ink applicators rarely if ever need to be refitted with a different engraved roll or color of ink.




Furthermore, because the machine has two ink applicators for each print roll, one of the ink chambers can be cleaned and refilled with a different color ink while the other ink chamber is in use. This provides the advantage of retracting and refitting one of the ink applicators for a different color of ink for the next print job while the machine is in operation, instead of between jobs with the machine idle.




Additional features of the invention provide the advantage of more efficiently and precisely adjusting the position of the multiple ink applicators, because each ink applicator is now moved between an engaged “in use” position and a retracted “out of use” position. In order to quickly and easily move the ink applicators, each ink applicator can be provided with an applicator adjustment mechanism and an incremental actuator for selectively operating the applicator adjustment mechanism in increments or steps. Thus, by actuating the actuator, the corresponding ink applicator can be quickly and easily moved toward and into a precise position of contacting engagement with the print roll, or retracted away from and out of contacting engagement with the print roll, independent of the other ink applicator. Also, the ink wells may have pivotal mountings so that when the ink applicators are retracted, the ink wells can be easily swiveled to the side for providing access for quick and easy cleaning and maintenance of the ink wells.




Additionally, the machine can be provided in a modular arrangement with a modular feed section, one or more modular print sections, and a modular cutter section, each separably coupled together. Any number of modular print sections can be provided, for example, four of the print sections can be operatively connected together in series with the feed section and the cutter section. The print sections and the feed section and/or cutter section are mounted so that the print sections can be rolled or otherwise moved apart from each other after they are decoupled. This provides the advantage of easy access to the ink applicators and other components for maintenance, and the ability to add, remove, or retrofit entire print sections as may be desired.




Moreover, the present machine includes a print registration adjustment mechanism that allows for efficiently adjusting the registration of the print roll. When the print roll becomes out of registration or before printing a batch of blanks having a different size, a registration adjustment gearmotor can be actuated to selectively drive a differential gear-set and adjust the position of the timing mark on the print roll relative to the leading edge of the blanks, independent of the main drive for the machine. The result is that the print registration can be easily monitored and adjusted, so that the printing is always applied at the desired location on the blank.




Generally described, the invention is a machine for operating on blanks, for example, for performing printing and cutting operations on corrugated paperboard blanks for assembly into boxes. In this configuration, the machine has a feed mechanism, a print mechanism, a cutter mechanism, and a rotary main drive. The feed mechanism has two rotary feed rolls that draw the blanks from a stack of blanks into the machine and transport the blanks in series through the machine.




The print mechanism has a rotary impression roll, a rotary print roll, and at least one ink applicator. The impression roll and the print roll are positioned proximate to each other so that the space between them provides a nip for receiving the blanks in series. Any of a variety of print plates can be mounted onto the print roll, with each print plate having a reverse image of the desired text and/or graphics. Each ink applicator has an ink chamber mechanism and a rotary engraved roll, with the ink chamber mechanism supplying ink to the engraved roll which in turn applies the ink to the print plate. The ink-laden print plate then prints the text and/or graphics onto the blank passing through the nip.




A vacuum transfer mechanism having rotary transfer rollers advances the printed blanks to the cutter mechanism. The cutter mechanism has a rotary anvil roll and a rotary cutting roll with cutting blades attached to it for cutting the blanks as desired, for example, to form flaps for folding into a box.




The main drive rotationally drives the feed mechanism, the print mechanism, and the cutter mechanism. Accordingly, the main drive has a rotary power source such as an electric motor that is operatively connected to one or more of the feed rolls, which is operatively connected to a rotary transmission shaft, which is operatively connected to the impression roll, the print roll, the engraved rolls, transfer rolls, the anvil roll, and the cutter roll.




According to one aspect of the invention, the machine can have two (or more) ink applicators for each print roll. Additional ink applicators can be provided for each print roll as may be desired in a given situation. Each of the engraved rolls can have a different surface texture, for example, one engraved roll for “fine” grade printing might have a textured surface with an ink-carrying matrix of a relatively large number of shallow cells. Another engraved roll for “coarse” grade printing might have a surface matrix of a smaller number of deeper cells. Of course, other engraved rolls with other textured surface matrices can be provided for producing the desired print grade.




Additionally, each ink chamber mechanism can have a support member, an ink well coupled to the support member for storing the ink, and two or more doctor blades extending from the ink well and contacting the engraved roll for applying the ink to the engraved roll. The ink wells can be coupled to the corresponding support member by a pivotal coupling, and the support members can be coupled to the corresponding engraved roll or other component so that the ink chamber mechanism and the engraved roll move together. Also, an ink chamber adjustment mechanism with at least one flexible tube can be provided for each ink chamber mechanism, for inflating and deflating the tube or tubes to move the ink chambers between an engaged position with the corresponding engraved roll and a retracted position.




Another aspect of the invention is an applicator adjustment mechanism for precisely moving each ink applicator, and actuators for quickly and easily operating each applicator adjustment mechanism. For example, each applicator adjustment mechanism can have two eccentric bearings for rotationally mounting the corresponding ink applicator to the machine, with the engraved roll axles off-center of the bearing axis so that rotating the eccentric bearings causes the ink applicator to move toward or away from the corresponding print roll independent of the other ink applicator. Also, each applicator adjustment mechanism can have an adjustment shaft with spur gears that drive spur gears on the eccentric bearings for rotating the eccentric bearings, a primary rotary actuator for rotating the adjustment shaft, a travel limiting mechanism for adjusting the rotational range limits of the primary actuator, and a secondary incremental actuator for incrementally adjusting the travel limiting mechanism. Thus, the ink applicators can be incrementally moved into the precise engaged position desired, or moved to the retracted position.




Alternatively, each applicator adjustment mechanism can have one or more pivot arms and actuators. The ink applicators are mounted on the pivot arms so that, upon operation of the actuator, the ink applicators pivot between the engaged and retracted positions. Additionally, the applicator adjustment mechanisms can include stops with eccentric cams for limiting and adjusting the pivotal travel of the pivot arms and ink applicators.




In a further aspect of the invention, the machine can be provided with a modular feed section, one or more modular print sections, and a modular cutter section. The modular feed section includes the feed mechanism and the feed drive supported by a feed section frame, the modular print sections each include one (or more) of the print mechanisms and one (or more) of the print drives supported by a print section frame, and the modular cutter section includes the cutter mechanism and the cutter drive supported by a cutter section frame. The feed drive transmission shaft is rotationally driven by the feed rolls, each print drive transmission shaft rotationally drives the corresponding print roll, impression roll, and engraved rolls, and the cutter drive transmission shaft rotationally drives the cutter roll and the anvil roll.




Any number of modular print sections can be provided, for example, four of the print sections can be operatively connected together in series with the feed section and the cutter section. The transmission shaft of each print section has an input end that can be separably coupled to an output end of the feed section transmission shaft (for the first print section) or to an output end of a preceding print section transmission shaft (for the second or third print section). Similarly, each print section transmission shaft of has an output end that can be separably coupled to an input end of the cutter section transmission shaft (for the fourth print section) or to an input end of another print section transmission shaft (for the second or third print section). The separable couplings can be provided by a spline-type coupling or another separable coupling permitting quick and easy disconnection of the transmission shafts. Additionally, the machine can have a track and roller bearings riding on the track and supporting the print section frames and the feed or cutter frame, so that the print sections can be rolled apart from each other after they are decoupled, for access to the ink applicators and other components for maintenance.




Accordingly, the machine can be employed in a method for retrofitting a pre-existing printer-cutter machine to provide increased printing options, where the pre-existing printer-cutter machine has a feed section, print section, and cutter section, each with a transmission shaft. In particular, the method comprises the steps of decoupling the transmission shaft of the pre-existing print section from the transmission shaft of the adjacent feed section or cutter section, and removing the pre-existing print section from adjacent the feed section and the cutter section. The method further comprises the steps of providing at least one print section having a rotary print roll, at least two ink applicators for each print roll, and a transmission shaft, wherein each ink applicator has an engraved roll and an ink chamber mechanism, disposing the print section adjacent the feed section or the cutter section, aligning the transmission shaft of the print section with the transmission shaft of the adjacent feed section or the transmission shaft of the adjacent cutter section and coupling the transmission shaft of the print section with the transmission shafts of the adjacent feed, print, and/or cutter section.




In still another aspect of the invention, each print drive can be connected to a registration adjustment mechanism. The registration adjustment mechanism has a differential gear-set that is operatively connected to a gearmotor and to the print roll, and that is selected so that actuation of the gearmotor changes the rate of rotation of the print roll. Thus, the print roll rate of rotation, which is controlled by the print drive, can be changed by actuation of the gearmotor.




