自我诊断 自我修复才是智能化

缪定蜀

苏州市纺织工程学会高级工程师



自我诊断 自我修复才是智能化

缪定蜀

苏州市纺织工程学会高级工程师

《中国纺织》：您认为目前国产纺机和进口纺机的主要优势和不足表现在哪些方面？

缪定蜀：国外依然占领着纺织制造业高地，秉承高科技、数码智能、高附加值、环保节能的宗旨开发高端产品，互联网可连接纺机公司全球服务网络系统 ，以太网实现大数据量快速、可靠、在线监测、实时传输，实现对关键质量参数精确控制与监督，优化纺机高效性能。

国内纺机近几年在创新设计、精细制造方面进步较大，特别是私企进步比国企更加明显，出现了不少“黑马”，打破了国外高端技术的垄断。国内纺机产业链正在经历从无序生产向有序生产方式的转化，纺纱新设备必须能够适应重定量、高速度、高效能、低能耗，尤其品种更换及适应性需求，在高端纺机研发，智能、自动化功能开发与单机连接方面取得较大突破，包括与之配套的高性能高端器材的研发及运用。

不足：设备稳定性、故障率、使用寿命等方面仍有不小差距，新设备磨合期比国外高达数倍，实际车速不理想，例如喷气织机，样机速度1000～1200rpm，实际只能开到550～700rpm。

原因如下：机械仿造国外设备部件，没有吃透每个部件的性能要求，关键部件不过关；设备开车性能不稳定，尤其提速后，磨损大、噪音大，故障率偏高；在精细加工上更需要下功夫，机台加长、负荷加重，磨损就加大；电气故障高，特别是变频器、编码器、传感器、电机等选配不当在磨合期就显现；与工艺上车配套的相关的技术不到位，没有专家系统作支撑，使工艺不能真正长期稳定上车。

《中国纺织》：未来纺机的发展趋势是什么？纺纱、织造等设备发展将会出现哪些新的特点？

缪定蜀：精细化、智能化、自动化、低能耗，低碳环保、资源节约型生产方式以及讲究质量、品质、品牌、品种多样化的可持续经营方式是大势所趋.

纺纱设备档次迅速提升，三无即“无卷、无接头、无梭”；“一连”即单机连续化；四化即“自动化、智能化、高速化、网络化”；二低即“能耗、故障”作为纺织技术发展努力方向。纺纱设备自动化、智能化、网络化将成为常态，具有代表性的赛络纺、集聚纺集落细纱机长车，采用一系列高速元素：模块化设计；电子牵伸；电子升降；节能电机；节能锭子；无机械波罗拉；高速钢领钢丝圈；实际车速突破2万转/分，达到国际先进水平。国产织造设备在高端纺机设备领域与国外差距比纺纱设备要大一些，近两年有所改观，喷气织机与剑杆织机实际运行速度分别可以突破1000rpm、650rpm。织机发展在高速前提下，更加注重个性化、市场化、智能化、模块化及机配件互换。并凭借其突破性创新技术，如在线智能控制及智能加工技术、经空气动力学优化设计元件及更高效技术，实现更高产能和更高效生产。质量差，恶性循环；薄弱环节仍然存在诸如无故障时间（MTBF），新机磨合时间，使用寿命，加工精度一致性等。

在技术研发深度、对市场敏感度与理念上还有不小差距，要从仿制向创造转变，从速度向品质转，从围绕价格转向围绕市场转。纺机应加快调整战略，提升战术，寻求突破，缩短与国际同行在设计、材料选用、精加工、工艺、热处理、装配调试等整体制造技术上差距，尤其要做到可靠性、故障率低，必须从设备设计初就融入零故障理念，计算降低产品全寿命周期成本费用，包括专用基础件、配套器材，突破传统设备固有结构限制、基础材料与工艺处理、器材配置等，参与国际合作，推行质量、标准、品牌、信誉的经营理念。

《中国纺织》：您认为国产纺机设备稳定性、可靠性不足的原因主要有哪些？国产纺机要和进口设备在国际市场上同台竞技，还需要在哪些方面上努力和加强？

缪定蜀：与国外设备相比，国产纺机往往速度上去了，机身就会晃动、磨损就会加大、噪音大，能耗高，断头高，效率低，

《中国纺织》：您今年参加纺机展吗？如果参加的话，参加的主要目的是什么？每届展会的收获大吗？

缪定蜀：本人期待纺机展，并目睹本届纺机展的盛况。今年纺机展是在纺织业市场大调整、供给侧改革重要节点上会有不少亮点、看点。希望纺机提供下游产品做到故障、能耗低；产能、质量高；品种适应性强的精品。每一届纺机展都感受到我国纺机企业不懈努力，与国外的差距逐渐在缩小。本届展会也不例外，在原创性、智能化、个性化的纺机设备将会有闪亮点，甚至会有惊喜。

《中国纺织》：您对国产纺机未来发展有哪些建议或意见？

缪定蜀：希望我国成为真正的制造强国，学习德国制造文化元素中专注、标准、精确、完美、秩序、厚实六大精神，抛弃急功近利的经营手法，要以全新超前创新思路、全新工匠制造精神、全新结构的概念打造世界级水平的纺机设备，要有更多“中国元素”的自主核心技术、原创技术和知识产权，加快实现“中国纺织制造”向“中国智造”转型。

提升纺机设计水平，将联网、云计算融入其中核心技术，通过Web方式、PC和手机客户端等形式实施远程监控，降低管理成本。但互联网是工具，是建立在现代化高性能高可靠设备基础上的，我国纺织企业整体装备水平与国外差距很大，要分阶段实施，决不可追求时髦和炒作概念。即使弄了几条样板智能生产线，目前还没有真正实行智能化纺纱线，只有实行自我诊断、自我修复才是完全智能化。

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