Fault Analysis and Cutting Problem in Perfect Binding Production

The ZXJD440A medium-speed plain binding glue line must stack different books in the production process, first make a sample book on the quality management, and after signing the quality inspection personnel, carry out production according to the sample. There are two aspects of quality control: one is the dataization and standardization of each process; the other is the management of process design and work flow. The former requires that all processes implement standardized operations, and the latter is the operational requirements for the formulation of work processes and processes.

In the production practice, 80% of quality accidents are caused by the lack of responsibility of the operators, and 20% are due to process reasons and materials. To make 80% of the accidents disappear in the bud, we must understand the technical requirements.

1. Failure in glue production

1) Round back

The height of the book in the book clip and the signature of the book Qitai are too low. The signature of the book should be controlled to be 11-12mm. The position of the tray should be increased. The height of the knife is too high and the position of the cutter head should be reduced. Groove depth is controlled within 1.0mm.

2) oblique endorsement

The glue temperature is too high. When the book is dropped, the back of the book is not solidified and falls. The glue temperature is adjusted according to the paper and seasonal changes. Generally, the temperature is controlled at 160-180C. If the speed is too fast, the glue with a short curing time should be used, and the speed should be reduced. The opening of the book clip is too large, and the thickness of the book is 15mm. At the same time, the book aisle and the lever are narrowed.

3) The book's opening and notches should not be rectangular. The parallelism and verticality of the tray and the holder should be adjusted so that the back of the book is the same.

4) The cover is bad

There is wild glue on the upper sealing roller, sticking to the cover of the book, and the bottom plate of the forming mechanism is viscose. The clamping plates on both sides are glued to seal the seal and seal the seal. Therefore, the residual glue is often removed and the methyl silicone oil is used to prevent the wild glue; The rubber on the wheel takes too long to produce wild glue. The glue application time should be fine-tuned. Try not to produce wild glue and minimize gum temperature.

5) Book cover fold or misalignment

If the book position in the book clip is too high, the position of the tray must be raised. If the knife is too high, the position of the cutter head should be reduced. If the temperature of the glue is too low, the temperature of the glue should be increased. The glue stick should be left with glue. The glue stick should be adjusted. The gap between the plastic sheets is made zero, and the working status of the heating tube in the slush bar is checked; if the binding speed is too fast, the machine speed should be lowered and the drying time should be extended before cutting.

6) Leverage

The signature of the book is too low or the book position is low in the book clamp. The position of the solid board should be reduced. If the notch is too low, the position of the cutter head should be increased; the clamping force on the side of the bracket is too large and should be outward. Adjust the side clamp plate position properly.

7) Bubble or honeycomb film

The height of the book in the book clip and the height of the tray are too low. The position of the tray must be raised. The temperature of the backing glue is too low or the temperature of the glue stick is too low. After the measurement, the temperature is increased.

8) Back rip or over-squeeze

Low book position in the book clip, the position of the solid plate should be reduced; the pressure of the upper seal roller is too large, the clearance between the upper seal roller and the bottom of the book holder body is 9mm, the glue on the glue wheel is excessive, and the glue wheel and the scraper The gap of the board is adjusted to 0.2-0.5mm; the rubber wheel is too high and the pressure is too high, ensuring that the rubber wheel is in contact with the back of the book and can open the back of the book so that the glue penetrates into the book in a small amount.

9) The book is opened or flanged before the book

The passivation of the milling cutter's cutting edge should sharpen the cutting edge and often remove the viscose. It is better not to use this machine for the return book processing. The adjustment of the milling backing support disc should be done properly.

10) Dispatch

Milling back depth is not enough; groove groove depth inappropriate, improper groove pitch, so that the depth of about 7.0mm, spacing between 5-10mm; hot melt adhesive temperature is too low, lack of fluidity and permeability, bonding is not strong , Should improve the glue temperature according to the paper; improper selection of hot melt glue, should choose the hot melt glue that is equivalent to the paper weight specification, save the high value of the coated paper book, avoid the use of hot melt glue process, use the first lock line After the way of gluing, prevent the spread of posts.

