The future of shaftless drive corrugated printing and processing
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In recent years, as the market demands for corrugated printing and processing continue to increase, faster production speeds and higher print quality are being widely proposed. However, the traditional mechanical transmission printing machine has limited the improvement of production quality due to the mechanical transmission torsional interference, and it has been difficult to adapt to the current market demand.
When traditional technologies can no longer meet market requirements, more new technologies have emerged on the market. Such as Bosch Rexroth SYNAX200, it is one of the more representative products. The independent and modular shaftless drive automatic control system of each unit is designed to meet the requirements of the market. The traditional mechanical long shaft will be replaced by the "electronic long axis". Below, we will take a corrugated printing machine as an example to give a detailed overview of how the various units of the system can improve performance in this new system control.
Leading edge paper feed
Leading edge paper has always been considered a key part of the overall printing effect. It is a key technology for mechanical cams in conventional mechanical transmissions, involving the design and manufacture of cams. Sometimes, even if people have a comprehensive understanding of the leading edge feed cam curve or have new ideas to improve the efficiency of the entire machine, it often seems to be a bottleneck to create a high-precision cam. At present, the high-precision cam mechanism of the leading edge paper feed mainly relies on the import. Once the mechanical structure or size of the paper feed part needs to be changed and the mechanical cam is also modified, it is almost impossible for the machine manufacturer.
The electronic cam is a high-precision servo motor installed in the mechanical transmission part, and the motor is operated by a previously calculated cam track to replace the original mechanical cam mechanism. The emergence of the Bosch Rexroth electronic cam solution completely broke the bottleneck and pattern of mechanical cams, which was mainly due to Bosch Rexroth's unique electronic cam derivative and generation tool software (CamBuilder). The customer can generate the cam curve according to the actual situation of his own machine, with position, speed, acceleration and variable acceleration, and customize the "cam" for himself. It is worth mentioning that even the first contact with the cam curve designer can use the built-in cam curve design wizard to generate the cam step by step. Through the internal calculation, the speed, acceleration and variable acceleration of the cam at different printing speeds can be understood very intuitively, and the required electronic cam curve can be obtained. It is worth noting that a reasonable electronic cam curve will directly affect the efficiency of the servo motor. Under the same working efficiency, the reasonable electronic cam curve determines the most cost-effective servo motor.
At present, two sets of electronic cam solutions are available on the market for users to choose. A set of system solutions for electronic cams, that is, electronic cam control becomes part of the whole system's shaftless drive system solution. The cam control is realized by the electronic cam synchronization function built into the motion control system (MC). The solution for the shaft drive press; the other is a single-axis solution with integrated electronic cam function in the drive, ie the electronic cam function can be implemented by a single drive. Bosch Rexroth's latest range of drives (IndraDrive) integrates motion and logic functions (MLD), which requires only the addition of an encoder to the original mechanical long shaft or main drive gear to achieve the leading edge feed mechanism and the entire The synchronization of the machine and the integrated PLC function of the drive enable independent control of the leading edge feed mechanism without modifying the original machine program. This upgrade and retrofit of the original machine functions is a very cost-effective solution.
The servo-driven transfer roller transports the paperboard at a smooth acceleration, minimizing the effects of slippage and minimizing print registration errors caused by the paper feed mechanism. At the same time, it can also cooperate with the automatic register control function inside the Rexroth SYNAX200.
Printing unit
The main factors affecting the printing effect of traditional mechanical transmission are: transmission mechanical rigidity and clearance, plate or plate accuracy, printing plate roll, suitable pressure between anilox roller and platen roller.
Now by installing a servo motor on each printing cylinder, these factors can be changed, making the printing cylinder a true "electronic axis" with an resolution of 1/8000000 rpm "electronic axis", they and the motion control system (MC) The internal "virtual spindle" (resolution is 220) is synchronized. The electronic synchronous steel effect far exceeds the mechanical steel effect, and the direct drive of the "electronic shaft" can avoid the influence of the traditional gear transmission meshing gap.
The independent drive of the printing roller avoids the torsional interference transmitted from the mechanical transmission gear. The “electronic shaft” with position memory function can easily enter the pre-established registration position before each power-on, and the printing length can be printed by the electronic gear. Make fine adjustments to reduce registration errors caused by misalignment during plate making or pasting. The automatic registration control inside the Rexroth SYNAX200 guarantees maximum print quality.
Indentation and slotting
At the indentation site, the servo motor is mounted on the side of the indentation knife to achieve fast and accurate positioning of the tool according to the width of the cardboard before starting. A database of conventional cardboard sizes can be generated in the system, and the customer can complete all parameter settings by simply selecting the board specifications to be produced prior to operation.
The basic task of grooving is to open one or two slots in the fixed position of the cardboard. By installing a servo motor on the grooving knife to change the position of the groove on the cardboard or to adjust the circumferential angle of the grooving knife, these can be Auto-complete without manual intervention. This flexible adjustment reduces the set-up time required to switch between different production orders.
Circular die cutting
The vibration caused by circular die cutting is the main component of the interference source in traditional mechanical gear transmission. On the one hand, the interference generated to the printing unit affects the printing quality; on the other hand, the power distributed to each unit by the mechanical gear transmission is uneven and interferes with each other, which affects the quality of the circular die cutting.
The die cutter roll and the anvil roll can be driven independently by two servo motors, which is a comprehensive solution to ensure production quality. In this way, the die cutter roller has sufficient power and position control to ensure the precision of the die cutting without bringing the vibration to other units, and the anvil roller prolongs the service life under the motion control of the servo motor.
In terms of circular die cutting, in addition to the SYNAX200 integrated automation system solution and the previously introduced leading edge feed solution, the latest series of drives (IndraDrive) integrated motion and logic functions (MLD) can be used to The die cutting of the machine is upgraded and modified.