Strategic, Intelligent Manufacture of Spunlace Nonwovens

 All Clean Natural China 

Abstract:  Spunlace nonwoven cloth manufactured by All Clean Natural China, Co. complies with the intelligent strategic direction of national industry and, employment, furthermore, exhibits quality with reducing energy consumption.

The realization of intelligent manufacturing of spunlace nonwovens adheres to the strategic development direction of China's industry. It also has a practical effect such as decreasing labor, advancing quality, and reducing energy consumption. Blend with the current situation of the country's spunlace nonwoven production line, the actions and processes to achieve the intelligent manufacturing of spunlace nonwovens are discussed from the perspective of production equipment. 

Introduction
Strategic, intelligent manufacturing is based on research and development for innovation on networking, big data, cloud computing, and other new generation of information and communication technologies and the design, composition, management, services, and other manufacturing activities of all aspects of integration, with self-perception, self-learning, self-decision, self-executing, adaptive, etc. 

Preface
Strategic, intelligent manufacturing is based on the integration of new-generation information and communication technologies such as web data, and cloud computing solutions with all aspects of production activities such as plan, production, management, and service.  It has functional new production techniques such as self-perception, self-learning, self-decision-making, self-execution, self-adaptation, etc.
 
The practical new production method 
 
 Realizing the strategic, intelligent manufacturing of spunlace nonwovens is of prominent significance: improving the industrialization and informatization level of China's nonwovens equipment; reducing labor, improving quality and reducing energy consumption, extending the cost advantage of China's nonwovens industry; the year 2020, through approved initiatives, upward integration of various systems, the user, supplier with parallel integration system off, develop the effectiveness and versatility of the entire supply chain.

1 Hydroentangled Nonwoven Fabric Production Line

The spunlace nonwoven production line is a typical process production chemical line, and constant production has an utmost degree of industrialization. At present, most of the spunlace non-woven textile production industries in China are semi-automatic production, as shown in Figure 1.

Compressed raw materials (fiber bundles) cotton, polyester, and viscose fibers are brought from the raw material warehouse by forklifts and various transport tools to the location of the fiber grabbing equipment.  Manually opened fiber bales are fed to the fiber grabbing equipment (cotton feeding measuring machine, alternating grabbing machine, the disc holding machine, etc.).  Fiber is then transported to the fiber blending storage device (extensive warehouse mixer, multi-bin mixer, etc.) through fiber conveying equipment (cotton feeding weighing machine matching cotton curtain opener) for fiber mixing; 
Mixed fiber textiles are then transported to the fiber opening equipment for slight opening and then transferred to the fiber temporary storage equipment.  The fiber temporary storage equipment regularly conveys the fibers to the carding equipment (air pressure cotton box, carding machine, cross-laid netting equipment machine, multi-roll drafting machine, etc.) to form and create "the web".

The fiber web is entangled by a spunlace equipment to form a spunlace cloth. Then dried by drying equipment, then it enters the winding machine to be rolled into a fabric roll; the spunlace cloth material enters the winding device.  Winding equipment is furnished with forefront inspection devices (weight inspection, moisture inspection, defect quality inspection, etc.).  The fabric roll is then reclined from the winding equipment and enters the rewinding slitting machine to remove defects and cut rolls into customized sizes based on the client's order.  Cut spunlace rolls are then manually forwarded with the packaging equipment for packaging; Packed fabric rolls are transported to the finished product warehouse using transportation such as forklifts.

The entire production process detailed above, demands hand-operated intervention on raw material conveying, fabric roll transfer (winding equipment down to rewinding slitting equipment), defect removal finished result packaging and finished product delivery. Besides, all below require manual adjustment of related method parameters: the product's weight and weight variation, precipitation, vertical and horizontal durability, density, etc.  It needs to invest a lot of human resources in these production processes, especially the rewinding process to remove defects that require artificial control to prevent the defects, which is very ineffective.

2 Strategic, Intelligent Manufacturing
The spunlace nonwoven industry in China began to evolve immediately around 2000, which hit the annual output of about 800,000 tons. The rate of the production line has developed from the most initial 50m/min to the current 200~300m/min (direct-lay production line). Spunlace nonwovens need and have the requirements to realize strategic intelligence.

2.1 Industrialization of the production line for spunlace nonwoven fabrics

Industrialization conditions are met to achieve strategic, intelligent manufacture of spunlace nonwovens.
The application of trolley can accomplish the automatic conveying of raw materials. Raw materials are stacked according to type, the program controls the operation of the trolley, and the trolley is grasped as needed.

