RU2759174C1 - System and method for controlling and adjusting a decorator for containers - Google Patents

Abstract

FIELD: controlling.

SUBSTANCE: invention relates to an apparatus and methods used to provide decoration of a given section of the body of a metal container. The decorator comprises a sensor reading the decoration on metal containers. The control system receives the information related to the decoration read by the sensor and then determines whether the decoration complies with at least the target quality indicators. The control system can automatically adjust elements of the decorator to eliminate a decoration defect, if necessary. In one variant of implementation the control system can automatically send a signal to the decorator to adjust the position of at least one of the following components: the paint distribution unit, the paint roller, the ductor roller, the transfer roller, the forming cylinder, the press plate, the offset cylinder and the offset blanket of the decorator, to eliminate the cause of the defective decoration.

EFFECT: decoration of a metal container by means of a decorator is provided.

25 cl, 30 dwg

Description

Cross-reference to related tickets

This application is a partially ongoing application and claims the priority and advantages of US patent application 15 / 875,968, filed January 19, 2018 and entitled "System and Method for Monitoring and Adjusting a Decorator for Containers", which is a partially ongoing application under which claims the priority and advantages of US Patent Application 15 / 654,255, filed July 19, 2017, entitled "System and Method for Aligning an Inker of a Decorator", which claims priority under 35 USC §119 (e) US Provisional Patent Application No. 62 / 364,728, filed July 20, 2016 and entitled "System and Method for Aligning an Inker of a Decorator", each of which is incorporated herein by reference in its entirety.

The technical field to which the invention relates

The present invention generally relates to the design of containers. More specifically, this invention provides an apparatus and method for monitoring and automatically controlling the position and application of paint on the outer surface of metal containers.

State of the art

Metal beverage containers offer numerous benefits to traders and consumers. The metal body of the beverage container ensures optimal food protection. For example, the metal body prevents the penetration of CO ₂ and the passage of ultraviolet radiation, which can damage beverages, adversely affecting the taste, appearance or color of the product. Metal beverage containers also offer an impervious barrier to light, water vapor, oils and fats, oxygen and microorganisms, and keep the contents of the container fresh and protected from external influences, thus guaranteeing a long shelf life. The surfaces of metal containers are also ideal for decorating with brand names, logos, advertisements, product information and / or other preferred brand names for identification, marketing and differentiation of the metal container and its contents from other products and competitors. Thus, metal containers offer bottlers, distributors and retailers a clear point of sale advantage.

The increased durability of metal beverage containers and aesthetic advantages over glass and plastic containers reduce the number of containers damaged during manufacture and transport, resulting in additional savings. In addition, metal beverage containers are lighter than glass containers of comparable size, resulting in energy savings during transport. Additionally, metal beverage containers can be manufactured with high burst pressure, making them ideal and safe for use as pressurized food storage containers such as carbonated beverage containers.

Additionally, many consumers prefer metal containers over containers made of glass or plastic. Metal containers are particularly attractive to consumers because of the amenities they offer. The light weight of metal containers makes them easier to carry than glass containers. Metal containers are particularly suitable for public and outdoor use because they are more durable than glass containers. Additionally, some consumers avoid plastic containers, expressing concern that plastics can release chemicals into consumable products.

As a result of these benefits, global sales of metal containers in 2014 were estimated at approximately $ 53 billion. A large percentage of the metal container market is occupied by beverage containers. According to one report, approximately 290 billion metal beverage containers were shipped globally in 2012. One US trade group reported that 126 billion metal containers were shipped in the US alone in 2014. To meet this need, metal container manufacturing facilities operate nearly as fast, if not the fastest production lines in the container industry. On some container manufacturing lines, such as those associated with impact molded metal containers, decorators can produce from about 120 to about 240 metal containers per minute. On beverage container production lines, production equipment containing decorators typically needs to operate at a speed of 500-2200 metal containers per minute or more. More preferably, decorators may be required to operate at production speeds of at least one thousand and even more preferably several thousand cylindrical metal containers per minute. Due to the high speeds of container production lines, technologies or processes that may operate in other industries or with containers formed from other materials do not necessarily operate at the high speeds required for metal container production lines. For example, the apparatus and methods for decorating sheets or rolls of paper and paperboard materials differ from those used for 3D objects such as metal containers. Accordingly, many of the operations used to form and shape metal containers often require specialized equipment and technology.

Metal containers are often decorated with images or brand names such as company name, logo, product information or design, through an offset or lithographic process. Various examples of printing methods and apparatuses are described in US Pat. No. 3,960,073; US patent No. 4,384,518; US patent No. 5,233,922; US patent No. 6,550,389; US patent No. 6,899,998; US Patent Application Publication No. 2012/0272846; US Patent Application Publication No. 2014/0360394; US patent application No. 2015/0183211; US Patent Application Publication No. 2015/0217559; WIPO Publications WO 2014/006517; WIPO Publications WO 2014/008544; WIPO Publications WO 2013/113616; WIPO Publications WO 2014/108489; and WIPO Publication WO 2014/128200, each of which is incorporated herein by reference in its entirety.

In offset printing, one or more printing plates with image areas are attached to the plate cylinder (or impression cylinder) of the decorator. The areas of the image can contain both areas that will accept ink and areas that will not accept ink. Ink distribution units transfer ink to printing plates located on the plate cylinder. The ink adheres to the ink receiving areas on each plate. The decorator may have a plurality of plate cylinders with ink distribution units for transferring ink of different colors to printing plates attached to each plate cylinder. For example, decorators used to decorate metal containers often have four to nine gravure cylinders, each with a paint distribution unit.

Each ink distribution unit transfers ink of a specific color onto the printing plate of one corresponding plate cylinder. Paint distributors typically contain an ink reservoir and an ink knife located along the outer surface of the ink roller. The amount of ink transferred to the ink roller and subsequently to the printing plates is controlled by changing the gap between the edge of the ink knife and the outer surface of the ink roller. The colorful knife can be divided into many individual segments known as knife segments.

The gap between the edge of the ink knife and the outer surface of the ink rollers can be adjusted along the length of the ink roller by moving the adjusting screws associated with the ink knife. More specifically, the adjusting screw can move forward to move the ink knife edge portion closer to the outer surface of the ink roller and reduce the amount of ink transferred to the ink roller portion. Likewise, the adjusting screw can be loosened to move the edge of the ink knife further away from the outer surface of the ink roller and increase the amount of ink transferred to the ink roller section. Some of the prior paint distribution assemblies are described in U.S. Patent 4,000,695, U.S. Patent 4,008,664, U.S. Patent 5,025,676, U.S. Patent 5,052,298, U.S. Patent 5,967,049, U.S. Patent 5,967,050, U.S. Patent No. 6,318,260, U.S. Patent No. 7,969,613, U.S. Patent Application Publication No. 2015/0128819, and U.S. Patent Application Publication No. 2015/0128821, each of which is incorporated herein by reference in its entirety. Another ink knife assembly is described in the "QuadTech® Digital Ink System" publication available at https://www.quadtechworld.com/downloads/brochures/Digital_Ink_System_en.pdf, which is incorporated herein by reference in its entirety.

After receiving ink, the printing plates transfer at least some of that ink onto a blanket (also called a "transfer blanket" or "secondary transfer mold") attached to a blanket cylinder (also known as a "blanket cylinder" "impression cylinder" or "segmented wheel ") of the decorator. Decorators used in the metal container industry typically have 2 to 12 blankets per blanket cylinder. As the plate cylinder and the blanket cylinder rotate, each of one or more printing plates comes into contact with the blanket and transfers ink of a specific color onto the blanket. When ink and image are transferred from the printing plate of each plate cylinder to the blanket, the final lithographic image is formed on the blanket. For example, if a decorator contains five plate cylinders, then one printing plate of each of these five plate cylinders will transfer inks and images onto one blanket to form a lithographic image on the blanket. The metal container then comes into rotational contact with the blanket of the blanket cylinder and the lithographic image is transferred from the blanket to the outer surface of the metal container.

The creation of acceptable decorations on metal containers using prior art decorators is dependent on the skill and care of the operator and is labor intensive and costly. More specifically, for each production run, in order to decorate metal containers with a decoration using a prior art decorator, the adjusting screws of each paint distribution unit are set to an initial position, which takes a significant amount of time. Since some metal container production lines can print over 15 different designs each day, the decorator will not be able to participate in production for several hours each day during customization to prepare the decorator to print other designs. Given the high production speeds that metal container production lines typically operate at, this creates significant downtime and lost productivity.

As will be appreciated by those skilled in the art, too much or too little ink may be supplied to the platen areas in the initial position of the adjusting screws. When this happens, the artwork transferred to the metal container may be defective because one or more of the parameters such as color, density, depth, alignment, and consistency of the artwork do not meet the consumer's goals. Accordingly, the decorator must be taken out of production to adjust the position of the paint adjusting screws, resulting in additional downtime and loss of productivity.

A decorator operator may also periodically check a sample of a decorated metal container during production to determine if the design of the sample meets the target requirements for color, density, depth, location and / or consistency. If the operator decides that the sample is defective, the operator must then determine why the design is defective. For example, an operator may need to determine which of a plurality of ink delivery adjusting screws for each of the paint distribution assemblies require adjustment and how to adjust the adjusting screws to create an acceptable finish. Determining which adjusting screws need to be adjusted to correct a defect can be difficult if the defect contains paint from two or more different paint distributors. For example, if the color is defective in the decorating area, the operator may have to increase the amount of the first ink applied to the axial portion of the first ink roller of the first ink dispensing unit and decrease the amount of the second ink applied to the corresponding axial area of the second ink roller of the second ink dispensing unit. The operator may also need to adjust one or more of the other decorator nodes in order to correct the defective decoration.

Additionally, the ink roller, printing plates and blankets can wear out and need to be adjusted or replaced during commercial operation. Accordingly, the volume of paint transferred during the decorating process to the outer surface of the metal container can change during industrial operation, changing the parameters of the design, such as color, density, depth, correct location and consistency. Thus, the decoration produced by well-known decorators must be checked frequently during industrial use and the paint adjusting screws are periodically adjusted to ensure the quality and consistency required by the consumer.

Manually identifying a defective decoration and then manually adjusting the decorator takes a significant amount of time. Due to the high speeds of beverage container production lines, several hundred or even several thousand defective metal containers can be produced before the operator identifies the problem and then properly adjusts the ink adjusting screws. Accordingly, decorators of the prior art often generate large amounts of scrap metal containers due to defective decoration. Additionally, after identifying the defective design, the operator can turn off the decorator to adjust the paint supply adjusting screws or other decorator elements. This wastes valuable production time and the lack of formalized metal containers can delay downstream production equipment.

Adjusting the adjusting screws of prior art decorators is difficult and can be dangerous. Some of the paint adjusting screws are difficult to access. Thus, the operator may be required to at least partially dismantle the decorator and use a tool to reposition the paint adjusting screws. Tools used to adjust the paint adjusting screws may inadvertently damage the decorator. Additionally, the tools used by the operator may inadvertently be inappropriate or be left inside the decorator node, leading to additional downtime and associated costs due to lost production. Additionally, when disassembling the decorator to access and adjust the adjusting screws, the operator may be injured.

Due to the limitations associated with existing methods and devices used to decorate metal containers, there is an urgent need for a device and method for automatically controlling and regulating decorator settings that create less waste, require less operator time and are less susceptible to human error than renowned decorators without sacrificing production cost-effectiveness or image quality in a high-speed beverage container production system.

The essence of the invention

The present invention provides various devices, instructions stored on a non-portable computer-readable medium, and methods for decorating metal containers in a cost-effective, fast and reliable manner. One of the approaches of the presented invention is a closed-type decorator assembly and a system containing a control system that can detect defective design of a cylindrical metal container. When the control system detects a defective design, the control system can determine the cause of the defect. The control system can then automatically correct the defect. Additionally or alternatively, the control system can alert the operator that specific adjustments are required. If the cause of the defect can be eliminated by adjusting the amount of ink applied to the metal container, then in one embodiment, the control system may send a control signal to at least one component of the ink dispensing assembly to adjust the amount of ink applied to the printing plate. The signal can cause the actuator to adjust at least one ink knife in order to correct the defect in subsequent metal containers. Additionally or alternatively, the signal can change the rotation speed of the ink roller or transfer roller of the ink distribution unit. Additionally, a signal can be sent to the production line equipment to reject any container that is defective. Defective artwork may include, but is not limited to, changes in color, ink density, paint coating thickness, paint color, misalignment of markings, and degradation of design quality. In one embodiment, when the defect cannot be repaired by the control system, the control system can automatically stop the production line.

Another approach of the present invention describes a decorator comprising at least one sensor in communication with a control system. The sensor collects or receives data related to the design of metal containers. The control system determines if the design is defective using the data received from the sensor. If the control system determines that the artwork or part of the design is defective, the control system uses the data to regulate one or more decorator nodes. For example, the control system can adjust one or more ink knives to change the amount of ink applied to the ink roller of the paint dispensing unit. Additionally or alternatively, the control system can change the rotation speed of the ink roller or transfer roller of the ink distribution unit to change the amount of ink applied to the printing plate. At least one sensor can collect optical and other types of data associated with the design of the metal container. The sensor is configured to collect data with sufficient resolution to recognize a design defect. In one embodiment, the sensor is a camera. In another embodiment, the sensor is configured to collect 3D art-related data.

In one embodiment, the sensor collects data about a design formed on a cylindrical body of a metal container. The sensor can collect data as the metal container rotates about the longitudinal axis so that the sensor collects data over the entire outer cylindrical surface of the metal container. In another embodiment, the at least one sensor comprises three or more sensors to collect data on the cylindrical surface of the metal container. Alternatively, these three or more sensors are located at substantially even intervals around the longitudinal axis of the metal container. Sensors can collect data essentially simultaneously. In one embodiment, the decorator comprises four sensors, each of which collects data associated with at least about 25 percent of the cylindrical surface. In another embodiment, each of the four sensors collects data on approximately 30 percent of the cylindrical surface. As would be appreciated by one of ordinary skill in the art, the apparatus and methods described herein can be used on any type of surface or container, such as an end cap or closed end wall, and are not limited to cylindrical portions of metal containers.

Alternatively, a light source may be associated with one or more sensors. The light source can create light continuously. Alternatively, the light source can emit light intermittently, like a strobe light source. Thus, the light source can emit light while the sensor connected to it collects data related to the design of the metal container.

In one embodiment, the at least one sensor collects data on target portions of the cylindrical surface. Alternatively, the target area can be associated with each colorful decorator knife. The decorator can contain from 20 to 80 individual colorful knives. For example, a decorator might contain four to eight paint distributors. Each paint distribution unit can contain 5 to 10 ink knives to control the amount of ink supplied to the 5-10 axial sections of the paint roller of the paint distribution unit. Accordingly, the at least one sensor can collect data on 20 to 80 different target areas of the cylindrical surface of the metal container. In this way, at least one sensor can collect data associated with the paint adjusted by each individual decorator's paint knife. In one embodiment, the sensor can sense changes in ink density within the design of the metal container.

The control system can use the sensor data to determine if the design meets the target values or is defective. The control system can use the sensor data to determine one or more of the following: (a) the paint is too light or too dark; (b) the design contains gaps; (c) the design contains blur; (d) the artwork is not positioned correctly (outside of the artwork); (e) the decoration was formed by a printing plate or blanket that is damaged (for example, cuts or tears); (f) the decoration contains a dirty stain; (g) the lacquer coating on the metal container is defective or missing; (h) the decoration contains contamination; (i) the metal container is damaged or out of specification; (j) decoration colors are distorted; and (k) the artwork contains the wrong color. The control system can determine the location of the change in the optical density of the paint layer on the cylindrical container body. By determining the axial section of the cylindrical container body associated with the location of the change in the optical density of the ink layer, the control system can determine the ink knife of one of four to eight ink distribution units responsible for the change in the optical density of the ink layer. The control system can then send a signal to an actuator associated with the ink knife to change the position of the ink knife and eliminate the defect caused by the change in optical density of the ink layer. The control system can also determine that the metal container has a damaged casing, which was caused by equipment that preceded the decorator.

Another approach of the present invention is a control system capable of controlling a decorator. The control system contains a command for determining how to adjust at least one decorator component to eliminate a design defect. The control system can receive data collected by the sensor on the design of the metal container. The control system can determine that the adornment is defective by comparing sensor data with target information for one or more print parameters. Print settings can contain at least one of such parameters as color, density, thickness, orientation and consistency of the design. The control system can use the sensor data to determine how to correct the defective decoration by adjusting one or more decorator components. When the decoration is defective, the control system can send a signal to an actuator associated with at least one ink knife to be adjusted. The signal causes the actuator to move the ink knife relative to the ink roller of the paint distribution unit. In one embodiment, the drive may move at least a portion of the ink knife towards or away from the ink roller. In this way, the control system adjusts the gap between the ink knife and the ink roller to change the amount of ink transferred to the corresponding axial section of the ink roller. Additionally or alternatively, the control system can send a signal to the actuator to change the rotation speed of the ink roller or transfer roller of the paint distribution unit. By varying the speed of rotation of the ink roller or transfer roller, the control system can increase or decrease the amount of ink supplied through the corresponding ink device to the printing plate attached to the plate cylinder. The sensor can collect data over the entire outer surface of the cylindrical body of a metal container. In one embodiment, the sensor comprises from 3 to 5 sensors arranged so as to interpret the quality of the decoration throughout the cylindrical body of the metal container. In one embodiment, the control system compares the sensor data with an image stored in the control system memory. In another embodiment, this image is a defect-free adornment image. In one embodiment, the control system compares the sensor data for the regions with a plurality of corresponding regions of the image portions of acceptable designs stored in memory. In one embodiment, the control system may also stop the decorator in response to a determination that the decoration is defective. More specifically, in one embodiment, the control system comprises a command to stop the decorator upon determination that a predetermined number of metal containers contain a defective decoration. In another embodiment, the control system comprises a command to stop the decorator after identifying a predetermined cause of the defective design. For example, the control system may contain a command to stop the decorator if the defective decoration is not due to an inappropriate amount of paint being transferred to the metal container. In another example, the control system may include an instruction to stop the decorator after determining that the decoration defect is associated with one or more of the following: defective ink, printing plate, blanket, damaged metal container, undefined cause, and incorrect position or misalignment of the decoration area. Additionally or alternatively, the control system may generate an alarm with information related to the design defect and the cause of the design defect. The alarm can be sent to a display screen or to an electronic device such as a computer, laptop, tablet device, or smartphone. The alarm can contain a text message.

Another approach of the present invention is to provide a decorator with a paint distribution unit. Alternatively, the decorator contains many paint distributors. The ink distribution unit contains one or more ink knives that can be radially adjusted relative to the ink roller. Accordingly, at least some part of each ink knife can be moved closer to or away from the ink roller. In one embodiment, each of the ink knives can optionally move axially relative to the ink roller. Thus, the amount (or density, thickness) of ink transferred from the ink reservoir to each axial portion of the ink roller can be controlled. In one embodiment, each ink knife is rotatable relative to the ink roller. Alternatively, in another embodiment, each ink knife may move linearly towards or away from the ink roller.

The movement of the ink knives can be provided selectively by a variety of mechanisms, as those skilled in the art will understand. In one embodiment, the movement of the ink knives is generally controlled by a control system. Colorful knives usually move in response to an applied force. In one embodiment, the force can be generated by one or more sources of electrical, pneumatic, hydraulic, and magnetic energy.

In one embodiment, the movement of one or more ink knives is typically driven. In another embodiment, a drive is associated with each individual ink knife. In another embodiment, multiple actuators may be associated with a single ink knife. In one embodiment, the actuator initiates a force transverse to the longitudinal axis of the associated ink knife. In this way, the ink knife or a selected portion of the ink knife is rotated or bent relative to the ink roller. In another embodiment, the actuator initiates a force that is generally parallel to the longitudinal axis of the associated ink knife. In this embodiment, the ink knife moves linearly and typically parallel to the knife axis towards or away from the ink roller. The drives can be controlled by the decorator control system.

In one embodiment, the movement of the ink knives is controlled by a control system. In one embodiment, the control system includes non-portable, computer-readable instructions stored in memory that control the movement of the ink knives. Alternatively, the control system contains a command to receive data from a sensor associated with the design of the metal container. In one embodiment, the sensor comprises a charge-coupled device (CCD) or complementary metal-oxide-semiconductor (CMOS) image sensor. In one embodiment, the sensor comprises a plurality of individual elements. Each sensor element collects data associated with an area of the metal container. In one embodiment, each sensor element collects one pixel of data.

The control system contains the command to analyze the sensor data related to the design. In one embodiment, the control system comprises an instruction to compare sensor data with stored data. In one embodiment, the stored data is associated with at least one suitable design. An acceptable design can be scanned and stored in a memory accessible to the control system. In one embodiment, the acceptable layout is scanned at such a resolution that the stored data associated with the acceptable layout contains a plurality of pixels, which may be based on the number of individual sensor elements. More specifically, an acceptable layout can be stored in memory with a resolution equal to the resolution of the data collected by the sensor. In another embodiment, the acceptable layout is stored at a different resolution than the sensor. Accordingly, in another embodiment, an acceptable appearance is maintained at a higher or lower resolution than the resolution of the data collected by the sensor. In one embodiment, the stored data is in a computer database. The database can be stored in the memory of the control system. Alternatively, the management system accesses the database via a network connection.

In one embodiment, the control system comprises commands for determining that the layout is defective when the sensor data differs from the stored data by a predetermined value. In one embodiment, the control system compares the plurality of pieces of sensor data with corresponding pieces of stored data. If the control system decides that the parts of the sensor data differ from the parts of the stored data, the design is defective. Alternatively, when parts of the sensor data differ from the corresponding parts of the stored data by a predetermined percentage, the control system decides that the design is defective.

In one embodiment, the control system includes commands to automatically adjust at least one of the ink knives to eliminate a design defect. For example, in one embodiment, the control system comprises commands to send a signal to the actuator. In one embodiment, the signal causes the actuator to move the ink knife in a specific direction to change the amount of ink transferred to the ink roller. Thus, the control system can automatically adjust the at least one ink knife without operator intervention. In another embodiment, the signal causes the actuator to move one or more of the following: ink roller, ink roller, plate cylinder, printing plate, blanket cylinder, blanket, or support in a specific direction to correct a design defect. Additionally or alternatively, the control system can send a signal to change the rotation speed of one or more ink rollers or transfer rollers of the ink dispensing unit to increase or decrease the amount of ink transferred to the printing plate attached to the corresponding plate cylinder.

In one embodiment, when the control system determines that the decoration is defective, the control system sends an alarm to the decorator operator. In one embodiment, the control system sends an alarm to the control system display. In another embodiment, the alarm may include an audible signal such as an alarm, siren, or voice message. In another embodiment, an alarm can be sent to a user device over a network connection. Accordingly, in one embodiment, an operator can receive an alarm on a smartphone, tablet, laptop, or other mobile device. The alarm may contain information about a design defect. Alternatively, the alarm may contain information related to adjusting at least one decorator component to correct the defective design. For example, an alarm can provide information about adjusting one or more of the following components: ink roller, ink knife, ink roller, transfer roller plate cylinder, printing plate, blanket cylinder, blanket, or support, as determined by the control system to correct a design defect. ... In one embodiment, the alarm is presented to the operator on a display of the control system.

In one embodiment, an operator can use an input device of the control system to confirm, not confirm, or change an adjustment of at least one decorator component scheduled by the control system to correct a design defect. More specifically, an operator can make an input to the control system to confirm (or support) a planned adjustment, change a planned adjustment, or not confirm a planned adjustment of at least one ink knife or other decorator component. In one embodiment, an operator can make an input through contact with a display. In another embodiment, operator input can be made using a "mouse" or other pointer on the control system. In yet another embodiment, input can be made using a keyboard.

In one embodiment, the control system comprises a command to automatically adjust at least one decorator component after a predetermined amount of time unless the operator rejects or cancels the scheduled adjustment. In yet another embodiment, the control system comprises commands to automatically adjust at least one decorator component after a predetermined amount of time if the operator does not confirm the scheduled adjustment.

In one embodiment, each ink knife has a width between about 0.5 inches and about 1.5 inches. Accordingly, a decorator having five or six ink knives per paint distribution unit can decorate the cylindrical body of a metal container up to about 7 inches in height. However, the paint distribution unit of the present invention can be used to decorate much larger cylindrical objects or containers, as would be appreciated by those skilled in the art. In one embodiment, the ink knives of each ink distribution unit have substantially the same width. Alternatively, the ink knives of each paint distribution unit may have different widths. In yet another embodiment, decorator paint dispensers have 5 to 10 colorful knives.

Yet another other approach of the present invention provides a decorator comprising an ejector. The ejector removes from the conveyor metal containers identified by the control system as having a design defect.

Another approach of the present invention is a decorator control system capable of determining an acceptable design for a metal container and whether the design quality falls within specified quality standards. When the management system establishes an acceptable design, the management system may detect a design that deviates from an acceptable design. Thus, the control system can determine that the metal container contains an invalid or defective design.

One approach of the present invention is to provide a device for decorating a metal container. The device generally includes, but is not limited to: (1) an ink distribution unit containing an ink roller, a plurality of ink knives, an ink reservoir, and a drive to move each ink knife relative to the ink roller to control the amount of ink transferred from the ink reservoir. paints on a paint roller; (2) a plate cylinder containing the printing plate at a predetermined specific location relative to the ink roller, so that the printing plate receives at least some ink from the ink roller; (3) a blanket cylinder containing the blanket at a predetermined location relative to the plate cylinder so that the blankets receive at least some ink from the printing plate; (4) a support member for receiving the metal container from the conveyor and moving the metal container into contact with the blanket of the blanket cylinder to transfer at least some ink from the blanket to the metal container to form a decoration on the outer surface of the metal container; (5) at least one sensor for collecting or receiving data on the design of the outer surface of the metal container; and (6) a control system that receives data from at least one sensor and determines if the decoration is faulty. If the control system decides that the design contains defects, then the control system has the ability to send a signal to the device drive in order to eliminate the defect. In one embodiment, a drive is associated with each ink knife. In one embodiment, the signal causes the actuator to adjust the ink knife to vary the amount of ink transferred to the ink roller. Additionally or alternatively, the signal can cause the drive element to change the speed of rotation of the ink roller to change the amount of ink transferred to the printing plate. In another embodiment, the support member comprises a plurality of container locations. Each place is adapted to receive a metal container. In another embodiment, these locations comprise rods. In one embodiment, the device comprises a plurality of paint distribution units. Each of the plurality of ink distribution units is configured to transfer ink to a corresponding printing plate.

Alternatively, in one embodiment of the present invention, the device further comprises an ejector associated with a control system. The ejector removes defective metal containers from the conveyor in response to receiving a signal from the control system.

In one embodiment, the sensor comprises a charge coupled device (CCD) or a complementary metal oxide semiconductor (CMOS) image sensor. In another embodiment, at least one sensor is configured to obtain data on one or more of the following: (A) decoration color; (B) density of decoration; (C) depth or thickness of the decoration; (D) correct clearance position; and (F) the consistency of the decoration. In one embodiment, the sensor is a camera. Alternatively, the device can contain from one to six sensors. In one embodiment, these one to six sensors are located around the circumference of the cylindrical body of the metal container. In one embodiment, each sensor can be adapted to obtain one type of data, such as color, density, depth or thickness, correct position, and consistency in terms of decoration. In another embodiment, the device comprises three to six sensors to acquire data regarding the cylindrical body of the metal container. In one embodiment, the at least one sensor receives data from a plurality of target areas on the outer surface of the metal container. In another embodiment, each of the plurality of target areas corresponds to an area on the outer surface of the metal container associated with one of the ink blades. In one embodiment, the at least one target area is associated with the paint of one paint distribution unit.

