Textile Machinery Automation Seeks New Ideas for "Low Carbon"

Business Club July 7th 2009 The Copenhagen conference held the term “low carbon” as a household name in China. With the increasing pressure on energy and environmental protection, China's textile industry is once again on the cusp of becoming a key target of governance. In such an urgent situation, the transformation and upgrading of textile technology and textile machinery have become the focus of Chinese textile machinery companies. At the same time, this is also a great opportunity for the Chinese textile machinery to go to the world of textile machinery.

At present, enterprises in various industries have spared no effort in promoting products while playing a key role in the "low-carbon" brand. In the textile industry, "low-carbon" has become a key breakthrough in competition among major companies. However, experts in the textile industry have appealed that "low-carbon" should not be the gimmick of corporate propaganda, but should devote more efforts to improving the performance of textile machinery.

Modular design improves textile machinery performance

Speaking of the technological development of textile machinery, we must mention the development history of textile machinery and electromechanical integration: preliminary mechatronics, basic mechatronics, highly mechatronics and then intelligent factories. Zhou Jintao, chief engineer of the Technical Center of Shanghai Erfang Machinery Co., Ltd. pointed out that textile machinery is a complex electromechanical combination system, and the transmission part is a key part of electromechanical integration, and it is the breakthrough of mechatronics. Therefore, after the integration of the motion control technology and the textile machinery, the evolutionary speed of the textile machine mechatronics has been greatly accelerated.

The transformation of the integrated structure into a modular structure is also one of the criteria for the technical breakthrough of textile machinery and electromechanical integration. According to Zhou Gong, modularization simplified the mechanical design, improved reliability, reduced costs, and increased production speeds. Moreover, the concepts, methods, and methods for the development of traditional textile machinery have been changed conceptually, and the updating cycle of textile machinery products has been accelerated. At the same time, modularity has laid the foundation for flexibility and intelligence. After integrating the intelligent technology modules formed by machine vision technology, direct drive technology and intelligent control technology, modern textile machinery has entered a stage of “highly mechatronics”. And laid the foundation for the establishment of the next intelligent factory. This also presents a blueprint for the development trend of domestic textile machinery enterprises: the simplified mechanical design means the saving of manufacturing materials and the reduction of manpower, and the realization of flexibility and intelligence makes the work of energy saving and emission reduction of the factory easier. Therefore, the modular design has not only improved the performance of textile machinery, but also enabled textile machinery companies to further achieve the "low-carbon" target at the technical level.

Management and Control Integration Will Promote the Development of Information Control Integration

With the development of automation technology from stand-alone control to factory automation and system automation, textile production companies conduct on-line collection and processing of information on production, quality, and equipment operation status in the production process, and perform comprehensive lean management in the workshop or corporate management. . According to Zhou Gong, in developed countries, due to high labor costs, rapid product renewal, and high quality requirements, more than 80% of textile manufacturing enterprises in developed countries have adopted integrated systems for control and control, and are currently developing in the direction of integrated control information. However, there is no practical system for our country to stay in the demonstration stage, let alone spread popularization.

Lu Yongxian, a textile machinery automation expert and senior engineer, also expressed his deep feelings about this. He gave an example: “In terms of chemical fiber equipment, the process flow basically comes from chemical industry, and the level of automation is relatively high. PLCs, human-machine interfaces, and frequency converters are already In this regard, the direction of development is mainly the integration of management and control, that is, the integration of production management and production control, and some real-time and specific information such as temperature and flow data in the production process should also be integrated via two-way communication. The system is managed by the system.” But he also pointed out that the existing large-scale production lines have achieved integration of management and control, but the level is still high or low. He suggested using small MES and other systems to improve the effectiveness of management and control integration. . Zhou Gong also emphasized that the competitiveness of textile companies has increasingly depended on the system's ability to integrate and respond, not the stand-alone level. To achieve integration, the key lies in how to exchange information and communicate information. The core point is not the physical layer network hardware and the basic network protocol, but the data content, or the application layer profile. The essence is to solve the communication between the MES and the device layer, to realize the interoperability of data is the real purpose, it should also be the main content of the industry standard. Only data sharing can control integration, and only data sharing can provide users with practical benefits.

It is understood that the current international advanced textile machinery companies are developing from the integration of management and control to the integration of information control, and China's textile machinery is gradually being developed from the integration of electromechanical integration to management and control. Zhou Gong believes that if we can grasp the important historical opportunities of electronic information technology from PC/network computing to the development of pervasive computing models, adopting advanced technologies and standards as far as possible can not only avoid detours but also have the possibility of producing late-comers and realize China's textile automation. The leap in technology has accelerated the pace of upgrading of textile machinery and textile enterprises in China. At the same time, it also adapted to the requirements of the international "low-carbon" production standards.

Textile machinery automation has huge room for improvement

Because the textile industry has complicated processes and many processes, the automation needs of different types of textile machinery are also diversified and specific. Lu Gaogong mentioned in an interview that in many types of textile machinery, the level of automation is not the same. But overall, the automation of textile machinery will bring about the following improvements: First, it will speed up production and improve the production process. Second, replacing labor by automation can standardize many production processes; On the other hand, the efficiency of automated testing is higher than that of artificial ones, and it is of great significance for the quality assurance of fabrics.

Specific to the technical level, Zhou Gong introduced that motion control technology has become a new topic in the application of textile machinery, including electrospinning (ie, independent driving), multi-motor combined driving of multiple actuators and slender shafts, and in order to solve spinning Machine special requirements for the development of new types of motors and other technologies have become the focus. At the same time, modern permanent magnet synchronous technology has replaced asynchronous technology, thus avoiding problems such as speed slip, efficiency, etc. The cost can also be controlled within a reasonable range. At present, many textile machines are also used in China, such as Shanghai Textile Machinery Co., Ltd. The EJK213 roving frame (48-spindle prototype) is produced using 96 permanent magnet synchronous motors to directly drive each of the flyers and bobbins, making it the world's first electrospinning roving machine.

Lu Gaogong introduced the importance of automation technology in the application of autoleveling technology on the draw frame. If the strips are too thick or too thin, they need to be detected by the equipment and timely adjusted by the implementing agency to meet the required standards and indicators. Specifically speaking, it is through detection first, then computer operation, and then using the AC servo to perform, from the sensor detection of the terminal to the servo motor responsible for implementation, which requires a series of automated mechanisms to operate. There is still a considerable gap between domestic similar products and imported products, which are still mainly imported. From the cost point of view, the price of the autoleveling device accounts for almost half of the price of the complete machine, which can be described as a relatively concentrated part of the cost of the entire machine. If the quality of the self-leveling device developed in China can be improved to better meet the requirements, So the cost of the whole machine is expected to be reduced to a great extent. From the application of automation technology on the draw frame, it can be seen that the domestic textile machinery automation technology has huge room for improvement.

The two experts all mentioned in the interview that the promotion of “low-carbon” in the textile industry cannot be superficial, and improving product technology is the top priority. The management and technical personnel of the machinery manufacturing enterprises must follow the attention of new products, new technologies and new trends in the application of textile machinery while studying the national policies. This is the basis for the textile enterprises, and it is also the Chinese textile machinery going to the world textile machinery. The only way for a strong country.

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