An intelligent automatic control device and control method for paper splicing of a gravure printing machine

Abstract

The present invention specifically relates to an intelligent automatic control device and control method for paper splicing in a gravure printing press. The device comprises a frame, a first unwinder and a second unwinder disposed on the front and rear sides of the frame for mounting paper rollers, a paper feed roller assembly mounted on the frame for guiding the paper out of the paper, and a guide roller disposed on the frame for feeding the paper roller into the paper feed roller assembly. The device also comprises a controller. The paper feed roller assembly is provided with an encoder for detecting the length of paper passing through the paper feed roller assembly, and the encoder is signal-connected to the controller. The first and second unwinders are provided with detection elements for detecting one rotation of the paper rollers on the first and second unwinders, respectively. The detection elements send signals to the controller, which calculates the current paper roller diameter using a circumference calculation formula based on the signal sent by the detection elements indicating the paper length detected by the encoders per rotation. This improves the accuracy of the device's operation and ensures that paper splicing instructions are stable, reliable, and consistent with actual conditions.

Description

Technical Field

[0001] The present invention relates to the field of printing technology, and in particular to an intelligent automatic control device and a control method for paper splicing in a gravure printing machine. Background Art

[0002] A gravure printing press has two reels, referred to as the A and B axes, designed to ensure continuous printing. While one reel is running, the other is being refilled and ready for operation. When one reel runs out, the other automatically takes over, preventing the machine from stopping. Automatic reel switching and refilling technology is now commonplace in printing equipment. To ensure rapid and automatic refill changes, accurate and stable reel diameter detection is crucial during operation. Instability or large detection errors often lead to significant waste, resulting in significant losses. Currently, reel diameter detection and calibration in printing equipment typically utilize proximity switches and potentiometers. The diameter of the new reel is calculated using the position of the proximity switch's extended arm, a photoelectric sensor signal, and the potentiometer value. This involves numerous sensors, brackets, and links, and over time, the various mechanical mechanisms are prone to positional drift, resulting in large diameter detection errors and inaccurate synchronization of the new reel. This can lead to unstable cutting, material breakage, machine downtime, and material waste. The current gravure printing equipment has high overprint accuracy and high printing efficiency, but the automatic paper splicing system of the unwinder has always been unstable. Paper splicing failures often occur during automatic paper splicing, resulting in production pauses and a large amount of waste. Automatic paper splicing is impossible. Currently, manual paper splicing is used to switch paper rolls, which often causes unexpected shutdowns due to paper splicing errors. At the same time, there is a problem of excessive paper tail splicing and paper waste.

[0003] Patent 202010631730.7 discloses an ultrasonic automatic cutting gravure printing machine, including a main shaft gear, a potentiometer gear, a rotating shaft, a spacer, a diaphragm coupling, a digital potentiometer, an ultrasonic sensor, an ultrasonic sensor bracket, a main shaft, a rotary drive, an operating side bracket, a manual cone top, a transmission side bracket, a rotary frame, a pneumatic cone top, and a material shaft drive. It is characterized in that: a main shaft is equipped with a main shaft gear and a potentiometer gear, the main shaft gear drives the potentiometer gear to rotate, and the potentiometer gear is connected to the digital potentiometer through a rotating shaft, a spacer, and a diaphragm coupling; the digital potentiometer is connected to the printing equipment unwinding PLC programming Controller electrical connection: The ultrasonic sensor is installed on the sensor bracket, and the sensor bracket is installed at the center of the bottom support of the material rack. The ultrasonic sensor is electrically connected to the PLC programming controller of the printing equipment unwinding; the digital potentiometer can accurately record the various positions required for the cutting process: the ultrasonic sensor can accurately detect the diameter of the material roll; the main shaft gear and the potentiometer gear have the same number of teeth, and the material rack rotates one circle and the potentiometer also rotates one circle at the same time. Each position of the material rack during rotation can be defined by the digital potentiometer: according to the data measured by the digital potentiometer and the ultrasonic sensor, the cutting and splicing device is controlled to complete the splicing.

