Precision Makes a Great Impression 08 the Future of Package Printing Built Lighter and Running Faster Than Ever, Ultra-Efficient Dr

03.16

The B&R Technology Magazine

High Precision Motion Control Precision makes functional printing a great impression

Additive manufacturing Will the disruption live up to the hype? Interview The future of package printing STREAMLINE YOUR CABINET. UNLEASH THE SERVO.

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< 1 cable for a modular machine design < Integrated safety technology CAT 4 / PL e / SIL 3 < STO, STO1, SBC, SOS, SS1, SS2, SLS, SDI, SLI, SMS, SLP, SMP, Safe Homing, Safe Robotics < Local I/O < 500 W up to 4 kW < CNC, robotics, motion control < reACTION Technology with 1 µs response time editorial

Dear Reader, publishing information As the dust settles on the electronic media revolution, the automotion: printing industry is displaying its extraordinary capacity for The B&R technology magazine, Volume 16 innovation by emerging stronger than ever. While other in- www.br-automation.com/automotion dustries spend much of their time discussing the implications of Industry 4.0, online print shops speed ahead as the undis- Media owner and publisher: puted front-runners in industrial implementation. Bernecker + Rainer Industrie-Elektronik Ges.m.b.H. B&R Strasse 1, 5142 Eggelsberg, Austria Tel.: +43 (0) 7748/6586-0 Digital printing and its natural counterpart, digital finishing, [email protected] are setting the stage for individualization and differentiation throughout the entire value-added chain – to a degree that few would have thought Managing Director: Hans Wimmer possible. At the same time, 3D and functional printing are opening up new prospects and dimensions for a promising future. All of this is made possible by fascinating new ma- Editorial staff: Alexandra Fabitsch chine designs and state-of-the-art automation technology. Editorial staff: Craig Potter Authors in this edition: Martin Dreher, Yvonne Eich, Engelbert Grünbacher, Stefan Hensel, Maybe you’re looking for innovative solutions on the threshold of process technology Irene Plats, Stéphane Potier, Franz Joachim and motion control or where the worlds of IT and automation intertwine. Or maybe you’re Rossmann, Huazhen Song, Adrian Tippetts in search of a practical big data solution that fits your everyday production reality. With the absolute latest in automation technology, hard-won engineering expertise and a Graphic design, layout & typesetting: global support network – B&R is a solid partner who is always “in-register” with your Linie 3, www.linie3.com printing needs. Printing: VVA Vorarlberger Verlags- anstalt GmbH, Dornbirn Come visit us at drupa in Düsseldorf from May 31 to June 10 (Hall 13, Booth E37). We look Edition: 100,000 Published at: B&R Strasse 1 forward to seeing you there! 5142 Eggelsberg, Austria Cover photo: shutterstock Happy reading!

All articles published in this magazine are protected by copyright. Translation, reproduction and duplication are prohibited without the expressed permission of the publisher. B&R assumes no liability for any errors they may contain. Thomas Rienessl Follow us Head of Business Development, Industries

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cover story interview

04 Precision makes a great impression 08 The future of package printing Built lighter and running faster than ever, ultra-efficient Dr. Martin Dreher, head of research at the DFTA technology modern presses are also more susceptible to vibrations. center in Stuttgart, talks about the advantages of flexo B&R has developed a set of advanced control functions to printing over gravure and digital. compensate for these disturbances. 20 Will the disruption live up to the hype? What can we expect as 3D printing moves from the makerspace to the plant floor? B&R asked Rainer Gebhardt from VDMA about the current hype.

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12 The digital difference 32 Flexible flexo The role of digital label printing is expanding. Nilpeter Qingzhou Ekofa has delivered hundreds of flexo presses worked closely with B&R to develop its PANORAMA label over the past decade. B&R control technology gives them printing and converting solution. the flexibility they need to meet the changing demands of an evolving market. 16 Made to measure In just a couple of hours, 3D printing systems from 36 Glass decoration with metallic effect voxeljet can create complex molds and models for Isimat – printing specialist for glass and plastic containers – cast metal components, or even custom movie sets has added a new machine to its portfolio. The new series and architectural models. of rotary printers also offers inline foiling for glass and plastic bottles. 24 Printing gets personal A box of muesli, a soccer ball or a running shoe – the 40 Beyond accuracy compact Jetmaster Dimension from Heidelberg can Shaanxi Beiren is among China's leading producers of print on nearly any object quickly, economically and in high-performance gravure presses. To ensure its control high quality. technology is equally advanced, the company has cooperated with B&R since 2003 to develop integrated 28 Intelligent integration of register control register control and shaftless drive technology. BST eltromat has equipped its RHS registration mark sensor with a POWERLINK interface, making it easier for OEMs to boost the performance of their printing, coating and laminating equipment through integrated register control.

03.16 03 04 cover story interviewreport impression makes agreat Precision High PrecisionMotionControl B&R hasdevelopedaset ofadvancedcontrolfunctions. and alloweventhefastest pressestoprintwithimpeccablequality– tionate increaseinvibrations. To compensateforthese disturbances– Unfortunately, asyouincreasespeed, you’refacedwithadispropor printing pressesarebeingaskedtoachievehigher andhigherspeeds. To keeppacewiththemarket’s insatiableappetite forproductivity, -

Photo: shutterstock Photo: shutterstock 03.16 B&R’s servodrives offerthenewHighPreci- quality. To mitigatethesesourcesoferror, tions alsohaveastrongerimpact onimage during operation.Disturbances andvibra- alignedwiththe targetpositionatthenip ly means thatthemotorpositionis notperfect- The resultingelasticityofthesesystems design thatutilizeslightweightmaterials. featureastreamlinedmechanical presses In contrast, a growing number of today’s firmware developmentteam. Grünbacher, headofB&R’s motioncontrol the printingprocess,“explainsDr. Engelbert tor’s encodersignalissufficienttocontrol rigidsystem,sothemo- press isarelatively tioning atthenipiscrucial. the printing cylinder. precise posi- Highly the impression cylinder with the plate on on howwellitcansynchronizetheweb ing pressisabletoachievedependsheavily The levelofqualitythataflexographicprint- “ A conventional A conventional turbance rejection, ing, model-basedcontrolandpredictivedis- passes threekeytechnologies:virtualsens- to completely preventthedisturbances,”to completely minimize this lag error, but will not be able “ sion MotionControl. es acertainamountofdisturbance torque. error. Eventheprintprofileitself production disturbancetorquethatresults inlag the resultinggapproducesafixed-posi- full circumferenceoftheprintingcylinder, coverthe Since theprintingplatedoesn’t Active disturbancerejection functions areexecutedeffectively. time ensuresthattheadvancedcontrol Control. Itsfast50-microsecondsampling suitedforHighPrecisionMotion perfectly B&R’s newestservodrive,theACOPOSP3,is oftheothers. and configuredindependently Each of these features can be implemented Fine-tuning thedriveparameters can cover story interviewreport “ explainsGrünbacher. “ This solutionencom- 05 06 es. This only appliestoquasi-stationary es. Thisonly ject periodic or fixed-position disturbanc- measuringit and usetheresultstore- ly termine thetargetpositionwithout actual- With avirtualsensor, itispossible tode- dynamicdrivecontrol Highly tual loadpositionsensor.” position of the load, what we have is a vir- calculate thehard-to-measurespeedand known. Ifweusetheseknownvaluesto easy tomeasure,andthemotortorqueis The speedandpositionofthemotorare angle ofrotationisgeneratedintheshaft. and massless.Atorqueproportionaltothe our calculations we will assume is flexible are joinedbyashaft,whichforthesakeof measure. other variablesthataremoredifficultto of thesystemtocalculatevalues measurable systemvariablesandamodel usingeasily ties. Virtualsensinginvolves sensing, however, therearenewpossibili- require anadditionalsensor. Withvirtual elastic mechanicalsystem,thatusedto get positionwithhighresolution.Onan you needtobeabledeterminethetar- In ordertorejectperiodicdisturbances, Virtual measurementoftargetposition improved printquality. The endresultisamorestablespeedand rameter tuning or mathematical models. minimizing lagerrorwithouttediouspa- This compensationoccursautomatically, torque tocompensate. bance, thedrivethenadjustsmotor thedistur- After measuringandanalyzing periodic orfixed-positiondisturbances. adaptive, predictivemethodofrejecting function calledRepetitiveControl–an and ACOPOSmultiservodrivesoffera says Grünbacher. AllofB&R'sACOPOSP3 cover story interviewreport bacher. a simpletwo-masssystem,“ explains Grün- direct-driven printing cylinder, wecanuse “ The motorandprintingcylinder “ To approximatethebehaviorofa synchronize theweb ontheimpressioncylinderwith plateontheprintingcylinder. onhow wellitcan The levelofqualitythataflexographic printingpressisabletoachievedependsheavily home foradvancedcontrolfunctionslikeHighPrecisionMotionControl. speed andprecision.Withitsfast50-microsecondsamplingtimes,B&R’s ACOPOSP3servodriveistheperfect When theprocessisdynamicandpositioningcritical,youneedamotioncontrolsolutionwithexceptional

