Printing equipment part management system and printing equipment part management method

Abstract

The invention provides a printing equipment part management system and a printing equipment part management method, and relates to the technical field of printing equipment. The printing equipment part management method comprises the steps that the preset number of rotation turns of parts is obtained, and the parts comprise a reference part and a part to be detected; the actual number of rotation turns of the reference part is obtained; according to the actual number of rotation turns of the reference part, obtaining the actual number of rotation turns of the to-be-detected part; the actual number of rotation turns corresponding to the part is compared with the preset number of rotation turns; if the actual number of rotation turns is larger than or equal to the preset number of rotation turns, an alarm signal is sent to replace the part. The actual number of rotation turns of the multiple to-be-detected parts can be obtained only by collecting the actual number of rotation turns of the reference part, a data collection module does not need to be independently configured for each to-be-detected part, the hardware composition and the installation structure are simplified, and the production cost is reduced.

Description

Technical Field

[0001] This disclosure relates to the field of printing equipment technology, and in particular to a printing equipment parts management system and a printing equipment parts management method. Background Technology

[0002] Printing equipment includes offset printing machines, gravure printing machines, flexographic printing machines, and digital printing machines. The components of printing equipment include paper feeding system parts, printing unit parts, drying system parts, paper delivery system parts, transmission and control parts, auxiliary parts, and other key components. The components also differ between different printing machines; for example, the components of a gravure printing machine are the gravure cylinders, or the flexible printing plates of a flexographic printing machine. In actual production, it is necessary to maintain and replace easily damaged parts according to the specific machine model.

[0003] During the printing process, the components of printing equipment are mainly responsible for paper separation and conveying, ink transfer, pressure and substrate handling, and supporting roller rotation. Their condition directly affects print quality and equipment lifespan. Print quality includes color accuracy, dot sharpness, and registration precision. However, as consumable parts, long-term operation of printing equipment components can lead to the following problems: 1. Uneven ink color, blurred dots, and misregistration, affecting print quality; 2. Frequent shutdowns for pressure adjustment or component replacement, reducing production efficiency; 3. Increased scrap rate and energy consumption, leading to higher operating costs; 4. Cracks or delamination in components may scratch the substrate or even cause mechanical failure, resulting in low safety performance.

[0004] Currently, the management of printing equipment parts mainly relies on the experience and judgment of technicians, which is highly subjective, unstable, and lacks coverage, making it difficult to detect hidden wear. This necessitates periodic shutdowns for disassembly and inspection, resulting in low detection efficiency. Furthermore, real-time monitoring is not possible, leading to relatively low detection accuracy.

[0005] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0006] This disclosure provides a method and system for managing printing equipment parts, which improves testing efficiency and reduces production costs.

[0007] Other features and advantages of this disclosure will become apparent from the following detailed description, or may be learned in part from practice of this disclosure.

[0008] According to one aspect of this disclosure, a method for managing printing equipment parts is provided, comprising: Obtain the preset number of rotations of the component, which includes a reference component and the component to be tested; Obtain the actual number of rotations of the reference component; The actual number of rotations of the component to be tested is obtained based on the actual number of rotations of the reference component. Compare the actual number of rotations corresponding to the component with the preset number of rotations; If the actual number of rotations is greater than or equal to the preset number of rotations, an alarm signal is sent to replace the component.

[0009] In some implementations, obtaining the preset number of rotations of the component includes the following steps: The preset number of rotations of the component is obtained based on the component's service life, rotation circumference, production line unit capacity, number of pages per booklet, and length of a single sheet of paper.

[0010] In some embodiments, the actual number of rotations of the component to be tested is obtained based on the actual number of rotations of the reference component, the rotation circumference of the reference component, and the rotation circumference of the component to be tested.

[0011] In some implementations, obtaining the actual number of rotations of the reference component includes the following steps: Obtain the cumulative total number of rotations in the database of the printing equipment; Get the number of rotations of the counter in the current beat; The actual number of rotations of the reference component is obtained based on the total cumulative number of rotations and the number of rotations of the counter in the current cycle.

[0012] In some embodiments, obtaining the cumulative total number of rotations in the database of the printing equipment includes the following steps: Obtain the total number of rotations of the printing equipment before the last shutdown; Get the number of rotations of the counter in the previous beat; If the number of rotations of the counter in the current cycle is greater than the number of rotations of the counter in the previous cycle, the printing equipment will run continuously, and the total number of rotations in the database of the printing equipment is the total number of rotations of the printing equipment before the last shutdown. If the number of rotations of the counter in the current cycle is less than or equal to the number of rotations of the counter in the previous cycle, the printing equipment is not running continuously. The total cumulative number of rotations in the database of the printing equipment is the sum of the total cumulative number of rotations of the printing equipment before the last shutdown and the actual number of rotations of the counter in the previous cycle.

[0013] In some implementations, the following steps are also included: Obtain the remaining usage time of the components; The next replacement time for a component is determined by summing its last replacement time and remaining usage time.

[0014] In some embodiments, obtaining the remaining usage time of the component includes the following steps; The remaining allowable number of rotations is obtained based on the actual number of rotations of the component and the preset number of rotations. Obtain the number of rotations per unit for the component; The remaining usage time is obtained based on the remaining permissible number of rotations and the number of rotations per unit of the component.

[0015] In some embodiments, obtaining the number of unit rotations of the component includes the following steps: Calculate the remaining allowable number of rotations of the component based on the production line unit capacity, number of pages per booklet, length of a single page, average daily production time, and the rotation circumference of the component.

