Coater and embosser-laminator process roll calibration

Abstract

Rolls of an embosser laminator unit may be calibrated with an iterative process of moving axial ends of the roll a set incremental distance until contact between the rolls is made and then making a correction to the distance based upon the end of the roll making contact. The rolls may be move an initial position where the faces of the rolls are devoid of contact with each other. One or both of the rolls may be rotated. The distance between the ends of the rolls may be decreased until the faces of the rolls make contact with each other. The distance between the first ends of the rolls may be increased by an incremental amount, and a determination of contact between the faces of the rolls may be made by alternate movement of the rolls by the incremental amount and position prior to contact.

Claims

1. A method of calibrating a distance and alignment between two rolls, wherein each of the rolls has a face, a first end, and a second end, the method comprising: (a) moving the rolls to an initial position where the faces of the rolls are devoid of contact with each other; (b) rotating at least one of the rolls; (c) decreasing a distance between the first ends of the rolls and a distance between second ends of the rolls until the faces of the rolls make contact on at least one of the ends of the first and second rolls; (d) increasing the distance between the first ends of the rolls by an incremental amount; (e) determining contact between the faces of the rolls after the distance between the first ends of the rolls is increased by the incremental amount such that: (I) when the faces of the rolls contact each other, the method comprises: recording the position of an actuator associated with controlling the distance between the second ends of the rolls, recording an instance of contact between the second ends of the rolls, increasing the distance between the second ends of the rolls by the incremental amount, decreasing the distance between the first ends of the rolls by the incremental amount, determining contact between the faces of the rolls such that: (1) when the faces of the rolls contact each other, the method comprises: recording the position of an actuator associated with controlling the distance between the first ends of the rolls, recording an instance of contact between the first ends of the rolls, increasing the distance between the first ends of the rolls by the incremental amount multiplied by a factor, and performing steps (c) through (e) until the first and second ends of the rolls contact each other a threshold number of instances of contact at which point the ends of the first and second roll are moved to a respective reference position; (2) when the faces of the rolls are devoid of contact with each other, the method comprises: performing steps (c) through (e) until the first and second ends of the rolls contact each other a threshold number of instances of contact at which point the ends of the first and second roll are moved to a respective reference position; (II) when faces of the rolls are devoid of contact, the method comprises: recording the position of the actuator associated with controlling the distance between the first ends of the rolls, and performing steps (c) through (e) until the first and second ends of the rolls contact each other a threshold number of instances of contact at which point the ends of the first and second roll are moved to a respective reference position.

2. The method of claim 1, wherein the step (a) includes increasing the distances between the first ends and the second ends of the rolls until the faces of the rolls are devoid of contact with each other.

3. The method of claim 1 wherein the actuator associated with controlling the distance between the first ends of the rolls and the actuator associated with controlling the distance between the second ends of the rolls are operatively connected to stops delimiting the distances between the ends of the rolls.

4. The method of claim 3 further comprising generating feedback signals representative of a relative position of the stops associated with the ends of the rolls, and determining the distance between the ends of the rolls based at least in part upon a feedback signals.

5. The method of claim 1 wherein the step (a) includes setting positions of the stops associated with the respective ends of the rolls at an initial position.

6. The method of claim 1 wherein the step (e) includes determining contact between the faces of the rolls by a change in a torque during rotation of the at least one roll.

7. The method of claim 1 wherein the step (e) includes determining contact between the faces of the rolls by a change in a speed during rotation of the at least one roll.

8. The method of claim 1 wherein the step (d) includes at least one of increasing and decreasing the distance between the ends of the respective rolls by the incremental amount of between 0.13 mm and 0.25 mm.

9. The method of claim 1 wherein the step (e) includes at least one of increasing and decreasing the distance between the ends of the respective rolls by the incremental amount of between 0.13 mm and 0.25 mm.

10. The method of claim 1 wherein step (e) includes increasing the distance between the first ends of the rolls by the incremental amount multiplied by a factor of 1.5.

11. The method of claim 1 wherein steps (c)-(e) are performed until the threshold number of instances of contact for each of the respective ends of roll is three.

