Engineer Training Mechanical Overview. Engineer Training Confidential 2 XL1500 is both Roll-to-Roll...

Engineer Training

Mechanical Overview

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Engineer Training

XL1500 is both Roll-to-Roll and Roll-to-Sheet Printer

Machine XL1500-2m XL1500-3m XL1500-5m

Length (total) 400 cm 501 cm 680 cm

Depth (total) 182 cm 182 cm 182 cm

Height (total) 238 cm 238 cm 238 cm

Weight (unpacked)

2700 Kg 3500 Kg 4400 Kg

Maximum printing width

220 cm 320 cm  520 cm

General Mechanical Specs

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Engineer TrainingXL1500 System Components

The XL1500 is comprised of four rotating axles, which are controlled by the motion control system, and a fifth independent collecting shaft.

1. X Axle – Linear motion along the printing table

2. Y Axle – Media advance

3. Z Axle – Media Tension and forward collection

4. T Axle – Backward collection

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Engineer Training

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Engineer Training

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Engineer TrainingXL1500 Ver. B Chassis

The XL1500 Ver. B has a metal frame of combined R.H.S metal profiles and metal sheets – constructed using the combined method of welding and fastened with screws.

Several reinforcements are installed on the side plates.

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Engineer TrainingGeneral Mechanic Chassis Structure

The XL1500 chassis is constructed from two Aluminum Side Plates, which are connected together by metal beams and hold all rotating shafts.

The Chassis is reinforced using Metal Brackets.

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Engineer TrainingGeneral Mechanic Chassis Structure

In each bottom corner of the chassis are the leveling pads and wheels:

The wheels are used only for moving and positioning the machine in its place.

The leveling pads are the permanent positioning pads of the machine and assist in the final leveling process.

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Engineer TrainingGeneral Mechanic - Leveling

5m machines have an additional support leg located in the middle of the main beams, in the front and in the back of the machine.

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Engineer TrainingLeveling Pads Positioning

2768 mm

1100 mm

1100 mm

1100 mm

3536 mm

2536 mm

3536 mm

1100 mm1100 mm1100 mm

2536 mm

2768 mm

5536 mm

5 metermachine

2 metermachine

3 metermachine

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Engineer TrainingLeveling Pads Position – 5m machine

Leveling pads and wheels position

Additional support legs

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Engineer TrainingVer. B Positioning Pads and Wheels

5m Model - 4977mm

2m Model - 2210mm

3m Model - 3246mm

2m Model - 2538mm

3m Model - 3574mm

5m Model - 5347mm

2675.5mm (Only in 5m Models)

Distance between Positioning Wheels

Distance between Positioning Pads

1099.8mm

(Wheels)

1119.8mm

(Pads)

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Engineer TrainingPrinting Table

The printing table is used for leading the Media between the Y and Z shafts.

From the Printing table the media goes to the Dryer.

The printing table is adjusted while the machine is in integration stages, and is not possible to readjust during installation.

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Engineer TrainingPrinting Table - Construction

The Printing Table is constructed of:

5 Printing Table Bases spread evenly along the Printing Table.

The Bases are connected to corresponding vertical frame beams, and accuratly positioned using the Table Spacers.

Printing TablePlates

Frame Support Beam

Backlit Glass

Printing Table Bases

Old printing table (2001-2050)

Printing TablePlates

Backlit Glass

Printing Table Bases

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Engineer TrainingPrinting Table

5 Table Profiles spread evenly from bottom to top connected to the Table Bases.

4 Printing Table Plates are inserted between the Profiles.

On top of the printing table base, the front roller is located.

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Engineer Training

Printing table base

Printing table profile

Printing table front roller

Printing Table (Cont.)

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Engineer TrainingMechanics – Printing Table

Under the printing table there is a rounded Teflon coated Profile, which is connected to the Chasis.

Above the printing table there is a roller which is connected to the printing table base as well.

Roller

Rounded profile

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Engineer TrainingThe Linear Unit

The Linear Unit in the machine consists of three elements:

1. Head Carriage

2. Linear Profile (Linear Beam)

3. Module X

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Engineer TrainingHead Carriage

The Head Carriage is constructed of the four sub elements:

1. Head Carriage CoverCompletely covers the headcarriage, protects the electronic|parts installed within, and includes 2maintenance doors and ventilationwindows.

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Engineer TrainingHead Carriage (Cont.)

2. Head Carriage Frame

Includes the printing heads plate, the printing heads and holders, the ink secondary tanks, and the air valves.

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Engineer TrainingXL1500

Head carriage frame was replaced with a new version.

The new frame allows lowering all secondary tanks (especially the Yellow secondary tank).

The bottom of the head carriage frame is open, yellow secondary tanks can go down.

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Engineer TrainingHead Carriage

3. Cards Plate

Holds the CCB2 cards, the 5/12 V P.S., the optic sensor, and the air manifold.

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Engineer TrainingHead Carriage (Cont.)

4. Head Carriage Base Plate

Groups all the above sub elements and connect to motion belt and the linear bearings.

The base plate is connected to the inner bearing using the head box plate support, which is also used for leveling the head carriage.

