Diana X 135

1. Modular structure: innovative technology - folding carton gluers owe their building-block structure to the use of separate servo drives.

Diana X 135 folding carton gluers owe their building-block structure to the use of separate servo drives. This means that machine configuration is not fixed from the start, but kept open to accommodate individual requirements. Even at a later stage, Diana X 135 can still be retrofitted or rebuilt simply by adding modules. Thus the machine is no longer defined by Heidelberg, but solely by the customer, who configures it based on his unique requirements.

Virtually all types of carton blank can be processed on Diana X 135 folding carton gluers. With the innovative turning module, sophisticated speciality cartons which previously required several runs through the machine can now be folded and glued in just one pass. As a result, production costs are slashed and profitability rises. And because it can be adapted so swiftly to the latest market trends, Diana X 135 not only offers high flexibility, but represents the best possible security for the future.

Heidelberg's productivity-enhancing options - the Diana Feeder and Diana Packer - can be readily integrated into the Diana X 135 configuration. These machines help ensure that blank feeding and delivery operations do not inhibit the huge potential of Diana X 135. Diana Feeder supplies the feeder of the folding carton gluer with an uninterrupted shingled stream of blanks - the prerequisite for perfect machine performance. Diana Packer safeguards top productivity at the delivery end by automatically packing the folded and glued cartons into shipping cases. The result is a lasting increase in output through higher production speeds.

2. Faster makeready times - thanks to directly accessible modules and trouble-free setup of Diana X 135.

More automation
Behind the Diana X 135 is an ultra-modern and forward-looking machine concept which has enabled a level of automation never achieved before. From the prefolder to the folding station, all upper and lower roller bars, including the center carrier, are integrated into the AutoSet system for fully automatic makeready. This makes for a substantial reduction in setup time. Other features which highlight the exceptional level of automation on
Diana X 135 are a touchscreen with graphic user interface, a modem, and integration into machine control of external equipment such as the jet glue unit and monitoring systems.

Optimal accessibility
Diana X 135 folding carton gluers have an open design and feature extremely low side walls. These allow the individual modules to be accessed at all times, so they are quick and convenient to set up. When replacing folding or transport belts, there is no need to remove the drive shafts. Thus ergonomic design has been key in securing higher productivity on Diana X 135 folding carton gluers.

Fast feeder setup
The innovative feeder of Diana X 135 folding carton gluers is easy to operate: the side walls and feed gates can be lifted pneumatically to speed setup, thereby assuring short makeready times. The electronically controlled, optional timed feeder is operated via a touchscreen and makes setting work easier, even in the case of difficult blanks such as lockbottom cartons with long lids. With the timed feeder, the blanks are fed into the machine gently and are kept absolutely straight at all times. The belt guides are easy to position by simply turning a handle. Central adjustment of the pile supports in the running direction is quick and easy to perform using a handwheel.

3. Equipment components: built for quality - Diana X 135 folding carton gluers guarantee high precision and optimal product processing.

Feeder
For ensuring that the blanks are fed accurately and perfectly straight into the machine, a choice can be made between the driven bridging shaft, the blank aligning module and the timed feeder. With the driven bridging shaft, blank intake is assisted by the upper feeding rollers which can be positioned anywhere along the shaft. The blank aligning module is recommended for board or corrugated board cartons - particularly when running at high speeds. With complex carton layouts, the aligning module can be backed up by the driven bridging shaft plus timed feeder.

Prefolder
The standard prefolder of Diana X 135 folding carton gluers is 3.5 meters (11 feet 6 inches) in length. Having a long folding path helps to assure that creaseline 3 is handled gently during the prefold, particularly on larger blanks. The compact machine version (Version B) also offers the option of installing a backfolding hook shaft in the prefolder for running four and six-corner collapsible boxes. In order to guarantee top production speeds, even when running larger blanks, the add-on module can be fitted to the prefolder to provide extra length.

Center carrier and tuck-in station
It takes just a few easy moves in the folding station to transform the upper roller bars of the optional center carrier into a tuck-in unit. The tuck-in unit boasts decades of successful operation on Diana folding carton gluers and is especially designed to facilitate the high-speed production of shallow lockbottom cartons. The lower section of the center carrier spans the full length of the folding station and especially serves to steady larger blanks as they pass through the machine. It is also possible to pull out the central roller bars of the carrier section so that they extend into the neighboring machine modules. The upper and lower carrier sections can simply be raised by motor jointly, without having to remove any drive shafts. This makes
Diana X 135 very operator friendly.

Folding station
The folding station of Diana X 135 is over 4,000 millimeters (13 feet) in length and thus offers long folding paths. Long folding paths assure the highest folding accuracy, even on large-sized blanks and at speeds up to 650 meters per minute (2,132 feet per minute) Since realizing superior folding quality also means finding the best folding belt position for optimal lever force, it is possible to move the folding belts sideways and upwards away from the creaseline.

