Which kind of doffing form is the most cost-effective?

Current spinning companies have encountered unprecedented difficulties: high raw material costs, difficulty in recruiting workers, and high labor costs have become the norm. Although smart doffing carts can solve the problem of higher labor costs, smart cars are a new thing, and their application has a lot to do with the variety of yarns produced by various spinning companies and their management level. It is precisely due to poor management and other reasons that certain companies have problems in the use of smart cars. Therefore, many spinning companies still adopt a wait-and-see attitude towards the use of intelligent doffing cars.

Smart car doffing time is short

Retaining the head less than a collective doff

Tongling Songbao Machinery Co., Ltd. started to launch smart doffing carts in 2010. It has been a full four years now. In the past four years, Songbao intelligent doffing cars have gradually been recognized by user companies, and the number of user companies that have comprehensively promoted the use of smart doffing carts is also increasing. In the past four years, Songbao smart doffing car sales have achieved a huge breakthrough. In 2013 alone, the company provided 380 automatic doffing carts for the domestic 2.3 million spindle spinning machines.

At the end of November 2012, Tongling Songbao Machinery Co., Ltd. and Wuhan Jiangnan Group reached an intent to cooperate. Jiangnan Group used Songbao S9 intelligent doffer to reform 100,000 spindle spinning machines.

At present, Wuhan Jiangnan Group's artificial doffing, smart doffing carts and long-faller doffs coexist in three doffing forms. The company has recorded and compared three types of doffing, and three kinds of doffing can be seen through analysis of experimental data. The difference in form.

Wuhan Jiangnan Group found that the single doffing time for manual doffing and group doffing is more than 500 seconds, while the smart doggy time for single doffing is less than 400 seconds. It can be seen that the single doffing time of smart cars is more than 100 seconds faster than that of the other two doffs; the retention rate of dodging smart cars is 94.6%, and the retention rate of group doffs can reach 97%. Yarn yarn stays slightly higher than that of smart cars. In terms of labor, we use 11 people for artificial doffing 11544 spindles (26 pcs), 3 pcs for intelligent doffing 24000 spindles (50 pcs), and 2 people for 22% (22 pcs) of collective doffing 22288 spindles. By comparison, it can be seen that the smart doffing labor is slightly more than the collective doffing. There are two reasons for this result; one is that the head rate of smart doff is lower than that of the colony, and the other is that the workload for operating smart doffing is too large. If these two major problems are improved, we can say with certainty that intelligence falls. The employment of yarn trolleys can achieve a goal that is less than that of a collective doff.

There are many factors that affect the improvement of retention rate, such as "three automatic" (full yarn stop, steel plate automatically drops to the doffing position, automatic positioning of the ring plate spinning position after doffing) reliable, brake accuracy, ring The board is up and down, the speed of starting and the type of spinning, but the doffing device is the main factor. Improving the retention rate has always been the main topic of Songbo Smart Doffing. The S9 intelligent doffer is equipped with a number of patented technologies to increase the retention rate. The application of these technologies has effectively improved the breakage caused by the doffing process. The Songbao S9 intelligent doffer has a promise rate of over 93% for customers. Overall, customers are still satisfied with the S9 intelligent doffer. In order to improve the doffing efficiency and shorten the gap with the colony, Songbao will also introduce a number of improvement measures in an effort to maintain the headline rate at the level of the colony.

Improve car automation

Significantly reduce enterprise labor

It is undeniable that the S9 intelligent doffer has many manual auxiliary actions during the entire doffing process: as required, each doffing machine is equipped with a doffing worker, and a group of 2 people cooperate with each other to take responsibility for doffing, driving, and working. . Due to the fact that there are various situations in the mills, especially when there are many newcomers, it is not common for two people to fully assume all the work. In most cases, the employment still needs three people. Therefore, it is particularly important to reduce manual assistance. At present, Songbao Company has launched a new solution for this problem, namely the group-controlled tour-type automatic doffing system. The system is expected to have 1 person to undertake the entire doffing work of 2 doffers. If 2 people cooperate with each other, it can finish the head and clean the work.

No matter which kind of doffing method, the choice of customers is very simple, that is, the province of labor, investment provinces, consumables province. From the investment cost analysis, there is no doubt that the investment in the collective long fall car is almost three times that of the smart doff. From the analysis of consumables, colonies need to be equipped with each spindle, which not only has a large number of consumables, but also has a wide range of defects for maintenance. The intelligent doffer is a multi-platform, and the maintenance quantity and objects have advantages of less concentration. Over time, the quality of the machine parts of intelligent doffers will also improve, and supplies will be less and less. While the development of long-distance collective locomotives has come more than 20 years, the current consumables have also been greatly reduced.

Intelligent doffer potential to be tapped

Short cars can also be linked together

At present, compared with the S9 intelligent doffer, the only short board is a little more labor. The only way to reduce the employment is to further improve and improve the automation of the S9 intelligent doffer in all aspects of the whole doffing process, significantly reducing the dependence on labor, and saving labor, Song Group launched the group control tour automatically The doffing system will solve this problem very well.

It is now also the most effective means for the spinning shop to reduce the use of labor. The longer the spinning machine is, the longer the purpose is to increase the efficiency of the network. However, there are not many applications in the market for the current connected devices. The reasons for this are various. For example, in addition to process problems, technical problems, and other reasons, high investment costs are also a major issue.

In recent years, many textile companies are willing to spend a lot of money to buy long-range cars. The real purpose is to save people. Others have no advantage over short cars. In order to meet the customer's demand for multiple quality and small batches, the spinning factory really feels that it is easy to use spinning or short cars. The answer is of course negative.

At present, the large-scale wind dump bucket type winder is already on the market. The feature of this type of bucket type winder is that it does not require a direct connection between the spinning frame and the winding machine. It should be said that this type of bucket winding machine is more suitable for China's national conditions. However, the speed of popularization of this winder in the current market is not fast. The main reason is that the tail yarn of the yarn is not easy to find, requires manual assistance, and is not suitable for the bobbin of the light spindle.

However, these two problems have solutions; the S9 intelligent doffer is controlled by the program during the doffing process, which can meet the requirements of the winding process on the yarn tail and can greatly improve the efficiency of the winder. Savio's Bona/E Premium fully automatic winder can process cop yarn produced by a spinning machine without automatic doffing device. In addition, the QPRO-VCF fully automatic winder from Murata of Japan is also It can cope with the light shaft spindle. Murata's machine was successfully combined with a S9 intelligent doffer at a spinning mill in Shandong.

Through the analysis of Wuhan Jiangnan Group's production practice data, we clearly see that the S9 intelligent doffer is worthy of us to explore in terms of satisfying the needs of the production process, or saving the potential for excavation of labor and investment savings, and we have reason to believe The S9 intelligent doffer will not be a transitional product, nor is it an expedient measure.