With the gradual increase of people's demand for books, the binding design and quality requirements of hardcover books have also changed. The previous manual hardcover production has been gradually replaced by the hardcover linkage line (Hardcover dragon). I will share with you the experience and lessons summarized in the production process analysis and quality control of hardcover books over the years.

印前工藝策劃和工藝評審，須對客戶的產(chǎn)品需求充分了解、掌握。

Prepress process planning and process review must fully understand and comprehensively grasp the product needs of customers.

(1)任何一本精裝書的實現(xiàn)必須提供成品尺寸。

(1) The realization of any hardcover book must provide the finished size.

(2)印張數(shù)。

(2) Number of printed sheets.

(3)使用材料，包括紙張類別、厚度等。

(3) Materials used, including paper type, thickness, etc.

(4)裝訂方式（圓背、方背），其后該精裝書的相關(guān)參數(shù)基本可以通過逆運算得到，包括內(nèi)單和外單裝箱規(guī)格、擱凳規(guī)格、單位噸重、貨柜規(guī)格等。

(4) Binding method (round back, square back), and then the relevant parameters of the hardcover book can be basically obtained through inverse calculation, including the packing specification of the inner list and the outer list, the stool specification, the unit weight, the container specification, etc.

(5)確認精裝書的規(guī)格尺寸是否符合精裝龍設(shè)計的三粘套合的尺寸范圍（超大、超小、超厚、超薄，大/小規(guī)16開，32開和正度64開均可在精裝龍上實現(xiàn)，特殊規(guī)格還可拆除部分防護進行操作），尤其要區(qū)分豎式開本和橫式開本，厚度要求必須到位，否則進不了機器。

(5) Confirm whether the specification and size of the hardcover book meet the size range of the three adhesive sleeve designed by the hardcover Dragon (super large, super small, super thick, ultra-thin, large / small size 16 open, 32 open and positive 64 open can be realized on the hardcover dragon, and some protection can be removed for special specifications for operation), especially distinguish between vertical and horizontal folios, and the thickness requirements must be in place, otherwise you can't enter the machine.

(6)系列書在書帖背上帶全帖次、折標(biāo)、書名的前提下，采用折標(biāo)分色，同時代碼標(biāo)識到位，防止混印、混裝。為確保折頁規(guī)矩，在印刷制版前，會添加一條固定印刷規(guī)矩的線，使用此線壓線印刷，能夠減少后續(xù)分切造成的折頁困難。

(6) On the premise of carrying full post times, folding labels and book titles on the back of the book, the series books adopt folding labels to separate colors, and the code marks are in place to prevent mixed printing and mixed loading. In order to ensure the folding rules, a line with fixed printing rules will be added before printing and plate making. Using this line to press the line for printing can reduce the folding difficulties caused by subsequent slitting.

(7)對于精裝書紙張尺寸的選定，除一定要滿足印刷設(shè)備的要求外，還需將后道精裝加工過程中的鎖線工序考慮在內(nèi)。如精裝書在印刷時要預(yù)留除切口外8～10mm紙邊，便于鎖線機開帖、分帖，防止鎖線夾層。

(7) For the selection of the paper size of hardcover books, in addition to meeting the requirements of printing equipment, the sewing process in the subsequent hardcover processing should also be taken into account. For example, when printing hardcover books, 8 ~ 10mm paper edges should be reserved except for the incision, so as to facilitate the opening and splitting of stitching machine and prevent the stitching interlayer.

印中按照客戶需求印制

Printed in accordance with customer requirements

印中必須嚴格按照客戶需求執(zhí)行，依據(jù)原稿跟色樣、內(nèi)容樣及后續(xù)裝訂，將產(chǎn)品印制到位。

Printing must be carried out in strict accordance with customer needs, and the products must be printed in place according to the original color sample, content sample and subsequent binding.

(1)產(chǎn)品必須檢查印刷機的橡皮布，需在確認橡皮布沒有壓損、壓癟的情況下，保證印品的圖文質(zhì)量。

(1) For key products, the blanket of the printing machine must be checked, and the graphic quality of the printed products must be guaranteed when it is confirmed that the blanket is not damaged or deflated.

