23 Factors That Easily Cause Prepress Plate-Making Equipment Failures
Prepress plate-making equipment is highly precise. In practice, a large proportion of equipment failures are caused by external factors rather than inherent defects. These causes are diverse, and solutions must be determined according to actual conditions.Based on long-term maintenance experience, the following 23 factors are summarized as common causes closely related to failures in plate-making equipment. While other factors may also exist, careful analysis and control of these points can effectively ensure stable operation and rapid troubleshooting.
1. Dust
Prepress plate-making equipment—especially scanners, imagesetters, and CTP-related devices—are precision machines. Dust is their greatest enemy. It can cause serious damage to components, making routine cleaning the most critical aspect of daily maintenance.2. Oil Contamination
Due to mechanical friction, almost all equipment requires lubricants. Over time, lubricating oil can mix with dust, heat, and metal particles generated by friction, forming oil contamination. This may cause mechanical resistance, local overheating, and mechanical failures.
3. General Dirt and Grime
Dirt includes oil contamination and mixtures formed when airborne particles combine with moisture. While initial buildup may not cause immediate problems, long-term accumulation can damage components, such as stains and spots on display screens.4. Material Residue Adhesion
This issue is most common in processors and proofing machines. During processing, chemical reactions between film surface materials and developer solutions can create residues that easily adhere to rollers. Similarly, proofing ink can stick to ink rollers and rubber drums if not cleaned promptly. Regular cleaning is the best prevention.5. Wear
Wear mainly occurs in frequently moving mechanical parts such as bearings, lead screws, and clamps. Proper and timely lubrication is the most effective way to reduce wear.6. Vibration
Vibration can cause both equipment malfunctions and product quality issues. In addition to proper installation, the stability and levelness of equipment should be checked regularly.7. Loosening
Loosening is usually caused by external factors such as vibration. During routine maintenance, all screws, fasteners, and fixed components should be checked and tightened as needed.8. Leakage
Leakage refers to cooling liquids or protective fluids escaping due to aging or impact damage to components. This can cause overheating and burnout of parts, such as cooling water leaks in copy lamp systems.9. Corrosion
Most volatile liquids can damage non-metallic components to varying degrees. Residues left on equipment surfaces and not cleaned in time are a major cause of corrosion.10. Creep
Creep develops slowly and is often not obvious. It can occur in both mechanical and electronic systems. During inspections, attention should be paid to subtle parameter changes.11. Stress Deformation
Stress deformation is a physical phenomenon that often occurs during operation. If equipment is not properly adjusted after use, long-term stress may cause deformation of mechanical structures or circuit board slots.12. Scratches
Scratches caused by external impact during operation can directly lead to serious failures or affect output quality, such as scratches on scanner or imagesetter drums.13. Cracks
Cracks are mainly caused by long-term exposure to excessive pressure or weight. Once cracks appear, repairs are generally not recommended, as they may lead to secondary cracking and further damage.14. Overheating
Electronic components generate heat when powered, and mechanical friction also produces heat. Electronics require auxiliary cooling systems, while mechanical parts rely on heat conduction. Monitoring operating temperatures is essential during routine checks.15. Abnormal Noise
Unusual sounds during operation often indicate issues related to wear, overheating, or misalignment. Equipment should be stopped immediately for inspection to prevent fault escalation.16. Short Circuits
Short circuits are often accompanied by damage to other components and are usually caused by aging parts or human error. After a short circuit occurs, power should not be restored until the root cause is fully identified and resolved.17. Poor Insulation
Aging equipment and heat buildup can reduce insulation performance, increasing the risk of short circuits. When replacing components or wiring, sufficient tolerance margins should be ensured.18. Poor Electrical Conductivity
This refers to situations where conductors, switches, or relays fail to allow current flow after actuation due to voltage, current, or contact resistance issues. Such problems are usually identified through powered testing.19. Fatigue
Equipment requires adequate rest periods. Continuous long-term operation leads to mechanical and electronic fatigue, which is directly related to many failures. Even equipment designed for continuous use benefits from 1–2 hours of daily downtime.20. Rust
Rust is specific to metal components. It appears as oxidation on metal surfaces, affecting performance. Insufficient lubrication or protective oil is a common cause of rust in moving parts.21. Parameter Drift
Parameter drift refers to the gradual loss or deviation of performance parameters during operation, often due to overload or design limitations in electrical performance.22. Poor Lubrication
Insufficient lubrication or excessive local oil temperature leads to poor lubrication. This causes direct metal-to-metal contact, resulting in mechanical failures and accelerated wear.23. Component Degradation
Due to material quality issues or electrical surges, components may undergo significant performance changes and fail to function properly. During maintenance, replacement parts should be accurately measured to prevent degraded components from causing secondary failures.| 0 Comments |
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