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Description  |
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BACKGROUND OF THE INVENTION
The invention relates to a corrugated paper installation for making printed
corrugated paper cuts with a corrugated paper machine and a therein
integrated rotary printing machine having several printing stages as well
as with at least one longitudinal cutter and at least one transverse
cutter or a punching press.
Such installations are known for relatively small band widths. For example,
a roller printing machine may be integrated in a corrugated paper
installation. The form cylinders extend over the width of the paper web to
be printed, so that the paper web is printed first in the installation via
the integrated printing stages, and then combined with a corrugated paper
web to form the corrugated paper. In this manner, printed patterns up to
approximately 800 mm widths can be applied to a corrugated paper web. It
is also possible to arrange several identical printed pictures with
identical pattern repeat adjacent one another, if the individual printed
picture has a correspondingly lower width.
If a switch is now to be made from one printed picture to another printed
picture, then the entire installation must be shut down in order to
exchange the form cylinders. After the installation of the new form
cylinders in the rotary printing machine the production on the corrugated
paper installation can be started up again. In this installation it is a
disadvantage that a change of the printed picture can be effected only by
interrupting the production of the corrugated paper installation that this
additionally requires a relatively long time.
If several identical pattern repeats are printed next to each other, then a
longitudinal cutter is provided at the end of the installation which
severs the printed corrugated paper web lengthwise. The individual repeats
are then severed by transverse cutters or rotary punches.
It is also known to use a preprinted web in a roller carrier of a
corrugated paper installation and to combine this web with the other
layers of the corrugated paper in a laminating station. This known
technique makes it possible to increase the width of the corrugated paper
web up to about 1600 mm. However, here also the conversion is time
consuming and expensive between the individual runs. Here, also, the
production of the corrugated paper installation must be interrupted if a
new web with other printed pictures is to be laminated. In addition, the
transverse cutters must be newly adjusted.
A rotary is known from German Patent No. 426,349 with which it is possible,
for example, to print a paper web by means of several printing stages with
respectively different pattern repeats in sequence, in order to obtain a
pattern repeat length which differs from the repeat length which is
determined by the circumference of the form cylinders. Here, one printing
stage after the other is utilized. From this patent it is also known that
the individual printing stages print upon a rubber cloth which passes
between a printing and counterpressure roller and acts as an intermediate
carrier for the individual printed pictures before it transmits these to
the material being printed.
From German Allowed Application 1,786,507 and from the "Boersenblatt fuer
den deutschen Buchhandel" of June 2, 1977, page 16, it is known to utilize
an endless band-shaped printing plate carrier which has several different
or identical pattern areas which are printed one after the other. In this
manner, whole books can be printed sequentially with their different
pages. The problems of a corrugated paper installation, however, are not
addressed in these pure printing machines.
SUMMARY OF THE INVENTION
The purpose of the invention is to provide a corrugated paper installation
for the manufacture of printed corrugated paper which permits the
continuous production of corrugated paper cuts which are printed at least
on one side, whereby several patterns arranged adjacent one another can be
obtained with if desired different pattern repeat, and in which the
individual printed pictures and pattern repeats can be changed rapidly and
without having to interrupt the production of the corrugated paper
machine.
According to the invention this is achieved in that printing stations are
integrated which are suitable for printing a paper web with laterally
adjacent pattern areas of different width and length, which are
connectable with the drive of the installation individually or in groups,
and which for each pattern repeat carry printing forms on an endless
exchangeable carrier band of different lengths, and that several
longitudinal cutters and transverse cutters or punching presses are
provided for the different pattern repeat lengths.
Thus, the invention proposes to arrange a plurality of specially
constructed printing stations integrated within a corrugated paper
installation, of which always only a part is in use, so that the printing
stations which at any moment are not printing can be changed over. The
individual printing stations which are known per se, are connectable with
the drive of the installation individually or in groups, so that they can
be used selectively for printing purposes. The arrangement of the printing
forms on endless exchangeable carrier bands of different lengths assures a
rapid change-over within the corrugated paper installation without having
to interrupt the production of the corrugated paper machine. All
counterpressure cylinders associated with the individual printing stations
can be constructed to extend over the whole width of the paper web. This
assures a guidance of the paper web in the area of the printing stations
even if the printing stations are not printing at any moment.
