Benefits of Electronic Line Shafting

Bosch Rexroth

Electric Drives & Controls Division Kin Yung – Printing & Converting Business Development Manager

Agenda- Benefits of Electronic Line Shafting

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Overview of typical Printing & Converting Machines Electronic Line Shafting (ELS) approach Evolution of ELS Technology ELS Benefits and its effect on Printing & Converting Machinery Question & Answer

A Typical Mechanical Printing Press

Mechanical press drive systems for: Label & Package printing, Commercial printing, Newspaper printing and Converting machines… - One motor powers the entire machine - Horizontal and vertical line shaft, gears and toothed belts, distribute the drive torque to all machine units.

- The mechanical linkage ensures synchronization of all cylinders and rollers.

A Typical Mechanical Printing Press Advantages and Disadvantages Advantages:

- Mechanical machines are sturdy and reliable.

- Press operators and service staff are familiar with the machine components for routine maintenance and breakdown.

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Disadvantages:

Mechanical machines are not flexible for today’s demands of short run, quick changeover and make ready.

- Print quality and accuracy are sometimes not sufficient due to mechanical wear and torque disturbances between units.

Electronic Line Shafting Approach

ELS - Distributed Drive System

The Electronic Line Shaft does not transmit force or torque disturbances between units

Electronic Line Shafting Approach

Electronic Line Shaft

SERCOS interface Position Speed Torque Position Speed Torque - The motion controller generates 32 bit position data of an electronic line shaft.

- These positions are transmitted to the digital drives via a Sercos fiber optic ring.

- High resolution and precision - Exact synchronization - Distributed drive intelligence - Drive integrated control loops (position, velocity, and current) - Motion path planner and interpolation - High resolution feedback (16M counts/rev) 

Excellent Print Quality

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No gear marks, reduces waste

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Highly flexible for quick changeover and short run

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Production Cost Savings

Evolution of ELS Technology Electronic Gearing

 Electronic gears without backlash replace mechanical gears  Gear ratio range (1:65000 to 65000:1)  Phase synchronization  Exact electronic register via fine adjust  For printing, die cutting,…  Speed synchronization  Continuous gear ratio fine adjustment, resolution of 0.000001%  Adjustable for optimum register and tension control  Transparent and precise

Evolution of ELS Technology Electronic Camming

  Replacement of mechanical cams and special gears   Use for non-linear movements Synchronization of draw rolls and rotary cutters to the web Synchronization of variable repeats for cross cutters Drive internal cam curve Slave

cutting angle Cutting area v=constant

web Master

Evolution of ELS Technology Electronic clutches / Flying job change

   Dynamic synchronization of a machine unit to the web at full production speed Reduction of downtime and fast product change “on the fly”  e.g. newspaper production with “flying plate change” Only possible with electronic gear box, no mechanical equivalence

Evolution of ELS Technology Process Controls

Winding Control      Without sensors With dancer + pneumatics With load cell Diameter calculation Inertia calculation Tension Control  In-feeds and out-feeds  Draw-rollers Registration Control      Direct and Indirect control Expectancy window Correction window Missed mark detection Trending correction Windows based setup, Pre-configured algorithms, Drive Diagnostics, and Help Tools

Evolution of ELS Technology Advanced Drive Functions

Referenzkurve mit Toleranzband Drehmoment außerhalb des Toleranzbandes

Drive Safety-On-Board

     Drive Interlock Safe Standstill, Operation Stop Safe direction of movement Safe max./limited velocity Safe limited absolute position

Scalable drives Power range up to 125Kw Drive Preventive Maintenance

   Extended range of drive diagnostics Less machine downtime Lengthens machine life cycle

Evolution of ELS Technology Direct Drives Direct Drives improves print quality

- Simplified machine design - High dynamics/stiffness - Outstanding control loop accuracy - Very low torque ripple (<0.1%) - High static and dynamic load rigidity - High positioning accuracy - Reduce operation noises - Maintenance free - no wear at motor parts Synchronization / Electronic Gearing

High Torque

up to 13.800 Nm

IndraDyn T High Speed

up to 30.000 rpm

IndraDyn H Linear

up to 21.500 N

IndraDyn L

Jogging Cam switch Winder Tension Registration Real and Virtual Master

Electronic Line Shafting Approach Evolution of ELS Technology Drive-based Solution

 Compact system for modular distributed architectures  Ready-to-use function libraries according to PLCopen  Drive-integrated motion-control and PLC runtime system according to IEC 61131-3  Reduced cabinet space Synchronization / Electronic Gearing Jogging Cam switch Winder Tension Registration Real and Virtual Master

Electronic Line Shafting Approach Evolution of ELS Technology System architecture PLC, Motion, HMI, Drives, Motors… Engineering Ethernet Motion Control w/Logic HMI Drives

Cross Communication

HMI Motors I/O

Pneumatics Hydraulics

Evolution of ELS Technology Applications

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More than 15 year of experience

gained in Printing & Converting industry concentrated in an open

technology library

for:             Label printing machines Form printing machines Flexogravure printing Rotogravure printing for packaging Screen printing machines Security paper printing Commercial printing machines Newspaper printing machines Converting machines Bag production machines Hygiene- and Tissue machines Corrugated board machines Synchronization / Electronic Gearing Jogging Cam switch Winder Tension Registration Real and Virtual Master

Automation Line Concept Flexible In-line Processing

 Flexible in-line configuration  of different machine modules  from different machine builders

Stacker / Packaging Converting 1 OEM4 Printing

ENVETRONIC

OEM3 OEM2 OEM1