In view of the foregoing, it will be appreciated that the present printer-cutter machine provides a substantial improvement over the prior art by producing a significant reduction in downtime between printing-cutting jobs. The specific techniques and structures employed by the invention to improve over the drawbacks of the prior systems and accomplish the advantages described above will become apparent from the following detailed description of the embodiments of the invention and the appended drawings and claims.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a longitudinal cross sectional view through an exemplary printer-cutter machine according to the present invention, showing a feed section, four print sections, and a cutter section.





FIG. 1A

is a detail view of a lower portion of one of the print sections of

FIG. 1

, showing two ink applicators and a print roll.





FIG. 1B

shows the printer-cutter machine with the ink applicators of the print sections configured in an exemplary arrangement.





FIG. 1C

shows the printer-cutter machine with the ink applicators of the print sections configured in another exemplary arrangement.





FIG. 2

is a cross sectional view through the ink applicator taken along line


2





2


of

FIG. 1B

, showing an engraved roll and an ink chamber mechanism.





FIG. 2A

is a cross sectional view through the ink applicator taken along line


2


A—


2


A of FIG.


2


.





FIG. 2B

is an exploded view of the ink chamber mechanism of

FIG. 2

, showing the ink well and other components of the ink chamber.





FIG. 2C

is a cross sectional view through the ink well taken along line


2


C—


2


C of FIG.


2


B.





FIG. 2D

is a cross sectional view through the ink well taken along line


2


D—


2


D of FIG.


2


B.





FIG. 2E

is a cross sectional view through the ink well taken along line


2


E—


2


E of FIG.


2


B.





FIG. 2F

is a cross sectional view through the ink well taken along line


2


F—


2


F of FIG.


2


B.





FIG. 2G

is a cross sectional view through the ink applicator taken along line


2


A—


2


A of

FIG. 2

, showing the adjusted position of the ink well after wear of the doctor blades of the ink chamber.





FIG. 2H

is a cross sectional view through an alternative ink applicator, showing a linearly adjusted alternative ink chamber mechanism in a retracted position.





FIG. 2I

is a cross sectional view of a support plate of the ink applicator of FIG.


2


H.





FIG. 2J

is a cross sectional view of the ink applicator of

FIG. 2H

, showing the ink chamber mechanism in an engaged position.





FIG. 2K

is a cross sectional view of the ink applicator of

FIG. 2H

, showing the ink chamber mechanism in an engaged position with worn blades.





FIG. 3

is a cross sectional view through the print section taken along line


3





3


of

FIG. 1A

, showing an engraved roll of one of the ink applicators, an applicator adjustment mechanism, a primary actuator for movably positioning the ink applicators, and an idle drive mechanism for independently rotating the engraved roll.





FIG. 3A

is a detail view of the actuator of

FIG. 3

, and showing a secondary actuator and travel limiting mechanism connected thereto.





FIG. 3B

a cross sectional view through the print section taken along line


3





3


, showing an alternative idle drive mechanism.





FIG. 3C

is a detail view of an alternative applicator adjustment mechanism, showing a dual pivot arm arrangement.





FIG. 3D

is a cross sectional detail view of a portion of the alternative applicator adjustment mechanism of

FIG. 3C

taken along line


3


D—


3


D, showing a cam stop arrangement.





FIG. 3E

is a detail view of another alternative applicator adjustment mechanism, showing a single pivot arm arrangement.





FIG. 3F

is a cross sectional detail view of a portion of the alternative applicator adjustment mechanism of

FIG. 3E

taken along line


3


F—


3


F, showing a cam stop arrangement

FIG. 4

is a side view of one of the print sections, showing the ink applicators and the transfer mechanism.





FIG. 5

is a cross sectional side view of the transfer mechanism taken through the print section along line


5





5


of FIG.


4


.





FIG. 5A

is a cross sectional plan view of the transfer mechanism taken through the print section along line


5


A—


5


A of FIG.


4


.





FIG. 6

is a right side view of the machine showing the transmission shaft of the rotary drive mechanism.





FIG. 7

is a right side view of the machine showing the belts and sprockets of the feed drive mechanism and the first print drive mechanism.





FIG. 8

is a left side view of the machine showing the belts and sprockets of the second rotary print drive mechanism.





FIG. 9

is a cross sectional view taken through the print mechanism showing the print registration mechanism.





FIG. 10

is a left side view of the machine showing the operator controls.





FIG. 11

is a left side view of the machine showing the ink and water supply lines.











DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS




Referring now to the drawings,

FIG. 1

illustrates an exemplary embodiment of the present invention, referred to generally as printer-cutter machine


10


. The machine


10


operates on blanks


12


made of materials such as corrugated paperboard, plastic, wood, fiberglass, fabric, composites, and so forth. While the embodiment described herein is a printer-cutter machine for printing and cutting the blanks, the invention can be embodied in a machine that only prints on the blanks. Also, the machine can be adapted for performing other operations on the blanks, such as painting, applying a film layer, affixing labels, folding, bending, perforating, scoring, and so forth.




The machine


10


has a machine frame


14


, a feed mechanism


16


, four print mechanisms


18




a


-


18




d


(collectively the “print mechanisms


18


”), and a cutter mechanism


20


. The feed mechanism


16


has two or more rotary feed rolls


22


that are rotationally mounted to the frame


14


by, for example, rotary bearings. The feed rolls


22


rotate in opposite directions, draw the blanks


12


from a stack of blanks into the machine


10


, and feed the blanks


12


in series to the print mechanisms


18


.




The print mechanisms


18


each have an impression member such as rotary impression roll


24


, and a rotary print roll


26


, which are each mounted to the frame


14


by, for example, rotary bearings. A print plate


27


can be removably mounted to the print roll


26


for printing the desired text and/or graphics for a particular print job. The space between the impression roll


24


and the rotary print roll


26


forms a nip


28


for receiving the blanks


12


in series.




The cutter mechanism


20


has a rotary anvil roll


30


and a rotary cutter roll


32


that are mounted to the frame


14


by, for example, rotary bearings. The blanks


12


are cut by the cutter roll


32


as the blanks


12


pass through the nip between anvil roll


30


and the cutter roll


32


.




The nip


28


of the print mechanism


18


, the nip of the cutter mechanism


20


, and the nip of the feed mechanism


16


are adjusted by conventional nip adjustment mechanisms known in the art. Also, the feed mechanism


16


, the print mechanism


18


, and the cutter mechanism


20


, can be driven by a rotary drive with sprockets and chained belts, by one or more gear trains, by a combination thereof, or by another drive assembly know in the art. An example of a belt-driven printer-cutter machine having a similar feed mechanism, cutter mechanism, impression roll, print roll, and nip adjustment mechanisms, with a detailed description of its components, manufacture, and operation, is provided by U.S. Pat. No. 6,062,751 to Baum, which is hereby incorporated by reference in its entirety.




In the present exemplary embodiment, the machine


10


is provided with the feed mechanism


16


, the print mechanisms


18


, and the cutter mechanism


20


each included in a modular feed section


34


, modular print sections


36




a-d


(collectively the “print sections


36


”), and a modular cutter section


38


, respectively. Accordingly, the modular feed section


34


includes the feed mechanism


16


rotationally driven by a rotary feed drive


35


(see

FIG. 6

) and independently mounted to a feed section frame


40


of the machine frame


14


. Similarly, the modular print sections


36


include the print mechanisms


18


which are rotationally driven by rotary print drives


37




a


-


37




d


(collectively the “print drives


37


”) (see FIG.


6


), and independently mounted to print section frames


42




a-d


(collectively the “print section frames


42


”) of the machine frame


14


. Furthermore, the modular cutter section


38


includes the cutter mechanism


20


rotationally driven by a rotary cutter drive


39


(see FIG.


6


), and independently mounted to a cutter section frame


44


of the machine frame


14


.




Alternatively, the machine


10


can be provided with the feed mechanism


16


, the print mechanism


18


, and the cutter mechanism


20


rotationally driven by a rotary main drive with only one or another number of belts or gear trains, and mounted to a unitary machine frame, as is known in the art. Also, the machine


10


can be provided with only the feed mechanism


16


and the print mechanism


18


, with only the feed mechanism


16


and the cutter mechanism


20


, with the feed mechanism


16


and/or the print mechanism


18


in combination with other machine sections for performing other operations on the blanks


12


, and in other sequences such as arranging the cutter mechanism


20


before the print mechanism


18


. Furthermore, although four of the print sections


36


are provided in this exemplary embodiment, any number of the print sections


36


can be suitably employed, as may be desired in a given application.