The invention can be advantageously further developed by using an
embodiment in which each carrier band extends over the width of the paper
web and the printing cylinder and the support and tension rollers are also
constructed to extend over the width of the paper web.
It is, however, also possible to construct the installation in such a
manner that each printing band with the support and tension rollers
extends only over a part of the width of the paper web and that the
respective carrier band with the printing cylinders and the support and
tension rollers is made movable transverse to the direction of advancement
of the paper web and is adjustable in accordance with the position of the
pattern area.
Both embodiments make it possible to print a paper web, which is then later
used to produce the corrugated paper web, up to a width of approximately
2.5 meters simultaneously with different patterns insofar as length and
width is concerned. For changing the printed picture it is no longer
necessary to interrupt production. It is only necessary to switch off the
corresponding printing stations and to switch on the other printing
stations. The carrier bands consist of a bendable web in form of an
endless band on which the printing forms are secured. One or several
patterns of identical pattern lengths may be provided on a carrier band.
In the case of differential pattern length the carrier bands themselves
are of course also of different lengths.
The carrier bands may themselves be constructed as printing forms, and the
carrier bands may either extend over the full width of the paper web or
else the carrier bands may extend over only a part of the width of the
paper web, as it is described with reference to the second embodiment. In
both cases the actual surface area portions which participate in the
printing, extend only over a part of the width of the paper web, unless in
a specific special case several identical patterns are arranged adjacent
one another.
The carrier bands assure that a printing station can be changed over in the
briefest possible time, because only the carrier band must be exchanged.
The tension rollers at the printing station must then be readjusted for
the possibly different loop-length of the carrier band. This is also
possible in the shortest amount of time. The printing stations are
provided approximately corresponding to double, triple or a multiple the
number of patterns. Advantageous appears the arrangement of approximately
twenty printing stations for a width of the paper web of approximately 2.5
m. At this width and with the stated number of printing stations it is
possible to work with three or even four pattern areas of different
printed pictures adjacent one another. It is understood that only one part
of the printing stations is used for the production run being printed at
any moment, with each printing station printing only a one color and in
the event of multi-color printing several colors being applied per pattern
area by different printing stations in sequence. The other printing
stations can be changed over in this time period and are then available
for printing the next successive run or order. If a printing order is
completed, then it is only necessary to switch off the corresponding
printing stations; the new printing stations are switched on. This is
effected without interrupting the manufacture of the corrugated paper.
In doing so, the following difficulty occurs.
In the integration of the special printing stations with the carrier bands
carrying the printing forms a peculiarity occurs, in contradistinction to
normal rotary printing machines which work with printing cylinders of
different diameters. The carrier bands which carry the printing forms do
not rest on the circumference of the printing cylinders, but are guided in
form of a loop and supported on supporting and tension rollers. The actual
printing cylinder carries no printing forms but serves only to press and
guide the carrier band.
In these special printing stations which are integrated according to the
invention there is no association between the angular speed of the
printing cylinder and the angular speed of the carrier band. While the
carrier band has the same circumferential speed on the printing cylinder
as the printing cylinder itself, it is not possible to arrive here at a
relationship between the angular speed of the carrier band and the angular
speed of the printing cylinder.
This is in contrast to a normal rotary printing machine in which the
printing forms are on the circumference of the printing cylinder. There,
it is always possible to determine that after a complete revolution of the
printing cylinder the printing form begins again with certainty,
respectively that the identical portion is used for printing. Because this
specific association is missing in the printing stations integrated
according to the present invention, a relative rapport between the
individual printing stations must be achieved in a different manner. This
relative rapport is, of course, necessary only for those printing stations
which must print one over the other with pattern rapport in a printing
order.
This will be explained by way of an example in more detail. While the
corrugated paper machine operates and for example a certain number of
printing stations is in printing operation, it is assumed that the
printing stations No. 1, No. 5 and No. 7 in a row of 10 printing stations
are standing still, so that they can be switched over for the next
following printing order requiring a three-color print.
Thus, three carrier bands with the printing forms are placed about the
printing cylinders and tension rollers of the printing stations 1, 5 and
7.
