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1. Project Overview
With the continuous development of domestic flexible packaging materials, the variety, quality and quantity of its packaging products are increasing, and the printing speed and printing accuracy of printing machinery are also getting higher and higher. The gravure printing machine has a wide range of applicable materials (BOPP, PET , PVC, PE, aluminum foil and web, etc.), high running speed (up to 400m / min) has broad prospects in the market.
Unit-type gravure printing machine (hereinafter referred to as gravure printing machine) is an important member of the printing machine family, he occupies an important position in the field of flexible packaging with exquisite printing quality. In order to ensure a good printing effect, it is necessary to carry out precise and stable control of the four-stage tension of the film.However, the traditional tension control method restricts the development of high-speed gravure printing machines. With the increasing perfection of high-speed technology, the use of AC motors for tension control has become a reality, and it is used by most high-speed gravure printing machines abroad.
In order to reduce costs, improve product grades, and improve product competitiveness, according to the characteristics of printing machines that require high control speed and stability of the control system, our company and Japanese technicians have successfully developed the AP series tension control system. The fully automatic control system with Japanese Mitsubishi PLC or German SIEMENS PLC as the core technology is suitable for various printing and packaging machinery systems.
The AP-T13C type tension control system is a highly reliable control system developed according to the development status of domestic gravure printing machines.It is driven by seven AC vector motors to drive the dual-position unwinding shaft, unwinding traction roller, The main motor, take-up traction roller, and double-station take-up reel are used for tension control, swing roller for tension detection, PLC for central control, touch-screen operation and simultaneous automatic winding diameter detection, automatic winding diameter calculation, and winding diameter alarm. Rewinding and unwinding automatic cutting, taper control, length counting, forward and reverse switching of rewinding and unwinding, tension retention during winding and unwinding, fault detection and fault diagnosis information technology, gravure printing machine management technology, remote technical support and other functions
2. System requirements
(1) To ensure that the material tension in each section is constant, the speed is synchronized, and the response is fast;
(2) Start and stop should be smooth and without impact, and the material must not be wrinkled;
(3) When receiving the material, the surface speed of the two rewinding surfaces is equal to achieve rapid rewinding;
(4) The tension of each section is constant and the swing of the pendulum is small;
(5) The acceleration and deceleration and operation should be stable without speed mutation;
(6) Good low-frequency torque characteristics and high speed accuracy;
(7) Convenient rewinding and reloading, no tension change affects color registration;
(8) Necessary protection and easy operation;
(9) The host starts to automatically calculate the diameter and material thickness.
Three, seven motor tension system basic composition and characteristics-unwinding tension control
The system is composed of five parts: double-station unwinding, unwinding traction, winding traction, double-station winding tension control and main motor control. The following describes the characteristics of these five parts:
1 Unwinding tension control
This part includes the tension detection unit, tension calculation unit, servo actuator, automatic winding diameter detection unit, pre-drive control and automatic cutting control.
(1) The tension detection unit used in the tension control system is an air pressure floating roller type tension detection device, which detects the film tension by adjusting the air pressure of the cylinder connected to the detection roller floating swing arm. After the air pressure of the cylinder is set, the thrust of the cylinder on the swing arm is a fixed value. The principle of this control mode is to calculate a matching frequency setting value f1 from the linear velocity of the material and the actual winding diameter, and then perform it through the tension (position) feedback signal. PID operation produces a frequency adjustment value f2, and the final frequency output is f = f1 + f2. f1 can basically match the linear speed of the take-up (unwinding) roll with the material linear speed, and then the f2 part needs to be adjusted slightly to meet the control requirements, which solves the contradiction between the fast response and the control stability in closed-loop control. . In the system in equilibrium, when strong interference occurs, if the system is too late to react, the tension fluctuation on the material film can be temporarily absorbed by the floating roller. Therefore, the floating roller detection is a superior detection method.
(2) We use the Japanese Mitsubishi PLC or the German SIEMENS PLC as the core of the tension calculation system. It has the characteristics of modularity, high speed, high precision, and strong anti-interference ability. It is very conducive to such complex and high-precision calculations of tension. In the mathematical model of the system, due to the use of a special algorithm, in theory, the fluctuations in tension caused by the change in speed and the diameter of the coil have been compensated. Both are very stable, even when changing the roll, the tension transition is also very smooth. Therefore, the system has reduced the register loss caused by the tension wave to a low level.
(3) The automatic winding diameter calculation unit is the general name of the hardware and software that automatically detects the diameter of each new feeding roll through the automatic detection device of the winding diameter and then sends it to the PLC for calculation. The unit adopts double-section broken line for curling diameter simulation operation, which overcomes the shortcoming of imported equipment using single-section straight line for curling diameter simulation deviation, which makes the pre-drive speed error smaller, and further reduces the tension disturbance during automatic cutting . The automatic winding diameter calculation unit is also set with a minimum winding diameter limitation function. When the diameter of the new loading coil is less than a certain limit value, the PLC will limit the continued execution of the automatic cutting action, which is beneficial to protect the mechanical structure from being damaged.
(4) Pre-drive control and automatic cutting control are the key to realize the smooth switching between the new and old material rolls. The motion control of this part is automatically completed by the PLC program. The user only needs to operate two buttons to automatically complete the material rack operation and material Frame positioning, cutting arm lifting, pre-driving, cutting rubber roller pressing, tape position detection, cutting, arm retracting, tension switching and other series of actions.
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Foshan City Misirui Furniture Co., Limited , https://www.nbmisiruifurniture.com