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Description  |
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FIELD OF THE INVENTION
The present invention is related to a printing unit for a web fed rotary printing press.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,127,322 purports to describe a web fed rotary printing press including a satellite printing unit with a central impression cylinder and four accompanying blanket cylinders. A corresponding plate cylinder is engaged with each
blanket cylinder. A web is fed downwardly through the printing unit, wound around the central impression cylinder, and exits upwardly through the printing unit. For changing the plates mounted on the plate cylinders, a moveable robot arm is provided.
The system purports to provide for rapid mounting and removal of printing plates.
U.S. Pat. No. 5,323,702 discloses a tubular printing blanket for a blanket cylinder in an offset printing press. The tubular printing blanket is axially mounted on, and removed from, a blanket cylinder. Conventional blankets and cylinders,
which have a gap which moves through the nip between the blanket cylinder and the plate cylinder and between the blanket cylinder and the impression cylinder, cause vibrations and shock-loads throughout the printing unit, which detrimentally affects
print quality. The use of the gapless tubular printing blanket enables a printing press to run at high speeds without excessive vibration or shock loads, with reduced slippage of printing surfaces which could smear the printed image, and without
overheating.
EP 0 225 509 B1 purports to disclose an apparatus for indirectly printing on a web which includes three printing mechanism cylinders which are respectively mounted with their ends in the two side walls of a printing press. The plate cylinder as
well as the blanket cylinder carry respective interchangeable sleeves. For changing the sleeve of the blanket cylinder, the printing press is stopped, the blanket cylinder is released from one of the associated side walls, and the sleeve is removed from
or installed onto the cylinder.
SUMMARY OF THE INVENTION
In accordance with the present invention, a printing unit for a web fed rotary printing press comprises a housing with a first and a second housing section, a central impression cylinder supportingly mounted in the first and second housing
section via a first and a second journal. The printing unit further comprises at least two blanket cylinders in rolling engagement with the central impression cylinder, and at least two print cylinders in rolling engagement with the blanket cylinders.
The blanket cylinders are cantilevered in the first housing section, i.e. supported only by the first housing section, during a make ready operation of the printing unit.
Since the blanket cylinders are cantilevered during make-ready, sleeve shaped printing blankets may be axially mounted on, and removed from, the blanket cylinder. This reduces make ready as compared with conventionally mounted flat blankets. In
addition, since the sleeve-shaped printing blanket has no gap in its outer surface, the vibrations and/or shock-loads which normally occur when the blanket cylinder rotates and the gap moves through the nip formed between the print cylinder and the
blanket cylinder are eliminated. Thus, material wear and print defects from these vibrations and shock-loads are reduced in comparison with conventional satellite printing presses using conventional flat blankets, and press speeds of 3000 feet per
minute are attainable.
In addition, the use of a cantilevered blanket cylinder provides greater accessibility to the printing unit during make-ready.
In accordance with a second embodiment of the present invention, the print cylinder is also cantilevered in the first housing section during make ready. This allows the use of sleeve-shaped print forms which can be quickly mounted axially on,
and removed from, the print cylinder. It also provides even greater accessability to the printing unit during make ready. Another advantage of using sleeve-shaped print forms and blankets instead of conventional blankets and printing plates is that
there is no gap in either the print form or the blanket to produce an unprinted area between two successive pages of a printed web. Consequently, if the sleeve-shaped print form is manufactured from a flat plate whose opposing ends are bonded together,
the only unprintable area remaining on the web will be from the slight seam in the print form. If the sleeve-shaped print form is also seamless, then there will be no unprintable area on the web.
In accordance with a further embodiment of the present invention, the blanket and/or print cylinder are cantilevered in one side wall while the printing unit is in production, as well as while it is in make ready. This further reduces the time
necessary for blanket and or print form changes because it eliminates the need for any releasing mechanism on the second housing section.