Photos: B&R Photos: B&R of elastic systems to vibrate. reducesthetendency brations. Thisgreatly suppresstorsionalvi- detect andactively tion andloadspeed–makingitpossibleto the motor position, motor speed, load posi- state oftheoverall system –consistingof ler. Thestatecontrolleraccountsforthe cludes a virtualsensorand a statecontrol- The model-based feedback controller in- cade controlstructure. loop is incorporated in the standard cas- combination. Themodel-basedcontrol orin elements canbeusedindividually pending ontheareaofapplication,these feed-forward andfeedbackelements.De- tic systemsiscomposedofmodel-based dynamiccontrolsolutionforelas- A highly Grünbacher. based control comes into play,“ notes namic requirements. dy- drive systemsaresubjectedtohighly processes. Oftenintheprintingindustry, paired withoptimum printquality. press, thisequatestohigher productivity in elasticmechanicalsystems.For aprinting tools neededtomaximizeperformance, even ACOPOSmulti servodrivesprovides allthe functions availableonB&R’s ACOPOS P3and sive rangeofHighPrecisionMotionControl lent dynamicperformance.Thecomprehen- The desiredbehaviorisachievedwithexcel- out overshooting. position followsthesetpointwith- tor torque is regulated so that the target Based onthemathematicalmodel,mo- substantial improvementshereaswell. point. Modelpredictivecontrolcanbring from rapidchangestothepositionset- bances onthecylindersurface,butalso fromdistur- Vibrations canresultnotonly Preventing vibration ty isminimized,”saysGrünbacher. effect of disturbance torque on print quali- 03.16 “ This iswheremodel- “ The adverse The adverse Model predictive control significantly reducesthetendencyof elasticsystemstovibrate. Model predictivecontrol significantly cascade controlstructure. The feed-forward and feedback elements of the model-based control loop are incorporated in the standard quality ontoday’s high-speedpresses.” “High PrecisionMotionControlisthekeytogettingperfectprint Control FirmwareDevelopment,B&R Dr. EngelbertGrünbacher, Team Leader-Motion cover story interviewreport 07 Printing trends The future of package printing

The package printing market – and the flexo segment in particular – is being shaped by trends that pose complex technical challenges. Dr. Martin Dreher of the DFTA technology center describes these trends and predicts the impact they are likely to have on the future of flexography. Photo: Follmann

08 cover story interview report Photo: Follmann

03.16 cover story interview report 09 Dr. Dreher, can you tell us about some of combination of matte finish and design the latest trends in package printing? elements to give it a particularly elegant If we look at the package printing market look. To accomplish that, the matte finish – particularly the flexo segment – we see has to be precisely aligned with the other currents moving in a number of directions. printed layers in the composite. Gravure For instance, there are trends toward thinner printing has had to deal with this for a substrates and substrates with a matte long time and is well prepared for it, finish. which is hardly the case with flexo. So, naturally, it would be nice to see more How does a thinner substrate affect the flexo presses being equipped accordingly printing process? in the future. While it does lower material costs, a thinner substrate also presents certain challenges Traditionally, print quality has been the that have to be solved by the printing main argument for gravure and digital. Is technology. With their ability to get good that still the case? results on very thin and elastic substrates, These days there are very few remaining rea- central impression (CI) flexographic presses sons you would choose gravure over flexo for are often a good match for this. film printing – and print quality is not one of them. Even with corrugated board, flexo has And what challenges are posed by a matte made such great progress that – if someone finish? does choose offset instead – they’re not A matte finish can be both a means of doing it for reasons of quality. differentiation and a way to convey an image of sustainability. However, these materials With regard to digital printing, the thing is are more delicate to process than glossy that you generally want to minimize pack- substrates, because even a minor distur- aging customizations so that you tie up bance could cause an abrasion that pro- less capital and maintain flexibility. Flexo is duces an unsightly shiny spot. We’re able to in a good position here, but does have to deal with that fairly well by printing on film compete with digital. with CI flexo presses, because there is relatively low risk of damaging the front of the What reasons are there for explicitly choos- substrate with guide elements in the press. ing flexography? Flexo is the only printing segment still devel- Sounds like flexo is ready for the future. What oping screens, so it also offers the broadest reasons are there for still using gravure? selection with regard to dot shapes, offset Something that’s popular right now is angles and methods of dot gain compensa-

laminated composite film printed with a tion. After a long period where it seemed in- Photo: DFTA

10 cover story interview report Dr. Martin Dreher, head of research at the DFTA technology center, talks about new trends in printing technology.

feasible, frequency-modulated screening is at least exploring – seven-color printing, also making a comeback – and is once again while others have already implemented producing spectacular results. four-color, or 4C, printing.

Screen rulings are growing finer and finer. The latter has been made possible by ad- There are already large-format film printers vances in the flexo process that allow it to using screens with 100 lines per inch as produce vibrant colors that not long ago standard. However, once you get beyond were unimaginable. Today it’s possible to the threshold that the human eye is able to create intensely colorful images with only resolve, a finer screen ruling no longer im- four process colors. proves print quality. What does the future hold for flexography? Are there differences or limitations to the These are dynamic times for package print- colors that can be printed? ing in general – and no less so for flexogra- Like most other package printing tech- phy. Some of the resulting challenges are niques except for digital, the common prac- easier to overcome than others, but over- tice is to print in CMYK+X. While the "+X" all, flexo technology is in a very strong po- does help match corporate colors more ac- sition and has the absolute best prospects curately, it also presents new challenges. for the future. These are increasingly being dealt with by

Photo: DFTA using a fixed color set. Some are using – or Great, thanks for your time!

03.16 cover story interview report 11 12 cover story interviewreport difference digital digital Digital labelprinting The The

Photo © shutterstock Photo © shutterstock 03.16 launched atthe2015LabelexpoEurope. Nilpeter DP-3printengine–whichit and convertingsolution–basedonthe B&R todevelopitsPANORAMA labelprinting with embossing. Nilpeterworkedclosely features, varnishing,hotfoilingand track-and-trace informationtosecurity features rangingfromvariabledataand turnarounds, butahostofvalue-adding shortrunsandfast demanding notonly markets isexpanding.Brandownersare The roleofdigitallabelprintingintoday’s cover story interviewreport 13 When short-run jobs were the exception, converters would often run them at a loss, subsidizing them from the profits of the long runs. With short runs becoming the norm, the drop in profitability can prove fatal.