In another embodiment, the control system is configured to detect a defect that contains an error in at least one of the following: (i) decoration color; (ii) density of decoration; (iii) thickness of decoration; (iv) the correct location of the decoration; or (v) the consistency of the decoration. In response to the detection of a defect in the decoration, the control system is able to change the position of at least one component of the device while the device is decorating the metal containers. In one embodiment, the control system sends a signal to change the position of one of the plurality of ink knives. The control system can send a signal to an actuator associated with one ink knife to selectively move the ink knife to a predetermined position relative to the ink roller. In one embodiment, the distance between the ink knife and the axial portion of the ink roller is changed. In another embodiment, the control system may send a signal to the drive element to change the rotation speed of the ink roller or transfer roller of the paint distribution unit.

Another aspect of the present invention provides a method for reading and correcting a design defect applied to the outer surface of a container. The method contains, but is not limited to only this, the steps in which: (1) provide a container; (2) decorate the container with a decorator; (3) obtaining data on the design of the outer surface of the container using at least one sensor; (4) determining, by the management system, whether the decoration contains a defect; and (5) if the adornment contains a defect, a signal is sent by the control system to the decorator to change at least the color or density of subsequent adornments. In one embodiment, the container is a metal container comprising a closed end wall and a body portion extending from the closed end wall. In one embodiment, the body portion is substantially cylindrical. Alternatively, the method may further comprise sending an alarm to the operator. In one embodiment, an alarm is presented on a display of the control system. In another embodiment, the alarm contains information about the failure. In one embodiment, the fault information comprises an image of the outer surface of the container obtained by at least one sensor. In another embodiment, the alarm contains information about the signal sent to the decorator by the control system.

In one embodiment of the present invention, the decorator comprises: (a) an ink distribution unit comprising an ink roller, a plurality of ink knives, an ink reservoir, and a drive for moving the ink knives relative to the ink roller to control the amount of ink transferred from the ink reservoir to the ink roller; (b) a plate cylinder containing the printing plate at a predetermined specific position relative to the ink roller so that at least some ink from the ink roller falls on the printing plate; (c) a blanket cylinder containing the blankets at a predetermined position relative to the plate cylinder so that at least some ink from the printing plate of the plate cylinder falls onto each blanket; and (d) a support device for receiving the container from the conveyor and bringing the container into contact with the blanket of the blanket cylinder to apply at least some ink from the blanket to the container so that a decoration is formed on the outer surface of the container. In one embodiment, the drive links the decorator components together. Alternatively, a drive is associated with each colorful knife. In another embodiment, the support device comprises a plurality of locations, each of which is configured to receive a container. In yet another embodiment, the decorator comprises two to twelve paint distribution units. Each of the paint distribution units is configured to transfer ink to the printing plate of the plate cylinder.

In one embodiment, the ink roller comprises a plurality of axial portions, where each axial portion is defined with an ink knife. In one embodiment, each axial ink roller portion comprises a cylindrical curved ink roller surface portion. Alternatively, a signal from the control system causes the drive element to change the speed of rotation of the ink roller.

In one embodiment, the signal causes an actuator associated with the ink knife to move the ink knife in a specific direction to change the amount of ink transferred from the ink reservoir to the axial portion of the ink roller. In another embodiment, the signal causes the actuator to rotate in a first predetermined direction to move the ink knife of the ink dispensing unit to a position that increases or decreases the amount of ink transferred to the axial portion of the ink roller. In yet another embodiment, the signal causes the decorator to change at least the color, density, thickness, position, or consistency of subsequent decorations.

In another embodiment, a signal causes at least one of the following: an ink dispensing unit, an ink roller, a plate cylinder, or a blanket cylinder to move in a specific direction. In yet another embodiment, the control system can send a signal to an actuator to change the position of at least a printing plate on a plate cylinder or a blanket on a blanket cylinder. In another embodiment, the control system may send a signal to an injector roller drive associated with the paint distribution unit. The signal can change the travel speed of the injector roller. In this way, the control system can control the amount of ink transferred to the printing plate associated with the ink dispensing unit. More specifically, the control system can send a signal to decrease or increase the travel speed of the die roll. Alternatively, in one embodiment, the method further comprises sending the control system a signal to the ejector to remove the defective container from the conveyor associated with the decorator.

In one embodiment, the at least one sensor comprises one to six sensors. In another embodiment, these one to six sensors are positioned to acquire barrel data substantially simultaneously. Alternatively, these one to six sensors are positioned around the cylindrical body of the metal container. In one embodiment, the at least one sensor comprises two to six sensors located substantially uniformly around the longitudinal axis of the metal container. In one embodiment, each of these one to six sensors may receive the same type of data. In another embodiment, these one to six sensors may receive different types of data. For example, in one embodiment, the at least one sensor comprises one or more of the following: (i) a first sensor for acquiring decoration color data; (ii) a second sensor for obtaining data on the density of the design; (iii) a third sensor for obtaining data on the depth of clearance; (iv) a fourth sensor for receiving adornment alignment data; and (v) a fifth sensor for obtaining texture consistency data.

In one embodiment, the method further comprises one or more of the following steps: (6) changing the position of at least one ink knife in response to receiving a signal from the control system; (7) provide a second container; (8) decorate the second container with a decorator; (9) waiting for a predetermined time so that the second decorator can reach at least one sensor; (10) obtaining data on the design of the outer surface of the second container; and (11) determining, by the control system, whether the defect contains the decoration of the second container.

In another approach, the present invention provides a management system for monitoring and identifying design defects and taking corrective action. The control system contains instructions stored on a non-portable computer-readable medium that, when executed by a processor of the control system, cause the control system to modify and change physical parameters and equipment to perform the methods described herein.

In yet another approach, there is a non-portable computer-readable medium that stores computer-executable instructions that cause the control system processor to perform a method for automatically eliminating a design defect formed by a decorator on a cylindrical surface of a metal container. Commands contain one or more of the following commands, but are not limited to these: (1) command to get data related to the decoration formed on the cylindrical surface of the metal container by the decorator; (2) the command to determine if the design contains defects; and (3) if the artwork contains defects, the command to define a decorator adjustment to correct the defect. In one embodiment, the defect may be associated with at least one of the following: color, density, thickness, correct position, or consistency of decoration. Alternatively, in another embodiment, the commands may further comprise an command to determine the cause of the defective design. More specifically, in one embodiment, the commands comprise an instruction to determine if the defect is related to one or more of the following: (i) an inappropriate amount of ink; (ii) defective paint; (iii) the printing plate or blanket of the decorator; (iv) improper placement or installation of a decorator component; and (v) a damaged or defective metal container. In one embodiment, the control system may determine that the defective design is associated with a printing plate or blanket that is defective, worn out, or improperly located based on the received data.

In one embodiment, the instructions further comprise an instruction to send a signal to the decorator to clear the design defect. In another embodiment, the signal may cause the decorator to change at least one of the following: color, density, thickness, correct position, or consistency of subsequent decorations generated by the decorator. More specifically, in one embodiment, a signal may activate a drive to move a decorator component in a specific direction. In one embodiment, the signal causes the actuator to move in such a way as to change the amount of ink transferred to the decorator ink roller. Additionally or alternatively, the signal may cause the drive element to change the rotation speed of at least the ink roller or transfer roller of the ink distribution unit.

In one embodiment, the commands further comprise a command to send a signal to the actuator to adjust the ink knife. In one embodiment, the signal causes the actuator to move the ink knife in a specific direction relative to the decorator ink roller to change the amount of ink applied to the ink roller portion. In another embodiment, the signal causes the actuator to move at least one decorator ink knife to a position that increases or decreases the amount of ink transferred to the ink roller portion.

In another embodiment, the commands may further comprise a command to send a signal to the decorator drive to move at least one of the following: ink distribution unit, ink roller, ink roller, plate cylinder, plate cylinder, blanket cylinder, or blanket in a predetermined direction ... Alternatively, the signal may change the speed of rotation of one or more ink rollers, transfer rollers, plate cylinders or blanket cylinders, or change the speed of movement of the injection roller.

In one embodiment, the data is collected by at least one sensor. Alternatively, the at least one sensor comprises three to six sensors spaced substantially uniformly around the circumference of the metal container.

In one embodiment, the command to determine if the decoration contains a defect further comprises an command to compare the received data with data stored in memory associated with the acceptable decoration. The method may optionally comprise a command to determine that the design contains a defect when the received data deviates from the data stored in the memory by a predetermined value. In one embodiment, the instructions further comprise an instruction to compare the plurality of chunks of received data with the corresponding plurality of chunks of data stored in memory. Alternatively, the commands may include a command to determine that the layout contains a defect when a specified percentage of the received patch data deviates from the corresponding patch data stored in memory.

In one embodiment, the stored data is stored in a database. The database can contain many areas related to acceptable design. In one embodiment, each region is associated with a colorful decorator knife. In another embodiment, at least one area of the database contains information related to the purposes of acceptable design. Targets can include one or more paint colors, paint consistencies, paint optical density, paint thickness, artwork orientation, and artwork location correctness.

Alternatively, the stored data may include sensor data from a plurality of metal containers that contain acceptable designs. More specifically, in one embodiment, the control system comprises commands to receive data from a sensor associated with a plurality of suitably shaped metal containers. The commands may include a command for the control system to parse the sensor data and a command to store the sensor data in the database areas.

Another approach of the present invention is a non-portable computer-readable medium provided on a storage medium containing instructions that, when executed by a processor of a control system, cause the processor to perform a method of reading and correcting a design defect formed on a cylindrical surface of a container by a decorator. Commands contain one or more of the following commands, but are not limited to: (1) command to get data associated with the appearance formed on the cylindrical surface of the container; (2) a command to determine if the design contains a defect; or (3) a command to send a signal to the decorator to change the subsequent appearance generated by the decorator. In one embodiment, data is received from a sensor. In another embodiment, the defect is associated with at least one of the following: color, density, thickness, correct position, or consistency of decoration. In yet another embodiment, the signal causes the decorator to change at least one of (i) color, (ii) density, (iii) thickness, (iv) correct position, or (v) consistency of subsequent decorations generated by the decorator.

Alternatively, the commands may additionally contain a command to compare the data received from the sensor with data of an acceptable design. In one embodiment, the instructions further comprise an instruction to determine if the defective artwork is associated with one or more of the following: (A) an incorrect amount of ink; (B) defective paint; (C) defective printing plate or decorator's blanket; (D) incorrect alignment of the decorator component; and (E) a defective or damaged container. In one embodiment, the instructions may also include an instruction to obtain a decision that the defect is due to an unknown cause.

In one embodiment, a signal causes at least one of the following: ink distribution unit, ink roller, ink roller, transfer roller of a printing cylinder, printing plate on a printing cylinder, blanket cylinder or decorator's blanket to move in a certain direction or rotate at a different speed ... For example, the signal can cause the drive element to rotate the ink roller or transfer roller at different speeds to vary the amount of ink transferred to the printing plate. In another embodiment, the signal causes the actuator to move the decorator ink knife to a position that increases or decreases the amount of ink transferred to the ink roller portion. In yet another embodiment, a signal causes an actuator associated with one or more of an ink dispensing unit, ink roller, ink roller, plate cylinder, plate on a plate cylinder, blanket cylinder, or decorator blanket to move in a specific direction. Alternatively, the signal can change the speed or select the moment of movement of the die roll. In this way, the amount of ink transferred to the printing plate can be varied.

In another approach of the present invention, a paint dispenser for a decorator is provided. The paint distribution unit usually contains, but is not limited to only this, one or more of the following: (1) an ink roller; (2) paint reservoir; (3) a plurality of ink knives located in the vicinity of the ink roller, each ink knife defining an axial portion of the ink roller; and (4) an actuator associated with the ink knives, in which, in response to a signal received from the control system, the actuator is capable of changing the position of the ink knife relative to the ink roller to control the amount of ink transferred to the ink roller. In one embodiment, the portion of each ink knife closest to the ink roller comprises a longitudinal portion and an end portion extending from the longitudinal portion. In one embodiment, the longitudinal portion and the end portion have shapes that are substantially flat. Alternatively, the end portion extends from the longitudinal portion at an angle between approximately 80 ° and approximately 100 °.

In one embodiment, a drive is associated with each of the ink knives. In another embodiment, each actuator comprises an axle associated with one corresponding ink knife. Alternatively, the axle is threadedly connected to the corresponding ink knife in such a way that rotation of the axle in a predetermined direction moves the corresponding ink knife closer to or further from the ink roller. In one embodiment, the actuator is a solenoid.

Alternatively, the paint distribution unit may further comprise a potentiometer associated with each of the plurality of ink knives. In one embodiment, the potentiometer is configured to measure the movement of the ink knives relative to the ink roller. In another embodiment, the potentiometer can detect rotation of the axis. In one embodiment, the potentiometer includes a first gear that meshes with a second gear associated with an actuator.

Another approach of the present invention is to provide the decorator with a roller that can be adjusted while the decorator is operating to decorate the metal containers. The drive is connected to the injector roller. The drive is made with the ability to change the speed of movement of the injector roller. In this way, the amount of ink transferred from the ink distribution unit to the printing plate can be varied. In one embodiment, the drive may vary one or more of the timing of the die roll. In another embodiment, the actuator is configured to receive a signal from the control system.

Another approach of the present invention is a decorator control system. The control system is connected to a sensor located after the decorator. The sensor is configured to collect data on a cylindrical surface of a metal container decorated with a decorator. Alternatively, the sensor may contain three to six sensors located around a metal container such that data is collected over all or a substantial portion of the cylindrical surface. In one embodiment, these three to six sensors are image sensors such as cameras. The control system contains a command to compare the data from the sensor with the base image. The control system contains a command to determine if the decoration on the metal container is defective in comparison with the base image. In one embodiment, a decoration is defective if one or more of decoration color, decoration density, decoration depth or thickness, decoration alignment, decoration consistency, or decoration position deviates from the base image by more than a predetermined value. Alternatively, the control system may determine that the adornment is defective if the adornment color in one or more target areas is different from the color of the corresponding target area of the base image. In one embodiment, the decoration is defective if the color differs (has ∆E) by more than a predetermined value.

In one embodiment, the control system comprises an instruction to determine the cause of the defective design. Specifically, the control system can determine if the defective decoration is caused by the decorator or prior equipment.

In one embodiment, the control system comprises an instruction to determine if the defect is caused by one or more of the following: misadjustment of the paint distribution unit; incorrect rotation speed of the ink roller or transfer roller; incorrect contact time of the die roller; incorrect alignment of the printing plate; or incorrect blanket alignment. The control system may optionally comprise a command to send a signal to one or more decorator actuators to correct one or more incorrect adjustments to the paint distribution unit; incorrect rotation speed of the ink roller or transfer roller; incorrect contact time of the die roller; incorrect alignment of the printing plate; or incorrect blanket alignment.

In another embodiment, the control system comprises an instruction to determine that the defective design is caused by a problem that cannot be corrected by the control system. A problem that cannot be corrected contains one or more of the following, but is not limited to: a damaged printable; damaged blanket; paint problem in the ink device; or a damaged container. In response to identifying a problem that cannot be corrected by the control system, the control system may contain alarm commands. Alternatively, the control system may contain a command to stop the decorator when a bad decorator is caused by a problem with the decorator that cannot be corrected. Additionally, or alternatively, the control system may include a command to the equipment upstream of the decorator when the defective design is caused by a damaged container.

One of the approaches of the presented invention is a device for controlling and regulating the decoration formed on the outer surface of metal containers. The device comprises, but is not limited to, one or more of the following: (1) a decorator comprising a paint distribution unit, a printing plate, a blanket and a support member for receiving a metal container and moving the metal container into contact with the blanket to transfer the decoration to a cylindrical outer surface of a metal container; (2) a sensor located after the decorator to receive data from predetermined target locations within the decoration of the cylindrical outer surface of the metal container, related to the quality of the decoration; and (3) a control system receiving data from the sensor, the control system being configured to compare the received data with stored data to determine if the artwork is defective. If the design is defective, the control system may send a first signal to adjust at least one of the paint spreader, the paint roller speed of the paint roll, the transfer roller speed of the nap, plate, or blanket to eliminate the cause of the defective design. Additionally or alternatively, the control system can also determine if the structure of the metal container is defective. If the structure of the metal container is defective, the control system can send a second signal to at least the display screen or to equipment preceding the decorator. Alternatively, the stored data is stored in a database accessible to the control system.

In one embodiment, the sensor comprises three to six image sensor devices arranged in a predetermined orientation to read portions of the cylindrical outer surface of the metal container. In another embodiment, the control system may determine if the defective decoration is associated with at least one of the following: decoration color, decoration density, decoration depth, decoration alignment, decoration consistency, and decoration position.

In one embodiment, the sensor is configured to collect data on one or more of the following: decoration color, decoration density, decoration depth or thickness, decoration alignment, decoration consistency, decoration position, and shape of the metal container.

In another embodiment, the first signal is sent to an actuator configured to change the amount of paint transferred to the office canvas during decorator operation. Alternatively, the drive is configured to adjust the position of the adjusting screw or ink knife of the paint distribution unit. The ink distribution unit may contain a plurality of ink knives, with each of the plurality of ink knives including a longitudinal axis. In one embodiment, each of the ink knives is configured to move, typically parallel to the longitudinal axis, in response to a drive force. The actuator can move the ink knife, usually linearly relative to the ink roller, to vary the amount of ink transferred to the printing plate. For example, the first signal can cause the actuator to rotate an axle threaded to the ink knife. By rotating the axis in the first direction, the drive can bring the ink knife closer to the ink roller, thus reducing the amount of ink transferred to the blanket. In one embodiment, a potentiometer is associated with each plurality of ink knives. Each potentiometer is configured to detect the movement of the respective ink knife relative to the outer perimeter of the ink roller. Additionally, the drive is configured to change the speed of the injector roller located between the ink distribution unit and the printing plate. In one embodiment, the first signal is configured to move one or more printing plates and blanket during decorator operation. Alternatively, the first signal can also cause the drive element to change the rotation speed of the ink roller and / or transfer roller to change the amount of ink transferred to the printing plate. The drive element may contain a motor.

Another approach of the present invention is to provide a method for optimizing the decoration formed by a decorator on the outer surface of a metal container. The method comprises one or more of, but not limited to, the following steps, in which: (1) a metal container is provided; (2) feeding the metal container into the decorator at a predetermined speed; (3) decorating the metal container with a decorator comprising a paint distribution unit, a printing plate, a blanket and a support element for moving the metal container into contact with the blanket; (4) obtaining images of the decoration of the outer surface of the metal container using the imaging device; (5) comparing by means of the control system the obtained image with the stored image of a metal container with an acceptable design; (6) determining, by the control system, whether the resulting image meets the density quality parameters corresponding to one or more criteria; and (7) sending, through the control system, a signal to the decorator to change at least one of the following: color, density, thickness, alignment, or consistency of the ink transferred to the blanket. Additionally or alternatively, the control system can send a signal to a display in communication with the control system.

In one embodiment, the signal is configured to cause at least one of the following: the ink dispenser ink knife, printing plate, or blanket to move in a specific direction during decorator operation. The signal can cause the actuator to move the ink knife, usually linearly relative to the decorator ink roller. In this way, the signal can change the amount of ink transferred to the area of the blanket. In another embodiment, during decorator operation, the signal changes the travel speed of the injector roller located upstream of the printing plate. Additionally or alternatively, the signal can change the rotation speed of the ink roller or transfer roller of the ink distribution unit. In this way, the signal can change the amount of ink transferred to the blanket.

Alternatively, the method may further comprise the steps of: determining by the control system that the metal container is defective; and a signal is sent by the control system to at least a display or equipment preceding the decorator. In another embodiment, the method further comprises the step of: when the obtained image does not meet the quality parameters, it is decided by the control system that the design is defective for one or more of such reasons as: inappropriate amount of ink, defective ink, defective printing plate, defective blanket or inappropriate alignment of the decorator component.

In one embodiment, the method comprises the steps of generating an image for storage by collecting images with an imaging device for a plurality of suitably shaped metal containers; and storing the stored image in a database accessible to the control system.

Still another approach of the present invention provides a non-portable computer-readable medium containing a set of instructions stored thereon that, when executed by a control system processor, causes the processor to adjust the container decorator component during container decorator operation by one or more of the following: (1) obtain data from the sensor, and receiving data associated with a decoration formed by the decorator of the container on the cylindrical outer surface of the metal container; (2) comparing the data with an image of an acceptable design; (3) determining whether the decoration of the cylindrical outer surface of the metal container contains a defect associated with at least one of such reasons as color, density, thickness, alignment, or consistency of the decoration; (4) preparing a team for the container decorator to address the cause of the defect; and (5) instructing the container decorator to adjust the container decorator component to correct the defect. The command may be configured to cause the container decorator to adjust at least the position of the ink knife, the rotation speed of the ink roller, or the rotation speed of the transfer roller. Alternatively, the commands further comprise determining if the design defect is due to one or more reasons such as inappropriate ink quantity, defective ink, defective container decorator plate or blanket, or misaligned container decorator component.

In one embodiment, sending a command causes the container decorator to change at least one of the following: color, density, thickness, alignment, or consistency of subsequent decorations. In another embodiment, the team directs the container decorator to change the installation or position of at least one of the following: ink distribution unit, ink roller, ink roller, transfer roller, plate cylinder, plate cylinder, blanket cylinder, and container decorator blanket.

In one embodiment, sending a command causes the container decorator drive to move at least one of the ink spreader ink knife, ink roller, plate, or blanket in a specific direction. The colorful knife contains a longitudinal axis. The team can force the drive to move the ink knife, usually parallel to the longitudinal axis of the ink roller. In this way, the team forces the ink knife to increase or decrease the amount of ink transferred to the printing plate. Alternatively, the team can force the drive to rotate an axle threaded to the ink knife. When the drive rotates the axis in the first direction, the ink knife moves towards the ink roller, thus reducing the amount of ink transferred to the printing plate area. Additionally or alternatively, the actuator can rotate the axis in the second direction to remove the ink knife from the ink roller, increasing the amount of ink transferred to the platen area. Additionally or alternatively, the team can cause the drive element to change the rotation speed of the ink roller or decorator transfer roller. Increasing the speed of rotation of the ink roller can increase the amount of ink transferred to the printing plate. Alternatively, decreasing the speed of rotation of the ink roller can reduce the amount of ink transferred to the printing plate. In one embodiment, the drive element is a motor, such as an electric motor.

In one embodiment, the sensor is a plurality of cameras located downstream of the container decorator in a predetermined orientation. Alternatively, at least one chamber contains from three to six chambers placed around the circumference of the cylindrical outer surface of the metal container. Multiple cameras are configured to collect data at specified target locations within a design.

In another embodiment, the container decorator comprises an ink distribution unit comprising at least one ink knife, a printing plate, a blanket, and a support member for moving the metal container into contact with the blanket. The control system may include, but is not limited to, one or more of devices such as a memory, an input device, an output device, and a processor in communication with the memory, the input device and the output device.

In one embodiment, the computer-readable medium further comprises: forming an image of an acceptable design by collecting images with a sensor of a plurality of metal containers with an acceptable design; and storing the image in a database accessible to the control system.

While it is commonly referred to herein as "metal container", "beverage container", "can" and "container", it should be understood that the present invention can be used to decorate containers of any size or shape, including, but not limited to, beverage cans. beverage bottles and aerosol containers. Accordingly, the term "container" is intended to encompass containers of any type or shape for any product and is not specifically limited to a container for beverages such as soft drinks or beer cans. The containers can also be at any stage of manufacture and can be formed through a drawing and drawing process or an impact molding process. Thus, the current invention can be used to form a "can" that is subsequently molded into a finished container, a "bottle blank" that is subsequently molded into a metal bottle, or "tubes" that is molded into an aerosol container body.

The terms "metal" or "metallic" as used herein refer to any metal material that can be used to form a container, including, but not limited to, aluminum, steel, tin, and any combination thereof. However, it should be understood that the apparatus and method of the present invention can be used in various forms and embodiments to decorate containers formed from any material, including paper, plastic, and glass.

The methods and apparatus of the invention can be used with any type or variety of paints. For example, one or more "specialty inks" including pigmented inks, thermochromic inks, photochromic inks, scented thermochromic inks, fluorescent inks, ultraviolet inks, invisible inks, infrared inks, phosphorescent inks, pressure sensitive inks, tactile inks, thermotactile paints, leuco paints, matte paints, and any other types of paints, colorants or varnishes that change appearance, color, phase and / or texture in response to changes in temperature or exposure to light or pressure can be used in conjunction with the decorator of the present invention.

Combinations of the words "at least one", "one or more" and "and / or", as used herein, are open expressions that, when used simultaneously, are both connecting and alternative. For example, each of the expressions "at least one of A, B and C", "at least one of A, B, or C", "one or more of A, B and C", "one or more of A, B or C "and" A, B and / or C "mean only A, only B, only C, A and B together, A and C together, B and C together, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities, sizes, conditions, etc., used in the description and the claims, in all cases, are to be understood as being varied by the term "approximately". Accordingly, unless otherwise indicated, all numbers expressing quantities, sizes, conditions, ratios, ranges, etc. used in the specification and claims may be increased or decreased by about 5% to achieve satisfactory results. In addition, all ranges described herein can be reduced to any sub-range or portion of the range, or to any value within the range, without deviating from the invention.

The term "object" as used herein refers to one or more such objects. Also, the terms "one or more" and "at least one" may be used interchangeably herein.

The use of the words "including", "containing" or "having" and their variations herein is intended to cover the items listed below and their equivalents, as well as additional items. Accordingly, the terms "including", "comprising", or "having" and variations thereof may be used interchangeably herein.

It should be understood that the term "agent" as used herein should be given its broadest interpretation in accordance with Section 112 (f) 35 U.S.C. Accordingly, a claim containing the term "agent" should cover all structures, materials, or acts recited herein and all their equivalents. Additionally, structures, materials or acts and their equivalents shall contain everything described in the Summary of the Invention, Brief Description of the Drawings, Detailed Description, Abstract, and Claims.

The term "automatic" and its variants, as used herein, refers to any process or operation performed without physical human intervention when the process or operation is performed. However, a process or operation may be automatic, even though physical or intangible human intervention is involved in the execution of the process or operation, if such intervention occurs before the execution of the process or operation. Human intervention is considered physical if the intervention affects how the process or operation will be performed. Human intervention that gives permission to carry out a process or operation is not considered "physical".

The term "bus" and its variations, as used herein, can refer to a subsystem that transfers information and / or data between various components. A bus generally refers to a data acquisition communication equipment interface, interconnections, bus architecture, standard, and / or protocol defining the design of a communication system and / or communication system. A bus can also refer to a piece of communication equipment that interfaces communication equipment with other components of a related communication network. The bus can be for a wired network, such as a physical bus, or for a wireless network, such as a part of an antenna or equipment that links communications equipment to an antenna. The bus architecture supports a specific format in which information and / or data is organized when sent and received over a communications network. The protocol can define the format and communication rules of the bus architecture.

