Smart manufacturing in the textile industry

In most people's minds, the spinning industry is a traditional labor-intensive industry, and in the era of intelligent industry, intelligent machines are replacing workers, and textile workers will also enter the situation of competing with intelligent machines for job opportunities. The latest results of the Chinese Enterprise-Employee Matching Survey (CEES) jointly conducted by the Wuhan University Quality Development Strategy Institute, the Chinese Academy of Social Sciences, Stanford University, and the Hong Kong University of Science and Technology Institute of Emerging Markets show that real wages have more than doubled in the past 10 years , Manufacturers are adopting automation technology, investing in research and development, and adding new products with higher added value. Recently, the reporter also happened to see in the intelligent production workshop of biomass regenerated fiber material of Suzhou Zhenlun Cotton Spinning Co., Ltd. The spacious and clean workshop maintained a constant temperature and humidity working environment, and a high-speed automatic machine replaced the original one. The busy scenes of rows of female textile workers running back and forth, and there are only a few workers patrolling and simple operations. All of the above subverted people's impression of the traditional textile industry.　　　　 According to the company’s deputy general manager Wu Jiankun, benefiting from the investment in intelligent equipment and technological process transformation, the original work of more than 100 people now only requires 20 people. Not only is the production efficiency greatly improved, but the product quality is also more stable.　　 　　 'Workers must first sharpen their tools if they want to be good at their work.' For an enterprise to continue to develop, it is inseparable from the 'intelligent manufacturing of sharp weapons' products. The biomass fiber workshop has introduced a large number of fully automated and internationally leading intelligent equipment such as German blowing-carding and drawing frames with online monitoring functions, fine-winding Zinser spinning frame, and Japanese fine-winding automatic winder. It has realized the automatic control of drawing feed, rotation speed, spinning rotation speed, viscosity, self-winding joint, conveying and other links. The intelligent workshop realizes the perfect integration of intelligent workshop information and ERP data through the integrated application of digital information technology, MES, ERP and other management systems. In the intelligent workshop, 'full production automationIt saves manpower and improves efficiency. The whole process maintains a high degree of continuity, reduces the chance of manual contact with the yarn, and the yarn quality is further stabilized and improved, which greatly improves production efficiency and labor productivity.　　　　 company chairman Shen Peirong said frankly that labor prices continue to rise and market competition is becoming increasingly fierce. If you still follow the old methods, you will gradually lose market competitiveness and may even be eliminated. This situation makes Zhenlun Cotton Spinning executives realize that intelligent manufacturing is a breakthrough in the development of traditional industries, and automation, intelligence, and information are the only way for enterprise development. 'It's not whether you want to do it or not, but the market and the environment are forcing you to do it. Reduce costs and find a way out of intelligent manufacturing. Intelligent manufacturing can double the production efficiency. I hope to hedge the high labor cost with intelligence. “The less you get, the more you make money” has become an unavoidable reality in the textile industry. There will be fewer and fewer professional workers in the textile industry in the future. There is no way out to increase production efficiency without reducing labor. This is the foundation of the transformation and upgrading foundation. There is no other way. '　　 　　 Reduced labor and labor intensity, increased work efficiency and added value, increased production capacity, and more guaranteed product quality... The benefits of this move are all-round. For example, Shen Peirong said: 'In 2005, the company employed 130 people for 10,000 spindles. Now it employs 35 people for biomass 10,000 spindles. Vortex spinning employs only 15 people for 10,000 spindles. The actual reduction in labor costs per 10,000 spindles per year is about 3.5 million yuan. The bobbin process requires manual operation. Now, each machine is equipped with a manipulator, which can unplug all 1200 bobbins at one time, and plug the empty tubes all at once through the manipulator.' 　　 　　' The update of the equipment also drives In the past, our products were dominated by ordinary ring spinning. Today, we follow the development trend of spinning technology and adopt the Siro compact spinning process. The same viscose yarn is comparable to ordinary ring spinning. Compared with the yarns, Siro compact-spun yarns can sell more than 3,000 yuan per ton, and the products are exported to the high-end global textile market. Many domestic and foreign first-line brands are long-term customers of Zhenlun.' Wu Jiankun said.　　　　 Since 2008, Zhenlun cotton spinning has invested more than 100 million yuan in production equipment transformation for several consecutive years, introduced advanced spinning equipment from Germany, Japan, Switzerland and other countries, and built Zhenlun biomass intelligent workshop.　　 　　 After several years of deep cultivation, Zhenlun cotton spinning has basically realized the full automation, intelligence and informationization of the workshop. At present, Zhenlun is building a model factory for the full-process digital, automated and intelligent production of the domestic chemical fiber industry. The company's spider web system monitoring software will be put into use. This system is like a spider web, connecting various machines, and the production process can be fully realized. On-line detection, the establishment of a visual intelligent main control system, to achieve data intercommunication and integrated management between machines. The company's goal is to build an intelligent spinning factory with interconnection of production equipment, real-time scheduling of production processes, automation of material transfer, traceability of product information, intelligent monitoring of workshop environment, intelligent monitoring of resource consumption, linkage and coordination of design, development and production.　　 　　 Shen Peirong said that the current textile industry has entered a new historical period. The company takes intelligent manufacturing and green development as an important starting point, accelerates the cultivation of new kinetic energy and core competitiveness, and embarks on a road of transformation and upgrading supported by intelligent technology and equipment. Article Keywords: 　Cotton Spinning Intelligent Manufacturing Zhenlun Cotton Spinning