Referring now to

FIG. 1A

, each of the print sections


36


has two ink applicators


46


. Each ink applicator


46


has a rotary ink roll such as engraved roll


50


, and an ink chamber mechanism


52


for supplying ink to the engraved roll. The engraved rolls


50


each have an axle


51


and rotate in a direction opposite to the print roll


26


, thereby transferring ink to the rotary print roll


26


. An ink applicator guard


48


can be mounted to the print section frame


42


adjacent to each ink applicator


46


.




Each ink applicator


46


is mounted proximate to the corresponding print roll


26


to which it applies ink. Proximate in this instance means that each ink applicator


46


is positioned sufficiently close to the print roll


26


so that the ink applicators


46


can be moved between an “engaged” position contacting the print roll


26


and a “retracted” position not in contact with the print roll


26


. Of course, additional ink applicators


46


can be provided for each print roll


26


, as may be desired in a given application for providing additional printing color and grade options. The machine


10


thereby can be configured with four (or another number) of print sections


36


each having two (or more) ink applicators


46


. This arrangement permits a wide variety of printing options by a single machine


10


without refitting the ink applicators.




For example, as shown in

FIG. 1B

, the machine


10


can be configured with each of the print sections


36


having one ink applicator


46


with a fine grade engraved roll


50


and another ink applicator with a coarse grade engraved roll. Each print section can have an ink chamber


52


with a different color of ink such a black, red, green, yellow, and/or another color. Such an arrangement provides the option of printing any or all of the primary colors, in either of two different print grades (where only one engraved roll is engaged at a time), in a single run of blanks


12


through the machine


10


without having to change out any engraved rolls.




Thus, for one print job, all four print sections


36




a-d


can have an ink applicator engaged. For instance, black and red can be printed in a fine grade by print section


36




a


and


36




b


, while green and yellow are printed in a coarse grade by print section


36




c


and


36




d


, all in one pass through the machine


10


.




For the next print job, only one or another number of print sections


36


might have an ink applicator


46


engaged. For instance, one of the ink applicators


46


of print section


36




a


can be engaged for printing black in a coarse grade for one print job. Then for the next print job, that black ink applicator can be retracted and another of the ink applicators of another print section


36




b


having a red ink and a fine grade engraved roll can be engaged, without having to replace any engraved rolls


50


.




In another example, as shown in

FIG. 1C

, the machine


10


can be configured with each of the print sections


36


having one ink applicator


46


with an ink chamber


52


having one color of ink such black, and another ink applicator with an ink chamber having another color of ink such a red. Each print section


36


can have engraved rolls


50


with different surface matrices (i.e., different line screens, cell volumes, and/or cell geometries, and so forth) for producing different print grades, as described above. For instance, the first print section


36




a


can have engraved rolls


50


of a first grade “G


1


” for printing very finely detailed images and vignettes, the second print section


36




b


can have engraved rolls of a second grade “G


2


” for printing images and fine vignettes, the third print section


36




c


can have engraved rolls of a third grade “G


3


” for printing intermediate thickness lines and text, and the fourth print section


36




d


can have engraved rolls of a fourth grade “G


4


” for printing heavy lines and solids. Such an arrangement provides the option of printing two different print colors in a four different print grades during one pass through the machine, without having to change out engraved rolls.




Thus, for one print job, all four print sections


36




a-d


can have an ink applicator


46


engaged. For instance, black can be printed in grades G


1


, G


2


, and G


4


, by print sections


36




a


,


36




b


, and


36




d,


respectively, while red is printed in grade G


3


by print section


36




c


, all in one pass through the machine.




For the next print job, only one or another number of print sections


36


might have an ink applicator


46


engaged. For instance, one of the ink applicators


46


of print section


36




d


can be engaged for printing black in grade G


4


for bold lettering. Then for the next print job, that coarse grade G


4


ink applicator can be retracted and another one of the ink applicators of print section


36




a


having a red ink and a fine grade G


1


engraved roll can be engaged, without having to replace an engraved roll.




Of course, the configurations shown in

FIGS. 1B and 1C

are only two of many possible machine configurations. Each machine


10


can be configured with the number of print sections


36


and the grade of engraved rolls


50


for each print section selected based on the type of printing typically done in each application. Because of the wide variety of available printing options provided, the engraved rolls


50


rarely if ever need to be changed out. Therefore, the machine


10


can be set up quickly and easily for a subsequent print job simply by retracting and/or engaging the appropriate ink applicators


46


to produce the desired print color and grade.




Referring now to

FIGS. 2 and 2A

, each engraved roll


50


has a textured surface


54


for receiving ink from the ink chamber mechanism


52


and applying the ink to the print plate


27


. For example, the textured surface can be provided by an ink-carrying cell matrix as described above so that ink supplied from the ink chamber mechanism


52


can accumulate in the cells of the surface matrix for transfer to the print roll


26


. For example, engraved rolls


50


having surfaces


54


with relatively shallow cells can be used to apply a relatively thin layer of ink for producing fine grade printing such as graphics and bar codes. Conversely, engraved roll surfaces


54


with relatively deep recesses can be used to apply a relatively thick layer of ink for producing relatively dense, bold, printing. The engraved rolls


50


can be made of or coated with a ceramic, or optionally can be made of or coated with a rubber, polymer, metal, composite, or other material known in the art and selected for the particular application. Suitable engraved rolls are commercially available, such as the ANILOX™ rolls made by the Harper Corporation of America, of Charlotte, N.C.




Referring to

FIGS. 2

,


2


A, and


2


B, the ink chamber mechanisms


52


each have a support member such as support plate


56


, a base member


64


coupled to the support plate


56


, an ink well


58


coupled to the base member


64


, and two or another number of doctor blades


60


extending from the ink well


58


generally towards the corresponding engraved roll


50


. The ink well


58


can be provided by an elongate U-shaped bar made of metal (see FIGS.


2


C-


2


F). Alternatively, the ink well


58


can be provided by a length of channel, a housing with a slit, or another structure that can hold ink in a recessed portion thereof, and which is made of a metal, plastic, glass, fiberglass, ceramic, composite, or other material. The blades


60


are semi-rigid with sufficient flexibility so that they can deflect to prevent getting caught in the textured recesses of the engraved roll surfaces


54


. Thus, the blades


60


can be made of a polyethylene, or optionally can be made of a metal, plastic, elastomer, fiberglass, composite, or other material. The leading blade


60


contains the ink in the chamber and the trailing blade doctors ink from the surface of the print roll


26


, except for the ink left in the engraved cells. The base member


64


can be provided by a tube, bar, block, or the like, that is made of a metal, plastic, composite, or other material.




The ink can be supplied to the ink wells


58


by an ink inlet line


57


connected to an ink reservoir


55


(see FIG.


11


). Ink can flow from the reservoir to the ink well


58


by the use of a pump


61


(see

FIG. 11

) or by gravity where the reservoir is positioned above the ink wells


58


. Also, an ink outlet line


59


can be connected to the ink well


58


for cycling or draining the ink from the ink well. Valving and metering (not shown) can be provided in the ink inlet and/or outlet lines


57


and


59


, as may be desired. Additionally, water or other fluid lines


63


(see

FIG. 11

) can be connected to the ink lines to provide for cleaning the ink applicators. This ink and water supply arrangement is well known in the art of printer-cutter machines. Alternatively, the ink chamber mechanisms


52


can be provided with replaceable ink cartridges that insert into and supply ink to the ink wells


58


, or the ink chamber mechanisms


52


themselves can be provided by ink cartridges with ink application pads, blades, or the like.




Additionally, the ink chamber mechanisms


52


can each have an adjustment mechanism for moving the corresponding ink chamber mechanism


52


between an engaged position with the corresponding engraved roll


50


and a retracted position. Each adjustment mechanism can include a generally flexible tube


62


mounted on the base member


64


and supporting the ink well


58


. A fluid line


63


for delivering pressurized air or another fluid is connected to the flexible tube


62


. The tube


62


can be selectively inflated to bias the ink well


58


and blades


60


against the corresponding engraved roll


50


as desired. Accordingly, the flexible tube


62


can be made of an elastomer, plastic, composite, or other material suitable for carrying pressurized air.




Referring to

FIG. 2G

, as the blades


60


wear from use, the flexible tube


62


expands with generally constant air pressure to adjust the position of the blades


60


to maintain proper contact pressure with the engraved roll


50


. Because the blades


60


are often arranged at different angles relative to the engraved roll


50


, they wear at different rates. To account for this, a pivotal member such as pivot arm


65


can support the ink well


58


and be pivotally mounted to the support plate


56


by a pivotal coupling as is known in the art. The ink well


58


is thereby permitted to pivot so that both blades


60


can be maintained with proper pressure of contact with the engraved roll


50


. As shown in this figure, when the blades


60


are worn down from use, the flexible tube


62


expands and the ink well


58


is pivoted by the pivot arm


65


to keep the worn blades


60


in contact with the engraved roll


50


.




