Methods and apparatus for adjusting nip rolls
Methods and apparatus for adjusting nip rolls are disclosed. In particular, a web material is moved between a first roll and a second roll opposite the first roll and a pressure value associated with an amount of pressure applied to the web material by the first and second rolls is determined. The amount of pressure applied to the web material is controlled by moving one of the first and second rolls based on the pressure value.
The present disclosure relates generally to printing processes and more particularly to adjusting nip rolls in printing processes.
BACKGROUNDA printing press is typically implemented using a plurality of rolls that are configured to guide a moving web material (e.g., a paper material, a plastic material, a textile material, etc.) through a printing press. The plurality of rolls often includes opposing nip rolls that are typically configured to nip, squeeze, or otherwise apply pressure or force to opposing sides of the moving web material. For example, folding machines (i.e., folders) include one or more sets of opposing nip rolls that are configured to receive and make one or more folds in the moving web. Opposing nip rolls may be used to form a fold in the moving web by pressing opposing faces of adjacent panels on either side of a fold line against one another and forming a crease at the fold line.
The pressure or force applied to the moving web by opposing nip rolls is typically set by adjusting the position of the nip rolls once during a make-ready process and locking the nip rolls into position for the duration of a production run. Many operations of the printing press may be adjusted during the make-ready process, which is typically performed prior to starting each production run. In particular, the pressure applied to the moving web by opposing nip rolls may be adjusted by separating the nip rolls by an optimal distance to ensure that the radial surfaces of the nip rolls apply an appropriate pressure to the moving web given the thickness of the web material. Moving the nip rolls too close to each other may result in marring, tearing, or otherwise damaging the moving web. However, moving the nip rolls too far apart may result in poor fold formations and/or other degradations in quality.
The optimal distance by which nip rolls should be separated is often empirically determined using known methods. One known method involves a skilled machine operator manually pulling one or more sheets of web material (e.g., paper) through opposing nip rolls and estimating the amount of pressure applied to the sheets of paper by the nip rolls based on the amount of force required to pull the material through the nip rolls. For example, too much pulling force indicates that the nip rolls are too close together and must be separated.
If the operator believes that the pulling force is either excessive or insufficient, the machine operator then changes the distance by which the nip rolls are separated to increase or decrease the pressure applied by the nip rolls. The nip roll adjustment process is then repeated one or more times until the operator determines that the amount of pressure applied by the nip rolls is correct for a given material at a given thickness, at which point the nip rolls are locked in position for the duration of the production run.
Traditional methods such as the method described above for adjusting nip rolls are often time consuming and require a skilled machine operator. In addition, locking the nip rolls in position for the duration of a production run prevents changing a web material type or thickness without shutting down the printing press and adjusting the nip rolls.
BRIEF DESCRIPTION OF THE DRAWINGS
Although the following discloses example systems including, among other components, software executed via hardware, it should be noted that such systems are merely illustrative and should not be considered as limiting. For example, it is contemplated that any or all of these hardware and software components could be embodied exclusively in hardware, exclusively in software, or in any desired combination of hardware and software. Accordingly, while the following describes example methods, systems, and apparatus, persons having ordinary skill in the art will readily appreciate that the examples provided are not the only way to implement such example methods, systems, and apparatus.
In general, the example methods and apparatus described herein may be used to adjust the nip rolls typically found in printing presses used to manufacture books, magazines, catalogs, or the like. Nip rolls are often used in folding machines (i.e., folders) to nip, squeeze, or otherwise apply pressure to a moving web material (e.g., a paper material, a plastic material, a textile material, etc.). Folders are configured to receive a moving web material and fold the moving web one or more times via a plurality of rolls. As described in greater detail below, a feedback loop is used to hold constant the pressure or force applied to the moving web by opposing nip rolls. Pressure changes between opposing nip rolls may be caused by, for example, changes in material thickness (e.g., within a roll of material, between rolls, etc.) and changes in web tension. Such pressure changes may be monitored using a load sensor operatively coupled to at least one of the opposing nip rolls. When the load sensor indicates a change in pressure, a control signal may be communicated to an actuating device to change or vary the distance between the opposing nip rolls.
In the example printing press 100, the web material 108 moves through the printer 102 at which point information is imaged or printed onto the web material 108. The web material 108 is then moved through the folder 104, which has a plurality of rolls including nip rolls as described in greater detail below in connection with
The lateral guide roll 204 is configured to receive the web material 108 from, for example, a supply roll, another machine (e.g., the printer 102), or another roll assembly within the folder 104 and to guide the web material 108 toward the forming rolls 206a and 206b.
