Model ATFG-IV High Speed Fully Automatic Printer Slotter and Die Cutter with Folder Gluer(Full Servo) (Fixed Type)

1. Control System

Automatic control system, merely an order of box parameters i.e. the axial and circumferential data of all units are input in touch screen, then the feeder, printer, slotter and die cutter will be set automatically, featuring accuracy and reliability to realize automation and enhance production efficiency.

2. Original Imported Swiss ABB Multi-Axis Servo Drive Front Edge Feeder 

1) Aote smart equipment has professionally developed a front edge feeding control system solution on European servo drive product platform to integrate the features such as internal cam controller, main encoder information acquisition, automatic feedforward, skip feeding, and free zero reset mechanism. It has completed the control of the servo drive integrated machine, meeting the high precision and integration requirements and aiming to provide customers with products of high cost performance.

2) Multi-axis servo front edge paper feeding, the latest control mode is composed of multiple servo drives and motors and preset encoder etc as well. Multiple feeding wheels are driven by a different servo motor. there is no direct transmission connection between the front edge feeder and main unit since the cam lift plate and cam feeding mechanism, etc. connected with the main unit were removed. Alternatively the phase and speed signals of main unit are collected through photoelectric encoders. Every feeder wheel acceleration, synchronization, deceleration and stop operations are controlled by the electronic cam driven by servo drive so as to reduce a large number of mechanical structures, making the operation and setting simpler, later maintenance cost lower, parameter adjustment convenient and maintenance simple.

3）Capacitor Energy Storage System

The servo leading edge feeding system solution provided by our company is equipped with the capacitor energy storage system produced by us. This system can store the electrical energy generated during deceleration and provide it to the driver during acceleration. Under normal circumstances, it can save approximately 40% to 70% of the electricity.

4) Left/right and back baffles are set on touch screen, which is eclectically set and digitally controlled and a side squaring is also installed to secure precise feeding.

3. Pull Roller 

1) Dual pulling roller system for more stable feeding.

2) The upper pulling roller's steel core surface is wrapped with buffering and abrasion proof rubber and the elastic positioning system ensures smooth and precise conveying to enhance printing registration. The bottom roller adopts steel material. 

3) Puling rollers’ clearances are set on touch screen with electrically setting and digitally control.

4. Auto Zeroing 

1) Feeder and printer are installed with auto zeroing devices.

2) With zeroing device, it will ensure all the units having the unified setting reference to be able to set at the correct position and minimize blank waste.

5. Duster (multiple brush row) 

The duster’s airflow and pressure are set by means of VF so as to adapt it to the blanks of different sizes and even warp ones to improve printing quality, moreover, brush rows equipped.

1.The world advanced non-stop plate changing technology enables plate replacement without machine shutdown to greatly reduce plate mounting and job setup, significantly improving production efficiency and equipment utilization.

2. Vacuum Case 

1).The printing unit adopts Swiss ABB servo motors with dual servo independent drive and dual power configuration for printing rollers and suction case. Printing units can be idled  separately; the corresponding printing rollers will stop running automatically after idle for better energy efficiency.

Phase adjustment can be completed on touch screen, with precise control by servo motors, supporting fine adjustment and quick zero reset. It allows 360°dynamic adjustment (adjustable both in running and stop status) with higher speed and accuracy (adjustment accuracy up to 0.2 mm).

No memory reset is required during group plate cleaning, the plate rollers will automatically and quickly return to original position after machine starts running.

2).The vacuum suction fans adopt variable frequency speed control, allowing flexible air volume adjustment according to board sizes to ensure stable printing for the boards of various sizes. When the minimum sheet conveying length is 300 mm, the overprint accuracy reaches ±0.5 mm. For a sheet passing length of 400 mm or above, the overprint accuracy is guaranteed at ±0.3 mm. While the system meets the adsorption requirements of various boards, it effectively reduces energy consumption, with a total fan power of 3×3=9 kW.

3).Features of Fixed Suction Case Structure in Printing Unit

More enhanced stability in printing and conveying: The suction case adopts a fixed structure for more stable operation, especially suitable for high-definition printing and high LPI and DPI printing, ensuring uniform and stable printing pressure, accurately meeting the precision requirements of color difference control, and maintaining stable printing accuracy for a long service life.

