www.sterlingtoggle.com

Die Co-Ordinator DC 1060 Digital Pre-Press Registration System

The Die Co-Ordinator DC-1060 is a die registration system that synchronizes alignment positions directly from the printed sheet.  The operator uses the digitizer to select two to four points per die.  The computer then records the x-y coordinates of each user-selected point.  The monitor displays key line cross hairs that allow the operator to first align the chase and then align the sheet to the press centerline.  Next, the camera auto scans the printed sheet by taking a picture at the pre-selected points.  Each picture of the printed sheet is then converted to a key line image that is displayed on the monitor.  The operator then switches to the “Die View” mode and selects the die he/she wants to lock-up. The superimposed key line image displayed on the screen assists the operator in aligning each die.

The methodology developed for Die Co-Ordinator allows the operator to position dies more accurately and efficiently.  This greatly reduces set-up and valuable press time as compared to traditional manual methods.

System Description:

Overview:

The Die Co-Ordinator DC-1060 consists of a base, digital camera, operator interface and digitizer.  The base is structurally solid, manufactured from 4-inch steel tubing.  It supports the honeycombs, digital camera, computer and operator interface.  The Die Co-Ordinator operator control interface is conveniently suspended over the die setup area and is able to swivel across the table.

Base:

Linear Slides

There are three linear slides that provide the movement of the digital camera.  All linear slides are controlled by the computer and powered by three servomotors and planetary gearboxes with a 5:1 ratio.  The overall accuracy of the camera position is ±0.001 inches with repeatability of 0.001 inches.

Honeycomb Support Rails

To support a variety of presses, the honeycomb support rails have different lockdown locations.  Each of the rails has cam rollers for easy loading and unloading of honeycombs.

Electrical Cabinet

The electrical cabinet is housed in the base, which allows easy access for maintenance and eliminates the need for an external electrical cabinet.  The electrical cabinet contains three drives that control the servomotors and a computer, which controls the drives.

Computer:

The computer is a Dell Intel based PC that controls the servo drives and camera, the intelligence of the system is powered with software written by Insight Graphic Systems in C++.

Schedule A (Cont.)

DIGITAL CAMERA

The digital camera is a machine vision unit with 640 X 480 pixel resolution.  The camera is equipped with 12X zoom optics with auto iris control and white balance to ensure a clear view of the honeycomb. The camera’s Wfine CCd integrates a primary color filter ensuring high color accuracy with square pixels and progressive scan.

RING LIGHT

Mounted just below the digital camera is an LED ring light that illuminates the honeycomb and dies eliminating any shadows that may occur with conventional overhead lighting.  The ring light is controlled via the software and is on at all times except when the camera is in the home position.

OPERATOR INTERFACE

20-inch Flat LCD Screen

The operator of the Die Co-Ordinator will be aided in die alignment by the 20-inch LCD flat screen that is mounted in the operator interface.  The monitor has high resolution providing a crystal clear picture of the honeycomb and dies.  The screen is viewable from 176 degrees horizontally and vertically.

Keyboard w/ Integrated Trackball

The keyboard is located at an ergonomic angle on the front of the operator interface and has an integrated 16mm trackball and two mouse buttons.

Included Options:

 ·         Digitizer and Personal Assistant Software- allows the operator to easily pick the points of registration of the printed with a mouse and automatically transfer the coordinates to the Die- Coordinator

 ·         Adjustable Quick Locking Rails - Sliding rails that lock in any position quickly to accept different size honeycombs. The Adjustable Quick Locking Rails are easier and faster to move than standard honeycomb support rails

Technical Data:

 Electrical Requirements

·         (1) 200/240VAC single phase

·         (1) 110VAC outlet

Repeatability

·         0.0002” (0.005mm)

Resolution

·         0.0012” (0.03mm)

Benefits of Die Co-Ordinator DC-1060

• Alignment positions are calculated directly from the scanned printed sheet using a digital camera
• Board stretch & heat expansion are automatically compensated for and eliminated
• Accurate positioning and alignment can be performed off-line at the inspection table
• The running cost of registering dies is minimized
• Final die positions can be scanned from the honeycomb bed at the end of a job for comparison with initial settings
• Repeated jobs can easily be stored
• Print management can determine the source of alignment problems accurately and quickly
• Greatly reduces valuable operator and press time by efficiently registering the dies off press

Limitations of Existing System

• Manual setting of the dies is labor intensive, time consuming and requires significant amounts of trial and error on the press before final settings are achieved
• Accuracy of control is limited by the skill and sensitivity of the individual operator
• Manual setting of the dies requires the operator to perform the majority of the adjustments
• Reference points are lost at the end of every job
• Repeat orders have to be re-measured and aligned, wasting valuable press time
• Board stretch & heat expansion requires the operator to set the job on press