Analysis of the characteristics of the virtual axis of the independent drive motor of the commercial reel
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Is the real axis or the virtual axis?
In just a few years, the web press drive with mechanical shafts has been replaced by a "virtual" shaft. Many independent motors replace a single main motor. Instead of mechanical energy, electrical energy now distributes independent motors that drive printing units, web bonding, folding and cutting devices. This is not just a question of which technical principle to adopt.
Independent drive motors have many specific advantages. For example, the user can benefit from the mechanically uncoupled design of the printing unit. The movement transmitted by the ordinary drive shaft is avoided, so that stable high-quality printing is obtained. At the same time, the printing unit with its own independent motor can be deployed very flexibly. It is easy and not expensive to add another set of "rubber roller to blanket cylinder" (B-B) or tandem printing unit.
Below is a detailed description of the more advantages of this new drive technology.
Complete printing equipment inspection
In the past, only the auxiliary drive motor was used to mechanically test the rubber roller one-on-one blanket cylinder printing unit. Now all mechanical and electronic properties can be inspected. Because the complete drive motor of the power converter and the electronic control unit is integrated in the printing unit. This space-saving design also allows any fault to be detected during the test run phase. All parts are thoroughly inspected before the printer leaves the factory, so the installation time of the customer in the factory can be greatly shortened.
Shorten reaction time
Independent motors can operate over a wider tolerance range than a combined mechanical drive motor. This is because the mechanical components require more time to adjust and the torque transmission changes as the mechanical shaft is twisted. With a separate motor, the deviation from the nominal value is reduced and the motor reacts faster.
Control and regulation of AC motors
In order to achieve precise synchronization of printing units driven by independent motors, AC motors are used. The position of the motor can be queried by an encoder that is 10 bits faster than its operating frequency. The position of the motor can be corrected frequently, ie the synchronization of the motor can be more precise, since the encoder technology and signal processing are more precise.
Web breaks less
When a periodic failure occurs in the force of the web, such as when the drum produces a certain pulling force on the web, the motor reacts very quickly. The web force remains constant over a smaller tolerance, the web breaks less, and stable production becomes an economic benefit.
In order to obtain an optimized web force, development engineers have taken the following basic assumptions - even if the printing line is operating well, it must be considered that there is a certain error. Not all press components can operate equally well, and there may be differences between the various printing units. For example, on a web bonding apparatus, the imbalance caused by the paper cylinder deviating from the perfect circle must be corrected.
The independent motor drive system greatly reduces the sensitivity to such roll paper force failures. The customer has confirmed that on a web press with a separate drive motor, the web force is extremely stable, especially during the speed change process.
Virtual axis reduces vibration
With the conventional drive shaft method, the disturbance of one printing unit is transmitted to the other printing units through the mechanical shaft. For an independent drive motor system, this interaction does not occur because the mechanical connection no longer exists. Previously affecting print quality, the small disturbances caused by DC motors and longitudinal axes have now been eliminated.
More remote diagnosis of the drive
Remote can identify the cause of the problem. This test is based on the evaluation of the drive data and can be adjusted for various individual drive motors. This can be seen in the comparison of Figures 2 and 3. The prerequisites are based on the system partner Siemens (Siemens Close cooperation of AG) - cooperation in motors, converters and control technology.
One of the results of this collaboration is SIMOLINK MONITOR (SLM), a SLM is called SIMOLINK (Siemens Optical Link's abbreviation) An interface to the high-speed data bus of the drive system is an extremely fast optical fiber that connects all the motors connected to the high-speed data bus and provides drive coupling in practical applications, thus a "virtual electronics" The shaft" runs through the printer. This SLM command system is used for diagnostics, and technicians can use this "diagnostic plug" to connect to the laptop and follow all drivers for a certain period of time.
With SLM, measurements can be taken simultaneously, so the possible causes of changes, such as registration changes due to component wear, can quickly and accurately determine the cause of the problem.
All data in the drive system can be extracted online, at the same rate as they appear during the printing process.
The possibility of using SLM for further diagnosis will develop in the future. Many metrics are available from a large amount of data, such as DAX and Dow Compared to indicators like Jones, these indicators provide a trend about choosing paper and distributing prices.
Reduced component losses
Rugged, surface-ventilated, asymmetrical motors do not require lossy components like carbon brushes. The electronic components inside the motor are highly enclosed to prevent moisture. Dust and other debris are unlikely to enter the motor and cause damage. At the same time, the control cabinet integrated in the press is also sealed to prevent moisture and dust from entering. The heat is taken away directly by the water cooling unit and does not affect the air conditioning in the pressroom.
Less change leads to higher performance
In the past, as many as 108 different main motors were used depending on the size of the press and the equipment. Today, there are only eight motors. For example, the two motors are suitable for various types of "blanket-to-blanket" printing units. Since these motors are standard, the possibility of failure is eliminated, which is advantageous for improving operational safety. The advantage of using a larger but smaller number of motors is that the design maturity of the individual motors is much higher than that of a nearly one-time motor. This has a positive effect on the quality of all products. At the same time, there are fewer different types of motors, and it is easier for manufacturers or agents to manage their warehouses. If a motor fails, it can be replaced quickly.
No post optimization process
With a DC drive motor, it is necessary to adjust all the motors to the mechanical mechanism of the press during a trial run, such as after 6 months. Now, there are fewer mechanical devices (no axes with auxiliary drive motors and no auxiliary motors), but these mechanisms still have to go through a trial run phase. However, independent motors can compensate for this by their adjustment techniques, so no post-optimization process is required.
Advantages when changing the encoder or motor
Calibration of the encoder or motor to be exchanged anywhere in the press can now be done electronically. Just press a button and you're done. The actuator fixed to the mechanism reports its position to the drive motor electronics, which avoids the cumbersome setup work on the printing unit.