Abstract
The present invention relates to an apparatus for mounting a flexible plate onto a print sleeve or cylinder, wherein the apparatus comprises at least two manipulator units located below the print sleeve or cylinder and support members provided on each manipulator unit, wherein each support member has a curved profile for arching the flexible plate prior to its mounting onto the print sleeve or cylinder
Claims
1. An apparatus for mounting a flexible plate onto a print sleeve or cylinder, wherein the apparatus comprises at least two manipulator units located below the print sleeve or cylinder and support members provided on each manipulator unit, wherein each support member has a curved profile for arching the flexible plate prior to its mounting onto the print sleeve or cylinder.
2. Apparatus according to claim 1, wherein the apparatus comprises a manipulator deck having a substantially curved profile for providing additional support to the arched flexible plate.
3. Apparatus according to claim 2, wherein at least part of the manipulator deck comprises a dimpled surface, preferably a raised dimpled surface.
4. Apparatus according to claim 2, wherein the manipulator deck comprises a motor for moving the manipulator deck between lowered and raised positions in a direction perpendicular to the axis of the print sleeve or cylinder.
5. (canceled)
6. Apparatus according to claim 1, wherein each support member comprises one or more apertures.
7. Apparatus according to claim 1, wherein each manipulator unit comprises vacuum means for temporarily securing the flexible plate to the surface of the support member.
8. Apparatus according to claim 1, wherein each manipulator unit comprises a camera operatively connected to a display screen, said camera being oriented upwards for viewing registration marks present on the flexible plate.
9. (canceled)
10. Apparatus according to claim 1, wherein each manipulator unit comprises a motor for adjusting the manipulator unit in an axial direction and/or a motor for adjusting the manipulator unit in a radial direction.
11. (canceled)
12. (canceled)
13. Apparatus according to claim 1, wherein each manipulator unit is independently controllable.
14. Apparatus according to claim 1, wherein the apparatus comprises a roller for rolling the flexible plate onto the print sleeve or cylinder.
15. (canceled)
16. Apparatus according to claim 1, wherein each manipulator unit comprises plate support wings.
17. (canceled)
18. Apparatus according to claim 16, wherein at least part of the plate support wing comprises a dimpled surface, preferably a raised dimpled surface.
19. Method for mounting a flexible plate onto a print sleeve or cylinder, the method comprising the steps of: providing a print sleeve or cylinder; providing a flexible plate having a relief surface; applying the flexible plate onto a support member, wherein the relief surface of the flexible plate faces the support member and wherein the support member is located below the print sleeve or cylinder and has a curved profile for arching the flexible plate; aligning the arched flexible plate with the print sleeve or cylinder, and mounting the flexible plate onto the print sleeve or cylinder.
20. Method according to claim 19, wherein the flexible plate is applied onto at least two support members, wherein the relief surface of the flexible plate faces each support member.
21. Method according to claim 20, wherein each support member is mounted onto a manipulator unit, and wherein the position of each manipulator unit is adjusted axially and/or radially to align the manipulator units with registration marks present on the arched flexible plate.
22. (canceled)
23. Method according to claim 21, wherein the step of aligning each manipulator unit with the registration marks on the arched flexible plate is an automated process and/or confirmed by visual inspection.
24. (canceled)
25. Method according to claim 21, wherein the manipulator units together move the arched flexible plate to a first mounting position below the print sleeve or cylinder.
26. Method according to claim 25, wherein the manipulator units are moved to a first mounting position below the print sleeve or cylinder before the flexible plate is applied onto the support members.
27. Method according to claim 25, wherein a first part of the flexible plate is brought into the print sleeve or cylinder by moving the manipulator units in a direction perpendicular to the axis of the print sleeve or cylinder until contact between the first part of the flexible plate and the print sleeve or cylinder is made.
28. Method according to claim 19, wherein the flexible plate is mounted onto the print sleeve or cylinder using a roller which rolls the flexible plate onto the print sleeve or cylinder.
29-30. (canceled)
Description
DETAILED DESCRIPTION OF THE INVENTION
[0038] In order that the invention may be more clearly understood an embodiment thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:
[0039] FIG. 1 shows a perspective view of a plate positioning and mounting apparatus according to the present invention.