[0016] According to a second aspect of the present invention, embodiments of the present invention also provide a printing equipment parts management system, comprising: The data acquisition module is used to obtain the actual number of rotations of the reference component; The data processing module, which is communicatively connected to the data acquisition module, is used to obtain the actual number of rotations of the component to be tested based on the actual number of rotations of the reference component, and to compare the actual number of rotations of the component with the preset number of rotations. The component includes the reference component and the component to be tested. An alarm module, communicatively connected to the data processing module, is used to send an alarm signal when the actual number of rotations of the component is greater than or equal to a preset number of rotations, so as to replace the component.

[0017] In some embodiments, the data acquisition module includes: The marking component is sleeved on the outside of the reference component, which is sleeved on the outside of the fixed shaft and is capable of transmission relative to the fixed shaft; A detection component is disposed on the side of the fixed shaft facing the detection component, and the detection component is used to detect the marking component.

[0018] In some embodiments, the identification component includes: A clamp is fitted onto the side of the reference component facing the fixed shaft. A raised marking is provided on the clamp, and the detection component is used to detect the raised marking. The first anti-slip component is fitted onto the outside of the reference component and located between the reference component and the clamp.

[0019] In some embodiments, the inner diameter of the clamp is adjustable.

[0020] In some embodiments, the detection component includes: The bracket includes a main body, a fixing part, and a mounting part. The fixing part and the mounting part are respectively disposed on both sides of the main body, and the fixing part is sleeved on the outside of the fixing shaft. A sensor, detachably connected to the mounting portion, is used to detect the marking component.

[0021] In some embodiments, the mounting portion is provided with a mounting hole for mounting the sensor, the mounting hole extending radially along the fixed shaft.

[0022] In some embodiments, the fixing part includes: Two jaws are located on both sides of the fixed shaft; An adjusting member is provided through the main body and the two jaws. The adjusting member is configured to rotate relative to the main body, so that the two jaws can move closer to or further away from each other, so that the two jaws can clamp the fixed shaft. The second anti-slip component is disposed on the side of the chuck facing the fixed shaft.

[0023] In some embodiments, the adjusting member has a screwing part at one end along the axial direction of the adjusting member and a limiting part at the other end, the limiting part being used to limit the distance between the adjusting member and the main body.

[0024] One embodiment of the present invention has the following advantages or beneficial effects: The printing equipment component management system provided in this embodiment allows the data acquisition module to obtain the actual rotation counts of multiple components to be tested simply by acquiring the actual rotation count of a reference component. This eliminates the need to configure a separate data acquisition module for each component to be tested, simplifying the hardware composition and installation structure and reducing production costs.

[0025] The printing equipment component management method provided in this disclosure indirectly calculates the actual rotation number of each component to be tested based on the actual rotation number of a reference component. This eliminates the need to deploy a separate data acquisition module for each component to be tested, simplifying the data acquisition path. Furthermore, it ensures the synchronization and conversion consistency of the actual rotation number statistics for multiple components to be tested.

[0026] By comparing the real-time value of the actual number of rotations of the component under test with the preset number of rotations, an alarm signal is actively sent when the actual number of rotations reaches or exceeds the preset number of rotations. This can promptly remind operators to replace the component under test, reduce excessive wear of the component under test, and reduce printing quality defects, thereby effectively reducing the scrap rate and the maintenance cost of printing equipment. Attached Figure Description

[0027] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure. It is obvious that the drawings described below are merely some embodiments of this disclosure, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0028] Figure 1 The diagram shown is a structural schematic of a printing equipment parts management system according to an embodiment of the present invention; Figure 2 The diagram shown is a structural schematic of a data acquisition module in a printing equipment parts management system according to an embodiment of the present invention; Figure 3 The diagram shown is an exploded view of the data acquisition module in a printing equipment parts management system according to an embodiment of the present invention; Figure 4 The diagram shown is a structural schematic of the data processing module and the alarm module in a printing equipment parts management system according to an embodiment of the present invention; Figure 5 The diagram shown is a flowchart of a printing equipment parts management method according to an embodiment of the present invention.

[0029] The reference numerals in the attached figures are explained as follows: 100. Component; 101. Reference component; 1011. Fixed shaft; 102. Component to be tested; 1. Data acquisition module; 2. Data processing module; 3. Alarm module; 13. Marking component; 131. Clamp; 132. Marking protrusion; 133. First anti-slip component; 10. Detection component; 11. Bracket; 111. Main body; 1111. First threaded hole; 1112. Slide groove; 112. Fixing part; 1120. Second threaded hole; 1121. Claw; 1122. Adjusting part; 1123. Second anti-slip part; 1124. Tightening part; 1125. Limiting part; 1126. Slider; 113. Mounting part; 1131. Mounting hole; 12. Sensor; 21. Controller; 22. Main unit; 23. Display screen; 31. Alarm light; 32. Buzzer. Detailed Implementation

[0030] Preferred embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While preferred embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0031] The terms "first" and "second" used in this document are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "multiple" means two or more, unless otherwise explicitly stated.

[0032] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0033] The following disclosure provides many different implementations or examples for carrying out different structures of this application. To simplify the disclosure, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or reference letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various implementations and / or arrangements discussed.

[0034] It should be noted that, unless otherwise specified, the embodiments of the present invention and the technical features thereof can be combined with each other.

[0035] The following detailed description of this exemplary implementation method is provided in conjunction with the accompanying drawings and embodiments.

[0036] This disclosure provides a printing equipment parts management system, such as... Figure 1As shown, the printing equipment parts management system includes a data acquisition module 1, a data processing module 2, and an alarm module 3. The data acquisition module 1 is used to acquire the actual number of rotations of the reference part 101. The data processing module 2 is communicatively connected to the data acquisition module 1 and is used to obtain the actual number of rotations of the part to be tested 102 based on the actual number of rotations of the reference part 101, and compare the actual number of rotations of the part 100 with a preset number of rotations. The part 100 includes the reference part 101 and the part to be tested 102. The alarm module 3 is communicatively connected to the data processing module 2 and is used to send an alarm signal when the actual number of rotations of the part 100 is greater than or equal to the preset number of rotations, so as to replace the part 100.

