The UNISET60 double-cylinder printing machine is a printing equipment that our company introduced from the German Manroland company in the mid-1990s. This equipment has a complete set of four-color overprinting devices, which can easily be Adjust the displacement of the plate roller and rubber roller of each color group to achieve axial and radial adjustment (also known as horizontal and vertical adjustment), and the result of the adjustment can be clearly displayed on the LCD screen of the operation console. It shows that this provides a reliable guarantee for printing high-quality newspapers and increasing the reporting rate. Today, this overprinting device of newspaper printing companies that have introduced the same equipment at the same time has often become very incomplete. Some manufacturers even simply remove the version motor and use the special tools provided by Roland Company when the machine needs to be operated. Go to each site to adjust manually. Although the newspaper can meet the requirements in this way, this adjustment method takes a lot of precious time after all, which is very inconvenient, and more importantly, the scrap rate has increased significantly.
Our company has two sets of such units, and each set has been used for an average of about 15 years. The overprinting device is still intact. Many peers appreciate it after understanding it. In fact, in the initial period of use, the failure rate of this device is also very high, the motor of the set is seriously damaged, and the potentiometer is damaged for a period of time. It is only after a serious and continuous summary of experience that the current effect is achieved. This article is now written through a comprehensive arrangement for peer reference only.
1 Conditions for using potentiometer as displacement sensor
Potentiometer is an electronic component commonly used by people, also known as variable resistance. For example, it is installed on the panel of the printing unit. As a speed given device of the inverter, it can adjust the speed of the water roller and ink roller motor to achieve printing. The machine printing speed is well matched with the required water volume and ink volume; as in the double closed-loop DC motor speed control device, the potentiometer is not only used for speed setting, the PID parameters and feedback coefficients of the speed loop and current loop are all Adjusted by the potentiometer, it has a wide range of uses. On the other hand, due to the poor accuracy of the potentiometer, with the rapid development of microcomputer technology, there are fewer and fewer places where potentiometers are used in electrical systems.
The mechanical displacement sensor is a sensor used to measure the geometric quantities such as displacement, distance, position, size, angle, and angular displacement. Where strict accuracy is required, the encoder is the best electrical component, but the encoder manufacturing process is very demanding and the price is naturally expensive. Although the accuracy of the potentiometer is not high, it has a high performance-price ratio, so it is still effective to use it as a displacement sensor in some places where the accuracy requirements are not strict.
The potentiometer is used as a general electronic component, and the resistance is manually adjusted by rotating the handle. For example, the potentiometer of model AL1710 can rotate ten times with the rotation of the rotation handle, and there is a dead point at both ends. At the dead point, no force will be applied in the same direction, and the potentiometer will not be easily damaged. The potentiometer is used as a displacement sensor. The rotary handle and a gear are fixed together. The plate adjustment motor in the overprinting device rotates. On the one hand, it drives the plate cylinder and rubber cylinder to move left and right in the direction of the wallboard. On the other hand, it uses mechanical mechanisms such as gears. Rotate the potentiometer to rotate the handle. However, because the motor has a certain inertia, the brake system is not very reliable after long-term use. Sometimes when the potentiometer is adjusted to the maximum and minimum points, it is not as perceptible as human adjustment. Continue to apply force will cause instantaneous damage to the potentiometer. [next]
2 Ways to solve the potential damage of the potentiometer
According to the use condition of the potentiometer as the displacement sensor, the solution to the potential damage of the potentiometer is to prevent the potentiometer from running near the limit position as much as possible, and to keep the potentiometer running in the middle position is the best choice.
1) The mechanical zero and electrical zero must be adjusted each time the potentiometer is replaced
The mechanical zero position means that the plate roller and the rubber roller are in the middle of the wallboard. Using the special caliper provided by Roland, along the horizontal direction of the plate cylinder or rubber cylinder, the special caliper can be inserted between the two end surfaces of the cylinder or rubber cylinder at the same time, and the mechanical zero position is adjusted. If the special caliper cannot be inserted between the two end surfaces of the roller or rubber roller and the wall board at the same time, one end is very loose and the other end is not inserted at all. You can remove the adjustment motor and adjust it with the special tool provided by Roland.
