Wallpaper is a high-tech product with the concept of green environmental protection, pay attention to environmental protection, use a variety of materials, with different artistic effects, consumers can choose their favorite style according to personal preferences. With the continuous development of China's economy and society and the continuous improvement of people's living standards, the use of wallpaper is becoming more and more extensive, and the amount of wallpaper is also increasing. The wallpaper market is extremely hot.
1. Equipment structure and process of wallpaper printing machine
The printing of wallpaper is mainly divided into two categories: gravure printing and rotary screen printing, and the two processes have their own merits. Gravure wallpaper is characterized by uniform inking, strong layering, and high printing accuracy; Rotary screen printing is characterized by a large amount of sizing, which prints PVC slurries of different colors and formulas onto the paper base, and then foams them in the oven to make these slurries foam into products with different heights, strong three-dimensional sense and soft feel. At present, the gravure printing machine or rotary screen printing machine on the market can no longer meet the production needs, and it has begun to be gradually replaced by the increasingly mature rotary screen gravure integrated wallpaper printing machine.
The process of rotary screen gravure integrated wallpaper printing machine equipment is roughly as follows:
Double-station unwinding→ ironing mechanism→ printing group unit (rotary screen and gravure), → (bedroom oven →embossing machine) or double-station winding
Note: At present, the round and concave integrated wallpaper printing machine on the market is generally in the case of an embossing machine, and there will no longer be a double-station winding behind it, but it will be replaced by a large roll or a small roll; In the absence of embossing machines, there will be double-station winding, because larger printing factories generally have a separate embossing production line, and smaller printing factories will install embossing machines on the wallpaper production line.
● Station unwinding: It is composed of a double-station unwinding frame and an input traction part, and the unwinding shaft adopts an air expansion shaft and a magnetic particle brake, equipped with magnetic particle tension detection and tension controller, which controls the unwinding tension and has the function of non-stop paper splicing.
● Ironing mechanism: It is composed of three internal hollow steel rollers filled with hot grease, and the diameters of these three steel rollers have a certain difference, and their main function is to press the flat roller tightly under the action of tension, and make the paper smooth under the thermal action of boiling oil.
● Printing group unit: The printing group unit includes gravure roller, rotary screen roller, vertical oven and cold water roller. Gravure rollers are generally carved on steel rollers by laser engraving, and gravure printing is a direct printing method that imprints the ink contained in the gravure pits directly onto the substrate. Rotary screen is made of nickel metal, also known as nickel mesh, hexagonal mesh, rotary screen printing is a printing method that uses a scraper to make the color paste in the rotary screen printed onto the fabric under the pressure drive. A vertical oven consists of an oven body, an axial fan and a burner. When the natural gas enters the burner, the air in the oven box will be heated, and under the action of the axial fan, the hot air will be evenly blown in the vertical oven, so that the wallpaper will be dried very evenly. The inside of the cold water roller filled with circulating condensate is a hollow steel roller, which is used to quickly cool down the wallpaper dried in the vertical oven to enter the next color group printing.
● Horizontal oven: its composition is the same as that of vertical oven, but it is shorter and longer than vertical oven, and its function is for rotary screen printing foaming.
● Embossing machine: It is composed of embossing roller and four-cylinder cooling mechanism, and its function is to make the wallpaper printing pattern foam at high temperature in the horizontal baking, which can form a three-dimensional wallpaper with uneven patterns. The function of the embossing machine is to use the embossing roller to press on the convex pattern to make it more three-dimensional.
● Double-station winding: The winding section adopts a double-station rotary receiving rack and an air expansion shaft for rewinding, and is equipped with a pendulum roller full closed-loop tension control system to control the winding tension, and the tension adjustment is set by a precision pressure regulator and performed by a low-friction cylinder.
Wallpaper production process:
Base paper is sent→ coated→ dried (gelatinized→), cooled→ printing, → → softened by heating→ embossed→ cooled→ trimming→ storage, inspection→ coiling→ packing → warehousing
2. Lenze automation system solutions
Lenze proposes an automation control system with the central motion controller 3200 C as the core. The perfect combination of a separate HMI p300 controller at the display level and I/O 1000 and 3200 C at the control level performs all logic control. The innovative i700 servo drive with its compactness and high flexibility and the compact, dynamically responsive MCS and MCA motors with pluggable link design on the drive level enable high-precision motion control functions to be implemented more reliably. The 3200 C motion control system based on the motion controller can provide more perfect control for more complex and precise equipment, and can improve the control performance of the equipment to a large extent. The control system adopts the on-board high-performance real-time bus system EtherCAT, whose protocol processing is completely carried out in hardware, and an ultra-high-speed control loop can be formed through the bus, which makes the network performance reach a new level and realizes the control concept that the traditional fieldbus system cannot achieve.
The system takes the 3200 C motion controller as the core, including a number of i700, a 9400, a number of MCS motors, an MCA motor and four asynchronous motors, among which the MCS and MCA motors that follow the virtual axis to synchronize the position respectively realize rotary screen printing, gravure printing, embossing and cold water roll tension adjustment, follow the virtual axis to do speed synchronization MCS motor to achieve full closed-loop tension control of the ironing machine, only use the virtual axis as the speed source, and the four independently controlled asynchronous motors realize winding and unwinding respectively.
Thanks to the excellent performance of the Lenze control system and the perfect cooperation with the customer's machine, the rotary screen gravure integrated wallpaper printing machine can produce gravure up to 100 m/min, rotary screen up to 80 m/min, and the overprint accuracy can reach 0.15 mm without registration.
3. Advantages of the solution
● i700 has the characteristics of small installation size, power supply through DC busbar, automatic download of parameters, firmware through the control system, pluggable connection technology, etc., which can save a lot of installation space for customers, improve the efficiency of power supply, more easily realize parameter modification and firmware upgrade, and bring more convenience to replacement and maintenance.
● The control system is equipped with EtherCAT, which makes the performance of the control network reach a new height and greatly improves the performance of the equipment.
● Equipped with Intel® Atom™ 1.6 GHz high-performance 3231C processor, battery-free and fanless design, ensuring that the device does not need to be maintained. In addition, the device is designed with a removable memory card for easy replacement.
● PLC Designer-based L_TT1A_Technology Modules develop special function blocks for specific applications, for example, there are Dancer-Controlled Winder Technology Module, Tension-Controlled Technology Module, For cam control, such as the FlexCAM Technology Module, Lenze has incorporated many years of industry application experience into it, making specific controls more professional, easier to operate, and significantly reducing the amount of programming work.
● Use the technical module Application Template PackML template based on PLC Desinger programming software.
● It takes 20% of the time to complete 80% of the work, which saves a lot of time for the customer's machine to be listed.
The war of Industry 4.0 has been ignited, and industrial automation control is the core, I believe that Lenze will create an automated control system with better performance with its excellent motion controller, perfect drive, and unparalleled reducer, and contribute to the fourth industrial revolution.
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