US20130296150A1

US20130296150A1 - Method and system for a dynamic multiple scanners system

Info

Publication number: US20130296150A1
Application number: US13/875,781
Authority: US
Inventors: Yaron SMIRNOV; Tal HARMON
Original assignee: Highcon Systems Ltd
Current assignee: Highcon Systems Ltd
Priority date: 2012-05-02
Filing date: 2013-05-02
Publication date: 2013-11-07
Also published as: WO2013164810A1

Abstract

A multiple laser-beam scanner system for applying pre-treatment to a cardboard item. While maintaining a substantially uniform velocity of conveying the cardboard item through the system, the cardboard item is logically divided into areas and one or more laser-beam scanners are assigned to the areas. As such, the complex areas of the cardboard can be made smaller and/or multiple laser-beam scanners can be assigned to the complex areas to help ensure that dwell time on the cardboard is not increased.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a utility patent application being filed in the United States as a non-provisional application for patent under Title 35 U.S.C. §100 et seq. and 37 C.F.R. §1.53(b) and, claiming the benefit of the prior filing date under Title 35, U.S.C. §119(e) of the United States provisional application for patent that was filed on May 2, 2012 and assigned Ser. No. 61/641,458, which application is incorporated herein by reference in its entirety.
This application is related to the following United States pending applications, which are hereby incorporated by reference: Ser. No. 13/108,389 having a filing date of May 15, 2011 and Ser. No. 13/684,196 having a filing date of Nov. 22, 2012, and the International Application bearing the title of “Cardboard-handling system and method” assigned serial number PCT/IL2012/000377.

TECHNICAL FIELD

The present disclosure generally relates to laser-beam (LB) scanners, and more particularly the disclosure relates to a system and method of LB scanner pre-treating a cardboard.

BACKGROUND

The rapid evolution of trade around the world (globalization) has created a significant demand for packaging in order to transfer/distribute goods to different remote areas. The transport of goods may be done by: ship, airplanes, trucks, as well as other transportations. The transport of goods may be performed by: the manufacturer; different suppliers; individual persons; etc. Further, a significant demand for different brochures, flyers, and the like also takes part in trade. The different brochures/flyers may have pre-folds and/or embossing and/or cuttings, for example. As a non-limiting example embossing may be Braille writing.
Packaging has taken on a major role in the marketing of products in today's environments. The package in which the goods are packed and presented, in a store for instance, may determine if the goods will be appealing to a potential buyer in the store or not. Thus the packaging appearance can have a direct effect on the sales of merchandise. The brochures, flyers, and similar collateral may also contribute to the sales and/or awareness with regards to a product and/or a service, for example.
Henceforth, throughout the description, drawings and claims of the present disclosure, the terms package, paperboard box, parcel, box, carton box, cardboard box, brochure, plastic box, flyers, etc. may be used interchangeably. The present disclosure may use the term package as a representative term for the above group as well as variants thereof.
In the process of constructing a package, it is well known in the art that as a preliminary requirement, a pre-treated cardboard and/or paper based material should be purchased or prepared. The paper based material may be constructed in a variety of forms and using a variety of different types of materials as well as combinations material types. For example, the material types may include, but are not limited to: waxed paper, cartridge paper, art paper, as well as other materials. Henceforth, throughout the description, drawings and claims of the present disclosure, the terms cardboard, card-stock, display board, corrugated fiberboard, paperboards of different paper based material, folding boxboard, carton, blanks, laminated paper, plastics sheets, any of these and other materials, may be used interchangeably and, the various embodiments as well as anticipated variants thereof may operate on any of these materials as well as combinations of these materials and other materials. Thus, while the present disclosure or certain embodiments may be presented as working with cardboard, this is just a representative term for the above groups well as variants thereof.
The pre-treatment of a cardboard may include one or more of the following actions: creating folding lines along the cardboard to ease and provide accurate folding of the cardboard; piercing the cardboard in different areas; creating embossment in different areas of the cardboard; cutting the raw cardboard into predefined profiles, cutting openings, slits or slots in the cardboard; a combination of two or more of the above-listed actions as well as other actions. Thus, any combination of these and other actions may also be performed. Henceforth, throughout the description, drawings and claims of the present disclosure the terms pre-folded cardboard, and pre-treated cardboard may be used interchangeably. The present disclosure may use the term pre-treated cardboard as a representative term for the above group of actions as well as combinations of these and other actions.
Some common techniques for preparing a pre-treated cardboard include the acts of placing the cardboard between dies. A few non-limiting examples of the types of dies include: a cutting-die; a creasing-die; an embossing-die; a scoring-die; a counter die; a combination of two or more of these different types of dies as well as other die types.
Other examples of common techniques for preparing a pre-treated cardboard may include using light sources, such as, but not limited to laser-beams. For example, some common laser-beam based techniques may employ the use of CO2, YAG or fiber lasers. A typical range of wavelength utilized in such laser-beam based techniques may be between 0.35 to 12.0 micro meter, (10.6 μm for CO₂, for example). A typical range of wavelength for a fiber laser based technique may be between 1-2 micro-meters. The laser-beam power may be in the range of a few tens of milliwatts to several hundred watts. A laser-beam source may deliver between 100 to 500 watts, and be used for pre-treating cardboard having widths of 0.2 to 9 mm, for example.
Examples of actions performed with laser-beam based pre-treatment of a cardboard may include: cutting, creasing, embossing, piercing, as well as a combination of two or more of these actions as well as other actions. Henceforth, throughout the description, drawings and claims of the present disclosure, the term laser-beam may be used as a representative term for a variety of light sources pre-treating a cardboard and the like.
When using a laser-beam for pre-treating a cardboard, a laser-beam scanning system (scanners) may be used. Laser-beam scanning may be a controlled deflection of the laser-beam, visible or invisible, by one or more moveable light reflecting planes.

SUMMARY OF THE DISCLOSURE

The present disclosure presents various embodiments of systems, devices and methods for processing of cardboard items in systems that employ the use of LB scanners. Although the various embodiments are presented as being applicable for cardboard handling systems, it should be appreciated that the various inventive techniques and systems may equally be applied in other settings in which media or other items are pre-treated at least partially but the use of an LB scanner. In general, the various embodiments include the ability to dynamically adjust the operation of one or more LB scanners operating within the cardboard handling system such that the throughput of the system is optimized.
More particularly, one embodiment includes a system and method of a dynamic, multiple scanner system (DMSS) that can be automatically and dynamically adjusted to modify the throughput of the method and system for each job and/or for each cardboard to be pre-treated. Embodiments may employ the use of two or more LB scanners while the cardboard is conveyed at a substantially constant velocity through the system. Advantageously, the ability to maintain a substantially constant velocity can allow for reducing the complexity of the mechanics of the cardboard handling system as having to vary the velocity can require expensive and complex components.
In various embodiments, the DMSS may automatically and dynamically define or adjust areas of responsibility for each of the LB scanners. This may be performed on a per job basis and/or on a per cardboard basis. Further, in various embodiments, the DMSS may automatically and dynamically make adjustments such that an overlap occurs in the areas of responsibility of two or more LB scanners thus allowing multiple LB scanners to work on complicated areas. Further, the DMSS may automatically and dynamically plan and change the order, method and/or algorithm of the pre-treatment actions performed in the pre-treatment of a cardboard according to the dynamic change of the areas of responsibility of one or more LB scanners, and/or vice versa.
In addition, in various embodiments the DMSS may automatically and dynamically change the defined time slot to pre-treat different divisions or areas of a cardboard. Some embodiments of a DMSS may automatically and dynamically change the size of one or more divisions. In various embodiments, an algorithm may be employed for the pre-treatment of a cardboard while it is being conveyed. As a non-limiting example, the algorithm may perform the actions of: (a) theoretically dividing the cardboard into a plurality of divisions, (b) assigning two or more of the LB scanner areas of responsibility.
Even further, in various embodiments, the DMSS may automatically and dynamically change the coverage areas of one or more of the LB scanners before and/or while pre-treating a conveyed cardboard. These and other aspects of the disclosure will be apparent in view of the attached figures and detailed description. The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure, and other features and advantages of the present disclosure will become apparent upon reading the following detailed description of the embodiments with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present disclosure will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:

FIG. 1A is a block diagram illustrating relative components of a portion of an exemplary cardboard-processing system.

