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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

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Leader vision system mounter l.jpg

Leader Vision System Mounter

Mounting Coordinate Concepts


Plates are stepped across the cylinder referenced from the web cylinder centerline in x direction l.jpg

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

-X

+X


Plate x locations across cylinder l.jpg

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 l.jpg

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 l.jpg

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


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


Slide7 l.jpg

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


Slide8 l.jpg

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


Slide9 l.jpg

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


Slide10 l.jpg

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


Slide11 l.jpg

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


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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


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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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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


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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 l.jpg

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


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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.


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The unique design and operation of the Leader Vision System Mounter making it all possible.


A snapshot of the mounting process l.jpg

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 l.jpg

The operator places the printing plate reasonably straight at the approximate center of the table.


When ready a wide angle camera moves to the first register l.jpg

When ready, a wide angle camera moves to the first register


When ready a wide angle camera moves to the first register29 l.jpg

When ready, a wide angle camera moves to the first register


When ready a wide angle camera moves to the first register30 l.jpg

When ready, a wide angle camera moves to the first register


When ready a wide angle camera moves to the first register31 l.jpg

When ready, a wide angle camera moves to the first register


The operator verifies the approximate register location with a point and click of the mouse l.jpg

The operator verifies the approximate register location with a point and click of the mouse.


When ready the telephoto camera moves to the first register l.jpg

When ready, the telephoto camera moves to the first register


When ready the telephoto camera moves to the first register34 l.jpg

When ready, the telephoto camera moves to the first register


When ready the telephoto camera moves to the first register35 l.jpg

When ready, the telephoto camera moves to the first register


When ready the telephoto camera moves to the first register36 l.jpg

When ready, the telephoto camera moves to the first register


When ready the telephoto camera moves to the first register37 l.jpg

When ready, the telephoto camera moves to the first register


Operator verifies the center location with a point and click of the mouse l.jpg

Operator verifies the center location with a point and click of the mouse


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The same process is repeated for the second register. The Leader Vision System Mounter now knowing the exact location of the registers.


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The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.


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The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.


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The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.


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The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.


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The printing plate is automatically rotated straight and the cylinder is automatically rotated to the proper mounting position.


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The plate table automatically moves left or right to position plate in proper position across the web.


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The plate table automatically moves left or right to position plate in proper position across the web.


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The plate table automatically moves left or right to position plate in proper position across the web.


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The plate table automatically moves left or right to position plate in proper position across the web.


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The plate table automatically moves left or right to position plate in the proper position across the web.


The cylinder automatically raises to engage the sticky back tape to the back of the plate l.jpg

The cylinder automatically raises to engage the sticky back (tape) to the back of the plate


The cylinder automatically raises to engage the sticky back tape to the back of the plate51 l.jpg

The cylinder automatically raises to engage the sticky back (tape) to the back of the plate


The cylinder automatically raises to engage the sticky back tape to the back of the plate52 l.jpg

The cylinder automatically raises to engage the sticky back (tape) to the back of the plate


The cylinder automatically raises to engage the sticky back tape to the back of the plate53 l.jpg

The cylinder automatically raises to engage the sticky back (tape) to the back of the plate


The cylinder automatically raises to engage the sticky back tape to the back of the plate54 l.jpg

The cylinder automatically raises to engage the sticky back (tape) to the back of the plate


The pressure roll automatically lowers to firmly apply the printing plate to the cylinder l.jpg

The pressure roll automatically lowers to firmly apply the printing plate to the cylinder.


The pressure roll automatically lowers to firmly apply the printing plate to the cylinder56 l.jpg

The pressure roll automatically lowers to firmly apply the printing plate to the cylinder.


The pressure roll automatically lowers to firmly apply the printing plate to the cylinder57 l.jpg

The pressure roll automatically lowers to firmly apply the printing plate to the cylinder.


The pressure roll automatically lowers to firmly apply the printing plate to the cylinder58 l.jpg

The pressure roll automatically lowers to firmly apply the printing plate to the cylinder.


The pressure roll automatically lowers to firmly apply the printing plate to the cylinder59 l.jpg

The pressure roll automatically lowers to firmly apply the printing plate to the cylinder.


The pressure roll automatically lowers to firmly apply the printing plate to the cylinder60 l.jpg

The pressure roll automatically lowers to firmly apply the printing plate to the cylinder.


The pressure roll automatically lowers to firmly apply the printing plate to the cylinder61 l.jpg

The pressure roll automatically lowers to firmly apply the printing plate to the cylinder.


The pressure roll automatically lowers to firmly apply the printing plate to the cylinder62 l.jpg

The pressure roll automatically lowers to firmly apply the printing plate to the cylinder.


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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.


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The front section of the plate table and roller automatically pivot to apply the front of the plate to cylinder


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The front section of the plate table and roller automatically pivot to apply the front of the plate to cylinder


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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 l.jpg

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.


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


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


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


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


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


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


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


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


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


The pressure roll automatically raises l.jpg

The pressure roll automatically raises.


The pressure roll automatically raises78 l.jpg

The pressure roll automatically raises.


The pressure roll automatically raises79 l.jpg

The pressure roll automatically raises.


The pressure roll automatically raises80 l.jpg

The pressure roll automatically raises.


The pressure roll automatically raises81 l.jpg

The pressure roll automatically raises.


The pressure roll automatically raises82 l.jpg

The pressure roll automatically raises.


You are now ready to set and mount the next plate l.jpg

You are now ready to set and mount the next plate.


The leader vision system mounter reads the job database to recall and mount plates l.jpg

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 l.jpg

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 l.jpg

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


Slide87 l.jpg

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


Slide88 l.jpg

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 l.jpg

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 l.jpg

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


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


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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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 -


Proofing with the leader vision system mounter l.jpg

Proofing with the Leader Vision System Mounter


Slide104 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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 l.jpg

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.


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The Leader Vision System Mounter

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


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