河北水墨印刷机厂

在商业印刷领域，海德堡四色机凭借自动化程度高、操作方便的优势，受到越来越多印刷同行的青睐。然而，经过长时间的使用，其难免也会出现一些故障，如果不及时处理，势必会影响设备的正常使用。此外，再好的设备也离不开维护保养，就算是品质至上的海德堡印刷机也不例外。为此，笔者将从多年来的领机经验出发，梳理海德堡四色机常见的3个机械气路小故障和排除方法。

In the field of commercial printing, Heidelberg four-color machine is favored by more and more printing colleagues with the advantages of high automation and convenient operation. However, after a long period of use, there will inevitably be some failures. If not processed in time, it will affect the normal use of the equipment. In addition, good equipment is also inseparable from maintenance, even the highest quality printing press in Heidelberg is no exception. For this reason, the author will start from the experience of many years' leading machine and comb out 3 common mechanical gas path failures and elimination methods of four color machines in Heidelberg.

故障一

Fault one

 墨斗电机故障巧排除

Skillful removal of the fault of the ink bucket motor

在一次印刷过程中，海德堡四色机CP操作窗调节墨量大小的按键出现异常状态，具体表现为机台人员调节合适的印刷墨量之后，机器运转几分钟，该色组墨键数值自动降低到最小，手动加大之后，过几分钟又变小，如此反复。反映到活件上则是该色组垂直墨区没有油墨从墨斗传出，墨键墨量关死，该色组墨色无法正常调节。检查墨斗上该色组墨键电机，发现控制墨键墨量大小的轴无法转动。于是，机台人员判断为该墨斗驱动电机损坏，需要更换新的墨斗驱动电机。要想快速准确地解决该故障，有以下操作技巧。

In a printing process, the CP operation window of Heidelberg four color machine regulates the size of the ink size of the key button. It is shown that the machine runs for a few minutes after adjusting the appropriate printing ink volume, and the color group ink key is automatically reduced to the minimum. After the manual increase, it becomes smaller in a few minutes and so repeated. It is reflected that the ink in the vertical ink area of the color group is transmitted from the ink fountain, and the ink value of the ink key is closed. The ink color of the color group can not be adjusted normally. Check the ink key motor on the ink fountain and find that the shaft that controls the ink value of the ink key can not rotate. Therefore, the machine personnel judged that the drive motor of the ink fountain was damaged, and the new ink drive motor needed to be replaced. To solve this fault quickly and accurately, there are the following techniques.

(1)先拆掉墨斗防护罩及损坏的墨斗驱动电机。

(1) first remove the ink shield and the damaged ink drive motor.

(2)将CP操作窗中该色组墨键数值降至0位。

(2) reduce the ink key value to 0 in the CP window.

(3)将墨斗上该墨键墨量调节轴关到最小，与CP操作窗墨键数值调至0位相对应。这是因为只有两者都保持在0位最低值，安装新墨斗驱动电机后的放墨量大小和CP操作窗的调节数值才能保持一致。如果更换时不使两者数值一致，会导致CP操作窗数据与实际墨量混乱，无法准确设置墨量大小。

(3) the inking axis of the ink bar is closed to the minimum, and corresponds to the 0 key position of the CP operation window ink key. This is because only 0 of them are kept at the lowest level, and the amount of ink after installing the new ink drive motor can be consistent with the adjustment value of the CP operating window. If the two values are not changed, the CP window data will be confused with the actual ink volume, and the ink volume can not be accurately set.

(4)将墨斗驱动电机装入固定位置后微调，在CP操作窗进行墨键数值的加减，观察效果。

(4) adjust the ink drive motor into fixed position and adjust the ink key value in the CP operation window to observe the effect.

一般按照以上技巧解决这样的故障，只需半个小时即可完成。

Generally, it is only in half an hour to solve such a failure according to the above skills.

故障二

Fault two

 电磁阀和气缸故障巧排除

Malfunction of the solenoid valve and cylinder

在一次印刷机季度保养之后，安装、调试机台辊子后，测试压力正常，但开机印刷活件后，发现第二色组的印版靠身侧带脏。停机排除故障，观察发现控制该色组靠版水辊的电磁阀排气孔漏气严重，手动按电磁阀控制按钮，发现靠身侧气缸动作不灵敏、动作慢，而靠外侧气缸工作正常。针对此故障，可以较为容易地判断为水辊控制电磁阀损坏，而实际的故障点不在电磁阀上，而是气缸出现了问题。在此，笔者将介绍我们判断该故障的技巧。

After a printer's quarterly maintenance, after installing and debugging the table roller, the test pressure is normal, but after the machine is opened, it is found that the plate of the second color group is dirty on the side of the body. It is found that the air leakage of the solenoid valve, which controls the color group by the plate, is serious, and the control button is controlled manually by the solenoid valve. It is found that the movement of the side cylinder on the back side is insensitive and the movement is slow, but the outside cylinder is working normally. For this failure, it is easier to judge the damage of the solenoid valve as the water roller controls, while the actual failure point is not on the solenoid valve, but a problem in the cylinder. Here, I will introduce our skills to judge the fault.

