Components & Accessories - Converting Machinery Subsystems

Corrugator-system upgrade presentation

Watch this Montalvo Corp. PowerPoint to learn how a customer upgraded a Langston corrugator line with the supplier's V-Series brakes.

posted on: 03/12/2010

Compact inspection features split-screen for print-color comparison

The InPrint Video Web Inspection system reportedly delivers an increased field of view, reduced glare when viewing reflective materials and additional software features that...

posted on: 02/04/2010

Pulsed-LED strobe inspection checks reflective labels, coatings, foils

New pulsed-LED versions of co.'s widely-used stroboscopic inspection lights are available in sizes from less than 18 in. up to 118-in. long.

posted on: 02/04/2010

Infrared sensors

NDC announces the launch of its updated 710 series of Infrared sensors for continuous web processes. The new family of gauges, designated as 710S, retains all of the excellent features of the current 710 line while achieving complete integration with NDC’s TDi (Total Distributed Intelligence) system family.  NDC have maintained the superb, unmatched 710 optical bench while integrating the Ethernet networking and high-powered DSP computer present in our TDi system. 

The 710S sensor utilizes a D-BRIC distributed control engine that incorporates the computational power of an entire process control system into a small 4” X 6” (10 cm x 15 cm) circuit board – the same D-BRIC used in NDC’s TDi system products.  Use of its high speed Digital Signal Processor results in enhanced measurement performance, the ability to handle more Infrared wavelengths, and support for additional measurement outputs (up to six separate measurements per gauge).  This new design further enhances end user benefits, such as reduced material usage and scrap, improved product quality, and reduced customer returns.

Configuration and diagnostics are easily managed by onboard graphical software via the standard TDi interface and can be locally or remotely accessed over an Ethernet or Internet connection.  With these enhanced diagnostic tools, maintenance is simplified; and since the gauge emits no ionizing radiation, the 710S is user-serviceable.

The 710S infrared sensor is available in the following versions to meet any web process application need:

·                                 FG710S for plastic films

·                                 TFG710S for ultra-thin plastic film (less than 12 microns)

·                                 NW710S for basis weight and moisture measurement of Spunbond Nonwovens

·                                 FS710S for moisture in paper

·                                 NDC710S for coating and moisture measurement

·                                 SR710 for measuring thin coatings on metallic webs

More information is available on NDC’s website at  www.ndcinfrared.com

posted on: 08/20/2009

Register control system

eltromat’s product lines stand for high efficiency as well as customer value and are the result of a technically mature product line concept, which relies on high-quality, state of the art technology from one source, comprehensive process knowledge as well as user-specific project planning combined with a global service network. The new eltromat platform concept based on in-depth integration provides innovative, tailor-made system solutions for all current printing machines and – in comparison to competitor’s systems – maximum flexibility for the future.

eltromat recognizes, like no other, the demands of their customers and features attractive solutions for cost savings for both new as well as retrofit projects.

To improve the performance of printing presses so that less operational effort is required, less waste is generated, and set-up times are reduced, eltromat has developed and introduced the new register control system regi_star 20 – the successor to the renowned dgc_650, dgc_655 and dgc_700.

The new real time system with XFC technology (eXtreme Fast Control) offers even higher ease of operation and a maximum of automation. With the regi_star 20, register is achieved quickly which means a considerable reduction in waste and set-up time, at the same time taking the pressure off the operators. This leads to increased productivity and reduced costs per job. This is especially important today when job run lengths continue to be cut and printing plants have to struggle with more and more job changes per day.

The operation is intuitive and carried out via a touch screen monitor with a simply structured Human Machine Interface (HMI) and integrated online support. Operators can view a live image of the register marks on the screen in their actual colour. This unique feature makes life for the operator even easier, saves time and thus reduces waste.