The forming rolls 206a and 206b are configured to initially form or prepare the outer edges of the web material 108 for a folding operation. In particular, the forming rolls 206a and 206b are spaced apart by a distance that is less than the width (w) of the web material 108. In this manner, the forming rolls 206a and 206b move the outer portions of the web material 108 closer together about a folding line 210 as shown in
The web material 108 is then moved between the opposing first and second nip rolls 208a and 208b. The nip rolls 208a and 208b are configured to fold the web material 108 about the folding line 210 to form adjacent panels having opposing faces pressed together. The nip rolls 208a and 208b may be configured to apply sufficient pressure or force to form a crease at the folding line 210. More specifically, the first nip roll 208a has a first radial surface 210a (i.e., a first outer surface) opposing a second radial surface 210b (i.e., a second outer surface) of the second nip roll 208a configured so that the nip rolls 208a and 208b apply an amount of pressure or force via their opposing radial surfaces 210a and 210b to the web material 108 as the web material 108 moves therebetween.
In general, a make-ready process may be performed prior to each production run of a production line (e.g., the example printing press 100 of
As is known the nip roll configuration shown in
After the stacked sheets 304, 306, and 308 are captured between the nip rolls 302a and 302b, the operator pulls the slip sheet 308 in a direction generally indicated by arrow 310. If the slip sheet 308 can be pulled out too easily, the operator may determine that the nip rolls 302a and 302b are positioned too far apart and, thus would not apply sufficient pressure to a web material (e.g., the web material 108 of
The first and second nip rolls 402a and 402b are separated by a distance that enables the rolls 402a and 402b to nip, squeeze, or otherwise apply a desired pressure or force to opposing sides of the web material 403. The nip rolls 402a and 402b may be substantially similar or identical to the nip rolls 208a and 208b described above in connection with
The actuator 406 is operatively coupled to the shaft 408, which is operatively coupled to the support block 410. In general, the actuator 406 is configured to actuate the shaft 408 to cause the support block 410 to move in the directions generally indicated by the arrow 416. The support block 410, the load sensor 412, and the support frame 404 are mechanically coupled so that actuation by the actuator 406 causes the first nip roll 402a to move relative to the second nip roll 402b to adjust an amount of pressure applied to the web material 403 by the nip rolls 402a and 402b.
The actuator 406 may be any device suitable for moving the support block 410 such as, for example, a stepper motor, a linear motor, a pneumatic cylinder, a hydraulic cylinder, a solenoid, etc. The shaft 408 and the support block 410 are configured to work with the actuator 406. For example, if the actuator 406 is implemented using a stepper motor, the shaft 408 may be implemented using a screw having threads 418 and the support block 410 may include a threaded bore 420 therethrough so that the shaft 408 may be threadably coupled to the support block 410 as shown in
The load sensor 412 is captured between the support frame 404 and the support block 410. The load sensor 412 is configured to measure an amount of force or pressure that is applied to the web material 403 by the first and second nip rolls 402a and 402b. The amount of force or pressure measured by the load sensor 412 increases as the support block 410 is moved toward the second nip roll 402b. For example, the pressure or force applied to the web material 403 and measured by the load sensor 412 may increase as the distance between the first and second nip rolls 402a and 402b decreases. The load sensor 412 may be implemented using any device suitable for measuring force or pressure such as, for example, a load cell.
The control system 414 may be implemented using a hardware system (e.g., the example system 600 of
The control system 414 includes an information display 422 and an input interface 424. The information display 422 may be implemented using, for example, a liquid crystal display (LCD) or a light emitting diode (LED) display and may be used to display the pressure or force measurement information provided by the load sensor 412. The input interface 424 may be implemented using any type of suitable buttons or user interface for entering information into the control system 414. The information display 422 and the input interface 424 may be used by an operator to configure parameters associated with the adjustment apparatus 400 and to monitor performance to ensure that the adjustment apparatus 400 is functioning properly. For example, the input interface 424 may be used to input desired or predetermined minimum and maximum force or pressure threshold values corresponding to the amount of pressure to be applied by the nip rolls 402a and 402b during a production run.
The actuator 406 and the load sensor 412 are communicatively coupled to the control system 414 to form a nip roll adjustment feedback loop. The feedback loop may be configured to control an amount of force or pressure applied to the web material 403 by substantially continuously monitoring via the load sensor 412 the amount of force or pressure applied by the nip rolls 402a and 402b to the web material 403. For example, to apply a constant amount of pressure to the web material 403, the control system 414 may monitor the amount of applied pressure detected by the load sensor 412 and vary the position of the nip roll 402a via the actuator 406 based on detected pressure variations.
