Energy Saving And Intelligence, Domestic Air-Jet Looms Have Good Prospects For Development And Development.

As a big textile country, our country has thousands of textile factories, and the weaving varieties are different.

With the development of society and the improvement of living standards, people's demand for product quality has also increased. The weaving technology, weaving speed and weaving quality of the existing textile industry can no longer meet the growing demand of people.

The emergence of high speed and high quality air-jet looms greatly alleviates this phenomenon.

What is the development process of air jet loom technology in China?

What is the development level of air jet looms in China?

In the development trend of intelligent manufacturing, what direction will the air-jet looms go in the future?

On these issues, the reporter interviewed Xi'an Polytechnic University professor Shen Danfeng and Shaanxi Changling textile machinery and Electronics Technology Co., Ltd. (hereinafter referred to as Changling spinning and weaving company) Deputy General Manager Wang Hua.

Speaking of the development of air jet looms in China, Shen Danfeng said that in the past 30 years, the market share of domestic air-jet looms has been negligible, and has grown to a half of the situation, and has made considerable progress.

According to Wang Hua, the introduction, development and scale production of air jet looms began in the early 90s of last century.

In 1992, in order to get rid of the passive situation that many textile machines rely on imports, the technology of "automatic winding machine and shuttleless loom technology import and localization" was included in the national major technology import and absorption project during the "85" period.

The "two machine" special project is a huge national system project, which includes 7 main hosts, such as automatic winder, air-jet loom, shuttle loom, blowing carding machine, warping machine, sizing machine, combing unit, etc., which are used in the main process of textile technology. There are 21 sub items for these main engines, such as oil-free air compressor, electronic control system and special accessories.

The second largest item in the project is the introduction of the whole set of production technology of ZA205i/ZA209i air-jet loom at that time.

The Changling textile and electric company has undertaken the "jet weaving machine control box" sub item, and imported the air jet loom electric control technology and manufacturing technology from Japan's Tianjin Tian Ju company, and developed China's first jet weaving machine control box, which has all the core technology of the air jet weaving electrical control box, filling the blank of our country's air-jet loom technology field.

With the introduction of the technology, the usage of electronic control system of air-jet looms has increased rapidly.

Up to now, Changling spinning and weaving company has accumulated PZK303/500/600 electric control box to reach tens of thousands of units, and the manufacturers are all over the country, which can match air-jet looms produced by many enterprises such as Changling, Japan, Titan, Xianyang textile machinery and so on.

This is followed by the twenty years of the development of the domestic textile machinery industry, and the manufacturers and accessories manufacturers of domestic air-jet looms have sprung up like mushrooms.

According to the market demand, Changling spinning and weaving company has developed the advantage of air jet weaving machine control box, and began to independently develop CA082 series air-jet loom in 2008.

On the basis of this, the technology of back-up injection is adopted to improve the weft insertion efficiency and reduce the consumption of the air valve. The warping and coiling functions increase the positive and negative speed, select the positive and negative sequence, and improve the adaptability of the loom to the yarn according to the functions of stopping and driving. The embedded real-time operation system and the large screen color touch display are used to output more information and operate more conveniently. The ARM control technology and the embedded real-time operation system in the operation and display part enhance the product performance while improving the integration of the air-jet loom electronic control system. It has the advantages of low cost, long working hours, powerful functions and high performance price ratio, and the performance is the leading position in the country, reaching the advanced level of the similar products. According to Wang Hua, the main control system of the product adopts a reasonable control chip and adopts three eye weft detection technology to improve the identification ability of the colored yarn.

For the development direction of air-jet loom technology, Shen Danfeng believes that the biggest difference between air-jet looms and other shuttleless looms is that they use air jet weft insertion technology to achieve higher speed.

If we do not consider the adaptability of raw materials, we will have an inherent advantage in the insertion rate of machinery, which is also the biggest magic weapon to compete with alternatives.

The design of modern air-jet looms should take this advantage to the extreme.

But to a certain extent, high-speed means high energy consumption and high energy consumption, but it is also a major disadvantage of air-jet looms compared to rapier looms and loom looms.

In the process of weaving, the energy consumption of the jet loom is mainly concentrated in two parts: the air compressor which supplies compressed air and the motor that drives the loom, in which the electric power of 60%~80% is used on the air compressor which supplies the compressed air.

At the same time of increasing vehicle speed, saving the air consumption of weft insertion is a new requirement for the development of air-jet looms.

Shen Danfeng introduced that from the perspective of the development trend of international air-jet looms, the emphasis of equipment control technology is no longer to increase vehicle speed and increase the insertion rate, but gradually develop towards energy saving and broadening the adaptability and intellectualization of air-jet loom weaving products after the insertion rate reaches 2800m/min~3500m/min.

"Simply obsessed with air-jet loom speed and insertion rate is unscientific.

Through a lot of statistics and experiments, we can conclude that under the same weaving conditions, the weft insertion rate increased from 1400m/min to 1800m/min, the speed increased by 30%, the energy consumption increased by more than 45%, the noise increased by more than 25%, but the output increased by only more than 20%.

Starting from China's national conditions, and considering factors such as sizing technology level, spinning level and related management level, the weft insertion rate of domestic air-jet looms in factories in the next few years is ideal at 1500m/min~1800m/min.

"Shen Danfeng said.