The ink well


58


and base


64


are mounted to a pivot plate


67


that is pivotally coupled to the corresponding support plate


56


by a pivotal coupling


66


such as a pin, rivet, dowel, bolt, screw, or other fastener permitting a pivotal motion. A lock secures the pivot plate


67


in place on the support plate


56


. For example, the lock can be provided by a removable lock pin


68


inserted through aligned apertures in the pivot plate


67


and the support plate


56


. When the lock pin


68


is removed, the pivot plate


67


can be pivoted about the pivotal coupling


66


and to the side to provide access to the ink well


58


for cleaning and maintenance. Alternatively, the lock can be provided by a removable lock pin or the like inserted through an aperture in the support plate


56


and abutting the pivot plate


67


, or by a clamp, pivotal arm, flange, or hook, or other lock mechanism.




The mounting of the ink chamber


52


allows the ink applicator to move toward or away from the print roll


26


. Accordingly, each support plate


56


is rotationally coupled to an eccentric bearing


78


(see

FIG. 2

) or another bearing supporting the corresponding engraved roll


50


. The rotational coupling can be provided by, for example, a bushing, rotational bearing, or another coupling, so that the ink chamber


52


can be moved into the engaged or retracted position together with the rotating engraved roll


50


. Alternatively, the support plate


56


can be rotationally coupled to the engraved roll axle


51


, the machine frame


42


, or another component of the machine.




Additionally, the ink chamber mechanism


52


is slidably coupled to the print section frame


42


so that the ink applicator


46


is permitted to slide toward and away from the print roll


26


. For example, the support plate


56


can have a slot


72


defined therein and the print section frame


42


can have a post


74


extending through the slot


72


, so that the support plate


56


can slide relative to the frame


42


(see FIG.


1


A). Alternatively, a slot can be defined in the frame and a post can extend from the plate, or other slidable mounting arrangements can be provided.




Referring now to

FIGS. 2H and 2I

, there is shown an alternative ink chamber mechanism


52




a


that can be linearly adjusted for selectively applying ink to the engraved roll


50


. Similar to the ink chamber mechanism


52


, the alternative ink chamber mechanism


52




a


has a support member


56




a


(see FIG.


2


H), a base member


64




a


coupled to the support member


56




a


, an ink well


58




a


coupled to the base member


64




a


, and an ink chamber adjustment mechanism such as a first inflatable flexible tube


62




a


disposed between the ink well


58




a


and the base member


64




a


. The base member has a first side


53




a


and a second side


55




a


that is opposite the first side


53




a


, and the first tube


62




a


is disposed adjacent the first side


53




a


. Also, the support plate


56




a


can have a stop hole


85




a


defined therein for receiving the lock pin


68




a


when the pivot plate


67




a


is pivoted about the pivot point


66




a


for cleaning and maintenance of the ink well


58




a


. Additionally, the ink chamber adjustment mechanism can include a linear guide mechanism having a guide plate


71




a


disposed adjacent the second side


55




a


, a second inflatable flexible tube


69




a


that is disposed between the second side


55




a


and the guide plate


61




a


, and one or a number of guide posts


73




a


coupled to the ink well


58




a


and the guide plate


71




a


and extending through the base member


64




a


. Any number of guide posts


73




a


can be provided, for example, four pairs of guide posts


73




a


have proven suitable. A housing can be provided for the base member


64




a


, first tube


62




a


, guide plate


71




a


, second tube


69




a


, and the guide posts


73




a


, as may be desired.





FIG. 2H

shows the alternative ink chamber mechanism


52




a


fitted with new blades


60




a


and in a retracted position.

FIG. 2J

shows the ink chamber mechanism


52




a


fitted with new blades


60




a


and in an engaged position.

FIG. 2K

shows the engaged ink chamber mechanism


52




a


after the blades


60




a


have worn down from use. As can be seen in the drawings figures, the first tube


62




a


can be selectively inflated and the second tube


69




a


deflated to bias the ink well


58




a


into an engaged position relative to the engraved roll


50


, and the first tube


62




a


can be selectively deflated and the second tube


69




a


inflated to bias the ink well


58




a


into a retracted position. The linear guide mechanism provides for linearly moving the ink chamber mechanism


52




a


between the engaged and retracted positions and in an axial direction relative to the corresponding engraved roll


50


. This provides the advantage of the angle of the blades


60




a


relative to the engraved roll


50


remaining constant as the blades


60




a


wear, for uniform printing over the life of the blades


60




a.






Referring now to

FIG. 3

, an applicator adjustment mechanism


76


is provided for moving each ink applicator


46


between the engaged and retracted positions. Thus, a print section


36


with two ink applicators


46


can also have two applicator adjustment mechanisms


76


, so that each ink applicator


46


can be engaged or retracted independent of each other ink applicator


46


. The exemplary applicator adjustment mechanism described herein includes eccentric bearings as described below, but other adjustment mechanisms for moving the ink applicators between the engaged and retracted positions can be suitably employed, such as those having a rack and pinion gear-set, piston-cylinder mechanism, cam arrangement, and so forth.




Each applicator adjustment mechanism


76


has two eccentric bearings


78


, with one of the eccentric bearings


78


rotationally mounted by, for example, a rotary bearing on one end of the engraved roll axle


51


and the other eccentric bearing


78


rotationally mounted by, for example, a rotary bearing on the other of the engraved roll axle


51


. Also, one of the eccentric bearings


78


is rotationally mounted by, for example, a rotary bearing to the left side of the print section frame


42


and the other eccentric bearing


78


is rotationally mounted by, for example, a rotary bearing to the right side of the print section frame


42


.




The eccentric bearings


78


are generally disc-shaped and mounted onto the engraved roll axle


51


at an off-center position of the eccentric bearings


78


. Alternatively, the eccentric bearings


78


can have another regular or irregular shape. Because the engraved roll axle


51


is off-center and rotationally mounted relative to the eccentric bearings


78


, rotating the eccentric bearings


78


causes the corresponding engraved roll


26


to move in a radial direction relative to the print roll


26


, that is, closer to or farther away from the print roll


26


.




Additionally, when the machine is stopped for rest breaks, lunch, maintenance, jams, etc., it is desirable to keep the inked engraved rolls rotating to prevent the ink on them from drying. Therefore, an idle drive mechanism can be provided for rotating the engraved rolls independent of the drive (described below) for the corresponding ink applicator. The idle drive mechanism can include a clutch


77


such as a FORMSPRAG™ overriding clutch Model 500 connected to one of the eccentric bearings


78


, the engraved roll axle


51


, or another component of the machine. A motor


79


such as an electric motor, and a gear-set


81


such as a MORSE RAIDER™ worm reducer Model 206QH56 Style QHVL can be connected to the clutch


77


for independently rotating the engraved roll


50


. Another clutch


77


, motor


79


, gear-set


81


, and/or control or other component of types known in the art can be provided, as may be desired.




In order to rotate the eccentric bearings


78


, each applicator adjustment mechanism


76


has an eccentric bearing gear


80


formed on or mounted to each of the eccentric bearings


78


, an adjusting shaft


82


rotationally mounted to the frame by, for example, a rotary bearing, and an adjusting shaft gear


84


mounted to or formed on the adjusting shaft


82


and driving the eccentric bearing gear


80


. The adjusting shaft gear


84


can mesh with and drive the eccentric bearing gear


80


directly, or one or more intermediate gears can be provided to accomplish the desired gear ratio, rotational direction, and/or axial separation. The adjusting shaft


82


can be rotated by a ratchet, wheel, crank, motor, or other mechanism for generating a rotary motion to move the corresponding ink applicator


46


.




Referring further to

FIG. 3A

, in order to provide for quick and easy adjustment of the ink applicators


46


between the engaged and retracted positions, a primary actuator


90


can be provided for rotating the adjustment shaft


82


. The actuator


90


is coupled to the adjusting shaft


82


and mounted to the print section frame


42


, a guard panel


92


, or another component of the machine


10


. The actuator


90


can be a rotary actuator


90


with a pinion gear


86


that mounts onto the adjusting shaft


82


, one or more rack gears


88


meshing with the pinion gear


86


, and one or more air or other fluid cylinders


89


(or other linear travel mechanism) each with a piston


91


that is slidable within the cylinder and that engages one of the rack gears


88


.




A suitable rotary actuator is Model 8000 sold by PHD™, Inc. of Fort Wayne, Ind. Alternatively, another type of rotary or linear actuator can be suitably employed, such as an electric motor that is coupled directly to the adjusting shaft


82


, a solenoid, piston-cylinder, or other linear travel mechanism driving a worm gear-set or a spring-loaded lever or pull rod, or anther actuator for rotationally driving the adjusting shaft


82


. In some applications, it may be desirable to provide the rack gear


88


and the pinion gear


86


separate from the actuator


90


and mounted to or formed on the adjusting shaft


82


. Thus, by actuating one of the actuators


90


, the machine operator can move the corresponding ink applicator


46


between the engaged and retracted positions.