The control system 414 may be configured to process the force or pressure measurement information via a hardware circuit and/or software executed on a processor (e.g., the processor 712 of
The feedback loop operates continuously so that as the actuator 406 moves the first nip roll 402a, the pressure sensor 412 can substantially simultaneously communicate force measurements to the control system 414. In this manner, the control system 414 may determine when to stop the actuator 406. In addition, the continuous operation of the feedback loop enables material properties (e.g., thickness) of the web material 403 to change during a production run without having to shutdown a production line (e.g., the example printing press 100 of
Although the adjustment apparatus 400 is described above as being configured to automatically and continuously adjust the nip rolls 402a and 402b, the adjustment apparatus 400 may also be configured to operate in a manual mode. In the manual mode, the feedback loop is disabled and an operator is responsible for observing the force measurement on the information display 422 and inputting control information to the control system 414 via the input interface 424 to actuate the actuator 406 based on the force measurement.
The example method 500 may be implemented in software, hardware, and/or any combination thereof. For example, the example method 500 may be implemented in software that is executed on the processor system 710 of
Initially, measurement information is obtained from a load sensor (e.g., the load sensor 412 of
A measured pressure value corresponding to an amount of pressure applied by the nip rolls 402a and 402b may then be determined (block 504). More specifically, the measured pressure value may be determined based on the measurement information received from the load sensor 412 using a conversion routine executed or performed by the control system 414. The conversion routine may involve the use of a look-up table stored in a memory (e.g., the system memory 724 and/or the mass storage memory 725 of
The measured pressure value may then be compared to a maximum threshold pressure value (block 506). If the measured pressure value is greater than the maximum threshold pressure value, the pressure applied to the web material 403 (
If it is determined at block 506 that the measured pressure value is not greater than the maximum threshold pressure value, the measured pressure value is compared to a minimum threshold pressure value (block 510). If the measured pressure value is less than the minimum threshold pressure value, the pressure applied to the web material 403 by the opposing nip rolls 402a and 402b is increased (block 512). The pressure may be increased by decreasing the distance between the opposing nip rolls 402a and 402b by causing the actuator 406 to drive the first nip roll 402a toward the second nip roll 402b.
If it is determined at block 510 that the measured pressure value is not less than the minimum threshold pressure value or after the operations of block 508 or block 512 are completed, it is determined if monitoring of the pressure should be continued (block 514). If monitoring of the pressure should be continued, control is passed back to block 502, otherwise the process is ended.
Of course, any one or more signal conditioning techniques may be implemented with the example method 500 such as, for example, signal averaging, signal filters, noise reduction algorithms, hysteresis, etc. The signal conditioning techniques may be used to prevent or minimize erroneous signal interpretation and/or system oscillation. For example, an averaging technique may be applied to the measurement information obtained from the load sensor at block 502 to suppress any electrical noise spikes that may otherwise be interpreted as pressure values exceeding the maximum or minimum threshold pressure values. Hysteresis may be used to prevent or minimize oscillatory control of the actuator 406 when the measured pressure values are equal to or substantially equal to the maximum or minimum threshold pressure values.
As shown in
The pressure meter 604 may be configured to convert the measurement information obtained from the load sensor 602 to a measured force or pressure value using, for example, a look-up table as described above in connection with block 504 of
The actuator 608 may be substantially similar or identical to the actuator 406 of
Although the above example methods and apparatus are generally described with regard to nip rolls (e.g., the nip rolls 402a and 402b of
The processor 712 of
The system memory 724 may include any desired type of volatile and/or non-volatile memory such as, for example, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, read-only memory (ROM), etc. The mass storage memory 725 may include any desired type of mass storage device including hard disk drives, optical drives, tape storage devices, etc.
The I/O controller 722 performs functions that enable the processor 712 to communicate with peripheral input/output (I/O) devices 726 and 728 via an I/O bus 730. The I/O devices 726 and 728 may be any desired type of I/O device such as, for example, a keyboard, a video display or monitor, a mouse, etc. While the memory controller 720 and the I/O controller 722 are depicted in
The methods described herein may be implemented using instructions stored on a computer readable medium that are executed by the processor 712. The computer readable medium may include any desired combination of solid state, magnetic and/or optical media implemented using any desired combination of mass storage devices (e.g., disk drive), removable storage devices (e.g., floppy disks, memory cards or sticks, etc.) and/or integrated memory devices (e.g., random access memory, flash memory, etc.).
