Press Automation and Retrofit Solutions using Embedded Technologies!
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The level of automation plays a key role in the productivity of any machine. The replacement of obsolete components, the inclusion of latest technology as well as upgrading the automation technology result ina higher level of automation and greater efficiency We thoroughly study the customer requirements and problems and apply a systematic approach to build a solution that optimizes its underlyiing processes to achieve more efficient results! Asaies having experience and expertise in latest machine vision and embedded technologies have delivered various automation solution for the printing and packaging industry. This presenation takes you through some of our implementations..
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Press Automation and Retrofit Solutions using Embedded Technologies!
- 1. Press Automation and Retrofit Solutions using Embedded Technologies ▪ Latest & Innovative Technologies ▪ Industry Proven ▪ Cost Effective ▪ Long Term Service Support
- 2. Introduction Offset Press usually have their mechanical systems have pretty longer life comparing to the electronic controls used. It's obvious that after many years of use, the electronic system get faulty and would need upgradation to ensure smooth functioning of the Press. By the time the technology would have been obsolete and a replacement of exact system from OEM would not be easy and affordable for many. This is where Asaies Automation comes into picture with its cost effective approach to replace legacy electronic control system using latest embedded technologies. Over the years Asaies Automation has successfully done many such customized replacement and retrofit solutions for customers across the globe! This helps customers to add life to their old, expensive and rugged machinery with long term service support from Asaies and also improve efficiency and throughput ! You will find details of our various installations on subsequent pages.
- 3. Communication Replacement on TKS Press Replacement of existing Communication ion System using CV500-RM 201 x 2 Nos, VID16 x 8 Nos and VOD x 8 Nos on TKS Press was successfully carried out with a Customized Communication by Asaies with a better logic and meeting all the existing functionalities. We have replaced 2 Master Communication devices and 16 Slave devices with our single controller to make it cost effective and hassle free future maintenance. BEFORE>> AFTER >> BEFORE AFTER PRODUCT 2021
- 4. Electronic Control Upgrade on TKS Press The press consists of three towers and the PLC system in one of the towers got issues. Omron CV1000 series of PLCs were in use. As there was no backup PLC/Program for that particular tower and Omron CV 1000 series PLC being outdated and not available in the market, the customer was looking for an affordable solution without replacing the master and other working PLCs in remaining towers. After having a detailed system study, we have built a customised solution where we have replaced one of the Omron PLCs with a new generation Phoenix Contact PLC and got it worked along with other Omron PLCs. It was a challenging task but we could be successful. BEFORE AFTER PRODUCT 2020
- 5. Ink Key Motor Driver for Heidelberg Press The Ink Key motor driver used in Heidelberg Harris Press were of 16 channel and 4 channel boards. One of our customers needed a customized replacement boards as the old boards were obsolete. We have developed a 8 Channel replacement board using a new approach and latest components and successfully done the delivery and installation. The new boards are advanced and cost effective with long term service support from Asaies! PRODUCT BEFORE AFTER 2021
- 6. Butler Splicer Model 5000 The Electronic Control System of Butler Splicer Model 5000 was faulty and customer needed a permanent solution. Asaies having prior experience in model 4000 and 6000 splicers, developed a customized main board that replaced almost 5 existing controller PCBs and displays. We have provided a single HMI incorporating all features of the datamat displays. BEFORE PRODUCT AFTER 2021
- 7. Butler Splicer Model 4000 The Electronic Control System of Butler Splicer Model 4000 was faulty and customer needed a permanent solution. Asaies having prior experience in Bulter splicers, developed a customized main board that replaced almost 5 existing controller PCBs and displays. We have provided a single HMI incorporating all features of the datamat displays. The installation has been done for the US based customer through remote online support and without making any site visit! PRODUCT BEFORE AFTER 2019
- 8. Butler Splicer Model 6000 The Electronic Control System including datamat displays of Butler Splicer Model 6000 was faulty and customer needed a cost effective upgrade. Asaies have undertaken a detailed study and developed a customized main board that replaced almost 5 existing controller PCBs and displays. We have provided a single HMI incorporating all features of the datamat displays. The installation has been done successfully for two splicers of Model 6000 2018 BEFORE AFTER PRODUCT
- 9. Vision enabled Automatic Plate Bending The vison punching on Nela-SF Bender got faulty and needed a replacement. The cost for OEM replacement was not cost effective. Asaies having experience in machine vision and image processing technologies, developed a vision based plate bending system for newspaper and commercial web offset printers with accurate positioning and plate bending operations. Printing plates are precisely registered utilizing 2 high resolution Registration Sensors and 2 register marks located on the plates. The system verifies the registration and send control instantly for quick plate bending. Highly user-friendly touch based operator console will help you improve the operator efficiency! 2021 BEFORE AFTER PRODUCT
- 10. Vision Sensor for Label Inspection The Pharma label inspection requires high level of accuracy and efficiency and visual inspections are error prone. One of customers needed a solution for implementation of vision enabled label inspection. Asaies Automation have developed a vision sensor specially customised for the application and implemented it. The solution have been successfully implemented in 6 printing units. 2020 PRODUCT AFTER BEFORE
- 11. Vision enabled Automatic Web Aligner The automatic web aligner in a Harris Press was faulty and customer needed a replacement. Asaies have given a cost effective proposal for the upgrade comparing with the OEM replacement. We have used a customized vision sensor along with a newly designed and manufactured actuator to ensure high precision web alignment in required in magazine printing! 2017 PRODUCT AFTER BEFORE
- 12. Our Hardware Controllers / Modules CIP3 Controller Data Controller Ink Motor Driver Ink Key Motor Controller for CIP3 Integration Programmable Data Controller for Communication 8 Channel Ink Key Motor Driver Board for Heidelberg Press
- 13. Our Hardware Controllers / Modules Motor Controller Vision Camera Camera Tigger Controller 4 Channel & 8 Channel Motor controller Machine Vision Camera Trigger Control Device
- 14. Our Hardware Controllers / Modules Vision Sensor Data Logger Cut-Off Controller Vision Sensor for Image Processing applications Machine Data Capturing Device Cut-Off Control Hardware
- 15. Product Installation Photos - ACERCON Color Register Control Color Register Control Color Register Control KOMORI-SYSTEM35 HEIDELBERG HARRIS KING PRESS - 5 COLOR
- 16. Product Installation Photos - ACERCON Color Register Control Color Register Control Color Register Control MANUGRAPH-CITYLINE MANUGRAPH-M360 KOMORI
- 17. Product Installation Photos - ACERCON Color Register Control Color Register Control Color Register Control ROTATEK- 8 COLOR ORIENT X-CEL ORIENT SUPER
- 18. Product Installation Photos - ACERCON Color Register Control Cut-Off Control Color Register Control GIDUE 10 COLOR - FLEXO KOMORI HEIDELBERG HARRIS
- 19. Product Installation Photos – CIP3 Ink Presetting CIP3 – Ink Presetting TKS HARRIS HARRIS CIP3 – Ink Presetting Ink Key Display Integration
- 20. Product Installation Photos Ink Key Motor Driver Replacement HARRIS PRAKASH NELA – SF BENDER Pharma Label Inspection Vision Punching
- 21. New Offering – Ink Data Analytics Workflow Ink Key Value ✓ Ink Estimation ✓ CIP3 Graph with key values ✓ Production Data Capturing & Ink Usage Monitoring ✓ Ink Estimated Vs Actual Consumption Analysis ✓ Ink Mileage Reports
- 23. Our Clients… 2 3