12. The method of claim 1 wherein step (b) includes rotating the first roll and the second roll.

Description

DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a left side, top perspective view of a mainframe structure for a laminating and embossing unit with an adhesive deck adapted and configured to be moved into and out of connection with the mainframe structure to allow installation and removal of one or more rolls associated with the laminating and embossing unit.

(2) FIG. 2 is right side, top perspective of the mainframe structure of FIG. 1;

(3) FIG. 3 is a partial, enlarged, left side perspective view of a left side actuator and stop for effectuating movement of a left side of an applicator roll of the adhesive deck relative to a left side of a steel embossing roll of the laminating and embossing unit taken from detail area 3-3 of FIG. 1;

(4) FIG. 4 is a partial, enlarged, right side, perspective view of a right side actuator and stop for effectuating movement of a right side of an applicator roll of the adhesive deck relative to a right side of a steel embossing roll of the laminating and embossing unit taken from detail area 4-4 of FIG. 2;

(5) FIG. 5 is an elevation view of the right side actuator and stop of FIG. 4, the left side actuator of FIG. 3 being a mirror image thereof;

(6) FIG. 6 is a left side, perspective view of a left side actuator and stop for effectuating movement of a left side of an applicator roll of the adhesive deck relative to a left side of a gravure roll of the adhesive deck; a right side actuator and stop being a mirror image thereof;

(7) FIG. 7A is a process flow for a roll calibration process using an electronic means of indicating mutual contact between rolls;

(8) FIG. 7B is a legend for FIG. 7A;

(9) FIGS. 8-21 are an example of rolls being calibrated using the process of FIG. 7A;

(10) FIG. 22A is a roll calibration process flowchart using electrical continuity as a means of indicating mutual contact between rolls; and

(11) FIG. 22B is a legend for FIG. 22A.

DETAILED DESCRIPTION

(12) FIGS. 1-6 show a mainframe structure 10 of a machine with a portion 12 that houses an embossing laminating unit and a portion with a subframe 14 that houses an adhesive deck. FIGS. 7A-7B show a process flow for calibrating the rolls, and FIG. 8-21 show an example of rolls being calibrated using the process of FIGS. 7A-7B, for example, a gravure roll and an applicator roll in a coater or an embosser-laminator.

(13) In general, the process described herein involves an iterative process of moving axial ends of one of the rolls being calibrated a set incremental distance until contact between the rolls is made and then making a correction to the distance based upon the end of the roll making contact. During the calibration process described below, one or both of the rolls being calibrated may be driven in rotation with a motor. In the case of calibrating an applicator roll and gravure roll, both rolls may be driven. Given characteristics of the system, for example inertia, static friction, and surface finish, rotating both rolls during the calibration process may be advantageous to improve resolution in detecting roll contact and/or to avoid damaging the rolls. Feedback regarding motor torque, roll position, or speed may be used to indicate a change of state between roll faces, that is whether the rolls are in contact or not in contact. The rolls being calibrated require a level of precision in distance and alignment such that a determination of the mere fact that the rolls are in mutual contact is insufficient. As such, the process requires a determination of which end of the rolls makes contact first as the rolls are loaded together.

(14) The processes described herein may be used to calibrate an applicator roll and a steel engraved roll in an embosser laminator. Since both rolls are driven, and the applicator roll is typically durable, there is low risk that the steel engraved roll will damage the applicator roll during the process. The processes described herein may also be used to calibrate a marrying roll and a steel engraved roll in an embosser laminator. Even though the marrying roll is sometimes not driven, it is typically very durable, and there is low risk that the steel engraved roll will damage the marrying roll during the process.