(2)印刷時每個印張均須簽樣，機長、帶班主任必須對文字、內(nèi)容、墨色、規(guī)格確認到位；在印中強調(diào)印刷規(guī)矩，便于下單鎖線工序操作，如16開，印刷規(guī)矩要左右居中；32開，印刷規(guī)矩要上下、左右居中。

(2) When printing, each printed sheet must be signed, and the captain and the head teacher must confirm the text, content, ink color and specification in place; During printing, the printing rules should be emphasized to facilitate the operation of the single locking process. For example, 16 open, the printing rules should be centered on the left and right; 32 open, the printing rules should be up and down, left and right in the middle.

(3)根據(jù)印數(shù)大小，必須有小時段留樣、自檢記錄。

(3) According to the print size, there must be a small period of sample retention and self inspection records.

(4)每個班次之間印刷的產(chǎn)品必須帶工號，以示區(qū)別。

(4) The products printed between each shift must bear the job number to show the difference.

(5)印刷中如有換版情況，當(dāng)班機長必須如實填寫換版記錄。

(5) If there is a version change during printing, the captain on duty must truthfully fill in the version change record.

(6)遵循先印先出的原則，產(chǎn)品標(biāo)識、狀態(tài)標(biāo)識要齊全。

(6) Follow the principle of first printing first out, and the product identification and status identification should be complete.

印后工藝改善及效果

Post press process improvement and effect

01封面

01 cover

精裝書的封面絲縷方向必須和書背平行，否則成型后溝槽處橫紋明顯，皺紋影響美觀，無法去除。具體鑒定辦法，通常查看來料標(biāo)注即可，如787mm×1092mm、889mm×1194mm，一般后面的尺寸就是絲縷方向。但是對藝術(shù)紙要非常小心，需到現(xiàn)場鑒定確認到位。

The direction of the silk thread on the cover of a hardcover book must be parallel to the back of the book, otherwise the transverse lines at the groove after forming are obvious, and the wrinkles affect the beauty and cannot be removed. The specific identification method is usually to check the incoming material label, such as 787mm × 1092mm、889mm × 1194mm. Generally, the size of the back is the direction of the thread. However, you should be very careful with art paper, and you need to go to the scene to identify and confirm it in place.

具體辦法有兩種，一是折頁法，看其折邊是否開裂，如果開裂該折邊方向一定是橫紋，和其垂直的方向就是順紋；二是操水法，將要測試的紙張順邊裁切一張16開大小，單面操水后看其四邊中的兩邊卷曲的方向，即絲縷方向。

There are two specific methods. One is the folding method, to see whether the folding edge is cracked. If it is cracked, the folding direction must be horizontal, and the direction perpendicular to it is parallel; The second is the water operation method. Cut a piece of paper to be tested along the side with a size of 16 Kai. After water operation on one side, look at the curling direction of both sides in its four sides, that is, the thread direction.

需要注意的是，冬季為了縮短判定時間要提高水溫，否則不能立竿見影。藝術(shù)紙如果在制殼前未將絲縷方向確認到位，如果是橫紋在圓背精裝制殼時，其250g/m2的中經(jīng)紙板和封面之間就會形成空泡和皺褶，無法生產(chǎn)合格的成品書殼；其次無論是方背、圓背精裝書，只要是橫紋套合成型后的溝槽一定會有皺褶，影響美觀。藝術(shù)紙的封面如果在制殼前還有其他工藝，損失將會更大。

It should be noted that in order to shorten the judgment time in winter, the water temperature should be increased, otherwise it can not be achieved immediately. If the thread direction of art paper is not confirmed in place before making the shell, and if it is horizontally tattooed in the round back hardcover, bubbles and wrinkles will be formed between the 250g/m2 medium warp paperboard and the cover, and the qualified finished book case cannot be produced; Secondly, whether it is a square back or a round back hardcover book, as long as the groove after the horizontal pattern is nested and formed, there will be wrinkles, which will affect the beauty. If there are other processes for the cover of art paper before shell making, the loss will be greater.

為了保證封面后續(xù)加工工藝的質(zhì)量，包括燙印、局部UV、套書書背字高度一致等，印刷時盡量減少拼印，必要時僅單拼印刷。覆膜產(chǎn)品如有燙印工藝，應(yīng)考慮先燙印還是先覆膜，需按照客戶需求來定，各有利弊。不覆膜的藝術(shù)紙制殼時，必須和其后的三粘套合同步進行，保持書殼紙張水分，否則溝槽容易開裂。

In order to ensure the quality of the subsequent processing technology of the cover, including hot stamping, local UV, consistent height of the back of the cover book, try to reduce the spell printing when printing, and only single spell printing when necessary. If there is a hot stamping process for film covered products, we should consider whether to hot stamping or film covering first, which should be determined according to the needs of customers. Each has its own advantages and disadvantages. When making art paper case without film covering, it must be carried out in step with the subsequent three adhesive sleeve to maintain the moisture of the book case paper, otherwise the groove is easy to crack.