The adaptive RGB register sensor in use even recognises inks with extremely low contrast, metallised inks as well as transparent lacquers. Due to the range of depth of focus of the fibre optics it is not necessary to change the scanning angle or to amplify the signal strength. The patented single head measurement enables the register marks to be measured in any sequence and guarantees that the mode of register control is optimally suited to the printing situation, e.g. during start-up, regi_star 20 operates in sequential mode to bring all the print units into register as quickly as possible,

An automatic register mark search to set the measuring gates as well as register mark centering are also part of regi_star 20‘s considerable range of functionalities. In addition, especially developed algorithms such as the patented automatic adaptation to press speed changes and web flutter make for quick compensation of these types of misregister. Repeat jobs can be prepared on regi_star 20 even while the present job is still running which means job changes can be carried out without delay.

The system has several options, e.g. the ability to make overall adjustments from each print unit; a waste protocol module that informs the operator once the set tolerance values have been exceeded and – provided a tagging system is available – marks the defective print; an external protocol module provides a comprehensive report for the complete job.

With Automatic Pilot Control the control parameters and correction speeds are automatically adapted to the different press states. This also leads to a considerable reduction in waste during make-ready, start-up, splice and speed changes. RGB camera systems can be installed instead of the previously mentioned fibre optics. This allows for the use of miniature dot shaped register marks and ensures the highly precise absolute measurement of the register without the previously required zero adjustment – even if the distance between web and camera should vary strongly – and still provide for secure register control and waste reduction. If required, the system can be fitted with various pre-setting modules enabling the register on the press to be set while it is stopped thereby reducing set-up time and waste considerably.

By means of intelligent linking of the regi_star 20 together with the new web viewing system webvideo_star 2000, it is possible to achieve completely automatic fine adjustment of the register whether it be for side register variations or skew-sensitive materials. Once the correct measurement time has been determined by regi_star 20, the webvideo_star 2000 measures the exactness of register on both sides of the web, the print width, as well as the amount of skew with a high degree of accuracy. The resulting fine corrections are then taken over by regi_star 20. Automatic fine tuning (_aft) enables a perfect register fit to be achieved automatically and with each job change, saving several hundreds of meters of waste. Another highlight is the automatic skew control (_sc), which is used in combination with motorised skew rollers in gravure printing units. The combination of automatic fine tuning and skew control is the optimal solution for all types of fine adjustments. Also, this is accompanied by a tremendous waste reduction at every press start-up and splice. info@eltromat.de

posted on: 08/20/2009

Splice-detection technology

R.K.B. Opto-Electronics, Inc. parent to S.D.T., announces the release of its new “Sentinel” Splice (Joint) Detection Technology.  The Sentinel is designed to monitor 1-16 webs of material and will detect any splice or joint that may exist within the web based process.  It is applicable to manufacturing processes that require the culling out of splices or joints prior to shipment. As a control in subsequent conversion processes, it prevents damage to sensitive equipment. Examples of these include soft rolls, print heads, coater applicators and print blankets.  Immediate detection, rejection and control of splices or joints create savings of up to tens of thousands of dollars per annum.

Unaffected by printed surfaces, material color, grade changes and process speeds the Sentinel guarantees 100% reliable detection every day; every shift.  The Sentinel is a self-calibrating system that is powered by 24VDC. It provides an opto-isolated, digital electronic output with a pulse width selectable for 1, 10 or 100 milliseconds. The re-designed alarm indicators are low power, low voltage LEDs that are clearly visible to machine attendants. The unit can be mounted anywhere along the web at any angle and either right side up or upside down.

The Sentinel can be connected directly to PLC control devices or interfaced into existing marking systems or directly control devices.  Modular in design, the new Sentinel requires 50% less energy to operate and can be equipped with auto tracking of the web edge eliminating operational intervention of deckle (web width) changes.  The Return on Investment (ROI) is most often as little as 24 hours of operation. Contact Bruce.Dobbie@usa.rkbopto.com