In order to provide for quickly and easily adjusting the ink applicators


46


into very precise engaged (and retracted) positions, a travel limiting mechanism


93


can be provided for precisely controlling the operation of the primary actuator


90


. Also, a secondary actuator


95


can be operatively coupled to the travel limiting mechanism


93


for precisely controlling the travel limiting mechanism.




Where the primary actuator


90


includes a piston-cylinder or other linear travel mechanism, the travel limiting mechanism


93


limits the linear travel of the rack gear


88


, and thus limits the rotation of the adjusting shaft


82


and the controls the exact position of the ink applicator


46


. In this case, the travel limiting mechanism


93


can be provided by an axial member


97


with an end that that extends into the actuator


90


, abuts the piston


91


, the rack gear


88


, or another component of the actuator (when the piston is at the end of its reciprocating travel), and can be linearly extended or retracted to adjust the limit of the travel. Thus, the axial member


97


can be provided by a threaded screw or bolt that mates with a corresponding threaded portion of the actuator


90


, and a first pinion gear


99


can be mounted to or formed onto the screw or bolt. Alternatively, the axial member


97


can be provided by a rack gear, worm gear, pin, cam, or the like.




The travel limiting mechanism


93


can further include a second pinion gear


101


connected to and driven by the secondary actuator


95


, and meshing with the first pinion gear


99


. The first and second pinion gears


99


and


101


can be selected to be sufficiently wide so that when the first pinion gear


99


is axially extended and retracted into and out of the actuator


90


, the first and second pinion gears remain meshed and operatively engaged.




The secondary actuator


95


can be mounted to the machine frame


42


, the machine guard panel


92


, or another component of the machine


10


. The secondary actuator


95


can be provided by an incremental actuator such as a commercially available stepper motor that can be operated in discrete, uniform increments, to very precisely control the position of the ink applicator. Thus, the secondary actuator


95


is selected for imparting a precise and controllable motion to the travel limiting mechanism


93


. An example of a suitable stepper motor is that made by Arrick Robotics™ of Hurst, Tex. Of course, other travel limiting mechanisms


93


and secondary actuators


95


can be selected as desired for limiting the travel of other types of rotary or linear actuators


90


.




Referring to

FIG. 3B

, there is illustrated an alternative idle drive mechanism for rotating the engraved rolls


50


independent of the drive (described below) for the corresponding ink applicator


46


. Similar to the above-described idle drive mechanism, there is provided a first overriding clutch


77




a


directly connected to the engraved roll axle


51


, or indirectly connected thereto via another component of the machine. A second overriding clutch


77




b


is connected to the first clutch


77




a


via a coupling


87


such as an Oldham™ coupling. A motor


79




a


such as an electric motor is connected to the second clutch


77




b


, for independently rotating the corresponding engraved roll


50


. Another number or type clutches


77




a


and


77




b


and/or coupling


87


can be provided, as may be desired.

FIG. 3B

also shows pivot arms


200


of an alternative applicator adjustment mechanism


76




a


described immediately below.




Referring to

FIGS. 3D and 3E

, there is illustrated alternative applicator adjustment mechanism


76




a


, which comprises pivot arm


200


and an actuator


202


. One applicator adjustment mechanism


76




a


is provided for each ink applicator


46


, with the ink applicator


46


mounted to the pivot arm


200


and the actuator


202


operatively coupled to the pivot arm


200


. Each pivot arm


200


is pivotally coupled to the frame


42


or another component of the machine at pivot point


204


. The actuators


202


are provided by conventional air cylinders, though hydraulic cylinders, other fluid cylinders, worm gear actuators, electric motors, or other actuators known in the art can be suitably employed. Alternatively, a rotational actuator can be positioned to engage the end of the pivot arm for pivoting the arm, by including gears if desired.




Upon operation of one of the actuators


202


, the corresponding pivot arm


200


is pivoted so that the corresponding ink applicator


46


is pivoted about the pivot point


204


and between the engaged position and the retracted position. The pivotal range of motion of the pivot arms


200


can be limited by stops


206


. Additionally, the stops


206


can be provided by eccentric cams


208


mounted on shafts


210


, which can be rotated to adjust the limit of the pivotal motion of the corresponding pivot arm


200


.




Referring to

FIGS. 3F and 3G

, there is illustrated another alternative applicator adjustment mechanism


76




b


comprising a pivot arm


300


and an actuator


302


(similar to actuator


202


). One applicator adjustment mechanism


76




a


is provided for two or more ink applicators


46


(and thus for each print roll


26


), with the ink applicators


46


mounted to the pivot arm


300


and the actuator


302


operatively coupled to the pivot arm


300


. The pivot arm


300


is pivotally coupled to the frame


42


or another component of the machine at pivot point


304


, with the pivot point


304


positioned between the ink applicators


46


. Upon operation of the actuator


302


, the pivot arm


300


and ink applicators


46


are pivoted between the engaged position and the retracted position. The pivotal range of motion of the pivot arm


300


can be limited and adjusted by stops


306


having eccentric cams


308


mounted on shafts


310


, similar to the arrangement described above.




It will be understood that the applicator adjustment mechanism can be provided with more than two pivot arms, each with at least one ink applicator, for each print roll. Additionally, three or more ink applicators can be provided on a single pivot arm. Furthermore, where multiple ink applicators are provided on each pivot arm, each ink applicator can be adjustable by an eccentric gear mechanism operatively coupled to the pivot arm, similar to the eccentric gear mechanism described above. Moreover, other configurations and combinations of pivot arms and eccentric gear mechanisms can be suitably employed.




Referring to

FIGS. 4

,


5


, and


5


A, the blanks


12


are drawn through the nip


28


of the print mechanism


18


by a transfer mechanism such as a vacuum transfer mechanism


94


. The vacuum transfer mechanism


94


has a suction mechanism


96


, a vacuum housing


98


, and one or a plurality of transfer rollers


100


. The suction mechanism


96


can be provided by a commercially available device for creating a vacuum. The vacuum housing


98


is connected to the suction mechanism


96


by a conduit


102


, which can be linear, curved, or have another shape. Also, the vacuum housing


98


has openings


104


defined therein for air intake, and the transfer rollers


100


extend through the openings


104


. The transfer rollers


100


can have covers made of urethane or another generally soft, pliable material that provides a high coefficient of friction.




Air is suctioned through the portion of the openings


104


not blocked by the rollers


100


and into the housing


98


, thereby drawing the blanks


12


up and into contact with the rollers


100


. Thus, the transfer rollers


100


contact and impart motion to the blanks


12


on their top sides instead of on their freshly printed bottom sides to avoid smudging the printing. The blanks


12


are thereby pulled through the print section


36


and transported on to another section for further operation as may be desired. Similar vacuum transfer mechanisms are known in the art, and other transfer mechanisms known in the art can be suitably employed.




Referring now to

FIG. 6

, the machine has a main drive mechanism that rotationally drives the feed mechanism


16


, the print mechanisms


18


, and the cutter mechanism


20


. The main drive mechanism includes a rotary power source such as an electric motor


106


, the modular feed drive


35


, the modular print drives


37


, and the modular cutter drive


39


. Alternatively, the main drive can have only one or two belts or gear trains that interconnect and rotationally drive the feed mechanism


16


, the print mechanisms


18


, and the cutter mechanism


20


all together. Thus, the term “main drive” as used herein includes drive systems having a plurality of sprockets interconnected and synchronously driven by a belt such as a toothed belt, chained belt, or chain, one or more gear trains with a plurality of meshing gears, and other mechanical and electrical drive trains known in the art.




Referring to

FIGS. 6 and 7

, in this exemplary embodiment, the rotary feed drive


35


has a first feed roll sprocket


108


and a second feed roll sprocket


110


each mounted to or formed on one of the feed rolls


22


, and a first feed belt


112


connecting the motor


106


to the first feed roll sprocket


108


, for rotationally driving the feed roll


22


. The rotary feed drive


35


also has a rotary feed transmission shaft


114


, a direction changing gear-set


116


connected to the feed transmission shaft


114


, a feed drive sprocket


118


connected to the right angle gear-set


116


, and a second feed belt


120


connecting the second feed roll sprocket


110


to the feed drive sprocket


118


, for rotationally driving the transmission shaft


114


. A suitable right angle gear-set is the ANDANTEX™ Model ZR20 precision spiral bevel gearbox. “Direction changing gear-set” as used herein includes right angle gear-sets as well as other gearing arrangements for converting rotation in one axial direction to rotation in another axial direction. Additionally, conventional belt tensioning mechanisms with belt tensioning rolls


122


can be provided as desired.




