Don'T Look At Cotton Spinning Enterprises With Old Eyes. These Enterprises Have Opened A New Era Of Intelligent Production.

In the traditional concept, the cotton spinning industry is a labor-intensive industry. It is "walking on the feet and making it by hand" in the flying cotton batten. But in fact, this is different from the past. At present, China's textile industry is in a period of transformation and development. "Intelligent manufacturing" is the core of the industry's transformation and upgrading, and high quality development. In order to enhance the competitiveness of the international market, China's cotton textile enterprises have never stopped the pace of development. From the point of solving the problems of labor shortage and low efficiency, the modern intelligent factory has been set up to open a new era of intelligent production.

Zhen Lun cotton spinning:

Dirty labels are long gone.

"Cotton spinning is not a high-end industry, but it has to be a high-end industry." Referring to the intelligent process of cotton spinning industry, Shen Peirong, chairman of Suzhou Zhen Lun Cotton Textile Co., Ltd.

In April of this year, Shinon cotton spinning invested about 10000000 yuan to transform two production lines in the factory, reduce labor costs and improve labor efficiency through industrial upgrading. At present, the company has reduced its employment from 70 to 20. Huang Jianxiang, deputy general manager of Zhen Lun cotton spinning, introduced that during the spinning process, from the 6 processes of cleaning flowers to finished products, the most heavy work is to take out the half finished product of roving Workshop - full tube roving and transport it to the spinning workshop. Before renovation, a skilled roving truck Pullman would pull out nearly 5 tons of roving, and bend over 5000 times. Nowadays, with the full automatic doffing roving machine, the workload of pulling, lifting, lifting and inserting each class will be zero. Moreover, the matching of full automatic doffing roving frame and roving conveyor system has realized the connection of thickness and fineness, and can accurately transfer different types of full-barrel roving to different spinning frames.

The transformation and upgrading of traditional spinning projects not only reduced the labor intensity of workers, but also greatly improved the efficiency of machine production and stabilized the quality of products. According to the introduction, the original doffing time of the original roving machine is 15 to 20 minutes, and now it is shortened to 2 to 3 minutes. The productivity of the single stand is increased from 85% to 95%. At the same time, by adding roving intelligent conveying system, it effectively avoids the problems such as human error feeding machine, oil pollution and grinding damage which are prone to appear in the spinning process of semi-finished roving products, and further strengthens product quality control.

It is understood that since 2006, the total investment of Zhen Lun in the industrial transformation and upgrading, equipment and technology transformation has exceeded 1 billion 500 million yuan, and the production process 100% self leveling and on-line testing has been realized, 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.

From the early days of the founding of the 4 spinning frames 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, 1 of which are intelligent manufacturing demonstration benchmarking workshops. At present, Zhen Lun cotton spinning has 3 wholly-owned subsidiaries in Wujiang, with 1300 employees and 500 thousand production capacity. The annual output of pure spinning and blended yarns is 80 thousand tons, with annual sales income reaching 1 billion 800 million yuan.

Huang Jianxiang said that in order to let cotton spinning enterprises no longer give people the impression of chaos and dirty, the truck drivers no longer become synonymous with pain and fatigue. In the past 16 years, Zhen Lun has been working hard to invest in huge amounts of money for automation transformation. Now, with the seamless convergence of main processes and the "intelligent interconnection", it is only one step away from automation. With continuous development, cotton spinning industry will usher in a new era.

Wuhan Yu Dahua:

Unattended at night

In the list of "intelligent manufacturing pilot enterprises in textile industry" in 2019, Yu Dahua became one of the only 3 cotton textile enterprises in the country. At present, the Wuhan Yu Dahua textile and Garment Group Co., Ltd. has owned the first intelligent production line of 100 thousand spindles, intelligent production line of 15000 tons, intelligent clothing production line and other intelligent manufacturing projects.

It is understood that the whole process intelligent spinning production line was developed jointly by Wuhan Yu Dahua Group and Jingwei Textile Machinery Group, and was appraised by the Ministry of industry and commerce as the new project of Intelligent Manufacturing in 2018. The original intelligent spinning production line of 100 thousand ingot in China, with its originality, intelligence and advanced nature, has pushed the intelligent spinning to a whole new height.

