Steps to Control the Work Process To confirm the work process, the data must be clearly recorded!
If you want to control the printing process, you must measure each measurable variable. If the data is not processed properly, it is wasted, so you must design a data entry sheet for each printing project. You must set up some baseline parameters and record the results from the process. Compare measured data with baseline data. When you start a project, you must set up an "emergency window" and you also need to know which parameters limit your maximum and minimum limits. When you are clear about these restrictions, you can get some tips and indicators in the process of troubleshooting.
A laser meter can also get the data you need as quickly as possible by walking with the product through the production line.
You also need to pay attention to and check the production line speed, number of lamps, setting, UV dose, and maximum energy value from time to time.
As your database grows, you can predict the diagnostic results you need and add the variables you need to pay attention to. At the same time, you can also predict when repairs are needed and plan for it during the downtime.
Don't speculate, but the measurement must be repeated due to process results. Therefore, to measure the parameters of your printing process, you must not refer to it.
Set baseline parameters:
What needs to be measured and checked? Among the numerous projects, the following items are more important in UV printing process control:
- Digital tachometer accurately measures the speed and production speed of the conveyor belt - Hour meter shows the age of the lamp - Ammeter to calculate the amount of current flowing through the lamp - Appropriate UV data measurement and monitoring equipment - Temperature sensor capable of measuring the highest temperature There are also other accessories that affect UV
Lamp output, such as ballast, current supply, capacitor, magnetron and line voltage, but these are not a complete maintenance manual.
The speed can be accurately measured to production speed using a cheap digital flow meter. Not relying on built-in speed monitors, because they are often inaccurate. Use data from different conveyor belt speeds to create a chart showing the set speed and true speed. Until you have a digital tachometer, you can use the chronograph to calculate the conveyor belt speed.
As with other parameters, the conveyor belt speed must also be measured permanently.
Hour meter This is the time the display light has been turned on and an indication of when the lamp needs to be replaced, but these calculation charts will not tell you how many times the lamp was turned on. Nor can they tell you when the light is turned on, the heat of the light and the effect of being cooled, the time it was last cleaned, or whether the light tube has been used on average. It will not tell you if the lamp is used properly and no impurities remain on the surface of the quartz to form a hot spot. In the end, the hot spot becomes a weak spot.
Hour meter will tell you when the lamp is turned on, but unfortunately it will not tell you there is not enough UV energy to completely dry your product.
Use the hour meter as a display of quality for your lamp.
An ammeter amp meter is an instrument that calculates how much current is supplied to the lamp, so it is a measure of how much current is supplied to the lamp. Since a lamp cannot convert energy into UV with 100% efficiency, in fact, only a small part of the total energy will be converted into UV output, and only a smaller part of UV will make the ink dry. Therefore, ammeters are not a good UV measuring instrument. However, the resulting data can play a role in troubleshooting.
Watt lamps are displayed in watts per centimeter (W/cm) or watts per inch (W/in). This is the energy emitted by the length of the lamp, but this is an indication of the amount of energy input, and very little of it is converted to UV energy.
The wattage number simply shows the energy loss display required for the light pipe but does not tell you the amount of UV energy output.
The watts of the lamp will be converted to UV, visible light will be converted into infrared (thermal energy).
Although the lamp is operating as usual, the lamp will age gradually, causing the energy output to gradually decline. Where does the energy go? It is not UV but heat energy.
Therefore we need to measure the UV output of the lamp regularly!
Many people will confuse Watts and Joules.
The intensity of the lamp will be in units of MilliWatts (mW). MilliJoules (mJ) is the cumulative amount of MilliWatts for some time. The formula for calculating J/cm2 is: UV lamp When you are entrusted with a job, you must consider the variables in it and do not guess the results. Get as much ink as you can from your ink or coating supplier to get the ink dry. What energy can make the initiator active? When this chemical program occurs, these data will certainly be known.
Most chemical suppliers have UV measuring instruments, so they can tell you what will happen under dry conditions. The UV instrument supplier you purchased will have spectral output data, intensity, and temperature data at the time of use. With this data, you may be looking for a lamp that matches your spectral response diagram.
Reflectors Most people will underestimate UV
The important role of emitter reflectors. The mirror can only reach 70% of the energy on the dry surface, others will be emitted directly by the lamp itself.
When the dried product passes through a strong UV and thermal energy space, the UV emitter attracts dust and smoke, causing the reflector to become dark. So the UV spectrum will be lost, even if the visible light is still bright. If you have instruments that measure different UV wavelengths, you can see that shorter wavelengths tend to flow and weaken. In this way you can predict when you need to clean the system, than if you only observe long wavelengths.
UV Measurement and Observation Methods Radiometers are very effective instruments for measuring UV radiation parameters such as UV maximum energy, UV dose, UV
Spectral, focus, mirror efficiency and highest temperature. They can provide you with conditions during the drying process.
The connected UV monitoring system can provide relative data data permanently, while UV DESIGN in Germany can provide a series of recording and monitoring instruments.
Maintaining periodic maintenance is very important and must be properly arranged. It helps the drying system to remain intact, perform well and prevent undesired failures. Care must be taken when reading and maintaining the supplier's information.
When the repair is complete, the drying system must be turned on again to stabilize it.
Once again, the data is measured. If the data is improved, no further action is required. However, if the digital display shows an out-of-specification variable, the lamp, reflector, or both must be replaced.
Regular measurements and records If you can make a regular measurement, you will be able to reduce your UV drying system problems.
If you can properly process and record the figures obtained, you can find a principle of comparison. Otherwise, you will only make records and measurements indiscriminately.
In fact, measuring and recording your drying system is best for you to improve quality to meet customer requirements. At the same time, you can avoid producing bad products.
Although digital records are a very time-consuming task, it can guarantee that you can get the rewards you deserve.
UV drying system is not magic, but science!