"Communication modality" can refer to any specific protocol or standard, or to a specific communication session or interaction, such as Voice-Over-Internet-Protocol (VoIP), cellular (e.g., IS-95, 1G , 2G, 3G, 3.5G, 4G, 4G / IMT-Advanced, 3GPP, WIMAX ™, GSM, CDMA, CDMA2000, EDGE, 1xEVDO, iDEN, GPRS, HSPDA, TDMA, UMA, UMTS, ITU-R, and 5G) , Bluetooth ™, text messaging or instant messaging (e.g. AIM, Blauk, eBuddy, Gadu-Gadu, IBM Lotus Sametime, ICQ, iMessage, IMVU, Lync, MXit, Paltalk, Skype, Tencent QQ, Windows Live Messenger ™ or Microsoft Network (MSN) Messenger ™, Wireclub, Xfire and Yahoo! Messenger ™), email, Twitter (eg, tweeting), Digital Service Protocol (DSP), etc.

The term "communication system" or "communication network" and variations thereof as used herein, may refer to an assembly of communication components capable of transmitting, relaying, interconnecting, controlling, and otherwise manipulating information or data from at least one transmitter to at least at least one receiver. Also, the communication can comprise a number of systems supporting point-to-point communication or broadcasting of information or data. A communication system can refer to an individual communication equipment for collecting data, as well as interconnections associated with that individual communication equipment and interconnecting this communication equipment. Communications equipment may refer to specialized communications equipment, or may refer to a processor associated with communications (i.e., an antenna) and executing software capable of using communications to transmit and / or receive a signal within a communications system. Interconnection refers to any type of wired or wireless communication link that connects various components, such as communication equipment, within a communication system. A communication network can refer to a specific organization of a communication system with a set of individual communication equipment and interconnections having a certain described network topography. The communication system may comprise a wired and / or wireless network pre-installed in a highly specialized network structure.

The term "computer-readable medium" as used herein refers to any physical storage device and / or transmission medium that participates in transmitting instructions to a processor for execution. Such media can take various forms, including, but not limited to, non-volatile media, volatile media, or transmission media. Non-volatile media contains, for example, non-volatile random access memory (NVRAM) or magnetic or optical disks. Volatile media contains dynamic memory such as main memory. Standard forms of computer-readable media include, for example, a floppy disk, floppy disk, hard disk, magnetic tape, or any other magnetic medium, magneto-optical media, read only memory (ROM), CD ROM), any other optical media, punched cards, punched tape, any other physical media with hole patterns, random access memory (RAM), programmable read only memory (PROM), and erasable programmable read only memory, EPROM), FLASH-EPROM, solid state memory such as a memory card, any other chip or memory cartridge carrying a signal as described below, or any other medium from which the computer can read. Attaching a digital file to an email or other stand-alone information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. When a computer-readable medium is configured as a database, it should be understood that the database can be any type of database such as relative, hierarchical, object-oriented, and / or the like. Accordingly, the invention is considered to include a physical storage medium or distribution medium and prior art recognized equivalents and successor media on which implementations of the software of the present invention are stored. It should be noted that any computer-readable medium that is not signaling can be considered immutable over time.

The term "display" and variations thereof as used herein can be used interchangeably and can be any panel and / or area of an output device that can display information to an operator or user. Displays may include, but are not limited to, one or more control panels, instrument case (s), indicator (s), meter (s), light bulb (s), computer (s), screen (- s), display (s), head-up display (HUD), and graphical user interface (s).

The term "module" as used herein refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or a combination of hardware and software that is capable of performing functional tasks associated with that element. ...

The term "desktop" refers to the metaphor used to represent the system. The desktop is usually considered a "surface" on which images, called icons, widgets, folders, etc., can be present, which can be activated, and / or on which applications, windows, cabinets, files, folders, documents, and other graphic positions. Icons can usually be selected to initiate a task through the user interface and allow the user to execute an application and / or perform other operations.

The term "display" refers to a portion of a physical screen used to display the computer's output signals to a user.

The term "displayed image" refers to an image displayed on a display. The typical displayed image is a window or desktop. The displayed image can occupy all or part of the display.

The term "email address" can refer to any address that can be contacted, including a phone number, instant messaging, email address, Uniform Resource Locator (URL), Global Universal Identifier, GUID), Universal Resource Identifier (URI), Address of Record (AOR), database alias, etc., and combinations thereof.

The term "screen", "touchscreen", "touchscreen" or "touchscreen" refers to a physical structure that allows a user to interact with a computer by touching areas on the screen and provides information to the user through the display. The touchscreen can sense contact the user by various means, such as changing an electrical parameter (for example, resistance or capacitance), acoustic wave variations, detecting the proximity of infrared radiation, detecting changes in illumination, etc. On a resistive touch screen, for example, through normally separated conductive and resistive metal layers an electric current passes through the screen.When the user touches the screen, the two layers contact at the touch point, thereby detecting the change in the electric field and calculating the coordinates of the touch point.In a capacitive touchscreen, a capacitive layer stores an electrical charge that is discharged to the user on contact with the touch screen, causing the charge of the capacitive layer to decrease. The reduction is measured and the coordinates of the touch point are determined. In a surface acoustic wave touchscreen, an acoustic wave is transmitted through the screen and the acoustic wave propagation is disrupted by the user's touch. The receiving sensor detects the user's contact point and determines the coordinates of the contact point.

The term "window" generally refers to a rectangular display image on at least a portion of a display that contains or provides content that is different from the rest of the screen. The window can cover the desktop. The size and orientation of the window can be configured by another module or by the user. When a window is open, it can occupy substantially all of the display space on the screen or screens.

The terms “defines,” “calculates,” and “counts,” and their variations as used herein, are used interchangeably and contain any type of methodology, process, mathematical operation, or technology.

The Summary of the Invention section is not intended and should not be construed as representing the full scope and scope of the present invention. In addition, references made herein to "the present invention" or its approaches are to be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to the specific description. It should be understood that other embodiments are possible using one, or in combination, one or more of the features set forth above or described below. For example, it is contemplated that various features and devices shown and / or described in relation to one embodiment may be combined or replaced by features or devices of other embodiments, regardless of whether such combination or substitution is shown or described herein. The present invention is formulated in varying levels of detail in the Summary of the Invention section, as well as in the accompanying drawings and in the Detailed Description section, and no limitation as to the scope of the present invention is intended to include or omit elements or components. Additional approaches of the present invention will become more apparent from the detailed description, particularly when studied in conjunction with the drawings.

Brief Description of Drawings

The accompanying drawings are contained herein and form part of the description, illustrate embodiments of the invention, and together with the Summary of the Invention above and the Detailed Description below, serve to explain the principles of these embodiments. In some cases, details that are not required to understand the disclosure or that make other details difficult to understand may be overlooked. It should be understood, of course, that the present invention is not necessarily limited to the specific embodiments shown herein. Additionally, it should be understood that the drawings do not need to be to scale.

FIG. 1 is a schematic block diagram of a decorator showing one embodiment of the invention and also showing a metal container decorated with the decorator of the present invention;

fig. 1A is a block diagram of another embodiment of a decorator of the present invention;

fig. 2A is a top view of various components of a paint distribution unit of one embodiment of the invention;

fig. 2B is a top view of an ink knife in one embodiment of the invention;

fig. 2C is a top view of another embodiment of an ink knife according to the invention, comprising transverse grooves defining sections of the ink knife;

fig. 2D is another top view of an inventive ink knife that contains a plurality of individual knife segments;

fig. 2E is another top view of an ink knife of one embodiment of the invention through which a plurality of ink channels pass;

fig. 3A is a cross-sectional side elevational view along line 3A-3A in FIG. 2A showing the first gap between the knife segment and the ink roller of the paint distribution unit;

fig. 3B is another cross-sectional side elevational view of the paint distribution unit taken along line 3B-3B in FIG. 2A showing a second gap between another knife segment and an ink roller of the paint distribution unit, in which the second gap is longer than the first gap;

fig. 3C, 3D are top views of an ink distribution unit of the invention generally showing axial movement of the ink knife relative to the ink roller;

fig. 4 is a front elevational cross-sectional view of a paint distribution unit of another embodiment of the invention;

fig. 5 is a top perspective view of the paint distribution unit shown in FIG. 4;

fig. 6 is a top perspective view of the paint distribution unit shown in FIG. 5, with some components removed for clarity;

fig. 7 is a front cross-sectional elevation view of the paint distribution unit shown in FIG. 4 taken along line 7-7 in FIG. 5;

fig. 8 is a right side perspective cross-sectional view of the paint distribution unit shown in FIG. 4 taken along line 8-8 in FIG. 7;

fig. 9 is a top perspective view of the ink knives and actuators of the paint distribution unit shown in FIG. 4;

fig. 10A, 10B are side elevational cross-sectional views of the ink knives relative to the ink roller of the paint dispensing unit shown in FIG. 4;

fig. 11 is a flowchart showing the flow of ink transfer operations from the axial portions of the ink rollers to the corresponding cylindrical portions of the metal container;

fig. 12A-12C are top views of sensors located about the longitudinal axis of the metal container to read the cylindrical surface of the metal container at predetermined locations in accordance with various embodiments of the invention;

fig. 13 is a block diagram of an embodiment of a control system according to the invention;

fig. 14 is a block diagram of an embodiment of a data structure for storing sensor data;

fig. 15 is a flowchart of a method used with a control system to recognize an acceptable design in accordance with one embodiment of the invention;

fig. 16 is a flowchart of a method for identifying the cause of a defective design;

fig. 17 is a flowchart of a process for automatically adjusting a decorator to correct a design defect in a metal container in accordance with one embodiment of the invention;

fig. 18 is a flowchart of a decorator operation in accordance with one embodiment of the invention; and

fig. 19 is another flowchart of another embodiment of a decorator action process.

Similar components and / or characteristics can have the same reference number. Components of the same type can be distinguished by the letter following the reference position. If only reference numerals are used, the description applies to any of similar components having the same reference numerals. To aid in understanding any of the embodiments of the present invention, the following list of components is provided herein, with accompanying numbering shown in the drawings:

Number Component 2 Decorator 4 First plate cylinder 6 Printing plate of the first plate cylinder eight First paint distribution unit ten Inking roller of the first paint distribution unit eleven Colorful device 12 Second plate cylinder 13 Ductor roller fourteen Printing plate of the second plate cylinder 16 Second paint distribution unit eighteen Inking roller of the second paint distribution unit 19 Colorful device twenty Axial section of the ink roller 21 Colorful knife 22 Colorful knife 24 Knife segments or sections 25 Grooves 26 Dye 27 Longitudinal edge of knife segments 28 Adjusting screw 29 Ink feed channel thirty Drive unit 31 Axis 32 The gap between the ink knife segment and the ink roller 33 Thread 34 Paint reservoir 35 The edge of the colorful knife 36 Offset cylinder 38 Offset blankets (or "printing blankets") 40 External area of the blanket surface 42 Support element 44 Space in the support for the metal container 46 Control system 48 Conveyor 49 Sensor 50 Sensor 51 Light 52 Undecorated metal container 54 Decorated metal container 56 Outer surface of a metal container 57 Cylindrical container sections 58 Registration 59 Target location 60 Defective metal container 62 Ejector 64 Decorator pre-equipment 66 Equipment located after the decorator 68 Casting 70 Setting plate 72 Swivel blocks 74 Side walls 76 Top plate 78 Line of paint 79 Back plate 80 Potentiometer 82 Tire 84 CPU 86 Input Devices 88 Output devices 90 Storage devices 92 Reader for computer-readable media 94 Communication system 96 Working memory 98 Processing acceleration unit 100 Database 102 Network 104 Remote storage / database 106 Operating system 108 Other code 110 Data structure 112 Ellipses 114 Ellipses 116 First data object 118 Identifier 120 Colour 122 Density 124 Thickness 126 Position / correct position 128 Consistency 130 Other 132 Recordings 134 Second data object 140 Control system programming method 142 Begin 144 Providing a metal container with decoration 146 Read clearance 148 The control system analyzes the sensor data 150 The control system stores the sensor data 152 Repeat 154 Providing a metal container with defective design 156 Defective design sensor 158 The control system recognizes defective design 160 End 166 Method for determining the cause of defective design 168 Begin 170 Get data from sensor 172 Determine if the design is satisfactory 174 Determine if an inappropriate amount of paint has been transferred 176 Determine if defective paint is present 178 Determine if there is a defective plate or blanket 180 Determine if the layout or alignment is incorrect 181 Determine if a metal container is damaged 182 Undefined defect 184 In some cases, relocate the defective metal container 186 In some cases, send an alarm 188 End 200 A way to automatically adjust the decorator to correct defective decoration 202 Begin 204 Move the adjusting screws to the starting position 206 Transfer the paint to the axial areas of the ink rollers 208 Transfer ink to printing plates 210 Transfer ink from printing plates to blankets 212 Transfer ink from blankets to metal containers 214 Wait a specified period of time 216 Read decoration from metal containers using at least one sensor 218 Determine if the design is satisfactory 220 In some cases, remove defective metal containers 222 Send alarm 224 Determine whether to continue the checkout operation 226 Adjust at least one decorator element 228 Transfer decorated metal containers to equipment located after the decorator 230 Determine if clearance operation should continue 232 End 238 The way the decorator works 240 Start 242 Metal container decoration 244 Receiving data from the sensor 246 Determining if the design is satisfactory 248 Determining if a defective layout is caused by a decorator 250 Signal transmission for decorator control 252 Determining if defective decoration is caused by prior hardware 254 Undefined defect 256 Alarm transmission 258 Determining if the production process should continue 260 End 262 The way the decorator works 264 Start 266 Metal container decoration 268 Receiving data from the sensor 270 Determining if the design is satisfactory 272 Determining if the cause can be eliminated by the control system 274 Signal transmission for correction 276 Alarm transmission 278 Determining if the production process should continue 280 End

Detailed description

The presented invention has significant advantages in a wide range of areas of activity. It is the intent of the Applicant that the present description and the appended claims be broad as to the scope and spirit of the disclosed invention, notwithstanding the apparent limitations imposed by expressions when referring to the requirements regarding specific disclosed examples. In order to better familiarize those skilled in the art most closely related to the present invention, a preferred embodiment is described here with reference to the accompanying drawings forming part of the specification, showing the best way considered here in order to put the invention into practice. The exemplary embodiments are described in detail without attempting to describe all the various forms and modifications in which the invention might be implemented. However, the embodiments described herein are illustrative and, as will become apparent to those skilled in the art, may be modified in numerous ways within the scope and spirit of the invention.

FIG. 1 is a schematic diagram of the process flow in the decorator 2 of the presented invention. Decorator 2 usually contains at least one plate cylinder 4, 12, at least one printing plate 6, 14 associated with each of the plate cylinders 4, 12, at least one ink distribution unit 8, 16 containing an ink roller 10, 18 associated with each plate cylinder 4, 12, blanket cylinder 36, blanket 38 associated with blanket cylinder 36, support element 42, control system 46, sensor 50, and, optionally, one or more lamps 51 and ejector 62.

The ink roller 10, 18 of each of the ink distribution units 8, 16 is in a predetermined position relative to the printing cylinder 4, 12 with which it is associated. The ink rollers 10, 18 of each ink distribution unit 8, 16 transfer ink of the same color to the printing plates 6, 14 of each plate cylinder 4, 12. The first ink distribution unit 8 transfers ink of the first color or type to one or more printing plates 6 of the first plate cylinder 4. Likewise, the second ink distribution unit 16 transfers ink of a second color or type to one or more printing plates 14 of the second printing cylinder 12. It should be understood that the decorator 2 may comprise any number of ink distributors and printing cylinders to transfer a plurality of inks to the blankets 38 of the blanket cylinder. 36. In one embodiment, the decorator 2 comprises from two to eleven paint distribution units and associated plate cylinders. In one embodiment, each plate cylinder 4, 12 has only one printing plate 6, 14.

In one embodiment, the ink rollers 10, 18 come into contact with a portion of the outer surface of the printing plates 6, 14. Alternatively, in another embodiment, the ink rollers 10, 18 do not contact the printing plates 6, 14. More specifically, the ink rollers 10, 18 transfer ink 26 to one or more intermediate transfer rollers of the ink device 11, 19. The intermediate transfer rollers form a path along which ink is transferred from the ink rollers 10, 18 to the intermediate transfer rollers of the ink device 11, 19 and then to the printing press. forms 6, 14. Each ink roller 10, 18 may have an associated ink device 11, 19. The ink rollers 10, 18 come into contact with the first transfer roller in each ink device 11, 19. The printing plates 6, 14 come into contact with the final transfer roller of each inking device 11, 19. One of the rollers of each inking device 11, 19 can be an injector roller 13. In about at the bottom of the embodiments, the ink rollers 10, 18 periodically come into contact with the inking roller 13. The drive or drive element may be associated with the ink rollers 10, 18, as well as one or more transfer rollers of the ink device 11, 19. In one of the embodiments, the ink rollers 10, 18 rotate at a different speed than the transfer rollers of the ink device 11, 19. Alternatively, the control system 46 may send a signal to the drive element to change the rotation speed of at least the ink roller 10, 18 or the transfer roller the ink device 11, 19 to change the amount of ink transferred to the printing plate 6, 14.

Any suitable inking device 11, 19 can be used in conjunction with the decorator 2 of the present invention. The intermediate transfer rollers of the inking devices 11, 19 can have many different diameters. Although only three intermediate transfer rollers are shown in the inking devices 11, 19, those skilled in the art will understand that the ink devices 11, 19 may comprise any number of intermediate transfer rollers. One example of an inking device that can be used in conjunction with the decorator of the present invention is described in US Patent Application Publication 2017/0008270, which is incorporated herein by reference in its entirety. In one embodiment, the ink rollers 10, 18 rotate in a first direction, while the printing cylinders 4, 12 rotate in a second opposite direction.

FIG. 2A shows a portion of a paint distribution unit 8A or 16A of one embodiment of the present invention. The amount of ink 26 transferred by the ink dispensing unit 8A, 16A to one or more printing plates 6, 14 associated with each plate cylinder 4, 12 can be individually adjusted along a plurality of axial portions 20A-20L of each ink roller 10, 18. More specifically, each the ink distribution unit 8A, 16A includes an ink knife 22 that measures the amount of ink 26 on the ink roller 10, 18. In one embodiment, the ink knife 22 is continuous along the ink roller 10, 18. Segments 24 of the ink knife 22 correspond to one of the axial portions 20 ...

As shown in FIG. 2B, in one embodiment, the ink knife 22A has a generally flat shape. The sections 24A-24L of the ink knife 22A may move relative to the respective axial sections 20A-20L of the ink roller 10, 18. In one embodiment, the sections 24 of the ink knife 22A may bend in response to force to move closer to the ink roller 10, 18 or further. From him.

Alternatively, and referring now to FIG. 2C, the ink knife 22B includes knife segments 24 formed by the cross-sections or grooves 25 in the ink knife 22B. The grooves 25 extend along at least a portion of the width of the ink knife 22B. The knife segments 24 are individually adjustable relative to the ink roller 10, 18. Each of the knife segments 24A-24L defines a corresponding axial portion 20A-20L of the ink roller 10, 18. In one embodiment, the grooves 25 extend through the longitudinal edge of the ink knife 22B, which is located near paint roller 10, 18.

Now referring to FIG. 2D, in another embodiment, the ink knife 22C comprises a plurality of individual knife segments 24A-24L. Each knife segment 24A-24L is formed separately from the other knife segments 24A-24L. In one embodiment, the longitudinal edge 27 of each knife segment 24 is located near the longitudinal edge 27 of at least one adjacent knife segment 24. In one embodiment, each knife segment 24A-24L defines an axial section 20 of the ink roller 10, 18. Each knife segment 24A-24L is individually movable relative to the ink roller 10, 18 and a corresponding axial section 20A-20L.

Alternatively, in another embodiment generally shown in FIG. 2E, the ink knife 22D may include a plurality of channels 29A-29L that guide the ink 26 to the corresponding axial portion 20 of the ink roller 10, 18. Unlike other ink knives described herein, in one embodiment, the ink knife 22D cannot move. relative to the ink roller 10, 18. In another embodiment, a pump directs ink 26 to channels 29. In one embodiment, the pump may individually control the amount of ink that flows in each of the channels 29. Alternatively, each channel 29A-29L may be associated with an individual pump.

Referring again to FIG. 2A, in one embodiment, an adjusting screw 28A-28L is associated with each of the knife segments 24. Each adjusting screw 28 can be individually twisted and unscrewed relative to the ink knife 22 and the corresponding knife segment 24. In one embodiment, the position of each adjusting screw 28A-28L can be adjusted by the actuator 30A-30L. In one embodiment, the ink knife 22 is flexible. In another embodiment, each individual knife segment 24A-24L is flexible. Accordingly, the portions 24A-24L of the ink knife 22 may be located in close proximity to the outer surface of the ink roller 10, 18, or alternatively further away from the ink roller 10, 18 in response to movement of the adjusting screws 28. In one embodiment, the ink knife 22 is offset away from the ink roller 10, 18. In this embodiment, movement of the adjustment screw 28 away from the ink roller 10, 18 allows at least a portion of the ink knife 22 closest to the adjustment screw 28 to move away from the ink roller 10, 18. How optionally, the ink knife 22 moves in rotation about the longitudinal axis of the ink roller 10, 18. In this way, the knife segments 24A-24L can be rotated relative to the outer surface of the ink roller 10, 18. Alternatively, the cycle speed of the inking roller 13 of the decorator 2 may be adjusted to vary the amount of ink on the ink roller 10, 18 after the ink is applied is carried by the segments 24 of the ink knife 22. In this way, the control system 46 can change the amount of ink transferred to the printing plate 6, 14.

As shown in FIG. 3A, in one embodiment, by screwing in the adjusting screw 28A, the section 24A of the ink knife 22 is pushed towards the ink roller 10, 18. In this way, the length of the gap 32A between the section 24A of the knife and the axial section 20A of the ink roller 10, 18 is reduced. This reduces the amount of ink 26 transferred to the axial region 20A of the ink roller 10, 18 and further to the printing plates 6, 14. In other words, the gap 32A generally determines the density or thickness of the ink 26 that is transferred to the ink roller 10, 18 and then to the metal container 52. The density of the ink is usually related to the amount of ink used to form the decoration. When the density of the ink is not correct, the color of the decoration may not be correct. For example, background paints may be visible at least in part through the decoration paint. In one embodiment, the gap 32 between the ink knife portion 24 and the axial portion 20 of the ink roller 10, 18 may range from about 0 inches to about 0.015 inches. In another embodiment, the gap 32 can be up to about 0.02 inches. In another embodiment, the spacing can be between about 0.001 inches and about 0.02 inches. In one embodiment, the movement of the adjusting screw 28A is initiated by the actuator 30A. The actuator 30A can receive a signal from the control system 46 to change the position of the adjusting screw 28A to change the size of the gap 32.

Alternatively, and referring to FIG. 3B, by unscrewing the adjusting screw 28B, the knife portion 24B moves away from the ink roller axial portion 20B. In this way, the length of the gap 32B increases, increasing the amount of ink 26 transferred to the ink roller axial portion 20B 10, 18 and further to the printing plates 6, 14. ...

As shown in FIG. 3C, 3D, in one optional embodiment of the present invention, the individual segments 24 of the ink knife 22C may be axially movable about the axis of rotation of the ink roller 10, 18. For example, in one embodiment, the knife segment 24F may be axially movable relative to the segments 24E , 24G knife. Alternatively, at least a portion of the knife segment 24F may overlap with one of the knife segments 24E, 24G, as generally shown in FIG. 3D. Those of skill in the art will understand that all knife segments 24 can change their axial position in the same or similar manner. Additionally, each of the knife segments 24 can move radially with respect to the ink roller 10, 18, as previously described.

FIG. 4-10 generally show a paint distribution unit 8B, 16B in accordance with another embodiment of the present invention. The paint distribution unit 8B, 16B is similar to the paint distribution unit 8A, 16A described in conjunction with FIG. 2-3 and working in the same way. In particular, the ink distribution unit 8B, 16B includes individual ink knives 21 that move generally linearly relative to the ink roller 10, 18. Each of the ink knives 21 can be individually positioned relative to the ink roller 10, 18. Although six ink knives 21A- are shown 21F, the ink dispensing unit may have any number of individual ink knives 21. In one embodiment, the ink dispensing unit 8B, 16B comprises two to twelve ink knives 21. In another embodiment, the ink dispensing unit contains four to eight ink knives. In one embodiment, each ink knife 21 is up to about 0.5 inches wide. In another embodiment, each ink knife 21 is up to about 1.5 inches wide. However, other sizes are also possible. Accordingly, in one embodiment, each ink knife controls ink flow to a corresponding axial portion 20 of the ink roller 10, 18, having a width of up to about 0.5 inches, or in another embodiment up to about 1.5 inches.

The paint distribution unit 8B, 16B generally contains casting 68, mounting plate 70, pivot blocks 72A, 72B that support the ink roller 10.18, side walls 74A, 74B, top plate 76, paint bar 78, back plate 79, inks knives 21 and drives 30. Ink bar 78, top plate 76, side walls 74, ink knives 21, and ink roller 10, 18 determine the size of the reservoir 34 for ink that will be transferred to the ink roller 10, 18. In one embodiment, the area the side walls 74 closest to the ink roller 10, 18 are shaped to be located at least partially around the ink roller.

The actuator 30 is mounted in the paint unit 8B, 16B at a predetermined distance from the ink roller 10, 18. In one embodiment, the actuator 30 is mounted in the paint unit 8B, 16B on the rear plate 79. However, other arrangements of the actuator 30 are possible. The actuator 30 can adjust the position of the ink knife 21 relative to the ink roller 10, 18. In one embodiment, each actuator 30 is connected to the ink knife 21 by an axis 31. In another embodiment, the actuator 30 is connected to a control system 46. Accordingly, in response to a signal from the control system 46, the actuator 30 converts electrical energy into mechanical force to adjust the position of the associated ink knife 21. The actuator 30 may be composed of a solenoid or other similar devices known to those skilled in the art.

In one embodiment, each axle 31 can optionally be associated with a respective ink knife 21. Accordingly, the distance between the ink knife 21 and the drive 30 is controlled by the drive. Alternatively, the shaft 31 includes threads 33 by which the end of the ink knife 21 is connected to the nearest actuator 30. In one embodiment, each ink knife 21 includes an internally threaded hole for connecting to the shaft threads 33.

In one embodiment, the edge section 35 of each ink knife 21 closest to the ink roller 10, 18 is substantially parallel to the longitudinal axis of the ink roller 10, 18. The edge section 35 is defined by a longitudinal section or top surface and an end section extending from the longitudinal section ... In one embodiment, the longitudinal section defines a plane that is generally parallel to the longitudinal axis of the ink knife. In another embodiment, the end portion is generally perpendicular to the shaft 31. In one embodiment, the longitudinal portion and the end portion have shapes that are substantially flat. Alternatively, the end portion extends from the longitudinal portion at an angle between approximately 80 ° and approximately 100 °. In one embodiment, the end portion is substantially perpendicular to the longitudinal portion. Alternatively, in another embodiment, the end portion is connected to the longitudinal portion at an angle that is not rectangular.

