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Production lines

Printing & Converting

Register accuracy per unit and stable web tension.

  • Typical axes3
  • NetworkEtherCAT
  • Control modeCSP · CST
  • Recommended seriesSDU3 · SMR · SD24-LP · Photoelectric
Start Product Selection See the solution
01
The sector at a glance

Printing & Converting

Colour register demands micron-level phase alignment between axes.

Three things that decide it on the shop floor

  1. 01

    Register accuracy

    Every print unit must stay locked to the same phase.

  2. 02

    Web tension

    A change in tension shows up as register error.

  3. 03

    Sync through speed changes

    Every unit must keep its ratio while accelerating.

02
Our advantages

Why SMB TECHNICS?

One set, controller to cable

Controller, drive, motor, cable and connector arrive checked against each other; interface problems are solved at the desk, not on the shop floor.

Open standards

EtherCAT, CANopen, Modbus RTU, CODESYS and CiA 402: your machine is not tied to a closed ecosystem.

Engineer-to-engineer support

The same team from sizing to commissioning, on site and remotely.

Documented products

Manuals, CAD, ESI/EDS and firmware in the Document Centre; every product you choose comes with its documents.

Our application know-how for this sector
  • Register control across print units
  • Web tension and sync through speed changes
  • Cylinders locked to a virtual master
03
How we build the system

From control chain to commissioning, which product goes where

3.1

The control chain and the recommended products

How the machine is driven and the SMB products we choose for it.

In printing and converting lines each print unit must run phase-locked to web speed and hold colour register to micron level. An electronic shaft (servo synchronisation instead of a line shaft) keeps the whole line in sync while allowing independent adjustment per unit. Stable web tension is a precondition for accurate positioning at the cutting and folding stations.

Engineering-led synchronization know-how runs printing units phase-locked to web speed and at micron accuracy.

The control chain

Print is registration. Every unit has to put its colour in the same place on a web that is moving and stretching, and the tolerance is smaller than anything else on this page. The chain is SD-LP and SDU3 drives on SM08 and SM10 motors running as a phase-locked group, photoelectric sensors reading the register marks, and shielded encoder cable that does not put noise into the one measurement the whole machine depends on.

What decides the result

  • Feedback resolution, again — but more so. Register error is measured in tenths of a millimetre across metres of web. The 17-bit BiSS and 23-bit BiSS-C options in the catalogue are what that tolerance needs.
  • Web stretch between units. The correction has to be made where the error is created, not where it is seen, which makes this a tension problem as much as a position one.
  • Start-up waste. How quickly the units come into register after a stop is what the job actually costs in material.

Sizing it

We need web width, line speed, the number of units and the register tolerance you have to hold. Bring the existing controller and fieldbus too — on a machine this coupled, the bus is not a detail. Start at the selection guide.

Select the products for this machine Enter power, torque and network; compare compatible drives and motors and add them to your basket. Selection guide
3.2

The architecture: which product goes where

The boxes show the real products; click one to open the series.

EtherCAT Operator panel HMI-R9 Controller · CODESYS MAT-LC CPU I/O and sensors MAT-LC I/O · PNP / NPN Safe stop STO · brake Supply protection EMI · braking resistor Print unit Drive · SDU3 CSP · EtherCAT Motor SMR Register correction Drive · SD24-LP CSP · EtherCAT Motor Photoelectric Unwind / rewind Drive · SDU3 CST · EtherCAT Motor SM10
  • EtherCAT
  • Ethernet
  • Power and feedback
  • Safety
Where this machine sits on the full SMB system map
CPU / PLC & Motion Control 3 series Expansion Rack / IO 10 products Ethernet switch Ethernet Operator Panels 3 series Sensors 3 series EtherCAT Servo Drives 17 products CANopen Servo Drives 6 products Modbus RTU Servo Drives 4 products Servo Motors 6 series Power and Encoder Cables 2 series CODESYS IEC 61131-3 PLCopen Motion Control CiA 402 Drive profile
EtherCAT Ethernet CANopen Modbus RTU Digital I/O Power and feedback

CPU / PLC & Motion Control

Expansion Rack / IO

Ethernet switch

The industrial switch distributes Ethernet traffic between the controller, the operator panel and the engineering PC. It is part of the architecture, not part of the SMB catalogue.

Operator Panels

Sensors

EtherCAT Servo Drives

CANopen Servo Drives

Modbus RTU Servo Drives

Servo Motors

Power and Encoder Cables

CODESYS

SMB controllers are programmed in CODESYS: the IEC 61131-3 languages, integrated motion and a single project covering both machine logic and the axes.

PLCopen

PLCopen Motion Control function blocks give every axis the same standard interface, so proven machine code carries over from one project to the next.