[0037] For example, the paper receiving section of the printing equipment is used as the reference station, and the paper receiving roller is used as the reference component 101, which can also be called the reference roller. The selection of the reference component 101 mainly considers the following aspects: 1. Prioritize the selection of the main drive roller with a constant transmission ratio as the reference component 101 to ensure the accuracy of the reference measurement point; 2. Ensure that the shaft end of the reference component 101 has sufficient installation space; 3. Prioritize the selection of rollers with a vibration amplitude of less than 0.1 mm as the reference component 101.

[0038] Among them, the component to be tested 102 can be a rubber roller corresponding to the printing section, gluing section, back strip section, crack line section, and circular knife section.

[0039] For example, the data acquisition module 1 can acquire the actual number of rotations of the reference component 101 and transmit the data to the data processing module 2. The data processing module 2 calculates the actual number of rotations of the component to be tested 102 based on the actual number of rotations of the reference component 101.

[0040] The data acquisition module 1 only needs to acquire the actual number of rotations of the reference component 101 to obtain the actual number of rotations of multiple components 102 to be tested. There is no need to configure the data acquisition module 1 independently for each component 102 to be tested, which simplifies the hardware composition and installation structure and reduces production costs.

[0041] Based on the actual number of rotations of the reference component 101, the data processing module 2 can calculate the actual number of rotations of each component 102 to be tested and perform a real-time comparison with the preset number of rotations to determine the wear state of the component 102 to be tested. Compared with the method of judgment by human experience, this improves the accuracy and real-time performance of the wear state assessment of the component 102 to be tested.

[0042] If the actual number of rotations of the component 102 under test is greater than or equal to the preset number of rotations, it means that the component 102 under test has reached the preset life limit. The data processing module 2 controls the alarm module 3 to send an alarm signal, instructing the operator to replace the component 102 under test. This avoids excessive wear of the component 102 under test, which could cause printing defects. It shifts from passive maintenance to preventive maintenance, reduces unplanned downtime, and ensures printing quality.

[0043] The printing equipment parts management system provided in this embodiment, with the cooperation of data acquisition module 1, data processing module 2 and alarm module 3, realizes the monitoring of the operating status and life control of printing equipment parts 100, avoids passive maintenance and sudden failure downtime, reduces equipment wear and production and maintenance costs, and improves the operating stability and reliability of printing equipment.

[0044] In one embodiment, such as Figure 2 As shown, the data acquisition module 1 includes an identification component 13, which is sleeved on the outside of the reference component 101. The reference component 101 is sleeved on the outside of the fixed shaft 1011 and can be driven relative to the fixed shaft 1011.

[0045] In this way, the marking component 13 moves synchronously with the reference component 101, which can truly and synchronously reflect the rotational running state of the reference component 101 and ensure the consistency between the detection signal and the actual motion state.

[0046] In one embodiment, such as Figure 2 As shown, the data acquisition module 1 also includes a detection component 10, which is disposed on the side of the fixed shaft 1011 facing the detection component 100. The detection component 10 is used to detect the marking component 13.

[0047] This layout shortens the detection path, reduces the detection spacing, and improves the detection accuracy and signal stability of the detection component 10. Simultaneously, it fully utilizes the limited installation space around the fixed shaft 1011, making the entire data acquisition module 1 compact and integrated, avoiding motion interference with other parts, and ensuring that the normal rotation of the reference component 101 is synchronized and stable with the detection operation.

[0048] In one embodiment, such as Figure 2 As shown, the marking component 13 includes a clamp 131 and a marking protrusion 132. The clamp 131 is sleeved on the side of the reference component 101 facing the fixed shaft 1011, and the marking protrusion 132 is disposed on the clamp 131. The detection component 10 is used to detect the marking protrusion 132.

[0049] The clamp 131 with the marking protrusion 132 is fitted onto the reference component 101. No secondary machining of the reference component 101 is required, and the marking protrusion 132 can be installed without damaging the structure of the component 101. The marking protrusion 132 rotates synchronously and coaxially with the reference component 101 through the clamp 131, ensuring complete matching of their rotational states. The detection component 10 directly detects the marking protrusion 132. The marking protrusion 132 serves as a clear and singular detection object, facilitating identification by the detection component 10 and reducing signal interference caused by surface texture, deformation, and other factors of the reference component 101, thereby improving detection accuracy.

[0050] Among them, clamp 131 is made of rigid material, such as stainless steel, which has high structural strength.

[0051] The inner diameter of the clamp 131 is adjustable, with an adjustment range of approximately 50mm to 150mm. For example, the clamp 131 is made of wound steel strip. The inner diameter of the clamp 131 is adjusted according to the diameter of the reference component 101 to match its dimensions, thus improving versatility.

[0052] In one embodiment, such as Figure 2 As shown, the marking component 13 also includes a first anti-slip component 133, which is sleeved on the outside of the reference component 101 and located between the reference component 101 and the clamp 131.

[0053] For example, the first anti-slip component 133 is made of rubber and can also be called an anti-slip rubber washer, with specifications in GB / T 3452.1-2005. The first anti-slip component 133 is sandwiched between the reference component 101 and the clamp 131 to prevent slippage between the clamp 131 and the reference component 101. At the same time, the first anti-slip component 133 can isolate the reference component 101 and the clamp 131, and to a certain extent, it also plays a role in buffering and protection, preventing mechanical damage to the reference component 101.

[0054] In one embodiment, such as Figure 2 As shown, the detection component 10 includes a bracket 11 and a sensor 12. The bracket 11 is disposed on the fixed shaft 1011 and is used to mount the sensor 12. The sensor 12 is used to detect the marking protrusion 132 of the marking component 13.