FIG. 10A, in one embodiment, an actuator 30A is shown that can rotate an axle 31A in a first direction. Since the drive 30A and the axis 31A are set at a fixed distance from the ink roller 10, 18, rotation of the shaft 31A in the first direction causes the ink knife 21A to move towards the ink roller 10, 18. The ink knife 21A can move generally parallel to the longitudinal axis of the ink knife. as shown by the arrow in FIG. 10A. With this method, the gap 32A between the edge portion 35 of the ink knife 21A and the axial portion 20A of the ink roller 10, 18 is reduced in length. This reduces the amount of ink 26 transferred to the axial portion 20A of the ink roller 10, 18 and to the printing plates 6, 14. More specifically, the gap 32A typically determines the density or thickness of the ink 26 that is transferred to the ink roller 10, 18 and further to the undecorated metal plate. container 52. In one embodiment, the edge portion 35 of the knife can move in contact with the axial portion 20A of the ink roller 10, 18 so that the gap 32A is closed. Thus, the ink knife 21A can impede ink flow to the axial portion 20A. In one embodiment, the gap 32 between the ink knife 21 and the ink roller axial portion 20 may range from about 0 inches to about 0.015 inches. In another embodiment, the gap 32 may be approximately 0.02 inches. In another embodiment, the gap may be between about 0.01 "and about 0.02". In one embodiment, the movement of the ink knife 21A is initiated by the actuator 30A. The actuator 30A can receive a signal from the control system 46 to change the position of the ink knife 21A to change the size of the gap 32.

Similarly, and as shown in FIG. 10B, by rotating the axis 31B in the second direction, the actuator 30B causes the axis 31B to move the ink knife 21B away from the ink roller 10, 18. The ink knife 21B may normally move parallel to the longitudinal axis of the ink knife, as shown by the arrow in FIG. 10B. This increases the length of the nip 32B between the ink roller 10, 18 and the edge portion 35 of the ink knife 21B. This movement of the ink knife 21B accordingly increases the amount of ink transferred to the axial portion 20B as well as the density (or thickness) of the ink transferred to the metal container 52.

As shown in FIG. 9, an angle sensor and / or a rotation detection sensor can be used. For example, in one embodiment, potentiometer 80 may optionally be associated with each actuator 30 or ink knife 21. Potentiometer 80 is configured to detect movement of ink knife 21. In one embodiment, potentiometer 80 is configured to sense movement of axis 31 The potentiometer 80 can transmit the amount and direction of movement of the axis to the control system 46. For example, potentiometer 80 may transmit a signal, such as a voltage, indicative of the amount and direction of movement of the axis 31 to the control system 46. The control system 46 may use the information received from the potentiometer 80 to determine the position of the ink knife 21 relative to the ink roller 10, 18. In one embodiment, the potentiometer 80 is configured to sense the rotational movement of the axis 31 and the difference between rotation in the first and second directions. In one embodiment, potentiometer 80 is associated with shaft 31. Alternatively, potentiometer 80 and shaft 21 may comprise meshed gears. Alternatively or additionally, other sensors can be used to detect the movement of the axle 31. That is, one or more rotation sensors 80 and / or angle sensors 80 may use or otherwise comprise a Hall sensor, one or more rotary encoders, including, but not limited to, mechanical, conductive, and optical rotary encoders, contactless image acquisition systems, etc.

Referring again to FIG. 1, if additional gravure cylinders are provided, then more than two colors or types of ink 26 can be used with decorator 2 cylinders 4, 12. In one embodiment, the decorator 2 comprises from two to eight gravure cylinders 4, 12, each of them receiving paints of a different color or of a different type from an associated paint distribution unit 8, 16.

Alternatively, one or more printing plates 6, 14 may have an image formed on the outer surface. Additionally, although the individual printing plates 6, 14 are shown connected to the printing cylinders 4, 12, with a decorator 2 according to the present invention, a single sleeve or cylinder can also be used which circumferentially surrounds each printing cylinder 4, 12.

Each plate cylinder 4, 12 is in a predetermined position relative to the blanket cylinder 36 and blankets 38 associated with it. Accordingly, as the blanket cylinder 36 rotates, the blanket 38 rotates in contact with the first printing plate 6 of the first plate cylinder 4. The first printing plate 6 transfers at least some of the first ink 26A to a portion 40 of the outer surface of the blanket. 38. As the blanket cylinder 36 continues to rotate, the blanket 38 rotates in contact with the second printing plate 14 of the second plate cylinder 12. The second printing plate 14 transfers at least some of the second ink 26B to the area 40 of the outer surface of the blanket. blanket 38. Alternatively, a single continuous blanket can be positioned around the circumference of the blanket cylinder 36. In one embodiment, the blanket cylinder 36 rotates in a first direction.

After the blanket 38 has received the first and second inks 26A, 26B from the printing plate 6, 14 of each plate cylinder 4, 12, a portion 40 of the outer surface of the blanket 38 rotates into contact with the outer surface 56 of the undecorated metal container 52. Blanket 38 transfers at least some of the first and second paints to the outer surface 56 of the metal container 52. Thus, the decoration 58 is formed on the outer surface 56 of the container. It should be understood that the design can contain any combination of images, text, numbers, and symbols.

As shown in FIG. 11, the cylindrical outer surface 56 of the metal container 54 comprises cylindrical portions 57 that correspond to the axial portions 20 of the ink rollers 10, 18 of the paint distribution units 8, 16. Accordingly, for the decorator 2, which contains the ink rollers 10, 18 with six axial portions 20A-20F defined by six ink knife regions 24A-24F 22 (as shown in Fig. 2) or six individual ink knives 21A-21F (as shown in Fig. 9), the metal container 54 contains six corresponding cylindrical regions 57A-57F. The amount of the first ink 26A transferred to the cylindrical portions 57A-57F by the printing plates 6 attached to the first plate cylinder 4 can be controlled by adjusting the ink knives 21 or the ink knife portions 24 with respect to the axial portions 20A-20F of the first ink roller 10. Likewise, the amount of the second ink 26B transferred to the metal container 54 by the printing plates 14 of the second plate cylinder 12 can be adjusted by changing the gaps 32 (shown in FIGS. 3, 10) between the ink blades 21 or the ink knife portions 22 and the axial portions 20A-20F of the second ink roller 18.

As generally shown in FIG. 11, the metal container 54 may have two or more different shapes 58A, 58B. As will be understood by those skilled in the art, designs 58A, 58B may contain different types or colors of paint. For example, in one embodiment, the adornment 58A is formed by the first inks 26A of the first paint dispenser 8. Similarly, the adornment 58B may be formed by the second ink 26B of the second paint dispenser 16. Additionally, each adornment 58A, 58B may contain regions with different colors. Accordingly, in one embodiment, the reference numerals 58C of the decoration 58B may be formed with an ink different from the second ink 26B. For example, in one embodiment, the decoration area 58C is formed by the first paint 26A of the first paint distribution unit 8. Alternatively, the decoration area 58C may be formed by another third paint of a different paint distribution unit of the decorator 2.

In one embodiment, the support member 42 receives an undecorated metal container 52 from prior equipment 64. The metal container 52 may be a beverage container such as a beverage can, beverage bottle, aerosol container, or any other type of food container. In one embodiment, the metal container 52 comprises a ground coat such as, but not limited to, a white ground coat. Alternatively, the metal container is not primed.

The pre-decorator equipment 64 may comprise both an stretch molding line and an impact molding production line. An example of a well-known metal container stretch forming production line is generally shown and described in "Inside a Ball Beverage Can Plant" available at http://www.ball.com/Ball/media/Ball/Global/Downloads/How_a_Ball__Metal_Beverage_

Can_ Is_Made.pdf? Ext = .pdf (last visited April 30, 2016), which is incorporated herein in full by reference. Preceding decorator equipment 64 may typically comprise a cupper, one or more bodymakers to mount vessels into containers, trimmers to trim containers to equal heights, washers that clean containers, and ovens that dry containers. ... The metal containers 56 are transported from the equipment 64 preceding the decorator 2 to the decorator in no particular order. Methods and apparatus for forming metal containers in an impact molding production line are described in US Patent Application Publication No. 2013/0068352 and US Patent Application Publication No. 2014/0298641, each of which is incorporated herein by reference in its entirety.

Alternatively, an undecorated metal container 52 can be obtained from a pallet. For example, in one embodiment, the metal container 52 is manufactured at a location separate from the decorator 2 and transported to the decorator. In another embodiment, metal container 52 is received from storage regardless of production location.

In one embodiment, the pre-decorator hardware 64 comprises at least one sensor. The sensor may be the same or similar to the sensor 50. Accordingly, in one embodiment, the control system 46 may receive data collected or received by the sensor of the pre-decorator equipment 64 associated with the outer surface 56 of the metal containers 52 before the metal containers 52 reach the support member. 42.

The support member 42 moves the metal container 52 to contact the blanket 38. In one embodiment, the support element 42 includes a plurality of locations 44 for receiving and holding the metal containers 52 in position relative to the blanket cylinder 36. Alternatively, the sensor 50 may be associated with support member 42. The sensor may receive data on the position or orientation of the metal container 52 secured in place 44. The sensor 50 may provide data to the control system 46. In this way, the control system 46 can determine whether the metal container 52 is in a predetermined orientation or position relative to the blanket 38 of the blanket cylinder 36. In one embodiment, the locations 44 include recesses to receive a portion of the metal container. Alternatively, in another embodiment, the locations may include rods protruding from the support member 42. A portion of each rod is configured to extend at least partially through the open end into the interior cavity of the metal container 52. One example of a support member 42 that can used in conjunction with Decorator 2 of the present invention is described in US Pat. No. 9,452,600, which is incorporated herein by reference in its entirety.

Returning again to FIG. 1, in one embodiment of the present invention, one or more paint distribution units 8, 16 may move in response to a signal received from the control system 46. More specifically, in one embodiment, the ink distribution units 8, 16 or at least the ink roller 10, 18 can be moved to reposition the ink distribution units 8, 16 and / or ink rollers 10, 18 relative to the plate cylinders 4, 12. In one embodiment, the paint distribution units 8, 16 and the ink rollers 10, 18 can move in a variety of directions. Alternatively, the paint distribution units 8, 16 and / or the ink roller 10, 18 may move in one or more of the following directions: (1) axial or "z-direction" (substantially perpendicular to the plane of FIG. 1); (2) lateral or "x-direction" (substantially perpendicular to the axial direction); and (3) vertical or "y-direction" (substantially perpendicular to both directions, axial direction and lateral direction). In one or more embodiments, each of the ink dispensing assemblies 8, 16 and / or the ink roller 10, 18 may move or otherwise rotate about an axis of rotation. In one embodiment, one or more actuators are associated with each of the paint distribution units 8, 16 and / or ink rollers 10, 18. Each of the actuators is configured to move the respective paint distribution unit or ink roller in one or more x, y and z directions in response to a signal from the control system 46. In this way, the control system 46 can send a signal to an actuator associated with the ink dispensing units 8, 16 and / or ink rollers 10, 18 to change one or more positions and positions of ink transferred from the ink rollers to the printing plates 6.

In another embodiment, one or more of the printing cylinders 4, 12, the blanket cylinder 36 and the support member 42 may move in response to a signal from the control system 46. For example, in one embodiment, one or more printing cylinders 4, 12, blanket cylinder 36, and support member 42 may be connected by drives. In response to a signal from the control system 46, the actuators can move at least one of the printing cylinders 4, 12, the blanket cylinder 36 and the support member 42 in a plurality of directions. In one embodiment, the one or more printing cylinders 4, 12, the blanket cylinder 36, and the support member 42 can move in at least one of the x-axis, y-axis and z-axis in response to a drive force. Accordingly, when the control system 46 determines that the layout or alignment of the decoration is defective, the control system 46 can adjust the positions of one or more printing cylinders 4, 12, the blanket cylinder 36, and the support member 42 in a plurality of specific directions. Additionally or alternatively, the control system 46 may send a signal to the drive to change the movement of the injector roller 13. Specifically, the swing time of the injector roller 13 may be varied by the control system. The touch time is the period of time that the inking roller contacts the respective ink roller 10, 18. Alternatively, the control system 46 may send a signal to a drive element associated with one or more ink rollers 10, 18 and the transfer roller of the ink device 11, 19. The signal can cause the drive element to change the rotation speed of the ink roller or transfer roller. In this way, the control system 46 can change the amount of ink transferred by the ink distribution unit 8, 16 to the printing plate 6, 14.

The drives associated with the ink dispensing units 8, 16, ink rollers 10, 18, ink roller 13, plate cylinders 4, 12, blanket cylinder 36 and support member 42 (not shown in FIG. 1 for clarity) may be the same or similar to actuators 30. Additionally, one or more potentiometers may be associated with each of the actuators. Potentiometers or rotation sensors may send data to the control system 46 so that the control system 46 can determine the relative positions of the paint distribution units 8, 16, ink rollers 10 18, plate cylinders 4, 12, blanket cylinder 36 and support member 42.

After the metal containers 54 are decorated with the decorator 2, the sensor 50 collects the decoration data 58. The sensor 50 is positioned to read the entire cylindrical surface 56 of the metal container 54. In one embodiment, the sensor 50 reads the decorated metal containers 54 while while the containers are associated with support 42. Alternatively, the shaped metal containers 54 are transported, for example, by conveyor 48 to sensor 50. Any suitable conveyor 48 may be used with decorator 2 of the present invention. In one embodiment, conveyor 48 comprises a belt. In another embodiment, the conveyor 48 is a rod conveyor. Examples of rod conveyors that can be used with the decorator are described in US Patent Application Publication 2012/0216689 and US Patent Application Publication 2017/0334659, each of which is incorporated herein by reference in its entirety. Cycle speeds of support member 42 and conveyor 48 can be controlled by control system 46.

Alternatively, in one embodiment, metal containers 54 are sequentially transported by conveyor 48 to sensor 50. For example, when conveyor 48 is a core conveyor, metal containers 54 are transported to sensor 50 in the order in which they were decorated. In one embodiment, each metal container 54 exiting the decorator is counted. Additionally, in one embodiment, the rod or rod chain carrier 48 may be associated with a specific blanket 38. In one embodiment, the number of rods or holders on the conveyor is a multiple of the number of blankets on the blanket cylinder 36. In this way, the decoration 58 on the metal container 54 can be traced back to a specific decorator blanket 38. After the metal containers 54 are transported past the sensor 58 (or the sensor 58A), the metal containers 54 are placed on the main conveyor, and then the order in which they were decorated becomes random.

Alternatively, the rods of the chain conveyor 48 and / or blankets 38 may contain tags or sensors. For example, each conveyor bar 48 may include an RFID tag or the like. Additionally, each blanket 38 may also be tagged, such as RFID. In this way, a particular conveyor rod 48 can be associated with a blanket 38 that forms a metal container 54 when the rod receives a metal container 54 from a support member 42. When the rod transports a metal container 54 to a sensor 49, 50, the RFID of the rod can be read to identify which blanket 38 was in contact with the metal container 54.

In one embodiment, the sensor 50 is positioned such that the sensor 50 collects data about the metal container 54 while the paint 26 forming the decoration 58 is dry. oven, which further fixes the paint.

Alternatively, one or more operations can be performed on the metal containers 54 after the decoration 58 is applied to the metal containers 54 and before the metal containers 54 are read by the sensor 50. More specifically, the metal containers 54 can be dried with a core oven, shown as equipment 66, located after the decorator. Accordingly, there may be a predetermined delay time from the moment the decoration 58 is formed on the container 54 until the metal container 54 is read by the sensor 50. Thus, although the sensor 50 is generally shown in FIG. 1, upstream equipment 66 downstream of the decorator, the sensor 50A may be located downstream of the downstream equipment 66. For example, in one embodiment, after passing the support member 42, the metal containers 54 are transported to one or more tester, cleaner, and oven. The sensor 50A collects data from the metal container 54 when the paint 26 forming the decoration 58 has dried or hardened.

A period of time may elapse after the metal container 54 receives the decoration 58 and before the sensor 50A reads the cylindrical surface 56 of the container. Thus, the sensor 50A and the control system 46 must take into account and adjust the delay time that elapses after the adjustments of the decorator 2 and before the metal container with the decoration formed after the adjustments reaches the sensor 50A. In one embodiment, approximately 100 to 500 decorated metal containers are disposed on the conveyor 48 between the support 42 and the sensor 50A, depending on the length of the conveyor. In another embodiment, approximately 350 to 500 containers are located between the support member and the sensor 50A. In yet another embodiment, conveyor 48 transports approximately 400 metal containers between support member 42 and sensor 50A. Regardless of this, the number of containers between the support member 42 and the sensor 50A is known and can be taken into account by the control system 46.

The sensor 50 is positioned to read the outer surface 56 of the metal container 54. The sensor 50 sends data associated with the decoration 58 of each metal container 54 to the control system 46. More specifically, the sensor 50 collects design data 58 of the metal container 54. The control system 46 uses the data collected by the sensor 50 to determine if there are any defects in the design 58. For example, the sensor 50 may collect or receive data related to color , density, depth, consistency, alignment of the decoration 58. Alternatively, when the sensor 50 collects data regarding the decoration 58, the metal container 54 may be substantially stationary.

Sensor 50, in one embodiment, is different from sensors used to evaluate images formed on flat substrates such as paper or continuous web. Specifically, the sensor 50 should collect data for approximately 1,800 containers per minute. Additionally, the shape of the metal containers requires a sensor 50 that is different from known sensors associated with continuous web decorators. The sensor 50 should be capable of rapidly collecting data on the curved cylindrical surface 56 of the metal container. Accordingly, the sensor 50 must acquire data over the arcuate surface. Due to the arcuate or cylindrical surface 56 of the container, the portions of the container are at different distances from the sensor 50.

Some designs 58 do not completely cover the cylindrical surface 56, leaving the bare metal of the metal container visible. Bare metal makes it difficult for sensor 50 to collect data because bare metal can be reflective or shiny. The ink 26 is not absorbed by the metal container 54, which also differs from paper product decorators such as continuous paper web. Some paint (or paint color) does not completely cover the metal of the metal container 54 such that the metal material of the cylindrical surface 56 shines through the paint, increasing the difficulty of collecting design data for the sensors 49, 50. In one embodiment, the sensors emit energy and collect data associated with reflection of energy received from a metal container. For example, in one embodiment, the sensors emit sound or light and register sound or light reflections from the cylindrical surface 56. In one embodiment, the sensor 50 is a laser. Alternatively, ultrasonic or infrared sensors can be used to collect design data 58.

In one embodiment, the sensor 50 comprises an optical or visual sensor. In another embodiment of the present invention, the sensor 50 comprises a camera. The camera can be a device for high-speed shooting. In yet another embodiment, the sensor 50 comprises a laser. In yet another embodiment, sensor 50 comprises a hyperspectral imaging unit. In one embodiment, the sensor 50 may collect data in three dimensions. In one embodiment, the optics, zoom resolution, or optical shutter of the camera are controlled by the control system 46. In one embodiment, the sensor 50 is configured to read up to about 700 metal containers per minute. In another embodiment, sensor 50 is configured to read up to about 2,000 metal containers per minute.

The sensor is configured to detect and measure one or more characteristics of the metal container 54 and the decoration 58. In one embodiment, the sensor 50 is configured to measure one or more colors of the paint 26 forming the decoration 58. The sensor 50 or control system 46 may further describe color as a number corresponding to one or more color space standards. Color space standards provide various means for measuring or characterizing colors. The color space standard can be as described by the International Commission on Illumination (CIE). Alternatively, sensor 50 may characterize adornment 58 in one or more L * a * b * (or “CIELAB”) color space, L * u * v * (or “CIELUV”) color space, RGB (or “CIE RGB "), XYZ (or" CIE XYZ ") color space, CMYK (or" CMY ") color model, HSI color space, LCh (or“ CIELCh ”) color space, and user-specified color space. In one embodiment, the sensor 50 may measure the density of the decoration 58. In another embodiment, the sensor 50 may measure the deviation or distance between the target color of the decoration (such as the target color value in one of the color spaces) and the paint color of the decoration on the metal container 54. Alternatively, the color deviation can be expressed by the ΔE (or "delta E") sensor in the CIE.

In one embodiment, one or more target locations 59 are selected on the outer surface 56 of the container to be read by the sensor 50. The target locations 59 may be selected by the control system 46. Additionally or alternatively, the target locations 59 may be set by the operator of the decorator 2. In one embodiment, the target locations 59 are determined at least in part by the decoration 58 to be applied to the metal container 54. More specifically, the target locations 59 may be selected based on locations where one or more paints 26 are to be applied to outer surface 56. Additionally, target locations 59 may also be selected at locations where no paints are to be applied to outer surface 56. Accordingly, the target location 59 may change from the first appearance to the second appearance.

Referring again to FIG. 11, one or more target locations 59 may be located at a plurality of predetermined locations on the outer surface 56 of the container. In this manner, the sensor 50 collects data associated with the paints 26 applied by each paint distribution unit 8, 16. In one embodiment, at least one target location 59 is associated with the paint 26 of each paint distribution unit 8, 16. In one embodiment, the target location 59 is associated with each of the ink knives 21 or segments 24 of the ink knife 22 for each paint distribution unit. In this way, the target location 59 will be associated with each colorful knife 21 or decorator segment 24. Accordingly, target location 59 will exist for each ink knife or knife segment for each ink 26 used by decorator 2.

For example, for a decorator 2 with four to eight paint distribution units, each of which has five to ten ink blades 21 or segments of ink knives 22, the sensor 50 can collect data on approximately 20 to 80 target locations 59. Specifically, if the decorator has four paint distributors each having five colorful knives, at least 20 target locations will be selected on the outer surface of the container. In this way, the control system 46 obtains almost continuously data related to the quality, thickness and position of the ink 26 applied by each ink knife 21 and each segment 24 of the ink knife 22 of each ink distribution unit 8, 16.

Alternatively, at least one light source or lamp 51 may be associated with the sensor 50. In one embodiment, the lamp 51 is configured to provide strobe illumination so that the corresponding sensor 50 can receive data from moving metal containers 54. Operation the lamps 51 can be controlled by the control system 46. Thus, the illumination provided by the lamp 51 is synchronized with the collection of data from the sensor 50. In one embodiment, the lamp 51 comprises at least an incandescent lamp, an LED lamp, a high intensity lamp, a laser, a fluorescent lamp, a xenon flash lamp, or arc discharge lamp. The lamp 51 is selected to generate illumination at a predetermined wavelength based on the requirements of the sensor 50.

In one embodiment, the lamp 51 is typically parallel to the sensor reference direction, as generally shown in FIG. 1. In one embodiment, one or more diffusers and lenses are associated with lamp 51. In one embodiment, the diffusers and lenses are positioned such that the illumination provided by the lamp 51 is generally parallel to (or aligned with) the longitudinal axis of the metal containers 54. In one embodiment, the diffuser has a width that is approximately equal to the height of the metal containers. containers. Accordingly, the lamp 51 can illuminate one or more areas of the outer surface 56 of the metal containers 54.

Alternatively, at least one lamp can provide one or more lighting angles. In another embodiment, the lamp 51 comprises two or more lamps located at different angles relative to the metal container 54. For example, in one embodiment, the first lamp 51 may be positioned at an angle of approximately 90 ° over a portion of the metal container 54 to be read by the sensor 50 In another embodiment, the second lamp 51 is positioned at an angle between approximately 10 ° and approximately 90 °, or between approximately 1 ° and approximately 10 °, with respect to the portion of the metal container 54 that is to be read. Accordingly, the angle of the light emitted by the lamp 51 relative to the metal container 54 can be chosen such that the decoration 58, which can contain a plurality of surfaces or paints located at different heights from the cylindrical surface 56 of the metal container 54, reflects light differently than other areas. the outer surface 56 of the metal container 54.

In one embodiment, the sensor 50 can read the entire outer surface 56 of the metal container. In contrast, some prior art decorators for decorating continuous webs or substrates include a sensor that can only read a portion of the width (known as a "strip") of the continuous web between the first longitudinal edge and the second longitudinal edge of the web. The prior art sensor can periodically move from the first longitudinal edge to the second longitudinal edge of the web. However, at any given time, the sensor can only read part of the web width. Accordingly, when reading the first strip, the prior art sensor cannot detect a printing error or defect in the second strip.

Due to the curved or arcuate shape of the cylindrical outer surface 56 of the metal container, image processing and correction techniques may be required. More specifically, the sensor 50 is required to collect data (or create an image) of the curved outer surface. After the sensor 50 has collected data on each metal container, the data is sent to the control system. The control system 46 merges together multiple images of each metal container to form a composite image of the cylindrical outer surface 56 and design 58 of each metal container 54.

In another embodiment, while reading the metal container 54, the sensor 50 is substantially stationary. Accordingly, the data (such as images) collected by such a sensor 50 cannot contain artifacts caused by the movement of the sensor. Alternatively, while the sensor 50 is being read, the metal container 54 rotates about the longitudinal axis of the metal container. Accordingly, additional processing techniques may be required to remove distortions in the images obtained by the sensor 50 due in part to the rotation or movement of the metal container 54. In contrast, some sensors or cameras of prior art decorators for continuous web move laterally across the web width. Camera movements can reduce the accuracy of camera images. Additionally, in some prior art decorators for continuous webs, sensors or cameras move while the camera is taking an image. This simultaneous movement can cause additional distortion in camera images. Simultaneous movement also increases the complexity of controlling the camera and identifying the causes of design defects, as well as the corrections required to eliminate defects.

Alternatively, the metal containers 54 move substantially continuously relative to the sensor 50. More specifically, in one embodiment, the metal containers 54 move laterally perpendicular to the longitudinal axis of the metal containers as the sensor 50 reads the outer surface 56 of the metal containers. Alternatively, in another embodiment, while reading the metal container, the metal containers 54 are substantially stationary relative to the sensor 50.

While FIG. 1 shows only one sensor 50, it will be appreciated by those skilled in the art that any number of sensors 50 can be used with the decorator 2 of the present invention. Accordingly, and with reference now to FIG. 1A generally shows another decorator 2A of the present invention. Decorator 2A contains one or more plate cylinders 4, 12, ink distribution units 8, 16, ink rollers 10, 18, ink devices 11, 19, blanket cylinder 36, support cylinder 42, sensor 50 and ejector 62, which are the same or similar. in that the decorator 2. In particular, the decorator 2A contains a plurality of additional sensors 49. The sensors 49 may be the same or similar to the sensor 50. Additionally, the sensors 49 can provide data to the control system 46. Lamp 51 may be associated with one or more sensors 49.

In one embodiment, the sensor 49A is positioned to collect data on the outer surface 56 of the undecorated container before the undecorated container is received by the support member 42. The control system 46 may use the data from the sensor 49A to determine if the outer surface 56 of the container 52 any flaws or defects. For example, the control system 46 may determine that the container 52 is damaged (eg, scratched, dented, bent, etc.) or out of specification (eg, the wrong height or diameter).

Another sensor 49B may be positioned to collect data and / or images on the plates 6 of the first plate cylinder 4. Similarly, an additional sensor 49C can be positioned to collect data on the plates 14 of the second plate cylinder 12. In one embodiment sensors 49B, 49C collect data associated with inks transferred to printing plates 6, 14 by respective ink dispensing units 8, 16. In this way, the control system 46 can determine that ink has been improperly transferred to printing plates 6, 14. For example, in one from the embodiments, the control system 46 may determine that an inappropriate amount of ink has been transferred to the plates 6, 14 or to a portion of the plates. Alternatively, the control system 46 may use data from sensors 49B, 49C to determine that ink is being applied to inappropriate areas of the printing plates. In yet another embodiment, sensor data from sensors 49B, 49C may indicate that one or more of the paint distribution assemblies 8, 16 is applying the wrong type or color of paint. The control system 46 may also, based on data received from one or more sensors 49B, 49C, determine that ink 26 applied by one of the paint distribution units 8, 16 is defective. In yet another embodiment, the control system 46 may, using data from sensors 49B, 49C, determine that one or more printing plates 6, 14 are not properly seated on the corresponding plate cylinder 4, 12.

