This project involved developing a programmable logic control (PLC)-based system for a duplex xerographic printing press. The PLC controller—a TI565—consisted of approximately 100 discrete I/O points and 50 analog I/O signals. We developed all software for the system controls (consisting primarily of motor controllers), liquid toner ink control system, main press drive control, dryer control, web transport control and a user interface terminal. Closed-loop process control of print engine parameters allowed for improved print quality and consistency. This required use of high-level special functions within a PC programming environment, such as analog alarms, proportional integral derivative (PID) loops and special function programs. The main drive system consisted of a general Electric DC-300 four quadrant, regenerative motor controller. The power distribution system consisted of transformers, circuit breakers, motor starters, contactors and fuses. The user interface terminal consisted of Panelmate 1 and provided icons, alarms and both automatic and diagnostic modes of operation. For the design of the liquid toner ink control system, we were awarded U.S. Patent number 5,003,352.

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