[0004] The above patent has made some improvements to the problems existing in the prior art. However, when using ultrasound to measure the diameter of the paper roller, inaccurate measurements still exist. The problems of the prior art, such as many links, complex structure, unstable paper splicing, and paper waste, have not been fundamentally solved. The reason why the current equipment fails to splice paper is that the timing of the paper splicing action is unstable. When the paper runs out, the equipment is still in the preparation state, resulting in paper splicing failure. Summary of the Invention

[0005] In response to the problems existing in the above inventions and the prior art, the purpose of the present invention is to provide an intelligent automatic control device and control method for paper splicing in a gravure printing machine, which has a simple structure, saves costs, uses mechanical measurement to calculate the precise paper roll diameter, replaces the original ultrasonic signal, can accurately measure, improve the accuracy of paper roll detection, realize automatic paper splicing, save labor, improve work efficiency, and at the same time can reduce the amount of tail paper and save paper.

[0006] In order to achieve the above-mentioned object, the technical solution adopted by the present invention is: an intelligent automatic control device for paper splicing of a gravure printing press, comprising a frame, a first unwinder and a second unwinder arranged on the front and rear sides of the frame for mounting paper rollers, a paper feed roller assembly mounted on the frame for guiding the paper output direction, a guide roller arranged on the frame for feeding the paper on the paper roller toward the paper feed roller assembly, and also comprising a controller for controlling the operation of the first unwinder and the second unwinder, and a calculation module that sends a signal to the controller, the paper feed roller assembly being provided with an encoder for detecting the length of paper passing through the paper feed roller assembly, the encoder being signal-connected to the calculation module; the first unwinder and the second unwinder being provided with a detection element for detecting one rotation of the paper rollers on the first unwinder and the second unwinder, the detection element sending a signal to the calculation module, and the calculation module calculating the current paper roller diameter using a circumference calculation formula based on the signal of one rotation of the paper roller sent by the detection element and the paper length detected by the encoder.

[0007] The above-mentioned intelligent automatic control device for paper splicing in a gravure printing machine, the detection element includes an A-axis proximity switch and a B-axis proximity switch, the first unwinder includes an A roller and an A-roller motor for providing power to the A roller, an A-axis is provided at the connection between the A roller and the A-roller motor, the A-axis is provided on the A-axis for sending a signal to the controller, and the A-roller motor receives the controller signal; the second unwinder includes a B roller and a B-roller motor for providing power to the B roller, a B-axis is provided at the connection between the B roller and the B-roller motor, the B-axis is provided on the B-axis for sending a signal to the controller, and the B-roller motor receives the controller signal.

[0008] The above-mentioned intelligent automatic control device for paper splicing in a gravure printing machine, the paper roller assembly includes several paper feed rollers of the same length and different diameters, the encoder is fixedly mounted on the frame through a connecting assembly, and is connected to one end of the paper feed roller with the longest diameter in the paper roller assembly.

[0009] The above-mentioned intelligent automatic control device for paper splicing in a gravure printing machine, the connecting assembly includes a shock-absorbing pad that matches the outer diameter of the encoder, and a bracket connected to the frame for cooperating with the shock-absorbing pad to fix the encoder. The bracket is connected to the encoder at one end and is provided with a threaded rod that matches the fixing hole on the encoder, and also includes a nut for fixing the encoder to the bracket.

[0010] In the above-mentioned intelligent automatic control device for paper splicing of a gravure printing press, the central axis of the encoder and the central axis of the paper feed roller with the longest diameter are on the same straight line, and the shock-absorbing pad is a rubber pad.

[0011] The above-mentioned intelligent automatic control device for paper splicing of a gravure printing machine is characterized in that: the controller is a PLC controller.

[0012] The above-mentioned intelligent automatic control device for paper splicing of a gravure printing machine has an observation window on the side of the frame and a frame base at the bottom of the frame.

