Trouble-shooting in the processing of books and periodicals

The universal application of paper-bound perfect binding automatic production lines in book and printing companies has laid a solid foundation for the development of post-press processing to high speed and automation. Direction development. However, there are still many equipment failures in the binding process, affecting the production cycle and product quality. Now I have summarized the problems and solutions that I often encounter in equipment management and quality management for reference by colleagues.

Troubles and elimination of paper-bound wireless perfect binding linkage line

Our factory takes the paper binding wireless perfect binding linkage line as the main binding equipment, and there are also some stand-alone machines. Once the equipment fails, even a small failure will affect the production cycle.

Fault 1: There are more posts and fewer posts in the page, and the return rate is high

In order to ensure the quality, the collating machine has an automatic detection device for multiple posts and few posts. After the pages are collated, there are staff to check the book blocks. Through such repeated inspections, there are basically no major errors such as multiple posts and few posts in the book. The workshop strictly implements a layer-by-layer check system, and the work responsibilities of each process are implemented to people, so that the return rate of books can be guaranteed below zero per 100,000. Five national standards. However, the wireless binding line is generally arranged by two staff per class to be inspected by the staff, and the book is "ten drawn and one" checked. For some occasional problems, it is not easy to find out that it is impossible to complete each book after the package is completed. , Can be checked in turn. Especially for the 32-book double-book, if there is a double-post wrong, there are two books in the hands of the readers, which increases the rate of returning books. The causes of faults caused by the collating machine are as follows:

(1) The signature detection wheel of the ZXJ440 hybrid collating machine is worn or the gripper position of the gripper is not the same as the proximity switch operating point.

The working principle is that when the signature rotates with the gripping paper wheel to the detection pressure roller, after rolling, if the thickness of the signature is greater or less than the adjusted thickness, the displacement sensor acts to transmit the signal to the detection control box, which is controlled by the computer The next ten collating machines stopped collating and sent the signature to the bad book bucket. The detection of multi-posted signatures is based on the gripping of the paper wheel to read the signatures and then to the detection pressure roller. After rolling, the multi-post signatures are eliminated by the lever of the detection pressure roller and the work of the proximity switch; The detection is the detection signal through the photoelectric switch, which is controlled by the computer to eliminate the less post. Due to the long-term rolling of the detection pressure roller, the working face is worn out, and the lever amplification effect will be lost. The installation position of some gripper wheels will change, and the working contact surface of gripper and detection pressure roller will change, which cannot be detected normally.

Remedy: refer to the adjustment method of the nine-hole disk of the ZXJD440A medium-speed paperback wireless perfect binding linkage line, check the detection position according to the requirements of the manual, check the working time of the proximity switch and the displacement signal in the computer, replace the worn detection roller, and then adjust the thickness To ensure that multi-post book blocks are eliminated.

(2) The book lever on the book collection chain does not match the drop position of the signature on the grip wheel.

The main reason is that the double-sized 32-page double-headed book is longer and requires accurate fall. If the fall is too late, the previous post will fall on the post of the post, resulting in more posts in the latter book and less in the previous book Post.

Remedy: Move the book chain backwards so that the signature falls on the middle position of the two dials. And was taken away by the book lever.

Malfunction 2 Malfunction of electromagnetic gas valve and gas valve of collating machine

(1) Every three collating tables have an electromagnetic gas valve. The common fault is that the electromagnetic gas valve cannot be cut off or the gas path is not open.

Failure analysis: paper wool and paper dust are blocked in the air path of the solenoid valve, which prevents the valve core from running normally.

Removal method: Use the air pump to blow the air circuit and blow the suction pipe regularly to remove the accumulated paper wool, paper dust, and when the blockage is serious, the two screws connected to the valve body can be removed and the upper part of the valve body can be unscrewed. Plastic cover, remove the valve. Core, clean up the deposits, and put it back as it is

(2) Malfunction of V-3-1-1 / 4B valve of collating machine

Failure analysis: The air valve is a must-use item for each collating table. The general failure is also because the paper dust enters the valve sleeve of the air valve, the air intake is reduced, and the post is not smooth.

