Abstract
A method for monitoring production of a fluid film, including: activating a dispenser to deliver appropriate material from a storage duct to a metering system for even distribution of a fluid film; allowing the fluid film to pass a sample retrieving roller; measuring the fluid film on the sample retrieving roller using a data reading device to obtain film thickness data; transmitting the data to an analyzer to examine the data against a predetermined reference value; transmitting a comparison result in real time by the analyzer to a production equipment controlling console; controlling the storage duct to dispense material through the material metering system and adjusting the film thickness; repeating the above steps to make a film thickness within the reference range; and maintaining the thickness at the narrowest tolerance deviation, and continuously delivering the film onto a substrate for production.
Claims
1. A method for monitoring the production of a fluid film and for delivering the fluid film onto a substrate comprising the steps of: a) activating a dispenser to deliver an amount of raw material through a first path from a storage duct to a metering system and distributing the amount of raw material from the metering system to produce a fluid film; b) allowing the fluid film to pass through the first path to a sampling roller; c) measuring the fluid film on the sampling roller using a data reading device to obtain a film thickness; d) comparing the film thickness with a predetermined reference value and producing a comparison result; e) transmitting the comparison result in real time to a production equipment controlling console; f) adjusting the amount of the raw material by the production equipment controlling console according to the comparison result; g) setting a tolerance deviation, and repeating a)-f) to obtain a fluid film having a film thickness within the tolerance deviation from the predetermined reference value; and h) only subsequent to g), continuously delivering the fluid film having the film thickness within the tolerance deviation from the predetermined reference value obtained in g) through a second path from the metering system onto a substrate.
2. The method of claim 1, wherein the fluid film is a printing ink film.
3. The method of claim 1, wherein a pre-determined neutral black value is treated as a reference value for related primary and subsequent neutral grey component color printing units, and based on the pre-determined neutral black value, the analyzer calculates the reference value for each color printing unit.
4. A method of delivering a fluid film onto a substrate comprising the steps of: a) dispensing an amount of a fluid through a first path from a metering system onto a sampling roller to form a fluid film on the sampling roller; b) measuring a film thickness of the fluid film on the sampling roller; c) comparing the measured film thickness of the fluid film on the sampling roller with a predetermined reference value; d) adjusting the amount of the fluid dispensed from the metering system onto the sampling roller such that the film thickness of the fluid film on the sampling roller is within a tolerance deviation from the predetermined reference value; and e) only subsequent to step d), continuously delivering an amount of the fluid through a second path from the metering system onto a substrate to form a fluid film on the substrate having a film thickness that is also continuously within the tolerance deviation from the predetermined reference value.
5. The method of claim 4, wherein the fluid film is a printing ink film.
6. The method of claim 4, wherein a pre-determined neutral black value is treated as a reference value for related primary and subsequent neutral grey component color printing units, and based on the pre-determined neutral black value, the reference value is calculated for each color printing unit.
7. The method of claim 1, wherein step c) is performed with a single scanning head that is traveled back and forth over the sampling roller.
8. The method of claim 1, wherein step c) is performed with a plurality of scanning heads placed along the sampling roller.
9. The method of claim 4, wherein step b) is performed with a single scanning head that is traveled back and forth over the sampling roller.
10. The method of claim 4, wherein step b) is performed with a plurality of scanning heads placed along the sampling roller.
11. A method of delivering a fluid film onto a substrate comprising the steps of: (1) using a data reading device to pre-examine a film thickness and to determine an even metering volume by: (a) dispensing an amount of a fluid film through a first path onto a sampling roller; (b) measuring a film thickness of the fluid film on the sampling roller; (c) comparing the measured film thickness of the fluid film on the sampling roller with a predetermined reference value; (d) adjusting the amount of the fluid film dispensed onto the sampling roller such that the film thickness of the fluid film on the sampling roller is within a tolerance deviation from the predetermined reference value; and (e) using the adjusted amount of the fluid film dispensed onto the sampling roller to determine an even metering volume; (2) delivering an amount of material to a metering unit that corresponds with the determined even metering volume; and (3) using the metering unit to deliver the amount of material through a second path onto a substrate as a fluid film only when a film thickness of the fluid film on the substrate is also continuously within the tolerance deviation from the predetermined reference value.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1: a schematic diagram of an initiative proactive fluid type films controlling method and device.
(2) FIG. 2: a schematic diagram of an initiative proactive fluid type films controlling method and device with adoption of the neutral gray balance monitoring system.
