The transformation and upgrading of intelligent technology equipment in the textile industry

In most people's minds, the spinning industry is a traditional labor intensive industry,and in the era of smart industry, intelligent machines are replacing workers, and textile workerswill step into the battle for opportunities with smart machines.

The latest results from the China Enterprise-Employee Matching Survey (CEES),jointly conducted by the Wuhan University Quality Development Strategy Research Institute, the Chinese Academy of Social Sciences, the Stanford University, and the Hong Kong University of Science and Technology Emerging Markets Institute, show that the actual salary has more than doubled in the past 10 years. Manufacturers are adopting automation technology, investing in research and development, and adding new value-added products.

Recently, the reporter also saw in the intelligent production workshop of biomass regenerated fiber materials in Suzhou Zhenlun Cotton Textile Co., Ltd. that the spacious and tidy workshop maintained a constant temperature and humidity working environment, and a high-speed automatic machine replaced the original one. Rows of textile women workers rushing back and forth in busy scenes, some of which are only a few workers on tour and simple operations, all of which have subverted people's impression of the traditional textile industry.

According to Wu Jiankun, deputy general manager of the company, benefiting from the investment in intelligent equipment and process transformation, the original work of more than 100 people now only needs 20 people, not only the production efficiency is greatly improved, but also the stability of product quality is higher.

"If you want to do something good, you must first sharpen your tools." Enterprises must continue to develop, and they cannot do without the products of "smart weapon." The biomass fiber workshop introduces a large number of fully automated and internationally leading smart devices such as the German cleaning comb and draw frame with the on-line monitoring function, the fine-linking type Zinser spinning machine, and the Japanese fine-connected automatic winder. It realizes the automatic control of the feeding, rotation speed, spinning speed, viscosity, self-winding joint and conveying. The intelligent workshop integrates through digital information technology, and the management systems such as MES and ERP realize the perfect integration of intelligent workshop informationization and ERP data.

In the intelligent workshop, “production automation”, “control system intelligence” and “online monitoring informationization”, Wu Jiankun introduced that each spindle will be connected via sensors, and the system can monitor each spindle in the production line in real time, saving a lot of money. The manpower has improved efficiency. The entire process maintains a high degree of continuity, reducing the chance of artificial contact with the yarn, and the yarn quality is further stabilized and improved, greatly improving production efficiency and labor productivity.

Shen Peirong, chairman of the company, said frankly that labor prices are rising and market competition is becoming increasingly fierce. If you follow the old methods, you will inevitably lose market competitiveness and may even be eliminated. This situation makes the high-rise of Zhenlun Cotton Textile realize that intelligent manufacturing is the breakthrough of traditional industry development, and automation, intelligence and informationization are the only way for enterprise development. "It's not that you want to do it, but the market and the environment force you to do this. Reduce costs, find a way to smart manufacturing, smart manufacturing can double production efficiency, and hope to intelligently hedge labor costs, 'human use The less the more money, the more difficult it is to avoid the textile industry. The future of the textile industry will be less and less, and there will be no way to reduce the employment efficiency. This is the basis of the transformation and upgrading foundation. There is no other way. ”

The reduction in labor and labor intensity, the improvement of work efficiency and added value, the expansion of production capacity, and the guarantee of product quality... The benefits brought by this move are all-round. For example, Shen Pei-rong said: "In 2005, the company used 130 people for 10,000 spindles, and now employs 35 people for biomass and 10,000 spindles. The vortex spinning has only 15 employees. The actual cost per 10,000 spindles is about 3.5 million yuan per year. The bobbin process requires manual operation. Now, each machine is equipped with a robot. It can pull all the 1200 spindles at once, and plug the empty tubes all at once through the robot."

“The update of the equipment has also led to the progress of the process. In the past, our products were mainly made of ordinary ring spinning. Today, we are following the development trend of spinning technology and adopting the Siegel compact spinning process. The same viscose yarn Compared with the yarns of ordinary ring spinning, the siro-spun yarn can sell 3,000 pieces more per ton, and the products are exported to the global textile high-end market. Many domestic and foreign first-line brands are long-term customers of Zhenlun.” Wu Jiankun said .

Since 2008, Zhenlun Cotton Spinning has invested more than 100 million yuan in production equipment every year for several years, and introduced advanced spinning equipment from Germany, Japan, Switzerland and other countries to build a seismic workshop for Zhenlun Biomass.

After several years of deep cultivation, Zhenlun cotton spinning has basically realized the full automation, intelligence and informationization of the workshop. At present, Zhenlun is building a model factory for the whole process of digital automation and intelligent production in the domestic chemical fiber industry. The company's spider system monitoring software will be put into use. This system is like a spider web. The machines are connected and the production process can be realized. Online detection, establish a visual intelligent master control system to achieve data interoperability and integrated management between machines. The company's goal is to create an intelligent spinning factory that integrates production equipment, real-time scheduling of production processes, material transfer automation, product information traceability, workshop environment intelligent monitoring, resource consumption intelligent monitoring, design development and production linkage.

Shen Peirong said that the current textile industry has entered a new historical period. The company takes intelligent manufacturing and green development as the important hands, accelerates the cultivation of new kinetic energy and core competitiveness, and embarks on a road of transformation and upgrading with the support of intelligent technology and equipment.