Collating / Gathering and Book Sewing Machines

Introduction

The production line is configured with up to three AUSCP (SX220/43, SX200/ SX NO SPACE) fully automatic book sawing machine and multiple sets of AUSCP PY43 collating station linked together (up to48 collating stations can be connected, with a standard configuration of 15 collating stations).

DESIGN CONCEPT

The collating and book sewing line is currently the fastest way to complete the collating and book sewing processes on a single production line, making it the perfect combination of automatic collating and automatic book sewing machines. It eliminates the need for manual handling and storage, saves labor and space for transfer, reduces worker fatigue, improves production efficiency, and save production costs

PRODUCT CONFIGURATION

• Two AUSCP (SX220/43, SX200/51, SX NO SPACE) book sewing machines with two manipulators and two AUSCP PS Automatic feeding conveyor chains.
• 15 collation stations and 2 hand stations.
• AUSCP DJ43 book receiving stacker.

Function and Features

COLLATING MACHINE

• Intelligent control system, programmable via menu, the machine comes standard with a 12-inch color touch screen on a rotating arm, which can control machine operation, alarm information, and facilitate timely troubleshooting for the operator. It is easy to operate and simple to learn.
• The collate station is equipped with sensors for detecting missing signatures, multi-signatures, jams, dropped signatures, as well as indicator lights for quick troubleshooting.
• The collating station will collate disordered signatures into a predetermined sequence and stack up to a maximum height of 90 mm, then transport it to the distribution station to allocate signatures to different sewing machines accordingly.
• The collating machine has continuous start-up and emptying functions and automatically feeds according to the needs of the automatic wire stitching machine without manual intervention.
• The collating machine adopts a roller-type pasting design; signatures run vertically and friction-free during rapid operation.
• The transport channel adopts a drum-type frictionless design to prevent pages from being rubbed and ensure smooth transport.
• Each sewing machine is equipped with a storage channel (tank tread) for feeding on demand and automatic filling of downtime caused by unexpected stoppage.
• Modular design, freely combinable, with a maximum of 48 collating stations.

BOOK SEWING MACHINE

• High speed and precision: maximum speed of up to 200 signatures per minute, with three fully sealed cam control boxes filled with lubricating oil for smooth and durable operation. The flywheel accurately drives paper feeding, conveying, and saddle stitching. The book signature on the saddle is precisely positioned through synchronized belt structure with puller.
• Intelligent control system: colored touchscreen monitors the entire production, including paper feeding, conveying, lock stitching, and receiving, ensuring the quality of lock stitching.
• Fault detection & identifying: when faults such as a missing signature, multi-signatures, jams, dropped signatures, shortened signatures, and broken signatures occur, the machine will alarm and pause while displaying the fault.
• Automatic miss-signature detection function.
• Memory storage: can store up to 20 different book sewing programs and recall them as needed.
• Automatic template adjustment: by setting the size of the signature on the touchscreen and confirming the page-turning method, the transmission system automatically positions the conveyor belt, opens the page-turner, adjusts the position of the fixed saddle, drive chain, and acceleration wheel, and prepares the height of the finished book platform. Simple and easy to learn, fast operation, and quick template switching, which improves production efficiency.
• Signature separation: the blower and mechanical arm separate the bottom signature from the pile, and the suction cup extracts the separated signature from the feeder. The mechanical arm clamps the book signatures to the conveyor. The tilting device helps eliminate scratches on the surface of the signature.
• Automatic page-turning: the page-turner is equipped with four programmable vacuum suction cups at both the upper and lower sides, which can perform 4+4 vacuum page-turning and can handle signatures with even or uneven header and footer. It can automatically flip through sets of pages, loose pages, pages without long or short edges, and unevenly thick signatures. It can also turn pages of signatures with edges over 8 mm difference.
• Signature conveying: the signature is placed on the conveying saddle after being turned and is pushed by the conveyor chain. The acceleration wheel sends the signature into the active lockstitch saddle, and the speed of the acceleration wheel automatically adjusts according to the speed of the machine.
• Automatic signature separation and thread cutting: the automatic signature separation and thread cutting device cuts the excess thread to about 8-10 mm for easy binding/gluing and can separate the book signatures one by one according to the setting, regardless of the number of signatures in the book.
• Flatlock: uses fine ultra-short needles (16 mm) with a narrow stitch spacing (10 mm) to make the product firmer and flatter, reducing the chance of glue leakage and ensuring high-quality book sewing. The lockstitch device consists of an integrated control cam box, which not only reduces noise but also extends the longevity of the cam.
• Equipped with a book stacking machine, it can stack books with locked binding up to a height of 120 mm and neatly convey them to the book collection platform for easy palletizing.
• Lubrication on demand: equipped with a centralized oil supply lubrication system, oil pressure alarm, and oil storage device. When the machine is in operation, lubricant is precisely supplied through pipes to wherever necessary in a timely manner.

Specification