In one embodiment, another sensor 49D may be installed to collect data from the blankets 38 on the blanket cylinder 36. Using the data from the sensor 49D, the control system 46 can determine that one or more inks 26 transferred to the blanket 38 by the printing plates 6, 14 is not aligned properly. The control system 46 can also determine that the design formed on the blanket 38 with inks is defective. For example, the control system may determine that one or more of the decoration targets are defective while ink is on the blanket 38. In one embodiment, using data received from sensor 49D, control system 46 may determine that one or more of the color, density, depth, position, or consistency of the ink on the blanket 38 does not match the design parameters.

In another embodiment, the decorator may also include a sensor 49E downstream of the ejector 62. In one embodiment, the control system 46 may compare the data received from the sensor 49E with the data received from the sensor 50. In this way, the control system 46 can determine whether it has changed. whether the decoration of the metal container 54 after the metal container has been read by the sensor 50. In one embodiment, the control system 46 may determine that the decoration formed on the metal container 54 has been damaged during transport by the conveyor 48. For example, the decoration may be scratched or otherwise damaged during transport after moving further downstream of the sensor 50.

In one embodiment, the decorator 2 comprises three to six sensors 50 located around the longitudinal axis of the metal containers 54. In this way, the cylindrical body 56 of the metal container 54 can be read in a single operation. In other words, these three to six sensors 54 are positioned to read the cylindrical body 56 substantially simultaneously. The data or images for each metal container 54 collected by these three to six sensors 54 can be stitched together to form a composite image of the cylindrical outer surface 56 and decoration 58.

As shown in FIG. 12A, in one embodiment, the decorator 2 comprises three sensors 50A, 50B, 50C, each of which reads at least about one third of the cylindrical body 56. The sensors 50A-50C are spaced substantially evenly around the longitudinal axis of the metal container 54. The three images of each metal container taken by the sensors 50A-50C are subsequently stitched together to form a single composite image of each metal container. The longitudinal axis of the container is substantially perpendicular to the plane of FIG. 12A. In another embodiment, generally shown in FIG. 12B, decorator 2 comprises four sensors 50A, 50B, 50C, 50D, each of which senses at least one quarter of the cylindrical body 56. Similar to FIG. 12A, the sensors 50A-50D are disposed substantially uniformly about the longitudinal axis of the metal container 54. Alternatively, and referring now to FIG. 12C, in one embodiment, each of the five sensors 50A-50E of the decorator 2 reads at least a fifth of the cylindrical body 56, the five sensors being substantially evenly spaced about the longitudinal axis of the metal container 54. These three to five sensors 50A-50E may be stitched together to form a composite image of the cylindrical body 56. In one embodiment, the composite image may include a predetermined portion or the entire circumference of the cylindrical body 56.

In one embodiment, these three to five sensors 50A-50E are positioned to read metal containers in front of equipment 66 so that paint 26 is dry. Additionally or alternatively, the sensors 50A-50E can be located after an oven or curing device (such as equipment 66 downstream of the decorator) and the paint 26 forming the decoration 58 will dry.

These three to five sensors 50A-50C are also located at a predetermined distance from the metal container. In one embodiment, the metal container 54 is positioned on the bar of the rod belt 48. Accordingly, the sensors 50A-50C may be positioned so as not to interfere with movement of the conveyor 48 or contact with the metal container.

Each of one to six sensors 50 can collect or receive the same type of information. Such information from the sensors can be in the form of an image; accordingly, the images can be processed and analyzed to obtain the color, optical density of the ink layer, location, depth and / or texture of the decoration. In accordance with at least one embodiment, at least one sensor 50 reads a type of information different from the type of information read by the other one to six sensors. For example, in one embodiment, a first sensor may collect a first type of decoration related data 58, and a second sensor of a different type may collect a second type of decoration related data 58. Alternatively, in one embodiment of the present invention, the first sensor collects data on the color of the decoration, the second sensor collects data on the density of the decoration, the third sensor collects data on the position of the decoration, the fourth sensor collects data on the depth of decoration, and the fifth sensor collects data on the consistency (or uniformity) of the decoration. In another embodiment, each sensor 50 is configured to sense colors, including red, green, and blue. In yet another embodiment, each sensor 50 is configured to sense variations or gradations of color within each cylindrical portion 57 of the metal container. In yet another embodiment, the sensors 50 are configured to discriminate the ink density or ink color in the first cylindrical section 57 from the ink density or color in the second cylindrical section 57.

Now, in FIG. 13 shows the overall control system 46 of one embodiment of the present invention. More specifically, in FIG. 13 shows one of the embodiments of the control system 46 of the present invention, configured to detect and correct defects in the decoration applied by the decorator 2 to the outer surface of the metal container. The control system 46 is generally shown with hardware elements that can be electrically coupled to one another via a bus 82. The hardware elements can comprise one or more central processing units (CPUs) 84; one or more input devices 86 (eg, mouse, keyboard, etc.); and one or more output devices 88 (eg, display, printer, etc.). The control system 46 may also comprise one or more memory devices 90. In one embodiment, the memory device (s) 90 may be disk drives, optical memory devices, solid state storage devices such as random access memory (RAM) and / or read-only memory. (ROM), which may be programmable, capable of being updated via flash memory, and / or the like.

The control system 46 may further comprise one or more readers 92 for computer-readable media; communication system 94 (eg, modem, network card (wired or wireless), infrared communication device, etc.); and a work memory 96, which may contain RAM and ROM devices as described above. In some embodiments, control system 46 may also include a processing accelerator 98, which may include a DSP, dedicated processor, and / or the like. Alternatively, the control system 46 also contains a database 100.

Reader 92 for computer-readable storage media may further be associated with computer-readable storage media, together (and optionally in combination with storage device (s) 90) comprehensively representing remote, local, fixed and / or removable storage devices. plus a storage medium for temporarily and / or permanently storing computer readable information. Communication system 94 may allow communication with network 102 and / or any other data processing. Alternatively, control unit 46 may access data stored in a remote storage device, such as database 104, by connecting to network 102. In one embodiment, network 102 may be the Internet.

The control system 46 may also include software elements shown as being presently located within the working memory 96. The software elements may comprise an operating system 106 and / or other control programs 108, such as a control program that implements one or more of the methods and approaches of the present invention. ...

Those of skill in the art will understand that alternative embodiments of the control system 46 may have numerous variations of the above. For example, dedicated hardware may also be used and / or specific elements may be implemented in hardware, software (including mobile software such as applets), or both. Additionally, a connection with other computer devices such as network I / O devices can be used.

In one embodiment, the control system 46 is a personal computer, such as, but not limited to, a personal computer running an MS Windows operating system. Alternatively, the control system 46 may be a smartphone, a computer tablet, a laptop, and the like. In one embodiment, the control system 46 is an information processing system that includes one or more of the following, but is not limited to: at least one input device (eg, a keyboard, mouse, or touch screen); at least one output device (eg, display, speaker); graphic card; communication device (such as an Ethernet card or wireless device); read-only memory (such as a hard drive); temporary memory (for example, random access memory); machine instructions stored in permanent memory and / or temporary memory; and a processor. The control system 46 may be any programmable logic controller (PLC). One example of a suitable PLC is the Controllogix PLC manufactured by Rockwell Automation, Inc., although other PLCs are proposed for use with embodiments of the present invention.

In one embodiment, the control system 46 communicates with one or more of the following: ink distribution unit 8, 16, injector rollers 13, plate cylinders 4, 12, actuators 30, potentiometers 80, blanket cylinder 36, support element 42, sensors 49, 50, light 51, conveyor 48, ejector 62, equipment 64 upstream of the decorator, and equipment 66 downstream of the decorator. Accordingly, the control system 46 receives data from sensors 49, 50 associated with undecorated metal containers 52, decorated metal containers 54, plates and blankets 40. Using the data, the control system 46 can determine if the design 58 is defective or satisfactory. More specifically, the control system 46 can determine whether the decoration 58 achieves at least targets corresponding to one or more of such parameters as color, density, depth, position, and consistency. Targets can be supplied by the client or by the operator of decorator 2. One or more parameters can contain the target range. If the sensor data associated with a parameter falls within the lower and upper range limits, then that decoration parameter is at least acceptable. In one embodiment, when the adornment 58 fails one or more objectives, the adornment is defective.

Control system 46 compares data from sensor 50 to targets for features / adornments 58. In one embodiment, control system 46 compares data associated with a plurality of adornment / feature image areas received from sensor 50 with a target level for the respective adornment areas. In this way, the control system 46 can determine whether one or more of color, density, depth (or thickness), alignment, or consistency for each decoration region differs from the target values or position for each decoration region. If the sensor data for the decoration area differs from one or more target values, the control system 46 can determine that the decoration is defective.

In one embodiment, the control system 46 recognizes the defective design by inspecting at least one metal container with an acceptable design 58. For example, metal containers 54 with an acceptable design 58 can be read by the sensor 50. The control system 46 receives data from the sensor associated with an acceptable design 58. With this information, the control system 46 can create a database 100, 104 data. The database 100 may be stored in a memory of the control system 46, such as memory 96. Alternatively, the database 104 may be accessed via a network connection 102. The database may contain a variety of areas that describe the characteristics of an acceptable layout. Characteristics can contain one or more characteristics such as color, density, depth (or thickness), position (or alignment), and texture consistency. Based on the sensor data, a value can be assigned to each of the characteristics. In one embodiment, each region of the decoration 58 (or target 57) sensed by the sensor 49, 50 is associated with an area of a plurality of areas. In this way, data associated with each read-out area of the design can be stored in a database and accessed by the control system 46.

FIG. 14 generally shows one embodiment of a data structure 110, such as a database. The data structure can contain one or more data files or data objects 116, 134. Thus, the data structure 110 can represent various types of databases or storage devices for data storage, for example, object-oriented databases, simple file data structures, relational database data or other types of data storage location. The embodiments of the data structure 110 disclosed herein may be separate, combined, and / or distributed. As shown in FIG. 14, data structure 110 may have more or fewer chunks as represented by dots 112. Additionally, data structure 110 may have more or fewer files or records 132 as represented by dots 114. In one embodiment, data structure 110 is stored in memory control system 46, such as database 100. Additionally or alternatively, the data structure 110 may be accessed by the management system 46 using the network 102. Accordingly, in one embodiment, the data structure 110 is stored at a remote location, such as a database 104.

The first data object 116 may relate to data collected in at least one known acceptable design by the sensor 50. In one embodiment, the data of the first data object 116 is collected while the control system 46 is programmed to recognize an acceptable design prior to commercialization. ... The data object 116 may contain multiple chunks 118-130 representing different types of data. Each of these types of data may be associated with a skin 58 read by the sensor 50. Within the first data object 116, one or more records 132 and related data may be stored.

In one embodiment, each record 132 contains an identifier 118. For example, identifier 118 may be associated with each container read by sensor 50. Other fields contain different data collected by sensors 49, 50 for each adornment. Margins may include, but are not limited to, a margin 120 associated with color (s), a density region 122, a thickness or depth region 124, a margin 126 associated with a layout position and / or alignment, a margin 128 for consistency decoration, and field 130 for other data. In one embodiment, field 120 may contain information associating an ink color with an ink distribution unit 8, 16. More specifically, a field 120 may contain information for identifying a color of a first ink 26 of a first ink distribution unit 8. Field 120 may also contain information for identifying a color of a second paint 26 of the second paint distribution unit 16. In this way, the control system 46 can determine which paint distribution unit 8, 16 is associated with the defect of the paint 26 of the decoration 58. The control system 46 can also identify which ink knife 21, 22 is associated with the defect of the paint, based on one or more cylindrical areas 57 that contain a paint defect. In one embodiment, an image of each design read by the sensors 49E, 50 is stored in each record 132. In one embodiment, an image is stored in a region 130.

The setting of the ink knives 21, 22 can be stored in the data structure 110. In one embodiment, the ink knife settings may be stored in area 130. Alternatively, the ink knife settings may be entered into the control system 46 through an operation. In another embodiment, the ink knife settings can be determined by the control system. In one embodiment, prior to starting the production line, the decoration image to be generated by the decorator 2 is received by the control system 46. The control system 46 can analyze the image and automatically determine the settings of the ink knives 21, 22. In another embodiment, the control system 46 stores the settings of the ink knives 21, 22 associated with each metal container read by the sensor 50. In this way, when the decoration contains a defect, it is possible to study the settings of the colorful knife and other settings of the decorator 2 that took place when the defective decoration was formed.

Alternatively, the data structure 110 may contain a second data object 134. The data object 134 may contain the same or similar fields 118-130 as the first data object 116. In one embodiment, control system 46 may store data received from sensors 49, 50 during manufacturing in a second data object 134. Accordingly, the second data object 134 may contain a plurality of records 134 associated with metal containers decorated by the decorator during production. In contrast, in one embodiment, the data object 116 may optionally contain data collected by the sensors 49, 50 before the manufacturing process begins.

FIG. 15 shows one embodiment of a method 140 commonly used with a control system 46. Although the general order of the steps of method 140 is shown in FIG. 15, method 140 may include more or fewer steps, or may arrange the steps in a different order than that shown in FIG. 15. Additionally, although the steps of method 140 may be described as sequential, many of the steps may actually be performed in parallel or concurrently. In general, method 140 begins with start step 142 and ends with end step 160. Portions of method 140 may be executed as a set of computer-executable instructions executed by a computer system and encoded or stored in a computer-readable medium. One example of a computer system may include, for example, a control system 46. An example of a computer-readable medium may include, but is not limited to, the memory of the control system 46. Hereinafter, method 140 will be explained with reference to control system 46, decorator 2, and components described in conjunction with FIG. 1-14.

At step 144, a metal container 54 with adornment 58 is provided. Alternatively, adornment 58 is generated by decorator 2. Data associated with the adornment 58 of metal container 54 is collected by at least one sensor 49, 50 at step 146. Control system 46 then receives the collected data from at least one sensor 49, 50. The sensor 49, 50 may be located in front of the drying oven or after the oven.

At 148, the control system analyzes the collected data received from the sensor. In one embodiment, the control system considers data associated with a plurality of target locations 59 on the outer surface 56 of the container. In another embodiment, the control system 46 analyzes data collected on one or more cylindrical sections 57 of the metal container 54. The control system 46 can identify the characteristics of the design 58 such as, but not limited to, color, thickness, density, consistency, and position.

At step 150, the control system 46 optionally stores the collected data in memory. Specifically, the control system 46 may store data collected from one or more read metal containers 54. Alternatively, the control system 46 can store data collected from each metal container 54 that has been read. In one embodiment, the management system stores the collected data in record 132 of database 110. Alternatively, the collected data may be stored in the first data object 116 of the database 110.

In one embodiment, method 140 at step 152 creates a loop with a predetermined number of repetitions. For example, method 140 may comprise reading a predetermined number of times of metal containers 54 with acceptable designs. In one embodiment, method 140 creates a loop of 50 to 500 repetitions. Specifically, the method 140 may be repeated until the control system 46 has received sensor data for approximately 50-500 metal containers with an acceptable design. In this way, the control system 46 learns or monitors to recognize defective designs.

In one embodiment, data, such as images, of each suitably shaped metal container 54 are stitched together to form a base image. In this way, a base image is created using metal containers 54, decorated with decorator 2, using sensors 49, 50 associated with the decorator. Specifically, in one embodiment, the base image is specific to the decorator 2. Additionally, the base image can be created for each manufacturing process.

When a sufficient number of designs 58 have been read by the sensors 49, 50, the base image is stored in memory. The base image can then be used to determine if subsequent skins 58 generated by decorator 2 are acceptable. By creating a base image from the data collected by sensor 49, 50 associated with decorator 2, skins 58 of subsequent metal containers 54 are evaluated using similarly generated skins. collected by the same sensors 49, 50. In this way, a comparison of the adornments with the base image generated on the same decorator 2 can correctly recognize acceptable and defective adornments.

In contrast, if skins 58 were evaluated against a base image rendered by a different decorator using data collected by other sensors, there will be more adornment variables and sensor dataset 49, 50 to account for. For example, a lamp 51 associated with a sensor 49, 50 may produce light with a different wavelength or luminous intensity compared to a similar lamp associated with a different decorator. The lens of the sensor 49, 50 can also transmit light in a different way than a similar sensor of another decorator. Accordingly, the base image rendered by another decorator is likely to contain variables that are difficult to account for when evaluating the appearance.

Alternatively, in one embodiment, method 140 may comprise reading at least one metal container 60 containing a known defect. The design may be defective in one or more parameters that deviate from the purpose. The parameters may include, but are not limited to, at least one of such parameters as color, density, thickness (or depth), position and / or alignment, and texture consistency. Alternatively, the sensor 50 can read a plurality of metal containers 60 with defective designs. In one embodiment, at least one of the defective designs is associated with an inappropriate amount of paint. Another defective design is due to defective paint. Other other defective designs are caused by defective (or misplaced) printing plates. Other defective design may be due to a defective (or misplaced) blanket. Another defective artwork may be related to misplaced (or placed) artwork. Specifically, the defect may comprise a first ink 26 from a first paint dispensing unit 8 that is misaligned (or overlapped) with a second paint 26 from a second paint dispensing unit 16.

For each metal container 60 that is read that contains a known defective design, the control system 46 may store sensor data in a record 132 that contains a data field indicating the reason the design is defective. In one embodiment, the field may contain data indicating actions to be taken by the control system 46 if such a defect design is read by at least one of the sensors 49, 50 during the manufacturing process of decorator 2. For example, the database 110 may contain an action in the "others" field 130 to alert the operator when reading the defective design. In another embodiment, when a defect associated with an incorrect amount of ink is read, the "others" field 130 may contain commands to adjust the position of one or more ink knives 21 or portions 24 of the ink knife 22. In this way, the control system 46 may change the amount of ink 26. transferred to the ink roller 10, 18 and, subsequently, to the metal container. Additionally or alternatively, if an incorrect amount of ink is read on one or more of the cylindrical portions 57 of the container, the control system 46 may send a signal to a drive associated with the inking roller 13 or to the ink roller drive element 10, 18 or to the transfer roller of the ink device 11. 19 to change the amount of ink 26 transferred from the 10/18 ink roller to the corresponding printing plate 6, 14. Specifically, the control system 46 may change the movement of the injector roller 13 to adjust the timing of the ink roller contact. Additionally or alternatively, the control system can adjust the drive element to change the rotation speed of the ink roller and / or transfer roller to change the amount of ink transferred to the printing plate 6, 14. In another embodiment, if the decoration is defective due to misalignment or alignment, the control system may contain commands for adjusting the position of one or more elements of the decorator 2. For example, the control system 46 may contain movement commands for at least one of such devices as an ink distribution unit 8, 16, an ink roller 10, 18, a plate cylinder 4, 12, a blanket cylinder 36, and a support member 42. In this way, in one embodiment, the control system 46 can correct a defect caused by improper positioning or alignment of the decoration formed on the metal container.

If a predetermined number of metal containers has not been read by sensor 50, control system 46 may determine at step 152 that steps 144-150 should be repeated. Accordingly, method 140 communicates YES to step 144. Alternatively, control system 46 may determine that the number of decorated metal containers read is sufficient (or as specified) and thus steps 144-150 should not be repeated. In this case, method 140 on NO communication proceeds to step 154.

The method 140 may then, alternatively, at steps 154-158, test the ability of the control system 46 to recognize the defective design. More specifically, at step 154, a metal container 60 with a known defective design is provided. In step 156, at least one sensor 49, 50 collects defect data.

At block 158, the control system 46 evaluates the collected data in a similar manner to block 148. The control system 46 then determines if the adornment is defective. In one embodiment, the control system 46 compares the collected data with a base image. If the control system 46 does not identify the defective design, the method 140 proceeds over the NO link to step 144 and the control system reads and analyzes the additional metal containers with the design. More specifically, the control system 46 analyzes sensor data associated with one or more skins that contain acceptable or defective skins.

Alternatively, if the control system 46 correctly identifies the defective design, the method 140 via YES continues to end step 160. In one embodiment, correct recognition of the defective design comprises a control system 46 correctly identifying why the design is defective. For example, a design may be defective due to one or more parameters such as paint color, paint density, paint thickness, amount of paint, paint consistency, and position or alignment of the artwork.

In one embodiment, the correct identification of the defective design further comprises a control system 46 correctly identifying the action that is required to correct the defective design. For example, if the decoration is defective due to an incorrect amount of ink, the control system may indicate one or more ink knives 21 or ink knife segments 22 to be adjusted to correct the defect. Additionally or alternatively, the control system can identify the ink roller 10, 18, the inking roller 13, or the transfer roller for which the speed of movement or rotation must be changed in order to adjust the amount of ink transferred to the printing plate 6, 14. Likewise, if the location or alignment of the design is defective, the control system 46 can identify at least one ink distribution unit, ink roller, plate cylinder, blanket cylinder, or support element that must be adjusted to correct the defective design.

When the control system 46 is trained to recognize the acceptable appearance, the control system 46 can detect the appearance 58 that differs from the acceptable appearance. Specifically, when the control system 46 has counted a sufficient number of adornments 58 to create a base image, the base image can be used to further determine whether the generated adornments 58 are acceptable or defective. In this way, the control system can determine that the metal container contains an unacceptable or defective design. In one embodiment, the control system 46 can be trained to recognize an acceptable design when fewer than 100 metal containers with acceptable designs are read by the sensor 50 and stitched into a base image. Alternatively, in another embodiment, the control system 46 is trained to recognize an acceptable design after acquiring sensor data for approximately 100-200 metal containers with acceptable design and generating a baseline image. In one embodiment, data from about 200 to about 600 suitably shaped metal containers are collected by sensors and then stitched together to form a base image. Alternatively, the base image will be generated after 500 suitably shaped metal containers have been read by the sensors 49, 50. In accordance with embodiments of the present invention, the control system 46 may use supervised and / or unsupervised machine learning techniques such as, but but not limited to, vector support machines, stimulated decision trees, and / or one or more neural networks to recognize an acceptable design.

In one embodiment, control system 46 compares sensor data received from one or more sensors 49, 50 with a known reference stored in memory. For example, control system 46 may compare sensor data or a portion of an acquired image with a base image. The base image, in one embodiment, is stitched from data collected from a plurality of metal containers 54 with a layout 58 that is acceptable. In another embodiment, a base image is created from an image of a single metal container with a suitable design and is stored in memory. Alternatively, the base image is generated by the control system and stored in memory. In yet another embodiment, the base image is generated by the operator or client and loaded into the memory of the control system.

The base image of the metal container can be stored in the memory 90, 92 of the control system 46. In another embodiment, the base image may be stored in a database 110 with which the control system 46 communicates, such as when connected to the network 102.

The decoration may be defective if one of the ink dispensing units 8, 16 transfers excessive or insufficient ink 26 to the printing plate area 6, 14. In another embodiment, the decoration may be defective if the ink distributing units 8, 16 transfer ink 26 to the inappropriate printing area. forms 6, 14. The design can also be defective if the inking roller 13 transfers the wrong amount of ink from the corresponding ink roller 10, 18 to the printing plate 6, 14.

If the control system 46 determines that the adornment 58 is defective, the control system 46 may operate to determine if any component of the decorator 2 needs to be adjusted to produce an acceptable adornment 58. More specifically, in one embodiment, the control system 46 may determine which paint distribution unit 8, 16 is associated with the defect based, at least in part, on the color of the paint 26 of the defect. In one embodiment, the control system 46 may retrieve data from field 120 of data structure 110 to determine which paint distribution unit 8, 16 is associated with an ink color. The control system 46 may determine at least one ink knife 21, 22 of this paint distribution unit 8, 16 that is associated with the defect based on the location of the design defect in one or more cylindrical portions 57. For example, in one embodiment, the paint distribution unit 8 comprises the first paint 26A of the first color. Database 110 contains information in field 120 associated with first paint 26A and first paint distribution unit 8. One or more sensors 49, 50 receive data associated with metal container 54 (shown in FIG. 11) that contains adornment 58B. The control system 46 may determine that the decoration portion 58B formed by the first ink 26A is defective. The defect can be located in the cylindrical section 57E. Accordingly, the control system 46 may determine that the ink knife 21E or 22E of the ink distribution unit 8 is in the wrong position relative to the axial portion 20E of the first ink roller 10. If too little or too much ink is the cause of the design defect, the control system 46 may determine that movement the injector roller 13 must be adjusted. Alternatively, the control system 46 may determine that the speed of rotation of one or more ink rollers 10, 18 or the transfer roller of the ink device 11, 19 should be changed in order to change the amount of ink transferred to the printing plate.

The control system 46 may cause one or more respective actuators 30 to change the arrangement of the ink knives 21 or the ink knife 22 to increase or decrease the gap 32. In one embodiment, the control system 46 may automatically send a signal to one or more corresponding actuators 30 to change the arrangement. ink knives 21 or ink knife 22 to increase or decrease the gap 32. In this way, the control system 46 can regulate the amount of ink 26 transferred to the printing plates 6, 14 of one or more plate cylinders 4, 12 without the intervention of the operator of the decorator 2.

Additionally, the control system 46 may optionally send a signal to the actuators 30 to adjust the axial position of the corresponding knife segment 24 relative to the ink rollers 10, 18. More specifically, in one embodiment, a signal from the control system 46 may cause the actuator 30F to move along at least a portion of the corresponding knife segment 24F towards the knife segment 24E or knife segment 24G, as generally shown in FIG. 3D.

In another embodiment, the control system 46 can send a signal to an actuator associated with at least one element of the decorator 2, such as the paint distribution units 8, 16, ink rollers 10, 18, plate cylinders 4, 12, blanket cylinder 36 and support element 42 The signal can cause the actuator to move the corresponding element to automatically correct the faulty adornment associated with the adornment position or alignment. The actuator can move the corresponding element in one or more specific directions, including along one of such directions as the x-direction, the y-direction and the z-direction. In another embodiment, the control system 46 may send a signal to an actuator associated with the inking roller 13. The signal may cause the actuator to vary the speed at which the inking roller 13 moves to adjust the amount of ink 26 transferred from the ink device 11, 19 to the printing plate 6 , fourteen.

In another embodiment, the control system 46 may inform the operator of changes made to the elements of the decorator 2 to correct the defective design. In one embodiment, the message may include changes in the radial or axial position of one or more ink knives 21 or segments 24 of the ink knife 22 required to correct a defect. Additionally or alternatively, the message may contain changes in other elements of the decorator 2 that are required to correct the defective design, such as changes in the operation of the injector roller 13.

The message may be presented on an output device 88 of the control system 46, such as a display. In this way, the operator can at least view changes such as changes for the ink blades 21 or the segments 24 of the inking knife 22 prepared by the control system 46. In one embodiment, the operator must confirm the planned changes before the control system 46 sends a signal to the actuators 30 to change positions. In another embodiment, an operator can use an input device 86 such as a pointer (such as a mouse, touch pad, or trackball), a keyboard, or a touch screen of the control system 46 to approve, reject, or change changes planned by the control system.

In one embodiment, the control system 46 waits for a predetermined amount of time after informing the operator of the planned changes to the elements of the decorator 2. Alternatively, if the operator does not reject the planned changes within a predetermined period of time, the control system 46 sends a signal to the actuators 30 to implement the planned changes. In another embodiment, if the operator does not confirm the planned changes within a predetermined time, the control system 46 will not send a signal to the actuators 30 and ink knives 21 or the segments 24 of the ink knife 22 and other decorative elements will remain in their current position.

