新涂布机培训资料(英文版).ppt

1、GL CoaterTraining Sea Dragon PM 4, - 2005,A Technological part B Technical components C Operation D Maintenance E Safety,Task of GL Coater,Uniform application of fluid in order to:,Improve printability 改善印刷质量 Improve opacity and gloss 提高透明度和光泽度 Prevent curling and dusting 防止卷曲和除尘,Pigmenting and coat

2、ing,Applicationprinciple,1backing roll(背辊) 2roll applicator unit(辊式涂布装置) 3framing(机架) 4 return system(回流系统) 5 metering beam(刮刀梁),Application principle,Metering elements,Contour coat涂层轮廓,with metering rod,Blade coat,Stiff/Bent Blade(硬/软 刮刀),Metering rod(计量棒),Design Data,GL COATER STATION Control func

3、tion hydraulic with roll application system. The coater can be used with rod or blade.,Design Data,Design Data,Web width 5650 mm Max. operation speed 620 m/min Design speed 700 m/min,Design Data,Coating machine Dryness before coating machine 93 % Dryness at reel 93 % Coating weight 12 g/m Solid cont

4、ent 60 % Coating colour viscositiy 350 2000 cps (100 rpm, # 4 Spindle, 35C) Coating metering type rod / Stiff blade Coating drying type Air Dryers (customers provision) Coating weight control CD manual MD automatic,Design Data,Applicator roll Diameter 450 mm Face 5.860 mm Cover thickness 20 mm Cover

5、 material rubber MagnaSize Cover hardness 25 P&J Body and journals of steel, caps of cast iron.,Design Data,Backing roll Diameter 1.000 mm Face 5.850 mm Cover thickness 25 mm Cover material rubber, Topcoat Cover hardness 70 P&J Body and welded on journal of steel,A Technological part B Technical com

6、ponents C Operation D Maintenance E Safety,GL Coater,machine shop assembly,1backing roll(背辊) 2rope pulley segment(引纸绳滑轮组) 3Rope(引纸绳),Backing roll,Applicator roll,1color pan(颜料盘) 2color distribution pipe(颜料分配管) 3applicator roll(涂布辊),Applicator roll speed approx. 20% of backing roll speed.(涂布辊的速度大约为背辊

7、速度的20%),Applicator roll swivelling,1roller applicator unit(辊式涂布装置) 2hydraulic cylinder(液压缸) 3pivot bearing(旋转轴承),Applicator roll swivelling,Applicator roll gap,1screw jack element(螺旋千斤顶) 2handwheel with position indicator(操纵轮和位置指示器) 3limit stop(限位器) 4 Stand(支架),1Handwheel(操纵轮) 2spacer unit(定位架) 3lim

8、it stop(限位器),A = 0,5 - 0,8 mm,Applicator roll gap,Applicator roll gap,Framing,1backing roll bearing(背辊轴承) 2stand(支架) 3metering beam bearing arm(刮刀梁的轴承座) 4 pivot bearing(传动轴承),Color pan,1application zone(施涂区) 2color distribution pipe(颜料分配管) 3cooling duct(冷却剂导管) 4 Header(总管) 5 color pan(颜料盘),Color dis

9、tribution pipe,1inlet(入口) 2exit holes(出口) 3Header(总管) 4 bypass holes(旁通孔),Color distribution pipe swivelling,1hydraulic cylinder(液压缸) 2color pan(颜料盘) 3color distribution pipe(颜料分配管),1color distribution pipe (颜料分配管) 2hydraulic cylinder (液压缸) 3color pan (颜料盘),Color distribution pipe swivelling,Color d

10、istribution pipe swivelling,1sealing strip(密封条) color distribution pipe (颜料分配管) 3application roll(涂布辊),A = 1 mm,Color distribution pipe seal,1seal(密封条) 2color distribution pipe(颜料分配管) 3clamping strip(夹紧条) 4 applicator roll(涂布辊) 5 fastening screw(螺栓),Splash guard,5 mm,Edge doctor,1holder with clamp 2