FIG. 1B is a block diagram illustrating relevant elements of another exemplary embodiment of a cardboard-processing system.

FIG. 1C is a conceptual drawing illustrating relevant elements of an example of a cardboard.

FIG. 2A schematically illustrates a simplified example of a design of a pretreated cardboard.

FIG. 2B schematically illustrates a simplified example of a section of the pretreated cardboard illustrated in FIG. 2A.

FIG. 3A is a schematic diagram illustrating a simplified block diagram with relevant elements of an exemplary laser scanning system (scanner).

FIG. 4A schematically illustrates a portion of a simplified block diagram with relevant elements of an exemplary scanner coverage area.

FIG. 4B is a conceptual drawing illustrating the maximum coverage area of an exemplary LB scanner.

FIGS. 5A-B is a schematic illustration of simplified block diagrams with relevant elements of an example of a DMSS, implemented according to teaching of the present disclosure;

FIGS. 6A-B schematically illustrates a simplified example of a dynamic automatic responsibility areas of laser scanners of a DMSS, implemented according to teaching of the present disclosure;

FIGS. 7A-F schematically illustrate a simplified example of a dynamic automatic division of a cardboard and a coverage area of DMSS scanner, implemented according to teaching of the present disclosure;

FIGS. 8A-C schematically illustrates a simplified portion of a flowchart with relevant actions of an example of a DMSS method for preplanning a cardboard pre-treatment, implemented according to teaching of the present disclosure;

FIG. 9 schematically illustrates a simplified portion of a flowchart with relevant elements of an example of an automatic dynamic pre-treatment cardboard method by a DMSS, implemented according to teaching of the present disclosure;

