After decades of development, the technology and production capacity of the domestic hosiery machine industry has reached a new level. However, the ensuing problems are also obvious. With the popularization of hosiery machine manufacturing technology and the continuous expansion of manufacturing capacity, the demand for socks in the socks market has begun to become saturated. Under such an environment, homogeneous 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 research and development 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 full computer 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 stop, the motor continues to move forward. Some distance.
Do the math, how many fewer socks do you produce every day?
Even if the current market is relatively good, there is an overshoot of about 5 stitches, and there are 10 stitches every time. The time of the 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 a sock is 145 seconds. A machine can produce 595 socks 24 hours a day. The conservative calculation is 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 improving the efficiency of these 10 stitches is of extraordinary significance.
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, which is unacceptable to both the machine manufacturer and the end user.
To solve the overshoot problem, all integrators and servo manufacturers' explorations over the years have proved 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 early, advance the overshoot deceleration distance, and ensure that the position can be reached. Deep customization of the servo system is required, and the in-depth cooperation between computer system manufacturers and servo manufacturers 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 whole industry is in the hands of system integrators who have accumulated a lot of technology. They have many years of technology 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 of 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 cannot 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 break the traditional differentiated business path first, who is 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 more severe.
