Heidelberg 102 series offset printing machine

(This article is an original article from Bisheng. It is forbidden to reprint, and reprinting must be corrected)

It is no exaggeration to say in China that anyone who knows a little about printing will have heard the word "Heidelberg". The absolute advantage Heidelberg offset press holds in the Chinese printing market has become an indisputable fact. Today, Heidelberg presses continue to bring high profits and high returns to users, but also continue to cause various headaches due to improper use, normal wear and tear of the machine, overdue service and other reasons.

As we all know, imported equipment like Heidelberg printing presses are not only ridiculously expensive, but also the maintenance cost will make even a printing company with a certain scale stick out its tongue. If you are using new equipment, it is good, but we can see more equipment in China more than 5 years and 8 years, and even a considerable part of the second-hand or N-hand equipment that has changed hands from Hong Kong and Southeast Asia. In the course of using these devices, problems of one kind or another will constantly appear. In order to adapt to market demand, some places have established repair companies that specialize in repairing Heidelberg multicolor offset presses. However, in order to pursue high profits, most maintenance companies use a large number of replacement parts during equipment maintenance, which makes the maintenance cost of a four-color offset press as high as several hundred thousand yuan or even more than one million yuan. Some manufacturers are overwhelmed, and a large number of printing presses are running ill, and cannot perform their due performance.

Therefore, it is quite necessary to discuss how to use, maintain and repair Heidelberg equipment here. At the same time, I hope that through more such exchanges, more users can learn more about the maintenance and repair of equipment such as Heidelberg. Minimize the cost of repairing equipment.

The first part, the adjustment and maintenance of the paper positioning part

The positioning part of the paper mainly consists of a front regulation, a side (pulling) regulation, a paper feeding board, and a control system. For a printing machine, whether the positioning system is normal is the prerequisite for the normal production and smooth printing of the printing machine. In the following, we introduce the adjustment, maintenance, and related problems encountered in the positioning system of Heidelberg 102 series printing equipment in several parts.

1. Pre-regulation

1. Pre-standardized regulation

(1) Height adjustment of front gauge

â‘ Before adjusting the height of the front gauge, you must first check the following two parts:

a. Whether the plane of the cardboard is flat, generally use a spirit level to check it is more accurate;

b. Whether the gap between the delivery tooth pad and the cardboard is accurate, if it is not the standard gap, adjust it as follows:

Adjust the delivery tooth pad to the printing "paper" position, and jog the machine in front to make the delivery tooth in the gripping position, that is, the tooth pad and the cardboard are 90O (Figure 3). At this position, the delivery pad and the delivery The distance of the cardboard should be 0.15-0.20mm.

Use a feeler gauge to measure this gap on each part, and adjust the cardboard according to the requirements.

It is best to use the measurement tool WLm22 753 for this adjustment.

â‘¡ Jog the machine forward to lower the front gauge to the lowest position, at this time the indicated value on the dial is about 269o

â‘¢Turn the front gauge height adjustment knob A (transmission surface and operation surface) to the "0" position. At this time, the distance between each front gauge pressure tongue B and the conveying board C should be 0.1mm. Use a 0.2mm thick feeler gauge to check this distance . When inserting this plug gauge between the front gauge tongue and the cardboard, it feels a little resistance. This adjustment can ensure the smooth conveyance of paper, and is also suitable for other general thickness papers (Figure 1).

â‘£ When adjusting, loosen the hexagon socket screws D, loosen the screws E if necessary, and then tighten these screws slightly. After the adjustment, tighten these screws fully.

When using the above method to adjust the front gauge cannot meet the requirements, you must loosen the three coupling screws of the 66.072.030 (drive surface) or 66.072.031 (operation surface) positioning plate 66.072.032 of the support.

Then repeat this process on the other front gauge tongue depressing parts until all the front gauges and the paperboard are of appropriate height and level with each other.

(2) Adjustment of pre-regulatory exercise time

The movement time of the front gauge can be adjusted on the transmission gear 66.072.110 or cam 66.072.110 or cam 66.072.027. When the current rule starts to let paper at the cardboard feeding station, the machine angle is 344o. Generally, the equipment that needs to be adjusted is only on the old machine that has been used for many years (due to the wear of the cam and other parts). When the adjustment is made on the cam, the hinge pin hole must be re-equipped after the adjustment.