FIG. 10 is a functional block diagram of the components of an exemplary embodiment of system or sub-system operating as a controller or processor, implemented according to teaching of the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Turning now to the figures in which like numerals and/or labels represent like elements throughout the several views, exemplary embodiments of the present disclosure are described. For convenience, only some elements of the same group may be labeled with numerals. The purpose of the drawings is to describe exemplary embodiments and is not for production purpose. Therefore features shown in the figures are for illustration purposes only and are not necessarily drawn to-scale and were chosen only for convenience and clarity of presentation.
It will be appreciated by one of ordinary skill in the art that the incorporation of LB scanners into a pre-treatment process can impose restrictions on the throughput capacity of a cardboard handling system. Unlike the use of dies, the use of a LB scanner may require additional time and/or passes over a cardboard in order to fully achieve the desired pre-treatment. As a result, the movement of the cardboards through the system can be delayed while the LB scanner is performing the pre-treatment actions.
Many advantages can be realized in the use of LB scanners in a cardboard handling system. For instance, the ability to control the movement of a LB by software and/or hardware based controllers allows a cardboard handling system to by dynamically adjusted by a controller rather than having to disassemble, adjust and modify the cardboard handling system.
FIG. 1A is a block diagram illustrating relative components of a portion of an exemplary cardboard-processing system 100 a. The illustrated embodiment of the cardboard-processing system 100 a may include, but is not limited to, a feeder 102, a cardboard pre-treatmenter 104, a stacker 106, a controller 112, and one or more conveyors 108 and 110.
The feeder 102 may receive, retrieve or otherwise obtain a cardboard and feed it toward a conveyor 108. The conveyor 108 may convey the cardboard toward the cardboard pre-treatmenter 104. The cardboard pre-treatmenter 104 may then perform one or more pre-treatments to the cardboard such as: creasing, cutting, embossing, piercing, printing, imaging, as well as a combination of two or more of these actions as well as other treatments. Once the pre-treatment is completed, the conveyor 110 may convey the pre-treated cardboard toward the stacker 106.
The stacker 106 may stack the pre-treated cardboards into a pile. In some embodiments, the stacker may comprise the conveyor 110. The controller 112 may control and/or synchronize the operation of one or more of the modules of the cardboard-processing system 100 a. It should be appreciated that the illustrated modules in the cardboard processing system 100 a, as well as in any other of the illustrated embodiments in this disclosure, is just one example of a workable configuration. The modules are provided to delineate and illustrate functionality and may not necessarily be required to exist as separate physical components. For instance, two or more of the illustrated modules may be combined into a single module, as well as other configurations. Likewise, functionality from one module can be spread across multiple physical modules. Further, other embodiments of a cardboard-processing system may include other modules.
FIG. 1B is a block diagram illustrating relevant elements of another exemplary embodiment of a cardboard-processing system 100 b. The illustrated cardboard-processing system 100 b is shown as including a feeder 120, a die-rule and counter-die 122, a laser 124, a stacker 126, a controller 130, and a conveyor 128. Arrow 150 represents the flow-direction of cardboard items being passed through the cardboard-processing system.
The feeder 120 may receive, retrieve or otherwise obtain a cardboard and transmit it toward the conveyor 128. The conveyor 128 may convey the cardboard toward and/or through the die-rule and counter-die 122. The die-rule and counter-die 122 may pre-treat the cardboard.
The one or more die rules and counter dies 122 may include: a steel-rule die industry, and/or surface-adhesive-rule technology (SART), laser-beam industry, a combination of these, as well as others. More information on surface-adhesive-rule technology (SART) may be found in related United States non-provisional application bearing the title of “Method and system for surface adhesive rule technology” having serial number U.S. Ser. No. 13/108,389, which application is incorporated by reference in the Cross-reference to related applications section.
The conveyor 128 may then convey the pre-treated cardboard toward the laser 124 to be further pre-treated. The laser may operate to provide additional pretreatment actions to the cardboard. The conveyor 128 may then convey the pre-treated cardboard toward the stacker 126. The stacker 126 may stack the pre-treated cardboard into a pile. The controller 130 may synchronize and control one or more of the modules of the cardboard-processing system 100 b.
The controller 130 may obtain inputs from different sensors along the cardboard-processing system 100 b, and accordingly send commands to one or more modules. A few non-limiting examples of the types of commands that the controller 130 may send to a module include commands to: adjust the velocity of the conveyor, start/stop operation, hold/release cardboard, forward/reverse the cardboard feed, accelerate/decelerate movement; as well as a combination of two or more of these commands and/or other commands. In some embodiments, the controller may obtain information from an operator and/or relevant computer files and job descriptions. Computer files can supported in a variety of formats and a few non-limiting examples include DXF and PDF.
Other examples of cardboard-processing systems may comprise other modules, more of the same modules, only some of the described modules, and so on.
More information on examples of embodiments of cardboard-processing systems may be found in related US patent applications bearing the title of “Cardboard-handling system and method” having serial number U.S. Ser. No. 13/684,196 and PCT patent application bearing the title of “Cardboard-handling system and method” having serial number PCT/IL2012/000377, each of which are incorporated herein above in the Cross-reference to Related Applications section.
Other systems and/or modules that may be part of a cardboard-processing system and/or similar to the cardboard-processing system may comprise: coating systems (lamination coating, for instance); selective coating systems, printing systems, pre-print systems, post-print systems; finishing systems; as well as other modules or systems and/or combinations of such modules or systems.
FIG. 1C is a conceptual drawing illustrating relevant elements of an example of a cardboard 150. Arrow 130 represents the machine-direction of a cardboard-processing system in which cardboard 150 is passed and pre-treated. The leading edge 142 of the cardboard 150 is the edge to first pass the through the machine, in reference to machine-direction 130. The trailing edge 144 of the cardboard 150 is the edge last to pass through the machine, in reference to machine-direction 130.
FIG. 2A schematically illustrates a simplified example of a design of a pretreated cardboard 200 a. The pretreated cardboard 200 a may comprise a plurality of sections 204 a-n. Each section 204 a-n may represent: a package layout; a printed image; a laminated area, a processed area; as well as other configurations and/or a combination of two or more configurations. Henceforth throughout the description drawing and claims of the present disclosure the word ‘section’ may be used as a representative term for the above group and the like.
The operations and treatments, as well as settings and parameters of such that are applied to pre-treated cardboards 200 a may vary between jobs. The parameters may include, but are not limited to: width 206, length 202, type of material, thickness (not shown in drawing), etc. Furthermore, each job may differ from another job in a variety of manners, such as the layout of the sections, the number of sections 204 a-n, layout of the sections, the actions applied to the sections, the sections themselves, as a few non-limiting examples.
FIG. 2B schematically illustrates a simplified example of a section of the cardboard illustrated in FIG. 2A. The illustrated section 200 b of cardboard 200 a may be a package layout as a non-limiting example. The package layout 200 b may comprise a plurality of creases 218 a-d, which creases may operate to ease future folding of the cardboard at required places. The package layout's 200 b surrounding may be an un-continuous cut line 216 comprising a plurality of joints 214 a-n (un-cut areas in rib liked shapes, for instance). The joints 214 a-n may be used to keep the package layout 200 b connected to a pre-treated cardboard from which it is created. The section may also include cuts in the package layout, such as cut 220 for instance.
The throughput of a cardboard-processing system is an important aspect of a cardboard processing system. The throughput of a cardboard-processing system may be defined as the amount of cardboards it is able to pre-treat over a defined period of time (such as 1500 cardboards per hour, for example). The throughput of the cardboard-processing system has an effect on the economic-value of the system and may determine whether that system will be purchased/used in particular applications.
Common cardboard handling systems for pre-treating cardboards typically require expensive and complex mechanics and electronics to provide the capabilities for acceleration, stopping, decelerating etc., while processing the cardboards through the different modules of the system.
In typical cardboard-processing systems for pre-treating cardboards, if a laser-beam (LB) scanner is one of the systems modules used for pre-treating the cardboards, the LB scanner may slow down the throughput of the cardboard-processing system and thus, may be a bottle neck in the productivity of a system, such as the cardboard-processing system similar to the cardboard-system 100 b described in conjunction with FIG. 1B, for example.
Unlike die-cuts/die-creases that can operate to create a required layout in a single stroke (even for complex layouts) and in a plurality of sections on a cardboard (cardboard 200 a in FIG. 2 a, for example), a laser-beam (LB) scanner may require more time as it may need to go over each specific area that requires laser treatment.
The power of a laser-beam hitting a certain area may decrease when the laser-beam is deflected in certain angles. Due to this phenomenon, additional dwell time may be required at those specific areas to create the required pre-treatment (cut, crease, pierce, etc.). This is even more so required if the laser power is already near the maximum power value. The additional dwell time required to perform these pre-treatments with an LB may slow down the system. When working near the maximum power strength of a laser, the LB scanner coverage area in which the LB can be steered for pre-treatment of a cardboard may be limited. More particularly, the coverage area of the LB scanner is a function of the scanner's field of view angle and the distance from object. The field of view of a scanner may be a function of mechanical limitations together with velocity requirements; placement of LB source in relation to the scanner's reflecting plane, the laser power, as well as other factors.
In addidtion, the LB scanner itself may have limitations that may further slow down the production of a cardboard handling system. A few non-limiting examples of such limitations may include: the maximum coverage area; the maximum power specification; the mechanical limitation of the scanning system; and the mirror diameters. Mechanical limitations of the scanning system may be due to the placement of the LB scanner in the cardboard-processing system, the velocity of the different motors driving the various elements of the LB scanner, the precision of the LB scanner, the delay time when adjusting one or more reflector plans from one angle to another, as well as other limitations and/or combinations of any of these limitations.
