Speedmounter Wide Servo

Colour CCTV system with motorized camera carriages

15 inches colour LED LCD displays with electronic generated cross line. The colour system is rich in shades and provides excellent image quality regardless of the tape or plate colours to be mounted.
The crosses are suitable for mounting plates with microdots or register crosses configuration. Magnification on LCD displays: x60-x70.

Colour industrial cameras with precision Japanese optics, LED lights, laser pointers, linear rails and stepper motors. The motorised carriages can be moved and focus of the optics can be adjusted by joysticks on remote pad. For easy position determination of cameras a red laser light indicates each of the actual camera position on the sleeve face.

Positioning of camera carriages ensured by Heidenhain optical linear encoder.

Built-in air mandrel rotation by gearless DDR servo drive

Extreme precision rotation and circumferential positioning of the sleeve is guaranteed with the latest gearless DDR (Direct Drive Rotation). The non rotating stator of the DDR motor is fixed in a robust support block and the rotor (hub with magnetic poles) is fixed on the shaft of the built-in air cylinder which rotates in bearings supported by large bearing housing blocks. There is 1 mm air gap between the magnetic poles of the rotor rotating together with the air mandrel and the magnetic poles of the fixed stator, so there are no frictioning, wearing parts. That is why accuracy and precision of DDR motors do not change as the time goes on. This fact has been verified by testing DDR motors built into our first SWS machines.

The plates can be positioned on any desired point on the face as the system can do spiral mounting. Rotation of sleeve is done via 2 foot pedals or fine rotation is through 2 push buttons on the remote pad.

All functions of the mounter are PLC controlled. PLC control results in constant and reliable operation.

Sleeve system

Makes it possible to change sleeves in the mounting machine.
The cone head of the sleeve arm unit fits in precisely with the built-in air mandrel left shaft. The arm is folded in and out by hand but the closing and opening of the cone is done by pneumatics.

The bearing sites of the built-in air mandrel are individually fitted to the housing with an accuracy of 0.005 mm allowing integration and rotation of the air mandrel as precisely as it is mechanically possible.

In the case of repeat length greater than 900 mm a shaft lift assists the cantilever sleeve arm operation to ensure extremely long lifetime for the conical support head stabilizing the air mandrel.

Single lead-on table

Motorized movement single lead-on table in mounting machine sets up automatically to the inserted sleeve diameter height. The simple lead-on table is made from a stainless steel covered 650 mm long guiding plate. It supports printing plates along their full width during the initial sticking and squeezing.

The vertical movement of the lead-on table is realized by the totally closed, compact, German made RK Rose&Krieger electric lifting legs. The synchronized drive granted by the control system developed by FlexoTech. There are precise and massive horizontal and vertical linear rails for guiding the lead on table motion.

First of all, we recommend this simple table design for spiral mounting (mounting many plates onto the sleeve in shifted position).

Using double lead-on table at spiral mounting increases the mounting time, because of necessary movement of the double table is for each printing plate.

Planar mounting with double lead-on table

The optional double lead-on table creates a completely planar surface above the sleeve, so that the plates can be moved on this surface with ease. With the use of double lead-on plate makes unnecessary for the operator to place protecting paper onto both side of sleeve shell in order to the plates contact with double sided adhesive only on the area under the cameras.

That delicate procedure can be cancelled what waits for operator after the first sticking, namely removing the earlier placed protecting paper under the plate. Depending on operator’s dexterity and the materials of plate and adhesive tape, the procedure may result in the shift of the already successfully stick plate and may need to repeat the first sticking. In critical cases this problem discovered only after the complete mounting, further increase the duration of mounting.

Automatic height setting to applied sleeve diameter,
No need additional protecting papers during first sticking,
Accuracy of mounting duration depends less on operator’s ability,
Drastically reduces the duration of mounting work process.

