After decades of development, the technology and production capacity of the domestic hosiery machine industry has reached a new level. But the problems that followed are also obvious. With the popularization of hosiery machine manufacturing technology and the continuous expansion of manufacturing capacity, the demand for the hosiery market has begun to become saturated. In this environment, homogenized low-price competition is becoming more and more serious. Compressing the profit margins of enterprises, many small and medium-sized enterprises are getting more and more difficult. The fundamental reason for this phenomenon is also that our innovative R&D capabilities are weak, and the rapid development of the industry has made domestic hosiery machine manufacturers quickly reach a technical bottleneck and it is difficult to break through.
At present, almost all of the domestic hosiery electrical control system adopts a fully computerized control system, which cooperates with the servo system. The servo system quickly, stably and accurately executes various instructions issued by the computer system. At present, most of the servos are customized for the hosiery machine industry. In order to achieve stability and stability during rapid rotation, but the rapidity still lacks some "heating", resulting in overshoot every time commutation, that is, at the position where the process should be stopped, the motor continues to move forward. Some distance.
Do the math, how many socks do you produce less every day?
Even if the current market is relatively good, there are about 5 stitches of overshoot, and there are 10 stitches once and again. The time of these 10 stitches is wasted. According to statistics, the efficiency of solving the overshoot problem can be increased by 4%- 6%. Take the most common hoop socks as an example. The time to produce one socks is 145 seconds. A machine can produce 595 socks 24 hours a day. It is conservatively calculated at 4%. If there is no overshoot, it can produce 23 more socks a day. For socks, if a socks factory has 100 machines, it can produce 2300 more socks in one day. The biggest cost of the current hosiery factory is labor, so it is of extraordinary significance to improve the efficiency of these 10 stitches.
How to solve the overshoot problem?
The overshoot problem seems simple, but it is actually quite troublesome, because the computer system uses pulses to control the start and stop of the servo, but the computer system must stop sending pulses when the motor is in place. The servo system has a deceleration process from high-speed operation to stop. In a strict sense, this deceleration process is the distance of overshoot. If the servo is too rigid and stops too fast, it will have a greater impact on the machine during rapid rotation and reduce the service life of the mechanical structure. This is unacceptable to both the machine manufacturer and the end user.
To solve the overshoot problem, all integrators and servo manufacturers have tried so many years to prove that traditional control schemes are difficult to achieve. In fact, it is not difficult in theory to solve this problem, that is, to ensure that the motor reaches the designated public position, but also to save time, just let the servo stop ahead of time, advance the overshoot deceleration distance, and ensure that the position can be reached. In-depth customization of the servo system is required, and the in-depth cooperation between the computer system manufacturer and the servo manufacturer is required.
How to seek common ground while reserving differences in the in-depth cooperation of the "Trinity"?
At present, the electrical control of the entire industry is in the hands of system integrators who have accumulated a lot of technology. They have many years of process accumulation and experience, but they are not very professional in servo systems; most of the servo manufacturers are general-purpose servo manufacturers entering the industry. The craftsmanship is almost black at one's eyes. This creates a situation where the generals in the industry do not know the soldiers, and the soldiers do not know the generals. It is difficult to achieve in-depth technical cooperation, and it is impossible to break through the existing technical bottlenecks.
With the increasingly fierce market competition, users will inevitably put forward higher technology and more reasonable cost-effective requirements for the required products. Dozens of domestic sock machine manufacturers, large and small, are all seeking new technical solutions. Blindly relying on foreign models to "innovate" will inevitably enter the next cost-competitive environment. The in-depth cooperation between machinery manufacturers, electronic control system manufacturers, and servo manufacturers is indispensable. Whoever can first break the traditional differentiated operation will be bound to take the lead in the next more fierce competition. Development is like sailing against the current. If you do not advance, you will retreat. If you are obsessed with the original manufacturing field and business mode, and do not actively change the way to seek breakthroughs, the situation will be even more severe.