The electrical zero position means that the potentiometer is in the middle position, and the LCD display has coordinates reflecting the horizontal and vertical adjustments. At both ends of the coordinates, there are numbers to show the position values ​​of the plate cylinder and rubber cylinder. The abscissa is at the zero position and the number is zero, indicating that the plate roller is the electrical zero position. Similarly, the ordinate is at the zero position and the number is zero, indicating that the rubber roller is the electrical zero position.
The adjustment of the electrical zero position must be carried out after the adjustment of the mechanical zero position. First fix the potentiometer, then turn the potentiometer 5 times. Disconnect the power supply, connect the wires at both ends of the potentiometer and the middle tap (be sure to pay attention to the wiring direction, and the reverse installation is also a cause of damage to the potentiometer). Then turn on the power, and slightly adjust the rotary knob of the potentiometer. Observe that the horizontal or vertical adjustment of the printing color set of the corresponding printing unit on the LCD display is at the coordinate origin and the number is zero. Finally, fix the connected gears.
2) Properly adjust the voltage across the potentiometer
When the printer adjusts the value, it is sometimes inevitable to adjust to the limit position. In order not to damage the potentiometer, the process of the electrical system requires the motor to stop immediately at this position, but the motor has inertia, and there is still a certain time until the motor stops. , In fact, the potentiometer has been damaged. In order to solve this problem, the following methods can be used:
Manroland applies a DC voltage of ± 15V across the potentiometer, which means that the voltage at the maximum position and the minimum position are + 15V and -15V, respectively. When the electrical system detects this voltage value, the version motor must be in this It stops in the direction. With this feature, we can appropriately increase the voltage within the reasonable fluctuation range of the DC voltage, so that when the potentiometer outputs ± 15V, the rotary handle is not in the limit position, and a buffer is obtained like the adjusted motor. Space, even if the printer adjusts to the limit position, the potentiometer will not be destroyed. [next]
3) Principles to be followed by printers
Due to the fact that there is a certain registration error when making the PS version (including imposition and bending machine bending), plus the factor of paper, the registration must be adjusted every time it is printed. After the printer is turned on, the printer takes a newspaper out of the newspaper outlet and observes the cross label on the newspaper (this cross label is pre-made on the PS plate of 4 colors), the first step is to look at the horizontal coordinate, the middle of the 4 cross labels The color group is used as the reference color group without adjustment. According to experience, adjust the displacement of the other 3 color groups until the 4 cross labels are aligned horizontally. What should be emphasized here is why the horizontal adjustment should be performed first? After the horizontal adjustment according to the requirements of the mechanical process, the equipment of Manroland will automatically adjust about one third of the horizontal direction. Naturally, if the vertical direction is adjusted first, the horizontal direction must also be adjusted. Adjust again.
The second step is to adjust the vertical register, then take a newspaper that has been adjusted horizontally, observe the cross label on the newspaper, and also select the color group in the middle of the vertical as the reference color group. No adjustment is made, and other three colors are adjusted appropriately according to experience. The longitudinal displacement of the group until the 4 cross labels are vertically aligned.
According to this method, the printing technicians of our company stand out among the technical competitors in the printing industry of Jiangsu Province, print high-quality newspapers within the demanding time, pass the journey all the way until they reach the finals, and finally receive a few winning awards. In fact, this is inseparable from the soundness of the overprinting device and proficiency in the overprinting technology.
In 2003, our company introduced the UNSET75 unit of the German manroland company. Apart from the mechanical differences between the overprinting device and the UNSET60 unit, the electrical principles are basically the same. The potentiometer is used as a displacement sensor, even the potentiometer models are all There has been no change and almost no damage has occurred in the past seven years. In addition, the overprinting device of the Beiren single cylinder printing machine also uses the potentiometer as a displacement sensor. Although the mechanical installation method and mechanical zeroing are different from the UNSET60 unit, after we master the above technology, the overprinting device is still very successful.
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