Sheet-fed high-end printing presses refer to multi-color printing presses with high speed, high precision and high efficiency. They are sophisticated electromechanical equipment with complex structures and reflect a country's cutting-edge manufacturing technology and level. At the beginning of this century, China became the fastest-growing printing press market, but domestic sheet-fed printing presses were low in speed and efficiency. High-end sheet-fed printing presses with more than 13000 sheets per hour were completely dependent on imports. The price was more than 10 million yuan, which remained high. Core technology was monopolized by a few countries such as Germany and Japan. The key to the development and manufacturing of high-end sheet-fed presses is the paper, ink volume, printing process control technology and digital printing process technology at high speeds. Based on the strategic needs of the country and the industry, this achievement has overcome a series of key technologies after nearly 10 years of industry-university-research research, developed core devices with completely independent intellectual property rights and high-end sheet-fed printing presses, and successfully implemented industrialization. The innovative results are as follows:
(1)Breakthrough through key technologies such as transfer, detection, and timing control related to high-speed paper control, invented high-speed paper transportation, transfer, and handover technology, and developed a high-speed paper inspection system combining optical fiber limited reflection and ultrasonic technology, achieving accurate paper timing control, can adapt to one-sided printing of more than 17000 sheets/hour and two-sided printing of more than 15000 sheets/hour.
(2)Breaking through key technologies such as high precision, strong real-time, and wide printing format of ink layer control, we have developed the first high-performance automatic ink volume control system in China. The ink delivery accuracy of the ink fountain roller reaches 0.002 mm, and the sampling time for ink volume control is less than 2ms. The printing format can adapt to 2000 mm.
(3)It has overcome key technologies such as automatic registration, gap adjustment, loose tail deformation, and ink balance involved in high-precision printing process control, invented a cylinder arrangement structure that adapts to thick paper printing and the minimum number of paper transfers, and developed a printing plate that does not rely on cylinder tilt adjustment. The tilt adjustment device has invented stepless adjustment technology for tooth pad height and paper loose tail pre-deformation technology, with an overprint accuracy of 0.007 mm. A mathematical model of ink balance was established to solve the problem of automatic adjustment of ink under different printing speeds and colors.
(4)It has overcome key technologies such as printing machinery characteristic matching, fault diagnosis, and network control, and developed a digital, networked, and intelligent printing process system that conforms to the international standards of CIP3/CIP4 and supports the integrated management and control architecture of printing companies, which can realize printing operations. Process automation greatly improves printing efficiency.
This achievement has been authorized for 5 China invention patents, 43 utility model patents, and 16 software copyrights. It has formed 3 national standards, 2 industry standards, compiled 1 book, and published 39 papers. Apply for 8 China invention patents, 1 U.S. invention patent, and submit 1 national standard and 5 industry standards for submission. The printing press series products using this achievement have won honorary titles such as national key new products, national independent innovative products, and green equipment awards. The third-party evaluation shows that the comprehensive technology of this achievement has reached the international advanced level, and some technical indicators are at the international leading level. As of 2012, 18 large printing press manufacturing companies in China have selected this achievement, and it has been applied in about 90% of high-end sheet-fed printing press manufacturers. Since 2008, this achievement has been applied in famous foreign printing press manufacturing companies. More than 1,000 printing companies have used this achievement and exported it to Japan, Russia, South Africa, Brazil and other countries. Shanghai Guanghua has grown into China's largest R & D and manufacturing base for high-end sheet-fed printing machines, and Shanghai Huatai has grown into China's largest professional supplier of printing press control systems and devices. This achievement has filled the domestic gap and forced the import price of foreign sheet-fed high-end printing presses to significantly reduce. The market share of domestic sheet-fed high-end printing presses has increased year by year and entered the international market, with significant direct and indirect economic benefits. The application of this achievement has greatly promoted the improvement of printed matter quality and printing efficiency, reduced material waste, and reduced costs, enabled China's printing to develop towards green printing, and promoted the scientific and technological progress of China's printing presses and printing industry as a whole.