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At present, China's manufacturing industry has entered a new era of high-quality development, and intelligent manufacturing is the only way to achieve high-quality development. Intelligent manufacturing is the product of the continuous integration and development of advanced information technology and advanced manufacturing technology. With the innovation and development of technology, the whole manufacturing system continues to iterate and evolve. According to different development stages and technical characteristics, intelligent manufacturing is divided into three paradigms: digitization, networking and intelligence. Digitalization is the basis of intelligent manufacturing. Networking is the use of industrial Internet and industrial cloud technology to realize the connection and integration of equipment on the basis of digitization. Intelligence is the deep integration of artificial intelligence technology and advanced manufacturing technology, It has become the core driving force of the new round of industrial revolution.

 

 

Intelligent manufacturing is a large system, which runs through all aspects of the whole life cycle of products, production and services. It reshapes the production factors and production mode of manufacturing industry, and leads to significant and profound changes in the development concept, value form and industrial ecology of manufacturing industry.

Production characteristics of industrial textiles

 

The industrial textile industry has a good foundation for the implementation of intelligent manufacturing, and the development of the industry has also produced a huge demand for intelligent manufacturing. Industrial textiles are mainly intermediate products. Except for some products (such as personal protective equipment), they all show very obvious characteristics of process production, among which the production of non-woven fabrics is particularly prominent.

 

The degree of automation in the production of industrial textiles is high, the single-line production capacity is relatively large, and the investment amount of production equipment is relatively high. Especially with the improvement of the level of domestic equipment, the automation and digitalization of the production line have improved significantly. With the gradual acceleration of the production line production speed and the gradual improvement of single-line production capacity, higher requirements are put forward for product quality control. The energy consumption of the production process is high, and energy accounts for a high proportion of the cost structure. Therefore, the quality control and energy consumption control of industrial textiles production is a key issue in the industry.

 

At present, China's industrial textile industry is growing rapidly, the adjustment of industrial structure is accelerated, new technologies, new products and new models are constantly emerging, and enterprises have a great demand for advanced management and advanced manufacturing. The phenomenon of difficult and expensive employment in the manufacturing industry has become increasingly prominent. Enterprises need to implement intelligent transformation to reduce employment, improve the working environment and reduce labor intensity.

 

Traditional management methods and production models have been difficult to adapt to the expanding scale of enterprises, as well as the needs of enterprise fine management; the intensification of market competition and the pressure of industrial upgrading have prompted enterprises to continuously improve product quality, reduce costs and enhance customer service. The effect of traditional methods is almost close to the limit in these aspects. Industrial textile enterprises need to cooperate more closely with institutional users in product development and application, and constantly expand new business models.

Industry intelligent manufacturing status
1. Information and automation construction
Management information and equipment automation is the basis for the implementation of intelligent manufacturing. In terms of information technology, the focus is on promoting the application of ERP software in enterprises. With the gradual maturity of China's self-developed ERP software and the promotion of various cloud services, the cost of purchasing and implementing ERP has been greatly reduced. Therefore, in large and medium-sized enterprises in the industry, ERP software has a high degree of popularity, for the standardization of enterprise management processes, improve operational efficiency has played an important role.

 

In terms of automation construction, the industry focuses on promoting the application of non-woven fabric full-process automated production lines in the industry, especially the application of domestic equipment. At present, the automatic silo has been applied in spunbonded nonwovens enterprises, which greatly improves the work efficiency and ensures the consistency of raw material quality. In terms of polyester spunbonded nonwovens, enterprises have adopted the melt straight spunbonded process, greatly reducing logistics costs and energy consumption. Spunlaced nonwovens companies have begun to use AGV trolleys for raw materials delivery, which effectively reduces labor intensity. Tire base fabric production enterprises to develop automatic starch and automatic glue equipment, improve the production site environment, significantly reduce the work intensity.

 

Nonwovens on-line detection, automatic rolling, slitting, packaging, labeling and transportation into storage are more labor-intensive processes in nonwoven production, so they are also the focus of automation construction. Hunan Zhongnan Intelligent Equipment Co., Ltd. developed the non-woven fabric online inspection and automatic winding system has been widely used in the tire base fabric industry, and achieved good results. Spunbonded and spunlaced nonwovens enterprises have also realized the automation of this link by selecting advanced equipment, and collected a large amount of production data in real time while reducing labor.

 

In the production process of filter bags and safety protection textiles, enterprises have begun to use a large number of automatic hanging systems, intelligent cutting systems, and advanced software systems to improve production efficiency and save a lot of raw materials.

 

2. Digital and network transformation
Enterprises in the management of information technology and production automation construction at the same time, simultaneous digital transformation of production equipment and network construction. The non-woven fabric production line has a good foundation for digital transformation. Enterprises with weaving processes realize data collection of equipment configuration parameters, status, production data and operation process by installing sensors on old equipment, and transmit data through wired network, WIFI and 5G.

