Rockwell Automation and M&M Electronics have successfully installed an impressive 172 axes of CIP Motion at Times Media (TMG) printing company in Port Elizabeth.
The project, the biggest installation of CIP Motion axes count in the world to date, came about when TMG acquired a second Goss Community Press in order to maximise efficiency at its plant. Its first press, a shaft-driven press with four towers and two folders, and the new acquisition, a five-tower press with one folder, had to be configured into one installation that could run up to three separate print jobs simultaneously.
The first stage of the plant upgrade was twofold: to convert the newspaper printing press from a common mechanical driveshaft, with a single DC drive, to a shaftless system; and to convert the existing AC register motors with analogue feedback potentiometers to a servo-based solution.
To achieve this, Rockwell Automation system integrator M&M Electronics fitted each of the nine printing towers with HPK AC servo motors and Allen-Bradley PowerFlex 755 AC drives. The system is controlled by Allen-Bradley ControlLogix L7x processors using Ethernet/IP for all the control networking, including motion control. At the heart of the system sits an Allen-Bradley ControlLogix PAC (Programmable Automation Controller) which forms the core of the Rockwell Automation Integrated Architecture System deployed in this installation.
The ControlLogix processors provide high-speed motion command and axis trajectory planner execution ideal for complex, high performance motion applications. The PACs, optimised for the control of high performance motion drives on Ethernet, have proven with this installation that they are capable of supporting as many as 172 axes of motion.
The printing towers are controlled by means of electronic gearing to one of three folder positions using PowerFlex 755 AC Drives on EtherNet/IP. The register motors were replaced with Allen-Bradley MPL AC servo motors and Allen-Bradley Kinetix 6500 AC servo drives. Visualisation is provided by five VersaView PCs, running Rockwell Software Factory Talk View Machine edition.
In the second stage of the project, to achieve correct paper unwinding and tensioning for the press, M&M installed Rockwell Automation’s high performance RDD direct-drive servo motors, which assist in addressing the growing energy requirements of the printing plant. The RDD-Series are high performance direct drive motors that connect directly to the load, eliminating the need for gearboxes, timing belts and pulleys. The direct coupling of the motor to the load helps reduce energy consumption while delivering higher dynamic performance, faster settling times and better overall control of the load.
Additionally, M&M installed automatic registration control in the third stage. This new registration system allows the press to run more efficiently by controlling, through the PAC, all ink colours, registration and present systems from DTP right through to printing. All new systems that formed part of the third stage were fully incorporated into the existing PAC – creating an entirely seamless running press.
Several challenges needed to be overcome to complete this turnkey project. “The biggest challenge was that this type of motion solution has never been done on this scale before,” explains Mike Sprake-Jones, managing director of M&M Electronics.
“It was relatively easy to change the registration to an electronic line shaft as was the installation of touch-screen operator interfaces, but what differentiates this job from others is that it is Ethernet based and, of course, the 172 axes.”
Trevor Woodgett, plant manager at TMG, expands on the benefits of the conversion. “The independent printing towers allow us to plate up while other towers are printing. This lets us print up to three different products at the same time. The press is also much quieter and smoother than when it was shaft driven.
“The reduced make-ready time is also a big bonus for us, because our work is deadline driven and we cannot afford to be late. The servo motors result in better register and quicker start-up of the press, thus helping to reduce paper wastage. I am extremely pleased with the service, experience and technology provided.”
For more information contact Sean Homan, Rockwell Automation, +27 (0)11 654 9700, [email protected], www.rockwellautomation.co.za
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