Does CTP also suffer from 'holiday syndrome'? The top ten issues that cannot be ignored
Holiday syndrome, also known as post holiday syndrome, refers to various physiological or psychological discomfort symptoms that people experience after a long holiday. Machines, like humans, can also experience post holiday syndrome if they are not properly maintained. However, they will not provide you with the opportunity to serve you, will not express discomfort through their senses or language, and may even go on strike directly. But it's okay, engineers can use their professional skills to find the problem with the machine in the clues and make adjustments and repairs. In this article, the author will explain one by one the most common problems of CTP systems after holidays, hoping to help you.
CTP process server failure
The workflow is a management system that ensures the normal operation of the computer direct plate making process, enabling the coordinated and smooth operation of various equipment, data, and information involved in the direct plate making system, making full use of various resources, and maximizing the efficiency of the system. It covers two important parts: CTP digitalization process and hardware server. It is an indispensable component of a complete CTP system solution and the most easily overlooked part by users. It is usually placed in a relatively inconspicuous corner and works silently in the background.
01/Process server time lost, causing the process to fail to start
The server date and time have changed, possibly to January 1, 1980, causing the process software to fail to start. The fundamental reason for the time inconsistency between the client and server is that the clocks between the two are not synchronized.
This is one of the most common issues during holidays, mainly due to the button battery that supplies power to the server BIOS running out and unable to provide effective energy. You can change the date first and then replace the battery. There are various methods to change time to synchronous network time, which can be automatically synchronized through NTP (Network Time Protocol) or manually set. Regardless of the method used, as long as the clocks of the client and server are synchronized, the process can run normally.
02/Server Raid information lost, server system cannot start
Once the array is created, theoretically speaking, the Raid information will not change. However, unexpected power outages and other unexpected situations can easily lead to the loss of Raid information. Long term shutdowns can also cause the battery attached to the Raid to run out and lose its memory of Raid information.
When the server is turned off, unplug all hard drives (remember the location of the hard drives on the server, and do not make mistakes when plugging them back in). Power on the server without a hard drive and clear the residual Raid information on the Raid card (clear config). If there are multiple sets of Raid Group Raid information, be careful not to delete them incorrectly. After clearing them, shut down and then plug in all hard drives while in the shutdown state. Then, enter the Raid card management interface after booting up, and you will be prompted with "foreign configuration". Import the Raid information from the hard drives into the Raid card and it will work normally.
03/Server network IP address error, unable to connect to all related devices and computers
Server IP address errors may be caused by network configuration errors, IP conflicts, or DHCP service failures. By checking the network connection, confirming whether the IP address is correct, changing the network adapter settings, and running network troubleshooting programs, it is possible to attempt to fix IP address errors and restore network connectivity. Enter the 'ipconfig' command and press Enter to check if the IP address conflicts with other computers on the network. If there is a conflict, the IP address needs to be changed to resolve the issue.
This network issue is also the most common problem after long-term shutdown, with router allocation address conflicts. It is recommended to set all CTP related devices and computers to a fixed IP address. Solutions include checking network settings, reallocating IP addresses, restarting DHCP services, etc.
CTP software and hardware system malfunction
One of the key aspects of computer direct plate making technology is the matching of the printing plate and imaging system. The system engineering consisting of CTP software and hardware is responsible for completing this task. Its structure mainly consists of four parts: mechanical system, optical system, circuit, and pneumatic system. When we talk about CTP, we mostly refer to CTP hardware. No matter how perfect other parts are, if CTP does not work, the entire system will be paralyzed. Therefore, CTP system is a system with CTP hardware as its core.
01/Machine pressure error, all actions stop working
Pneumatic transmission refers to a technology that uses compressed air as a power source to drive and control various mechanical equipment to achieve mechanization and automation of the production process. Pneumatic technology is widely used in various fields. The transmission part of CTP relies entirely on pneumatic control. Generally, the pressure of CTP system is controlled at around 0.8MPa. If there is a large pressure fluctuation, the machine will report an error or malfunction.
Adjust the air pressure value to the appropriate level and adjust the system pressure parameters to within the range, not too high, to avoid energy consumption or cylinder damage; Also, it should not be too low to avoid unstable equipment operation due to insufficient supply pressure. Normally, the adjustment system attached to the machine can stabilize the air pressure within the correct range.
02/CTP sensor error, related motion mechanism stops working
A sensor is a detection device that can sense the measured information and convert it into electrical signals or other required forms of information output according to certain rules, in order to meet the requirements of information transmission, processing, storage, display, recording, and control. It is the primary step in achieving automatic detection and control. The sensors in CTP include pressure sensors, temperature and humidity sensors, photoelectric sensors, flow sensors, position sensors, etc. After a holiday break, CTP related sensing devices may fail without power or changes in ambient temperature. Sensor failures mainly include complete failure, fixed deviation, drift deviation, and accuracy deviation.
