Digital Transformation "Weaves Out" A New Future

The textile industry is one of the most direct and closely connected industries with the people's better life. Every change in the textile industry has a profound impact on human life style. What is the process of turning a piece of cotton into yarn? How does Smart Spinning spin yarns with stable quality? Recently, the reporter came to a spinning factory in Nantong, Jiangsu Province to explore how "one silk" can weave "great wisdom".

　　 One cotton "wisdom" changes into a roll of thread

The original cotton should be preliminarily cleaned by the crochet machine, and then enter the carding machine after removing impurities and short fibers. The metal comb needles on the machine will comb the cotton to make it become a loose fiber mesh. Then through the drawing frame, multiple fiber webs are combined to form continuous and uniform slivers through drafting and compaction. The sliver is then fed into the roving machine, which is drawn and twisted to make thicker yarn, called roving. The roving passes through the spinning frame to form a finer yarn, which can accurately control the yarn fineness and evenness. Spinning machine is the most critical equipment in yarn production. In the winding cylinder, the spinning yarn is wound into a package or a winch for the subsequent dyeing or weaving process.

There is a saying in the textile industry that "thousands of people yarn, thousands of people cloth". Now, Jiangsu Dasheng Group Co., Ltd. 100000 spindle intelligent spinning factory has realized intelligent operation, intelligent equipment and digital manufacturing. Automatic bag grabbers, carding machines and intelligent packaging systems replace manual work to complete production processes. Winders and packaging links are connected by overhead lifting rails. Yarns are transported by AGV robots, packed by global baling machines, and finally automatically warehoused.

Interior view of 100000 spindle intelligent spinning factory. Provided by Jiangsu Dasheng Group Co., Ltd

"From the blowing carding unit, through parallel connection, parallel connection, parallel rough connection, coarse fine connection, fine networking, to the end of the package warehouse connection, the intelligent logistics system enables all production equipment to operate intelligently. 100000 spindles rotate at high speed, all processes are automated and intelligent, and workers only need to handle faults according to the system prompts." Xia Jing, deputy director of Dasheng Group's smart spinning factory, said.

　　 Breaking the "information island" of the production workshop

In the intelligent production process of yarn, the sensors on all machines can collect production information in real time, and then upload the data to the intelligent management cloud platform through 5G for data analysis, monitor the production status in real time, adjust the process in time, reduce downtime, and improve production efficiency.

The platform uses Internet of Things technology, edge computing technology and mobile interconnection technology to realize the interconnection between devices and people. Production management, equipment management, energy management, production scheduling, process management, and cost accounting support each other and work together to support the efficient operation of the smart spinning factory.

Dasheng intelligent management cloud platform. Provided by Jiangsu Dasheng Group Co., Ltd

Zhao Zhihua, deputy general manager of Dasheng Group, said, "We all use spinning yarn single spindle detection technology, and each spinning yarn has a single spindle detection. If there is a broken end, it will send a signal to the mobile phone through the platform in time to guide the barricade to find the location in time and handle the fault."

　　 "Black Light Factory" Shines with the Light of "Intelligent Manufacturing"

Intelligent factory operation has greatly liberated the productivity. Even when the lights are turned off, the machines in the workshop can operate automatically 24 hours a day. By turning off the lights without interruption, the "black light factory" can be operated.

The factory lighting system uses human body sensing and light sensing technology. When there is no personnel passing or work demand, the light will go out automatically. Take spinning production line as an example, when the number of broken ends is less than three, the light is always off, and only when manual treatment is required, the light will be on.

From the traditional "ten thousand people factory" to today's "black light factory", behind each step of transformation, the demand for electricity is growing day by day. Therefore, the power service system is also constantly upgrading. At the same time of the construction of the smart spinning factory, Dasheng Yarn Factory has independently built a 110 volt power supply system to support the power demand of the entire industrial park.

Gu Xuefeng, Safety Director and Head of General Management Department of Dasheng Group, said: "The implementation of the 'Black Light Factory' system and the application of energy-saving technology have enabled the current smart chemical plants to consume 3400 kilowatt hours per ton of electricity, which is 20% lower than the traditional spinning plants."

　　 Digital transformation "weaves out" a new future

Jin Xin, secretary-general of Nantong Textile Association, Jiangsu Province, said, "China's textile industry is actively promoting the deep integration of advanced technologies such as big data, artificial intelligence and the Internet of Things with the textile industry. In the future, China's smart textile industry is continuing to increase investment in technology research and development, promote innovation and breakthrough in key technologies such as new fiber material smart sensors and electronic devices, and more reflect humanistic care and responsible development. "

Qi Yingbin, Secretary of the Party Committee and Chairman of Dasheng Group, said: "The textile industry is a big power consumer, and the green and low-carbon development path is the key innovation of the industry development. Dasheng Group is planning to build China's first zero carbon spinning workshop, enabling the green development of the industrial chain."

From Zhang Jian, the pioneer of China's machine spinning, to the completion of the first domestic smart spinning factory. The digital transformation of the textile industry is not only the upgrading of technology, but also a profound reflection on the future of the traditional textile industry. Through the power of digital technology, we will open up a more intelligent, efficient and environmentally friendly development path for traditional industries.

(Source: People's Daily Online)