新涂布机培训资料(英文版).ppt

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1、GL CoaterTraining Sea Dragon PM 4,-2005,A Technological partB Technical componentsC OperationD MaintenanceE 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 coating,Ap

2、plicationprinciple,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 function hydra

3、ulic with roll application system.The coater can be used with rod or blade.,Design Data,Design Data,Web width 5650 mmMax.operation speed 620 m/minDesign speed 700 m/min,Design Data,Coating machineDryness before coating machine 93%Dryness at reel 93%Coating weight 12 g/mSolid content 60%Coating colou

4、r viscositiy 350 2000 cps(100 rpm,#4 Spindle,35C)Coating metering type rod/Stiff bladeCoating drying type Air Dryers(customers provision)Coating weight control CD manual MD automatic,Design Data,Applicator roll Diameter 450 mmFace 5.860 mmCover thickness 20 mmCover material rubber MagnaSizeCover har

5、dness 25 P&JBody and journals of steel,caps of cast iron.,Design Data,Backing rollDiameter 1.000 mmFace 5.850 mmCover thickness 25 mmCover material rubber,TopcoatCover hardness 70 P&JBody and welded on journal of steel,A Technological partB Technical componentsC OperationD MaintenanceE Safety,GL Coa

6、ter,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速度的20%),Applicator roll swivelling,1roller applicator u

7、nit(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)3limit stop(限位器),A=0,5-0,8 mm,Applicator roll gap,Applicator roll

8、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 distribution pipe,1inlet(入口)2exit holes(出口)3Header(总管)4 bypass holes(旁通孔),Co

9、lor 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 distribution pipe swivelling,1sealing strip(密封条)color distribution pipe(颜料分配管)3appli

10、cation 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 clamp2doctor blade3applicator roll,Edge doctor,1paper web2backing roll3doctor blade4 holder5 clamp,

11、Edge doctor,Mind that the color will flow outwards after the edge doctor,Edge doctor,Edge doctor,Metering beam,1spacer unit2cross member3hydraulic cylinder4 device for adjusting metering beam angle5 bearing arm6 metering beam bearing arm7 blade holder,Metering beam,1intermediate flange2gear cam limi

12、t switch3screw jack element4 servomotor5 guard6 angle encoder7 motor flange,Stiff blade,1paper web2loading blade3press-on hose,Stiff blade,1blade guard2pressing strip3press-on hose4 coating blade,Stiff blade,Standard stiff blade types:,Stiff blade,Bent blade,Bent blade,Bent blade,Choose a blade angl

13、e and calculate the metering beam angle,Blade angle,Metering beam angle,Bent blade,Example:Blade loading-6,0 mm Deflection angle 22,5W3=22,5+W2,1pressing strip2press-on hose3metering rod4 metering-rod bed5 blade,Rollflex,Rollflex,Metering rod drive,1metering rod with quick coupling2cover hood3motor

14、with gearbox4 drive shaft5 moveable drive shaft,Metering rod drive,GL-CoaterBlade clamping,closed,open,Profiling spindles,1profiling spindle2blade guard3coating blade4 press-on hose5 pressing strip6 clamping hose7 supporting strip,For Rollflex,Basic alignment/adjustement of pressing strip,For stiff

15、balde and bent blade,Metering beam swivelling,Metering beam swivelling,Metering beam operating position,1screw jack element2handwheel with position indicator3bracket4 pivot bearing5 metering beam bearing arm6 thrust piece,Gauge for rollflex,A=1,0 mm,Metering beam operatingposition,1gauge2profiling s

16、pindle3pressing strip,Gauge for stiff blade and bent blade,A=sheet thickness,e.g.0,4 mm,Metering beam operatingposition,1gauge2profiling spindle3pressing strip,Parts for adjusting the gab between Applicator beam and Back roll,FS,Remark:After roll change the distance device must turned out complete,R

17、emark:The adjusting blade must be attached each 300-500 mm of outside.Guaranteeing that the adjusting blade fit correctly.,Remark:Turning the hand 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 th

18、e indicator and set the zer position(0000,00“).-In order to avoid a not wanted change,the shaft should be stuck.,Blade angle adjusting unit,Color return system,1strainer insert(filter)2return line3color pan4 return plate(water cooled),Color return system,Color return flow from metering element at re

19、turn plate,Color return system,Color overflow at back side of color distribution pipe,Coating,Sizing,Backing roll edge spray,1paper web2 coating application3 edge spray,Edge spray,Backing roll edge spray,Backing roll shower(for cleaning only),1cleaning spray pipe2 application roll3 backing roll,Mete