[0055] Specifically, sensor 12 is a photoelectric sensor. The detection distance of sensor 12 is approximately 10-15 mm, the response time is ≤1 ms, and the distance between sensor 12 and clamp 131 is approximately 3-5 mm.

[0056] The bracket 11 is made of high-strength aluminum alloy and its surface is anodized. Specifically, the bracket 11 includes a main body 111, a fixing part 112, and a mounting part 113. The fixing part 112 and the mounting part 113 are respectively disposed on both sides of the main body 111. The fixing part 112 is sleeved on the outside of the fixing shaft 1011, and the mounting part 113 is used to mount the sensor 12.

[0057] The sensor 12 is detachably connected to the mounting portion 113, facilitating the installation and removal of the sensor 12. Specifically, as shown... Figures 2-3 As shown, the mounting part 113 is provided with mounting holes 1131, and the sensor 12 is mounted to the mounting holes 1131 by bolts. The bolts are loosening bolts, M6×20, grade 8.8.

[0058] The mounting hole 1131 extends radially along the fixed shaft 1011, which facilitates the adjustment of the position of the sensor 12 relative to the mounting part 113 to accommodate reference parts 101 with different diameters.

[0059] In one embodiment, such as Figure 3 As shown, the fixing part 112 includes an adjusting member 1122 and two jaws 1121. The two jaws 1121 are located on both sides of the fixing shaft 1011. The adjusting member 1122 passes through the main body 111 and the two jaws 1121. The adjusting member 1122 is configured to rotate relative to the main body 111, so that the two jaws 1121 move closer to or further away from each other, so that the two jaws 1121 can clamp the fixing shaft 1011.

[0060] The adjusting component 1122 is a lead screw or threaded rod, the fixing part 112 is provided with a first threaded hole 1111, and the jaws 1121 are provided with a second threaded hole 1120. The adjusting component 1122 passes through the first threaded hole 1111 and the second threaded hole 1120. By rotating the adjusting component 1122, the two jaws 1121 are opened and closed to clamp the fixed shaft 1011. In this way, the distance between the two jaws 1121 is adjustable to accommodate fixed shafts 1011 of different diameters, making it highly versatile.

[0061] The adjusting component 1122 is periodically lubricated with grease, such as lithium-based grease, to further ensure the smooth rotation of the adjusting component 1122.

[0062] Specifically, one of the claw 1121 and the main body 111 is provided with a slider 1126, and the other is provided with a groove 1112. For example, the slider 1126 is provided on the side of the claw 1121 facing the main body 111, and the second threaded hole 1120 is provided in the slider 1126. The main body 111 is provided with a groove 1112, and the slider 1126 is disposed in the groove 1112 and slides in cooperation with the groove 1112, which serves as a guide to plan the movement path of the claw 1121.

[0063] In one embodiment, one end of the adjusting member 1122 along the axial direction is provided with a screwing part 1124, which facilitates the operator to screw the adjusting member 1122. One end of the adjusting member 1122 along the axial direction is provided with a limiting part 1125, which is used to limit the relationship between the adjusting member 1122 and the main body 111, preventing the adjusting member 1122 from coming out of the main body 111 during the screwing process.

[0064] In one embodiment, such as Figures 2-3 As shown, the fixing part 112 also includes a second anti-slip member 1123, which is disposed on the side of the claw 1121 facing the fixing shaft 1011.

[0065] For example, the second anti-slip component 1123 is made of rubber, and the Shore hardness of the second anti-slip pad is approximately 65-75. The second anti-slip component 1123 is clamped between the fixed shaft 1011 and the claw 1121 to prevent slippage between the fixed shaft 1011 and the claw 1121. At the same time, the second anti-slip component 1123 can isolate the fixed shaft 1011 and the claw 1121, and to a certain extent, it also plays a role in buffering and protection, preventing mechanical damage to the fixed shaft 1011.

[0066] In one embodiment, such as Figure 4 As shown, the data processing module 2 includes a controller 21. The output terminal of the sensor 12 is connected to the input module of the controller 21 via a signal line, and the output module of the controller 21 is connected to the alarm module 3 via a signal line. Specifically, the controller 21 is a PLC, specifically an industrial-grade controller with high-speed counting capabilities. The counting frequency of the industrial-grade controller is ≥100kHz, and the controller 21 can be set with a cyclic interrupt sampling period of approximately 30ms. The input module is a PNP type. The signal line uses twisted-pair shielded cable, for example, RVSP 2×0.75mm². If the transmission distance between the sensor 12 and the controller 21 exceeds 10m, a signal repeater can be installed between them. The transmission method can be serial communication, Ethernet socket communication, or other communication methods; this embodiment does not limit the specific transmission method.

[0067] The controller 21 integrates a counter, and the counter and sensor 12 are independent functional units that work together. The photoelectric sensor 12, as a front-end detection element, converts the rotational mechanical motion of the reference component 101 into periodic electrical pulse signals. The controller 21 integrates a counter for real-time high-speed accumulation and counting of the electrical pulse signals. The controller 21 then transmits this data to the host 22. The host 22 analyzes the data, converting the data read by the counter into the actual number of rotations of the reference component 101. This digital quantization facilitates subsequent calculations. Through this two-stage conversion between motion signals and electrical pulse signals, and between electrical pulse signals and digital values, the actual number of rotations of the reference component 101 is accurately acquired.

[0068] In one embodiment, such as Figure 4 As shown, the data processing module 2 also includes a host 22 and a display screen 23. The controller 21 is connected to the main body via a communication cable, and the display screen 23 is electrically connected to the host 22 to display the software operation interface.

