At the beginning of this year, the “Key Technology Development and Application of Ultra High-speed Digital Printing Equipment” jointly completed by Zhejiang University, Ningbo University, Zhejiang University of Science and Technology and Hangzhou Honghua Digital Technology Co., Ltd. won the second prize of 2017 National Technology Invention. Has caused widespread concern in the industry.

At present, as a new generation of printing equipment that meets the " Made in China 2025" personalized custom production demand and "fast fashion" consumer demand, ultra-high speed digital printing equipment has gradually become an important factor in promoting the transformation and upgrading of the textile printing industry and enhancing the international competitiveness of products. power.

The key technology ultra high-speed digital printing equipment Breakthrough

Honghua Digital Zheng Jing, deputy general manager in an interview with reporters, said the current, ultra-high-speed digital printing there is a large data flow, easy to deformation fabric printing, print quality automatically detect major technical problems and other difficulties, have an urgent need for research and development ultra-high-speed digital printing equipment independent intellectual property rights.

The project of “Key Technology Development and Application of Ultra-High-speed Digital Printing Equipment” won the second prize of National Technology Invention, and broke through a number of key technologies of digital printing: the project invented a real-time parallel processing engine for large-flow digital printing data. The ultra-high-speed real-time processing and transmission of digital printing data; in order to solve the problem of fabric deformation and nozzle clogging during printing, a real-time monitoring and control method based on video printing process was invented; a printing image based on image quality evaluation model was invented. The automatic detection method of quality defects, and remote monitoring of the working state of the equipment through video coding and network transmission, successfully developed ultra-high speed digital printing equipment.

According to Chen Yaowu, a professor at the School of Biomedical Engineering and Instrument Science at Zhejiang University, the high-speed real-time monitoring and control method and system for video-based nozzles proposed by the project is to capture high-resolution patterns in real time through cameras and pre-stored patterns in the system. The image processing system sends the detection result to the nozzle control system in real time through comparison and determination by an algorithm. When the blockage occurs, the nozzle will automatically clean. When ultra-high-speed digital printing equipment is industrially produced, fabric textures and printed image patterns are often complicated, and traditional machine vision inspection systems cannot achieve high-precision real-time micro-defect detection under high-speed production conditions. Once the printing defects occur, a large number of defective products appear, resulting in a serious waste of raw materials is almost inevitable. "By inventing the online automatic detection method and system for printing defects based on high-performance embedded processor, the project team installed the machine's 'eyes of fire' to identify defects. When the system determines that defects are generated, it can pass alarms, automatic shutdown, etc. Reduce losses to a minimum," Chen Yaowu said.

High-quality low-cost environmentally friendly equipment acclaimed

Practical application is an important criterion for verifying the success of a research project. From the academic research to the “last mile” journey of landing application, Honghua Digital has become a major promoter of the project and has gone very solid.

Zheng Jing told reporters that during the implementation of the project, Honghua Digital mainly undertakes the industrialization technology research, industrialization transformation, application promotion and industry standard formulation of large-scale video surveillance system project products. Nowadays, Honghua Digital has successfully launched the VEGA3000DL/DT high-speed digital printing machine and VEGA3000P high-speed digital printing machine based on the key technology of ultra-high-speed digital printing equipment.

VEGA3000DL/DT high-speed digital printing machine is the “flagship” digital printing machine currently promoted by Honghua Digital. The device has four performance characteristics. First, high-speed stability, high-speed data transmission, high-speed scanning and stepping drive, stable production in 24 hours, the daily output reaches 3000~10000 square meters. The second is high-quality, high-precision industrial nozzles, variable dot technology, high-precision tape, high-precision full-closed stepping, high-precision linear motor scanning, the highest printing accuracy of 1800dpi. The third is to save ink and low cost, intelligent cleaning nozzles, reasonable control of ink volume, effective recovery of ink, and the price is very competitive. The fourth is intelligent environmental protection, intelligent patrol positioning, intelligent dual nozzle protection, intelligent analog proofing, and effective environmental protection system.

