Device and Method for Measuring and Setting the Web Tension Between Inking Stations of a Multicolor Press

Abstract

The present invention describes a device for measuring and setting the web tension on a printing press (8) comprising several inking units (Dn), in which device measuring means (Mm,n) for measuring the web tension and setting means (Fn) for setting the web tension are provided, using which the web tension can be set actively in the case of unsteady web tension conditions.

Description

The invention relates to a device and a method for measuring and setting the web tension between inking units of a multicolor rotary printing press, as outlined in claims 1 and 2.

Settings of multicolor rotary printing presses are changed frequently. After such changes have been made, the printing press often generates maculature or at least print images of restricted quality.

The object of the present invention is to suggest a device and a method that reduce the printing of maculature or print images of restricted quality.

It has been seen that changes affecting the web tension between inking units of the multicolor printing press exert an especially lasting influence on the print quality.

For purposes of the invention, the term “settings” is therefore meant to connote print parameters that influence the web tension between inking units of the multicolor printing press.

Such settings can be changed during an ongoing print job. These settings effected during the printing process include the positioning of print rollers or a change in printing speed. The term “settings” within the afore-mentioned meaning also includes any predominantly mechanical measures taken when pulling a proof. The positioning of print rollers, the printing start, and pre-registering play an especially important role in this context.

Some of the known devices provided on printing presses and used to measure the web tension include measuring rollers in which the force exerted on the axis of the roller by the web tension can be measured. Other alternatives for measuring the web tension also include measuring the torque of the rollers that transport the web of printable material. It is further known to influence the web tension prevailing in a printing press when pulling a proof by controlling the winder and unwinder or the in-feed unit and drag roller.

The present invention is based on the finding that a special web tension develops between two inking units once the cylinders carrying the print image are positioned against the impression cylinders. The cylinders carrying the print image are those that transfer the print image onto the web of printable material by rolling on the latter. The cylinders carrying the print image are mostly printing plate cylinders, but can also be blanket cylinders in some forms of offset printing.

It has been seen that the special web tension prevailing between the printing units as a result of the setting processes defined above (also due to the positioning of the cylinders carrying the print image) is subjected to an automatically set adaptation. In the wording of this document, there exists an unsteady web-guiding condition between the two related printing units. After a certain period of time, the automatic adaptation process of web tension comes to an end and the web tension changes per unit of time either only within defined tolerance values or it merely fluctuates by an average value. This condition is referred to hereinafter as “steady web-guiding condition”.

The afore-mentioned loss in quality as a result of the setting processes mainly comes into existence when unsteady web-guiding conditions are observed. The associated variations in web tension change inter alia the longitudinal register of the printing press, since web tension also results in web elongation and the changing web length causes register errors which then have to be compensated by controlling the register based on the errors occurred. However, the change in web elongation can also result in the print images appearing distorted. It can take a very long time, especially after pulling a proof, until steady web-guiding conditions develop between all the printing units of a multicolor printing press. The present invention addresses this issue by suggesting that:

• • at least one measuring means records measured values of the web tension between two inking units,
  • and that at least one setting means sets the web tension between the print areas of these two inking units based on the measured values,
  • and a control device be used, which controls the at least one setting means based on the measured values of the at least one measuring means.

This makes it possible to shorten the duration of the unsteady conditions of web tension and thus reduce the accumulation of print substrate of low quality.

Web-guiding elements such as guide rollers defining the path of the web of printable material can be used, to advantage, for setting the web tension. When the web-guiding elements change their position relative to the print zones of the (positioned) inking units adjacent thereto, the length of the transport path between the inking units and thus the web tension changes. Another option for influencing the web tension between two inking units is to move those rollers of the adjacent printing units that carry the print images in such a way that their angular position relative to each other changes. It is advantageous, though not necessary, to pre-position these print rollers when they are lifted off from the web of printable material. This is advantageous especially during pre-registration. The previously set longitudinal register can be retained if the amount of this pre-positioning is equal to that of the subsequent setting movement and its algebraic sign is unlike that of the setting movement (other direction of rotation).

