Commercial web offset · Advantages of commercial web offset Printing of both paper side in one ......

Copyright © Siemens AG 2008. All rights reserved.

Automation and Drive concepts

Safety Integrated

Bus Topology

Infeed Concepts

Navigation

Navigation

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Products, Features

Requirements, Solutions

Products, Features

Commercial web offset

Commercial web offset Copyright © Siemens AG 2008. All rights reserved. Industry DT MC PM BR

Commercial web offset press

MAN-Rotoman Original: MAN Roland

GOSS-Sunday4000 Original: GOSS-Iternational


Typical products

Typical products

Magazines Journals

Advertising products


Features of commercial web offset presses

Eine Illustrations-Rollenoffsetdruckmaschine ist gekennzeichnet durch:

4 or more print units

Typical number of pages: 16, 32, 48, 64, 72, 80 Fix format

Fast exchange of printing plates at production change Printing speed up to 15 m/s

Advantages of commercial web offset

Printing of both paper side in one production step

Several pruducts can be printed with one cylinder In addition to the basic colors also special colors can be printed

Trends Wider and faster machines: 96 pages, 18m/sec

more multidrive functions, especially in the folder, cam curve applications


Printing basics: Offset printing

Offset printing is an indirect print technology where the print color is first transferred

from a mostly thin, flexible aluminum plate to a rubber cylinder and then to the material to be printed.

The four colors cyan, magenta, yellow and black are printed one after the other and finally produce a high-precision color picture.

Ink rollers

Plate cylinder Water rollers

Blanket cylinder

Paper web


Machine overview

Paster

Print units Dryer

Chill

Folder

Typical data of commercial web offset presses:

Length: 20m - 60m Width: 2m - 3m

Hight: 3m - 10m Printing speed: 5 – 15 m/s

Number of pages: 16 - 72 Printing speed: 35.000 – 100.000 copies/h Number of servo drives: 2 – 40 (depending on the degree of automation)

Total drive power: 50kW – 600kW Cut register accuracy: +/- 100 m

Color register accuracy: +/- 10 m


Requirements Solutions

High printing quality Dynamic servo control and angular synchronism with

high precision and little Jitter

High reliability High control quality with excellent web lead and

constant web tension trough multi drive technology

Interfacing to third party

systems

Encoder emulation as high precision virtual encoder

Variable production to several

folders

Synchronization via PROFINET for inter production

of independent presses and for building redundant

PROFINET networks

Commercial web offset Requirements and solutions


Requirements Solutions

Higher degree of automation PRINTstandard is prepared for many machine types.

The open architecture allows the add on of own ideas

and new features.

Wider and faster machines Book size: up to 107 kW drive power

Chassis: up to 800 kW drive power

AC/AC or DC/AC drives

Air- , Cold plate- or 2nd level cooling

Wide range of synchronous and asynchronous motors,

torque motors

Self cooled, forced ventilation or water cooled

Commercial web offset Requirements and solutions

Tendency to wider -e.g. 96 paes-, faster -e.g. 18 m/sec- and more automated

machines -e.g. increased number of servo drives in the folder- can be seen


Automation and Drive concept AC synchronous and asynchronous motors

Standard asynchronous motors 1LAx

Reluctance motors 1FP5

SIEMOSYN Motors 1FUx

Torque motors 1FWx Linear motors 1FN3

Compact asynchronous motors 1PH7, 1PL6 water cooled 1PH4 as build in motor 1PH2

Synchronous servo motors 1FT6, 1FK6, 1FK7 ex proof 1FS6


Automation and Drive concept SINAMICS S120 drives for synchronous and asynchronous motors

1,6–107kW

Booksize design

AC/AC Drives

for single axis

applications

DC/AC Drives

(with infeed)

for multi axis

applications

0,25–90kW

Blocksize design

75–1.200kW

Chassis design

110–250kW

Chassis design


Automation and Drive concept DriveCliQ - interface for drive components

SMC20 SMC30

Motor with DRIVE-CLiQ interface

Motor without DRIVE-CLiQ interface

DRIVE-CLiQ encoder

Conventional encoder

Digital-/Analogue- Periphery

System interface DRIVE-CLiQ

Electronic name plates: Identification of modules, motors, …


Automation and Drive concept SIMOTION for motion control and drive PLC control

SIMOTION C: Controller based

S7-300 design

SIMOTION P: PC based

Motion Control software in PC

SIMOTION D: Drive based

Motion Control software + drive software Direct connection of the motor modules

Motion Control Positioning

Angular synchronism

CAM curves

PLC Functions KOP / FUP

ST programs

Motion Control


Automation and Drive concept Overview

SIMATIC STEP 7

SIMOTION SCOUT

SIZER

STARTER

Asynchronous motors Synchronous motors

Systems Tools

SIMATIC S7 PLC control system

SIMOTION Motion Control system

SINAMICS

S120

SINAMICS Drive system


Automation and Drive concept SIMOTION / SINAMICS overview

Paster Print units Dryer Folder Chill Web catcher


Automation and Drive concept Central design

The complete motion program is calculated in one SIMOTION D control unit.

