Air-Jet Spinning Load Distribution via Segmentation
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Solution Overview
Problem
Spinning machines experience peak power requirements during start-up or after long-term shutdown, leading to inefficient operation and increased costs due to the need for high-capacity power supplies, which are not optimally loaded after reaching steady-state.
Innovation Solution
A method where spinning units are divided into groups with common power supplies, and the spinning-in process is monitored to interrupt high-load groups and distribute the peak load across other groups with lower power demands, allowing for the use of lower-capacity power supplies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all spinning units are spun-in successively in order during start-up, then each spinning unit achieves steady-state spinning, but the power supply must be designed for peak load which is more than 30% higher than steady-state requirement
Solution Approach 1:
The spinning units are divided into groups, with each group supplied by a separate power supply. During spinning-in, when one group reaches a predetermined load threshold, the system switches to spin-in another group, effectively segmenting the peak power demand across multiple power supplies rather than requiring one oversized power supply for all units simultaneously
Solution Approach 2:
The system dynamically monitors the actual load of power supplies during spinning-in and adaptively switches between groups based on real-time load conditions. This dynamic load management allows the system to distribute peak loads across different groups at different times, preventing any single power supply from needing to handle the full peak load of all spinning units
2Reliability
If power supplies are designed for peak load, then all spinning units can be spun-in successfully, but the power supplies are not optimally loaded after steady-state is achieved
Solution Approach 1:
By dividing spinning units into multiple groups with separate power supplies, each power supply handles a subset of spinning units during spinning-in. After steady-state is achieved, the load is distributed across multiple power supplies rather than concentrated on one oversized unit, improving overall system efficiency and reducing idle capacity
Solution Approach 2:
The system changes the operational parameters of power supplies by switching between different groups during spinning-in. This allows each power supply to operate closer to its optimal load range, improving efficiency while still ensuring all spinning units can be successfully spun-in
3Reliability
If power supplies with higher output are installed to handle peak load, then spinning-in can be performed, but purchase costs and operating expenses increase
Solution Approach 1:
Instead of installing one large power supply capable of handling the peak load of all spinning units simultaneously, the system segments the spinning units into groups, each with its own smaller power supply. The sum of these smaller power supplies is less costly than a single large power supply with equivalent peak capacity
Solution Approach 2:
The dynamic switching between groups during spinning-in allows the system to use multiple smaller power supplies in sequence rather than requiring one large power supply to handle all peak loads simultaneously, reducing both purchase costs and operating expenses
Data Source
Figure 1
AI summary
The invention relates to a method for spinning-in on a spinning machine, particularly on an air-jet spinning machine or an open-end spinning machine, containing a plurality of spinning units (11 to 34), provided with individual drives, which are divided into groups (1 to 3), where the spinning units (11 to 34) of each group (1 to 3) are supplied by common power supply (10 to 30), whereby the spinning machine is equipped with at least one service device (5), capable of moving along the row of the spinning units (11 to 34) and of spinning-in of each of them. The principle of this method than consists in that during the process of sequential spinning-in of the spinning units (11 to 34) of respective serviced group (1 to 3) the actual load of the power supply (10 to 30) of individual groups (1 to 3) of spinning units (11 to 34) is monitored and after achieving or exceeding a predetermined value of its load the spinning-in process of the respective group (1 to 3) of the spinning units (11 to 34) is interrupted and the spinning-in of another group (1 to 3) of the spinning units (11 to 34) is started, the current load of the power supply (10 to 30) of which is lower than the predetermined value.