11) The middle part of the book is not even

When the book falls, the gap is too big, and a groove is made in the small board. When the glue temperature is too high, the book is not evenly thick and thin when it is glued. The groove is not clean, the paper hair is not removed, the adhesive cannot be leveled, and the milling and backing tool is not The sharpness, the angle of the blade is not correct, and the clearance between the blade and the plate is too large, which causes the back of the milling to be not smooth, and is not even after the glue is applied. The position of the solid plate is too low.

13) Wide Book Back

Slotted knife support plate is not aligned with the book clip; the upper seal roller is too high, forming excessive pressure on the back of the book; the rubber on the back rubber is too high, so that the glue penetrates between the pages; the book block is not loosely tied; the milling back is not Smooth, rough.

14) Wedge

The distance between the squeegee and the bottom surface of the book holder is too small, and the position of the sizing wheel should be reduced.

15) Non-uniform film

The height of the side glue and the bottom glue device and the inside and outside position are not well adjusted; the clearance between the rubber wheel and the scraper plate, the glue stick and the scraper plate is improperly adjusted and should be readjusted; the distance between the glue stick and the book block is inaccurate, and the glue The rod is not heated well, and the glue stick is not parallel to the back of the book.

16) Wedge film

The glue stick is not parallel to the bottom surface of the book holder body; the solid sheet is not parallel to the bottom plane of the book clip and should be readjusted.

17) The glue has voids

The adhesive in the adhesive device is too small, and the amount of glue should be ensured; when the temperature of the glue is too low, the glue temperature should be controlled.

18) Booklet cover positioning offset

The book cover conveyor guide chain is not aligned, and each pair of drawbars should be parallel and perpendicular to the side gauge; the upper drum is slightly lower, the cover and the back of the book are unmatched, and the cover is reset after being hit.

19) The cover is not firmly bonded

The machine speed is too fast, the glue opening time is long, and the hot melt adhesive matching the machine speed should be used; a small amount of the cover off the defective book is not cleared; the book is empty, the real-time agency improperly adjusts, the realizing pressure is too small, and it should be increased. The adhesive layer is too thin and the bonding is not strong. The back adhesive and the side adhesive layer should be thickened.

2. Cutting problem

1) Inconsistent ups and downs

The slitting knife should be aligned with the slitting line, so that the two books are basically the same.

2) Left and right skew

In the process of sending books, the parallel lines of the two pushing blocks are not perpendicular to the middle knife or the tracks are too narrow to produce a skew; the pressures on both sides of the pressure plate are inconsistent or too light; the cutting is continuous or the raw edges are serious, and the floor plate and the cutting blade must be frequently changed mill.

3. Three-sided cutting problem

1) After cutting, the large and small blades on the finished book are blunt, which makes the size of the door knife inconsistent; the delivery trolley is not perpendicular to the working platform and the pressure of the paper press is light; the cutting height exceeds the design height, resulting in pressure on the paper press , Pulling force increases, the paper is bent and deformed greatly; the side blade is too narrow or the upper side of the back is knocked when the sharpening knife is sharpened, and the knife edge and the cutting surface should be at a certain angle.

2) There are bevels

The delivery car trolley is not parallel to the doorknife, resulting in incisions; improper booklet aisle gaps, excessively tight transport resistance, too loose and swaying; front and rear cutters on the turret measure in different sizes and should be replaced Calibrate the knife holder; the brush is not in place and the book block is not aligned. The book is not stable.

3) Book breaks

Should ensure that the glue layer is between 0.8 and 7.2mm, the plastic tray is level and the package is empty; the cover paper is poor or the paper is not in the correct direction; the book-bundling time is too short or tight; the milling back is not Smooth and clean, it made the back of the rubber loose and increased the thickness of the book. Slots are not smooth, fast, and the side glue is too thick; the jacking plate is not used properly, it is not pressed on the cutter head of the sky or the ground, and tearing occurs; the stapled book is slanted back; the blade is not fast and the corner angle is too small. Scoop up the glue on the blade and wax or talc; use a guillotine machine with a broaching knife.