Furthermore, in cardboard-processing systems in which the cardboard is in motion in one direction (machine direction, for example) while being pre-treated by the LB, there may a requirement of a pre-defined plan on the pre-treatment of the cardboard, in order not to miss any area that needs to be pre-treated by the LB. For each job, the pre-defined plan may need to be defined before the pre-treatment. Thus, the slowest area to be pre-treated in a cardboard may define the throughput for the whole system.
FIG. 3A is a schematic diagram illustrating a simplified block diagram with relevant elements of an exemplary laser scanning system (scanner) 300. The scanner 300 may include: a laser-beam source 302 that may emit a laser-beam 332 and one or more moveable light reflecting planes 304 and 306 that may reflect and steer reflections (336 and 338) of the emitted laser-beam 332 toward one or more cardboards 310 or surfaces of one or more cardboards.
Some embodiments of a scanner 300 may require moving and positioning the focus of the laser-beam in three dimensions. This may be achieved by a servo-controlled lens 308, usually called a ‘focus shifter’ or ‘z-shifter’ for example. In some embodiments, the lens 308 may be placed between the emitted laser-beam and the reflecting plane 304. The lens 308 may move in direction similar or opposite to direction of arrow 320. In other embodiments the lens 308 may be placed between the reflecting plane 306 and the cardboard 310, between the reflecting plane 304 and the reflecting plane 306, and so on. Some embodiments may utilize multiple lenses as well.
The moveable light reflecting planes 304 may be provided through employment of: a mirror; a prism; an array of polygon mirrors; as well as other similarly suitable objects. In various embodiments, the reflected laser-beam may be steered in one, two or three dimensions. When steering the laser-beam, the reflecting planes 304 and/or 306 may be moved in a periodic motion, such as a step function, and/or in a continuous motion.
Some scanners 300 may utilize a rotary encoder (not shown in the drawing) and control electronics (not shown in the drawing) to move or position the light reflecting planes 304 and 306 to a required position and/or angle at a required velocity. The encoder and control electronics can provide a suitable electrical current to a motor or to a galvanometer for a desired angle or phase. Other embodiments may utilize piezoelectric actuators, or magnetostrictive actuator, or a combination of these as well as other options.
The scanner 300 may include or be associated with a controller 312. The controller 312 may control different modules of the scanner 300. Modules such as, but not limited to: the reflecting planes 304 and 306, the encoder, the control electronics, and so on.
In some embodiments, the scanner 300 may move and position a reflected laser-beam 334 in two dimensions. The scanner 300 may rotate the reflecting plane 304 around an axis 312 in the directions indicated by arrow 322, wherein axis 312 may be along the center of the length of the reflecting plane 304. Further, the scanner 300 may rotate the reflecting plane 306 around an axis 314 in the directions indicated by arrow 324, wherein axis 314 may be along the center of the width of the reflecting plane 306.
The emitted laser-beam 332 may be passed through the lens 308 to change the focus of the laser-beam. The focused laser-beam 334 may then be reflected and steered by reflecting plane 304 to create reflected laser-beam 336. Next the reflected laser-beam 336 may be reflected and steered again by reflecting plane 306 to create re-reflected laser-beam 338 which is guided toward the cardboard 310. The re-reflected laser-beam 338 may then strike the cardboard 310 to treat the cardboard 310 by cutting, piercing, creasing, or performing other actions as indicated above. The treatment of cardboard 310 may be performed in accordance with a job description. The controller 312 may determine and control the power level of the emitted laser-beam 332 according to different criteria, such as, but not limited to: the angle of the laser-beam when hitting a certain point in the cardboard, the required treatment (cut or crease, for example) the required velocity of the treatment, and so on. The source for the laser-beams 302 may adjust the parameters of the emitted laser-beam based on commands received from the controller 312, for example.
It will be appreciated by one of ordinary skill in the art that although the configuration illustrated in FIG. 3A presents two reflecting planes, other embodiments may reflect the laser-beam with only one reflecting plane while other embodiments may utilize more than two reflecting planes. Some laser-beam scanners further allow changing the intensity of the laser-beam for different actions or desired results. By varying the intensity or power of the laser-beam, the influence of the laser-beam on a working piece can be modified. As a non-limiting example, if the power is increased to a sufficient level, the laser-beam can operate to completely remove a material. Advantageously cutting can be performed by the laser-beam when operated at a sufficient power level. Further, the power of the laser-beam can be lowered if it is desired to only score or remove only a partial surface.
FIG. 4A schematically illustrates a portion of a simplified block diagram with relevant elements of an example of a maximum coverage area 420 of a LB scanner 426. Wherein the coverage area is a function of the field of view 432 angle and the distance 440 from the scanned object. The field of view of a scanner may be a function of mechanical limits together with velocity requirements placement of laser-beam source in relation to the scanner's reflecting plan, and laser power, for example.
FIG. 4B schematically illustrates a portion of a simplified block diagram with relevant elements of an exemplary pre-treated cardboard 400 The pre-treated cardboard 400 may include a plurality of pre-treated sections 404 a-n. Some of the pre-treated sections 404 a-n (or part of a section) may be created by the LB while the cardboard 400 is been conveyed in constant velocity in a direction similar to arrow 430 (machine direction that the laser is part of, for instance).
The cardboard 400 being pre-treated by an LB scanner may have dimensions larger than the LB scanner maximum coverage area. In some embodiments, the length 406 of the pre-treated cardboard 400 may be greater than the length 424 of the LB scanner maximum coverage area 420. In other embodiments, the width 402 of the pre-treated cardboard 400 may be greater than the width 422 of the LB scanner maximum coverage area 420. In yet other embodiments, both dimensions (402 and 406) of the pre-treated cardboard 400 may be greater than both dimensions (422 and 424) of the maximum coverage area 420 of the LB scanner.
Because a cardboard may have a predefined length and width, and a predefined layout comprising a plurality of a pre-treated sections, if only one LB scanner is used, then the throughput of the system may be greatly diminished. In some embodiments, the system may be required to accelerate and decelerate the cardboard. Such a requirement can result in a complex and expensive system.
The above-described deficiencies in common laser scanning and cardboard-processing system industries should not be construed to limit the scope of the embodiments described in the present disclosure in any manner. They are merely presented for illustrating an existing situation.
The present disclosure presents embodiments of, among other things, a novel system and method of a dynamic, multiple scanner system that can be automatically and dynamically adjustable adjusted to modify the throughput of the method and system for each job and/or for each cardboard to be pre-treated. The dynamic, multiple scanner system (DMSS) include among, other things, pre-treating a cardboard with two or more LB scanners while the cardboard is been conveyed in the machine direction from one place to another in a substantially constant velocity between and through the majority of the different modules of the cardboard-processing system. Advantageously, the substantially constant velocity of conveying the cardboard may result in reducing the complexity of the mechanics of the cardboard handling system. Such complexity reductions may be realized because there may be no need for extreme acceleration, stopping deceleration and other actions. Thus less expensive mechanisms may be used to control the movement of the cardboard. As non-limiting examples, less precise sensors, actuators with lower torque or strength may be employed.
In some embodiments, the DMSS may automatically and dynamically define, on a per job basis and/or on a per cardboard basis, areas of responsibility for one or more of the LB scanners. The area of responsibility of an LB scanner may be an area of a cardboard for which the LB scanner is responsible for pre-treatment of the cardboard. The responsibility area of a scanner maybe smaller or similar to the maximum coverage area that scanner can cover. Wherein coverage area is a function of the scanner's field of view angle and distance from cardboard been pre-treated, laser power, velocity requirements, placement of laser beam, a combination of two of these as well as other.
In some embodiments, the DMSS may automatically and dynamically make adjustments such that an overlap occurs in the areas of responsibility of two or more LB scanners. The DMSS may automatically and dynamically define and change the areas of responsibility of one or more of the LB scanners according to different criteria. The automatic and dynamic changing of the areas of responsibility may be performed on a per job basis, and/or per cardboard being pre-treated basis, and/or during the pre-treatment of a cardboard.
When performing pre-treatment of cardboard areas in which the required layout of pre-treatment is complex, the DMSS may automatically and dynamically assign two or more LB scanners to pre-treat that area instead of it being pretreated by only one LB scanner. Advantageously, this capability may increase the throughput of the DMSS and/or improve the pre-treatment of a cardboard. After that area has been substantially pre-treated, the DMSS may automatically and dynamically re-define the areas of responsibilities for the different LB scanners. Thus, the different LB scanners can be utilized in a dynamic manner according to the specific layout of the cardboard being pre-treated.
Further, the DMSS may automatically and dynamically plan and change the order, method and/or algorithm of the pre-treatment actions performed in the pre-treatment of a cardboard according to the dynamic change of the areas of responsibility of one or more LB scanners, and/or vice versa.
As non-limiting examples of embodiments of a DMSS system and method, a cardboard that needs to be pre-treated by the DMSS while it is being conveyed, may be theoretically divided into a plurality of divisions or areas. For instance, a pre-treated cardboard may be theoretically divided into a plurality of even and/or un-even sized divisions in various shape, such as: rectangular, circular, hexagonal, square, as well as other shapes and/or combination of two or more of any of these shapes. Each section may include a sub-layout area to be pre-treated. Throughout the description, drawings and claims, the terms ‘theoretically divided’ and ‘divided’ can be used interchangeably.
As a non-limiting example of a DMSS in which the cardboard is being conveyed in a substantially constant velocity while being pre-treated, each division may have a pre-defined time slot to be pre-treated by an LB scanner. The time slot may be dependent on the size of the division, for example. If the sizes of the division are substantially the same, then the slot time may be substantially the same, for instance.
The DMSS may automatically and dynamically change the defined time slot to pre-treat different divisions. The change may be made in accordance with the difference in complexity of the sub-layout to be pre-treated, for example. If the next division to be pre-treated by an LB scanner is complex, then the DMSS may dynamically allocate that division more slot time at the expense of another division's time slot which has a simpler sub-layout. Advantageously, such capabilities can result in not changing the total time the cardboard has while passing through the laser module.