(3) FIG. 3: a schematic diagram of an initiative proactive fluid type films controlling method and device, each production color unit has its own individual inking control and continuously maintain the color correction continuously and each production color unit does not have any grey color balance relationship.
(4) FIG. 4: a schematic diagram of an internal type single unit data reading device, back and forth measuring.
(5) FIG. 5: a schematic diagram of an external type single unit data reading device, back and forth measuring without sampling roller attachment.
(6) FIG. 6A: a schematic diagram of an external type single unit data reading device, back and forth measuring with sampling roller attachment.
(7) FIG. 6B: a three-dimensional diagram of an external type single unit data reading device, back and forth measuring with sampling roller attachment.
(8) FIG. 7A: a schematic diagram of a fixed external type single unit data reading device with adoption of the rotational mirror or similar device, by diffract the measuring angle direction back and forth the sampling roller.
(9) FIG. 7B: a three-dimensional diagram of external type single unit data reading device.
(10) FIG. 8A: a schematic diagram of a fixed external type single unit data reading device with adoption of the mirror or similar device, by diffract 90 degree the measuring angle back and forth the sampling roller, and this system has attached with the sampling roller.
(11) FIG. 8B: a three-dimensional diagram of an external type single unit data reading device.
(12) FIG. 9: a schematic diagram of a fixed internal type multi unit data reading device measuring.
(13) FIG. 10: a schematic diagram of an external type multi unit data reading device without the sampling roller attachment.
(14) FIG. 11A: a schematic diagram of an external type multi unit data reading device with the sampling roller attachment.
(15) FIG. 11B: a three-dimensional diagram of external type multi unit data reading device with the sampling roller attachment.
(16) FIG. 12: Laser theory
(17) FIG. 13: a schematic diagram of a laser distance measurement of the bare sampling roller without carrying the color film.
(18) FIG. 14: a schematic diagram of a laser distance measurement of the sampling roller carrying with the color film.
(19) FIG. 15: Ultrasonic theory
(20) FIG. 16: a schematic diagram of an ultrasonic distance measurement of the bare sampling roller without carrying the color film.
(21) FIG. 17: a schematic diagram of an ultrasonic distance measurement of the sampling roller carrying with the color film.
(22) FIG. 18: a schematic diagram of an optical color density and color gamut value reflection measurement.
(23) FIG. 19: a schematic diagram of an optical color density and color gamut value transmission measurement.
(24) FIG. 20: Look up table for Ink film thickness, color density, and color gamut value.
(25) FIG. 21: Grey balance color value determination, measurement, analyzing, calculation, and correction execution control circuit diagram.
(26) FIGS. 22, 23: Fluid type film direct correction system and device schematic diagram.
(27) FIGS. 24, 25: Fluid type film in-direct correction system and device schematic diagram.
(28) FIG. 26: The proactive intelligent controlling method for fluid printing ink film thickness value vs the traditional passive system color film thickness controlling method.
DETAILED DESCRIPTION OF THE EMBODIMENTS
(29) The following embodiments of this invention with the content for further elaboration:
Example 1
Initiative Proactive Intelligent Controlling Method and Application Device for Fluid Type Films
(30) See FIG. 1, an initiative proactive intelligent controlling method for fluid type films device comprises a production control system console 7, production units 1, 2, 3, and 4, metering unit 52, a data reading device 5, and a referencing quality analyzing system 6.
(31) To implement this invention which is a kind of initiative proactive intelligent controlling method for fluid type films device comprising: entering the predetermined metering material reference value to the analyzing device 6 as the monitoring reference usages. The analyzing device determines the metering film thickness from the look up table (table 20) which is the relationship between the film thickness and material requirement value. By giving command to the dispensing system for delivering the appropriate amount of material to the metering unit 52 and execute the even film metering via the sampling roller 9; operate the data reading device 5 to measure the film thickness from the sampling roller 9, obtain the data and transmits to the analyzing system 6 against the film thickness reference for comparison. If the comparison result is not acceptable, the analyzing system 6 will deliver in real time the film thickness correction value to the production control system 7 for controlling the dispensing system through the metering unit to correct the production film thickness. The above description is a repeatedly operation process, it can rapidly provide the film thickness to achieve the reference range, and maintain within the narrowest tolerance deviation, continuously deliver onto the substrate for production. It can maintain the highest quality result and achieve the closest tolerance as well as minimum wastage. For each production unit, the even film thickness does not have any color balance relationship, the operator can freely determine the film thickness setting to achieve the product requirement.
