Labeling and grouping unit in a packaging line for toothbrushes
Koch Pac-Systeme, Germany
Companies in the printing industry face challenging conditions, with customers requiring the highest print quality, customizability, short production times, and small batch sizes. This makes it all the more important to have intelligently automated, highly flexible systems for digital, 3D, and packaging printing. As a printing press manufacturer, you can develop these systems efficiently and scalably with the help of PC- and EtherCAT-based control technology from Beckhoff. We also offer a central software platform for engineering, runtime, and diagnostics in the form of TwinCAT, which will allow you to implement all processes and functions in a seamlessly networked and future-proof manner.
How you benefit from PC-based control in the printing industry:
- one platform, all control functions – PLC, motion control, robotics, HMI, image processing, safety and measurement technology, and IoT integration
- precise automation – with modular, precisely scalable components
- high compatibility – due to open interfaces for problem-free integration into established production environments, also ideal for implementing retrofit concepts
- simple engineering – via TwinCAT as central automation software
Efficiency from A to Z: Automation solutions for the printing industry
Our technologies for your printing press
Integrated and flexible for fast-changing print jobs
Machines and systems for the printing industry are expected to enable efficient production processes – with short processing times and easy handling even in the case of frequently changing print jobs, short runs, or personalized print products in a lot size of one. PC-based control is the perfect solution in this regard.
The automation platform enables end-to-end control of the entire process chain: from digital image creation to final inspection. All of the functions are mapped in software, eliminating the need for time-consuming retooling and changes to the hardware. The control processes are easily scalable and open to ever-evolving requirements.
How you benefit from PC-based control:
- High flexibility: Due to consistently software-based control and fundamentally modular machine and system concepts.
- Process efficiency: With a reduced number of interfaces between prepress and machine control and increased printing speeds.
- Future-proof: PC-based control is technology-agnostic and ready for integration into IT and cloud environments.
The global standard for real-time signal transmission
The EtherCAT system bus developed by Beckhoff in 2003 has become the global standard in the printing industry. With short cycle times, ultra-fast signal transmission, and synchronization precision in the nanosecond range, EtherCAT guarantees consistent print quality at the highest level.
Another high-performance technology is eXtreme Fast Control (XFC). In combination with EtherCAT, XFC synchronizes the control processes for printing presses and systems within microseconds. This makes it possible to achieve levels of accuracy that ensure a precise printing image, even for the most demanding jobs.
How you benefit from EtherCAT:
- Maximum precision: All processes in the machine or system are precisely coordinated with the help of XFC. For a top-quality printing image.
- Maximum output: Through the combination of short cycle times with PC-based control and synchronization in the nanosecond range with EtherCAT.
- Secure investment: EtherCAT is constantly being further developed and is also established as an open standard in many third-party solutions.
One platform for all requirements in the printing industry
With TwinCAT, printing press manufacturers benefit from a central software ecosystem with runtime systems for the real-time execution of PLC, NC, or robotics applications. The software bundles all functionalities into one package: from motion control and HMI to image processing, safety and measurement technology, cloud communication, IoT integration, and analytics.
TwinCAT also offers various connectivity modules which support communication from the sensor to the cloud, ERP systems, or other IT structures. MQTT or http/HTTPS communication can be used to access databases or integrate 3D printers into cloud systems just as easily.
How you benefit from TwinCAT:
- Compatibility: TwinCAT stands for efficient machine-to-machine communication and supports protocols such as OPC UA, EtherCAT, Modbus, TCP/IP, PROFINET, and many more.
- Functionality: With a large choice of librariesand modules, TwinCAT offers solutions for all requirements in the printing industry.
- Openness: TwinCAT allows easy integration of database systems.
Our product highlights for your printing press
Machine vision for modern printing processes
In the printing industry, machine vision is a key technology for process reliability and reproducible print quality. With TwinCAT Vision, you can seamlessly integrate real-time machine vision into your control environment – in both new and existing systems. Regardless of whether you are looking for targeted monitoring of web guiding and register control or the integration of a complete inline inspection system, the vision portfolio from Beckhoff offers you tailor-made complete solutions comprising hardware and software. This makes the traditional separation of vision and automation technology a thing of the past.
How you benefit from Beckhoff machine vision:
- machine vision and control are synchronized and linked precisely
- increased output with consistently high print quality
- robust vision hardware for continuous operation
- scalable complete solutions comprising software and hardware
Control cabinet-free automation
The printing industry needs highly flexible modular machines with a small footprint. This is where the MX-System comes in – it enables control cabinet-free automation solutions for printing and finishing systems, saving resources and creating space for innovation.
The MX-System consists of a baseplate in the machine and function modules that are simply attached to the baseplate and screwed into place. The individually configured combination fulfills all the tasks of a control cabinet: power supply, fuse protection and distribution, sequence control, control of motors and actuators, as well as the field-side integration of all components. The internationally certified assemblies significantly reduce the time and effort required for planning, assembly, installation, and service.