The benefits of printing digitally Digital printing enables cost-effective production of short runs by eliminating the time-consuming and costly processes that make conventional printing unprofitable. Prepress is reduced to the generation of digital files, generally in PDF format. There is no need for films, plates or chemistry; nor is any time needed to set up the press or run waste until proper color and register are achieved.

Only what is needed is printed. Reprints can be produced by simply calling up the file and ensuring the right substrate is in place. This Nilpeter's PANORAMA is controlled by a tablet. enables just-in-time delivery and significantly reduces – or eliminates – costly warehousing. It also eliminates the large portion of printed products – typically around 50% of everything printed – des- tined to sit around until they are obsolete. These excess quantities were traditionally made attractive by the “unit cost” model, in which costs appeared to be driven down by printing more than was required.

Ideal partner for inline synchronization While these efficiencies are great, the Nilpeter PANORAMA takes it a decisive step further. As an inline solution, there is an uninter- rupted flow from raw substrate to finished label – complete with all the special features including numbering, flood coating or spot varnishing (using flexo or screen printing), hot foiling, embossing and other enhancements, as well as final die-cutting and matrix The PANORAMA features a simple and highly intuitive user interface, removal. presented on a 42" color touch screen. (Source: Nilpeter) This combination of digital and mechanical (analog) processes calls for a high degree of control and automation, which is where Modern consumer marketing is driven by a variety of factors, all of B&R comes in. Nilpeter has worked with B&R for years on flexo and which impact the production and timely delivery of labels and offset litho systems. Familiar with the capabilities of B&R and its packaging. Today’s brand strategies focus on brand extension and products, Nilpeter knew they would make an ideal partner for its differentiation – designed to increase market share and physically PANORAMA project. B&R’s experience and expertise helped take occupy more shelf space. the project from kickoff to launch in only nine months.

This has resulted in a dramatic increase of SKUs and a consequen- “One of the strengths B&R brought to this project was its ability to de- tial reduction in label run length per item. When printed conven- liver systems with real-time capability,” said Søren Ringbo, Nilpeter’s tionally (by offset lithography or flexography) the fall in run length manager of digital products and PANORMA project manager. “This can have a serious impact on a label converter’s margins – and means that adjustments for register, web tension, positioning, and so

ultimately their profitability. on are instantaneous – without compromising productivity and quality.” Photos © Nilpeter

14 cover story interview report Photos © Nilpeter tial toensureaccuratecolorregistration.Thisalsoappliesdown and laterally,Proper placement of the web, both linearly is essen- ent printingstations. plication –andcuringofindividualcolorstakesplaceatdiffer- like adesktopprinter. Whiletherearefewermovingparts,theap- web inasingleoperation,ratherthanusingscanningprocess pass UV ink technology. That means that ink is applied across the The PANORAMA labelprintingandconvertingsolutionusessingle- Recognizing digitaldifferentiation edge basetocreateinnovativesolutions.” is abletodrawideas,conceptsandprinciplesfromabroaderknowl “And, because B&R has experience beyond the printing industry, it explainsRingbo. have pragmaticapproachestoproblemsolving,” a rotary, semi-rotaryorflatbedsolution.“BothNilpeterandB&R can beusedinthemodularPANORAMA line,whichcanbesetupas This isnosmallfeatgiventhevarietyofoptionalequipmentthat 03.16 PANORMA projectmanager, Nilpeter Manager ofdigitalproductsand Søren Ringbo the printingindustrythatgivesitabroaderknowledgebasetocreateinnovativesolutions." B&Ralsohasexperiencebeyond "Both NilpeterandB&Rhavepragmaticapproachestoproblemsolving. - ers’ expectations.” cations, usingB&R’s systems,withresultsthatmeetbrand-own- reliableandproductivedigitalprintingfinishingappli- highly processes foroptimumresults.WithPANORAMA, wecannowdeliver spearheaded technologiesthatbringtogetherallthedifferent beenanadvocateof’combinationprinting’andhas has always Jakob Landberg, Nilpeter’s sales and marketing director. “Nilpeter “There isnowinningtechnologythatcoversallapplications,”says complex. The labelandpackageprintingmarketsareextremely may requireanumberofdifferenttechnologies. no universaldigitalprintingtechnology, andconvertingprocesses tion formostlabelapplications,italsounderstandsthatthereis While NilpeterbelievesthatusingUV-curableinkisthebestsolu- label increaseswitheachprocess. grows more important at these later stages as the value of the the linetoprintenhancementsanddie-cutting.Infact,it cover story interviewreport 15 16 cover story interviewreport to measure Made 3D printing ensures thatevenlargeprintjobscanbehandled reliably, andtruetodetail. precisely automation andcontrolsolutionbasedonhigh-performance B&Rtechnology, which production runs,prototypesandmodels.Allof thisissupportedbyaversatile,integrated offer, appreciateisthetremendoustimesavingstobe gainedwithsmall whatusers really Beyond thehighlevelsofprecisionandunprecedented designcomplexitythat3Dprinters models forcastmetalcomponents,orevencustom moviesetsandarchitecturalmodels. In justacoupleofhours,3Dprintingsystemsfrom voxeljetcancreatecomplexmoldsand

Photo © voxeljet AG Photo © voxeljet AG 03.16 space andthen breaks it down into print layers. In order to process The printer’s softwareplacesthe3DCADmodelina virtualwork- cy downtothesmallestdetail. simultaneously. Byusing theCADdatadirectly, itensuresaccura - to producelargeindividualcomponentsorseveralsmallerparts ness of300micrometers.ThespaciousplatformallowstheVX4000 just 75secondswith a resolutionof300dotsperinchandthick- printseachlayerin First producedbyvoxeljetin2009,theVX4000 1,000 millimeters(LxWxH). sand layerbyonaplatformmeasuringupto4,000x2,000 x to betheworld’s largest3Dprintingsystem–buildsshapesof printer’s platform.Inthisway, –whichvoxeljetclaims theVX4000 piece tobecreatedontopofathincoatingparticles the intheshape of thework- of ink.Thebinderisappliedselectively pany’s developedprintheadusesaliquid binderinstead specially used bytraditionalink-jetprinters.Thedifferenceisthatthecom- The printingtechniqueusedbyvoxeljetisquitesimilartothat Largest 3Dprintingsystemintheworld anysize.” virtually developing afullspectrumofdevicestohandleworkpieces ing ourrangeofprintingservices,whileatthesametime cial tools.We expand- haverespondedtothistrendbydrastically and without spe- types, small production runs and models quickly truewhen it comestoproducing proto- eljet. “Thisisparticularly explains BjörnMatthes,responsibleforelectricalplanningatvox- range ofotherindustriesdiscoverthepotential3Dprinting,” and heavyindustry, weareseeingnewcustomersinanexpanding space industries,aswellmachinemanufacturing,shipbuilding “In additiontoourprimarycustomersintheautomotiveandaero- cover story interviewreport 17 The largest 3D printer in the world has a print chamber measuring 4,000 x 2,000 x 1,000 millimeters (LxWxH). With its high-quality components, it is designed for continuous operation.

the large volumes of data involved, the voxeljet system uses an cluded its selection process with a clear favorite. "B&R’s seamless industry-grade PC featuring an SSD system disk and an additional portfolio, which includes integrated safety and a universal devel- hard disk with at least 1 terabyte of storage to hold the data. opment and configuration tool, really convinced us that we had found the right partner. The B&R system gives us everything we A seamless product portfolio without rival need as well as plenty of room for future innovations." “On all the 3D printers we built prior to the VX4000, the PC was also responsible for controlling the entire system via a CAN bus con- The decision was sealed in a meeting with application engineers nection,” says Matthes. In developing the VX4000, voxeljet intro- from B&R, where voxeljet was able to see firsthand just how easy duced an additional level of abstraction in order to further simplify it is to build a gantry system using B&R technology. the control architecture and relieve some of the burden from the PC. They also needed to develop a gantry system to drive the two Flexible architecture portal systems on which the print head and particle recoater are In the automation solution for the VX4000, which uses B&R tech- mounted. nology for everything except the PC, a PLC from B&R’s X20 series functions as the motion controller. Movement commands generat- "We’ve learned from experience that if different suppliers are in- ed by the PC are transmitted via standard Ethernet to the CPU volved in producing the drive system, problems can arise due to module, which converts them into corresponding motor move- miscommunication and unclear responsibilities," explains Mat- ments. In addition to the 4 servo motors controlling the Z axis of thes. "That’s why we were looking for a partner who could handle the two portals of the gantry system, the VX4000 uses up to an the entire automation system, from the gears right through to the other another eight servo motors which are partially synchronized control system and HMI." Matthes notes that voxeljet quickly con- (2 x X1 and 2 x X2).

