Method and an apparatus for making laser engravures on a moving web
09950390 ยท 2018-04-24
Assignee
Inventors
- Quirino Sestini (Rosignano Marittimo, IT)
- Giovanni Masotti (Sesto Fiorentino, IT)
- Carlo Giovannucci (Sesto Fiorentino, IT)
Cpc classification
B23K26/082
PERFORMING OPERATIONS; TRANSPORTING
B41J2/471
PERFORMING OPERATIONS; TRANSPORTING
B23K26/0846
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23K26/082
PERFORMING OPERATIONS; TRANSPORTING
B41J2/44
PERFORMING OPERATIONS; TRANSPORTING
B23K26/08
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for making laser engravings on a web of paper, including prearranging a paper web conveying device; defining a working area along a path of the web; prearranging an emitter of laser pulses; prearranging a movable pointing device, selecting an engraving pattern to be engraved on the web; calculating an instruction file containing pointing instructions; selecting an emission power of the emitter of laser pulses; emitting laser pulses through the emission power; and operating the movable pointing device according to the instruction file.
Claims
1. A method for making laser engravings on a paper web, said method comprising the steps of: prearranging a web conveying means configured for conveying a paper web in a predetermined direction; defining a working area along a path of said web; prearranging a laser pulse emitter for emitting laser pulses that have a power set to form engravings on said web; prearranging a movable pointing means that comprises a reflection means and a focus means, said movable pointing means configured for sending said laser pulses into said working area; selecting an engraving pattern, comprising a plurality of points to be engraved on said web by said laser pulses emitted as pulse packets, said pattern associated with a first function that defines the position of said plurality of points in said working area with respect to a first reference system that is integral to said web; calculating an instruction file containing pointing instructions for operating said movable pointing means in such a way that a predetermined position of said movable pointing means corresponds to each pulse packet, a predetermined position of said plurality of points on said working area corresponding to said predetermined position of the movable pointing means; selecting an emission power of said laser pulse emitter; emitting laser pulses at said emission power through said emitter; operating said movable pointing means according to said instruction file, so that said movable pointing means sequentially reaches each predetermined position by continuously changing the direction of said laser pulses in said working area reproducing said pattern on said web; wherein said step of calculating an instruction file provides a transform of said first function from said reference system that is integral to said web, into a second reference system that is integral to said emitter, wherein a second transformed function is obtained, by said transform, which is defined in said working area, and wherein said instructions of said instruction file operate said pointing means in such a way that said laser pulses describe said transformed function with respect to said second reference system, in said working area, such that said packets of laser pulses reach said web, and engrave said pattern on said web as if said web were motionless.
2. The method according to claim 1, wherein said step of prearranging a movable pointing means comprises a step of prearranging galvanometers as actuators of said reflection means.
3. The method according to claim 1, comprising the steps of: learning position data of a point of said web with respect to said second reference system that is integral to said emitter of laser pulses; computing a conveying speed of said web; and wherein said transform of the first function from said reference system that is integral to said web, into said second reference system, which is integral to said emitter, is defined by a tracking correlation, that is, a tracking algorithm, comprising said speed, wherein said tracking correlation is expressed by:
x=xXc(t)=v(t)*t[1]
y(t)=y(t)[2], wherein: x, y are the coordinates of a true pointing position, that is, the coordinates of an engraving point of the pattern with respect to said second reference system that is integral to said emitter of said laser pulses; x,y are the coordinates of an engraving point of said pattern with respect to said reference system that is integral to said conveyed web; Xc is the position, according to an advancement coordinate of the paper web; v is the conveying speed of said web with respect to said second reference system that is integral to said emitter of said laser pulses, wherein said method also comprises a step of computing an acceleration of moving said web, and said correlation also comprises the acceleration of said web, wherein said correlation is expressed by:
x=xXcv(t)*(t)a(t)t.sup.2[3]
y(t)=y(t)[4] where: a is the conveying acceleration said web with respect to said second reference system that is integral to said means of emission of laser pulses.