To gain a partial cloth coil rewinding device automatically shifted from the cutting device to the wound, compared to spunlace now, the mainstream for machinery used to make the following enhancements: winding machine needs at least 3 of the mandrel group, a storage station, the core axis is possible roll change automatically to reach the indicated station; after wound fabric roll from the winding station by a detachable push rolls temporary station behind the winding device, when rewinding cutting equipment is set, the cloth roll yielding within the interim station rewinder will slit and unwind work in an operative state; when the cloth roll in the slitting device rewinding unwound detecting apparatus to a given time of unwinding defect stop position, after the dismissal of the artificial defects continue to work goes further, androids are used to remove defects corresponding to the automatic removal of the cloth surface; the cloth is returned to the mandrel after cutting, and once completed is then stored in the storage station.

The cut cloth roll (mandrel B is automatically drained) and forward over to the transport trolley, the mandrel B drew out is returned to the compound station and placed into the paper tube to ready for the next round of cutting work. The conveying trolley carries the cut cloth rolls to the assigned station, which is picked up by the operator and used for packaging and signing by automatic packaging equipment. Yield conveyor may be employed, self-gripping carriage wrapped cloth roll and is delivered to product storage.   Wooden pallets are used to stack products while fulfilling requisition inventory.  Fully automated technology spunlace nonwoven fabric raw production line is improved based on the above production process.  The extensive opening of the package and removal of defects may be accomplished manually if the cost of the equipment is to consider.

2.2 Digitization of the production line

Digitization of the production line is divided into the following sections for data collection:
(1) To collect temperature, moisture, dust content, other plants relative pressure link environmental data, to meet production requirements.
(2) Including dust filter devices, exhaustion suction equipment, drying equipment fan and outside exhaust volume, pressure, moisture content, and other data, to meet the necessities of production and discharges.
(3) Accumulate and supply raw water, recycled water, discharge sewage flow, turbidity, and other pointers to meet production and discharge requirements.
(4) Manage thermal energy expense data such as the pressure and flow rate of natural gas; collect power consumption data such as the frequency and current of the motors and reducers in the production line.
(5) Collect machine status data such as the rotation speed of the rotating parts of each stand-alone equipment, the vibration, noise, and bearing the temperature rise of crucial equipment.
(6) Obtain the cotton feeding outlay of the cotton feeding weighing machine.  Production process data such as wind speed and wind pressure of the fiber conveying pipeline, the pump pressure and flow rate of the water the circulation processing system, the level of the standard water temporary storage equipment, the water supply pressure and flow rate of the high-pressure pump, the speed of the production line.
(7) Collect product weight, thickness, defects (including metal), precipitation content (before drying), moisture (after drying), and other property pointers.

2.3 Aspects of strategic, intelligent manufacture of spunlace nonwoven
The success of full automation and digitalization of the strategic, intelligent manufacture of spunlace nonwoven can approximately be summarized into three aspects: (a) people recount the machine what to do, and the machine does it; (b) the machine indicates to people what the product is producing and its condition (c) people and the machine analyze together to improve product quality and increase production efficiency, reduce production, energy depletion and lower production failures.
The command issued by the first man-machine interface, an input product woven specification (e.g., yield product weight, the ratio of raw materials, the thickness, length of a single cloth, cutting width, etc.). The machine according to the percentage of raw material distribution and standard mixing weighed; comb device feed roll speed commencing weight control product using weight detection apparatus according to the subject automatically adjust the determined result; high-pressure water pressure in accordance with the continuing velocity, density, covered around the product The effect of bond impact automatically settles the spunlace pressure; the dehydration fan automatically improves the negative suction pressure according to the product moisture (before drying); the dryer automatically adjusts the air volume of the condensation exhaust fan according to the product moisture (after drying); the slitting machine according to the cutting modifies the width of the cutter position, and insert the core shaft B into the paper tube of equal width.

Throughout the contact product process, each monitoring location outputs several high pointers of the nonwoven fabric product and the operating status of the equipment itself to the man-machine interface, such as product weight, production line speed, carding machine main cylinder speed, high-pressure pump oil temperature, and suction fan vibration, Turbidity of discharged sewage, etc. After running for a certain period, the machine secures and processes various data of the production situation, and proposes preparatory suggestions to improve product quality, increase production efficiency, decrease production energy consumption, and reduce production failures. Parameters are corrected after human analysis. The spunlace nonwoven production line has accomplished the above three functions and meets the requirements of strategic, intelligent manufacturing from the prospect of production equipment.

3 Product Application in Various Production Lines

Strategic, intelligent manufacture of spunlace the nonwoven application includes wet wipes, hygiene wipes, adult wipes, baby wipes, makeup remover, pet wipes, household or kitchen wipes, baby diapers, adult diapers, facial masks sheets, medical dressing, disposable materials, a mask covering, etc.

4 Resolution

After the production line has completed the requirements for strategic, intelligent manufacturing, it is now strategically in parallel with All Clean Natural standard procedures.  Product life cycle management system, business resource, engineering management system, and horizontally integrated with industry chain-related systems such as customer relationship management system, using diverse technologies to establish a product simulation system, and establish a spunlace nonwoven smart factory to achieve the true meaning of spunlace nonwoven smart manufacturing.