As a non-limiting example of a DMSS in which the cardboard is being conveyed at a substantially constant velocity while being pre-treated, each division may begin to be pre-treated when the division reaches a pre-defined point in the coverage area of an LB scanner (substantially middle of coverage area, for example). The DMSS may automatically and dynamically change the start of the pre-treatment of a division according to the sub-layout of that division and other divisions. For example, if a particular division has a simpler sub-layout than the sub-layout of the immediately preceding division, the DMSS may delay the pre-treatment of that particular division X cm after the originally pre-defined point in the LB scanner coverage area, advantageously enabling more time and resources to be devoted to the previous, more complex division.
Some embodiments of a DMSS may automatically and dynamically change the size of one or more divisions. The change in the size may be determined in accordance with the: layout, overlap in LB scanners, the sub-layout of that division, the sub-layout of the divisions near it, as well as other criteria. As non-limiting examples, in areas of a cardboard in which the layout is simpler than other areas of that cardboard, the size of the divisions may be bigger than the size of the divisions of the complex layouts.
Each LB scanner may be responsible to pre-treat a plurality of divisions in its area of responsibility. The responsibility areas may be changed automatically and dynamically between jobs and/or between one cardboard to another, and/or during the pre-treatment of a cardboard. In some examples, the number and/or size of the divisions may be changed between jobs and/or cardboards. In some examples, they may be changed during the pre-treatment of a cardboard.
The responsibility area of an LB scanner may be determined in accordance to different criteria/needs. A few non-limiting examples of such criteria/needs are the LB scanner coverage area, the velocity of scanning, the power capabilities of the laser, the mechanical movement capabilities, the cardboard layout that needs to be pre-treated by the laser, the velocity of the cardboard being conveyed, the various parameters of the cardboard (thickness, length, width, material, texture, etc.) the method of pre-treating the cardboard, as well as other criteria/needs and/or combination of two or more of these criteria/needs.
The method for pre-treating a cardboard by the DMSS while it is being conveyed may be selected based on one or more different parameters. As a non-limiting example, the method may be selected based on the size of each area, the overlap of the LB scanner areas (coverage area and/or responsibility), the velocity of the conveyed cardboard, the required layout of the pre-treated cardboard, the time it takes to pre-treat a part of a layout, the number and sizes of divisions, etc.
In various embodiments, an algorithm may be employed for the pre-treatment of a cardboard while it is being conveyed. As a non-limiting example, the algorithm may perform the actions of: (a) theoretically dividing the cardboard into a plurality of divisions, (b) assigning two or more of the LB scanner areas of responsibility and (c) automatically adjusting the coverage area to one or more of the LB scanners. For each division to be pre-treated, pre-treatment may be delayed until the cardboard is conveyed to a point at which the middle of a division substantially coincides with the middle of the coverage area of the LB scanner. At this point the pre-treatment for that division by the LB scanner may commence.
In divisions in which the layout is complex (i.e., many crease/cuts, etc), the LB scanner may be automatically adjusted to start pre-treatment of the division before the middle of the division reaches the middle of the coverage area. Further, another LB scanner may be adjusted to performa pre-treatment of the same division as well by automatically and dynamically changing its responsibility area. In divisions that have simple layouts to be pre-treated, the responsible LB scanner may begin pre-treatment after the division has passed a few mm from the middle of the LB coverage area—thus enabling that LB scanner to work on other divisions before pre-treating this particular divions. Thus the above automatic change of responsibilities and/or timing of pre-treatment of divisions is dynamically performed in accordance with the layout and/or job description.
When changing a responsibility area of a LB scanner and/or its coverage area, the DMSS may automatically adjust the laser power and the velocity of scanning of the LB scanner according to different criteria. As a non-limiting example, this criteria may include the angle of the reflected LB to the cardboard that needs to be pre-treated, the velocity of conveyed cardboard, the complexity of the layout and the required layout (i.e., creases or cuts for example).
Further, the present disclosure comprises among other things, a novel method and system for automatically and dynamically changing the coverage areas of one or more of the LB scanners while pre-treating a conveyed cardboard.
The DMSS may automatically and dynamically define, calibrate and change the coverage area of one or more of the LB scanners. The automatic and dynamic change of the coverage area may be performed on a per job basis and/or for each cardboard that is being pre-treated. The automatic and dynamic change of the coverage area may be performed during the pre-treatment of a cardboard and/or before pre-treatment of a cardboard. Advantageously, this capability may result in increasing the throughput of the DMSS and/or improve the pre-treatment of a cardboard.
An example of an embodiment of automatic and dynamic change of the coverage area of one or more LB scanners may include setting one of the LB scanners coverage areas to be as wide as the cardboard dimension (i.e., by changing the height of the reflecting plan and/or the height of the conveyor on which the cardboard is placed). In such an embodiment, the LB scanner with the widest coverage area may pre-treat the peripheral areas of the cardboard, while the other LB scanners pre-treat the internal areas of the cardboard.
Another example may be that the LB scanner with the widest coverage area may pre-treat a different cardboard then the other LB scanner(s). For example the in-coming and out-going cardboards on the conveyor may be pre-treated by one LB scanner while the other LB scanner(s) pre-treat a cardboard on the conveyor placed between the in-coming and out-going cardboards. Thus, two or more cardboards may be pre-treated in parallel.
Further, the DMSS may automatically and dynamically plan and change the order, method and/or algorithm of the pre-treatment process in which it pre-treats a cardboard according to the dynamic change of the coverage area of one or more LB scanners, and/or vice versa.
In some embodiments in which the DMSS is part of a system that has automatic dynamic attributes itself, the DMSS and, that one or more other module of the system may automatically dynamically change in relation with and/or in accordance with the other. Advantageously, this functionality may further improve the overall throughput, and/or quality of pre-treatment of the cardboards. A surface-adhesive-rule die technology (SART) may be a module that may dynamically and automatically change its dies to pre-treat a cardboard, for example.
FIG. 5A schematically illustrates a simplified block diagram with relevant elements of an example of embodiment of a DMSS. The DMSS 500 a may include among other things: a plurality of LB scanners; a conveyor 504; a plurality of laser-beam sources (not shown in drawing); and a controller 506.
The number of scanners employed may be based on a variety of different criteria. Non-limiting examples of the criteria may include one or more of: the maximum size (width and/or length and/or thickness) of a cardboard that may need to be pre-treated; the minimum and maximum coverage areas of a scanner; material of a cardboard; layout requirements; as well as others.
As a non-limiting example, if the largest cardboard that the system has to pre-treat is 10.6 cm in length (measured along machine direction) and 75 cm in width (measured perpendicular to machine direction wherein machine direction is shown by arrow 516.), and the pre-treatment requires cutting the cardboard via the lasers; and each LB scanner has a coverage area of 32 cm by 32 cm, but when working with the laser at its high power settings, for fast throughput and/or high performance, has a maximum field of view of 25 cm by 25 cm, then three LB scanners placed next to each other side by side in a direction perpendicular to the machine direction can be used as shown in FIG. 5A.
Each scanner may have two or more moveable-light-reflecting planes, each operating similar to the scanner described in conjunction with FIG. 3A. For convenience and clarity of presentation, each scanner in FIG. 5A may have one moveable-light-reflecting plane 502 that may pivot around two axes. For example, a first LB scanner may have a moveable-light-reflecting plane 502 a that may pivot around axis 512 in direction similar and/or opposite to the direction of arrow 511, and may also pivot around axis 514 in direction similar and/or opposite to the direction of arrow 513. Wherein axis 512 may be centered along the length of moveable-light-reflecting plane 502 a, and axis 514 may be centered along the center of the width of moveable-light-reflecting plane 502 a width.
The second and third LB scanners may each have a moveable-light-reflecting plane (502 b and 502 c, accordingly) that may pivot in a similar manner as described for moveable-light-reflecting plane 502 a, around an axis along their length and width (axis not shown in drawing for each plane).
Each scanner may be associated with an LB source (not shown in the drawing). Each LB source may emit an LB 520 a-c toward the relevant moveable-light-reflecting plane 502 a-c. The moveable-light-reflecting planes 502 a-c may reflect the LB and steer the reflected LB 522 a-c toward and along a cardboard 510.
Furthermore, one or more of the LB scanners may include a ‘focus shifter’ lens or ‘z-shifter’ lens (not shown in drawing). The ‘focus shifter’ lens or ‘z-shifter’ lens may be placed between the LB source (not shown in drawing) and the moveable-light-reflecting plane 502 a-c. In other embodiments, the ‘focus shifter’ lens or ‘z-shifter’ lens may be placed between the moveable-light-reflecting plane 502 a-c and a cardboard 510 been pre-treated. In other embodiments of the DMSS 500 a, each scanner may have two or more moveable-light-reflecting planes.
The multiple-scanner system (DMSS) 500 a may pre-treat a cardboard 510 while the cardboard is being conveyed by the conveyor 504 by performing one or more actions such as: cutting, creasing, scoring, embossing, or other actions. The cardboard may be conveyed in a substantially constant velocity in the machine direction shown by arrow 516. Advantageously, enabling the cardboard to traverse through the system as a substantially constant velocity reduces the cost and complexity of the system due to the elimination or reduction of accelerating, stopping deceleration or otherwise modifying the movement of the cardboard. Further, precision due to stitching between the different scanners and timing of the pre-treatment is achieved.
Each scanner's moveable-light-reflecting plane 502 a-c may be responsible to pretreat a pre-defined area of the cardboard 510. The pre-defined area of the cardboard 510 may be determined based on the coverage area of each scanner. The responsibility area of a scanner may be smaller or similar to the maximum coverage area of the scanner.
In some embodiments of the DMSS 500 a, there may be an overlap between the coverage area of two or more of the scanners (30 mm overlap, for example). Thus the responsibility areas of each scanner may be automatically and dynamically defined before and/or during the pre-treatment of the cardboard 510, such that some of the scanners may have an overlap in responsibility areas.
The DMSS may automatically and dynamically define and/or change the areas of responsibility of one or more of the LB scanners according to different criteria. The automatic and dynamic change of the areas of responsibility may be performed on a per job basis and/or for each cardboard being pre-treated, and/or during the pre-treatment process of a cardboard.