The spacing between the first printing station and the fifth printing
station as well as the spacing between the fifth and seventh printing
station are known and do not change, since the printing stations are
fixedly arranged relative to one another.
It is now necessary to adjust the three printing stations for pattern
rapport in idle mode, i.e. such that the printed pictures can be printed
upon the advancing paper web in proper relationship to one another and
over one another, when the counterpressure cylinders press the paper web
against the carrier bands. As is known, no printing occurs but the
pattern-rapport adjustment is necessary. This is accomplished as follows:
First, the three printing stations No. 1, 5 and 7 are started up and
brought up to speed, whereby a friction coupling between the drive of the
printing stations and the continuous main drive of the corrugated paper
machine is engaged. When this production speed is reached, the
transmission of each printing station is fixedly coupled via a
mechanically interengaging coupling, for example a tooth coupling, with
the main drive, i.e. with the through going main shaft of the corrugated
paper machine.
Now the printing cylinders of the individual printing stations are turning
at working speed, but thus far no relative rapport has been achieved
between the carrier bands of the printing stations 1, 5 and 7.
If the printing stations were to be switched on in this condition, i.e. if
they were to print, then a substantial amount of scrap corrugated paper
would be printed, which would not be properly printed because the printed
pictures would be shifted with reference to one another.
In order to accommodate for this error of the mutual shifting (relative
pattern rapport) it is now necessary to observe marks provided at the
carrier bands at defined locations and to shift the carrier bands
additionally relative to one another in such a manner that the relative
pattern rapport is obtained. One of the three printing stations to be
adjusted can be taken as the main printing station, the carrier band of
which need not be shifted relatively. This may, for example, be the
printing station No. 1.
The carrier bands of the printing stations No. 5 and No. 7 must now be
adjusted. With the aid of an observation device and a computer the phase
position of the marks of the carrier bands for the printing stations No. 5
and 7 is observed on an indicating instrument, for example on a screen.
Depending upon the deviation from the mark of the carrier band of printing
station No. 1 a setting device and a planetary gear stage provided in the
transmission of each printing station are used to effect a shifting of the
carrier band during idling, until the three marks of the three carrier
bands are in rapport, i.e. until relative pattern rapport has been
reached. It is known that a planetary gear stage has two inputs and an
output, so that it operates as a differential device permitting via the
setting device and the planetary gear stage each carrier band to be
positionable relative to another carrier band.
Only when the relative pattern rapport of the three printing stages No. 1,
No. 5 and No. 7 has been reached and the preceding printing run is
completed, interrupting the operation of the corrugated paper machine a
switchover is effected at the printing stages, i.e. the printing stages of
the just completed run are switched off whereas the preprinting stages No.
1, No. 5 and No. 7 are pressed for operation of the counterpressure
cylinders against the paper web, so that without or with only a small
amount of scrap the production of corrugated paper can be carried on
continuously.
In place of the heretofore described single setting device each printing
station may have two setting devices for a coarse and a fine setting of
the relative pattern rapport, whereby a coupling is provided between the
setting device for the fine adjustment and the second input of the
planetary gear stage.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be variously embodied. It is described in the drawing
with the aid of several exemplary installations and will hereafter be
described further.
FIG. 1 shows a schematic side view of an installation;
FIG. 2 shows a schematic side view of another installation;
FIG. 3 shows a schematic side view of an individual printing station;
FIG. 4 is a top view of the corrugated paper web subdivided into printed
areas;
FIG. 5 is a top view of the corrugated paper web of FIG. 4 after the
exchange of some printing stations;
FIG. 6 is a schematic top view of the transmission of each printing station
.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The installation illustrated in FIG. 1 serves to produce corrugated paper
which is printed on one side. A paper web 2 is pulled off a roller carrier
1 and is formed in a corrugated paper machine 3 to corrugated shape and
here united with a paper web 4 coming from a roller carrier 5. The web 6
thus produced advances into a storage 7 and is pulled from there through
the next-following parts of the installation without here undergoing any
further treatment. The storage 7 can also be omitted.
A paper web 9 travels from a roller carrier 8 into a storage 10 and from
there via a pulled-off drive 11 into a printing machine 12 which has a
plurality of individual printing stations 13, for example, twenty of them.
