"Digital Butterfly" Of Changyuan Textile

"Thousand people yarn, 10000 cloth" is the old impression of people's traditional textile industry. But in Changle, with the help of the digital economy, the textile industry, which is a labor intensive industry, has undergone tremendous changes.

Recently, the reporter went to Fujian Changyuan Textile Co., Ltd., located in Changle, to explore the "digital butterfly" course of the first batch of two integration enterprises (informatization driven industrialization and industrialization promoting informatization).

Transforming manufacturing into "intelligent manufacturing"

The number of million ingots decreased from 200 to 25.

Walking into the green demonstration workshop of Changyuan textile, it is seen that tens of thousands of square meters of factory buildings are clean and tidy, and dozens of machines are running at a high speed, but only a few workers are traveling around. The roving product has just come off the line, queuing up to "take the" automatic track in the air, go to the spinning equipment at the other end, and enter the next process; in the winding process, the manipulator holds the ends of the thread in the palm of the hand, twists lightly, and blink the yarn easily to complete the joint work, without the joint rate of 100%.

Wang Zhaosheng, assistant general manager of the company, has been engaged in the textile industry for more than 30 years. Looking at the intelligent equipment in front of him, he reviewed the production situation of the old enterprises in the past, and he was filled with emotion. "Before the textile workshop is crowded, a machine needs to match more than one labor force, the workshop noise is big, the cotton wadding is flying. Now the automation level is high, the working environment is obviously improved, one person can take care of several machines." Wang Zhaosheng said that in the 80s and 90s of last century, the average number of textile industry employing 10000 spindles was about 200, and now the number of 10000 ingots in the Changyuan green demonstration workshop is only 25.

The manufacturing of Changyuan has become "intelligent manufacturing", which originated from the integration of two technologies in 2013. The current source not only has advanced production lines, but also has made breakthroughs in the application of information integration.

Walk into the "data center" of Changyuan, the information integration and processing system control room of production process, rolling up and updating product data, workshop equipment and production environment on several computer screens. How much electricity per unit consumed on the same day, and how many products were produced by "handling", which teams are on duty now, and how are the workers coming to work? Login system can be seen at a glance.

"The system monitors and displays the production and operation information of all processes and equipments in real time through more than 500 pictures. More than 40000 point data are real-time integrated, analyzed and processed to realize the whole process management information and data. It can control and adjust in real time, control the dynamics of the inter vehicle and production lines, and realize fault diagnosis, alarm, and quality monitoring and analysis in the production process." Pan Liuyi, director and director of production.

Information, data and intelligence have won lower labor costs and energy consumption for the Changyuan. Compared with the previous transformation, the production of one ton of yarn can also reduce the power consumption of 10 kwh ~20 kwh a year, which can save at least 600 thousand yuan a year in electricity consumption for a long source of over 100 thousand tons of annual capacity.

Change to fight for unity

Government enterprise research think tank helps digital upgrade

Recently, Changyuan textile has ushered in a group of "old friends", Professor Wang Yonghua and his team, School of electrical and information engineering, Zhengzhou light industry university. Their trip is to plan a new upgrade plan for the data integration software of Changyuan.

"Our cooperation with Zhengzhou light industry university began at the beginning of the integration of the two technologies. They were one of the earliest universities in the industry to try digital transformation of textile industry. We introduced PROFIBUS technology from industrial field bus. Wang Zhaosheng said that the introduction of advanced software technology into the workshop does not mean that it can directly enter the intelligent operation, but also requires software to further run in with the hardware of the workshop. For this reason, Changyuan has also worked closely with the institutes of Chinese textile science, Xi'an Polytechnic University, Donghua University and Taiwan Feng Jia University and other colleges and universities. "Expert teams are stationed in the factory, combined with the specific circumstances of enterprises, and tailored to the digital transformation plan of the production line according to our product variety, technology and technology." In this regard, relevant departments of provinces, municipalities and districts have provided corresponding guidance and policy support to help coordinate problems and meet the needs of enterprises. Through the combination of government, enterprise and research, the digitalization upgrading and high quality development of Changyuan textile have been coordinated.

Not only that, Yao Mu, academician of the Chinese Academy of engineering and honorary president of Xi'an Polytechnic University, also led the team to set up academician workstations in Changyuan to carry out strategic consultation, innovation guidance and technical training services in enterprises.

The strong and strong alliance has increased the "internal strength" of the long source and promoted the self promotion of the skilled workers. Sun Yuanxiu, who has worked in the textile production line for 23 years, has studied the technical essentials of intelligent and informational spinning equipment in his spare time, and developed a new spinning operation method combining tradition with innovation. She also grew from the spinning and weaving machine to the "cotton craftsman" in the national cotton textile industry. She worked in a series of textile workers who worked in Changyuan textile company to convey, help and bring out a lot of work. Hong Wei, her apprentice, recently won the honorary title of "technical expert in the textile industry" with her excellent operation skills.

Change from being controlled by others to independent innovation

Digital simulation helps green product development

For Changyuan, the ultimate goal of informatization, digitalization and intellectualization is to satisfy customers' higher requirements for wearing.

In recent years, a green fiber textile material with low carbon and environmental protection and no pollution to environment has become a new market favorite in recent years. "But before that, the prices of foreign materials of these products were high, and the core technology was once monopolized abroad, so it was difficult to build our own brand." Dr. Chen Anbang, director of Changyuan Textile Technology (R & D) center, said, "later, we cooperated with China Textile Science Research Institute, using their green fiber materials, relying on intelligent production line to carry out R & D experiments. Digitalization has played a great role in R & D. Through data system, we can quickly read the raw material parameters, adjust them in time, and understand the different effects produced by different proportions in the way of simulation test, so that the R & D process is more efficient and smooth. Changyuan's own green fiber products have been tested by the international authoritative technical institutions, and the quality of various technical indicators is excellent. The fabrics made are soft, light and skin friendly. This year, the product has been listed as a new product promotion catalogue announced by the provincial labour office, and has become the only textile yarn product selected, and has won the national textile product development award.

"The surging wave of digital economy and innovation in Changle has greatly encouraged us to invest more in the transformation and upgrading of informatization, digitalization and intellectualization. Innovation and development has brought good economic and social benefits to Changyuan textile industry. Recently, we have won the award of the national manufacturing champion." Wang Zhaosheng disclosed that at present, they are actively promoting the implementation of the "functional yarn intelligent transformation project", and a new "butterfly change" is being bred.