Upgrading a 10-Color Packaging Printing Press: A Comprehensive Inverter Retrofit Solution from SSD AC690+ to Parker AC30

In the premium plastic film and shaped aluminum foil packaging manufacturing industry, 10-color printing presses demand extremely stringent synchronization and tension control. For machines with a lifespan spanning over 20 years, while the mechanical systems remain exceptionally robust, the legacy electrical systems—such as the SSD Drives AC690+ inverter series—often become obsolete, slow to respond, and face a severe shortage of replacement spare parts.

biến tần AC690+ SSD Drive

Upgrading to the next-generation Parker AC30 drive, combined with high-speed communication architecture and precise control algorithms, is the golden key to ‘reviving’ these legendary machines. This setup pushes operating speeds up to 260 meters per minute while ensuring absolute accuracy with zero color misregistration.

1. The Essence of Synchronization Technology in High-Speed Printing Presses

To ensure stable machine operation at a high speed of 260 m/min, the drive systems controlling the 5 main sections must coordinate seamlessly under a tightly integrated architecture:

  • Main Drive (Master Drive): Sets and maintains an absolutely precise Line Speed. The Main Drive acts as the primary master axis, transmitting this standard Line Speed reference to all other sections for real-time synchronization.

  • Rewind/Unwind and Infeed/Outfeed Stations: Receive the Line Speed command from the Main Drive and trigger independent PID scan loops to handle any physical and mechanical deviations of the film.

2. Detailed Control Solutions for the 5 Technological Sections on Parker AC30

AC30 Parker

Unwind & Rewind Stations – Precise Diameter Calculation Combined with PID Control

For both the Unwind and Rewind stations, the continuous change in material roll diameter is the primary factor causing tension instability. The solution on the Parker AC30 is to utilize a continuous diameter estimation algorithm (Diameter Calculator) embedded directly within the drive’s processor memory. This algorithm constantly calculates the diameter based on the speed ratio, then integrates it with a precise PID feedback loop from the tension sensor (Loadcell) or the dancer arm position (Dancer). This combination enables smooth speed/torque control of the rewind/unwind axes, completely eliminating film jerking or telescoping/weaving, even when the machine speed reaches the 260 m/min threshold.

Infeed & Outfeed Stations – PID Scan Loops for Oscillation Control

  • Infeed: Tasked with isolating tension fluctuations from the unwind roll, creating absolutely flat pre-tension for the film.

  • Outfeed: Positioned after the high-temperature drying hoods, it pulls the film out of the printing zone and stabilizes any thermal expansion/contraction before the material is fed into the rewind station.

Both the Infeed and Outfeed stations on the Parker AC30 are configured to run ultra-precise PID loops (typically dancer position PID). The inverters continuously receive the Line Speed signal from the Main drive for coarse speed matching, while the PID loop concurrently performs continuous fine-tuning (Speed Trim) to keep the web perfectly stable, preventing any slack or over-tensioning.

Main Drive Station (Master Axis) – Maintaining Absolute Precision in Line Speed

Serving as the ‘conductor’ of the entire 10-color production line, the Main drive motor is controlled by the Parker AC30 operating in Closed-loop Flux Vector mode (via the 7001-00-00 Encoder Feedback Card). The inverter controls the Main axis to maintain an absolutely precise Line Speed down to the millisecond, preventing any voltage dips or speed slips when the mechanical impression cylinders press down on the web. This benchmark Line Speed signal is then transmitted via high-speed digital communication to all satellite stations (Unwind, Infeed, Outfeed, Rewind).

3. Advantages of Modernizing the Electrical System with Parker AC30

  • Breakthrough Speed: Switching from the legacy analog system to high-speed digital communication between the AC30 drives completely eliminates signal propagation delay, allowing the older printing press to operate smoothly at a speed of 260 m/min (far surpassing the legacy system’s limitations).

260 m/p

  • Ultra-Durable Circuit Boards: The packaging printing press environment is typically characterized by high levels of evaporated solvents and inks. The AC30 circuit boards feature standard 3C3 and 3C4 conformal coating, providing complete resistance to chemical corrosive agents and ensuring long-term cabinet durability over the years. Modern Programming Platform: The PDQ software enables engineers to easily optimize and reconfigure PID functions as well as diameter calculation algorithms in an intuitive and highly accurate manner.

  • Conclusion Upgrading the electrical system from the SSD AC690+ to the Parker AC30 is the perfect solution for aging packaging printing presses. The combination of absolute Line Speed precision from the Main drive, robust PID loops handling dynamics at the Infeed/Outfeed, and diameter calculations integrated with PID control at the Rewind/Unwind stations has delivered proven real-world efficiency: Helping a 21-year-old machine continue running powerfully to achieve a high productivity of 260 m/min, while saving billions of VND in new machinery investment costs for the enterprise.

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