[0069] In one embodiment, such as Figure 4 As shown, the alarm module 3 includes an alarm light 31 and a buzzer 32, and the controller 21 is communicatively connected to the alarm light 31 and the buzzer 32.

[0070] When the actual number of rotations is greater than or equal to the preset number of rotations (e.g., the preset number of rotations is 90% of the maximum number of rotations), an alarm prompt box pops up on display screen 23, and an alarm signal is sent to controller 21. Controller 21 controls alarm light 31 to flash, and buzzer 32 sounds an alarm to remind on-site operators to confirm the situation and replace part 100. When on-site operators replace part 100 and confirm the alarm cancellation, the counter continues to collect data for the next cycle.

[0071] It should be noted that, in order to facilitate data management, the entire record line of component 100 is highlighted in yellow and placed at the top of the display area of ​​the software data management interface on the display screen 23, so that on-site personnel can view it in real time and make preparations for stock preparation.

[0072] This disclosure provides a method for managing printing equipment parts, such as... Figure 5 As shown, the method for managing printing equipment parts includes the following steps: S102. Obtain the preset number of rotations of component 100, where component 100 includes reference component 101 and component 102 to be tested; S104. Obtain the actual number of rotations of the reference component 101; S106. Obtain the actual number of rotations of the component to be tested 102 based on the actual number of rotations of the reference component 101. S108. Compare the actual number of rotations of component 100 with the preset number of rotations. S110. If the actual number of rotations is greater than or equal to the preset number of rotations, send an alarm signal to replace part 100.

[0073] The printing equipment component management method provided in this embodiment indirectly calculates the actual rotation number of each component to be tested 102 based on the actual rotation number of the reference component 101. This eliminates the need to deploy a separate data acquisition module 1 for each component to be tested 102, simplifying the data acquisition path. It also ensures the synchronization and conversion consistency of the actual rotation number statistics of multiple components to be tested 102.

[0074] By comparing the real-time value of the actual number of rotations of the component 102 to be tested with the preset number of rotations, an alarm signal is actively sent when the actual number of rotations reaches or exceeds the preset number of rotations. This can promptly remind the operator to replace the component 102 to be tested, reduce the printing quality defects caused by excessive wear of the component 102 to be tested, and effectively reduce the production scrap rate and the operation and maintenance cost of printing equipment.

[0075] In one embodiment, obtaining the preset number of rotations of the component 102 to be tested includes the following steps: The preset number of rotations of component 100 is obtained based on the service life of component 100, the circumference of component 100, the unit capacity of the production line, the number of pages per booklet, and the length of a single sheet of paper. The preset number of rotations can also be referred to as the maximum number of rotations.

[0076] Specifically, taking the paper receiving roller of the paper receiving section of the printing equipment as the reference component 101, the calculation formula for the preset number of rotations D of the reference component 101 is as follows: D = T × (P × N × L / C); Wherein, D is the preset number of rotations of the reference component 101 (single: rotations), T is the service life of the reference component 101 (unit: h), P is the unit capacity of the production line (unit: book / h), N is the number of pages per book (unit: page / book), L is the length of a single page (unit: mm / page), and C is the rotation circumference of the reference component 101 (unit: mm / rotation).

[0077] For example, the following parameters of the reference component 101 are known: the service life of the reference component 101 is T=1000 h, the production line unit capacity is P=3900 books / h, the number of pages per book is N=40 pages / book, the length of a single page is L=210 mm / page, and the rotation circumference of the reference component 101 is C=320 mm / revolution. Substituting these parameters into the formula, the preset number of rotations of the reference component 101 is calculated to be D=102,375,000 revolutions.

[0078] It is understandable that when calculating the preset number of rotations of other parts 102 to be tested, one only needs to replace their corresponding service life and rotation circumference to use the above formula to calculate their preset number of rotations.

[0079] It should be noted that the service life refers to the recommended service life of component 100 at the time of manufacture. Component 100 includes, but is not limited to, component 102 to be tested or reference component 101. In actual production, the service life of components is related to factors such as installation quality, load conditions, working environment, and maintenance. Therefore, in the initial stage of the management method for printing equipment components, it is necessary to adjust the service life of component 100 in the database according to the actual wear and tear and the experience of on-site operators.

[0080] It should be noted that different production lines have different unit production capacity P, number of pages per book N, and length of paper per page L. These parameters need to be replaced with the relevant parameters of the corresponding production line for calculation.

[0081] In one embodiment, the actual number of rotations of the reference component 101 is obtained based on the actual number of rotations of the reference component 101, the rotation circumference of the reference component 101, and the rotation circumference of the component 102 to be tested.

[0082] Specifically, the formula for calculating the actual number of rotations D1 of the component 102 to be tested is as follows: D1 = D0 × C0 / C; Wherein, D1 is the actual number of rotations of the component 102 to be tested (single: rotations), D0 is the actual number of rotations of the reference component 101 (single: rotations), C0 is the rotation circumference of the reference component 101 (unit: mm / rotation), and C is the rotation circumference of the component 102 to be tested (unit: mm / rotation).

[0083] The data read by the counter is the actual number of rotations D0 of the reference component 101.

[0084] Specifically, when the production line is fixed, a single sheet of paper passes through the component to be inspected 102 and the reference component 101. The product of the actual number of rotations D1 of the component to be inspected 102 and the rotation circumference C of the component to be inspected 102 equals the length of the paper produced by the production line. Similarly, the product of the actual number of rotations D0 of the reference component 101 and the rotation circumference C0 of the reference component 101 also equals the length of the paper produced by the production line. Since the length of the paper produced by the production line is a fixed value, there is a proportional relationship between the actual number of rotations D1 of the component to be inspected 102 and the actual number of rotations D0 of the reference component 101. After calculating the actual number of rotations D0 of the reference component 101 using a counter, since the ratio of the rotation circumferences of the component to be inspected 102 and the reference component 101 is a fixed value, the actual number of rotations D1 of the component to be inspected 102 can be calculated.

