Abstract:
A mounting system is disclosed for removably mounting rollers and cylinders in a machine for quick and easy removal and replacement by other rollers and cylinders. The mounting system provides for rapid separation of the journal from the roller or cylinder so that only the roller or cylinder is removed, and the mounting system has particular applicability with respect to ink rolls in printing machines.

Description:
FIELD 
     This invention relates to the field of rotary printing, and more particularly, to an ink roll or other cylinder which may be removed and replaced with another ink roll or cylinder much more easily and quickly than previously possible. 
     BACKGROUND 
     In rotary printing, such as in flexographic printing of multi-colored images, it is well known that different ink rolls having different surface configurations must be used so as to print most clearly in different situations. For example, so-called “high line-count” ink rolls are required for high or detailed graphics, while “low line-count” ink rolls are required for solid color or so-called “block” printing. This is particularly true when printing on sheets of corrugated cardboard so as to form advertising displays, or containers for many different products. In flexographic printing, aqueous inks are used, and the ink rolls are sometimes referred to herein as anilox rolls. 
     As a result of the above-indicated requirements, it is often necessary to remove one ink roll of a certain line-count and replace it with another ink roll of a different line-count before beginning the next run of sheets to be printed. In the past, the removal and replacement of ink rolls has taken many hours and has resulted in substantial losses of production. For example, the ink roll is closely surrounded by other structures such as the ink fountain and the printing cylinder, as well as the train of drive gears in a multi-stage printing machine. Thus, it has been necessary to disassemble many components of the machine in order to free the ink roll and its one-piece journal so as to remove it from the machine. In addition, it will be understood that each ink roll may be in the order of 10 feet in length, and may weigh 1,500 pounds or more, which further complicates the removal and replacement process, and results in many hours of down time for the operator. 
     SUMMARY 
     The present invention provides a mounting system for quick and easy removal and replacement of ink rolls and other cylinders by providing mounting structures which are vertically split, and a two-piece ink roll and journal structure which enables the ink roll to be separated from the journal, thereby allowing the journal to remain mounted in the printing machine while only the ink roll or cylinder is removed and replaced. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is an elevational cross-sectional view of the journal and ink roll removably mounted in the printing machine; 
     FIG. 1A is an enlargement of a portion of FIG. 1; 
     FIG. 2 is a perspective view showing the journal and ink roll partly assembled; 
     FIG. 3 is a cross-sectional view perpendicular to the longitudinal axis of the machine; 
     FIG. 3A is a cross-sectional view of an alternative construction of the plate-and-bolt assembly; 
     FIG. 4 is an exploded view of a second embodiment of the invention; 
     FIG. 5 is a perspective view showing the second embodiment partially assembled; and 
     FIG. 6 is a perspective view of the second embodiment fully assembled. 
    
    
     DETAILED DESCRIPTION 
     Referring first to the embodiment shown in FIGS. 1-3, numeral  10  indicates an ink roll which is permanently secured to an internal support  12  such as by a force-fit or welding or other means. Support  12  includes a portion  14  of reduced diameter, and it will be understood that elements  10 ,  12  and  14  form a one-piece ink roll which remains an integral unit when the ink roll is installed or removed from the machine. 
     As shown most clearly in the left portions of FIGS. 1 and 2, a journal  20  extends to the right toward the ink roll. Journal  20  includes a slightly enlarged bearing surface portion  22 , and a substantially enlarged flange portion  24 . The journal is centered by a radial-and-thrust bearing  26  which is mounted in an annular housing  28 . Housing  28  is connected by bolts  30  or otherwise to an inner frame member  32  or to another stationary and permanently mounted structure of the printing machine. Bearings  26  are preferably retained in place by a retention ring  34  and an annular retainer ring  36 , and it will be understood that a drive pulley or sprocket (not shown) is mounted on the end of journal  20  in order to rotate the ink roll. 
     Referring to the right-hand portion of FIG. 1, it will be noted that a second set of radial bearings  40  are contained in and centered by housing  28 , and that bearings  40  surround reduced diameter portion  14  of the ink roll. Thus, both the ink roll and removable journal are mounted in and centered by housing  28 . This assures perfect alignment between the journal and the ink roll being removed, and between the journal and the new ink roll being introduced into the machine. It will also be noted from FIGS. 1-3 that housing  28  extends 180° around the center of revolution and longitudinal axis of the ink roll, and that the other 180° is enclosed by removable semi-circular covers  28 A and  28 B. 
