Commercial web offset - Siemens - Industry Sector

Commercial web offset Products, Features Requirements, Solutions Automation and Drive concepts Safety Integrated Bus Topology Infeed Concepts Navigation Navigation Navigation

Copyright © Siemens AG 2008. All rights reserved.

Commercial web offset press

GOSS-Sunday4000 Original: GOSS-Iternational

MAN-Rotoman Original: MAN Roland

Commercial web offset

Industry DT MC PM BR

Slide 2 Copyright © Siemens AG 2008. All rights reserved.

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

Ink rollers Plate cylinder Water rollers Blanket cylinder Paper web

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. Commercial web offset



Machine overview Print units

Folder Dryer

Chill

Paster

Typical data of commercial web offset presses: Length: Width: Hight: Printing speed: Number of pages: Printing speed: Number of servo drives: Total drive power: Cut register accuracy: Color register accuracy:


20m - 60m 2m - 3m 3m - 10m 5 – 15 m/s 16 - 72 35.000 – 100.000 copies/h 2 – 40 (depending on the degree of automation) 50kW – 600kW +/- 100 m +/- 10m




Requirements and solutions

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





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 Chassis: up to 800 kW AC/AC or DC/AC drives Air- , Cold plate- or 2nd

drive power drive power

level cooling

Wide range of synchronous and asynchronous motors, torque motors Self cooled, forced ventilation or water cooled 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 Commercial web offset



Automation and Drive concept

AC synchronous and asynchronous motors

Standard asynchronous motors 1LAx Reluctance motors

1FP5

SIEMOSYN Motors

1FUx

Torque motors Linear motors

1FWx 1FN3

Compact asynchronous motors 1PH7, 1PL6 water cooled 1PH4 as build in motor 1PH2 Synchronous servo motors ex proof


1FT6, 1FK6, 1FK7 1FS6




SINAMICS S120 drives for synchronous and asynchronous motors

AC/AC Drives

0,25–90kW Blocksize design

110–250kW Chassis design

1,6–107kW Booksize design

75–1.200kW Chassis design

for single axis applications

DC/AC Drives (with infeed) for multi axis applications





DriveCliQ - interface for drive components System interface DRIVE-CLiQ

SMC30

SMC20

Motor with Digital-/Analogue- DRIVE-CLiQ Periphery interface

Motor without DRIVE-CLiQ interface

DRIVE-CLiQ encoder

Conventional encoder

Electronic name plates: Identification of modules, motors, … Commercial web offset




SIMOTION for motion control and drive PLC control

SIMOTION D: Drive based Motion Control software + drive software Direct connection of the motor modules

Motion Control

Motion Control

SIMOTION P: PC based Motion Control software in PC

Positioning Angular synchronism CAM curves

PLC Functions

SIMOTION C: Controller based S7-300 design Commercial web offset


KOP / FUP ST programs


Automation and Drive concept Overview

Tools

Systems SIMATIC S7 PLC control system

SIMOTION Motion Control system

SIMATIC STEP 7 SIMOTION SCOUT SINAMICS Drive system SIZER STARTER

Asynchronous motors



SINAMICS S120 Synchronous motors


Automation and Drive concept SIMOTION / SINAMICS overview

Paster

Print units


Web catcher

Dryer


Chill

Folder


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 controllers are integrated.

OEM Central line control


For more axis a CX32 is used.

Service - PC with SCOUT




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 Central line control




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.







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.






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

1

DP

2

E

1

E

2

s

S

S I C

I C M A

A

S I N

S I N

M

S IC M A IN S s

s

s

2 * Motor Module

445

DP

2 * Motor Module

s

D

Motor Module

SIMOTION D4x5

AC/DC Line Module

SI

S I N

M

O

A M

T IO

I C

N

S

SINAMICS S120

Drive Control Synchronization to the virtual axis Plate cylinder positioning Speed control of ink and water roller drives

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

Ink and water roller drives Geared motors




Automation and Drive concept Example of a folder

Roller top of former (RTF)

Pull rollers under the former

Folder main drive auxiliary drives

Tendency: - Folder gets a lot more complex (3…30…? Servo drives)

- Use of electronic Cam Commercial web offset



Automation and Drive concept Example of a splicer

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


Infeed unit

Infeed Turret Reel axis movement

Core drive

Drive Control with splice automation and reelstand PLC functions Dancer control Infeed control and automation

Core drive

Dancer control

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



Safety Integrated 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 increases security at printing machines Commercial web offset



Safety Integrated

Enabling of safety functions through failsafe communication

PROFIsafe Telegram*

Failsafe CPU dbSI 2

2

Sensors

Drive based Safety Integrated

* 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 reduces costs Commercial web offset



Safety Integrated

Safety functions via failsafe terminal module TM54F

Sensors

2

2 2

TM54F

Sensors ASIsafe

dbSI

Safety device

Drive based Safety Integrated

Reading sensor signals though safety devices Processing of signals through safety devices Enabling of drive based safety functions via failsafe terminal module TM54F

Integrated Safety even with hardwired solutions Commercial web offset



Set point distribution

virtual master axis via PROFINET Global master virtual axis for global operation

S I M O T IO N

S I M O T IO N

Local master

s

master axis for local operation

s

D 435

D 435

DP 1 DP 2

DP 1 DP 2

E1

E1

E2

E2

Real axis

One SIMOTION controller calculates the virtual master axis. Several axis can be calculated and transferred. Commercial web offset



Set point distribution

PROFINET – Example bus topology

Option board CBE30 with Switch technology

SIMOTION controller with PROFINET Switch CBE30

To central line control PROFINET or Ethernet External PROFINET Switch SCALANCE X204 IRT




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. Commercial web offset



Infeed Concepts

Local Infeed – local drives

Single axis AC-AC module Brake resistor for fast an E-STOP

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



Infeed Concepts Central Infeed

Chassis units Multi motor units Booksize

expandable scalable

*)

DC link

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

DC link

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

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


