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Automation Concept
Products, Characteristics
Requirements, Solutions
Copyright © Siemens AG 2008. All rights reserved.
Register control
Safety Integrated
Rotogravure Printing
Products, Characteristics
Slide 2
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Rotogravure Printing
Slide 3
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Commercial and rotogravure printing for packaging Typical products
Magazines (i. e. Spiegel, Stern)
Catalogs (z. B. Quelle, Otto) Cardboard boxes
Tetra-Paks Film packaging
Slide 4
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Decor printing Typical products
Decor- and furniture-surfaces
(i. e. wood and stone) Wallpaper printing
Acryl-foam printing
Slide 5
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Principles of gravure printing
The printing motive is engraved onto the gravure cylinder.
The ink is pressed into the cells of the rotating gravure cylinder. During inking-up the printing and none printing areas are flooded with ink.
The needless ink is doctored with the blade. The impression cylinder presses the printing material on the
gravure cylinder.
The ink is transferred from the gravure cylinder onto the printing material.
gravure cylinder
impression cylinder
blade ink fountain
Slide 6
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Characteristics of rotogravure printing for packaging
Characteristics
8 to 10 printing units per machine Every production has a different set of printing cylinders
The machine can be extended by additional converting elements Machine speed from 300m/min to 700m/min
Advantages of rotogravure presses Variable printing formats through different printing cylinder diameters
long lifetime of printing cylinder (>1.000.000 copies) Front- and backside printing in one step
Many different kinds of printing colors applicable
Many different materials may be printed High printing quality
Simple printing principle
Limitations
Solvent based colors (environment policy) The gravure of the printing cylinder is very costly
Slide 7
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Machine configuration
printing units infeed outfeed
quality check
unwinder
with flying spice
Quelle: Handbuch der Printmedien
rewinder
with flying spice
Slide 8
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Structure of a printing unit
printing cylinder
impression roller
dryer
chilling roller
In rotogravure printing
the wet ink cannot be overprinted.
Therefore drying is
obligatory after each printing element .
Quelle: Handbuch der Printmedien
Slide 10
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Rotogravure printing for packaging: requirements and solutions
Requirements Solutions for rotogravure printing machines
High product quality Control quality
Modular design with PROFINET Synchronization via PROFINET for connection
of all press modules
Safety functions Integrated safety functions in SINAMICS S120
Certified acc. to EN 954-1, Cat. 3 and IEC 61508, SIL 2
Compact drives
for modular concepts
DC/AC Book Size*: feeding unit (BLM/ALM) up to 120 kW
DC/AC Book Size*: single-/double motor module up to 107 kW
AC/AC Blocksize*: single motor module up to 90 kW
SIMOTION D for single-/ multi axis application
* Line voltage 3-ph 380V to 480V
Servomotors Synchronous- / asynchronous- and torque motos in compact
design in natural-/ air- and water cooled from 0,05 up to 180kW
Explosion-proof servomotors available
Integrated functions Register control integrated into SIMOTION D.
Decoupled register set point calculation for less waste
Slide 11
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Rotogravure printing: requirements and solutions
requirements solutions
High product quality Control quality
Modular design Synchronisation via PROFINET for connection of all moduls of
the machine
Safety functions Integrated safety functions of SINAMICS S120 terms to IEC
61800-5-2
Antriebsleistung DC/AC Book Size*: single-/double motor module up to 107 kW
DC/AC Chassis*: up to 800 kW
AC/AC*: up to 250 KW
* Line voltage 3-ph 380V to 480V
Servomotors Spectrum from 0,2 to 630kW
Water cooled motors up to 120kW
Explosion-proof servomotors
Functions In SIMOTION D integrated register controller with decoupled register
for less maculature
Slide 13
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Configuration for centralized concepts
Ethernet
PROFIBUS
HMI
One drive module for:
Unwinder Printing unit
Winder
Slide 14
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Configuration for a decentralized concept
Ethernet
HMI One drive module for:
Unwinder Printing unit
Winder
Slide 16
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Principles of register control
measurement
Visualization / Operation
printing marks
corrective
actuation Sensor/ Camera
Calculation of register deviation
control loop algorithm
Visualization of register difference
Register control
Corrective actuation
Measurement of register marks
register deviation
Slide 17
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Camera system
The camera system is the key component of the register control system
The flash and complete analysis of the picture is implemented
in the camera system
printing marks
on the web Intelligent Camera System“ =
Picture recording, analyzing
and flash triggering
transmit the measured to the closed
control loop of the drive system
Slide 18
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Closed loop control
The closed control loop is realized in a
SIMOTION Control Unit.
