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Industrial AutomationAutomation IndustrielleIndustrielle Automation
Automation of newspaper printing machines: visit at CIEL
Prof. Dr. H. KirrmannABB Research Center, Baden, Switzerland
2006 April, HK, 1/36
2 CIEL visit - Printing principlesEPFL - Industrial Automation
Offset printing
The most common form of printing low and high-volume jobs used today is "offset" - used for everything from fliers to magazines and newspapers.
Offset printing uses an intermediate medium between the printing plate and the paper - the rubber-coated "blanket" is inked by the plate roller under relatively low pressure, to prevent the image from deforming. Half a revolution later the same image is printed on sheet or continuous (web) paper under much higher pressures. The plate is continually inked to maintain the image on the blanket.
Printing plates don't have any "relief" - there is no change in depth where the image isn't printed - instead the plate uses Teflon to repel water from some areas.
http://www.umax.co.uk/support/binuscan/technotes/nbi03.htm
3 CIEL visit - Printing principlesEPFL - Industrial Automation
Offset plates
The printing plate is initially coated with a light-sensitive material that protects the water-repellent Teflon layer below - this top layer retains water, preventing ink from building up and being printed on the blanket.
In areas where the Teflon has been revealed water will not stay on the surface of the plate, but ink will - hence the exposed areas are those that 'print'. The coating of the plate is removed using a photographic process and (typically) a negative copy of the image-setter films.
To produce the plate, films are held in place over the coating (usually via a vacuum frame to ensure perfect contact) while areas of the plate are exposed by a high-intensity UV light source. The plate is then chemically processed to expose the Teflon and fix the coating.
4 CIEL visit - Printing principlesEPFL - Industrial Automation
Halftones - Dot Shape, Screen Ruling and Screen Angles
To give the illusion of a continuous tone image when printed, all images have to be recreated using "halftone" patterns of regularly spaced ink dots, of varying sizes.
To "fool" the eye into seeing a continuous tone image, the lines of dots are very close together: typical line screen rulings are 133 lpi for mono (sometimes 120 lpi) or 150 lpi for colour (or higher). Although these general values are valid for "conventional" printing, uncoated stocks and especially newsprint dramatically reduce the line screens used (e.g. 100 lpi mono / 120 lpi colour).
The size of these dots, measured in a percentage tint, represents the lightness/darkness of each small area of the image.
The spacing of the dots is the "screen ruling", normally measured in Lines per Inch (lpi).
5 CIEL visit - Printing principlesEPFL - Industrial Automation
Colour printing
Colours are reproduced by combining four inks: (CMYK)Cyan, Magenta, Yellow, blacK
web lead
plate cylinder printing cylinder
A page printed in full colour must therefore pass through four cylinders, in the order CMYK.
bande de papierPapierband
6 CIEL visit - Printing principlesEPFL - Industrial Automation
Moiré and rastering
Overlaying several halftones produces interference patterns, called "moiré".
The most effective dot shape in 4-colour printing is elliptical - this allows overlaid colours to be "angled" to minimise interference.
The angle between Cyan and Magenta is critical as interference is obvious;
Yellow is far less critical as the colour is so light against white paper;
Black will give interference effects but is usually only reinforcing dark areas of an image where moiré is obscured.
The screen ruling (measured in lines per inch) varies between colours to reduce “rosette” patterns - the four "irrational screening" angles will usually average the output LPI, with black typically the highest ruling, angled at 45º.
7 CIEL visit - Printing principlesEPFL - Industrial Automation
Computer-to-Plate
In Computer-To-Plate (CTP), there are no films anymore: the plates are directly etched by a powerful laser and treated chemically.
The plate precision is in the order of 0.05 mm, so that the different colours blend without visible shadows.
The next step will be Computer-to-Cylinder: there will be no more plates, the cylinders will be directly written by a laser (and erased for the next production). However, this technology is not yet mature and the number of copies produced in one run (before rewriting the cylinder) is insufficient for a newspaper production.
8 CIEL visit - Printing principlesEPFL - Industrial Automation
plate
Around a cylinder
waterfaucets
homogenizer
ink supply
rubber cylinder(blanket) ink
water
9 CIEL visit - Printing principlesEPFL - Industrial Automation
Two cylinders
plate
rubberblanket
rubber blanket
plate
10 CIEL visit - Printing principlesEPFL - Industrial Automation
Cylinder arrangements
each manufacturer has its preferred cylinder arrangement
11 CIEL visit - Printing principlesEPFL - Industrial Automation
Tower and Folder
web
folder
turner bar
draw roller
folder roller
upper H
lower H
reelstand
dancer roller
infed
tour d'impression
barres de retournement
entonnoir
bobines
cylindres
plieuse
bande
12 dN/m
20 dN/m
25 dN/m
trotteuse
débiteur
tensionvalue
12 CIEL visit - Printing principlesEPFL - Industrial Automation
The folder
The folder folds one or several webs into bundles ("cahiers").(picture taken while introducing the paper in the machine)
13 CIEL visit - Printing principlesEPFL - Industrial Automation
10 75
14
10
3
7
Simple and Double production
16
12
1
5
14
10
3
7
16
12
1
5
12
8
6
1
3
5 68 1
8
6
1
3
5 68 1
double productiontwo newspapers per rotation of the cylinder – the same plates are mounted twice on the cylinder.
