Intellectualization Of Chemical Fiber Equipment Realizes Quality Improvement And Saves Manpower.

As labor costs continue to rise and

From labor intensive to technology intensive, the level of intellectualization of chemical fiber production has been increasing.

In the production workshop of Sheng Hong Polytron Technologies Inc, clean space, clean ground, machine roar, and white silk cake is grabbed by a mechanical hand along the production line, and accurately placed in the pport car that runs back and forth.

The silk cake is fully automated from all aspects such as dropping, conveying, storing, inspection and classification, packing to palletizing, and so on.

According to the introduction, Sheng Hong Polytron Technologies Inc uses intelligent logistics system to save about 50% of the total labor.

As long as the workers push the silk car onto the storage line, all the subsequent processes will be controlled by the pre-set automation program.

It is understood that similar automatic wire cutting and conveying system has been used in many chemical fiber enterprises in China.

On the basis of digitized automation of chemical fiber production line, the automatic connection of production processes and the integration with intelligent logistics system are promoting the further intellectualization of chemical fiber production.

Upgrading the NC level of complete sets of equipment

According to the characteristics of chemical fiber production and the change of production mode, modular, modular, and modular design of chemical fiber machinery products with large capacity, continuous automation and mechanical products has become a trend.

The application of computer technology and digitalization technology in chemical fiber equipment will further enhance the level of intelligence. By achieving full automation of the process, efficiency and quality improvement and labor saving can be achieved.

According to Wang Shouzeng, a Limited by Share Ltd expert at Heng Tian heavy industry, recent years

The rapid development is digital control and network communication. Not only can the network communication from production workshop to management layer be achieved, but also remote control and remote diagnosis can be achieved.

The level of automatic control has also been improved rapidly in the aspects of fault parking, fault linkage and so on.

Through the digital control, the accuracy of the chemical fiber mechanical equipment is improved, the reliability is improved, and the operation process is stable, thus making the employment less and less.

There used to be a lot of labor in the past production line, and now 2~3 is enough for 2 production lines.

Take the polyester staple fiber equipment as an example, the whole line of "Nissan 200 ton polyester staple fiber digital complete set" launched by Heng Tian heavy industry Limited by Share Ltd adopts PLC control technology and network communication integration technology to form an online monitoring and management system for the whole production process, which makes process adjustment, fault display alarm, on-line monitoring, information collection and processing more perfect, and improves the automation and digitalization control level of the combined machine.

Chen Ying, deputy general manager of Pacific Electrical and mechanical equipment, said that embedding remote monitoring system in chemical fiber FCS control system to achieve remote monitoring and diagnosis is an important step towards digital spinning machine.

At present, the fieldbus control system FCS is widely used in chemical fiber equipment, because the control system is huge and complex, which brings difficulties to users' maintenance and maintenance.

The Pacific Group Company adopts remote monitoring and diagnosis and maintenance technology in large tonnage chemical fiber equipment. Through remote monitoring of the operation of PLC, it helps users troubleshooting, enabling users to keep in touch with the equipment manufacturer for a long time at low cost, so that the equipment can operate safely at both sides at any time.

Logistics Intelligence further saves labor

With the continuous improvement of the automation of production equipment, automation of pportation and packaging has become a breakthrough point for further intelligent production of chemical fiber.

According to Mei Feng, chief engineer of Sheng Hong Polytron Technologies Inc, the packaging and logistics module of the existing polyester filament device is mainly carried out by manpower, with large investment and low output, which is not compatible with the efficiency of the existing production equipment.

The traditional manual packaging is very large, and all the packaging process and inspection process are completed by manual operation. According to the output of the existing workshop, the weight of 6 kilograms of silk rolls is packed into the carton box. The repetitive action takes 2200 times per class, and 6600 times a day. The workers need to put in a lot of energy and at the same time consume a lot of physical strength.

According to the statistical data of artificial packaging lines, the rate of man-made reduction caused by various reasons is about 1.46%, resulting in a lot of unnecessary losses.

At the same time, there are many process links, high management complexity, difficult traceability of products, and large storage area.

In 2010, Sheng Hong and Beijing Machinery Industry Automation Research Institute began to build and implement the intelligent logistics system of chemical fiber production.

The system is mainly composed of robot, chain conveyor, turntable, lifting platform and other equipment. In addition to realizing full automation of dropping, conveying, storing, testing classification, packing and stacking, it can also intelligently recognize the product. The pmission of every silk coil in inspection and packaging process is all carried out by identifying three bit code, which is accurate and efficient.