(32) Any similarity of the following examples' methodologies and devices to this example will not be repeated.
Example 2
Initiative Proactive Intelligent Controlling Method and Application Device for Fluid Type Films with the Adoption of the Neutral Grey Balance Production Technology
(33) See FIG. 2, a device comprises a production control system 7, production units 1, 2, 3, and 4, metering unit 52, data reading device 5, and the neutral grey balance comparison system 6. Based on the pre-determined printing color sequencing order, freely place the black, cyan, magenta, and yellow ink onto the printing units 1, 2, 3, and 4. Enter the pre-determined black ink value to the neutral grey balance analyzing device 6 as the neutral grey balance requirement referencing usages. The analyzing device will determine the metering film thickness from the look up table (table 20) which is the film thickness and material dosage value. The black, cyan, magenta, and yellow inking unit data reading device 5 will measure the film thickness from the sampling roller 9, by using the initiative and proactive method to provide the neutral grey balance information to the analyzing device 6 to compare with the pre-determined black inking value. If it is not acceptable, it calculates the grey balance value for the neutral grey balance component colors to determine the correction ink film thickness value, and transmit to the production control system 7, by giving command to each printing unit inking dispensing system to deliver the appropriate amount of printing ink to the metering unit 52 and execute the ink film metering. The above process is a repeated operation, it can be highly accurate to provide the film thickness for achieving the reference range and maintaining within the tolerance, before delivering to the production line for production, as it is an initiative proactive mode, automatically makes correction in real time bases, continuously maintain the highest quality result and achieves at the closest tolerance as well as minimum wastage.
Example 3
Initiative Proactive Intelligent Independent Production Controlling Modular for Controlling the Fluid Type Film Thickness
(34) See FIG. 3, for example in each printing unit, the special color ink can be chosen in printing unit 1 for production. The data reading device 5 will initiatively and proactively measure the color data from each ink zone. The unevenness ink zone result will be sent directly to such unit's ink zone controller 8 in real-time for repeated adjustment, without using the production control system 7 for correction. The operator can also use the production control system 7 as the optional choice for changing the ink value(s). Any similarity to this embodiment will not be repeated.
Example 4
Built-in Monitoring Type of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(35) See FIG. 4, provided is a housing of the production equipment 13. A single data reading device is attached to the drive shaft 10, the data reading device 5 travels back and forth as the arrow direction along the drive shaft 10, carries the scanning head back and forth, accurately reads the ink film thickness from the surface of the ink film thickness sampling roller 9. Using optical, electronic, digital transmission connection 11 delivers the data to the PLC programmable control device 12 for digitize the reading; it is an initiative and proactive production system for continuous monitoring and correction usages.
Example 5
Independent Single Piece External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(36) See FIG. 5, the production machine is not equipped with a sampling roller. This invention system needs to design an independent mechanical anchorage device, equipped with a frame 40, by using fastening screws 41 to secure the connection bars 42 against the production machine's metering system housing 13. Drive shaft 10 is equipped with a single data reading device 5 with operating back and forth as the arrow indication direction and working along the drive shaft 10, to accurately scan the ink film thickness from the surface of the sampling roller 9 for the thickness value. Any similarity to this example will not be repeated.
Example 6
Independent Single Piece External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(37) See FIGS. 6A, 6B, the system is equipped with a sampling roller. The system basic functionality is similar to that of FIG. 5, and the only different is that the ink film thickness sampling roller 9 is installed at the frame 40 as part of the single piece monitoring modular. Any similarity to the embodiment 4 will not be repeated.
Example 7
Independent Single Piece External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(38) See FIGS. 7A, 7B, the system is equipped with a sampling roller. The system needs to design an independent anchorage device, equipped with an installation frame 40, by using fastening screws 41 to secure the connection bars 42 against the production machine metering system housing 13. A single data reading device 5 is fixed onto the bracket. The reading device can collect the ink film thickness from the rotational reflector or similar reflection device, by changing the angle of measurement in between the sampling roller 9 surface, to accurately scan the ink film thickness for reading the value. Any similarity to the example 4 will not be repeated.
Example 8
Independent Single Piece External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(39) See FIGS. 8A, 8B, the system is equipped with a sampling roller. The system needs to design an independent mechanical anchorage device, equipped with an installation frame 40, by using fastening screws 41 to secure the connection bars 42 against the production machine metering system housing 13. A single data reading device 5 is fixed inside the frame 40, the reflector or similar reflective device is attached to the drive shaft 10, back and forth traveling as arrow indicated direction, the reflector or similar reflective device has changed the measurement direction by 90 degree angles between the sampling roller 9 surface. Any similarity to the example 4 will not be repeated.