The print drives


37


each have a rotary print transmission shaft


124


and a first print drive mechanism with a first direction-changing gear-set


126


connected to the print transmission shaft


124


, a first print drive sprocket


128


connected to the right angle gear-set


126


, a print roll sprocket


130


mounted to or formed on the print roll


26


, and a first print belt


132


connecting the first print drive sprocket


128


to the print roll sprocket


130


, for rotationally driving the print roll


26


. Additionally, conventional belt tensioning mechanisms with belt tensioning rolls


134


can be provided as desired.




Referring to

FIGS. 6 and 8

, each print drive


37


also has a second print drive mechanism with a second print direction-changing gear-set


142


connected to the print transmission shaft


124


, a connector shaft


143


extending across a substantial portion of the width of the machine


10


and connected to the second right angle gear-set


142


, a second print drive sprocket


144


connected to the connector shaft


143


, an impression roll sprocket


146


mounted to or formed on the impression roll


24


, an engraved roll sprocket


148


mounted to or formed on each of the engraved rolls


50


, a transfer roll sprocket


150


mounted to or formed on at least one of the transfer rollers


100


, and a second print belt


152


connecting the second print drive sprocket


144


to and rotationally driving the impression roll sprocket


146


, the engraved roll sprockets


148


, and the transfer roll sprocket


150


. Additionally, conventional belt tensioning rolls


154


and belt tensioning mechanisms


156


can be provided as desired.




Thus, the first print drive mechanism (with the first print drive sprocket


128


driving the print roll


26


) and the second print drive mechanism (with the second print drive sprocket


144


driving the impression roll sprocket


146


, the engraved roll sprockets


148


, and the transfer roll sprocket


150


) are disposed on opposite sides of the machine


10


. Alternatively, the first and second print drive sprockets


128


and


144


can be arranged on the same side of the machine


10


, in a generally vertical or staggered configuration, or in other arrangements.




Referring back to

FIG. 6

, the cutter drive


39


has a first cutter drive mechanism that is similar to the first print drive mechanism, and a rotary cutter transmission shaft


158


. Thus, the first cutter drive mechanism has a first direction-changing gear-set such as a right angle gear-set


160


connected to the cutter transmission shaft


158


, a first cutter drive sprocket


162


connected to the right angle gear-set


160


, a cutter roll sprocket (not shown) mounted to or formed on the cutter roll


32


, and a first cutter belt (not shown) connecting the first cutter drive sprocket


162


to the cutter roll sprocket (not shown), for rotationally driving the cutter roll


32


. Additionally, conventional belt tensioning mechanisms with belt tensioning rolls (not shown) can be provided as desired. Such cutter drives


39


are known in the art.




The cutter drive


39


also has a second cutter drive mechanism that is similar to the second print drive mechanism. The second cutter drive mechanism has a second direction-changing gear-set such as a right angle gear-set


170


connected to the cutter transmission shaft


158


, a connector shaft


172


extending across a substantial portion of the width of the machine


10


and connected to the second right angle gear-set


170


, a second cutter drive sprocket


174


connected to the connector shaft


172


, an anvil roll sprocket (not shown) mounted to or formed on the anvil roll


30


, and a second cutter belt (not shown) connecting the first cutter drive sprocket


162


to the anvil roll sprocket (not shown), for rotationally driving the anvil roll


30


. Additionally, conventional belt tensioning mechanisms with belt tensioning rolls (not shown) can be provided as desired.




Referring now to

FIG. 9

, in order to quickly and easily adjust the registration of the print roll


26


, the machine


10


is provided with a print registration adjustment mechanism


136


having a gearmotor


138


that is connected to and drives a differential gear-set


140


, which can be integrally provided with or connected to the printer first right angle gear-set


126


(see also FIG.


6


). The gearmotor


138


can be provided by a conventional rotary electric motor or the like, such as BROWNING™ helical gearmotor Model 56-2101. The gearmotor


138


can be provided with two speeds, with a fast speed for use when mounting the print plate and a slow speed for use when making precise print roll registration adjustments. Where the differential gear-set


140


and the printer first right angle gear-set


126


are provided as one unit, a suitable unit is the ANDANTEX™ Model DR7-213. The differential gear-set


140


is selected so that operation of the gearmotor


138


allows the print roll


26


to rotate at a faster or slower rate than it is being driven by the print transmission shaft


124


. Thus, the print roll registration can be adjusted by actuating the gearmotor


138


for a period of time until the timing mark of the print roll


26


aligns or coincides with the leading edge of the blanks


12


entering the nip


28


, and then turning off the gearmotor


138


. Alternatively or additionally, a stepper motor or other incremental actuator can be connected to and drive a control shaft of the differential gear-set, with the actuator controlled by a programmed computer, for precise adjustment of the print registration. Of course, another print registration adjustment mechanism having another gearmotor, differential gear-set, and/or brake motor as are known in the art can be suitably employed.




Referring back to

FIG. 6

, in order to quickly and easily adjust the registration of the cutter roll


32


, the machine


10


can be provided with a cutter registration adjustment mechanism


164


similar to the print registration adjustment mechanism


136


. Accordingly, the cutter registration adjustment mechanism


164


can have a gearmotor


166


connected to and driving a differential gear-set


168


that is provided separately from and connected to or provided integrally with the cutter second right angle gear-set


170


. The structures provided by the print and cutter registration adjustment mechanisms


136


and


164


can also be employed to adjust the registration of the feed rolls and/or other rotary rolls for performing other operations on the blanks.




As discussed above, the print sections


36


are modular so that one or more of the print sections


36


can be retrofit onto certain existing printer-cutter machines and so that the print sections


36


can be quickly and easily separated for access to the ink applicators


46


for cleaning and maintenance. In order to provide this modularity feature, an input end


176


of the transmission shaft


124


of the modular print drive


37


is connected by a separable input coupling


178


to an output end


180


of the transmission shaft


114


of the modular feed drive


35


(for the first print section


36




a


) or to an output end of a preceding print section transmission shaft (for the second, third, or fourth print section


36




b


-


36




d


). Similarly, an output end


182


of the transmission shaft


124


of the modular print drive


37


is connected by a separable input coupling


178


to an input end


184


of the transmission shaft


158


of the modular cutter drive


39


(for the last print section


36




d


) or to an input end of a subsequent print section transmission shaft (for the first, second, or third print section


36




a


-


36




c


). The separable couplings


178


can be provided by a spline-type coupling, bolted plates, removable pins, a threaded engagement, mating eccentric flanges, a pawl and sprocket, gear couplings, toothed couplings, or another separable coupling permitting ready disconnection of the transmission shafts.




Furthermore, to facilitate quickly and easily moving apart the print sections


36


after they are decoupled for access to the ink applicators


46


, the print sections are mounted on roller bearings


188


which are guided on a fixed linear track


186


. The track


186


can be secured to a floor, platform, table, or other base by conventional fasteners. The roller bearings


188


are guided by the track


186


and support the feed section


34


, each print section


36


, and/or the cutter section


38


. The roller bearings


188


can be provided by free-wheeling bottom rollers


188


. Alternatively, the roller bearings


188


can be provided by a rotating thread, a lubricated junction, a motorized platform, a tilting table, a jack, a lifting or lowering mechanism, a swiveling table, or the like. The roller bearings


188


can be connected to the track


186


, or to the feed section


34


, print sections


36


, or the cutter section


38


.




Accordingly, the machine


10


can be employed in a method for retrofitting one or more of the modular print sections


36


onto a pre-existing machine, for example, a pre-existing machine having one or more print sections each with only one ink applicator. The method includes the steps of disassembling and removing a pre-existing print section, for example, by disconnecting separable couplings in the transmission shafts and rolling the modular sections apart. The new modular print section with two (or more) ink applicators is then positioned adjacent the feed section, cutter section, or other print section, as desired. The transmission shafts are aligned, the sections are rolled together, and the transmission shafts are coupled together. Additional connections for power, ink, and water supply can be made as desired. One, four, or any other number of modular print sections can be retrofit, depending on the number of pre-existing print sections and the available space. Because the print section is modular, old printer-cutter machines with single ink applicator print sections can be upgraded without the expense of purchasing and installing an entirely new machine.




Referring to

FIG. 10

, some or all of the controls for the machine


10


can be located on the left or operator side of the machine. The controls can include a feed mechanism nip adjustment control


190


, a print mechanism nip adjustment control


192


for each print section


36


, a cutter mechanism nip adjustment control


194


for each cutter section


38


, a transfer mechanism adjustment control


196


for each print section


36


and cutter section


38


, and the actuators


90


for adjusting the engraved rolls. Additional controls can be provided for the various motors, the transfer mechanism, and other components as is known in the art.




