1. Accurate judgment and concise method
The maintenance work requires a short time, so it is necessary to accurately identify the faulty location, take the most concise repair method for maintenance, and solve the problem in the shortest possible time. When replacing accessories, you should choose good quality accessories, the installation work is accurate and in place, to avoid leaving trouble. Here are a few examples of daily maintenance.
Fault 1: When the feeder feeds the paper, the transmission surface is always fast
The method adopted by the manufacturer: repair the Feida valve-scrape the inner hole of the valve housing of the valve valve, plate the valve spool, and replace the paper receiving wheel.
Mistakes: After repairing, the air leakage of the valve is more serious, and the quality of the replaced splice wheel is not as good as before.
Correct method: The main reason for the paper skew is that the feeder is not parallel to the host when the machine is installed. Correct the parallelism of the feeder relative to the host.
Fault 2: When printing, there is a "peeling" fault
The operator's approach: adjust the adjustment screw on the teeth of the impression cylinder to try to increase the gripping force of the teeth.
Error: The gripping force of the teeth of the Heidelberg printing machine is determined by the spring force and the precision of the tooth processing. The above method cannot adjust the gripping force of the teeth, but can only change the handover time of the cylinder row, causing overprinting failure.
The correct method: check the wear of the dental tablets and pads and replace if necessary; check whether there is "dead tooth" on the dental row and solve the "dead tooth" problem; check the hand-over relationship between the dental rows and adjust if necessary.
Fault 3: "Swing angle" fault
The operator's method: adjust the screw under the tooth pad of the small transfer cylinder, adjust the ink viscosity, and adjust the printing pressure.
Mistakes: Adjusting the screw under the tooth pad of the small transfer roller changes the adjustment benchmark of the height of the small pad's dental pad, which makes the future calibration work more cumbersome; the ink viscosity and printing pressure should be determined according to the needs of the printed matter, not because of overprint Problems and deliberately change. These methods can not solve the problem of "swing angle" of printed products.
Necessary note: Equipment that has been used for many years and has not undergone system maintenance generally suffers from "angle swing" failures. There are many factors that cause this kind of failure, and only when the equipment is overhauled can it be solved more thoroughly.
Second, make a record
Keep a record of equipment failures, solutions, replacement parts and after-effects, etc. for future reference, and provide references for future periodic inspections and comprehensive inspections.
3. Avoid the practice of quick success
When the production task is busy, the manufacturer takes improper maintenance methods to turn on the machine as soon as possible, which will bring trouble to the future equipment maintenance work or cause hidden accidents. Practice has proved that this approach may cause greater losses. The following are some examples in this regard.
Fault 1: Ink roller gear damaged
The operator heard the abnormal sound of the machine, shut down, and disassembled the protective cover above the transmission surface, and found that there was a damage to the ink roller gear. Because the printing business is busy, the maintenance personnel continue to turn on after simple processing. After running the equipment for a period of time, it was found that a total of 8 gears in the ink supply part and the wet part were severely damaged.
It was proved afterwards that the initial cause of the gear damage was that the bearing behind the ink roller gear was damaged by the abnormal external force, and the balls in the gear fell, causing damage to the gear.
In fact, the initial damage to the gear was relatively light and could be repaired. After the machine has been running for a period of time, more balls fall out, which aggravates the gear damage. The damaged gears and the intact gears crush each other, causing more gears to be more seriously damaged. Fortunately, the ball of the bearing did not fall on the drum gear, otherwise the consequences would be unimaginable.
The correct method: thoroughly investigate the cause of gear damage, replace damaged bearings, dismantle damaged gears, and carefully repair them.
Fault 2: The main motor carbon brush alarm symbol appears on the console of the Heidelberg CD102-4 offset press
The manufacturer's treatment method: directly replace the original carbon brush. The carbon brush is only used for about 2 days, and the carbon brush alarm symbol appears again. The inspection revealed that the carbon brushes had worn out.
Correct method: Before replacing the carbon brush, the surface of the copper head of the motor must be checked. If there is obvious wear, it must be strictly handled. The steps are as follows:
â‘ Disassemble the motor and disassemble the motor rotor.
â‘¡Process the worn parts on the copper head of the motor rotor on the lathe.
â‘¢Use a sharp tool to clean the grooves on the copper head, so that the mica material in it can not contact the carbon brush, so as to increase the service life of the carbon brush.
â‘£Assemble the motor, but do not install the carbon brush.
⑤ Drag with another motor to rotate the repaired motor, use fine sandpaper to polish the copper head of the motor until it reaches a higher finish requirement, and use an air compressor to remove the copper powder generated by polishing.
â‘¥ Install the carbon brush, and use fine sandpaper to polish the contact surface of the carbon brush and the copper head.
⑦ Use another motor to drive, and make the main motor rotate for more than 12 hours.
⑧ Install the main motor on the machine at a speed of 3000 rpm, and check if there is any obvious spark at the carbon brush. If the spark is obvious, the above steps should be repeated. If there is no spark, it can be turned on and used. The speed of the previous day or two should not exceed 8000 rpm, and check the wear of the carbon brush at any time. After everything is stable, it can run at normal speed.
Trouble 3: When the delivery cylinder is in contact with the impression cylinder, it breaks through the paper
The operator's approach: bend the delivery teeth.
Mistakes: After the delivery teeth are deformed, the size of the gripper paper becomes smaller, which can easily cause the “peeling†failure of the final unit and cause trouble for the adjustment of the delivery teeth row in the future.
The correct method: check the gap between the delivery pad and the impression cylinder and the opening and closing time of the cylinder row, and adjust it. If some of the parts on the delivery line are worn, they should be replaced in time.
4. For large faults, choose maintenance personnel carefully
In the event of a failure that cannot be handled by your own maintenance force, outside maintenance personnel should be asked to perform equipment maintenance. At present, there are many maintenance companies or individual maintenance personnel engaged in Heidelberg offset presses, and their levels vary widely. Some maintenance personnel or maintenance companies often undertake equipment failure repairs that exceed their own capabilities. As a result, they not only did not solve the problems of the equipment, but also brought other problems with the equipment and caused hidden accidents.
Fault 1: Breaking fault of the plate ink roller swing frame
Due to improper operation of the Heidelberg HD102V offset printing machine, which was shipped in 1985, the two units were broken by the plate ink roller swing frame.
Treatment method: Because I don't know how to disassemble the small wallboard of the ink supply part of the machine, the two ends of the original ink inking roller are cut off, and the domestic ink inking roller is replaced.
Trouble 2: There is a quality problem with the ink roller
The position of the 8mm hole on the shaft of the transmission surface of the replaced inking roller is too large to be installed, and the hole is enlarged. The pin is reconfigured, but there is still a positional deviation.
Error: The bearing at the position of the ink roller gear is damaged due to unreasonable force. The broken bearing ball falls into the gear, causing most of the water and ink parts to be damaged. The direct economic loss is more than 50,000 yuan.
The correct method: remove the small wall plate on the operation surface of the ink supply part, take out the ink inking roller in its entirety, and replace the plate-type ink roller swing frame.
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