Digital Printing Device Synchronization in Web Presses
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Solution Overview
Problem
The integration of a digital printing device for dynamic printing in a web-fed printing press is not user-friendly and requires significant effort, particularly for inline dynamic printing of statically printed substrate webs.
Innovation Solution
A digital printing device is connected to the web-fed printing press via a signal source that provides a speed signal and a cylinder trigger signal, with a position sensor controller generating a synchronization signal and a speed signal transformer creating a feed signal, allowing the digital print head controller to synchronize and control the digital print heads for dynamic printing, while exchanging time-critical data as hardware signals and non-time-critical data as network signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a digital printing device is integrated into a web-fed printing press for inline dynamic printing, then individualization of printed copies is enabled, but the integration complexity and setup effort increase significantly
Solution Approach 1:
The patent introduces a synchronization signal as an intermediary mechanism that coordinates between the web-fed printing press and the digital printing device. This synchronization signal acts as a mediator to align the timing and positioning of dynamic printing operations with the existing static printing process, thereby enabling integration without requiring direct complex interconnection between the two systems.
Solution Approach 2:
The digital printing device is designed to work universally with the web-fed printing press by utilizing existing signals (synchronization signal, speed signal) already present in the press system. The device can be controlled through the press's existing control infrastructure, making the integration multi-functional and reducing the need for separate dedicated control systems.
2Adaptability or versatility
If a digital printing device is integrated into a web-fed printing press for inline dynamic printing, then individualization of printed copies is enabled, but the setup time and operational difficulty increase
Solution Approach 1:
The digital printing device is designed to automatically synchronize with the web-fed printing press using signals already generated by the press itself. The device self-adjusts its timing and positioning based on the synchronization signal and speed signal, eliminating the need for manual setup and configuration by operators. The system serves itself by utilizing existing press infrastructure for coordination.
Solution Approach 2:
The synchronization signal is generated in advance by the web-fed printing press's control system, preparing the timing information before it is needed for dynamic printing. This preliminary generation of synchronization signals allows the digital printing device to be pre-configured and automatically aligned with the press's operating rhythm, reducing setup effort when dynamic printing is activated.
3Manufacturing precision
If time-critical data is exchanged between the digital printing device and web-fed printing press, then dynamic printing control precision is improved, but the risk of interference with existing control systems increases
Solution Approach 1:
The synchronization signal serves as an intermediary that carries time-critical positioning information without requiring direct integration with the press's control system. By using this intermediate signal mechanism, the digital printing device can access precise timing data while maintaining separation from the press's existing control infrastructure, thereby avoiding interference risks.
Solution Approach 2:
The digital printing device uses copies of existing press signals (synchronization signal, speed signal) that are already generated by the press's control system. Instead of creating new complex control connections, the device utilizes replicated versions of existing signals that convey the necessary timing and positioning information, thereby achieving precise control without adding complexity or interference risk to the original control system.
Data Source
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AI summary
Digital printing device for dynamically printing at least one web of substrate statically printed in a web press, wherein the digital printing device performs the dynamic printing inline with the static printing in the web press, with at least one position sensor (23) which, together with at least one digital printhead (22), is movable on at least one crossbeam (24) transversely to the transport direction of the respective web of substrate and which serves to measure the respective web of substrate for controlling a printing position for the dynamic printing, wherein a signal (28) can be provided to the digital printing device via an interface (26) from a signal source (27) of the web press, which includes at least a speed signal of the web press and a cylinder trigger signal of the web press,wherein a position sensor controller (29) generates a synchronization signal (31) for the digital printing device from the cylinder trigger signal and measured values (30) of the position sensor(s) (23) and provides it to a digital printhead controller (25), wherein a speed signal transformer (33) generates a feed signal (34) for the digital printing device from the speed signal and provides it to the digital printhead controller (25), depending on the speed signal and a predetermined dynamic print resolution, and wherein the digital printhead controller (25) controls the digital printhead(s) (22) depending on the synchronization signal and depending on the feed signal.