Shock Fiber Spinning Towards High-End Industry

Shen Caiying is a doffing worker in the front spinning workshop of Suzhou Zhen Lun cotton spinning Co., Ltd.. Every time she stops doffing for more than 10 minutes, she has to stoop and take the cone, then bend down and empty the cylinder. She is skilled, deft, and natural. She acts at least 5000 times a day. From the second production lines of the automation and reconstruction project of the past few days, the doffing process only needs to be delivered on the machine operating platform, and the doffing workers no longer need to stoop to pick up the cylinder and put the drum out.

With the completion of continuous production and transformation processes such as blowing and carding and thin link connection, the key step of "intelligent interconnection" started in April this year is the transformation of thickness and scale automation. In July, first production lines were put into operation, and at the end of October, second production lines entered production and operation, indicating that automatic spinning completely replaced manpower and reduced the number of million spindles from 60-70 to 20.

All of the doffing bowed movements are "zeroing".

In traditional people's impression, the cotton spinning industry is a labor-intensive industry. The workshop is full of flying objects. The truck driver has been pulling hands and shoulders, working environment is poor, and the labor intensity is great. Now, the workshop of Zhen Lun biomass Fiber Co., Ltd. is a modern production scene. The spinning machine of different shapes is running at high speed, and the workshops are in constant temperature and humidity.

Huang Jianxiang, deputy general manager of Zhen Lun cotton spinning, introduced that the traditional cotton spinning production was divided into 6 processes, namely, flower cleaning, carding, drawing, roving, spinning and winding, and the transformation began more than ten years ago, and the interconnection of production processes such as blowing carding and thin linking has been completed.

After deciding to set up the Synthetic Fiber Co., Ltd., Zhen Lun invested heavily in the production process transformation. Since April this year, the company has invested about 10000000 yuan, the first in Suzhou cotton textile enterprises to complete the automatic transformation of thickness and thickness, the company workshop has become the provincial intelligent manufacturing demonstration benchmarking workshop. "Before pulling out the roving full of roving, placing it in the conveyor car, and then dropping the empty cylinder, about 4-5 tons per person per class, bending over 5000 times, one day is definitely a backache." Shen Caiying said that after the transformation of the thickness and automation system, the automatic doffing roving machine had completed these movements for them, and all the stooping movements were all zeroed.

The output per unit increased by more than 10% per day.

The reporter saw in the pre spinning workshop, which had been completed in the transformation of thickness and automation. An employee pressed the button, the equipment began to run automatically, the semi finished roving tube was automatically removed one by one, and the empty roving tube was automatically cleaned up after the tail yarn cleaning machine was automatically cleaned, and it was automatically returned to the frame of the roving machine.

The fully automatic doffing roving machine solves the problem of high labor intensity of doffing workers, inserting air exchanging tubes, and manually pulling out full barrel roving. It can be used in conjunction with roving conveying system to achieve real thickness. Different kinds of roving can be automatically and precisely conveyed to different kinds of spinning frames. The automation transformation of thickness and thickness not only greatly reduces the labor intensity of employees, but also improves the efficiency of machine production and improves the quality of products. At the same time, when the original roving was sent to the downstream spinning process through the transport vehicle, different varieties of people appeared to send the wrong machine platform. During the transportation process, the roving surface of the semi finished products was also prone to produce oil pollution risk, and the risk of roving surface being shaved or damaged by grinding was solved, and the product quality was further improved.

"The output per unit is increased by 10-15% per day, and the production efficiency has increased from 85% to 95%." Gu Zhiming, deputy general manager of Zhen Lun cotton spinning, who is responsible for the transformation of the thickness and joint project, introduces that the half finished roving tube on the original spinning frame needs to be removed in batches and transported to the manual roving yarn cleaning machine one by one for manual cleaning. The working process is cumbersome and the transportation vehicles are various. After the transformation, the staff can increase the production efficiency greatly by simply passing the "one button delivery" button through the coarse and fine conveying system. The original doffing time is 15 minutes to 20 minutes, and now it is shortened to 2 to 3 minutes. It improves production efficiency and stabilizes product quality.

"One step away" to achieve full automation

"Cotton spinning is not a high-end industry, but it has to be a high-end industry." This is the strategic positioning made by Shen Peirong, chairman of Zhen Lun cotton spinning, in 2003. He once said that cotton spinning enterprises must take the green development road of "high starting point, rapid development, high efficiency, low consumption and zero pollution".

It is understood that since 2006, the total investment of Zhen Lun in the industrial transformation and upgrading and equipment transformation has exceeded 1 billion 500 million yuan, and 100% of the production process is self levelling and on-line testing, so as to achieve continuous, automatic and intelligent spinning production. This year, under the complicated and severe economic situation, the yarn of Lun cotton spinning has become the designated product of many famous clothing enterprises both at home and abroad, and has always been booming in production and marketing.

In the past 16 years, from the early stage of the establishment of the first 4 spinning machines and 1680 ingots, the Lun cotton spinning has developed into a model of transforming traditional industries with modern technology. 3 provincial intelligent manufacturing demonstration workshops have been built, and 1 intelligent manufacturing benchmarking workshops have been built. At present, Lun cotton spinning has 3 wholly-owned subsidiary companies in Wujiang, with 1300 employees and 500 thousand ingots, with an annual output of 80 thousand tons of pure spinning and blended yarns based on regenerated cellulose fibers, with an annual sales income of 1 billion 800 million yuan.

Huang Jianxiang said that as chairman of the cotton textile industry veteran, chairman Shen Peirong has always had a complex: let cotton spinning enterprises no longer give people the impression of chaos and dirty, the truck drivers no longer become bitter and tired pronoun. In the past 16 years, Zhen Lun has been working hard to invest in huge amounts of money for automatic transformation. Now, with the seamless convergence of the main processes and the "intelligent interconnection", it is only one step away from the whole process of automation. With the development of science and technology and the continuous development of Zhen Lun, cotton spinning industry will usher in a new era.