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Gearless Servo Flexographic press has become increasingly popular among the printing and packaging industry. A Servo Flexographic press is able to maintain print quality, reduce startup time and waste better. Many know that gearless servo presses are more precise when it comes to color registration and impression control when compared to a geared press. But why is it more precise? When is it more precise? Are there any other advantages besides being more precise? In this article we will understand why a servo gearless is more precise, we need to understand what is affecting the print precision in the first place. The accurate synchronization of the anilox roller and the plate cylinder at each print deck plays an important role in print precision. In the flexographic printing process, the anilox roller contacts the plate cylinder that carries the plate with dot patterns that form the print image. During the contact, ink is transferred over from the anilox roller over to the dot patterns. To be able to provide a constant ink coverage is crucial to the print quality and this depends on maintaining consistent motion between the surface of the anilox roller and the plate cylinder. Whenever the print cylinder moves faster than the anilox roller, less ink is transferred to the print cylinder, resulting in a light section In the printed piece. Whenever the anilox roller moves faster than the print cylinder, more than the normal amount of ink is transferred, resulting in a dark section. Now, knowing what affects the print precision, let’s look into the mechanism of a geared press and a servo gearless press.This type of mechanism creates a backlash in the geared system. Backlash causes the roller and cylinder to rapidly accelerate and decelerate as the gear teeth bounce back and forth against each other.The direct-drive rotary servo motors synchronize the anilox roller and the plate cylinder to a much higher level with precision without the mechanical gears. The servo gearless mechanism eliminates gearing together of the anilox, plate and impression cylinder through a single motor. Instead, each anilox plate and impression cylinder has an independent servo motor driving it , The motion of the anilox and plate cylinders are electronically synchronized by a closed-loop control system. The motion feedback device provides the servo motors with far more accurate position and velocity information that the controller compares to its programmed motion profile and based on this signal sends velocity commands signals to the amplifier that drives the servo motor. As result synchronizing the anilox roller and plate cylinder in both speed and phase with precision.

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