In accordance with a further embodiment of the present invention, the sleeve-shaped print forms and/or the sleeve shaped printing blankets are expanded by compressed air which is transmitted through apertures located on an outer circumferential
surface of the blanket and/or the print cylinders in order to allow the print forms and/or printing blankets to be installed or removed from their respective cylinders.
In accordance with a still further embodiment of the present invention, an automatic register system is provided for automatically adjusting the circumferential register of the printing unit. An electric motor rotates a wheel which is in contact
with the outer circumferential surface of the sleeve-shaped print form while the print form is expanded by compressed air. As the wheel rotates under the control of the electric motor, the sleeve-shaped print form is rotated about the print cylinder
until circumferential register is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a satellite printing unit in accordance with the present invention.
FIG. 2 shows a cross sectional view of the printing unit of FIG. 1 with a cantilevered blanket cylinder according to the present invention.
FIG. 3 shows a schematic cross sectional view of the printing unit of FIG. 1 with a cantilevered blanket cylinder and a cantilevered print cylinder in accordance with the present invention.
FIG. 4 shows a cross sectional view of the printing press of FIG. 1, in which the print cylinder and the blanket cylinder are additionally supported by a plate mounted in a second side wall.
FIG. 5 shows an automatic register adjustment system according to the present invention.
FIG. 6 shows a print or blanket cylinder with two sleeves mounted thereon.
FIG. 7 shows a print or blanket cylinder with four sleeves mounted thereon.
FIG. 8 shows a print cylinder with three sleeve-shaped print forms mounted thereon, and having a pin for lateral register adjustment.
FIG. 9 shows a print cylinder with three sleeve-shaped print forms having three cone-shaped pins for lateral register adjustment.
FIG. 10 shows a view of a pin and corresponding actuating mechanism for moving the pin.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a satellite printing unit 1 which is may be used, for example, in web fed rotary printing presses for printing newspapers. It comprises a central impression cylinder 2 located in the middle of the unit 1 and four blanket cylinders 4
in rolling engagement with the central impression cylinder 2. Four print cylinders 6 are disposed in rolling engagement with respective blanket cylinders 4. Each print cylinder is also in rolling engagement with a respective ink station 8 having ink
rollers 9. The ratio of the circumference of the central impression cylinder to the blanket cylinders may be 2:1, 4:1, or any integer number. Although FIG. 1 shows only one ink station 8, it should be understood that there is a respective ink station 8
for each print cylinder 6. Each ink station 8 applies a different color to its associated print cylinder 6 so that, in the illustrated printing unit 1, four different colors, e.g. black, magenta, cyan, and yellow, can be printed on the web 12.
Naturally, the printing unit 1 could alternatively be configured to print a fifth color, e.g. gold or some other specialty color, by providing an additional print cylinder 6, blanket cylinder 4, and inking station 8 disposed on the impression cylinder 2.
Additional colors can also be added by separating the ink stations such that an ink station can print two colors at once. For example, if the web 12 is more than one page wide, each print cylinder can have several ink stations associated
therewith, with each ink station applying ink to a different page, or set of pages.
Dampening systems 10 are shown associated with each print cylinder 6. The dampening systems 10 apply dampening fluid to the plates 6 when the printing unit 1 is used for wet offset printing. When using the printing unit 1 for dry-offset,
waterless or single fluid printing, the dampening systems 10 are not used. If the printing unit 1 is to be used exclusively for dry-offset printing, the dampening units 10 may be omitted completely.
The web 12 is fed into the printing unit 1 from a top entry of the printing unit 1, is wound around the central impression cylinder 2, through the nips formed between the blanket cylinders 4 and the central impression cylinder 2, and then leaves
the printing unit 1 though the top entry. Naturally, the web 12 can also be fed into the printing unit 1 from the left, the right or bottom, and exit the printing unit in any desired direction. For example, in some applications, it might be desirable
to have the web exit from a different direction than it entered. In order to alter the path of the web after it exits the last blanket cylinder, a low pressure air roller can be employed to change the web direction without smearing the image on the web.