The integrated implementation is superior to
existing systems.
The camera is directly connected to the
SIMOTION controller. The register controller are interconnected by
the drive bus system.
disturbance i. e. from winder
Siemens Motion Controller Competitor
disturbance i.e. from winder
register error register error
Slide 19
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Influence of register movement
Die Auswirkungen einer Registerverstellung lassen sich elektronisch entkoppeln
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 G2 L Register Error (ohne Entkopplung) (mm) G2 L Register Error (mit Entkopplung) (mm)
Sec
-1.25 -1.00 -0.75 -0.50 -0.25
0 G3 L Register Error (ohne Entkopplung) (mm) 1_G3 L Register Error (mit Entkopplung) (mm)
Sec
-0.9 -0.7 -0.5 -0.3 -0.1 0.1
G4 L Register Error (ohne Entkopplung) (mm) 1_G4 L Register Error (mit Entkopplung) (mm)
Sec 17:01:50 17:02:00 17:02:10 17:02:20 17:02:30 17:02:40
r
r
r
0 0.5 1.0 1.5 2.0 2.5 3.0 G2 L Register Error (ohne Entkopplung) (mm) G2 L Register Error (mit Entkopplung) (mm)
Sec
-1.00 -0.75 -0.50 -0.25
0 G3 L Register Error (ohne Entkopplung) (mm) 1_G3 L Register Error (mit Entkopplung) (mm)
Sec
-0.7 -0.5 -0.3 -0.1 0.1 G4 L Register Error (ohne Entkopplung)
1_G4 L Register Error (mit Entkopplung) (mm)
Sec 17:23:15 17:23:25 17:23:35 17:23:45 17:23:55
r
r
r
v = 200 m/min v = 100 m/min
1.DW 2.DW 3.DW 4.DW EZW
Slide 20
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Modular controller setup
pre control & uncoupled
register
alarm message
decentralised concept
with linked algorithm
register controller
Slide 22
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Safety Integrated
Fail-safe drives – SINAMICS S120,
the flexible drive system for sophisticated drive tasks
Safety Integrated increases security at machines
SINAMICS S120 offers following Safety-Integrated-applications:
(terms acc. to IEC 61800-5-2)
Safe Torque Off (STO) Safe Brake Control (SBC)
Safe Stop 1 (SS1 => at n=0 STO)
Safe Stop 2 (SS2 => at n=0 full torque available) Safe Operating Stop (SOS)
Safely Limited Speed (SLS) Safe Speed Monitor (SSM)
Slide 23
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Safety Integrated Enabling of safety functions through failsafe communication
Sensors
Failsafe CPU
drive
based
Safety Integrated
2
dbSI
2
Acquisition of sensor signals through failsafe periphery
Processing of signals through failsafe CPU
Enabling of drive based safety functions via PROFIBUS with PROFIsafe telegram
Safety Integrated reduces costs
PROFIsafe Telegram*
* Enhancement to PROFINET in pipeline
Slide 24
Rotogravure Printing Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR
Safety Integrated Enabling of safety functions via failsafe terminal module TM54F
Sensors
Safety
device
Integrated Safety even with hardwired solutions
drive
based
Safety Integrated
TM54F dbSI
Sensors
ASIsafe
2
2
2
Acquisition of sensor signals though safety devices
Processing of signals through safety devices
Enabling of drive based safety functions via failsafe terminal module TM54F