(15) In calibrating the rolls, opposite ends of the one of the respective rolls (side 1 and side 2 in the drawings 8-21) may be moved using an actuator. Side 1 and side 2 refer to ends of the rolls, such as the operator side and the drive side. As shown in the drawings (in particular, FIGS. 3-5), a left side actuator 16 and a stop 18, and a right side actuator 20 and a stop 22 may be provided on respective sides of the mainframe structure 10 adjacent the bearings and may be configured to adjust the distance between the applicator roll and the steel embossing roll. For instance, opposite axial ends of the applicator roll may be adjusted relative to the mainframe/subframe. Also, as shown in the drawings (in particular, FIG. 6), a left side actuator 24 and a stop 26, and a right side actuator 28 and a stop 30 may be provided to adjust the distance between the applicator roll and the gravure roll. For instance, opposite axial ends of the gravure roll may be adjusted relative to the mainframe/subframe. The actuators may include pneumatic actuators, such as a Firestone model W01-358-6952, or an electric motor driven actuator with a ball or acme leadscrew. The distance between the rolls may be delimited by stops provided with feedback regarding the positions of the stops. The distance between the rolls may be changed by changing the position of a stop wedge, or by operating a threaded member to change the position of the stop, at the end of the rolls.

(16) The rolls may be loaded to increase or decrease the distance between the roll axes of rotation by actuating the actuators. The incremental distance x by which the distance between the rolls is changed may correspond to a defined gap that can be used for physical verification, for example 0.25 mm or 0.13 mm (a 0.010 gage feeler stock or a 0.005 gage feeler stock). The set incremental distance may also be set based upon the geometry of the faces of the rolls, the resolution of the actuators and position indicators, roll surface finishes, and cylindrical runout. As shown in FIGS. 8-21, once the ends of the rolls (sides 1 and 2) on both sides of the machine have made contact once, contact typically alternates between the sides until a number of instances of each side making contact is reached. Each side making contact a predetermined number of times, for example three times (a threshold number of instances of contact or maxIterations in FIGS. 7 and 22) may be a sufficient number of instances of contact for the precision required in coating or lamination. When the process indicates that both sides make contact simultaneously, one side can be moved by the incremental distance multiplied by a factor, for example 1.5, in order to continue through the calibration process.

(17) In one aspect, the method involves, step (i) of positioning the rolls in a state which the faces of the rolls are not in mutual contact; and step (ii) of rotating at least one of the rolls and sampling baseline motor torque or speed. Contact between the faces of the roll may be indicated by one or more of: motor torque, roll angular position error, or change in roll speed. In the description herein, torque is used. If sampled motor torque exceeds an established threshold for motor torque corresponding to free rotation of the roll (i.e., the roll not being in contact), the rolls are already in contact and must be disengaged by increasing the distance. Likewise, if change in roll speed is used as an indication of contact, if change in roll speed exceeds an established threshold for speed corresponding to free rotation of the roll (i.e., the roll not being in contact), the rolls are already in contact and must be disengaged by increasing the distance. This step is shown at SU in FIGS. 7A&B. As mentioned earlier, once the rolls are devoid of contact and an initial position is established, the settings delimiting the distance between the roll axes of rotation, for example, the positions of the stops associated with the ends of the respective rolls, may be set and recorded. This may further include enabling at least one of the actuators and stops to generate feedback signals representative of the relative position of the stops and/or actuator associated with the ends of the rolls and determining the distance between the ends of the rolls based at least in part upon the feedback signals.

(18) Once it is established that the sampled motor torque is below the threshold level, the calibration method may proceed (for instance, to A in FIG. 7A) to step (iii) of decreasing the distances between the first ends and the second ends of the rolls until contact between the faces of the rolls is indicated by sampled motor torque being above the threshold level. By way of example, the status of the rolls after completing steps (i)-(iii) is shown in FIG. 8. This step is shown at B in FIG. 7A.

(19) In a further aspect of the method, step (iv) may be performed to increase the distance between the first ends of the rolls by a set incremental amount. For instance, as shown in FIG. 9, side 1 of the roll is moved away from side 1 of the other roll by 0.50 mm while side 2 is fixed. Because the rolls continue to rotate, a change in motor torque may be used as an indicator to determine whether the contact between the faces of the rolls maintains or is removed at step (iv). This step (iv) is shown at C in FIG. 7A. In the example, side 1 is the first side to make contact, but it should be appreciated that side 2 can be the first side to make contact given different initial conditions.

