SmartGap® System

SmartGap® Simply smart

Whether ultra-thin substrates, through-cuttings, large working widths or high production speeds: With the adjustable anvil SmartGap® you can easily achieve perfect die-cutting results.

WHY ADJUSTABLE?

The variety of materials and ever thinner liners place special demands on all die-cutting components. Adjustable anvil cylinders allow variable adjustment of the gap dimension and thus the cutting depth. In many cases, however, conventional adjustable systems struggle with problems – especially with cutting-through, large working widths and high production speeds.

Wink‘s SmartGap® system overcomes these limitations. The SmartGap® enables you to flexibly and accurately adjust the cutting depth to your needs. The system convinces with a highly precise gap adjustment on both sides and a particularly stable construction, which ensures unique running smoothness.

SMARTGAP® VERSIONS

All SmartGap® versions use the same proven stable design, with the extra wide bearing rings of the support roller backing the body of the anvil cylinder. While the basic ADVANCE version is controlled purely mechanically using adjustment knobs, the TOUCH digital version is controlled via a control unit and display.

The Touch model provides a number of powerful functions that make die-cutting more efficient than ever. The basic Advance version can be easily upgraded to the digital Touch version, which can be extended with an AutoControl package. No matter which version you choose, with the SmartGap® you are perfectly equipped for the future of rotary die-cutting.

SMARTGAP® BENEFITS AT A GLANCE

Leading printers and press manufacturers worldwide rely on the SmartGap® system, which sets new standards in terms of functionality, stability and efficiency.

Basis Data
  • system for easy gap adjustment, consisting of adjustable anvil cylinder and a support roller, both solid and hardened. The digital version includes a touch display and a control unit.
  • adjustment range ± 80 microns
  • individual adjustment on both sides, at standstill and when machine is running
  • construction possible for all common machine types and working widths
  • suitable for cutting from below
Basic functions:
Advance
Touch
AutoControl
Technical basis:
Through-hardened anvil cylinder with high-precision eccentric adjustment unit and special support roll for maximum stability
Through-hardened anvil cylinder with high-precision eccentric adjustment unit and special support roll for maximum stability
Through-hardened anvil cylinder with high-precision eccentric adjustment unit and special support roll for maximum stability
Adjustment range:
± 80 microns
± 80 microns
± 80 microns
Minimum adjustment steps:
0.5 microns
standard: 0.5 microns; optionally down to 0.1 microns
standard: 0.5 microns; optionally down to 0.1 microns
Operation/control
analog (rotary knobs)
digital (touch screen)
digital (touch screen)
Display
only gap value
Gap value (metric or imperial), controls and additional information
Gap value (metric or imperial), controls and additional information
Gap adjustment left/right individually
yes
yes
yes
Gap adjustment left/right simultaneously
no
yes
yes
Product information, care instructions, cutting tips
no
yes
yes
Network connection
no
yes
yes
Monitoring of web and die-cutting result
no
no
yes
Automatic adjustment of gap dimension
no
no
yes

SmartGap® Advance

As the basic model in the SmartGap® range, the ADVANCE already meets the highest demands in the production of labels and other narrow web products. Thanks to its unique stability, you can easily achieve perfect die-cutting results even at high speeds. To further increase efficiency, you can easily upgrade the Advance to the digital versions TOUCH and AUTOCONTROL

THE SOLID BASIS FOR YOUR DIE-CUTTING SUCCESS

The gap between the magnetic cylinder and the anvil cylinder, also known as “clearance“ or “undercut“, is of particular importance during die-cutting. In combina-tion with the thickness and composition of the liner material, the gap dimension determines the opti-mum height of the flexible die.Changes in the gap size (e.g. due to wear or heating) have a negative effect on the cutting result. More-over, there are further challenges in die-cutting: tool tolerances, fluctuating liner gauges and ever thinner liners. With the adjustable SmartGap® system, you have the cutting process under control at all times. A high-precision eccentric mechanism quickly and precisely regulates the gap (and therefore the cutting depth).

EASY HANDLING - MAXIMUM PRECISION

Using two rotary knobs on the unit frame, you can individu-ally adjust the gap on both sides to compensate for one-sided wear, inaccuracies in the cutting tool and fluctuations in material thickness.If the knob is turned in the “GAP +“ direction, the gap size is reduced and thus the cutting becomes deeper. Turning the knob in the “GAP -“ direction reduces the cutting depth by increasing the distance between the cylinders. Adjustment is possible both at standstill and while the machine is running. The adjustment steps are only half a micron, so that even the smallest corrections can be made.

Basis Data
  • system for easy gap adjustment, consisting of adjustable anvil cylinder and a support roller, both solid and hardened. The digital version includes a touch display and a control unit.
  • adjustment range ± 80 microns
  • individual adjustment on both sides, at standstill and when machine is running
  • construction possible for all common machine types and working widths
  • suitable for cutting from below
  • SmartGap® cylinder
  • adjustment knobs
  • adjustment units
  • support roller

SmartGap® Touch

The adjustable anvil SmartGap® Touch offers much more than perfect die-cutting results at the touch of a button. On the way to fully automatic label production, it offers a wide range of smart functions to make the die-cutting process faster, easier and more efficient.

SAFE. EFFICIENT. DIGITAL.

In contrast to the analog Advance version, the touch version is adjusted by digitally controlled stepper motors. The central “BlackBox” control unit can be flexibly attached to the machine. The system is operated via a touch display, which is fixed to the cutting unit via a freely swivelling magnetic holder. When the operating elements are activated, the corresponding signals are transmitted via the BlackBox to the adjustment units, thereby adjusting the gap dimension with high precision.

DIE-CUTTING AT THE TOUCH OF A BUTTON

The display also serves as a clear indication of the currently set gap dimension values. In addition, job and tool data are displayed on request, which you can read in via QR code with the integrated camera. All job data and gap dimension adjustments are stored in order to start with the appropriate settings directly for repeat jobs, thus saving set-up time.

Basis Data
  • system for easy gap adjustment, consisting of adjustable anvil cylinder and a support roller, both solid and hardened. The digital version includes a touch display and a control unit.
  • adjustment range ± 80 microns
  • individual adjustment on both sides, at standstill and when machine is running
  • construction possible for all common machine types and working widths
  • suitable for cutting from below
  • SmartGap® cylinder
  • Touch display
  • Blackbox control unit
  • adjustment units
  • support roller
  • Wiring

SmartGap® AutoControl

Lean back! With the SmartGap® AutoControl you get an automatic gap adjustment that takes a large part of your die-cutting work off your hands.

DIE-CUTTING ALMOST BY ITSELF

With the AutoControl extension, you are taking another big leap towards automation. A specially developed sensor bar continuously monitors the die-cut material on the web. If the cutting is not deep enough, labels are pulled up with the waste matrix. The system detects these missing labels and reacts within fractions of a second if a threshold value is exceeded. The cutting depth is then automatically increased until the die-cutting result is perfect again.At the same time, AutoControl offers a configurable control function against cutting too deep to prevent damage to the liner material.Of course, the AutoControl function can also be de-activated so that manual corrections can be made via the display, if necessary

Basis Data
  • system for easy gap adjustment, consisting of adjustable anvil cylinder and a support roller, both solid and hardened. The digital version includes a touch display and a control unit.
  • adjustment range ± 80 microns
  • individual adjustment on both sides, at standstill and when machine is running
  • construction possible for all common machine types and working widths
  • suitable for cutting from below
  • SmartGap® cylinder
  • Touch display
  • Blackbox control unit
  • scan bar
  • adjustment units
  • support roller
  • wiring