Linear motion is key to die-cutting accuracy

Edited by the Engineeringtalk editorial team Jun 11, 2003

To create a new die-cutting machine that incorporates speed, accuracy and reliability, Baysek Machines called on THK to supply a dependable linear motion solution.

To create a new die-cutting machine that incorporates speed, accuracy and reliability, Baysek Machines called on THK to supply a dependable linear motion solution that could provide superior performance at the highest processing speeds.

Established in March 2001, Baysek Machines launched its first die-cutting machine, the Cutter, in October of the same year.

Featuring multiple SSR linear motion guides and linear slide packs supplied by THK UK, the new machine has received critical acclaim from the corrugated conversion sector of the packaging industry.

Its success can be attributed to the machine's ability to process 2000 sheets of uncut cardboard - or corrugated board - every hour while requiring only one person to operate it.

"We wanted to create a fast, accurate and reliable machine that could process 60 million square feet of board a year", says Ron Aberdeen, Managing Director of Baysek.

As the GBP 165,000 machine becomes the main die-cutting facility for many of Baysek's customers, dependability was also clearly important.

To achieve this, Baysek's engineers sought guidance from THK, a linear motion component supplier they knew well from previous design work.

Featuring SSR linear motion guides and compact FBW slide packs, the Cutter processes board from a pallet by lifting individual sheets and placing them on a cutting die positioned underneath the sheet.

Holding the board in place via a series of vacuum pads, the die bed travels through two rollers that cut the board into the shapes embossed on the die.

While the finished work is removed and stacked neatly in a pile at the unload end, the die bed travels back to pick up the next sheet.

For each machine, 14 SSR linear motion guides featuring Caged Ball technology were specified along with four lightweight FBW slide packs to secure the alignment of the Cutter's feed stack.

The SSRs are used to facilitate the movement of the machine's cutting bed, support its load trolleys and activate the sheet-lifting apparatus.

"The THK components do their job exceptionally well", says Aberdeen.

"They play an important role in the movement of the die bed and in the stacking of the uncut board and finished work.

What's important to us is the reliability of the guides and their ability to cope with the processing speeds that can reach over 30 sheets a minute".

The SSR linear motion guides provide enhanced linear movements through THK's Caged Ball technology, which incorporate lubricant-compatible retainers that hold the guide's ball bearings at an equal distance from each other.

The resulting assembly eliminates ball-to-ball contact ensuring maintenance-free operation and superior performance at higher speeds.

As registration is also an important consideration, Aberdeen says THK's components were crucial in achieving the Cutter's accuracy levels, which reach +/-1mm for non-printed material and up to 4um for printed work.

THK's slide packs ensure that the Cutter's feed stack remains in the correct position so the top sheet can be placed accurately on the die bed.

The lightweight and compact FBW slider and dedicated rail provide reliable linear motion and remarkable levels of wear through a construction that resists the harsh die-cutting operating conditions.

Aberdeen believes effective delegation has been crucial in establishing Baysek and launching its new die-cutting machine.

"Being able to delegate the right job to the right company at the right time is an important part of business management.

It's also important to work with a company that has a good track record.

THK has been superbly supportive to us, particularly as a new company.

It has provided us with the knowledge that we have a supplier that is willing to support us and the confidence in a brand respected for its quality".