FIG. 2 shows the satellite printing press of FIG. 1 having blanket cylinders 4 which are cantilevered, and having print cylinders 6 which are supported on both ends. FIG. 3 shows the satellite printing press of FIG. 1 having blanket cylinders 4
and print cylinders 6 which are cantilevered. The cylinders 2, 4, 6 and rollers 9 are arranged in a housing 14 comprising a first housing section and a second housing section formed by side walls 14a and 14b, respectively.
As shown in FIGS. 2 and 3, the cylinders 2, 4 and 6 are each driven by a direct drive in the form of electric motors 16, 18, 20 and associated driving shafts connected to the cylinders. The motors 16, 18, 20 are connected to a central
controlling unit 21 of the printing press 1 which preferably controls the speed of each of the motors 16, 18, 20 separately. However, the cylinders 2, 4, 6 can alternatively be driven from a common drive. For example, a central motor could drive all
the cylinders 2, 4, 6 via conventional shafts and gear boxes, a gear train, or a belt and line shaft drive (not shown).
In accordance with a first embodiment of the present invention, the central impression cylinder 2 is rotatably mounted in the first and second side walls 14a, 14b of the housing 14 by a first and a second journal 22a, 22b and associated bearings
which are arranged in the side walls 14a, 14b respectively. The portion of the second side wall 14b carrying the second journal 22b of the central impression cylinder 2 is formed by a support 24 which preferably extends downwardly from the top of the
housing 14 as shown, for example, in FIGS. 1, 2 and 3.
In accordance with the embodiment of FIG. 2, the blanket cylinder 4 is rotatably cantilevered; i.e., it is supported only on one side at all times. Referring to FIG. 2, the blanket cylinder 4 is mounted in the first side wall 14a by a journal
26. The journal 26 is rotatably mounted within the first side wall 14a by a pair of bearings 29. Alternatively, a single large bearing can be substituted for the two bearings of FIG. 2. The print cylinder 6 is rotatably mounted in the first and second
side wall 14a and 14b of the housing 14 via a first and a second journal 28a and 28b and associated bearings. A print form 50 is radially mounted on the print cylinder 6 in a known manner, e.g., magnetically or via a gap in the print cylinder. An
opening 30 is provided in the second side wall 14b of the housing 14 to allow axial removal of a printing blanket 40.
In accordance with the embodiment of the invention shown in FIG. 3, the print cylinder 6, as well as the blanket cylinder 4 is cantilevered in the first side wall 14a in the same way as described above for the blanket cylinder 4. Both cylinders
4,6 are supported by the first side wall 14a via journals 28 and associated bearings. The opening 30 in the second side wall 14b is expanded to allow axial removal of both a print form 50 and printing blanket 40. In accordance with this embodiment, the
print form 50 is configured to facilitate axial installation and removal, e.g. by constructing the print form as a sleeve. Thus, the print form 50 and printing blanket 40 can be quickly and easily be removed from the printing unit 1 by simply pulling
them out of the housing 14 through the opening 30 formed in the second side wall 14b when the printing unit is not in operation.
In order to increase the strength of the housing 14, the second side wall 14a of the housing 14 can be completely or partially reinforced, particularly in the section where the cylinders 4 and 6 are cantilevered. In FIGS. 2 and 3, for example,
the side wall 14a is shown as partially reinforced with an additional support 31 supporting the cantilevered cylinders.
