Technological Innovation: The Technology Of Large Circular Knitting Machine Breaks The International Technical Bottleneck

A large circular knitting machine is running stably. Suddenly, the red alarm light above the machine lights up and the machine stops automatically. The blocking worker found a slight defect on the cloth surface. It turned out that there was a broken needle on the equipment. After the new needle was replaced, the machine continued to run normally.

Such scenes happen every day in a knitting factory in Keqiao, Shaoxing, Zhejiang Province. However, just a year ago, if there were broken needles, the blocking workers often could not find them in time, and then a large number of defective fabrics were produced. On average, the loss of each equipment per year was as high as thousands of yuan, which made Mr. Liu in charge of the enterprise worried.

"Relying entirely on human resources, it is difficult to achieve the stability of quality management. It is the only way for knitting enterprises to upgrade intelligently." Mr Liu said. "But the production environment of knitting enterprises is complex, and the degree of refinement and stability required are very high. We have tried some foreign knitting needle detection equipment before, but none of them can achieve the expected effect."

In fact, what Mr. Liu mentioned is the common problem encountered in the intelligent upgrading of the textile industry: if the technology is not perfect, the upgrading and transformation of the factory will not only fail to achieve the effect, but also cause the situation of "score reduction".

Taking the broken needle detection technology of circular knitting machine mentioned just now as an example, Mr. Liu said that the principle of this technology is not complicated in fact, but in actual production, the circular knitting machine will produce flying flowers and contaminate the lens of the detection equipment, resulting in false shutdown, which will not only affect the work efficiency, but also produce stop marks on the cloth surface and affect the product quality. In addition, the small vibration during the operation of the circular machine may also affect the detection signal. In short, the technical stability of intelligent equipment is the key to the intelligent transformation of enterprises.

In the past, when we mentioned the technical bottlenecks and key problems in this industry, we first thought of the solutions of foreign equipment. But in recent years, the rapid development of domestic textile industry, from the initial imitation and follow, "feeling the stone across the river", to now we have many fields with foreign enterprises standing in the same running line, or even the position of the leader, and further forward, there is no stone to touch.

Taking the broken needle monitor of circular knitting machine as an example, Mr. Liu of Shaoxing said: "at that time, we tried several foreign equipment repeatedly, but the effect was not ideal. Later, we contacted the product of a domestic enterprise. At first, we did not report too much hope. It was very difficult for Chinese enterprises to solve the problems that" foreigners "could not solve. But unexpectedly, the result is beyond our expectation. Domestic products fully meet the requirements of the enterprise in terms of precision and accuracy! "

The Chinese enterprise mentioned by Mr. Liu is Tianjin Hetian Electric Appliance Co., Ltd. Zhang Min, the person in charge and general manager of the company, said: "since 2006, we have set up a project to study needle breakage monitoring technology for circular machines, and have carried out five generations of product improvement and iteration. For example, Mr. Liu of Shaoxing mentioned the problems of flying flowers blocking the lens and the signal instability caused by machine vibration. After thousands of tests, we modified more than 100 schemes and finally solved them in 2019. At the same time, we obtained two national invention patents and seven practical new patents. At present, the latest generation of needle breakage monitor products can not only run normally on the 40 needle high machine number circular machine, but also maintain the industry record of continuous and stable operation of 10000 hours. "