20、ring beam heating system,Keeping metering beam at constant temperature to prevent unequal crowning due to thermal stress(friction,temperature of application fluid).Heating of metering beam before startup.Small heating/water circulation during operation.,A Technological partB Technical componentsC Op

21、erationD MaintenanceE Safety,Rollflex,Stiff blade,Bent blade,How to change the coat weight,Local control panels,Operating 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)Co

22、ating color supply low circulation4)Threading coater section5)Coating color supply upper circulation6)Start Sequence Coater 7)Adjust edge deckles and edge sprays,Automatic start sequence GL Coater,Stop sequence,1)Stop sequence Coater CleaningChanging of distribution device,Automatic stop sequence GL

23、 Coater,Web break procedure,1)Web break signal web cut-off ahead of Coater2)Stop coating sequence activated automatically3)Cleaning,Photocells,Photocell forpaper web detection,Knock-off device,Checks during operation,Check color layer on paper:Low or high gloss?(low or high coat weight)Check color l

24、ayer on paper:Equal coverage or stripes?Check application width:Set edge doctor positionCheck 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 partB Technical components

25、C OperationD MaintenanceE Safety,Cleaning,Cleaning,Color residues in color distribution 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

26、fault(blade scratches,metering rod worn out)Product change,i.e.change of application rateOther 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 scra

27、tch on the applicator roll surface!,Edge doctor blade change,Replacing a rollflex unit,Important items:Carry rollflex with 2-3 peopleCheck if an old metering rod can be re-usedMake records,attach a label to old rod,Assembly of new rollflex unit,1aligning aid2blademetering rod bed4metering rod5wooden

28、 strip,Assembly of new rollflex unit,Assembly of new rollflex unit,Assembly of new rollflex unit,1metering rod2quick-release coupling,3driver4 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 h

29、ose will de-aerate3)Take out old blade and install new blade4)Press clamp“button5)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 hyd

30、raulic supply and lubrication.4.Dismount drive shaft coupling.,Roll change,Roll change,Adjustments after roll change,Set operating position metering beamSet operating position applicator rollSet splash guardSet sealing gap(only applicator roll change),Roll change,Replacing hydraulic cylinder,Prepare

31、 cylinder change,1.Stop hydraulic 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 pin2cover3hydraulic cylinder4 bearing pin5 bellows6 bearing arm7 metering be

32、am8 shackle9 lifting aid,Replacing hydraulic cylinder,1block and tackle2rope3pivot pin4 cover5 hydraulic cylinder6 pivot pin7 color pan,Replacing hydraulic cylinder,Adjustments after cylinder change,Swivel metering beam while de-aerating cylinder.Set operating position applicator rollSet operating p

33、osition 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-on

34、 hose,1press-on hose2pressing strip3hose clip4 connection nipple5 pneumatic air connection6 holder7 clamping screw8 side shield9 metering beam10 profiling spindle,Press-on hose,Replacing clamping and press-on hose,1clamping hose2metering beam3hose clip4 connection nipple5 pneumatic air connection6 c

35、lamping screw7 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

36、2handwheel3bracket4 clamp,Replacing screw jack elements,1screw jack element2handwheelcover4 holder with clamp5 framing,Replacing screw jack elements,Adjustments after screw jack element change,Set operating position applicator rollSet operating position metering beam,Replacing metering beam angle ad

37、justing device,Prepare change,1 Stop hydraulic unit and close shutoff valves.2 Suspend metering beam with lifting gear to coater section framing.3 Remove servomotor with angle encoder.4 Secure screw jack element with ropes and remove.,Replacing metering beam angle adjusting device,1cross member2pivo

38、t pin3guard4 screw jack element5 cover6 pivot pin7 metering beam8 front blade9 shackle10 pull-lift hoist,Replacing metering beam angle adjusting device,1intermediate flange2gear cam limit switch3screw jack element4 servomotor5 guard6 angle encoder7 motor flange,Replacing metering beam angle adjustin

39、g device,Adjustments after change,Set metering beam 30 position.Set metering beam min angle(15)and max angle(55).Contact Voith Paper!,A Technological partB Technical componentsC OperationD MaintenanceE Safety,Safety instructions for operation,Do not reach into swivel range Do not touch rotating or moving parts Remove paper scrap only with suitable device If movement has not taken place,do not initiate by hand Read safety regulations operation manual chapter 2,1safety railings2guard plate,Specific hazards,