(3) Adjustment of the front gauge at the position of the cardboard

This adjustment is also carried out at the lowest position (269o) of the aforementioned front gauge descent.

â‘  First, turn the adjustment knob A (adjust the grip size) of the transmission surface and operation surface to the "0" position, which is equivalent to the front and back positions of the front gauge when the center or the white edge size of the grip is 11mm (Figure 2);

â‘¡Adjust the front and rear positions of each front stopper B with the adjusting screw C so that they are on the same straight line. The adjustment process is to adjust the central front ruler away from the center line, and then make precise adjustments from the two sides to the center one by one.

â‘¢ Manually arrange a piece of paper at the front gauge B, and then jog the machine to make the paper pass to the impression cylinder through the delivery teeth.

Measure the distance from the front edge of the paper to the front edge of the impression cylinder (see K). When the scale value is "0", the size is 6mm. It is best to use the WLm221265 (part number 00.894.0227) measurement tool for adjustment.

â‘£When correcting the size of the gripper, you must first move the adjusting screw D away from the roller E, and adjust the connecting rod F according to the size of the gripper. At the position shown in the figure, hold the screw D against the roller E and tighten the nut G. At the lowest point of the cam, the gap between the cam H and the cam roller I is 0.02mm, which can ensure that the front rule is still during the paper positioning process (static path), so that the positioning paper is accurately and stably positioned. It can be adjusted precisely by turning the backscrew D.

(4) Adjustment of the suction device at the front

All Heidelberg Speedmaster102 offset presses are equipped with a standard suction device under the cardboard

Use the following method to adjust the individual suction line (see Figure 6):

1. Jog the machine forward so that the roller A is at the highest point of the cam B, at this time the front gauge depressor is at the highest position.

2. Loosen the tube clamp D, adjust the suction tube E so that the distance between it and the cardboard F is 0.2mm, and tighten the tube clamp D.
Please pay attention to the correct positional relationship between roller A and cam B. If adjusted improperly, the cardboard may move with the suction tube as it rises and falls.

2. Failure analysis

(1) Reasons for paper breakage when the paper is handed over at the front

â‘ Some front gauge tongue depressor A (see Figure 3) is too low. When the paper is positioned at the front gauge, part of it does not enter under the tongue depressor. At this time, the height of the front gauge depressor should be adjusted;

â‘¡When the paper is not flat, you should knock the paper carefully before printing. For thicker paper, you can use the method of increasing the previous rule;

â‘¢The suction device at the front is out of order, and the paper does not enter the tongue depressor smoothly;

â‘£ The movement time of the front gauge is inaccurate, the time for the front gauge to fall to the lowest position is 2690, and the time to start swinging away from the positioning position is 120;

⑤ The time when the paper arrives at the front gauge is inaccurate. After the front gauge has fallen, the paper reaches the edge position of the front gauge tongue, so that the paper cannot fully enter under the front gauge tongue.

(2) Pre-positioning fault

â‘  The front rules are accurate when the side pull gauge is not used. Once the side pull gauge is used, the front rules are inaccurate because the front and side rules are not at right angles or the side rules are not adjusted properly;

â‘¡When the side pull gauge is not used, the front rules are not accurate, for three reasons:

a. Improper adjustment of the height of the front tongue depressor;

b. The front and rear positions of the front gauge are inconsistent (especially when printing thin paper);

c. Pre-positioning time is inaccurate;

d. The tooth row of the delivery paper tooth or the first impression cylinder is faulty.

(3) Attention!

Due to the impact of the paper when it reaches the front gauge, the front gauge baffle B (Figure 3) is prone to tiny grooves. Generally, it is not necessary to replace the baffle, and it can be repaired with a grinder.

When installing the front gauge, do not use the adjusting screw C as a tightening screw, it will break the screw.

2. Side Regulation

1. Daily adjustment of the pull gauge

Prepare a 20x1000cm note. Swing the paper stabilizer and paper feed table upward, and position the prepared paper strip on the front gauge. Put the machine in a safe state at Feida. Jog the printing machine forward slowly so that the paper strips are transferred to the gauge board. If the paper strip is correctly placed against the gauge board, the lever must be displayed on the display (printer display). If the lever is not on the display, you need to adjust the gauge controller. The adjustment steps are: turn the knurled head screw counterclockwise to display the control rod in PD, then turn the knurled screw clockwise to make the control rod disappear. Turn the knurled screw counterclockwise to make the control lever appear on the PD again, and continue to rotate 10 scales; remove the paper strip, then the control lever disappears (refer to Figure 6).