Exemplary criteria for automatic and dynamic change of responsibility areas of one or more LB scanners may be based on the complexity of the layout of the cardboard. In areas of cardboard 510 in which the required layout of pre-treatment is complex, the DMSS may automatically and dynamically assign two or more LB scanners to pre-treat that area instead of it been pretreated by only one LB scanner. Advantageously, this capability may increase the DMSS throughput and/or improve the pre-treatment of a cardboard. After that area has been substantially pre-treated, the DMSS may automatically and dynamically re-define the areas of responsibilities of the different LB scanners or revert to previous definitions or a default definition. Thus, the different LB scanners are utilized in a dynamic manner according to the specific layout of the cardboard being pre-treated.
The controller 506 may command, calibrate and synchronize the modules of the DMSS 500 a. A calibration phase may comprise stitching between the coverage areas of the LB scanners. For example, when a layout includes a cut and/or crease line that passes along two or more scanner responsibility areas, then the calibration phase makes sure that the line will be straight and in the correct dimensions even if part of it is made by one scanner and the other part by another scanner. The calibration may be done automatically on a periodic basis, and/or before a job begins and/or dynamically during the performance of a job. Furthermore, the controller 506 may synchronize between the DMMS 500 a and modules of cardboard-processing system that the DMSS 500 a is part of.
FIG. 5B schematically illustrates a simplified block diagram with relevant elements of an example of embodiment of a DMSS 500 b. The DMSS 500 b may be similar to the DMSS 500 a (illustrated in FIG. 5A). One or more of the moveable-light-reflecting plane 502 a-c of the LB scanners in DMSS 500 b may be automatically and dynamically moved in direction similar and/or opposite direction to arrow 518. The change in the planes 502 a-c may be performed before and/or during the pre-treatment of a cardboard by the LB scanners of DMSS 500 b. Advantageously, the coverage area of an LB scanner may automatically and dynamically change, thus coverage area of the cardboard 510 may change.
In various embodiments of the DMSS, one or more of the LB scanners may be placed at a distance further from the other LB scanner (not shown in drawing) along the machine direction 516. Advantageously, this capability may allow that LB scanner to pre-treat a cardboard before the cardboard reaches the other LB scanners. In these as well as other embodiments of the DMSS, one or more of the LB scanners may have a larger dimension from the other LB scanners (not shown in drawing). In these as well as other embodiments of the DMSS, one or more of the LB scanners may be responsible to pre-treat the peripheral areas of the cardboard while the other LB scanners pre-treat the interior of the cardboard.
FIG. 6A schematically illustrates a simplified example of a plurality of responsibility areas of LB scanners of a DMSS. The DMSS LB scanners may be placed substantially parallel to each other and side by side in an orthogonal direction (as shown by arrow 616) to the machine direction shown by arrow 614 of the cardboard-processing system.
In example FIG. 6A, a cardboard 602 is divided along its width 610 into three responsibility areas 604 a-c, each belonging to an LB scanner of the DMSS. The responsibility area 604 a-c of an LB scanner may be similar or smaller than the maximum coverage area of its LB scanner. The cardboard 610 may be conveyed while been pre-treated by the DMSS in direction similar to machine direction as shown by arrow 614. In some embodiments, the cardboard 610 may be conveyed in substantially continuous motion.
FIG. 6B schematically illustrates a simplified example of an automatic dynamic change of responsibility areas of one or more LB scanners of a DMSS. A DMSS may automatically and dynamically change the responsibility areas of one or more of its scanners according to different criteria.
In some jobs, the complexity of the required layout (cuts, creases, embossment, etc.) on a cardboard in the responsibility area of one of the DMSS's LB scanners is more complex than the required layout to be made on the cardboard in the responsibility area of another one of the DMSS's LB scanners. The LB scanner responsible for the complex layout area may slow down the throughput of the system.
As a non-limiting example, if the layout required to be made in responsibility area 604 b (FIG. 6A) is more complex than layout required to be made in responsibility area 604 a and/or 604 c (FIG. 6A), then a dynamic and automatic change of areas of responsibilities of some LB scanners may be made. The DMSS may automatically and dynamically enlarge the responsibility areas of the LB scanners responsible for 604 a and/or 604 c such that they may spread into the responsibility area 604 b of the other LB scanner.
Thus, the new responsibility division of the LB scanners may automatically be: 624 a and 624 b and 624 c, wherein area 624 b is smaller than 624 a, and 624 c. Thus, an overlap between the responsibility divisions of LB scanners may occur. In some embodiments, the strength of the LBs may be changed, and/or the dwell time of the LB, as well as other attributes.
In some embodiments, the automatic dynamic change of responsibility divisions between the LB scanners may be performed on a per job basis and/or for each cardboard being pre-treated. In some embodiments, the automatic dynamic change may be performed before the pre-treatment of the cardboard by the LB scanner while in other embodiments, it may be performed during the pre-treatment of the cardboard. Further, the automatic dynamic change of responsibility divisions may be performed multiple times during pre-treatment of cardboard and/or job.
FIG. 7A schematically illustrates a simplified block diagram with relevant elements of an example of theoretical division of a cardboard by a DMSS in which each area of responsibility of an LB scanner is divided into a plurality of divisions. A cardboard 702 to be pre-treated by an LB scanner of a DMSS may be theoretically divided into a plurality of divisions. In FIG. 7A the cardboard is divided into three rectangles (indicated by lines 706 a and 706 b). Each rectangle may be a responsibility area of a DMSS LB scanner wherein the responsibility area may be similar to or smaller than the coverage area of that LB scanner.
Furthermore, each rectangle (responsibility area) may be divided into a plurality of divisions 720 a-x. The number of division and the size of each division may be according to the different criteria. In FIG. 7A, the divisions 720 a-x have a substantially similar size and dimension however, in other embodiments the dimensions may vary. The cardboard 702 may have a required layout to be pre-treated by the LB scanners of the DMSS. The layout may include one or more of the elements of: creases, cuts, embossings, scorings, as well as other actions as described in conjunction with FIG. 2A and FIG. 2B. Thus, each division may comprise a sub-layout of the whole required layout to be pre-treated. The cardboard 702 may be conveyed in direction similar to arrow 714 while been pre-treated by the LB scanners of the DMSS.
FIG. 7B-FIG. 7D schematically illustrate a simplified block diagram with relevant elements of an exemplary DMSS method for pre-treating a division by an LB scanner of a DMSS. In FIG. 7B, a division 720 may be conveyed in a direction similar to arrow 714 while being pretreated by an LB scanner. The LB scanner may begin pre-treating the division 720 when the center of the division substantial reaches the center of the LB scanner's coverage area. The center of the scanner's coverage area is indicated by dashed-line 730 a.
FIG. 7C and FIG. 7D schematically illustrate an example of an automatic dynamic change at the beginning of pre-treating a cardboard by a DMSS LB scanner according to the division sub-layout required to be pre-treated by a LB. As illustrated in FIG. 7C, when the required sub-layout of a division 720 b to be pre-treated by the LB scanner laser-beam is complex, the LB scanner may start the pre-treatment of that division 720 b before the conveyed division 720 b has reached the center of the scanner's coverage area marked by dashed-line 730 b.
As illustrated in FIG. 7D, when the required sub-layout of a division 720 c to be pre-treated by the LB scanner laser-beam is simple, the LB scanner may start the pre-treatment of that division 720 c after the conveyed division 720 c has reached the center of the scanner's coverage area marked by dashed-line 730 c, thus enabling the LB scanner more time to pre-treat a more complex division.
The automatic and dynamic change of the beginning of pre-treating a sub-layout by an LB scanner may be done before the job begins and/or during the pre-treating of the cardboard.
An exemplary embodiment of a DMSS may receive inputs from a controller when the conveyed cardboard has reached a certain place and accordingly start its operation. In some embodiments the controller may get inputs from detectors sensing placement of the leading edge of the cardboard been conveyed. In other embodiments the controller may calculate the position of the conveyed cardboard from inputs on the velocity it is conveyed and it's length/width. In yet other embodiments the controller may obtain information on cardboard placement from an encoder associated to the conveyor conveying the cardboard. Some embodiments may use a combination of the above techniques, as well as other.
FIG. 7E schematically illustrates a simplified block diagram with relevant elements of an exemplary DMSS method for pre-treating a cardboard 760 while conveyed in a direction similar to the direction of arrow 714. The cardboard 760 may be theoretically divided into three rectangles (indicated by lines 752 and 754). Each rectangle may be a responsibility area of a DMSS LB scanner, wherein the responsibility area may be similar or smaller than the coverage area of that scanner. The DMSS may further automatically and dynamically theoretically divide cardboard 760 into a plurality of different sized divisions 762 a-p.
The size of each division 762 a-p may be determined based on the sub-layout required to be pre-treated in that division. Division 762 h and 762 i may have complex layouts, thus there size may be smaller than division 762 r, for instance. Division 762 b may have a more complex sub-layout than 762 g, thus its size may be smaller than division 762 g, for instance, etc.
FIG. 7F schematically illustrate a simplified block diagram with relevant elements of an exemplary DMSS method for pre-treating a cardboard 780 while it is conveyed in a direction similar to direction of arrow 714. The cardboard 780 may be automatically and dynamically theoretical divided into a plurality of divisions 794 a-y where the size of each division may be determined based upon the sub-layout needed to be pre-treated by the LB scanner. Further, the responsibility areas of each scanner may change according to the sub-layout needed to be pre-treated by that LB scanner.
For example, division 794 h may have a complex sub-layout to be pre-treated and thus it has a size this is smaller than division 794 g which may have a simpler sub-layout to pre-treat. Further, three scanners may be responsible to pre-treat division 794 h, thus their responsibility areas overlap marked 782 a and 784 a.
Division 794 l may have a sub-layout complexity similar to 794 u and 794 c, thus the size of the divisions may be similar, and each scanner may be responsible for one of the divisions. Borders of responsibility areas of each LB scanner is marked by 782 b and 784 b, etc.
FIG. 8A-FIG. 8C schematically illustrate a simplified portion of a flowchart with relevant actions of an exemplary embodiment of a dynamic laser-beam-scanning system work-plan mode method 800. Method 800 may be executed 802 by a controller of a DMSS. At act 804, method 800 may allocate different resources, such as but to limited to: sensors, timers, scanners, input on job descriptions, etc.
Next method 800 may set the resources. Exemplary settings may include, calibrations, resetting timers, etc. Method 800 may wait 808 until all required job parameters are obtained. Non-limiting examples of parameters may be: layout required to be pre-treated by DMSS, cardboard parameters (length, width, thickness, material type, etc.), etc.
