Intelligent digital printing, gilding and die cutting process

Abstract

The application discloses an intelligent digital printing and gold stamping die cutting process, which integrates six processes of constant tension feeding, pre-positioning accurate correction, digital UV printing and instant curing, target searching and synchronous intelligent gold stamping, register linkage die cutting forming, waste discharge and material collection into the same continuous production line, and the printing material continuously moves in the whole process, and the whole process processing can be completed only by once feeding and once material collection. Through CCD visual correction, printing synchronous mark searching and positioning and triple closed loop register control technology, seamless connection and accurate alignment of three core processes of printing, gold stamping and die cutting are realized, and the overall register accuracy can reach ±0.1mm; meanwhile, local gold stamping and variable data gold stamping are supported, and the decoration effect and added value of the label product are greatly improved. Compared with the traditional decentralized production mode, the application is suitable for intelligent continuous production of various products such as adhesive labels, anti-fake labels and daily chemical labels.

Description

Technical Field

[0001] This invention relates to the field of label printing and processing technology, and in particular to an intelligent digital printing, hot stamping and die-cutting process. Specifically, it relates to an intelligent continuous production process that deeply integrates three core processes: digital UV printing, hot stamping enhancement and die-cutting. It is especially suitable for high-precision, high-efficiency and flexible production of self-adhesive labels, anti-counterfeiting labels, daily chemical product labels, food and drug labels and other products. Background Technology

[0002] With the rapid development of the packaging and printing industry, label products are increasingly demanding higher requirements for decorative effects, anti-counterfeiting performance, production efficiency, and customization capabilities. In the traditional label production model, the three core processes—digital UV printing, hot stamping, and die-cutting—are completed by separate digital printing machines, hot stamping machines, and die-cutting machines, respectively. These machines operate independently and are distributed across different locations, forming a segmented production process. This decentralized production model has been widely used in the industry for a long time, but as market demands upgrade, its inherent technical shortcomings are becoming increasingly apparent.

[0003] Chinese invention patent application CN118683177A discloses an integrated machine combining printing, hot stamping, and die-cutting functions. It integrates the feeding mechanism, varnishing mechanism, hot stamping mechanism, die-cutting mechanism, and winding mechanism into the same machine frame, realizing the physical splicing of multiple processes at the structural level, which reduces the equipment footprint and the transfer distance between processes to a certain extent. However, this technical solution is merely a simple parallel combination of equipment modules and does not achieve deep integration and intelligent linkage at the process level. Firstly, the hot stamping process does not establish a precise closed-loop feedback mechanism with the graphic positions of the front-end digital printing, lacking real-time positioning and dynamic adjustment capabilities based on printing synchronization marks. In actual production, the registration accuracy of hot stamping and printing is still difficult to break through ±0.3mm, which cannot meet the high-precision registration requirements of high-end labels. Secondly, the control systems of each process are independent of each other, and the operating parameters need to be debugged and set separately. The changeover debugging time is long, the parameter matching degree is low, and it is difficult to adapt to the flexible production needs of small batches and multiple batches. Thirdly, the solution does not set up pre-correction and full-process tension closed-loop control. Material deviation and tension fluctuations are prone to cumulative errors, resulting in insufficient stability for long-term continuous production.

[0004] Chinese invention patent CN104002571B discloses a UV printing hot stamping process and a UV matte varnish. While it enhances the adhesion of the hot stamping layer through two rounds of UV printing combined with a special UV matte varnish, the process still requires separate screen printing and hot stamping equipment. This necessitates manual transfer, rewinding, and alignment between processes, resulting in a lengthy production flow. Multiple loading and unloading operations generate significant waste at both ends, and repeated positioning increases cumulative errors, further reducing registration accuracy. Furthermore, the process lacks an integrated die-cutting step, preventing a single loading operation from printing to finished product, thus limiting production efficiency improvements.

[0005] Chinese invention patent CN110126440B discloses a modular flexographic printing press system for label printing and its production process, integrating flexographic printing, cold foil stamping, and die-cutting. However, it uses traditional flexographic printing methods, which fall under the category of analog printing. This results in long plate-making cycles and high costs, making it impossible to achieve variable data printing and personalized customization. Furthermore, the cold foil stamping process used is weaker than hot foil stamping in terms of metallic luster, foil layer adhesion, and abrasion resistance, limiting the decorative effect and product quality enhancement. In addition, the registration control of this solution only applies to the printing and die-cutting processes, failing to achieve a triple closed-loop registration across printing, foil stamping, and die-cutting. For high-end label products that simultaneously involve printing, foil stamping, and irregular die-cutting, the registration accuracy still cannot meet the requirements.

[0006] In general, the existing label printing production model mainly suffers from the following six core technical pain points: The equipment is scattered, and the production process is lengthy: In traditional production models, digital UV printing machines, hot stamping machines, and die-cutting machines are multiple independent pieces of equipment. Label materials need to go through multiple loading and unloading processes: "feeding → digital printing → rewinding → unwinding → hot stamping → rewinding → unwinding → die-cutting → receiving." Each machine operates separately, requiring manual transfer and rewinding alignment between processes. The production chain is long, with many intermediate links, resulting in high logistics and turnover costs. Even some integrated equipment is mostly a simple structural assembly, failing to achieve true process continuity, and there are still waiting and connection losses between processes.

[0007] High reliance on manual labor and significant overall losses: Due to the independent operation of multiple machines, each process requires dedicated operators responsible for tasks such as material loading, alignment, debugging, process monitoring, and material collection, resulting in high labor costs. Frequent loading, unloading, roll changing, and alignment operations not only increase the intensity of manual labor but also easily lead to problems such as material waste at the beginning and end of the roll, and scrapping due to positioning deviations. The overall material loss rate is typically between 8% and 12%, further increasing production costs.

[0008] High proportion of non-productive time and low production efficiency: Non-productive time such as material transfer between equipment, realignment, and roll change debugging account for a large proportion of the total production time. In the traditional decentralized mode in the industry, the effective production time accounts for only 60% to 70%, with a large amount of time consumed in roll change, alignment, waiting, and equipment debugging. At the same time, it is difficult for the operating rhythm of each piece of equipment to be perfectly matched, which easily leads to the accumulation of work-in-process or waiting in the process, making it difficult to further improve the overall production efficiency.

[0009] Limited efficiency enhancement functions and limited product added value: Most existing equipment are single-function models. Even some integrated equipment can only achieve basic full-page hot stamping or simple partial hot stamping. There is a lack of in-depth integration solutions for digital printing and hot stamping efficiency enhancement. It is impossible to achieve high-end efficiency enhancement effects such as variable data hot stamping and sheet-by-sheet differentiated hot stamping. It is difficult to meet market demands such as personalized customization and high-end anti-counterfeiting. The space for increasing product added value is limited.

