Commercial web offset

Transcription

1 Products, Features Requirements, Solutions Automation and Drive concepts Safety Integrated Bus Topology Infeed Concepts Navigation Navigation Navigation

2 press GOSS-Sunday4000 Original: GOSS-Iternational MAN-Rotoman Original: MAN Roland Slide 2

3 Typical products Typical products Magazines Journals Advertising products Slide 3

4 Features of commercial web offset presses Eine Illustrations-Rollenoffsetdruckmaschine ist gekennzeichnet durch: 4 or more print units Typical number of pages: 16, 32, 48, 64, 72, 80 Fix format Fast exchange of printing plates at production change Printing speed up to 15 m/s Advantages of commercial web offset Printing of both paper side in one production step Several pruducts can be printed with one cylinder In addition to the basic colors also special colors can be printed Trends Wider and faster machines: 96 pages, 18m/sec more multidrive functions, especially in the folder, cam curve applications Slide 4

5 Printing basics: Offset printing Ink rollers Plate cylinder Water rollers Blanket cylinder Paper web Offset printing is an indirect print technology where the print color is first transferred from a mostly thin, flexible aluminum plate to a rubber cylinder and then to the material to be printed. The four colors cyan, magenta, yellow and black are printed one after the other and finally produce a high-precision color picture. Slide 5

6 Machine overview Print units Dryer Folder Paster Chill Typical data of commercial web offset presses: Length: 20m - 60m Width: 2m - 3m Hight: 3m - 10m Printing speed: 5 15 m/s Number of pages: Printing speed: copies/h Number of servo drives: 2 40 (depending on the degree of automation) Total drive power: 50kW 600kW Cut register accuracy: +/- 100 m Color register accuracy: +/- 10 m Slide 6

7 Requirements and solutions Requirements High printing quality High reliability Interfacing to third party systems Variable production to several folders Solutions Dynamic servo control and angular synchronism with high precision and little Jitter High control quality with excellent web lead and constant web tension trough multi drive technology Encoder emulation as high precision virtual encoder Synchronization via PROFINET for inter production of independent presses and for building redundant PROFINET networks Slide 8

8 Requirements and solutions Requirements Higher degree of automation Solutions PRINTstandard is prepared for many machine types. The open architecture allows the add on of own ideas and new features. Wider and faster machines Book size: up to 107 kw drive power Chassis: up to 800 kw drive power AC/AC or DC/AC drives Air-, Cold plate- or 2nd level cooling Wide range of synchronous and asynchronous motors, torque motors Self cooled, forced ventilation or water cooled Tendency to wider -e.g. 96 paes-, faster -e.g. 18 m/sec- and more automated machines -e.g. increased number of servo drives in the folder- can be seen Slide 9

9 Automation and Drive concept AC synchronous and asynchronous motors Standard asynchronous motors 1LAx Reluctance motors 1FP5 SIEMOSYN Motors 1FUx Torque motors 1FWx Linear motors 1FN3 Compact asynchronous motors 1PH7, 1PL6 water cooled 1PH4 as build in motor 1PH2 Synchronous servo motors 1FT6, 1FK6, 1FK7 ex proof 1FS6 Slide 11

10 Automation and Drive concept SINAMICS S120 drives for synchronous and asynchronous motors AC/AC Drives for single axis applications 0,25 90kW Blocksize design kW Chassis design DC/AC Drives (with infeed) for multi axis applications 1,6 107kW Booksize design kW Chassis design Slide 12

11 Automation and Drive concept DriveCliQ - interface for drive components System interface DRIVE-CLiQ SMC20 SMC30 Digital-/Analogue- Periphery Motor with DRIVE-CLiQ interface Motor without DRIVE-CLiQ interface DRIVE-CLiQ encoder Conventional encoder Electronic name plates: Identification of modules, motors, Slide 13

12 Automation and Drive concept SIMOTION for motion control and drive PLC control SIMOTION D: Drive based Motion Control software + drive software Direct connection of the motor modules Motion Control SIMOTION P: PC based Motion Control software in PC SIMOTION C: Controller based S7-300 design Motion Control Positioning Angular synchronism CAM curves PLC Functions KOP / FUP ST programs Slide 14

13 Automation and Drive concept Overview Tools SIMATIC S7 PLC control system Systems SIMOTION Motion Control system SIMATIC STEP 7 SIMOTION SCOUT SIZER STARTER SINAMICS Drive system SINAMICS S120 Asynchronous motors Synchronous motors Slide 15