The method of the invention can be used to particular advantage during pre-registration. The pre-register method disclosed in the document WO 2004/048093 A2 must be mentioned in this context. In the afore-mentioned document, a method has been introduced that is particularly suitable for pre-registering. In this method, a web of printable material is provided with a marking that is transported on the web through the different inking units of the printing press. Sensors of any kind, which record the passage of the marking, are assigned to the individual inking units. The machine control system can derive information suitable for registration, preferably pre-registration, from the evaluation of the measured values (in particular, the time at which the marking passes the respective inking units). The teaching of the afore-mentioned document with respect to all components of the registering method outlined such as process flow, types of markings, sensors, and measuring methods, etc., are regarded as part of the present application. The applicant of the present invention reserves the right to revert to the disclosure of the afore-mentioned document for supplementing the present invention.

A control device within the meaning of the present document can be any combination of software and/or hardware features and that can generate the mentioned control commands.

Standard values that the web tension is supposed to assume in the steady condition may also be known to the control module. Against the background of these standard values and current measured values recorded in the unsteady condition, the machine control system—that is to say, the control device—can determine by what setting amount it can influence the web tension with the help of the setting means. In doing so, the control device can take the specification of the upcoming print job as the basis. These specifications include the material, its thickness, temperature, and elastic modulus, etc. In the light of this information, the control device can determine the setting amounts with the help of a calculation module, which may likewise be in the form of any software or hardware, taking as a basis the relations between physical properties of materials, for example, such as the Hooke's law. In place of or in addition to the predefined standard values for web tension prevailing in the steady condition, the required information can also be derived empirically on the same printing press and, as far as possible, during the same type of or similar print job. In this context, it is advantageous if the parameters of the print job and the associated web tension values and/or setting amounts for achieving steady web tension are matched to each other and stored. The related data could be in the form of a calibration table and they could also be in a random access memory directly accessible to the control device or at least retrieved there by a machine operator operating the control device.

Another possibility of implementing the method of the invention and thus acquiring empirical values in the first place is if the at least one measuring means informs the control device, before the first control process, about the algebraic sign of the automatically setting variation in web tension. The control device then controls the at least one setting means in such a way that there results another controlled variation in web tension with this algebraic sign and by a predefined amount. This procedure is repeated until the algebraic sign of the automatically setting variation in web tension changes—that is to say, until the value of the web tension prevailing in the steady web tension condition is crossed.

After the value of the web tension prevailing in the steady web tension condition is crossed, either the web tension is no longer regulated in the controlled fashion or the algebraic sign of the controlled variation in web tension is changed. In one form of this “test run” or this “process of actively approximating” the web tension prevailing in the steady web tension condition, it is advantageous if the amount of the controlled variation in web tension is made contingent on the rate of the automatically setting variation in web tension (variation in web tension per unit of time). If the web tension changes rapidly, it may be assumed that the amount of web tension to be changed for achieving the steady web tension (web tension prevailing in the steady condition) is still high. If the web tension changes slowly, this amount is low. Should the amount of the controlled variation in web tension be regulated in this way, this amount may also reduce successively so that the amount by which the steady web tension is crossed (overshoot amount) remains small. Without such a regulation of amount of the intended controlled variation in web tension between measurements, it is also possible to successively reduce the amount of controlled variation in web tension automatically.

It is advantageous to implement the control device with control programs that are suitable to execute the aforementioned advantageous setting methods. Usually, the web tension between two directly adjacent printing units is set. When pulling a proof, in particular, it is advantageous if those areas of the web of printable material that are located between two adjacent printing units and are also referred to as web-guidance sections are successively subjected to the method of the invention. The preferred sequence corresponds to the transport path of the web of printable material.

Additional exemplary embodiments of the invention are explained in the following description and claims.

In the individual Figures:

FIG. 1 is a lateral view of a printing press

FIG. 2 shows the normal course of web tension as a function of time

FIG. 2 a shows the positioning state of two adjacent inking units at a first point in time

FIG. 2 b shows the positioning state of two adjacent inking units at a second point in time

FIG. 2 c shows the positioning state of two adjacent inking units at a third point in time

FIG. 3 shows the course of the web tension as a function of time in a test run

FIG. 3 a shows the positioning state of two adjacent inking units at a first point in time

FIG. 3 b shows the positioning state of two adjacent inking units at a second point in time

FIG. 4 shows the course of the web tension as a function of time in a rapid setting process

FIG. 4 a shows the positioning state of two adjacent inking units at a first point in time