4. The method according to claim 1, further comprising the steps of: printing said pattern on said web, thus obtaining a printed pattern; reading at least one portion of said pattern printed on said web; wherein said step of selecting an engraving pattern comprises a step of selecting said at least one portion of said printed pattern, and said instruction file comprises instructions for engraving said pattern in an engraving zone on said web corresponding to said printed pattern, such that a one-to-one correspondence is obtained on said a piece of document between said engraving, which reproduces a data field, and the same data field as shown on said piece of document, wherein said step of reading comprises a step of scanning and optically recognizing types of said pattern printed on said web, wherein said step of engraving provides the reproduction of types of said data field by removing an amount of material without perforating the piece of document, by a plurality of local abrasions of the piece of document.
5. The method according to claim 1, also comprising the steps of: printing a predetermined activation or control code on said web; reading and optically recognizing said activation or control code from said web upstream of said working area; wherein said step of calculating said instruction file comprises a step of generating an instruction of engraving said pattern at a predetermined position on said web responsive to said activation or control code, which has been read and optically recognized.
6. The method according to claim 1, wherein said step of selecting an emission power comprises a step of defining a nominal emission power value and a plurality of increased emission power values higher than said nominal emission power value, and said step of emitting laser pulses is carried out by selecting in turn said emission power values decreasing between a first increased emission power value and a last increased emission power value and, subsequently, said nominal emission power value, wherein said increased emission power values are selected and used as emission power values such that, in a starting period of said step of emitting, said emitter emits a laser pulse at an emission power set between said nominal power value and a power value that differs from said nominal power value within a predetermined value range, wherein said emitter is operated according to a pulse-width modulation control signal in which a power emission duty-cycle is defined, and said plurality of increased power values is used for said nominal power through a step of changing said duty-cycle according to a working temperature of said emitter.
7. The method according to claim 1, wherein said pattern comprises two graphic elements which meet at a vertex forming a sharp angle, and said instruction file comprises first instructions for engraving first engraving points along the direction of a first segment and second instructions for engraving, after said first engraving points, second engraving points along the direction of said a second segment, and an instruction of adding a predetermined delay for prolonging a step of executing said first instructions, such that at least one engraving point is engraved at a distance from said vertex responsive to said delay, in order to obtain, in said pattern, as engraved on said web, at the intersection point of said two graphic elements, a connection of predetermined shape, wherein a step is provided of correcting a trajectory in order to engrave a point of said second engraving points at a predetermined position along said second segment.
8. The method according to claim 1, wherein said pointing instructions of said instruction file comprise focus instructions for said focus means, wherein said focus means is operated in such a way that: beams of said pulses directed by said pointing means reach with an own focus a first plurality of points of said web in said working area, and said beams reach a second plurality of points of said working area with said focus at a predetermined distance from said working area and from said web, such that an intentional focus defect is obtained at a region of said working area comprising said second plurality of points, wherein said focus instructions cause said focus means to: take a same focusing position for directing said beams to said first plurality of points of said working area that have a same distance from a predetermined point of said working area, said point arranged to be substantially perpendicularly attained by said beams starting from said pointing means; take a position different from said focusing position for directing said beams to said second plurality of points of said working area.
9. A method for making laser engravings on a paper substrate, said method comprising the steps of: defining a working area; prearranging said substrate in said working area; prearranging a laser pulse emitter for emitting laser pulses that have a power set to form engravings on said substrate; prearranging a movable pointing means that comprises a reflection means and a focus means, said movable pointing means configured for sending said laser pulses to said working area on said substrate; selecting an engraving pattern to be engraved on said substrate by said laser pulses emitted as pulse packets; calculating an instruction file containing pointing instructions for operating said movable pointing means in such a way that a predetermined position of said movable pointing means corresponds to each pulse packet, a predetermined position of said points on said working area corresponding to said predetermined position of the movable pointing means; selecting an emission power of said laser pulse emitter; emitting laser pulses at said emission power through said emitter; operating said movable pointing means according to said instruction file, so that said movable pointing means sequentially reaches each predetermined position by continuously changing the direction of said laser pulses in said working area reproducing said pattern on said substrate; wherein said step of selecting an emission power comprises a step of defining a nominal emission power value and a plurality of increased emission power values higher than said nominal emission power value, and said step of emitting laser pulses is carried out by selecting in turn said emission power values decreasing between a first increased emission power value and a last increased emission power value, wherein said increased emission power values are selected and used as emission power values such that, in a starting period of said step of emitting, said emitter emits a laser pulse at an emission power set between said nominal power value and a power value that differs from said nominal power within a predetermined value range.
