Faster, More Refined, More Stable--On the Development and Progress of Postpress Equipment (2)

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Fourth, saddle stitching production line

The saddle-stitching production line is one of the more mature types in domestic production lines. In the 1970s and 1980s, domestically-made PDQ-01 and PDQ-02 horse-riding staplers were commonly used. Their maximum production capacity was 6,000 copies/hour. , far from the international advanced level at that time (12,000 to 140,000 hours per hour). In the 1990s, Shanghai Ziguang Company (formerly Shanghai Stapler Factory) developed the LQD8 horse riding linkage motive, which has now developed into the LDQ8D, LDQ8E type, which consists of a pager unit, a folding pager, and a stapler unit. The three sides are composed of a book cutting unit and an electric control box, which can meet the needs of modern binding operations and complete a variety of operations. The PLC programmable controller is used to detect and control the signatures, and the whole line inspection and tracking is performed for missing posts, multiple posts, and posts. The transmission adopts frequency conversion speed control, and the maximum speed of the machine is 10,000 rpm. This production line not only greatly improves and enhances the technical performance, stability, reliability, and operation, but also has surface quality and appearance. Different degrees of improvement have greatly reduced the gap with foreign famous brands.

Heidelberg, Germany, Martini, Switzerland and FERAG are the main manufacturers of saddle stitching linkages. FGRAG's product speed is up to 25,000/h, and up to 40,000/h, Heidelberg and Martini. The horse-riding linkage motive is also up to 20,000 copies/hour. The uniqueness of the Heidelberg Rider King ST300 lies in the fact that all types of jobs can be reliably machined to ensure efficient production with an output speed of 13,000 copies per hour.

The control of the stapler unit is the SPS digital control system with fault diagnosis function. It not only displays the text of the exchange of information with the operator, but also displays the current production data. All units of the Heidelberg Rider ST400 are driven individually. Adjustable parts can be automatically positioned.

In order to meet the demand for short-lived work in recent years, Martini also produces medium- and low-speed machines, but the degree of automation is also high.

Fifth, paperback production line

In China, a large number of textbooks, novels, popular science books, and large-scale literary publications are all paperback books. Therefore, the plain packaging production line is the main equipment for the book printing shop's bookbinding shop, and it is also one of the major imported binding equipment in China. Since the 1970s, China has produced the first-generation production line PRD-1 type paperback production line (production speed 3600 ~ 6500 / h, stable production speed 4000 ~ 5000 / h), and later produced PRD-2 type, production The speed has decreased. The PRD-1 type paperback production line is mainly composed of pages and staples, and there is no cutting process, so it can only produce a wool book. The technology is backward and the output is low, which cannot meet the needs of the printing factory. For a long period of time, the paperback production line was mainly a wireless glue production line (in which the Northwest Machinery Factory and the State-owned 523 Factory produced a wire-smoothing production line, with a small amount), and it was unstoppable to the development and reached the international advanced level. The difference is getting farther and farther. At this stage, domestic large-scale book printing and printing plants have purchased foreign advanced paperback production lines. In the early 1990s, the Shanghai Stapler Factory (predecessor of the company) developed the ZXJD440 paperback production line consisting of a collating machine, a bookbinding machine, a slitter, a book cutter, and a counting stacker. The program controller controls, the collation machine adopts the vertical continuous post, can expand the connection for the book core machine, has adapted the high speed to send the post the need, the production speed achieves 10000 book/hours, has achieved the international 1980s advanced level. However, this line has a long process flow, large footprint, high cost, and poor machine stability. With too many imported machines, the line has not really formed production capacity. In recent years, Shangyu Ziguang Company has also developed the ZXJD440A automatic binding machine for flat binding machines, adopting advanced PLC technology, frequency control technology, PID self-tuning technology and other new technologies. Most of the data adjustments and settings have been made. Digital display for monitoring, easy and accurate adjustment, machine adaptability, the highest mechanical speed of 6000 rpm / hour, the aircraft reached the advanced level of similar equipment in Europe. In order to meet the needs of short-lived, the company has also developed a BBYL410 disc package based on the disc package. This machine can start from the start of collation to the completion of the package. It is a small paperback production line (not With three sides of the book), stepless speed regulation, production speed of 1600 ~ 4000 rev / h.

Internationally, the development of binders has always attached great importance. Martini, Heidelberg, Kolbs, and Warrenberg have all launched new products. Heidelberg's BINDER2Binder, production speed 2000 copies per hour; Martini's Corona perfect binding machine at 18,000 hours per hour, Corona compact binder at speeds of 12,000 copies per hour, using a modular structure, taking up very little space small. While developing high-speed machines, manufacturers have set pre-adjustment functions in order to meet the demand for more small and medium-sized batches and faster product conversion time. Martini's Seiko "Acoro" Perfect Binder offers flexibility, high efficiency, and good bookbinding quality. The machine through the commander system, using the touch screen can be directly input the production data, but also through the network, the production planning department of the personal computer, all the thickness of the book settings are controlled by the commander controller, about Five minutes to complete the machine conversion. The advanced glue booker equipment is becoming simpler and easier to handle, making adjustments more convenient. As a result, less and less time is spent on tuning.