Removal method: remove the accumulation.

However, the cause of its damage is not necessarily a clogged air valve. , Or it may be disassembly. Improper method leads to damage to the valve sleeve. In the past, due to full-time personnel to maintain workshop equipment, the problem of scrapping parts caused by some minor faults did not attract attention. Today, when promoting open source and reducing expenditure, the purchase of a gas valve costs 10,000 yuan and should be paid attention to. The air valve is correct. The disassembly method is to remove the air valve from the working position of the machine, place one end of the valve body on the side of the jaws of the clamp table, and the valve seat side of the valve body is aligned with the inner hexagon head of the M8X25 inner hexagon screw In the middle of the valve sleeve, the other side of the screw is pressed against the jaws, the purpose is to increase the contact area of ​​the screw, prevent the valve sleeve from breaking, and at the same time facilitate the removal of the snap ring. Then tighten the jaws of the vise; the valve seat moves inwards, use the circlip pliers to remove the circlip, and then relax the jaws of the pliers, pay attention to the removed parts at this time, pay attention to the spring assembly, and don't lose it. After removing the paper wool and paper dust, install it in the same way as before. With this method, one person can complete the disassembly and assembly of the valve with less damage. After using this method, no air valve has been purchased. In the past, the valve sleeve was damaged due to improper disassembly, and the valve with other accessories intact. You can purchase the valve sleeve of model 218794 and reinstall it, which saves a lot of money.

Malfunction 3: Malfunction of the gripper spring of collating machine

Failure analysis: The gripping tension spring designed on the collating machine has a large tensile force. Every time a post is matched, the gripping tension spring will rub against the hanging spring column. After a long time, some of the movable springs of the hanging spring column wear through, some The hanging spring column breaks from the root of the positioning stud on the sector plate. If it is not replaced at this time, it will have a serious impact on the relevant parts of the collating machine. After the gripper is out of control, it will sometimes collide with the connecting rod of the nozzle, and sometimes it will collide with the detection pressure roller. It must be stopped to solve. To replace the broken screw, the fan-shaped plate with broken wire must be removed first and then taken out. Therefore, it is necessary to loosen the positioning of the gripper wheel and release the swing lever on the gripper shaft controlled by the gripper time cam. However, because the gripper wheel of the collating machine is relatively compact, it is not easy to disassemble, and the gripper and detection pressure The relative position is the key mechanical part for detecting multiple posts. After disassembly, the recovery time is long, and the fastest time is two to three hours, which easily affects production.

Removal method: According to the outer diameter and height of the hanging spring movable sleeve and the size of the tension spring installation groove, a batch of movable sleeves are processed, but the inner diameter is changed to the through hole of the umbrella 8.1, and the other end is also processed with a hanging spring groove, using M8X70 hexagonal The head screw replaces the original set screw. Because there is no retreat slot, the phenomenon that the root of the hanging spring is properly positioned from the fan-shaped plate is reduced. If it is found that some of the movable sleeves are worn, without removing other parts, you can directly use the fork wrench to remove the M8 screw and turn the movable sleeve back to reuse. It only takes a few minutes to complete the original repair work for several hours. If the movable sleeve is processed, it is then quenched; it can not only increase the hardness but also be more resistant to friction;

Fault 4: The fault of the wireless perfect binding online binding machine

(1) There is some difference during the operation of the adhesive rubber wheel, or the phenomenon of jamming occurs.

Failure analysis: The operation of the rubber back wheel is driven by the meshing of the gear on the rhythm end of the rubber wheel and the power part of the binding machine. If the hot melt glue sticks to the gear, which affects the gear meshing operation, it needs to be cleaned in time, but some hot melt Poor glue quality is also the cause of failure. If the anti-aging ability of the hot melt adhesive is poor, the amount of titanium dioxide additive is large, the shaft and the seal ring will wear and rub against for a long time, the aging of the hot melt adhesive enters the shaft sleeve, blocks the lubricating oil inlet, so that the lubricating oil cannot enter, the bushing Lack of lubrication will produce abnormal noise. If it is not eliminated in time, the gummed axle may be twisted.