[0013] The control method using the above-mentioned intelligent automatic control device for paper splicing of a gravure printing press comprises the following steps:

[0014] (1) placing the paper roll to be processed on the first unwinder and the second unwinder respectively, introducing the paper roll on the first unwinder into the paper feed roller assembly through the guide roller, and providing paper to the gravure printing machine;

[0015] (2) The encoder connected to the paper roller with the longest diameter detects and calculates the length S of the paper by counting the number of revolutions of the paper roller and sends a signal to the calculation module;

[0016] (3) The detection element connected to the A axis counts one rotation of the A roller and sends a signal to the calculation module;

[0017] (4) The calculation module calculates the paper length S signal sent by the encoder when the A-axis paper roller rotates one circle, calculated by the detection element on the A-axis, and uses the circumference calculation formula: circumference S = π * diameter to calculate the current paper roller diameter;

[0018] (5) Subtract the diameter of the inner core of the paper roller used to mount the paper roller on roller A from the calculated diameter, and divide it by the thickness of the paper to obtain the remaining number of paper roller turns;

[0019] (6) Repeat steps (2) to (5) to accurately complete the number of turns of the remaining paper rollers;

[0020] (7) When the calculation module calculates that the remaining amount of paper on roller A reaches the handover range, the calculation module sends a signal to the controller, and the controller controls the paper roller on roller B to feed paper to the paper feed roller assembly, completing the automatic handover between the paper roller on roller B and the paper roller on roller A;

[0021] (8) Similarly, the remaining amount of paper on the paper roller on roller B is detected, and the paper roller on roller A is automatically transferred to the paper roller;

[0022] (9) When the calculation module receives the detection element signal that the paper roller is rotating, but the encoder does not send a paper passing signal to the calculation module, the calculation module sends an abnormal operation signal to the controller, and the controller controls the motor to stop rotating and sends an abnormal operation signal to the staff.

[0023] The beneficial effects of the intelligent automatic control device and control method for paper splicing in a gravure printing press disclosed herein are as follows: a high-precision encoder is added to the paper feed roller of the device to detect the length of the paper. Simultaneously, the components and connectors for installing the encoder are designed to ensure smooth and jitter-free encoder rotation, thereby reducing measurement errors. Detection elements are added to the A and B axes to calculate one rotation of the paper roller and send a signal to the calculation module. The calculation module and related auxiliary components monitor the encoder and detection elements. The length detected by the encoder after one rotation of the paper roller is used to calculate the precise paper roll diameter, replacing the original ultrasonic signal and achieving accurate paper splicing. This device can complete complex tasks at a low cost, has a simple structure, and is easy to maintain. It can completely avoid problems such as inaccurate paper roller measurement and incorrect paper splicing instructions caused by external factors, improve the accuracy of the device's operation, and ensure that the paper splicing instructions are stable, reliable, and consistent with actual conditions. An encoder with a shock-absorbing pad coaxially mounted with the longest-diameter paper feed roller ensures stable and jitter-free encoder operation, improving the encoder's operating accuracy. The encoder can also calculate the total number of meters of paper used during operation, improving the ability to collect data on paper usage. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the first unwinder side structure of the present invention;

[0025] Figure 2 This is a schematic diagram of the structure of the second unwinder side of the present invention;

[0026] Figure 3 This is an enlarged structural diagram of the encoder installation position of the present invention;

[0027] Figure 4 This is a schematic diagram of the installation position of the proximity switch of the present invention;

[0028] Figure 5 Schematic diagram of signal transmission in the workflow of the present invention. DETAILED DESCRIPTION

[0029] In order to enable those skilled in the art to better understand the present invention, the present invention is further described below with reference to the accompanying drawings and specific embodiments.

