自我診斷 自我修復才是智能化

繆定蜀

蘇州市紡織工程學會高級工程師

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自我診斷 自我修復才是智能化

繆定蜀

蘇州市紡織工程學會高級工程師

《中國紡織》：您認為目前國產紡機和進口紡機的主要優(yōu)勢和不足表現(xiàn)在哪些方面？

繆定蜀：國外依然占領著紡織制造業(yè)高地，秉承高科技、數(shù)碼智能、高附加值、環(huán)保節(jié)能的宗旨開發(fā)高端產品，互聯(lián)網(wǎng)可連接紡機公司全球服務網(wǎng)絡系統(tǒng) ，以太網(wǎng)實現(xiàn)大數(shù)據(jù)量快速、可靠、在線監(jiān)測、實時傳輸，實現(xiàn)對關鍵質量參數(shù)精確控制與監(jiān)督，優(yōu)化紡機高效性能。

國內紡機近幾年在創(chuàng)新設計、精細制造方面進步較大，特別是私企進步比國企更加明顯，出現(xiàn)了不少“黑馬”，打破了國外高端技術的壟斷。國內紡機產業(yè)鏈正在經(jīng)歷從無序生產向有序生產方式的轉化，紡紗新設備必須能夠適應重定量、高速度、高效能、低能耗，尤其品種更換及適應性需求，在高端紡機研發(fā)，智能、自動化功能開發(fā)與單機連接方面取得較大突破，包括與之配套的高性能高端器材的研發(fā)及運用。

不足：設備穩(wěn)定性、故障率、使用壽命等方面仍有不小差距，新設備磨合期比國外高達數(shù)倍，實際車速不理想，例如噴氣織機，樣機速度1000～1200rpm，實際只能開到550～700rpm。

原因如下：機械仿造國外設備部件，沒有吃透每個部件的性能要求，關鍵部件不過關；設備開車性能不穩(wěn)定，尤其提速后，磨損大、噪音大，故障率偏高；在精細加工上更需要下功夫，機臺加長、負荷加重，磨損就加大；電氣故障高，特別是變頻器、編碼器、傳感器、電機等選配不當在磨合期就顯現(xiàn)；與工藝上車配套的相關的技術不到位，沒有專家系統(tǒng)作支撐，使工藝不能真正長期穩(wěn)定上車。

《中國紡織》：未來紡機的發(fā)展趨勢是什么？紡紗、織造等設備發(fā)展將會出現(xiàn)哪些新的特點？

繆定蜀：精細化、智能化、自動化、低能耗，低碳環(huán)保、資源節(jié)約型生產方式以及講究質量、品質、品牌、品種多樣化的可持續(xù)經(jīng)營方式是大勢所趨.

紡紗設備檔次迅速提升，三無即“無卷、無接頭、無梭”；“一連”即單機連續(xù)化；四化即“自動化、智能化、高速化、網(wǎng)絡化”；二低即“能耗、故障”作為紡織技術發(fā)展努力方向。紡紗設備自動化、智能化、網(wǎng)絡化將成為常態(tài)，具有代表性的賽絡紡、集聚紡集落細紗機長車，采用一系列高速元素：模塊化設計；電子牽伸；電子升降；節(jié)能電機；節(jié)能錠子；無機械波羅拉；高速鋼領鋼絲圈；實際車速突破2萬轉/分，達到國際先進水平。國產織造設備在高端紡機設備領域與國外差距比紡紗設備要大一些，近兩年有所改觀，噴氣織機與劍桿織機實際運行速度分別可以突破1000rpm、650rpm。織機發(fā)展在高速前提下，更加注重個性化、市場化、智能化、模塊化及機配件互換。并憑借其突破性創(chuàng)新技術，如在線智能控制及智能加工技術、經(jīng)空氣動力學優(yōu)化設計元件及更高效技術，實現(xiàn)更高產能和更高效生產。質量差，惡性循環(huán)；薄弱環(huán)節(jié)仍然存在諸如無故障時間（MTBF），新機磨合時間，使用壽命，加工精度一致性等。