02紙板厚度

02 cardboard thickness

紙版厚度一定要按客戶要求執(zhí)行到位，一般在1.5～3.0mm，通常開本越大或書越厚要選用較厚實的紙板。開料后的紙板要用纏繞膜包裹，防止紙板中的水分流失。紙板的絲縷方向一定要和書背平行，否則成品后的起翹是不可逆的。

The thickness of the paper version must be in place according to the customer's requirements, generally 1.5 ~ 3.0mm. Generally, the larger the size or the thicker the book, the thicker the paperboard should be selected. It is best to wrap the opened cardboard with wrapping film to prevent the loss of water in the cardboard. The thread direction of the cardboard must be parallel to the back of the book, otherwise the warping of the finished product is irreversible.

如果紙板的絲縷方向是順紋，在制殼完成后的后續(xù)加工中如擊凸、壓凹、燙印等因防護不當(dāng)而形成變形，或者成品下線后因未進行必要的防護而形成起翹變形，可以用二次操水的辦法進行還原，是可逆的。如果是海棉加紙板，要確保能在制殼機實現(xiàn)，一定要用模切機下料，且注意雙面膠的粘貼方向。

If the thread direction of the paperboard is parallel to the grain, and the deformation is formed due to improper protection in the subsequent processing after the shell making, such as convex striking, concave pressing, hot stamping, etc., or the warping deformation is formed due to the lack of necessary protection after the finished product is offline, it can be restored by secondary water operation, which is reversible. If it is sponge plus paperboard, to ensure that it can be realized in the shell making machine, we must use the die-cutting machine to cut the material, and pay attention to the pasting direction of the double-sided tape.

03環(huán)襯絲縷

03 ring lined silk thread

精裝書前后環(huán)襯的絲縷方向必須和書背保持一致。有兩次以上沿頁時要事先預(yù)留沿口，確保書帖間粘接牢固。為防止沿好后的書帖相互粘連，盡量將環(huán)襯長度和書芯長度保持一致。

The thread direction of the front and rear ring linings of hardcover books must be consistent with the back of the book. When there are more than two times along the page, the edge opening should be reserved in advance to ensure that the bonding between the books is firm. In order to prevent the book stickers from sticking to each other, try to keep the length of the ring lining consistent with the length of the book block.

04內(nèi)文折頁

04 inside fold

銅版紙折頁時容易劃傷、擦傷，為防止折頁出現(xiàn)八字皺褶和死折，不能將折邊劃碎影響鎖線時的開帖、分帖。在保證花輪刀齒數(shù)不變的情況下，將花輪刀的刀齒缺口在砂輪機上再開大一點。

Coated paper is easy to be scratched and scratched when folding. In order to prevent zigzag folds and dead folds in the folding, the folding edge cannot be scratched to affect the opening and splitting of stitching. Under the condition that the number of teeth of the knurled cutter remains unchanged, open the notch of the knurled cutter on the grinder a little larger.

05配書

05 book matching

精裝書完成印前制作確認后，在后道產(chǎn)品裝訂合成時進行校核。配書必須在確保裝順正確的前提下，嚴防書帖間的劃傷和擦傷，小印張的書帖要調(diào)整好吸嘴位置，大墨量銅版紙書帖一定要降低儲帖高度，書帖的錯帖檢測裝置一定要在正常工作狀態(tài)。

After the pre press production and confirmation of the hardcover book, it shall be checked during the binding and synthesis of the subsequent products. On the premise of ensuring the correct loading, the books must be strictly prevented from scratches and scratches between the books. The position of the suction nozzle must be adjusted for the books on the small print sheet. The height of the storage of the books on the large ink coated paper must be reduced, and the wrong post detection device of the books must be in normal working state.