FIG. 4 b shows the positioning state of two adjacent inking units at a second point in time. FIG. 1 is a lateral view of an in-line gravure printing press. In general, the methods of the invention are especially suitable for use in in-line printing presses, often also referred to as stand machines. The web of printable material 3 is supplied by the unwinder 1 to the printing press in the direction of the arrow z. First, the web of printable material passes through the region of the dancing roller system 2 and then proceeds to the in-feed unit 4. In this connection, it is particularly worth mentioning that the web tension can be set permanently between the in-feed unit 4 and the drag roller 5. However, this setting is not a setting in the sense of the invention, as it is not based on measurements and adjustments between the individual inking units D₁ to D₄. Only the type of setting suggested by the present invention enables the web tension to be influenced specifically and rapidly in a web tension section A_nm. After the web of printable material 3 has passed the in-feed unit 4, it proceeds past the first web-tension measuring roller M_0,1. Next, it arrives in the region of the first printing unit D₁, which is equipped with the impression cylinder P₁ and the form cylinder F₁. After passing through the associated print zone between the two afore-mentioned cylinders, the web 3 passes through a drying unit TR₁ indicated in the figures, in order to then be guided again past a web-tension measuring roller M_1,2. Finally, the web of printable material reaches the second inking unit D₂, which comprises a second print zone. The first web-guidance section A_1,2 is disposed between the roller clearances of the first two printing units D₁ and D₂. After leaving the second print zone, the web of printable material consequently arrives into the region of the second web-guidance section A_2,3, which is completed by the third print zone assigned to the third inking unit D₃.

Since all inking units are equipped in a similar fashion in the present exemplary embodiment of a gravure printing press, it is not necessary to individually describe the other inking units D₃ and D₄.

The only point worthy of mention is that the form cylinders F₃ and F₄ of the inking units D₃ and D₄ are switched off in the present illustration in FIG. 1. The dancing roller system 2 disposed downstream of the unwinder 1 and the dancing roller system 7 disposed upstream of the winder 6 perform the function of festoons in order to permit the afore-mentioned web-tension regulating processes of the in-feed unit and the drag rollers without exerting tension on the unwinder or the winder. FIG. 2 plots the web-tension course f against time t. The figure shows the web-tension course, as it occurs when a normal proofing is performed at a stand machine and the web tension approaches the steady web tension condition S automatically, that is to say, without any additional control processes. During the period of time T₁, no form cylinder is positioned against the associated impression cylinder in the related press. The web tension is therefore determined exclusively by the in-feed unit and the drag roller. This level has the value A. The printing units that are switched off are shown in FIG. 2a.

FIG. 2 b shows the manner of positioning the two form cylinders against the associated impression cylinders P₁ and P₂. As a result of this measure, a sharp rise in the web tension can be seen in FIG. 2. The web tension rises extremely rapidly from the initial value A to the maximum value M. As a result of the unsteady compensation process during the period of time T₂, the web tension drops, similar to a disintegration function, to the value of the steady web tension S. During the period of time T₂, the printing press generates maculature since the web tension also affects the web elongation and therefore leads to difficulties especially in maintaining proper print registration between the printing units D₁ and D₂. FIG. 2c shows the two printing units D₁ and D₂, where both the form cylinders are positioned against their impression cylinders P₁ and P₂. This condition exists for the entire period of time T₂.