Referring to

FIG. 11

, the ink can be supplied to the ink wells


58


through the ink inlet line


57


which is connected to the ink reservoir


55


and the pump


61


. The ink is cycled back to the ink reservoir


55


by the ink outlet line


57


. Valving and metering (not shown) can be provided in the ink lines


57


and


59


for precise control of the ink volume supplied. Additionally, the water or other fluid line


63


connected to the ink lines and to the water or other fluid supply provides for cleaning the corresponding ink well and engraved roll. Alternatively, the ink wells and the engraved rolls can be cleaned manually or with other automatic cleaning mechanism as are known in the art.




Thus, it will be appreciated that the printer-cutter machine


10


provides a substantial improvement over the prior art by producing a significant reduction in downtime between printing-cutting jobs. This reduced downtime translates into a significant increase in the efficiency, productivity, and profitability of the machine


10


.




In the embodiments described above and the following claims, the words “a,” “an,” and “one” are not intended to mean only “one” but can also mean any number greater than one, unless specified otherwise herein. Additionally, the sequence of the above-described method steps is provided for illustration purposes only; the steps can be performed in other sequences as may be desired.




While certain embodiments are described above with particularity, these should not be construed as limitations on the scope of the invention. It should be understood, therefore, that the foregoing relates only to the exemplary embodiment of the present invention, and that numerous changes may be made therein without departing from the spirit and scope of the invention as defined by the following claims.