(20) At this point, in accordance with the method, step (v) may be performed to determine which ends of the rolls made contact. If the contact is removed as indicated by torque being below the threshold level, the first ends of the rolls are in contact, and the method may then proceed on path 1 as described below. If the contact maintains as indicated by torque being above the threshold level, the second ends of the rolls are in contact, and the method may then proceed on path 2 as described below. As shown in the example of FIGS. 8 and 9, the first ends of the rolls are in contact and the example of FIGS. 8 and 9 will continue along path 1.

(21) In accordance with path 1, the position of the actuator associated with controlling the distance between the first ends of the rolls from step (iii) may be recorded and the count of instances of contact of the first ends of the rolls may be incremented. This step is shown at D in FIGS. 7A&B. As the threshold number of instances of contact has not been reached, the process returns to point A in FIGS. 7A&B.

(22) In accordance with an aspect of the method, step (vi) may be performed to decrease the distance between the first ends of the rolls and the second ends of the rolls until contact between the faces of the rolls is indicated by sampled motor torque being above the threshold level. For instance, as shown in FIG. 10, the first and second ends of the rolls are moved to decrease the distance until contact is made (as shown in the drawings 0.50 mm). This step is shown again at B in FIG. 7A.

(23) In a further aspect of the method, step (vii) may be performed to increase the distance between the first ends of the rolls by a set incremental amount while keeping the second ends of the rolls fixed. For instance, as shown in FIG. 11, side 1 of the roll is moved away from side 1 of the other roll by 0.50 mm while side 2 is fixed. Because the rolls continue to rotate, a change in motor torque may be used as an indicator to determine whether the contact between the faces of the rolls is maintained or is removed at step (vii). This step is shown at C in FIG. 7A.

(24) At this point, in accordance with the method, step (viii) may be performed to determine which ends of the rolls made contact. If the contact is removed as indicated by torque being below the threshold level, the first ends of the rolls were in contact, and the method may then proceed on path 1. If the contact maintains as indicated by torque being above the threshold level, the second ends of the rolls are in contact, and the method may then proceed on path 2 as described below. As shown in the example of FIGS. 10 and 11, the first ends of the rolls are in contact.

(25) In accordance with path 1, the position of the actuator associated with controlling the distance between the first ends of the rolls from step (vi) (as shown in the drawings 0.50 mm) and another instance of contact of the first ends of the rolls may be recorded. This step is shown at D in FIG. 7A. As the threshold number of instances of contact has not been reached, the process returns to point A in FIG. 7A.

(26) Then, in accordance with an aspect of the method, step (ix) may be performed to decrease the distance between the first ends of the rolls and the second ends of the rolls until contact between the faces of the rolls is indicated by sampled motor torque being above the threshold level. For instance, as shown in FIG. 12, the first and second ends of the rolls have moved 0.25 mm when contact is made. This step is shown again at B in FIG. 7A.

(27) In a further aspect of the method, step (x) may be performed to increase the distance between the first ends of the rolls by a set incremental amount while keeping the second ends of the rolls fixed. For instance, as shown in FIG. 13, side 1 of the roll is moved away from side 1 of the other roll by 0.50 mm while side 2 is fixed. Because the rolls continue to rotate, a change in motor torque may be used as an indicator to determine whether the contact between the faces of the rolls maintains or is removed at step (x). This step is shown at C in FIG. 7A.

(28) At this point, in accordance with the method, step (xi) may be performed to determine which ends of the rolls made contact. If the contact is removed as indicated by torque being below the threshold level, the first ends of the rolls are in contact, and the method may then proceed on path 1. If the contact maintains as indicated by torque being above the threshold level, the second ends of rolls are in contact, and the method may then proceed on path 2 as described below. As shown in the example of FIGS. 12 and 13, the second ends of the rolls are in contact.