11、doctor blade 3applicator roll,Edge doctor,1paper web 2backing roll 3doctor blade 4 holder 5 clamp,Edge doctor,Mind that the color will flow outwards after the edge doctor,Edge doctor,Edge doctor,Metering beam,1spacer unit 2cross member 3hydraulic cylinder 4 device for adjusting metering beam angle 5

12、 bearing arm 6 metering beam bearing arm 7 blade holder,Metering beam,1intermediate flange 2gear cam limit switch 3screw jack element 4 servomotor 5 guard 6 angle encoder 7 motor flange,Stiff blade,1paper web 2loading blade 3press-on hose,Stiff blade,1blade guard 2pressing strip 3press-on hose 4 coa

13、ting blade,Stiff blade,Standard stiff blade types:,Stiff blade,Bent blade,Bent blade,Bent blade,Choose a blade angle and calculate the metering beam angle,Blade angle,Metering beam angle,Bent blade,Example: Blade loading -6,0 mm Deflection angle 22,5 W3 = 22,5 + W2,1pressing strip 2press-on hose 3me

14、tering rod 4 metering-rod bed 5 blade,Rollflex,Rollflex,Metering rod drive,1metering rod with quick coupling 2cover hood 3motor with gearbox 4 drive shaft 5 moveable drive shaft,Metering rod drive,GL-Coater Blade clamping,closed,open,Profiling spindles,1profiling spindle 2blade guard 3coating blade

15、4 press-on hose 5 pressing strip 6 clamping hose 7 supporting strip,For Rollflex,Basic alignment/adjustement of pressing strip,For stiff balde and bent blade,Metering beam swivelling,Metering beam swivelling,Metering beam operating position,1screw jack element 2handwheel with position indicator 3bra

16、cket 4 pivot bearing 5 metering beam bearing arm 6 thrust piece,Gauge for rollflex,A = 1,0 mm,Metering beam operatingposition,1gauge 2profiling spindle 3pressing strip,Gauge for stiff blade and bent blade,A = sheet thickness, e.g. 0,4 mm,Metering beam operatingposition,1gauge 2profiling spindle 3pre

17、ssing strip,Parts for adjusting the gab between Applicator beam and Back roll,FS,Remark: After roll change the distance device must turned out complete,Remark: The adjusting blade must be attached each 300-500 mm of outside. Guaranteeing that the adjusting blade fit correctly.,Remark: Turning the ha

18、nd wheel counterclockwise. The feeler must move easy between roll and adjusting blade. Carrying out this procedure at both side (FS and DS).,Remark: Take out the indicator and set the zer position (0000,00“). - In order to avoid a not wanted change, the shaft should be stuck.,Blade angle adjusting u

19、nit,Color return system,1strainer insert (filter) 2return line 3color pan 4 return plate (water cooled),Color return system,Color return flow from metering element at return plate,Color return system,Color overflow at back side of color distribution pipe,Coating,Sizing,Backing roll edge spray,1paper

20、 web 2 coating application 3 edge spray,Edge spray,Backing roll edge spray,Backing roll shower (for cleaning only),1cleaning spray pipe 2 application roll 3 backing roll,Metering beam heating system,Keeping metering beam at constant temperature to prevent unequal crowning due to thermal stress (fric

21、tion, temperature of application fluid). Heating of metering beam before startup. Small heating/water circulation during operation.,A Technological part B Technical components C Operation D Maintenance E Safety,Rollflex,Stiff blade,Bent blade,How to change the coat weight,Local control panels,Operat

22、ing modes,Start Sequence,1) Set operating modes: operation“ + automatic“ + coating“ + e.gstiff blade“ 2) Set coater parameters: blade load mm, press-on hose pressure bar, metering beam angle 3) Coating color supply low circulation 4) Threading coater section 5) Coating color supply upper circulation

23、 6) Start Sequence Coater 7) Adjust edge deckles and edge sprays,Automatic start sequence GL Coater,Stop sequence,1) Stop sequence Coater Cleaning Changing of distribution device,Automatic stop sequence GL Coater,Web break procedure,1) Web break signal web cut-off ahead of Coater 2) Stop coating seq