[0010] Multiple positioning steps lead to large cumulative errors, making it difficult to guarantee registration accuracy: Production methods involving multiple loading and unloading processes and repeated re-alignment result in accumulated positioning errors at each stage, causing a gradual decrease in the registration accuracy between the hot stamping position and the printed pattern, and between the die-cutting outline and the hot stamping image. In traditional decentralized production models, the overall registration accuracy of printing-hot stamping-die-cutting typically only reaches ±0.3mm to ±0.5mm. For intricate graphics, narrow-border labels, and high-precision anti-counterfeiting labels, quality problems such as hot stamping misalignment and die-cutting deviation are highly likely to occur, resulting in a low finished product pass rate.

[0011] The dispersed equipment layout results in a large footprint: multiple independent machines, plus material buffer areas and transfer channels between processes, occupy a large overall area, leading to low workshop space utilization and hindering workshop layout optimization and capacity expansion. For manufacturing enterprises with high land costs, site occupancy costs become a significant burden.

[0012] In response to the numerous shortcomings of the existing technologies, the industry urgently needs a process solution that can deeply integrate digital UV printing, intelligent hot stamping and die-cutting to achieve continuous, intelligent and high-precision production throughout the entire process, fundamentally solving the efficiency, precision, cost and functional bottlenecks of the traditional decentralized production mode. Summary of the Invention

[0013] To address the shortcomings of existing technologies, the purpose of this invention is to provide an intelligent digital printing, hot stamping, and die-cutting process. This process deeply integrates three core steps—digital UV printing, hot stamping enhancement, and die-cutting—into an intelligent continuous production line, achieving a continuous production mode of "one-time loading, full completion." This simplifies the production process, reduces manual intervention, improves production efficiency, and reduces material waste. Simultaneously, closed-loop registration control technology ensures high-precision registration, and the deep integration of digital printing and hot stamping enables diverse enhancement functions, increasing product added value and effectively reducing equipment footprint and optimizing workshop layout.

[0014] This invention addresses the technical shortcomings of existing integrated equipment, which only involves physical splicing of mechanisms, independent control of each process, accumulation of multiple positioning errors, and insufficient overall registration accuracy. It provides a digital printing, hot stamping, and die-cutting integrated process with three-level closed-loop registration throughout the entire process. The process converges positional errors layer by layer from the feeding end to the finished product end, achieving a high registration accuracy of ±0.1mm in continuous production mode, while ensuring production stability, reducing material waste, and expanding efficiency-enhancing functions.

[0015] The above-mentioned objective of this invention is achieved through the following technical solutions: A smart digital printing hot stamping and die-cutting process includes the following steps: Step S1, Constant tension feeding: Install the roll of label printing material on the unwinding shaft, and continuously feed the printing material with constant tension through a closed-loop tension control system, with the feeding tension fluctuation controlled within ±5%. Step S2, Pre-printing Precision Correction: Before the printing material enters the printing unit, the lateral position of the printing material is detected and dynamically adjusted in real time by a CCD vision correction device, and the correction accuracy is controlled within ±0.05mm. Step S3, Digital UV Printing and Instant Curing: The substrate enters the digital UV printing unit and is digitally inkjet printed according to the preset printing graphic data. After printing, it is simultaneously cured by a UV-LED curing device to form a printed graphic layer with satisfactory adhesion and a dry surface. Step S4, Intelligent Hot Stamping with Tracking: The printed substrate is directly and continuously fed to the hot stamping unit. The tracking sensor identifies the synchronous mark next to the printed image and obtains the real-time position information of the printed image. Based on this position information, the hot stamping timing and lateral position of the hot stamping component are controlled in a closed loop to perform precise hot stamping at the designated position of the substrate and form a hot stamping decorative layer. Step S5, Registration and Die-cutting: The hot-stamped substrate is continuously fed to the die-cutting unit. The die-cutting unit performs registration calibration based on the position information of the printed image and the hot-stamped layer, and cuts the substrate into individual label units according to the preset die-cutting pattern. Step S6, Waste Removal and Finished Product Collection: The die-cut printing material is cleaned of edge waste by the waste removal device, and the finished labels are collected by the winding mechanism or by the single-sheet collection mechanism. Throughout the entire process, the printing material is fed continuously, with only one loading and one unloading operation. The three processes of printing, hot stamping, and die-cutting are seamlessly connected and closed-loop registration control is achieved, with an overall registration accuracy of ±0.1mm.

[0016] Furthermore, in step S1, the closed-loop tension control system uses an unwinding magnetic powder brake in conjunction with a high-precision tension sensor to form a closed-loop feedback loop. The unwinding speed is linked in real time with the linear speed of subsequent printing, hot stamping, and die-cutting processes. The production line's operating linear speed ranges from 10 to 80 m / min and can be steplessly adjusted according to product type and process requirements. The printing substrate includes, but is not limited to, any one of self-adhesive paper, PET film, PVC film, synthetic paper, and aluminum foil. The applicable material thickness ranges from 25 μm to 300 μm, covering the substrate requirements of most label products.

[0017] Furthermore, in step S2, the CCD visual correction device includes a linear CCD image acquisition unit, a correction calculation controller, and a servo-driven correction execution mechanism. The linear CCD image acquisition unit acquires real-time images of the position of the side baseline or edge of the printing material using a high-speed scanning method. The correction calculation controller calculates the lateral deviation of the material through an image edge extraction algorithm and outputs a high-precision adjustment signal to drive the servo correction execution mechanism, which in turn drives the feeding rack or intermediate guide roller group to perform lateral displacement adjustment. The correction response time is ≤10ms, which can effectively correct lateral position deviations caused by uneven roll material, material deviation, and tension fluctuations, providing a precise feeding reference for subsequent printing processes.

[0018] Furthermore, in step S3, the digital UV printing unit adopts an industrial-grade piezoelectric inkjet printhead array with an inkjet physical resolution of no less than 1200×1200dpi. It supports any combination of CMYK four-color printing, spot color printing, white ink printing, and varnish printing, enabling various printing effects such as color graphics, solid colors, white background contrast, and spot varnishing. The UV-LED curing device uses a water-cooled UV-LED lamp assembly with an emission wavelength of 365~395nm. The surface curing energy can be precisely adjusted within the range of 80~200mJ / cm² according to the ink type and printing speed. After curing, the adhesion of the printed graphic layer reaches the Class 0 standard specified in GB / T9286-1998, and the surface abrasion resistance is ≥500 times, meeting the scratch and wear resistance requirements of label products.