In accordance with the embodiment of FIG. 4, the print and blanket cylinders 4, 6, are supported during printing within both side frame 14a and side frame 14b. During throw-off, however, the blanket cylinder 4 and/or the print cylinder 6 are
supported only by side frame 14a. Therefore, as shown in FIG. 1, a side plate 32 is mounted in the opening 30, and supported in the side frame 14b. The plate 32 includes releasable clamps for clamping and releasing the cylinders 4, 6. In accordance
with the present invention, bearings 33 may be permanently mounted in bearing housings on respective journals 26b/2 and 28b/2, and the releasable clamps configured to clamp and release the bearing housings. Alternatively, the bearings may be permanently
mounted in the plate 32, and the releasable clamps configured to clamp and release the respective journals. The plate 32 is preferably pivotable about a vertically extending axis by a actuating device in order to automatically open and close the opening
30. An illustrative plate 32, including releasable clamps are described in more detail in U.S. Pat. No. 5,241,905 to Guaraldi.
In accordance with a further embodiment of the present invention, the blanket 40 on the blanket cylinder 4 is formed as a gapless sleeve which is preferably constructed in the manner described in U.S. Pat. No. 5,323,702. For easily mounting
the sleeve-shaped blanket 40 on the blanket cylinder 4, at least one set of apertures 42 are arranged around the circumferential surface of the blanket cylinder 40 and are connected to a compressed air supply 44 via a valve 46. The valve 46, in turn, is
actuated by the central control unit 21. When the printing press is stopped, the control unit 21 actuates the valve 46 and compressed air is supplied from the air supply 44 through the apertures 42, thereby expanding the blanket 40. Once expanded, the
blanket can be easily removed from the blanket cylinder 4 through an opening formed in the side wall 14b of the press. FIG. 2 shows three sets of apertures 42 across the length of the cylinder 4.
In a further embodiment of the present invention, the print forms 50 mounted on the print cylinder 6 are formed as a sleeve. The mounting of the sleeve-shaped print form 50 can be performed in the same manner described above for the blanket 40.
The print form 50 is installed and removed through the opening formed in the side wall 14b of the printing unit 1. Compressed air is transmitted from a compressed air supply 44, through a valve 56 actuated by the central control unit 21, and out through
apertures 52 on the circumferential surface of the print cylinder 6.
In accordance with a further embodiment of the present invention, a plurality of sleeve shaped blankets or print forms 40, 50 can be mounted on each respective blanket or print cylinder 4,6. The apertures 42, 52 are arranged so that at least one
set of apertures 42, 52 are under each respective blanket or print form 40, 50 as it is slid onto the cylinder 4, 6 or removed from the cylinder 4, 6. Therefore, the spacing of the apertures 42, 52 is arranged such that the distance between two sets of
apertures is slightly less than the width of the respective blankets or print forms 40, 50.
In accordance with a preferred embodiment of the present invention, however, the apertures 42, 52 are arranged so that at least two sets of apertures 42, 52 are under each respective blanket or print form 40, 50 as it is slid onto the cylinder 4,
6 or removed from the cylinder 4, 6. In accordance with this embodiment, the spacing of the apertures 42, 52 is arranged such that the distance between two sets of apertures is slightly less than half the width of the respective blankets or print forms
40, 50.
In accordance with the embodiment of the present invention shown in FIG. 5, an automatic register adjustment system 60 for the sleeve-shaped print forms 50 can provide automatic register adjustment both while the printing unit 1 is running and
while the printing unit is stopped. As shown in FIG. 5, the system 60 comprises an electric motor 62, preferably a stepper motor, which is controlled, for example, by the central control unit 21 of the printing press. While the compressed air system is
activated and the print form is in its expanded state, the motor 62 is controlled to automatically rotate the sleeve shaped print form 50 via a wheel 66 which contacts the outer surface of the print form 50. The automatic register adjustment system 60
further comprises a first sensor 68 connected to the unit 21, for sensing the position of the print form 50, e.g., by detecting the a first mark 70 located on the print form 50. Preferably, the mark 70 is located at one end of the print form 50. In
addition, in accordance with a further embodiment of the invention, the air pressure applied through the apertures 52 is less than the air pressure used for axial removal of the print form 50, but enough to overcome the friction between the print form 50
and the print cylinder 6 and allow automatic register.
