Craftsmanship, continuity, complete sets; high speed, high efficiency, save maintenance; standardization, serialization, generalization; low energy consumption, low noise, low public health, is the characteristics and direction of modern textile machinery.
Process
In recent times, people's understanding of the structure and physical and chemical properties of fibers continue to deepen, and thus create more and more advanced process methods, which can more fully play the characteristics of fibers and fabrics. In order to cooperate with this development, modern textile machinery using mechanical technology, electrical technology, especially weak electricity technology to create a wide range of categories, different performance processing machines. For example, the preparation process of industrial coated fabrics are coated, rolled and laminated three kinds of method, the design of the machine also has three different structures accordingly. Another example of synthetic fibers on the dye affinity is small, for this point on the creation of can shorten the dyeing time and achieve good dyeing fastness of high temperature (130 ℃), high pressure (2.7 kg / cm) dyeing equipment.
Continuity
The continuity of textile machinery is subject to the process. For example, spinning 20.8 to 27.8 cotton yarn, from cotton to spinning the total drafting times of 13,900 to 19,000 times. The process needs to go through the clearing, carding, and bar, roving, spinning and other processes, so the draft must be allocated to the corresponding equipment to complete the process. Another example of resin processing (see wrinkle finishing), the fabric is first impregnated with resin in the dipping mill, and then in the roaster by high temperature treatment so that the resin in the fibers between the condensation, and finally in the flat washing machine by the soap washing, washing to remove the resin residue is not combined, and then drying machine drying. The whole process is determined by the process requirements and cannot be reversed, unconditionally omitted or combined processes.
Sets of
Textile machinery sets also belong to the process. For example, according to the cotton spinning process configuration of complete sets of machines, machine types arranged in order of priority, the number of machines between the fixed relationship between the process requirements are determined. Another example is a certain range of loom weaving products, the need to configure the corresponding range of work inspection, amount of cloth, as well as dyeing and finishing equipment, also belongs to the complete set. Therefore, the complete sets of textile machinery exists not only in a factory, also exists in the factory and factory.
High speed
Modern textile machinery, a major feature of the development is to continuously improve the operating speed of the machine, so as to obtain a high yield, in order to reduce the number of equipment with the number of units, reduce the size of the plant, saving investment and labor, with less money to achieve greater results. Table 1, Table 2, Table 3 in the figures illustrate the tendency of high speed textile machinery.
The main measure to improve the operating speed of textile machinery is to more rationally design parts and components structure, the use of good performance materials and improve processing accuracy.
High efficiency
The high efficiency of textile machinery is based on high speed plus the corresponding other measures to achieve. Such as exhaust cotton box and carding machine self-leveling device developed successfully, the realization of the joint clearing and carding, thus eliminating the roll process and clearing the cotton into a roll device, saving a lot of handling work, improve efficiency. Combed wool spinning due to the use of self-adjusting leveling device (see draw self-adjusting leveling) so that the number of pre-spinning process by the 40's 7 to 10 channels reduced to 4 to 7 channels, reducing the machine with the table, saving the plant area, saving investment and labor, reducing costs. Mechanization, automation devices gradually replace heavy manual labor and reduce the number of operators, is to improve the efficiency of textile machinery is another measure. Modern spinning machine with automatic drop yarn insertion tube head device, instead of heavy manual drop yarn operation; automatic joint device instead of artificial circuit joints. Textile machinery is the original simulation of human action is constantly improved, has become a highly automated machinery with artistry and sophistication. As a result of the development of large-scale integrated circuits produced by microelectronics technology, microprocessors and electronic computers, began to penetrate the single and complete sets of textile machinery. High-speed automatic winder equipped with electronic yarn clearer, can automatically detect yarn defects and coarse details, automatic removal and automatic knotting, but also with the microprocessor interface for yarn defects, coarse details of the classification statistics. Equipped with microprocessor fabric inspection machine can use the display screen will be related to the defects of the category of the number of statistics, the location of the defects, the length of each roll of cloth (minus the bad part of the cloth) and the weight of the statistical form, and in a batch of cloth inspection after the output of the total number of rolls of cloth, classification of the number of defects and the deduction of bad amount of cloth report, but also can print out the results or recorded on tape for future inspection.
Save maintenance
Modern textile machinery in the design of the full attention to reduce maintenance and prolong service life. In the selection of materials and the development of heat treatment process after careful consideration, to ensure that the parts of the long life, reliable action. Some of the components used in the assembly of a full lubricant, in a number of years without refueling; the use of detection devices to prevent accidents; the use of special processing to make the parts have a mirror finish, and so on.