在技術研發(fā)深度、對市場敏感度與理念上還有不小差距，要從仿制向創(chuàng)造轉變，從速度向品質轉，從圍繞價格轉向圍繞市場轉。紡機應加快調整戰(zhàn)略，提升戰(zhàn)術，尋求突破，縮短與國際同行在設計、材料選用、精加工、工藝、熱處理、裝配調試等整體制造技術上差距，尤其要做到可靠性、故障率低，必須從設備設計初就融入零故障理念，計算降低產品全壽命周期成本費用，包括專用基礎件、配套器材，突破傳統(tǒng)設備固有結構限制、基礎材料與工藝處理、器材配置等，參與國際合作，推行質量、標準、品牌、信譽的經(jīng)營理念。

《中國紡織》：您認為國產紡機設備穩(wěn)定性、可靠性不足的原因主要有哪些？國產紡機要和進口設備在國際市場上同臺競技，還需要在哪些方面上努力和加強？

繆定蜀：與國外設備相比，國產紡機往往速度上去了，機身就會晃動、磨損就會加大、噪音大，能耗高，斷頭高，效率低，

《中國紡織》：您今年參加紡機展嗎？如果參加的話，參加的主要目的是什么？每屆展會的收獲大嗎？

繆定蜀：本人期待紡機展，并目睹本屆紡機展的盛況。今年紡機展是在紡織業(yè)市場大調整、供給側改革重要節(jié)點上會有不少亮點、看點。希望紡機提供下游產品做到故障、能耗低；產能、質量高；品種適應性強的精品。每一屆紡機展都感受到我國紡機企業(yè)不懈努力，與國外的差距逐漸在縮小。本屆展會也不例外，在原創(chuàng)性、智能化、個性化的紡機設備將會有閃亮點，甚至會有驚喜。

《中國紡織》：您對國產紡機未來發(fā)展有哪些建議或意見？

繆定蜀：希望我國成為真正的制造強國，學習德國制造文化元素中專注、標準、精確、完美、秩序、厚實六大精神，拋棄急功近利的經(jīng)營手法，要以全新超前創(chuàng)新思路、全新工匠制造精神、全新結構的概念打造世界級水平的紡機設備，要有更多“中國元素”的自主核心技術、原創(chuàng)技術和知識產權，加快實現(xiàn)“中國紡織制造”向“中國智造”轉型。

提升紡機設計水平，將聯(lián)網(wǎng)、云計算融入其中核心技術，通過Web方式、PC和手機客戶端等形式實施遠程監(jiān)控，降低管理成本。但互聯(lián)網(wǎng)是工具，是建立在現(xiàn)代化高性能高可靠設備基礎上的，我國紡織企業(yè)整體裝備水平與國外差距很大，要分階段實施，決不可追求時髦和炒作概念。即使弄了幾條樣板智能生產線，目前還沒有真正實行智能化紡紗線，只有實行自我診斷、自我修復才是完全智能化。

China Textile： What do you think about the main advantages and disadvantages of domestic and imported machinery？

Miu Dingshu： Foreign textile manufacturing industry still occupies highland，with purposes of high-tech， digital intelligent， high value-added， as well as environmental protection and energy saving to develop high-end products. Based on the global service network system， the Ethernet realizes fast， reliable online monitoring and real-time transmission of a large amount of data， and precise control and supervision of key quality parameters， optimizing high performance of textile machinery.

In recent years， domestic textile machinery enterprises make great progress in innovative design and fine manufacturing， especially for private enterprises with many “dark horses”， and break the foreign monopoly in high-tech to meet the requirements of high-tech weaving special equipment at national strategic level. With the transformation of domestic textile industry chain from disordered production mode to order one， new spinning equipment can meet the requirement of big ration， high speed， high efficiency， and low energy consumption， and especially the change of varieties and adaptability can meet the market demand. It makes great breakthroughs in R&D of high-end textile machinery，development of intelligence and automation， and single connection， as well as the development and application of high-end equipment with high performance.

Disadvantages： There is a wide gap with foreign machinery in equipment stability， failure rate， service life and so on，and even in the several times of run-in period of new equipment， which exists various potential problems of hidden danger，reliability and stability， etc.. Actual speed is not ideal， such as air-jet loom， with prototype speed of 1000～1200rpm， but actual speed of 550～700rmp.