 

MES system is the core of enterprise digitization and networking, and most of the enterprises in the current industry for intelligent construction have purchased MES system. Some non-woven complete equipment enterprises provide some functional modules of MES system with the production line, and some software enterprises develop MES system for non-woven industry. MES system purchased by enterprises generally includes modules such as production scheduling, equipment management, energy management, production document management, etc.

 

The MES system of industry enterprises has basically realized the integration with ERP system, realized the integrated management and seamless connection of enterprise production, procurement, finance, sales and warehousing information, broke the information island within the enterprise, and made important data and processes visible and controllable.

 

Intelligent storage system is more versatile, the technology is relatively mature, more suppliers, so it has become the focus of the industry enterprises to build and achieve more results in the field.

 

Enterprises carry out intelligent workshop construction on the basis of digitalization and networking, and some leading enterprises carry out intelligent factory construction. Jinan Yongxin New Material Technology Co., Ltd. jointly with universities and central enterprises, the construction of spunlaced nonwovens intelligent factory, the formation of replicable, can be promoted in the industry application of spunlaced nonwovens intelligent factory construction mode.

 

3. Construction of Industrial Internet Platform
Fucheng Street, Funing County, Jiangsu Province, has built an industrial Internet platform and a big data center for the filter material industry. It is connected to the filter material production enterprises in the park, which can display the technical parameters of the products produced by the enterprises, monitor the product quality in real time, protect the interests of the terminal market, and help local enterprises to actively seize the market. In the future, the platform will also introduce more industry application software and services to provide market information, product quality, product development and other services to enterprises in the region.

 

4, the current industry intelligent manufacturing work difficulties and problems
The industrial textile industry has achieved phased results in intelligent manufacturing, especially in digital and networked transformation. However, there are still many difficulties and challenges in the large-scale promotion of intelligent manufacturing in the industry and the development of intelligence to a higher level.

 

First of all, the investment in intelligent manufacturing is large and there are many uncertain factors. The industrial textile industry is dominated by small and medium-sized enterprises, the budget for intelligent manufacturing is not high, the enterprise project decision-making is very cautious, the scale of the project is too small, it is difficult to attract powerful large suppliers to enter the industry to provide services.

 

Secondly, there are many varieties of industrial textiles, complex processes, and large differences in demand in intelligent manufacturing, which makes it difficult for suppliers, especially software enterprises, to accurately understand the production process of the industry and grasp the needs of enterprises. it also increases the development cost.

 

Third, because the intelligent transformation involves professional knowledge in equipment, informatization and software systems, enterprises lack professionals in these fields, so it is difficult to grasp the overall intelligent manufacturing scheme and system planning, and it is difficult to further promote intelligent manufacturing projects.

 

Fourth, enterprises still have a large number of old equipment, as well as equipment from different equipment manufacturers, especially imported equipment, these equipment data interface standards are different, and even some equipment manufacturers do not open the interface, which brings great difficulty to the digital transformation of enterprises, but also affects the effect of data collection.
Fifth, in terms of industrial intelligence, the industrial textile industry, like most industrial fields, is still in the exploratory stage, lacking industry big data models, basic data, analysis frameworks and application cases, and manufacturing systems do not yet have the ability to learn independently and analyze complex systems.

Industry "14th Five-Year Plan" Intelligent Manufacturing Work Outlook
The "14th Five-Year Plan" is an important opportunity for my country's industrial textile industry to upgrade the modernization of the industrial chain and achieve high-quality development. Intelligent manufacturing technologies such as industrial Internet, 5G, and artificial intelligence will provide important technical support. In the future, the industry will focus on the following work in intelligent manufacturing.

 

 

1. Promote the development and application of advanced equipment.
We will continue to work with key equipment enterprises to break through the industry's shortcomings in advanced production lines and core equipment of production lines, improve the stability of equipment under high-speed operation, improve the degree of digitization of equipment, vigorously promote the application of automation and digital equipment, and realize the automation of the whole process of production.

 

2, vigorously promote the digital, network transformation of enterprises.
Support the industry to apply new technologies such as the Internet of Things, big data, 5G, and artificial intelligence, promote the digitization and network transformation of key links in enterprises, and accelerate the use of advanced digital equipment, online monitoring and feedback systems, intelligent warehousing and logistics systems, advanced manufacturing and management software systems, etc. Industry application to realize digital management with "MES ERP" as the main feature. We will promote the construction of digital factories in the fields of non-woven fabrics, medical and health textiles, geotechnical construction textiles, transportation textiles, flexible composite materials and cables. At the end of the "14th Five-Year Plan", more than 70% of the digital and network transformation of non-woven fabric enterprises will be completed.