[0019] Furthermore, in step S4, the targeting sensor is a high-speed photoelectric targeting sensor or a CCD vision targeting sensor, and the synchronization mark is a cross mark or rectangular mark pre-printed on the side of the substrate by a digital printing unit, with the mark spacing strictly consistent with the longitudinal spacing of the label layout. The hot stamping assembly adopts a rotary hot stamping roller structure, with a built-in multi-zone independent heating module, allowing for precise adjustment of the hot stamping temperature within the range of 80~160℃, with a temperature control accuracy of ±1℃; the hot stamping pressure is controlled by a precision pneumatic pressurization mechanism, with a pressure range of 0.2~0.8MPa, and the hot stamping line speed is synchronized with the overall line speed of the production line in real time through an electronic gear ratio, ensuring stable consistency of hot stamping pressure and stamping time under different production speeds.

[0020] Furthermore, the intelligent hot stamping in step S4 supports two working modes: partial hot stamping and variable data hot stamping. In partial hot stamping mode, by pre-setting the hot stamping area vector data, the hot stamping component is controlled to perform hot stamping transfer only in a specified local area of ​​the printed graphics, achieving precise matching between graphics and hot stamping. In variable data hot stamping mode, combined with the variable graphics information output by the digital printing unit, the hot stamping position and hot stamping pattern outline are adjusted for each label, achieving differentiated hot stamping effects for different labels within the same roll. This can be widely used in the production of high-end products such as personalized custom labels and anti-counterfeiting traceability labels.

[0021] Furthermore, in step S5, the die-cutting unit adopts a servo-driven rotary die-cutting roller structure, and the die-cutting blade roller uses a high-precision carbide blade with excellent edge sharpness and wear resistance. The die-cutting depth is precisely controlled by a differential screw adjustment mechanism with an adjustment accuracy of ±0.01mm, which can precisely control the die-cutting depth according to different material thicknesses, achieving half-through die-cutting or full-through die-cutting. The die-cutting unit has a built-in registration feedback module, which collects the position data of the printing synchronization mark and the hot stamping edge in real time through a high-speed vision sensor, and dynamically adjusts the rotation phase and lateral offset of the die-cutting roller to achieve triple registration calibration of the die-cutting contour, printed graphics, and hot stamping decorative layer, thereby eliminating cumulative positioning errors from a mechanism perspective.

[0022] Furthermore, an online printing quality inspection process is set between steps S3 and S4. A high-speed linear array vision inspection system performs 100% full-width real-time inspection of the printed graphics, automatically identifying printing defects such as insufficient ink, broken lines, color registration deviation, pattern defects, and smudges. Defective products are electronically marked, and the inspection data is fed back to the printing control system in real time for dynamic correction of parameters such as ink volume and printhead phase, achieving closed-loop control of printing quality. Between steps S4 and S5, a hot stamping quality inspection process is set. A vision inspection system identifies defects such as positional deviation of the hot stamping layer, missed stamping, incomplete stamping, and bubbling, and simultaneously feeds this information back to the hot stamping control module for automatic compensation of temperature and pressure parameters, ensuring stable hot stamping quality.

[0023] Furthermore, in step S6, the waste removal device adopts a combined waste removal structure that combines negative pressure waste suction with mechanical stripping. The die-cut edge waste is first initially separated by the stripping roller, and then the waste is adsorbed and transported to the waste winding roller for winding and recycling by the negative pressure waste suction pipe. The waste removal is stable and reliable, and is suitable for removing waste from various complex die-cut shapes. The winding mechanism adopts a composite winding structure of center winding plus surface pressure roller. The winding tension is automatically reduced as the roll diameter increases through a taper control algorithm, ensuring that the neatness of the winding end face is ≤0.5mm. The maximum winding roll diameter can reach 600mm, reducing the frequency of roll changes and increasing continuous production time.

[0024] Furthermore, the entire process is centrally controlled by an intelligent control system. This system integrates printing control, hot stamping control, die-cutting control, tension control, web guiding control, and quality inspection modules. These modules communicate and link parameters in real time via the Profinet industrial bus. The central intelligent control system has a built-in process parameter database storing mature process parameters for different materials and product types, supporting one-click access and rapid order changeovers. Order changeover and debugging time is reduced by more than 70% compared to traditional equipment. Simultaneously, the system supports integration with the factory's MES (Manufacturing Execution System), enabling real-time uploading of production data, intelligent order allocation, production progress monitoring, and equipment operation and maintenance management, meeting the digital management needs of intelligent factories.

[0025] In summary, compared with the prior art, the present invention has at least one of the following beneficial technical effects: Significantly simplifying the production process and achieving true continuous production: This invention deeply integrates the three core processes of digital printing, hot stamping, and die-cutting, which were originally scattered across multiple independent machines, into a single production line. This completely eliminates intermediate steps such as manual transfer, rewinding, and multiple alignments between processes, achieving a fully continuous production model of "one-time loading, complete process." The production process is simplified from the traditional 6-8 process nodes to a single linear flow, significantly reducing logistics and intermediate management costs, and making the production organization model more concise and efficient.

[0026] Significantly improves production efficiency and reduces non-productive time: Through continuous material feeding and seamless connection throughout the entire process, non-productive time such as waiting for transfers between equipment, roll changing and alignment, and repetitive debugging is completely eliminated, increasing the effective production time from the traditional 60%~70% to over 90%. Under the same capacity conditions, production efficiency is increased by 30%~40%, and output per unit time is significantly increased. At the same time, the one-click order change function of the central control system greatly shortens product changeover time, making it particularly suitable for flexible production scenarios with small batches and multiple shipments.

[0027] Reduced labor requirements and material waste lower overall production costs: The integrated production line requires only one operator to monitor and operate the entire process, reducing the number of operators by more than 60% compared to the traditional decentralized model, thus significantly reducing labor costs. Simultaneously, by eliminating the waste generated from multiple loading and unloading operations and alignment adjustments, the overall material loss rate is reduced from the traditional 8%~12% to 3%~5%, reducing material waste by more than 25%, significantly lowering production costs and increasing product profit margins.

[0028] Enhancing the efficiency of hot stamping and significantly increasing product added value: This invention, through deep data linkage between digital printing and hot stamping processes, can not only achieve conventional full-page hot stamping and partial hot stamping, but also high-end enhanced effects such as variable data hot stamping and sheet-by-sheet differentiated hot stamping. It can meet diverse market demands such as personalized customization, high-end anti-counterfeiting, and brand upgrading, significantly improving the decorative, anti-counterfeiting, and grade-of-life aspects of label products, increasing product added value by 20% to 50%, and helping enterprises expand into the high-end market.

[0029] Triple closed-loop registration control ensures high-precision production quality: A three-level closed-loop control system—including pre-positioned CCD correction, synchronous printing marking and positioning, and die-cutting registration feedback—controls positional accuracy throughout the entire process from material feeding to finished product, completely resolving the cumulative error problem caused by traditional multiple positioning methods. The overall registration accuracy of printing-hot stamping-die-cutting reaches ±0.1mm, far exceeding the ±0.3mm~±0.5mm level of traditional decentralized production methods. This meets the quality requirements of high-end products such as fine graphics, narrow borders, and high-precision anti-counterfeiting labels, increasing the finished product qualification rate to over 98%.