Remedy: First pour off the glue in the glue pot, remove the glue wheel and shaft, clean the foreign body of the shaft sleeve, add a small amount of high temperature resistant butter after clearing the oil path. Then, polish the shaft, replace the damaged seals at both ends, and install the appropriate amount of lubricant after installation. Finally, turn it by hand, the rubber wheel runs freely, and then push it into the operating station.

(2) There is no side glue on the bound book, which causes the cover to fall.

Failure analysis: the side glue wheel of the perfect binding machine falls into the glue pot during operation ÷ causing some glue-bound books to have no side glue.

Removal method: carefully observe the positioning shaft of the side rubber wheel, there is a mark pressed by the top wire at the location, measure the thickness of the side rubber wheel and the length of the positioning plate to the top wire and add 0.2mm on this basis, and leave it as the side rubber wheel Running clearance. Used in the top silk mark, assorted files to file out a 2mmX5mm platform. After installing the original positioning shaft and side rubber wheel into the station, tighten its fixing screws. Because the short shaft has a step, it not only restricts the rotation of the positioning shaft, but also the positioning shaft cannot move up and down. After this processing and positioning, the problem of no side glue is solved, and the side rubber wheel rarely drops. [next]

Disc package local machine failure and troubleshooting

Failure 1: BBY45 / 8 disc package machine shutdown failure

Failure analysis: When the cover is transported to the supporting platform, it is easy to cause the malfunction of the photoelectric switch of the cover detection, which causes the machine to stop frequently. As long as it is down, at least 3 books of book binding quality will be affected. After the machine is stopped, the glue layer cannot be applied to the back of the book normally; or the glue wheel stops, causing uneven glue application and loose book binding; or when the glue is dry, the cover is easy to fall off. After exchanging the computer memory of the two disc packs, after checking and analyzing the working conditions of the photoelectric switch, proximity switch, and gas valve, it is considered that the simplest method is to increase the force of the sealing wheel to make the cover convey Speed ​​up. However, due to the shadow of the cover across the bridge, the adjustment effect is not good. There is no downtime when the package is small, and the fault reappears when the package is 32.

Removal method: through two comparison adjustments, the possibility of electrical failure is eliminated. When the supporting platform reaches the lowest point, adjust the connecting rods of the left and right bookshelf; make its connecting shaft and rubber roller contact in advance \ When the cover output is found during the test machine, the supporting platform just drops to the lowest point, and the cover does not There will be jamming. Therefore, it is required that the debugging personnel not only know whether the photoelectric switch is working properly, but also be diligent in observing the equipment, and can accurately determine the location of the fault and solve it in time.

Fault 2: When the cover has no side glue or the book block slams the side glue pot away

Failure analysis: the two 103 bearings on the large rubber wheel shaft on the side glue pot of the disc package are blocked by the aging material of hot melt adhesive, resulting in the bearing not moving, so that the big rubber wheel on the side glue pot does not move, the side glue The system has no power and there is no glue on the side glue wheel. At this time, the side glue pot is easily knocked away by the book block.

Remedy: first remove the positioning screw, then remove the lock nut on the large rubber wheel, remove the circlip, remove the 103 bearing, remove the residue of aging hot melt adhesive, replace the high temperature resistant sealing ring under the bearing, and manually test run After that, install it in the original station.

Malfunction 3: BBY40 / 5 disc pack machine does not realize the phenomenon of adhesive

Failure analysis: The main reason is that the positioning ring on the adjusting screw of the rubber wheel frame of the upper bottom glue device is loose. After the machine runs, it is driven downward by the chain, causing the height of the bottom rubber wheel to drop, which is inconsistent with the height of the second book drop platform. The upper rubber wheel can not push the book block, causing the glue to be untrue.

