Double Cyclone Dust Separator for Winding Waste
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Solution Overview
Problem
Existing separation devices for dust and yarn pieces during winding processing are inefficient and require shutdown for cleaning, leading to productivity losses and increased energy consumption due to pressure losses and environmental conditioning needs.
Innovation Solution
A self-cleaning separation device with individual rotary aspirators for each winding unit, utilizing centrifugal rotors and frequency-controlled electric motors for varying suction pressures, and a multi-cyclone system with compressed air nozzles for enhanced dust separation, allowing continuous operation and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing separation devices are used for dust and yarn pieces, then dust separation is achieved, but the devices require shutdown for cleaning causing productivity loss
Solution Approach 1:
The patent implements self-cleaning functionality through automated mechanisms that clean the separation device during operation. The system uses reverse airflow or mechanical cleaning elements that automatically remove accumulated dust and yarn pieces from the separation chambers and filters, eliminating the need for manual intervention and shutdowns.
Solution Approach 2:
The patent incorporates preliminary cleaning actions by designing the system to prevent clogging before it occurs. Cleaning mechanisms are activated proactively based on sensor detection of accumulating debris, or continuously at low intensity, ensuring the separation device maintains optimal performance without interruption to production.
2Productivity
If existing separation devices operate continuously, then productivity is maintained, but energy consumption increases due to pressure losses
Solution Approach 1:
The patent employs dynamic adjustment of operational parameters including variable speed motors that adjust suction power based on real-time dust generation rates, and adjustable airflow valves that optimize pressure differential across separation elements. This dynamic operation maintains effective separation while minimizing energy consumption during low-dust periods.
Solution Approach 2:
The system changes operational parameters such as airflow rate, suction pressure, and separator rotation speed based on detected dust concentrations and operational conditions. Sensors monitor system performance and automatically adjust parameters to maintain separation efficiency while reducing energy input when full power is not required.
3Object-affected harmful factors
If existing separation devices are used, then dust collection is achieved, but additional equipment and environmental conditioning are required
Solution Approach 1:
The patent designs multi-functional components that perform multiple operations within a single integrated system. The separation device incorporates dust collection, yarn piece separation, filtered air recirculation, and automatic cleaning functions in one unit, eliminating the need for separate equipment for each function and reducing overall system complexity.
Solution Approach 2:
The patent merges previously separate functions into unified components. The separation device combines filtration, separation, and cleaning functions into integrated assemblies, and merges the separation system with the existing winding machine airflow system, allowing the same air handling infrastructure to serve multiple purposes without requiring additional environmental conditioning equipment.
Data Source
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AI summary
A winding machine of the type comprising a plurality of winding units (23) and at least one aspirator (22) able to intake impurities and hair of the yarn, that is the dusts, or pieces of yarn deriving from the restoration and junction interventions of the yarn, said at least one aspirator (22) being connected through a common duct (70) to a common multi-cyclone type general filter (80) for collecting the winding waste, comprising in series and in depression with an aspirator (71), a double cyclone device (81) for separating the pieces of yarn from the dusts and a filter device of said dusts exiting from said double cyclone device, characterized in that said double cyclone device (81) of the pieces of yarn from the dusts comprises an annular central portion (84) and two frustum-conical portions (82A, 82B) respectively lower and upper arranged at the opposite sides of said annular portion (84) for generating two cyclones respectively of the pieces of yarn and of the dusts and for conveying the same from said central portion (84) to the reduced-diameter mouths (86, 89) of said two frustum-conical portions {82A, 82B), wherein said double cyclone device comprises primary nozzles (88) for injecting tangential flows of compressed air into said double cyclone device (81).