How you benefit from the MX-System:
- exact scalability for individual printing production requirements
- modular, flexible design to save on installation space
- diagnostics integrated into each module for high machine availability
- IP67 protection rating for demanding production environments
- reduced work for engineering, installation, commissioning, and maintenance
Distributed drive solutions for printing presses
In terms of drive technology, there is hardly a more demanding application than the printing industry. Its machines – whether they are for offset or digital printing – are often equipped with over 100 rotating, positioning, or lifting axes. Distributed, control cabinet-free drive concepts from Beckhoff are ideal for this purpose, as they significantly reduce space requirements and costs: Both with regard to design and engineering and when it comes to maintenance and service. This is because the compact, distributed drives combine a motor and servo drive in one housing, are supplied with power and data via EtherCAT P, and integrate the technology into the machine. This allows highly dynamic web control, fast positioning movements, or complex winding processes to be implemented effectively.
In combination with TwinCAT CNC, the drives also demonstrate their full strengths in 3D printing applications.
Advantages at a glance:
- less space and hardware required due to control cabinet-free integration
- integrated TwinSAFE functionality without additional safety hardware
- quick installation due to standardized cables and plug-in systems
- space-saving designs and flexible machine topologies
Robust inline measurement for consistently high quality
Reliable web tension detection and control is crucial for consistent quality in both digital and offset printing. The EP3356-0022 EtherCAT Box enables both directly on the machine – even in damp and dusty environments. The box module is designed in accordance with protection class IP67 and obtains data from force measuring rollers or strain gauge cells. 24-bit resolution and sampling rates of up to 100 µs guarantee fast and highly precise signal evaluation.
The box module is seamlessly integrated into the I/O system via EtherCAT and is easy to install. Its robust design and reliable signal processing reduce effort and increase process reliability.
Advantages at a glance:
- compact, robust data logging for the web tension
- 24-bit resolution
- two measuring channels in one box module
- alternatively available as EL3356 for the control cabinet
EtherCAT measurement terminals from the ELM series
Up-to-date machine and process data is essential for the efficient control of modern printing presses. The EtherCAT measurement terminals provide a suitable portfolio for this purpose: The terminals in the ELM series collect and process analog measurement and test data with maximum precision. The measuring accuracy is in the range of 100 ppm, which means maximum deviations of just 0.01 percent.
In combination with innovative software libraries such as TwinCAT Analytics, you can implement comprehensive monitoring of machine states. This makes it possible, for example, to monitor the print head at any time and from any location for predictive maintenance, thus reducing machine downtimes in the long term.
Advantages at a glance:
- precise, fast, and robust terminals for all DAQ applications
- high measuring accuracy of ±0.01% (100 ppm)
- plug-compatible with standard EtherCAT Terminals; measurement terminals can be integrated into one and the same terminal segment
- durable and well protected due to sturdy metal housing
Beckhoff solutions for innovative printing processes
TwinCAT CNC: All-in-one platform for industrial 3D printing
Additive manufacturing using 3D printing is becoming the process of choice for more and more manufacturers, especially for small quantities. This requires a control solution that guarantees maximum flexibility, high process speeds, and consistent quality, such as TwinCAT CNC. The all-in-one solution for engineering modern 3D printing systems supports all CNC functions. State-of-the-art control algorithms ensure highly synchronized movements.
Open interfaces such as TcCOM allow you to integrate your own process logic. Suitable drive solutions can be found in our portfolio too: The spectrum ranges from servo terminals and motors with integrated servo drives to high-performance servo drives.
Advantages at a glance:
- all-in-one software platform for highly precise CNC machining
- open, modular I/O system for maximum flexibility
- scalable drive technology for every performance requirement
PC-based control for high-throughput digital printing presses
Digital printing is developing from a former niche segment into the printing technology of the future. The process, known as non-impact printing (NIP), does not require a static printing form and offers maximum flexibility, a wide range of variants, and cost-effective production. Whether it is commercial sheetfed or web printing, label production, or packaging printing: Digital printing is suitable for a wide variety of materials and geometries, but requires open and high-performance control technology. With PC-based control, we can provide you with this technology for the entire process chain: from digital image processing to the finished product.
Advantages at a glance:
- higher process efficiency due to fewer interfaces
- maximum print quality due to precise synchronization of all printing processes
- increased availability through effective diagnostics, predictive maintenance, and machine learning
- cycle times in the µs range for innovative machine concepts and maximum performance
Precision and flexibility for a strong first impression
Packaging printingrequires high-quality printing images, along with sustainability and flexibility for rapid product changes. At the same time, cost pressure is increasing. The requirements also vary depending on the industry: Pharmaceutical customers expect maximum traceability, while short production cycles are important in the food and consumer markets. Personalized designs, frequent format changes, and the rapid introduction of new products require flexible machine control.
You can lay the foundation for this with PC-based control from Beckhoff. The modular and scalable platform combines all control processes for packaging printing in an integrated architecture, increases the economic efficiency of the printing systems, and strengthens your competitiveness.
Advantages at a glance:
- complete integration of vision and measurement technology for higher print quality
- software-based format changes minimize changeover times
- EtherCAT and XFC from Beckhoff enable maximum synchronization in the printing process
- open interfaces and support for industry standards such as PackML