Fully Servo Satellite Flexographic Printing Machine

Central Impression Cylinder

Central Impression Cylinder

■ The central impression cylinder's direct-drive motor achieves 1:1 torque coupling with the cylinder, eliminating color registration errors caused by:

· Gear backlash (conventional systems: 0.08-0.12mm)

· Belt elasticity deformation (≥0.15% transmission error)

■ In response to the operation problem of printing equipment under continuous high-load conditions, a water-cooled constant temperature module is installed on the central roller motor. Through the integration of a closed-loop liquid cooling circulation system, efficient thermal management is achieved. This scheme uses coolant as the medium and combines fluid dynamics design with intelligent temperature control technology to ensure that the operating temperature of the motor remains stable within the safety threshold, thereby enhancing the reliability and service life of the equipment.

■ Dual-layer water-cooled temperature control design

· Hard chrome-plated surface (HRc59-62)

· Field-repairable surface damage (localized restoration)

· Rotary union for cooling connections

■ Pneumatic emergency brake system

This maintains all original specifications in a clean, industry-standard format. Let me know if you'd like any adjustments.

■ Pneumatic nip roller assembly (1 set)

■ Ultra-high resolution encoder

· Resolution: 36,000 pulses/revolution

· Accuracy: ±2 arc-seconds (with interpolation)

· Application: Nano-level precision positioning

Plate Cylinder Drive System

Plate Cylinder Drive System

■ High-power servo direct drive with 1:1 torque coupling between motor and plate cylinder

Eliminates registration errors caused by:

· Gear backlash

· Belt elasticity deformation

■Intelligent Pneumatic Sleeve Ejection System for Plate Cylinders:

During plate-changing operations, a single touch triggers the automatic precision ejection of the plate cylinder to the operator-side workstation, eliminating the traditional manual pulling process. This significantly enhances changeover efficiency, enabling swift and effortless plate replacement.

· 80% reduction in manual intervention

· 70% reduction in operator labor intensity

· Over 50% faster sleeve changeover time

Equipped with multi-layered safety mechanisms (photoelectric sensors + emergency stop devices), the system not only boosts efficiency but also prevents human errors and eliminates traditional safety risks during plate changes, setting a benchmark for intelligent printing equipment upgrades.

Additional Features:

· Includes sleeve mounting/dismounting aids to prevent plate damage during replacement.

■Plate Cylinder Printing Pressure System:

· Servo Motor Adjustment:

· Utilizes high-precision, heavy-duty linear roller guides and ball screws (machine-tool grade).

· Servo Drive System:

o High-performance servo motor with precision reducer (1:1 ratio)

o Absolute encoder for digital pressure position memory and closed-loop control

o Repeat positioning accuracy: ±0.005mm

o Precision transmission mechanism with 4 sets of ground-grade ball screw assemblies

o Preload backlash elimination design

o Linear guideway guidance system

■Intelligent Sleeve Change System:

o One-touch quick sleeve change function

o Automatic separation mechanism synchronizes anilox/plate cylinder retraction

o Position memory and auto-reset during sleeve changes

System Advantages:

1. Modular design enhances maintenance efficiency

2. Digital pressure control replaces mechanical adjustment, minimizing manual intervention

3. Dynamic pressure compensation ensures print stability (including high-speed compensation)

4. HMI interface stores/recalls process parameters (saves printing recipes for instant reuse)

5. Pre-pressure adjustment:

· Input parameters on the main control screen → servo motor auto-positions to theoretical pressure

· Only minor manual fine-tuning required

■Structural Innovations:

· Dual-support sleeve mandrel bearing seats for:

o Enhanced pressure stability

o Reduced vibration

■Servo motor-driven for transverse adjustment (±8mm range).

■Steel-constructed plate cylinder sleeve mandrel，Integrated pneumatic lifting device for assisted sleeve replacement operations

■Cylinder-actuated mandrel closure – eliminates manual bearing block handling; button-activated operation.