2. Adjustment of the mechanical position of the side gauge

When repairing and replacing parts related to the side gauge, sometimes the side gauge control mechanism needs to be adjusted. The following are the adjustment steps:

(1) Remove the protective cover 78 / 86.021.022 (on the transmission surface);

(2) Jog the machine in front until the pulling gauge moves to half of the paper pulling distance, that is, at the position where the closing time of the delivery tooth is about 20o earlier, the angle is 3520;

Usually one needs to make a comprehensive adjustment to one of the side rules first, and then adjust the other side rule.

(3) Adjust the side gauge cover A so that the distance from the paper transport board or magnetic board B is 0.1 mm. To this end, cut a piece of 100g /? Paper (width less than 8mm) between the pull gauge roller C and the side positioning plate D, adjust the adjustment screw of the pull paper roller C until the paper is pulled out There is a slight resistance.

After the two side gauges are all adjusted, check whether the falling time of the pull gauge and paper roller on the transmission surface and the operation surface is the same.

When correction is required, loosen the screw E to adjust the cover A up and down.

Then adjust the pull gauge cover (0.1mm).

(4) Jog the machine so that the paper-pulling ball has just left the pull gauge and started to move upward. The time for the paper-pulling ball to start moving upward must be between 100-10030 ′.

It can be adjusted on the transmission surface cam F58.022.021 or 66.072.021. Take out the positioning pin of cam F, loosen the fixing screw of the cam and gear 66.072.010 (M8 hexagon socket screw), tighten the screw after adjusting, and re-hing the positioning pin hole.

If this adjustment cannot be completed within the screw hole range, the gear must be removed and installed in a more suitable location.

Then check the drop time of the pull gauge. The drop time of the SM102 printer pull gauge is 3120.

After loosening the nuts G and H on the lever 166.072.018, this time can be corrected.

Reposition the cam F after checking the lifting and falling times of the side gauge several times.

2. Vulnerable parts of the gauge part and their repair measures

(1) Pull gauge chute C and pull gauge slider B (see Figure 8)

For the old model, due to the role of paper dust and lubrication problems, the bottom of the side pull gauge chute, the side gauge slider B and the flat needle roller bearings are often worn. At this time, the height of the pull rule will be lower than that of the cardboard. And can not move steadily, causing lateral positioning failure. Especially when printing thick paper, if there is no special adjustment, the paper will not be pulled in place. The ideal height position of the pull gauge is flat with the magnet plate or 0.05mm higher than the magnet plate. Below we introduce the repair method of a sliding groove:

â‘ Replace the flat needle roller bearing with copper plate, and restore the height of the tension gauge by grinding the copper plate;

â‘¡ Flatten the worn part of the bottom of the slide slot of the gauge, add a steel sheet of appropriate thickness here according to the removal amount;

â‘¢ Changing the thickness of the gap-adjusting gasket of the chute cover can change this positional relationship, but the thickness of the gasket under the gauge slot must also be changed to keep the height of the paperboard unchanged.

The part of the flat needle roller bearing at the bottom of the slider is sometimes worn out and can be repaired by repair welding.

(2) Pull gauge copper seat A (see Figure 9)

Due to the high frequency of movement of the pull gauge drive shaft, it is extremely prone to wear in the drive shaft hole E of the pull gauge seat, making the positioning time of the pull gauge uncontrollable. In this case, the pull gauge copper seat should be replaced.

(3) Pull gauge drive arm ball D and flat key C

In Figure 9, the wear of the driving arm ball D and the flat key C will cause the pull gauge ball to be lifted too late, resulting in the grabbing phenomenon of the pull gauge and the delivery tooth during the handover, making the paper come and go and up and down directions There are overprint errors, and these parts should be replaced at this time.

(4) Pull regulations

After years of use, dents will appear on the surface of the pull strip. In fact, this has little effect on the accuracy of overprinting. I suggest replacing it only when the pull gauge is very worn.

(5) Pull the ball D (see Figure 10)

Under normal circumstances, the wear of the pull gauge ball is very light, and its main failure is inflexible rotation. This is caused by glue stains or rust in the inlet water. Such problems can be solved by timely maintenance.

