Quality monitoring program operation of the binding line
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The binding linkage line is linked by one machine, and the whole process of wireless binding can be completed online, which is suitable for binding of large-volume books and magazines. This kind of production line has a high degree of automation and high unit output, and it is particularly important to implement effective full-process quality monitoring. This article combines the practice of the author's company, talk about the quality monitoring program operation of the binding line.
First, what is quality monitoring program operation
The programmatic work method is a management method that regulates the operational behavior of workers in production positions. It adopts a scientific classification and compilation method, and according to the inherent law of controllable factors, the entire work content of the relatively independent working face of the production process is compiled into a set of standardized working procedures. Each program has corresponding work standards and schedule requirements, and has been inspected and evaluated by field inspection to ensure the implementation effect and minimize the negative impacts caused by different operating habits. The programmatic operation of quality monitoring is to apply the programmatic work method to the implementation of quality control to ensure the full implementation of the monitoring target. Programmatic work methods are two types of time series and process type. According to the characteristics of water quality production of quality monitoring and binding linkage line, we adopt the process-based work method, which is to complete the binding work process, divide the monitoring stage according to the quality monitoring steps, determine the key control points, and mark the monitoring and early warning. , the preparation of monitoring operating procedures, standards and acceptance procedures.
Second, quality monitoring projects
According to the requirements of comprehensive quality control, we will list the quality monitoring items of the binding line as Table 1.
Third, the implementation of quality monitoring projects
This article only focuses on the implementation of several quality monitoring projects for raw and auxiliary materials, milling back and rubber.
Raw material
This refers to the processing object, ie the signature and the cover. The captain and the captain of the mainframe should carefully review the transfer book, compare the sample and proofs, carefully review the specified book, and master the title, opening number, algebra, starting and ending order of each page, book thickness, cover rules, and confirm the need to bind. The product must be complete and correct.
Monitoring and warning:
(1) The influence of the signature on the appearance quality of the finished book back is very important. The folding page should be in place and accurate, without hollowness or wrinkle. Otherwise, it is easy to cause the book to be milled continuously, so that the signature inside can not be glued. Caused a page drop. A book with a thick paper and a large number of folds should be cut into small pieces and then folded. For this reason, it should be considered to print the relevant rules when arranging printing. After the folding, the signatures should be tied tightly, and the setting time should be no less than 2 days to prevent rebound and fainting after unbundling. The signature should not be too dry or wet. Excessive drying, poor permeability, adhesion of the glue to the surface, affecting the bond strength; excessive moisture, slow curing, affecting the quality of forming and cutting. In winter, the indoor and outdoor temperature difference is large, and the signatures to be processed should be placed in the workshop in advance, so that the temperature of the signature can be processed after being adapted to the room temperature. Otherwise, because the temperature of the signature is too low, the glue layer is cold after the glue is applied, the surface temperature drops sharply, the fluidity and permeability decrease, and the bond strength is affected. When stacking and handling the folded post, you should pay attention to it, do not deform it, and make sure that the signature is very flat after unbundling. The signatures that are flattened by the flattening machine should be placed neatly, and placed on the pressure plate for each layer for more than 2 days before being glued on the machine.
(2) The cover rules should be as consistent as possible, and the cutting line marks should be added. In the last seal, the marker is the cover of the rule. If there is no mark, it can be picked out in advance and processed separately to avoid waste and work. When cutting the cover, the upper and lower knife errors should be minimized to ensure the consistency of the rules. The amount of cutting is about 250 per cut, and the cover should be too thick. The cover must be cut to ensure a vertical angle. It is not advisable to use too much thinner or dusting on the color printed cover to avoid affecting the bonding fastness. The linkage line is automatically sealed. It should be printed with quick-drying ink. There are no knife flowers on all sides. Before the upper seal, it should be loosened to prevent sticking. The dimensional error should be less than 0.2mm. When printing the cover, if the paper is not affected, the size of the head and the foot should be increased in an appropriate amount to prevent the glue from overflowing during the encapsulation.