Although certain methods, apparatus, and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. To the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
Claims
1. A method of adjusting nip rolls, comprising:
- moving a web material between a first roll and a second roll opposite the first roll;
- determining a pressure value associated with an amount of pressure applied to the web material by the first and second rolls; and
- controlling the amount of pressure applied to the web material by moving one of the first and second rolls based on the pressure value.
2. A method as defined in claim 1, wherein determining the pressure value associated with the amount of pressure applied to the web material comprises:
- obtaining measurement information from a load sensor; and
- retrieving the pressure value based on the measurement information.
3. A method as defined in claim 2, wherein the measurement information is associated with at least one of a voltage value, a current value, an analog value, or a binary encoded value.
4. A method as defined in claim 1, wherein controlling the amount of pressure applied to the web material comprises:
- comparing the pressure value to a threshold value; and
- controlling an actuator based on the comparison of the pressure value to the threshold value.
5. A method as defined in claim 4, wherein the threshold value is associated with an operating range.
6. A method as defined in claim 4, wherein the threshold value is a maximum threshold pressure value or a minimum threshold pressure value.
7. A method as defined in claim 4, wherein the actuator is a stepper motor, a hydraulic cylinder, a pneumatic cylinder, or a solenoid.
8. A method as defined in claim 1, wherein moving one of the first and second rolls includes varying a distance by which the first and second rolls are separated.
9. A method as defined in claim 1, wherein controlling the amount of pressure applied to the web material includes maintaining a constant pressure.
10. A method as defined in claim 1, wherein the web material is a paper material, a plastic material, or a textile material.
11. A method as defined in claim 1, wherein the load sensor is a load cell.
12. A method as defined in claim 1, further comprising displaying the pressure value on a display.
13. A method of adjusting nip rolls, comprising:
- applying a force to a web material via a radial surface of a roll;
- obtaining measurement information from a load sensor operatively coupled to the roll and configured to monitor the force applied to the web material; and
- changing the force applied to the web material by the radial surface based on the measurement information by translating the roll relative to the web material.
14. A method as defined in claim 13, wherein changing the force applied to the web material by the radial surface based on the measurement information comprises:
- determining a measured force value based on the measurement information;
- comparing the measured force value to a threshold value; and
- changing the force applied to the web material based on the comparison of the measured force value and the threshold value.
15. A method as defined in claim 14, wherein the threshold value is associated with an operating range.
16. A method as defined in claim 14, wherein the threshold value is a maximum threshold pressure value or a minimum threshold pressure value.
17. A method as defined in claim 14, further comprising displaying the measured force value on a display.
18. A method as defined in claim 13, wherein changing the force applied to the web material includes controlling an actuator operatively coupled to the roll.
19. A method as defined in claim 18, wherein the actuator is a stepper motor, a hydraulic cylinder, a pneumatic cylinder, or a solenoid.
20. A method as defined in claim 13, wherein the load sensor is a load cell.
21. A method as defined in claim 13, wherein the measurement information is associated with at least one of a voltage value, a current value, an analog value, or a binary encoded value.
22. An apparatus for adjusting nip rolls, comprising:
- a first roll having a first outer surface;
- a second roll having a second outer surface located adjacent the first outer surface, wherein the first roll and the second roll are configured to receive a moving web material between the first and second outer surfaces;
- a pressure sensor operatively coupled to the first roll and configured to generate an electrical signal based on a pressure applied to the moving web material by the first outer surface and the second outer surface; and
- an actuator operatively coupled to the pressure sensor and configured to change the pressure applied to the moving web material based on the electrical signal by moving the first roll relative to the second roll.
23. An apparatus as defined in claim 22, further comprising a pressure meter communicatively coupled to the pressure sensor and configured to obtain the electrical signal from the pressure sensor and determine a measured pressure value associated with the pressure applied to the moving web.
24. An apparatus as defined in claim 23 further comprising a comparator communicatively coupled to the pressure meter and the actuator and configured to obtain the measured pressure value from the pressure meter and compare the measured pressure value to a threshold value and control the actuator based on the comparison.
25. An apparatus as defined in claim 24, wherein the threshold value is a maximum threshold value or a minimum threshold value.
26. An apparatus as defined in claim 22, wherein the actuator is a stepper motor, a hydraulic cylinder, a pneumatic cylinder, or a solenoid.
27. An apparatus as defined in claim 22, wherein the load sensor is a load cell.
28. An apparatus as defined in claim 22, wherein the electrical signal is associated with at least one of a voltage value, a current value, an analog value, or a binary encoded value
Type: Application
Filed: Dec 2, 2004
Publication Date: Jun 8, 2006
Inventor: James Fieffer (Westminster, CA)
Application Number: 11/002,508
International Classification: B65H 20/02 (20060101);