How Can We Shorten The Gap Between The Reliability Of Domestic Equipment And The Needs Of Users?

In recent years, our country

The technological level of the equipment has improved by leaps and bounds, not only with better foundation.

The intelligentization of the complete sets of equipment has improved significantly, even though relatively weak printing and dyeing and nonwoven equipment have made considerable progress.

But with these achievements, the reliability of domestic textile machinery is still an embarrassing problem.

A survey of the use of domestic textile machinery shows that up to 81.5% of the users believe that they are made in China.

The stability of the equipment is poor. Therefore, there is still a certain gap between the reliability of domestic equipment and the needs of users.

Then how can we shorten this gap?

Reliability has lost the reputation of domestic spinning machines.

In annual interviews, we often hear enterprises reflect this problem to us.

Foreign equipment to the enterprise, after installation and commissioning, in a week will be able to run smoothly; and domestic equipment is often a month after the operation, and within three months, people have to track, but also often minor problems, had to stop maintenance, not only reduced efficiency, but also increased the maintenance costs of enterprises.

Although many textile machinery enterprises often clap their breasts and say that the price of imported equipment is 1/3 lower than that of imported equipment, the user enterprise generally considers it to be cost-effective to buy imports.

China's textile machinery industry began to carry out reliability work from the end of the 80s to the beginning of the 90 century. The reliability evaluation papers of various textile machinery developed by China Textile Machinery Association have also been released. The reliability of domestic textile machinery products has been greatly improved.

For example, the average working time of foreign roving machines in the same grade was 1800 hours before, while the domestic roving machine was 400 hours better. Later, through the improvement of product reliability in production enterprises, the trouble free working time of the product basically reached the level of the imported machine.

Therefore, the domestic roving machine has a high share in the domestic market and has basically replaced imported products.

However, compared with imported spinning machines, there is still a big gap in the overall level of domestic spinning machines.

Zhu Xianmin, chief engineer of China Textile Machinery Association, believes that the gap is mainly manifested in the following aspects: first, the high failure rate of the main engine, the large gap between the reliability index and the high life cycle cost.

The two is the poor consistency of product quality or accuracy, early failure and life index below the level of international famous brand products.

Three is the equipment running in a long period of time, does not adapt to the user's high quality, high efficiency, low consumption requirements.

At present, textile machinery enterprises generally attach importance to product reliability. Many enterprises have made great efforts to improve product reliability, but often the effect is not obvious.

The reason is that Zhu Xianmin believes that reliability integrates the applications of various disciplines, such as systems engineering, management engineering, value engineering, ergonomics, and so on, and runs through all aspects of spinning machine products from design to manufacture to sales service, involving many aspects such as production, management, manufacturing base and so on.

To improve the reliability of textile machinery, we need to pay attention to all aspects, and at the same time, we need to cooperate in many ways.

Almost thought is difficult to produce.

Talking about the reliability of the domestic spinning machines, Li Ziming, chairman of Huzhou Huasheng Machinery Co., Ltd., speaking of the European International Textile Machinery Exhibition (ITMA2015) not long ago, saw the shock of stoke in Holland: in Holland, stoke did not have a machine in China for ten years. Others thought it was useless. As a result, it launched the first SPG digital printing machine this year, which is the attitude of foreign textile enterprises to make products.

As a matter of fact, how many enterprises in the country have the determination that they are not perfect products, do not have the factory to make decisions, fail to do well, fail to redo the courage, do the best and have the confidence of too many people holding the same ideas, even feel that it is not necessary to be perfect. The machine can not be used for a few years, and it can not escape the fate of elimination if it is done well.

It is precisely this kind of thinking that will not strive for the best in material selection, and it will be difficult to refine in the production process, and naturally it will be difficult to produce good products.

It is precisely because of this idea that even though we have the most factories in the world, there are few top world companies, making it difficult for us to produce sophisticated equipment even with huge manufacturing capacity.

Domestic enterprises often believe that the reliability of products and the quality of products are checked by inspectors. Foreign well-known textile machinery enterprises have no special inspection organizations and inspectors except their external parts, and each process and every post must be self tested.

This is a very big gap between us and foreign advanced enterprises.

