The general application of paperback glue automatic production lines in book printing companies lays a solid foundation for the high-speed and automated development of post-press processing, and at the same time, it also promotes the integration of post-press processing machinery into intelligent, digital, and machine, light, and electricity. The direction of development. However, there are still many equipment failures in the binding process, affecting the production cycle and product quality. The problems and solutions that are often encountered in equipment management and quality management are summarized here for reference by peers.
Failure of the paperback binding line and its elimination
Our factory uses paper-binding bindery binding lines as the main binding equipment. There are also some stand-alone machines. Once the equipment fails, even minor faults will affect the production cycle.
Fault 1: with more than one page, less posts, high return rate
In order to ensure quality, the collation machine has automatic detection devices for multiple posts and less posts, and the staff checks the book block before the page layout. Through such repeated inspections, there are basically no major mistakes in the book, such as many posts and few posts. The workshop strictly enforces the system of layer-by-layer checks and the responsibility for the work of each process is fulfilled. This ensures that the book withdrawal rate is less than one-hundredth of a millionth. Five national standards.
However, the wireless glue-binding linkage line is generally arranged for two-inch inspection personnel per class to carry out “10-stroke-one-out†inspection of books. For some accidental problems, it is not easy to find, and it is not possible to complete each book after the package is completed. , can be examined in turn. In particular, for 32 copies of the book, if there is a double misprint, there are two copies in the hands of the reader, increasing the book withdrawal rate. Reasons for faults caused by the collation machine include the following two points.
(1) The signature detection wheel wear of the ZXJ440 hybrid collation machine or the position of the pick-up teeth of the pick-up roller is not correct for the operation point of the proximity switch.
The working principle is that when the signature turns with the pick-up wheel to the detection pressure wheel and is rolled, if the thickness of the signature is larger or smaller than the adjustment thickness, the signal is transmitted to the detection control box through computer control. The next 10 collator stops the collation and sends the book to the bad book. The detection of its multiple signatures is based on the scrolling of the pickup wheel to read the test roller, and after rolling, through the detection of the lever's lever magnification and the work of the proximity switch, the multi-post signature is removed; the less the signature is. The detection is through the photoelectric switch detection signal, through the computer control, to delete the few posts.
Due to long-term rolling of the test roller, the working surface will wear out and lose the leverage amplification effect. The installation position of some pickup rollers will change, and the working contact surface between the tooth decay and the detection pressure roller will change and cannot be detected normally.
Remedy: Refer to ZXJD440A mid-speed flat binding wireless binding linkage nine hole adjustment method, according to the requirements of the manual check the detection position, view the working time of the proximity switch and the displacement signal in the computer, replace the worn detection pressure roller, and then adjust the thickness , to ensure that multiple posts are removed.
(2) The position of the book on the book chain and the position of the book on the pickup wheel do not match.
It is mainly a large book with 32 copies of the size of the book. It is required to be accurate when it falls. If it falls too late, the previous post will fall on the post of the next post, resulting in multiple posts in the next book. Posts.
Remedy: Move the collection chain back so that the signature falls on the middle of the two dials. And was successfully removed by the dial.
Fault 2 Electromagnetic Valve and Valve Failure of Collator
(1) Each of the three collating tables has an electromagnetic valve, and the common fault is that the electromagnetic valve cannot be cut off or the air is blocked.
Fault analysis: paper hairs and paper dust are blocked in the air path of the electromagnetic valve, so that the valve core cannot operate normally.
Remedy: Regularly use the air pump to blow the air path and back blow the suction tube to eliminate accumulated paper and paper dust. When the plugging is serious, the two screws connected to the valve body can be removed and the upper part of the valve body can be removed. Plastic cover, remove the valve. Core, cleaning debris, and then back to the original (2) V-3 1/4B valve fault analysis: valve is used for each page table, the general failure is due to paper ash into the gas In the valve sleeve, the intake air volume is reduced, and the next thread is not smooth.
Remedy: Remove deposits.
However, the cause of the damage is not necessarily the blockage of the valve. It may also be dismantled. Improper method, resulting in damage to the valve sleeve. In the past, due to the maintenance of workshop equipment by dedicated personnel, no attention was paid to the scrapping of parts caused by minor faults. Today, when it comes to advocating the opening up of sources of income, it is necessary to pay attention to the purchase of gas valves, which cost 10,000 yuan. The gas valve is correct, the removal method is to remove the valve from the working position of the machine, the end of the valve body is placed on the jaw side of the clamp table, the valve seat side of the M8X25 inner hexagonal screw with the hexagonal head alignment The middle position of the valve sleeve, the other side of the screw on the jaws, the purpose is to increase the contact area of ​​the screw, to prevent breaking the valve sleeve, and easy to remove the card spring. Then tighten the clamp jaws; move the valve seat, remove the retainer with the circlip pliers, and then loosen the clamp jaws. At this time, pay attention to the removed components, pay attention to the spring components, and do not lose. After removing the paper and paper dust, it is finally assembled in the same way as the original. With this method, one person can complete the valve assembly and disassembly, and less damage. After using this method, no gas valve was purchased. For the past due to improper demolition, resulting in valve sleeve damage, and other accessories intact valve, can buy model 218794 valve sleeve can be re-installed, which saves a lot of money.
Fault 3: Collation machine faults hanging spring column failure
Failure Analysis: The tandem puller spring tension design on the collation machine is relatively large, each with a quote, the tooth extension spring will friction with the hanging spring column, a long time later, some hanging spring column wear sets wear, some The suspension springs break from the root of the locating stud on the sector plate. If the replacement is not performed at this time, the relevant parts of the collation machine will be seriously affected. After the tooth decays, it may sometimes collide with the connecting rod of the suction nozzle, sometimes colliding with the detection pressure wheel, and must be stopped to solve the problem. To replace the broken screw, you must first remove the sector plate with the broken wire and then remove it. Therefore, the position of the pick-up roller must be released, and the oscillating rod controlled by the time-lapse cam of the jaw shaft should be released. However, due to the compact installation of the pick-up roller of the collation machine, it is inconvenient to disassemble, and the tooth decay and pressure are detected. The relative position is the key mechanical part for detecting multiple posts. After unpacking, the restoration time is long, and the fastest time is two or three hours, which easily affects the production.
Remedy: According to the outer diameter of the spring sleeve, height and the length of the spring installation slot processing a batch of activities, only the inner diameter of the 8.1 to the hole through the umbrella, the other also processing a hanging spring groove, with M8X 70 The hexagonal head screw replaces the original set screw. Because there is no undercut, the phenomenon that the hanging spring column breaks the root of the stud from the sector plate is reduced. If it is found that some of the active covers are worn and the other parts are not removed, the M8 screw can be removed directly with a fork wrench, and the active cover can be turned over for use. The original hours of repair work can be completed in just a few minutes. If the movable sleeve is processed and then quenched, not only the hardness but also the friction resistance can be improved.