Björn Matthes Electrical Planner, voxeljet AG

“From the very first training session, it was clear that B&R really thinks ideas through from start to finish to ensure that they are implemented right. The level of support at B&R is outstanding and has helped us many times to answer questions quickly and develop our engineering skills." Photos © voxeljet AG, Franz Joachim Roßmann

18 cover story interview report Artwork produced using 3D printers from voxeljet. These printers can create items The operator terminal of the new VX2000 from voxeljet is based on a Power of virtually unlimited complexity (including undercuts) from all types of raw material, Panel with touch screen from B&R. The HMI application runs on the same PC including molding sand and plastic. that prepares the print data for the 3D printer.

voxeljet uses exclusively servo motors in order to keep the archi- ard slices without affecting the safety-related areas,” continues tecture flexible, respond quickly to future requirements and opti- Matthes. Automation Studio offers a number of clear benefits for mize inventory. All motors are powered by ACOPOSmulti drives, voxeljet. It provides a single tool that unifies the entire range of which communicate with the controller via POWERLINK. These B&R automation components, including control software, HMI and drives are used for more than just motion control. They are also safety functions. The comprehensive diagnostic functions make used to coordinate the sequence of lower-level functions that analyzing software and troubleshooting errors much easier. Of regulate tasks directly related to printing, such as moving the particular value is the clear structuring of the engineering envi- print head (Y) and filling the recoater. ronment and the ability to synchronize hardware configurations thanks to the integrated EPLAN interface. All new automation pro- “The prototype VX4000 that was built using this architecture is still jects from voxeljet are created using Automation Studio 4. working efficiently and reliably at our service center,” says Matthes. “Of course, the architecture has continued to evolve since then.” Virtual master axes simplify reuse In addition to the integrated safety functions, voxeljet has since Effortless setup with openSAFETY also incorporated the concept of virtual axes into the system’s The automation solution now incorporates the Safe Torque Off architecture. Now all master axes are implemented as virtual axes. (STO) and Safely Limited Speed (SLS) safety functions. Both func- For voxeljet this means that, when developing the control soft- tions were implemented by voxeljet developers using ACOPOSmulti ware, it doesn’t matter which drive will later be connected to a inverter modules with integrated SafeMOTION safety technology particular axis or how the axes should work together. “This allows and Safe I/O modules from the X20 system. “Even with the large us to simulate the drive hardware and test the automation solu- dimensions of the printer, which measures 20 meters long and 7 tion even before the system is completed,” explains Matthes. meters wide, service and setup are much easier because person- “What’s more, using virtual axes makes it much easier to reuse nel can safely move around inside the printer and monitor the pro- the automation architecture for other systems.” cesses without having to hold down an enable switch,” says Mat- thes. “The hardware and time needed to integrate the safety func- Matthes speaks from experience – voxeljet has already reapplied tions was minimal thanks to the openSAFETY communication the B&R-based automation solution to its VX2000 with only mini- protocol.” mal modification.

The system was designed with the I/O modules split into two “We received excellent support from B&R when introducing this strands. While the safety I/O channels are connected directly to and other technologies,” says Matthes. “From the very first train- the CPU, the non-safety-related I/O channels are isolated via ing session, it was clear that B&R really thinks ideas through from POWERLINK. Originally this separation didn’t exist. “By separating start to finish to ensure that they are implemented right. The level the channels we’ve made it easier to expand the system. Another of support at B&R is outstanding and has helped us many times to

Photos © voxeljet AG, Franz Joachim Roßmann bonus is being able to disconnect the power supply for the stand- answer questions quickly and develop our engineering skills.”

03.16 cover story interview report 19 20 cover story Manufacturing Workgroup, VDMA Rainer Gebhardt,HeadoftheAdditive live uptothehype? Will thedisruption Additive manufacturing interview report engineering association. manufacturing workgroupatGermany’s VDMA with RainerGebhardt,whoheadstheadditive automotion satdowntodiscussthistopic hype throughouttheindustry. on alargerscalehassentshockwavesof for thistechnologytoreshapemanufacturing successive layersofmaterial.Thepotential three-dimensional objectsbylayingdown first tobuildsimpledevicesableproduce tech-savvy DIYenthusiastswereamongthe home inthemakercommunity, where Until recently, at 3Dprintingwasprimarily

Photo © iStock Photo © iStock 03.16 cover story interview report 21 Mr. Gebhardt, how did you come to be involved with the topic of additive manufacturing? Until three years ago, I was with the printing press manufacturer MAN Roland, where I got to know the printing industry from the perspective of OEMs and users and gathered experience and know-how about the technologies used and the market in general. From there I moved to the trade association for print and paper technology at the VDMA, which gave me the chance to get involved in additive manufacturing. And now I’ve led the additive manufacturing workgroup since it was created in May of 2014.

3D printing and additive manufacturing are hot topics these days. Can you explain these terms briefly for the non-experts among us? The term additive manufacturing, or AM for short, is basically the opposite of the subtractive methods we’re used to, where material is removed through machining processes like turning, milling, grinding and EDM. Instead, material is built up – or printed – layer-by-layer to create a three-dimensional object. This is where the term 3D printing comes from.

What does your additive manufacturing workgroup do? We observe additive manufacturing along the entire process chain – that is, from the perspective of the equipment builder, the user and the powder supplier. It’s important to us that our focus spans all the different methods, including lamination and hybrid techniques for metals and plastics. As a workgroup, we also offer a network for the ex- change of know-how throughout the machine manufacturing industry. We also have com- mittees dedicated to current topics such as production quality or process automation.

There is a lot of excitement surrounding 3D printing. What stage in the hype cycle would you say additive manufacturing is in? The impressive growth rate of over 25%