Pneumatic lay-down roll

The lay-down roll integrated into the lead-on table allows pneumatic smoothing in full width of the sleeve. The lay-down roll is a dia. 70 mm soft plastic foam covered cylinder. While selecting suitable cover material for lay down roll the material of the printing plate and its thickness had to be considered. The flexible plastic foam – in contrast to other solutions – ensures the best condition for plate application without air bubbles and distortions.

The optimal pressure in the power cylinder for squeezing is only 3 bars. Using higher force induced by higher air pressure can cause damage to the printing plate that is why not recommanded. In case of neccessity, applying of double side adhesive tape with micro channels helps equal stronger sticking without air bubbles. Squeezing by manual roller is recommanded only in exceptional cases to eliminate air bubbles, because of uneven squeezing force distort the plate and does not allow standard mounting conditions.

Standardization

By use of lay-down roll the application of double side adhesive tape and printing plate proceeds standard way means under equal pressure and speed for all sleeves. The machine operator will not have a chance to make any mistake in sticking procedures while the the accuracy and precision remains same at every case.

Adhesive tape support

Double sided tape is supported on aluminium shaft by cone shaped adapters on each side. Ensures precise and user-friendly application of tape.
Tapes with core diameters between: 35-95 mm can be used in the support. The unit moves on a linear rail and can be removed all together to gain comfortable access to the whole cylinder face. The tape support can be folded down easily providing maximal space for further mounting cycles.

We propose its use for sleeves with working width up to 900 mm, where the adhesive tape applied in one piece unwinded directly from its roll. In case of wider sleeves it is better to apply adhesive tape also in one piece turned crosswise, instead of fitting several adhesive strips near each other. That way gaps between the strips can be avoided and also the lead time of the tape application will be much shorter.

However, the whole tape application operation could be outsourced to a MASTER DMT tape mounting and plate&tape removing machine in order to multiply plate mounting capacity of the plate mounter machine.

Remote pad for objectives with motorized focus

The optical magnification excludes the “falling apart” and pixelfull effect, what comes out at other systems with software generated picture at higher zoom value. Operator adjust the focus to the given sleeve diameter with a joystick in one phase. No need separate sharpness adjustment.

The remote control pad locating on the cabinet side of the mounting machine can be taken by one motion for positioning the camera carriers and focusing of the lenses directly in front of the LCD displays using the two joysticks and also two pushbuttons on the remote pad.

The fine adjustment pushbuttons are rotating the built-in air mandrel driven by the direct drive servo motor in steps of 0.01 mm CW and CCW.

Colour touch screen HMI terminal

Operation of SWS machine and also the HMI terminal is very easy and fast. The startup time less then 5 seconds. The operator can concentrate fully to his job and should not think about the way of machine handling. Graphical Touch Screen panel can display 10 plate positions at one time. Most functions are operated through the colour touch screen panel.

User-friendly programming results in quick workflow.
Clear and easy menus show both camera positions as well as the sleeves actual circumferential position to an accuracy of 0.01. Allowing operators to choose between plates with just one touch (cameras then move automatically to position), these positions can be saved under job names and recalled at any later stage. With the circumferential measurement facility you can make longitudinal measurements, controlling plate lengths.

The following functions are available on the terminal:
Viewing of actual camera positions;
Viewing of built-in air mandrel or sleeve circumferencial position;
Camera movement;
Rotation of built-in mandrel or sleeve;
Other camera movement functions;
Job storage and reload; AutoMount program; APPC function;
Service setup and help

Automatic Plate Position Calculation (APPC)

The 4th generation of the APPC function serves the further time reduction of work process duration. The most conspicuous novelty is the large touch screen where the mounting tasks can be performed in a nicer graphic environment. The APPC function acquits the operator of plate positions calculation. In case of one or more plates mounting, only enter three data is sufficient, and the program automatically calculates the plate position. So there is no need for plate position calculation and thereafter data input on touch screen even for a few minutes.