CA092 air-jet loom

According to Wang Hua, according to the requirements of users for increasing the speed and consumption of air-jet looms, in 2014, Changling spinning and weaving company developed the first batch of 8 energy-efficient CA092 air-jet looms and delivered them to Shaanxi Wuhuan group.

CA092 air-jet loom is a new energy saving and consumption reducing product developed by Changling spinning and weaving company on the basis of CA082 air-jet loom and co operated with Xi'an Polytechnic University.

The CA092 air-jet loom adopts the advanced modular technology of integrated technology of light, machine, electricity and gas, and integrates many patent technologies. It has the characteristics of low energy consumption, high efficiency, stable quality and wide variety adaptability, especially the intelligent control of weft insertion system, which greatly reduces the consumption of gas and has high cost performance.

CA182 air-jet loom developed by Changling spinning and weaving company

2018 China International Textile Machinery Exhibition and ITMA Asia exhibition, Changling spinning and weaving company first used air-jet loom flat weave openings to weave three fabric, with high efficiency and high cloth quality.

In addition, the CA182 air-jet loom developed by the company represents the most advanced air-jet loom technology in China. It mainly embodies in: solid and stable rack and enhanced design pmission system, optimized design of beating up system, intelligent weft insertion system with low consumption, rich optional configuration (including APR, WBS, folding edge) and two-way network to realize intelligent management of weaving process.

Taking a look at the development of domestic air-jet looms in recent years, Shen Danfeng believes that while we see progress, we should clearly realize the deficiency: Although there are some innovations in technology, the basic structure of the domestic air-jet looms is still in the stage of imitation of Japanese products, with poor independent innovation ability and lack of core technology; the quality control consciousness of the supporting manufacturers of all the specialized air-jet looms is not strong enough, and the requirement for doing fine and meticulous still has a long way to go; the market homogenization and low level competition are serious, and the profitability of the enterprises is poor, and the R & D investment is insufficient.

Shen Danfeng suggested that as the development and manufacturer of domestic air-jet looms, emphasis should be laid on the following aspects.

First, the development of intelligent expert system.

There are thousands of textile factories in China. The weaving varieties are very different. There is an urgent need for a large number of advanced processes and talents to ensure that the qualified products can be produced with reasonable energy consumption.

However, many small weaving enterprises in China still lack such talents.

Therefore, developing an expert system for weaving intelligence with its own characteristics is particularly important.

The expert system for weaving intelligence should include many kinds of machine parameters, the adjusting range and steps of each part, and the automatic setting function of important parameters.

In the weaving process, the loom control system will automatically adjust the output value of the pneumatic pressure, the opening and closing time of the solenoid valve and the rotation speed and angle of the servo system automatically according to the feedback parameters of the weft arrival, the fluctuation of the pressure and the change of tension, etc., and automatically adjust the output value of the pneumatic valve, the opening and closing time of the electromagnetic valve, and the rotation speed of the servo system, so as to achieve the smoothness and efficiency of the weaving process, and reduce manual intervention.

At the same time, ensure the low energy consumption in the production process and achieve the purpose of energy saving.

Second, research and development of online cloth inspection system.

With the continuous improvement of air-jet loom's electrical control level and the maturity of CCD detection technology, the development of on-line inspection system for air-jet looms has already had a fairly reliable technical foundation and controllable cost budgeting.

First, the electrical control system can completely record the real-time warp and weft stop records, parameter requirements and texture formats of looms, and make cloth inspection system have good adaptability to cloth surface detection.

Secondly, the weaving speed of most air-jet looms is about 15cm/min ~ 100cm/min. The speed of single CCD lens scanning and subsequent image processing can meet the requirements.

Finally, the electrical control system and cloth inspection system can achieve interactive control and unified man-machine interface. The quality control of cloth surface can achieve good real-time performance and avoid large scale cloth quality accidents.

Third, the development of automatic operation management system.

At present, the air-jet looms used in China have been processed and repaired manually after the warp and weft stop.

Under normal circumstances, the average vehicle handling time is 3~10 times per hour, which takes about 2~10 minutes.

With the rising cost of human resources and the increasingly difficult recruitment of textile mills, the development of air-jet looms automatic operation management system is imminent.

Among them, APR automatic weft removal will be the key development area of air-jet loom control technology in the next five years.

First of all, the weft stop automatic operation system and the weft automatic yarn changing system that meet the weaving characteristics of our country should be introduced, and then the automatic operation system of meridional parking will eventually realize the automatic operation and management control of air-jet looms.

Wang Hua said that in recent years, according to the demand of the market, Changling textile and electric company has made full use of the potential of R & D and production of textile electronic equipment for many years and the advantages of the air-jet loom control box, integrating the characteristics of various looms, constantly carrying out technological innovation, and actively developing high level air-jet looms with unique technical advantages.

They have successively made bold designs and improvements in the "eight jet multi arm air-jet loom", "new digital energy saving high-speed air-jet looms", "air-jet loom weft unit technology improvement", "adjustable side support series design", "intelligent weaving process management" and other aspects, which not only expanded the application scope of Changling air-jet looms, but also greatly improved the product performance.

Shen Danfeng said that the domestic air-jet looms have a huge market and good prospects for development.

The development of air-jet looms with independent intellectual property rights to replace imported products is conducive to the technological progress of China's textile industry and the competitiveness of enterprises in the international market.