I plant an important newspaper printing equipment --Orient Super web offset printing machine (hereinafter referred to as the "Oriental machine") is still in use for more than ten years. The two most recent three years, it has been found in mis-registration emerge Mexican bars and other printing failure affecting the quality of the printed product, folding machine is not running smoothly. In order to solve these equipment problems, our factory carried out a 15-day overhaul on the Dongfang machine, mainly for the comprehensive repair and upgrade of the printing host and folding machine. After the overhaul, the production and performance of the Dongfang machine has been significantly improved, and the maintenance work has achieved the expected results.
This article is based on the work record during the overhaul, summed up and summarized, and detailed the implementation process of the overhaul work.
Printing host maintenance
The printing host is a double-sided four-color printing tower. The maintenance of it is mainly divided into the following steps.
1. Complete removal of peripheral components of the mainframe
In the first step, disassemble the drive belt guard of the main engine, the operation surface shield, the transmission face gear box cover, and the oil pipe in each gear box.
In the second step, the dampening solution water tank, the inlet pipe, the return pipe, and the water baffle are first removed, and then the printing rubber roller is removed for cleaning and inspection.
The third step is to disassemble the drive belt (synchronous belt) and the pulley. In order to reduce the post-overlay debugging time, the drive belt and the pulley can be marked. Next, the drive shafts of the respective towers (one printing group divided into four color groups of S1, S2, S3, and S4, and each color group are simply referred to as 1 tower, 2 towers, 3 towers, and 4 towers) are removed and marked.
In the fourth step, disassemble the transmission gears on each tower's printing cylinder (pre-made the engagement marks), clean and inspect the gears and coupling keys, and dispose of the damaged parts.
2. Removal of the printing cylinder
The reverse plate cylinder of each tower of Dongfang Machine is the benchmark for printing pressure debugging, and its eccentric sleeve does not produce eccentric displacement. Therefore, the wear of the eccentric sleeve and the wall panel hole is small. After confirming that the drum body was not seriously damaged, we decided not to disassemble the reverse plate cylinder of each tower.
Due to the frequent printing pressure debugging, the eccentric sleeves of the original plate cylinders and the anti-backing blanket cylinders of the Oriental machine are very worn, which can lead to printing defects in printing products. . Therefore, it is necessary to remove these rollers for the repair work of the eccentric sleeve and the wall panel hole.
Roller disassembly process: Firstly, use the hoisting screw holes on the 4 tower wall panel of the Oriental machine to fix the drum hoisting frame, install the hoisting hoist and fix the steel wire rope. Then, according to the order of the genuine plate cylinder, the genuine blanket cylinder and the reverse blanket cylinder, the eccentric sleeve and the bearing of the drum are respectively removed, and the four printing drums of the four towers are hoisted. Then, the hoisting frame is not moved, and the hoist is hoisted downward, and the printing cylinders of the 3 towers, the 2 towers, and the 1 tower are successively lifted out.
After the drum is disassembled, clean and inspect the surface and bearing position of each drum body. Since the drum bodies are not seriously damaged, the drum body is not repaired.
3. Maintenance and treatment of the drum eccentric sleeve
The genuine plate cylinder eccentric sleeves of the Oriental Machine towers and the corresponding wall plate holes are not seriously worn, so no maintenance is required.
Check the wall hole size corresponding to each eccentric sleeve of the blanket cylinder and record it (as a basis for repair). According to the wear of each wall panel hole, the processing size of the eccentric sleeve is determined. Clean and inspect the removed roller bearings and retain the bearings that can be used. Clean and inspect the eccentric sleeve, retain the eccentric sleeve number that can be used, and send the remaining eccentric sleeve to the outer processing. Handling the folding machine failure (described later) while waiting for the eccentric sleeve to be returned to the factory.
Remove the eccentric sleeve and bearing on the side of the operating surface of the reverse plate cylinder of each tower. Clean the eccentric sleeve and inspect and replace the roller bearing. After the bearing is heated, it is mounted on the drum; after the eccentric sleeve is filled with grease, it is attached to the drum. Disassemble the eccentric sleeve and bearing on the side of the transmission surface of each plate counter plate cylinder. Clean the eccentric sleeve and inspect and replace the roller bearing. After filling the bearing and the eccentric bushing, install it on the drum.
4. Handling ink roads, waterways, paper roads
Before the external processing eccentric sleeve is not returned to the factory, the ink road and waterway are repaired: replacing the ink fountain roller, the ink blade, the anilox roller, the water roller, the brush roller and the brush, the plate water roller and the plate roller ( Clutch with water, ink roller) eccentric transposition (cam and cover), water roller and ink roller of the squeezing roller, check and clean the transmission of the water roller and the squeezing roller, repair the fountain solution sink, replace it Paper roll and its bearings.
5. Repair the wall plate hole where the eccentric sleeve is located
After the external processing eccentric sleeve is returned to the factory, it is paired and grouped after the test is normal. According to the outer circle size of the eccentric sleeve, the worn wall hole is rounded (for the wear of the wall hole, grinding, boring, etc.). After the wall plate hole is repaired, install the eccentric sleeve and perform the rotation test.
6. Install the printing roller of each tower
Before installing the drum, dredge the grease pipeline on the side of the operating surface of each tower and replace the damaged oil pipe; unblock the oil passage and oil return hole on the back cover of each eccentric sleeve; heat the bearing, add the lubricating oil and grease to the eccentric sleeve .
According to the order of the anti-plate blanket cylinder, the genuine blanket cylinder, and the genuine plate cylinder, the printing cylinders are sequentially installed from 1 tower to 4 towers. After each tower roller is installed, a barrier layer is placed on it to prevent the falling object from damaging the surface of the drum body.
After the printing cylinder is installed, the eccentric sleeve positioning holes of the four genuine plate cylinders are processed, so that the eccentric sleeves can perform a certain amount of eccentric displacement. In this way, the pressure between the positive plate cylinder and the positive blanket cylinder can be better adjusted.
7. Install transmission components
In the first step, the transmission gears on the printing cylinders of each tower are installed to improve the connection mode of the plate-making gears (circumferential plate-making mechanism).
In the second step, install the drive shafts of each tower, adjust the gear meshing clearance, and mark well.
In the third step, install the oil pipe and oil pump in each tower gear box.
In the fourth step, the drive belt and the pulley are installed according to the mark.
In the fifth step, the lubricant is filled in the gearbox.
In the sixth step, the drive belt guard and the transmission face gear box cover are installed.
8. Inspection and maintenance of oil and gas roads
Install all the grease lines on the operating surface of each tower in place, thoroughly check the oil supply and replace the damaged oil circuit breaker.
Check and replace damaged air pipes, cylinders, solenoid valves, and pressure regulating valves.
9. Printing host debugging
Debug the printing cylinder pressure.
Install the printing roller and adjust the rubber roller pressure.
Install dampening solution tank, inlet pipe, return pipe, and water baffle.
Main drive clutch repair
1. Disassembly of the clutch
First, remove the clutch from the main unit and the main motor and remove the clutch. Next, remove the bearing end caps of the clutch and remove the two drive shafts and clutch forks of the clutch. Finally, remove the bearings on the drive shaft (there are double-row self-aligning bearings that require careful removal).
2. Clutch inspection and installation
Clean and inspect the components of the clutch and replace the bearings, install the drive shaft and the bearing end cover (note the bearing clearance). After the drive shaft is mounted for flexible rotation, place the clutch on the base.
After the clutch is adjusted to the horizontal state, the clutch is connected to the base, the main unit and the main motor. After confirming that the clutch is smoothly engaged and rotating smoothly, grease is added to it.
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