Zhejiang: Spinning Enterprises Adopt 8 New Technologies To Quicken The Pace Of "Machine Substitution"

In recent years, Zhejiang Province

Like the spinning enterprises across the country, it is facing increasingly severe market environment.

The increasing cost of processing, the pressure brought about by the low price products of the neighboring countries, the obsolete equipment, and the excessive employment, make many enterprises producing conventional products face losses, insolvency, failure to maintain normal production or even bankruptcy.

In response to these phenomena, many spinning enterprises in Zhejiang actively adopt 8 new technologies of intelligence and automation to speed up the pace of "machine substitution".

Technology 1: automatic mixing machine and wool machine are used instead of manual labor.

Effect: raw materials mix evenly, reduce labor 2/3 or more.

At present, along with

The development of multi-component and multicolor fiber blending direction is an important prerequisite for spinning yarn.

In order to make the blending and blending more uniform, many enterprises use artificial mixing (or mixed wool), but this way of mixing is not only time-consuming, but also difficult to achieve the requirement of mixing (uniform).

In recent years, Zhejiang Huafu color spinning company and Zhejiang Zhong Ding textile company have worked with the relevant machinery manufacturers to take the lead in the development of digital automatic blending machine and wool machine to replace manual blending.

It makes use of various raw materials (or a variety of color raw materials) at intervals to feed and pversely displace the principle of dislocation, so that the multi-component (multi color) raw materials have reached the full mixing uniformity, and can also reduce labor employment by more than 2/3.

At present, the automatic cotton blending technology is being applied in Zhejiang spinning enterprises.

Technology two: expansion of blowing carding applications and pformation of traditional equipment

Effect: save more than 50% of labor and improve yarn quality.

Blowing carding is a mature and advanced technology. In recent years, Zhejiang spinning enterprises have adopted two methods to speed up the application of blowing carding: one is to actively adopt the equipment of blowing carding made at home and abroad, the other is to carve up and connect the traditional cotton opener and carding machine and pform it into a simple blowing carding machine.

The simple blowing carding unit has the advantages of low retrofit and good flexibility.

Ningbo's Vico, Hangzhou Hongyu and many other enterprises have achieved three effects after renovation. First, they have omitted the cotton cleaner and cotton roll pport workers. At the same time, because of the need to manually change the cotton rolls, the carding machine can expand the number of watches and save more than 50% of the labor.

Two, the self levelling device installed on the carding machine can effectively control the weight difference of the sliver and improve the evenness and evenness of the yarn.

The three is that after the cotton is cleared, the cotton is always fed into the carding machine in loose state. It can not only improve carding degree of the carding machine, but also reduce the fiber damage. It also has a positive effect on reducing neps in the carding sliver.

Technology three: drawing frame adopts self leveling and automatic changing cylinder technology.

Effect: saving labor force 1/2~1/3, effectively reducing energy consumption.

The drawing is a process that connects the preceding and the following. The intelligent self leveller is installed in the drawing process, especially on the end drawing frame. The weight difference of the output bar can be effectively controlled by the automatic pmission of the front and rear rollers, replacing the traditional backward method of manually controlling the weight of the output bar by changing gears.

The self leveling technology of the drawing frame realizes the online automatic control and reduces the number of drawing lines.

The spinning enterprises of Zhejiang province have already used the single spinning process when spinning the cotton combed yarn. The spinning of the blended yarns can also be changed from the original three strips to two. Due to the decrease of the number of drawing frames, the labor force 1/2~1/3 can be saved and the energy consumption can be reduced.

In addition, after many technological innovations, the drawing speed of the drawing frame has been continuously improved. At present, the output speed has reached 1000 m / min, and the normal speed is also between 400~500 M / min. However, the increase of speed will shorten the time of changing the cylinder and increase the workload of the loader.

Therefore, in recent years, the spinning enterprises in Zhejiang province have actively adopted the drawing frame with automatic barrel changer, and there are 3 spare barrels at most, so that the equipment can automatically change the drum 3 times without stopping the machine, so that the operator can be changed for one hour to change the cylinder operation, which not only reduces the labor intensity of the workers, but also expands the grandstand ability.

If the Zhejiang spring Jiang Textile Group adopts two new technologies, the ability of the grandstand will increase from 6 to 10~14.

Technology four: roving machine adopts automatic doffing and thickness combined technology.

Effect: Employment decreased by 50% or less.

The coarse and fine connection technology will automatically deliver the roving yarn from the roving frame to the roving frame of the spinning frame directly through the automatic control sprocket pport system, and return the empty roving tube used by the spinning frame to the roving machine.

The popularization and application of two new technologies of roving automatic doffing and thickness and thickness in Zhejiang spinning enterprises not only reduce roving doffing and roving pport workers, but also reduce the roving defects of artificial doffing, and also have a certain effect on improving the quality of yarns.

In addition, through the renewal and pformation, the original roving machine driven by the mechanical pmission of the cone wheel is changed into a multi motor intelligent control roving frame, so that the output speed of the roving machine, the synchronism of the speed of the spindle and the flyer rotation speed are increased, and the constant tension force of the large middle small yarn and the front and back rows of roving is realized, thus eliminating the details of the switch car.

