Mechanical Leading-Edge Paper Feeding Principle (as shown in Figure I):

 

The paperboard is initially placed on the table, in close contact with the table due to suction. When starting, wheels 1, 2, and 3 rotate together, and the table sinks mechanically. Three rows of rubber rollers protrude and contact the paperboard, and the paperboard is pushed past the front guide into axes A and B, and then fed into the printing unit by axes A and B.

Regardless of the width of the paperboard, the number of revolutions of wheels 1, 2, and 3 is fixed, approximately 18-22cm. At this time, the table rises, lifting the paperboard away from the rubber rollers. At this time, a stack of paperboards is stacked on top, plus the suction force on the paperboard below. If the paperboard is to move forward smoothly, axes A and B must increase the pressure, otherwise the paperboard will slip, causing inaccurate paper feeding and waste. Increasing the pressure on axes A and B will also damage the corrugation of the paperboard, directly affecting its compressive physical indicators. Cardboard factories have to increase the basis weight of the paper, resulting in unnecessary waste.

Servo paper feeding involves installing a servo motor on each of the 1, 2, 3, and 4 rubber rollers. The four rows of rubber rollers are permanently extended beyond the table. The cardboard is directly and tightly coupled with the rubber rollers via suction. Before starting, the cardboard width is set on the computer; for example, if the cardboard is 45cm, it is set to 45cm. When starting, rollers 1, 2, 3, and 4 rotate together to advance the cardboard. When the cardboard advances, roller 4 is exposed first, and it stops. When the cardboard advances to expose roller 3, roller 3 also stops, and so on until roller 1 is exposed and stops. At this point, the entire 45cm cardboard is fed into the paper guide air box. The second cardboard falls onto the rubber rollers, which wait for the second cycle to feed another 45cm. This process repeats. The cardboard passes the front baffle and is sucked by the paper guide air box, and then conveyed forward by the three rows of rubber rollers in the paper guide air box. The three rows of shafts of the paper guide rollers are uniformly conveyed by the servo motor via a timing belt. Their speed is synchronized with the printing roller, so the cardboard is smoothly fed into the printing section. The cardboard does not experience any pressure from entry to exit, so the corrugation is undamaged, ensuring the cardboard's compressive strength physical indicators without increasing the grammage of the corrugated paper and facing paper to guarantee the compressive strength parameters.

Comparison of Mechanical Leading-Edge Paper Feeding and Servo Leading-Edge Paper Feeding

With the same compressive strength physical parameters, servo paper feeding can save 40g/m2 of paper for five-layer cardboard and 20g/m2 for three-layer cardboard.

Daily production of 20,000 m2 of five-layer cardboard: 20,000 * 40 = 800,000g = 800kg * 3000 yuan/ton = 2400 yuan.

Annual production: 300 days * 2400 yuan = 720,000 yuan

Printing Section Function Introduction

I. Printing Rollers

1. The printing rollers use high-quality steel with a ground surface and hard chrome plating. There are center reference lines in the axial direction and plate mounting reference lines in the circumferential direction.

2. Dynamic balance adjustment ensures smooth operation and suitability for high-speed operation.

3. Ratchet-fixed plate roller shaft with plate hanging groove for quick plate changing.

4. High-precision planetary gear phase adjustment mechanism, allowing 360-degree positive and reverse adjustment in both dynamic and static states, controlled by an encoder.

5. Equipped with a foot switch for convenient plate mounting and cleaning.

6. Computer-controlled axial adjustment mechanism for the printing roller. The maximum momentum is ±5mm.

7. Reset switch returns the printing roller to the zero position for convenient job change operation, shortening job change time and reducing cardboard waste.

II. Impression Rollers

1. Made of high-quality seamless steel pipes, precision-processed, dynamically balanced, smoothly operating, with a ground surface and hard chrome plating.

2. The printing gap is adjusted using a lifting device with a quick-handle adjustment and a scale display for convenient adjustment.

3. The bridge support plate is made of high-strength alloy aluminum mold and fixed to the impression shaft and paper guide shaft bearing seats via a bracket. It rises and falls with the shaft, allowing smooth conveyance of warped cardboard. This structure is a domestic innovation.

III. Anilox Rollers

1. Pneumatic anilox roller automatic lifting and automatic rotation during shutdown. When feeding paper, the anilox roller descends to contact the printing plate. When paper feeding stops, the anilox roller automatically rises to separate from the printing plate to protect the printing plate. When not printing, it automatically idles to prevent ink from drying.

IV. Rubber Rollers

1. Made of high-quality seamless steel pipes, precision-processed, and dynamically balanced.

2. The steel pipe surface is wrapped with imported natural rubber, with high surface smoothness and consistent hardness. The triple wrapping process ensures surface hardness, intermediate buffering, and increased overall roller elasticity for better inking, higher clarity for fine printing of small dots and characters, and longer service life.

3. Overrunning clutch-type automatic idling device prevents ink from drying.

4. Medium-high surface grinding is suitable for high-precision and large-area printing of dots.

5. Pressure fine-tuning adjustment devices are installed at both ends of the rubber roller to ensure consistent pressure across the entire roller, resulting in better inking.