[0030] Saving space and optimizing workshop layout: Compared to a layout with multiple independent machines and buffer areas, an integrated production line can reduce the overall floor space by about 40%, significantly saving workshop space resources. At the same time, the layout of a single production line is more regular, which facilitates workshop logistics planning and capacity expansion, and helps enterprises optimize production layout and increase productivity per unit area. Attached Figure Description

[0031] Figure 1 This is a flowchart of the independent production process of a digital UV printing machine in the existing technology; Figure 2 This is a flowchart of the independent production process of a die-cutting machine in the existing technology; Figure 3 This is a simplified flowchart of the overall process structure of the intelligent digital printing hot stamping and die-cutting process described in this invention.

[0032] Figure 4 This is an overall flowchart of the intelligent digital printing, hot stamping, and die-cutting process described in this invention. Detailed Implementation

[0033] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0034] First, the traditional decentralized production process will be explained with reference to the accompanying drawings to clearly demonstrate the improvement basis and innovation of this invention.

[0035] like Figure 1 The diagram shows the independent production process of a digital UV printing machine in the prior art. Traditional digital UV printing is a standalone, independent process. The specific steps are as follows: First, the material is loaded onto the unwinding shaft of the printing machine. Then, the material is released by the unwinding mechanism, undergoes simple mechanical alignment, and enters the digital UV printing unit for printing. After printing, it is cured by a UV curing device. Finally, the rewinding mechanism rewinds the printed semi-finished product back into a roll. The entire process requires at least one operator to handle loading, alignment, adjustment, and rewinding. The printed semi-finished product needs to be manually transferred to the next process equipment to await hot stamping or die-cutting. This independent process only completes the printing function and cannot perform subsequent enhancements or forming processes. Furthermore, the rewinding and subsequent unwinding processes result in material loss at both ends.

[0036] like Figure 2 The diagram shows the independent production process of a die-cutting machine in the prior art. The traditional die-cutting process is also a standalone operation. The specific process is as follows: First, the semi-finished roll material with printing or hot stamping completed is installed onto the unwinding shaft of the die-cutting machine for secondary feeding and alignment adjustment; then, the material is fed out, and after positioning and correction, it enters the die-cutting unit for cutting and shaping; after die-cutting, the waste material is removed by a waste removal device; finally, the finished product is collected by a rewinding mechanism or a single-sheet collection mechanism. This process also requires at least one operator, and because it involves secondary feeding, re-alignment calibration is required, which is not only time-consuming but also introduces new positioning errors, making it difficult to guarantee the registration accuracy with the previous process. If a hot stamping process is also included, an additional independent hot stamping equipment operation is required, further lengthening the production chain and increasing error accumulation.

[0037] like Figure 3 and Figure 4 As shown, the intelligent digital printing, hot stamping, and die-cutting process of this invention is carried out continuously in a linear process of "material feeding → correction → digital printing → intelligent hot stamping → die-cutting → waste removal → material collection". The substrate material is kept in a continuous feeding state throughout the process, without rewinding, transfer, or secondary feeding in the middle, truly realizing the completion of the entire process from raw materials to finished labels in one feeding.

[0038] The following three specific embodiments illustrate the process details and implementation effects of the present invention. Those skilled in the art can fully reproduce the technical solution of the present invention and achieve the expected technical effects based on the content disclosed in this specification.

[0039] Example 1: Production of Coated Paper Self-Adhesive Labels This embodiment uses common 80g coated paper self-adhesive labels as the production object to explain in detail the specific implementation process and process parameters of the present invention.

[0040] The printing material used in this embodiment is an 80g coated paper face stock + water-based adhesive + glassine backing paper self-adhesive roll, with a roll width of 320mm, a roll diameter of 400mm, and a total material thickness of approximately 150μm. The hot stamping material is a general-purpose gold electroplated aluminum foil with a thickness of 12μm.

[0041] The production line consists of a feeding unit, a CCD correction unit, a digital UV printing unit, an online printing inspection unit, an intelligent hot stamping unit, a hot stamping inspection unit, a rotary die-cutting unit, a waste removal unit, a receiving unit, and a central intelligent control system. All units are arranged sequentially along the material feeding direction, sharing the same frame and feeding path. The central control system uses an industrial-grade PLC with a touchscreen architecture, and all units communicate via a Profinet bus.

[0042] Step S1: Constant tension feeding: Install and lock the self-adhesive roll onto the unwinding shaft. After threading the material around the guide rollers, introduce it into the subsequent unit. Activate the closed-loop tension control system, setting the nominal unwinding tension to 15N. The system provides braking force through a magnetic powder brake at the unwinding shaft end. The tension sensor detects the strip tension in real time and forms a closed-loop feedback, controlling tension fluctuations within ±5%, meaning the actual tension is stable within the range of 14.25~15.75N.

[0043] The feeding speed is linked to the main production line speed. In this embodiment, the main production line speed is set to 30 m / min. The feeding unit automatically matches this speed and adjusts the unwinding shaft speed in real time according to changes in the roll diameter to maintain a constant strip speed. The feeding unit is also equipped with a roll diameter detection sensor and a receiving platform, enabling rapid material receiving without stopping the machine and further improving continuous production capacity.

[0044] Step S2: Precise pre-positioning correction: After the material strip is fed out of the feeding unit, it first enters the CCD vision correction unit. The CCD vision correction device used in this embodiment includes a 2048-pixel linear CCD camera, an LED strip light source, a correction controller, and a servo-driven intermediate guide roller assembly. The linear CCD camera acquires image data of the right edge of the material strip in real time at a scanning frequency of 5000 lines per second. The correction controller calculates the actual lateral position of the material strip using a sub-pixel edge extraction algorithm and compares it with a set reference position to obtain the lateral deviation.

[0045] When the material strip deviates laterally, the correction controller outputs a control signal to drive the servo motor to adjust the lateral displacement of the intermediate guide roller group. The correction response time is 8ms, and the correction accuracy is controlled within ±0.05mm. Through pre-correction, the lateral position of the material strip is ensured to be accurate and consistent when it enters the printing unit, eliminating feeding deviations caused by uneven roll material and skewed feeding, and providing a reliable foundation for subsequent printing registration.

[0046] Step S3: Digital UV Printing and Instant Curing: The corrected tape smoothly enters the digital UV printing unit. This embodiment uses a digital UV printing unit equipped with a 4-color CMYK piezoelectric printhead array, a physical resolution of 1200×1200 dpi, and a maximum printing width of 330 mm. Label printing image data is pre-imported into the control system, with a 4-column × N-row array layout. The label size is 60 mm × 40 mm. A 2 mm × 2 mm square synchronization mark is printed on the right side of each label column, with the vertical spacing of the mark matching the vertical spacing of the label, both being 45 mm.

