Development Of Cotton Blending Technology In Spinning Management System

The quality of cotton is difficult to find at present. In order to ensure the quality of yarn to meet customer requirements, cotton blending is very important in technical management. The so-called cotton blending is to meet the requirements of the spinning process and yarn quality of a certain specification yarn, choose the most suitable cotton batches from the raw cotton stock and stipulate the appropriate proportion of each cotton batches. In cotton spinning enterprises, raw materials account for about 70% of the total cost, which directly affects the economic benefits of enterprises. Therefore, the right cotton blending work is very important. The performance of raw cotton in China shows diversity and diversity, making cotton blending more complicated and difficult. Cotton spinning process has many characteristics such as long process, long cycle and continuous production. When the variety changes frequently, the quality of the product can not be changed due to the change of raw materials. Therefore, continuity, stability and various specific requirements of raw cotton selection must be taken into consideration, so that the fiber properties can be used as much as possible and the residual quality can be reduced.

Development of cotton blending technology in 1 cotton textile enterprises

The cotton blending work has a history of more than 100 years, and has accumulated rich experience. With the development of science and technology, cotton blending technology is constantly developing. The development of cotton blending technology has gone through two periods, namely, artificial cotton blending and computer assorting cotton.

1.1 artificial cotton blending

For a long time, cotton blending is done through manual calculation, and it is a passive behavior. It does not specify the situation of raw cotton or the target of the yarn. It just mix all kinds of raw cotton (in fact, the performance may vary greatly) to ensure the continuous production and make no strict restrictions on the ratio. With the accumulation of production practice experience, cotton blending has become an active and purposeful technology link. The purpose is to ensure quality and reduce costs. People even synthesize empirical formulas or regression equations by empirical and experimental results, and then use regression equation or empirical formula to guide cotton blending.

1.2 computer assorting cotton

The effect of manual allocation of cotton blending depends to a large extent on human experience and the degree of meticulous handling of problems, often one-sided and accidental. In order to do a good job in cotton blending, the cotton blending technicians must grasp the production situation in time, understand the stock situation of various raw cotton and the physical properties of raw cotton, analyze the quality of the yarn in the past, and consider it comprehensively and comprehensively, not only the calculation is large, such as the replacement cotton calculation can only calculate two Zhang Biao per day, and it is unavoidable to be careless. Therefore, people are eager to find a more effective and convenient modern method to assist or replace artificial cotton blending. The initial idea of computer distribution technology is generated under such a background.

2 development of computer distribution management system at home and abroad

2.1 overseas situation

The computer has been used in the textile industry for more than 30 years. Many enterprises have already ordered the raw cotton and finished the use of cotton by computers. India's computer aided cotton production began in 70s. The earliest computer matching experiment was completed by Indore company. With the help of computer experts, the company tried to reduce the blending cost of 4.9tex yarn, and its artificial cotton blending cost was 10.50 rupees /kg. Through the use of computer assorting cotton, the cost has been reduced to 9.95 rupees /kg, saving about 5%. Many enterprises are very willing to adopt this achievement, but in the further promotion of computer cotton distribution, no satisfactory results have been obtained, which is due to inaccurate historical data and unreliable experiments of batches of cotton.

The successful cotton blending software is the cotton and cotton blending management system of Spinl AB and FiberControls company. In 80s, the EFS (Engineered Fiber Seleetion) computer distribution management system was developed and applied in Europe and the United States. Its characteristics are: cotton is no longer merely classified according to its head, but is reclassified according to the indexes measured by the instrument and numbered by bar code. Cotton is divided into more detail according to its properties, and its performance is more fully utilized. The system uses HVI test data for cotton blending. It is reported that the accuracy of the test data is high, so that the cotton blending effect is better. In 90s, the best expert system developed by Chent Belgium University textile department was said to be able to determine the best matching function of raw materials.

2.2 domestic situation

As early as the late 70s, some cotton mills in China began to try to use computers to match cotton. The cotton blending model is based on the linear programming principle. With this method, the proportion of cotton can be selected and planned on the computer so as to achieve the best ratio. However, because this method is isolated in stages, it can not solve continuity and stability problems. Some special requirements can not be expressed by equations, such as docking, batches, batches, whole packages and other specific requirements, and the problems of climate, color, and technological status can not be solved one by one. In fact, this method can only be used as an assistant for artificial cotton blending, so it can not be used formally in production.