The paper web 9 is here printed on its upper side by several of the
printing stations 13.
The printed paper web 14 travels at the end of the printing machine 12 into
a laminating station 15 where it is united with the web 6 to form a
corrugated paper web 18.
At the end of the installation there are provided pull-off devices 16 and
longitudinal cutters 17; the longitudinal cutters 17 cut the corrugated
paper web 18 lengthwise according to the printed-on laterally adjacent
numbers of pattern repeats. Transverse cutters 19 or rotary punches are
also provided in order to cut the web transversely and to separate the
individual cuts from the partial webs.
The installation according to FIG. 2 is basically similar, but here both
sides of the corrugated paper web 18 are printed. The paper web 4 is
pulled off the roller carrier 5 and supplied via the storage 7 and the
drive 11 to the first part of the printing machine 12. Here, three
printing stages 13 are illustrated. It is understood that the number
thereof can be varied here also. These three printing stations 13 serve to
differently color or print the paper web 4 in accordance with the pattern
distribution. The paper web 4 is then supplied to the corrugated paper
machine 3. The paper web 2 which forms the corrugation is pulled off the
roller carrier 1. In the corrugated paper machine 3 the webs 2 and 4 are
united with one another. The web 6 is obtained which is advanced through
the storage 7 and the following aggregates up to the laminating station
15.
The paper web 9 is pulled off the roller carrier 8 and supplied via the
storage 7 and a further pull-off drive 11 into the second part of the
printing machine 12, where again a number of printing stations 13 is
provided. Since here the outer side of the later cut is to be printed, a
comparably larger number of printing stations is provided, analogous to
the installation in FIG. 1. The printed paper web 14 is united with the
web 6 in the laminating station 15 and the corrugated paper web 18 is
obtained which, just as in the embodiment of FIG. 1, is subdivided by
longitudinal cutters 17 and transverse cutters 19.
FIG. 3 shows an individual printing station 13 of the printing machine 12
in schematic view. The paper web 9 to be printed is passed between the
guide rollers 20, 21, 22, 23, 24, 25, 26 and 27 through the printing
station 13. The printing cylinder 28 is stationarily journaled. Oppositely
it there is provided a counterpressure cylinder 29 which can be pushed
against or pushed away from the printing cylinder 28. The printing
cylinder 28 is embraced by the carrier band 30 which according to the
length of the pattern and possibly the number of patterns can have a
different length and carries the printing forms. Different support and
tension rollers 31, 32, 33 are provided which are shiftably mounted in
order to permit an accommodation to the respective lengths of the carrier
band 30. The carrier band 30 is wider than the corrugated paper web and
has in the projecting marginal areas perforations which serve for its
drive. The drive means necessary for this are individually connectable
with the machine drive for the entire installation. It is also possible to
connect groups of printing stations 13 for joint operation. The printing
forms on the carrier band 30 are inked via an inking station 34. A drying
installation 35 is provided between the guide rollers 22 and 23.
The operation which is possible with the installation shown in FIGS. 1 and
2 can best be understood with reference to the corrugated paper web 18
shown in FIGS. 4 and 5. FIG. 4 shows the moment at which the corrugated
paper web 18 leaves the laminating station 15, i.e. at which the printing
is completed.
According to FIG. 4, four patterns are printed over the width of the
corrugated paper web 18, namely the double pattern with the printed
picture A and the pattern length 36, at the center a different pattern
with the printed picture B and the pattern length 37 and at the other edge
a third pattern with the printed picture C and the pattern length 38.
It is understood that this corrugated paper web 18 is then severed by the
longitudinal cutters 17 which are indicated only by arrows. The transverse
severing is effected by the transverse cutters 19, respectively, rotary
punches.
FIG. 5 shows again the corrugated paper web 18, but after the print
application with the printed picture A has been completed. In its place a
print application with the printed picture D was carried out. The print
application B was retained because here for example the required number
has not yet been reached. In addition, the switch-over from the printing
run with the printed picture C to the printed picture E is just being
illustrated. The pattern with the printed picture D has the pattern length
39 and the print with the printed picture E has the pattern length 40. As
a rule, such a change of production results only in a very small amount of
scrap (see change-over of the printed pattern C to E).