(6) Pull the ball swing arm A (see Figure 10)

The wear of part B in Fig. 10 will cause the pull-up time of the pull gauge to be too late, which can be repaired by repair welding. The needle roller bearings in the ball swing arm of the pull gauge will rust due to the idle time or water intake (especially the driving surface pull gauge), and the rotation is not flexible, making the positioning time inaccurate. At this time, the needle roller bearings should be replaced.

(7) The reason why the pull gauge cannot be fixed

Due to improper operation, the upper slider B or the lower slider F in FIG. 9 will be stuck due to the occurrence of burrs, and the pull gauge cannot be locked at this time.

(8) Positioning time and adjustment of the drawing gauge

The lifting time of the side gauge roller is 10O-10 O30 ′. When adjusting, the positioning pin on the control cam F of the transmission surface pull gauge should be pulled out, and the fastening screws with the gear should be loosened. After adjustment, tighten these screws and re-hing the pin holes.

The time for the side gauge roller to fall is 312 O, and this time can be adjusted on the rod I by loosening the tightening nuts G and H.

The movement of the pulling bar is controlled by two cams 66.072.023 (operation surface) and 66.072.024 (driving surface) respectively. The end time of the movement is 15 O (after passing the paper gripper 3 O), and then pulling the bar Sports.

For machines with serial numbers after 519.057, the return movement of the tension gauge is controlled by the compression spring (see Figure 8A).

(9) Precautions when adjusting the pull gauge

â‘  When there is a paper pulling fault, do not blindly adjust the eccentric shaft of the pull gauge ball (see Figure 10C), and do not mistakenly think that this can change the paper pulling force;

â‘¡When there is a paper pulling fault, in addition to checking the above items, you should also check whether the front and side specified position plates are at right angles;

â‘¢If the gauge seat is worn and cannot be replaced in time, you can intentionally pull the gauge seat back a bit according to experience when fixing the gauge, so that the lifting time of the gauge will be a little later, so as not to grab with the paper delivery tooth paper.

3. Paper Positioning Control System BAK

The paper positioning control system BAK is used to detect the positioning of paper at the front gauge and generate corresponding functions.

The system includes electric eye box BAE, photoelectric eye RL1 / RL2 and proximity switch AS with control panel. Among them, the movement of the control panel and the machine are synchronized, and the detection point of the paper is determined by the proximity switch AS. The photocells RL1 and RL2 have detection heads ANK and FÇ–K. ANK is the front positioning control detection head (early arrival, late arrival, empty sheet) and FK is the paper offside control detection head.

1. Control process (see Figure 11)

(1) Control paper transport

Press the button "Open Feida" until the edge of the control panel â‘  passes the proximity switch AS, at this time Feida automatically runs under the action of BAE. After the air pump is turned on and the paper starts to be transported, the first paper passes through the paperboard to reach the front gauge and is detected by the ANK detection head of the photoelectric eye RL1 / RL2. When the first or later paper reaches the front gauge, the vacancy of the control panel (between the edges â‘  and â‘¡) must pass the proximity switch. The position of the paper is detected at the edge â‘¡ of the control panel, and then the "compression signal" is issued according to the preset situation. Press the "stop feeder" button, under the action of BAE, the feeder stops automatically when the edge of the control panel â‘¡ turns over the proximity switch.

(2) The first paper detection control

If the first sheet of paper reaches the ANK detection head of the front photocell RL1 / RL2, the non-notched part of the control panel (between the edges â‘¡ and â‘ ) passes the proximity switch, the feeder stops, and the printing press stops immediately.

(3) Crooked or empty control

If the paper skews or arrives too late during printing so that no or only one ANK detection head detects the paper when the edge of the control panel passes the proximity switch, the feeder stops, the press is depressurized and runs at a low speed.

(4) Paper overload

When the machine is running, if the edge of the control panel â‘¡ passes the proximity switch and the F position K detects the paper, the feeder stops, and the machine rotates for 1 week and stops after the pressure is released.

2. Function display

There are 7 display lights on the panel of the electric eye box, and their corresponding functions can enable the operator to determine the fault location and adjust it, see Table 1.