[0030] like Figure 1-4As shown: An intelligent automatic control device for paper splicing in a gravure printing press, comprising a frame 1, a first unwinder 2 for placing a paper roll is installed on the front side of the frame, a second unwinder 3 for placing a spare paper roll is installed on the rear side of the frame, an inner core for mounting the paper roll on the first unwinder or the second unwinder is provided in the middle of the paper roll, a paper feed roller assembly 4 is installed on the frame for guiding the paper on the paper roll to the printing part of the gravure printing press to discharge the paper, the paper feed roller assembly comprises a plurality of paper feed rollers of the same length and different diameters that can rotate simultaneously, a guide roller arranged on the frame 1 for controlling the paper roll to feed paper to the paper feed position of the paper feed roller assembly 4, and also includes a controller 5 for controlling the operation of the first unwinder 2 and the second unwinder 3. The controller can use a PLC controller, which is installed on the front side of the frame and is signal or linearly connected to other control units. A calculation module that sends signals to the controller is also connected to the controller. The calculation module is a computer that can receive signals and use a circular calculation formula for calculation. The paper feed roller assembly 4 is equipped with an encoder 6 for detecting the length of paper passing through the paper feed roller assembly. Encoder 6 is installed on the paper feed roller with the largest diameter using a connecting assembly, and the encoder sends a paper length signal to the calculation module. The encoder connecting assembly includes a shock-absorbing pad 61 that matches the outer diameter of the encoder. Shock-absorbing pad 61 can be a rubber pad, and a bracket 62 connected to the frame where the paper feed roller is installed to cooperate with shock-absorbing pad 61 to fix encoder 6. Bracket 62 is connected to encoder 6 at one end and has a threaded rod 63 that matches the fixing hole on the encoder. A nut is tightened on the threaded rod to fix the encoder. Encoder 6 is connected to the controller 5 by signal.

[0031] The first unwinder 2 and the second unwinder 3 are provided with a detection element 7 for detecting that the paper roller on the first unwinder and the second unwinder rotates one circle. The detection element sends a rotation signal of the paper roller to the calculation module. The detection element can use a proximity switch. The detection element is installed on a component that rotates synchronously with the rotating shaft for mounting the paper roller of the first unwinder and the second unwinder. When the rotating shaft for mounting the paper roller rotates one circle, the detection element completes a work and sends a signal to the calculation module.

[0032] The rotating shaft for installing the paper roller on the first unwinder is A roller 21, and an A roller motor 22 is also provided to provide power for the A roller. An A shaft is provided at the connection between the A roller and the A roller motor. The A shaft rotates synchronously with the A roller, and the detection element on the first unwinder is installed on the A shaft.

[0033] The rotating shaft for installing the paper roller on the second unwinder is the B roller, and a B roller motor 32 is provided to provide power for the B roller. A B shaft is provided at the connection between the B roller and the B roller motor. The B shaft rotates synchronously with the B roller, and the detection element on the second unwinder is installed on the B shaft.

[0034] An observation window 11 is provided on the side of the frame for observing whether the guide roller and the paper feeding part are working normally. A base 12 for fixing the frame is installed below the frame.

[0035] The intelligent automatic control device for paper splicing in a gravure printing machine of the present invention has a simple structure and saves costs. It uses mechanical measurement and then calculates the precise paper roll diameter through mathematical conversion to replace the original ultrasonic signal. It can accurately measure and improve the paper roll detection accuracy, realize automatic paper splicing, save labor, improve work efficiency, and at the same time reduce the amount of tail paper and improve the success rate of paper splicing.

[0036] When working, the working method steps are as follows:

[0037] (1) Install the paper roll on the first unwinder, introduce the paper roll into the paper roller assembly through the guide roller, and start the gravure printing machine. Install the spare paper roll on the second unwinder and wait for use;

[0038] (2) The encoder connected to the paper roller with the longest diameter detects and calculates the length S of the paper passing through the paper roller on the first unwinder by counting the number of revolutions of the paper roller, and sends a signal to the calculation module; the longer the diameter of the paper roller connected to the encoder, the higher the accuracy of the encoder detection. The encoder can also calculate the length of all the paper passing through the encoder, which is convenient for the staff to count the length of the used paper;

[0039] (3) The detection element connected to the A axis of the first unwinder calculates one rotation of the A roller and sends a signal to the calculation module; the larger the diameter of the paper roller, the longer it takes for the detection element to detect one rotation of the paper roller;

[0040] (4) The calculation module calculates the paper length S signal sent by the encoder when the paper roller on the A-axis rotates one circle based on the detection element on the A-axis, and uses the circumference calculation formula: circumference S = π * diameter to calculate the current paper roller diameter;

[0041] (5) Subtract the diameter of the inner core of the paper roller used to mount the paper roller on roller A from the calculated diameter, and divide the result by the thickness of the paper to obtain the number of paper turns within the effective diameter of the paper roller. Then divide the number of turns within the effective diameter by two to obtain the remaining number of paper turns.

