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Leader Vision System Mounter. Mounting Coordinate Concepts. Plates are stepped across the cylinder, referenced from the web (cylinder) centerline in X direction. -X. +X. Plate X locations across cylinder. Cylinder X reference =0. Plate 1 X= -635mm. Plate 2 X= +635mm.

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leader vision system mounter

Leader Vision System Mounter

Mounting Coordinate Concepts

plates are stepped across the cylinder referenced from the web cylinder centerline in x direction

Plates are stepped across the cylinder, referenced from the web (cylinder) centerline in X direction

-X

+X

plate x locations across cylinder

Plate X locations across cylinder

Cylinder X reference =0

Plate 1

X= -635mm

Plate 2

X= +635mm

NOTE THAT PLATE X MOUNTING LOCATION IS CENTER OF PLATE

slide4

Likewise, the Y location around the cylinder is referenced from the cylinder zero (scribe/keyway). Plate Y zero is the center of the plate and is the mounting point of the plate (X0,Y0).

Plate Y Zero is center of the plate

Cylinder Zero reference.

Locations for plate mounting on the cylinder are by circumferential distance.

0 º

270 º

90 º

180 º

slide5

The Leader Mounter looks at the cylinder mounting locations in the Y as if the cylinder circumference were opened and laid out flat

slide6

The Leader Mounter looks at the cylinder mounting locations in the Y as if the cylinder circumference were opened and laid out flat

slide7

The Leader Mounter looks at the cylinder mounting locations in the Y as if the cylinder circumference were opened and laid out flat

slide8

The Leader Mounter looks at the cylinder mounting locations in the Y as if the cylinder circumference were opened and laid out flat

slide9

The Leader Mounter looks at the cylinder mounting locations in the Y as if the cylinder circumference were opened and laid out flat

slide10

The Leader Mounter looks at the cylinder mounting locations in the Y as if the cylinder circumference were opened and laid out flat

slide11

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

X0,Y0

slide12

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

X0,Y0

Y

X

slide13

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

Plate mounting location on cylinder = X0,Y0

Plate X0,Y0

Y

X

slide14

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

Plate mounting location on cylinder = X0,Y-254

Plate X0,Y0

Y

X

slide15

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

Plate mounting location on cylinder = X0,Y+455

Plate X0,Y0

Y

X

slide16

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

Plate mounting location on cylinder = X0,Y0

Plate X0,Y0

Y

X

slide17

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

Plate mounting location on cylinder = X-250,Y0

Plate X0,Y0

Y

X

slide18

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

Plate mounting location on cylinder = X+250,Y0

Plate X0,Y0

Y

X

slide19

The Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

Plate mounting location on cylinder = X+250,Y-300

Plate X0,Y0

Y

X

slide20

Two plates across and two plates around.

Plate mounting location on cylinder = X-250,Y-300

Plate mounting location on cylinder = X-250,Y+300

Y

Plate mounting location on cylinder = X+250,Y+300

Plate mounting location on cylinder = X+250,Y-300

X

slide21

We now know how the plate location on the cylinder is determined, but how is the plate center determined by the mounter?

The center is known because the registers are referenced from the center of the plate. Thus the register X,Y location tell us the center of the plate.

Plate center X0, Y0

X-280, Y0

X+280, Y0

slide22

The Leader mounter adds a new feature to mounting by permitting registers to be located anywhere on the printing plate. Also the register do not have to overlap between colors.

Plate center X0, Y0

X-280, Y280

X+320, Y-300

slide23

This saves the customer consider plate material cost by making plates only large enough to contain the graphics. That is, all plates do not have to be the same size for the sake of overlaying registers.