[0047] During printing, the printhead precisely jets ink according to the graphic data, and the ink ribbon passes through the printing area at a uniform speed of 30 m / min. After printing, the ink ribbon immediately enters the UV-LED curing unit. This embodiment uses a water-cooled UV-LED lamp assembly with a wavelength of 385 nm and a curing energy of 120 mJ / cm². The ink is fully cured within 0.1 seconds, forming a dry, highly adhesive printed graphic layer. Testing shows that the cross-cut adhesion of the cured printed graphic reaches level 0, and the 45° angle rubber abrasion resistance reaches 600 cycles, meeting the requirements for self-adhesive labels.

[0048] During the printing process, the automatic printhead maintenance system regularly cleans and moisturizes the printheads to ensure stable inkjet quality. The central control system monitors the working status of each printhead in real time and automatically activates a compensation printing algorithm when nozzle blockage occurs to minimize printing defects.

[0049] Online Printing Quality Inspection: After printing and curing, the tape passes through an online printing quality inspection unit. This unit is equipped with a high-speed linear array vision inspection system with a resolution of 300 dpi. The inspection speed is synchronized with the production line, performing 100% full-screen inspection of the entire tape. The system automatically identifies printing defects such as insufficient ink, broken lines, color registration deviation, pattern defects, smudges, and ink splatter, electronically marking the defect locations and recording their coordinate information.

[0050] The detection data is fed back to the printing control module in real time. When a regular color registration deviation occurs, the system automatically adjusts the printhead phase of the corresponding color group for compensation. When a certain color is too light overall, the system automatically adjusts the ink volume of the corresponding ink path, achieving closed-loop control of printing quality. For products with serious defects, the system will mark or reject them in the subsequent die-cutting and receiving stage to ensure the finished product pass rate.

[0051] Step S4: Intelligent Hot Stamping with Tracking Synchronization Printed and inspected tapes do not require rewinding and are directly and continuously fed to the intelligent hot stamping unit. This embodiment adopts a rotary hot stamping structure, equipped with a gold-plated electroplated aluminum foil unwinding and rewinding mechanism, a hot stamping roller with a diameter of 200mm, and six built-in independent heating modules.

[0052] Before entering the hot stamping unit, the material strip first passes through a high-speed photoelectric tracking sensor. The sensor accurately identifies the square synchronization marks printed on the side of the material strip, and sends a synchronization trigger signal to the hot stamping control system for each detected mark. The hot stamping control system calculates the actual feed speed and phase of the material strip in real time based on the synchronization signal, and controls the rotation speed and phase of the hot stamping roller through electronic gear ratios to ensure precise alignment between the hot stamping pattern and the printed text.

[0053] This embodiment employs a partial hot stamping mode. Vector data for the hot stamping area is pre-imported into the control system. The hot stamping area is the brand logo area at the top of the label, measuring 20mm × 8mm. The hot stamping temperature is set to 120℃ with a temperature control accuracy of ±1℃; the hot stamping pressure is set to 0.4MPa, stably controlled by a precision pressure regulating valve. The hot stamping roller and the impression roller are precisely aligned, accurately transferring the gold aluminum layer on the electroplated aluminum foil to the designated area of ​​the printed image, forming a glossy hot stamping decorative layer.

[0054] After hot stamping is completed, the waste film of the electroplated aluminum foil is automatically wound up by the winding mechanism, and the material strip continues to be conveyed forward. Through synchronous control of the alignment, the registration accuracy of hot stamping and printing in this embodiment can be stably controlled within ±0.08mm, which is far higher than the registration level of traditional independent hot stamping equipment.

[0055] Hot stamping quality inspection: After hot stamping, the strip passes through the hot stamping quality inspection unit. A vision inspection system identifies defects such as positional deviations, missed spots, incomplete stamping, bubbles, and scratches. Inspection data is fed back to the hot stamping control module in real time. When incomplete stamping is detected, the system automatically adjusts the hot stamping temperature or pressure to compensate. When positional deviations occur, the system automatically adjusts the phase of the hot stamping rollers to ensure consistently stable hot stamping quality.

[0056] Step S5: Alignment and Die-cutting Forming The hot-stamped strip is continuously fed to the rotary die-cutting unit. In this embodiment, a servo-driven high-precision rotary die-cutting roller is used. The die-cutting roller is made of carbide, with high blade sharpness and good wear resistance. The die-cut shape is consistent with the label outline and is a 60mm×40mm rounded rectangle.

[0057] The die-cutting unit has a built-in registration feedback module that uses a high-speed vision sensor to collect the printing synchronization marks on the material strip in real time, while simultaneously identifying the edge position of the hot stamping area. The actual positions of these two marks are compared with the phase of the die-cutting roller to calculate the die-cutting registration deviation. The system dynamically adjusts the rotation phase and lateral position of the die-cutting roller through a servo motor to achieve triple registration calibration of the die-cutting outline, printed graphics, and hot stamping layer.

[0058] In this embodiment, the die-cutting depth is set to half-cut, meaning it only cuts through the face material and adhesive layer without severing the backing paper. The die-cutting depth is precisely adjusted via a differential screw mechanism with an adjustment accuracy of ±0.01mm. In this embodiment, the die-cutting depth is set to 0.12mm, which just cuts through the face material and adhesive layer while preserving the integrity of the backing paper. Through triple registration control, the overall registration accuracy of die-cutting, printing, and hot stamping is stabilized within ±0.1mm, completely eliminating the cumulative error of traditional multiple positioning.

[0059] Step S6: Waste Discharge and Finished Product Receiving: After die-cutting, the material strip enters the waste removal unit. In this embodiment, a combination of mechanical peeling and negative pressure suction is used for waste removal. The material strip first passes through the peeling roller, and the edge waste separates from the label backing paper under the reverse tension of the peeling roller. The separated waste edges are then absorbed by the negative pressure suction port and transported through a pipeline to the waste winding roller for winding and recycling. The waste removal process is stable and smooth, and even die-cut waste with complex shapes can be reliably peeled off without problems such as waste breakage or waste carrying.

[0060] After waste removal, the backing paper strip with the finished labels enters the winding unit. This embodiment uses a center-wound winding structure with surface pressure rollers. The winding tension adopts a tapered control mode, with an initial tension of 12N. As the roll diameter increases, the tension decreases proportionally to ensure consistent tension between the inner and outer layers and neat end faces. The neatness of the winding end faces is controlled within 0.3mm, and the maximum winding roll diameter can reach 600mm. A single roll can hold tens of thousands of finished labels.

[0061] After the roll is finished, you get a finished label roll that integrates printing, hot stamping, and die cutting. It can be used directly for subsequent labeling without any further processing.