posted on: 08/20/2009

High-force load cell

The Montalvo Corporation, international specialists in industrial web control systems, announces its U-120 series load cell made for large-scale operations. The cells are commonly used for measuring and monitoring tension in high force applications such as wet felts, dryer felts and wires, extrusions and laminates such as aluminum and steel foils and sheets.
President Ed Montalvo says, "It's been designed from the ground up to replace Montalvo¹s UPB (under pillow block) Series load cells but with a lower profile. We've simplified the mechanics and made it easily accessible for repair or replacement."
The U-Series load cell is made of stainless steel construction and features a water and corrosion resistant housing. They are available in three sizes with load ratings ranging from 100 to 22,000 pounds. This product uses tension and compression strain gauges; as tension bends the beams slightly, the gauge resistances change and produce an output signal proportional to web tension. And they have built-in overload stops.
www.montalvo.com 

posted on: 08/20/2009

Cost-effective air chuck

CAC (Converter Accessory Corporation) adds a new, uniquely designed air chuck to its proven line of COR-LOK air and mechanical chucks. This new COR-LOK-XE model air chuck utilizes a pneumatically expanding, spirally wrapped external element to engage the core. These chucks are available for 2” – 18” diameter cores and use split bushings to lock to thru shafts for fast and easy placement and installation.

According to Jeff Damour, CAC’s engineering manager, COR-LOK-XE pneumatic chucks are effective with virtually all types of cores in light to heavy duty applications. CAC’s unique split bushing design clamps and releases quickly and easily, holding the COR-LOK-XE model chuck securely in place and will not mark or damage the thru shaft to which it is mounted.

“CAC’s new COR-LOK-XE model air chucks offer our customers a cost effective, simple answer to demanding applications where effective core holding is required. They are designed with standard, universal parts, so no matter what diameter air chucks our customers use; all parts remain consistent for all sizes. These chucks are designed to last with extremely limited maintenance. However, when maintenance is required, it is done with standard, stocked parts in less than 15 minutes.” Damour said.

COR-LOK -XE pneumatic chucks feature a tubing (bladderless) design, contoured to match the geometry of the company’s unique, spiraled shaft body. The contoured tubing allows exceptional, even gripping torque across the full length of the chuck, an extremely long tubing life and easy replacement. To inflate, they only require 70 PSI and can easily handle up to 120 PSI. COR-LOK-XE air chucks feature unique, wear resistant external element locking system and ensure zero core damage. All models are lightweight and designed for easy, safe operation.

For more information contact Jeff Damour, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433-2413, CAC@epix.netwww.converteraccessory.com

posted on: 08/17/2009

Ultrasonic distance measurement sensor

SICK, a manufacturer of sensors, safety systems, machine vision, and automatic identification products for factory and logistics automation, today announced the launch of its UM30-2 Ultrasonic Distance Measurement Sensors, featuring a new EasyTouch display and keypad that enables easier setup, configuration, and access to advanced problem solving features. The UM30-2 line offers increased measurement performance and is 25% shorter, providing more installation options.  These sensors are ideal for detection and distance measurement applications, such as roll diameter control, level control, clear bottle detection, and collision avoidance. Contact www.sickusa.com

posted on: 08/17/2009

Load cells

If your equipment requires load cells but space is tight, the Montalvo Corporation, international specialists in industrial web control systems, now offers its F-Series load cell made primarily for limited space applications.The new load cells are ultra slim and come in three sizes (F17, F25, F35), ranging in overall thickness from 38 mm (1.496 inches) to 65 mm
(2.559 inches). Features of the F-Series include:
           ›  new high-tensile aluminum construction
           ›  wide load ranges
           ›  unique adjustable hard stops -- factory set for optimum protection
           ›  overload protection which is 10 times normal loads
           ›  can be mounted inside or outside the machine frame
           ›  measuring range of 1:25
           ›  reliable repeatability
President Ed Montalvo says, ³The F-Series is engineered to fit virtually any application where  space is limited and can be specified and configured to the customer¹s needs by our specialists.²
The F-Series uses tension and compression strain gauges connected in a full-bridge configuration. As tension forces deflect the beam, the gauge resistances change and this produces an output signal which is proportional to web tension. For more information contact The Montalvo Corporation at 50 Hutcherson Drive, Gorham, Maine, USA, 04038; telephone 1-800-226-8710, www.montalvo.com

posted on: 08/17/2009

Air chucks for maximum torque

Shaftless applications become a cinch with self-centering air mechanical chucks from NimCorproviding maximum torque with positive, bladderless gripping action.

