Shaftless CNC automation of printing machinery
We are a big printing company in Shenzhen China . We offer all book publications, hardcover book printing, papercover book printing, hardcover notebook, sprial book printing, saddle stiching book printing, booklet printing,packaging box, calendars, all kinds of PVC, product brochures, notes, Children's book, stickers, all kinds of special paper color printing products, game cardand so on.
For more information please visit
http://www.joyful-printing.com. ENG only
http://www.joyful-printing.net
http://www.joyful-printing.org
email: info@joyful-printing.net
Under the premise of ensuring the safety and environmental protection of mechanical products, the high productivity, high quality and ability to reduce labor intensity of equipment have always been the three major goals of people's pursuit. The constant innovation, development, improvement, and replacement of any mechanical product is always accompanied by the development track of printing pillows.
First, there are axes, no axes, CNC
In order to maintain the synchronization and regular movement between the units, the basic characteristics of the drive are: the power source drives the transmission components of each unit through a long shaft, and then drives the actuators of the equipment through the transmission components to complete the input of the equipment. , output tasks, this is the traditional "axis drive" of printing machinery, but also the most basic transmission principle. With the development and application of modern numerical control technology, the conditions for canceling this long axis are fully mature. This means that each printing (or functional) unit has one or several servo motor drives, which can also meet the printing requirements, printing machinery. The industry often says "shaftless technology", "shaftless drive", "electronic shaft drive" or "independent drive" is the concept.
From the perspective of standard specifications, the “no-axis” formulation from the shaft-driven transmission is not scientific enough, and the insiders understand that other industries sound like the second monk is puzzled. Therefore, I suggest that it is still called "CNC technology" as well.
As we all know, the biggest part of China's machinery manufacturing industry is the automobile manufacturing industry, which reflects the comprehensive technical level of the machinery manufacturing industry, the large-scale production program and the pursuit of maximum profits, and the production process has been highly automated. At present, a large proportion of CNC machine tools, machining centers, and FMS (Flexible Machining Systems) are facing the automotive market. The machinery manufacturing industry, which is given priority by the state, also has key equipment and machine tool industries. It reflects China's ability and technical level to provide equipment to the defense, aviation, shipbuilding, automobile, power generation and other industries. These DC servo motors are an AC servo motor development process. The contemporary machine tool has gone through the automatic machining of the three axes above the CNC machine tool through programming. The machining center automatically changes the tool. The first generation FMS (using the exchange table to realize the automatic flexible processing of multiple devices) FMS (automatic stereo library and automatic flexible processing of multiple devices) a third-generation FMS (cancel the auto-stereo library, using industrial robots to automate the entire process), the common feature of these three generations of FMS flexible systems is. Achieving the human ideal of unmanned chemical plants. While CNC technology is widely used, another trend in the development of CNC machine tools is the emergence of composite machine tools. The processing range of machine tools has been further expanded, resulting in turning, milling, milling and grinding. At the center, the process flow for part processing is greatly shortened. Some entrepreneurs boldly proposed: a person, a composite machine tool, is a factory, a car engine box assembly, can complete all milling, boring, drilling, expanding, tapping, in a car, milling center, In a car and other processes, a flame CNC cutting machine can make a small bridge.