Example 9
Built-in Type Multi Units Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(40) See FIG. 9, the production equipment housing 13 with permanent frame equipped with multi data reading devices 5, accurately read the film thickness values from the surface of the film thickness sampling roller 9. Any similarity to the example 4 will not be repeated.
Example 10
External Type Independent Multi Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(41) See FIG. 10, the system is equipped with a sampling roller. The system needs to design an independent mechanical anchorage device, equipped with an installation frame 40, by using fastening screws 41 to secure the connection bars 42 against the production machine metering system housing 13. The multi unit data reading device 5 is fixed onto the permanent structure to accurately scan the ink film thickness values from the surface of the sampling roller 9. Any similarity to the example 4 will not be repeated.
Example 11
Independent Multi Heads External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(42) See FIG. 11A, 11B, the system is equipped with a sampling roller. The system basic design is similar to that of FIG. 9, and the only different is that an ink film thickness sampling roller 9 is installed onto an independent anchorage device 40. Any similarity to the example 4 will not be repeated.
Example 12
Laser Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(43) See FIG. 12, provided is a laser construction. The system comprises active material 17, which is placed between two reflective type mirrors 15, 16. A resonator 19 is formed by two reflective mirrors and the laser reflective material, by using this to provide the light beam. The atom of the laser active material has been activated by the external energy 21, excited to the higher energy lever condition. The light beam bounces back and forth 20 between two mirrors and then forms an accurate fixed speed of light beam. To release the light beam from the resonator, one of the mirrors 16 can only rebound half of the light beam; this can allow the other half of the laser light beam 18 to freely go through the mirror.
(44) See FIG. 13, the data reading device 5 has been equipped with the laser resonator device, laser beam resonator, and light beam receiver to measure the light beam emission and receiving time, and calculate and record the non ink film bare roller surface 22 and the distance 31 between the data reading device. The mathematical formula is as below: displacement=speed of lightthe total light traveling time between emission and receiving/2 times (Back and forth journey).
(45) See FIG. 14, the data reading device 5 has been equipped with the laser resonator device to measure the time between the light emission and receiver, and calculate and record the ink film thickness surface 23 and the distance 32 between the data reading device. The displacement result is used to calculate the ink film thickness. The ink film thickness mathematical formula as: the ink film thickness=the bare sampling roller without the ink film displacement 31the sampling roller adhering with ink film displacement 32.
Example 13
Ultrasonic Scanning Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(46) See FIG. 15, provided is an ultrasonic emitter 24 which is an electro-gas type ultrasonic generator 27. Piezoelectric emitter comprises two pieces of transmitter chip 25 and a resonance plate 26, and the ultrasonic resonance is generated by applying an external pulse signal onto the transmitter chip and creates vibration. Conversely, the ultrasonic receiver 30 comprises two piezoelectric chips 25, the resonance plate 26 receives the external ultrasound 29, and the ultrasonic wave energy will vibrate the resonance plates, which can convert this mechanical motion to electrode signal for time computing usages.
(47) See FIG. 16, the data reading device 5 is equipped with the ultrasonic emitter to measure the time between the sound wave emission and receiving, and calculate and record the bare roller surface 22 without ink film and the distance 31 between the data reading device. The ink film thickness mathematical formula as: displacement=340 (the speed of sound)the total sound wave traveling time between emission and receiving/2 times (Back and forth journey)
(48) See FIG. 17, the data reading device 5 is equipped with the ultrasonic emitter, to measure the time between the sound emission and receiver, and calculate and record the ink film thickness surface 23 and the distance 32 between the data reading device. The displacement result is used to compute the ink film thickness. The ink film thickness mathematical formula as: the ink film thickness=the bare sampling roller without ink film displacement 31the sampling roller adhering with ink film displacement 32.
Example 14
Optical Type Measuring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
(49) See FIG. 18, provided is an optical color density and color gamut brightness reflective measuring. The measuring system comprises a standard illumination lighting 43, optical lenses construction component 44, filter 45, spectrometer 46, and optical computing device 50. The reading method is to measure the light reflective data 48 from the reflective material 47. By using the appropriate light source D50, D60 to shine over the measuring subject, the reflective measurement such as paper 47. Such light source penetrates through the examination material to the substrate layer, and then bounces back through the examination material with carrying certain density (the rate of filtering) to reduce the intensity for computing the color density or color brightness or individual color value digitally. The measuring material under illumination by lighting system, the amount of light of reflection, through the optical lenses component and filter, are directly transmitted to the spectrometer or digital imaging device (CCD, CMOS) for measurement. Use the optical computer to accurately analyze the color density or color gamut brightness values.