Transfer station
The transfer station comes equipped as standard with speed control. Thanks to a variable drive, the upper and lower belts can also be driven at different speeds. This facility offers a simple and effective way of correcting folding inaccuracies which are material-related, especially on corrugated board cartons.

Ejector
The ejector is available as an option and reliably ejects defective cartons - be they straightline or lockbottom cartons, or four and six-corner collapsible boxes. Thus the ejector is a safeguard for smooth production and consistently high product quality.

Compression and delivery section
The pressure in the compression and delivery section is generated pneumatically. Microregulating valves on the left and right of the machine allow the pressure to be set separately on each side. In this way, the pressure applied to the cartons is kept constant, assuring optimal gluing over the whole order batch - even on special cartons which have a different number of layers on each side.

4. Flexibility bonus - add-on modules create more variety and optimize production.

Turning module
Depending on format, the turning module is able to rotate blanks by up to 180 degrees to the left or right. This means that carton styles which would normally require a second machine run can be folded and glued in one pass. The turning module is operated via the central touch screen. Settings are simply stored in the system memory, making it extremely easy to set up the machine for a repeat order. With the turning module, smooth processing of countless new carton layouts becomes possible, giving carton designers fresh scope for new creations.

Lockbottom module
Highly dynamic front folding hooks with a brand-new design make pressure setting and adjustment absolutely trouble-free. And since they are highly resistant to wear, the front folding hooks also enhance output. All cross-folds on lockbottom cartons are made in the lockbottom module. This keeps the full length of the prefolder free for prefolding creaselines 1 and 3. Short makeready times are thereby assured, and there is no longer any need to add or remove format-related parts at the prefolder. Apart from processing lockbottom cartons, the lockbottom module can also be used to extend the prefolding section. This ensures that large blanks are handled gently, even at top speeds.

Module 150 - the multipurpose module
Module 150 enables collapsible boxes to be run and can also be used for extending the pre-folding path of creaseline 3. Furthermore, working in conjunction with the lockbottom module and assisted by a choice of optional attachments, Module 150 makes it possible to run other types of speciality carton.

Backfolding
Backfolding shafts driven by servo-motors, required for running collapsible boxes can be installed in the prefolder, Module 150 and lockbottom module. This is particularly important for running special styles of carton which require several backfolds. Depending on the particular machine configuration, up to four backfolding shafts can be fitted at various points in the machine. Here Diana X 135 not only demonstrates its huge versatility, but the undeniable benefits of highly modular design.

5. Electronic concept DIAlog - centralized control for smooth production.

Touchscreen operation
A touchscreen with Heidelberg design graphic user interface makes operation of Diana X 135 fast and trouble-free. All along the Heidelberg product line - from the printing press and die cutter through to the folding carton gluer and packer - the same symbols are used, so that data entry is kept as simple as possible for the operator. With DIGIset and AUTOset, the dimensions of the various carton formats and even of special carton layouts are input directly at the touchscreen and stored. The correct machine settings are then automatically calculated. This even applies to complex carton layouts such as four-corner and six-corner collapsible boxes with backfolding powered by servo-motor.

DIAlog electronic concept
The DIAlog process control computer acts as the interface between man and machine. At the touchscreen, data can be entered quickly and easily and all basic machine functions operated. Also on hand is a cordless radiocontrolled operating unit which can be used to control the principal machine functions from any position. So setting work is made much more convenient for the operator and makeready times are shortened. An integral part of the Diana X electronic concept is the diagnostic system. This system records and processes information relevant to maintenance and servicing. Error reports and their diagnosis data are automatically stored in the central computer of the Diana X 135. The machines also come equipped with a modem for remote diagnosis. This puts the Diana X user directly in contact with the Heidelberg Service Team. As a result, fewer service calls are needed and service costs can be reduced. Furthermore, all machine and production data can be optionally relayed to the customer's plant data collection system.

Setting systems
Diana X 135 offers a choice of three systems for setting the machine:

• MANUset for manual setting
• DIGIset for semi-automatic setting
• AUTOset for fully automatic setting

With MANUset, all machine settings are made manually. With DIGIset and AUTOset, only a few blank parameters need to be entered for the machine settings to be calculated automatically. Machine control then relays the setting values to the digital position displays around the machine. With the DIGIset semi-automatic system, the setting is made manually according to the target value displayed. With AUTOset, the machine elements of
Diana X 135 move fully automatically into their correct position. This means that settings can be exactly reproduced, which safeguards high product quality. Whenever required, all the basic settings from any customer order stored once can be swiftly put in place on the machine. Thus a whole catalog of settings can be made available for retrieval, lightening the operator's workload and leaving him free to concentrate on fine adjustment. All-in-all, Heidelberg positioning systems minimize setup times and get folding carton gluer production underway faster.

Installation of quality control systems
A variety of monitoring systems can be integrated into the modules of
Diana X 135 folding carton gluers. These include glue line monitors, code readers, detectors for double-blank infeed, window scanners and ejectors. All monitoring systems can be directly integrated into Diana X 135 machine control.

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