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Web Processing - Rotary Logo Printer Application and Cut to Register Feed Drive System

Web Processing - Rotary Logo Printer Application

Web Processing - Rotary Logo Printer Application
Machine: Single color printing station that prints a logo on a web of preprinted plastic material

Application Description: A spool of preprinted material with a registration mark is fed through a single color printing station. The web is driven by a prime mover at various speeds depending on the type of product. The logo must be printed and aligned with the registration mark on the preprinted material. The printing pitch on the spool of preprinted material can be various sizes, depending on production requirements, while the diameter of the print drum is fixed.

Application Solution: The EMAX 1-1/2 axis controller is chosen for this master/slave electronic cam application.

  • An encoder is connected to the web feed roller to provide a master web speed/position reference
  • A servo motor is coupled to the printing and backup drums via a precision gearbox
  • A touch-screen display is selected as a simple operator interface
  • A high speed registration sensor is mounted above the web to sense the registration mark

An application program is developed with the Emerald Motion Language (EML) PC software for the EMAX controller that has the following sequence:

  1. When a new spool of preprinted material is loaded into the machine the web starts moving with the print head stationary but clear of the web. The EMAX, using the registration sensor measures the pitch of the preprinted material.
  2. An electronic cam is then calculated to have the servo motor match web line speed when the print head is engaged with the web and then advance or retard when the print head is free. The advance or retard amount compensates for the difference in the circumference of the print cylinder and the pitch of the printing.
  3. The print head motion starts at the proper angle to print the logo on the web during the speed match portion of the printing cycle. Once the print head is free of the web the motor slows down or speeds up as necessary to print the logo on the next pitch of the web.
  4. The operator programs a positional watch window in which to expect the registration mark. If the mark occurs in the window the motion profile is retarded or advanced to compensate for slight pitch to pitch printing variations. If the mark is not found for several printing pitches an alarm is sounded to alert the operator of the problem.

Additional Application Features:

  • Automatic teach and learn of the preprint material pitch
  • Operator adjustment:
    • Number of registration marks missed before alarm
    • Distance between registration mark and logo
    • Width of the registration mark watch window
  • Keypad/display for startup, operator messages and diagnostics
  • High speed sensor registration
  • Operator warning for loss of material or preprint registration marks

Other Industry Applications:

  • Web perforation
  • Multi-color printing
  • Labeling machine
  • Rotary die cutter
  • Pouch insertion

Cut to Register Feed Drive System

Cut to Register Feed Drive System
Machine: Feed, punch and cut mechanism for converting a spool of raw material into sections

Application Description: The web of raw material containing registration marks must be punched and cut in precise registration to the printed mark on the web. The length of the cut piece, and batch count changes depending on production requirements and must be entered by the machine operator.

Application Solution: The EMAX 1-1/2 axis controller with touch-screen operator interface provides a simple solution for this application. A servomotor is configured to drive the feed rolls, and the following I/O's are connected:

  • Outputs: Cutter, punch
  • Inputs: Registration sensor, UP/DOWN limits on both cutter and punch
  1. The operator loads a fresh spool of material into the machine and enters the cut length and batch count.
  2. The operator then presses initialize on the touch-screen operator interface and the servo feeds the material forward and stops at the registration mark.
  3. The operator presses start and the feed sequence begins:
    • Turn on the punch and cutter
    • Wait for punch and cutter to be down
    • Turn off punch and cutter
    • Wait for punch and cutter to be up
    • Start servo feed
    • During the feed search for the registration mark
    • Stop at registration mark
    • Repeat
  4. The feed sequence continues until the batch count is reached, a fault is detected or the operator manually stops the feed sequence.

Additional Application Features:

  • The motion profile is a bell shaped minimum jerk profile to minimize web stretch and feed roller slip
  • A double feed, one for cut and one for punch can be used to change the cut to punch dimension
  • Loss of registration mark warning and/or shutdown
  • Output from EMAX signals run sequence to unwind stand

Other Industry Applications:

  • Perforating press
  • Cut and seal
  • Feed drive
  • Progressive die part transfer

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