Using intelligent doffing machine can save doffing time, reduce labor intensity and improve labor productivity. This is an effective way to solve the problems of difficult recruitment and high labor cost in textile enterprises
1、 Features of intelligent doffer
1. The multi axis connecting rod manipulator grabs and puts, the top grabs, the vertical pulling and inserting completes once.
2. Only one person is needed for one side operation, which greatly reduces the labor intensity.
3. Suitable for doffing of bare and aluminum ingots.
4. Suitable for spinning from low count to high count, such as ordinary spinning, compact spinning, hydrogen fiber core covering and siro spinning.
5. It is suitable for any long and short models.
6. There is no need to clean the tail yarn of the bare spindle, so the maintenance work is reduced.
7. Active display of fault report, realizing "automation".
8. Suitable for spinning tube with length of 180-260mm.
2、 Production management
1. The spindle bar is pulled up when the yarn is falling, which affects the pulling and intubation of the yarn. In the early stage of using intelligent doffer, the main problem is that the spindles are often pulled up together when doffer is doffer. This also exposes the shortcomings of the enterprise in the equipment maintenance management before. By gradually repairing or replacing the spindles with invalid spindles, we can ensure that the ring plate is even, the position of the separation plate in and out is unified, the height of the leaf plate is the same, and the height of the spindles is the same.
2. Replace the imported blade to prevent continuous yarn tail cutting. The scissors sometimes cut the end of the yarn continuously when the yarn is falling, which causes the yarn to be torn off when the car is walking, and the end of the yarn is too long. By replacing the tail yarn blade in time, the enterprise keeps it sharp all the time to avoid the phenomenon of continuous cutting. At present, the enterprise uses imported blades with long service life and reduced replacement times.
3. Reduce the number of executives to avoid spinning spindle. It is inevitable that there will be a return on the spindle when spinning. Moreover, the tail of the intelligent doffer is longer than that of the artificial doffer, and it is easier to increase the return. During manual doffing, the doffing union cleans up these returns in time, but it is often not timely to use the automatic doffing machine in order not to affect the doffing speed. The main reason for the formation of loopback is the blocking of the top eye of the spinning tube, which causes the phenomenon of senior management. The doffer is required to pick out all the spinning executives who are not inserted in place and put them into the bag equipped with the car for centralized maintenance or elimination. After a cycle of car washing, the return on the spindle will not accumulate a lot, which has little impact on doffer. In addition, if the starting position of the spinning is properly adjusted, the amount of yarn returned will also be reduced. After a period of practice, the return yarn is obviously reduced, the yarn dropping efficiency is greatly improved, and the problem is solved.
4. Install start switch to reduce stop time. There is no start button at the end of FA506 spinning locomotive. In order to start the joint ahead of time and reduce the stopping time after doffing, a start switch is installed at the end of spinning locomotive. In this way, when the doffing machine runs from the front to the back of the car, the doffiner can start the joint at the back of the car, without running to the front of the car to start, which saves not only the parking time, but also the physical strength of the workers.
5. Place the yarn basket and fan-shaped tube box reasonably. The space at the front of the car is the place for changing the basket and tube of the doffing car, and there are also various transport vehicles. The place is crowded. In order to make the road as smooth as possible, the doffer shall place the yarn basket and fan-shaped tube box reasonably before doffer starts to doffer, so that the doffer can change the basket and tube conveniently and will not hinder the doffer from moving to the next machine.
3、 Personnel allocation and division of labor
1. Staffing of doffing personnel: some enterprises use automatic doffing machine to doffing by three people, that is, two people are responsible for normal doffing, including head trimming, basket changing and tube loading, and the third person is only responsible for joint. This way can speed up the doffing speed and improve the utilization rate of doffing frame. According to statistics, in general, 3 people drop yarn 20% faster than 2 people. If two people drop the yarn 80 times in a class, then three people can drop nearly 100 times. That is to say, three people doffing can increase the total number of machines in a doffing group, and reduce the number of doffing machines. However, due to too many doffing frames in charge of one doffing group, it is difficult to stagger the doffing time, which affects the production efficiency of the spinning frame and is not suitable for doffing of many varieties. At the same time, due to the fact that the doffer is not responsible for the joint, it is easy to cause more end breakage after doffer driving. So choose 2 people to drop the yarn, each group has about 75 drops. When two people drop the yarn, the relative sense of responsibility of the doffing workers is strong. There are few doffing ends and the average rate of end breakage is only 1.5%. By comparison, a 60000 spindle workshop can save three doffing workers. Because the number of machines in each doffing group is less than that of three doffing workers, the work intensity of the workers is significantly reduced, and the production management is also convenient.
2. Cleaning operation quota: FA507 spinning frame, because there is no circulating air blowing and suction, the workload of machine cleaning is relatively large. Before, the cleaning work was basically done by the doffer. After the doffer was changed, the number of doffer was greatly reduced. Moreover, the free time after doffer was very short, and there was no time for cleaning. The cleaning work could only be done by another person. A workshop with more than 60000 ingots specially arranges 15 cleaners and 5 cleaners in a class. At the same time, these cleaners can also be used as substitutes for the preparatory doffing work.
3. Allocation of maintenance personnel: the company has more than 210000 spindles, divided into four workshops, each of which has one maintenance personnel. On average, one maintenance man is responsible for 8 doffers to ensure the normal use of doffers. In addition to the repair of the broken machine, the professional maintenance personnel should also carry out periodic maintenance of the doffer, inspection and periodic replacement of vulnerable parts. Every day, the doffer should also clean the machine he uses, and learn to deal with common simple faults by himself to avoid affecting doffer.
4. Yarn dropping time arrangement: in the past, there were few machines in each group during manual doffing, and the doffing time was relatively short. Each group could finish doffing for about 45 minutes, and the setting of doffing time could completely avoid the shift. After using the doffing machine, every doffing can be completed in about 60 minutes. The extension of doffing time makes the doffing process inevitably cross the shift. At the same time, it should be noted that in the process of using the doffer, it is inevitable that there will be faults, resulting in the stop of the spinning frame. In order to reduce the stop, in a workshop, set each group of drop time to stagger the drop, so that the drop frame is not centralized. Once a doffer breaks down, other doffers can be temporarily used as a backup top, which will not affect production.
4、 Using experience
The enterprise has used the intelligent doffer for more than one year, and the overall effect is satisfactory. The use of doffing frame also let us see our own problems. At the same time, we realize that for the promotion and application of new technology, as users, we should have a positive attitude, not rely on the manufacturers blindly, and should carry out a series of corresponding technical measures and system reform for the inadaptable spinning frame.
At present, the number of doffing sets in the doffing group has increased from 24 to 33, and the per capita doffing amount has increased from 14 per shift to 38.5. The number of doffing workers in the workshop has been reduced from 66 to 24 now, and the total number of 15 specially equipped cleaners is 39, which saves 41% of the labor force. It has really achieved high efficiency and labor saving, and the labor intensity of the workers has been greatly reduced.