10. The method according to claim 9, wherein said emitter is operated according to a pulse-width modulation control signal in which a power emission duty-cycle is defined, and said plurality of increased power values is used for said nominal power through a step of changing said duty-cycle according to a working temperature of said emitter.
11. A method for making laser engravings on a paper substrate, said method comprising the steps of: defining a working area; prearranging said substrate in said working area; prearranging a laser pulse emitter for emitting laser pulses that have a power set to form engravings on said substrate; prearranging a movable pointing means that comprises a reflection means and a focus means, said movable pointing means configured for sending said laser pulses to said working area on said substrate; selecting an engraving pattern, comprising a plurality of points to be engraved on said substrate by said laser pulses emitted as pulse packets; calculating an instruction file containing pointing instructions for operating said pointing means in such a way that a predetermined position of said movable pointing means corresponds to each pulse packet, a predetermined position of said points on said working area corresponding to said predetermined position of the movable pointing means; selecting an emission power of said laser pulse emitter; emitting laser pulses at said emission power through said emitter; operating said movable pointing means according to said instruction file, so that said movable pointing means sequentially reaches each predetermined position by continuously changing the direction of said laser pulses in said working area reproducing said pattern on said substrate; wherein said pattern comprises two graphic elements, which meet at a vertex forming a sharp angle, wherein said instruction file comprises first instructions for engraving first engraving points along the direction of a first segment and second instructions for engraving, after said first engraving points, second engraving points along the direction of a second segment, and an instruction of adding a predetermined delay for prolonging a step of executing said first instructions, such that at least one engraving point is engraved at a distance from said vertex responsive to said delay, in order to obtain, in said pattern, as engraved on said substrate a connection of predetermined shape between said graphic elements.
12. The method according to claim 11, wherein a step is provided of correcting a trajectory in order to engrave a point of said second points at a predetermined position along said second segment.
13. A method for making laser engravings on a paper substrate, said method comprising the steps of: defining a working area; prearranging said substrate in said working area; prearranging a laser pulse emitter for emitting laser pulses that have a power set to form engravings on said substrate; prearranging a movable pointing means that comprises a reflection means and a focus means, said movable pointing means configured for sending said laser pulses to said working area on said substrate; selecting an engraving pattern to be engraved on said substrate by said laser pulses emitted as pulse packets; calculating an instruction file containing pointing instructions for operating said movable pointing means in such a way that a predetermined position of said movable pointing means corresponds to each pulse packet, a predetermined position of points on said working area corresponding to said predetermined position of the movable pointing means; selecting an emission power of said laser pulse emitter; emitting laser pulses at said emission power through said emitter; operating said movable pointing means according to said instruction file, so that said movable pointing means sequentially reaches each predetermined position by continuously changing the direction of said laser pulses in said working area reproducing said pattern on said substrate; wherein said pointing instructions of said instruction file comprise focus instructions for said focus means wherein said focus means is operated in such a way that: beams of said pulses directed by said movable pointing means reach with an own focus a first plurality of points of said substrate in said working area, and said beams reach a second plurality of points of said working area with said focus at a predetermined distance from said working area and, therefore, from said substrate, such that an intentional focus defect is obtained at a region of said working area comprising said second plurality of points.
14. The method according to claim 13, wherein said focus instructions cause said focus means to: take a same focusing position for directing said beams to said first plurality of points of said working area that have a same distance from a predetermined point of said working area, said predetermined point arranged to be substantially perpendicularly attained by said beams starting from said pointing means; take a position different from said focusing position for directing said beams to said second plurality of points of said working area.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention will be now shown with the following description of exemplary embodiments, exemplifying but not limitative, with reference to the attached drawings in which:
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DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS
(13) With reference to
(14) Laser engraving head 100 comprises an emitter or laser gun 14 of known type that is configured for emitting a laser pulse beam 15,16 with a power suitable for making engravings on web 10.
(15) The material of the web is preferably a paper material, but it may also be a natural or artificial polymeric material such as a fabric, a metal material, or another material.