makes it clear that there’s some substance Photos: iStock, shutterstock

22 cover story interview report behind all the talk. There are numerous com- Where there’s light, there are bound to be to think about how to encourage creative panies offering industrial 3D printing solu- shadows. What are the challenges people new designs, while at the same time pro- tions that are already being used commer- face when implementing 3D printing? tecting them as intellectual property. cially for tasks such as prototyping, tooling Not everything that is technically feasible and mold-making as well as to fabricate re- makes good economic sense. In addition to What does the future hold for this technolo- placement parts. Other applications are ex- the high material costs and the time needed gy? Are there other challenges besides the ploring new geometries that will offer advan- for printing itself, the components also need technical ones you’ve mentioned? tages such as weight reduction and improved to be designed in a way that is conducive to Like with the topic of Industry 4.0, there are stiffness. And there are many other applica- 3D printing. The design process must be cre- both technical and sociopolitical aspects. tions that haven’t yet reached maturity. ative; 3D printing should not be considered a Consider the design and development pro- simple substitute for conventional manu- cess. Engineers need to get more creative if There are so many different additive manufacturing. Only then will the technology live they’re going to take concepts that are oth- facturing techniques. Can you give us a quick up to its full potential. erwise hard to imagine and implement them overview of which ones are already available? in a CAD system for 3D printing. We can ex- The best method to use will vary depending Additive manufacturing does already have pect some breakthroughs when it comes to on what materials you’re working with and some commercially successful applications. commercializing new ideas, because a 3D what the parts will be used for. The first tech- Can you briefly summarize the advantages it printer lowers the cost barrier for producing nology on the scene was stereolithography. offers? prototypes. Over the years, this has given rise to other The advantages come when you’re produc- techniques for metals and plastics. For met- ing parts in small quantities or parts that are Do you think we’ll start seeing conventional als, you have selective laser melting and too complex for conventional methods – or manufacturing processes supplanted by ad- electron beam melting. For plastics, there are that would otherwise involve high up-front ditive ones? techniques like thermal 3D printing. It’s also tooling costs. OEMs can use service provid- I think the idea of straight-up substitution is possible to use liquid resin, which is then ers to have parts produced quickly, close-by wishful thinking. In reality, it seems like addi- printed using stereolithography and digital their customers and without the complica- tive manufacturing will be more of a comple- light processing. Other popular methods are tions of a lengthy supply chain. mentary technology. Still, there will surely be lamination, polyjet and hybrid systems. areas where individualization and lightweight Are there any areas that are definitely not construction are in high demand, and where What areas of use are there for parts pro- suited to additive manufacturing? the shift from subtractive to additive manu- duced on 3D printers? Additive manufacturing won’t likely offer the facturing will happen relatively quickly. OEMs are already using 3D printing to create economies of scale you get with conven- prototypes without the costly and time-con- tional manufacturing any time in the near When it comes to the industrialization of ad- suming process of first creating the neces- future – so you won’t yet see it being used ditive manufacturing, we’re still at the very sary tools. The same applies to replacement for mass production. beginning. Which industries will be the first parts, which a 3D printer can produce re- to demonstrate the benefits of additive man- motely, on demand in small quantities – elim- As automation specialists, it’s in our nature ufacturing in mass production? inating the need to maintain a central inven- to focus on how processes and equipment We’re seeing the highest growth rates in the tory for years. Another use is to make target- can be optimized. Where do you see the ob- aerospace and automotive industries, but ed repairs to very complex components that stacles, technical or otherwise, preventing tool manufacturers are also very involved. would otherwise require extensive hardfac- 3D printing technology from more wide- Another active industry is medical technolo- ing, milling or grinding. Additive manufactur- spread use? gy, where they’re working on custom pros- ing allows the production of new structures Additive manufacturing is not yet on par with thetics, hearing aids and dental prostheses and designs that would be impossible to the long-established conventional methods that really highlight the social value, flexibil- create with conventional machining. You can of production. There is also still some poten- ity and benefits of 3D printing. make components that are extremely pre- tial for optimizing the automation of the 3D cise, lightweight, stable and integrated, like printing process. Aerospace and other in- those used in machine tooling. And these dustries place particularly high demands on

Photos: iStock, shutterstock are only a few of the many possibilities. the quality of produced parts. We also have Very exciting – thanks for your time!

03.16 cover story interview report 23 24 muesli-mix homeinacustompackage theygettodesignandprinton-site. Customers oftheMyMueslishopinHeidelberg, Germany, carrytheirpersonal Custom labeling cover story interviewreport gets personal Printing components, theJetmasterreliesonB&Rtechnology. high quality. synchronized Foritsprecisemovementsequencesandperfectly any objectquickly,Jetmaster Dimensioncanprintonnearly andin economically Whether it’s aboxofmuesli,soccer ballorarunningshoe–thecompact companies arenowabletooffercustomprintingofthree-dimensionalobjects. With Heidelberg’s innovativedigitalprintingmachine,evensmalltomidsized

Photo © Heidelberg Photo © Heidelberg and-a-half-dimensional these personalizednoveltieshave beenlimitedtoflator tom-printed itemssuchasgreeting cardsandt-shirts.Untilnow, forms andonlineretailershavebeensosuccessfulofferingcus - der, then,thatbig-namesportinggoodscompanies,Internetplat- forthetorturous taskoffindingtheperfectgift.Nowon- it weren’t Christmas, weddings,birthdays.Theycouldallbesowonderful –if has traditionally been cost-prohibitive – except in quantities of has traditionally ventional presses.Forthree-dimensional objects,personalization 03.16 ” objectsthatcanbeprintedusing con- “ two- Custom-printed 3Dobjects as smallone. for short)isnowopeningupthis coveted serviceforbatchsizes erages orcosmetics.HeidelbergerDruckmaschinenAG(Heidelberg around tenandup(padprinting)ormass-produceditemslikebev - “ partners tocreatetheJetmaster Dimension, head ofadvancedevelopment, Dr. BernardBeier. We withB&Randother leading technology collaboratedclosely cover story interviewreport ” saysHeidelberg’s “ For thefirst 25 Holger Leonhardt Team Leader - 4D Technology, Heidelberg

“B&R’s technology is 100% series production friendly and fits perfectly into our production process.“

time, this standard machine can print custom text and photoreal- istic images on virtually any 3D object with minimal adaptation. And, it can do it quickly and in high quality. Now, even smaller en- terprises can win new customers by offering personalized products at attractive prices.” A number of companies have already taken advantage of the opportunity. MyMuesli recently set up a Jetmaster Dimension 250 at its store in Heidelberg, Germany. On top of creating their own personal muesli-mix, customers can now also choose the images, color and text that go on the package.

Single-pass printing “If you look closely, you can see that the objects we’re printing on – like MyMuesli’s paper cups – often deviate from their ideal shapes,” reveals Beier. “That’s why each object is measured individually pri- or to printing.” After that, an atmospheric plasma coating is applied to prepare the surface. One of the reasons the printer is so fast is that it uses a 6-color single-pass print head. Unlike con- ACOPOS drives draw their software from a central location on the B&R cont- ventional inkjet printing, this process deposits all the ink for each roller without requiring any manual intervention. Increased precision allows dot in the image in a single pass. An ultraviolet LED lamp immedi- for larger quantities, shorter production cycles and better quality. ately dries (or “pins“) each dot to prevent unwanted mixing. Once complete, another ultraviolet lamp cures the finished image so that the product is immediately ready for use.

The Jetmaster Dimension 250 features a four-axis robot that posi- tions and rotates the object for each of the fixed processing stages – measurement, surface preparation, printing and curing. To achieve good quality at a resolution of 300 dots per inch, these positioning movements have a tolerance of less than 20 micrometers. That means the robot axes need to be controlled with absolute precision and perfectly synchronized with the printhead controller.

Leading technology partners on board “We knew from the start that we wanted to team up with partners who are specialists in their fields,“ says Beier. “The idea is that this approach gets us access to the most advanced technology and ensures that projects run quickly. And we were right – it only took us ten months to get from the first CAD drawing to a working prototype."

Going into the project, the requirements for the drive and control technology demanded not only extreme path precision, but also an automation system open and flexible enough to incorporate the var- ious subsystems into single, homogeneous unit. “We were looking

More than just remote I/O, the X20 system is a complete control solution. Its for automation technology that offered the functions we needed,“ modular components can be arranged in whatever configuration is needed explains Holger Leonhardt, who headed Heidelberg’s 4D technology for the application at hand. team. “But at the same time, it also had to be suitable for series

production, which many of the controllers on the market are not.“ Photos © B&R, Heidelberg

26 cover story interview report For Leonhardt, a controller is only suitable for series production if it can be commissioned without having to go through the development environment and if it can be configured at runtime. Also, a source control system must be in place for the control software, and it must be possible to update the controller and connected automation components automatically.

