An excellent press mailing service: decentralised systems

C.M.C. srl is an Italian company based in Citt di Castello (Perugia) since 1980. They are leaders in developing innovative systems in the fields of mailing, graphics and packaging on demand.

The company is able to offer high-speed machines for managing envelope inserts which are completely integrated within the production line, reading and printing systems. C.M.C. is a proud pioneer in automated mailing: C.M.C. machines can process up to 30,000 envelopes per hour with detailed digital printing tailored to your needs. Thanks to a strong engineering and informatics department, the company is able to promptly deliver on clients' needs and can speed up the variable packaging programme when sending out the materials and in the finishing process.

One of the last challenges this company took on was that of creating a customised plant which could answer to the needs of a major enterprise at European and international level. It consisted of printing and sending out publicity materials which needed promotional coupons to be printed in a short timeframe, and at the highest quality as well as being custom made. A head start on this project was consolidated technology that is market proven. Its strength, however, was the winning idea: the machine was tailored to the needs of the client, thanks to the company's research and development department, strong communication with the client on the one hand and the support of Kollmorgen on the other.

The challenge was to produce high-quality print on fine coated paper, customise, pack and send the materials with the maximum precision, quality and speed. Enrico Martinelli - Production Manager, Mailing Department, says: "For years we tried to reduce the switchboard dimensions." Sales Manager Maurizio Giacchi adds: "Thanks to Kollmorgen's solutions we were able to decentralise each drive along the three production lines that are part of the plant."

Every line is made up of three machines equipped with 24 stations matching the number of coupons, some which were customised, whilst others were standard. The objective was achieved by removing the control panel drives used previously and therefore drastically reducing the size of the switchboard, number and length of cables involved: from a four-frame stand-alone one built on alongside the machine and 2m wide, we moved to an integrated electric switchboard, saving in the process some external space. The AKD-N series drives, installed close to the motor only have one connection cable. The client also benefits from this since they are able to save space for the materials: this transformed the machine to improve efficiency at reduced cost (Total Cost of Ownership).

AKD-N Multiaxis Servo Amplifier System: the winning input

The keystone to this project was the use of the AKD-N Multiaxis Servo Amplifier System, an innovative technology with excellent performance that comes in a very compact size. Thanks to the robust structure and the IP67 protection class, the new decentralised AKD-N Kollmorgen servo drives can be placed close to the motor. Plug-in connections, freedom of choice of motor, most suitable mounting point, and wide range of functions: these decentralised AKD-N servo drives can offer complex Motion Control systems with EtherCAT fieldbus and/or other automated interfaces such as ProfiNet, EtherNet I/P and Modbus TCP/IP. The system offers everything necessary for new-generation machines without losing out on simplicity. Power supply as well as safety (STO) and EtherCAT fieldbus are combined in one single hybrid cable of only 11mm diameter. On the motor side there is also only one cable needed for power, brake control and feedback. This leads to more than 80 per cent of machine cable savings.

AKD-N servo amplifier - benefits:

• More compact machines
• Smaller and lighter integrated switchboards
• Servo amplifier placed closer to the machines
• Robust structure made of protection class IP67, no need for protective casing
• Easy to clean and service for hygienic environments
• High operating security - thanks to the robust structure
• Faster machine debug and test thanks to less cabling
• Higher flexibility in machine design (modularity and scalability)

C.M.C. has attained the highest benchmark through Kollmorgen components and in choosing a decentralised system. Kollmorgen is a specialist in Motion Control devices, offering a wide range of servo drives, servo amplifiers, pre-wired cabling and technical support with the highest level of experience, providing step-by-step support to the client during the entire project development. The global scale of the Kollmorgen brand has enabled C.M.C. to venture into the US and to tap into established markets.

AKM Servomotors, a step further

In terms of motors, even the wide range of AKM Servo Motors contributed to C.M.C. choosing Kollmorgen as their partner in this project: AKM practically has an unlimited number of configurations and therefore allows for unprecedented choice and flexibility as well as top-level performance and an excellent power density. It is worth noting that the AKD servo drives are easy to set up and use thanks to their plug-and-play motor recognition and self-adjustment.

Fabio Massari, Senior Sales & Key Account Manager at Kollmorgen concludes: "I'm really pleased to be working with the C.M.C. team; it's a dynamic company, full of innovative ideas, with young and talented staff. Working closely from the start with the management team and being able to share our respective needs has allowed us to provide a solution, which in this specific case has brought about a reduction in the amount of cabling used; from the old system which required 1500m down to 240m. We were able to save on more than one entire kilometre of cabling. I hope that we will be able to undertake new challenges ahead together, with the added value that has allowed us to stand out to date."

For more information please visit www.kollmorgen.com.