Effectively reducing the wear during high-speed operation: It reduces roller bounce of printing roller shafts during high-speed running, significantly extending the service life of key components such as suction case rollers, roller shafts, bearings and timing belts, and lowering equipment maintenance costs.

Better adaptability for board thickness: The reference plane of suction case and lead edge feeder keep the same height corresponding to roller surfaces. When printing corrugated boards with a thickness of 1.5–10mm, the accuracy of feeding and color registration are not affected by changes of board thickness, ensuring stable and reliable performance throughout the process.

4).The impression roller is made of high-quality seamless steel tube delicately and calibrated by both static and dynamic balance test. The surface is precisely ground and hard chrome -plated, showing the virtues of excellent wear resistance, smooth operation and low vibration.

5).It adopts specially designed precise row roller shafts, equipped with high-precision Japan -made self-aligning ball bearings, together with a multi-point forced lubrication system to ensure continuous and sufficient lubrication over all bearings, greatly extending the service life and improving feeding stability.

6).The vacuum suction fan adopts intelligent variable frequency control, air volume can be flexibly adjusted according to board thickness and width. Combined with pneumatic damper adjustment, it meets the suction requirements for different sizes of board.

7).It supports non-pressure feeding mode, with the blank conveying achieved by strong and uniform vacuum suction, significantly reducing board indentation, deformation and damage, and improving product yield and printing quality.

3.The distance between adjacent printing units of the fixed-type machine is 1210 mm, 2.4 times that of conventional movable-type ones. The increased unit spacing effectively extends the drying time of water-based ink, significantly improving drying performance and better adapting to high-speed, and high-efficiency continuous production.

4. Anilox Cylinder and Doctor Blade System 

1).It adopts imported ceramic anilox cylinders and Taiwanese doctor blade system, paired with a high-quality closed ink chamber, ensuring uniform ink distribution and stable printing.The doctor blade gap is pneumatically controlled with precise fine-tuning, enabling quick adjustment and blade replacement, greatly improving job change efficiency. A bidirectional diaphragm pump provides automatic ink supply, with the ink volume synchronously matched to the main machine.The chamber structure is designed for easy and rapid cleaning, effectively reducing water-based ink consumption, with simple maintenance and high cleaning efficiency.

2).The anilox roller gap is digitally and electrically adjusted via touch screen, without the manual fine-tuning. Parameters are precise and controllable, ensuring efficient and convenient operation. 

5. Flexo Ink Cycle 

1).A quick dismountable enclosed ink trough is installed.

2).Equipped with high-pressure water cleaning device and pipeline system, it is convenient for cleaning of high LPI anilox roller, scraping cavity and rubber roller quickly, so as to ensure the printing effect.

1.Automatic production control system, merely an order of box information is input on touch screen, the clearances, axial and circumference data of feeder, printer, slotter and die cutter will be set automatically featuring accuracy and reliability without personal interference to realize full automation and enhance production efficiency. 

2.The slotting unit adopts a full servo independent drive structure, with each unit equipped with individual power, featuring high synchronization accuracy and convenient adjustment, effectively improving slotting precision and overall machine operation stability.

3.With high precise original imported linear guide rail from Taiwan, the precise spiral gears driven five knives in linkage makes the moving more flexible and accurate.

4.Equipped with imported 12 inches high-definition color Germany Siemens touch screen, featuring clear display, easy operation, large capacity orders save and automatic order change function. 

5.The gaps of each cutter boss setting are done on touch screen in electric setting and digital control. 

6.Quick change, adjustable pre-creasing and scoring structure ensure the pre-creasing and scoring effects on diverse blank thickness. 

7. Slotting Phase Setting 

⑴.Slotting wheel shaft is made of quality steel, whose surface is chromed after milling, then through static/dynamic balance tests to enhance the running stability. 

⑵.When the slotted box height is being adjusted and up/down knife bosses moving transversely, a anti-collision protection device is arranged to protect the machine.

8. Slotting Axial Setting 

⑴.Automatic production control system can fulfill the settings of box height, phase and axial shifting automatically in case all the data of orders are entered into touch screen without any human interference featuring accuracy and reliability. Coupled with transmission spindle, the top/bottom knives are well aligned to prolong their durability. 