FIG. 3 plots the course of the web tension against time. Here, the web tension is adapted to the steady web tension in a controlled manner after having positioned the print rollers. As in the case of FIG. 2, an initial time span T₁ with web tension A is observed in FIG. 3. In this time span T₁, the web tension is again determined solely by the in-feed unit and drag roller. The positioning of the two form cylinders F₁ and F₂ against their respective impression rollers P₁ and P₂ again results in an abrupt rise in web tension. After this rise, the unsteady phase T₂ begins, initially with an automatically set compensation process concerning the web tension. This automatically set compensation process causes the web tension to drop by an amount M₁, which is recorded by the web-tension measuring roller M_1,2. The recorded measured values are fed to the control device, which can then determine the algebraic sign of the automatically set change. The control device can also measure the changes in web tension between two measuring points MP_A and MP_B and determine the rate of the variation in web tension by calculating the rate of variation in tension per unit of time. Based on the information of the rate of the variation in web tension between the measuring points MP_A and MP_B, the control device determines the stroke or the amount of the controlled variation in web tension H₁, the algebraic sign of which it has determined already. After the controlled variation in web tension by the amount H₁, the measuring means M_1,2 repeats the measurement between the measuring points MP_C and MP_D and measures the automatically set variation in web tension M₂. The control device can again determine the algebraic sign and the amount of the automatically set variation in web tension M₂ from the measuring points MP_C and MP_D. Once again, the rate of the variation in web tension between the two afore-mentioned measuring points can be determined from these data. The control device again changes the web tension in a controlled fashion by the amount H₂ by controlling the setting means, and determines the algebraic sign and amount of the variation in web tension based on the measured values. The control device again measures the variation in web tension between the measuring points MP_E and MP_F with the help of the measuring means M_1,2 and establishes that the algebraic sign of the automatically set variation in web tension M₃ has changed and that the rate of the variation in web tension is very low. The web tension thus need not be changed in a controlled fashion any further. The amount by which the web tension at the measuring point MP_E falls below the steady web tension S is referred to hereinafter as overshoot. In comparison to the situation shown in FIG. 2, note should be taken of the fact that the time span T₂, in which the compensation process of the web tension is performed up to the steady web tension prevailing in the time span T₃ is very much shorter than the one in FIG. 2 in which this steady web tension is exclusively set automatically. Naturally, the printing press generates much less maculature in a situation shown in FIG. 3 during the time span T₂ than in the situation shown in FIG. 2.

FIGS. 3 a and 3b again show the positioning and compensation behavior of the printing units during the setting processes. In the case described, the setting processes are executed with the help of movements of the form cylinder—that is to say, in this case F₂. These setting processes are symbolized by the arrows pf. They result in a change in the relative angular position of the two form cylinders F₁ and F₂.

FIG. 4 again shows another controlled compensation process, which is executed with the stroke H₃. The speed of the unsteady compensation process is again higher as compared to FIG. 3. The stroke H₃ compensates almost the entire difference in web tension between the measuring point MPH and the steady web tension S. Such compensation processes can come into existence, in particular, if the steady web tension S is known to the control device from the outset. This may be the case if the control device operates auto-adaptively. That is to say, that the steady web tension prevailing on a printing unit during a print job is known to the control device in the form of a calibration table since such a web tension has already been set once when processing an earlier print job.

A particularly advantageous embodiment of the invention will become obvious from a review of FIGS. 4, 4a, and 4b:

During the phase T₁, the form cylinders F₁ and F₂ are lifted off from the impression cylinders and the web 3. It is possible to determine a register target position either by means of a special pre-registration process (e.g. a web-cylinder process) during this phase or by way of a pre-registration before this phase T₁. Normally, it would then be most advantageous to mutually coordinate the angular position of the two form cylinders F₁ and F₂ based on this register target position, and this coordination is usually performed by means of a corresponding movement of the rear cylinder, which is F₂ in this case. This movement can also be implemented in connection with the method suggested by the present invention. However, it is more advantageous to preset an angular position deviating from the target position RF [sic: RS] by an angle α instead of the exact register target position RF [sic: RS] of the two cylinders in relation to each other. A rotation around the angle α is suitable in the printing position (FIG. 4b) in order to adjust the stroke H₃ in the course of the web tension, as shown in FIG. 4. The active compensation process represented by the stroke H₃, as shown in FIG. 4b, is compensated by an angular rotation around α, that is to say, a rotation around the angle α in the reverse direction. The required steady web tension S is usually known to the control device of the printing press. It is extremely easy to determine the required web tension stroke H₃ by measuring a web tension prevailing during the period of time T₂. Even before this measurement is performed, such a web tension stroke or the automatically setting web tension can be known to the control device by way of an estimation or by means of empirical values (measured values in earlier or optionally similar print jobs. The web tension can be similar after the positioning of the rollers). In this case, the method of the invention also includes measurement operations even if these have been performed in printing processes that have already been completed. A printing press suited to implement this method therefore also includes such measuring devices. However, it also appears possible to implement such a method on at least one or more web-guidance sections, if not in the entire printing press, without performing measurements there or without subjecting the related web-guidance sections A_n,m to corresponding web-tension measuring devices. In this case, calculated and/or empirical values (e.g. of other printing presses) would have to form the background of the setting process.