100% series production friendly: B&R technology The first exploratory discussions at drupa 2012 were soon fol- lowed by more intensive talks with B&R experts. “We were surprised to see that B&R met 75% of our requirements right from the outset,“ notes Leonhardt. “That was impressive.“

One of B&R’s most convincing arguments was its suitability for series production. The Automation Studio engineering environment features built-in source control. As Heidelberg required, software can be loaded onto B&R controllers via USB drives or via an Ether- net connection. Each time the system is started up, the controller checks a definable location for updates and installs them automatically. The Jetmaster Dimension from Heidelberg introduces one-off custom ACOPOS drives also draw their software from a central location printing for 3D objects such as cans, balls and athletic shoes. on the B&R controller without requiring any manual intervention. “Since the control software can be configured at runtime and the wiring lists can be manipulated using the tools provided, we’re able to use the same software project for multiple machine configurations,“ says Leonhardt. “B&R’s technology is 100% series production friendly and fits perfectly into our production process.“

Technological convergence made easy With that, B&R was a sure thing for Heidelberg. Its expansive portfolio of fully scalable products played a pivotal role in helping the company keep pace with its ambitious development schedule for the Jetmaster Dimension. The openness and flexibility of B&R’s solution made it easy to bring together new and diverse technologies to be handled by a single controller.

Leonhardt was equally impressed by the support his team received before and during the project: “After a less-than-enjoyable experience with a very large controls supplier, we were pleasantly surprised by B&R’s service, which far exceeded our expectations,“ praises Leonhardt. “Their employees are experts in their fields and extremely knowledgeable on the topic of automation. They were able to see the challenges from our perspective and find appropri- B&R’s control and automation technology is perfect for series-built machines and

Photos © B&R, Heidelberg ate solutions.“ grants the Jetmaster Dimension the precision it needs for optimum printing results.

03.16 cover story interview report 27 Printing registration Intelligent integration of register control

BST eltromat International has equipped its proven RHS registration mark sensor with a POWERLINK interface. This makes it substantially easier for OEMs to boost the performance and efficiency of their printing, coating and laminating equipment through integrated register control. Photo © shutterstock

03.16 cover story interview report 29 The POWERLINK interface and seamless integration in Automation Studio make it easy to integrate register control logic into standard B&R controllers.

“The option of integrating register control directly into their own longitudinal and side register error and sends this information to machine control solution really strikes a chord with many machine the controller in hard real-time via the integrated POWERLINK builders,” says Volker Reinholdt, product manager for print in- interface. If required, the sensor can link this information with spection at BST eltromat International. “B&R is a respected partner position data from an encoder or drive in order to identify the for automation in the printing industry. With the combination of absolute position of the marks. POWERLINK allows cross-commu- B&R controllers and POWERLINK communication featured prominently nication with the drives in the network, which makes it possible in many successful printing solutions, there is naturally a great to create especially fast control loops. With this approach, the deal of interest in the prospect of integrated register control.” machine controller handles register control as well – eliminating the need for a dedicated controller and making the solution The sensor offers reliable and high-resolution detection of block extremely compact, reliable and efficient. Processing stations and arrow registration marks – even with minimal contrast or can be readjusted much more quickly, which helps minimize color differences and on highly reflective materials. It can also prepress waste. handle specialty paints, finishes and transparent substrates without a problem. As a result, it is not only suitable for synchro- Configuration and updates over the network nizing subsequent processing steps in a printing press, but also Integration of the register control technology in the Automation for use in coating and laminating lines. Studio engineering environment streamlines and simplifies the development process. Users enjoy full access to all sensor data, Reliable detection and can integrate the register control solution seamlessly into The highly reliable detection offered by eltromat’s intelligent the user interface. sensor is owed to the sophisticated, specially-developed signal processing technology. Light from a white LED is transmitted via Like all B&R components, the sensor can be configured and new fiber optic cable to the substrate bearing the registration marks, software can be installed via the machine network, the intranet which can move past the sensor at a rate of over 1,000 meters or the Internet – without ever interrupting operation. Since eltromat’s per minute. The reflected light is carried by the fiber optics back sensor doesn’t require a manual teach-in step, there are no long to the sensor, which then evaluates the red, green and blue delays during product changeover. components. There is no need for separate lighting. The RSH sensor is not sensitive to web flutter, and thanks to the ATEX- This powerful sensor makes it easy for OEMs to implement register certified fiber optic cable it can also be used in potentially explo- control and make their machines even more efficient and produc- sive areas. tive. In response to the high level of interest, BST eltromat Inter- national is working on a POWERLINK version of a camera-based POWERLINK for fast control loops sensor that will open up even more design possibilities for register With its onboard intelligence, the RSH sensor calculates the control solutions. Photos © BST eltromat International

30 cover story interview report Volker Reinholdt Product Manager - Print Inspection, BST eltromat International

“B&R is a respected partner for automation in the printing industry. With the combination of B&R controllers and POWERLINK communication featured prominently in many successful printing solutions, there is naturally a great deal of interest in the prospect of integrated register control.”

Photos © BST eltromat International BST eltromat International developed the ATEX-certified RSH registration mark sensor specifically for block and arrow marks.

03.16 cover story interview report 31 32 cover story interviewreport

Photo: shutterstock Photo: shutterstock 03.16 Flexible flexo Flexographic printing demands of an evolving market. demands ofanevolving machines havetheflexibilityittakestomeetchanging world. ThankstoB&Rcontroltechnology, Ekofa'snew provided hundredsofflexopressesforcustomersalloverthe flexo pressmanufacturers.Overthepastdecade,Ekofahas This isgoodnewsforQingzhouEkofa,oneofChina'slargest conscious, thesoftpackagemarkethasseenrapidgrowth. environmentally With consumersgrowingincreasingly cover story interviewreport 33 34 tures offered by B&R is that its register For Ekofa,one of the most attractive fea- Register controlasstandardsoftware B&R technology. with developingthenewmachine basedon confidence theyneededtomoveahead printing industrygavetheEkofateam Studio. B&R'sextensiveexperienceinthe versal engineeringplatform,Automation gister controlsolution,aswellitsuni- drawntoB&R'sintegratedre- immediately tion foritshigh-endmachines,theywere When Ekofabeganseekingacontrolsolu- flexo press. Ekofa createdafasterandmoreefficient drying. Indesigningthesenewmachines, new upperweb-passingdesignforfaster witha which theEkofaXLSseriessolves places newrequirementsonmachinedesign, presses thatusewater-basedink.This sult, thereisagrowingmarketforflexo food safetyandgreenpackaging.Asare- heightened demandsonproductquality, stic economy, Chineseproducersface With the rapid development of the dome- Machines thatusewater-basedinkhaveuniquedesignrequirements,whichEkofameetswithitsnewupperweb-passingdesign. cover story interviewreport gistration controland electronic gears and the modulesforcolormarkdetection, re- core oftheprintingprocess.By combining B&R's registercontrolfunctions formthe ting afewparameters. requirements isasimplematterofadjus- to anypaperorfilmwithdifferenttension other controlmodesforrollers.Adapting ment open-loop,closed-loopandvarious used in web printing to imple- le, is widely B&R's tensioncontrolmodule,forexamp- reduce thetimeandcostofdevelopment. reusedtofunctions canbeeffortlessly dustry. Standardizedandmodular, these decade ofexperienceintheprinting- trol algorithmsisbasedonmorethana B&R's specializedlibraryofregistercon- to theprevioussystem. petitiveness andcost-efficiencycompared trol tologicandHMI–aclearjumpincom- everything frommotionandregistercon- A PowerPanelfromB&Risabletohandle units forlogic,motionandregistercontrol. like atraditionalsolutionwithseparate integrated,un- control technologyisfully manually. experience requiredtoadjustthe pressure gree ofaccuracywithoutthe extensive achieveahighde- operators caneasily fer. settingafewparameters, Bysimply for printingpressureandanilox inktrans- Ekofa machinesfeatureservocontrols toever-changingrequirements. adapt adjustment andfastchangeover–to with greaterflexibility–includingonline The printingindustrydemandsmachines with maximumefficiency. to encapsulate their expertise and reuse it such astheautomaticmarklockingfunction, tools. Theycanalsocustomizemodules, back andforthbetweendifferentsoftware tensive librarieswithouthavingtoswitch neers benefit from Automation Studio's ex- During projectdevelopment,Ekofaengi- Double theflexibility lopment ofitsXLSandKangtai IIIseries. uses thissoftwareformoreefficientdeve- machine's processesandsystems.Ekofa shortened thedevelopmentcyclefor cams formotioncontrol,B&Rhasdrastically