⑵.Slotting knife is 7mm wide and the serrated blade is made of steel alloy through thermal treatment to render it elastic and hard. The steel alloy trimming knife thermally treated assumes sharp and precise. (10mm thickness knife can be optioned according to customer's needs to meet the requirements of different carton board thickness).

⑶.Elastic angle cutter is able to cut off the blanks of single wall and double wall corrugated boards without any setting for easy handling. 

⑷.The human/machine interface alarm indication displays the machine abnormal situation so as to remove the faults in time. 

9. Pre-scoring Wheel 

⑴.The top/bottom prescoring shafts are made of quality steel under static/dynamic balance tests, and its surface is chromed and finely milled. 

⑵.It is of 5 group prescoring wheel design, the bottom prescoring wheel surfaces are chromed and upper wheels, wrapped with PU material to protect the blanks. 

⑶.The gap setting is done on touch screen in electric setting and digital control. 

10. Scoring Wheel 

⑴.Top/bottom scoring shafts are made of quality material through static/dynamic balance tests, chromed and finely milled. 

⑵.Scoring wheels surfaces are wrapped with PU to protect the blanks. 

⑶.Scoring wheels and slotter knives work synchronously to secure the unified slotting and scoring. 

⑷.Slotting clearance is set on touch screen in electric setting and digital control.

⑸.Slotting phase and box height are controlled with converter at dual speed. 

11. Secondary Creasing 

1).It adopts a two-stage creasing design to ensure stable and consistent creasing forming of cartons to effectively avoid problems such as crease damage, board breakage, and misalignment between creasing and slotting positions.

2).The gap of the feeding rollers is digitally and electrically adjusted via touch screen, featuring precise control and easy operation.

1.Die Cutter Control

⑴.Die cutting cylinder phase and axial settings can both be done on touch screen in the mode of electric setting and digital control. 

⑵.The die cutter with the dual servo motor from ABB Swiss, the computer controlled speed can be synchronous with printer, the servo motor independent drive finds a good solution of die cutting vibration impact to printing quality from the fore dectiom of printers so as to guarantee the overprinting accuracy.

⑶.The die cutter phase setting is executed at 360 degrees on touch screen with servo motor control and dual high or low speed (available for running and stop), featuring high setting accuracy (at 1mm setting amount).                          

(4).Die-cutting phase positioning is done on touch screen with servo motor control, and the off-position will not occur when unit is being releasing or in phase setting.

(5).All the clearances setting of cylinders can be fulfilled on touch screen in CNC mode.

(6).Printing and die cutting phases are concentratedly controlled and also their micro setting can be available in running. 

2.Die cutter Cylinder (bottom cylinder)【Independent Servo Motor Drive】

⑴.Die cutter cylinder is made of quality steel and processed with best workmanship through static/dynamic balance tests to enhance stable and smooth running and secure accurate die cutting.

⑵.Die cutter cylinder left/right shifting are done on touch in CNC mode and digital control within ±10mm range.

3.Anvil Cylinder (top cylinder) 【Independent servo motor drive】

⑴.It is made with quality steel, best workmanship, static/dynamic balance tests and the wrapped die cutting cushion blanket is imported from Taiwan. 

⑵.The anvil cylinder is equipped with tracing compensation system by Independent servo motor drive to control its speed and the offset range is ±3mm. 

⑶.Anvil blanket uses trimming system to maintain the blanket flat to maximize its life and minimize costs. 

4. Differential Speed Compensation Device 

This device functions in automatic linear speed offset caused by speed change due to die cutting blanket trimming so as to guarantee die cutting accuracy. When the anvil cylinder diameter becomes smaller due to the wearing or trimming, its linear speed varies accordingly, in this case, a differential compensation device installed on cylinder end is able to keep the same linear speed between die cutter and anvil cylinders, therefore, to maintain blanks size of every lot complete same, and it is able to secure die cutting quality even the blanket are trimmed twice. 

1.Feeder 

●Vacuum adsorption leading edge feeder, suitable for high-speed feeding.

●Accurate board feeding, even the warped and thin corrugated boards can be processed normally.

●Accurate feeding, warped and tiny corrugated board can operate normally.

●The paper collecting area adopts a dual waste cleaning system of three row brushes and four high-pressure air knives to effectively remove the slotted die-cut waste chips, and is equipped with a metal baffle and an upper and lower double-row brush at the cutting edge, and the gap can be adjusted to effectively prevent the sheets from entering into the gluing part.

