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Solution for Industrial Printing & Textile Machines | Elmo Motion Control


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Our G-MAS uses a CANopen virtual encoder to improve master-slave performance on advanced industrial printing machines.
Find out how you can save money by using motion controllers virtual encoder.

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Solution for Industrial Printing & Textile Machines | Elmo Motion Control

  1. 1. ECAM-Based Motion Control Solution for Printing & Textile Machines Application Study
  2. 2. 2 Solution Application for Different types of printing machines Letterpress, electrostatic , screen printing (textiles, ceramics, metal, wood, paper, glass and plastic), offset printing, digital printing, label printing, flexo printing, CD and Wafer printing machines Different types of textile machines Knitting, weaving, weaving and braiding, etc.
  3. 3. 3 Printing Station Up to four color printing stations are used.
  4. 4. 4 Machine Description For decoration of cylindrical plastic tubes using a silk screen and/or flexo printing technology. Uses 32 servo drives to operate axes at stationary stations located around 24 mandrels on a round table.
  5. 5. 5 There are 32 axes located on the stationary part of the machine. There are 24 rotating mandrels arranged in a circular configuration on the main perimeter rotating platform. Machine Description
  6. 6. 6 Main Perimeter Rotating Platform Mandrels pass through stationary stations, each responsible for a different part of the printing process: Tube feeding/tube removing Heating Cleaning Coating UV drying I mark finding (capturing) Printing Etc.
  7. 7. 7 18-60mm mandrel diameter Direct motor cupling Mandrels are driven by individual servo-motors (no gear). Allows very simple and quick “change-over” Enables high printing precision Requires high-power/small-size drives, located behind the motor Mandrel
  8. 8. 8 Up to four color printing stations are used. Printing Station
  9. 9. 9 Transforming a mechanical CAM-based machine into an electrical ECAM. Transferring high power and communication via special slip rings. High speed of operation that ultimately results in a high-throughput machine. One central electronic station to control all mcahine operations via serial communications channel. Solution Challenges
  10. 10. 10 High performance of the System due to synchronization, speed, accuracy, etc. High reliability, working in an EEC industrial vibrating environment. Limited machine space. Solution Challenges
  11. 11. 11 Elmo network based Solution
  12. 12. 12 Host–G-MAS Communication Host HMI station for controlling the machine via standard Modbus TCP/IP or EtherNet/IP channel. Elmo Solution Highlights
  13. 13. 13 G-MAS real-time deterministic network-based master controller Deterministic network management Error handling Callback functionality for fast processing of events Management of ECAM functionality And much more… Multi-Axis Motion Controller Get more details- Gold Maestro motion controller
  14. 14. 14 Distributed CANopen fieldbus Intelligent servo drives for enhanced and high overall system processing power Synchronized cyclic ECAM mode of operation High throughput up to 200 tubes/min Network-Based Solution
  15. 15. 15 DS406 CAN encoder support Virtual master encoder support Virtual master axis (internal G-MAS virtual axis profiler) Real master encoder (mapped via PDOs) Elmo Solution Highlights
  16. 16. 16 Compact, high-power Elmo servo drives located in EEC vibrating environment Elmo Solution Highlights
  17. 17. 17 High Precision & Fast I Mark Registration I Mark Triggering Auxiliary Position Scan (ECAM table Entry from Main station Encoder) of one station Mandrel Stop and disengage from ECAM on IMARK sensing Mandrel Start It’s ECAM following when engaging the next station Synchronization jitter is <1mSec Elmo Solution Highlights
  18. 18. 18 Real-time drive disengagement/engagement from ECAM table Command to Disengage on the next ECAM cycle Disengage from ECAM Engage to ECAM Table without loosing Synchronization Command to Disengage on the next ECAM cycle Elmo Solution Highlights
  19. 19. 19 Advanced servo tools to achieve high motion performance on the single-axis drive level: Frequency domain analysis Advanced high-order filters Elmo Solution Highlights
  20. 20. 20 ECAM_LeftRightUnit(Mandrel_Size, EndPos, FirstScan); ECAM table profile calculation Fast ECAM table downloading to each drive using fast asynchronous binary interpreter functions: G-MAS Program Main Functions
  21. 21. 21 ConfigVirtualEncoder(MainAxisRef); Virtual encoder options: Generated from a position profile of a virtual axis Received from a master axis in the system via mapped RPDO In both options, the G-MAS sends position data to a group of axes via TPDO3 or TPDO4 Virtual encoder configuration ENC_HIGH_POS, ENC_LOW_POS, ENC_GROUP_ID, ENC_ACTUAL_POS_MODE (PX) ENC_TARGET_POS_MODE (PA, used in virtual axis) G-MAS Program Main Functions
  22. 22. 22 ConfigAxisToRecieveVirtualEncoderPosition (iAxisCount); Sending SDOs to configure all axes in the System into a CAN encoder special mode of operation RPDO position mapping (via RPDO3 or RPDO4) ECAM interpolation time setting Interpolation on every sync Set drive to Can encoder special mode(-3) G-MAS Program Main Functions
  23. 23. 23 EcamTrigger(); Axis immediate home (BIN interpreter) Axis ECAM triggering MainAxisImmediateHome(); Master axis immediate home StateFunction_1_PTPMotion(); Main axis PTP motion G-MAS Program Main Functions
  24. 24. 24 Advanced motion and servo control Distributed networking Advanced drive level programming High power density High reliability Rigidness High efficiency Complexity reduction High machine throughput Why Elmo?