Interoffice Memo

5340 Argosy Ave., Huntington Beach CA 92649 PHONE 714-893-4534 FAX 714-892-7010

GRAPHIC MACHINERY

To: Mike Lee

From: Jeff Schwarz

cc: Klaus Kalthoff, Helmut Thissen, Ralf Schifferer, Michael Schoenen, Mike Volbeding, Mark Legac, Jacky Ng, John Kipp, Axel Tuebke, Horst Steinhart, Gunnar Streidt, Bjoern Geller

Date: 12/07/09

Re: RS-38 Design Review 2

 

Background • From the first design review – Appearance and robustness were seen as the most critical

requirements for the success of the RS-38. • From recent emails – User friendliness and reliability are equally important. • Presentation of MID design, first looking at the weak points itemized in their report, and then

at their proposals 1 and 6.

RS-38 Design Review 2 Page 2

Discussion of RS‐38 • Presentation of RS-38, discussing strategic use of skins and sizing guards to achieve MID

appearance:

• Footprint will be slightly larger than an RS-36. • Question to group: Is it better to use perforated steel or tinted plastic for guards?

o Final consensus is that plastic is preferred due to better appearance when new despite the long-term degradation.

• Discussion on the problems associated with the steep angle of the infeed following the squeeze rollers, especially with thin products.

o Strong opinions expressed that a shallower infeed angle is more important than ability to reach a low infeed height.

o Helmut suggested decreasing the range for infeed height adjustment, making 800mm to 1000mm standard.

• A suggestion was made to extend squeeze roller drive shafts for ease of belt maintenance. • Integrated side guard / tunnel guard would cause a problem with close-coupled blocking units

and strappers. A separate upper bin guard should be standard on all machines. • Presentation of high infeed with extension and wide belts:

RS-38 Design Review 2 Page 3

Features of the RS‐38 1. Single cylinder to drive forks in and out. 2. Servo lift on both left and right forks assembly. 3. Servo motors mounted below the level of the turntable. 4. Gapper will be more durable:

a. Discussion on historic problems with RS-36 gapper. b. Several changes were made about a year ago. Improved performance may not yet be

fully apparent in service. c. Discussion of a report from Ari detailing gapper problems. d. A proposal was made to optionally mount a second gapper at the infeed. Use the lower

gapper for cut-edge leading and thin products and the upper gapper for 16 pages+. e. The lower gapper must be able to lift out of the way for thick products. f. Cut-edge leading gapper requires the longer stream aligner.

5. Turntable basket: a. A-dimension to be adjustable in small increments plus or minus ½” while in

production. b. Motorized version to be lower cost and more durable.

6. All Festo pneumatics: a. All metric tubing. b. Request was made for all push-in style fittings.

7. Gate springs to be more durable: a. No complaints from Asia and US techs. b. Breaking springs is a problem associated with older machines.

8. Lower bin will have wider top clamps and gate plates. 9. Pusher:

a. Upsize from 400 watts to 750 watts. b. Use wider pusher instead of round bar to help with wider stacks.

10. Upper Bin – Upsize servo from 200 watts to 400 watts. 11. Vibrators:

a. Redesign for quieter operation. b. Using Festo oiler, with the solenoid valve in front of the oiler.

12. Software: a. Gapper settings to follow stacker speed. b. New screens have been added to the RS-34.

RS-38 Design Review 2 Page 4

c. More sensors on the pneumatic cylinders for improved control. d. Periodic maintenance reminders. e. Better troubleshooting guides. f. Include an on-line manual. g. Remote control and diagnostics is standard. h. Request for a clean-out mode where, at the end of a press run, the stacker goes into

slow-speed mode to capture the last of good product. 13. Keyence laser counter standard, with Denex or Baumer options available.

Final comments 1. Need for durability stressed once again, with the comment that our stackers have problems as

they reach one to two years old. 2. A retractable handle on the stream aligner would be good.

RS‐38 Project Outline and Summary Description  Start  % Comp  Resp. 

        1.  Appearance/Robustness  11/17/09 25%  ML   a)     Make side frame 7ga (.189)            b)     Reduce visible screw heads (Zinc screws on outside)        JS   c)     Make cross brace for front leg tubes  11/17/09 10%  ML   d)     Make rigid floor lock        JS 

  e)    Make infeed range smaller, starting at ~800mm to reduce transition angle after squeeze roller        JS 

2.  Accessibility            a)     Wider & taller doors on lower side and rear  11/30/09 10%  JS   b)     More open on upper side  11/30/09 5%  JS   c)     Magnetic door switches  11/30/09 20%  JS 

  d)     Make OIP more accessible (swing arm or swivel mounting)        ML   e)     Make side step 1.5" higher and top edge 1.5" lower        JS 3.  Divert            a)     2 medium belts (6” w/2” gap)  10/23/09 20%  MS   b)     Replace DC motor with AC          4.  Stream Aligner          

  a)    Make hex pulleys so they don’t stall (more grip belt to pulley)  10/29/09 15%  MS 

  b)     Make handles retractable        MS 5.  Squeeze Roller            a)     Possible larger upper roller        ML   b)     Possibly move drive belt to outside        ML 6.  Gapper            a)     Indicator for setting gap (scale?)        JS 

RS-38 Design Review 2 Page 5

  b)     More durable        ML   c)     More forgiving for thicker product (>64p)        ML 

  d)    Make sure that the gapper blade has enough spring tension for thinner products.        ML 

  e)    Make the "Gunze" style gapper an option (for <16pp products)        HS 

7.  Upper Bin            a)     Make fork actuation like RS34     10%  HS   b)     Make lift like RS36S (servo)     10%  HS   c)     Move servo motors to bottom     10%  HS   d)     Go to 400W motors        JS 8.  Turntable Basket            a)     Outside adjustability (non‐motorized, +/‐ 1/2")        ML   b)     Lower cost/more durable motorized option        ML/HS   c)     Double acting gate cylinder  10/21/09 17%  TD 

  d)    Wider top clamp and side gates (for newspaper applications)        ML 

10.  Pusher            a)     Upsize motor 400w to 750w        ML   a)     Wider pusher surface (~2") (Don't forget the prox sw!)        ML 9.  Delivery Table            a)     Make belt/air standard  11/2/09 25%  TD   b)     Replace air cylinder with new Festo composite  10/29/09 25%  TD   c)     Replace Oriental motor with ??  10/21/09 25%  TD   d)     Quick release air/power connector  11/3/09 17%  TD 10.  Vibrators            a)     Make more quiet (but not too quiet)  11/5/09 20%  TD   b)     Make rear bin plate vibrate            c)     Outside adjustability of regulator  11/5/09 10%  TD   d)     Minimum pressure so that it doesn’t stall  11/5/09 10%  TD 11.  Software            a)     Simpler screens with common bitmaps with System        IR   b)     More self diagnostics (predictive maintenance)        IR/JK   c)     Maintenance reminders        IR/JK   d)     Guided Troubleshooting        IR/JK   e)     On‐Line Manual/Help        IR/JK   f)     Remote Control/Diagnostics        IR/JK   g)     Add end of run "Cleanout" mode        IR/JK 12  General            a)     Use push‐in fittings on every place         JS   b)     Make 10‐pin connector standard for interface        JS 

  c)    Make Keyence laser counter standard (Denex or Baumer will be offered as option)     100%  JS