Rossini Evolution A.W.S.


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Rossini Evolution A.W.S.

  1. 1. EVOLUTION AUTOMATIC WASHING SYSTEM “CLOTH TECHNOLOGY”Technical documentation release : Rossini_rev.0_11_2010
  2. 2. 1. FUNCTIONAL DESCIPTION Printed Production Anilox CIC New Production New RollThe Rossini Automatic Washing System thanks to its unique technology guarantees top levelperformance, the special design of the washer creates a uniform application of the mechanical action,while a patented distribution system of the cleaning agent prepares an even humidification of the cloththat is in contact with the central impression drum surface.The combined work of the cleaning agent (chemical action) evenly distributed on the cloth…...combined with the correct & uniform mechanical action across the complete width of the drum …. Parked Position Working Positionthe fastest, more efficient and most reliable automatic washing cycle today available on the market. 2
  3. 3. The flexibility of the system comes also from the availability of different washing programs and theuser friendly interface for the operators.SOME PLUS POINTS ….  The design of the system has been developed to work with different ink systems: solvent or water based inks. All the Components including the finished assembly have been certified according to the EEx standard, where the washer is located.  Installed at 12 o’clock position on the cylinder, Rossini’s device is the only automatic system performing the cleaning action with the material present inside the machine: no need to remove the web from the cylinder means a clear saving in terms of time and waste of material!  Oscillation : do not forget that the washer has been designed to oscillate on the lateral side when is in contact with the CI drum  high frequency oscillation per second (!) added to a proper mechanical action and chemical action create the real plus of Rossini’s washing device. But Why oscillate?During the printing process the ink often creates a build up on the lateral side edges of the material;this build up can by the end of a print run be to be up to 5 [mm] wide and up to 1[mm] thick andAROUND the complete circumference of the CI drum!If you want to work with a cloth system … the cloth gets full of dirt immediately in the area of thebuild-up thus forcing you to move continuously the cloth itself to bring “new” clean cloth in touchwith the cylinder’s surface  Final result: meters of cloth to make one washing cycle …?Not possible to handle this situation during the standard production (we must cut the material tochange the cloth; we use too much cloth, etc.).Rossini’s system moves the washer back and forth with high level frequency to “break anddistribute” the thick build up of ink and only after this first phase of the cleaning cycle starts theratcheting action of the cloth that will keep the dirt inside the cloth.  Clean & Dry : the special design of the washer guarantees that there will be no carry over of cleaning agent after the washer itself  no problem also when printing very low weight paperTHESE ARE ONLY some of the advantages of Rossini Automatic Washing System that make thisdevice the CORRECT & PROPER choice for an automatic washing cycle for the CI drum of Flexomachines if you want to work with: SHORT WASHING TIME  ALMOST HIDDEN WHEN WASHING DURING SET-UP SAFE CONDITION FOR THE OPERATOR  NO CONTACT WITH CLEANING AGENTS AND MACHINE COMPLETELY “PROTECTED” 3
  4. 4. RELIABLE WASHING RESULTSThe cleaning agent spray, the washing cycle timing, the cloth ratcheting, the contact time andnumbers of contacts between washer and cylinder are some of the main parameters and functions thatare controlled by the system whose main components are: - an electro-pneumatic-hydraulic unit ( EPU unit) - a control console (touch screen type) for the operator interface - an electronic control box (PLC and related input/output cards)A hardwired interface with potential free contacts is prepared in order to create a communicationbridge between the Rossini system and the flexo press to guarantee the right process steps and therequired safety condition of the activity.1.1 WASHING CYCLES  IN PRODUCTION WASHThis washing cycle is performed with the material inside the press, typical during the set-up phase.This washing cycle optimizes the use of consumables (cloth and cleaning agent) with a propercleaning result.The washing cycle has to be selected by the operator referring to the residual dirt present on the CIdrum surface after the printing.  OUT OF PRODUCTION WASHIt is available also a washing cycle without the material inside the machine; at the production change(when moving from a narrow web to a wider web, especially) it is important to have a clean cylinderin order to print. The operator starts the washing cycle ( with the machine in safety condition i.e.closed guards and safety switches completely activated ) and in some minutes you will find thecylinder clean and ready to go while doing some other activities ( anilox change, color check , etc.). 4
