Rotogravure Printing. Products, Characteristics Requirements, Solutions Automation Concept Register control Safety Integrated

Transcription

1 Products, Characteristics Requirements, Solutions Automation Concept Register control Safety Integrated

2 Slide 2

3 Commercial and rotogravure printing for packaging Typical products Magazines (i. e. Spiegel, Stern) Catalogs (z. B. Quelle, Otto) Cardboard boxes Tetra-Paks Film packaging Slide 3

4 Decor printing Typical products Decor- and furniture-surfaces (i. e. wood and stone) Wallpaper printing Acryl-foam printing Slide 4

5 Principles of gravure printing The printing motive is engraved onto the gravure cylinder. The ink is pressed into the cells of the rotating gravure cylinder. During inking-up the printing and none printing areas are flooded with ink. The needless ink is doctored with the blade. The impression cylinder presses the printing material on the gravure cylinder. The ink is transferred from the gravure cylinder onto the printing material. impression cylinder gravure cylinder blade ink fountain Slide 5

6 Characteristics of rotogravure printing for packaging Characteristics 8 to 10 printing units per machine Every production has a different set of printing cylinders The machine can be extended by additional converting elements Machine speed from 300m/min to 700m/min Advantages of rotogravure presses Variable printing formats through different printing cylinder diameters long lifetime of printing cylinder (> copies) Front- and backside printing in one step Many different kinds of printing colors applicable Many different materials may be printed High printing quality Simple printing principle Limitations Solvent based colors (environment policy) The gravure of the printing cylinder is very costly Slide 6

7 Machine configuration quality check infeed printing units outfeed unwinder with flying spice rewinder with flying spice Quelle: Handbuch der Printmedien Slide 7

8 Structure of a printing unit chilling roller dryer In rotogravure printing the wet ink cannot be overprinted. Therefore drying is obligatory after each printing element. impression roller printing cylinder Quelle: Handbuch der Printmedien Slide 8

9 Rotogravure printing for packaging: requirements and solutions Requirements High product quality Modular design with PROFINET Safety functions Compact drives for modular concepts Servomotors Solutions for rotogravure printing machines Control quality Synchronization via PROFINET for connection of all press modules Integrated safety functions in SINAMICS S120 Certified acc. to EN 954-1, Cat. 3 and IEC 61508, SIL 2 DC/AC Book Size*: feeding unit (BLM/ALM) up to 120 kw DC/AC Book Size*: single-/double motor module up to 107 kw AC/AC Blocksize*: single motor module up to 90 kw SIMOTION D for single-/ multi axis application * Line voltage 3-ph 380V to 480V Synchronous- / asynchronous- and torque motos in compact design in natural-/ air- and water cooled from 0,05 up to 180kW Explosion-proof servomotors available Integrated functions Register control integrated into SIMOTION D. Decoupled register set point calculation for less waste Slide 10

10 Rotogravure printing: requirements and solutions requirements High product quality Modular design Safety functions Antriebsleistung Servomotors Functions solutions Control quality Synchronisation via PROFINET for connection of all moduls of the machine Integrated safety functions of SINAMICS S120 terms to IEC DC/AC Book Size*: single-/double motor module up to 107 kw DC/AC Chassis*: up to 800 kw AC/AC*: up to 250 KW * Line voltage 3-ph 380V to 480V Spectrum from 0,2 to 630kW Water cooled motors up to 120kW Explosion-proof servomotors In SIMOTION D integrated register controller with decoupled register for less maculature Slide 11

11 Configuration for centralized concepts One drive module for: Unwinder Printing unit Winder HMI Ethernet PROFIBUS Slide 13

12 Configuration for a decentralized concept One drive module for: Unwinder Printing unit Winder HMI Ethernet Slide 14

13 Principles of register control Visualization / Operation Measurement of register marks Visualization of register difference Register control Corrective actuation Calculation of register deviation control loop algorithm corrective actuation measurement Sensor/ Camera printing marks register deviation Slide 16

14 Camera system The camera system is the key component of the register control system The flash and complete analysis of the picture is implemented in the camera system printing marks on the web Intelligent Camera System = Picture recording, analyzing and flash triggering transmit the measured to the closed control loop of the drive system Slide 17

15 Closed loop control The closed control loop is realized in a SIMOTION Control Unit. The camera is directly connected to the SIMOTION controller. The register controller are interconnected by the drive bus system. The integrated implementation is superior to existing systems. Competitor Siemens Motion Controller disturbance i. e. from winder disturbance i.e. from winder register error register error Slide 18

16 Influence of register movement EZW 1.DW 2.DW 3.DW 4.DW Die Auswirkungen einer Registerverstellung lassen sich elektronisch entkoppeln r 3.5 G2 L Register Error (ohne Entkopplung) (mm) 3.0 G2 L Register Error (mit Entkopplung) (mm) Sec r 3.0 G2 L Register Error (ohne Entkopplung) (mm) 2.5 G2 L Register Error (mit Entkopplung) (mm) Sec r 0 G3 L Register Error (ohne Entkopplung) (mm) _G3 L Register Error (mit Entkopplung) (mm) r 0 G3 L Register Error (ohne Entkopplung) (mm) 1_G3 L Register Error (mit Entkopplung) (mm) Sec Sec r 0.1 G4 L Register Error (ohne Entkopplung) (mm) _G4 L Register Error (mit Entkopplung) (mm) v = 100 m/min -0.7 Sec :01:50 17:02:00 17:02:10 17:02:20 17:02:30 17:02:40 r 0.1 G4 L Register Error (ohne Entkopplung) 1_G4 L Register Error (mit Entkopplung) (mm) v = 200 m/min 17:23:15 17:23:25 17:23:35 17:23:45 17:23:55 Sec Slide 19

17 Modular controller setup register controller register alarm message pre control & uncoupled decentralised concept with linked algorithm Slide 20

18 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 machines Slide 22

19 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 pipeline Acquisition of 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 23

20 Safety Integrated Enabling of safety functions via failsafe terminal module TM54F Sensors 2 2 Sensors ASIsafe Safety device 2 TM54F dbsi drive based Safety Integrated Acquisition of 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 24