20170314 china asia textile forum rieter automation encnblowroom&...

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

Automation in yarn manufacturing

China & Asia Textile Forum 2017纺纱生产过程中的自动化

2017中国亚洲纺织论坛

Michael Hubensteiner 胡本石 2017.03.14

Machines & Systems 设备与系统The systems supplier – From bale to yarn for 4 spinning technologies系统供应商—从棉包到纱线的四种纺纱技术

20160314 Automation in yarn manufacturing M. Hubensteiner

Air-JetSpinning

RotorSpinning

SpinningPreparation

FibrePreparation

RingSpinning

CompactSpinningCompactSpinning

2

环锭纺纤维准备纺纱准备转杯纺紧密纺喷气纺

3

Automation in yarn manufacturing纺纱生产过程中的自动化

• Point of departure / Introduction讨论的起点/背景

• Automation by Rieter立达提供的自动化

• Case study: Ring mill China案例分析：中国环锭纺纱厂

• SPIDERweb – Mill Control System蛛网纱厂管理系统


5

• Automation in spinning mills is gaining importance in almost all markets aroundthe globe.纺纱厂自动化在全球几乎所有市场都越来越重要

• Labor shortage, reliability of mill staff and quality consistency are the maindrivers for this trend劳动力短缺、纺纱厂员工的可靠性和质量稳定性都是这一趋势的主要驱动因素

• The decision about the right degree of automation is not easy and requirescareful planning of the customer specific needs.确定自动化的适当程度不易，需要对客户特定需求进行仔细的规划

• It is important to find out the right balance between investment cost, complexityof the system and the real savings in labor force (and labor cost).在投资成本、系统复杂性和真正的劳动力节省（和劳动力成本）方面找到适当的

平衡是非常重要的

Point of departure 讨论的起点



6

Substitution of labour force Automation not too complex

Market requirements regarding automation

市场对于自动化的需求



代替劳动力自动化不能过于复杂

13th Five-year Plan 2016 – 2020十三五规划（2016 – 2020）

Main tasks in 13th Five-year plan in China Cotton Spinning Industry

中国棉纺行业十三五规划主要目标

20160314 Automation in yarn manufacturing M. Hubensteiner 7

Main index target in period of "13th Five-year Plan"

Items Index Unit 2015 2020 average annual growth (%)

Economy index

main business income - - 5 - 6total profit - - 2 - 3exports value - - 2 - 3investment - - 15

Production

spinning capacity 10,000 spindles 12,000 10,000 - (3 - 5)weaving capacity 10,000 machines 118 106 - (2 - 3)yarn production 10,000 tons 1,850 2,000 1 - 1.5fabric production 10,000 tons 585 610 1 - 1.5knitting : home textile : garment (yarn consumption) rate 44:23:33 48:22:30 -

Product structure adjustment

cotton mill consumption 10,000 tons 675 750 2MMF mill consumption 10,000 tons 1,260 1,550 3New-type fibre yarn 10,000 tons 115 180 8 - 9

Technology upgrade

link of roving & ring & cone winder + automatic packing 10,000 spindles 230 2,000 50 - 55

compact spinning 10,000 spindles 2,107 3,500 10 - 11air-jet spinning 10,000 positions 13.5 25.0 13high-speed weaving looms 10,000 machines 38.0 53.0 6 - 7

Sustainable development

comprehensive power consumption (standard coal / ton) % -4.7 -4.7 - (4 - 5)

Data source: CCTA

• Build up reference of intelligentialized and digitalized mills (workshops) with features of automated and intelligentialized production, online monitoring and controlling on process and quality, automatic transportation & packing, intelligent stock, intelligent management.

• 开展以自动化和智能化生产、在线工艺和质量监控、自动输送包装、智能仓储、智能管理为主要特征的数字化、智能化工厂（车间）试点示范

• Spinning capacity with link of roving & ring & cone winder + automatic packing, should reach 20 million spindles in 2020 from 230,000 spindles in 2015, with annual growth of 50%

• 配备粗细连，细络联，自动打包系统的纱锭数从2015年的23万锭，至2020年增长到2，000万锭，年增长率达到50%以上

9

Ringspinning plant: Process overview

环锭纺纱厂：流程概览


Blowroom & Carding 开清和梳棉

Drawframe并条

Combing preparation 精梳准备

Combing 精梳

Drawframe并条

Roving 粗纱

Ringspin细纱

Cone winding 络筒

Palletizing 码垛

stretching & labelling捆包&贴标


10

Step 1: 1000mm cans in preparation line

步骤1：前纺工序上的直径1 000 mm的条筒



Drawframe并条


Combing 精梳

Drawframe并条

Roving 粗纱

Ringspin细纱

Cone winding 络筒

Palletizing 码垛

stretching & labelling 捆包&贴标



11


步骤1：前纺工序使用直径1 000 mm的条筒



Card à Drawframe à Lap Winder à Comber à Drawframe



步骤1：前纺工序使用直径1 000 mm的条筒

梳棉机 à 并条机 à 条并卷联合机à 精梳机 à并条机

13

• Labor reduction: 40% less can movements between process steps

节省用工：减少各个工序之间的条筒移动达40 %

• Efficiency: around 3% higher efficiency (especially lap winding)

