FAG icmd. Inline Color Measurement Device. Preliminary Datasheet. All rights reserved by Fag Graphic Systems SA This document is preliminary!

FAG_iCMD FAG iCMD Inline Color Measurement Device Preliminary Datasheet ‚All rights reserved by Fag Graphic Systems SA This document is preliminary!...
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FAG_iCMD

FAG iCMD Inline Color Measurement Device Preliminary Datasheet

‚All rights reserved by Fag Graphic Systems SA This document is preliminary!

Status: preliminary 24.07.2003

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Lukas Pescoller

FAG_iCMD

1 Index 1 2 3

4 5 6 7

Index................................................................................................................................... 2 ICMD Market..................................................................................................................... 2 ICMD System..................................................................................................................... 3 3.1 Key items.................................................................................................................... 3 3.2 Customization............................................................................................................. 3 3.3 System modules.......................................................................................................... 3 Datasheet: ........................................................................................................................... 5 4.1 General ....................................................................................................................... 5 4.2 ICMD reliability goals ............................................................................................... 6 System ................................................................................................................................ 8 Availability......................................................................................................................... 8 Contact ............................................................................. Error! Bookmark not defined.

2 iCMD Market The quality needs for the printing process have grown together with the possibility to produce quality. In past and even today there are used hand held densitometers, spectrofotometers or scanning densitometers and scanning spectrofotometers to quantify the actual printing situation in terms of solid density, dot gain, balance, trapping, CIEL*a*b*, CIEL*Ch etc. On one hand a high quality production process nowadays is essential to compete on the printing market, especially on markets with high volume (packaging, labels, high volume commercial printing). On the other hand the improvement of quality reduces costs in terms of wastage, time, image, complaints. Handheld densitometers and spectrofotometers as well as press external scanning devices are a good solution, but they will not be suitable for any situation. The quality control need a person who is taking the readings or operating the scanning device. ICMD is an On-line densitometer and goes beyond handheld and scanning solution due to the following applications: •





Web to Web: A Web to Web printing process does not allow to take measurements with external measurement devices without stopping the press, cutting out a piece of paper and restarting the press. This is a very inefficient way of quality control und the only practicable solution is a On-line Densitometer or Spectrofotometer. Web to folding: The location of colour problems on ink key based presses can not be identified on multi-up jobs after cutting, folding and die-cutting. Therefore the measurements have to be taken somewhere before. Normally it is not possible to get a sheet out of the printing process road on the way without stopping the press. The only possibility is to measure On-Line Sheet fed: Handheld Spectro-densitometers and scanning Spectro-densitometers are basically adequate for the quality control on sheet fed presses. An On-line system like the ICMD could make the quality control more efficient: the operator does not need to walk back and forwards between press and control console to take sheets, more sheets (any) could be measured with an On-line system, the control intervals are shorter, operation errors can be avoided.

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FAG_iCMD Automation takes place in any technical production process and the ICMD is a basic component for the fully automated printing road.

3 iCMD System 3.1 Key items The FLASH2 is a inline Spectrodensitometer designed to be embedded into offset, flexo and gravure presses. • • • • • • • •



iCMD is a complete system with easy hardware and software interface feasible for OEM and upgrade business iCMD has high speed sensors conforming to DIN 16536-2, Ansi Status I, Reflection with polarisation filter, 45°/0° geometry, CMYK Possible press speed > 16m/sec. Easy to enhance to multi color (CMYK+OGB) and spectral sensor (16 filters) Auto trigger and Scanning approach makes the system tolerant to paper shrinkage, motion and stretch on and across the grain High maintainability and serviceability due to modular design, auto configuration, easy mechanical interface and error diagnosis A simple communication Interface (RS422, TCP/IP planned) makes the integration of the iCMD into existing environments easy. iCMD measures control strips with > 4mm with a sophisticated scanning approach, that needs only approx. 30% more sheets than there are patches to be measured per sensor (goal). Example: 4 Patches / Ink key zone, one sensor for two zones requires approx. 12 sheets for a full scan. Competitive price

3.2 Customization FAG offers FLASH2 as a complete system with a simple, well defined mechanical, electrical and communication interface (TCP/IP UDP, RS232). The iCMD System is available in various configurations, customized for different applications • • • •

Number of measurement heads 1..24 / side Face printing or face and back side printing Measurement head type: 4 color Densitometer CMYK (Multi-color densitometer CMYKOGB, Spectrofotometer CIELab planned) Static system (keyless inking systems) or Scanning system (ink key based inking systems)

3.3 System modules The iCMD has a modular design and is composed by modules of the following type. •

The FLASH controller is the unique interface between the iCMD On-line Spectro-densitometer and the operator (PC). A simple set of communication commands allow the setup of a job parameters, i.e. job specific behaviour of the

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FAG_iCMD system like number of control patches per ink key zone, trigger mark configuration, sheet length, etc. The iCMD controller manages the auto configuration, such as there can be removed, added, or replaced one single module (Trigger, Reference head, or densitometer) without the need of external configuration. A simple RESET of the system will auto-configure the system. The auto configuration functionality is essential to enable the customer to replace a faulty module by himself. Errors during configuration can be avoided and the mean time to repair can be reduce. The iCMD controller collects trigger data, the reference data, and the measurement data, evaluates the data, applies a patch recognition and reports sheet number, press speed, cross speed, cross position, and measurement data to the PC. One iCMD controller unit can handle two FLASH lines, face and back printing with up to 24 densitometers each. •

The trigger unit finds the measurement position directly on the print without any angle encoder with an accuracy of 0.1mm on a range of 5xTrigger mark size. This unit makes the iCMD flexible for the mounting position. The flexibility is essential for the upgrade business because there are many different types of presses installed and any press has its optimal measurement position in terms of space, environment parameters, temperature, wet or dry ink, dust etc. The measurement position on the sheet on grain can vary absolutely by the sheet length from job to job and ≤ 2mm during the run of off the press. The trigger mark can be configured and is part of the control strip over the cross motion area of the trigger unit.



