Q-Line with Board Handling System – BHS180

The new Q-Line with board handling system – BHS180 and UNDERCAM is a comprehensive system solution. It is specifically tailored to the requirements of highly automated, industrial finishing in the digital production of displays and printed packaging. This new system makes it easier than ever for display and packaging manufacturers to optimize their production processes and increase their efficiency.

The individual components of this digital production solution, i.e. the board feeder with UNDERCAM, Q-Line cutter, and off-load unit, are perfectly coordinated to enable next-level productivity. Together, they offer the user highly stable and reliable cutting and thus efficient, economical processing of printed board material.

Perfectly coordinated
The Q-Line with BHS180 offers exceptional performance for every packaging and display manufacturer. Whether the BHS180, UNDERCAM, or Q-Line – each component of this digital cutting solution is packed with exciting new features. In combination, they guarantee uninterrupted, unattended production, providing users with an enormous potential for savings, irrespective of company size. The bottom line: an investment with exceptionally high value retention.

The entirely new machine concept behind the Q-Line with BHS180 is redefining performance. New machine components, such as the solid, mineral-cast substructure, the new linear drive, and beams made of carbon fiber-reinforced plastics work together to provide impressive machine speeds of up to 2.8 m/s.

Unprecedented performance also manifests itself, among other things, in an impressive acceleration of up to 2.1g, which enables extremely high processing speeds and significantly shorter cycle times per job.

Q-Line cutters are a force to be reckoned with. Based on the latest technology, the new tool modules are capable of exerting a creasing pressure of up to 500 N.

The new Q-line substructure is made from a highly stable mineral casting. It can handle any load level and, even at extremely high speeds, ensures exceptionally smooth operation and maximum cutting accuracy.

New Modules
The new AUTOMO E and AUTOMO L modules are compatible with the new generation of tools. The particular strength of AUTOMO E lies in the speed with which it lowers and lifts the tools. AUTOMO L is all about force. It is slightly larger and can exert a downward pressure of 500 N.

The first module in the module carrier is INCAM. This sensor module can capture registration marks, QR codes, and detect material edges.

Beams made from CFR plastic
The beams are made from carbon fiber-reinforced plastic, which makes them very lightweight but exceedingly strong. This means even demanding materials can be processed at top speeds and the highest quality levels.

The new workstation comes with a touchscreen for even more intuitive cutter control. The latest 4.0 version of the Zünd Cut Center ZCC, a handheld scanner for smart tool management, and a joystick to manually move the module carrier ensure operating the system is as user-friendly as possible.

Safety concept
The Q-Line is loaded with features that place greater demands on user safety. Zünd has given this fact a great deal of consideration and developed a sophisticated safety concept for Q-line cutters. Protective screens, which descend automatically, prevent access during production while allowing a clear view of the working area. A light curtain creates an additional, virtual barrier and the beams also have light barriers on each side, which are activated during processing for timely detection of any protruding material edges.

The cutters from the Q-Line are tested and certified by the German Social Accident Insurance (DGUV) organization in accordance with the European Machinery Directive 2006/42/EC.

Automated tool management
The new tool magazines have a total of seven slots. This allows the user to plan for tooling in advance in order to maximize machine utilization and significantly extend unattended production time. Any manual interventions related to tool changeovers are reduced to a minimum. The integrated DMC scanner automatically detects the type and location of tools. Consequently, there is no manual assignment of tools to a given job, and improper tool allocation is a thing of the past.

The new Q-Line with BHS180 tool management makes digital finishing more efficient than ever before. The Tomac Tool Management Client takes care of tool management to ensure easy and, above all, automated processes. Tool management digitally links the tool with presets, which also saves valuable time in setup and tool changes.

The Q-Line with BHS180 comes standard with three tool modules. Speed is of the essence for the two AUTOMO E modules, whereas AUTOMO L is all about force, producing a pressure of up to 50 kg. This makes it the obvious solution for creasing with large crease wheels such as CRETO 150. The third module, INCAM, is the sensor module. It captures registration marks, QR codes, and detects material edges.

AUTOMO is compatible with a wide range of tools. To best meet different application requirements, the modules are available in two versions.

AUTOMO serves as carrier module for many different tools. Compatible Zünd tools can be used in a wide range of applications and require different properties.

The Universal Cutting Tool is capable of processing (via Thru Cut) many different types of materials precisely and efficiently.

UNITO is suitable for through-cutting and scoring a wide range of materials. Zünd recommends the use of this tool especially for processing cardboard and different types of films.

DRAWTO is a cost-effective tool for precise marking and drawing on textiles, leather, rubber, or Teflon.

A wide range of materials can be easily marked up using this drawing tool. DRAWTO is a very economical tool since it uses readily available inserts such as ballpoint or felt-tip pens in various line widths.

It is mainly used to produce patterns in the textile and leather industries.

The ELOSTO 5 | 25 is a universal cutting tool for processing many different materials. It is always used whenever it is no longer possible to process materials simply with a drag knife.

ELOSTO is ideal for cutting soft and moderately dense materials. The high stroke frequency of this tool enables very high processing speeds and great efficiency.

ELOSTO is available with a 0,5 mm | 0,2 in or 2,5 mm | 1 in stroke depending on the application. Zünd offers a wide range of pointed or flat-tipped oscillating blades that can be used with the ELOSTO tool to accommodate specific material requirements and contour cuts.

Different material properties require different creasing tools. Zünd’s creasing tools are suitable for processing many different types of materials.

This is made possible by a wide range of crease wheels. Creasing can be performed in either position mode or pressure mode. In position mode, the crease wheel is lowered to a predefined creasing depth. This processing method is best suited for solid cardboard. When creasing corrugated cardboard, Zünd recommends using pressure mode. In this mode, the tool exerts specific, adjustable pressure on the material.

PERTO is designed to hold perforating knives. These knives can produce perforation lines more efficiently than an oscillating tool. Among other things, perforations help when folding/bending crease lines, making them more precise. Films can be perforated as well as more typically, corrugated and solid cardboard, or polypropylene (PP).

For even more information about the Zund G3 machine please visit the manufacturer’s website

UNDERCAM – the ultimate in efficiency
The UNDERCAM integrated in the board feeder captures the precise location of the graphics printed on the board. It reliably detects any distortions in the print and perfectly matches the cut to the print every time. With every scan, the software adjusts the cut paths to the printed image, on the fly and in real time, significantly reducing the cycle time for each job.

Identifying the board position
Sensors on the board feeder identify the material edges for proper alignment. If the board is not within tolerance, the board feeder grabs it once more and realigns it so that it can be fed onto the cutter without interruption. This allows even imperfectly stacked materials to be processed, which further streamlines the production workflow.

To ensure reliable board and sheet separation during the loading process, redeveloped suction cups can be individually adjusted for different materials via Zünd Cut Center – ZCC.

Perfect unloading and stacking
The innovative design of the off-load system allows bridge-free cut boards to be stacked easily and reliably, making it easier to handle completed jobs in the stack. Different jobs are stacked slightly offset, which speeds up the subsequent job separation by the operator. Any faulty boards are also set aside with an offset and are therefore easy to spot as the pallet is removed.