06鎖線

06 sewing

(1)根據(jù)精裝書的成品尺寸，制定相應(yīng)的針組數(shù)，書芯的針組數(shù)原則上以不出天頭和地腳為限。

(1) According to the finished size of the hardcover book, the corresponding number of needle groups shall be formulated. In principle, the number of needle groups of the book block shall not exceed the sky and the foundation.

(2)正文開料尺寸依據(jù)開本規(guī)格不同，預(yù)置書帖折好后的大小紙邊，原則上鎖線盡量多用開帖刀分帖，少用吸嘴分帖，具體由鎖線機的配置而定。

(2) The cutting size of the text is different according to the size of the folio. The size of the paper edge after the book post is folded is preset. In principle, the locking line should be divided by the opening knife as much as possible and the suction nozzle as little as possible, which depends on the configuration of the sewing machine.

(3)當(dāng)出現(xiàn)內(nèi)外套帖或內(nèi)中外套帖時，在確保書帖大小紙邊一致的前提下，需了解馬天尼鎖線機的錯帖識別裝置，其他型號機器依據(jù)各自配置各有不同。

(3) When there are inner and outer stitches or inner middle and outer stitches, it is necessary to understand the wrong stitching identification device of Martini sewing machine on the premise of ensuring that the size of the book stitches is consistent with the paper edges. Other types of machines are different according to their respective configurations.

(4)正文是銅版紙或者是高定量紙張，遇到版面是滿版實地墨色時，一定要在該頁的折邊處預(yù)留3mm白邊，以增大摩擦力、帖與帖間的粘接強度，否則鎖線后漿背時，該帖次易引起書芯錯位，針孔處溢膠，影響產(chǎn)品品質(zhì)。

(4) The text is coated paper or high weight paper. When the layout is full-size field ink, 3mm white edge must be reserved at the hem of the page to increase the friction force and the bonding strength between posts. Otherwise, when the back of the paste is locked, the post is easy to cause the dislocation of the book block, the glue overflow at the pinhole, and affect the product quality.

(5)為保證書芯的版面平整一致，壓脊機壓脊后，還需規(guī)范碼放在擱凳上，用包裝帶收緊后進行人工時效處理，碼放時要求每把印品錯位碼放，壓實書背，書口錯開。

(5) In order to ensure that the layout of the book block is flat and consistent, after the ridge pressing machine presses the ridge, it is also necessary to stack it on the bench in a standardized manner, and then conduct artificial aging treatment after tightening with the packaging tape. When stacking, it is required that each printed matter is stacked in a staggered manner, the back of the book is compacted, and the mouth of the book is staggered.

07漿背

07 pulp back

漿背要控制好膠量，防止膠液滲透到內(nèi)文，有條件時可自帶包邊紙，杜絕書本與書本之間的粘連。

The amount of glue on the back of the pulp should be controlled to prevent the glue from penetrating into the text. If possible, you can bring your own wrapping paper to prevent the adhesion between books.

08三面刀裁切

08 three sided knife cutting

裁切后的光本成品尺寸必須滿足規(guī)定的要求，三粘套合后的三面瓢口要基本一致。依據(jù)精裝圖書開本大小8開～64開，在2.5～4.5mm之間。

The size of the cut finished product must meet the specified requirements, and the three sides of the scoop mouth after the three adhesive sleeve must be basically the same. According to the size of hardcover books, it is 8 ~ 64 Kai, between 2.5 ~ 4.5mm.

09精裝龍生產(chǎn)

09 hardcover dragon production

圓背精裝書在精裝龍上實現(xiàn)的基本工作原理為三面刀裁切后，經(jīng)檢驗合格的光本流轉(zhuǎn)到精裝龍的入口處，通過光本輸送帶經(jīng)光控探頭依次通過五星輪翻轉(zhuǎn)后，書背朝上進入書芯模塊底板上，模塊底板的寬度比書芯小2～3mm，書芯通道比書芯大2～3mm。

The basic working principle of the round back hardcover book on the hardcover dragon is that after cutting with a three-sided knife, the checked and qualified light books flow to the entrance of the hardcover dragon, and then turn over through the five-star wheel through the light control probe through the light conveyor belt in turn, and the back of the book faces up into the bottom plate of the book block module. The width of the module bottom plate is 2 ~ 3mm smaller than the book block, and the channel of the book block is 2 ~ 3mm larger than the book block.