效率：提高效率达3 %（特别是条并卷工序）

• Quality: less manual sliver piecings

质量：减少手工棉条接头

• Remark: becomes standard in green field projects

备注：成为Green Field项目的标准

Step 1: Customer benefits

步骤1：客户受益



14

Step 2: Automation in the combing section (ROBOlap + SERVOlap)

步骤2：精梳工序的自动化（ROBOlap + SERVOlap）


Roving 粗纱

Ringspin细纱

Cone winding 络筒

Palletizing 码垛



Drawframe并条


Combing 精梳

Drawframe并条



15




- ROBOlap棉卷自动接头系统


16




- SERVOlap棉卷自动运输系统

17

• Labor reduction: elimination of manual lap transportation with trolleys

节省用工：利用棉卷运输车无需人工运输棉卷

• Efficiency: 2% higher comber efficiency

效率：提高精梳机效率达2 %

• Quality: better piecing quality (CV%)

质量：提高接头质量（CV%）

• Remark: fast growing demand (industry standard in somemarkets already)

备注：快速发展需求（在某些市场中已成为行业标准）





18

Step 3: Transport automation from Roving to Winding (SERVOtrail + Link)

步骤3：从粗纱至络筒的运输自动化（SERVOtrail + Link）




Drawframe并条


Combing 精梳

Drawframe并条

Roving 粗纱

Ringspin细纱

Cone winding 络筒

Palletizing 码垛





步骤3：从粗纱工序至络筒工序的运输自动化（SERVOtrail + Link）

SERVOtrail粗纱自动运输系统

20

• Labor reduction: elimination of manual roving and cops transport节省用工：无需人工粗纱和管纱运输

• Efficiency: up to 5 % higher roving frame efficiency效率：粗纱机效率提高达5 %

• Quality: improved roving quality due to contact free transport质量：粗纱质量提高得益于无接触的运输

- no uncontrolled intermediate storage of bobbins避免工序间存储纱管（粗纱和管纱）管理无序- prevention of material mix-up避免原料混淆

• Remark: clear must for modern spinning mills 备注:现代化纺纱厂标准配置




步骤3：从粗纱工序至络筒工序的运输自动化（SERVOtrail + Link）

21

Step 4: Automatic bobbin handling (cooperation with 3rd parties)

步骤4：筒纱自动处理（与第三方合作）




Drawframe并条


Combing 精梳

Drawframe并条

Roving 粗纱

Ringspin环锭纺

Cone winding 络筒

Palletizing 码垛



Automatic bobbin transport system Centralized palletisation system




自动粗纱纱管运输系统集中码垛系统

23

• Labor reduction: elimination of manual bobbin handling and transport节省用工：无需人工纱管处理和运输

• Efficiency: higher machine efficiency (especially at coarser counts)效率：提升机器效率（特别在生产粗支纱时）

• Quality: consistent quality, no danger that bobbins are damagedduring manual handling

质量：稳定的质量，在人工处理过程中无筒纱受损的风险

• Remark: trend in bigger mills, already standard in US.备注：在较大的纺纱厂已成为趋势，在美国已成为标准。





25

Example: Ringspinning mill for Ne 30, PES/CO combed, 1’200 kg per hour

Management Summary (Case study: location China)

管理总结（案例研究：中国）



示例：环锭纺纱厂加工纱线，Ne 30，涤/精梳棉，1 200 kg/h

26

4 mill types with different degrees of automation.


Mill Setup纺纱厂

Can size [mm]条筒尺寸

ROBOlap SERVOlap SERVOtrail Link System细络联系统

Bobbinhandling筒纱处理

1 600/500 No无 No无 No无 No无 No无

2 1000/600 No 无 No 无 No 无 No 无 No 无

3 1000/600 Yes 有 Yes 有 Yes 有 Yes 有 No 无

4 1000/600 Yes 有 Yes 有 Yes 有 Yes 有 Yes 有


Management Summary (Case study: location China)

管理总结（案例研究：中国）

自动化程度不同的四种纺纱厂

27

051015202530354045

Mill setup 1 Mill setup 2 Mill setup 3 Mill setup 4

Winding/LogisticRoving/RingCombingDrawingBR&Carding

Roving/Ringspinning is most intensive labour process

粗纱/细纱工序是用工需求最大的工序


- 33%

Number of operators per shift

43

39

30 28 (*)

(*) corresponds to 17 operators / 10’000 Spindles (3 shifts)


每个班次的用工数量

(*)对应于17个挡车工/10 000锭（3个班次）

纺纱厂设置1 纺纱厂设置2 纺纱厂设置3 纺纱厂设置4

络筒/运输粗纱/细纱精梳

并条

开清&梳棉

28

0

20

40

60

80

100

Mill setup 1 Mill setup 2 Mill setup 3 Mill setup 4

total investment

yarn conversion cost per kgoperators per shift

Management Summary: the total overview

管理总结：总览


in percent [%]

Remark: base for calculation are Chinese capital and labour cost


纺纱厂设置1 纺纱厂设置2 纺纱厂设置3 纺纱厂设置4 备注：计算基于中国资金和人工成本

用百分比表示[%

]

总投资

每千克纱的加工成本

每个班次用工

SPIDERweb – Mill Control System蛛网纱厂管理系统

Competence in intelligent control increases economic viability in spinning.