[0085] By combining the actual number of rotations D0 of the reference component 101 with the rotation circumference C0 of the reference component 101 and the rotation circumference C of the component to be tested 102, the actual number of rotations D1 of the component to be tested 102 can be accurately derived. Only the actual number of rotations of the reference component 101 needs to be collected uniformly to calculate the actual number of rotations of multiple components to be tested 102. There is no need to configure a separate sensor for each component to be tested 102. While reducing production and installation costs, it can also simultaneously count the actual number of rotations of multiple components to be tested 102.

[0086] In one embodiment, obtaining the actual number of rotations of the reference component 101 includes the following steps: Obtain the cumulative total number of rotations in the database of the printing equipment; Get the number of rotations of the counter in the current beat; The actual number of rotations of the reference component 101 is obtained based on the total cumulative number of rotations and the number of rotations of the counter in the current cycle.

[0087] Specifically, the formula for calculating the actual number of rotations Y of the reference component 101 is as follows: Y = A + B; Where Y is the actual number of rotations of the reference component 101, A is the total cumulative number of rotations in the database of the printing equipment, and B is the number of rotations of the counter in the current cycle.

[0088] For example, the cumulative total number of rotations A in the database of the printing equipment is the last current rotation number recorded in the database before the printing equipment was last shut down or restarted, and this current rotation number is the number of rotations already completed. The initial value of the data in the database is 0, and the data in the database is updated in real time.

[0089] For example, when the printing equipment is running, the reference component 101 rotates relative to the fixed axis 1011. After the sensor 12 detects the detection protrusion that rotates with the reference component 101, it transmits the motion signal to the controller 21 and triggers the counter integrated inside the controller 21 to count. Then the controller 21 transmits the data to the host 22. The host 22 parses the data and converts the data read by the counter into the actual number of rotations of the reference component 101. After digital quantization, it is convenient for subsequent calculations.

[0090] By retrieving the total cumulative rotation count pre-stored in the database and the current clock cycle rotation count of the counter in real time, and combining the two types of values ​​to calculate the actual rotation count of the reference component 101, the problem of losing historical operating data that is easily caused by relying solely on the real-time reading of the counter is avoided, ensuring the accuracy of numerical statistics and further improving the timeliness and reliability of replacing the component 102 to be tested.

[0091] It is understandable that when the printing equipment restarts or the counter is reset, the counter reading is updated to zero; when the component to be tested 102 is replaced, the cumulative total number of rotations in the database of the printing equipment is updated to zero. Therefore, it is necessary to consider multiple situations such as printing equipment restart, counter reset, and replacement of component to be tested 102.

[0092] Therefore, obtaining the cumulative total number of rotations in the database of the printing equipment includes the following steps: Obtain the total number of rotations of the printing equipment before the last shutdown; Get the number of rotations of the counter in the previous beat; If the number of rotations of the counter in the current cycle is greater than the number of rotations of the counter in the previous cycle, the printing equipment will run continuously, and the total number of rotations in the database of the printing equipment will be the total number of rotations of the printing equipment before the last shutdown. If the number of rotations of the counter in the current cycle is less than or equal to the number of rotations of the counter in the previous cycle, the printing equipment is not running continuously. The total cumulative number of rotations in the database of the printing equipment is the sum of the total cumulative number of rotations of the printing equipment before the last shutdown and the actual number of rotations of the counter in the previous cycle.

[0093] For example, A is the total number of rotations of the printing equipment before the last shutdown, B is the number of rotations of the counter in the current cycle, C is the number of rotations of the counter in the previous cycle, D is the preset maximum number of rotations for the reference component 101, and Y is the actual number of rotations of the reference component 101.

[0094] When B>C, the counter value continues to increase, which means that the printing equipment is running continuously and the counter is not reset, and the database Y=A+B and C=B are updated in sequence.

[0095] When B ≤ C, the value of the counter does not increase continuously, which means that after the printing device is restarted or the counter is reset, a new round of counting is started, and the database is updated in sequence: A = A + C, Y = A + B, C = B.

[0096] By comparing the current beat of the counter with the number of revolutions in the previous section, different working conditions of the printing device being in continuous operation or shutdown and restart state, or the counter continuously counting or being reset can be identified.

[0097] For the working conditions of the printing device in continuous operation or the counter continuously counting, the historical cumulative total number of revolutions in the database is directly used to improve the data processing efficiency. For the working conditions of the printing device not in continuous operation or the counter being restarted, the cumulative total number of revolutions of the printing device before the last shutdown and the number of revolutions of the counter in the previous beat are added to obtain the latest cumulative total number of revolutions, which can automatically compensate for the lost running revolutions due to the restart or reset of the printing device or the counter, avoid the distortion of the cumulative total number of revolutions caused by power-off, reset, start-stop operations, ensure that the cumulative total number of revolutions in the database is always consistent with the true cumulative rotation amount of the reference component 101, provide data support for the calculation of the actual number of revolutions of the reference component 101 subsequently, and further improve the accuracy and reliability of the detection of the component 100.

[0098] After updating the actual number of revolutions Y of the reference component 101, when Y < D, it means that the reference component 101 is within the service life range and can normally execute the next beat.

[0099] When Y >= D, it means that the service life of the reference component 101 exceeds the upper limit, an alarm signal is sent to prompt the operator to replace the reference component 101. After the operator confirms the replacement, the database is updated in sequence: Y = 0, A = -C, and at the same time the actual replacement date is updated, then the counter reading is obtained to perform the counting of the next beat.