Standardization
The repeatability of the same part of each machine is another feature of textile machinery. To spinning machine, for example, each with 400 spindles, while spinning 400 yarn, you need the same steel collar, spindle, etc. 400 only. As for the knitting machine with the number of needles is even more huge. 6.6 meters working range of high-speed warp knitting machine needs 7,280 grooved needles per unit. Production of these parts of the machine shop needs to be designed according to the batch size of the parts of the corresponding tools, fixtures, molds and dies up to the special multi-station automatic machine tools or special assembly lines to ensure that the production of these parts of high efficiency, high quality and low cost. Textile machinery parts of the complexity is also manifested in the type, because the processing object is different, the need for cotton, hemp, wool, silk, chemical fiber and other different raw materials design and manufacture of different types of parts. For example, wool spinning spindle to have a larger size than the cotton spindle, but the structure is similar. Again, because of the fabric width of the various must have the structure of the same principle but the working range of different types of machines. If you let the above parts and machine parameters arbitrary development, it will give the textile machinery factory product design efficiency, production management and production costs and other adverse effects, and will make the textile factory equipment management, wear parts reserves, maintenance and replacement of increased workload, and even cause disorders in factory management. The purpose of standardization is to meet the different process requirements under the principle of simplification as far as possible, the distribution of the main technical parameters of the appropriate numerical spacing as a group of different capacities of the machine design basis. Such as spinning machine according to the spindle distance, loom and dyeing machine according to the working range, knitting machine according to the diameter of the cylinder, each forming a series of design.
Serialization
In the series design of a group of machines in a part of the machine series parameters have nothing to do with the machine parts or components, can be applied to a certain range of machines in this series, such as spinning machine head part, lifting part of the parts. In addition, some parts in different types of machines to play the same function, such as printing and dyeing machine guide rollers, rollers and so on. These parts are called universal or universal device, in the printing and dyeing machine is further developed into a universal unit machine.
Generalization
In the mechanical product design, in addition to try to use the common parts, common device, common unit machine, people are conscious of the structural layout of the appropriate amendments, as much as possible to implement the principle of generalization. Textile machinery standardization, serialization, generalization has begun to cross the boundaries between countries and towards internationalization, such as the drafting mechanism parts and needles, needle cloth, etc., in many countries have adopted the same parameters.
Low energy consumption
Textile machinery to save energy focus on dyeing and finishing equipment, because there is a lot of potential. For example, in the hourly output of 1000 kilograms of flat washing machine, the use of discharge temperature of 98 ℃ wastewater heating itself required fresh water, only by single-shift calculations can save tens of thousands of dollars a year. The use of jet dyeing machine, can make the dyeing bath ratio from ordinary dyeing machine 1:20 ~ 1:30 reduced to 1:5 ~ 1:15, dyeing time can be reduced by 50%. Although the machine needs to use large-capacity pumps to spray dyeing liquid and increase power consumption, but the total energy is still saving. Transfer printing in the 70's has been applied to the production of practical, it is characterized by low emission, energy saving, less pollution. The use of solvent sizing can reduce the amount of water and energy consumption.
Low noise
Textile machinery in the use of the process of public health hazards are mainly noise, dust and debris, toxic and hazardous gases and wastewater containing harmful substances. The reasons are equipment factors and process factors in two aspects. Noise is by the air as a carrier of a mechanical vibration wave. The vast majority of textile mills in the workshop, especially the weaving workshop in the mechanical noise is very large. In the textile machinery can take measures are: cover wall lining sound-deadening materials, with flexible toothed drive belt instead of chain drive and gear drive, improve the precision and dynamic balance of moving parts, high-speed parts and racks installed between shock absorbing washers and so on. However, some anechoic measures also bring negative factors, such as the installation of soundproof cover operation and maintenance inconvenience. Creative improvement of mechanical design is to reduce the noise of the fundamental measures, such as shuttleless loom (see weaving) of the noise has gradually close to the requirements of environmental protection. In order to reduce the equipment operation process of micro-dust raised, can improve the design of the spinning machine, such as improving the sealing of the outer cover, you can also use air-conditioning device to absorb the dusty air in the workshop centralized filtration, and then send fresh air back to the workshop; or the use of secondary filtration equipment for clearing, carding, combing, etc. machine, the emission of dusty air filtration and the falling cotton recycling, so that the air to meet the requirements of the regulations on environmental protection.
Low harm
In addition, the change in the composition of textile machinery materials is also characterized by the development of modern textile machinery. Cast iron was originally the main structural material of textile machinery, because it is abundant, inexpensive, easy to process, can be cast into complex shapes, relatively corrosion-resistant, but also has a good vibration damping, but gradually replaced by profiled steel parts, welded parts, alloy die-castings, in each machine in the weight of the percentage of the weight is significantly reduced. Wood is also the original textile machinery, the main structural materials, due to excessive deforestation, resources are becoming increasingly scarce, gradually replaced by engineering plastics and light metals, and composite engineering plastics more wood does not have excellent performance, such as high strength, corrosion resistance, water resistance, weather resistance, abrasion resistance and so on. High-quality steel is also more often used as drive shafts, gear blanks, connecting rods, cams and other materials. In order to resist the acidic corrosion of dyeing and chemical materials and organic materials, high temperature corrosion, dyeing and finishing machinery more molybdenum-containing, titanium-containing nickel-chromium stainless steel for containers, machine room walls, guide rollers, and other parts in contact with fabrics and media. Chemical fiber machinery more widely used heat and acid-resistant high-grade alloy steel made of spinnerets, screw extruders, metering pumps and other parts in contact with polymers and high temperatures in the liquid containing organic solvents work in the parts.