[0040] FIGS. 2A-B show perspective views of a manipulator unit according to the present invention.
[0041] FIG. 3 shows a perspective cut away view of the manipulator deck according to the present invention.
[0042] FIG. 4 shows a cross-sectional view of the manipulator deck in its lowered position.
[0043] FIG. 5 shows a cross-sectional view of the manipulator deck in its raised position.
[0044] FIGS. 6A-G show perspective views of the plate positioning and mounting apparatus in use when mounting a flexible plate onto a sleeve.
[0045] FIG. 7 shows a perspective view of the plate positioning and mounting apparatus with plate support wings.
[0046] FIG. 1 shows a plate positioning and mounting apparatus 1 according to the present invention. The apparatus 1 is provided with a rotatable mandrel 2 that supports a removable sleeve 3. Provided below mandrel 2 and sleeve 3 is a manipulator deck 4 that houses a pair of manipulator units 5. A support member 6 is mounted onto each manipulator unit 5, with each support member 6 comprising a plurality of apertures 7. Each manipulator unit 5 comprises a camera (not shown) located below its respective support member 6, said camera being oriented through an aperture 7 in the direction of mandrel 2 for viewing registration marks (not shown) on a flexible plate (not shown) applied onto the support member 6. The apparatus 1 further comprises a roller (not shown) for rolling the flexible plate onto the sleeve 3, a display screen 8 operatively connected to the camera and a foot control 9 for manual intervention.
[0047] FIGS. 2A-B show a manipulator unit 5. The support member 6 has a curved profile for supporting and arching a flexible plate 10. The support member 6 in the form of a platen comprises a metal plate member 11, the upper surface of which is provided with a layer of a resilient material 12 such as rubber. The support member 6 is provided with apertures 7a, which in use, enable the flexible plate 10 to be temporarily secured to the support member 6 by vacuum means 13. The support member 6 comprises a further aperture 7b that functions as a viewing hole for a camera 14 so that registration marks (not shown) on the flexible plate 10 may be viewed and aligned with the manipulator unit 5 by using an automated alignment process.
[0048] FIG. 3 shows a perspective view of the manipulator deck 4. The manipulator deck comprises a body 15. The body 15 comprises walls 16, the upper parts of which extend radially inwards to define a gap 17. The body 15 has a profile that is suitable for maintaining the arched profile of the flexible plate 10 once it has been applied onto support member 6. A roller 18 in its parked position is located under the radially inwardly extending wall 16 and is programmed to move along a programmed path, horizontally and in a direction perpendicular to the axis of the mandrel 2, with the position of the roller being controlled by a plurality of pneumatic or electric actuators 19. The manipulator deck further comprises a hollow body 20 that extends along the longitudinal axis of the manipulator deck 4. The hollow body 20 having a substantially square cross-section supports a guide rail 21. The guide rail 21 extends substantially along the length of the hollow body 20. Mounted onto to the guiderail 21 is a platform 22 that is axially movable along the guiderail 21. As best shown in FIGS. 4 and 5, the platform 22 is connected to the manipulator unit 5 via an axially extending arm 23. This enables the manipulator unit 5 to move axially along the guiderail 21 as required during positioning and mounting operations.
[0049] FIGS. 4 and 5 both show cross-sectional views of the manipulator deck 4. The manipulator deck 4 is fixed to a collar 24 that is slidably moveable along a beam 25 that extends upwardly in a direction substantially perpendicular to the axis of the mandrel 2. This assembly allows the manipulator deck 4 to be moved between lowered (as shown in FIG. 4) and raised positions (as shown in FIG. 5) as required. The manipulator deck may be lowered and raised automatically by a motor.
[0050] FIGS. 6A-G show perspective views of the plate positioning and mounting apparatus 1 in use when mounting a flexible plate 10 onto a sleeve 3.