The reasons are as follows： mechanical imitation of foreign equipment components， without full understanding of performance requirements， and the key components of poor equipment； serious wear， big noise and high failure after speeding-up；the need of more efforts in fine processing， as well as longer machine and heavier load with increasing wear； high electrical fault will appear in the run-in period with improper transducer， encoder， sensor， motor and others； lack of related techniques and expert system can’t realize long-term stability of the process.

China Textile： What are the future trends of textile machinery？ What are the new features of the equipment of spinning， weaving and others？

Miu Dingshu： The general trends areproduction patterns of refinement， intelligence， automation， environmental protection and resource-saving， and sustainable business methods with high quality， brand and diversification of varieties.

The level of spinning equipment increases rapidly， with non twist， non joint，and non shuttle， continuity of single machine， low energy consumption and low fault， as well as automation， intelligent，high speed and network as the development direction of the textile technology. It will be normal for spinning equipment with automation， intelligent and network， and the representative siro spinning and compact spinning frame adopt a series of advanced elements， including modular design， electronic drafting， electronic lifting， energy saving motor， and energy saving spindle，roller without mechanical wave and high speed ring-traveller， and actual speed of over 20 thousand rpm/min at the international advanced level. Under the premise of high-speed development， it pays more emphases on personalization， marketization，intellectualization， modularity and interchange of parts for weaving machine. It can achieve a higher capacity and more efficient use of resources， by its innovative technology， online intelligent control and intelligent processing technology， optimized design components with aerodynamic and more efficient technology.

China Textile： What are the main reasons for the deficiency of equipment stability and reliability of domestic textile machinery？ What aspects need to be strengthened， if domestic textile machinery and imported equipment compete in the international market？

Miu Dingshu： Compared with foreign equipment， domestic machinery is in a vicious circle， with body shaking，serious wear， noise， high energy consumption， low efficiency and poor quality， if the speed is increased. Weak links still exist many problems， such as MTBF， runningin period， service life， the consistence of processing precision， etc..

There is still a big gap in the depth of R&D， market sensitivity and concept， so it is necessary to transform from imitation to creation， from speed to quality， from price-base to market-orientation. Textile machinery should speed up the adjustment of strategy with breakthrough， shorten the gap between international counterparts in the design， material selection， fine processing， technology， heat treatment，assembly debugging and so on， especially for the reliability and low failure rate，which must integrate the concept of zero fault in the design， and calculate the cost of reducing life cycle of products， including special basic parts， supporting equipment， as well as break inherent structure limitation of traditional equipment， basic materials and processing， and equipment configuration.

China Textile： Will you participate in textile machinery exhibition this year？ If so， what are the main purposes？Any harvest？

Miu Dingshu： I look forward to seeing the textile machinery. There will be many highlights under the background of market adjustment and supply front reform. It’s expected for products with low fault and energy-consumption， high capacity and quality， competitive products with adaptability. It is obvious that textile machinery enterprises have improved a lot with tireless efforts. There will be lots of surprises in the original， intelligent and personalized equipment.

China Textile： Do you have any suggestion or advice on the future development of the domestic textile machinery？

Miu Dingshu： I hope that our country could be real manufacturing power of textile machinery to learn the qualities in German cultural elements and abandon the utilitarian business practices. We should create world-class textile equipment with advanced innovative ideas， new craftsman spirit and new structure concept， as well as more independent core technology， original technology and intellectual property rights to accelerate the realization of “made with wisdom” from “made in China”.

The saturation of spindles makes textile machinery improve design level with the core technology of networking and cloud computing， and reduce management cost by remote monitoring of Web， PC and mobile phone. But as a tool， Internet is on the basis of high performance and high reliable equipment， and overall equipment level of China’s textile enterprises is far behind foreign ones， so it should be implemented in phases without speculation. Without real intelligent spinning line，it must implemented self diagnosis ans self repair to realize complete intelligent.

Suzhou Textile Engineering Society Miu Dingshu

Senior Engineer