Quality control is nothing more than two aspects: one is the data and standardization of each process; the second is the process design and management of the work flow. The former requires standardized operation of each process, the latter is to formulate the workflow and operation requirements of each process. This shows that in addition to unified process management, everyone is required to do their utmost and bear their own responsibilities. In the production practice, 80% of the quality accidents are caused by the lack of responsibility of the operators. 20% is caused by technological reasons and materials. To make 80% of the accidents disappear in the budding state, it is necessary to understand the technical requirements, not to stay in a half-knowledge, and to have the spirit of excellence. Let's take ZXJD440A medium-speed paper binding line as an example to talk about personal views on common problems in the production process.
1. Failures in the production of perfect binding
1) Round back
The height of the book stand in the book clip and the level of the signature are too low, the extension of the signature should be controlled at 11-12mm, and the position of the solid board should be increased The groove cutter is too high, the position of the groove cutter should be lowered, and the depth of the groove of the signature should be controlled within 1.0mm.
2) Oblique endorsement
The glue temperature is too high, the back of the book is not cured and falls when the book is dropped, and the glue temperature should be adjusted according to the paper quality and seasonal changes, generally controlled at 160 ~ 180 ℃; the machine speed is too fast, the glue with short curing time should be used and reduced Machine speed; the opening of the book clip is too large, it should be adjusted to the thickness of the signature plus 15mm, and the book aisle and the bar should be narrowed at the same time.
3) Book stapling and cutouts are not rectangular
The parallelism and verticality of the solid support plate and the book holder should be adjusted to make the book back stapling consistent up and down.
4) The cover is sticky
There is wild glue on the upper sealing roller, which sticks to the book cover, and the bottom plate of the forming mechanism is glued, and the clamping plates on both sides have glue to seal the first and fourth seals, so the remaining glue should be removed frequently, and methyl silicone oil should be used to prevent wild glue; If the glue time of the rubber wheel is too long to produce wild rubber, the glue time should be fine-tuned to minimize the rubber temperature and reduce the glue temperature.
5) Book cover is wrinkled or misaligned
If the book holder in the book clip is too high, the position of the supporting plate should be increased; the slotting knife is too high, the slotting knife position should be lowered; the glue temperature is too low, the glue temperature should be increased; if the glue is left in the glue stick, the glue stick should be adjusted and scraped The gap of the rubber sheet should be zero, and check the working condition of the heating tube in the uniform glue stick; if the binding speed is too fast, the machine speed should be reduced and the drying time should be extended before cutting.
6) Bar line
If the signature is too high or the book holder is low, the position of the supporting plate should be lowered; the grooving knife is too low, the position of the grooving knife should be increased; the side clamping force of the supporting mechanism is too large, it should be outward Properly adjust the position of the side clamping plate.
7) Bubble or honeycomb film
The height of the book holder in the book clip is too high and the supporting plate is too low. The position of the supporting plate should be increased; the temperature of the adhesive is too low or the temperature of the glue stick is too low. After the measurement, increase the temperature.
8) Crack or excessive squeeze on the back of the book
The position of the book holder in the book clip is low, and the position of the supporting plate should be reduced; the pressure of the upper seal roller is too large, and the gap between the upper seal roller and the bottom surface of the book clip body should be 9mm, and the upper rubber wheel 1 is glued too much. The gap between the wheel 1 and the rubber scraper is adjusted to 0.2 ~ 0.5mm; the upper rubber wheel 1 is too high and the pressure is too large. It should be ensured that the upper rubber wheel is in contact with the back of the book and can open the back of the book to allow the glue to penetrate into the book pages.
9) Split or flang at the front of the book
The blade of the back milling blade is passivated. The blade should be sharpened and the glue should be removed frequently. It is best not to use the machine for rework. The back plate of the back milling cutter is not adjusted properly and should be readjusted.
10) Random posts
The depth of the milling back is not enough; the groove depth of the groove is not appropriate, the groove distance is not appropriate, the depth of the groove should be about 1.0mm, and the spacing is between 5-10mm; the temperature of the hot melt adhesive is too low, lack of fluidity and permeability, and the bonding is not good The adhesive temperature should be increased according to the quality of the paper; the selection of hot melt adhesives is inappropriate, and hot melt adhesives with the same weight as the paper weight should be selected. For high-preservation coated paper books, the hot melt adhesive process should be avoided as much as possible, or The method of first locking the thread and then gluing is used to prevent loose posts.
