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The Road to Transformation and Upgrading of Intelligent Technology and Equipment in Textile Industry
In most people's impression, 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 position of competing with intelligent machines for jobs.
The latest results of the China Enterprise - Employee Matching Survey ( CEES ) jointly conducted by the Institute of Quality Development Strategy of Wuhan University, the Chinese Academy of Social Sciences, Stanford University and the Emerging Markets Research Institute of Hong Kong University of Science and Technology show that manufacturers are adopting automation technology, investing in research and development, and adding new products with higher added value in view of the fact that real wages have more than doubled in the past 10 years.
Recently, the reporter also happened to see in Suzhou zhenlun cotton spinning co., ltd's intelligent production workshop of biomass regenerated fiber materials that a constant temperature and humidity working environment was maintained in the spacious and tidy workshop, and a high-speed automatic machine replaced the busy scene of the original rows of textile workers travelling back and forth, with only a few workers patrolling and simply operating, all of which subverted people's impression of the traditional textile industry.
According to Wu Jiankun, deputy general manager of the company, thanks to the investment in intelligent equipment and technological process transformation, more than 100 people now need only 20 people to do the work, which not only greatly improves the production efficiency but also improves the stability of product quality.
" If you want to do good work, you must first benefit from it. " Enterprises can not develop continuously without the products of" intelligent weapons ". The biomass fiber workshop introduced a large number of fully automatic and internationally leading intelligent equipment such as German carding and drawing machine, fine winding type Qingze spinning frame, Japanese fine winding type automatic winder with online monitoring function, which realized automatic control of drawing feeding, rotating speed, spinning speed, viscosity, self winding joint, conveying and other links. Intelligent workshop integrates digital information technology, MES, ERP and other management systems to achieve perfect integration of intelligent workshop information and ERP data.
In the intelligent workshop, " automation of the whole production process", " intelligence of the control system" and " informatization of online monitoring", Wu Jiankun introduced that each spindle will be networked through sensors, and the system can monitor the situation of each spindle on the production line in real time, greatly saving manpower and improving efficiency. The whole process maintains a high degree of continuity, reduces the chance of manual yarn contact, further stabilizes and improves the yarn quality, and greatly improves the production efficiency and labor productivity.
Shen Peirong, chairman of the board of directors of the company, said frankly that the labor price is rising and the market competition is becoming increasingly fierce. If we still follow the old methods, we will surely lose market competitiveness gradually 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 informatization are the only way for enterprises to develop. " It's not whether you want to do it or not, but the market and environment force you to do it. To reduce costs and find a way out of intelligent manufacturing, intelligent manufacturing can double the production efficiency, hoping to hedge the high labor cost with intelligence and make money as less people use it will become an unavoidable reality in textile industry. There will be fewer and fewer professional workers in textile industry in the future, and there is no way out without reducing labor to improve production efficiency. This is the basis of transformation and upgrading, and there is no other way out. "
The benefits of this move are all - round. Shen Peirong, for example: " In 2005, the company employed 130 people for 10,000 spindles, now 35 people for 10,000 spindles of biomass, and only 15 people for 10,000 spindles of vortex spinning. Each year, the actual labor cost per 10,000 ingots is reduced by about 3.5 million yuan. In the past, the tube pulling process required manual operation. Now, each machine is equipped with a manipulator, which can pull out all 1200 spindles at one time and insert all empty tubes at one time through the manipulator. "
" The renewal of equipment has also promoted the progress of technology. In the past, our products were mainly ring spinning. Today, we follow the development trend of spinning technology and adopt siro compact spinning technology. The same viscose yarn, compared with ordinary ring spun yarn, can sell 3000 pieces more per ton, and the products are exported to the high-end textile market in the world. Many domestic and foreign first-line brands are long-term customers of Zhenlun. " Wu Jiankun said.
Since 2008, Zhenlun Cotton Spinning System has been investing more than 100 million yuan per year in production equipment renovation for several consecutive years, introducing advanced spinning equipment from Germany, Japan, Switzerland and other countries, and building a Zhenlun Biomass Intelligent Workshop.
After several years of intensive cultivation, Zhenlun cotton spinning has basically realized full automation, intelligence and informatization of the workshop. At present, Zhenlun is building a model factory for the whole-process digital automation and intelligent production of 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 all the machines together. The production process can all be tested online, and a visual intelligent master control system can be established to realize data exchange and integrated management among the machines. The company's goal is to build an intelligent spinning factory with interconnected production equipment, real-time scheduling of production processes, automation of material transfer, traceability of product information, monitoring of workshop ambient intelligence, intelligent monitoring of resource consumption, and coordination of design, development and production.
Shen Peirong said that the textile industry has entered a new historical period, and the company has taken intelligent manufacturing and green development as its important starting point to speed up the cultivation of new energy and core competitiveness and to walk out a road of transformation, upgrading and development supported by intelligent technology and equipment.