In addition, the coil information of each operation station is classified and managed according to the process section, and the master control dispatching is unified.

After building the intelligent system, the product workshop cancelled the relevant process of the original manual classification, boxing and code board, and the number of workshops decreased from 480 to 260.

The labor force has been greatly liberated. As long as the workers push the silk car onto the storage line, all the subsequent processes will be controlled by the pre-set automation program.

After the system was put into use, it saved about 50% of the total labor.

At the same time, compared with the original daily production volume of each manual production line of 190 tons, after fully automated packaging, the daily packaging output reached 250 tons.

Intelligent logistics system is more convenient for systematic management. It can acquire real-time data from the production device through real-time data acquisition interface, and send it to the database for other functional modules, such as enterprise ERP system call processing.

In terms of performance appraisal, the system has unique advantages. It can automatically calculate the production capacity and production efficiency of each team, check data, process parameter assessment, alarm assessment, yield assessment, yield assessment, consumption assessment, and so on, and play a role in improving product quality and management level.

Domestic equipment and systems are maturing

The intelligent logistics system developed by Beijing Institute of mechanical industry automation and Sheng Hong joint stock company is the first domestic intelligent logistics system for chemical fiber production in China's chemical fiber industry.

On this basis, after many revisions and improvements, the automatic drop system introduced by Beijing Institute of automation of machinery industry has been applied in many chemical fiber production enterprises.

The system realizes the automation of wire dropping, loading and pportation, and can meet the needs of multi variety production and loading at the same time according to a single lot number, and automatically completes the tracking and label printing of silk cake information.

Among them, the multi axis automatic wire dropping vehicle has improved the capability of falling and pferring, and adopted a new ground operation mode, which is beneficial to upgrading and upgrading old factories.

The system has been authorized by 1 invention patents and 1 utility models patents with independent intellectual property rights.

At present, 46 sets of automatic falling wire system have been put into use, the production is stable, the technology is advanced and reliable, the cost performance is high, the industrialization has been realized, the performance indexes and other requirements have been met, and the economic and social benefits are remarkable.

In addition, Wuxi Hongyuan Electrical and mechanical Polytron Technologies Inc has also developed a chemical fiber filament cake automatic drop conveying system.

The system is specially designed for post-processing equipment of silk cake, which is specially designed for the production line of chemical filament yarn. It can complete the automatic dropping and conveying function of the silk cake, so as to enhance the automation level of the process after the production of chemical filament yarn, improve the product quality and reduce the labor cost.

Wuxi Hongyuan uses modern design theory and method to develop automatic drop and conveying system for chemical filament yarn cake. It has fewer types of products, high substitution, simple structure and convenient maintenance. It can facilitate users to form personalized chemical fiber filament production automation auxiliary system according to actual demand combination module.

The main components are automatic dropping, automatic conveying of silk cake, automatic storage of silk cake, track and so on.

The automatic dropping module assumes the function of dropping the silk cake on the winding machine and pferring it to the cake conveying module or directly pferring to the automatic storing cake Cart module.

The system makes full use of modern driving, modern control and communication technology, and the numerical control rate of host equipment can reach 98%.

The drop module has the function of automatic addressing and positioning, and completes the dropping task according to the prescribed optimization path.

Equipped with double insurance positions to detect and optimize the movement rules to ensure the safety and reliability of the whole device and the movement stability, and the action drive fully takes into account the demand for energy saving and consumption reduction.

The conveying module can simplify the control of pre positioning handover cake, and double support arm structure, and enlarge the capacity of the cake.

Track according to user needs, customize different direction and length of the guide, to deliver the cake to the designated location.

The system can satisfy the requirement of automatic dropping of 5 different varieties at the same time.

Industry experts said chemical fiber production

The intelligent measurement and control technology and devices, such as robots, automatic cars, stereoscopic warehouses, PLC systems, workshop management system MES, and large-scale production logistics system integration, all have certain technical foundation, equipment preparation and engineering experience, but the reliability is relatively weak.

In addition, some domestic packaging machines have gaps with foreign products and need to be imported.

It is believed that through the combination of production, teaching, research and utilization, the upstream and downstream enterprises can tackle key problems together, and the domestic enterprises will be able to develop engineering practical sets of equipment and systems, and reach the international advanced level.