A second sensor 69 is also connected to the unit 21 for sensing the position of the cylinder 6, e.g., by detecting the a second mark 71 located on the cylinder 6. The second mark 71 provides a reference position to which the first mark 70 is
tracked, and proper registry is defined as a desired displacement between the first and second marks. For example, the system 60 could be configured to maintain the first mark 0,45, or 90 degrees ahead of the second mark.
The first and second sensors 68, 69 may be of any known construction, e.g., optical sensors or proximity switches. Moreover, the first sensor need not be of the same construction as the second sensor.
In the illustrative examples set forth below, the system 60 is configured to define proper registry as a 0 degree displacement between the first and second marks. An illustrative procedure for providing circumferential register while the press
is stopped is as follows: First, the cylinder 6 is rotated until the second sensor 69 detects that the second mark 71 has reached a desired reference position. Then, the compressed air is engaged to expanded the print form 50, and the control unit 21
drives the electric motor 62 until the first sensor 68 senses the first mark 70 and switches off the compressed air. When the compressed air is switched off, the print form 50 contracts and tightly clamps on the cylinder 6. The automatic register
adjustment system 60 allows register adjustment of one, two or more print forms 50 mounted on one cylinder 6, by providing a respective number of electric motors 62. wheels 66, sensors 68, 69 and marks 70, 71. As shown in FIG. 5, the apertures 52
associated with each sleeve shaped print form 50 of the print cylinder 6 can be connected to the compressed air supply 44 via separately actuated valves 56, so that the print forms 50 can be adjusted independently.
An illustrative procedure for providing registry while the press is running is as follows: First, the press is taken "off impression"; i.e., the blanket cylinder 4 is taken out of contact with the print cylinder 6. Then, while the cylinders 4, 6
are still rotating, the compressed air is engaged, and the print form 50 is expanded. Then, the electric motor 62 at first rotates the sleeve 50 with the same speed and in the same direction as the print cylinder 6, so that there is substantially no
relative speed differential between the sleeve shaped print form 50 and the cylinder 6. Then the control unit 21 monitors the output of the first and second sensors 68, 69. If the control unit 21 detects a time differential between the triggering of
the first and second sensors, then the speed of the motor 62 is reduced or increased until the time differential is eliminated. When using a stepper motor 62 controlled by the unit 21, the reduction or increase of the speed of the motor 62 can be
achieved by respectively increasing or decreasing the number of steps per second.
According to the embodiment of the invention shown in FIGS. 6 and 7, two or more blankets 40 or print forms 50 may be mounted on a single blanket or print cylinder 4, 6. Using two or more print forms 50 allows the print jobs to be quickly and
easily changed. This is particularly useful when printing newspapers since this application requires frequent changes to the image being printed. By using two or more blankets 40 on one blanket cylinder 4, it is possible to exchange these blankets
periodically. Exchanging blankets 40 is advantageous when, for example, a blanket has been printing the same image for a long period of time. By exchanging blankets, different portions of the blankets will be used for printing, thereby enhancing print
quality and blanket life. In addition, if damage to the blankets occurs on only one part of the blanket cylinder, it is possible to simply exchange the one blanket which has been damaged, while leaving the other blankets in place on the cylinders. For
example, if a single blanket is used, damage to one page of a 38" web will require replacement of a full 38" blanket. In contrast, if two 19" blankets are used, damage to one page of the web will only require replacement of one 19" blanket, thereby
reducing the cost resulting from the damage.
In accordance with the embodiment of the invention shown in FIGS. 8, 9 and 10, to provide lateral register adjustment of one, two or more print forms 50 (e.g. the three print forms 50a, 50b, 50c shown in FIG. 8 and 9), pins 80 are disposed at
least at one end of the print cylinder 6. The pin 80 shown in FIG. 8 is preferably a straight pin which is located at the end of the print cylinder 6 mounted in housing 14(a). Th | | |
