The document discusses an ecam-based motion control solution designed for various types of printing and textile machines, highlighting its application across multiple printing technologies and textile operations. It outlines the machine's architecture, which includes a rotating platform with servo-driven mandrels, and details the challenges and features of the Elmo network-based solution for high-performance synchronization and control. Additionally, it emphasizes the advanced motion control capabilities and benefits such as high throughput and precision in the operational environment of the machines.

1. ECAM-Based Motion Control Solution
for Printing & Textile Machines
Application Study

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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.

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Printing Station
Up to four color printing stations are used.

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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.

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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

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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.

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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

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Up to four color printing stations are used.
Printing Station

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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

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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

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Elmo network based Solution

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Host–G-MAS Communication Host HMI station for controlling the machine via standard Modbus TCP/IP or EtherNet/IP channel.
Elmo Solution Highlights

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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

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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

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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

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Compact, high-power Elmo servo drives located in EEC vibrating environment
Elmo Solution Highlights

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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

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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

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Advanced servo tools to achieve high motion performance on the single-axis drive level: Frequency domain analysis Advanced high-order filters
Elmo Solution Highlights

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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

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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

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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

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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

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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?