The concept of enterprise decision level plays an important role in improving product reliability. Many operators regard their product production and sales as short-term behavior. There is no clear understanding of reliability or misunderstanding, which makes enterprises lack effective reliability management and mechanism.

The higher the degree of reliability is attached to, the greater the reliability of product reliability will be.

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Focus on system integration

In the past, many enterprises regarded reliability as the quality of manufacturing unilaterally, so when it comes to improving product reliability, it only checks from the angle of parts manufacturing, and then expands to assembly.

In fact, reliability is a systematic project that runs through design, manufacture, assembly and after sale service. It should even be combined with national standards and industry standards.

Some countries recognize reliability to the strategic height of industry or enterprise development.

It is precisely because our enterprises do not fully understand the reliability. Therefore, over the past decade, the reliability and reliability of China made textile products have been improved significantly, both in terms of design level and processing capacity.

Hu Xudong, Dean of the school of mechanical and automatic control of Zhejiang Sci-Tech University, said that the following points should be noted in order to improve product reliability.

First, before the design, the R & D Department of the enterprise should compare and test the technical indicators of the existing products and imported products, and find out the advanced points.

The MTBF (mean time between failures) and the quality problems that occurred in the same kind of products are analyzed, the fault points are found, the failure modes and hazards are analyzed, and the improvement measures are put forward.

At the same time, we should make repeated investigations on the site and evaluate the disturbance factors at the scene, so as to ensure the reliability design in the conception stage, to put forward the reliability index and to confirm the reliability plan.

Second, strengthen information collection and management, and accumulate historical data.

The collected information includes installation and debugging information, usage information, fault information, maintenance information, textile quality information, and information about domestic similar products and foreign advanced products.

Through comprehensive analysis and comparison of information, we find weak links and find out the key points to overcome, and put forward corresponding suggestions for improvement.

Third, we should strengthen the construction of testing institutions, attach importance to personnel training, and establish reliability testing standards.

The supply department checks the incoming raw materials according to the standard requirements to ensure the integrity and reliability.

The production department strictly follows the standard production, processing, assembly and commissioning to ensure the reliability of each production link, and the reliability of the products must be checked.

Industry university research cooperation promotes development and upgrading

The improvement of the reliability of textile machinery is the integration of many disciplines. For example, the speed to be solved by textile machinery involves mechanical dynamics; the life of key components involves the wear mechanism of fiber and metal, fiber and ceramics; and the drying equipment of textile materials involves heat pfer dynamics and so on.

It should be noted that there are still many obstacles to the path of independent innovation. The strength of integration of scientific research achievements, knowledge, technology, capabilities and experience is thin after all, and it is a more inevitable choice to take the path of industry university research cooperation to accelerate innovation and development.

Some major, common technology and forward-looking technologies and key equipment, supported by the state, are jointly funded by related enterprises, which not only lower the cost of repeated introduction, but also have their own intellectual property rights, which is conducive to enhancing core competitiveness and forming their own brand products.

In 2011, Chongqing Jinmao Textile Equipment Co., Ltd., Changzhou hang Yue Textile Machinery Co., Ltd., Shanghai Far East wire Clothing Co., Ltd., Wuxi owl Textile Equipment Co., Ltd., Qingdao Fengyi Textile Equipment Co., Ltd. and other 5 steel wire ring production enterprises set up a new generation of textile equipment ring conveyor technology innovation alliance, and cooperated with Tsinghua University national tribology key laboratory to develop the surface treatment technology research project of the steel wire ring. At present, the project has successfully solved the major technical problems of the surface treatment of the steel wire ring.

The life of the traveller treated by this technology reaches more than 15 days (the life of imported high-quality ring travellers is 15 days ~20 days), and the quality reaches the international advanced level.

Practice has proved that whoever can form an industry university research linkage will get the commanding heights of technology.

In addition, enterprises can introduce advanced technology through joint ventures, cooperation, technology pfer, and hiring foreign experts, so as to enhance the quality level of products.

For example, Guangshan white shark Knitting Co., Ltd., located in Henan Province, has jointly established with Guangshan, Spain, Frederick fir, the introduction of Spanish elastic card clothing manufacturing technology and equipment, and has significantly improved its technical level and quality of such products as wool spinning and napping.