Once all parameters are obtained, method 800 may calculate and define 810 the number of theoretical divisions and there sizes of a cardboard to be pre-treated by the DMSS. Method 800 may further calculate and define 810 the responsibility areas of each scanner along the different divisions of the cardboard. Method 800 may calculate and define 812 the coverage area of each LB scanner. In some embodiments, a DMSS LB scanner may have its coverage area automatically and dynamically changed. The coverage area of a scanner may be a function of the field of view angle of the scanner and its distance from the cardboard need to be pre-treated.
Accordingly, method 800 may calculate and define 814 the laser power required for each LB source for the layout required. The laser power may be a function of the layout type (cut, crease, etc.), the cardboard parameters, the scanner working that area and its placement, etc. Next, method 800 may proceed to act 820 FIG. 8B.
At act 820 of FIG. 8B, the method 800 may calculate the required 820 scanning velocity of each scanner for the different pretreatment (cuts, crease, scoring, etc.). The velocity may be a function of the angle of the reflecting-plane and the cardboard, the type of pretreatment, the laser power, as well as others and combinations of such functions. The velocity of each skipping of the reflected steered LB from one place to another may also be calculated and/or defined 824. The delay of beginning and stopping each pre-treatment may be calculated and defined 824 as well.
Accordingly, method 800 may plan 826 each division order of pretreating and accordingly calculate 828 the velocity required to convey the cardboard while pre-treating that division. If 832 the required velocity of all divisions require velocity that is faster than a pre-defined threshold, then method 800 may output the substantially constant velocity the cardboard may be conveyed. The substantially constant velocity may be similar or slower than the minimum velocity calculated for the different divisions of the cardboard. Method 800 may proceed to act 902 of method 900 FIG. 9.
If 832 the required velocity of all divisions is faster than a pre-defined threshold, then method 800 may require an automatic change and go to act 840 FIG. 8C. The information relating to the division with a required velocity slower than the threshold velocity is obtained 840 from memory a storage/register. Method 840 estimates whether adding another LB scanner to work on that division together with the LB scanner assigned to a division that is already under its responsibility will improve velocity. If yes 846, then method 800 may automatically and dynamically change the required LB scanners responsibility area definitions, for that division's pre-treatment.
If 842 not, than method 800 may estimate if changing the length of the division (machine direction-wise) will help increase the required velocity of conveying cardboard while pre-treating that division. If 848 yes, then method 800 may redefine 850 the time to start pre-treating that division. Next, method 800 may recalculate 852 the slowest velocity required for pre-treating a division from all divisions. If 854 the calculated velocity is slower 854 than a threshold, method 800 returns to act 840 for more optimization.
If 854 no further optimization is required, than method 800 may output the maximum velocity required to pre-treat the cardboard. This velocity may define the substantially constant velocity the cardboard is being conveyed while pre-treated by the DMSS. Method 800 may further send commands to the required modules of the DMSS on new responsibility areas and theoretic division sizes. Next, method 800 may end.
FIG. 9 schematically illustrates a simplified portion of a flowchart with relevant actions of an example of embodiment of a DMSS automatic dynamic cardboard pre-treatment method 900. Method 900 may be executed by a DMSS controller. Method 900 may obtain 902 a set up plan and work plan for pre-treating a cardboard. The work plan may comprise different information, such as but not limited to: cardboard divisions size and placement, DMSS LB scanner responsibility areas for each division, required layout to be pre-treated in the cardboard, time to start pre-treatment of each division, etc.
Next, a loop from act 904 and extending to act 910 may start for each DMSS LB scanner. The responsibility areas of the DMSS LB scanners may be automatically and dynamically adjusted 904 for their next division to be pre-treated. Adjustments may be mechanical, laser power, etc. Each LB scanner of the DMSS may wait 906 until the division that it needs to pre-treat reaches a defined point in its coverage area. Once it is detected that the division has reached the predefined point, the LB scanner may start pre-treating the division required sub-layout. Once finished, method 900 checks if 910 another division needs to be pre-treated. If 910 another division is to be pre-treated, method 900 returns to act 904. If 910 another division does not need to be pre-treated, method 900 may check if 911 more cardboards are needed to be pretreated (counter for example). If 911 no cardboards remain to be treated, then method 900 may end. If 911 additional cardboards need to be treated, then method 900 may return to act 902.
FIG. 10 is a functional block diagram of the components of an exemplary embodiment of system or sub-system operating as a controller or processor 1000 that could be used in various embodiments of the disclosure for controlling aspects of the various embodiments. It will be appreciated that not all of the components illustrated in FIG. 10 are required in all embodiments of the controllers, modules or other systems or subsystems, but each of the components are presented and described in conjunction with FIG. 10 to provide a complete and overall understanding of the components.
The controller can include a general computing platform 1000 illustrated as including a processor 1002 and memory device 1004 that may be integrated with each other or communicatively connected over a bus or similar interface 1006. The processor 1002 can be a variety of processor types including microprocessors, micro-controllers, programmable arrays, custom IC's etc. and may also include single or multiple processors with or without accelerators or the like. The memory element of 1004 may include a variety of structures, including but not limited to RAM, ROM, magnetic media, optical media, bubble memory, FLASH memory, EPROM, EEPROM, etc.
The processor 1002, or other components in the controller may also provide components such as a real-time clock, analog to digital convertors, digital to analog convertors, etc. The processor 1002 also interfaces to a variety of elements including a control interface 1012, a display adapter 1008, an audio adapter 1010, and network/device interface 1014. The control interface 1012 provides an interface to external controls such as but not limited to: sensors, actuators, drawing heads, multiple-orifice nozzles, cartridges, pressure actuators, leading mechanism, drums, step motors, a keyboard, a mouse, a pin pad, an audio activated device, as well as a variety of the many other available input and output devices or, another computer or processing device or the like.
A display adapter 1008 can be used to drive a variety of alert elements 1016, such as, but not limited to: display devices including an LED display, LCD display, one or more LEDs or other display devices. An audio adapter 1010 may interface to and drive another alert element 1018, such as a speaker or speaker system, buzzer, bell, etc. A network/interface 1014 may interface to a network 1020 which may be any type of network including, but not limited to the Internet, a global network, a wide area network, a local area network, a wired network, a wireless network or any other network type including hybrids. Through the network 1020, or even directly, the controller 1000 can interface to other devices or computing platforms such as but not limited to: one or more servers 1022 and/or third party systems 1024. A battery or power source may provide power for the controller 1000.
Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure pertains. In case there is a conflict in the definition or meaning of a term, it is intended that the definitions presented within this specification are to be controlling; however, embodiments may also encompass the elements in accordance with the definition within this specification and the commonly understood definitions. In addition, the materials, methods, and examples that are presented throughout the description are illustrative only and are not necessarily intended to be limiting.
Reference in the specification to “one embodiment” or to “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure, and multiple references to “one embodiment” or “an embodiment” should not be understood as necessarily referring to the same embodiment or all embodiments.
Implementation of the method and/or system of embodiments of the disclosure can involve performing or completing selected tasks manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of embodiments of the method and/or system of the disclosure, several selected tasks could be implemented by hardware, by software or by firmware or by a combination thereof and with or without employment of an operating system. Software may be embodied on a computer readable medium such as a read/write hard disc, CDROM, Flash memory, ROM, etc. In order to execute a certain task, a software program may be loaded into or accessed by an appropriate processor as needed.
The foregoing description is not intended to summarize each potential embodiment or every aspect of the present disclosure, and other features and advantages of the present disclosure will become apparent upon reading the following detailed description of the embodiments with the accompanying drawings and appended claims.
Furthermore, although specific embodiments are described in detail to illustrate the inventive concepts to a person of ordinary skill in the art, such embodiments are susceptible to various modifications and alternative forms. Accordingly, the figures and written description are not intended to limit the scope of the inventive concepts in any manner.
In the description and claims of the present disclosure, each of the verbs, “comprise”, “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements, or parts of the subject or subjects of the verb and further, all of the listed objects are not necessarily required in all embodiments.
As used herein, the singular form “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “a material” or “at least one material” may include a plurality of materials, including mixtures thereof.
In this disclosure the words “unit”, “element”, and/or “module” are used interchangeably. Anything designated as a unit, element, and/or module may be a stand-alone unit or a specialized module. A unit, element, and/or module may be modular or have modular aspects allowing it to be easily removed and replaced with another similar unit, element, and/or module. Each unit, element, and/or module may be any one of, or any combination of, software, hardware, and/or firmware. Software of a logical module can be embodied on a computer readable medium such as a read/write hard disc, CDROM, Flash memory, ROM, etc. In order to execute a certain task a software program can be loaded to an appropriate processor as needed.
The present disclosure has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the disclosure. The described embodiments comprise different features, not all of which are required in all embodiments of the disclosure. Some embodiments of the present disclosure utilize only some of the features or possible combinations of the features. Many other ramifications and variations are possible within the teaching of the embodiments comprising different combinations of features noted in the described embodiments.
It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention.
It will be appreciated by persons skilled in the art that the present disclosure is not limited by what has been particularly shown and described herein above. Rather the scope of the disclosure is defined by the claims that follow.