■All bearings feature grease injection nipples for streamlined lubrication

Anilox Roller Drive Structure

Anilox Roller Drive Structure

Anilox Roller Sleeve Intelligent Pneumatic Ejection System

■Core Innovation:

· One-Touch Automated Sleeve Change

o Single-button operation precisely ejects anilox roller sleeve to operator station

o Eliminates manual pulling - no physical handling required

■Efficiency Gains:

✓ 80% reduction in manual intervention

✓ 70% decrease in operator fatigue

✓ 50% faster sleeve replacement vs traditional methods

■Safety & Precision:

· Multi-protection system:

· ▶ Photoelectric sensors for collision avoidance

· ▶ Emergency stop redundancy

· Zero-error positioning: <0.05mm deviation

· Anti-damage sleeve tools included for scratch-free installation

■Anilox Roller printing pressure

· Servo motor-controlled with industrial-grade heavy-duty linear roller guides & ball screws

· Closed-loop servo drive system featuring:

· ✓ High-performance servo motor + precision reducer (1:1 ratio)

· ✓ Absolute encoder for digital pressure positioning (repeatability: ±0.005mm)

· ✓ 4 sets of precision-ground ball screw assemblies

· ✓ Preload anti-backlash structure

· ✓ Linear guideway alignment system

Intelligent Sleeve Change Technology

· One-touch automated sleeve exchange

· Synchronized anilox/plate cylinder retraction via auto-separation mechanism

· Position memory & auto-reset function

System Advantages

1. 1. Modular design reduces maintenance time by 40%

2. 2. Digital pressure control replaces mechanical adjustment (manual input ↓90%)

3. 3. Dynamic pressure compensation ensures stability at speeds up to 800m/min

4. 4. HMI recipe management stores 200+ printing parameter sets

5. 5. Pre-pressure positioning:

· Servo auto-positions to theoretical pressure (manual fine-tuning ≤5%)

· Dual-support mandrel bearing seats:

· ▶ 30% vibration reduction vs single-support designs

· ▶ 15% longer bearing lifespan

· Steel mandrel with pneumatic assist:

· ▶ Zero-touch sleeve handling

· ▶ 3-second cylinder-activated clamping

· Full-bearing lubrication ports for 10,000-hour maintenance intervals

Inking & Automatic Cleaning System

■Inking System Specifications:

· Fully enclosed chambered doctor blade system

o Electric peristaltic ink pumps

o High-hardness anodized components (HV800-1000)

· Mechanical blade clamping system

o Quick-change blade mechanism

o Blade specifications: 35mm×0.3mm & 45mm×0.2mm

o High-temperature resistant rubber ink dams

· Large-capacity ink chamber

o Air venting function

o Splash guards on both sides of anilox roller

· Stainless steel ink pan

o Non-stick coated surface

o Equipped with ball valve

■Aluminum doctor blade holder

■Equipped with splash guards:

· Drive side: Fixed type (permanently installed)

· Operator side: Manually removable for anilox sleeve replacement

■Centralized Ink Delivery System:

8 electric peristaltic pump units for precision ink supply

· Digitally controlled micro-flow adjustment (±0.5% stability)

· Progressive delivery reduces ink shear force by 62% (typical)

· 83% fewer bubbles (lab-verified) vs. pneumatic diaphragm pumps

Technical Benefits:

✓ Eliminates dot gain/ink unevenness from turbulence

✓ Optimized for UV/metallic inks (shear-sensitive fluids)

✓ 30% lower ink waste & maintenance costs

■Automatic Cleaning System

Each printing unit is equipped with an automatic cleaning system consisting of:

· Electric valves

· PLC logic control program

· Pneumatic diaphragm pumps

Operation Process:

1. After printing completion, the operator selects the desired printing unit for cleaning via the operating system

2. Three cleaning intensity levels available:

· Light cleaning

· Medium cleaning

· Heavy cleaning

3. The system sequentially performs:

· Doctor blade cleaning

· Anilox roller cleaning

4. Final step: Operator manually wipes residual moisture from the anilox roller surface

Drying system

■Drying System Configuration:

7 interstation drying units (between color stations)

1 centralized final drying unit

■Oven Structure Specifications

Central Drying Oven:

· Cover operation:

o Operator side: Pneumatic cylinder opening

o Drive side: Hinged design

· Airflow system:

o 45° angled air knife at infeed (creates air curtain)

o 45° angled air knife at outfeed (maintains negative pressure)

o Combined nozzle blowing/perforated suction maintains air pressure balance

· Sealing system:

o Full silicone gasketing

o Continuous sealing strips at all cover contact points

Interstation Drying Ovens:

· Fixed, non-opening structure

· Triple-layer construction:

o Inner layer: 304 stainless steel (fully welded, leak-proof)

o Outer layer: Powder-coated carbon steel

o Insulation layer: Thermal barrier material

■Oven Air Supply/Exhaust Structure

Central Drying Oven Configuration:

· 3 supply air fans

· 1 set of hot air temperature control device

System Features:

· Each oven has 1 exhaust outlet

· Equipped with exhaust air pressure regulating valve

· Independently adjustable negative pressure for each oven

· High-temperature resistant hoses connect:

o Supply air fans to oven

o Exhaust outlets to oven

■The entire hot air supply and exhaust duct system is constructed with 304 stainless steel, externally wrapped with insulation layer.