In SIMOTION D also up to 6 drive con- trollers are integrated.

For more axis a CX32 is used.

OEM

Central line control

Service - PC

with SCOUT


Automation and Drive concept Central – Separation of print units and folder

A motion program for the print units and folder is calculated by a

SIMOTION D controller. The synchronization is done

via PROFIBUS or PROFINET.

OEM


Service - PC

with SCOUT

To other synchronized

components


Automation and Drive concept Modular

Each print unit and each other equipment assembly has ist motion controller.

The synchronization is done via PROFINET.

OEM


Service - PC

with SCOUT OEM



Automation and Drive concept Modular drives, central control

Mixed design: Local drives (AC/AC) in the print units.

Central control of print units and folder.

OEM


OEM



Automation and Drive concept Example of a print unit (modular)

Ink and water roller drives

Geared motors

Drive Control Synchronization to the

virtual axis Plate cylinder positioning Speed control of ink and

water roller drives

S I M O T I O N

DP 1 DP 2 E 1 E 2 D 445

s

S I N A M I C S

s

S I N A M I C S

s

S I N A M I C S

s SIMOTION D4x5

SINAMICS S120

AC

/DC

Lin

e M

odule

Moto

r M

odule

2 *

Moto

r M

odule

S I N A M I C S

s

2 *

Moto

r M

odule

Print unit motor Drives both plate and blanket cylinders and inker via an integrated gear.


Roller top of former (RTF)

Pull rollers under the former

Folder main drive

auxiliary drives

Automation and Drive concept Example of a folder

Tendency:

- Folder gets a lot more complex

(3…30…? Servo drives)

- Use of electronic Cam


Option: Machine encoder e.g. HTL 2048 Inc.

Dancer control Infeed unit

Core

drive

Core

drive

Infe

ed

Turr

et

Reel axis

movem

ent

Drive Control

with splice automation and

reelstand PLC functions Dancer control

Infeed control and

automation

Automation and Drive concept Example of a splicer

Failsafe remote periphery with PROFIBUS interface IM151-7- F CPU and PROFIsafe telegram


Safety Integrated

Safety Integrated increases security at printing machines

Fail-safe drives – SINAMICS S120,

the flexible drive system for sophisticated drive tasks

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)


Safety Integrated Enabling of safety functions through failsafe communication

Sensors

Failsafe CPU

Drive

based

Safety Integrated

2

dbSI

2

Safety Integrated reduces costs

PROFIsafe Telegram*

* Enhancement to PROFINET in preparation

Reading sensor signals through failsafe periphery

Processing of signals through failsafe CPU

Enabling of drive based safety functions via PROFIBUS with PROFIsafe telegram


Safety Integrated 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

Reading sensor signals though safety devices

Processing of signals through safety devices

Enabling of drive based safety functions via failsafe terminal module TM54F


Set point distribution virtual master axis via PROFINET

One SIMOTION controller calculates the virtual master axis.

Several axis can be calculated and transferred.

S I M O T I O

N

DP 1 DP 2 E 1 E 2

D 435 s

S I M O T I O

N

DP 1 DP 2 E 1 E 2

D 435 s

Global master virtual axis for

global operation

Local master master axis for

local operation

Real axis


Set point distribution PROFINET – Example bus topology

External PROFINET Switch

SCALANCE X204 IRT

Option board

CBE30 with Switch

technology

SIMOTION controller

with PROFINET Switch CBE30

To central line control

PROFINET or Ethernet


Infeed Concepts: Local Infeed – modular drive concept

Several motor modules

with a common infeed unit

Easy expandable

...

Several units of the press can be individually tested.


Single axis

AC-AC module

Infeed Concepts Local Infeed – local drives

Decentralized concept is a typical solution for print units with one unit drive

Brake resistor

for fast an E-STOP


self-commuted, pulsed rectifier / regenerative unit Active Line Module

Multi motor units Booksize

Chassis units

DC link

Infeed Concepts Central Infeed

*) Parallel interconnection of the DC link with Chassis ALM units

self-commuted, pulsed rectifier / regenerative unit Active Line Module

expandable

scalable

DC link

*)

Commercial web offset · Advantages of commercial web offset Printing of both paper side in one ......

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