[0042] (6) Repeat steps (2) to (5) continuously while the paper roller rotates to accurately complete the remaining number of turns of the paper roller;

[0043] (7) When the calculation module calculates that the remaining amount of paper on the A roller reaches the handover range, the handover range is set in advance in the calculation module, and the number of paper turns of the remaining paper roller is set to 5-10 turns. The calculation module sends a signal to the controller, and the controller controls the B roller motor to start working and controls the spare paper roller on the B roller to feed paper to the paper feed roller assembly. When the calculation module calculates that the number of turns of paper remaining on the paper roller is 1-2 turns, the calculation module sends a signal to the controller, and the controller controls the automatic handover of the paper roller on the B roller and the paper roller on the A roller. During the handover process, the controller controls the A roller motor and the B roller motor to reduce the rotation speed, thereby controlling the reduction of the rotation speed of the paper rolls on the A roller and the B roller, thereby improving the accuracy of the handover paper.

[0044] (8) Similarly, the remaining amount of paper on the paper roller on roller B is detected, and the paper roller on roller A is automatically transferred to the paper roller;

[0045] (9) When the calculation module receives the detection element signal that the paper roller is rotating, but the encoder does not send a paper passing signal to the calculation module, the calculation module sends an abnormal operation signal to the controller, and the controller controls the motor to stop rotating and sends an abnormal operation signal to the staff.

[0046] The above embodiments are intended only to illustrate the structural concepts and features of the present invention. Their purpose is to enable those skilled in the art to understand the present invention and implement it accordingly. They are not intended to limit the scope of protection of the present invention. Any equivalent changes or modifications made based on the essence of the present invention should be included in the scope of protection of the present invention.

Claims

1. An intelligent automatic control device for splicing paper in a gravure printing press, comprising a frame, a first unwinder and a second unwinder disposed on the front and rear sides of the frame for mounting paper rollers, a paper feed roller assembly mounted on the frame for guiding the paper in a paper delivery direction, and a guide roller disposed on the frame for feeding paper on the paper roller toward the paper feed roller assembly, characterized in that: It also includes a controller for controlling the operation of the first unwinder and the second unwinder, and a calculation module that sends a signal to the controller. The paper feed roller assembly is provided with an encoder for detecting the length of paper passing through the paper feed roller assembly, and the encoder is connected to the calculation module signal; the first unwinder and the second unwinder are provided with a detection element for detecting one rotation of the paper roller on the first unwinder and the second unwinder, and the detection element sends a signal to the calculation module. The calculation module calculates the current paper roller diameter using a circumference calculation formula based on the signal sent by the detection element that the paper roller rotates one circle and the paper length detected by the encoder; the detection element includes an A-axis proximity switch and a B-axis proximity switch. The first unwinder includes a plurality of paper rollers, each of which is connected to the paper feed roller assembly by a plurality of means. The invention relates to a paper feed roller assembly, comprising an A roller and an A roller motor for providing power to the A roller, an A shaft is provided at the connection between the A roller and the A roller motor, an A shaft is provided on the A shaft for sending a signal to the controller, and the A roller motor receives the controller signal; the second unwinder comprises a B roller and a B roller motor for providing power to the B roller, a B shaft is provided at the connection between the B roller and the B roller motor, a B shaft is provided on the B shaft for sending a signal to the controller, and the B roller motor receives the controller signal; the paper feed roller assembly comprises a plurality of paper feed rollers of the same length and different diameters, the encoder is fixedly mounted on the frame through a connecting assembly, and is connected to one end of the paper feed roller with the longest diameter in the paper feed roller assembly; When the calculation module calculates that the remaining amount of paper on roller A reaches the handover range, the handover range is set in advance in the calculation module, and the number of paper turns of the remaining paper roller is set to 5-10 turns. The calculation module sends a signal to the controller, and the controller controls the B roller motor to start working and controls the spare paper roller on roller B to feed paper to the paper feed roller assembly. When the calculation module calculates that the number of turns of the remaining paper on the paper roller is 1-2 turns, the calculation module sends a signal to the controller, and the controller controls to complete the automatic handover of the paper roller on roller B and the paper roller on roller A. During the handover process, the controller controls the A roller motor and the B roller motor to reduce the rotation speed, thereby controlling the rotation speed of the paper rolls on the A roller and the B roller to improve the accuracy of the handover paper; Similarly, the remaining amount of paper on the paper roller on roller B is detected, and the paper roller on roller A is automatically handed over; When the calculation module receives the detection element signal that the paper roller is rotating, but the encoder does not send a paper passing signal to the calculation module, the calculation module sends an abnormal operation signal to the controller, and the controller controls the motor to stop rotating and sends an abnormal operation signal to the staff.

