Leader Vision System Mounter

Leader Vision System MounterMounting Coordinate Concepts

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

Plate X locations across cylinderCylinder X reference =0Plate 2 X= +635mmPlate 1 X= -635mmNOTE THAT PLATE X MOUNTING LOCATION IS CENTER OF PLATE

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).0 90 180 270 Plate Y Zero is center of the plateCylinder Zero reference. Locations for plate mounting on the cylinder are by circumferential distance.

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

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

X0,Y0XYThe Leader Mounter looks at the cylinder mounting locations as if the cylinder circumference were opened and laid out flat with center as X0,Y0.

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,Y0Plate X0,Y0XY

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-254Plate X0,Y0XY

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+455Plate X0,Y0XY

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,Y0Plate X0,Y0XY

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,Y0Plate X0,Y0XY

Plate mounting location on cylinder = X+250,Y0Plate X0,Y0XYThe 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-300Plate X0,Y0XYThe 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+300XYTwo plates across and two plates around.Plate mounting location on cylinder = X+250,Y+300Plate mounting location on cylinder = X-250,Y-300Plate mounting location on cylinder = X+250,Y-300

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.X+280, Y0X-280, Y0Plate center X0, Y0

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.X+320, Y-300X-280, Y280Plate center X0, Y0

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.Parrot foodConventional methodLeader methodParrot food

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.

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

A Snapshot of the Mounting ProcessPutting 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.

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.

When ready, the telephoto camera moves to the first register

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

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

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

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

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

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

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.

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

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

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.

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.Mounting Jobs Database StorageMounting jobs viewer and selectorMounting jobs data source Plate sizes Register locations on plate Plate locations on the cylinder Job number and description

How the Leader Vision System Mounter calculates the plate location on the table 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.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.

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

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

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

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

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

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

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

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.

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 in this case), as shown in next slide.0 90 180 270 Plate Y zeroLength of plate in Y direction

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 .270 0 90 180 Plate Y ZeroDistance = circumferencial cylinder (at sticky back) distance (distorted)

Summary of Leader Vision System Mounter coordinate system Cylinder Y axis (zero point in position for plate pick-up)Plate X axis Y axis zero for cylinder and plate in this instanceRight Register X = 10, Y = 0 from center of plateLeft Register X = -10, Y = 0 from center of plateX +X -Y -Y +Cylinder mounting X zeroRegisters at Y zero (center of plate)Direction of Motion

Proofing with the Leader Vision System Mounter

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

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.In this instance, the X distance error is shown as .0004 and the Y distance error is 0.Each small tick mark is .001 or .0254 mm or 25.4 micronsThe error is automatically recorded for this plate in the proofing history databaseDistance measuring tool

Job proofing history (deviations) is saved in the proof database for immediate or future viewing.Job selection showing mounting start date and timeMounted plate register deviations from desired locationRotated plate register deviations prior mounting; to diagnose art or plate errorThe proof data can be visually analyzed

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)..005 ticks.001 ticksVisual analysis of overlaying register deviations from the desired mounting location. Registers are shown in actual deck colors.Actual measured register deviation in X and Y direction.Total deviation of both registers = plate deviation. This error is not important if the error is nearly the same for all.First RegisterSecond RegisterSequence through plates

Another example of the visual proof analysis tool.Registers clustered within +/- .0025or lessRegisters 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.This demonstrates deviation in artwork, plate making and/or plate shrinkage, since these registers are not clustered like those at the left.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.

The Leader Vision System MounterClearly, the next generation of mounters to meet the tolerances of todays presses.

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Leader Vision System Mounter