The “Min Yin†service platform launched by Hangzhou Honghua Digital Technology Co., Ltd. has developed an online design business to meet the various professional needs of users from design to production.
In the factory production workshop, the assembly line runs smoothly. Through the preset control program, the products with different characteristics are automatically and quickly produced, but almost no shadows are seen. Whether it is clothing or home textiles, simply place an order with a mobile phone, and the network will automatically send orders and personalized requirements to the factory, which will purchase raw materials, design and produce them, and then deliver them directly to consumers through network distribution. These scenes no longer happen in the "future" but in the "now".
Since the party's 18th National Congress, China's textile industry has been in the stage of major transformation and upgrading, and industrial transfer, and it has also ushered in the spring of textile intelligence. It can be said that intelligence is not only an inevitable trend in the development of textile machinery equipment in the future, but also the most important feature of the development of the textile machinery industry in recent years.
Machine substitution form
In recent years, in addition to facing the current situation of weak market demand, the rising labor costs have added a problem to textile enterprises. Under the pressure of the situation, it is a general trend to help textile enterprises solve the problem of rising raw materials and labor costs through "machine substitution" and to produce products with higher performance and better quality with higher efficiency.
In the spinning process with the strongest work intensity and the largest amount of people, saving labor and improving efficiency through “machine substitution†will bring huge benefits to the enterprise. The continuous intelligent equipment such as cleaning and combing, thick and thin, and fine-linking realizes the automatic cleaning, doffing, packing and conveying in the spinning production, which frees the workers from the heavy labor and greatly improves the work. Productivity. At present, the application ratio of China's cleaning and carding has been relatively high, and the combination of thick and thin, with the collective doffing spun yarn has become the main variety of market sales, and the application of fine-linking is gradually expanding. The emergence of Qingdao Global HTBW yarn intelligent packaging logistics system, intelligent handling robot, Jiangsu Kaigong intelligent cotton coil handling system and other products, has achieved the unmanned connection between the various stages of the spinning process. For the auxiliary links such as doffing and tube management, the automatic doffing equipment and automatic tube management machine have become hot spots for the development of textile machinery enterprises. The ring spinning intelligent doffer (dropping trolley) pioneered by Tongling Songbao Intelligent Equipment Co., Ltd. has excellent performance in reducing labor intensity, reducing labor costs, increasing output and increasing yarn retention rate. It is welcomed by many textile companies. A series of pipe-manufacturing machines developed by Jiangyin Kaiye Textile Machinery Manufacturing Co., Ltd. can be matched with the spinning frame and the automatic winder, which can reduce the work of the fine yarn tube by 70%, and realize the automatic docking of the yarn and the yarn tube reserve.
According to the characteristics of chemical fiber production and the changes in production methods, the modularization of large-capacity, continuous, automated and mechanical product design of chemical fiber machinery products has become a trend. The chemical fiber equipment further applies computer technology and digital technology to enhance the level of intelligence, and achieves efficiency, quality improvement and labor saving by fully automating the process. Taking polyester staple fiber equipment as an example, the “100-tonne polyester staple fiber digital complete equipment†launched by Hengtian Heavy Industry Co., Ltd. adopts PLC control technology and network communication integration technology to form an online monitoring and management system for the whole production process. The process adjustment, fault display alarm, online monitoring, information collection and processing are improved, and the digital control level of the joint machine automation is improved.
The intelligent water of knitting machinery has been steadily improved, and new products have appeared frequently. Cixing automatic intelligent knitting upper machine can three-dimensionally weave 3D upper, realize full-form one-time weaving of knitted upper. The intelligent warp knitting production line developed by Wuyang Textile Machinery Co., Ltd. has subverted the traditional mode of garment production from weaving, cutting to sewing, and turned 3D printing, integrated molding and a variety of clothing production into reality. Putting the yarn into the machine, we can weave the garments at once, and adjust the style and details at any time according to the customer's needs, completely overturning the traditional production process. In addition, the integration of Swiss, Italian and Chinese technical resources by Cixing has successfully completed the automatic suture system of the knitted sweaters, which has improved the sewing efficiency and reduced the operator's Use eye strength.
At present, the intelligence level of single printing and dyeing equipment in China is constantly improving. Through intelligent printing and dyeing equipment, automatic feeding can be realized, and the water, electricity and steam consumption can be accurately controlled to reduce unnecessary waste. On the other hand, the digital on-line detection and control technology of printing and dyeing equipment process technology has made great progress. The on-line detection and automatic distribution system of concentrated alkali and hydrogen peroxide concentration, the automatic distribution system of dyes and additives, and the online monitoring system of shaping machine are constantly developing. Application improves productivity and process accuracy.
Intelligent control quality improvement
Based on intelligent equipment, the information management system and intelligent logistics system are established, and various information in the production process is collected and processed, and the whole process is intelligentized between different production processes, so as to further improve the intelligent level of manufacturing.
