Wider and faster machines: 96 pages, 18m/sec ... Printing basics: Offset printing.
Offset printing is an indirect print technology where the print color is first ...
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
Commercial web offset
Industry DT MC PM BR
Slide 3 Copyright © Siemens AG 2008. All rights reserved.
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
Commercial web offset
Industry DT MC PM BR
Slide 4 Copyright © Siemens AG 2008. All rights reserved.
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
Industry DT MC PM BR
Slide 5 Copyright © Siemens AG 2008. All rights reserved.
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:
Commercial web offset
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
Industry DT MC PM BR
Slide 6 Copyright © Siemens AG 2008. All rights reserved.
Commercial web offset
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
Commercial web offset
Industry DT MC PM BR
Slide 8 Copyright © Siemens AG 2008. All rights reserved.
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 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
Industry DT MC PM BR
Slide 9 Copyright © Siemens AG 2008. All rights reserved.
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
Commercial web offset
1FT6, 1FK6, 1FK7 1FS6
Industry DT MC PM BR
Slide 11 Copyright © Siemens AG 2008. All rights reserved.
Automation and Drive concept
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
Commercial web offset
Industry DT MC PM BR
Slide 12 Copyright © Siemens AG 2008. All rights reserved.
Automation and Drive concept
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
Industry DT MC PM BR
Slide 13 Copyright © Siemens AG 2008. All rights reserved.
Automation and Drive concept
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
Industry DT MC PM BR
KOP / FUP ST programs
Slide 14 Copyright © Siemens AG 2008. All rights reserved.
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
Commercial web offset
Industry DT MC PM BR
SINAMICS S120 Synchronous motors
Slide 15 Copyright © Siemens AG 2008. All rights reserved.
Automation and Drive concept SIMOTION / SINAMICS overview
Paster
Print units
Commercial web offset
Web catcher
Dryer
Industry DT MC PM BR
Chill
Folder
Slide 16 Copyright © Siemens AG 2008. All rights reserved.
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
Commercial web offset
For more axis a CX32 is used.
Service - PC with SCOUT
Industry DT MC PM BR
Slide 17 Copyright © Siemens AG 2008. All rights reserved.
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 Central line control
Commercial web offset
Service - PC with SCOUT
Industry DT MC PM BR
To other synchronized components
Slide 18 Copyright © Siemens AG 2008. All rights reserved.
Automation and Drive concept Modular
Each print unit and each other equipment assembly has ist motion controller. The synchronization is done via PROFINET.
OEM Central line control
Commercial web offset
OEM Central line control
Service - PC with SCOUT
Industry DT MC PM BR
Slide 19 Copyright © Siemens AG 2008. All rights reserved.
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 Central line control
Commercial web offset
OEM Central line control
Industry DT MC PM BR
Slide 20 Copyright © Siemens AG 2008. All rights reserved.
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
Commercial web offset
Industry DT MC PM BR
Slide 21 Copyright © Siemens AG 2008. All rights reserved.
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
Industry DT MC PM BR
Slide 22 Copyright © Siemens AG 2008. All rights reserved.
Automation and Drive concept Example of a splicer
Option: Machine encoder e.g. HTL 2048 Inc.
Commercial web offset
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
Industry DT MC PM BR
Slide 23 Copyright © Siemens AG 2008. All rights reserved.
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
Industry DT MC PM BR
Slide 25 Copyright © Siemens AG 2008. All rights reserved.
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
Industry DT MC PM BR
Slide 26 Copyright © Siemens AG 2008. All rights reserved.
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
Industry DT MC PM BR
Slide 27 Copyright © Siemens AG 2008. All rights reserved.
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
Industry DT MC PM BR
Slide 29 Copyright © Siemens AG 2008. All rights reserved.
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
Commercial web offset
Industry DT MC PM BR
Slide 30 Copyright © Siemens AG 2008. All rights reserved.
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
Industry DT MC PM BR
Slide 32 Copyright © Siemens AG 2008. All rights reserved.
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
Industry DT MC PM BR
Slide 33 Copyright © Siemens AG 2008. All rights reserved.
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
Commercial web offset
Industry DT MC PM BR
Slide 34 Copyright © Siemens AG 2008. All rights reserved.