The angle α corresponding to the stroke H₃ is likewise either known to the printing press or is determined by means of known relations between physical properties of materials, such as the Hooke's law. In this connection, it is advantageous to have the most precise possible knowledge of material parameters (such as the elastic modulus) of the web of printable material 3.

The course of the method shown in FIGS. 4, 4a, and 4b can be outlined as follows:

• • the web tension is set after implementing a pre-registering method, in which a register target position RF [sic: RS] is determined, but not necessarily set,
  • the cylinders (F_n) carrying the print image are pre-positioned (around the angle α in relation to the register target position) before the setting process, and this pre-positioning is effected while the related cylinder carrying the print image is lifted off from the web (3),
  • the cylinders (F_n), which carry the print image and are pre-positioned before the setting process by the amount (angle α) required for the settings, are set (in particular, for the purpose of regulating the web tension to the specified value of steady web tension S by rotation about −α), the pre-positioning and the setting having unlike algebraic signs,
  • so that the previously determined register target position RS for longitudinal registration is set.

The term “setting” or “setting process” above is primarily used for the setting of the web tension.

The printing plate cylinder/s can be rotated into the register target position before their pre-positioning. However, it seems advantageous to directly bring about that angular position of the adjacent, consecutive printing plate cylinders that results when the pre-setting (around the angle α) occurs additionally (pre-positioning around the angle α in relation to the target position RF [sic: RS]) at the register target position RS.

This method considerably accelerates the (normally passively occurring) “active” setting of the steady web tension. The isolated application of each of the afore-mentioned process steps therefore appears to be advantageous in itself. When applying the entire method, it even appears possible, in this way, to bring about this setting while a single web section of the length of the web path between the unwinder and the winder passes through the printing press. This would also significantly reduce the amount of maculature generated.

The afore-mentioned process steps can be implemented by a control device. Here, the term “control device” must be understood as a functional expression. A control device in the form of an industrial computer is usually present as a central unit that combines a large part of the intelligence required for operating the printing press. However, this term also encompasses all possible, decentralized forms of control units.

A control unit can be supplied with control means for automatically executing defined processes. Such control means could be function commands—thus mainly software. But such control means can also include hardware components such as electronic components like AND or NAND components.

List of reference numerals
1                Unwinder
2                Dancing roller system
3                Web of printable material
4                In-feed unit
5                Drag roller
6                Winder
7                Dancing roller system
8                Printing press
A{dot over (n)}m Web tension section
A1,2, A2,3       Web-guidance section
D1,2,3/Dn        Printing unit 1, 2, 3
F1,2,3,4/Fn      Form cylinder 1, 2, 3, 4
H3/Az            Stroke (here, active variation in web tension)
Mm,n             Web-tension measuring roller 0, 1
MPA-PH           Measuring point
P1,2,3,4/Pn      Impression cylinder 1, 2, 3, 4
T1,2,3/Tn        Periods of time
pf               Arrow in the direction of the setting movement
                 of the form cylinder
TR1,2,3          Drying unit 1, 2, 3
f                Web tension course, web tension control variable
S                Steady web tension
α                Angle (amount) of the pre-setting movement
                 of the form cylinder
−α               Angle (amount) of the setting movement
                 of the form cylinder

Claims

1. Device for measuring and setting the web tension on a printing press (8) comprising several inking units (Dn), in which device measuring means (Mm,n) for measuring the web tension and setting means (Fn) for setting the web tension are provided, using which the web tension can be set actively in the case of unsteady web tension conditions, said device being characterized in that at least one measuring means (Nm,n) and at least one setting means (Fn) are disposed in such a manner that the web tension can be measured and set between the print areas of two inking units,and a control device is provided, which controls the at least one setting means based on the measured values of the at least one measuring means (Mm,n)

2. Device according to claim 1 characterized by a control device, which is provided with the following control means by using hardware and/or software components: First control means for setting the web tension in a pre-registering method for determining a register target positionsecond control means for bringing about the pre-positioning of the cylinders (Fn) carrying the print image, which control means pre-position at least one of these cylinders before the setting process around an angle (α) in relation to the register target position, this pre-positioning being effected preferably while the related cylinder carrying the print image is lifted off from the web (3),third control means, which adjust at least one cylinder carrying a print image around an angle (−α), the pre-positioning (α) and the setting (−α) having unlike algebraic signs and equal amounts,so that the previously determined register target position for longitudinal registration is set.