2. The intelligent automatic control device for paper splicing of a gravure printing press according to claim 1, characterized in that: The connecting assembly includes a shock-absorbing pad that matches the outer diameter of the encoder, and a bracket connected to the frame for cooperating with the shock-absorbing pad to fix the encoder. One end of the bracket connected to the encoder is provided with a threaded rod that matches the fixing hole on the encoder, and also includes a nut for fixing the encoder to the bracket.

3. The intelligent automatic control device for paper splicing of a gravure printing press according to claim 2, characterized in that: The central axis of the encoder and the central axis of the paper feed roller with the longest diameter are on the same straight line, and the shock-absorbing pad is a rubber pad.

4. The intelligent automatic control device for paper splicing of a gravure printing press according to claim 3, characterized in that: The controller is a PLC controller.

5. The intelligent automatic control device for paper splicing of a gravure printing press according to claim 4, characterized in that: An observation window is provided on the side of the frame, and a frame base is provided at the bottom of the frame.

6. The control method of the intelligent automatic control device for paper splicing of a gravure printing press according to any one of claims 1 to 5, characterized in that: The following steps are involved: (1) Place the paper roll to be processed on the first unwinder and the second unwinder respectively, introduce the paper roll on the first unwinder into the paper feed roller assembly through the guide roller, and provide paper to the gravure printing machine; (2) The encoder connected to the paper roller with the longest diameter detects and calculates the length S of the paper by counting the number of revolutions of the paper roller and sends a signal to the calculation module; (3) The detection element connected to the A axis calculates the rotation of roller A and sends a signal to the calculation module; (4) The calculation module calculates the paper length S signal sent by the encoder when the A-axis paper roller rotates one circle based on the detection element on the A-axis, and uses the circumference calculation formula: circumference S = π * diameter to calculate the current paper roller diameter; (5) Subtract the diameter of the inner core of the paper roller used to mount the paper roller on roller A from the calculated diameter, and then divide it by the thickness of the paper to obtain the remaining number of turns of the paper roller; (6) Repeat steps (2) to (5) to accurately complete the number of turns of the remaining paper rollers; (7) When the calculation module calculates that the remaining amount of paper on roller A reaches the handover range, the calculation module sends a signal to the controller, and the controller controls the paper roller on roller B to feed paper to the paper feed roller assembly, completing the automatic handover between the paper roller on roller B and the paper roller on roller A; when the remaining amount of paper on roller A reaches the handover range, the controller controls the motor of roller A to reduce the rotation speed; (8) Similarly, the remaining amount of paper on the paper roller on roller B is detected, and the paper roller on roller A is automatically transferred to the paper roller; (9) When the calculation module receives the detection element signal that the paper roller is rotating, but the encoder does not send a paper passing signal to the calculation module, the calculation module sends an abnormal operation signal to the controller, and the controller controls the motor to stop rotating and sends an abnormal operation signal to the staff.

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