The APPC function enables the operator of plate position calculation. In case of one or more plate mounting, only three data entry is sufficient for the program to automatically calculate the plate position.
Hence there is no need for plate position calculation and thereafter data input on the touch screen is even faster. After entering the basic data the motorized cameras move with a single touch to the operator’s chosen plate position within a few seconds.

The calculated plate positions can be saved with a given job name and it can be loaded back from the memory.

Automount function

When "AutoMount" function is selected the mounter automatically and precisely applies the plate onto the sleeve without torsion and free of air bubbles.
The operator only has to do the initial positioning of the plate onto the sleeve surface. By pressing the AutoMount function the pneumatic lay-down roll is activated together with the two way rotation of the built-in air mandrel. The “AutoMount” function is a pre-programmed row of steps that reduce downtime in the mounting process.

Standardization

The “AutoMount” function standardizes the entire plate mounting cycle. It ensures equal plate mounting conditions for all sleeves of a job. The sticking of the printing plate always proceeds at the same speed and pressure conditions. The machine operator is not able individually affect the sticking procedure and the sticking accuracy is always precise and the same.

Job storage

The already positioned or mounted plates can be saved under proper job names or job numbers in the PLC memory and can be recalled later at any desired time. Positions of up to 10 plates are stored under one job number. It represents a multiple of demand for printing houses. The job data are saved on memory sticks That is why job data will not be lost in case of hardware damage.

Optional Ethernet connection is also available. Saving job data to usual PC from the pendrive is possible where post-edition of the data also possible if necessary. A 2 Gbyte memory stick is able to store data of approx. 2 million jobs

Easy register

The printing plates will be positioned to these register stripes. The sensors in the printing press will check only the position of the register stripes. If the stripes are is position then the printing plates must be in their exact positions.

Of course, our SWS machine meets and can serve Easy Register System, because it is basic requirement for W&H presses.

Separated air inlet unit

For larger repeat lenghts an adapter (bridge sleeve, carrier) should be inserted between the air mandrel and the sleeve. There are two types of compressed air supply applied for the precisely machined adapters. The precisely machined adapters. The flow-through type or bridge adapters do not have internal air channel circuit for making air cushion for inserting sleeve onto the adapter. There are only passing through holes in the adapter positioned exactley to the air outlet holes of the air mandrel. These bridge adapters are fixed by bayonet-shaped groove on positioning pin of the air mandrel. In case of other type adapters with independent air supply the compressed air received on right sidewall of the adapter and distributed via its own internal air channel circuit. These channels are not connected to the air supply holes on the air mandrel.

This last solution ensures loss-free, perfect compressed air supply to form air cushion between the adapter and the sleeve.

The optional Separated Air Supply Unit supplies high pressure compressed air directly to the adapter ensuring perfect and ease change of sleeves on the adapter. The Unit moves on linear rail and can be fixed in positions adjusted for different sleeve lengths.

Omron PLC control and Heidenhain measuring system

The purpose of plate mounting machine is the very precise lateral and longitudinal positioning of printing plate on the sleeve. The requirements can be fulfilled only by using the latest technology.

We use only the most reliable components of industrial standards. We grant stable operation using PLC-HMI. Further advance of the HMI terminal is that all information which is necessary for the plate mounting is found very easily there.

For lateral positioning we use products of Haidenhain which is the world market leader in measuring systems. In the camera positioning system of SWS we use optical measuring scale. In this system there is a thin gap between the scan heads and the scale so it does not content wearing part. That is why the reliability of this system is extremely high: it will be as accurate after 20 years operation as at the start-up.

On-line diagnostic

The on-line diagnostics allows remote accessibility to the SWS machines installed in printing houses for our engineers. The remote investigation may reveal potential failures and can help eliminate them shortly.

The diagnostic test is performed through a suitably prepared mini laptop connected to the SWS machine. The laptop is supplied with the machine allows full access to the PLC, the servo drive and the HMI terminal. Only requirement is the available local WLAN connection.