Main excipient
That is, the hot melt adhesive is glued. Its quality is directly related to the bond fastness of the book. The main component of the hot melt adhesive is EVA (ethylene vinyl acetate copolymer). At present, the quality and price of hot melt adhesives of various manufacturers on the market vary greatly, mainly because the raw materials are different. For example, hot melt adhesives rely on paraffin as a diluent to regulate fluidity. Some manufacturers use imported synthetic wax, and some use the lowest grade paraffin. Another example is tackifier resin, which is made of imported hydrocarbon resin and EVA resin. The lowest grade is also used with rosin resin and plasticizer. Due to the oxidation of rosin in the air and the precipitation and transfer of plasticizers, the aging and embrittlement speed of the rubber is accelerated. This low-grade, low-cost hot melt adhesive can be imagined if it is used for binding books. Talc powder is also added to the hot melt adhesive to increase the hardness, and the color of the glue is changed by the titanium white powder. The various materials in its constituent components are themselves a contradictory combination. In the process of binding, the infiltration of the book block relies on the fluidity at high temperatures, and the high temperature accelerates the aging of the glue, and the bond strength is lowered, and the low temperature resistance is deteriorated.
Monitoring and warning:
(1) The paper of the book block is different, and the requirements for the glue are different. For example, the book core is newsprint, book paper, and ordinary hot melt adhesive; the book core is coated paper and double-adhesive paper. Because of its coated or large-area ink, the heat dissipation is fast, the absorption is poor, and the penetration is low. Glue; textbooks, reference books, books, slotting depth is not allowed to increase, but also to withstand frequent folding, use high-grade glue; some products that need to be torn when used, you can use low-grade glue.
(2) The production season is different, and the glue should be different. Especially in the north, cold in winter, to ensure the temperature of the production environment, and choose a slow curing glue, the glue temperature should be 3 ° C ~ 5 ° C higher than the summer, or use halogen lamps, iodine tungsten lamps above the rubber wheel Bake to ensure the temperature of the glue. In the summer, the glue with faster curing speed should be selected to prevent the book block from loosening and rebounding after the binding, resulting in loose pages.
Under normal circumstances, the glued hot melt adhesive meets the conditions in Table 2 before it can be put into use.
Milling back
Adjust the depth of the milling back according to the thickness of the signature. Let the innermost page of the signature be milled into a single sheet. The edge of the milling back should be smooth, the back of the book should be flush, the milling groove should not be hairy, and the spacing and depth should be the same. If the milling back is beveled, the thickness of the rubber layer is uneven, the spine is difficult to flatten, and the bond strength is greatly affected. The edges of the milling back and the milling groove are hairy, the glue is not poured into the groove, and the pages of the book are folded back and forth, which is easy to cause the falling frame. The spacing also affects the bond strength. Under the same conditions, the spacing of the milling groove is changed from 10mm to 5mm, and the initial tensile strength can be increased by about 1.5kg (see Table 3 and Table 4 for technical parameters of milling back and milling).
Monitoring and warning:
(1) The depth and width of the coated paper and double-coated paper book core milling groove should be appropriately increased to ensure the bonding strength.
(2) Milling cutters and milling cutters should use special thickened carbide inserts from professional brand manufacturers. The blade is resistant to wear, has a sharp blade and a smooth milling surface.
Glue
The glue temperature should be controlled within a certain range. The temperature of the glue is too high. For example, when the temperature is above 170 °C, the fluidity of the glue is good, but the foaming is more, the glue is easy to be glued, and the glue is aging and brittle; the temperature of the glue is too low, such as below 140 °C, the glue is not melted. Thorough, low permeability, low bond strength, easy to cause loose pages, dropped pages. Generally, due to the high ambient temperature in summer, the glue temperature can be appropriately lowered by 3 °C ~ 5 °C, but not lower than 150 °C; in winter, it should be appropriately increased by 3 °C ~ 5 °C, but not more than 170 °C. Due to continuous heating under static conditions, it will lead to aging, failure, etc., so when the machine is stopped for a long time (such as 2 hours or more), the temperature of the glue should be reduced by 30 ° C ~ 40 ° C to delay aging. Long-term storage in the natural state, the glue will also age and become brittle, so pay special attention to the production date and shelf life.
Monitoring and warning:
(1) The glue should be pre-melted, and it should be added and added every time to keep the glue temperature relatively constant.
(2) The glue temperature display is often quite different from the actual glue temperature. It should be equipped with a 50°C～300°C thermometer and often test the glue temperature.
In recent years, wireless binding has become the main method of book binding. In particular, the continuous introduction of the binding line is gradually changing the traditional manual labor binding. Therefore, it is of great significance to explore and perfect the binding process and continuously improve the quality management of the binding. This article throws bricks and attracts jade, and hopes that the peers will give more advice.