CiA 402

SMB servo drives implement the CiA 402 drive profile: the same state machine and the same operating modes over EtherCAT and over CANopen.

3.3

Product placement, axis by axis

Each axis, its task, its control mode and the drive–motor pair on it.

  1. 01
    Print unit Cylinder locked to the master
    CSP · EtherCAT
    SDU3 Drive SDU3 Series Three-phase 380 V AC EtherCAT servo drives with power steps from 400 W to 7.5 kW. SMR Motor SMR Series Low-inertia servo motors in 60–130 mm frames, single-phase 220 V AC and three-phase 380 V AC, 400 W–7.5 kW, with BiSS absolute encoders.
  2. 02
    Register correction Phase correction from the print mark
    CSP · EtherCAT
    SD24-LP Drive SD24-LP Series Flagship EtherCAT low-power servo drive line. Photoelectric Motor Photoelectric Sensors M8-body photoelectric sensors with 110 mm–1 m sensing range and PNP/NPN, NO/NC outputs.
  3. 03
    Unwind / rewind Constant web tension
    CST · EtherCAT
    SDU3 Drive SDU3 Series Three-phase 380 V AC EtherCAT servo drives with power steps from 400 W to 7.5 kW. SM10 Motor SM10 Flange Family 100 mm-frame servo motors, 220/380 V AC, 1–3 kW, with BiSS and incremental encoder options.

CSP: cyclic synchronous position · CSV: cyclic synchronous velocity · CST: cyclic synchronous torque · PP: profile position. The series is confirmed by load and supply voltage.

3.4

The build, step by step

From requirement to support; the SMB products and tools each step uses.

  1. 1

    Requirements and sizing

    The motion profile, load and cycle time of every axis are collected; torque, speed and inertia ratio are calculated per axis.

    • Peak and RMS torque, top speed
    • Load-to-motor inertia ratio and gearing
    • Supply: 220 V AC, 380 V AC or 24–70 V DC
    Sizer Selection guide
  2. 2

    Architecture and product choice

    The network (EtherCAT, CANopen, Modbus RTU), the controller and the drive–motor pair per axis are chosen; the safety and power side is drawn at this step.

    • EtherCAT for synchronised axes, CANopen for independent ones
    • Drive current covers the motor peak current
    • STO and braked motors come from the risk assessment
    SM10-DIN13-100B0 SDCE0101-H MATSPS1M8-350P4NOC MAT-SDU3-MP-300-D3-E
  3. 3

    Cabinet, cabling and EMC

    Power and encoder cables run in separate ducts with their shields bonded 360°; an EMI filter goes at the drive input and a braking resistor where the load regenerates.

    • Flexible cable for the cable chain
    • Shields are earthed at both ends
    • The braking resistor is sized from the braking energy
    Power / Motor Cables Encoder Cables SMKP Power Connectors SMKE Encoder Connectors EMI Filters Braking Resistors
  4. 4

    Software and network

    In the CODESYS project the axes are defined with PLCopen blocks; the drives join the network through their ESI/EDS files and run the CiA 402 state machine.

    • IEC 61131-3 languages and PLCopen Motion Control
    • ESI (EtherCAT) and EDS (CANopen) in the Document Centre
    • EtherCAT coupler for remote I/O
    MAT-LC CodeSys CPU MAT-LC I/O Modules MAT-LC System Modules
    CODESYS FAQ Document centre
  5. 5

    Commissioning and tuning

    After wiring and direction checks the gains are tuned and the axes homed; the operator panel carries the machine recipes.

    • Direction, limit and emergency-stop tests
    • Speed and position loop gain tuning
    • Backing up the parameter sets
    HMI-R9 Series
    Commissioning FAQ Troubleshooting
  6. 6

    Support and lifecycle

    Alarm codes, spare parts, firmware and training, from the same engineering team.

    • Alarm-code and troubleshooting guides
    • Manual, CAD and firmware downloads
    • Remote and on-site support
    Technical support Document centre
3.5

The solution package: what comes with the product

Hardware, software, engineering and lifecycle.

02

Software and know-how

The CODESYS project, PLCopen motion blocks and know-how specific to this machine.

  • Register control across print units
  • Web tension and sync through speed changes
  • Cylinders locked to a virtual master
03

Engineering support

Sizing, architecture, commissioning and tuning, on site and remotely.

  • Motor and drive sizing per axis
  • System architecture and network choice
  • Commissioning, gain tuning and homing
04

Lifecycle

Manuals, ESI/EDS files, spare parts and training.

  • Document Centre: manuals, CAD, firmware
  • ESI and EDS files, parameter backups
  • Spare parts and user training
Engineering knowledge base

Commissioning this application

The topics engineers in this industry ask about most, each with answers, checklists and troubleshooting steps.

EtherCAT CODESYS Analog control Servo commissioning & tuning

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