[0062] The entire production process is centrally controlled by an intelligent control system, which displays real-time information such as the operating status, process parameters, production speed, output, and yield of each unit. Operators only need to set product parameters and process requirements on the main control panel, and the system can automatically call up mature process parameters from the database and start production with one click. Production data can be uploaded to the factory's MES system in real time, realizing digital management of the entire production process.

[0063] In this embodiment, only one operator is needed for monitoring and material changing of the entire production line. Compared with the traditional model of three operators for three independent machines, the manpower is reduced by 67%. The production speed is 30m / min, the effective production time accounts for 92%, and the overall production efficiency is improved by 38% compared with the traditional model. The overall material loss rate is about 4.2%, which is reduced by about 60% compared with the traditional model. The overall qualified rate of finished products reaches 98.5%, and the product quality is significantly improved.

[0064] Example 2: Production of PET film anti-counterfeiting labels This embodiment uses 25μm transparent PET film anti-counterfeiting labels as the production object, and focuses on illustrating the application and parameter configuration of the present invention in variable data hot stamping and high-precision anti-counterfeiting label production.

[0065] Raw material and product requirements: The printing material is 25μm transparent PET film, with a roll width of 350mm, and self-adhesive and release liner on the back. The product is a variable data anti-counterfeiting label, with each label having a unique variable QR code and serial number, and a differentiated hot stamping anti-counterfeiting mark in the corresponding position. The registration accuracy of printing-hot stamping-die-cutting is required to be ≤±0.1mm.

[0066] Constant tension feeding: Due to the thinness and easy stretching and deformation of PET film material, the nominal feeding tension in this embodiment is set at 8N, with tension fluctuations controlled within ±3%. A low-inertia magnetic powder brake and a high-precision tension sensor are used to ensure stable strip tension and avoid material stretching and deformation affecting registration accuracy. The production line speed is set at 20m / min to balance production efficiency and fine processing quality.

[0067] Pre-cCD correction: A CCD vision correction device is used, with the printing baseline on the side of the PET film as the correction reference, rather than the material edge, to further improve correction accuracy. The correction accuracy is controlled within ±0.03mm, with a response time of 10ms, ensuring accurate and stable feeding position of thin materials.

[0068] Digital UV printing and instant curing: The printing unit is equipped with 6 printheads, including CMYK four-color ink, white ink, and varnish. First, a white background is printed on the PET film as a backdrop. Then, color graphics, variable QR codes, and serial numbers are printed. Finally, a partial varnish layer is printed. High-opaque UV white ink is used, and two layers are printed to ensure adequate coverage. Variable data is automatically generated by the system, and each label's QR code and serial number are uniquely matched.

[0069] The UV curing process employs a two-stage curing configuration: a first-stage semi-curing is performed after printing white ink, and a second-stage complete curing is performed after printing color ink and varnish. The total curing energy is 150 mJ / cm², ensuring excellent ink adhesion on the PET film, achieving a cross-cut adhesion test level of 1 or higher. Synchronous markings, using black cross marks, are printed on both sides of the material strip for easy and precise positioning at multiple workstations.

[0070] Variable Data Intelligent Hot Stamping: This embodiment adopts a variable data hot stamping mode, with the hot stamping unit equipped with a CCD vision tracking sensor and a high-precision servo hot stamping roller. The system binds the variable data information of each label to the hot stamping pattern data one by one. After the tracking sensor identifies the synchronous mark of each label, the system calls up the hot stamping data of the corresponding label and dynamically adjusts the phase of the hot stamping roller and the local hot stamping area to achieve differentiation in the hot stamping position and shape of each label.

[0071] In this embodiment, the hot stamping pattern is a micro-anti-counterfeiting texture, with each label having a unique hot stamping texture that corresponds to the variable QR code information, providing strong anti-counterfeiting capabilities. The hot stamping temperature is set to 110℃, the hot stamping pressure to 0.3MPa, and thin electroplated aluminum foil is used, resulting in high-definition hot stamping edges without smudging or burrs. Through variable data hot stamping, the label's anti-counterfeiting level is significantly enhanced, making it difficult to counterfeit.

[0072] Triple registration die-cutting: The die-cutting unit uses a high-precision servo die-cutting roller, and the die-cutting shape is an irregular rounded rectangle. It has a built-in vision registration system that simultaneously recognizes the edges of printed marks and hot stamping textures, performs dual position calibration, and dynamically adjusts the die-cutting phase and lateral position. Due to the high resilience of PET material, the die-cutting depth is set to full-through die-cutting, with depth accuracy controlled within ±0.01mm, ensuring complete cutting without damaging the backing paper.

[0073] Through closed-loop control of the entire process, the overall registration accuracy of printing-hot foil stamping-die-cutting in this embodiment is stable within ±0.08mm, which fully meets the high precision requirements of high-end anti-counterfeiting labels, and the finished product qualification rate is over 98%.

[0074] Waste Disposal and Sheet Collection: Since this product is delivered sheet by sheet, a sheet collection mechanism is used after waste disposal. A peeling plate peels the finished labels from the backing paper, and a conveyor belt transports them to the receiving station for neat stacking. The backing paper is then wound up and recycled by a backing paper winding mechanism. The entire receiving process is automated and requires no manual handling.

[0075] This embodiment fully demonstrates the advantages of the present invention in the production of variable data, personalized, and high-precision anti-counterfeiting labels. It deeply integrates the variable data capability of digital printing with hot stamping efficiency and die-cutting, realizing the production of high-end anti-counterfeiting labels that traditional processes cannot achieve, and greatly expanding the value space of label products.

[0076] Example 3: High-speed production of thick paper food labels This embodiment uses 250g white cardboard food labels as the production object to illustrate the application and effect of the present invention in a high-speed production mode.

[0077] Raw materials and production requirements: The printing material is 250g food-grade white cardboard, with a roll width of 300mm and a material thickness of approximately 300μm. The product is a general food label, with high demand, requiring high-speed, large-volume production while maintaining both production efficiency and quality stability.

[0078] High-speed constant tension feeding: The feeding tension is set to 25N to meet the tension requirements of thick paper materials, with tension fluctuations controlled within ±5%. The production line speed is set to 60m / min to achieve high-speed mass production. The feeding unit is equipped with a large-diameter unwinding shaft, with a maximum unwinding diameter of 600mm, reducing the number of roll changes and increasing continuous production time.

[0079] Fast response correction: High-speed photoelectric correction combined with CCD auxiliary calibration is adopted, with a correction response time of 5ms, which can meet the position adjustment requirements under high-speed material feeding. The correction accuracy is ±0.05mm, ensuring stable position during high-speed feeding.