Sixth, hardcover production line and sewing machine

Due to the long process flow and high processing costs, hardcover books were mainly used in classic books, dictionaries, and other books. With the improvement of people's lives, the demand for hardcover books is on the rise. In the 1970s, our country produced the JZX-01 hardcover production line. This line consists of eight main engines and four auxiliary engines. It is based on the Kolbus AK36 model to improve the design and production, with low speed and high price. It belongs to the phase-out model, so only a limited number of sets have been produced, and only a few types of mainframes have been produced according to the order for the rest of the time. Therefore, the hardcover production lines required for domestic large-scale book printing and printing plants are almost all imported machines.

Hardcover books in developed countries are the main preservation books, and they are in great demand. Therefore, the development of the hardcover production line is remarkable. In the 1970s and 1980s, KOLBUS produced 70 models (70 copies per minute) and Compact 40 models (40 copies per minute). Later, the compact 40 model was developed to 2000 models. Computer-controlled pre-adjustment system greatly shortens the conversion time of the product; at the same time, Stahl also develops the VBF BL200 hardcover linkage production line, which is equipped with a CAC microprocessor system and automatic data storage electronic measurement station and monitoring. The system, the size of the book can be input and stored in advance through the electronic measurement platform, can adjust all the key adjustment points at the same time on the linkage line, all adjustments only need a few minutes. In recent years, Scrooge-Coles has introduced a hardcover production line to process one book per second, and Martini's Diaman hard-shell production line has achieved an efficiency of 3,600 copies per hour. Uses today's most advanced shaftless transmission technology, as well as automatic viscosity adjustment coating system.

The sewing machine for thick paperback books and hardcover books is an important supporting machine for hardcover machines. The domestic sewing machine has evolved from the SXZ-02 model to the SXZ440 and SXZ440A models controlled by the microcomputer. Compared with the automatic sewing machine, the SX440A automatic line sewing machine has a book-laying part which is placed flat upright for vertical placement. Page turning and counting are controlled by a single computer, canceling the counter, and also affecting the performance of the bookshelf. The cam line and the outline cam line of the push book were optimized. The other cams were also rigorously checked and corrected, thereby reducing the vibration and noise of the machine; the B-type and A-type machines are all mechatronic products, but due to The process of the machine is complex, and the requirements for manufacturing precision and assembly accuracy are high. The quality stability and reliability of the machine are still far from those of advanced foreign models, and thus the production volume is not high. In recent years, the newly developed SXZ370 automatic sewing machine (maximum binding width 370mm × 300mm, the maximum mechanical speed of 7200 rev / h) has frequently appeared in various printing exhibitions. The machine adopts a fully-enclosed type, safe operation, low noise, electrical PLC programmable control technology, a page up and down part of the total of 4 paper remover, on the cover page, loose leaf, no length and length and thickness of the non-uniformity of the signature All pages can be automatically paged, and the loose-leaf booklet can be opened up and down. Faults such as shrinking, breaking, and rolling books are provided.

The highest speed of foreign advanced sewing machines has reached 200 posts/hour, which can automatically match and send posts. Taking the ASTRONIC 180 sewing machine as an example, it adopts Siemens electronic system to provide simple programming and adjustment of the height of the entire machine, conveyor belt and chain and desk, so as to minimize the exchange time. The machine is equipped with a light control sequence inspection system that can check the sequence of signatures. The 20 optical pickups placed in the hopper can read the 20mm x 110mm printed portion of each signature, if the read information and stored memory The difference is that the machine appears mismatched page information and shuts down to ensure the lock page sequence. The machine's compact rotary monitoring system can be programmed by symbols and can store up to 30 programs. The program can be recalled or modified to stop production without stopping. Once stopped, warning information can be displayed automatically. The speed can be automatically adjusted in the production process. ASTRONIC 180 Sewing machine adopts Siemens electronic system. It is equipped with a light control sequence inspection system section that can check the order of signatures. The relevant production data can be calculated, programs and data. Can also print directly. In addition, the machine can also be online production, Multiplex system can make the collation and lock line (up to three sewing machines) can be completed in a continuous process, the book block after the lock line can be published by the automatic discharge system and follow That is sent to the upper adhesive or manual unloading station.

The gap between domestically produced flat-packed production lines and hardcover production lines and foreign ones is obvious. In particular, hardcover production lines are actually blank. In the twenty-eight-character printing technical guideline, the state clearly requires that the application of glue-binding technology should be promoted, and the development and perfection of wireless adhesive order machines and linkage machines, hard-packed stand-alone machines and linkage lines.

Seventh, conclusion

Nowadays, the needs of the bookbinding market are developing in the direction of diversification, such as the diversification of varieties of books and periodicals, the high standardization of quality requirements, the personalization of on-demand processing, the miniaturization of production batches, the environmental protection during processing, and so on. It is a new challenge to the original post-press processing technology, materials and equipment. How to adapt to this social demand is a major issue before us.

Although great achievements have been made in post-press processing, they are still the weakest link in the printing industry. It is not a matter of overnight to change this situation of post-press processing. With the development of post-press processing in the developed countries in recent years, the attitude of the domestic printing industry towards post-press processing is also changing. The pre-press, printing, and post-press are regarded as indispensable system engineering and cannot be ignored. The concept of post-press processing is becoming the consensus of everyone. This change in concept may seem more important than the development of several post-press processing equipment. The development of post-press processing machinery towards diversification, mechatronics, linkage, automation, and digitization and networking is a general trend. The concept of changing the above goals is the most important. In this respect, today's printing magazines can do a lot.