NimCor’s air-operated mechanical chucks provide a strong, air-assisted grip and maximum torque ideal for shaftless applications. These rugged, air mechanical core chucks are designed for heavy-duty applications, providing positive, bladderless gripping action to secure the core to the chuck with no slippage. Chucks are easy to use with convenient air valve access through the flange or outside edge of the chuck. As the lugs expand pneumatically, the chuck self-centers. Air mechanical chucks from NimCor are available standard to fit 3 in. and 6 in. cores. Special 5 in. and 8 in. size chucks and a 3-6 in. step chuck are also available. 

NimCor: www.nimcor.com 

posted on: 08/17/2009

Fife Corp. celebrates 70 years of industry service

Oklahoma City, OK - Fife Corp., an industry leader in the manufacture and engineering of web-guiding systems, celebrates 70 years of success in the web-handling industry with a commitment to continuous product improvement and education.

posted on: 08/12/2009

Carbon-fiber rolls

NimCor has manufactured composite air shafts and rolls for years. NimCor’s in-house composite tube winding operations provide exacting roll performance in meeting applications where greater control is needed throughout the web converting process – especially with new substrates, such as thin-gauge films and nonwovens. A lightweight alternative to steel and aluminum rolls, live and dead shaft custom composite rollers are readily available from NimCor without long lead times and without the premium pricetag. Customers can also specify roller bearings in order to minimizes their spare parts inventory. NimCor, www.nimcor.com 888-464-6267

posted on: 08/07/2009

Open gearing from stock

Boston Gear offers a comprehensive range of standard open gearing products including spur, helical, miter, bevel, worms and worm gears.  Thousands of gears are available for immediate shipment from the company’s extensive inventory at distribution centers in North Carolina, Nevada and Ontario, Canada.

Boston Gear also provides stock altering services (reboring, keyways and setscrews) along with custom gearing design and manufacturing from its North Carolina facility.  A brand of Altra Industrial Motion, Boston Gear designs and manufactures gears in steel, cast iron, brass or non-metallic materials to the strictest quality standards.

Visit the company’s website, www.bostongear.com, to access BostSpec, a unique program which assists engineers with gearing selection and provides CAD drawings in the most popular 2D and 3D formats.  On the website, engineers can also view Boston Gear’s current 164-page catalog of gearing products and accessories, including a comprehensive overview on gear theory which explains gear nomenclature, tooth formulas, backlash, tooth strength, torque and horsepower requirements and other standard gear selection formulas.

For information on any of these technology leaders, visit www.AltraMotion.com

posted on: 08/07/2009

High-speed gluing and inspection

The new Valco Melton 524 series glue valves feature advanced solenoid technology for short glue patterns at high machine speeds. Unique to the 500 series is the ability to easily convert between non-contact and contact glue patterns. Simply change the output nozzle to the type of glue pattern desired. No valve modifications or special adapters are required. Also new is the Valco Melton AS302 optical glue pattern sensor. Designed for use with the 500 series valve, the AS302 can verify glue patterns or dots at speeds up to 600m/min. Together they offer quality assurance for applications such as folding carton, specialty corrugated, envelope and other high-speed finishing and converting requirements.
Visit www.valcomelton.com for more info or call 515.874.6550.

posted on: 08/07/2009

Softal electronic GmbH declares bankruptcy

Softal electronic has declared financial insolvency in Hamburg. Due to increasing pressure exerted in large part by the very slow payment of customers strained by the worldwide financial squeeze, the family of shareholders lead by Brigitte Lichtenauer Blumenfeld will not accept the recently modified terms spelled out by the financial industry. The newly incorporated Softal Corona & Plasma GmbH now has the opportunity to adapt the company’s long existing potential to the present conditions of the market and to restructure its organisation in order to overcome stagnation brought on by the global crisis.