3. Method for measuring and setting the web tension on a printing press (8) comprising several inking units (Dn), in which method measuring means (Mm,n) are used for measuring the web tension and setting means (Fn) are used for setting the web tension, said method being characterized in that the at least one measuring means (Mm,n) records measured values of the web tension between two inking units (Dn)and the at least one setting means adjusts the web tension between the print areas of these two inking units (Dn) based on the measured values,and a control device is used, which controls the at least one setting means based on the measured values of the at least one measuring means (Mm,n).

4. Method according to the preceding claim characterized in that web-guiding elements determining the course of the web of printable material (3) are used as setting means (Dn) [sic: (Fn)].

5. Method according to claim 1 characterized in that the cylinders carrying the print image are used as setting means (Fn).

6. Method according to the preceding claim characterized in that the cylinders (Fn) carrying the print image are pre-positioned before the setting process, this pre-positioning being effected preferably while the related cylinder carrying the print image is lifted off from the web (3).

7. Method according to the preceding claim characterized in that the cylinders (Fn) carrying the print image are pre-positioned before the setting process around the angular amount (α) required for setting the web tension, the pre-positioning (α) and the setting (−α) having unlike algebraic signs.

8. Method according to claim 1 characterized in that the web tension is adjusted in order to accelerate the setting processes when pulling a proof.

9. Method according to claim 1 characterized in that the web tension is set after a pre-registering method has been implemented, in which a register target position is determined.

10. Method according to the preceding claim characterized in that, in the pre-registering method, a web of printable material provided with a web marking is guided through at least two printing units (Fn) [sic: (Dn)], and the time at which the marking passes through the print zones of the at least two inking units (Dn) is recorded and these measured values are taken by the machine control system as the basis for pre-registration.

11. Method according to claim 1 characterized in that standard values for the web tension prevailing between the at least two inking units (Dn) are known to the machine control system and that the web tension is set based at least on the measured values and the standard values.

12. Method according to claim 1 characterized in that the measuring means (Mm,n) measures the algebraic sign of the automatically set variation in web tension in the case of unsteady web tension conditions, and/orthat the machine control system determines the algebraic sign of the variation in web tension based on the cause of the unsteady web tension conditions,that the control device thereupon controls the setting means in such a waythat a controlled variation in web tension is effected by a predetermined amount with the algebraic sign of the automatic variation in web tension.

13. Method according to the preceding claim characterized in that the first controlled variation in web tension by a predetermined amount is followed by at least another controlled variation in web tension.

14. Method according to claim 12 characterized in that after the controlled variation in web tension, the at least one measuring means (Mm,n) records the automatically set variation in web tension and that no other controlled changes in web tension (Hn) having the original algebraic sign are effected,if the algebraic sign of the automatically set variation in web tension changes or if the automatically set variation in web tension is no longer measurable.

15. Method according to the preceding claim characterized in that the control device records, in a storage unit, the amount and the algebraic sign of the setting processes (Hn) which are performed until the algebraic sign of the automatically set variation in web tension changes or until the automatically set variation in web tension is no longer measurable, and the control device adjusts this amount and/or algebraic sign during the subsequent occurrence of an unsteady web tension condition.

16. Method according to claim 1 characterized in that the control device has a calculation module, which calculates the amount and algebraic sign of the controlled setting processes from measured values of the web tension prevailing in a steady condition, in which the automatically set variation in web tension per unit of time is below defined target values, and the current measured values of the web tension.

17. Method according to the preceding claim characterized in that the calculation unit takes into account specific data of the print job—such as the type and thickness of the printed materials—when calculating the amount and algebraic sign of the setting processes.

18. Method according to the preceding claim characterized in that, in the storage device, the amount and the algebraic sign of completed or calculated setting processes are assigned to specific data of that print job—such as the type and thickness of the printed materials (3)—during which the related settings were made.

19. Method according to claim 1 characterized in that the measurements and settings are performed in the regions located between two directly adjacent inking units (Dn).

20. Method according to the preceding claim characterized in that the measurements and settings are performed in at least two regions in the order, in which the web of printable material (3) passes through the printing press.