The Introduction Of Automation Equipment Is Only The First Step. What Can Traditional Mills Rely On To Realize "Digital Butterfly Transformation"?

"After the intelligent transformation of traditional mills, every production link and every mechanical action has been digitized and incorporated into the sensor control system, realizing the full data exchange in the production process, forming a closed-loop control system of" data acquisition analysis early warning result feedback. " Talking about the intelligent transformation of spinning mills, Xu Weilin, President of Wuhan Textile University, once said, When the most traditional cotton mills meet the most intelligent intelligent manufacturing, the spinning enterprises have changed, and realized the "digital butterfly change".

Indeed, although "thousand people's yarn and ten thousand people's cloth" are people's old impressions of the traditional textile industry, today, with the rapid development of industrial Internet, spinning enterprises have realized that intelligence, informatization and digitization are the future development trends, and have changed "manufacturing" into "intelligent manufacturing".

Changyuan textile

Integration of industrialization and industrialization to improve economic benefits

In the green demonstration workshop of Fujian Changyuan Textile Co., Ltd. (hereinafter referred to as "Changyuan textile"), the daily production scene is as follows: dozens of rows of machines are running at high speed, and a few workers are on patrol. At the end of the yarn winding process, the end of the roving process will be finished easily

Wang Zhaosheng, assistant to the general manager of Changyuan textile, has been engaged in the textile industry for more than 30 years. Facing intelligent equipment, he sighed: "in the past, there were so many people in the textile workshop. One machine had to be equipped with more than one labor force. In the workshop, the noise was loud and the cotton wadding was flying. Now the degree of machine automation is high and the working environment is obviously improved. One person can take care of multiple machines." Wang Zhaosheng said that in the 1980s and 1990s, the average number of workers employed per 10000 spindles in textile enterprises was about 200. Today, the number of employees employed in Changyuan green demonstration workshop is only 25.

Changyuan's transformation from manufacturing to intelligent manufacturing stems from the integration of industrialization and industrialization in 2013. Now Changyuan not only has an advanced production line, but also has a breakthrough in the application of information integration processing.

According to reports, Changyuan's "data center" - the production process information integration and processing system, the computer screen in the control room can instantly scroll update product data, workshop equipment and production environment. How much electric energy is consumed by each equipment on the same day, how many products are produced by "handling", which team is on duty now, and how are the workers on duty Log in to the system and you'll see.

"Through the centralized monitoring of more than 500 pictures, the system displays the production and operation information of all processes and equipment in real time, and integrates, analyzes and processes the data of more than 40000 points in real time. It can realize real-time control and adjustment, control the dynamics of various workshops and production lines in the plant, and realize fault diagnosis, alarm, quality monitoring and distribution in the production process Analysis. " Changyuan textile factory director, engineer pan Liuyi introduced.

Last year, Changyuan textile upgraded the data integration software. “ Our cooperation with Zhengzhou University of light industry began when the integration of water and industrialization was carried out. They were one of the first universities in the industry to try digital transformation of the textile industry. We introduced Profibus Technology from them. ”Wang Zhaosheng also said that the introduction of advanced software technology into the workshop does not mean that it is necessary to run in advanced software technology in the workshop. To this end, Changyuan also cooperates closely with Chinese Academy of textile science, Xi'an Engineering University, Donghua University and Taiwan Fengjia University and other institutes and universities, "the expert team stationed in the factory, combined with the specific situation of the enterprise, and according to our product varieties, technical process, etc., tailor-made digital transformation scheme of the production line."

For Changyuan textile, information, digital and intelligent transformation can not only save labor costs and improve production efficiency, but also meet the higher requirements of customers.

In recent years, a kind of green fiber with low carbon and environmental protection in the manufacturing process and no pollution to the environment after abandonment has become a new favorite in the market. "But before this kind of product's foreign raw material price is high, the core technology was once monopolized by foreign countries, so it is very difficult to build our own brand." Dr. Chen Anbang, director of Changyuan Textile Technology (R & D) center, said, "later, we cooperated with China Textile Research Institute to use their green fiber raw materials and carry out research and development experiments relying on intelligent production lines. Digital system plays an important role in R & D. Through the data system, we can quickly read the raw material parameters, make timely adjustments, and understand the different effects of different proportions in the way of simulation test, so as to make the R & D process more smooth and efficient. " The green fiber products independently developed by Changyuan have passed the inspection of international authoritative technical institutions, and the technical quality indicators are excellent. The fabrics made by Changyuan are soft, light and close to the skin. Since they were put into the market last year, they have been ordering continuously.