Again, as shown in FIG. 11, the control system 46 may determine that one or more adornments 58A, 58B (or a portion of one of adornments 58) is defective. For example, the decoration region 58B on the cylindrical region 57E may be defective. One or more sensors 49, 50 may have a target 59E associated with a cylindrical portion 57E. In one embodiment, control system 46 may use data from sensors 49, 50 to determine that a defect is due to an inappropriate amount of one or more of the first and second inks 26A, 26B transferred to the cylindrical portion 57E. Using the sensor data, the control system 46 can determine that the inappropriate amount of ink is caused by one or more of the following reasons: (1) too much of the first ink 26A comes from the axial portion 20E of the first ink roller 10; (2) too little of the first ink 26A is supplied from the axial portion 20E of the first ink roller 10; (3) too much of the second ink 26B is supplied from the axial portion 20E of the second ink roller 18; and (4) too little second ink 26B is supplied from the axial portion 20E of the second ink roller 18.

After determining the cause of the defect for the decoration part 58B on the cylindrical section 57E, the control system 46 can send a signal to the actuator 30E associated with the axial section 20E of the first ink roller 10 to change the gap 32 between the axial section 20E of the first ink roller 10 and the corresponding ink knife 21 or segment 24E of the ink knife 22. The signal may result in an increase or decrease in the amount of the first ink 26A transferred to the axial portion 20E of the first ink roller 10. If the defect is associated with an incorrect amount of the second ink 26B transferred to the cylindrical portion 57E, the control system 46 may send a similar signal to the actuator 30E associated with the axial portion 20E of the second ink roller 18 to control the amount of the second ink 26B transferred to the cylindrical portion 57E. Alternatively, in another embodiment, the control system 46 may send a signal to the pump to change the amount of ink supplied to the ink channel 29E of the ink knife 22D of the first or second ink roller 10, 18.

Alternatively, the control system 46 may determine that the defect is not related to an inappropriate amount of paint 26A, 26B transferred to the metal container 54. As would be appreciated by one of ordinary skill in the art, the defect may be associated with other problems such as, but not limited to only this: a problem with one of the printing plates 6, 14, a problem with a blanket 38, a defective ink 26 and a problem with a support element 42. Problems with plates 6, 14 and blankets 38, among other things, include: damaged, defective and uneven printing plates 6, 14 or blankets 38.

Plates 6, 14 and blankets 38 gradually wear out during production. For example, frequent contact of printing plates 6, 14 with ink rollers 10, 18 (or transfer rollers of inking devices) and blankets 38 causes surface wear of printing plates 6, 14. Blankets 38 are also subject to wear due to contact with printing plates 6, 14 and metal containers 54. Control system 46 can compensate for wear by substantially continuously adjusting the amount of paint 26A, 26B transferred to metal containers 54, as described above. In one embodiment, wear can cause a design defect such as misalignment or misalignment. In response to a determination based on sensor data that a defect is caused by misalignment or misalignment of one or more decorations 58, the control system 46 may send a signal to move one or more of the paint distribution units 8, 16, ink rollers 10, 18, plate cylinders 4 , 12, blanket cylinder 36 or support member 42 in a specific direction. In this way, the control system 46 can automatically correct for defective adornments caused by misalignment or misalignment of adornments.

Sometimes printing plate 6, 14 or blanket 38 are damaged. Damage can occur either before the start of the production process or during the production process. The printing plate 6, 14 or the blanket 38 may also contain a defect that affects the quality of the design. Additionally, the printing plates 6, 14 or blanket 38 may not be properly positioned relative to the corresponding plate cylinder 4, 12 or blanket cylinder 36. Alignment problems can arise during production. For example, the high speed of rotation of the printing cylinders 4, 12 or blanket cylinder 36 can cause the printing plates 6, 14 or blanket 38 to go out of alignment, which negatively affects the design formed on the metal containers 54.

The control system 46 can determine that the defective design 58 is due to a problem with the printing plate 6, 14 or blanket 38, as the defective design 58 is periodically repeated on other metal containers 54. More specifically, a metal container 54 with defective design caused by a problem with a printing plate 6, 14 or blanket 38 can be between satisfactorily shaped metal containers.

The control system 46 may associate the cause of the defective design with the plates 6, 14 or with the offset cover 38 based on how often the defective design is repeated on metal containers. More specifically, in one embodiment, the number of printing plates 6, 14 on the printing cylinders 4, 12 is different from the number of blankets 38 on the blanket cylinder 36. Accordingly, the defective design caused by the problem with the blanket 38 will be repeated at a different speed. from defective design resulting from a problem with the printing plate 6, 14. If the defective design is repeated at a rate equal to the number of blankets 38, the control system 46 may determine that the defective design is caused by a problem with one of the blankets 38. Otherwise, if the defective design is repeated on each metal container and is positioned in the same position for each defective design, the control system 46 can determine that the problematic printing plate 6, 14 is the cause of the defective design. In one embodiment, each plate cylinder 4 , 12 contains only one plate 6, 14, samples Lemme with one of the printing plates 6, 14 will cause a defective design for each metal container.

The defect design can be traced by the control system 46 either to the printing plates 6 of the first plate cylinder 4 or to the printing plates 14 of the second plate cylinder 12, based on whether the intermittent defect design is associated with the first or second ink 26A, 26B. For example, if defective designs are observed and the defect is associated with only the first ink 26A, then the control system 46 may determine that the first printing plate 6 has a problem. Alternatively, if a decoration defect occurs on each metal container and is associated with only the second ink 26B, the problem is with the second printing plate 14. In one embodiment, the control system 46 may send a signal to one or more plate cylinders 4, 12 to change position plate 6, 14 and correct the position of the plate on the plate cylinder. In this way, the control system 46 can correct a defective layout due to misalignment or misalignment of the printing plate 6, 14. In another embodiment, the control system 46 can send a signal to the drive of the blanket 36. The signal can instruct the drive to move the blanket 40 in a specific direction. to correct misaligned blanket 40.

A problem with the support 42 can be identified by the control system when artwork is misaligned or placed on the metal container 54. For example, the support 42 may be misaligned with the blanket cylinder 36. When this happens, artwork transferred to the metal container 54 may be incorrect. be placed on a metal container. For example, the decoration may be too high or low on a metal container. Alternatively, the decoration may not be aligned with the axis of the metal container. Defective decoration may also be caused by the metal container 54 not being properly aligned with the location on the support 44. For example, the location 44 may be damaged or worn out so that the metal container 54 cannot be properly aligned with the blanket 38. In one of the embodiments, the support member 42 comprises a plurality of rods 44. The rod 44 may be damaged such that the metal container 54 thereon is not properly aligned with the blanket 38. The control system 46 may determine that the support 42 or location 44 on the support element is associated with a design defect based at least in part on the frequency with which the design defect occurs. In one embodiment, the control system 46 may send a signal to an actuator associated with the support member 42 to move the support member 42 or support rod 44 in a specific direction to correct a design defect. In another embodiment, the control system 46 may send an alarm to the operator indicating that the defect is associated with the support member 42.

Defective ink 26 may contain one or more of the following: ink of an inappropriate color, improper ink viscosity, impurities in the ink, and ink at the wrong temperature. The control system 46 can determine that the defective design is due to defective paint if similar deficiencies are observed on a plurality of metal containers and adjusting the amount of paint transferred to the metal containers does not correct the defect. In one example, the control system 46 can recognize the defective design and determine that the wrong amount of paint is the cause. The control system 46 may adjust the position of one or more ink knives 21 or a portion of the ink knife 22 associated with at least the first ink roller 10 or the second ink roller 18. Additionally or alternatively, the control system 46 may change the travel speed (or travel times) the ink roller 13 to change the amount of ink transferred to one or more printing plates 6, 14. More specifically, the contact time of the ink roller 13 with the corresponding ink roller 10, 18 can be increased or decreased. If such defective designs are identified by the control system 46 after adjusting the ink knives 21 or portions of the ink knife 22 or moving the ink roller 13, the control system can determine that defective ink is the cause of the defective designs.

In another embodiment, the control system 46 may determine that the defective ink is causing the defective designs when the defect is observed in two or more of the cylindrical portions 57 of the cylindrical body 56 of the metal container. More specifically, an incorrectly adjusted ink knife 21 or segment 24 of the ink knife 22 should only affect one cylindrical portion 57 of the metal container. In contrast, when the defective ink is fed to the ink dispensing unit 8, 16, the defective ink will be carried over all axial portions 20 of the ink rollers 10, 18. Accordingly, the design flaws will comprise at least two cylindrical portions 57 of the metal container 54.

The control system 46 may assign an error value to each defective design. In one embodiment, the error value may be stored in location 130 of database 110. In one embodiment, the control system 46 may perform various actions based on the level of the error value. For example, in one embodiment, the control system 46 may take first action on a first error value and second action on a second error value. In another embodiment, the first measures may comprise sending a signal to the actuator to adjust the decorator element 2. The signal may activate the actuator to move the corresponding ink knife 21, 22, the ink distribution unit 8, 16, the ink roller 10, 18, the plate cylinder 4, 12, blanket cylinder 36 or support element 42 in a specific direction. Alternatively, the signal can cause the drive to change the speed of travel of the injector roller 13. The first measures can also include sending an alarm to the operator. The second measure may include sending a signal to the ejector 62 to remove the defective metal container from the conveyor 48. In one embodiment, the second measures may also comprise sending a signal to decorator 2 to stop the decorator. In one embodiment, the first error value is at the warning level and the second error value is at the scrap level. In another embodiment, the first error value is associated with a defect associated with the first layout density. The first density can be obtained by one or more sensors 49, 50 and transmitted to the control system 46. The second meaning of the error may be related to the second density of the defective design. In one embodiment, by assigning a warning level before assigning a scrap level, the control system 46 is given a period of time before stopping the decorator to adjust the decorator 2 and fix the defective decoration.

In another embodiment, the error value increases in accordance with the increase in the defect value. The error value can be related to one or more of the parameters such as color, density, alignment, depth, and consistency of the defective design. In one example, the error value is proportional to the surface area for the outer surface 56 of the container covered by the defective decoration. Additionally or alternatively, the error value may be below a predetermined value if the defect is invisible to the human eye. Likewise, the error value can be higher than the specified value if the defect is visible to a person.

The error value can also be related to the frequency of intermittent design defects. For example, the error value associated with a printing plate problem 6, 14 or blanket 38 (which, in some cases, cannot be corrected by the control system 46) may be higher than the error value for a defect related to the amount of ink. transportable to a metal container (which can be corrected by the control system 46). In one embodiment, the design defect caused by the printing plate 6, 14 will give a higher error value as judged by the control system 46 than for the design defect caused by the blanket 38. The error value associated with the design defect caused by the printing plate 6, 14 is higher than the error value associated with the defect caused by the blanket 38, because the defect due to the printing plate will occur more often than the defect due to the blanket, since each plate cylinder 4, 12 contains only one printing plate. forms 6, 14. Accordingly, a defective printing plate 6, 14 will cause a design defect on each metal container decorated by decorator 2.

In one embodiment, the error value may increase based on the number of defective metal containers observed. More specifically, defective design may be related to the first error value. The first error value can be a warning level. If additional defective metal containers are identified within a predetermined time, the control system 46 may increase the error value to a second error value. The control system 46 can then send a signal to the decorator 2 which causes the decorator to stop. In one embodiment, when the control system 46 detects a predetermined number of defective metal containers 60, the control system 46 sends a signal that causes the decorator 2 to stop.

Alternatively, the control system 46 may assign an error value based on the ΔE difference between the target color value and the color value measured by the sensor 49, 50. For example, if the ΔE is within a predetermined percentage of the target value, the control system may assign a first value to the defective design errors. In response, the control system 46 can determine the cause of the defective design. In one embodiment, the control system 46 may send a signal to an actuator associated with the decorator component 2 that may be adjusted to correct the defect. In one embodiment, when ΔE is within about 5% of the target color value, the control system will assign the first error value.

When ΔE is within the second predetermined percentage of the target value, the control system may designate a second error value for clearance. The second error value can cause the control system 46 to activate the ejector 62 to remove the defective metal container 60 from the conveyor 48. Similar to the first error value, the control system 46 can determine the cause of the defective design and, if the adjustment of the decorator component 2 can eliminate the cause of the defective design, control system 46 may optionally send a signal to one or more decorator actuators 30. Alternatively, upon assigning a second error value, the control system 46 may generate an alarm. In one embodiment, a second error value is assigned to a defect design for which ΔE is within about 15% of the target color value.

When the ΔE exceeds the predetermined value, the control system 46 may designate a third error value for the defect. In one embodiment, the third error value is assigned to a decoration that has ΔE greater than about 15% of the target color value. In one embodiment, upon assigning a third error value to the defect, the control system 46 may send a signal to stop decorator 2. Additionally or alternatively, the control system 46 may send an alarm associated with the third error value to the operator.

In another embodiment, for a defective design that the control system 46 determines to be caused by defective ink 26, the control system 46 may assign an error value that is higher than the error values associated with problems with plates 6, 14 and blanket 38. More a high error value for defective ink is set because defective ink can cause defective designs at a higher frequency than defective designs caused by problems with printing plates 6, 14 and blankets 38.

The control system 46 may generate an error or alarm code associated with defective designs. In one embodiment, the error or alarm code is stored in field 130 of database 110. The alarm code may contain information about the reason for the defective design, as determined by the control system 46. The error value assigned to the defect by the control system 46 may be included in the alarm code. In one embodiment, the control system 46 may generate an alarm code when the defective design is associated with an inappropriate amount of ink transferred to the metal container, a problem with the printing plate 6, 14 or blanket 38, or defective ink. In another embodiment, an alarm code is generated when the error value assigned to the defect exceeds a predetermined value. In yet another embodiment, an alarm code may be generated for each defect identified by the control system 46. In one embodiment, an alarm code may be generated for defects that the control system cannot fix or that cannot be repaired. For example, a faulty design that the control system cannot correct by sending signals to the actuators 30 to adjust the amount of ink transferred to the metal containers 54, or by adjusting the position of one or more of devices such as an ink distributor unit, ink rollers, plate cylinders, the blanket cylinder and support member can cause the control system 46 to generate an alarm code. In another embodiment, the control system 46 may generate an alarm code for defective designs for which the control system cannot recognize the cause.

Additionally or alternatively, the control system 46 may stop the decorator 2 after detecting a defective design based on rules stored in the memory 96 of the control system 46. In one example, the rules can cause the control system 46 to stop decorator 2 when the error value is greater than a predetermined value. In this way, the control system 46 can stop the decorator upon one or more of the following events: (1) defective decoration occurs at or above a predetermined frequency; (2) the defective design has a surface area greater than a predetermined value; (3) the number of defective designs is detected that is more than the specified one; (4) similar defects are detected after the position of at least one ink knife 21 or a portion of the ink knife 22 is controlled by a signal from the control system 46 to the actuator 30; and (5) similar defects are detected after the rotation speed of one or more ink rollers 10, 18 and the transfer roller of the ink device 11, 19 is changed by a signal from the control system 46 to the drive element.

Alternatively, when the control system 46 determines that the metal container 60 has a defective design 58, the control system 46 operates to send a signal to activate the ejector 62. The ejector 62 is configured to remove the metal container 60 from the conveyor 48 as shown in FIG. 1 by rejecting the metal container 60. In this way, the defectively decorated metal containers 60 are not transported to the downstream equipment 66 after the decorator.

In one embodiment, the control system 46 sends a signal to the ejector 62 to remove metal containers 54 containing a defective design with an error value greater than a predetermined level. Some defective designs may be difficult to see. Although the defective artwork does not meet design standards, the defect may not be obvious to the human eye. Accordingly, the control system 46 can adjust the ink knives 21 or portions of the ink knife 22 to eliminate the defect; however, if the defect is not detectable by the human eye, the control system 46 may allow the metal container 54 to continue to the downstream equipment 66. 1, the defective color is probably invisible to a human observer. In one embodiment, when the decoration contains ΔE less than about 1, the metal container 54 is not rejected. Other defective designs may be obvious to the human eye. In one embodiment, designs with a ΔE greater than about 1 are discarded. Designs visible to humans may be assigned a higher error value because metal containers 60 with clearly defective designs require rejection. Accordingly, the control system 46 can send a signal to the ejector 62 to prevent the flow of the metal containers 60 with visible defects exceeding a predetermined error value from passing to the equipment 66 located after the decorator.

In one embodiment, the ejector 62 uses a discharge of compressed gas, such as air, to remove defective metal containers 60 from the conveyor 48. In another embodiment, the ejector 62 contacts and applies mechanical force to the defective metal containers 60. The force is used to remove the metal containers 60 from the conveyor 48.

Metallic containers 54 with acceptable decoration 58 are transported past the ejector 62 to equipment 66 located downstream of the decorator. In one embodiment, downstream equipment 66 comprises one or more of a priming machine, an oven, a waxing machine, a neck punching machine, a tester, a test point, a sensor, and a stacker. The primer applies varnish (or other material) to the interior surface of the metal container 54. In one embodiment, the primer is positioned before the sensor 50. Accordingly, in one embodiment, the metal containers 54 may be varnished before being read by the sensor 49. 50. The oven cures the varnish. A thin layer of lubricant can be applied by a waxing machine to the portion of the container body closest to the open end of the metal container 54. The neck punching machine reduces the diameter of the portion of the metal container body and folds over the aerosol containers. The tester checks the container for accidental holes or leaks. At the inspection site, the shape or other features of the metal container 54 can be checked. Alternatively, the equipment 66 downstream of the decorator includes at least one sensor. The sensor can be the same as sensors 49, 50, or the like. Accordingly, in one embodiment, the control system 46 may receive data collected by a sensor associated with the outer surface 56 of the metal containers 54 of the equipment 64 downstream of the decorator. The stacker can bundle finished metal containers 54 for loading or storage.

FIG. 16 generally illustrates one embodiment of the method 166 of the present invention for determining the cause of the defective design of the metal container 54. While FIG. 16 shows the general order of steps of method 166, method 166 may include more or fewer steps, or may operate in a different sequence than that shown in FIG. 16. Additionally, although the steps of method 166 may be described sequentially, many of the steps may actually be performed in parallel or concurrently. In general, method 166 begins at 168 and ends at 188. At least a portion of method 166 may be executed as a set of computer-executable instructions executed by a computer system and encoded or stored on a computer-readable medium. One example of a computer system may include, for example, a control system 46. An example of a computer-readable medium may include, but is not limited to, the memory of the control system 46. Hereinafter, method 166 will be explained with reference to control system 46, decorator 2, and components described in conjunction with FIG. 1-15.

In step 170, the control system 46 receives data from the sensor 49, 50. The control system 46 can then determine, in step 172, whether the design is satisfactory. In one embodiment, the control system 46 compares the sensor data with stored data of an acceptable design. Alternatively, the stored data is associated with a base image containing data collected from a plurality of suitably shaped metal containers. Alternatively, the stored data of an acceptable design is provided by the operator or the customer. In one embodiment, the stored data of an acceptable design is formed from an image of a single metal container.

When the sensor data deviates from the stored data by a predetermined value, the control system 46 can determine that the design of the metal container 60 is defective. Specifically, if the sensor data for adornment deviates by more than a predetermined value from the base image, the adornment is defective. In one embodiment, any discrepancy between the sensor data and the base image results in the control system 46 marking the adornment 58 as defective. Accordingly, the control system 46 can determine the cause and remedy for the defective design.

Alternatively, the control system 46 may set an error value for the defective design. As previously described, the error value can be associated with one or more, but not limited to, the type of flaw, the frequency of flaw, whether or not the flaw is visible to humans, and the amount of deviation of the flaw color from the target color value ( such as ΔE).

In one embodiment, the error value is a warning level or a scrap level. The control system 46 may determine that the adornment is defective for one or more reasons. For example, the control system 46 may determine that the adornment is defective due to one or more of the following: incorrect amount of ink, defective ink, defective plate or blanket, incorrect ad position, misaligned adornment, and so on. In one embodiment, the control system determines that the design is satisfactory or defective, as described in conjunction with block 158 in FIG. 15. If the decoration is unsatisfactory, the method 166 jumps over the NO link to step 174. When the decoration is satisfactory, the method 166 jumps over the YES link and the end step 188.

At step 174, the control system 46 may determine if the defect is caused by an incorrect amount of paint 26 transferred to the metal container 60. The incorrect amount of paint may contain too much or too little paint transferred to one or more axial portions 20 and further to the metal container. 60. The wrong amount of ink can result in a defective design that has the wrong color, wrong ink layer density or wrong thickness. The control system 46 can determine that the faulty design is due to the wrong amount of paint based on the data received from the sensor 50.

In one embodiment, when the decoration 58 is defective in only one cylindrical section 57 of the metal container 60 and the defect is repeated in a plurality of metal containers 60, the control system 46 may determine that the defective decoration is due to insufficient ink 26 transferred to the axial section 20 of one of the the ink rollers 10, 18. Additionally or alternatively, the control system 46 may determine that the defective decoration is the result of an incorrect amount of ink if at least one of the parameters such as color, density or thickness of at least the decoration region 58 is different from the color, density and thickness of an appropriate area of acceptable design, such as an acceptable design, stored in data object 116 of database 110.

Additionally, at step 174, the control system 26 may determine which ink knife 21 or portion of the ink knife 22 is associated with the cylindrical surface 57 that contains the inappropriate amount of ink 26. When the inappropriate amount of ink is the cause of the defective decoration, the inappropriate amount of ink will be substantially uniform density or thickness throughout the cylindrical portion 57 of the metal container 60. Accordingly, an incorrectly adjusted ink knife 21 or a portion 24 of the ink knife 22 will generally correspond to a cylindrical portion 57 with an inappropriate amount of ink.

For example, if the cylindrical portion 57B of the container 54 shown in FIG. 11 contains a decoration 58A formed with an inappropriate amount of ink, then the ink knife 21B or the knife segment 24B of the ink knife 22 is incorrectly adjusted relative to one of the ink rollers 10, 18. The control system 46 can also determine if the ink distribution unit 8, 16 contains an incorrectly adjusted the ink knife 21B or the knife segment 24B based at least in part on the type or color of ink 26 associated with the defect identified in the cylindrical portion 57B. More specifically, if the ink knife 21B or the knife segment 24B of the first paint distribution unit 8 is misadjusted, then the defective design will be associated with the first ink 26A. The control system 46 may also consider the data received from the potentiometer 80B associated with the ink knife 21B or the knife segment 24B to determine the current position of the knife segment or ink knife. The data received from the potentiometer may indicate that the ink knife 21B or the knife segment 24B has inadvertently or unexpectedly moved from the starting position.

In one embodiment, the control system 46 may also consider data received from one or more sensors 49B, 49C with respect to ink on printing plates. Data from sensors 49B, 49C may indicate that the ink knife 21 or knife segment 24 of one of the paint distribution units 8, 16 is carrying the wrong amount of hard hat 26. Accordingly, the control system 46 can view data from multiple sensors 49, 50 and potentiometers 80 to determine if which ink knife 21 or knife segment 24 is not properly adjusted.

The control system 46 may also determine that an inappropriate amount of one type or color of ink 26 has been applied to more than one cylindrical portion 57 of the container 54. Specifically, the density of the ink 26 may not be correct across the entire outer surface 56 of the container. In response, the control system 46 may determine that adjusting the speed or timing of the inking roller 13 of the ink device 11, 19 associated with the inks 26 should correct the defect. Alternatively, the control system 46 may determine that the inappropriate amount of ink transferred can be adjusted by changing the rotation speed of the ink roller 10, 18 and the transfer roller of the ink device 11, 19. The ink rollers 10, 18 and transfer rollers may be driven by drive elements associated with a control system 46. The control system can send signals to one or more drive elements associated with the ink roller 10, 18 and the transfer roller to control the amount of ink transferred by the ink distribution unit 8, 16 to the corresponding printing plate 6, 14. Alternatively, the ink rollers 10, 18 can rotate at a speed that differs at least from the speed of one transfer roller in the corresponding ink device. In one embodiment, increasing the speed of rotation of the ink rollers 10, 18 can increase the amount of ink transferred to the transfer roller and further to the printing plate.

If the defect is not the result of an incorrect amount of ink, method 166 proceeds on the NO link to step 176. If the defect is a result of the wrong amount of ink, the method 166 proceeds on the YES link to step 184.

At 176, the control system 46 may determine that the flaw is associated with the defective paint 26. More specifically, if the flaw is observed on each of the plurality of metal containers 60 and the flaw extends to more than one cylindrical portion 57 of the metal container 60, the control system 46 may determine that the defect is the result of defective paint or other causes.

In one embodiment, the control system 46 may determine that defective ink 26 is the cause of the defective design when adjusting the position of the ink knife 21 or the area of the ink knife 22 and / or changing the operation of the ink roller 13 to change the amount of ink transferred to the metal containers. eliminate the defect. Alternatively, the speed or timing of movement of the injector roller 13 can be varied. In another embodiment, the control system 46 may determine that the defective ink 26 is causing the defective appearance when the defect is observed in sensor data associated with two or more cylindrical portions 57 of the cylindrical body 56 of the metal container. More specifically, an incorrectly adjusted ink knife 21 or segment 24 of the knife 22 should only affect the cylindrical portion 57 of the metal container 60. However, when defective ink is fed to the ink dispensing units 8, 16, the defective ink will be carried across all axial portions 20 of the ink rollers 10. 18. Accordingly, at least two cylindrical portions 57 of the metal container 60 will contain design defects.

Additionally, or alternatively, the control system 46 may determine that defective ink 26 is the cause of the defective design when data from one or more sensors 49, 50 indicates variations in color, density, or ink thickness within one cylindrical portion 57 of the container 60. More specifically, ink 26 that is not defective should have a uniform color, density and thickness when transferred from the axial portion 20 of the ink roller 10, 18 to the cylindrical portion 57 of the container. However, if the ink 26 is defective, the data from the sensor 50 associated with the cylindrical portion of the container may contain variations. Paint can be defective if it is contaminated (for example, particles, other paint, etc.), is at the wrong temperature, is improperly mixed, or has the wrong viscosity.

When ink is contaminated with particles, one of the sensors 49E, 50 can detect particles in one or more of the cylindrical portions 57 of the container. In one embodiment, one of the sensors 49B, 49C, 49D can detect particles in ink 26 on a printing plate 6, 14 or on a blanket 38. In one embodiment, ink contaminated with particles can be detected when a particle in the ink interferes with or interrupts the transfer of ink to the ink roller 10, 18. For example, a particle trapped in the nip 32 between the ink roller 10, 18 and the ink knife 21 or the ink knife section 24 may result in no ink transfer to the circular section of the ink roller 10, 18 A circular lack of ink on the ink roller 10, 18 may result in an unpainted strip on the printing plate, blanket, or on the metal container 60. Accordingly, when the control system 46 detects an unpainted strip around the metal container, the control system 46 can determine that the ink is contaminated with particles. ...

If the defective ink is at the wrong temperature, improperly mixed, or has the wrong viscosity, ink may flow unevenly through the gap 32 between the ink roller 10, 18 and the ink knife 21 or the ink knife portion 24. Accordingly, ink 26 may be unevenly distributed over at least one axial portion 20 of the ink roller 10, 18. For example, the sensor 50 may collect data from two target locations 59A, 59B within the cylindrical portion 57B of the metal container, as generally shown in fig. 11. The control system 46 receives data associated with target locations 59A, 59B, and can determine that the ink associated with the target location 59A is different from the ink associated with the target location 59B. The sensor data may indicate that the ink at target locations 59A, 59B is of different thickness, different density, different color, and unevenness.

