摘要
印版的图文着墨部分凹陷下去,低于印版平面,这种印刷工艺称为凹版印刷,它与胶印、凸印和柔印组成四大印刷工艺体系,具有承印材料广泛、承印幅面宽、印品质量好、印刷图案鲜艳、层次丰富和印刷速度快等独特优势,具有广阔的市场前景。目前,市场上的先进凹版雕刻机的控制器大多为国外产品,控制精度和自动化程度高,但价格也相当昂贵,因此为促进我国包装工业的进一步发展,研制具有较高性价比的雕刻机控制系统具有很重要的现实意义。本论文研究和开发了一种基于FPGA(Field Programmable Gate Array)的凹印雕刻控制系统,完成的主要工作如下：
研究了采用CTP(Compute to Plate)技术的凹印雕刻机的运动原理,分析凹印雕刻工艺,主要以铜版为雕刻材料,研究探索雕刻频率、滚筒转速、雕刻头横向速度对于网穴形态和网穴线数的变化规律,建立可雕刻任意网穴角度的菱形网点的传动关联模型。
研究了雕刻头的输入端的直流分量和交流分量对雕刻头工作电流的关系,以网穴的生成过程为研究对象,建立了网穴形态与交流振幅的关系模型,从而建立了网穴深度和形态的数学模型。
为保证凹印加工精度、稳定性和网穴质量,建立一种基于FPGA的多轴运动控制系统,并针对三轴各自的速度性能要求,分别制定优化的速度控制策略,并建立一种兼容三种速度要求的柔性加减速曲线模型,并采用VerilogHDL语言将算法实现。
为满足凹印制版电子雕刻机对大量图像数据传输的要求,研究了采用VerilogHDL语言实现PCI(Peripheral Component Interconnect)总线设计方法,设在Altera公司的Cyclone系列芯片上实现了从设备模式PCI总线下的简化协议,并以Driver Studio为开发平台完成PCI设备WDM(Windows Driver Model)驱动程序的设计,实现PC机与控制卡的高速通信。
最后,将该设计方案应用于8KHz的凹印高速电子雕刻机,对多轴运动控制、雕刻数据传输和雕刻头电流驱动进行检测和调试,并进行图像试雕。实测雕刻结果的正确性和实测数据的误差分析验证了设计方案。
The gravure printing process, in which the printing was done with a plate bearing an image lower than the printing plate, called intaglio printing. Together with offset printing, relief printing and flexible printing, they are considered as four most important printing processes. Intaglio printing has many merits, such as being suitable to many materials, broad printing width, high quality of the printing, vivid color, and high rapid of the printing process, which means a broad market prospect. Nowadays, many of the gravure engraving machines available on the market are produced abroad, which possess the attributes of high control precision and automatic degree, as a consequence, they have a high price. Therefore, in order to promote the development of our packaging, developing the control system of carving machine, which has high performance cost ratio, would have a very important realistic significance. In this study, we develop a control system of gravure engraving machine based on embedded numerical control method. The major works are presented as follows:
In the study, the motional principle of gravure engraving machine using CTP Technology was studied. The process of the intaglio printing was also analyzed. Based on the major material of copper plate, we studied the carving frequency, roll velocity and the longitudinal velocity, which would place influence on the lines and cell's angle, three-axis transmission association model was established to engrave cells of diamond shape with any cell angle.
The relationship between DC component and AC component of the input of carving head which influences the work current of engrave printing gravure cylinders head was studied. Based on the study of cell's generative process, the relation model of the cell's shape and amplitude of alternating current was established. Accordingly, the model of the depth and the shape of cell was established。
In order to maintain the precision of engraving process, stability and the quality of the cells, a multi-axes motion control system based on Field Programmable Gate Array (FPGA) was proposed. And aiming at the performance requirements of three-axis velocity, an optimized velocity control strategies was proposed and a flexible accelerate-and-decelerate curvature model which is compatible of the three kinds of velocities was also established. And these algorithms are carried out by a programming language of VerilogHDL.
To satisfy the requirements of large-scale image data transmission, a multi-axes motion control system based on PCI bus was proposed and the simplified PCI functions were realized in Altera's Cyclone chips. Based on exploitation platform of Driver Studio, a WDM driver program of PCI equipment was designed and thus the high-speed communication between the PC and control card was achieved.
At last, this design was used in the 8 KHz high speed gravure engraving machine. The testing and debugging of the machine was done including multi-axes motion controlling, the engraving data transmission, current driving of engrave head. The image engraving was tested. The design was verified by the correct engraving consequence and the error analysis of testing data.
引文
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