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Industrial Automation Automation Industrielle Industrielle Automation

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Presentation on theme: "Industrial Automation Automation Industrielle Industrielle Automation"— Presentation transcript:

1 Industrial Automation Automation Industrielle Industrielle Automation
Automation of newspaper printing machines: visit at CIEL Prof. Dr. H. Kirrmann ABB Research Center, Baden, Switzerland 2006 April, HK, 1/36

2 Offset printing The most common form of printing low and high-volume jobs used today is "offset" - used for everything from fliers to magazines and newspapers. Offset printing uses an intermediate medium between the printing plate and the paper - the rubber-coated "blanket" is inked by the plate roller under relatively low pressure, to prevent the image from deforming. Half a revolution later the same image is printed on sheet or continuous (web) paper under much higher pressures. The plate is continually inked to maintain the image on the blanket. Printing plates don't have any "relief" - there is no change in depth where the image isn't printed - instead the plate uses Teflon to repel water from some areas.

3 Offset plates The printing plate is initially coated with a light-sensitive material that protects the water-repellent Teflon layer below - this top layer retains water, preventing ink from building up and being printed on the blanket. In areas where the Teflon has been revealed water will not stay on the surface of the plate, but ink will - hence the exposed areas are those that 'print'. The coating of the plate is removed using a photographic process and (typically) a negative copy of the image-setter films. To produce the plate, films are held in place over the coating (usually via a vacuum frame to ensure perfect contact) while areas of the plate are exposed by a high-intensity UV light source. The plate is then chemically processed to expose the Teflon and fix the coating.

4 Halftones - Dot Shape, Screen Ruling and Screen Angles
To give the illusion of a continuous tone image when printed, all images have to be recreated using "halftone" patterns of regularly spaced ink dots, of varying sizes. The size of these dots, measured in a percentage tint, represents the lightness/darkness of each small area of the image. The spacing of the dots is the "screen ruling", normally measured in Lines per Inch (lpi). To "fool" the eye into seeing a continuous tone image, the lines of dots are very close together: typical line screen rulings are 133 lpi for mono (sometimes 120 lpi) or 150 lpi for colour (or higher). Although these general values are valid for "conventional" printing, uncoated stocks and especially newsprint dramatically reduce the line screens used (e.g. 100 lpi mono / 120 lpi colour).

5 web lead plate cylinder printing cylinder Colour printing
bande de papier Papierband web lead Colours are reproduced by combining four inks: (CMYK) Cyan, Magenta, Yellow, blacK A page printed in full colour must therefore pass through four cylinders, in the order CMYK. plate cylinder printing cylinder

6 Moiré and rastering Overlaying several halftones produces interference patterns, called "moiré". The most effective dot shape in 4-colour printing is elliptical - this allows overlaid colours to be "angled" to minimise interference. The angle between Cyan and Magenta is critical as interference is obvious; Yellow is far less critical as the colour is so light against white paper; Black will give interference effects but is usually only reinforcing dark areas of an image where moiré is obscured. The screen ruling (measured in lines per inch) varies between colours to reduce “rosette” patterns - the four "irrational screening" angles will usually average the output LPI, with black typically the highest ruling, angled at 45º.

7 Computer-to-Plate In Computer-To-Plate (CTP), there are no films anymore: the plates are directly etched by a powerful laser and treated chemically. The plate precision is in the order of 0.05 mm, so that the different colours blend without visible shadows. The next step will be Computer-to-Cylinder: there will be no more plates, the cylinders will be directly written by a laser (and erased for the next production). However, this technology is not yet mature and the number of copies produced in one run (before rewriting the cylinder) is insufficient for a newspaper production.

8 ink water Around a cylinder plate rubber cylinder (blanket)
homogenizer water faucets ink supply

9 Two cylinders plate rubber blanket rubber blanket plate

10 Cylinder arrangements
each manufacturer has its preferred cylinder arrangement

11 Tower and Folder tension value draw roller web 25 dN/m turner bar
bande tension value draw roller web 25 dN/m turner bar barres de retournement upper H entonnoir tour d'impression folder cylindres lower H 20 dN/m folder roller infed débiteur 12 dN/m plieuse dancer roller trotteuse reelstand bobines

12 The folder The folder folds one or several webs into bundles ("cahiers"). (picture taken while introducing the paper in the machine)

13 Simple and Double production
simple production one newspaper per rotation of the cylinder – all plates of a cylinder are different double production two newspapers per rotation of the cylinder – the same plates are mounted twice on the cylinder. 16 12 1 5 14 3 8 6 1 3 8 6 1 3 cylinder (flattened) 10 7 16 12 1 5 14 3 10 7 5 6 5 6 8 1 8 1 16 1 14 3 12 5 10 7 1 1 1 1 1 1

14 Web path web colours turner bar bars web folder web width
couleurs des bandes turner bar barres de retournement bars web folder plieuse web width largeur de la bande reelstands, changeurs de bobines

15 Paper colour and cylinder arrangement
Every newspaper is different. The web path is switched after each production and the paper is thread in by a carrier system.