     In order to removably connect each ink roll to the journal, flange  24  of the journal and reduced diameter portion  14  of internal support  12  are connected by removable connector assemblies  44  as illustrated in FIGS. 1-3. In one preferred embodiment, connector assemblies  44  comprise plates  46  and  47  bolted to both journal flange  24  and portion  14  of the ink roll by removable bolts  48 . Plates  46  are relatively thick and rigid, whereas plates  47  are thinner and slightly flexible so as to compensate for any deviations in the matching dimensions of portions  14  and  24  beyond preset tolerances. Alternatively, shims may be employed instead of flexible plate  47 . If the tolerances of portions  14  and  24  are maintained, such as by precision machining, then the flexible plates and shims may be eliminated as illustrated in FIG.  3 A. In this embodiment, plates  46  alone bridge across journal portion  24  and reduced diameter portion  14  of ink roll support  12  and removably connect the ink roll to the journal. In either case, it will be understood that the end surface  15  of support portion  14  and the end surface  25  of journal flange  24  form mating planar surfaces as shown in FIGS. 1 and 1A, and that the bolt and plate assemblies  44  bridge these mating surfaces and removably secure journal  20  to the ink roll. 
     Operation of the First Embodiment 
     When it is desired to change ink rolls, bolts  50  are removed, and semi-circular cover  28 A is removed. This provides direct access to bolts  48  as shown in FIG. 2 such that plates,  46  may be removed. Removal of plates  46  disconnects journal flange  24  from reduced portion  14  of the ink roll. The ink roll is then supported temporarily, by a support structure (not shown), while. cover  28 B is removed. The ink roll is then removed, such as sideways to the left as viewed in FIG.  3 . The present invention makes it possible to remove an ink roll in only the time that it takes to remove bolts  50  and  48 , and slide the ink roll out of the machine. The required time for this removal is substantially less than one hour, whereas, prior mounting systems have required many hours to remove each ink roll. It will also be understood that the same mounting structure may be used to make printing cylinders, feed rolls, impression cylinders, die cutter cylinders and other rotary components of a printing machine easily removable and replaceable. 
     The present invention includes a second preferred embodiment as illustrated in FIGS. 4-6 in which the same numerals represent counterpart elements of the previous embodiment. The right-hand portion of FIG. 4 shows ink roll  10  with an internal support  12  which comprise a one-piece construction as previously described. The left-hand portion of FIG. 4 shows journal  20  with bearing surface  22  and an integral flange portion  24 , and it will be understood that journal  20  is permanently connected to the machine as previously described. The middle portion of FIG. 4 illustrates an alternative adapter assembly comprising first and second adapters  52  and  54 . Adapter  52  comprises a first circular portion  56  having a diameter equal to the inner diameter of the ink roll. Portion  56  includes bolt holes  58  which are aligned with threaded bores  60  of ink roll support  12  so that adapter  52  may be semi-permanently bolted to the ink roll in precise alignment with the axis of rotation of the ink roll; the term semi-permanently being further defined hereafter. 
     Adapter  52  includes an integral, arcuate portion  62  which extends 180° around the circumference of portion  56  of adapter  52 . Arcuate portion  62  has an external diameter equal to the internal diameter of the ink roll, and includes angled bore holes  64  for receiving bolts tangentially. Thus, when adapter  52  is semi-permanently secured to the end of the ink roll, the assembly is as shown in the right-hand portion of FIG.  5 . 
     As shown in the left portion of FIG.  4  and in FIG. 5, adapter  54  includes an arcuate portion  66  having a diameter equal to that of adapter portion  56 . Adapter  54  also includes an integral, circular portion  68  having a circumference equal to the curvature  70  of portion  62  of adapter  52 . Portion  68  is provided with bores  72  which may be aligned with bores  74  of journal flange  24 . 
     Operation of the Second Embodiment 
     It will be understood that ink roll  10  is semi-permanently connected to adapter  52 , and that journal  20  is permanently connected to adapter  54  which is permanently connected to the machine as previously described. Accordingly, the journal and the ink roll are as shown in FIG.  5 . For connecting the ink roll to the journal; the ink roll may be simply moved to the left as shown by arrow A in FIG. 5, and bolts inserted through bores  64  and into threaded bores  78  of adapter  54 . The ink roll and journal are then removably connected as shown in FIG.  6 . Removal of the ink roll only requires that the bolts be removed, and the ink roll and adapter  52  may be disengaged as a one-piece unit and removed sideways from the machine in the reverse direction of arrow A. Adapter  52  may then be disconnected from the ink roll if it is to be used with the replacement ink roll to be inserted into the machine. Accordingly, the term “semi-permanently connected” is intended to mean that the ink roll and adapter  52  are removed and installed as a one-piece unit, and if an additional adapter  52  is available for the replacement ink roll, adapter  52  may remain permanently connected to the ink roll being removed. 
     From the foregoing description of two preferred embodiments of the invention, it will be apparent that numerous variations may be made in the invention by a person skilled in the art, and it will be apparent that the subject invention may be employed for mounting other types of rollers and cylinders for rapid removal and replacement in machines other than printing machines. Accordingly, it is to be understood that the foregoing description is intended to be illustrative of the principles of the invention, and not exhaustive thereof, and that the true invention is intended to be limited only as set forth in the following claims interpreted under the doctrine of equivalents.