6. An inking device is installed between the anilox roller and the rubber roller, eliminating the side plates and ensuring no ink leakage during high-speed operation, fundamentally solving the traditional ink-slinging problem.

V. Doctor Blade Inking System

1. The doctor blade inking system uses a Habot design, and the inking chamber is made of aviation aluminum processed by a machining center, with high strength and toughness, and is not easily deformed.

2. The pressure adjustment method uses a pneumatic oil design, which is stable and is not affected by pressure changes due to the air compressor starting and stopping.

3. The blades use original American nylon blades, which are wear-resistant and protect the ceramic rollers, ensuring high-precision printing effects and extending the service life of the ceramic rollers.

4. The ink return method uses a large-circulation natural reflux design. No felt needs to be installed at both ends of the ceramic roller, and ink will never splash out from both ends.

5. The Habot original design of the ink supply, return, and washing pipelines makes cleaning more convenient and ink more economical, greatly reducing the workload of the operator. It is currently the most advanced and economical doctor blade system in China.

6. Ink shortage alarm: Each group has independent ink supply. Mechanical and electronic devices automatically detect whether the ink in the ink tank is used up. Once ink is low, the operator is alerted by an electric bell, and the computer displays which group is low on ink, helping to reduce cardboard waste.

VI. Ink Supply System

6. Ink shortage alarm. Each group has independent ink supply. Mechanical and electronic systems are used to automatically detect whether the ink in the ink barrel is used up. Once the ink is insufficient, the operator will be prompted through an electric bell. It is connected to the computer and a reminder of which group is short of ink will appear on the display screen, which helps to reduce the waste of cardboard.

VI. Ink supply system

1. The pneumatic diaphragm pump uses the Taiwan Yangzi Petrochemical brand. Internal components are made of high-hardness stainless steel, which will not be corroded by acids and alkalis. The diaphragm pump pad adopts a seven-layer composite structure, with better elasticity and longer service life.

2. Automatic circulation cleaning, automatic inking.

3. The filter screen filters impurities to ensure printing quality.

4. The ink fountain is made of stainless steel and is not easily corroded.

5. Ink shortage alarm. Each group has independent ink supply. Mechanical and electronic cooperation automatically detects whether the ink in the ink tank is used up. Once the ink is short, the operator will be alerted by an electric bell, and it will be connected to the computer, and a prompt indicating which group is short of ink will appear on the display screen, which helps to reduce cardboard waste.

VII. Phase Adjustment Mechanism

1. Planetary gear structure

2. Electrically adjust the printing plate 360 degrees. (Can be done whether the machine is running or stopped)

3. Equipped with a 7.0-inch color touch screen, printing roller phase and lateral adjustment, encoder signal transmission, and fully electric control.

VIII. Phase Fixing System

1. Electromagnetic braking device.

2. Machine clutch, the original meshing point of the transmission gear remains unchanged.

3. When the machine is stopped for plate wiping, use the foot switch. The phase motor uses frequency conversion control. That is, if the phase is fine-tuned, it uses low frequency to ensure accurate adjustment. When wiping the plate, it automatically switches to high frequency to accelerate the rotation of the plate roller, saving plate wiping time.

 

 

Die-cutting Unit Function Introduction

1. Using German "Kobi" servo control, the computer follows the speed independently, completely solving the impact of the die-cutting impact force on the printing unit and printing effect. This printing and die-cutting dual-power principle means that all gears in the printing paper feeding section are no longer stressed, improving service life and ensuring printing accuracy and effect. After many years, if the die-cutting error becomes larger, only check the condition of this set of die-cutting gears. The cost of replacement or repair will be greatly reduced.

2. The die-cutting plate roller and rubber pad roller are made of high-quality 45# steel, precision-machined, and hard chrome-plated after surface grinding.

3. Static and dynamic balance correction, good running stability.

4. Pneumatic die separation device, the die is pneumatically separated during idling and phase adjustment to protect the rubber pad and extend its service life.

5. A mechanical spiral wheel-type lateral 42mm travel device is installed on the rubber pad roller to extend the service life of the rubber pad.

6. Phase adjustment device: planetary gear structure, large torque, small transmission gap, minimal mechanical wear of gears, long-term maintenance of transmission accuracy, and extended service life.

7. Equipped with a 7.0-inch color touch screen, the die-cutting phase is controlled by PLC and fully computer-controlled, and can be adjusted 360 degrees (adjustable during operation and stop), with an adjustment accuracy of 0.02mm.

8. Speed difference compensation device, which can control the linear speed of the surface of the rubber pad roller (because the outer diameter of the rubber pad is constantly decreasing during use). The compensation device can make the linear speed of the rubber pad roller completely controlled by the die, so that the corrugated boxes and cartons die-cut are completely consistent with the shape of the die.

9. Rubber pad grinding device, a certain number can be set during the die-cutting production. When the rubber pad needs to be repaired, the die-cutting motor can be started (the main unit is also started at the same time) for repair, so that the rubber pad can be used repeatedly, improving the utilization rate of the rubber pad.