[0051] FIG. 6A shows the manipulator deck 4. The manipulator units 5 are located in their park positions at opposite ends of the manipulator deck 4. Each manipulator unit 5 has a motor (not shown) for moving the manipulator units 5 in an axial direction during positioning and mounting operations. As shown in FIG. 6B, the manipulator units are centralised and positioned at theoretical target positions prior to applying the flexible plate 10 over the manipulator units 5. The flexible plate 10 is then inverted and draped over the manipulator units 5 thereby forcing the flexible plate 10 into an arched profile (FIG. 6C). The manipulator deck 4 having a substantially curved profile provides additional support and helps maintain the arched profile of the flexible plate 10. The flexible plate 10 comprises two registration marks (26a, 26b) along its centre line. The locations of the registration marks (26a, 26b) are pre-programmed into a video recognition control system (not shown). Each manipulator unit 5 is then independently controlled by a computer program to seek and find the registration marks (26a, 26b) on the inverted, arched flexible plate 10. The position of each manipulator unit 5 may be adjusted axially as required, and for fine adjustments, the position of the support member 6 can also be adjusted in a radial direction. Once the program and/or operator is satisfied that the arched flexible plate 10 is appropriately aligned on the support members 6 of the manipulator units 5 (by software or visual inspection of the display screen 8) a vacuum may be applied in order to temporarily secure the arched flexible plate 10 to the surface of the support member 6. A vacuum suction device 13 mounted below the support member 6 is suitable for this purpose. The video recognition control system is also pre-programmed with one or more axial positions for accurately aligning the arched flexible plate 10 with the sleeve 3 prior to the mounting operation. As best shown in FIG. 6D, the manipulator units 5 together transport the arched flexible plate 10 to a first axial position below mandrel 2 onto which sleeve 3 has been mounted. Then, the manipulator deck 4 is moved into a raised position (FIG. 5) until contact is made between a first part of the arched flexible plate 10 and double sided adhesive tape (not shown) provided on sleeve 3. The vacuum is subsequently turned off and the manipulator deck 4 is lowered allowing the manipulator units 5 to return to their respective parked positions at opposite ends of the manipulator deck 4. The roller 8 is thereafter raised, appropriately aligned and brought into contact with the centre line of the flexible plate 10. The roller 8 comprises a rubber surface layer which enables an even pressure to be applied to the surface of the flexible plate 10 as the flexible plate 10 is rolled onto the sleeve 3. This ensures that air pockets are not formed between the flexible plate 10 and the sleeve 3 during the mounting operation. The mandrel 2, which is a motor driven rotatable air mandrel, is then rotated in a first direction to wrap one end of the flexible plate around the sleeve 3. To complete the mounting operation, the rotational direction of the mandrel 2 is reversed so as to wrap the other end of the flexible plate 10 around the sleeve 3. Following its programmed path, the roller 8 is retracted back to its park position and the manipulator units 5 with their cameras 14 return to their first axial positions in order to assess whether the position of the mounted flexible plate 10 corresponds with the programmed position. The automated system may thereafter advise the operator of any differences in the mounted and programmed positions. The process is repeated as shown best in FIGS. 6E-6G until the sleeve 3 is fully mounted with the required number of plates 10, in this case three. The sleeve 3 with flexible plates 10 mounted thereon is removed from the mandrel 2 and replaced by a new sleeve 3 for mounting further flexible plates 10 as required.
[0052] FIG. 7 shows a perspective view of the plate positioning and mounting apparatus 1 which has been provided with plate support wings 27a, 27b. In this embodiment a rectangular body 28 is integrally formed with and extends between the two plate support wings 27a, 27b. Each support wing 27a, 27b comprises a dimpled surface 29 and is adapted to follow the profile of the radially inwardly extending deck walls 16. As best shown in FIG. 7, the lower portion of each wing 27a, 27b comprises raised dimples 29 in a regular layout. In use, the rectangular body 28 extends across the gap 17 defined by the radially inwardly extending walls 16 and is attached to a manipulator unit 5 using suitable fastening means (not shown) so that the flexible wings are able to move with the manipulator unit. Such an arrangement ensures that the flexible plate 10 experiences reduced frictional drag from the surface of the manipulator deck walls 16 as the flexible plate 10 is transported from one end of the apparatus 1 to a mounting position below the print sleeve 3. The above embodiment is described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims.