Claims
  • 1. A machine for operating on blanks, comprising:a machine frame; at least one impression member supported by the frame; at least one rotary print roll supported by the frame and disposed proximate to the impression member, wherein the impression member and the print roll define therebetween a nip for receiving the blanks in series and transporting the blanks through the machine; at least two ink applicators for each print roll, each ink applicator comprising a rotary ink roll that rotates on an axle and an ink chamber mechanism disposed adjacent the ink roll, with each ink roll disposed proximate to the print roll and each ink applicator supported by the frame, wherein the ink chambers apply ink to the corresponding ink roll, which selectively apply ink to the print roll, which prints on the blanks; at least two applicator adjustment mechanisms, wherein each applicator adjustment mechanism comprises two eccentric bearings, with one eccentric bearing rotationally mounted between an end of the axle and the frame and the other eccentric bearing rotationally mounted between another end of the axle and the frame, wherein at least one of the eccentric bearings has an eccentric bearing gear, and wherein each adjustment mechanism further comprises at least one adjusting shaft rotationally mounted to the frame and disposed proximate to one of the ink rolls, and at least one adjusting shaft gear coupled to the adjusting shaft and driving the eccentric bearing gear, wherein one applicator adjustment mechanism is operatively connected to one ink applicator and the other applicator adjustment mechanism is operatively connected to the other ink applicator, wherein each ink applicator is moved between an engaged position and a retracted position relative to the print roll in response to rotation of the adjusting shaft.
  • 2. A machine for operating on blanks, comprising:a machine frame; at least one impression member supported by the frame; at least one rotary print roll supported by the frame and disposed proximate to the impression member, wherein the impression member and the print roll define therebetween a nip for receiving the blanks in series and transporting the blanks through the machine; at least two ink applicators for each print roll, each ink applicator comprising a rotary ink roll and an ink chamber mechanism disposed adjacent the ink roll, with each ink roll disposed proximate to the print roll and each ink applicator supported by the frame, wherein the ink chambers apply ink to the corresponding ink roll, which selectively apply ink to the print roll, which prints on the blanks; at least two applicator adjustment mechanisms, wherein one applicator adjustment mechanism is operatively connected to one ink applicator and the other applicator adjustment mechanism is operatively connected to the other ink applicator, wherein each ink applicator can be moved between an engaged position and a retracted position relative to the print roll in response to actuation of the corresponding applicator adjustment mechanism; and at least two primary actuators, wherein one primary actuator is operatively connected to one applicator adjustment mechanism and the other primary actuator is operatively connected to the other applicator adjustment mechanism.
  • 3. The machine of claim 2, wherein one of the ink applicators can be disposed in the engaged position for printing while at the same time another one of the ink applicators can be disposed in the retracted position for cleaning.
  • 4. The machine of claim 3, wherein each ink chamber mechanism comprises a support member, an ink well coupled to the support member, and two or more blades extending from the ink well and contacting the corresponding ink roll for applying ink to the ink roll.
  • 5. The machine of claim 4, wherein each ink chamber mechanism further comprises a pivotal member that is coupled to the corresponding support member and that supports and permits a pivotal movement of the ink well, wherein the ink well can be pivoted away from the corresponding ink roll for accessing the ink well.
  • 6. The machine of claim 3, wherein each ink chamber mechanism comprises a support member and an ink well coupled thereto and disposed proximate to the corresponding ink roll, the support member slidably coupled to the frame and rotationally coupled to the corresponding ink roll, applicator adjustment mechanism, or machine frame, wherein the ink chamber mechanism moves together with the ink roll.
  • 7. The machine of claim 2, further comprising at least two travel limiting mechanisms and at least two secondary actuators, wherein one travel limiting mechanism is operatively connected to one primary actuator to limit the rotation of the corresponding adjusting shaft and operatively connected to and driven by one of the secondary actuators, and another travel limiting mechanism is operatively connected to another primary actuator to limit the rotation of the corresponding adjusting shaft and operatively connected to and driven by another secondary actuator.
  • 8. The machine of claim 7, wherein each of the travel limiting mechanisms comprises an axial member that movably extends into the corresponding primary actuator to limit the rotation of corresponding adjusting shaft, a first pinion gear mounted to or formed onto the axial member, and a second pinion gear connected to and driven by the corresponding secondary actuator and meshing with the first pinion gear.
  • 9. The machine of claim 8, wherein each of the secondary actuators is provided by an incremental rotary actuator for delivering a rotary motion to the second pinion gear in discrete increments or steps.
  • 10. A printing machine, comprising:at least one rotary print roll; at least two ink applicators for each print roll that are independently operable so that one of the ink applicators can be disposed in an engaged position for printing while at the same time another one of the ink applicators can be disposed in a retracted position for cleaning.
  • 11. The machine of claim 10, further comprising an applicator adjustment mechanism for each ink applicator, wherein each of the applicator adjustment mechanisms comprises a pivot arm with the corresponding ink applicator coupled thereto and an actuator operatively coupled to the pivot arm, wherein each ink applicator can be pivoted between the engaged position and the retracted position relative to the print roll in response to actuation of the corresponding applicator adjustment mechanism.
  • 12. The machine of claim 10, further comprising an applicator adjustment mechanism comprising a pivot arm with the at least two ink applicators coupled thereto, an actuator operatively coupled to the pivot arm, and a stop mechanism having a cam that engages and limits the travel of the pivot arm, wherein each ink applicator can be pivoted between the engaged position and the retracted position relative to the print roll in response to actuation of the actuator.
  • 13. A machine for operating on blanks, comprising:a machine frame; at least one impression member supported by the frame; at least one rotary print roll supported by the frame and disposed proximate to the impression member, wherein the impression member and the print roll define therebetween a nip for receiving the blanks in series and transporting the blanks through the machine; at least two ink applicators for each print roll, each ink applicator comprising a rotary ink roll and an ink chamber mechanism disposed adjacent the ink roll, with each ink roll disposed proximate to the print roll and each ink applicator supported by the frame, wherein the ink chambers apply ink to the corresponding ink roll, which selectively apply ink to the print roll, which prints on the blanks; and at least two clutches and at least two motors, wherein one clutch is coupled to one applicator adjustment mechanism and one motor is coupled to the one clutch for rotating the corresponding ink roll independently of the rotary main drive mechanism, and wherein another clutch is coupled to another applicator adjustment mechanism and another motor is coupled to the other clutch for rotating the corresponding ink roll independently of the rotary main drive mechanism.
  • 14. A machine for operating on blanks, comprising:a machine frame; a feed mechanism having at least two feed rolls supported by the frame, wherein the feed rolls draw each of the blanks from a stack of blanks into the machine and transport the blanks in series through the machine; a plurality of print mechanisms each supported by the frame, each print mechanism comprising a rotary impression roll, a rotary print roll, and at least two ink applicators for each print roll, wherein the impression roll and the print roll define therebetween a nip for receiving the blanks in series and transporting the blanks through the machine, wherein each ink applicator comprises a rotary ink roll and an ink chamber mechanism, wherein the ink roll of each print mechanism has a different textured surface matrix relative to each other ink roll of the same print mechanism, wherein each ink chamber mechanism comprises a support member, an ink well pivotally coupled to the support member, and two or more blades extending from the ink well and contacting the ink roll for applying ink to the ink roll, the support member slidably coupled to the frame and rotationally coupled to the corresponding ink roll, applicator adjustment mechanism, or machine frame; at least two applicator adjustment mechanisms for selectively moving the ink applicators between an engaged position contacting the corresponding print roll and a retracted position, wherein one applicator adjustment mechanism is operatively coupled to one ink applicator and the other applicator adjustment mechanism is operatively coupled to the other ink applicator; at least two primary actuators, wherein one primary actuator is operatively connected to one applicator adjustment mechanism and the other primary actuator is operatively connected to the other applicator adjustment mechanism; at least two travel limiting mechanisms, wherein one travel limiting mechanism is operatively connected to one primary actuator to limit the movement of the corresponding ink applicator, and another travel limiting mechanism is operatively connected another primary actuator to limit the movement of the corresponding ink applicator, wherein each of the travel limiting mechanisms comprises an axial member that movably extends into the corresponding primary actuator, a first pinion gear mounted to or formed onto the axial member, and a second pinion gear meshing with the first pinion gear; at least two secondary actuators, wherein one secondary actuator is operatively connected to and drives the second pinion gear of one travel limiting mechanism, and another secondary actuator is operatively connected to and drives the second pinion gear of another travel limiting mechanism, wherein each of the secondary actuators is provided by an incremental rotary actuator for delivering a rotary motion to the corresponding second pinion gear in discrete increments or steps; a cutter mechanism having at least one cutter roll and at least one anvil roll supported by the frame, wherein the cutter roll and the anvil roll operate to cut or score the blanks; and a rotary main drive supported by the frame, wherein the drive rotationally drives the feed mechanism, the print mechanism, and the cutter mechanism.
  • 15. The machine of claim 14, further comprising at least two clutches and at least two motors, wherein one clutch is coupled to one applicator adjustment mechanism and one motor is coupled to the one clutch for rotating the corresponding ink roll independently of the rotary main drive mechanism, and wherein another clutch is coupled to another applicator adjustment mechanism and another motor is coupled to the other clutch for rotating the corresponding ink roll independently of the rotary main drive mechanism.
  • 16. The machine of claim 14, wherein the rotary main drive comprises:a rotary feed drive having a rotary power source operatively connected to one of the feed rolls, and at least one rotary feed transmission shaft operatively connected to the rotary powered feed roll; a plurality of rotary print drives, with one print drive for each print mechanism, each print drive having at least one rotary print transmission shaft that rotationally drives the corresponding impression roll and ink rolls; a rotary cutter drive having at least one rotary cutter transmission shaft that rotationally drives the cutter roll and the anvil roll; and a plurality of separable couplings for operatively connecting the feed drive, the print drives, and the cutter drive, wherein one of the separable couplings operatively connects the feed transmission shaft to one of the print transmission shafts and another one of the separable couplings operatively connects the cutter transmission shaft to one of the print transmission shafts.
  • 17. The machine of claim 16, further comprising a registration adjustment mechanism having a differential gear-set operatively connected to the main drive and a gearmotor operatively connected to the differential gear-set, wherein a rate of rotation of the print roll changes upon actuation of the gearmotor.
  • 18. The machine of claim 14, further comprising a vacuum transfer mechanism comprising a suction mechanism, a vacuum housing in communication with the suction mechanism and having openings defined therein, and one or more transfer rollers disposed in the housing with a portion of at least one of the transfer rollers extending through at least one of the openings for contacting and transferring the blanks through the machine.
  • 19. A modular print section for a machine for operating on blanks, the modular print section comprising:a print section frame; a rotary impression roll supported by the print section frame; a rotary print roll supported by the print section frame and disposed proximate to the impression roll, wherein the impression roll and the print roll define therebetween a nip for receiving the blanks in series and transporting the blanks through the print section; at least two ink applicators supported by the print section frame and disposed proximate to the print roll, each ink applicator comprising a rotary ink roll and an ink chamber mechanism disposed adjacent the ink roll, each ink roll disposed proximate to the print roll, wherein the ink chambers apply ink to the corresponding ink roll, which selectively apply ink to the print roll, which prints on the blanks; and a rotary print drive supported by the print section frame, wherein the print drive rotationally drives the impression roll, the print roll, and the ink roll, the print drive having a rotary print transmission shaft having an input end for operatively connecting to a preceding transmission shaft output end of a preceding section of the machine, and having an output end for operatively connecting to a subsequent transmission shaft input end of a subsequent section of the machine.
  • 20. The print section of claim 19, wherein the print drive further comprises an impression roll sprocket coupled to the impression roll, an ink roll sprocket coupled to the ink roll, a print drive sprocket, at least one belt interconnecting the impression roll sprocket, the ink roll sprockets, and the print drive sprocket, and a direction changing gear-set operatively connected to the drive sprocket and the print transmission shaft.
  • 21. The print section of claim 19, further comprising a separable input coupling for operatively connecting the input end of the print transmission shaft to the preceding transmission shaft output end of the preceding feed or print section of the machine, and a separable output coupling for operatively connecting the output end of the print transmission shaft to the subsequent transmission shaft input end of the subsequent print or cutter section of the machine.
  • 22. The print section of claim 19, further comprising at least one applicator adjustment mechanism operatively coupled to the ink applicators, wherein the applicator adjustment mechanism is operable to move the ink applicators between an engaged position contacting the corresponding print roll and a retracted position.
  • 23. The print section of claim 22, wherein each ink chamber mechanism comprises a support member and an ink well coupled thereto and disposed proximate to the corresponding ink roll, the support member slidably coupled to the frame and rotationally coupled to the corresponding ink roll, applicator adjustment mechanism, or frame, wherein the ink roll and the ink chamber mechanism move together between the engaged and retracted positions in response to actuation of the corresponding applicator adjustment mechanism.
  • 24. The print section of claim 19, further comprising a track and a least one roller bearing supported by the track and supporting the print section frame, wherein the print section frame is movable relative to the track.
  • 25. The print section of claim 19, further comprising a registration adjustment mechanism having a differential gear-set operatively connected to the print transmission shaft and a gearmotor operatively connected to the differential gear-set, wherein a rate of rotation of the print roll changes upon actuation of the gearmotor.
  • 26. The modular print section of claim 19, wherein one of the ink applicators can be disposed in an engaged position for printing while at the same time another one of the ink applicators can be disposed in a retracted position for cleaning.
  • 27. A machine for operating on blanks, comprising:a machine frame; at least one rotary impression roll supported by the frame; at least one rotary print roll supported by the frame and disposed proximate to the impression roll, wherein the impression roll and the print roll define therebetween a nip for receiving the blanks in series and transporting the blanks through the machine; at least one ink applicator supported by the frame and disposed proximate to the print roll, wherein the ink applicator has an ink roll, wherein the ink applicator is adapted to apply ink to the print roll and the print roll is adapted to print on the blanks; at least one rotary print drive supported by the frame, wherein the print drive comprises a rotary print transmission shaft operatively connected to and rotationally driving the impression roll, the print roll, and the ink roll, wherein the print drive further comprises a first direction changing gear-set operatively connected to the print transmission shaft, a print roll sprocket coupled to the print roll, a first print drive sprocket, and a first print belt interconnecting the first print drive sprocket and the print roll sprocket; and a print registration adjustment mechanism having a differential gear-set operatively connected to the first direction changing gear-set and to the first print drive sprocket and a gearmotor operatively connected to the differential gear-set, wherein a rate of rotation of the print roll changes upon actuation of the gearmotor.
  • 28. The machine of claim 27, wherein the print drive further comprises a second direction changing gear-set operatively connected to the print transmission shaft, a connector shaft operatively connected to the second direction changing gear-set, a second print drive sprocket operatively connected to the connector shaft, an impression roll sprocket coupled to the impression roll, two ink roll sprockets with each ink roll sprocket coupled to one of the ink rolls, and a second print belt interconnecting the second drive sprocket, the impression roll sprocket, and the ink roll sprockets.
  • 29. The machine of claim 27, further comprising at least two clutches and at least two motors, wherein one clutch is coupled to one applicator adjustment mechanism and one motor is coupled to the one clutch for rotating the corresponding ink roll independently of the rotary main drive mechanism, and wherein another clutch is coupled to another applicator adjustment mechanism and another motor is coupled to the other clutch for rotating the corresponding ink roll independently of the rotary main drive mechanism.
CROSS REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 60/270,187, filed Feb. 20, 2001, which is hereby incorporated by reference in its entirety.

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Provisional Applications (1)
Number Date Country
60/270187 Feb 2001 US