Innovative Workshop | The cost is only 20% imported, and my country's high-end packaging and printing equipment has made new breakthroughs and achieved a high degree of localization
On November 3, the results of the 2020 National Science and Technology Awards were officially announced. It is worth noting that in the awards issued this time, printing and packaging people are also on the list: the second prize of the National Science and Technology Progress Award-high-end packaging and printing equipment key technology and series product development.
Main performers: Mei Xuesong, Li Yanfeng, Xu Wencai, Zhao Fei, Xue Zhicheng, Huang Xiaojun, Wang Yiming, Chen Liang, Tao Tao, Han Jian.
Main units: Xi’an Jiaotong University, Shaanxi Beiren Printing Machinery Co., Ltd., Beijing Institute of Graphic Communication, Xi’an Aerospace Huayang Electromechanical Equipment Co., Ltd., Weinan Kesai Electromechanical Equipment Co., Ltd.
High-end packaging and printing equipment is the core equipment for high-precision and green printing, which plays an indispensable role in commodity circulation and traceability. For a long time, my country's high-end packaging and printing equipment all relied on imports. It is of great significance to win the second prize of the National Science and Technology Progress Award for key technologies and series of high-end packaging and printing equipment. It has achieved a high degree of localization of my country's high-end packaging and printing equipment, and made "Made in China" a "Chinese seal."
In this article, let us walk into Xi’an Jiaotong University to understand how the team represented by Professor Mei Xuesong, Professor Tao Tao, and Researcher Zhao Fei solved multiple technical problems of high-end packaging and printing equipment, overcome difficulties, and helped realize another device. Localization.
The reversal from dependence on imports to a high degree of localization
With the rapid development of the market economy, food, medicine, daily necessities, and other products that have strict requirements on printing residues, have an increasing demand for high-end printing. It is understood that the total output value of my country's high-end packaging and printing industry has approached one trillion yuan, and the large number of applications of smart packaging products brought about by Internet technology in recent years is an urgent need for high-fidelity and environmentally-friendly high-end packaging and printing equipment.
Due to high energy consumption and easy generation of harmful gases, the packaging and printing industry has been listed as a key environmental protection monitoring industry by the country. In addition to focusing on printing precision and accuracy, providing online fault detection and cloud services, this achievement also tackles the technical problems of ink drying to timely recover waste heat, peculiar smell, organic gas, etc. generated after the ink is heated. The packaging industry reduces carbon emissions as a whole, realizes my country's "dual carbon" goal and safe packaging of food and drugs is of great significance.
Professor Mei Xuesong, Professor Tao Tao, and Researcher Zhao Fei led the team to research key problems for many years, and completed the project of "Key Technology and Series Product Development of High-end Packaging and Printing Equipment".
The project solved many technical problems of high-end packaging and printing equipment, built a high-speed and high-precision electronic axis control theory and technical system, developed a distributed electronic axis control system integrating synchronization, tension control and defect detection, and invented hot air The energy-saving ink drying system for energy recycling has proposed an online fault diagnosis method based on built-in sensors and support vector machines, and has developed a two-layer operation and maintenance management and control platform of the manufacturer's service cloud and the user's own cloud.
Up to now, the team has developed two types of high-end packaging and printing equipment, the main indicators are at the leading level of similar products in the world, and the intelligent control of the operation and maintenance process of high-end packaging and printing equipment has been realized internationally for the first time, reducing enterprise operation and maintenance costs by more than 40% .
The project results have greatly improved the market competitiveness of domestic high-end packaging and printing equipment, reducing the share of similar foreign products in the Chinese market from 95% to less than 10%, and realizing the reversal of exports greater than imports. The technology application unit of the project results was awarded the 2019 National Technological Innovation Demonstration Enterprise and the first batch of "Manufacturing Individual Champion Cultivation Enterprise" by the state, leading the development of my country's packaging and printing equipment industry and achieving the goal of China's packaging and printing equipment for China.
Solve multiple technical problems of high-end packaging and printing equipment
Professor Mei Xuesong introduced: "Electronic axis control is the key core technology in printing equipment. The focus of our entire project is mainly on three aspects. The first is to improve the printing accuracy and accuracy, the second is to solve the technical problems of ink drying, and the third is Provide online fault detection and cloud services."
The printing materials are generally very thin paper and plastic film. At present, countries all over the world are increasingly demanding energy conservation and emission reduction in the packaging and printing industry, and green packaging printing has become the mainstream of the future development of the global printing industry. Therefore, the paper and plastic film used in printing are getting thinner and thinner, and the thinnest plastic film is even less than 10 microns, which places extremely high technical requirements on packaging and printing equipment.
The electronic shaft transmission printing machine has many advantages such as high speed, high precision, simple structure, good flexibility, low energy consumption, and strong anti-interference ability. Each color that appears on the printed matter is controlled by an electronic axis. After different colors are "mixed and matched" printed in different proportions, colorful packaging printed matter will be formed.