(29) In accordance with path 2, in a further aspect of the method, step (xii) may be performed to increase the distance between second ends of the rolls by the set incremental amount while maintaining the distance between the first ends of the rolls fixed. This is shown at E in FIG. 7A. In the example of FIG. 14, the distance between the second ends of the rolls is increased by 0.50 mm. Also, in accordance with the method, step (xiii) may be performed, and the position of the actuator associated with controlling the distance between the second ends of the rolls from step (ix) may be recorded (as shown in the drawings 0.25 mm) and an instance of contact of the second ends of the rolls may be recorded. This step is shown at F in FIG. 7A.

(30) Then, in accordance with an aspect of the method, step (xiv) may be performed to decrease the distance between the first ends of the rolls by the set incremental amount while the second ends of the rolls is fixed. This step is shown again at G in FIG. 7A and FIG. 15.

(31) At this point, in accordance with the method, step (xv) may be performed to determine whether the first ends of the rolls also made contact during the performing of step (ix) (that is, the distance between the first ends of the rolls and the second ends of the rolls is decreased until there is contact between the faces of the rolls). If there is no contact after performing step (xiv) (that is, decreasing the distance between first ends of the rolls while the seconds ends are fixed) and the threshold amount of allowed instances of contact for the first and second ends has not been reached, then in accordance with the method, the process may return to point A of FIG. 7A, and the distance between the first and second ends of the rolls may be decreased until contact is made as indicated by torque above the threshold level, which is shown at B in FIG. 7A. If there is contact after performing step (xiv), which indicates that the first ends of the roll were also in contact when the second ends of the roll were in contact, the position of the actuator associated with controlling the distance between the first ends of the rolls from step (ix) and another instance of contact of the first ends of the rolls may be recorded. This step is shown at H in FIG. 7A. Further, the distance between the first ends of the rolls may be increased by a factor applied to the set incremental distance, for instance, 1.5 times the set incremental distance. This step is shown at I in FIG. 7A. If the threshold number of instances of contact has not been reached, the process returns to point A in FIG. 7A.

(32) Making reference to the example shown FIG. 16, where steps (xiv) and (xv) indicate that the first ends of the roll were not in contact and the threshold number of instances of contact has not been reached, the process returns to point A in FIG. 7A. In accordance with an aspect of the method, step (xvi) may be performed and the distance between the first ends of the rolls and the second ends of the rolls may be decreased until contact between the faces of the rolls is indicated by sampled motor torque being above the threshold level. For instance, as shown in FIG. 16, the first and second ends of the rolls have moved 0.25 mm when contact is made. This step is shown again at B in FIG. 7A.

(33) In a further aspect of the method, step (xvii) may be performed and the distance between the first ends of the rolls may be increased by a set incremental amount while keeping the second ends of the rolls fixed. For instance, as shown in FIG. 17, side 1 of the roll is moved away from side 1 of the other roll by 0.50 mm while side 2 is fixed. Because the rolls continue to rotate, a change in motor torque may be used as an indicator to determine whether the contact between the faces of the rolls maintains or is removed at step (xvii). This step is shown at C in FIG. 7A.

(34) At this point, in accordance with the method, step (xviii) may be performed to determine which ends of the rolls made contact. If the contact is removed as indicated by torque being below the threshold level, side 1 of the rolls are in contact, and the method may then proceed on path 1. If the contact maintains as indicated by torque being above the threshold level, side 2 of rolls are in contact, and the method may then proceed on path 2 as described below. As shown in the example of FIGS. 16 and 17, the first ends of the rolls are in contact.

(35) In accordance with path 1, the position of the actuator associated with controlling the distance between the first ends of the rolls from step (xvi) may be recorded (as shown in the drawings 0.25 mm) and another instance of contact of the first ends of the rolls may be recorded. This step is shown at D in FIG. 7A. Provided the threshold number of allowed instances of contact of the first and second ends has not been reached, the process may continue as described above.

(36) Continuing from the example shown in FIGS. 16 and 17, in accordance with an aspect of the method, step (xix) may be performed and the distance between the first ends of the rolls and the second ends of the rolls may decreased until contact between the faces of the rolls is indicated by sampled motor torque being above the threshold level. For instance, as shown in FIG. 18, the first and second ends of the rolls have moved 0.25 mm when contact is made. This step is shown again at B in FIG. 7A.