FIG. 6 shows a part of the main drive shaft 39 of the corrugated paper
machine. The main drive shaft 39 extends throughout the entire length of
the corrugated paper machine. All drives are derived from it in the area
for each of the printing stations. Each individual printing station 13 has
a transmission 40 as diagrammatically shown in FIG. 6. This transmission
40 consists of the following individual components: The core of the
transmission 40 is a planetary gear stage 41. The one input 43, i.e. for
example the outer gear of the planetary gear stage, meshes with a gear 43
which is journaled on the main drive shaft 39 via a ball bearing 44. A
first coupling (friction coupling 45) and a second mechanical engagement
coupling 46 are provided between the gear 43 and the main drive shaft.
When the printing station is not in operation, the two couplings 45 and 46
are disengaged.
An arresting device 47 which may be for example electromechanically
operable, having a pin that can be pushed between the teeth of the gear
43, can be used to additionally block the gear 43.
This is always effected when a carrier band 30 at this printing station 13
is to be exchanged. The second input 49 of the planetary gear stage 41 is
connected via a gear 50 with a setting device 51 for fine adjustment.
Between the setting device 51 and the gear 50 a coupling 52 is provided.
An additional gear 54 is mounted on the shaft 53 and cooperates with a
further gear 55 on the shaft 56 of a second setting device 57 for coarse
adjustment purposes.
The two setting devices 51 and 57 may be constructed as setting motors, for
example it is achieved that during a step of approximately 200
milliseconds of the setting device 51 for the fine adjustment a correction
at the circumference of the counterpressure cylinder 28 of approximately
0.16 mm is obtained.
At the output 58 of the planetary gear stage 41 there is provided a bevel
gear stage 59 with the shaft 60, which leads to the printing cylinder 28.
In this manner, a deflection of the drive through 90.degree. is obtained.
This is necessary because the main drive shaft 39 extends in longitudinal
direction of the machine, whereas the printing stages are integrated
transversely thereto in the corrugated paper installation.
When the gear 43 is arrested by the device 47 one or both of the setting
devices 51 and 57 can operate it, whereby the installed carrier band of
the corresponding printing station advances slowly. Thus, a certain
pre-adjustment of the mark on this carrier band can be effected in
preparation for the relative pattern rapport.
Subsequently thereto, the setting of the relative pattern rapport of the
printing stations relative to one another is obtained, which printing
stations are associated with a particular printing run. For this, the gear
43 is first released by the device 47 and the friction coupling 45
engaged, so that with still as yet unoperated setting devices 51 and 57
the printing cylinder 28 is started up and accelerated, until it has a
circumferential speed corresponding to the drive of the main drive shaft
39.
Once this is achieved, then additionally the coupling 46 is engaged, and
the friction coupling 45 may remain in engagement during this period.
The printing cylinder 28 now idles corresponding to the drive of the main
drive shaft 39, via the planetary gear stage 41. The speed of the carrier
band thus corresponds to the intended production speed, but the relative
pattern rapport has not yet been achieved.
The phase position of each mark of each carrier band of the printing
stations associated for a particular operating run is now observed via an
observation device and a computer as well as a subsequentially arranged
indicating instrument, for example a screen. If this phase position does
not yet agree, i.e. if the relative pattern rapport has not yet been
reached, then actuation of one or both setting devices 51 and 57 briefly
supplies a drive to the second input 49 of the planetary gear stage 41, so
that the corresponding carrier band is additionally accelerated or
delayed, depending upon the direction of rotation effected by the setting
device 51. In this manner, the mark of the carrier band of one printing
station can be shifted relative to the mark of the carrier band of another
printing station, until the relative pattern rapport is achieved, taking
into account the distance between the two associated printing stations.
When the marks overlap one another, i.e. are in rapport, then the time has
come at which these two pr:nting stations can be pressed against the paper
web, i.e. at which printing is immediately possible in rapport without
printing of scrap and without interrupting of the corrugated paper
manufacture.
This switch-over from idling to printing is mostly effected by appropriate
displacement of the counterpressure cylinder 29, which is moved against
the printing cylinder 28.
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