通過鏈輪導(dǎo)桿位移到翻圓輪下，翻轉(zhuǎn)成圓背，翻轉(zhuǎn)的高度由起脊塊決定，依據(jù)是后面的虎鉗夾板夾書高出部分，再通過往復(fù)夾書板，夾送到起脊虎鉗夾板，夾板的小距離比書芯小2～3mm，進行扒圓起脊，書芯高出夾板2～3mm左右，上壓模的弧長比書背大6mm左右，起脊后由往復(fù)夾書板交接給高度調(diào)整夾板，調(diào)整光本高度后，由往復(fù)夾板交接給主機鏈輪，由主機鏈輪繼續(xù)將書芯位移到上膠輪粘背膠后，如圖1所示。

Move the chain wheel guide rod under the rounding wheel and turn it into a round back. The height of turning is determined by the ridging block. The basis is that the book is higher than the book in the back vise clamping plate, and then it is clamped to the ridging vise clamping plate through the reciprocating book clamping plate. The minimum distance of the clamping plate is 2 ~ 3mm smaller than the book block. Carry out rounding and ridging. The book block is about 2 ~ 3mm higher than the clamping plate, and the arc length of the upper die is about 6mm larger than the book back. After ridging, the reciprocating book clamping plate is handed over to the height adjustment clamping plate, After adjusting the height of the glossy book, the reciprocating splint is handed over to the host sprocket, and the host sprocket continues to move the book block to the first gluing wheel, as shown in Figure 1.

書芯移上膠輪粘背膠

Move the book block to the first upper rubber wheel and stick the back glue

背膠輪的寬度大于書芯弧長2～3mm，膠溫為60℃～75℃，特殊情況可以再提高，膠輪高度緊貼在書背上，膠量適宜，具體看拉絲情況。繼續(xù)位移粘貼紗布，紗布寬度在書芯弧長基礎(chǔ)上再加40～50mm，一分為二居中，長度是書芯長度減掉25～30mm，如圖2所示。

The width of the back rubber wheel is 2 ~ 3mm longer than the arc length of the book block, and the rubber temperature is 60 ℃ ~ 75 ℃. It can be increased under special circumstances. The height of the rubber wheel is close to the back of the book, and the amount of rubber is appropriate. See the drawing situation for details. Continue to move and paste the gauze. The width of the gauze is 40 ~ 50mm on the basis of the arc length of the book block. It is divided into two and centered. The length is the length of the book block minus 25 ~ 30mm, as shown in Figure 2.

調(diào)整紗布寬度

Adjust the width of gauze

其后在主傳動鏈輪的傳送下繼續(xù)到達第二上膠輪上背膠。再位移粘貼堵頭布書背紙，書背紙及堵頭布的寬度比書背弧長0.5mm左右。書背紙粘帖后，繼續(xù)由主機鏈輪傳送到柔性成型架，壓實后將書芯送出經(jīng)推書塊后，移送分書刀定位前規(guī)后由半月板挑起施膠。書殼由棘輪推送出整面壓輪后，書殼的中徑紙板經(jīng)過預(yù)熱板，再位移圓背成型模塊定型后推出，如圖3所示。

After that, it continues to reach the upper back of the second rubber wheel under the transmission of the main drive sprocket. Then shift and paste the back paper of the plug cloth. The width of the back paper and the plug cloth is about 0.5mm longer than the back arc of the book. After the paper on the back of the book is pasted, it will continue to be transferred to the flexible forming frame by the sprocket of the main machine. After compaction, the book block will be sent out, pushed through the book block, transferred to the front gauge of the positioning of the dividing knife, and then lifted by the meniscus for sizing. After the book case is pushed out of the whole pressing wheel by the ratchet, the medium diameter paperboard of the book case passes through the preheating plate, and then moves to the round back forming module to be finalized and pushed out, as shown in Figure 3.

圓背成型模塊定型

Shaping of round back forming module

掃環(huán)襯和書殼套合形成三粘的完成，經(jīng)過輸送帶流轉(zhuǎn)五星翻轉(zhuǎn)輪光控探頭后，由溝槽夾板移送整幅夾板，依次交接后，流轉(zhuǎn)下線。檢驗合格后碼放到位。

The completion of the three glues formed by the sleeve of the sweeping ring lining and the book case is transferred to the five-star turnover wheel optical control probe through the conveyor belt, and then transferred from the groove splint to the whole splint. After being handed over in turn, it is transferred offline. Stack in place after passing the inspection.