Table 1

Sign

name

Features

Operation display Once the electrical system can start working, this light is on. Fault display When the feeder stops or the electrical system detects a fault signal and closes the feeder, this light is on. Combined pressure display, when the device can be combined, this light is on, but if the preset speed switch is not pressed, this light is also on. This light comes on when the ANK detection head that shows at least one photoelectric eye detects paper late. This light is on when the FüK detection head with at least one photoelectric eye detects the paper. The proximity switch indicates that the vacant part of the control panel passes through the proximity switch every time, this light is on, so the light turns on every time the machine rotates once. Adjustment control When the ANK signal is transmitted to the electrical system according to the specified logic, this light is on, that is, when two ANK detection heads detect paper at the same time, this light is on together with the ANK light.

3. Adjust the proximity switch and control panel

(1) In addition to having to place the control panel in the center of the proximity switch slot, it must also maintain a distance of 2 mm from the bottom of the proximity switch;

(2) The edge of the control panel â‘¡ is used to adjust the control time;

(3) The bar turning machine makes the machine transfer the tooth pad and the cardboard into 900 as the reference position, the adjustment method is as follows:

Adjust the dial accurately to the 120 position. Use WLm22 149 to check whether the "0" position is in line with the "D" score line of the impression cylinder, and turn the machine back to the position of 3440 ± 30 ". Then adjust the control panel so that the edge ② is close to the switch slot position, and at the same time make of" "The answer indicator light just turned on or off.

Note: When the control panel passes through the control switch slot, the "" "The indicator light will always be on.

4. Adjust the photoelectric detection head

(1) The position of the photocell can be adjusted by adjusting the adjustment screw shown in FIG. 2. Each turn of the screw 900 corresponds to a distance change of 0.2mm. Turning the screw to the right reduces the distance from the front edge of the paper to the photocell, and turning it to the left increases the distance.

(2) Adjust the front gauges of the transmission surface and the operation surface to the "0" position, he Feida and jog the machine without paper until the transfer pads are at the same height as the front regulations "BAE" "The proximity switch indicator lights.

(3) Place half a sheet of paper under each photocell, write a mark at the end of the paperboard, and move it back slowly and carefully until the BAE control indicator light just goes out. Measure the distance between the end of the paper and the mark just noted. This distance should be 1 ~ 1.5mm. If it is not this distance, you must readjust.

The circuit diagram of the paper positioning control system is shown in Figure 12.

5. Analysis of common failure causes (see Table 2)

Table 2

4. Other

1. Adjustment of paper-pressing reed

Everyone knows that all presses with hem-type front gauges (Heidelberg SM102 series offset presses) are equipped with paper pressure springs. When the feeder stops due to empty sheets or skewed paper, it can hold down the paper just before the front gauge.

After the adjustment process (see Figure 13):

(1) Adjust the stopper A (66.012.074) so ​​that the distance between the top pin B (66.012.134) and the swing lever C (66.012.081) is 1mm, and the brake spring D (66.012) can be disengaged after the paper pressure spring is released .127) on the adjustment.

(2) Adjust the paper pressure spring E (66.013.051) so that the distance between it and the cardboard F is 9mm.

(3) When adjusting, you need to loosen the hexagon socket screw II on the clamping block I (see Figure 14). After adjusting the distance of 9mm, tighten this screw to check the performance of the platen spring. Transport cardboard (see arrow in Figure 14). After pressing the electromagnet, the distance should be about 2 ~ 3mm, if necessary, adjust the position of the electromagnet.

(4) After completing the adjustment of the paper pressure spring, start the machine and check whether the opening of the delivery tooth is large enough to prevent the paper from gripping when the electromagnet is attracted (late or empty). Check with thick cardboard.

When correction is needed, replace the shock absorber G under the ejector pin B (Figure 13) or use a spacer of appropriate thickness (selected from 66.012.153) to cushion the shock absorber.

Washers 66.012.153 (optional set of gaskets) include:

66.012.150 = 0.50mm

66.012.151 ＝ 0.75mm

66.012.152 = lmm

66.012.136 = 1.5mm

2. Paperboard

The unevenness of the paperboard will cause the phenomenon of flicking of the printed product, and it may also cause the toothing of the transfer tooth sheet to grip the paper at the front gauge, making the printing in front and back directions inaccurate.

Don't change the cardboard easily because it can still be used after platform correction. After adjusting the height of the pull gauge bar, the positions of the pull gauge grooves (66.072.003 and 66.072.004) must also be accurately adjusted to ensure that after the cardboard is installed, the magnet plate and the cardboard are flat and the conveyor The cardboard remains flat.

By increasing or decreasing the shims, and adjusting the position of the fixing seat below the paperboard, the flatness of the paperboard can also be corrected.

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