“Is it the current strategy of the banking system to pull back credit lines before new lines will be granted?” asks Dr. Philipp Lichtenauer, CEO/shareholder.„As a shareholding owner I have to consequently seek a determined posture for my businesses. As the CEO I am disappointed that we have had to take this path. Softal’s successful orchestration of innovative products/technologies and consistent marketing and distribution is needlessly being slowed down. The marketplace is being denied of much needed innovative products that could provide more efficient production tools.

Softal’s employees who have been with the firm for many years are very concerned. They have all supported the growth strategy of the international leading supplier of surface treatment technology. Furthermore everyone is absolutely convinced that this strategy would be successful under normal circumstances.

For the industry this was unexpected news. Customers as well as partners in the market have responded supportively. There is clearly a common consensus that Softal should emerge stronger due to this course of action. Philipp Lichtenauer adds: "In contrast to the manufacturing businesses like ours that invest intensively in research, businesses which are not dependent on the credit system had an easier time of it. Our claim to leadership in R&D requires a higher level of working capital."

At present the managing board of Softal is seeking advice of the experienced insolvency administrator Jens-Soeren Schroeder, Hamburg, in order to guarantee the well known reliability of the company’s services. In a first phase, the Softal Corona & Plasma GmbH was incorporated in order to ensure upcoming business and to guarantee the supply of spare parts.

Dr. Philipp Lichtenauer is convinced: these proactive and timely measures will provide an organised and stable restructuring in order to guarantee the continuing stability of all of Softal’s valued relationships.

Softal has been in the business of developing surface treatment systems for the past 50 years and has sold systems in 45 countries. The manufacturers of semi-finished and finished products in various industrial sectors implement Softal technology to improve efficiency in the automotive industry, the aircraft and aerospace industry, the textile and packaging industry, the production of medical equipment and in the paper industry, to name but a few.

posted on: 08/03/2009

Print-quality workflow management

BST Pro Mark announces the availability of Lector Work Flow Management - a high performance software tool for managing print quality and throughput from printing to shipping across multiple machines.

Lector Work Flow Management is a new product that is used in conjunction with the companies Shark 100% Inspection systems or Premius Print Process Management systems, installed on presses or re-winders up to 80” web widths. 

Lector Work Flow Management is used to display and evaluate process job data and to help manage throughput from one machine to the next - for example, press to re-winder - and to generate reports for jobs that have been produced on machines with BST Shark or Premius systems as the inspection / print quality assurance system.  It is installed and operated on a personal computer, which is linked to the inspection / quality assurance systems in the process, and accesses the job data via a network.

Lector Work Flow Management provides access to all events and information collected by the inspection / quality assurance system, from basic job information (name, customer, operator, machine, start and stop times and number of rolls) to detailed defect information and images.  This includes all defects identified (color coded by type of defect) and the “master” image, as well as exactly where in the roll each occurred and precisely where on the web each is located.  An image of each defect is also kept in the database and displayed.  “Events” are also tracked and shown, such as roll changes.

Job data can be viewed from the beginning of the job or from the end of the roll, and can be sorted by customer name, machine or job name, simply by clicking on an icon.

The user can view the data on a selected job in either table view or graphical web view, simply by clicking on an icon.  Navigate through the jobs via the scroll bar, keyboard, or navigation icons on the Lector Work Flow Management interface. In graphic mode, a scale provides location in web running direction.

Lector Work Flow Management  simplifies the process of reviewing a job and its quality issues, typically done by the Quality Manager - and facilitates subsequent removal of all bad material from the web prior to shipment.

Check boxes allow easy management of the data, which can be done individually or in groups.   The user can mark defects for downstream removal, deactivate defects or events determined to be irrelevant, and can mark those that need to be subsequently reviewed in a downstream process.  Defects or events marked can later be cancelled.

Specific defects in each jobs database can be selected, and a window displays the actual defect area, with the identified defect marked and color coded, next to the golden master image, for reference. This makes defect evaluation simple and easy.  The user can look at detailed information on a specific defect, or for a particular roll, or an overview of the entire job.

