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

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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?