[0080] High-speed digital UV printing: Employing a high-speed industrial-grade piezoelectric printhead array, the printing resolution is 600×1200dpi, increasing printing speed while ensuring print quality. The UV-LED curing device uses a high-power lamp assembly with a curing energy of 180mJ / cm², ensuring complete ink curing and achieving the required adhesion at a speed of 60m / min. High-contrast black markings are used for simultaneous printing, facilitating subsequent high-speed marking and identification.

[0081] High-speed synchronous hot stamping: The hot stamping unit uses a large-diameter hot stamping roller, coupled with a high-speed photoelectric tracking sensor, achieving a tracking response frequency of up to 2000 times / minute, fully adaptable to a production speed of 60m / min. The hot stamping temperature is set at 140℃, and the hot stamping pressure is 0.6MPa. High-speed electroplated aluminum foil is used to ensure adhesion and gloss at high speeds. The registration accuracy between hot stamping and printing is consistently within ±0.1mm.

[0082] High-speed die-cutting and waste removal: High-precision rotary die-cutting rollers are used, with die-cutting speed synchronized with the production line and precise control over die-cutting depth. The waste removal unit adopts a powerful negative pressure waste suction system, adaptable to waste stripping and conveying at high speeds, ensuring stable and uninterrupted waste removal. The winding adopts a dual-station winding mechanism, which can realize automatic roll changing without stopping the machine, further improving continuous production efficiency.

[0083] In this embodiment, the production line operates at a stable speed of 60m / min, with a daily output of over 100,000 labels. The production efficiency is more than twice that of the traditional decentralized mode, while maintaining excellent registration accuracy and finished product quality, making it very suitable for large-scale production of general-purpose labels.

[0084] To enable those skilled in the art to more fully understand the technical solution of the present invention, the core control principle of the present invention, the triple closed-loop quasi-control system, is described in detail below.

[0085] The high-precision alignment capability of this invention is not achieved by a single device, but through a three-level closed-loop control system of "feed end correction - inter-process alignment synchronization - die-cutting end triple calibration", forming a full-process position accuracy control chain.

[0086] The first-level closed loop: the pre-positioned CCD correction closed loop. Before the material tape enters the printing process, CCD vision inspection and a servo correction actuator control the lateral position deviation of the material tape within ±0.05mm, eliminating feeding position errors at the source and providing a unified position reference for all subsequent processes. This is the foundation of the entire registration system; if the feeding position deviation is too large, the adjustment range of subsequent processes will not be able to compensate.

[0087] The second-level closed loop: Hot stamping alignment synchronization closed loop. After the printing process is completed, the synchronization mark is integrally formed with the graphic, and its position is relatively fixed. The hot stamping unit obtains the actual position of the graphic by recognizing the printing synchronization mark, and adjusts the phase and lateral position of the hot stamping roller based on this, achieving precise registration between hot stamping and printing. This level of closed loop eliminates longitudinal and lateral deviations caused by tape stretching and speed fluctuations, ensuring the positional accuracy of hot stamping relative to printing.

[0088] The third-level closed loop: the die-cutting triple registration closed loop. The die-cutting unit simultaneously collects the position information of the printing synchronization mark and the hot stamping edge. Based on the actual positions of the two, it dynamically adjusts the phase and lateral position of the die-cutting roller to ensure that the die-cut contour is simultaneously aligned with the printed graphics and the hot stamping layer. This level of closed loop eliminates the residual errors of the first two processes as well as the deformation errors of the hot stamping strip, ultimately ensuring the overall registration accuracy of the finished product.

[0089] The three-stage closed-loop system is progressive and complementary, with each stage controlling the positional error within an extremely small range, ultimately achieving a comprehensive alignment accuracy of ±0.1mm for the entire production line. This is something that cannot be achieved in traditional decentralized production with multiple independent positioning operations, and it is one of the core creative innovations of this invention.

[0090] Meanwhile, constant tension control throughout the entire process is also a crucial guarantee for alignment accuracy. Through multi-stage closed-loop tension control during feeding, intermediate traction, and retraction, the tension of the strip remains stable and deformation is minimal throughout the entire production process. This avoids material expansion and contraction deformation caused by tension fluctuations, thus ensuring the stability of positional accuracy from a physical perspective.

[0091] The integrated production line corresponding to this invention adopts a linear modular layout, with all process units arranged sequentially along the material feeding direction, sharing the same machine frame and feeding system, resulting in a compact overall structure. Taking a conventional 320mm wide production line as an example, the entire line is approximately 8 meters long, 1.5 meters wide, and occupies an area of ​​approximately 12 square meters.

[0092] In the traditional decentralized model, a digital printing machine of the same width occupies approximately 6 square meters, a hot stamping machine approximately 5 square meters, and a die-cutting machine approximately 5 square meters. Including intermediate buffers and transfer channels, the total footprint is at least 25 square meters. In contrast, the integrated production line of this invention reduces the footprint by more than 50%, significantly saving workshop space.

[0093] Meanwhile, the layout of a single production line is well-organized, requiring only connection to a power supply, air supply, and ventilation system to commence production. The installation and commissioning cycle is short, facilitating workshop capacity planning and expansion. For manufacturing enterprises, more production lines can be arranged within the same workshop area, significantly increasing capacity per unit area.

[0094] The intelligent digital printing hot stamping and die-cutting process described in this invention can be widely used in the production of various label products such as self-adhesive labels, anti-counterfeiting labels, daily chemical labels, food and drug labels, and electronic labels. It is compatible with various printing materials such as paper, film, and synthetic paper. The process parameters can be flexibly adjusted, which can meet the high-speed production of large-volume general products as well as the flexible production of small-volume customized products.

[0095] The technologies involved in this process, such as digital UV printing, servo control, visual inspection, and closed-loop control, are all mature and reliable technologies in the current industrial field. This invention organically integrates these technologies through innovative process integration and control logic design, forming an integrated production process with significant technological advantages. This solution does not rely on special materials or rare equipment and can be fully realized and stably mass-produced under existing industrial manufacturing conditions, possessing outstanding industrial practicality and promotional value.

