Transcript Benefits of Electronic Line Shafting
Benefits of Electronic Line Shafting
Bosch Rexroth
Electric Drives & Controls Division Kin Yung – Printing & Converting Business Development Manager
Agenda- Benefits of Electronic Line Shafting
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
No gear marks, reduces waste
Highly flexible for quick changeover and short run
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
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