Remedy: Loosen the two hex screws of the U-shaped board, then loosen the adjusting screw, position the retaining ring on the adjusting screw according to the thickness of the U-shaped board, and weld it. Finally adjust to the bottom of the first upper bottom rubber wheelbase 8.5mm, which is the same as the height of the second book drop platform. [next]

Trouble shooting of ZYH660 hybrid folding machine

Trouble 1: Hunan Xinshao ZYH660 Hybrid Folding Machine Paper Feed Sheet

Failure analysis: The hollow sleeve and the outer sealing sleeve of the valve body of the suction wheel are worn out, which causes the wind wheel to continue to gas, and the paper is fed continuously, which is a waste.

Exclusion method: According to the air supply control principle of the wind wheel of the ZYH920 hybrid folding machine, it can be modified on its own.

First, remove the valve sleeve connected to the solenoid spool screw. The hexagonal head of M12X100 hexagonal head screw is processed into a cone top. The other end of the screw rod is drilled with a deep M5X25 wire hole, which is connected to the electromagnet screw, and a support spring is placed in the middle to ensure the smooth operation of the jack. On the air path connected to the wind wheel, use "plastic king" (polytetrafluoroethylene) to process the outer diameter of the solenoid valve mounting seat with the same diameter, the column height is 20mm, and the inner diameter is 6mm. The cone top of the rod is matched, and the other end is in communication with the air path of the wind wheel, and then fixed. Due to the use of "Plastic King", the more the plastic column is used, the brighter it is, and the air tightness is better. The air path is opened when the solenoid valve is closed, and the suction is reset by the support spring when it is relaxed. The closing performance can be controlled by adjusting the relative position of the ejector rod and the solenoid valve.

Fault 2: Zihong, ZYH660D hybrid folding machine, the second fold when folding thin paper, the bottom corner is uneven, wrinkled or broken

Failure analysis; the paper-pressing mechanism of this machine is different from that of Hunan's Xinshao Folding Machine. The distance between the upper and lower pressing strips is larger, and it is different from that of Hunan when folding 65g / m2 paper. The Xinshao folding machine makes no difference but when folding thin paper, the problem is more obvious. The speed of the hybrid folding machine is faster,-the paper on the conveyor belt will inevitably have a large impact force on the back stop. When the distance between the upper and lower bead is large, the paper is easy to curl; and the curling degree on both sides is inconsistent. The edges are naturally uneven, and the errors of the folded pages are beyond the standard.

Remedy: reduce the speed of the machine properly and reduce the medium-strike force of the paper backwards. The discharge of the paper pressing balls can also be adjusted accordingly. Press two rows of pressing balls on the side of the rear stop to prevent the paper from curling up. At the front edge of the paper of the rear stopper, press four rows of pressing balls to prevent the paper from retreating and creating uneven corners. Adjust the cam feed time of the proximity switch. As soon as the paper is in place, the folding knife is lowered to reduce the backward force of the paper caused by the paper feed: the medium-strike force prevents the folding of the paper. Adjust the descending depth of the folding knife to prevent the paper from being taken away by the folding roller when the machine is jogged.

To determine whether the folding knife has fallen too deep, just observe that the paper is taken away by the folding roller; and the folding knife is too deep before it starts to lift. The edge of the paper is curled unevenly, and the folding knife is lowered too deep. At this time, the fold of the folding paper is prone to occur. You can adjust the pressure of the edge of the broken folding roller appropriately and raise the folding knife. On the side where the paper is not transported in place: use the method of increasing the pressure of the discharge ball, apply a large pressure and adjust the conveying belt to make the tension consistent, and promote the paper to the gauge. In addition, first ensure that the paper comes out from the tenth fold fence, and the conveying speed is consistent, and then use the creasing knife to provide the condition for the first: two-fold folding. By adjusting the placement of the paper ball, the pressure adjustment of the folding roller, • the adjustment of the depth and degree of the folding knife, the paper feeding time is adjusted to the adjustment of the folding knife time, and the pressure is installed. Mark knife: the method, the second corner of Ke Yue Gen thin and soft paper is uneven, wrinkled or broken. Mouth failure.

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