[0096] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An intelligent digital printing hot stamping and die-cutting process, characterized in that, Includes the following steps: Step S1, Constant tension feeding: Install the roll of label printing material on the unwinding shaft, and continuously feed the printing material with constant tension through a closed-loop tension control system, with the feeding tension fluctuation controlled within ±5%. Step S2, Pre-printing Precision Correction: Before the printing material enters the printing unit, the lateral position of the printing material is detected and dynamically adjusted in real time by a CCD vision correction device, and the correction accuracy is controlled within ±0.05mm. Step S3, Digital UV Printing and Instant Curing: The substrate enters the digital UV printing unit and is digitally inkjet printed according to the preset printing graphic data. After printing, it is simultaneously cured by a UV-LED curing device to form a printed graphic layer with satisfactory adhesion and a dry surface. Step S4, Intelligent Hot Stamping with Tracking: The printed substrate is directly and continuously fed to the hot stamping unit. The tracking sensor identifies the synchronous mark next to the printed image and obtains the real-time position information of the printed image. Based on this position information, the hot stamping timing and lateral position of the hot stamping component are controlled in a closed loop to perform precise hot stamping at the designated position of the substrate and form a hot stamping decorative layer. Step S5, Registration and Die-cutting: The hot-stamped substrate is continuously fed to the die-cutting unit. The die-cutting unit performs registration calibration based on the position information of the printed image and the hot-stamped layer, and cuts the substrate into individual label units according to the preset die-cutting pattern. Step S6, Waste Removal and Finished Product Collection: The die-cut printing material is cleaned of edge waste by the waste removal device, and the finished labels are collected by the winding mechanism or by the single-sheet collection mechanism. Throughout the entire process, the printing material is fed continuously, with only one loading and one unloading operation. The three processes of printing, hot stamping, and die-cutting are seamlessly connected and closed-loop registration control is achieved, with an overall registration accuracy of ±0.1mm.

2. The intelligent digital printing hot stamping and die-cutting process according to claim 1, characterized in that, In step S1, the closed-loop tension control system uses an unwinding magnetic powder brake in conjunction with a tension sensor to form a closed-loop feedback. The unwinding speed is linked in real time with the line speed of subsequent printing, hot stamping, and die-cutting processes. The production line operating line speed ranges from 10 to 80 m / min. The printing substrate includes any one of self-adhesive paper, PET film, PVC film, synthetic paper, and aluminum foil paper, with a material thickness range of 25 μm to 300 μm.

3. The intelligent digital printing hot stamping and die-cutting process according to claim 1, characterized in that, In step S2, the CCD vision correction device includes a linear CCD image acquisition unit, a correction calculation controller, and a servo-driven correction execution mechanism. The linear CCD image acquisition unit acquires the position image of the side baseline or edge of the printing material in real time. The correction calculation controller performs edge extraction and deviation calculation on the image and outputs an adjustment signal to drive the servo correction execution mechanism to drive the feeding rack or intermediate guide roller group to perform lateral displacement adjustment. The correction response time is ≤10ms, which effectively corrects the lateral position deviation caused by material deviation and uneven roll.

4. The intelligent digital printing hot stamping and die-cutting process according to claim 1, characterized in that, In step S3, the digital UV printing unit adopts an industrial-grade piezoelectric inkjet printhead array with an inkjet physical resolution of not less than 1200×1200dpi, supporting any combination of CMYK four-color printing, spot color printing, white ink printing, and varnish printing; the UV-LED curing device adopts a water-cooled UV-LED lamp group with an emission wavelength of 365~395nm, and the surface curing energy can be adjusted within the range of 80~200mJ / cm². After curing, the adhesion of the printed graphic layer reaches the Class 0 standard specified in GB / T9286-1998, and the surface abrasion resistance is ≥500 times.

5. The intelligent digital printing hot stamping and die-cutting process according to claim 1, characterized in that, In step S4, the tracking sensor is a high-speed photoelectric tracking sensor or a CCD vision tracking sensor. The synchronous mark is a cross mark or rectangular mark pre-printed on the side of the substrate by a digital printing unit, and the mark spacing is consistent with the vertical spacing of the label layout. The hot stamping assembly adopts a rotary hot stamping structure with a built-in partitioned heating module. The hot stamping temperature can be precisely adjusted within the range of 80~160℃, with a temperature control accuracy of ±1℃. The hot stamping pressure is controlled by a pneumatic pressurization mechanism, with a pressure range of 0.2~0.8MPa. The hot stamping line speed is synchronized with the overall line speed of the production line in real time.

6. The intelligent digital printing hot stamping and die-cutting process according to claim 1 or 5, characterized in that, The intelligent hot stamping in step S4 supports two modes: partial hot stamping and variable data hot stamping. In partial hot stamping mode, by pre-setting the hot stamping area vector data, the hot stamping component is controlled to perform hot stamping transfer only in a specified local area of ​​the printed graphics. In variable data hot stamping mode, by combining the variable graphics information output by the digital printing unit, the hot stamping position and hot stamping pattern outline are adjusted for each label to achieve differentiated hot stamping effects for different labels within the same roll, meeting the needs of personalized customization and anti-counterfeiting.

7. The intelligent digital printing hot stamping and die-cutting process according to claim 1, characterized in that, In step S5, the die-cutting unit adopts a servo-driven rotary die-cutting roller structure, the die-cutting blade roller adopts a high-precision carbide blade, and the die-cutting depth is precisely adjusted by a differential screw mechanism with an adjustment accuracy of ±0.01mm. The die-cutting unit has a built-in registration feedback module, which collects the position data of the printing synchronization mark and the hot stamping edge in real time through a high-speed vision sensor, and dynamically adjusts the rotation phase and lateral offset of the die-cutting roller to achieve triple registration calibration of the die-cutting outline, the printed graphics, and the hot stamping decorative layer.

8. The intelligent digital printing hot stamping and die-cutting process according to claim 1, characterized in that, An online printing quality inspection process is set between steps S3 and S4. A high-speed linear array vision inspection system performs 100% full-width real-time inspection of the quality of the printed graphics, automatically identifying defects such as insufficient ink, broken lines, color registration deviation, and pattern defects. Defective products are electronically marked, and the inspection data is fed back to the printing control system in real time for dynamic correction of ink volume and phase parameters. A hot stamping quality inspection process is set between steps S4 and S5. Visual inspection identifies defects such as positional deviation of the hot stamping layer, missed hot stamping, and incomplete hot stamping, and synchronously feeds back to the hot stamping control module for parameter compensation.

9. The intelligent digital printing hot stamping and die-cutting process according to claim 1, characterized in that, In step S6, the waste discharge device adopts a combined waste discharge structure that combines negative pressure waste suction and mechanical peeling. The die-cut corner waste is first initially separated by the peeling roller, and then the waste is absorbed and transported to the waste winding roller by the negative pressure waste suction pipe for winding and recycling. The winding mechanism adopts a composite winding structure with center winding and surface pressure roller. The winding tension is automatically reduced as the roll diameter increases through the taper control algorithm to ensure that the neatness of the winding end face is ≤0.5mm, and the maximum winding roll diameter can reach 600mm.

10. The intelligent digital printing hot stamping and die-cutting process according to claim 1, characterized in that, The entire process is uniformly managed by a central intelligent control system, which integrates printing control module, hot stamping control module, die-cutting control module, tension control module, web guiding control module, and quality inspection module. The modules communicate and link parameters in real time through an industrial bus. The central intelligent control system has a built-in process parameter database, which supports one-click access to process parameters for different materials and products. It also supports access to the factory's MES production management system to realize real-time uploading of production data, intelligent order allocation, production progress monitoring, and equipment operation and maintenance management.

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