Our factory imported German P44-82VCF KBA in 1992--Praneita sheet-fed four-color offset printing press. Accident occurred in 1996, resulting in 2 and 3 color group transfer roller gears, 3 and 4 color group impression cylinders. The gear and the 3 color set rubber roller gear 5 gears are damaged.
After inquiry: It takes more than RMB 400,000 to import 5 gears, which takes 4 months. In order to save costs and save time, we use domestic gear instead. Its practice is as follows:
1. First, the damaged gears will be surveyed and mapped, and various technical parameters of the gears will be calculated, and then the verification and technical parameters will be measured.
2. Verify gear material, after testing the original gear material is equivalent to domestic material QT45-5.
3. According to the validated technical parameters and the determined materials, the final drawings are drawn.
4. Send drawings that are correct for inspection to the gear machining center for processing.
5. After the gears are processed, the technical accuracy is reviewed item by item. After contact, the installation and commissioning fees for foreign personnel are RMB 100,000. To save expenses, it is determined that the technical personnel of our factory will perform the installation and debugging.
6. During installation, clean all the damaged parts and install a simple gantry lifting frame for lifting.
7. Lifting gears and leaves to draw the newly installed gear and the original gear position combination point line.
8. After lifting. Gear radial runout and plane oscillation are calibrated using dial gauges and are adjusted within 0.01mm to 0.015mm.
9. The gear meshing clearance is adjusted within 0.15mm to 0.2mm.
10. After replacing all the damaged gears according to this method, use the manual crank to rotate the assembly gear and rotate it several times to check the meshing of the gears. If there is no problem, then tighten all the fixing bolts.
11. The jog press runs at low speed and checks all gear operation. Finally, it is equipped with a positioning pin for newly installed gears.
12. Check all lubrication points, replace the new oil, and then inspect the gears for lubrication at low speed.
After nearly 10 days of installation, commissioning and test printing, the printing quality has met the requirements of the original machine. After one and a half years of use, there is no abnormality in the replaced gears and the entire machine.
The use of domestic gears to replace imported gears, gear processing money is 55,000 yuan, only 1/8 of the imported gear (imported gear needs more than 40 million). Self-installation, saving installation fee of 100,000 yuan, from machine damage to installation, a total of 56 days, 1 month ahead of the imported gear.