In recent years, with the continuous improvement of the market's requirements for corrugated paper printing and processing, faster production speeds and higher printing quality are being generally proposed. However, the traditional mechanical transmission printing machine has limited the improvement of production quality due to the torsional interference of mechanical transmission, 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 appeared on the market. Such as Bosch Rexroth SYNAX200, it is one of the more representative products. Its independent modularized shaftless drive automatic control system is designed to meet market requirements. The traditional mechanical long shaft will be replaced by an "electronic long shaft". In the following, we will take corrugated paper printing machine as an example to outline in detail how each unit of its system will improve the performance in this new system control.
Leading edge paper feed
Leading-edge paper feed has always been considered a key part of the overall printing effect. It is the key technology of mechanical cam in traditional mechanical transmission, which involves the design and manufacture of cam. 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 that creating a high-precision cam is a bottleneck. At present, the high-precision cam mechanism for leading-edge paper feeding mainly depends on imports. Once the mechanical structure or size of the paper feeding part needs to be changed, the mechanical cam must also be changed accordingly, which is almost impossible for machine manufacturers.
The electronic cam is to install a high-precision servo motor in the mechanical transmission part. The motor runs on the cam track calculated in advance to replace the original mechanical cam mechanism. The emergence of Bosch Rexroth's electronic cam solution has completely broken the bottleneck and pattern of mechanical cams. This is mainly due to Bosch Rexroth's unique electronic cam calculation and generation tool software (CamBuilder). Customers can generate cam curves with position, speed, acceleration, and variable acceleration according to the actual situation of their own machinery, tailoring their own "cam". What's more worth mentioning is that even the designer who came into contact with the cam curve for the first time can generate the cam step by step through the built-in cam curve design wizard. Through internal calculations, you can intuitively understand the speed, acceleration, and variable acceleration of the cam at different printing speeds, so as to obtain the required electronic cam curve. It is worth noting that a reasonable electronic cam curve will directly affect the working efficiency of the servo motor. Under the same working efficiency, the reasonable electronic cam curve determines the most cost-effective servo motor.
At present, such two sets of electronic cam solutions for users to choose have been launched on the market. A set of system solutions for electronic cams, that is, electronic cam control becomes a part of the system's shaftless drive system solution, and the cam motion is built by the electronic cam synchronization function built in the motion control system (MC). The solution of the shaft drive printing machine; the other is the single-axis solution of the electronic cam function integrated in the drive, that is, the electronic cam function can be realized by a single drive. Bosch Rexroth's latest series of drives (IndraDrive) integrates motion and logic functions (MLD), so only need to install an encoder on the original mechanical long shaft or main transmission gear, you can achieve the leading edge of the paper feed mechanism and adjustment The synchronization of the machine and the PLC function integrated in the driver can independently control the leading edge paper feed mechanism without modifying the original machine program. This is a very cost-effective solution for the upgrade and transformation of the original machine functions.
The servo-driven conveyor roller conveys the cardboard at a smooth acceleration to minimize the effects of slippage and minimize printing registration errors caused by the paper feed mechanism. At the same time, it can also cooperate with the automatic registration control function of Rexroth SYNAX200.
Printing unit
The main factors affecting the printing effect of traditional mechanical transmission are: the rigidity and gap of the transmission machinery, the precision of plate making or plate mounting, the appropriate pressure between the printing plate roller, the anilox roller and the impression roller.
Now by installing a servo motor on each printing roller, these factors can be changed to make the printing roller a true "electronic axis" with a resolution of 1/8000000 revolutions "electronic axis", they and the motion control system (MC) The internal "virtual spindle" (resolution 220) is synchronized. The effect of electronic synchronous rigidity far exceeds that of mechanical rigidity, and the direct transmission of "electronic shaft" can avoid the influence of meshing clearance of traditional gear transmission.
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 start. The printing length can be adjusted by the electronic gear Carry out fine adjustment to reduce the registration error caused by misalignment during plate making or plate-laying. The automatic register control function inside Rexroth SYNAX200 can guarantee the printing quality to the greatest extent.
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Indentation and slotting
In the indentation part, install the servo motor on the indentation knife roller side, so that the cutter can be quickly and accurately positioned according to the width of the cardboard before starting. A database of conventional cardboard sizes can be generated in the system. The customer only needs to select the specifications of the cardboard to be produced before the operation, and all parameter settings can be completed.
The basic task of slotting is to open one or two slots at a fixed position of the cardboard. By installing a servo motor on the slotting knife to change the position of the slot on the cardboard or adjust the circumferential angle of the slotting knife, these can be Automatically completed without manual operation. This flexible adjustment method 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 generated interference is transmitted to the printing unit, which affects the printing quality; on the other hand, the power distributed to each unit through 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 anvil roll can be driven independently by two servo motors, which is a solution to comprehensively guarantee the production quality. In this way, the die cutter roller has sufficient power and position control, which not only ensures the accuracy of die cutting, but also does not bring vibration to other units. The anvil roller extends the service life under the motion control of the servo motor.
In the aspect of circular die cutting, in addition to the solution using the SYNAX200 overall automation system and the previously introduced leading edge paper feeding solution, the motion and logic functions (MLD) integrated in the latest series of drives (IndraDrive) can also be used. The die-cutting of the machine is upgraded and transformed.
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