"Traditional industries must produce unconventional products and produce and manage them in an unconventional way." Yu Dahua Textile Co., Ltd., the relevant person in charge, said that the 100 thousand spindle whole process intelligent spinning production line adopts the Internet of things technology. Through the deep development of the "E system", it can conduct intelligent production scheduling, optimize cotton blending and logistics scheduling, and can monitor production, quality data and remote communication in real time, and achieve intelligent control of information flow and logistics, and intelligent coordination of equipment status and remote operation and maintenance. It is possible for spinning factories to be unattended at night.

The intelligent spinning project has created the unique new mode of spinning production, including the three major highlights of the whole process automatic logistics delivery system, the whole process intelligent return receipt and payment system, and the whole process quality traceability system.

After the blowing carding unit automatically changes the bucket, the AGV trolley, stepping guide rail, intelligent ferry car and bucket changing lifting robot will form a complete intelligent logistics transportation system through the "E system". Among them, it involves sensors, RFID, bar code recognition, industrial robots, automatic navigation and database technology.

The whole process intelligent return and payment can automatically recycle and pack the flowers and objects in each process, and then reuse or classify them according to needs. The falling objects in the entire spinning process can be swept away.

The whole process quality traceability is the comprehensive introduction of digital identification in the production of yarn products, recording the production date, production process and quality test data of each product. Through identifying and tracking defects in the tray, roving tube and spinning tray, defect tube and automatic recognition device of defective cylinder is arranged on automatic winder and automatic baler, thus achieving full coverage intelligent quality traceability.

After intelligent transformation, Yu Dahua's 10000 spindles spinning production line has been reduced from 55 to 15, which has greatly improved production efficiency, reduced operation cost and achieved product quality traceability.

Wei Qiao Textile:

Intelligent unmanned factory put into operation

Weqiao textile Limited by Share Ltd has built an automatic and intelligent spinning and weaving production line this year to achieve industrial upgrading, improve the proportion of high-end products and achieve the principle of high quality development. At present, the first phase of the new green intelligent textile integrated chemical plant has been completed, and the equipment has been basically installed, and has entered the commissioning stage. It is estimated that the intelligent plant can produce 15 thousand tons of high-grade compact spinning and 35 million yards of high-grade fabrics annually.

The project adopts the measures of "Internet +", product automatic inspection, robot application, automatic transportation tools, and energy saving equipment. The intelligent rail transportation system of the production line has a length of 35 km. It is fully automated transportation from the roving to the product storage, automatic packaging, and the whole process is free from any artificial direct participation. With the help of intelligent control system platform, the production line can be managed remotely by mobile phone, tablet, computer and other terminal devices, and real-time monitoring of each process and operation point can be carried out. In addition, the production line also has many functions, such as order progress warning, equipment state warning, quality early warning, environmental warning, energy consumption over warning, one button production quality report, real-time monitoring of quality data, order real-time tracking, seamless integration of ERP and other functions. All devices will realize data integration analysis.

It is reported that the production line will be built and put into operation, which will bring about a substantial increase in production efficiency. For example, the blowing carding system reduces the number of cylinder changers by 10%, automatic winding, automatic joint and automatic cotton roll are achieved by the automatic rolling and combing automation system. The intelligent automatic track system can realize the doffing stopping in 3 minutes, the success rate of doffing, the success rate of replacement of the ATC, and the power of generating the raw silk close to 100%. The spinning frame adopts 1824 spindles ultra long spinning frame, and the AGV cylinder conveying system realizes the tube self. Dynamic conveying, precise positioning; the automatic monitoring system of Lida, which is equipped with parallel processes, can significantly improve weight unevenness and evenness; loom insertion rate reaches 2565 times / minute. These data, representing the leading industry level, reflect the new kinetic energy generated by Wei Qiao textile technology.

In terms of employment, the relevant person in charge of the enterprise said that the number of workers used in the production line was 90% lower than that in Wei Qiao textile, and that the workers' labor intensity and labor cost were reduced. Meanwhile, the quality of products was improved and the competitiveness of Wei Qiao textile was enhanced.

In the cotton textile industry, more and more enterprises are promoting the industrial transformation and upgrading through intelligent production, and enter the new era of intelligent manufacturing. Regarding this, Gao Yong, secretary and Secretary General of the China Textile Industry Federation, said that intelligent manufacturing is the core of the transformation and upgrading of China's textile industry and the development of high quality. During the "14th Five-Year" period, China's textile industry will still put "intelligent manufacturing" in the first place of transformation and upgrading. However, the current "intelligent manufacturing" in China's textile industry is still in the "3 stage of missed lessons", which is far from the "industrial 4" and the real "Ai". For the textile industry, enterprises still need to improve their intelligence level step by step.