2.Folder

●The upper/lower conveying belts of front conveyor belt of folder/gluer are moving forward with boards clamped. The board inlet gap can be electrically adjusted, and the upper and lower belts gaps can be also set automatically.

●The clearance between each pressing wheel and lower folding beam can be separately adjusted by board feed-in section’s pressing wheel.

●The body of feeding folding unit is mainly composed of left and right giant beams, and lower beam, which feature strong rigidity and good stability,  fitting for high-speed machine running.

●The conveyor belt at the back section of folder adopts vacuum adsorption belt to transport corrugated board forward. At the same time, it is also equipped with a lower folding belt, whose speed can be adjusted separately to rub the folded box sheet surface to avoid the board slip to cause the scissors difference.

●Correction belts are arranged on both sides of the folder to achieve accurate folding.

●The left and right movement of folding beam is driven and adjusted by two servo motors and can be adjusted automatically according to the order.

●The main belt uses a new suction belt installed in the rear folding section to prevent distortion and facilitate the smoothly delivery of the carton out.

●The strengthened folding track assumes good rigidity: moreover the lower track and vertical steel plates on both sides are also reinforced to completely eliminate the vibration when boards pass.

●The speed of both left/right folding belts can be set separately by means of servo motor according to the length and width of size requirements.

●Lower folding belt is independently driven by motor.

●The pressure of left/right main belt and gap between upper and lower beams are adjusted by a independent motor.

●The second half section of folding beam is controlled with an independent modifying servo motor to ensure it is not affected by main belt; its single side is installed with aluminum alloy correction wheel.

●An air cylinder is used to finely adjust the carton forming to ensure the satisfied carton shape.

●Four vacuum suction motors (two on each side) strengthen air adsorption.

●Upper/lower folding arms are driven by screw rod, and the upper/lower folding beam move synchronously, featuring more stability and accuracy.

●Both ends of board feeding and squaring works with linear slide rails to render the movement more smooth.

3.Gluer Spraying System（Valco System From USA）

●Large graphical LCD display for easy configuration and programming.

●“Plug-and-run” connectors and a compact design for quick and easy installation. 

●Up to 4 product scanner triggering inputs with scanner lock. 

●“Continuous” and “Stitch” pattern gluing capabilities. 

●Jogging mode reduces glue volume when boxes are being moving slowly through folder gluer. 

●Job storage (100 group carton sizes), reducing downtime.

●Password protection for system parameters to avoid operator maloperation.

●Auto-gluing features fitting random box lengths correctly each time. 

●4-channel controls to set 10 programmable intermittent gluing in different lengths in each cycle.

●4 trigger signal inputs to maximize production flexibility and max optimal sprayer lay outs, and the mini speed be be adjustable.

Adjustable minimum speed.

●Fitting for multi-spaying valves, complex gluing route patterns setting such as the continuous, stitch, jogging,and intermittent  spraying lines. 

●The function of optimal glue volume automatic tracking and compensation (option) can provide precise glue volume under the condition of variable-speed production on the production line.

4.Power Equipment

●The main power adopts frequency conversion speed regulating motor to work with printers synchronously by means of special encode and the set program

● All the transmission power is done by synchronous belt, featuring simple structure, low noise, stable operation and less vibration.

● Moving parts are composed of imported ball screw and linear guide rails.

5.Counter Ejector

●Counter is add with a board pressing fan to increase the pressure to prevent them from impacting.

● Counter is installed with a board press servo motor.

● The counter is equipped with independent motors on both sides, working with rack pinion and linear guide rail.

● Photoelectric switch does the accurate counting.

● Precise counting for accumulated stacked goods output function by four set of servo motors under high-speed operation is jointly achieved.

● The high speed separating rod is controlled by a servo motor to ensure the precise counted lots division. 

● The use of pneumatic auxiliary board-collecting bar to let carton stacking more smooth and flat. 

● Pneumatic board stacking mechanism ejects the well stacked cartons out neatly.

● Strong air pressure device prevents cartons from up-warping when ejected out from the folder, to ensure the neat stacking, and the direction of tuyere can be deflected arbitrarily.

● The tailgate can be adjusted electrically (automatically or manually) according to board specifications.