"Changle's surging digital economy wave and innovation atmosphere greatly encourage us to increase investment in the transformation and upgrading of informatization, digitization and intellectualization, and bring good economic and social benefits for Changyuan textile through innovation and development." Wang Zhaosheng revealed that at present, they are promoting the implementation of "functional yarn intelligent technology transformation project", and a new butterfly change is in the making.

Anji Beihao

The cloud on the device enables the machine to "think"

In early November, the intelligent production management system of coos cosmoplat was launched in Zhejiang Huzhou Anji Beihao Textile Co., Ltd. (hereinafter referred to as "Anji Baihao"). The planner in charge of the production scheduling of the factory said that he no longer needed to rush back and forth in a workshop of several thousand square meters. Instead, he had a large electronic screen in front of him and constantly beating equipment data, "this is much more accurate than I can copy by hand."

It is reported that Anji Beihao was founded in 2014. At the beginning of its establishment, the company introduced high automation equipment such as flower clearer, carding machine, drawing frame, roving frame and spinning frame. Although the use of automatic machinery and equipment has greatly reduced the number of workers in textile mills, the mode of "man in charge of machines" has brought new problems to production and management.

The first is to check the operation status of the equipment. In order to obtain the equipment operation information, the personnel of planning department can only collect one by one through on-site inspection. "Even the most skilled planner here can only complete inspection and inventory twice a day." The staff said, "when we use Excel to simulate the delivery date of various orders according to the results of on-site inspection, the situation of equipment and orders often has new changes, and people will never catch up with the machines."

The operation and maintenance of the equipment is also one of the daily problems of Anji Baihao. There are many kinds of yarn production, and the process is not the same. In the face of the frequent multi variety and small batch orders, the staff are busy with the variety and process modification, and configure the process parameters for the equipment, so they can't separate the time and energy for the daily maintenance and analysis of the equipment. In addition, the historical maintenance record of the equipment is incomplete. Once the equipment has problems, it is difficult for the maintenance workers to identify the equipment fault at the first time, and the maintenance efficiency will be greatly reduced It is always difficult for the machine to achieve maximum efficiency. In the process management, starting from receiving the order, making production plan, transferring process list, arranging team production and counting order output all rely on offline. A large number of paper records and transmission are not only inconvenient for data archiving, but also prone to errors, which affect production. In this way, how to give full play to the existing equipment conditions, optimize the production process and realize intelligent production has become an urgent problem for Anji Beihao, which is also the reason why it chose the spinning intelligent fabric management solution created by Haizhiyun, a subsidiary of cosmoplat.

"Enterprises have invested a lot in production equipment, and the degree of equipment digitization is also very high. However, due to the low rate of equipment networking, production materials are confused and the efficiency is not stable," said the person in charge of the project

After the introduction of spinning intelligent IOT management solution, Anji Beihao has configured a modular production management system, which covers the whole process of daily operation and equipment management on the production site, and realizes the full implementation of the production process. In terms of equipment operation and maintenance, Anji Baihao has built an online monitoring system through the Internet of things technology to ensure that each staff member can obtain the output information of the equipment in real time. In addition, through access to ERP enterprise resource management system, Anji Beihao can record and analyze the real production data, effectively improving the end-to-end response speed of "production sales purchase production".

According to reports, After all the systems are installed and put into operation, Anji Beihao saves 3-5 workers in production, reduces the cost of accessories by 10%, and improves the efficiency of equipment by 5%. It can save about 500000 yuan per year. More importantly, through the real-time tracking and free flow of data, Anji Beihao can optimize the allocation of human, financial and material resources, reasonably reduce the inventory of work in process and energy consumption, improve the management and production efficiency, and truly realize intelligent production.

"The introduction of automated equipment is only the first step towards intelligence." "With the addition of cosmoplat, machines in the workshop will be able to 'think' and 'judge', and data will replace people to drive production, which truly realizes the digitalization, networking and intellectualization of the manufacturing process," said the head of Anji Beihao workshop