16 Web tracks (Chemins de papier)
Nearly every production requires a different threading

17 The transporter The transporter carries the printed newspapers to the expedition. En route, insets (advertising, prefabricated parts) can be inserted.

18 Drives The cylinders were formerly connected by a shaft (Axe, Welle). Today, the shaft is replaced by an electronic synchronization based on a hard real-time bus, SERCOS. The precision of the drives position is about 0.05 mm, i.e. 2.5 microseconds at 20 m/s web speed.

19 Section control A section is a number of towers producing into exactly one folder (towers can be assigned to different folders depending on the number of pages).

20 Several sections (folders)

21 Example WIFAG machine THE DALLAS MORNING NEWS
U Sectionbus AF100/2 RC T RS CC PM Backup EP Key of Symbols Lower H-Unit Control (AC110) Mounted in Bridge Upper H-Unit Control (AC110) Turner Bar Unit Control (AC110) Mounted on Press S Section Unit Control (AC110) Mounted in Cubicle SK F Folder (Double) Unit Control (AC110) G General Fct Unit Control (AC110) Mounted in Cubicle NK Reelstand Coupler (CS31) Linebus AF100 RC THE DALLAS MORNING NEWS ArcNet Sectionbus AF100/1 T3 T6 F T S F1 T8 T10 T4 L U R11 T1 T2 T5 T7 S T9 R2 RS R1 R8 R6 R4 R3 R5 R7 R9 R10 L RIP Interface to Parascan Report Printer MPS Inform 710 (Option) PC U 1 U 2 Terminal Server Bridge Remote Diagnosis Modem Ethernet Report Printer DB Server and Workplace MPS Production Computer 760 DEC Personal Workstation Backup DB Server and Mounted in Cubicle SK RS Reelstand Control System (WPOS) Mounted on Reelstand PM PressMaster System Mounted in Cubicle PMR CC MPS Control Console (LS) Ethernet CC PM EP Event & Fault Printer PD MPS Prod. Computer Distribution Integrated in Cubicle MRV PD

22 The console The console allows to: load the machine configuration save the settings adjust the ink and water for each page display the state of the machine display alarms and events support diagnostics Console = Leitstand, pupitre

23 Console: adjusting the colour for each lane (screw)
a page is divided into lanes, each each controlled by a "screw“ that adjusts the ink and water ("vis d'encrage“ Farbschraube) in the console at right, 11 lanes are visible

24 Console: adjusting the web tension
the web tension defines the print quality, it varies as the machine warms up and humidity changes, but shall not lead to paper tear.

25 Console: Alarms there are some 1000 different alarms, categorized by severity. Alarms must be acknowledged.

26 displayed with Acrobat
Console: On-line help By clicking on ? a help text corresponding to the actual windows is displayed with Acrobat

27 Control Structure of an H
Work controller IBS long-distance bus SERCOS -drive IBS-M Display Local bus BA DIO MCU LBA check controller loop IO IO IO IO IBS-M BA AIO MCU LBA loop IO IO IO IO IBS safety bus functions: local display, local command buttons, supervision of paper tear, color screws, water Turmbus

28 Networking a printing machine section
to production preparation (Ethernet) bridge standby standby LS LS LS PM PM GW GW Pressmasterbus (Ethernet) Section bus C (AF100) V-Sercos V-Sercos V-Sercos Towers IBG IBG IBG V-Sercos Interbus-S 4G IBG IBG IBG IBG Interbus Interbus Interbus H-Sercos KT94 KT94 KT94 KT94 KT94 KT94 H -PLCs KT94 KT94 KT94 KT94 KT94 KT94 KT94 KT94 Service-ARCnet Falz- und Tower-ARCnet AC160 AC160 AC160 Wendeturm- AC160 Turmsteuerung Turmsteuerung Turmsteuerung steuerung Section bus B Section bus D Section bus C Line bus - AF100 Rollen- Rollenwechsler- wechslerkoppler I KT94 MR93 Sektions- Sektions- koppler A steuerung AC160 steuerung Oxydry-Arcnet Interbus-S Reelstands KT94 ODC Auro Oxydry PECOM-ARCnet

29 Multiple sections MPS MPS Production MPS Control Console LS LS LS PM
tower and folder control B E C D SS2 SS3 SS4 SS5 Section Control OP1 Oxydry (washing) reelstand control Reelstands

30 Speed and hierarchy response time MPS production Messages Ethernet
consoles Arcnet section control section control AF100 tower/folder control tower/folder control tower/folder control Interbus-S cylindres SERCOS motors Process variables

31 Organisation of newspaper production

32 Production Order

33 Roll logistics

34 Prepress and Workflow with MPS Cockpit

35 WIFAG Based in Bern, worldwide number 3 WIFAG and ABB pioneered the shaftless press, which is standard today.

36


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