The technological development of printing machinery and equipment is bound to follow this path. Since the earliest invention of engraving by humans, the invention of movable type printing by Bidan 4, and the invention of the metal type letterpress printing machine by Königbauer in Germany, it has also undergone several hundred years of improvement to reach the advanced level of contemporary printing machines. . Take the web printing machine as an example to review the history of modern technology development. A similar conclusion can be drawn. In the early 1930s, sheetfed letterpress printing machines have become the main force in the printing industry. Since the printing process is discontinuous, the printing speed is limited by the structure of the equipment, and the speed increase is restricted, so a continuous printing press appears. , so that the printing speed is greatly improved. The power source of the sheetfed press is a mechanical inorganic shifting mechanism. Most of the equipments use slip motors. The power source of the web press is powerful, and the stepless speed regulation requires a new power source. DC motor and thyristor speed regulation. After the automation of the printing process, the device has successively solved the automation of paper control, folding, paper feeding, delivery, registration, printing, cleaning and the like. However, the web press is still a side or two parallel power source that drives the various movements and functions of the entire device through a long axis. In the late 1990s, China's frequency conversion speed regulation technology was mature. Printing machinery widely used AC motor, frequency converter speed regulation, followed by DC speed regulation, slip motor speed elimination, driving long shaft is still the traditional structure of this equipment. In the mid-20th century, the numerical control technology that has been widely used in the machine tool industry began to introduce the control system of printing machinery. First applied to web printing presses, after entering the 21st century, foreign web presses no longer use traditional power sources, and CNC systems are widely used instead of traditional long-axis transmission, which is the printing machinery manufacturing industry. "Shaftless technology". In recent years, this technology has been applied to printing equipment such as web gravure printing machines, saddle stitch binding machines, form machines, flexographic printing machines, and sheet-fed paper machines. The application of CNC technology in China has just begun. Only a few companies have launched prototypes. The systems used are all supplied abroad, which is a big gap compared with foreign companies. Compared with the domestic machine tool industry, there is also a considerable gap.
Introducing the CNC system to the printing machine will bring the following advantages:
1. The numerical control system is used to connect the long-axis to the whole machine, and the single-unit servo motor is driven by the mountain. The realization of some functions is also done by the independent motor. The structure of the equipment is greatly simplified, not only the long axis is eliminated, but also a large number of structural parts in the transmission process are eliminated, so that the equipment cost is greatly reduced.
2. The long axis is eliminated, so that each unit is relatively independent and self-contained, and the connection of each unit is replaced by a virtual electronic shaft, which brings convenience conditions for large-scale assembly of the assembly line. Changes in production methods will also change the online test run to a single unit test to shorten the equipment production cycle.
3. Make each unit relatively independent and self-contained. It is possible for the user to purchase equipment according to individual needs. The printing machinery enterprise can overcome the traditional production organization method of formulating the production plan according to the needs of the user, and according to the plan of the unit, the parts are produced according to the unit, so that the product is standardized and universalized. The level of improvement will be made possible by the expansion of the functions of printing machinery deformation products and printing machinery products.
4. In addition to the transmission using the numerical control system, other functions of the printing machine can also be realized by the numerical control system, such as paper tension, printing registration, combination of various printing methods, cutting, die cutting, electronic cam, clutch pressure, ink Balance and so on.
5. The biggest highlight of Drupa's 2004 printing show was the introduction of JDF's fully automated workflow. It combines pre-press, print, and post-press in a standard form, so that the entire process of printing is automatically completed. JDF is also a language in which devices from different manufacturers can be connected into one production line to accomplish the same task. The printing process is fully automated and the entire drive system must be a CNC system.
6. Another advantage of using the numerical control system is that the printing process can be completely flexible. Which units can be started at will according to the individual requirements of the printed products, which operations can be stopped, no mechanical clutch is needed, no cam needs to be replaced, and the front and back can be opened as needed. The upper version can reduce the upper version in parallel with several units Time and so on.
7. The timing of the use of CNC systems in printing machinery has matured. Some CNC technology companies have achieved continuous power output of up to 375 kW, AC grid voltage of 380-480 volts, maximum rated torque of 600 Nm, transmission ratio of up to I: 65000 to 65000:1, and registration accuracy of up to 1 /4000000 rpm, electronic gears can be precisely adjusted to 32 positions, these requirements can fully meet the technical requirements of printing machinery products.
Two. Three major scientific and technological achievements in contemporary printing industry
1. CTP technology revolution. The biggest highlight of the development of contemporary printing technology is CTP. CTcP digital technology. With the emergence and development of digital printing machines, digital direct platesetters, digital proofing machines, and digital inkjet printers, traditional plate-making equipment and traditional proofing equipment are facing elimination, and the advertising industry and the fast printing industry market are strongly affected. Traditional printing equipment used for mass production has also been challenged as never before. A number of machine-based printing presses, plateless printing presses, laser imaging presses, and inkjet printers have been industrialized and have a certain market share.