智能控制系统提升纺纱生产的经济生存能力


Customer Benefits客户获益• Mobile alert for quick action• 移动终端报警可快速反馈• Energy monitoring for optimized consumption

• 能源监测可优化生产能耗• Quality control for constant yarn properties

• 质量控制可确保纱线品质一致性• Climate watch for optimal production• 环境监测可优化生产过程• Assistant modules for build in knowledge

• 辅助模块可建立专业能力储备• SPIDERweb for high productive quality spinning

• 蛛网系统可确保高产、高质的纱线生产

SPIDERweb – Mill Control System蛛网纱厂管理系统

• More than 20 years experiencein production 超过20年的实际运行经验

• Online monitoring system fordaily production of spinning mill实时在线监测纺纱厂生产状况

• 9 modules to optimize millmanagement efficiency 九大模块协助优化工厂管理水平

• Real-time fault diagnosis byRieter via connection with Rietercentral server 通过连接立达服务器实现故障实时诊断

Features of SPIDERweb蛛网纱厂管理系统的特点


Raw materialUtilization原料利用

Quality level质量水平

Labour Efficiency用工效率

Time to market市场反应

Asset utilization资产使用

Energy consumption能源消耗

Value driver

ISM单锭监测

Wallboard壁挂显示屏

Client客户端

SPIDERweb蛛网系统

Alert报警

E

Energy能耗

Climate环境监测

Assistant辅助

Cockpit座舱显示

Existing features 原有功能Value driver价值驱动

New feature 新增功能

31

SPIDERweb – The Modular Concept蛛网系统 – 模块化设计理念

32

WallBoard - SPIDERweb data at a glance

壁挂显示屏 –蛛网系统数据一目了然


Most important information visible for the operator from up to 40 m distance.为操作人员显示最重要的生产信息，可视距离达40米

• Displaying information for the machine operator

• 为设备操作人员显示生产信息

• Promotes self controlling

• 便于自我管理

• Leads to more efficiency in spinning

• 提高纺纱生产效率

Cockpit Module 座舱显示模块

33

èMobile report of the most important spinning mill data for fast remote analysis.

è在移动终端（手机）上显示最重要的纱厂生产数据，实现远程快速分析

• Main Selection 可供视图选项• Mill Selection 工厂选择• Cockpit 座舱显示• Machine list 设备列表• Single machine status 单机状态• Shift Reports 班组报告• Preferences 自选设定

Mill is on your cell - Overview 手机上的纺纱厂 –概述


Alert Module报警模块

34

High design accuracy of components for best fibre selection

纺纱专件完美匹配各种纤维


• Mobile brief information of exceeded alarm limits for prompt debugging

• 若实际生产中出现超出设定范围的情况，在移动终端（如手机）上显示故障信息，方便快速排除

• Main Points 要点• Default Setting 默认设定• Personnel Setting 个人设定• Alert 警报• Filtering 信息过滤功能

Alert


Energy Module - way to a sustainable yarn production

能耗模块 –通向可持续化纱线生产


Yarn count纱支

Cotton Type棉花等级

Energy (kWh)(Wh/kg)能耗

Advantages 优势

• Optimisation of energy consumption 优化能耗• Provides flexibility for analysing with customised parameters.• 可灵活选择不同指标进行分析• Easy conversion cost calculation 成本计算非常便捷


Display of energy consumption per quantity of yarn, time period or machine. 可按某时间段或某台设备显示生产每千克纱所需能耗，

Energy Module - way to a sustainable yarn production

能耗模块 –通向可持续化纱线生产


3%

9% 5%

83%

Rotor yarn转杯纺

2%

8% 5%

85%

Air-jet yarn喷气纺

2% 6%3%6%

62%

21%

Ring yarn环锭纺

Blowroom CardingDraw frames RovingSpinning Winding

100 % Viscose, India, Ne 30 100%粘胶，印度，30支

End spinning the most energy consuming process step in spinning followed by carding.

后纺是整个纺纱工序中能耗最高的一环，紧接着是梳棉

37

THANK YOU FOR YOUR KIND ATTENTION 谢谢大家！

Automation in yarn manufacturing

纺纱生产过程中的自动化


20170314 china asia textile forum rieter automation encnblowroom&...

Documents