(16) By the expression engravings local modifications of web 10 are intended that are made by a supply of laser energy that moving web 10 receives from laser beam 16. This supply of energy firstly causes a local heating of web 10, which can lead to a local burn or evaporation of the material of web 10. As a consequence of this local burn, a local loss of material occurs at points 25 where laser beam 16 reaches web 10. The loss of material may occur in the whole thickness of the material, such that at the engraved points a through hole is made. In alternative, the loss of material may only partially affect the thickness, such that more or less deep surface cavities are formed. These two operation modes are called cut and kiss-cut, respectively. Furthermore, at points where beam 16 engraves the surface of the web, it is possible to cause surface modifications that can be optically perceived, for example local color modifications.
(17) Laser engraving head 100 further comprises a movable reflection means or mirrors 22,23, i.e. a reflection means that is configured for changing its own orientation in the space, in order to reflect a laser beam 15,15 that hits them, thus forming a reflected beam 15,16 that has a direction depending upon the orientation of mirrors 22,23. In particular, mirrors 22,23 can rotate about respective rotation axes 28,29 by respective rotary actuators 28,29. Preferably, rotary actuators 28,29 comprise galvanometers, which, as known, are widely used in mirror systems for directing laser beams, and which allow controlling the orientation of mirrors 22,23, by suitable current signals.
(18) In particular,
(19) Laser engraving head 100 also comprises a focus means 33, for focusing, i.e. for converging beam 16 to a predetermined point, i.e. the focus, which is located on the line along which the trajectory of the laser beams propagates, as shown in particular, in
(20) By suitably arranging rotation axes 28,29, as well known in the art, output laser beam 16 can be directed in such a way that the focus is moves along a plane. If working area 12, along which slides web 10, is arranged according to this plane, the focus of laser beam 16 can reach any point 25 of working area 12.
(21) Laser engraving head 100 also comprises further reflection means or fixed mirrors 17. The position and the orientation of fixed mirrors 17 depend upon the position of emitter 14 with respect to movable mirrors 22,23. Typically, the focus means is located between fixed mirrors 17 and movable mirrors 22,23.
(22) With reference now also to
(23) Pattern 20 is a set of graphic elements that may form, for instance, a type as shown in
(24) In program means 50 a calculation means 52 is provided that, starting from engraving control signal 30, i.e. from pattern 20 selected by the user, is configured for producing a work programme in the form of a function 31, by which an effect such as a perforation or a surface modification of web 10 is associated to each point of working area 12. Such a function 31 is therefore defined in the working area 12 and represents pattern 20 in a reference system 11 integral to web 10. For instance, as shown in
(25) File 24, according to the prior art, is formulated as a sequence of instructions for carrying out a pattern 20, which define the order according to which the single points of pattern 20 are reproduced.
(26) To take into account that pattern 20 is reproduced at least in part, while web 10 advances, a means 51,55 is provided associated/belonging to program means 50, for learning or calculating a speed data 61 of web 10 while the latter crosses working area 12. For instance, this may occur through a conventional input means such as keyboard 51. The smaller the change of speed 61 once data speed 61 has been learnt or calculated, the more accurate the reproduction of the pattern.
(27) In alternative, a web speed detection means can be provided of a type known to a skilled person. For instance, a means 48 can be provided for measuring the position of the web, which comprises an encoder associated with the means for advancing, as diagrammatically shown in
(28) In an exemplary embodiment, speed computing means 55 is also configured for calculating the acceleration of web 10. For instance, the speed and preferably the acceleration of the web may be calculated as average values of two consecutively read data position values, which are read at regular intervals, i.e. in predetermined reading windows of predetermined amplitude, for example, of amplitude set between 1 millisecond and 10 milliseconds, so that the average values can be considered substantially instantaneous values.
(29) Still in order to take into account the movement of the web during the reproduction of pattern 20, program means 50 of laser engraving head 100 comprises (
(30) In an exemplary embodiment, computing means 56 (
x(t)=x(t)X.sub.c(t)v(t)*ta(t)t.sup.2[3]
y(t)=y(t)[4]
where X.sub.c indicates the position, according to an advancement coordinate of web 10.
(31) Emitter 14 of laser pulses (
(32) With reference to
(33) In particular,
(34) The apparatus may be configured for causing reading head 130 to scan the data contained in a visibly printed data field 112 of each document 110, to recognize optically types or other symbols written in data field 112, and may be configured for subsequently causing laser engraving head 100 to engrave types 113 in an engraving field 113, said types corresponding to printed types 112 of printed data field 112.
