Winder And Rewinder Control System Of Shaftless Drive Gravure Printer Design And Application

In the unit gravure printing control system,rewinder and unwinder systems are important parts,which face two major challenges in control:one is tension control,and the other is precise control of cutting material tail while changing wind.Tension control is very important,which directly affects the accuracy of register color system.At present,high-grade gravure printer adopts double-station non-stop rewinding mode,which can easily cause tension fluctuation,and has uncontrollable tail cutting when changing the roll,which affects the subsequent color registration hence leads to too much waste.Therefore,it is of great significance to develop a control system for gravure printer with strong anti-interference ability and minimum waste production.Firstly,this paper analyzes the multi-stage control of the tension system of the gravure printer,and divides it into two tension control areas according to the different functions and control modes.A control system for rewinder and unwinder of gravure printing is designed.Direct tension control is adopted for the closed-loop control.The pendulum roller is selected as the tension detection device.The rewinder and unwinder drive mechanism is driven by motor to realize double working position rewinding and unwinding.Secondly,the tail-cutting problem and the current cutting methods are analyzed.The tension system of gravure printer is nonlinear and strong coupling with strong interference and varying parameters.Especially during rewinding and unwinding,the conventional control strategy is difficult to guarantee the dynamic performance of the printing process.Based on the idea of "control error with error"in PID control,this paper adopts the ADRC as the system control algorithm,and in view of the limitations of the nonlinear ADRC itself and the limitations of field debugging conditions,finally selects the linear ADRC algorithm with fewer parameters,which is easy to adjust and more suitable for industrial application.Thirdly,the calculation method of winding diameter during operation is improved,the nonlinear controlling strategy of winding taper is designed,to optimize the tension control performance.The minimum waste control with controllable cutting tail is designed,which can control the pressing distance of the roller and the length of the cutting tail,reduce the overprinting error effectively.The simulation system is built on Automation Studio platform for verification.The results show that the designed control algorithms and control strategies have fast response and less overshoot,improve the stability especially under disturbance and time-varying parameters.This is particularly suitable for gravure printing tension control system that has many interferences and time-varying parameters.In this paper,a hardware system based on POWERLINK control bus is built with the high performance controller PPC of B&R,and the master and slave stations of the gravure printer control system are designed.According to production process of the gravure printing machine,the software is built.The designed control strategy is applied in field,and the final field results show that in the stable operation and feeding process of the gravure printer,the control precision and stability of the system are improved,and the overprinting error can be effectively reduced in the process of rewinding.