(50) See FIG. 19, provided is an optical color density and color gamut brightness penetration measuring. The measuring system comprises a standard illumination lighting 43, optical lenses construction component 44, filter 45, spectrometer 46, and optical computing device 50. The reading method is to measure the light penetration data 48 through the sampling material 49. Use the appropriate light source D50, D60 to shine onto the measuring subject, and get the penetrative measuring from the transparent film media 49 density. Such light source will depend on the density of the measuring material (rate of transparent) to reduce the intensity for computing the color density or color gamut brightness or individual color value digitally. The measuring material under illumination by lighting system, the amount of light of penetration, through the optical lenses component and filter, are directly transmitted to the spectrometer or digital imaging device (CCD, CMOS) for measurement. Use the optical computer to accurately analyze the color density or color gamut brightness values.
(51) Implementation of the method for the fluid type films is equipped with the direct and indirect controlling systems and devices.
(52) Set a fixed distance 33 in mechanical way that the fluid thickness can pass through. The excessive fluid film 37 will be collected by the adjustable mechanical spacing roller 34 and doctor blade 35. This controlling system is equipped with data reading device 5 for monitoring whether there is any excessive fluid film and real time re-adjust the dispensing value and re-set the distance 33 for controlling the film thickness. The doctor blade installation can be a direct and in-direct method.
Example 15
(53) FIG. 22 and FIG. 23 show a direct-type system and device. The sampling roller 9 is equipped with a doctor blade 35 with pre-determined distance for collecting the excessive fluid type film. Such a distance 33 is the spacing which can make the fluid films pass through. The excessive fluid film 37 will be removed by the doctor blade and store at the container 36 for re-cycling back to the dispensing duct. The container is equipped with a data reading device 5, which is used to monitor whether there is any excessive fluid film collected. If the device 5 has detected signal, then the amendment command will be sent in real time to the PLC controlling unit 12 for digitize the signal. The material duct changes the dispensing value and the spacing 33 by the doctor blade 35 for direct control of the film thickness. This system is an initiative and proactive consistent monitor to amend the fluid film thickness requirement.
Example 16
(54) FIG. 24 and FIG. 25 show an indirect-type system and device. The sampling roller 9 is equipped with a roller 34 with pre-determined spacing to collect the excessive fluid film. The roller surface is equipped with a tight fit doctor blade 35. Such a distance 33 is the spacing for fluid films to pass through. The excessive fluid films 37 will be removed by the pre-determined spacing roller; the tightly contacted doctor blade will continuously collect the excessive fluid from the pre-determined spacing roller and store at the container 36 for re-cycling back to the dispensing duct. The container is equipped with a data reading device 5, which is used to monitor whether there is excessive fluid films collected. If the device 5 has detected signal, then the amendment command will be sent in real time to the PLC controlling unit 12 for digitizing the signal. The material duct amends the dispensing value and re-determines the spacing 33 by the pre-determined spacing roller 34 for direct control of the film thickness. This system is an initiative and proactive consistence monitor to amend the fluid film thickness requirement.
Example 17
(55) FIG. 26: show the different work flow for the proactive intelligent controlling method for fluid type color printing ink film thickness value vs the traditional passive color film thickness controlling method.
(56) The proactive intelligent controlling method for fluid printing ink film thickness value work flow has begun with: a) color film delivered by production equipment to begin the production; b) by using the proactive control system for checking color film thickness value to analyze the color film thickness whether acceptable or out of range; c) if out of range, the closed loop repeated adjustment for color film thickness to determine the new thickness value for color film delivered by production equipment and continuous the next production cycle; and d) if acceptable, the correct color film will deliver onto the substrate for finishing printing to become finished product.
(57) The traditional passive color film thickness controlling method work flow has begun with: a) color film delivered by production equipment to begin the production; b) whatever color film thickness on the equipment will deliver onto the substrate for finishing production to become finished product; c) after the product being made, the passive system of quality control module to conduct the quality inspection process for analyzing whether the finished product is unacceptable or not; d) for any unacceptable product shall become defect products which has already been produced; and e) based on the defect result to determine the correction value, and then execute the delivering correction color film thickness process for entering the next production cycle.