 

3, the establishment of industrial Internet demonstration platform.
With the goal of shared design, collaborative manufacturing, quality traceability and supply-demand docking, we will promote the construction of regional and industrial industrial Internet platforms in the fields of personal protection and industrial filtering, develop industry-specific industrial APP, improve the service capability of industrial Internet and big data platforms in the industrial cluster region, and improve the collaborative manufacturing capability and emergency rapid response capability of the industrial chain.

 

 

4. Promote the intelligent construction in the field of nonwovens.
Development of non-woven fabric spinning, drafting, laying, spunlace, needle punching and other key process simulation system, the establishment of non-woven fabric big data model, the initial construction of data-driven, process optimization, quality control, energy management, equipment maintenance and other characteristics of intelligent capabilities.

 

5, continue to promote the industry enterprises to connect with high-quality intelligent manufacturing suppliers.
We will continue to expand the ranks of suppliers of intelligent equipment and software systems, encourage suppliers to develop software systems with the characteristics of industrial textiles, low cost and replicable promotion, and help suppliers connect with industry enterprises to promote solutions.

 

6, continue to carry out intelligent manufacturing pilot demonstration work in the industry.
Expand the scope of pilot enterprises, upgrade the pilot level, connect high-quality innovative resources and suppliers, support pilot enterprises in product collaborative development, online quality inspection, energy management, quality control and upgrading, equipment predictive maintenance and other aspects of development, the formation of mature experience and model, in the industry to promote.

 

7, increase the development and promotion of intelligent textiles.
Development of flexible sensor technology, energy collection and storage technology, data transmission technology for smart textiles to improve the reliability and consistency of flexible sensing materials. Develop and promote smart wearable products for sports, medical and health, safety protection and other fields, expand the application of smart textiles in geotechnical, construction, filtration and other fields, and improve real-time quality monitoring and predictive maintenance capabilities.

The industrial textile industry has officially carried out intelligent manufacturing work in the industry since 2016, taking nonwovens as the key field of industry intelligence, and taking informatization and digital construction as an important means to enhance the advanced manufacturing capacity of the industry. In the process of implementation, the enterprise has achieved phased results in high-standard planning, advance layout, and phased advancement.

 

The China Industrial Textiles Industry Association (hereinafter referred to as the "Association") has conducted a large number of enterprise surveys, held many seminars to understand the current situation and needs of enterprise intelligence, analyzed the main models and implementation paths of intelligent manufacturing in the industry, and determined the industry's "Thirteen The main tasks of intelligent manufacturing during the Five-Year Plan period have formed the" Implementation Plan for Intelligent Manufacturing in the Nonwovens Industry ".

 

The association has carried out a pilot demonstration of intelligent manufacturing of nonwovens enterprises in the industry. According to the situation of enterprises in equipment, information construction and internal management, combined with the wishes of enterprises, the association has carried out two batches of intelligent manufacturing pilot demonstration work in the industry, a total of 11 enterprises and 1 industrial cluster to participate in the industry intelligent manufacturing pilot demonstration work. The Association cooperates with Fucheng Street, Funing County, Jiangsu Province to build an intelligent filter material park to promote the construction of industrial Internet platform in the park and the intelligent transformation of key enterprises. The association organizes experts to diagnose the intelligent manufacturing situation of the pilot units and provide professional advice, connect with excellent supplier resources, and track the progress of the implementation of intelligent manufacturing projects every year. After three years of hard work, the units participating in the pilot have made significant progress in the construction of intelligent production lines, intelligent warehousing, intelligent factories, and industrial Internet platforms in the park. The three member enterprises of the association were selected as the pilot demonstration enterprise of intelligent manufacturing of the Ministry of Industry and Information Technology and the comprehensive standardization and new model application enterprise of intelligent manufacturing.

 

The association has established a team of intelligent manufacturing suppliers including advanced equipment enterprises, automation enterprises and software enterprises, and established a strategic cooperative relationship with Hunan Zhongnan Intelligent Equipment Co., Ltd. to help it promote the application of intelligent equipment in the field of geotechnical construction textiles and spunlaced nonwovens. Intelligent manufacturing solution suppliers have provided a large number of mature and affordable equipment and software to the industry, which has played an important role in promoting the digitalization and information construction of the industry.

 

The association promotes the standardization of intelligent manufacturing in a timely manner. The industry is relatively mature in the construction of spunmelt nonwoven intelligent production line and spunlaced nonwoven intelligent factory, and has achieved certain results. In order to promote the intelligent work in the two important areas of spunlaced nonwovens and spunlaced nonwovens, the association invited key enterprises to take the lead in the preparation of "spunlaced nonwovens intelligent manufacturing production line evaluation" and "spunlaced nonwovens intelligent factory" two group standards. At present, the first draft of these two standards has been completed and will soon be consulted in the industry.


Text/China Industrial Textiles Industry Association

Source: Jung-International Nonwovens Industry