Zouping: Science And Technology Enabling To Build Intelligent Digital Textile Production Demonstration Base

Shandong Province is a big textile province. As one of the five trillion level industries, the textile and garment industry plays an important role in the national textile industry system. Because of its unique geographical location and historical heritage, Zouping has formed a unique textile industry environment. Zouping is the largest cotton textile industry base in China, and has been awarded the title of "China's famous cotton textile city", and the cotton textile industry cluster has been rated as China's top 100 industrial clusters. There are 28 Textile Enterprises above Designated Size in Zouping City, including two listed companies of Weiqiao textile and Hongcheng home textile, with spinning capacity of more than 7 million spindles, an annual output of 1.6 million tons of yarn, 3 billion meters of cloth, more than 10 million pieces of clothing and 13.5 million pieces of household textiles, with 120000 employees. Shandong Weiqiao venture group is the most competitive enterprise in China's cotton chemical fiber textile processing industry and the largest cotton textile enterprise in the world. Weiqiao venture group was born in the early 1980s. With the continuous transformation of the reform and opening up wave, the textile industry cluster has been gradually cultivated and strengthened.

In order to accelerate the transformation of new and old kinetic energy, promote the transformation and upgrading of enterprises, and realize high-quality development, Weiqiao venture group has built a green and intelligent textile production line project, which is the key project of Weiqiao venture group to accelerate the transformation of new and old kinetic energy and achieve high-quality development. It is also another green intelligent spinning after the 125000 spindle intelligent spinning production line built in 2016 Weaving integration project. The project adopts the most advanced production equipment in the world, and is equipped with a powerful big data platform and advanced management system to realize the intelligent management of the whole production process.

The project will start at the end of May, 2019, and will be completed in November. The project adopts "Internet + +", automatic product inspection, robot application, automatic transportation tool application, energy-saving equipment use and other measures. The intelligent rail transportation system of the production line is up to 35 km long. From roving to product warehousing, the whole process is fully automatic transportation and automatic packaging, without any direct human participation. With the help of intelligent control system platform, the production line can be remotely managed by mobile phone, tablet, computer and other terminal equipment, and each process and operation point can be monitored visually in real time. In addition, the production line also has many functions, such as order progress warning, equipment status early warning, quality exceeding warning, environment over standard warning, energy consumption exceeding warning, one click production and quality report generation, quality data real-time monitoring, order real-time tracking, seamless integration of ERP and other functions. All equipment will realize data integration and analysis.

The intelligent doffing roving machine can realize automatic doffing and tube changing. After the roving is full, it can be converted between the manipulator and the empty tube, and the empty tube will return to the doffing frame automatically. The full yarn will be transported to the yarn warehouse through the track, and then transported to the spinning workshop, which reduces the auxiliary workers such as yarn changer and yarn carrier, and also avoids the potential quality problems in yarn transportation. In the production workshop, the AGV transport car guided by 5g laser can easily transport a cotton sliver cylinder with a diameter of 1 m and a weight of 100 kg from the carding process to the drawing process, and the whole process does not require direct manual participation. Compared with the previous magnetic strip navigation car, this transport car has the functions of automatic obstacle avoidance and automatic charging, which can be connected with the weaving fabric, and realize the whole process intelligent textile logistics.

Intelligent textile mill has established intelligent order and process big data platform system for the first time in the field of cotton textile. According to the order, the raw materials are automatically evaluated and classified by EFS electronic cotton blending system of the United States, and the best cotton blending scheme and packing diagram are formulated. The utilization rate of raw materials is improved and the yarn quality is guaranteed. In terms of software, a fully integrated information and physical integration manufacturing system based on intelligent process equipment and automatic and efficient production line, MES management and control as the core, network data central control platform as the support, and ERP big data analysis as the expansion, to build an intelligent digital textile production demonstration base with full process coverage.

The number of workers used in the production line is reduced by 90% compared with the current number of workers in the same scale production line of the company, which not only reduces the labor intensity and labor cost, but also improves the product quality. The company's competitiveness in the textile industry is greatly enhanced, realizing high-quality development and promoting the upgrading of the whole industry.