The rules for the treatment, installation and removal of gears on the anilox roller are the same as the bearings. As with bearings, when the gears are installed incorrectly, it may cause the drum to jump, make noise, or change the coordination of the entire machine, which may damage the shaft sleeve, keyway and gear.
When a keyway suffers transient damage, it is best to roll out a new keyway on the original bushing, which is 180 degrees away from the old keyway. In the process of rolling a new keyway, the most notable area is the center of the keyway: it must be exactly at the center of the roll shaft. Otherwise, the keys cannot be fixed. To achieve a close fit, whether the keyway has the proper length and width is also very important, just as a proper grinder is as important as the correct keyway shape. Changing the width of the keyway requires the use of a more precise gauge, rather than a card gauge.
Another trouble with gear stepping is that people do not pay enough attention to stepping TIR. If there is a transition deviation in any step of the anilox roller sleeve, it will cause many problems. If the bottom of the gear drops to the lowest point or the surface of the gear is not uniform, the gear shakes and sounds. When the situation is serious, this jitter will also affect the transmission mode and seriously affect the quality of the printed matter. This condition can also damage the gear prematurely.
It can be seen from the many scratches and grooving on gear steps or adjacent steps that people often handle them incorrectly. Scratches and hook grooves are cosmetic damage and do not necessarily require extensive repairs. These deficiencies may only increase the difficulty of the moving or installation process, just file a little bit on the burrs or the replaced metal. The problem for anilox roll suppliers is when these machine damages (perhaps only on the surface) will affect the measurement of parameter changes.
The TIR reading of a general gear step is about 0.005 inches, at which time the performance of the drum will not be affected. But the reading also varies with the printer manufacturer and gear tolerances. Some machine designs are sensitive to roller deflection, so their OEMs (original equipment manufacturers) have very strict requirements for gear stepping. In this way, the deflection of the machine should be considered in the tolerance so that it does not affect the performance of the drum. During the initial and final stages of the entire process, all anilox roll suppliers should check all roll shafts for bending or damage, and record the inspection results. Especially in the initial inspection stage of the old drum, paying attention to whether the journal is bent or damaged will help solve the problem, hoping to reduce damage and future repair costs by modifying operations and procedures.
In most cases, the person who ordered the anilox roller is not the one who moved or installed the anilox roller, so it is necessary to communicate clearly between the parties. Poor communication can lead to blaming meetings, which is why good communication / recording between anilox suppliers and customers is so important.
3. Balance process
Depending on the tolerance of the printing press and the level of print quality required, the balance of the anilox roller is a crucial factor. There are two balancing processes: static and dynamic. A similar example is the balance of car tires. The old bubble balance method is a static process, while the spinning balance method is a dynamic process.
An unbalanced cylinder will cause coordinated changes of the machine at different speeds, which will cause various problems on the printing press. The anilox roll supplier must check the balance of the drum during the initial inspection of the anilox roll repair and report the results to the customer. In the manufacturing process of the drum, it is often found that there are welded balance weights (weights) inside the pipe. In some cases, the weights are loose and you can hear them rattling in the drum duct, which should cause you to be alert enough.
Sometimes in the manufacturing process, the loosened balance weight may be absorbed by other debris in the drum pipe, which will be silenced. At this time, it is necessary to extract a large amount of material from both ends of the completed drum with a better balancing technique, make the area empty to reduce the quality, or insert an iron bar to increase the weight when necessary, and then locate the welding spot at the correct position. If the original drum tube is far from the equilibrium state, it may be necessary to use an internally welded balance weight. Dynamic balancing is generally used for a special roller RPM or FPM (surface size / minute).
Generally, narrow-width rollers no longer need balance adjustment, because they are mostly made of solid materials instead of metal pipes. The cylinder size, configuration and dynamic operation of narrow-width cylinder printing machines are different from those of printing machines with large cylinders.
When manufacturing a new cylinder for any wide-format printing press or corrugated printing press, high-quality tubular materials must be used to minimize the need for mechanical balance.
The more popular is the "drum heat seal" tubular material, because even strict parameters require this material to ensure that the wall thickness of the pipe is uniform, thus reducing the need for excess balance.
As with many things in life, your efforts are proportional to your gains, so high-grade piping materials are also accompanied by expensive prices. The gap between the price of high-grade pipe materials and low-grade pipe materials is very obvious. Anilox roll suppliers have a parameter standard for evaluating advanced piping materials for all new anilox rolls.
To reduce downtime, save costs, and maintain high print quality, it is important to understand the spatial parameters of the anilox rolls and how they affect the printing press, the performance of the printing press, and the maintenance of the anilox rolls.
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