■The air supply and exhaust system adopts a hot air recycling design, enabling heat energy recovery and reducing heating energy consumption by over 50% (compared to traditional hot air systems).

■All fans feature variable frequency drive (VFD) control, while air dampers utilize electric adjustment. The system enables customized airflow and temperature settings based on printed patterns, with capability to memorize and store parameters and presets.

Pre-registration Operation Sequence:

1.Camera Positioning

Horizontally aligns to registration mark location after startup

2.Automatic Detection

Captures mark images during press operation

Calculates X/Y positional errors between color stations

3.Closed-loop Correction

Transmits error data to PLC via Ethernet

Adjusts servo positions in real-time

4.Iterative Process

Repeats steps 2-3 until:

✓ Lateral error ≤ ±0.1mm

✓ Circumferential error ≤ ±0.15mm

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Configuration

Industrial Camera

• Pixel accuracy: 0.04mm/pixel

• Resolution: 2592×2048 (5MP)

• Field of view: 103.68×81.92mm

Industrial Lens

• High-definition optical lens

• 100mm working distance

Vision Lighting

• High-brightness LED illumination

• Programmable light controller

Industrial Computer

• High-performance industrial PC

• Runs proprietary vision algorithm software

HMI Interface

• 19" touchscreen display

• Interactive operation panel

Software

• Custom-developed vision processing software

• Embedded AI algorithms for:

Automatic mark recognition

Registration error calculation

Configuration

1.Industrial Camera

Line-scan industrial camera with a horizontal resolution of 16,384 pixels.

· Pixel resolution: 0.15 mm, supporting a maximum print width of 2,200 mm.

2.Industrial Lens

· High-definition lens specifically designed for line-scan cameras.

3.Vision Lighting

· Dedicated LED lighting for line-scan cameras, dual-channel for enhanced brightness.

4.Industrial PC (IPC)

· High-performance industrial computer for image acquisition and display.

5.Human-Machine Interface (HMI)

· 85-inch display for full-image visualization, controlled via keyboard and mouse.

6.Software

· Proprietary vision processing software developed in-house.

2. Winding structure

Turret-type Winding with Non-Pneumatic Shaft Core Winding Mode.Four high-power spindle servo motors independently drive the paper cores. Two motors each for A Roll and B Roll,enabling dual-side driving.

Equipped with 4 sets of 6-inch rotary paper head units.

Automatic positioning and clamping of paper material without damaging the core.

Enhances core reusability for improved efficiency.

Paper Head Movement Hydraulically Driven

Hydraulic system enables left/right, synchronized left, and synchronized right movement of paper rolls.

Includes complete hydraulic system.

Dual-Sided Winding Capability

· Equipped with two sets of cutting/splicing knife mechanisms

· Supports forward winding and reverse winding modes (selectable)

Siemens Drive-Based Tension Control System

· Floating roller + linear potentiometer for real-time tension feedback

· Constant tension control with automatic A/B axis switching

· Automatic web tightness adjustment – Simply set the desired tension value for fully automated operation (no manual intervention required)

Turret Rotation System

· Powered by a high-power worm gear reduction motor

· Features built-in safety self-locking function

Cutting & Splicing Unit (1 set)

· Lap splicing method for paper joining

· Automatic cutting and clamping upon completion of preparatory steps

· Equipped with automatic roll change preset function

Pneumatic Paper Press Roll (1 set)

Adjustable Guide Roller (1 set)

3. Roll Unloading Operation

Hydraulic Lifting Shaft Device

· Primary function: Loading/unloading paper rolls without forklifts or additional tools

4. Main Technical Parameters

The maximum roll diameter is 1500mm

The maximum roll changing speed is 300 meters per minute

12-inch HMI (Human-Machine Interface) Control Panel

Infrared Paper Edge Positioner

Supports Three Automatic Roll-Change Modes:

1. Roll-to-Roll (Continuous web transfer)

2. Length-Based (Pre-set meter counting)

3. Diameter-Sensing (Automatic detection of roll diameter)