The use of intelligent doffing machines can save doffing time, reduce labor intensity, and improve labor productivity. This is one of the effective ways to solve the current problems of difficulty in recruiting workers and high labor costs in textile enterprises.
1. Features of intelligent doffing machine
1. Multi-axis The connecting rod manipulator grabs and places, grabs the top, and vertically removes and inserts in one go.
2. Only one person is required to assist the operation on one side, greatly reducing labor intensity.
3. Adapt to light spindle rod and aluminum spindle rod doffing.
4. Suitable for ordinary spinning, compact spinning, hydrogen fiber core spun and siro spinning, etc. from low to high count yarns.
5. Suitable for modification and use of any long or short model.
6. The tail yarn of the light spindle rod does not need to be specially cleaned, reducing the maintenance workload.
7. Fault reports are automatically displayed to achieve “automation”.
8. Suitable for spun yarn tubes with a length of 180-260mm.
2. Production management
1. Pulling up the spindle bar during doffing will affect the Doffing and removing the cannula. The main problem faced in the initial stage of using the intelligent doffing machine is that the doffing machine often pulls up the spindles when doffing. This also exposed the company’s previous deficiencies in equipment maintenance management. By gradually repairing or replacing the spindles with failed spindle feet to ensure that the ring plates are flush, the entry and exit positions of the gauze plates are uniform, the blade plates are at the same height, and the spindles are at the same height, the problem is solved.
2. Replace the imported blade to prevent continuous yarn tail cutting. When doffing, the scissors sometimes fail to cut the yarn tail, causing the trolley to tear the yarn while walking, causing the yarn tail to be too long. The company replaces the tail yarn blade in time to keep it sharp and avoid the phenomenon of continuous cutting. At present, the company uses imported blades, which have a long service life and reduce the number of replacements.
3. Reduce the number of high-end pipes to prevent the spindle rod from wrapping around the wire. When doffing spun yarn, there will inevitably be yarn residue on the spindle bar, and the yarn tail of the intelligent doffing machine is longer than the yarn tail of the manual doffing, making it easier to increase the yarn residue. During manual doffing, the doffing union will clean up these waste yarns in time. However, when using an automatic doffing machine, the cleaning is often not timely in order not to affect the doffing speed. The main reason for generating yarn waste is that the eye of the spun yarn tube is blocked, causing the phenomenon of high tube. The doffing workers are required to pick out all the spun yarn tubes that cannot be inserted in place, and put them into the bags equipped on the trolley for centralized repair or elimination. After one cycle of car washing, the waste yarn on the spindle bar will not accumulate a lot, which will have no impact on the doffing. big. In addition, appropriately raising the spinning position of the spun yarn will also reduce the amount of yarn waste. After a period of practice, the yarn waste was significantly reduced, the doffing efficiency was greatly improved, and the problem was solved.
4. Install a start switch to reduce parking time. There is no start button at the rear of the FA506 spinning machine. In order to start the splicing in advance after doffing and reduce the doffing and parking time, a start switch is installed at the rear of the spinning machine. In this way, when the doffing machine runs from the front of the car to the back of the car, the yarn is doffed and the tube is inserted, and the trolley returns to the front of the car by itself, the doffer can drive the joint at the back of the car instead of running to the front of the car to drive, which not only saves parking time, but also Saves workers’ physical strength.
5. Arrange the yarn basket and fan-shaped tube box reasonably. The space at the front of the car is where the doffing car changes baskets and tubes. There are also various transport vehicles, so the place is quite crowded. In order to make the road as smooth as possible, the doffing workers should place the yarn baskets and fan-shaped tube boxes reasonably before starting doffing, so that it is convenient for the doffing workers to change baskets and tubes, and it will not hinder the doffing car from moving to the next machine. .
3. Staffing and division of labor
1. Doffing staffing: used by some companies Automatic doffing machines usually use three people for doffing, that is, two people are responsible for normal doffing including head sorting, basket changing, and tube loading, and the third person is only responsible for splicing. This method can speed up the doffing speed and improve the utilization rate of the doffing machine. According to statistics, under normal circumstances, three people doffing is 20% faster than two people doffing. If 2 people doff a class of 80 doffs, then 3 people can doff nearly 100 doffs. In other words, three people doffing can increase the total number of machines in a doffing group, which relatively reduces the number of doffing machines invested. However, since one doffing group is responsible for too many doffing machines for three-person doffing, it will be difficult to stagger the doffing time, which affects the production efficiency of the spinning machine and is not suitable for multiple varieties of doffing. At the same time, three people doffing because the doffing workers are not responsible for splicing, which can easily lead to more broken ends after the doffing is started. Therefore, we choose 2 people to doff, and the amount of doffing in each group is about 75 doffs. There are two people doing doffing, and the doffing workers have a stronger sense of responsibility. There are very few doffing breakages, and the average breakage rate is only 1.5%. By comparison, a production workshop with 60,000 spindles can save 3 doffing workers. Since the number of machines in each doffing group is less than 3 doffing workers, the work intensity of workers is significantly reduced, and production management is also facilitated.
2. Cleaning operation capacity: FA507 spinning machine, because there is no circulating blowing and suction air, the workload of machine cleaning is relatively large. In the past, the cleaning work was basically done by doffing workers. After the switch to doffing machines, the number of doffing workers was greatly reduced, and the free time after doffing was very short. There was no time for cleaning anymore. The cleaning work had to be assigned to additional personnel. Come and do it. A workshop with more than 60,000 spindles has 15 cleaners, 5 in a shift. At the same time, these cleaners can also serve as substitutes for preparatory doffing work.
3. Maintenance personnel allocation: The company has more than 210,000 spindles, divided into 4 workshops, and each workshop is assigned a maintenance personnel. average one dimensionThe repairman is responsible for 8 doffing machines to ensure the normal use of the doffing machines. In addition to repairing faulty machines every day, professional maintenance personnel also perform periodic maintenance on doffing machines, inspect and periodically replace vulnerable parts. Doffers also need to clean the machines they use every day, and learn to deal with common simple faults by themselves to avoid affecting doffing.
4. Doffing time arrangement: In the past, there were fewer machines in each group of manual doffing, and the doffing time was relatively short. Each group of doffing could be completed in about 45 minutes. The time setting can completely avoid shift handover. After switching to a doffing machine, each doffing takes about 60 minutes to complete. The extension of the doffing time makes it inevitable that the doffing process will span the handover shift. At the same time, it should be noted that the doffing machine will inevitably malfunction during use, causing the spinning machine to stop. In order to reduce downtime, in a workshop, the doffing time of each group is set to stagger the doffing so that the doffing machines are not used intensively. Once a certain doffing machine fails, other doffing machines can be temporarily used as backup without affecting production.
IV. Experience of use
The enterprise has been using the intelligent doffing machine for more than a year, and the overall effect satisfy. The use of doffing machines also allows us to see our own problems. At the same time, we realize that as a user, we should have a positive attitude towards the promotion and application of new technologies. We cannot blindly rely on manufacturers and respond to unsuitable spinning machines. , and implement a series of corresponding technical measures and institutional reforms.
At present, the number of doffing units in the company’s doffing group has increased from the original 24 to 33, and the per capita doffing volume has increased from the original 14 doffing units per shift to the current 38.5 doffing units. The number of doffers in the workshop has been reduced from the original 66 to the current 24, plus 15 specially equipped cleaners, a total of 39 people, saving 41% of labor, truly achieving high efficiency and labor saving, and the labor intensity of workers has been greatly reduced. </p