Photos: Ekofa, B&R Photos: Ekofa, B&R meter calculations inordertoenterthere- a few internal para- confirmation with only position manually. It can achieveautomatic function avoidstheneedtoconfirm mark ware design.Theautomaticmark locking chine reduceswastethrough smart soft- With itsfullservomode,thenewma- waste. produce are processesthatcaneasily Roll changing,proofingandregistercontrol Reduced wasteandincreasedyield is anissue. China's westernregionswheregridstability relevant in operation, which isespecially range from230to480VAC ensures reliable tage overothersystems.Itspowerinput drive iscloseto1–animpressiveadvan- mains. ThepowerfactorofanACOPOSmulti to regeneratebrakingenergybackintothe ves withacommonDCbus,whichareable why EkofaselectedACOPOSmultiservodri- when itcomestolong-termsuccess.That's is the topic of energy consumption really Experienced plantoperatorsknowhowvital quality, butneedstodosoatminimalcost. A printingmachineshouldprovidehigh Energy-efficient drivesystem for ourideas." can beencapsulatedandcontinued.AutomationStudiofromB&Risverysuitable "Ekofa aimsatlong-termmarketinnovation.We hopethatourstrengthinthisarea Wang Haifeng,GeneralManager, Ekofa 03.16 demands. Itisour commonvision." develop machinestomeetour customers' Wang. "Inthefuture,wewillcontinueto benefit oflong-termcooperation," notes satisfied customers means we gainthe satisfied withthereducedwaste. "Having the printingindustry. Endusersarealso helps keepEkofaatitsleadingpositionin speeds upto180metersperminuteand Wang Haifeng.Thenewmachineachieves countered," saysEkofa'sgeneralmanager effective solutions toeach challenge en- findcost- ability ofB&R'steamtoquickly team. "We impressedbythe weredeeply expertise ofawell-versedengineering Developing aprinterthiscomplextakesthe Expert cooperation well asensuringprintingquality. helps implementcontinuousprintingas reduce waste.Automaticrollchanging callinordertosavetimeandcan easily can bestoredinrecipes,whichoperators (roller size,pressureandtemperature) Sets ofprocessconfigurationparameters byreducingtheriskofdeviation. efficiency gister process quickly. It alsoimproves are important. tion taskwhereefficiency, ROIandhighavailability ACOPOSmulti is a universal solution for any automa- Beyond itsimpressivetechnicalspecifications,the expertise. encapsulate andexpandtheir mation StudioallowsEkofato of customizedmachines. Auto efficient long-termdevelopment objects andisessentialtothe platform integratesalltasksand tion forsmartdevelopment.The Automation Studioisthefounda- cover story interviewreport - 35 36 ly cost-effective. cost-effective. ly reliablebutalsoextreme- type offoil–makingtheprocess notonly anymetallictonebyoverprintingasingle tem cancreatevirtually ing, andevensuitableforthin-walled glass.Theinlinefoilingsys- easiertousethanconventional hotstamp- makes itconsiderably glass orplasticcontainerswithout excessive pressure orheat.This metallic coatingsto inline foilingprocessmakesitpossibletoapply with flexoprintinganditspatent-pendinginlinefoilingprocess. The for the first time – the ability to combine familiar screen printing introduced R-series, Isimat offers its customers – With its recently with metalliceffect Glass decoration Inline foiling cover story interviewreport ACOPOSmotor hasintroducedwholenewlevelsofmodularity, flexibilityandavailability. B&R technology. ThecombinationofPOWERLINKanddistributedcomponentssuchasthe With thenewseries,Ismatisalsointroducingadriveandcontrolarchitecturebasedon portfolio. Thenewseriesofrotaryprintersalsooffersinlinefoilingforglassandplasticbottles. Isimat –printingspecialistforglassandplasticcontainershasaddedanewmachinetoits less than90minutes.“ takes over toawholenewproduct with different design generally explains area sales manager Robert Kovačević. “Even changing module ontheR-seriesinamatter ofminuteswithoutanytools,” handled bysemiskilledworkers.“You canexchangeaprinting print job.Exchangingtheprintingmodulesiseasyenoughto be printing, flexoandinlinefoilingmodulestomeettheneedsof any eight printingstationsallowforacustomconstellationofscreen The RF-8isthefirstofIsimat’snewR-seriestohitmarket. Its Product changeoverinunder90minutes

Photo © Isimat The new R-series printers from Isimat combine screen printing, flexography and foiling to beautifully decorate glass surfaces

03.16 cover story interview report 37 The RF-8 features a fully modular construction based on B&R technology, accommodating up to eight exchangeable printing units on a very small footprint.

These fast setup times are only possible thanks to the machine’s POWERLINK can be distributed via remote IP67 connection boxes complete modularity and automation of the setup process in the outside the cabinet. This approach further simplifies installation control software. The foundation for this was laid by a complete re- and commissioning, facilitates the modular design and accelerates vamp of the drive and control architecture based on B&R technology. product changeover. It’s more than just the flexible cabling that makes POWERLINK so helpful during commissioning, however. “Prior Compact performance: ACOPOSmotor to the B&R solution, we had to set the addresses of networked A key element of the new architecture is the ACOPOSmotor. This components using jumpers on each of the connectors – a tedious servo motor with an integrated inverter is designed specifically for job that was prone to errors,” explains Fuchsloch. “On top of that, applications that demand distributed drive solutions in limited we had to implement the evaluation logic in the program ourselves. space. On the RF-8, these conditions apply to nearly every machine In a POWERLINK line topology, node number assignment occurs au- component, including the printing units and the rotary table – which tomatically without any help from the control application.” is why some configurations feature more than 60 ACOPOSmotor modules. The printing modules alone are each equipped with up to Plug-and-play printing modules three ACOPOSmotor modules, which allow the screen printing With Isimat’s new drive and control solution, it’s not just POWER- module, for example, to print even non-cylindrical items with Isi- LINK bus nodes that are detected automatically. The control appli- mat’s preferred straight screen. The outgoing POWERLINK bus con- cation also identifies newly added printing modules and handles nection on the ACOPOSmotor can be used to connect additional all the necessary configurations automatically. This makes it sig- components, such as B&R’s IP67-rated I/O modules or a stepper nificantly faster to train new operators. “What made this possible motor to give the printing modules an additional axis for adjust- was the openness and flexibility of B&R’s software,” says Fuchs- ment. “This feature allows us to build and test the RF-8 as an au- loch. “In face, that was one of the main reasons we chose B&R.” Of tonomous production unit,” says Isimat’s chief electrical engineer, particular value to Isimat is that the B&R software solution allows Norbert Fuchsloch. “That simplifies diagnostics and drastically them to encapsulate the software in components that mirror the accelerates installation and commissioning.” modular design of the machine. As Fuchsloch explains: “The Auto- mation Studio development environment allows us to program in a Minimal cabling high-level language. Object-orientated programming is ideal for The printing modules are connected to the drive system using a modular machinery and makes the software more readable.” single hybrid cable that includes all the power (DC bus) and signal lines, as well as the POWERLINK communication network. While the One software project – many machines

power modules are located in the control cabinet, the DC bus and No less important for Isimat: the software is also easier to create Photos © Isimat, Franz Rossmann

38 cover story interview report The rotary table on the RF-8 20 is equipped with 20 compact ACOPOSmotor The outgoing POWERLINK connection on the ACOPOSmotor can be used to con- modules that rotate the printed item in sync with the printing units. nect I/O modules from B&R’s X67 system. This allows Isimat to build and test its printers as autonomous production units.