Conventional method

Leader method

Parrot food

Parrot food

slide24

We have seen how the Leader mounter uses two register locations and the cylinder location for mounting. The plate length is also required for mounting to estimate Y0 of the plate. X0 is known since the plate center is placed at the approximate table center in the X direction.The following Leader mounting process explains this in more detail.

a snapshot of the mounting process

A Snapshot of the Mounting Process

Putting details aside for now, let us look at the basic concept of no hands alignment and mounting with the Leader Vision System Mounter

the operator places the printing plate reasonably straight at the approximate center of the table
The operator places the printing plate reasonably straight at the approximate center of the table.
slide39
The same process is repeated for the second register. The Leader Vision System Mounter now knowing the exact location of the registers.
slide40
The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.
slide41
The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.
slide42
The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.
slide43
The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.
slide44
The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.
slide45
The plate table automatically moves left or right to position plate in proper position across the web.
slide46
The plate table automatically moves left or right to position plate in proper position across the web.
slide47
The plate table automatically moves left or right to position plate in proper position across the web.
slide48
The plate table automatically moves left or right to position plate in proper position across the web.
slide49
The plate table automatically moves left or right to position plate in the proper position across the web.
slide63
Mounter shown with the pressure roll in the down position. The weight is distributed across the plate

The mechanism above the pressure roll moves the pressure roller laterally to keep it supported on the cylinder when the table is positioned to mount plates toward the cylinder edges.

slide64
The front section of the plate table and roller automatically pivot to apply the front of the plate to cylinder
slide65
The front section of the plate table and roller automatically pivot to apply the front of the plate to cylinder
slide66
The front section of the plate table and roller automatically pivot to apply the front of the plate to cylinder
the mounter shown with the pressure roll pivoted forward to mount the front edge of the plate
The mounter shown with the pressure roll pivoted forward to mount the front edge of the plate

The front portion of the plate is transferred from the plate table to the cylinder.

slide68
The front section for the plate table and roller automatically pivot back with roller slightly raised
slide69
The front section for the plate table and roller automatically pivot back with roller slightly raised
slide70

Pressure roller again automatically lowers to the printing plate and the cylinder turns to firmly mount the printing plate without air bubbles.

slide71

Pressure roller again automatically lowers to the printing plate and the cylinder turns to firmly mount the printing plate without air bubbles.

slide72

Pressure roller again automatically lowers to the printing plate and the cylinder turns to firmly mount the printing plate without air bubbles.

slide73

Pressure roller again automatically lowers to the printing plate and the cylinder turns to firmly mount the printing plate without air bubbles.

slide74

Pressure roller again automatically lowers to the printing plate and the cylinder turns to firmly mount the printing plate without air bubbles.

slide75

Pressure roller again automatically lowers to the printing plate and the cylinder turns to firmly mount the printing plate without air bubbles.

slide76

Pressure roller again automatically lowers to the printing plate and the cylinder turns to firmly mount the printing plate without air bubbles.

the leader vision system mounter reads the job database to recall and mount plates
The Leader Vision System Mounter reads the job database to recall and mount plates.

Mounting jobs data source

Mounting jobs viewer and selector

Mounting Jobs Database Storage

  • Job number and description
  • Register locations on plate
  • Plate sizes
  • Plate locations on the cylinder
how the leader vision system mounter calculates the plate location on the table
How the Leader Vision System Mounter calculates the plate location on the table

3. Register positions from center of plate are known from the job database.

4. The computer can now calculate register locations on table and move the wide angle camera to them.

1. Approximate Y location of plate is known from lead edge located at a fixed mounter scribe line.

2. Approximate X location (center) of plate known by approximate center placement.

slide86
The wide angle camera moves to the approximate location of the register and the operator verifies the register proximity.
slide87

Knowing the first register location, the 70x magnification camera automatically moves to that register for determining the precise register center.

slide88
The camera steps are repeated for the second register and the mounter now knows the real world X and Y location of both registers
slide89

The computer compares the angle of the art work registers (in job database) to the actual camera measured angle and rotates the plate accordingly

Rotating table

slide90
The computer calculates the rotated register positions, and the 70x camera moves to each, visually verifying the rotation to the operator.
slide92

The computer calculates position of the register locations after rotation, and the 70x camera moves to them, visually verifying the rotation

slide94

How the mounter knows where to place the plate on the cylinder

The computer knows the location of plate center because register X,Y locations are referenced from the center.

The computer knows the plate mounting location on the cylinder from cylinder X,Y location in the job database.