"Printing requires 8 bits for the color depth of digital color images. That is to say, high-end packaging and printing equipment generally has at least 8 axes. The richer the color, the more electronic axes are needed. How to make each electronic axis It can not only complete its own "prescribed actions", but also achieve "seamless connection" with other electronic axes, and realize the synchronization of multiple electronic axes. This is a problem that high-end packaging and printing equipment must solve."
Mei Xuesong introduced that in order for the equipment to print exquisite patterns, it is necessary to control the error within 0.1 mm on the 100-meter-long plastic film on the electronic axis when the online speed exceeds 350 meters per minute. Otherwise, there will be deviations in printed patterns, resulting in "big face" or even blurring.
In order to solve the problem of printing accuracy, the team marked the printing patterns of different electronic shafts from the perspective of "measurement + feedback", found the color group marks through measurement software, and adopted a distributed control method. Each electronic shaft communicates with each other. With a gigabit network as the framework, the real-time performance can reach 1 millisecond, which can ensure the response speed of each electronic axis; each electronic axis can control its own printing accuracy and process, and can also use control algorithms to monitor the film in real time. No matter how many electronic shafts are superimposed, the accuracy error of the printing position is less than 0.1 mm.
Ink drying is also a key link to ensure clear printing patterns. When the printing press is running at high speed, the ink drying must be completed within a very short time after passing through the color group to ensure that each color "returns to its place". Mei Xuesong introduced that the energy-saving ink drying system using hot air energy recycling can not only dry the ink within 0.3 milliseconds, but also timely recover the waste heat, peculiar smell and organic gas generated by the ink after heating. The overall reduction of carbon emissions, the realization of my country's "dual carbon" goal and the safe packaging of food and drugs have very positive significance.
Ink blending is an important task in the color printing process, which is directly related to the printing quality of the product. Bright colors, good brightness, and accurate hue are the basic requirements of color printing products. To meet this requirement, the printing inks of each color group must be accurately deployed. In the past, the work of blending inks had to be done by experienced technicians, and it was more difficult, took a long time to debug, and wasted a lot of printing materials. With the cloud platform, professional knowledge such as ink and equipment can be stored on the cloud platform for users of packaging and printing machinery to query and use. Moreover, each machine can be connected to the Internet, and the operation and maintenance work is completed by the cloud platform.
help equipment localization, the cost is only 20% imported
Before 2007, my country's high-end packaging and printing equipment mainly relied on imports from Germany, Switzerland, Japan and other countries. The price of an imported high-end packaging and printing equipment is about 50 million yuan, causing low-end equipment to flood the market, with poor printing quality, high energy consumption, and high pollution.
With economic development and social progress, my country's demand for high-end packaging and printing equipment is increasing. Mei Xuesong said: "Use the money to buy half of a plane to buy a printing press. The cost is too high, and we want to lower it."
Since 1993, the team of Professor Mei Xuesong has been committed to the research and development of motion control technology for CNC equipment, and has cooperated with relevant industry leaders to start the research and development process of localization of high-end packaging and printing equipment.
"We have mainly adjusted the hardware architecture of the equipment. For example, the previous equipment was a'brain' to control 8 electronic axes, and there may be signal lag, a certain electronic axis reacts "half a beat" slowly, etc. Now it is dismantled. Separately, each electronic axis is controlled by its own "brain", and the high-speed signal transmission between multiple electronic axes guarantees the connection, so that they can not only complete the synchronization and cooperation, but also can adjust their own processes. Each electronic axis can adjust its own process parameters in time through the feedback of the registration error, so as to complete the printing work more accurately." Mei Xuesong said.
In addition, the team also carried out a large number of experiments on the oven structure, heating temperature, wind speed, energy consumption ratio and other factors, and proposed an online fault diagnosis method based on built-in sensors and support vector machines. Each equipment can be connected to the Internet to realize the manufacturer Dual operation and maintenance control with enterprise users.
In the fierce market competition environment, it is precisely by virtue of the excellent technical level that the high-end packaging and printing equipment developed by the team has been favored by many domestic and foreign enterprise users.
"Now, printing companies have bid farewell to the history of buying a printing machine with 50 million yuan. They can buy domestic high-end packaging and printing equipment at one-fifth of the price. According to rough statistics, more than 70% of domestic high-end packaging printing Products are manufactured using our products. In other words, most of the packaging and printing of the items you see in the supermarket are made from domestically produced equipment. We have achieved the goal of'Made in China' to have a'Print in China'! "Mei Xuesong said.
High-end packaging and printing equipment is the result of the interdisciplinary "complex electromechanical control and high-end packaging printing". "High-speed and high-precision motion control technology" is the long-term main scientific research direction of the innovation team led by Professor Mei Xuesong. In the next step, a team of 23 teachers and nearly 200 students will continue to work on the in-depth combination of high-speed and high-precision motion control and laser processing technology, and develop high-end CNC machining equipment and intelligent manufacturing for important industry fields in response to major national needs. system.
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