The author has been engaged in the maintenance of printing machinery for more than ten years. Through continuous practice and exploration, he has concluded a set of methods for judging faults-"look, smell, ask, cut" to judge the faults of printing machines. "hope" 1. Look at product quality Rely on the analysis and analysis of printing quality to find out the rules to determine the cause of the failure. If the printed product is false, you can think of whether the pressure of the cylinder is adjusted improperly; if the white bar is produced from the printed product, you can think of whether it is improperly adjusted by the plate water roller; if the ink bar is produced by the printed product, you can think of whether it is improperly adjusted by the plate ink roller; The cutting of the paper machine is skewed, and it can be thought whether the stacker is improperly adjusted. Once, when the factory used Heidelberg four-color offset printing machine to print the printed products, the printed products were wrinkled locally. Observe the paper before printing, the flatness is very good, and then carefully observe the wrinkled parts of the printed product. It is found that except for the first color, the second, third, and fourth colors are all printed after wrinkling. According to this judgment, the wrinkle failure occurs between the first color group and the second color group. Between the first and second color groups, there are a set of double-diameter rear transfer rollers, two sets of front-transfer rollers, a total of 3 rollers, and 4 sets of tooth rows. Carefully check the 4 sets of tooth rows and find that there is a row of grippers on the double-diameter roller Paper teeth have inconsistent gripping force, and there are individual "dead teeth". After performing corresponding treatment and adjusting to make the gripping force of each gripper be the same, the test machine will wrinkle the printed matter and disappear. 2. See if there are any signs of damage to the parts after the equipment fails When the equipment fails, observe the equipment for scratches, break marks, friction marks, squeezing marks, etc., and analyze the force situation to determine the cause of the failure. Our factory produced a two-color offset printing press in Taipei. The black group printing had a ghosting problem and could not print normally. Check the printing pressure, lining, machine transmission, bearings, etc. After careful observation, the author found that the chrome plating layer on the surface of the black plate cylinder and rubber cylinder operation surface was severely damaged and there were obvious signs of extrusion. Judging that this ghosting failure is caused by the shoulder iron exerting too much pressure on the drum and causing vibration, it indicates that the thickness of the drum lining is wrong. After inspection, it was found that the thickness of the lining of the printing plate cylinder was not standardized for many years because of the irregular operation. As a result, the pressure of the shoulder iron had exceeded the standard when the pressure of the cylinder body reached the standard. Unsteady motion produces ghosting. Based on this analysis, we standardize the lining of the plate cylinder and rubber cylinder, and then test the machine to solve the ghosting problem. 3. See if the actions of each mechanism in the operation of the equipment are normal During a printing process, the front gauge tension spring of our Heidelberg four-color offset press suddenly broke, causing the positioner bracket to be misaligned and the positioning pins to be all cut. After the accident, we carried out a comprehensive inspection of all parts and components and restored to the original condition according to the standard. After the test run, it was found that the printed products were inconsistent and the rules changed. Check the paper teeth of the positioner, even gripping force. After careful inspection, it was found that the timing of the open teeth rollers on both sides of the gripper's gripper teeth row entering the cam track was obviously out of sync. It is concluded that when the positioner grips the paper from the cardboard and delivers it to the impression cylinder, the closing time of the gripper teeth is inconsistent, resulting in paper handover errors. Therefore, the positioning pins of the open-tooth cam track were inspected, and it was found that there were obvious shear marks on the surface of the pins. Although they were not cut, they were enough to cause positioning errors. After replacing the pin, try the machine again, and the inconsistency between the front and back of the printed product disappears. "smell" Judging by hearing whether each part of the equipment is operating normally. If abnormal sound is emitted, the source of the abnormal sound should be found, so as to identify the cause of the failure and determine a reasonable solution. The key to this method is to judge whether the sound is normal from the nuances. This method is often used to judge whether the rotating parts of the machine are balanced, whether the fasteners are loose, whether the moving parts that cooperate with each other are well coordinated, and whether there is more serious wear. "ask" "Ask" mainly refers to inquiries from two parties. 1. Ask the machine operator. Mainly include: â‘ some abnormal phenomena before the fault occurs; â‘¡ the process of the fault occurrence; â‘¢ whether measures have been taken after the fault occurred, what measures have been taken, and what effect has been taken. 2. Inquiries to relevant personnel who have repaired or handled similar failures of this model mainly include: â‘ the phenomenon of the failure at that time and the cause of the failure; â‘¡ the treatment method and treatment effect at the time. Through inquiries, it can be used as a reference for judging the cause of the fault, and reduce the fault detour. But at the same time, we must avoid partial belief and listening, and do not allow others' thinking to limit their own thinking and imagination. You can only use some other people's methods and thoughts as a reference, and they must not be blunt. In the repair of equipment, there are often some faults that are similar in appearance but have different causes and mechanisms. "Ask" is just an auxiliary method, the most important thing is to conduct specific analysis, thinking, judgment and processing through your brain and practice. "cut" There are three main contents. 1. Check whether the device has abnormal temperature changes by touching. Damage to rolling or sliding bearings, poor operation of electrical circuits, poor cooling or lubrication, etc., can cause abnormal temperature rises. 2. Check whether the device has abnormal vibration by touching. Unbalanced rotating parts of the equipment, loose fasteners or abnormal impact may cause abnormal vibration. 3. Use touch to determine whether there are signs of wear and damage on parts that are not easily seen by the eyes, to check and judge the equipment failure. In short, when the equipment fails, we can conduct a comprehensive analysis and judgment through one or more of the above four judgment methods, quickly and accurately determine the cause of the failure, take the right medicine, and formulate a scientific and economic solution to avoid detours , Less parts removal, save time, and ensure the quality of repairs.
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