Combing Machine Phase Offset Power Smoothing
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Solution Overview
Problem
Modern combing machines experience high power consumption due to discontinuous power requirements from the pilgrim step movement and oscillatory movements of shafts, leading to inefficient operation of the main drive motor, especially with multiple combing heads.
Innovation Solution
Implementing a phase offset between the comb clearances of different groups of combing heads, allowing power compensation through coupling, where acceleration phases of one group are fed by deceleration phases of another, thereby smoothing the power curve and optimizing motor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple combing heads are operated synchronously with common shafts, then design effort is reduced and synchronous operation is ensured, but power consumption increases due to discontinuous acceleration and deceleration phases
Solution Approach 1:
The patent applies periodic action by offsetting the combing cycles of different combing heads so that they operate in alternating phases. Instead of all heads operating synchronously (which causes simultaneous acceleration and deceleration peaks), the heads are staggered in time, creating a periodic distribution of power demands that smooths the overall power consumption curve.
Solution Approach 2:
The patent changes the operational parameters of the combing heads by introducing phase offsets between them. This parameter change transforms the power consumption pattern from discontinuous peaks to a more continuous, smoothed curve, allowing the motor to operate more efficiently without requiring additional design complexity.
2Productivity
If the main drive motor operates with discontinuous power requirements from pilgrim step movement and oscillatory movements, then the combing function is achieved, but the motor cannot operate at optimal torque levels
Solution Approach 1:
By implementing periodic, offset combing cycles across multiple heads, the patent transforms the motor's workload from discontinuous peaks to a more continuous demand pattern. This allows the motor to maintain more stable torque levels and operate closer to its optimal operating point throughout the cycle.
Solution Approach 2:
The patent achieves continuity of useful action by staggering the combing cycles of different heads. While one head is in its acceleration phase, another is in its deceleration or idle phase, creating a continuous distribution of power demands that eliminates idle periods and maintains steady motor operation.
3Productivity
If shafts and working cylinders are accelerated and decelerated across comb clearance, then the combing operation is performed, but power consumption increases due to repeated torque generation in opposite directions
Solution Approach 1:
The patent uses periodic action with phase offsets to distribute the acceleration and deceleration events of working cylinders across different time periods. Instead of all cylinders reversing direction simultaneously (causing high peak power consumption), they do so in staggered sequences, smoothing the power demand and reducing overall energy consumption while maintaining combing productivity.
Data Source
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AI summary
The invention relates to a combing machine (100) for spinning preparation, comprising a machine frame (10) in which at least two combing heads (11) are arranged, and comprising a main drive motor (12) for driving the combing heads (11). According to the invention, a main shaft (15) is operatively connected to the main drive motor (12), the main shaft (15) drives the at least two combing heads (11), and the combing heads (11) are operatively connected to the main shaft (15) in such a way that during operation of the main drive motor (12), the combing cycles of the combing heads (11) are phase-shifted relative to one another.