Report 36 d,e,f,s,i.qxd:Report - KBA

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Newspaper Production | Innovation With KBA PlateTrans it is possible to partially or fully automate plate transport to, loading at and removal from the PlateTronic automatic plate changers at Cortina and Commander CT presses 36 Report 36 | 2010 Closing the automation gap between pre-press and press Automated plate logistics with KBA PlateTrans In the industrialised world, rapid advances have been made in automating and integrating the individual sequences in newspaper production. And, as so often, Koenig & Bauer has taken the lead in the empowering technology. As early as Drupa 2000 we launched a totally new type of newspaper press – the waterless, ultra-compact Cortina boasting automatic plate change. This was followed in 2007 by a conventional counterpart, the equally compact Commander CT. At Ifra Expo 2009 we unveiled a key link in the printshop automation chain. Developed in collaboration with Beil-Registersysteme in Abensberg, the modular KBA PlateTrans plate-transfer system closes the automation gap between pre-press and press in plate logistics for these innovative compact presses, allowing productivity and cost reserves to be exploited to the full. Depending on the equipment chosen, KBA PlateTrans fully or partially automates the supply of plates to the feed magazines at the Cortina and Commander CT and the disposal of the used plates – sequences which at present are executed manually and entail a lot of legwork. KBA PlateTrans can even be retrofitted on recent models. The automatic register-true plate change itself is still performed by our practice-proven KBA PlateTronic system. But this new development KBA teamed up with the Beil Group at Ifra Expo 2009 to demonstrate KBA PlateTrans, a module-based system for automating plate logistics between pre-press and press. The photo shows the PlateRail track with PlateTrain transport vehicle for PlateBox transport magazines eases the press crew’s workload by relieving them of peripheral tasks so that they can concentrate on controlling the printing process to de- liver the best possible product. The result is a substantial boost to productivity and cost efficiency, particularly where large numbers of plates are processed. PlateTrans eliminates the risk of costly down times due to misallocation – a frequent occurrence with manual
plate loading and mounting. The system can be automated in stages. Plates conveyed as if by an unseen hand Automatic plate feed and disposal at the press are controlled by a computer-assisted plate logistics management system (PLM). In the first step the exposed plates are seized from the delivery of the punching and bending machine by KBA Plate- Sorter, an intelligent robot gripper. They are then identified via a barcode, subjected to a quality check (optional) and sorted according to the designated printing couple into the KBA PlateBox transport magazine, which has already been locked onto the transport vehicle. The intelligent transport vehicle, KBA PlateTrain, can hold up to five magazines, one of which is reserved for the first used plates to be removed from the tower. Each of the other magazines holds four new single plates or two new doublespread plates plus slots for used plates. Two and three carriages respectively are required for one side of a 4/2 and a 6/2 tower. KBA Plate- Train, which is suspended from an overhead rail that is freely configurable to suit plant architecture, conveys the plates to a position above the relevant tower. Tracking level Planning level KBA PlateLoader removes the PlateBox magazines from the PlateTrain transport vehicle and passes them, correctly positioned, to the PlateTronic automatic plate changers in the press Plate logistics management (PLM) Printshop management and tracking system Production scheduling system Console Plate workflow control Pre-press Execution level Sequence Plate logistics management system KBA PlateTrain KBA PlateBox scheduling Exposure Plate bending Plate inspection Magazine loading Plate change KBA PlateSorter Plate exchange Co-ordination level KBA PlateTrain Interim storage Magazine transport Plate removal Ready KBA PlateLoader KBA PlateTronic plate change Magazine transport The computer-controlled PLM system co-ordinates, monitors and controls all individual sequences as well as the entire KBA PlateTrans plate-logistics process Specifications KBA PlateBox transport magazine • Max. weight: 3 kg • Capacity: 4 single or two-double-spread plates plus used plates • Identification via 2-D matrix code KBA PlateTrain transport vehicle • Max. load: 50 kg • Average speed: 0.7 to 1 m/s Unrivalled plate-changing speed In the next step the PlateBox magazines with the new plates are transferred by the KBA PlateLoader robot to the KBA PlateTronic automatic plate-changing units in the press. Prior to this the robot will have removed any magazines with used plates and transferred them to the train. The plate-changing sequence itself takes just two minutes or so and is thus twice as fast as any other robotic systems available on the market. High-performance Multicar system KBA PlateRail is an unmanned system for conveying plate magazines to the Cortina and Commander CT printing towers. Unlike similar systems from other manufacturers KBA PlateRail incorporates Swisslog- Telelift’s MultiCar system, which allows the individual towers and optional buffer sections to be reached via a system of switchpoints. On its return journey the train stops at an offloading station where the used plates are removed automatically and the PlateBox magazines reallocated. The magazines are subsequently reinserted in the train at the loading station ready to accept new plates. The flow chart above shows how the relevant sequences are coordinated and controlled, how the processes in subordinated systems interact, and how the entire process is safeguarded and monitored by the computer-assisted plate logistics management system PLM. Klaus Schmidt klaus.schmidt@kba.com Report 36 | 2010 37
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Page 3 and 4: Two views of the press room: on the
Page 5 and 6: Terminic gained second place in the
Page 7 and 8: Website: www.nacion.com Sheetfed Of
Page 9 and 10: €569.03 parable press is 15% lowe
Page 11 and 12: Managing director René de Heij:
Page 13 and 14: Cutting-edge control technology mak
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Page 17 and 18: The KBA LogoTronic production manag
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Page 21 and 22: “ We wanted to be one of the firs
Page 23 and 24: Classic packaging configuration: si
Page 25 and 26: Antistatic nozzles and heads Antist
Page 27 and 28: the fount solution in a moment’s
Page 29 and 30: Editora Abril in Sao Paulo Compacta
Page 31 and 32: The webs of the two presses can be
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Page 35: Koenig & Bauer ships further Comet
Page 39 and 40: On 14 December 2008 the first of se
Page 41 and 42: Websites: www.onlineprinters.com |
Page 43 and 44: Mousepads Display wobblers Flexible
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Page 47 and 48: Longstanding KBA customer Oceano in
Page 49 and 50: KBA users among winners of Druck&Me
Page 51 and 52: Print Week Awards 2009: KBA custome

Report 36 d,e,f,s,i.qxd:Report - KBA

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