Web-fed Printing Press Autonomous Control Retrofit
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Solution Overview
Problem
Existing web-fed printing presses face difficulties in integrating processing devices like inkjet printing units without a printing forme, as there are no options for providing control commands within the existing printing press control system, making retrofitting with such devices challenging.
Innovation Solution
Assigning a sensor to each processing device to measure the printed substrate web and control its operations independently, with an operating device providing control commands autonomously, requiring only the transport speed of the web as input, thus allowing for independent operation without altering the printing press control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a processing device is integrated into an existing web-fed printing press, then the functionality for individualizing printed webs is improved, but the control system complexity increases and integration becomes difficult
Solution Approach 1:
The control system is segmented into two independent parts: the existing printing press control system that manages static printing, and a new autonomous control unit for the processing device that handles dynamic individualization. This segmentation allows each system to operate independently without increasing overall complexity.
Solution Approach 2:
The processing device is equipped with its own autonomous control unit that independently measures web parameters via sensors and automatically adjusts processing parameters without requiring integration with or commands from the printing press control system. This self-service capability eliminates control system integration complexity.
2Adaptability or versatility
If control commands for the processing device are provided through the existing printing press control system, then system integration is improved, but the ease of operation and retrofitting becomes more difficult
Solution Approach 1:
The control functionality for the processing device is extracted from the printing press control system entirely. The processing device receives control commands exclusively from its own autonomous control unit, which independently processes sensor measurements and generates appropriate control signals. This extraction simplifies retrofitting as no modifications to the existing printing press control system are needed.
3Ease of operation
If the processing device operates autonomously with its own control unit, then the ease of retrofitting is improved, but the level of automation and coordination with the printing press may be reduced
Solution Approach 1:
The autonomous control unit continuously receives feedback from sensors that measure web parameters such as position, speed, and properties. Based on this real-time feedback, the control unit automatically adjusts processing parameters to maintain optimal coordination with the printing press operation, achieving high automation without requiring integration with the printing press control system.
Data Source
Figure 1
AI summary
The invention relates to a roll-to-roll printing machine with at least one printing form-based printing unit (10) for statically printing at least one substrate web (12) with a static print image for printed copies of a print job, and with at least one processing device (14) positioned downstream of the printing form-based printing units and upstream of a folding unit, in particular a printing form-less printing device for dynamically printing at least one substrate web surface of a substrate web with a print image that is variable for at least some printed copies inline, in addition to statically printing the same.According to the invention, each processing device (14) is assigned a sensor (15) which automatically measures a statically printed substrate web (12) and, depending on the measurement of the substrate web, controls the respective processing device (14) in order to position the processing to be carried out with the processing device (14), in particular the dynamic print image to be printed, in the transport direction and/or transverse to the transport direction of the substrate web at the desired position on the substrate web, wherein each processing device (14) is assigned an operating device (16) in order to provide control commands to each processing device independently of a printing press control system.