If it does not fail or malfunction during work, most sensors can be restored to normal by simply cleaning the photoelectric head and transparent parts, without the need for replacement or disassembly for repair. Especially during holidays when problems arise, cleaning is usually enough to solve the problem.
03/CTP temperature and humidity alarm, the machine cannot be started to the running state
Usually, CTP monitors temperature in at least three places. Firstly, the laser controller inside the laser head always has temperature data to ensure that the laser head operates at the appropriate temperature; Secondly, the base or screw of the machine will also have temperature monitoring to ensure that the plate material will not be overprinted due to thermal expansion and contraction; The third is to detect the temperature and humidity of the plate box to prevent the liner paper from sticking to the plate material, especially the laser head part. If it does not reach the normal value, the machine will stop working.
We can check the current temperature and humidity status through the diagnostic program inside the machine, and process and release the residual moisture inside the air compressor as required. We can turn on the indoor air conditioning in advance to accurately control the temperature at 22 ± 2 ℃ and maintain the humidity at 55% ± 5%, ensuring that the equipment operates in the required environment.
04/CTP laser head error, machine cannot expose correctly
The laser in CTP plate making machine is one of the key components for transferring digital images to the printing plate. Its stability, accuracy, and reliability have a significant impact on the quality of plate making and production efficiency. In general, long-term shutdown has no effect on the laser part, and the laser has reliable performance, long lifespan, and can work continuously for a long time. However, external factors such as power supply, temperature, humidity, and connection signal lines may cause errors or stop working of the laser head.
The method to eliminate peripheral faults is to detect the fault points through diagnostic software and eliminate them one by one. After the machine starts up normally, wait for about 30 minutes to start working, which can ensure that the machine works normally.
05/CTP network disconnection, resulting in loss of internal authentication of the machine
In addition to an internal network card, there is also a network card used to connect CTP plate making machines. This network card has some special settings and drivers for connecting to GMCE motherboards. The GMCE motherboard is the brain of the entire machine, used for data transmission, power distribution, information control, etc. The hardware is the main part, and some internal program firmware is the command system of the machine motherboard. Short term shutdown usually does not cause machine motherboard failure. Only when the power supply or its components are unstable will there be major errors. However, because GMCE is the main core control board, all errors may be reflected on the motherboard.
Check if the network card address and settings of the connected machine are correct. If the internal network firewall is not whitelisted, it is best to turn off the firewall as well. Generally, changing it to the correct settings and restarting the machine or computer can restore normal operation.
CTP development system malfunction
Developing solution can reveal the latent image formed by exposure on the printing plate, obtaining a printing layout and layout performance that meets printing requirements. A developing machine is a pre press processing equipment that partially or completely completes the developing, rinsing, gluing, drying, and other processes of the CTP exposed printing plate through semi-automatic and fully automatic programs. A developing machine generally consists of a transmission system, a developing system, a rinsing system, a drying system, a program control system, and other components.
01/CTP plate material itself malfunction
If the plate is left in a bright environment for a long time and the temperature is too low or too high, it will produce thermal shock effects on the exposure machine, which can easily cause problems during exposure, especially for non rinse plates.
Effectively control the ambient temperature to 5-25 ℃ and humidity to within 60%. Dustproof, stain resistant, wrinkle resistant, and scratch resistant. The warehouse should not have too strong lighting to avoid dark reactions on the organic photosensitive material film surface of the plate material.
02/Condensation of plate making machine, abnormal operation of developing machine
There are three reasons that can easily cause the developer to condense. One is temperature changes. When the chemical composition in the developer changes temperature, its solubility will change, resulting in crystallization; Secondly, the concentration is too high. If the concentration of the developing solution is too high, the excessive concentration will cause too many solutes in the solution, resulting in the precipitation and formation of crystals; Thirdly, impurities are mixed in. If impurities are mixed in the developing solution, they may become the core of crystallization, promoting the formation of crystals and increasing the resistance of machine operation.
Don't rush to add developer after the holiday, you can first fill the machine with clean water and turn on the plate washer to make the equipment run. Thoroughly inspect the rubber rollers and brushes to ensure they are functioning properly without any jamming or stagnation. Check whether the liquid circulation system, water washing circulation system, and glue circulation system are operating normally. After confirming that everything is normal, drain the clean water and refill the liquid. Wait for the liquid temperature to rise to the normal range before putting it into operation.
Holiday syndrome is just a psychological emotion. If people can quickly return to work and study life, adjust their schedule, and try to live in an orderly manner, they can return to normal in a short period of time. However, machines have to work for a long time or overtime, and are not good at expressing themselves. The perception of machines is objective, and they can only process based on programs and algorithms. They cannot have real subjective feelings and emotions, and will only show their discomfort by throwing tantrums. Therefore, taking preventive measures, being proactive, and regular maintenance are the only way to prevent CTP failures.