When the control system 46 determines that the defect in step 176 is caused by the defective ink 26, the method 166 proceeds over the YES link to step 184. When the defective ink is not the cause of the defect, the method 166 over the NO link proceeds to step 178.

At step 178, the control system 46 determines if the defective design is repeated. More specifically, a defective design associated with a defective printing plate 6, 14 or a defective blanket 38 will recur periodically on metal containers. Accordingly, a defective blanket or printing plate will result in the same or similar defective design on multiple metal containers 60. When defective design 58 is repeated on each of the metal containers 60, the control system 46 can determine that the defective design 58 is a consequence of a defective printing plate 6, 14. The defective printing plate 6, 14 may be incorrectly positioned on one of the printing cylinders 4, 12. Alternatively, the defective printing plate 6, 14 may be worn out or damaged. In one embodiment, the control system 46 may receive data from at least one of the sensors 49B, 49C, 49D, which indicates that the printing plate 6, 14 or blanket 38 is defective.

In one embodiment, the control system may determine the plate cylinder 4, 12 to which the defective printing plate 6, 14 is associated, based on the ink 26 associated with the defective design. More specifically, the defective plate 6 on the first plate cylinder 4 will be associated with the ink 26A of the first ink dispensing unit 8. Similarly, the defective plate 14 on the second plate cylinder 12 will be associated with the ink 26B of the second ink dispensing unit 16.

The control system 46 may also determine that the defective design is associated with the blanket 38 when the defective design 58 is repeated with a period associated with the number of blankets 38 on the blanket cylinder 36. When the defect is due to a defective printing plate or blanket, the communication method 166 YES proceeds to step 184. If the defect is not associated with the printing plate or blanket, the method 166 on the NO link proceeds to step 180.

In one embodiment, the control system 46 may also determine at step 180 that the adornment is misaligned or positioned on the metal container 60. More specifically, the control system 46 may compare the data received from the sensor 50 with the associated data stored in the database 110. with an acceptable design. If the alignment or position of the adornment 58 on the metal container differs from the acceptable adornment stored in memory, the control system can determine that the adornment is not properly aligned.

In one embodiment, the control system 46 may determine that the adornment is not properly positioned or aligned on the metal container by comparing the positions of the two adornment regions. More specifically, and referring again to FIG. 11, the control system 46 may receive sensor data associated with the position of the decoration 58A on the cylindrical section 57B and the decoration 58B on the cylindrical sections 57C-57F. If the positions of the adornments 58A and 58B are separated by a distance other than the setpoint, the control system 46 may determine that the adornment is defective due to improperly aligned or positioned adornments 58A, 58B. Additionally, the decoration 58C formed by the first ink 26A cannot be fixed with respect to the throat, the decoration 58B formed by the second ink 26B. In this way, the control system 46 can determine that one or more of the plates 6, 14 are not aligned correctly. In general, different colors or types of paint 26A, 26B must be separated by a predetermined distance. In one embodiment, inks 26A, 26B should be spaced up to approximately 0.005 inches. In one embodiment, control system 46 may view data from at least one of sensors 49B, 49C, 49D to determine which plate 6, 14 or blanket 38 is misaligned. Additionally, in one embodiment, metal containers 54 are sequentially transported from decorator 2 to sensor 49, 50. In another embodiment, each metal container 54 is transported on a conveyor bar 48 that holds the metal container in place while transporting them to the equipment. located after the decorator. Accordingly, the control system 46 can determine the blank 38 associated with the defective design based on one or more orders of metal containers and the rod transporting the defective metal container.

When the defect is due to misplaced or misaligned decoration, method 166 proceeds on YES link to step 184. If the defect is not associated with a printing plate or blanket, method 166 on NO link proceeds to step 181.

At step 181, the control system 46 may determine that the defective design is associated with a damaged metal container. Damage can be caused to equipment 64 prior to the decorator. For example, a body forming machine may cause a dent, line, scratch, or wrinkle in the cylindrical body 56 of the metal container 54. The damaged portion of the cylindrical body 56 cannot properly contact the blanket 38. Accordingly, the damaged portion cannot properly receive ink, resulting in as a result, to the area with missing paint or to the unpainted area of the outer surface 56 of the container and to defective decoration. Defective decoration can look like emptiness or lack of decoration. Additionally or alternatively, the damaged area may receive an inappropriate amount of ink from the blanket 38. Likewise, the equipment 64 preceding the decorator may cause abrasions, drawn dents and scratches. Scuffs, dents and scratches can render the decoration defective.

If damage caused by equipment 64 preceding the decorator is repeated periodically, a similar dents, an unformed area or an area with an inappropriate amount of paint on the outer surface 56 will be detected by the sensor 49, 50. Although damage can be repeated in similar areas on numerous metal containers (for example following approximately the same distance from the closed end wall of the metal container), since the metal containers 54 reach the decorator at random, the damaged portion of the metal container will randomly align with the blanket 38. Specifically, the damaged portion of the first metal container will enter contact with the first section of the first blanket, and a second metal container with a similar damaged section will come into contact with another second section of the second blanket. A damaged area of metal containers will accordingly render various areas of the design defective. In this way, the control system 46 can determine that the defective decoration is the result of damage to the metal container caused by the equipment 64 preceding the decorator.

Washers preceding the decorator 2 can also cause stains on the outer surface 56 of the metal container. Stains can contain droplets, etchants and other marks left on the outside of the washer. When the stained metal container is decorated, the stain will change color or paint will develop to form the decoration 58. For example, paint cannot completely cover the stain. The stain can also repel paint. The spot, when compared to the base image, may cause the control system 46 to judge the adornment as defective.

When the control system 46 determines that the defect is due to a damaged metal container, method 166 proceeds over YES to step 184. If the defect is not associated with a damaged metal container, method 166 proceeds through NO communication to step 182.

The control system 46 may not be able to classify the cause of each identified defect. Accordingly, at step 182, the control system 46 may register the defect as caused by an undefined cause. Characteristics of the defective design, such as, but not limited to: (a) a prior defect was the cause of the defective design; (b) color ∆E defect; and (c) the locations of the defect will be stored in the memory 90, 96 of the control system 46. Defective characteristics may also be stored in record 132 of data structure 110. In this way, archived data on defective designs are available for additional analysis. Some causes of defective designs can only be identified after the same or a similar defect is observed on a large number of metal containers. Accordingly, the control system 46 can continue the production process and receive data from sensors 49, 50 associated with a design that is defective for the same or similar reasons. If the localization of the defect is repeated on multiple metal containers, the control system 46 can further determine the previously undetermined cause. Method 166 then continues to block 184.

In step 184, the defective metal container 60 is optionally removed from the conveyor 48. For example, in one embodiment, when the error value associated with the defective design is at the scrap level, the control system 46 may send a signal to the ejector 62. to remove the metal container.

At step 186, the control system 46 may send an alarm. The alarm can contain information about the type of defect identified by the control system. For example, an alarm can indicate that a defective design is due to one of the reasons such as inappropriate ink quantity, defective ink, defective plate or blanket, inappropriate positioning or alignment of the design, and a damaged metal container. In one embodiment, the alarm may comprise sending a defective image collected by the sensor 50 to a display 88 of the control system 46. In another embodiment, the decoration area that is defective is highlighted and / or enlarged. Alternatively, if the control system 46 was unable to determine the cause of the flaw, such that method 166 proceeds from step 180 to step 182 on NO communication, an alarm may indicate that the control system 46 cannot determine the cause of the flaw. In one embodiment, the alarm may also contain information about the measures recommended by the control system 46 to correct the defective design. Accordingly, the alarm can identify one or more ink knives 21 or portions of the adjusting screws 22 to be adjusted to correct the defect. In another embodiment, the alarm may identify one or more ink dispensing units, ink rollers, transfer rollers, plate cylinders, blanket cylinder, and support member to be adjusted to correct the defect. Additionally or alternatively, the alarm may indicate adjustment of the operation of one or more of the injector rollers 13.

In one embodiment, the control system 46 can automatically adjust one or more ink knives 21 or ink knife sections 22, ink distribution units 8, 16, ink rollers 10, 18, ink transfer rollers 11, 19, plate cylinders to correct the defect. 4, 12, a blanket cylinder 36 and a support member 42. Specifically, the control system 46 can send a signal to one or more actuators to move the ink knife 21, the ink knife 22, the ink distribution unit 8, 16, the ink roller 10, 18, the plate cylinder 4, 12 and the blanket cylinder in a specific direction. In yet another embodiment, the control system 46, to correct the defect, may send a signal to the actuator to move the plate 6, 14 or blanket 38 in a particular direction. Additionally or alternatively, the control system 46 may send a signal to the inking roller 13 or the inking roller or transfer roller drive element to change the travel speed of the inking roller, inking roller or transfer roller. In this way, the control system 46 can change the amount of ink 26 transferred by the respective ink device 11, 19 to the printing plate 6, 14.

In one embodiment, an alarm or visual indication on the display screen may identify the cause of the defect, which may or may not be corrected by the control system 46. For example, if the defective design is caused by defective ink, defective printing plate or blanket, or structural damage to the container caused by the pre-decorator equipment 64, the adjustments of decorator 2 will not correct the defective design. Instead, the operator of decorator 2 may be required to eliminate the cause of the defective design by altering the defective ink or replacing the damaged printing plate or blanket. Alternatively, if the control system 46 cannot correct the design defect, the control system 46 can send a signal to stop the decorator or provide an operator with a visual indication or alarm that a problem exists. In one embodiment, if the defect is caused by damage caused by upstream equipment 64, the control system may send a signal to stop the equipment upstream of the decorator. Alternatively, the control system 46 may shutdown the decorator 2 and / or the pre-decorator equipment 64 if damage caused by the pre-decorator equipment is observed for more than a predetermined number of metal containers. For example, if more than 50 metal containers, using data from sensors 49, 50, are identified as containing a defective decoration caused by damage, the control system 64 may send a signal to stop the decorator and / or equipment located upstream of the decorator.

The alarm generated by the control system 46 may also include recommended measures such as “replace paint at paint station 8”. In another embodiment, an alarm may indicate which of the printing plates or blankets are defective and misaligned. In yet another embodiment, an alarm may indicate that the control system cannot correct the defect. In one embodiment, an alarm may indicate that the cause of the defect has not been determined. After sending the additional alarm, method 166 proceeds to end step 188.

Now in FIG. 17 shows one embodiment of a method 200 for automatically adjusting a decorator 2 to correct a design defect in accordance with one embodiment of the present invention. While FIG. 17 illustrates the general order of steps of method 200, method 200 may contain more or fewer steps, or may arrange the order of steps differently than shown in FIG. 17. Additionally, although the steps of method 200 may be described sequentially, many of the steps may actually be performed in parallel or concurrently. In general, method 200 begins at start block 200 and ends at end block 232. At least a portion of method 200 may be implemented as a set of computer-executable instructions executed by a computer system and encoded or stored on a computer-readable medium. One example of a computer system may include, for example, a control system 46. An example of a computer-readable medium may include, but is not limited to, the memory of the control system 46. Hereinafter, method 200 will be explained with respect to control system 46, decorator 2, and components described in conjunction with FIG. 1-16.

In step 204, the control system 46 sends a signal to the actuators 30 associated with the paint distribution units 8, 16 of the decorator 2. The signal causes the actuators 30 to move the ink knives 21 or segments of the ink knife 22 closer to or further from the ink rollers 10, 18. In one embodiment of the present invention, the drives 30 are low voltage motors.

Alternatively, actuators 30 may comprise (or be associated with potentiometers 80 that provide position feedback to control system 46. Control system 46 may use information received from one or more rotation or displacement sensors, such as potentiometers 80, to determine position of the ink knives 21 or the ink knife 22 (or ink knife segment) relative to the respective ink roller 10, 18. For example, in one embodiment of the present invention, each actuator 30 comprises a low voltage DC motor associated with a respective adjusting screw 28 or an axis 31. How option, in another embodiment, the actuators 30 comprise a solenoid associated with an adjusting screw 28. In this way, the control system 46 adjusts the gap 32 between each ink knife 21 or segment 24 of the ink knife 22 and the ink rollers 10, 18 in the initial position. measure for a given amount of ink 26 for each axial portion 20 of the ink rollers 10, 18 required to form a decoration 58. In one embodiment, the control system 46 automatically determines the starting position of each ink knife 21 or segment 24 of the ink knife 22 by analyzing the decoration 58 entered by the operator to the database 110 of the control system 46. In another embodiment, the operator enters the start position of each ink knife 21 or segment 24 of the ink knife 22 into the control system 46.

In step 206, ink 26 is transferred to the axial portions 20 of the ink rollers 10, 18. The amount of ink 26 transferred to the axial portions 20 is determined by the gap 32 between the ink blades 21 or segments 24 of the ink knife 22 and the ink rollers 10, 18 based on the initial settings. the respective adjusting screws 28 or pivots 31. Ink 26 is sequentially transferred to the printing plates 6, 14 in step 208, to the blankets 38 in step 210 and then, in step 212, to the outer surface 56 of the undecorated metal containers 52. In one embodiment one or more sensors 49B, 49C collect data on at least the amount of ink 26 transferred to the printing plates 6, 14. In another embodiment, the sensor 49D collects data on the amount of ink on the outer surface 40 of the blankets 38.

Decorated containers 54 are subsequently transported to sensor 50. In one embodiment, method 200, optionally at step 214, waits for a predetermined amount of time during which metal container 54 is transported from support member 42 to one or more sensors 49E, 50. More specifically, depending on the position of the sensors 49E, 50 relative to the support member 42, it may take a few seconds or a period of several minutes for the metal container 54 to be decorated based on the modified components of the decorator 2 (after adjusting the position of the ink knives 21 and the ink knife segments 22) was able to reach sensors 49E, 50. If sensor 49E, 50 precedes equipment 66 downstream of the decorator (for example, when the sensor is positioned to read wet paint 26 of decoration 58), the delay may be less than about 1 minute. However, if the sensor 50A is located after the equipment 66, which is located after the decorator, then the delay can be more than 1 minute. In one embodiment, when the sensor 50A is located downstream of the core oven, approximately 350-500 metal containers must pass by the sensor 50A before the metal container decorated with the new decoration component settings reaches the sensor 50A. Regardless of the position of the sensor 49, 50, the amount of time lag between the metal container 54 leaving the support member 42 to reach each of the sensors 49E, 50 is known. Accordingly, while waiting for a period of time at step 214, the control system 46 may determine the position of the ink knives 21 and the ink knife segments 22 when the metal container has been shaped. In one embodiment, up to about 500 shaped metal containers 54 may be in transit between the outlet of the support member 42 and a sensor 50A located downstream of the drying oven 66. Accordingly, after adjusting the decorator component 2 adjustment to about 500 metal containers 54 must pass through sensor 50A before the metal container 54 decorated with the modified decorator settings is read by the sensor 50. When the sensor 50 is positioned before the drying oven 66, fewer metal containers pass between the decorator 2 and the sensor. Accordingly, less than about 100 and only 20 metal containers may be in the path between the decorator 2 and the sensor 50. Because of this, the sensor 50 may respond more quickly to defective decoration compared to the sensor 50A located downstream of the drying oven.

The embellishments 58 on the metal containers 54 are read in step 216 by at least one of the sensors 49E, 50. In one embodiment, the decorated metal containers 54 are transported by a conveyor 48 to the sensors 49E, 50. Alternatively, the sensors 49E, 50 are positioned to sense the decorated metal containers. metal containers 54 on support 42.

Sensors 49E, 50 are aligned to read or display adornments 58 on decorated metal containers 54. Sensor 50 and optionally sensor 49E collect adornment data 58 requiring one or more of the following parameters to be determined: adornment color; the density of the design; depth (or thickness) of the design; alignment of the design; and the consistency (or uniformity) of the appearance. In one embodiment, the sensors 49E, 50 are cameras. Alternatively, decorator 2 contains three to six sensors 50 or sensors 49E. These three to six sensors 49E, 50 may be disposed about the longitudinal axis of the metal container 50 to substantially simultaneously read the entire outer cylindrical surface 56 of the metal container.

In step 218, the control system 46 receives admission data 58 collected by one or more sensors 49E, 50. The control system 46 is configured to determine if ado 58 is acceptable or defective based on targets such as one or more of the following: color, density, depth, alignment and consistency. Target parameters can be set by the client. In one embodiment, the control system 46 compares the sensor data with an image of an acceptable design stored in memory 96, 100, 104. In one embodiment, the image may be a base image generated by reading a plurality of metal containers with an acceptable design. In one embodiment, images of a plurality of acceptable layouts are stored in memory, such as described in conjunction with FIG. 15. The base image can be stitched together from images of individual acceptable designs. Alternatively, in another embodiment, the base image of the metal container with an acceptable image is provided to the control system 46 and stored in memory. The base image can be provided by the operator or the client. Accordingly, the control system 46 can compare portions of sensor data with corresponding portions of a plurality of images or with a base image stored in memory. Alternatively, the control system 46 is programmed to recognize an acceptable design. For example, control system 46 may be programmed to receive data on a variety of acceptable designs, as generally described in method 140 of FIG. 15. The control system 46 may also, at 218, determine the cause of the defective design. In one embodiment, the control system determines the cause of the defective design, as described in conjunction with FIG. 16.

In one embodiment, the control system 46 obtains data from all of the metal containers decorated by the decorator 2. Alternatively, the control system 46 acquires data for some of the decorated metal containers 54. In one embodiment, the control system 46 determines that the decoration is defective, as described in in conjunction with block 172 in FIG. 16. If the decoration 58 is satisfactory, the method 200 on the YES link proceeds to step 228. When the decoration 58 is defective, the method 200 on the NO link proceeds to step 220.

Alternatively, at step 220, the control system 46 may send a signal to the ejector 62. The signal causes the ejector 62 to remove the defective metal container 60 from the conveyor 48. In one embodiment, the control system 46 sends a signal to the ejector 62 when an error value associated defective, exceeds the specified value. In another embodiment, control system 46 may send a signal to ejector 62 for each defective metal container 60. Alternatively, the control system 46 can determine if the defect is visible to the human eye. For example, defective design may not reach the target value; however, the defect may be too small or otherwise invisible to the human eye. If the defect is visible to the human eye, the control system 46 may cause the ejector 62 to remove the metal container 60. If the defect is invisible to the human eye, the control system 46 may allow the metal container to continue its passage to the equipment 66 located after the decorator.

At 222, control system 46 may optionally send an alarm. An alarm may be presented on an output device 88 of the control system 46, such as a display. In one embodiment, the alarm is audible. Alternatively, the control system 46 can send an alarm to a smart device such as a smartphone, tablet, or mobile computer via a network connection. In one embodiment, the alarm may contain a text message.

The alarm can provide information related to the type of defect identified in the adornment 58. In one embodiment, the information may include an error value associated with the defect design. The information may also include measures taken or planned by the control system 46 to correct the defect, such as a list of ink knives 21 or ink knife segments 22 associated with ink rollers 10, 18 that have been or will be adjusted. In one embodiment, the alarm contains information about adjustments to positions or operations of ink dispensers, ink rollers, injector rollers, transfer cylinders, printing plates, blanket cylinder, blanket, or support that are required to correct a defective design. Alternatively, in one embodiment, the operator can use the input device 86 of the control system 46, such as a pointer, keyboard, or touch screen, to validate the adjustments provided by the control system 46. In another embodiment, the operator can use the input device to make changes in the decorator 2 to correct the defect. In this way, the operator can activate one or more actuators 30 to change the position of one or more ink knives 21 or segments 24 of the ink knife 22. Additionally, the operator may change the setting of the drive associated with the inking roller 13 to adjust the travel speed of the inking roller. Specifically, the speed or timing of the movement of the injector roller can be increased or decreased to change the amount of ink transferred to the printing plate. Additionally or alternatively, the operator can change the operation of the drive element to change the speed of rotation of the ink roller 10, 18 or the transfer roller in the ink device 11, 19. In yet another embodiment, the operator can change the adjustments planned or made by the control system 46 to eliminate defect.

At 224, the control system 46 may decide to stop the production process. More specifically, in one embodiment, the control system 46 may decide that the manufacturing process should stop based on a rule stored in the memory 96 after determining in step 100 that the design 58 of the metal container 54 is defective. In one embodiment, the rule is associated with an error value assigned by the control system 46 for defect design. If the error value is greater than a certain value, the control system 46 may send a signal to stop decorator 2. In one embodiment, the rule is associated with the number of defective designs found within a certain amount of time. More specifically, if the control system 46 determines that more than a predetermined number of metal containers contains defective decoration, the control system can send a signal to the decorator 2 to stop the production process. In another embodiment, the rule may be associated with the type of defect identified by the control system 46. Accordingly, if the defect is of a type that can be corrected by the control system 46 by activating at least one actuator 30 to change the position of the ink knife 21 or a portion of the ink knife 22, or change the timing of the touching of the ink roller 13, the control system 46 may decide that the production process continues. Likewise, when a defect can be corrected by the control system 46 by sending a signal to the actuator to adjust the printing plate 6, 14 or blanket 38, the control system can continue the production process. Alternatively, when the defect cannot be corrected by the control system 46, the control system 46 may stop the production process. Specifically, if a defect occurs due to a defective metal container 54, the control system 46 may stop the decorator. With this method, the equipment 64 upstream of the decorator can be inspected and serviced, if necessary. In one embodiment, the control system 46 may stop the manufacturing process in response to an operator input. If the control system 46 decides that the checkout process should continue, the method 200 on YES communication proceeds to block 226. Alternatively, when the control system 46 decides that the checkout process should be stopped, the method 200 on NO communication proceeds to end 232.

In step 226, the control system 46 identifies one or more elements of the decorator 2 to adjust to correct a defect in the identified decoration 58. In one embodiment, the control system 46 uses the data received from the sensor 50 or the sensor 49E to identify the elements of the decorator that should be regulated. For example, the control system 48 may identify one or more ink knives 21 or segments 24 of the ink knife 22 that require adjustment to correct a design defect 58 using data from one or more sensors 49B, 49C, 49D, 49E, and 50. Specifically , the control system 46 can determine that one or more axial portions 20 of at least one ink roller 10, 18 should receive more (or less) ink 26. Accordingly, the control system 46 can send a signal to one or more actuators 30 to move the ink knife 21 or the ink knife segment 22 closer to or further from the ink rollers 10, 18. The movement of the drives 30 adjusts the gap 32 between the respective ink knife 21, 22 and the ink rollers 10, 18 to measure the adjusted amount of ink 26 for the corresponding axial ink section 20 rollers 10, 18 to form a satisfactory design 58. Additionally, the control system 46 can send a signal to at least one actuator 30 to adjust the axial position of at least one of the segments of the ink knife 24. In this way, the control system can, for example, change the alignment of the design. Likewise, in one embodiment, the control system 46 may send a signal to a drive associated with the ink roller 13. The signal may alter the operation of the ink roller 13 (for example, by changing the speed or frequency of the ink roller) to change the amount of ink transferred to the printing plate. 6, 14. In addition, the control system 46 can send a signal to the drive element to accelerate or decelerate one or more ink rollers and transfer rollers to change the amount of ink transferred to the printing plate.

In another embodiment, the control system 46 may determine that a misaligned or positioned appearance can be corrected by changing the alignment of one or more elements of the decorator 2. Accordingly, the control system 46 may send a signal to at least one actuator associated with the paint distribution unit 8, 16, ink roller 10, 18, plate cylinder ;, 12, printing plate 6, 14, blanket cylinder 36, blanket 38, and support cylinder 42. The signal can activate the drive for movement in a given direction. In this way, the control system 46 can correct a defect caused by misaligned or misaligned decoration. In one embodiment, control system 46 determines the cause of the defect by performing one or more of the steps of method 166 described in conjunction with FIG. 16.

In one embodiment, the control system 46 automatically controls the actuators 30. In another embodiment, the operator must confirm activation of the actuators 30 before the control system 46 sends a signal to the actuator 30. In another embodiment, the control system 46 automatically sends a signal to the actuator 30 after a predetermined amount of time has elapsed since the alarm is sent in step 104. The operator can cancel the scheduled adjustment of the ink knives 21, 22 for a predetermined amount of time. Accordingly, in one embodiment, the operator must confirm the adjustment of the ink knives 21, 22 scheduled by the control system 46.

The method 200 then returns to step 206 and ink 26 is transferred to the axial portions 20 of the ink roller using the adjusted settings of at least one of the ink knives 21, 22, or altered alignment of another decorator element. Method 200 again performs steps 208-218. After the adornment 58 generated with the adjusted settings is transferred to the metal container 54 in step 212, the method 200 again reads the adornment in step 216 and determines in step 218 whether the adornment is satisfactory. In one embodiment, the method 200 will alternatively wait for a predetermined amount of time before the metal container 54 with the shape 58 formed with the adjusted settings reaches one or more sensors 49E, 50. In one embodiment, the control system 46 does not sends signals to the actuators 30 for a certain period of time delay of step 214. In this method, the control system 46 does not send signals to the actuators 30 to correct defects that may conflict or override the adjustments of the ink knives 21, 22 sent by the control system 46 to eliminate a previously discovered defect.

At step 228, decorated metal containers 54 with satisfactory decoration 58 are transported by conveyor 48 to equipment 66 downstream of the decorator. The control system 46 at step 230 determines whether the production process should continue. For example, the control system 46 can determine that the production process should be stopped if there is a malfunction of the equipment, if there is a defect in the supply (such as a lack of paint or a defect in undecorated metal containers 52), after receiving a stop command from an operator, or when a preset has been decorated. the number of metal containers 54. If the control system 46 decides that the production process should continue, the method 200 on the YES link goes to step 206. If the production process is to be stopped, the method 200 on the NO link goes to the end step 232.

Now in FIG. 18 shows one embodiment of a method 238 for operating decorator 2 in accordance with the present invention. While FIG. 18 illustrates the general order of steps of method 238, method 238 may include more or fewer steps, or may arrange the order of steps differently than shown in FIG. 18. Additionally, although the steps of method 238 may be described sequentially, many of the steps may actually be performed in parallel or concurrently. In general, method 238 begins at start step 240 and ends at end step 260. At least a portion of the method 238 may be implemented as a set of computer-executable instructions that are executed by a computer system and encoded or stored on a computer-readable medium. One example of a computer system may include, for example, a control system 46. An example of a computer-readable medium may include, but is not limited to, the memory of the control system 46. Hereinafter, method 238 will be explained with reference to control system 46, decorator 2, and components described in conjunction with FIG. 1-17.

Method 238 begins at step 240. In one embodiment, undecorated metal containers 52 are supplied to decorator 2 from prior equipment 64. Alternatively, in another embodiment, metal containers are removed from storage.

The metal containers 52 are decorated by the decorator in step 242. The conveyor 48 transports the decorated metal containers 54 to the sensor 49, 50, which collects the decoration 58 generated by the decorator. In one embodiment, conveyor 48 transports decorated metal containers to sensor 49, 50 in the sequential order in which they were decorated. Control system 46 receives data from sensor 49, 50 in step 244.

