Gearless printing

Many people are surprised that there is no gear printing machine how to register and how to register? In fact, this is the " Gearless Printing Technology " that has been around for a few years. That is , the press has switched to the A/C servo motor and synchronous drive motor system to replace the original gear and shaft drive system. It is also called shaftless (shaftless) transmission.

Without relying on gear transmission, what are the benefits?

1. First, the accuracy of the drive increases. There are several million pulses per revolution of the motor, which can be used for very precise positioning, proportion and speed control. With smart drives and high-speed microprocessors, the control of register accuracy can be greatly improved. Such electronic circuits instead of to the shaft drive system ELS (Electronic Line Shafting) that the concept of sub-unit drive is achieved. The so-called ELS advanced control technology uses an ultra-high resolution encoder ( mounted directly in the motor ) and a high-speed microprocessor to specify the correct position of each axis in the system and can be accurately reset.

2. It is easy to understand that inevitability of torque instability and gear hysteresis in the use of gears and shaft drive systems will cause the registration to drift, especially during acceleration or deceleration. If more and longer drive shafts, the more gears, the greater the cumulative error coefficient. This error can be avoided in new transmission and control systems. Not to mention the mechanical wear of gears in use, the error will increase. Gears are also the main source of streaks ( or bars ) in printing .

3. It is worth emphasizing that without the use of gears, the rotation of the cylinder on the printing press is no longer limited by the gear pitch, and there is no fixed limit on the length of the printed matter, and it can be adjusted at will. This is particularly popular on flexo presses that are adapted to the diversified needs of packaging print specifications. As long as the circumference of the plate cylinder is exchanged to the requirement and the repeat length data is input to the control center, it is sufficient.

4. In addition to eliminating the need for high-powered drive motors and reducing power consumption, a series of mechanical transmission mechanisms have also been eliminated. These include: driving gears, gear boxes, belt pulleys, belts, transmission shafts, etc. of plate cylinder impression cylinders. After the simplification of the structure, spare parts reserves are reduced, and maintenance downtime is reduced. Moreover, the A/C servo motor and the synchronous motor are brushless structures, and their maintenance is simpler than the brushed motor.

5. The servo motor and the synchronous motor provide a highly constant torque throughout the operation, and the inertia or hysteresis is low during quick shifting. Therefore, the resulting defective waste will be greatly reduced, resulting in improved production efficiency. Especially in the short-lived situation, it shows its superiority.

6. There are two methods for gearless overprint: position register method and dynamic register method.

The position registration method is basically the normal line registration method of the general color set. Using the servo motor and ELS control methods already mentioned above, registration can be easily achieved. As for the dynamic register method, an optical sensor is used to supervise the positioning mark on the take-up roll, and then the drive controller receives two encoders ( one is placed in the roll before the printing unit and the other is loaded in the roll. Printed out of the baking mouth or cooling roller ) , the time difference signal obtained when the material rolls in and out of the printing unit, to adjust the speed and overprint accuracy of each group of rollers. When the servo motor receives the feedback signal, it will immediately and accurately make adjustment compensation. This kind of dynamic registration method is often used to print a layer of cold sealant and anti smog coating on the back of the printed material. Either overprint or partially polish the previously printed material. Can also be used to expand production capacity, such as the addition of the unit after the original unit, even with several printing presses on-line production, can guarantee that the overlay is highly accurate.

7. This type of ELS control system is often equipped with a touch screen computer console with a strong sense of intuition. Operators lacking actual printing experience can quickly master the system and get accurate printed products. For the enterprise, it solves the problem that experienced operators are hard to find and costly. For operators, the work is easy and enjoyable.

Therefore, gearless printing technology can be regarded as a kind of revolutionary technical measure for the printing industry. The interest is very bright, and it will surely develop very quickly, and will be further improved and evolved.