  5. 5. 2. SCOPE OF SUPPLY1(ONE) ROSSINI AUTOMATIC WASHING SYSTEM includes 1(ONE) Single washer, whose main components are:  Brake Side : it includes the components to stop the cloth and to produce the required back tension on the cloth when moving one step ahead  Cloth ratcheting Side : inside it has the components to move the cloth and the connection to the utilities ( compressed air and hydraulic connection to the pumping station)  Main Central Body: strong aluminum bar that distributes the cleaning agent on the cloth by mean of a patented channels system and also supports the rubber pads that move against the cylinder pressing the cloth on the cylinder’s Brake Side surface thus giving the required mechanical Clean Cloth action.  Spindles : steel shafts that bring the clean and Safety dirt cloth Central Lever body The washer has been designed according to the following points: Cloth  The cleaning agent must be dosed and sprayed Ratcheting on the cloth in an even and perfect distribution Side and in a “closed” and protected environment.  All the residuals of the printing process and the cleaning agents used are taken by the cloth. There is no contact between the operators and the chemical cleaning agents used to wash. 1(ONE) Set of Brackets: The washer is installed inside the press thanks to long lateral side brackets to give to the operator the possibility to bring the washer from “cloth change” to the working position (and vice versa) where he can remove the spindles with the dirt cloth and change them with a new cloth roll without removing the complete device Cloth Change Position from the machine ! 5
  6. 6. The working position is on a set of movable plates where the washer is also connected with Plug-in Connections to the EPU for hydraulic and pneumatic distribution. Working Position The movable plates can oscillate when the washer is in contact with the cylinder thanks to a pneumatic system located outside the “printing” area. High number of oscillation means up to 10 per second!!!Movable plates + Pneumatic systemMovable plates + Pneumatic system + washer Movable plates + Pneumatic system + washer -- installed 6
  7. 7. PIPING Electro-Pneumatic box Electro-Pneumatica Unit (EPU) 1(ONE) EPU Unit: pump with electro-pneumatic valves, cleaning agent storage tank are located inside this cabinet. The EPU Unit is connected to: - the washer by mean of a tube  from the pump to the washer to distribute the cleaning agent - the Electro-pneumatic box  connection to inform for low level of cleaning agent inside the tank and to drive the electro-valves of the pump All plug-in connection to avoid time waste during the installation and to minimize possible mistakes during the connections. 1(ONE) Control console: touch-screen type with user friendly interface to select the washing programs and see eventual alarms or messages from the system To be installed on the operator working desk, the connection cable is supplied with the console. 1(ONE) Electro-Pneumatic Box: Installed over the bridge, it is the place where you can find the electronic and pneumatic (electro-valves) components to handle the system. The set of pipes from the washer to the box and the interface cable from the box to the press terminal box are included in the supply. 7
  8. 8. Consumables Clean Cloth Roll 1(ONE) Box of Pre-wound rolls: Each box includes 15 rolls of cloth that is wound on a PVC Core. Spindle3. CUSTOMER RESPONSIBILITIES  Cleaning agent: the customer has to select the product in the authorized cleaning agent list attached to the instruction manual. The selected product must be available for the start-up of the system (min. 1000 liters )  Complete set of documents related to the press like drawings (general lay-out and detailed drawings), electrical schemes, etc.  Positioning of the EPU according to the approved General Lay-out  Compressed air supply: 7 [bar] constant pressure - 500 [Lt/Min] (dry and clean air). Rossini’s EPU is designed with fast connection for plastic pipe external diameter 15 [mm] inside diameter 12 [mm]  Current supply: the system needs 2 different connections: 1 x 24 VDC 4 Amps - 1 x 24 VDC 6 Amps this last connection under safety circuit.  Eventual supply and positioning of channels or trays for the cables and pipes required for the system installation  If the customer wants a full integration of the Rossini system with the press; eventual software costs from the press manufacturer are not included in the present offer  Analogue telephone connection or VPN connection for remote control and maintenance support to the Control Box of the system 8