The densitometer is a complete unit with 3 ANSI Status I glass interference filters (430nm, 530nm, 610nm, 20nm width each, black calculated by application of the – V-lambda curve), with polarisation filter and a 45°/0° geometry. It is conform to the DIN 16536-2 requirements.



The reference head is manufactured equal to the Densitometer and has a ceramic white plaque mounted as measurement patch. It measures the spectral variations of the flash.



The FLASH unit illuminates via fiber optics the measurement patch triggered by the Trigger unit.



The positioning device is composed by a beam with two suspensions, one driven by a servo motor, one freewheel and a servo motor control device.



Mechanical parts for mounting and alignment. The parts are developed and customized by VIPTONIC and need to guarantee a correct alignment inside the press. The iCMD modules need to be cleaned, replaced etc. by one single operator. The system is mechanically fail save.

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FAG_iCMD The Application Software enables the customer to check the actual press situation and to document the job. It contains the following functions: •

• • •

A Job database containing a simple customer database, job parameters, and job measurement data. The job database interface manages the insertion of reference values and tolerances, the restart of the measurements storage after the setup time, and reports and printouts of measurement data. Visualization of the actual measurements as Density/Ink key (Bar diagram), Statistic/Ink key (Box plots), Trend/Ink key and Table of Density numbers. The software enables the operator to start and stop the measurement process The software receives System Warnings and Errors and displays warnings to the operator and offers functions (as far as possible) to react on these warnings.

4 Datasheet: 4.1 General Environment Trigger mark on print

Measurement subject

Parameter configurable 3 lines ≥ 0.2mm each white spaces ≥ 0.2mm part of control strip Control strip ≥ 4 mm Patch hight ≥ 2.6mm Patch width ≥ 4mm Constant patch width

Comment Example:

4mm brutto including white space before and after the control strip One patch / Densitometer is paper white for relative density measurements.

Ink key based presses

≤24 densitometers / side One densitometer for max. 90mm zone with configurable (1,2 or 3 zones depending on real zone width) flexible mounting of densitometers densitometer width = 29.6mm

Short inking presses Sheet width

… Configurable ≥ 500mm ≤ 1200mm Configurable in 0.05mm ≥ 600mm ≤ 1300mm

Sheet length Number of patches / zone Substrate type Substrate thickness Status: preliminary 24.07.2003

Min(8, Zone width / 4) Offset papers, Flexo substrates Gravure substrates 0,025..0.15mm 5/5

Number of Densitometers and space between two densitometers Max. measurement speed of 20Hz could require an empty sheet between two measurements Patch width ≥ 4mm

Lukas Pescoller

FAG_iCMD Distance Sensor/Substrate Distance variation due to unround web Stretch, shrinkage of paper across the grain Paper motion, Strech, shrinkage on job start across the grain Paper motion across the grain during the run of a job Control strip position variation on grain on job start Measurement frequency

5mm (-0.5mm) < 0.05mm

Press speed Working temperature Storage temperature Working humidity Storage humidity Communication Interface iCMD dimensions without opening radius

0.5m/sec..16m/sec 10°..60° -20°..80° 30..65% relative 5..90% relative RS232 / UDP/TCP-IP Depth Height Length 600x400x250 (h/w/d)

Box containing Controller Unit & power supply (external to press)

< 1%

Scanning approach

±10mm

Scanning approach

≤ 2mm

Scanning approach

Any ≤ 20Hz

Automatic frequency recognition and frequency reduction

Compressor for oil free compressed air

≤ 250mm ≤ 150mm ≥ 800mm ≤ 1500mm Contains 1x power supply including fuses 1x Controller Unit 2x Motor controller unit (1x Ethernet adaptor) optional

4.2 iCMD reliability goals Parameter Distance sensitivity Density range Standard deviation S of one single Densitometer for Density ≤2.0

Goal Comment 1’000’000 factory hours Artificial maturing by exposing the parts to extreme environment conditions and calibrating the units afterwards. 100 years data retention -RESET & Auto configuration 1’000’000 RW Cycles -Job configuration -Calibration (~10’000 factory hours) It has to be checked, what are the differences in light deviation after the change of the flash lamp.

MTBF Electorinical Parts

MTBF EEProm MTBF Calibration

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FAG_iCMD

Measure RESET

Controller

LNG Schuko connector 220V

220VAC Switch &Fuses Reset key Enable Meas key Key

Encoder

LED red Emnable

DB25M

CAN-Bus Vcc/GND Rs422 Signale

PC-Data Service

LED green LED red Measure Error

Positioning

Fiber optics

Back print

Power Supply 220VAC/ 5VDC 4,6A

Engine-Control 2x

Flash

DB25M

220V

DB25F

Flash

DB9F

Fiber optics

DB9M

Front print

Positioning

5 iCMD System

6 Availability In August 2002 the iCMD 4-Color open loop system will be launched.

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