Claims

What is claimed is:

1. A dynamic-multiple-scanner system, comprising:

a controller;

a conveyor; and

two or more laser-beam scanners communicatively coupled to the controller and configured to pre-treat a cardboard while the cardboard is been conveyed on the conveyor at a substantially constant velocity;

wherein the controller is configured to dynamically and automatically assign responsibility area to at least one of the two or more laser-beam scanners to pre-treat the cardboard.

2. The dynamic-multiple-scanner system of claim 1, wherein the controller is further configured to divide the cardboard into a plurality of divisions and automatically and dynamically associate at least one of the two or more laser-beam scanners with one or more of the division during pre-treatment of a cardboard.

3. The dynamic-multiple-scanner system of claim 2, wherein the controller is further configured to synchronize the starting point of pre-treatment of each division by the associated one or more laser-beam scanners.

4. The dynamic-multiple-scanner system of claim 1, wherein the controller is further configured to divide the cardboard into a plurality of divisions and associate a laser-beam scanner with one or more of the division based at least in part on a job description for that cardboard.

5. The dynamic-multiple-scanner system of claim 4, wherein the controller is further configured to synchronize the starting point of pre-treatment of each division by the associated one or more laser-beam scanner

6. The dynamic-multiple-scanner system of claim 1, wherein the responsibility area of two or more laser-beam scanners at least partially overlap.

7. The dynamic-multiple-scanner system of claim 1, wherein two or more laser-beam scanners are placed substantially parallel to each other.

8. The dynamic-multiple-scanner system of claim 1, wherein the number of laser-beam scanners pre-treating a cardboard is a function of the cardboard size.

9. The dynamic-multiple-scanner system of claim 1, wherein cardboard is conveyed in one direction.

10. The dynamic-multiple-scanner system of claim 1, wherein the application of a pre-treatment of a cardboard comprises cutting the cardboard.

11. The dynamic-multiple-scanner system of claim 2, wherein the size of a division is adapted to the sub-layout of the division required to be pre-treated by the laser-beam scanner.

12. The dynamic-multiple-scanner system of claim 2, wherein the pre-treatment of each division by the relevant one or more laser-beam scanner is started in accordance with the sub-layout of the division required to be pre-treated by laser.

13. A method of applying pre-treatment to a cardboard item using a dynamic-multiple-scanner system, the method comprising the actions of:

obtaining a required layout of a cardboard for laser-beam pre-treatment;

dividing the cardboard into a plurality of divisions;

defining one or more laser-beam scanner responsibility areas for one or more divisions;

defining one or more laser-beam scanner pretreating starting points for one or more divisions.

14. The method of claim 13, further comprising the action of:

obtaining the cardboard and pre-treating it while it is being conveyed at a substantial constant velocity.

15. The method of claim 13, further comprising the action of: automatically and dynamically controlling and synchronizing one or more laser-beam scanner according to the division.

16. The method of claim 13, wherein the actions are done during pre-treatment of a cardboard item.

17. The method of claim 13, wherein the action of defining one or more laser-beam scanner responsibility area includes overlapping between one or more scanners responsibility area.

18. The claim 14, wherein the cardboard is conveyed in one direction while the pre-treatment is applied.

19. The method of claim 14, wherein the action of pre-treating the cardboard includes cutting the cardboard.

20. The method of claim 13, wherein the step of dividing the cardboard into a plurality of divisions further comprises adapting a division size to the sub-layout of the division required to be pre-treated by the laser-beam scanner.

21. The method of claim 13, wherein the action of defining one or more laser-beam scanner pretreating starting point for one or more divisions is at least partially based on the sub-layout of the division required to be pre-treated by laser.