Head box plate support

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Engineer TrainingThe Linear Profile

The Linear Profile consists of the five main elements:

1. The Linear Beam

2. Two Pulleys on each end of the beam

3. Tension Belt

4. Tenacity block, which adjusts the tension of the belt

5. Three Linear Bearings

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Engineer TrainingThe Linear Profile (Cont.)

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Engineer Training

Upper view of Linear Profile

Linear Bearings

Tenacity Block

Linear Bearings

The Linear Profile (Cont.)

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Engineer TrainingThe Linear Profile (Cont.)

The linear profile is laid on top of the machine’s front chassis beam with a set of adapters, which are specially design to allow the very fine adjustment of the profile’s position (twist and leveling).

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Engineer Training

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The Linear Profile (Cont.)

Operation (acc’ to screw number):

1. Y axis pulling screw down

2. Y axis direction locking screws

3. X axis direction locking screws

4. X axis Pushing backwards screws

5. Locking screws

6. Y axis pushing up screws

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Engineer TrainingThe Linear Profile (Cont.)

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Engineer TrainingModule X

Module X consists of four main elements:

1. Coupling

2. Gear Adapter

3. Gear, decreases the speed of the motor at a ratio of 1:5.

4. Electric Servo Motor, which powers the X axis.

432

1

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Engineer TrainingY Axis

The Y-axis consists of five basic parts:

1. Rubber Shaft, which grips the substrate and determines its advance.

2. Two Bearing Holders, holding the rubber shaft in place. One bearing holder allows free axial movement.

3. Two Bearings

4. Coupling

5. Module Y

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Engineer TrainingY Coupling

The Coupling consists of two basic elements:

1. Torsionsstefie Kuppling ,bridge element between the Gear output shaft and the rubber shaft.

2. Two Clampex, one for the output shaft from the gear (2a) and one for the rubber shaft (2b.).

1

2b

2a

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Engineer Training

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Y Shaft

Module Y

The Module Y consists of four parts :

1. Electric Servo Motor

2. Gear with a ratio of 1:91

3. Gear Adapter

4. Gear Connection Shaft

5. Module Y coupling

Note: Installation of Module Y tn18_Installing New Coupling Y

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Engineer TrainingZ AXIS

Z axle is comprised of two shafts:

Z rubber shaft

Teflon pressure shaft

When using the Roll to Roll printing mode, the substrate will be taped to the rubber shaft, which is the end of the media path.

Z Rubber Shaft

Teflon Pressure Shaft

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Engineer TrainingZ AXIS (Cont.)

When using a Roll-to-Sheet printing mode

1. The substrate will flow around the rubber shaft scope to the Teflon pressure shaft, creating an S shape in the substrate flow route.

2. The rubber shaft is then lowered to press the pressure shaft.

3. The pressure created between the rubber shaft and the Teflon pressure shaft, plus the friction between the substrate and the rubber shaft ensures the grip of the substrate and the tension needed for the printing process.

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Engineer TrainingZ AXIS (Cont.)

Note: When the standard Printing mode is selected, the Z shaft is pushed upwards by the two Pistons located at both sides of the shaft and than secured into position by the Free Fall Bracket Pin .

Media

Z –Shaft

Teflon Pressure Shaft

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Engineer Training

An Indicator Clock is mounted on each Free Fall Arm to assist in the adjustment of theZ-Rubber Shaft’s Parallelism and for each media type used in the Free Fall mode.

Z AXIS (Cont.)

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Engineer TrainingModule Z

The Module Z is constructed from four main parts:

1. Aluminum Coupling

2. Gear Adapter

3. Gear with a ratio of 1:50

4. Electric Servo Motor

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Module T

The Module T is constructed from four main parts:

1. Aluminum Coupling

2. Gear Adaptor

3. Gear with a ratio of 1:50

4. Electric Servo Motor

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Engineer TrainingTeflon Pressure Shaft – for Y axle

The Teflon Pressure Shaft Substrate Pressure Sub ASSY in the BOM, provides the initial pressure needed for traction between the substrate and the Y rubber shaft, and is constructed from the following:

1. Roller Tube

1

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Engineer TrainingTeflon Pressure Shaft – for Y axle (Cont.)

2. Support Arm - on which the the Roller Tube is laid. It is connected to the machine frame and to the pistons.

On the two ends of the tube the Arm is connected to the Tube, but not to the pistons.

2

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Engineer TrainingTeflon Pressure Shaft – for Y axle (Cont.)

3. Pneumatic Piston

The Pistons are supplied with 2.5 Bar air pressure.

Connection to the air tube is via Quick Connection.

The Quick Connection is also mounted to a flow valve which can increase and decrease the speed at which the piston is coming out or going in.

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Engineer Training

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Pneumatic Cylinders – for Y axle

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Engineer TrainingMedia Plates and Tube

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Engineer TrainingMedia Support Rollers

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Engineer TrainingMedia Support Rollers

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Engineer TrainingNew Head Carriage

4. Head Carriage Base Plate

Heads Carriage Base is designed to allow the adjustment in two axes:

Around the parallel axis to the Linear Profile.

Around the perpendicular axis to the Linear Profile and the Printing Table