From these two locations the computer can position the plate to the proper location across the cylinder

slide95

The table moves to the X mounting location based upon the actual plate location and the cylinder X mounting location given in the job database.

slide96

Based upon the job cylinder Y (around) mounting location, the computer calculates and rotates the cylinder to the position where the plate center will meet that location (270 º in this case), as shown in next slide.

Plate Y zero

Length of plate in Y direction

0 °

270 º

90 º

180 º

slide97

Here you can see that when the cylinder is brought up to “kiss” the plate and then rotated to pull off the plate, the center of the plate will meet the required mounting location of 270 º.

Plate Y Zero

Distance = circumferencial cylinder (at sticky back) distance (distorted)

270 º

180 º

0 º

90 º

slide98

Here you can see that when the cylinder is brought up to “kiss” the plate and then rotated to pull off the plate, the center of the plate will meet the required mounting location of 270 º.

Plate Y Zero

Distance = circumferencial cylinder (at sticky back) distance (distorted)

270 º

180 º

0 º

90 º

slide99

Here you can see that when the cylinder is brought up to “kiss” the plate and then rotated to pull off the plate, the center of the plate will meet the required mounting location of 270 º.

Plate Y Zero

Distance = circumferencial cylinder (at sticky back) distance (distorted)

270 º

180 º

0 º

90 º

slide100

Here you can see that when the cylinder is brought up to “kiss” the plate and then rotated to pull off the plate, the center of the plate will meet the required mounting location of 270 º.

Plate Y Zero

Distance = circumferencial cylinder (at sticky back) distance (distorted)

270 º

180 º

0 º

90 º

slide101

Here you can see that when the cylinder is brought up to “kiss” the plate and then rotated to pull off the plate, the center of the plate will meet the required mounting location of 270 º.

Plate Y Zero

Distance = circumferencial cylinder (at sticky back) distance (distorted)

270 º

180 º

0 º

90 º

summary of leader vision system mounter coordinate system
Summary of Leader Vision System Mounter coordinate system

Right Register X = 10, Y = 0 from center of plate

Left Register X = -10, Y = 0 from center of plate

Registers at Y zero (center of plate)

Plate X axis

Cylinder Y axis (zero point in position for plate pick-up)

Direction of Motion

Y +

Cylinder mounting X zero

X +

X -

Y axis zero for cylinder and plate in this instance

Y -

slide104

After each plate is mounted, the vision system camera automatically moves to the expected register locations, calculated from the job register and plate locations.

slide105

Once in position, the camera automatically snaps and displays a picture of the register. The center is confirmed with a mouse point and click and the error is displayed.

Each small tick mark is .001” or .0254 mm or 25.4 microns

The error is automatically recorded for this plate in the proofing history database

In this instance, the X distance error is shown as .0004 and the Y distance error is 0.

Distance measuring tool

job proofing history deviations is saved in the proof database for immediate or future viewing

Job proofing history (deviations) is saved in the proof database for immediate or future viewing.

Job selection showing mounting start date and time

Mounted plate register deviations from desired location

The proof data can be visually analyzed

Rotated plate register deviations prior mounting; to diagnose art or plate error

slide107

The visual proof analysis constructed from actual register deviation data in the proof history database, showing overlaying register pairs for all decks (plate by plate).

Visual analysis of overlaying register deviations from the desired mounting location. Registers are shown in actual deck colors.

.005” ticks

.001” ticks

First Register

Second Register

Actual measured register deviation in X and Y direction.

Sequence through plates

Total deviation of both registers = plate deviation. This error is not important if the error is nearly the same for all.

another example of the visual proof analysis tool

Another example of the visual proof analysis tool.

Registers clustered within +/- .0025”or less

Registers clustered on the opposite side of center tells you that actual distance is shorter than entered in Job Manager.

more on the job proof analysis tool

Note that actual registers would be at least ten tick marks wide (.01”), thus this tool provides much greater clarity and resolution than conventional ink proofing.

More on the job proof analysis tool.

This demonstrates deviation in artwork, plate making and/or plate shrinkage, since these registers are not clustered like those at the left.

slide110

The Leader Vision System Mounter

Clearly, the next generation of mounters to meet the tolerances of today’s presses.

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