2. The digital workflow continues to evolve. CIP3. The emergence of digital workflows such as CIP4 and 7DF enables the digital information of the desktop color system to be transmitted to the plate-making equipment and then to the adjustment system of the printing equipment. The drupa exhibition in 2004 will also digitally design these designs. Continue to pass to the post-press, integrate the entire production process of printed materials, realize resource sharing, save a lot of intermediate links, and become the highlight of the new exhibition.
3. CNC technology is the development direction of printing equipment. The first two scientific and technological achievements are revolutions in printing technology. The latter scientific and technological achievements are revolutions in the printing machinery manufacturing industry. It can also be called turning the electrical control of traditional printing machinery and equipment into digital control. At present, the companies that provide CNC systems for printing machinery companies include Siemens, Germany, Dr. Rexroth and Lenze, and Yaskawa, Japan. In addition, Japan’s FANUC has not yet entered the printing machinery industry, as well as some foreign machine tool factories. Such as Japan's major limit, Mazak, Mitsubishi, Hitachi have their own CNC system. There are more than ten CNC manufacturing companies in China, mainly providing numerical control system for machine tool factories. The main CNC system suppliers are: Beijing Aerospace CNC, Beijing KND, Shenyang Blue Sky CNC, Shanghai Kaitong CNC, Nanjing Tsinghua GM and Xinfangda CNC. Chengdu Top and Guangtai CNC, Shenzhen Zhongweixing CNC and so on. There are no manufacturers supporting printing machinery, and cooperation in this area should be strengthened.
In foreign countries, CNC technology has been widely used. The equipment for adopting DC speed regulation and frequency conversion speed control for web printing presses has been rare. Only a few companies in China have just launched prototypes using this technology, and there are still some processes away from industrialization. Great distance.
Third, accelerate the automation process
Since the invention of printing machinery and equipment, in the process of long-term development, it has gone through the stage from manual to mechanization. In modern times, in order to further improve work efficiency and reduce labor intensity, it is a road of gradual automation. Automation can be divided into the following Stages:
I. Semi-automated stage - the main operation of the printed matter is mechanized, and the substrate still needs to be manually input and output. Such as tiger mouth die cutting machine, hot stamping machine, screen printing machine, etc.
2. Single-machine automation stage The entire production process of the printed matter is mechanized. People are only responsible for the adjustment of the quality of the printed matter, replacement of working tools and accessories (such as substrates, plates, inks, tools, etc.). Related equipment, such as various printing methods, binding machines, box making machines, packaging and printing equipment.
3. The automation phase of auxiliary operation - on the basis of stand-alone automation, the level of auxiliary operation automation is continuously improved, such as equipment quality adjustment, automatic paper feeding, automatic printing, automatic inking and water. Such as foreign imports of web printing machines, high-end sheetfed printing machines.
4. Online automation stage—On the basis of stand-alone automation, several devices of the print production process are connected together and run automatically, such as saddle stitch binding machine, hardcover linkage line, perfect binding machine, flexo printing machine, etc.
There are no manual operation procedures for mechanization in China's printing process: paper prefabrication, upper plate, cleaning like leather cloth, automatic paper feeding on paper, automatic inking, and small printing enterprises still use manual matching and manual Folding, manual hardcover, manual inserts, manual bundling, etc.
The level of automation of printing machinery products is low, mainly in the pre-press equipment is in a semi-automatic stage. The printing equipment is in the online automation phase and the level of auxiliary operation automation is low. Most of the postpress equipment is in the stage of single machine automation, and there are fewer online automation equipment, mainly relying on imports.
Printing machinery and equipment face the challenges of major foreign manufacturers, and the market share in China is growing, especially for high-end equipment. How do we deal with this reality, especially when the current wave of application of CTP and digital workflow is surging, I believe that we should pay attention to the development trend of CTP technology and digital workflow, and actually promote the wide application of CNC technology. It is imperative to improve the automation level of products and solve the backward technical status of domestically produced equipment with high labor intensity, requiring more personnel and relying on people to control quality.