Benefits of Electronic Line Shafting
Bosch Rexroth
Electric Drives & Controls Division
Kin Yung – Printing & Converting
Business Development Manager
Agenda- Benefits of Electronic Line Shafting
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Overview of typical Printing & Converting Machines
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Electronic Line Shafting (ELS) approach
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Evolution of ELS Technology
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ELS Benefits and its effect on Printing & Converting Machinery
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Question & Answer
A Typical Mechanical Printing Press
Mechanical press drive systems for:
Label & Package printing, Commercial printing,
Newspaper printing and Converting machines…
- One motor powers the entire machine
- Horizontal and vertical line shaft, gears and
toothed belts, distribute the drive torque to all
machine units.
- The mechanical linkage ensures synchronization
of all cylinders and rollers.
A Typical Mechanical Printing Press
Advantages and Disadvantages
Advantages:
- Mechanical machines are sturdy and reliable.
- Press operators and service staff are familiar with
the machine components for routine
maintenance and breakdown.
Disadvantages:
- Mechanical machines are not flexible for today’s
demands of short run, quick changeover and
make ready.
- Print quality and accuracy are sometimes not
sufficient due to mechanical wear and torque
disturbances between units.
Electronic Line Shafting Approach
ELS - Distributed Drive System
The Electronic Line Shaft does not transmit
force or torque disturbances between units
Electronic Line Shafting Approach
Electronic Line Shaft
SERCOS interface
Position
Speed
Torque
Position
Speed
Torque
- The motion controller generates 32 bit position
data of an electronic line shaft.
- These positions are transmitted to the digital drives
via a Sercos fiber optic ring.
 Excellent Print Quality
- High resolution and precision
 No gear marks, reduces waste
- Exact synchronization
 Highly flexible for quick
changeover and short run
 Production Cost Savings
- Distributed drive intelligence
- Drive integrated control loops
(position, velocity, and current)
- Motion path planner and interpolation
- High resolution feedback (16M counts/rev)
Evolution of ELS Technology
Electronic Gearing
 Electronic gears without backlash replace
mechanical gears
 Gear ratio range (1:65000 to 65000:1)
 Phase synchronization
 Exact electronic register via fine adjust
 For printing, die cutting,…
 Speed synchronization
 Continuous gear ratio fine adjustment,
resolution of 0.000001%
 Adjustable for optimum register and tension control
 Transparent and precise
Evolution of ELS Technology
Electronic Camming
 Replacement of mechanical cams
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and special gears
 Use for non-linear movements
 Synchronization of draw rolls
and rotary cutters to the web
Synchronization of variable repeats
for cross cutters
Drive internal cam curve
web
Slave
cutting
angle
Cutting area
v=constant
Master
Evolution of ELS Technology
Electronic clutches / Flying job change
 Dynamic synchronization
of a machine unit to the web at full production
speed
 Reduction of downtime and fast product
change “on the fly”
 e.g. newspaper production with “flying
plate change”
 Only possible with electronic gear box,
no mechanical equivalence
Evolution of ELS Technology
Process Controls
Winding Control
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Tension Control
Registration Control
Without sensors
With dancer + pneumatics
With load cell
Diameter calculation
Inertia calculation
In-feeds and out-feeds
Draw-rollers
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Direct and Indirect control
Expectancy window
Correction window
Missed mark detection
Trending correction
Windows based setup,
Pre-configured algorithms,
Drive Diagnostics,
and Help Tools
Evolution of ELS Technology
Advanced Drive Functions
Drive Safety-On-Board
Drehmoment außerhalb
des Toleranzbandes
Drehmoment
Referenzkurve mit
Toleranzband
Istverlauf
Drehzahl
t
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Drive Interlock
Safe Standstill, Operation Stop
Safe direction of movement
Safe max./limited velocity
Safe limited absolute position
Scalable drives
Power range up to 125Kw
Drive Preventive Maintenance
 Extended range of drive diagnostics
 Less machine downtime
 Lengthens machine life cycle
Evolution of ELS Technology
Direct Drives
HighSpeed
Direct Drives improves print quality
- Simplified machine design
- High dynamics/stiffness
High Torque
- Outstanding control loop accuracy
up to
30.000 rpm
IndraDyn H
- Very low torque ripple (<0.1%)
- High static and dynamic load rigidity
Linear
- High positioning accuracy
up to 13.800 Nm
- Reduce operation noises
IndraDyn T
- Maintenance free - no wear at motor parts
up to
21.500 N
IndraDyn L
Synchronization /
Electronic Gearing
Jogging
Cam switch
Winder
Tension
Registration
Real and Virtual Master
Electronic Line Shafting Approach
Evolution of ELS Technology
Drive-based Solution
 Compact system for modular
distributed architectures
 Ready-to-use function libraries
according to PLCopen
 Drive-integrated motion-control and
PLC runtime system according to
IEC 61131-3
 Reduced cabinet space
Synchronization /
Electronic Gearing
Jogging
Cam switch
Winder
Tension
Registration
Real and Virtual Master
Electronic Line Shafting Approach
Evolution of ELS Technology
System architecture
PLC, Motion, HMI, Drives, Motors…
HMI
Engineering
Ethernet
Motion Control
w/Logic
Cross
Communication
I/O
HMI
Drives
Motors
Pneumatics
Hydraulics
Evolution of ELS Technology
Applications
 More than 15 year of experience gained in Printing & Converting industry concentrated in an open technology library for:
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Synchronization /
Electronic Gearing
Jogging
Label printing machines
Form printing machines
Flexogravure printing
Rotogravure printing for packaging
Screen printing machines
Security paper printing
Commercial printing machines
Newspaper printing machines
Converting machines
Bag production machines
Hygiene- and Tissue machines
Corrugated board machines
Cam switch
Winder
Tension
Registration
Real and Virtual Master
Automation Line Concept
Flexible In-line Processing
 Flexible in-line configuration
 of different machine modules
 from different machine builders
Stacker / Packaging
Converting 1
OEM4
Z510_04_805
0
BAHNBEOBACHTUNGSGERAET
Printing
Z510_04_805
0
BAHNBEOBACHTUNGSGERAET
ENVETRONIC
OEM3
OEM2
OEM1