By Xi 'an Jiaotong University, Shaanxi Beiren Printing Machinery Co., LTD., Beijing Institute of Printing, Xi 'an Aerospace Huayang Electromechanical Equipment Co., LTD., Weinan Kesai Electromechanical Equipment Co., LTD. Mei Xuesong, Li Yanfeng, Xu Wencai, Zhao Fei, Xue Zhicheng, Huang Xiaojun, Wang Yiming, Chen Liang, Tao Tao and Han Jian won the second prize of the 2020 National Science and Technology Progress Award for the "High-end Packaging and printing Equipment Key Technology and series product Development" project.
In the face of the high-end packaging printing output value of hundreds of billions of yuan market and almost all the previous dependence on imports, the project broke through the bottleneck restricting the high-end packaging printing equipment in the basic theory, key technologies and product development, broke the foreign monopoly, and realized the localization and application of high-end packaging printing equipment.
Break the dependence on industry-university-research cooperation to tackle key problems
Packaging and printing plays an indispensable role in market economic activities such as commodity circulation and product traceability, and is an important part of the national economy. High efficiency, energy saving and environmental protection and exquisite pattern printing have become the main market competitiveness of high-end packaging printing equipment.
Before the implementation of the project, China's high-end packaging and printing equipment almost all rely on imports, a single unit price of about 30 million to 40 million yuan, the high price has become China's packaging and printing enterprises can not bear the heavy, resulting in low-end packaging and printing equipment to dominate the market, low printing precision, high energy consumption, pollution. Independent research and development of high-end packaging and printing equipment has become an inevitable choice to master the initiative of national economic development and people's lives and health.
However, there are many difficulties in the development of high-end packaging printing equipment, including a thin film with a thickness of only 10 microns, which requires high overprinting accuracy; Residual solvent and VOCs emissions must meet national standards; High-end packaging and printing equipment has many precision parts, complex structure, difficult control adjustment and fault tracing. To develop high-end packaging and printing equipment, it is necessary to break through core technologies such as high-speed and high-precision electronic shaft control, ink drying and residue removal, precision manufacturing and intelligent operation and maintenance.
In response to the above problems, since 2007, Xi 'an Jiaotong University, Shaanxi Beiren, Beijing Institute of Printing, Aerospace Huayang, Weinan Kesai and other five units have formed a number of industrial, academic and research groups to jointly tackle the key problems, and have been supported by Shaanxi provincial government and national science and technology support projects and major science and technology projects, with a total investment of more than 200 million yuan in scientific research funds. Basic theoretical research on electronic axis control theory and strategy, ink drying design theory and optimization, fault perception and intelligent operation and maintenance theory are carried out. Key technologies such as integrated electronic shaft, drying oven and waste heat utilization, VOCs processing, fault diagnosis and process optimization for printing equipment; And high-end film gravure printing press and satellite flexographic printing press, intelligent operation and maintenance cloud service platform and other product development.
High-end packaging and printing equipment operation and maintenance control cloud platform
The three innovations have become technology leaders
At present, the core components of high-end packaging and printing equipment electronic shaft control system, central stamping drum, ink oven are all realized domestically, and the technology developed by the project is all applied in batches.
Since the project was completed and put into use, the market share of foreign high-end packaging and printing equipment in China has dropped from 95% to less than 10%, achieving a reversal of exports greater than imports, and the equipment developed has been sold to more than 1,000 packaging and printing enterprises in more than 30 countries and regions such as Europe and the United States, and more than 1,300 domestic enterprises have applied the products of this project.
One of the innovation points of this project is to build the theory and technical system of electronic axis control of packaging and printing equipment.
The project team proposed a full closed-loop control method with overprint error as real-time feedback, and a feedforward auto-disturbance rejection decoupling control strategy based on the overprint error compensation mechanism of the front color group to solve the high-speed and high-precision problem of electronic axis control. The integrated technology of load and inertia on-line identification and error detection is invented to solve the stability problem of electronic shaft control. Research and development of high power direct drive motor, simplify the mechanical structure, solve the electronic shaft control system data communication accuracy and real-time problems.
High-end printing equipment distributed electronic axis control system
The second innovation point is to put forward the design theory and optimization method of hot air drying system of ink.
Including the invention of an efficient drying system based on heat pumps, heat pipes and semi-suspended ovens to solve the problem of material deformation caused by hot air. By precisely controlling the wind speed, temperature and VOCS concentration of the oven valve, maximize the use of waste heat, to solve the printing process energy consumption, green environmental protection problems.
The third innovation point is to develop high-end packaging printing equipment precision manufacturing technology and intelligent operation and maintenance cloud platform.
The platform solves the problem of heat deformation of the central embossed cylinder, making China the only country to master this technology after Italy. At the same time, realize the intelligent online monitoring and fault diagnosis of high-end packaging printing equipment.
Based on the project results, we have developed 2 types of 16 series products, including green gravure printing presses and satellite flexographic printing presses, and a two-layer operation and maintenance control cloud platform for high-end packaging printing equipment. Among them, Shaanxi Beipeople's gravure printing press was selected as the first set of major technical equipment promotion products in China.
In addition, the project has also authorized 103 patents, 32 software Copyrights, published 2 monographs, formed 18 national and industry standards, and become the technology leader of the industry, promoting the scientific and technological progress of China's packaging and printing industry.