(1)一名机台人员手动合上控制靠版水辊气缸的电磁阀控制按钮，按下之后不要松开，另一名机台人员用手分别推动两侧的靠版水辊气缸。如果推不动，则说明气缸工作正常，这是因为气缸中有气压的存在。一般损坏的气缸由于内部串气，用手可以推动。解决故障时，我们发现靠身侧气缸可以推动，而靠外侧气缸推不动，说明故障原因为气缸出现了问题。

(1) one machine man manually controls the control button of the solenoid valve on the cylinder of the plate, and does not let it loose after the press, and the other desk personnel push the cylinder of the two sides of the water roll respectively. If it is not pushed, it indicates that the cylinder works normally because of the existence of air pressure in the cylinder. Generally damaged cylinders can be driven by hand because of internal cross flow. When we solve the problem, we find that the cylinder can be pushed by the side cylinder, but it is not pushed by the outer cylinder, which shows that the fault is caused by the problem of the cylinder.

(2)一般情况下一侧气缸出现问题，大部分原因是该侧气缸损坏，导致一侧水辊合不到位。而一旦是电磁阀出现故障，则会影响到两侧的气缸工作状态，导致两侧气缸都合压不到位，或者合压无力。所以结合手动推动气缸的技巧和推理分析两者结合，可以准确地判断出是一侧气缸出现了故障。

(2) generally, there is a problem on one side of the cylinder. Most of the reason is that the side cylinder is damaged, resulting in a side water roll not in place. Once the solenoid valve fails, it will affect the working state of the cylinders on both sides, causing both sides of the cylinders to be pressurized not in place or under pressure. Therefore, combined with the manual push cylinder technology and reasoning analysis, it can accurately judge that a side cylinder has failed.

(3)随后机台人员将该侧串墨辊点动至空间操作最大化（向另一侧点动串墨辊之后，更换气缸空间加大，有利于操作），更换新的气缸后，再次按靠版水辊电磁阀控制按钮，发现故障消失，气缸工作正常，电磁阀漏气现象消失。

(3) then the machine crew moved the roller point to the space operation maximization (after moving the ink roller to the other side, replacing the cylinder space to increase the operation), after the replacement of the new cylinder, again according to the control button of the solenoid valve, found the fault disappeared, the cylinder work was normal, and the leakage of the solenoid valve disappeared.

故障三

Fault three

 水路故障巧排除

Skillful exclusion of waterways

在一次印刷生产过程中，机台人员发现活件带脏，于是加大水量，但没有效果，反而带脏面积更大。于是机台开始检查故障原因。

In a printing production process, the machine personnel found dirty objects, so the amount of water increased, but no effect, but with a larger area of dirty. So the machine began to check the cause of the failure.

(1)检查发现水槽水位降低，首先怀疑是因为上水管道堵塞导致水槽不上水，于是开始疏通上水管道，疏通之后重新打开上水开关，但仍然无法上水。

(1) it is found that the water level of the tank is reduced. First, it is suspected that the water channel is not up because of the plugging of the water pipe, so the water pipe is dredged and the water switch is reopened after the dredging, but it still can not be put on the water.

(2)检查水箱发现回水量减少，并逐渐停止。检查水箱过滤网，观察管路过滤芯是否脏污堵塞。检查结果正常，未发现异常。

(2) check the water tank and find that the amount of backwater decreases and stops. Check the filter screen of the water tank to see if the filter element is dirty and blocked. The results were normal and no abnormalities were found.

(3)检查水槽水位探测头及水箱酒精浓度检测装置，指标正常，信号传递可靠，也没有发现问题。

(3) check the water level detection head and water tank alcohol concentration detection device, the indicators are normal, the signal transmission is reliable, and no problems are found.

(4)在以上常规检查无结果之后，我们开始怀疑制冷系统出现问题。打开水柜制冷机构，发现制冷降温机构外部冻结，温度传感器工作不良，造成制冷时间延长，当水流经过降温板时逐渐被其冻结成冰，形成冰堵，造成水路不畅，水槽中上水中断，上水泵发热，回水量减小。

(4) after the above routine inspection failed, we began to suspect that there was a problem in the refrigeration system. Open the refrigeration mechanism of the water cabinet, it is found that the cooling mechanism is frozen outside the cooling mechanism, and the temperature sensor is not working, which causes the cooling time to extend. When the water flow passes through the cooling plate, it is frozen into ice gradually, forming the ice jam, causing the waterway is not smooth, the water in the tank is interrupted, the water pump is heated and the return water is reduced.

(5)更换新的温度传感器之后，故障排除。水路系统工作恢复正常。

(5) troubleshooting after replacing the new temperature sensor. The work of the water system was restored to normal.