simple productionone newspaper per rotation of the cylinder – all plates of a cylinder are different
cylinder(flattened)
31416 1
11 1111
14 CIEL visit - Printing principlesEPFL - Industrial Automation
Web path
web
web colours
couleurs des bandesturner bar
barres de retournement
reelstands, changeurs de bobines
bars
folder
plieuse
web width
largeur de la bande
15 CIEL visit - Printing principlesEPFL - Industrial Automation
Paper colour and cylinder arrangement
Every newspaper is different. The web path is switched after each productionand the paper is thread in by a carrier system.
16 CIEL visit - Printing principlesEPFL - Industrial Automation
Web tracks (Chemins de papier)
Nearly every production requires a different threading
17 CIEL visit - Printing principlesEPFL - Industrial Automation
The transporter
The transporter carries the printed newspapersto the expedition.
En route, insets (advertising, prefabricated parts) can beinserted.
18 CIEL visit - Printing principlesEPFL - Industrial Automation
Drives
The cylinders were formerly connected by a shaft (Axe, Welle). Today, the shaft is replaced by an electronic synchronization based on a hard real-time bus, SERCOS.The precision of the drives position is about 0.05 mm, i.e. 2.5 microseconds at 20 m/s web speed.
19 CIEL visit - Printing principlesEPFL - Industrial Automation
Section control
A section is a number of towers producing into exactly one folder(towers can be assigned to different folders depending on the number of pages).
20 CIEL visit - Printing principlesEPFL - Industrial Automation
Several sections (folders)
21 CIEL visit - Printing principlesEPFL - Industrial Automation
Example WIFAG machine
Terminal Server
Bridge
Remote Diagnosis
Modem
Ethernet
Report Printer DB Server and
Workplace
MPS Production Computer 760
DECPersonal Workstation
Backup DB Server andWorkplace
Ethernet
CC
PM
Linebus AF100 RC
THE DALLAS MORNING NEWS
ArcNet
Sectionbus AF100/1
T3 T6
F TS
F1 T8 T10T4 T9
R2RSR1 R8R6R4R3 R5 R7 R9 R10
L
RIP Interface to Parascan
Report Printer
MPS Inform 710(Option)
PC
L U
R11
L U
T1 T2 T5 T7
SL U L UL L UL U
Sectionbus AF100/2
RC
L U L U T
RS RS RS RS RS RS RS RS RS RS
CC CC CC CC
PM
PM PMBackup
EP
Key of Symbols
L Lower H-Unit Control (AC110)
Mounted in Bridge
U Upper H-Unit Control (AC110)
Mounted in Bridge
T Turner Bar Unit Control (AC110)
Mounted on Press
S Section Unit Control (AC110)
Mounted in Cubicle SK
F Folder (Double) Unit Control (AC110)
Mounted on Press
G
G General Fct Unit Control (AC110)
Mounted in Cubicle NK
RC Reelstand Coupler (CS31)
Mounted in Cubicle SK
RS Reelstand Control System (WPOS)
Mounted on Reelstand
PM PressMaster System
Mounted in Cubicle PMR
CC MPS Control Console (LS)
EP Event & Fault Printer
PD
PD MPS Prod. Computer Distribution
Integrated in Cubicle MRV
U2U1
22 CIEL visit - Printing principlesEPFL - Industrial Automation
The console
The console allows to:
load the machine configuration
save the settings
adjust the ink and water for each page
display the state of the machine
display alarms and events
support diagnostics
save the settings
Console = Leitstand, pupitre
23 CIEL visit - Printing principlesEPFL - Industrial Automation
Console: adjusting the colour for each lane (screw)
a page is divided into lanes, each each controlled by a "screw“ that adjusts the ink and water
("vis d'encrage“Farbschraube)
in the console at right, 11 lanes are visible
24 CIEL visit - Printing principlesEPFL - Industrial Automation
Console: adjusting the web tension
the web tension defines the print quality, it varies as the machine warms up and humidity changes, but shall not lead to paper tear.