A safe investment in the future Fuchsloch already has his sights on new developments that will bring additional savings. “Our next project will be to revamp our Norbert Fuchsloch safety solution with B&R’s integrated safety technology.” The Chief Electrical Engineer, Isimat GmbH ACOPOSmotor is sure to play a key role here, too, with its integrated STO (Safe Torque Off) and SLS (Safely Limited Speed) func- ”The countless tool and configuration options offered tions. “We found that B&R offers a total package that just per- by the RF-8 need to be represented in the software, forms flawlessly and harmoniously across the board,” concludes which we then have to maintain. That’s why it was so Fuchsloch. crucial for us that the B&R system allows us to manage all of these variants in a single software project.“

and maintain. “The countless tool and configuration options offered by the RF-8 need to be represented in the software, which we then have to maintain,” explains Fuchsloch. The modular printing stations alone result in thousands of possible combinations. “That’s why it was so crucial for us that the B&R system allows us to manage all of these variants in a single software project, so that any maintenance only has to be done in one place.” This approach has proven itself so reliable and flexible that Isimat is al-

ready working together with B&R experts to expand the control The control application automatically recognizes which printing module is in- application for the company’s T-series printers, which are used for stalled at each of the eight stations on the RF-8. This makes it significantly

03.16 cover story interview report 39 Gravure printing Beyond accuracy Photo: iStock

40 cover story interview report Shaanxi Beiren is one of China's largest manufacturers of gravure presses for flexible packaging, decorative paper, tobacco products and printing. To ensure that its control technology is equally advanced, Shaanxi Beiren has cooperated with B&R since 2003 to develop integrated register control and shaftless drive technology.

The flexible packaging, printing and tobacco problem with integrated compensation industries have a strong need for high- technology that lowers jitter and improves quality gravure printing. As a pioneer in this accuracy. field, Shaanxi Beiren knows that its customers' expectations are rising – and their Together with an EnDat encoder, this gives requirements are growing more dynamic. the machine the accuracy it needs for Staying at the technological forefront is high-quality printing. Testing of the com- essential to winning customers' trust, so pleted machines in 2014 proved the effec- lean production, efficiency and quality are tiveness of this technology – with good a constant pursuit. transmission even at speeds of 400 to 450 meters per minute. Direct drive as the foundation for accuracy At the end of 2003, Shaanxi Beiren began development of the new SY400 machine, with the goal of achieving higher efficiency and quality with a speed of 400 meters per minute. The mechanical transmission, electric drive and control presented a great challenge. When the Shaanxi Beiren technical team began conceptual design for the project, it was immediately clear that a direct drive solution would be the best choice.

Since direct drive motors provide low speed and high torque, it is possible to control The modular drives in B&R's ACOPOSmulti family offer rollers without a deceleration mechanism. maximum flexibility and return on investment. Having fewer mechanical components not only simplifies machine design but also reduces the risk of downtime. The direct Dedicated module for dedicated application drive solution reduces the footprint of the High-precision drive technology is a solid machine as well as its price tag. basis for printing quality, but it is not enough. The truly decisive factor in printing Often, the trouble with direct drive motors accuracy is register control. For many years, is that the low speeds result in what's Shaanxi Beiren has cooperated with B&R known as the slot effect. When the rotor on an integrated register control system passes the slot it produces jitter that can that has proven highly competitive on the

Photo: iStock reduce transmission accuracy. B&R's ACOPOS market. Shaanxi Beiren's engineers also servo drives, however, easily eliminate this wanted to improve the ability to capture

03.16 cover story interview report 41 42 full rangeofcolors. forhigh-quality printingacrossthe silver weak colorssuchaslightyellow, whiteand of module allowsdetectionand analysis With theirexcellentsampling,the newX67 system, allonasingleplatform. network, drivesystemandmastercontrol achieved bysynchronizingthePOWERLINK control withmicrosecondcycletimesis more accurately. High-precisionregister lation calculationstocollect offset signals and it can achieve 1 microsecond interpo- printing speedsof600metersperminute, sampling timeof5microsecondssupports color processingintheprintingindustry. Its into play. for Itwasdevelopedspecifically This iswhereB&R'snewX67modulecomes tomers' mostdemandingrequirements. weak colormarksinordertomeetitscus- cover story interviewreport control with minimal waste. control withminimal waste. control library, itiseasytoachieve precise printing speeds. With B&R's temperature accommodate differentinks,materials and adjustedsystem canbeintelligently to the hotairintowaterfor reuse. This ne usesheatexchange,whichconverts utilized.Thenewmachi- but noteffectively meant thatthehotaircouldberecycled previous solutionusedhotairdrying,which nel isdesignedforenergysavings.The saving optimizations. Thenewdryingtun- energy- The new press features a variety of Energy-saving design ficient synchronization. space. APOWERLINKinterfaceensuresef- tection simplifywiringandsavecabinet M12 connectionswithahighdegreeofpro- onthemachine.M8or mounted directly With itsIP67rating,themodulecanalsobe dedicated service report provides informa- registration errormonitoringin realtime.A perform auto-zeroing,platecorrection and At thesametime,machine canalso fast proofingandtoavoidmaterial waste. For neworders,thismakesiteasy toachieve of eachprintingplate. cluding offsetcompensationandthephase configure printingprocessparametersin- for recipemanagement,userstheycan important feature.Withaflexibleinterface For operators, recipe management is an usability. and B&Rthereforeputalotofeffortinto ted. EngineersfrombothShaanxiBeiren something thatshouldn'tbeunderestima- to use,andthecostoftrainingoperatorsis Complex machinescanbequitedaunting Easy touseforendusers

Photos: Shaanxi Beiren, B&R Photos: Shaanxi Beiren, B&R new industrial design –anoveltyonthe ne madeastunningdebutshowing offits In November2015,thenewprinting machi- Stunning debut tant factories. package allowsimmediateaccesstodis- aremotemaintenance system. Additionally to diagnose I/Os, wiring and even the drive based diagnostics,whichmakeitveryeasy printing solutioncomeswithbuilt-inweb- the I/Oandelectricalsystems.TheB&R that makeiteasiertorundiagnosticson hand, aremoreconcernedaboutfeatures Electrical servicetechnicians,ontheother ment predictivemaintenance. addedinthefuturetoimple- be directly so avibrationmonitoringsolutionthatcan dicate necessary service tasks. There is al- tion forthemechanicalserviceteamtoin- 03.16 ting solutionbased onleanproduction."In nagement system forafactory-level prin- they areplanningafactoryoperation ma- its paceofinnovation.Together withB&R, chine, ShaanxiBeirenhasnoplans toslow Yet, evenwith the successofitsnewma- ting costs." high efficiency, highqualityandlowopera- onthismachinefor customers canrely Beiren's chief engineer, Xue Zhicheng."Our industry benchmark here," says Shaanxi previous generation. "We've created anew liable withalowerrejectionratethanthe meters per minute, it is still stable and re- Chinese market. Even operating up to 400 is versatileandeasytouse. The X20controlandI/Osystem port inpursuitof thesegoals." standards willprovideuswithexcellent sup- software incompliancewith international Beiren. "B&R'sopenplatformand hardware/ says LiYanfeng, general managerofShaanxi that helpsthemmeettheirmarket needs," nalized, moreintelligentproductionsystem want to provideourcustomersa more perso- line with the principles of Industry 4.0, we cover story interviewreport 43