Operation process of automatic dosing system for printing and dyeing
With the development of new textile printing and dyeing processes and new technologies With continuous development, textile printing and dyeing equipment is constantly updated. At present, new equipment is emerging in the printing and dyeing industry in terms of pre-processing, dyeing, printing and finishing. Especially the use of frequency conversion technology and microcomputer technology in electrical drag has greatly improved the synchronization performance of the equipment. Especially as the IT industry gradually enters the textile printing and dyeing industry, new printing and dyeing CAD/CAM technology and information digital technology have brought a new revolution to the printing and dyeing industry.
The printing and dyeing industry is a key industry for deep processing, finishing and increasing added value of textiles. It is a comprehensive reflection of the development and technical level of the textile industry. The textile printing and dyeing industry is my country’s main traditional industry and an important part of my country’s export earnings. However, due to the backward technological level of my country’s textiles, the product quality is low and the added value is low. It has always played a role in the international market. As a supplier of primary commodities, it has become an important factor restricting exports.
Among the key processes that currently affect the quality of printing and dyeing products in the domestic printing and dyeing industry, most of the processes in the dyeing process or printing process (scouring, bleaching, mercerization, weighing and color matching , color paste preparation, etc.) there are ingredients problems. The above batching process is basically controlled manually. The data generated in the entire production process of the enterprise is mainly analyzed and processed manually.
At present, printing and dyeing ingredients are mainly divided into the following aspects:
(1) Printing slurry ratio
(2) Printing auxiliary ratio
(3) Dyeing dye weighing material and laboratory dye ratio
(4) Dyeing auxiliary ratio
(5) Decoction and bleaching auxiliary ratio
Traditional In the proportioning process, the entire process is completed manually, with low precision, poor accuracy, large influence of human factors, high labor intensity, harsh operating environment, poor guidance of small samples for large-scale production, and technical files and materials rely entirely on manual experience. Accumulation and manual recording cannot realize the computer information management of technical files, and cannot complete the online calling and verification of technical data. Therefore, in production, the color is often inaccurate or the sample does not meet the requirements, resulting in the need for repair before leaving the factory. This not only results in delayed delivery, but also wastes manpower and material resources. At present, export products often require that the standards for left, center, and right color difference and intra-batch color difference be above level 4.5, and samples must meet orders above level 4.
The color matching light source has also developed from the original natural light and ordinary office fluorescent lamps to D65, CWF, TL84, U30 and other standard light sources, and the color matching has been increased from one light source to two Various light sources, and even require multiple light sources to not discolor, which are much higher than the requirements of national standards; on the other hand, in the current printing and dyeing industry, imitation color samples still use the method of first making small samples according to customer samples, and then enlarging the samples in the printing machine. In traditional practice, technical personnel who need to undergo a long period of training for sample proofing and color imitation in production can be competent in the color imitation work, so they still rely on experienced technicians to a large extent. As talent flows more frequently, corporate products will become unstable.
For this reason, automatic batching in the printing and dyeing process is bound to be a major issue before us. This article explains the research and international tracking of automatic batching technology in the printing and dyeing industry in recent years.
Current domestic situation
(1) Printing paste ratio and additive ratio
At present, most of the color paste preparation and ratio in China are completed manually, so all formula library management currently relies on manual recording and manual When operating color matching, the control of the entire process is mostly based on manual experience, which leads to poor color matching accuracy and difficulty in meeting customer needs. This often leads to customer refunds or even claims, which brings huge losses to the company.
In terms of printing paste preparation, the control of paste viscosity and the control of additives such as urea and soda ash are all manually controlled, which also directly affects the quality of the entire printed product.
Therefore, some domestic printing and dyeing manufacturers are currently using automatic pulp mixing systems to improve product quality and improve overall automation.
(2) Dyeing dye scale material ratio and laboratory drip material
At present, most domestic dyeing processes use the process of craftsmen issuing a bill of materials according to the formula, and then going to the material room to weigh the dyes. Each dye is weighed manually through an electronic balance. The weighed dye is then sent to the dye vat or high-level tank for dilution before entering production. If color difference occurs during the production process, adjust the formula of the dye in the dye vat or high-level tank.
Using this method, there is often color difference due to inaccuracies in manual weighing.
At present, some manufacturers have adopted automatic powder weighing systems. After inputting the formula into the computer, the computer automatically controls the powder warehouse according to the amount of material weighed, and the machine automatically weighs the dye as required. Supplied to the barrel. Although this method is highly automated, since the powder tank cannot be made too large, when weighing dark-colored materials (that is, when weighing a large amount of materials), usually more than 5KG, you have to rely on manual weighing. In addition, the moisture absorption problem in the dye warehouse also affects the error of weighing materials. In addition, the flying dust during the weighing process of powder dyes will also have a negative impact on the color and light of the formula.��Open the corresponding solenoid valve, and the dye is sent to the measuring cup of the electronic scale using the siphon principle. The entire system completes database optimization and batching control through the database management system.
The latest technological progress
(1) Automatic batching in the printing and dyeing process Application development
At present, many foreign manufacturers began to use some automatic batching technologies in the 1980s. They used computer pulp mixing systems for printing and automatic solid dye mixing systems for dyeing. The material weighing system uses an online controlled automatic proportioning system for additive proportioning.
Our country also introduced automatic batching systems for printing and dyeing in the early 1990s, but the usage conditions were not ideal. In the late 1990s, Hangzhou Kaiyuan Computer Technology Co., Ltd. These systems have been developed and put into use by manufacturers, and the overall response has been good, which has also promoted the application of these technologies in the entire industry.
In addition, in terms of additive ratio, there is currently no technology introduced in China, but we are currently doing research and development in this area, but the most important thing is application practice. We will also have new breakthroughs in applications recently.
(2) Technical development of automatic batching in printing and dyeing process
Currently The development trend of this technology is mainly to make some new breakthroughs in the following aspects: (1) using printing and dyeing product database expert systems for production management; (2) networked information technology application platforms; (3) using sensor technology to control the amount of ingredients and ingredients The concentration, consumption, etc. are fully controlled.
Conclusion
Printing and dyeing is a traditional industry, but after entering the WTO , has brought a great opportunity to China’s textile printing and dyeing, but the quality requirements for textile printing and dyeing products abroad are also constantly improving, and at the same time, it has also put forward higher requirements for our Chinese printing and dyeing enterprises. To this end, we must speed up technological transformation and improve Enterprise management is an urgent task in the current textile printing and dyeing industry.
In recent years, the development of computer technology has enabled textile printing and dyeing to develop from labor-intensive to automated and information-based. Frequency control technology, computer control technology, electronic color separation technology, electronic Screen making technology and digital printing technology have been gradually and successfully applied to printing and dyeing enterprises, promoting the application of new technologies in the printing and dyeing industry. Printing and dyeing equipment widely applies information technology, automatic control technology, network remote communication and other technologies, which will greatly improve production automation, continuity and intelligence, and provide technical support for printing and dyeing processing to enter real-time and accurate production.
To this end, the use of computer automation and information technology to transform the traditional printing and dyeing production process ingredients can not only meet the needs of user companies to reduce costs, improve product quality, and speed up product update cycles. demand, and shorten the gap between my country’s textiles and the international advanced level, enhancing the competitiveness of products. Build a solid platform to promote printing and dyeing enterprises to move towards high technology and improve information construction. </p