25 CIEL visit - Printing principlesEPFL - Industrial Automation
Console: Alarms
there are some 1000 different alarms, categorized by severity.
Alarms must be acknowledged.
26 CIEL visit - Printing principlesEPFL - Industrial Automation
Console: On-line help
By clicking on ? a help text
corresponding to theactual windows is
displayed with Acrobat
27 CIEL visit - Printing principlesEPFL - Industrial Automation
Control Structure of an H
IOIBS safety bus
loop
IBS-M
BA DIO MCU LBA
BA AIO MCU LBA
DisplayLocal bus
IBS-M
IO IO IO
SERCOS-drive
IOloop IO IO IO
functions:
local display, local command buttons, supervision of paper tear, color screws, water
Work controller
check controller
IBS long-distance bus
Turmbus
28 CIEL visit - Printing principlesEPFL - Industrial Automation
Networking a printing machine section
Falz- und Wendeturm-
steuerung
to production preparation(Ethernet) bridge
PMPMstandby
GW GWstandby
Section bus D
Line bus - AF100 Rollenwechsler- koppler A
Pressmasterbus (Ethernet)
Interbus-S
PECOM-ARCnet
Rollen- wechslerkoppler I Sektions-
steuerungMR93KT94
IBG
V-Sercos
IBG
Interbus
AC160 AC160
H -PLCs
Service-ARCnet
Turmsteuerung
Section bus BSection bus C
H-Sercos
IBG
V-Sercos
IBG
Interbus
AC160Turmsteuerung
IBG
V-Sercos
IBG
Interbus
AC160Turmsteuerung
IBG
KT94
KT94
KT94
KT94
KT94
KT94
KT94
KT94
KT94
KT94
KT94
KT94
KT94
KT94
ODC
KT94
Oxydry-Arcnet
Oxydry
Sektions-
steuerungAC160
Auro
Tower-ARCnet
LS LS LS
V-Sercos
Section bus C (AF100)
Interbus-S 4G
Towers
Reelstands
29 CIEL visit - Printing principlesEPFL - Industrial Automation
Multiple sections
Section Control
MPS Control Console
reelstand control
B C DE
SS3 SS4
MPS Production
OP1 Oxydry (washing)
Reelstands
SS5SS2
PMLSLSLSPMLSLSLSPMLSLSLSPMLSLSLS
MPS
tower and foldercontrol
30 CIEL visit - Printing principlesEPFL - Industrial Automation
MPSproduction
consoles
Speed and hierarchyresponse time
section control
tower/foldercontrol
Ethernet
Arcnet
tower/foldercontrol
tower/foldercontrol
section control
SERCOS
Interbus-S
AF100
Messages
Process variables
motors
cylindres
31 CIEL visit - Printing principlesEPFL - Industrial Automation
Organisation of newspaper production
32 CIEL visit - Printing principlesEPFL - Industrial Automation
Production Order
O r d e r D a ta
T ite l
D a te O f Is s u e
O rd e r N u m b e r
O rd e r V a r ia n t
Pr in t R u n 7 2 0 0 0 7 2 0 0 0 7 2 0 0 0 7 2 0 0 0G r a m m a g e 4 5 4 5 4 5 4 2 .5V o lu m e 6 8 1 4 1 6 4 8S e c t io n S tr u c tu r e B 1 8 /T 1 6 /B 1 8 /T 1 6 B 8 /B 6 B 8 /B 8 T 4 8Pa g e s + S p o t 0 2 0Pa g e s + 1 c 0 0 0 8Pa g e s + 2 c 4 0 0Pa g e s 4 c 8 2 8 1 6In s e r ts O m e g a B M W N ike
G N C" Pa g e s " Pla n n e d ( D - 1 ) 2 3 :0 5 :0 0 ( D - 1 ) 2 1 :3 0 :0 0 ( D - 1 ) 2 0 :1 5 :0 0 ( D - 2 ) 1 0 :4 5 :0 0D e liv e r y Pla n n e d ( D ) 0 4 :1 5 :0 0
0 8 -0 2 -0 0
M o rn in g S ta r K 0 0 5
1
E d it io n V e rs io n sE d it io n 43 4o f
P ro d u c t D a ta
3 W e s t
C o s ts
33 CIEL visit - Printing principlesEPFL - Industrial Automation
Roll logistics
34 CIEL visit - Printing principlesEPFL - Industrial Automation
Prepress and Workflow with MPS Cockpit
35 CIEL visit - Printing principlesEPFL - Industrial Automation
WIFAG
Based in Bern, worldwide number 3
WIFAG and ABB pioneered the shaftless press, which is standard today.
36 CIEL visit - Printing principlesEPFL - Industrial Automation