[0100] In one embodiment, the method for managing components of the printing device further includes the following steps: Obtain the remaining service time of the component 100; Based on the sum of the last replacement time and the remaining service time of the component 100, obtain the next replacement time of the component 100.

[0101] Exemplarily, the calculation formula for the next replacement time T2 of the component 100: T2 = T1 + T0; where, T2 is the next replacement time of the component 100, T1 is the sum of the last replacement time and the remaining service time of the component 100, and T0 is the remaining service time of the component 100.

[0102] By obtaining the remaining usage time of component 100 and calculating the next replacement time of component 100 by adding the last replacement time of component 100 to the remaining usage time, the usage time of component 100 is dynamically calculated and predicted. This allows on-site staff to directly check and replace component 100, avoiding printing quality problems caused by untimely replacement of component 100.

[0103] In one embodiment, obtaining the remaining usage time of component 100 includes the following steps; The remaining allowable number of rotations is obtained based on the actual number of rotations of component 100 and the preset number of rotations; Obtain the number of unit rotations of component 100; The remaining usage time is obtained based on the remaining allowable number of rotations and the number of rotations per unit of component 100.

[0104] For example, the formula for calculating the remaining service time T0 of the reference component 101 is as follows: T0 = ​​(YD) / V; Wherein, T0 is the remaining usage time of the reference component 101 (unit: h), Y is the preset number of rotations of the reference component 101 (single number: revolutions), D is the actual number of rotations of the reference component 101 (single number: revolutions), and V is the unit number of rotations of component 100.

[0105] The remaining allowable number of rotations is calculated by subtracting the preset number of rotations from the actual number of rotations of component 100. This remaining allowable number of rotations represents the remaining lifespan of component 100 and calibrates its remaining wear. The remaining usage time is obtained by calculating the ratio of the remaining allowable number of rotations to the unit number of rotations, ensuring that the remaining usage time matches the actual remaining lifespan of component 100 and achieving accuracy in predicting the lifespan of component 100.

[0106] In one embodiment, obtaining the number of unit rotations of component 100 includes the following steps: Calculate the remaining allowable number of rotations of component 100 based on the production line unit capacity of component 100, the number of pages per booklet, the length of a single sheet of paper, the average daily production time, and the rotation circumference of component 100.

[0107] For example, the formula for calculating the number of rotations V per unit of component 100 is as follows: V = P × N × L × S / C; Wherein, V is the number of rotations per unit of component 100 (odd number: rotations), P is the production line capacity per unit of component 100 (odd number: books / h), N is the number of pages per book (odd number: pages / book), L is the length of a single page (odd number: mm / page), L is the average daily production time (odd number: h / day), and C is the rotation circumference of component 100 (odd number: mm / rotation).

[0108] Therefore, based on the above two formulas, the formula for calculating the remaining service time T0 of the reference component 101 is obtained as follows: T0 = ​​(YD) × C / P × N × L × S; For example, the preset number of rotations Y of the reference component 101 is 102,375,000, the actual number of rotations D of the reference component 101 is 10,000, the production line unit capacity P of component 100 is 3,900 books / hour, the number of pages per book N is 40 pages / book, the length of a single page L is 210 mm / page, the average daily production time L is 22 hours / day, and the circumference C of component 100 is 320 mm / rotation.

[0109] Substituting the above values, the remaining service life T0 of the reference component 101 is approximately 45.45 days. Then, the host 22 synchronizes these data to the display screen 23, which displays the remaining allowable number of rotations, remaining service life, and next replacement time of the reference component 101.

[0110] It is understood that the present invention uses the parameters of the reference component 101 as an example for calculation. After obtaining the actual number of rotations of the reference component 101 through the counter, the actual number of rotations of the component to be tested 102 is obtained based on the actual number of rotations of the reference component 101, the circumference of the reference component 101, and the rotation circumference of the component to be tested 102. Then, by substituting the relevant parameters into the above formula, the remaining allowable number of rotations, the remaining usage time, and the next replacement time of the component to be tested 102 can be obtained.

[0111] In some other embodiments, when calculating parameters such as the preset number of rotations and the remaining allowable number of rotations for component 100, the cumulative number of rotations of the reference component 101 can also be used as a reference. For example, when the reference component 101 has rotated a cumulative total of 10,000 times, one of the components to be tested 102 has reached the preset number of rotations; when the reference component 101 has rotated a cumulative total of 20,000 times, another component to be tested 102 has reached the preset number of rotations. By statistically analyzing a large amount of production data, the service life of other components to be tested 102 can be normalized to the cumulative number of rotations of the reference component 101. Therefore, by simply statistically analyzing the cumulative number of rotations of the reference component 101, the service life of other components to be tested 102 can be controlled. The algorithm is simple and the operation is convenient.

[0112] The printing equipment component management method provided in this disclosure can detect the operation of component 100 online in real time and accurately predict the replacement time of component 100, thereby improving the production efficiency and product quality of printing equipment.

[0113] It should be noted that since most of the testing equipment on the production site is offline, the data processing module 2 in this embodiment stores the results in .db format on the host 22. With the development of automation, intelligence and the Internet of Things in the workshop, the collected data can be stored in the cloud simultaneously, and unified management of data from multiple printing machines, multiple production lines or even multiple factories can be achieved, establishing an intelligent management system, facilitating the traceability of the entire life cycle of parts, making the production process more transparent and facilitating production management.

[0114] It should be noted that the printing equipment parts management method can be developed using Python, with the user interface designed using the QT framework, the program written using PYQT5, and SQLite used as the backend database. This allows for the unified management of parts 100 using the printing equipment parts management system. It also features real-time display of parts 100 replacement data, alarm function for parts 100 reaching the end of their lifespan, a visual interface, and simple operation, meeting the needs of parts 100 replacement and management.