(37) In a further aspect of the method, step (xx) may be performed and the distance between the first ends of the rolls may be increased by a set incremental amount while keeping the second ends of the rolls fixed. For instance, as shown in FIG. 19, side 1 of the roll is moved away from side 1 of the other roll by 0.50 mm while side 2 is fixed. Because the rolls continue to rotate, a change in motor torque may be used as an indicator to determine whether the contact between the faces of the rolls maintains or is removed at step (xx). This step is shown at C in FIG. 7A.

(38) At this point, in accordance with the method, step (xxi) may be performed to determine which ends of the rolls made contact. If the contact is removed as indicated by torque being below the threshold level, side 1 of the rolls are in contact, and the method may then proceed on path 1. If the contact maintains as indicated by torque being above the threshold level, side 2 of rolls are in contact, and the method may then proceed on path 2 as described below. As shown in the example of FIGS. 18 and 19, the second ends of the rolls are in contact.

(39) In accordance with path 2, in a further aspect of the method, step (xxii) may be performed and the distance between seconds ends of the rolls may be increased by the set incremental amount while maintaining the distance between the first ends of the rolls fixed. This is shown at E in FIG. 7A. In the example of FIG. 20, the distance between the second ends of the rolls is increased by 0.50 mm. Also, in accordance with the method, step (xxiii) may be performed and the position of the actuator associated with controlling the distance between the second ends of the rolls from step (xix) may be recorded (as shown in the drawings 0.25 mm) and an instance of contact of the second ends of the rolls may be recorded. This step is shown at F in FIG. 7A.

(40) Then, in accordance with an aspect of the method, step (xxiv) may be performed and the distance between the first ends of the rolls may be decreased by the set incremental amount while the second ends of the rolls is fixed. This step is shown again at G in FIG. 7A and FIG. 21.

(41) At this point, in accordance with the method, step (xxv) may be performed to determine whether the first ends of the rolls also made contact during the performing of step (xix) (that is, the distance between the first ends of the rolls and the second ends of the rolls is decreased until contact between the faces of the rolls). If there is no contact after performing step (xxiv) (that, is decreasing the distance between first ends of the rolls while the seconds ends are fixed) and the threshold amount of allowed instances of contact for the first and second ends has not been reached, then in accordance with the method, the process may return to point A of FIG. 7A, and the distance between the first and second ends of the rolls may be decreased until contact is made as indicated by torque above the threshold level, which is shown at B in FIG. 7A. If there is contact after performing step (xxiv), which indicates that the first ends of the roll were also in contact when the second ends of the roll were in contact, the position of the actuator associated with controlling the distance between the first ends of the rolls from step (xix) and another instance of contact of the first ends of the rolls may be recorded. This step is shown at H in FIG. 7A. Further, the distance between the first ends of the rolls may be increased by a factor applied to the set incremental distance, for instance, 1.5 times the set incremental distance. This step is shown at I in FIG. 7A.

(42) In keeping with the example shown in FIGS. 8-21, the process will continue until the threshold number of instances of contact are made. In particular, the process shown in FIG. 16-21 will continue with first ends of the rolls making contact and second ends of the rolls making contact. Once the threshold number of instances of contact are made, the first and second ends may be brought to reference positions and the normal operation of the machine may begin. This is indicated at J in FIG. 7A.

(43) FIGS. 22A and 22B show a similar process where electrical continuity rather than instrumentation (motor torque, motor speed, electronic position sensors) is used to determine contact between the first ends of the rolls and the second ends of the rolls. So, FIG. 22A does not include steps of moving an end of the roll away and sampling motor torque to determine whether contact was made at the respective end of the roll.

(44) Further embodiments can be envisioned by one of ordinary skill in the art after reading this disclosure. In other embodiments, combinations or sub-combinations of the above-disclosed invention can be advantageously made. The example arrangements of components are shown for purposes of illustration and it should be understood that combinations, additions, re-arrangements, and the like are contemplated in alternative embodiments of the present invention. Thus, various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims and that the invention is intended to cover all modifications and equivalents within the scope of the following claims.