In 80s, computer aided cotton technology has developed greatly. With the help of modern applied mathematics, some computer matching systems have been developed. This system makes full use of the speed of computer operation, makes the cotton distribution work more accurate and perfect, reduces the cost, improves the production efficiency, and ensures the yarn quality. For example, a cotton blending management system, which is very close to the practical experience of manual cotton blending, is developed. The cotton blending model is based on Fuzzy clustering analysis. This method simulates the process of human brain analysis and synthesis, carries out "comparative scoring" and establishes membership function. The Fuzzy clustering analysis simulates the human brain's observation and analysis in multidimensional space, and classifications according to the heaviest weight path under the equivalence relation. The result is very close to the essence of things.

The computerized cotton distribution management system in 80s is more comprehensive. However, due to the limitations of the development tools and some specific test conditions, there are still some practical problems, which have not been widely promoted in production, and a few manufacturers are using them. There are many textile application softwares developed in recent years, most of which focus on automatic control and textile CAD. Only a few people have optimized the computer distribution management system. In some aspects, some improvements have been made to the computer distribution management system in the past, but there are still few practical problems to be solved.

3 the function and shortcomings of the early computerized cotton management system

3.1 system functions

In fact, cotton blending is the quantitative calculation of the optimal solution under the condition of multiple controllable variables. These cotton management systems play the following three roles with the help of the computer.

(1) a great leap has been made from traditional manual cotton blending to computer automatic cotton blending.

(2) obvious economic benefits have been achieved, the cost of assorting cotton has been reduced to varying degrees, and the quality has been guaranteed.

Example: an enterprise in Hebei has used computers to distribute cotton. Only one 28tex variety reduces costs by 0.02 yuan /kg, and saves 140 thousand yuan throughout the year. After promotion, it can save 500 thousand yuan a year. An enterprise in Jiangsu has used computers to distribute cotton, reducing its cost by 0.015 yuan /kg. An enterprise in Hubei chooses cotton blending scheme of 28tex cotton by computer. The grade is reduced from 2.18 to 3.66, and the length is reduced from 28.53mm to 26.63mm. The cost of cotton blending is reduced from 3.738 yuan /kg to 3.4502 yuan /kg, and the yarn quality is still superior grade, and the cost of reducing cotton blending is about 0.02 yuan /kg-0.095 yuan /kg.

(3) the efficiency is improved. The best plan can be shown by general 20min-30min. The previous manual cotton blending method needs several times to get a feasible plan.

3.2 inadequate system:

(1) most of the systems are solved by linear method. The cotton assorting personnel need to stipulate some batches of raw cotton in advance and list the equations.

(2) there is only one target equation which can not meet the requirements of many objectives in actual production, and there is no special demand forecasting module for the system.

4 the development of a new computerized cotton blending management system has the following characteristics:

1) it is able to automatically establish prediction equations, which is low in users' requirements, and makes use of multiple dynamic prediction equations to make the system have strong predictive function.

2) using target programming to optimize cotton blending scheme can improve the shortage of cotton blending in linear programming.

3) apply fuzzy clustering and fuzzy comprehensive evaluation in fuzzy mathematics to select the right cotton to replace the original cotton.

4) the function module of raw material demand forecasting is added to guide the procurement of raw materials.

5) the system is developed and optimized on the basis of the original cotton management system, taking into account the actual situation, equipment, raw materials and other factors of cotton spinning in China at present, and has strong practicability.

5 Conclusion

Computer aided cotton can make use of the advantage of fast computing speed to make up for the defects of man-made errors in artificial cotton production, stabilize production, ensure product quality, and guide raw material purchase strategy. In today's information age, computers have been more and more widely used in the textile industry. It is an inevitable trend for cotton blending technology to develop cotton blending with computers. It is also a necessary step for cotton spinning industry to develop towards automation, intelligence and information technology. Computer assorting cotton is the only way for cotton textile enterprises to establish a rapid reaction mechanism.

In order to popularize computer assorting cotton technology smoothly, we need to solve the following problems:

1) 1 reliable data base. Whether cotton blending is effective depends on the scientificity and objectivity of the experimental data. It is necessary to have a more reliable data base to make the prediction reach a certain degree of accuracy.

2) we must have a perfect and practical software system. It makes the cotton distribution management system more practical and reliable, and it also meets the actual needs of production.

3) responsible management and technical personnel should be responsible for the correct application of the cotton distribution management system.