At the same time, due to the decrease of the failure rate and the decapitation rate in the roving frame operation, the roving stand capacity increased from the original 1~2 / person to 3~4 station / person.

Because the roving automatic doffing technology and the popularization and application of the intelligent roving frame have reduced the utilization of the roving process by about 50% than the original one, it is now being extended and applied in the spinning enterprises of Zhejiang province.

Technology five: adopt automatic doffing spinning machine and automatic doffing car.

Effect: reduce labor by about 50%, and increase production efficiency.

Spinning is the most frequently used spinning process. In order to reduce the employment of spinning process, Zhejiang spinning enterprises have accelerated the pace of adopting automatic collective doffing spinning machine in recent years.

At present, more than 2000 sets of automatic doffing spinning machines have been used in production in Zhejiang Province, accounting for more than 20% of the total spindles in the province.

The collective automatic doffing spinning machine realizes automatic and intelligent operation of manual doffing, intubation and bobbin pportation.

Taking ten thousand spindles and one doffing team as an example, the doffing workers can be reduced from 6 to 2, and three shifts can save 12 doffing workers and greatly reduce the heavy labor of the original doffing workers.

In addition, the doffing stopping time can also be shortened from about 5 minutes to about 3 minutes, effectively improving the production efficiency.

The intelligent doffing car is a new technology for reducing the labor intensity of workers and reducing doffing workers at present.

At present, there are also many spinning enterprises in Zhejiang expanding, such as Zhejiang Bailong Orient Corp has adopted this new technology in large area.

After more than one year's practice, the company has two doffing cars for 14.8~18.5 tex yarn automatic doffing 1.5~2.0 million spindles per hour, and doffing workers can be reduced from 6 to 3, saving 50% of labor force.

The adoption of intelligent doffer car can also achieve the purpose of saving labor, and the cost of retrofit is less. It is welcomed by small and medium-sized enterprises with weaker economic strength, and its use will be further expanded.

In spinning process, Zhejiang spinning enterprises are currently promoting the application of single spindle intelligent on-line monitoring technology.

This technology is equipped with a sensor on each spindle, real-time monitoring each spindle running and production efficiency data, and timely feedback to the workshop and plant management computer through network technology, to help eliminate abnormal spindles and defective parts in time, so that the equipment is in good working condition.

Zhejiang Hongyang Textile Group has used spinning single spindle on-line monitoring technology for nearly a year. Because the technology has better achieved the combination of information and networking, it has created good economic benefits for enterprises.

Technology six: use automatic winding machine and double twister.

Effect: save about 50% of yarn winder and improve yarn quality.

In recent years, the pallet type automatic winding machine developed by domestic and foreign enterprises has realized automatic and intelligent operation of the spinning tube, automatic output of the empty yarn tube, and automatic operation of the automatic winding of the winding, so that the number of per unit of the winder can be expanded to 3~4. According to the example of 3 spindles per 10000 spindles, the pallet type automatic winding machine can only be easily monitored by 1 truck drivers per ten thousand spindles, so that the winding process can be used as the least working procedure from the labor force, which fully shows the superiority of "machine replacement".

In addition, replacing the traditional ring twister with high speed large volume twister is also an effective measure to save labor.

Because the doubling twister can be directly wound into a cheese, the winding process after twisting is omitted, and the yarn winder can be saved by about 50%. Meanwhile, the volume of the bobbin processed by the twister is large and the number of the joints is reduced, which is conducive to the improvement of the yarn quality.

Technology seven: application of intelligent on-line inspection technology for foreign fibers

Effect: completely replace artificial

The foreign fiber in cotton is also known as "three silk". If it can not be effectively removed during spinning, it will seriously affect the quality of yarn and final product.

There are three ways to eliminate foreign fibers in domestic spinning enterprises.

It is difficult to clean up because of artificial eye difference; two is to install foreign fiber detection and picking equipment in the opening and cleaning process, and use different pmittance differences of different substances to discharge foreign fibers; three, increase the function of removing foreign fibers on the electronic clearer of automatic winder.

It is unrealistic to manually pick foreign fibers in the current difficult recruitment situation. Zhejiang spinning enterprises adopt second and third methods to control the foreign fibers in yarns.

There are several models for the installation of different fiber inspection control equipment in the open and clear cotton. However, the principle of digital imaging is applied to detect and remove the foreign fibers that can not be pmitted through the light source under a specific light source. It effectively substitutes the method of manually selecting the foreign fibers in raw cotton, and realizes the "machine replacement" and saves a lot of manpower.

Technology eight: adopting new rotor spinning and air-jet vortex spinning technology.

Effect: the cost of work cost is 1000 yuan / ton lower than that of ring spinning.

Compared with ring spinning, rotor spinning and air-jet vortex spinning have many advantages, such as short spinning process, high production efficiency, low labor consumption and low energy consumption. In recent years, the use of these two new spinning equipments in Zhejiang is expanding.

According to preliminary estimates, Zhejiang has owned about 400000 kinds of rotor spinning machines and more than 500 air-jet spinning machines totaling over 4.5 million spindles.

Produced by new spinning technology.