At present, continuous spinning equipment can realize the trace of the source of product quality problems and help enterprises improve product quality. At the same time, through the information integration of the production process, it also provides the basis for the integration of informationization and automation. Although the information management of cotton spinning production is still in its infancy, the improvement of production efficiency is very obvious. The Jingwei e system is a digital intelligent control system based on the complete process automation equipment of Jingwei Textile Machinery. The system focuses on data collection of cotton textile equipment, integrating product quality data, environmental data, energy consumption data, and personnel data to build an enterprise production data platform. The Jingwei e system can count the production capacity of each link (process), accurately predict the input and output of each process, and can realize the halving of materials between processes, and even make some enterprises close to zero inventory, thus saving capital occupation. Play a positive role in production quality control. In addition, the e system's prediction of the doffing time can effectively arrange the doffing sequence, reduce the trouble-free stoppage time caused by the machine waiting for the doffing, and increase the doffing efficiency by 30%~40%.
In the case of continuous improvement in the automation of production equipment, the automation of transportation and packaging has become a breakthrough point for further intelligentization of chemical fiber production. The chemical fiber production intelligent logistics system launched by Beijing Machinery Industry Automation Research Institute realizes the automation of wire dropping, loading and transportation, and can meet the needs of multi-variety production and loading at the same batch level, and automatically complete the tracking of silk cake product information. Label printing. After the wire is off the line, the silk cake is fully automated from the falling, conveying, storage, inspection and classification, packaging and palletizing. The automatic drop conveyor system for chemical fiber filament cake developed by Wuxi Hongyuan Electromechanical Technology Co., Ltd. is a silk cake post-processing equipment specially designed for the chemical fiber filament production line, which can complete the automatic doffing and conveying function of the silk cake to enhance The automation level of the chemical fiber filament production process, improve product quality and reduce labor costs.
In terms of printing and dyeing production, the digital automatic dyeing system for cheese yarn developed by Shandong Kangpinna Group has realized the transformation from manual mechanization to single automation to automation system, making China the first country in the world to break through the whole process automatic dyeing technology and realize engineering application. . The robotic mechanism is introduced into the automated cheese yarn dyeing production logistics system to realize the automation process from chemical material to dyeing to material transfer. This set of equipment can be used for dyeing various kinds of cheese yarns such as cotton yarn, wool yarn, cotton yarn, etc. It can also be expanded into the fields of dyeing and printing of grey fabrics, which can save 27% of water per ton of yarn, save 19.4% of steam, save 12.5% ​​of electricity, and reduce sewage. Emissions were 26.7%.
The intelligent warp knitting production line management system independently developed by Wuyang Textile Machinery can realize real-time monitoring for each production link of the factory, carry out data collection, transmission and control throughout the whole process, and also grasp the order production situation and delivery progress in real time through the network. The workload and even the salary of an operator can be quickly counted and displayed. The intelligent warp knitting production line management system can help enterprises achieve comprehensive information management and provide remote services to customers.
Quick response personality customization
The combination of traditional manufacturing with cloud platforms, big data, and the Internet provides a broad space for the development of the textile machinery industry. With the gradual intelligence of textile manufacturing, it is possible to diversify and produce small quantities according to the individual needs of consumers.
In recent years, digital printing equipment has gradually broken through the shortcomings of cost and speed. With its advantages of diversification, small batch, personalized customization and short delivery time, it has brought unprecedented personalized experience to the textile printing and dyeing industry.
Based on the innovative research and development of digital printing equipment, Hangzhou Honghua Digital Technology Co., Ltd. launched the “Miyin†service platform, vigorously developed the online design business, and strived to meet the various professional needs of users from design to production.
Honghua Digital creates a closed-loop industry by designing clouds, printing and dyeing clouds, and producing three clouds. In view of the slow response speed and unstable market matching of the existing design development model, the artificial intelligence design can generate the design with one button, and the artificial intelligence design takes only 19 seconds. The flower-shaped intelligent design cloud built with big data and machine learning technology provides designers with efficient and convenient auxiliary tools, which improves design efficiency and shortens the design cycle. At the same time, it can keep up with the fashion trend, and input a large number of fashion pictures into the neural network to automatically generate trend judgments on the current fashion trends. Based on the judgment of the trend of the neural network, the intelligent generation of a large number of popular seasonal draft designs. Printing and dyeing cloud uses the technology of big data to solve the problem of digital printing color consistency management. Production cloud realizes “flexible production†of textile printing and dyeing through unified management and distributed scheduling, realizes remote monitoring of production big data such as printing fabric, ink remaining amount, pre- and post-processing technology, realizes barcode-based “production by piece†and automatic Schedule scheduling, production schedule tracking, etc. The flexible production chain makes it possible to produce a custom finished product at the price of mass production. The number of registered users of the Miyin platform has reached 12,000. The platform has more than 100,000 flower-type libraries, 10,000 international top-notch models, and an accumulated order of 30,000.
Whether it is the concept of Industry 4.0 or the introduction of China Manufacturing 2025, it all indicates that a new round of scientific and technological revolution and industrial transformation has arrived. It has formed a historic convergence with China's accelerated transformation of economic development mode, which will definitely drive the development of China's manufacturing industry. As a traditional manufacturing industry, the textile industry has become increasingly popular in continuous and automated equipment applications. The online monitoring technology in production processes has made breakthroughs. However, in order to achieve continuous operation, digital control, real-time monitoring and adaptive control, and manual replacement, it is still necessary to vigorously Strengthening research and development breakthroughs in key equipment and management systems still requires steady and steady progress from intelligent production lines to digital factories.
Editor in charge: Xu Yuehua
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