(35) Besides being configured for substantially reproducing data field 112 in engraving field 113 by removing an amount of material, laser engraving head 100 is also configured for making cut engravings, as shown in
(36) Still with reference to
(37) In particular, activation or control code 132 may be printed on a web or piece of document side portion 111 that can be removed from the rest of the piece of document, typically at the end of the operation.
(38) Furthermore, the apparatus comprises a program means 50 configured to generate a perforation signal 145 upon reading activation or control code 132. Finally, laser engraving head 100 is configured for engraving a text on piece of document 110, according perforation signal 145.
(39) As described above, laser engraving head 100 is arranged to create an engraving field 113 that reproduces printed data field 112, responsive to activation or control code 132, and/or makes it possible to make a tear-off line 124 between each document 110 and an adjacent piece of document 110. More in detail, activation or control code 132 is an optical code selected between a bar code 132 (
(40) In particular, optical codes 132 can contain data for reproducing data field 112 by laser engraving head 100, and/or data for making tear-off lines 124 on web 10 or also clean cuts for immediately separating each of the several documents from one another. This way, the laser engraving based on activation or control code 132 makes it possible to obtain, for each type of piece of document 110, a dedicated reproduction of data field 112, or a dedicated configuration of the tear-off lines. In other words, by using activation/control codes 132, makes it possible to carry out different operations on each document 110 on a same printing line.
(41) While making, i.e. engraving a point 25 of the pattern on a substrate paper 10, for example an advancing web 10, emitter 14 is operated according to a pulse-width modulation or PWM control signal, in which a duty-cycle is selected between a minimum value and a maximum value in a time window of about some seconds, in which trains of pulses follow one another, and each pulse has a prefixed shape, at a frequency of 20/30 kHz.
(42) However, as indicated in
(43) This trend of instantaneously supplied power, under a same power set point W.sub.0, can lead to both cut and kiss-cut uneven performances and, therefore, it can worsen the overall quality of an engraving on a given substrate.
(44) In accordance with the second aspect of the invention, in order to compensate for the difference between nominal power W.sub.0 and instantaneous power W that occurs during heating transient period 89, a step is provided of temporary increasing the nominal power with respect to predetermined nominal value W.sub.0, and this is done preferably through decreasing values. In particular, the step of temporary increasing the power comprises a step of selecting a plurality of increased emission power values W.sub.1, W.sub.2, W.sub.3, W.sub.4, here listed in the decreasing order, that are higher than nominal emission power W.sub.0, and the step of emitting is carried out by setting these increased power values as nominal values, in the same order as they are listed. The increased emission power values W.sub.1, W.sub.2, W.sub.3, W.sub.4, which correspond to the trend of actually emitted power 84,84,84,84, are selected in such a way that, in a initial period of the step of emitting, emitter 14 emits laser pulses at a power acceptably close to nominal power W.sub.0. The curve of generated power W coincide, starting from time t.sub.0 at which power begins to be supplied, with the curves of delivered power 85,85,85,85 which correspond to power W.sub.1, W.sub.2, W.sub.3, W.sub.4, respectively, until with power 83 is obtained a power value that is close enough to predetermined nominal power W.sub.0. In other words, increased emission power values W.sub.1, W.sub.2, W.sub.3, W.sub.4 are selected in such a way that, in an initial period of the step of emitting, emitter 14 emits a laser pulse 15 at an emission power set between nominal power W.sub.0 and a value W that approximates the nominal power and that differs from nominal power within a predetermined range .
(45) In particular, program means 50 (
(46) As shown in
(47) In accordance with the fourth aspect of the invention, the pointing instructions of instruction file 24 comprise focus instructions for controlling focus means 33 so that laser pulse beam 16, which is orientated by pointing means 22,23,33, do not reach the whole working area 12 with its own focus on paper substrate 10, in particular on advancing web 10, but in such a way that in some points of working area 12, which preferably belong to a region 65 of working area 12 (
(48) In the prior art, as shown in
(49) As shown in
(50) The foregoing description various exemplary specific embodiments will so fully reveal the invention according to the conceptual point of view, so that others, by applying current knowledge, will be able to modify and/or adapt for various applications such embodiment without further research and without parting from the invention, and, accordingly, it is meant that such adaptations and modifications will have to be considered as equivalent to the exemplary embodiments described. The means and the materials to realize the different functions described herein could have a different nature without, for this reason, departing from the field of the invention. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.