Decentralized Suction System for Spoolers

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Solution Overview

Problem

Existing spooler suction systems face issues with uniformity of suction across units, high energy consumption, and inefficiency during simultaneous batch processing, particularly due to the need for continuous high depression suction and variable frequency interventions.

Innovation Solution

A decentralized suction system with individual low-power suction devices for each spooling unit, supplemented by a central low-head suction for dust removal, and a high-head suction device for intermittent tasks, allowing independent control and modulation of suction parameters based on unit needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a centralized high-head suction device is used for all spooling units, then high depression suction is available for thread piecing operations, but energy consumption increases and suction uniformity across units deteriorates

Engineering Contradiction:

Improvesuction availability for thread piecingVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The suction system is divided into three independent parts: individual low-power suction devices for each spooling unit, a central low-head suction for dust removal, and a central high-head suction for intermittent thread piecing operations. This segmentation allows each component to be optimized for its specific function, reducing overall energy consumption while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The central high-head suction device operates intermittently only during thread piecing operations rather than continuously. Individual low-power devices provide continuous low-level suction, while the high-head device is activated periodically when needed, significantly reducing energy consumption compared to continuous operation.

Inventive Principle:

Principle #19Periodic action

2Productivity

If continuous high depression suction is provided to all units, then thread piecing operations are effective, but energy consumption increases and cost increases

Engineering Contradiction:

Improvethread piecing efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by stationary object

Solution Approach 1:

The suction system transitions from static continuous high depression to dynamic variable depression. Individual spooling units can activate high depression suction only when thread piecing is required, while maintaining low depression suction continuously. This dynamic adjustment optimizes productivity while reducing energy consumption and costs.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If individual suction devices are provided for each spooling unit, then suction uniformity improves and flexibility increases, but device complexity increases

Engineering Contradiction:

Improveflexibility in suction controlVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Each spooling unit is equipped with a universal control system that can manage multiple suction modes (individual low-power, central low-head, central high-head) through a single integrated interface. This multi-functionality approach increases adaptability while managing complexity through standardized control mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Device complexity

If a single centralized suction system is used, then device complexity is reduced, but suction uniformity across units deteriorates and energy consumption increases

Engineering Contradiction:

Improvesystem simplicityVSAvoidsuction uniformity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The suction system implements local quality by providing individualized suction control for each spooling unit through dedicated low-power devices, while maintaining centralized coordination for dust removal and thread piecing operations. This ensures uniform suction performance across all units while managing complexity through a hierarchical structure.

Inventive Principle:

Principle #3Local quality

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 uniform suction across units, reduces energy consumption by limiting high depression service to intervention times, and enhances flexibility and efficiency, achieving energy savings of 20-40% and cost savings of 15-30% compared to traditional systems.

Implementation Method 1

a suction device serving spooling stations of a spooler... continuous service for sucking with the mouth 20, currently known as dust removal... discontinuous and limited to the times of their intervention, lasting of the order of 1-4 seconds at a time

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentEP1950162B1Suction system for spoolers

Publication Date: 2012.02.29 SAVIO MACCHINE TESSILI SPA

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Figure 2B

AI summary

Spooler served by a suction system that provides both continuous low depression suction, for the dust removal service, and discontinuous high depression suction, for interventions for interruption and piecing of the thread and for starting a new spool, in which the discontinuous high depression suction is supplied by individual suction devices (60) with which each spooling unit (30) is equipped and only put into service for the time of the intervention cycle that is carried out by the unit itself.