24、uence activated automatically 3) Cleaning,Photocells,Photocell for paper web detection,Knock-off device,Checks during operation,Check color layer on paper: Low or high gloss? ( low or high coat weight) Check color layer on paper: Equal coverage or stripes? Check application width: Set edge doctor po

25、sition Check if there is sufficient return flow from metering element,Checks during operation,Check paper gloss after coater,Checks during operation,Adjust edge deckle position,A Technological part B Technical components C Operation D Maintenance E Safety,Cleaning,Cleaning,Color residues in color di

26、stribution pipe,Cleaning,Cleaning,Never use sharp objects to clean the backing roll!,When to replace wear parts?,Metering elements (blade, rollflex),Application quantity can not be reduced any more (blade worn out) Application fault (blade scratches, metering rod worn out) Product change, i.e. chang

27、e of application rate Other reasons, e.g. after every web break,When to replace wear parts?,Damaged metering rod,Worn out blades,When to replace wear parts?,Edge doctor,Doctor blade worn out. DANGER: The metal support blade must not scratch on the applicator roll surface!,Edge doctor blade change,Re

28、placing a rollflex unit,Important items: Carry rollflex with 2-3 people Check if an old metering rod can be re-used Make records, attach a label to old rod,Assembly of new rollflex unit,1aligning aid 2blade metering rod bed 4metering rod 5wooden strip,Assembly of new rollflex unit,Assembly of new ro

29、llflex unit,Assembly of new rollflex unit,1metering rod 2quick-release coupling,3driver 4 drive shaft,Replacing a stiff blade or bent blade,1) Press coating stop“ button metering beam will swivel to standby position. 2) Press unclamp“ button clamping hose will de-aerate 3) Take out old blade and ins

30、tall new blade 4) Press clamp“ button 5) Press coating start“ button,Prepare roll change,1. Swivel metering beam, applicator roll, and color distribution pipe to cleaning position. 2. Switch off drives and safeguard against restarting. 3. Disconnect pneumatic and hydraulic supply and lubrication. 4.

31、 Dismount drive shaft coupling.,Roll change,Roll change,Adjustments after roll change,Set operating position metering beam Set operating position applicator roll Set splash guard Set sealing gap (only applicator roll change),Roll change,Replacing hydraulic cylinder,Prepare cylinder change,1. Stop hy

32、draulic unit and close shutoff valves. 2. Drain hydraulic cylinder. 3. Suspend metering beam with lifting gear to coater section framing. 4. Remove hydraulic cylinder.,Replacing hydraulic cylinder,1pivot pin 2cover 3hydraulic cylinder 4 bearing pin 5 bellows 6 bearing arm 7 metering beam 8 shackle 9

33、 lifting aid,Replacing hydraulic cylinder,1block and tackle 2rope 3pivot pin 4 cover 5 hydraulic cylinder 6 pivot pin 7 color pan,Replacing hydraulic cylinder,Adjustments after cylinder change,Swivel metering beam while de-aerating cylinder. Set operating position applicator roll Set operating posit

34、ion metering beam,Replacing clamping and press-on hose,Prepare hose change,1 Press unclamp“ button. 2 Remove tube holder and side shields. 3 Pull old hose out of groove. 4 Trim new hose and grind clean. 5 Use soap sud to facilitate drawing the new hose into the groove.,Replacing clamping and press-o

35、n hose,1press-on hose 2pressing strip 3hose clip 4 connection nipple 5 pneumatic air connection 6 holder 7 clamping screw 8 side shield 9 metering beam 10 profiling spindle,Press-on hose,Replacing clamping and press-on hose,1clamping hose 2metering beam 3hose clip 4 connection nipple 5 pneumatic air

36、 connection 6 clamping screw 7 side shield,Clamping hose,Replacing screw jack elements,Prepare screw jack element change,1 Remove handwheel and position indicator. 2 Remove cover with holder and clamp. 3 Secure screw jack element with rope. 4 Remove screw jack element.,Replacing screw jack elements,1screw jack element 2handwheel 3bracket 4 clamp,Replacing screw jack elements,1screw jack element 2handwheel cover 4 holder with clamp 5 framing,Replacing screw jack elements,Adjustments after screw jack element change,Set operating positio