The characteristics of VEGA3000P high-speed digital printing machine are mainly reflected in the following aspects: stable production in 24 hours, daily output up to 6800~10000 square meters; printing precision up to 1200dpi, application of special high-precision industrial nozzle and variable ink point technology; . Intelligent management of production and ink volume; intelligent and environmental protection, application of intelligent dual nozzle protection to effectively achieve environmental protection.

“These two types of equipment have been well received since they were introduced to the market, and equipment orders have continued. The company’s sales in 2017 increased by 30% compared with 2016. Especially since the second half of 2016, the company’s main digital printing equipment Not only sold well in domestic and Southeast Asian countries, but also successfully entered the European market such as Italy, and was well received by local customers.” Zheng Jing said.

In addition, the energy saving and environmental protection, this process also played an active role. Chen Yaowu said that unlike traditional printing, the ink is applied to the paddle, more than 50% of the dye on the cloth surface will be washed away, resulting in a large amount of high-polluting wastewater. In the ultra-high-speed digital printing process, the use of dyes is distributed by the computer on demand. The consumption of chemical dyes and wastewater discharge are greatly reduced. The wastewater can be recycled after simple treatment, which provides a new possibility for the textile printing industry to be replaced with “green new clothes”.

Innovative R&D provides a complete solution for users

The output of digital printed fabrics has increased year by year, and the demand for digital printing machines has increased. This has not only made the industry generally optimistic about the development of digital printing equipment, but also many foreign companies have begun to enter the field. However, is the digital printing machine really ushered in the market eruption period?

In this regard, vice president of China Textile Machinery Association, Li believes that although digital inkjet printing machine developed rapidly, but is limited by the speed of printing and printing costs, the current yield is still high total number of digital prints, prints in the market than only At 3%, it is not a substitute for traditional printing.

Li said the high-tech integrated digital inkjet printing system, set printing equipment, ink, software and textile pretreatment and finishing technology in one, any one handled badly, can not be completed production orders. At present, the core technology of the digital printing machine, the manufacturing technology of the printing nozzle, is still in the hands of Japanese companies. It has selective requirements for the ink used in the equipment and is expensive. The proportion of the nozzles in the single-machine manufacturing cost is nearly half, and the digital printing The machine nozzle is prone to blockage, the color stability is not high during industrial production, and the maintenance and adjustment techniques are difficult. At the same time, the printing nozzle generally has a service life of only one and a half years. If it is used improperly, the service life may be shorter. Once it is damaged, it cannot be repaired, only replacement, which imposes a heavy burden on the factory. In addition, the highly regarded "Single Pass digital printing machine" is also due to the high cost of the nozzle and the research on the high-speed inkjet printing process of textiles. If the market expands rapidly, the speed may not be reached.

Talking about the development of digital printing equipment, Li Yi said that under the leadership of the “fast market” trend in the downstream apparel market, the online sales platform for small batches and fast delivery orders promoted the transfer of printing paper printers, paint printers and sublimation. The sales growth of printers has driven assembly-oriented equipment companies to develop low-cost equipment, but corporate profits are becoming weaker. To achieve healthy development of the industry, key enterprises with innovative capabilities and R&D capabilities should adhere to the high-end development route, tend to develop and manufacture high-end equipment, and promote high-speed, ultra-high-speed digital printing equipment, including digital printing + round (flat) network. The joint machine, and provide users with a full set of solutions, empowering the printing production enterprises, enabling the printing production enterprises to directly cooperate with the clothing enterprises, and ultimately promote the transformation and upgrading of the textile and garment industry.

This is also the development goal of Honghua Digital's development. Zheng Jing said that as the leading digital printing equipment manufacturer in China, the company is striving to realize how to make traditional printing factories accept digital printing machines for large printed goods orders. Zheng Jing said frankly that to achieve this goal, it is inseparable to greatly reduce the cost of use and further improve the stability of production. Only when this part of the market demand is shaken can it really enter a period of rapid development. In this regard, the company not only needs to strengthen technology research and development, but also strive to improve the market response speed, help customers to quickly achieve return on investment, and promote the further development of digital printing equipment.