Adaptive Relay Nozzle Control for Air-Jet Weaving Energy Optimization
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Solution Overview
Problem
Existing air-jet weaving machines face inefficiencies in compressed air consumption and energy usage due to fixed interval settings of relay nozzles, leading to potential weft insertion errors and suboptimal energy management.
Innovation Solution
The method involves determining the statistical mean and deviation of weft arrival times to dynamically adjust the operation intervals of relay nozzles based on the angle of the working cycle, optimizing compressed air consumption and energy intensity through adaptive control of the relay nozzles' engagement times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relay nozzles operate with fixed time intervals throughout the entire weft insertion period, then compressed air is continuously supplied to ensure weft insertion, but energy consumption increases significantly
Solution Approach 1:
The relay nozzles are divided into multiple groups that operate in periodic sequences rather than continuously. Each group is activated at specific time intervals corresponding to the position of the weft thread, allowing compressed air to be supplied periodically only when needed for weft insertion, rather than continuously throughout the entire insertion period.
Solution Approach 2:
The relay nozzles are segmented into multiple groups along the weft inserting channel. Each group can be independently controlled and activated based on the real-time position of the weft thread, allowing selective operation of only the necessary nozzle groups rather than all nozzles simultaneously, thereby reducing overall compressed air consumption.
2Use of energy by moving object
If relay nozzles are activated in multiple groups along the weft inserting channel, then compressed air consumption is reduced, but weft insertion errors may occur if timing is not precisely controlled
Solution Approach 1:
A sensor detects the actual position of the weft thread during insertion and provides feedback signals to the control device. The control device uses this real-time position information to dynamically adjust the activation timing of each relay nozzle group, ensuring precise synchronization between nozzle operation and weft thread position, thereby maintaining insertion accuracy while enabling selective nozzle activation.
Solution Approach 2:
The operation timing of relay nozzle groups is made dynamic rather than fixed. The control device adjusts the activation moments of each nozzle group based on real-time feedback about weft thread position, allowing the system to adapt to variations in weft insertion speed and maintain precision even when nozzles are selectively activated.
3Use of energy by moving object
If the operation interval of relay nozzles is shortened to reduce energy consumption, then compressed air usage decreases, but weft insertion errors increase
Solution Approach 1:
The control device continuously monitors weft insertion progress through sensor feedback and dynamically adjusts the duration and timing of each relay nozzle group's operation. This ensures that each nozzle operates for the minimum necessary time to effectively propel the weft thread, avoiding both excessive energy consumption and insufficient insertion reliability.
Solution Approach 2:
The system dynamically changes operational parameters (timing and duration of each nozzle group's activation) based on real-time conditions. By adjusting these parameters according to actual weft insertion progress, the system optimizes the balance between energy consumption and insertion reliability, activating nozzles only when and for as long as needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures adaptive optimization of compressed air consumption and energy intensity, reducing energy requirements while maintaining accurate weft insertion by adjusting the timing of relay nozzles' operation based on real-time statistical data from previous insertions.
Implementation Method 1
the weft thread is arranged in a weft metering device and passes through the main weft inserting nozzle (the front end of the weft yarn is arranged in the main weft inserting nozzle), which is with its outlet directed in a known manner to the weft inserting channel formed in the weaving reed
Implementation Method 2
during which the weft thread is during its passage through the shed acted upon by an auxiliary air flow from relay nozzles
Data Source
Figure 1~2
Figure 3
AI summary
A method of controlling weft insertion into a shed (6) in an air jet weaving machine, in which a weft thread (5) is during its passage through the shed (6) acted upon by an auxiliary air flow from relay nozzles (8), whereby weft (5) arrival times are monitored and according to them parameters of the auxiliary air flow from the relay nozzles (8) are adjusted during the next insertion. From the weft (5) arrival times during a plurality (n) of successive weft insertions, the statistical mean value and statistical deviation from the mean value are continuously determined at least for each section (9) of the relay nozzles (8) along the weft insertion length, whereby the mean value is used for setting the mean value of the interval of the engagement of each section (9) of the relay nozzles (8) for supporting weft insertion depending on the angle of the working cycle of the machine and the statistical deviation value is multiplied by coverage factor (k) of the probability (p) of the weft arrival and this multiplied value is used to set the start and the end of the interval of the engagement of each section (9) of the relay nozzles (8) to support the weft insertion depending on the angle of the working cycle of the machine, and so the moments of the start and the end and therefore also the length of the individual sections (9) of the relay nozzles (8) are adaptively and automatically adjusted on the basis of the statistics of the weft arrival times of a pre-determined number (n) of the previous weft insertions, which, consequently, allows adaptive optimization of compressed air consumption and energy intensity in accordance with the current actual conditions on the machine. The invention also relates to a weaving machine for performing the method.