Unit 2018-03-19T16:43:23+00:00

UNIT

Automatic Gathering and Sewing Line

Smyth automatic gathering and sewing line mod. UNIT consists of a vertical gatherer mod. P12 connected in line with an automatic book sewing machine series 4D (FF-250 and FF-280).

This automated solution is designed for small and medium runs, and it is distinguished by the patented gatherer that gives the advantage of loading one or two signatures in each gatherer station, depending on their size. Thanks to this feature, the floor space required for this line is dramatically reduced and only one operator is needed to run the whole production system.

  • Ideal solution to drastically reduce the production costs of the sewn book
  • Exceptional compact design
  • Automatic enabling of the gatherer stations for drastic reduction of set-up times

Reduced set-up timesReduced set-up times

The simple loading of signatures on the gatherer stations automatically enables their use, drastically reducing the set-up times.

Signatures doublingSignatures doubling

In the same gatherer station the operator can load signatures having size up to 640 mm or two signatures in sequential order, having head to tail size up to 320 mm.
Therefore, for example, the gathering line composed of 9 stations transforms into a line having 18 stations.
In this way it is possible to double the number of signatures to be collected, reducing the overall need of floor space and facilitating the loading / unloading operations that can be performed by only one operator. (Smyth Patent)

Hand feeding stationHand feeding station

The UNIT line is equipped with a hand feeding station to feed pre-gathered signatures. This station allows to complete the book, if the number of the signatures is higher than the available gatherer stations.

Easy restartEasy restart

In case of signature jam, the gatherer finger that transports the signature is automatically released. Once the jam has been removed, the finger automatically repositions itself, making the machine restart easier and faster.

Operator interfaceOperator interface

Programming and diagnostics are performed through OMRON PLC and a new software designed by the in-house team of Smyth engineers. A colour touch screen is positioned centrally on the book sewing machine and additional touch screens are provided on the gatherer – every 3 (6) stations- , to enable all machine functioning parameters to be checked, together with the setting of the main automatic machine adjustments.

Smyth stacker Easy StackSmyth stacker “Easy Stack”

Smyth UNIT is equipped with the stacker that makes piles of sewn books delivered by the sewing machine in order to facilitate the unloading operations. Pile height is programmable up to 120 mm.

Signature size: It varies according to the book sewing machine model
FF-280 4D
Max 320 (spine) x 420 (width) mm
Min. 80 (spine) x 135 (width) mm (optional 65 x 135)
FF-250 4D
Max 560 (spine) x 340 (width) mm
Min. 80 (spine) x 135 (width) mm (optional 65 x 135)
Max mechanical speed: It varies according to the book sewing machine model
FF-280 4D: 180 cycles/min
FF-250 4D: 150 cycles/min
Feeder openings: 4 upper + 4 lower + integrated LAP opener
No. of sewing stitches: It varies according to the book sewing machine model
FF-280 4D: 9 stitches
FF-250 4D: 13 stitches
Sewing stitch length: 24 mm
Air consumption: Max 600 Nl/min. at 6 bar
Power consumption: 12 Kw
Standard voltage: 380V – 50Hz three-phase
Total weight: 3500 Kg
Dimensions: FF-280 4D + 6 (12) gathering stations: 9,31 mt
FF-250 4D + 6 (12) gathering stations: 9,61 mt

Courier DeviceCourier Device

To improve the versatility of the system, Smyth UNIT can be equipped with the courier device. This device is installed between the gatherer and the sewing machine, and it conveys gathered signatures to the in-line sewing machine and to an additional off-line book sewing machine, doubling the production capacity of the whole system. This is possible thanks to the gatherer high production capacity.
If the number of the signatures that compose the book is higher than the available gatherer stations, the courier device can also be used to produce the gathered signatures needed to complete the book.

Gathering sequence controlGathering sequence control

The gathering sequence control is a self-learning system performed by Omron Camera which is located in the hopper of the book sewing machine. This camera performs the gathering sequence control by reading bar codes, text and images. Thanks to continuous measurements, this system ensures the highest level of control by filtering data and info, preventing false alarms and unnecessary stops.

Modular designModular design

Thanks to the modular design, the number of gathering stations can be increased even after the installation of the line. This is possible by adding single gathering modules composed of 3 stations (which turn into 6 stations when doubled).

Signature bidirectional transport systemSignature bidirectional transport system

The gathering machine can be supplied with a 2-way signature transport system. This system allows the conventional use of the gatherer connected in line with the sewing machine, or its use in line with an existing perfect binder / stacker.
This solution is subject to technical feasibility assessment performed by Smyth engineers.

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UNIT

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