Lector Work Flow Management also has a powerful filter function which allows the user to produce reports with only selected information shown.  This is useful when  sharing data across multiple machines and processes and for preparing reports for internal or external customers.

Five types of filters – events, defect type, classification, defect size and lane – and some very creative software make the process very simple and easy. 

Reports are saved in XML or PDF format and can be exported to other programs or networks, with or without defect images.

When using Lector Work Flow Management with a re-winder, a unique “Sync” function allows synchronization of the graphic report view with the winding progression of the web. The Sync function facilitates synchronization of processes and machines such as a press to a re-winder.  It is commonly used to help facilitate removal of faulty material in downstream processes, without having to print on the web. www.bstpromark.com

posted on: 08/03/2009

RPM AC motors

Baldor Electric Company announces a wide range of RPM AC motors from stock. Applications include extruders, converting, web processing and printing, cut-to-length applications and winders.

The BaldorœReliance RPM AC motors offer compact square laminated steel frames for inverter duty and vector duty applications.   They are available from stock in totally enclosed fan or blower cooled and drip proof designs from 3 through 1,000 horsepower.  They are designed to handle the most demanding high performance industrial applications in frame sizes that are up to three times smaller than traditional NEMA or IEC motors.  RPM AC motors feature low-inertia for use on high response applications and are optimized for use with adjustable speed drives.  They offer big power in smaller frame sizes and high efficiency for energy savings. 

BaldorœReliance RPM AC motors are available from Baldor warehouses across North America and also from Baldor international locations.

For more information about Baldorœ-Reliance products or Dodge products, visit our web site at www.baldor.com

posted on: 08/03/2009

Sleeves for smartGPS

Flint Group Flexographic Products is the first sleeve supplier to be qualified to manufacture sleeves for the ‘smartGPS’ system from Fischer & Krecke (F&K), Bielefeld/Germany. Flint Group Flexographic Products can rely on  many years of experience with RFID (Radio Frequency Identification) technology – for more than 10 years rotec sleeves have been available with this technology.

As all rotec  sleeves for the ‘smartGPS’ system are equipped with a RFID - Chip and a register sensor, relevant data like the actual print diameter, the actual job design as well as the used materials can be recorded and stored already during plate mounting. The data is then recalled in the printing unit, where the printing sleeves are moved fully automatically into the exact register and impression setting. As the traditional press proof is no longer required, material usage and set-up times are significantly reduced with extremely high register.

The challenge for the sleeve production is to insert the sensor very precisely within tight tolerances. Extensive tests at F&K with rotec Blue Light Sleeves demonstrate that they are even below the specified tolerances. As the sensor and the chip are inserted during the sleeve production process, both are located with exact positioning and protected from being damaged. The modification of the sleeve has no effect on the print result and the complete surface can be utilised for plate mounting.

rotec  Sleeves with ‘smartGPS’ are obtainable in wall thicknesses up to 100 mm, in all lengths up to 4000 mm and with a guaranteed diameter tolerance of 0.02 mm (measured on carrier cylinder at TIR & 0.005 mm). They are optionally available in a conductive version with the proven rotec  Omega-Surface Technology and with a stainless steel register ring.

For more information, visit www.flintgrp.com

posted on: 08/03/2009

Clutch/brake modules

Warner Electric, an Altra Industrial Motion company, offers the advanced design of its Gen 2 electromagnetic packaged clutch/brake modules for flexibility and performance in motion control for material handling, food processing, packaging and other industrial applications.

Several performance enhancements over the original C-face design are achieved through improvements in materials and manufacturing technologies.  Internal component mounting and an external housing fin design increase heat dissipation and optimize stop/start frequencies, particularly in enclosed configurations.  Also, improved  input-to-output axis alignment reduces vibration, noise, and wear. 

Integrated, custom mounting bolts make installation easier and allow the conduit box to be located directly on top of the unit for consistent orientation across the product line.

Optional cover kits readily convert vented units into fully enclosed modules that keep contaminants out and wear particles in for clean, quiet operation. www.AltraMotion.com

posted on: 08/03/2009