The control system 46 then determines in step 246 whether the design is satisfactory or defective. The control system 46 can compare the data received from the sensor 49, 50 with a base image stored in memory. Alternatively, the control system 46 may determine if the design is satisfactory or defective, as determined in one or more blocks 158 of FIG. 15, step 172 in FIG. 16 and step 218 in FIG. 17. If the design 58 is satisfactory, the method 238 on the YES link proceeds to step 242. If the design is defective, the method 238 on the NO link proceeds to step 248.

At block 248, the control system 46 may determine if the decorator is responsible for the decorator 2. In one embodiment, the control system may determine that the decorator is responsible for the decorator when the data indicates that the deco contains a defect associated with at least one of such parameters. like color, density, thickness, alignment and consistency to the decoration. Specifically, the control system 46 may determine that the defective design is caused by one or more (but not limited to) such indicators as incorrect ink quantity, defective ink, defective printing plate or blanket, and misalignment of the printing plate, blanket or metal. container. In one embodiment, the control system 46 determines the cause of the defect, as described in FIG. 16. When the defect design is caused by the decorator, the method 238 on the YES link proceeds to step 250. Alternatively, when the defect design is not caused by the decorator 2, the method 238 on the NO link proceeds to step 252.

The control system 46 may alternatively, at step 250, send a signal to decorator 2 to correct the defective design. The signal can cause Decorator 2 to regulate one or more decorator components. In one embodiment, the signal is configured to cause at least the ink dispensing knife, printing plate, or blanket to move in a specified direction while the decorator is in operation.

More specifically, the signal can cause the actuator 30 to adjust the position of the ink knife 21 or portion 24 of the ink knife 22 to change the amount of ink transferred to the printing plate 6, 14, adjust the movement of the injector roller 13, change the position of the printing plate 6, 14 on the plate cylinder 4 , 12, move the printing cylinder 4, 12 relative to the ink device 11, 19 and / or the blanket cylinder 36, change the position of the blanket 38 on the blanket cylinder 36 and change the position of the support element 42 relative to the blanket cylinder 36. Additionally or alternatively, a signal can cause the element drive to rotate at least the ink roller 10, 18 and the transfer roller of the ink device 11, 19, to rotate faster or slower. In this way, the control system 46 can cause the decorator 2 to change at least one of such parameters as color, density, thickness, alignment, or consistency of subsequent decorations 58.

If the control system 46 determines that the defective design cannot be corrected without operator intervention, then the control system will not send a signal at step 250. For example, if the defective design is associated with one of the following: defective ink, defective printing plate, or defective blanket then the control system 46 will not send a signal.

At 252, the control system 46 may determine if the defect is caused by equipment 64 located in front of the decorator. As described herein, some defective designs are caused by damage to the undecorated metal container 52 by equipment located upstream of the decorator. The damage can be a gouge, a drawn image, or a scratch caused by pre-decorator equipment such as a carcass machine. Other equipment in front of the decorator, such as washers and ovens, can also damage the cylindrical surface 56 of the undecorated metal containers 52. A washer or oven may contaminate the cylindrical surface with, for example, stains, dirt or droplets. A damaged metal container can result in defective design 58 due to uneven or incomplete ink transfer of blanket 38 to cylindrical surface 56. Likewise, a stain on cylindrical surface can repel ink from blanket 38 or see through the ink.

The control system 46 can determine that the defect is caused by the prior equipment 64 in many ways. One way of determining that upstream equipment is causing the defective decoration is described in conjunction with block 182 in FIG. 16. Additionally, the control system 46 can determine that the equipment located upstream of the decorator is causing the defect based on the frequency at which the defect is observed. More specifically, if the defect does not occur in every metal container 54, then the defect is not caused by the printing plate 6, 14. If the frequency is not related to the number of blankets 38, then the defect is not caused by the blanket. So the defect is likely to be due to malfunctioning hardware upstream of decorator and not related to decorator 2.

In another embodiment, control system 46 may determine that pre-decorator equipment is causing the defect based on the location of the defect. More specifically, if the housing machine does not work properly and damages the metal containers 52, damage can occur at the same locations on a large number of metal containers. However, since the metal containers are not oriented relative to the blanket 38, when ink is transferred to the cylindrical surface 56, the damaged areas of the metal containers will align with different areas of the blankets. Accordingly, the damaged areas of the metal containers will be aligned randomly with respect to the design formed on the blankets 38. When the sensors 49, 50 collect data on the defective designs caused by damage to the decorator, the defect will not occur in the same place. On the contrary, the decorator problem will occur in the same place on every faulty layout.

Alternatively, in another embodiment, the control system 46 may determine that the equipment located upstream of the decorator is causing the defective design after an unsuccessful attempt to correct the defective design by sending a signal to the decorator 2 at step 250. If the sensors 49, 50 detect the defective design after adjustment decorator and the defective design is the same (or similar) to the previously observed defective design, the control system 46 can determine that the cause is the equipment preceding the decorator.

At block 254, the control system may determine that the cause of the defective design cannot be attributed to either the decorator or the equipment 64 located in front of the decorator. Additional data may be required to determine the cause of some defective designs.

At 256, the control system 46 may send an alarm to the operator. The alarm can be as described here. The alarm may contain information about the defective design observed by the control system 46. Additionally, the alarm may contain information about the reason for the defect (eg, due to decorator 2 or due to equipment 64 preceding the decorator) and measures taken by the control system 46 to correct the defect. Alternatively, the alarm may contain recommended actions for the operator to take to correct the defect.

The control system 46 may determine at block 258 whether the production process should continue. The control system 46 may determine that the manufacturing process should continue as described in steps 224, 230 of method 200. The manufacturing process may continue based at least in part on the error value assigned by the defect management system to the flaw. Additionally or alternatively, the control system 46 may consider the frequency of defect design, determining whether to continue with the manufacturing process. Additionally, in one embodiment, the control system 46 may send a signal to stop the production process if the cause of the defective design cannot be eliminated by a signal from the control system 46 to the decorator or equipment located upstream of the decorator. More specifically, in one embodiment, if the defective design is caused by one or more of defective ink, defective printing plate, defective blanket, or damaged metal container, the control system 46 will send a signal to stop the production process. In one embodiment, when the control system is unable to determine the cause of the defective design (at 254), the control system can decide that additional information should continue to be collected during production.

In one embodiment, the control system 46 may signal to stop pre-decorator equipment 64 after determining that equipment upstream of the decorator is causing the defective design. In one embodiment, the control system can send a signal to stop the equipment 64 located in front of the decorator after a predetermined number of defective metal containers caused by the equipment 64 upstream of the decorator have been observed. Alternatively, the predetermined amount can be determined by the operator. In one embodiment, the predetermined number can be from 25 to 50 metal containers within a predetermined amount of time.

When the control system 46 decides that the manufacturing process should continue, the method 238 on the YES link proceeds to step 242 and the decorator 2 continues to decorate the metal containers. Alternatively, method 238 with NO communication proceeds to end step 260.

Now in FIG. 19 shows one embodiment of a method 262 for operating a decorator 2 according to the present invention. While FIG. 19 illustrates the general order of steps of method 262, method 262 may contain more or fewer steps, or may arrange the order of steps differently than shown in FIG. 19. Additionally, although the steps of method 262 may be described sequentially, many of the steps may actually be performed in parallel or concurrently. In general, method 262 begins at start block 264 and ends at end block 280. At least a portion of method 262 may be implemented as a set of computer-executable instructions that are executed by a computer system and encoded or stored on a computer-readable medium. One example of a computer system may include, for example, a control system 46. An example of a computer-readable medium may include, but is not limited to, the memory of the control system 46. Hereinafter, method 262 will be explained with reference to control system 46, decorator 2, and components described in conjunction with FIG. 1-18.

In step 266, the decorator receives an undecorated metal container 52 from pre-decorator equipment 64. Decorator 2 then decorates the metal container 54 as described herein at step 266. The metal container 54 is transported by a conveyor 48 to a sensor 50 located in front of the equipment 66 located after the decorator, such like an oven. Additionally or alternatively, the metal container is transported by a conveyor 48 to a sensor 50A located downstream of the oven. At 268, the control system 46 receives data collected by the sensor 50, 50A.

At block 270, the control system determines if the layout 58 is satisfactory, as described herein. In one embodiment, control system 46 compares sensor data with data stored in a database. Specifically, the control system 46 can compare the sensor data with the base image. The base image can be provided by the user or the client. Alternatively, the control system can create a base image by reading a predetermined number of skins that are acceptable skins. Accordingly, the base image can be generated by the control system 46 by stitching together images of a plurality of acceptable layouts. If the clearance is satisfactory, the method 262 on the YES link proceeds to block 266 and continues to design the metal containers. If the design is unsatisfactory, the method 262 proceeds over the NO link to step 272.

At step 272, the control system 46 may determine if the cause of the defect can be corrected by the control system. The control system 46 can first determine the cause of the defective design. For example, a decoration may be defective due to one or more problems: (1) the color of the decoration; (2) density of decoration; (3) depth of decoration; (4) alignment of the layout; (5) consistency of decoration; (6) clearance position. Each of the problems 1-6 above can be fixed by adjusting the decorator component. Accordingly, if the control system determines that one of the six above-mentioned problems is the cause of the defective design, the problem can be corrected by the control system 46 sending a signal to decorator 2. Method 262 then proceeds to 274 via YES.

Alternatively, some of the causes of defective designs may not be suitable for correction by the control system. More specifically, the control system 46 may determine that the cause of the defective design is one or more of the following: (a) defective or contaminated paint; (b) defective or damaged printing plate; (c) defective or damaged blanket; (d) damaged outer surface of a metal container. If the cause of the defective design is one of the problems a-d listed above, the control system 46 cannot correct the defect by sending a signal to the decorator 2. Accordingly, the method 262 on NO communication proceeds to step 276.

At step 274, control system 46 may optionally send a signal to decorator 2. The signal may cause decorator 2 to adjust one or more components to correct the defective decoration. More specifically, the signal can cause the decorator to change at least one of the following parameters: color, density, thickness, alignment, and consistency of subsequent decorations. In one embodiment, the signal may change the setting or position of at least one of the following components: ink distribution unit, ink roller, ink roller, plate cylinder, printing plate on plate cylinder, blanket cylinder, and blanket of the container decorator. In another embodiment, the signal may change the rotational speed or position of one or more of the ink roller, transfer roller, plate cylinder, blanket cylinder, and decorator support 2. In one embodiment, the operator must confirm the change. Alternatively, in another embodiment, the control system can automatically send a signal to the decorator.

The control system 46 may optionally send an alarm to the operator at step 276. The alarm may be provided on a display screen. In one embodiment, the alarm may include a visual element and a sound element. In another embodiment, the alarm is a text message. An alarm can provide information related to the reason the design is defective. Information related to regulatory action to correct the defective design can also be included in the alarm.

At step 278, the control system 46 may determine if the production process should continue. In one embodiment, if the cause of the defective design cannot be corrected by the control system, the control system will send a signal to stop operation of one or more devices such as decorator 2 and its predecessor equipment 64. Other ways to determine whether to stop or continue the production process are described herein and may be used by the control system 46.

If the control system 46 decides that the manufacturing process should continue, the method 262 on the YES link proceeds to step 266. Alternatively, if the manufacturing process is to terminate, the method 262 on the NO link proceeds to step 280.

By providing additional background information, context, and to further meet the written requirements of §112 35 U.S.C., the following references are incorporated herein by reference in their entirety: US Patent 5,724,259; US Patent 5,992,318; US patent 6,142,078; US patent 6,178,254; US patent 6,184,988; US patent 6,543,350; US patent 6,867,423; US patent 7,013,803; US patent 7,017,492; PCT Publication WO 2013/113616; and PCT publication WO 2016/087876.

The description of the present invention has been presented for purposes of illustration and description, but it is not intended to be exhaustive or to limit the invention to the form disclosed. Numerous modifications and variations will be apparent to those skilled in the art. The embodiments described and shown in the drawings have been selected and described to best explain the principles of the invention, their practical application, and to enable those skilled in the art to understand the invention.

While various embodiments of the present invention have been described in detail, it will be appreciated that modifications and variations will occur to those skilled in the art. In addition, references made herein to "the present invention" or to its approaches are to be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments of the present disclosure. It should be clearly understood that such modifications and changes are within the scope and spirit of the present invention, as set forth in the following claims.

While the exemplary approaches, embodiments, options, and / or configurations shown herein demonstrate various system components located in the vicinity, some system components may be located remotely, in remote parts of a distributed network such as a local area network (LAN) and / or Internet, or within a specialized system. Thus, it should be understood that the components of the system can be combined in one or more devices, such as a personal computer (PC), laptop, netbook, smartphone, personal digital assistant (PDA), tablet, etc., or located in the neighborhood on a specific node in a distributed network, such as an analog and / or digital communications network, a packet switching network, or a circuit switched network. From the previous description and for reasons of computational efficiency, it should be understood that the components of a system can be located anywhere within a distributed network of components without affecting the operation of the system. For example, various components can be located on a switch such as a private branch exchange (PBX) and media server, gateway, one or more communication devices, one or more user premises, or some combination thereof. Likewise, one or more functional parts of the system may be distributed between the communication device (s) and the corresponding computing device.

Additionally, it should be understood that the various channels connecting the elements may be wired or wireless channels, or any combination thereof, or any other known or later developed element (s) that is capable of supplying and / or transmitting data to or from associated elements. These wired or wireless channels may also be secure channels and may be capable of transmitting encrypted information. The transmission medium used as the channels, for example, can be any suitable carrier of electrical signals, including coaxial cables, copper wire and optical fibers, and can take the form of acoustic or light waves, such as those generated during data transmission in range of radio waves and in the infrared range.

In addition, while the flowcharts have been discussed and illustrated with reference to a particular sequence of events, it should be understood that changes, additions, and deletions to this sequence may occur without materially affecting the operation of the disclosed embodiments, configurations, and approaches. Additionally, many variations and modifications of the disclosure can be used. It may be possible to present some features of the disclosure without presenting others.

Alternatively, the systems and methods of the present disclosure may be implemented in conjunction with a dedicated computer, programmed microprocessor or microcontroller, and peripheral integrated circuit element (s), ASIC or other integrated circuit, digital signal processor, hardwired electronic or logic circuitry such as discrete circuit, programmable logic device or gate array such as PLD, PLA, FPGA, PAL, dedicated computer, any comparable means, etc. In general, any device (s) or means capable of implementing the methodology shown herein can be used to implement the various approaches of this disclosure. Exemplary hardware that may be used for the disclosed embodiments, configurations, and approaches include computers, portable devices, telephones (e.g., cellular, Internet-enabled, digital, analog, hybrid, and others), and other hardware known in the art. ... Some of these devices contain processors (for example, single or multiple microprocessors), memory, non-volatile memory, input and output devices. Additionally, alternative software implementations including, but not limited to, distributed processing, distributed component / object processing, parallel processing, or virtual machine processing may also be designed to implement the methods described herein.

In one embodiment, the disclosed methods may be readily implemented in conjunction with software using object or object oriented software development environments that provide mobile source code suitable for use on a variety of computer or workstation platforms. Alternatively, the disclosed system may be implemented in part or in whole in hardware using standard logic circuits or ultra high level integration (VLSI) designs. Whether to use software or hardware to implement systems in accordance with the present disclosure depends on the speed and / or efficiency requirements of the system, the specific function and the specific software or hardware systems or microprocessor or microcomputer systems used.

In yet another embodiment, the disclosed methods may be implemented in part in software, which may be stored on a storage medium, executed on a programmed general purpose computer using a controller and memory, on a dedicated computer, microprocessor, or the like. In these cases, the systems and methods of this disclosure may be implemented as a program embedded in a personal computer, such as an applet, JAVA®, or computer-generated imagery (CGI) graphics, as a resource residing on a server or computer workstation. as a program embedded in a specialized measuring system, system component, etc. The system can also be implemented by physically incorporating the system and / or method into a hardware and / or software system.

Although the disclosure presented herein describes the nodes and functions implemented in approaches, embodiments, and / or configurations with reference to specific standards and protocols, the approaches, embodiments, and / or configurations are not limited to such standards and protocols. There are other similar standards and protocols not mentioned here that are believed to be contained in the disclosure provided. In addition, the standards and protocols mentioned here, and other similar standards and protocols not mentioned here, are periodically replaced with faster or more efficient equivalents that have essentially the same functionality. Such superseded standards and protocols having the same functions are considered equivalents contained in this disclosure.

Examples of processors described herein may include, but are not limited to, at least one such processor as Qualcomm® Snapdragon® 800 and 801, Qualcomm® Snapdragon® 610 and 615 with 4G LTE integration and 64-bit architecture, processor Apple® A7 64-bit architecture, Apple® M7 motion coprocessors, Samsung® Exynos® series, Intel® Core ™ processor family, Intel® Xeon® processor family, Intel® Atom ™ processor family, Intel Itanium® processor family, Intel® Core® i5-4670K and i7-4770K 22nm Haswell, Intel® Core® i5-3570K 22nm Ivy Bridge, AMD® FX ™ processor family, AMD® FX-4300, FX-6300, and FX-8350 32nm Vishera, Kaveri® processors , Texas Instruments® Jacinto C6000 ™ vehicle infotainment processors, Texas Instruments® OMAP ™ automotive grade mobile processors, ARM® Cortex ™ -M processors, ARM® Cortex-A and ARM926EJ-S ™ processors, other equivalent industrial processors, and may perform computing functions, isp Using any standard, command set, library and / or architecture known or developed in the future.

The disclosure presented in various approaches, embodiments, and / or configurations comprises components, methods, processes, systems, and / or devices substantially as depicted and described herein, including various approaches, embodiments, configurations, subcombinations and / or subsets thereof. Those of skill in the art upon studying the present disclosure should understand how to implement and use the disclosed approaches, embodiments, and / or configurations. The present disclosure, in various approaches, embodiments, and / or configurations, comprises provisioning devices and processes not present in the items shown and / or described herein or in various approaches, embodiments and / or configurations thereof, including such missing devices and processes. items that may have been used in prior devices or processes, for example, to improve performance, achieve ease of use, and / or reduce implementation costs.

Claims (63)

1. A device for monitoring and regulating the design formed on the outer surface of metal containers, containing a decorator including an ink distribution unit with a plurality of ink knives and an ink roller, a printing plate, a blanket and a support element for receiving the metal container and moving the metal container in contact with the blanket to transfer the design to the cylindrical outer surface of the metal container, each colorful the knife comprises a body extending from the first end wall to the second end wall, the axis protruding from the drive associated with each ink knife is in engagement with the first end wall; an oven located after the decorator for drying the paint used to form the decoration on the cylindrical outer surface of the metal container; a sensor located downstream of the furnace in the direction of travel to obtain data from predetermined target locations in a specified design on the cylindrical outer surface of a metal container, related to the quality of design; and a control system configured to receive data from a sensor and to compare said data with data stored in memory to determine if the design is defective, wherein the control system is configured to evaluate a plurality of data collection points associated with predetermined target locations in the data received from the sensor, and if the decoration is defective, the control system sends a first signal to adjust at least one of the following parameters: the ink knife of a plurality of ink knives and the rotation speed of the ink roller to eliminate the cause of the defective decoration. 2. The device according to claim 1, which comprises a rod chain conveyor for transporting the metal container from the support element through the oven and to the sensor, in which the sensor comprises from three to six image capturing devices arranged in a predetermined orientation to read portions of the cylindrical outer surface of the metal container, while the image capturing devices are located so as not to interfere with the movement of the rod chain conveyor. 3. The device according to claim 1, in which the control system is configured to determine whether the defective decoration is associated with at least one of the following indicators: decoration color, decoration density, decoration depth, decoration alignment, decoration consistency and decoration position, and the sensor is configured to collect data on one or more of the following indicators: decoration color, decoration density, decoration depth or thickness, decoration alignment, decoration consistency, decoration position, and shape of the metal container. 4. The apparatus of claim. 1, wherein the control system is configured to determine the delay time that occurs after the said first signal is sent to eliminate the cause of the defective design and when the metal container with the corrected design reaches the sensor. 5. The device according to claim 1, which is configured to send a first signal to a drive associated with the ink knife to change the amount of ink supplied to the blanket during decorator operation, said axis having a distal end held in an inner hole, passing into said first end wall, the first signal causing the distal end to move deeper into the inner opening, while the inner opening does not pass through the second end wall. 6. The device according to claim 5, which comprises a second ink distribution unit with a plurality of second ink knives for transferring the second ink to the second printing plate, wherein if the control system detects a design defect due to an inappropriate amount of second ink from the second ink distribution unit, the control system configured to send a second signal to the second drive for adjusting the second ink knife from the specified plurality of second ink knives to change the amount of the second ink transferred to the second printing plate area and then to the blanket, the second drive comprising an axis inserted into the second ink knife ... 7. The apparatus of claim 1, wherein each ink knife has a longitudinal axis and said axis of a drive associated with each ink knife is approximately concentrically aligned with said longitudinal axis. 8. The device according to claim 1, in which the control system is configured to: determining the starting position of each of the plurality of colorful knives based on the decoration image stored in the database; and sending a signal to an actuator associated with each of the plurality of ink knives to move each ink knife to its starting position before starting the metal container decorating production run. 9. The device according to claim. 1, in which the control system is configured to determine the color change, expressed as ΔE between the target color of the decoration and the actual color of the decoration, measured by the sensor, while the control system is configured to send the first signal to eliminate the cause of the defective design when ΔE is in the range from about 5% of the target value to about 15% of the target value. 10. A method for optimizing the decoration formed by a decorator on a cylindrical outer surface of a metal container, characterized in that: provide a metal container; a metal container is fed into a decorator, which includes a paint distribution unit with an ink roller and a plurality of ink knives, wherein each ink knife comprises a housing extended between the first end wall and the second end wall, the drive being connected to each ink knife by an axis extending from the front the side of the drive, which is engaged with the first end wall; an impression cylinder with a printing plate, blanket cylinder with blanket and a support member for moving the cylindrical outer surface of the metal container in contact with the blanket; determining, by means of a control system, the starting positions for each of the plurality of colorful knives; decorate the cylindrical outer surface of the metal container using a decorator; positioning the metal container on the bar chain conveyor; transporting the metal container on a bar chain conveyor through the decoration paint drying oven; transporting the metal container on a rod chain conveyor after passing through a plurality of image capturing devices located downstream of the oven; a captured image of the design is obtained on the cylindrical outer surface of the metal container using an image capturing device; comparing with the help of the control system the specified captured image with the image stored in the memory of an acceptable design; the control system evaluates a plurality of acquisition points associated with multiple target areas of the cylindrical outer surface in a captured image obtained from the image capturing devices; determining, using the specified control system, whether the decoration in the captured image meets the density quality parameters corresponding to one or more criteria; the control system detects a color change between the target adornment color value and the actual adornment color in the captured image; and a signal is sent by said control system to adjust at least one of the following parameters: the position of the ink knife of a plurality of ink knives and the rotation speed of the ink roller of the paint distribution unit to change at least one of the following parameters: color, density, thickness, and consistency ink transferred to the blanket when the color change is between about 5% of the target value and 15% of the target value. 11. A method according to claim 10, wherein said signal causes a drive with an axis inserted into the ink knife to move in a specific direction of the ink knife during decorator operation, wherein the end of the axis is located inside an inner hole formed in the ink knife body, and which has an opening in a first end wall, the first drive side being oriented towards the first end wall of the ink knife. 12. The method of claim 10, wherein said signal changes the rotation speed of the ink roller located in front of the printing plate during decorator operation. 13. The method according to claim 10, wherein is determined by the control system that the design is defective due to an inappropriate amount of both the first paint from the first paint distribution unit and the second paint from the second paint distribution unit, while the signal from the control system causes the drive with the axis inserted in the paint knife to move the paint of the knife in the first direction, and the control system sends a second signal to the second actuator with the axis inserted into the second ink knife of the second ink distribution unit to move the second ink knife in the second direction. 14. The method according to claim 10, wherein additionally, when the captured image does not meet the density quality parameters, the control system determines that the decoration is defective for one or more of the following reasons: inappropriate ink quantity, defective ink, defective printing plate, defective blanket, inappropriate decorator component alignment, and damage to the metal container; and a decorator stop signal is sent by the control system after determining that the decoration is defective due to at least one of the following reasons: defective ink, defective printing plate or defective blanket. 15. The method of claim 10, wherein the control system determines a delay time that occurs after the signal is sent to clear the defect before the second metal container with the redefined shape reaches the image capturing devices. 16. A computer-readable medium for long-term storage of information, containing a set of instructions stored on it, which, when executed by the processor of the control system during the operation of the decorator of metal containers, cause the processor to adjust the decorator component of metal containers, while retrieving the design image from the database; determining a starting position for each of the plurality of colorful knives of the metal container decorator based on said image; receiving data from a sensor, said data being associated with a paint of a decoration formed by a metal container decorator on the cylindrical outer surface of the first metal container, the paint being dry when the sensor collects data; comparing said data with an image, the control system evaluating a plurality of data collection points associated with multiple target areas in the data received from the sensor; determining whether the decoration on the cylindrical outer surface of the first metal container contains a defect associated with at least one of the following indicators: color, density, thickness, alignment and consistency of the decoration; prepare a team for a decorator of metal containers to eliminate the cause of the defect; and send a command to the metal container decorator to adjust the position of the colorful knife from the plurality of colorful knives to eliminate the indicated defect, and determine the delay time that occurs after the command is sent to eliminate the cause of the defect until the second metal container with the corrected design reaches the sensor located after the furnace in the direction of travel. 17. The computer-readable medium of claim 16, wherein sending the command causes the decorator to change the metal containers at least one of the following: color, density, thickness, alignment and consistency of subsequent designs, wherein when the sensor collects data, the first metal container located on the bar chain conveyor. 18. The computer-readable medium of claim 16, further comprising sending a stop signal for the metal container decorator after determining that the defective design is due to one or more of the following: defective ink, defective printing plate, or defective offset cover of the metal container decorator. 19. The computer-readable medium of claim 16, wherein said command causes the drive to move the ink knife generally parallel to the longitudinal axis of the ink knife to increase or decrease the amount of ink transferred to the printing plate of the metal container decorator, wherein the drive comprises a first side oriented towards the first end of the ink knife, the opening extending at the first end of the ink knife, and an axis that protrudes from the first side of the actuator comprises a distal end located within the opening. 20. The computer-readable medium of claim 16, wherein the command causes the drive to move the axis in the first direction so that the ink knife moves closer to the ink roller, thereby reducing the amount of ink transferred to the printing plate, with the axis extending in generally linearly between the drive and the colorful knife. 21. The computer-readable medium of claim 16, further comprising sending a signal to an actuator associated with each of the plurality of ink knives to move each ink knife to its starting position. 22. The computer-readable medium of claim 16, wherein the metal container decorator comprises a first ink distribution unit containing a plurality of ink knives, a first printing plate associated with the first ink distribution unit, a second ink distribution unit containing a plurality of second ink knives, a second printing plate associated with a second ink distribution unit, a blanket and a support element for moving the cylindrical outer surface of the first metal container in contact with the blanket. 23. The computer-readable medium of claim 22, wherein the defect is associated with an inappropriate amount of ink and the commands cause the processor to detect one or more ink knives of the first ink distribution unit and the second ink distribution unit to adjust to correct the defect. 24. A computer-readable medium according to claim 16, wherein the control system comprises: memory; input device; output device; and a processor associated with memory, input device, and output device. 25. A computer-readable medium according to claim 16, further comprising: detecting the change in paint color between the target paint value of the decoration and the actual color of the decoration, which is detected by the sensor; and sending a command to the decorator when the color change is between about 5% of the target and 15% of the target.

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