12) The middle part of the back of the book is uneven
When the book falls, the drop is too large, and a groove is punched on the small link board; the temperature of the glue is too high to make the back of the book uneven in thickness when glued; the groove is not smooth, the paper hair has not fallen, and the glue cannot be smooth; the milling knife is not Sharpness, incorrect blade angle or excessive gap with the backing plate, resulting in unclean milling back and unevenness after gluing; the position of the solid plate is too low. Coping with symptoms.
13) Wide book back
The slotted knife support plate is not aligned with the large plane of the book clip body; the upper sealing roller is too high, which causes excessive pressure on the back of the book; the rubber wheel 1 on the back glue is too high, so that the glue penetrates between the book pages; the book block is loose and not tied tightly, etc. ; Milling back is not smooth and rough. Coping with symptoms.
14) Wedge
The distance between the upper rubber wheel and the bottom plane of the book clip body is too small, so lower the upper rubber wheel 1 position.
15) Uneven film
The height of the side glue and bottom glue device and the position of the inside and outside are not adjusted properly; the gap between the upper glue wheel and the rubber scraper, the glue stick and the glue scraper is not adjusted properly, and it should be readjusted; The rod is not heated well, the glue stick is not parallel to the back of the book, etc. Coping with symptoms.
16) Wedge-shaped film
The glue stick is not parallel to the bottom surface of the book clip body; the solid support plate is not parallel to the bottom surface of the book clip. Should be readjusted.
17) There is a gap in the glue layer
If there is too little glue in the adhesive device, the amount of glue should be guaranteed; if the glue temperature is too low, the glue temperature should be controlled.
18) Position offset of cover of book signature book
The guide rail chain of the book cover is not aligned, so that each pair of pull-out blocks is parallel and perpendicular to the side gauge; the upper cover roller is slightly lower, the cover and the back of the book do not match well, and the cover is reset after being supported.
19) The cover is not well bonded
The machine speed is too fast, the opening time of the glue is long, the hot melt glue matching the machine speed should be used; a small amount of defective books with the cover off are not cleared; the back of the book is empty, the supporting mechanism is not adjusted properly, and the supporting pressure is too small, it should be increased ; The adhesive layer is too thin, the bond is not strong, the adhesive layer and the side adhesive layer should be thickened.
2. Cutting problem
1) The upper and lower links are inconsistent
The middle knife should be aligned with the cutting line so that the two books above and below are basically the same.
2) Skew left and right
The parallel line of the two push blocks is not perpendicular to the middle knife or the track is too narrow during the book delivery process. The pressure on the two sides of the pressure plate is inconsistent or too light; the cutting is continuous or the burrs are serious. The bottom plate should be changed frequently and the cutting blade should be edged. mill.
3. Three-sided cutting problem
1) After cutting, the finished book is big and small
After the blade is blunt, the size of the door knife is inconsistent; the book feeding carriage is not perpendicular to the working platform and the pressure of the paper press is light; the cutting height exceeds the design height, which causes the pressure of the paper press to increase, the pulling force increases, and the paper bends and deforms greatly ; The side blade is too narrow or the upper edge of the back is knocked up when grinding the knife, so that there is a certain angle between the blade and the cutting surface. Coping with symptoms.
2) Right and left bevel
The carriage of the book-feeding carriage is not parallel to the door knife, resulting in a cut; the aisle clearance of the book is inappropriate, the conveying resistance is too tight, and the looseness is unstable. The side knife has different sizes before and after measurement on the knife holder. Calibrate the knife holder; the brush is not in place and the book pushing block is uneven, and the book pushing is not stable.
3) Broken book
Make sure that the glue layer is between 0.8 and 1.2mm, the rubber support is level, and the bubble of the package is eliminated; the cover paper is too poor or the direction of the paper thread of the cover is incorrect; the binding time of the book block is too short or not tight; the milling back is not Smooth, loosen the rubber back and increase the thickness of the book back. Grooving is not smooth, unpleasant, and the side glue is too thick; the use of the jack pressure plate is not correct, and it is not pressed on the head of the sky and the foot, causing tearing; the oblique back of the bound book; the blade is not fast and the angle of the blade is too small, it should be frequent Shovel off the glue on the blade and apply wax or talc powder; use a book cutter with a road cutter device.
4) Maokou
The blade cutting blade is generally about 0.5mm, and the quality blade and blade should be changed frequently.
5) Knife flower
The blade is broken, there is a gap or chipping phenomenon.
6) The size of the door knife is large and small
In the carriage assembly, if the adjustment gauge screw cannot be locked, it will be loose; the rollers in the carriage track will be worn and improperly adjusted; the needle bearings in the swing arm bushings of the carriage will be worn and damaged, resulting in a large swing of the carriage small.
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