[0115] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the embodiments of the present invention.

[0116] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0117] The above provides a detailed description of a method for managing printing equipment parts provided by the present invention. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

[0118] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the appended claims.

Claims

1. A method for managing parts of printing equipment, characterized in that, include: Obtain the preset number of rotations of the component, which includes a reference component and the component to be tested; Obtain the actual number of rotations of the reference component; The actual number of rotations of the component to be tested is obtained based on the actual number of rotations of the reference component. Compare the actual number of rotations corresponding to the component with the preset number of rotations; If the actual number of rotations is greater than or equal to the preset number of rotations, an alarm signal is sent to replace the component.

2. The method for managing printing equipment parts according to claim 1, characterized in that, Obtaining the preset number of rotations of the component includes the following steps: The preset number of rotations of the component is obtained based on the component's service life, rotation circumference, production line unit capacity, number of pages per booklet, and length of a single sheet of paper.

3. The method for managing printing equipment parts according to claim 1, characterized in that, The actual number of rotations of the component to be tested is obtained based on the actual number of rotations of the reference component, the rotation circumference of the reference component, and the rotation circumference of the component to be tested.

4. The method for managing printing equipment parts according to claim 1, characterized in that, The process of obtaining the actual number of rotations of the reference component includes the following steps: Obtain the cumulative total number of rotations in the database of the printing equipment; Get the number of rotations of the counter in the current beat; The actual number of rotations of the reference component is obtained based on the total cumulative number of rotations and the number of rotations of the counter in the current cycle.

5. The method for managing printing equipment parts according to claim 4, characterized in that, Obtaining the cumulative total number of rotations in the database of the printing equipment includes the following steps: Obtain the total number of rotations of the printing equipment before the last shutdown; Get the number of rotations of the counter in the previous beat; If the number of rotations of the counter in the current cycle is greater than the number of rotations of the counter in the previous cycle, the printing equipment will run continuously, and the total number of rotations in the database of the printing equipment is the total number of rotations of the printing equipment before the last shutdown. If the number of rotations of the counter in the current cycle is less than or equal to the number of rotations of the counter in the previous cycle, the printing equipment is not running continuously. The total cumulative number of rotations in the database of the printing equipment is the sum of the total cumulative number of rotations of the printing equipment before the last shutdown and the actual number of rotations of the counter in the previous cycle.

6. The method for managing printing equipment parts according to any one of claims 1-5, characterized in that, It also includes the following steps: Obtain the remaining usage time of the components; The next replacement time for a component is determined by summing its last replacement time and remaining usage time.

7. The method for managing printing equipment parts according to claim 6, characterized in that, The process of obtaining the remaining usage time of the components includes the following steps; The remaining allowable number of rotations is obtained based on the actual number of rotations of the component and the preset number of rotations. Obtain the number of rotations per unit for the component; The remaining usage time is obtained based on the remaining permissible number of rotations and the number of rotations per unit of the component.

8. The method for managing printing equipment parts according to claim 7, characterized in that, Obtaining the number of unit rotations of the component includes the following steps: Calculate the remaining allowable number of rotations of the component based on the production line unit capacity, number of pages per booklet, length of a single page, average daily production time, and the rotation circumference of the component.

9. A printing equipment parts management system, characterized in that, include: The data acquisition module is used to obtain the actual number of rotations of the reference component; The data processing module, which is communicatively connected to the data acquisition module, is used to obtain the actual number of rotations of the component to be tested based on the actual number of rotations of the reference component, and to compare the actual number of rotations of the component with the preset number of rotations. The component includes the reference component and the component to be tested. An alarm module, communicatively connected to the data processing module, is used to send an alarm signal when the actual number of rotations of the component is greater than or equal to a preset number of rotations, so as to replace the component.

10. The printing equipment parts management system according to claim 9, characterized in that, The data acquisition module includes: The marking component is sleeved on the outside of the reference component, which is sleeved on the outside of the fixed shaft and is capable of transmission relative to the fixed shaft; A detection component is disposed on the side of the fixed shaft facing the detection component, and the detection component is used to detect the marking component.

11. The printing equipment parts management system according to claim 10, characterized in that, The identification component includes: A clamp is fitted onto the side of the reference component facing the fixed shaft. A raised marking is provided on the clamp, and the detection component is used to detect the raised marking. The first anti-slip component is fitted onto the outside of the reference component and located between the reference component and the clamp.

12. The printing equipment parts management system according to claim 11, characterized in that, The inner diameter of the clamp is adjustable.

13. The printing equipment parts management system according to claim 10, characterized in that, The detection component includes: The bracket includes a main body, a fixing part, and a mounting part. The fixing part and the mounting part are respectively disposed on both sides of the main body, and the fixing part is sleeved on the outside of the fixing shaft. A sensor, detachably connected to the mounting portion, is used to detect the marking component.

14. The printing equipment parts management system according to claim 13, characterized in that, The mounting part is provided with mounting holes for mounting the sensor, and the mounting holes extend radially along the fixed shaft.

15. The printing equipment parts management system according to claim 13, characterized in that, The fixing part includes: Two jaws are located on both sides of the fixed shaft; An adjusting member is provided through the main body and the two jaws. The adjusting member is configured to rotate relative to the main body, so that the two jaws can move closer to or further away from each other, so that the two jaws can clamp the fixed shaft. The second anti-slip component is disposed on the side of the chuck facing the fixed shaft.

16. The printing equipment parts management system according to claim 15, characterized in that, The adjusting member has a screwing part at one end along the axial direction and a limiting part at the other end. The limiting part is used to limit the distance between the adjusting member and the main body.

17. The printing equipment parts management system according to any one of claims 9-16, characterized in that, The alarm module includes an alarm light and a buzzer.

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