14 Automation and Drive concept SIMOTION / SINAMICS overview Paster Print units Web Dryer Chill Folder catcher Slide 16

15 Automation and Drive concept Central design The complete motion program is calculated in one SIMOTION D control unit. In SIMOTION D also up to 6 drive controllers are integrated. For more axis a CX32 is used. OEM Central line control Service - PC with SCOUT Slide 17

16 Automation and Drive concept Central Separation of print units and folder A motion program for the print units and folder is calculated by a SIMOTION D controller. The synchronization is done via PROFIBUS or PROFINET. OEM Central line control Service - PC with SCOUT To other synchronized components Slide 18

17 Automation and Drive concept Modular Each print unit and each other equipment assembly has ist motion controller. The synchronization is done via PROFINET. OEM Central line control OEM Central line control Service - PC with SCOUT Slide 19

18 Automation and Drive concept Modular drives, central control Mixed design: Local drives (AC/AC) in the print units. Central control of print units and folder. OEM Central line control OEM Central line control Slide 20

19 DP 1 DP 2 E 1 E 2 s D 445 s s s Automation and Drive concept Example of a print unit (modular) Drive Control Synchronization to the virtual axis Plate cylinder positioning Speed control of ink and water roller drives SIMOTION D4x5 S I M O T I O N S I N A M I C S S I N A M I C S S I N A M I C S AC/DC Line Module SINAMICS S120 Motor Module 2 * Motor Module S I N A M I C S 2 * Motor Module s Print unit motor Drives both plate and blanket cylinders and inker via an integrated gear. Ink and water roller drives Geared motors Slide 21

20 Automation and Drive concept Example of a folder Roller top of former (RTF) Pull rollers under the former Folder main drive auxiliary drives Tendency: - Folder gets a lot more complex (3 30? Servo drives) - Use of electronic Cam Slide 22

21 Automation and Drive concept Example of a splicer Dancer control Infeed unit Drive Control with splice automation and reelstand PLC functions Dancer control Infeed control and automation Core drive Core drive Infeed Turret Reel axis movement Option: Machine encoder e.g. HTL 2048 Inc. Failsafe remote periphery with PROFIBUS interface IM F CPU and PROFIsafe telegram Slide 23

22 Safety Integrated Fail-safe drives SINAMICS S120, the flexible drive system for sophisticated drive tasks SINAMICS S120 offers following Safety-Integrated-applications: (terms acc. to IEC ) Safe Torque Off (STO) Safe Brake Control (SBC) Safe Stop 1 (SS1 => at n=0 STO) Safe Stop 2 (SS2 => at n=0 full torque available) Safe Operating Stop (SOS) Safely Limited Speed (SLS) Safe Speed Monitor (SSM) Safety Integrated increases security at printing machines Slide 25

23 Safety Integrated Enabling of safety functions through failsafe communication PROFIsafe Telegram* Failsafe CPU Sensors 2 2 dbsi Drive based Safety Integrated * Enhancement to PROFINET in preparation Reading sensor signals through failsafe periphery Processing of signals through failsafe CPU Enabling of drive based safety functions via PROFIBUS with PROFIsafe telegram Safety Integrated reduces costs Slide 26

24 Safety Integrated Safety functions via failsafe terminal module TM54F Sensors 2 2 Sensors ASIsafe Safety device 2 TM54F dbsi Drive based Safety Integrated Reading sensor signals though safety devices Processing of signals through safety devices Enabling of drive based safety functions via failsafe terminal module TM54F Integrated Safety even with hardwired solutions Slide 27

25 Set point distribution virtual master axis via PROFINET Global master virtual axis for global operation S I M O T I O N S I M O T I O N Local master master axis for local operation s s D 435 DP 1 DP 2 E 1 E 2 D 435 DP 1 DP 2 E 1 E 2 Real axis One SIMOTION controller calculates the virtual master axis. Several axis can be calculated and transferred. Slide 29

26 Set point distribution PROFINET Example bus topology Option board CBE30 with Switch technology SIMOTION controller with PROFINET Switch CBE30 To central line control PROFINET or Ethernet External PROFINET Switch SCALANCE X204 IRT Slide 30

27 Infeed Concepts: Local Infeed modular drive concept Several motor modules with a common infeed unit Easy expandable... Several units of the press can be individually tested. Slide 32

28 Infeed Concepts Local Infeed local drives Single axis AC-AC module Brake resistor for fast an E-STOP Decentralized concept is a typical solution for print units with one unit drive Slide 33

29 Infeed Concepts Central Infeed Multi motor units Booksize Chassis units expandable scalable DC link *) DC link self-commuted, pulsed rectifier / regenerative unit Active Line Module self-commuted, pulsed rectifier / regenerative unit Active Line Module *) Parallel interconnection of the DC link with Chassis ALM units Slide 34