Hexagonal Textile Duct Cyclone Flow Waste Removal
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Solution Overview
Problem
Conventional automatic winders with ducts face issues in efficiently removing yarn waste due to air flow stagnation and complex manufacturing processes, particularly with curved inner surfaces that require intricate processing and welding, making it difficult to connect suction piping and maintain effective waste removal.
Innovation Solution
The duct is designed with a hexagonal or pentagonal cross-sectional shape to generate a cyclone flow, reducing the need for strong suction forces and simplifying manufacturing by using easily processed plate-shaped members, with air inflow holes guiding air in a constant direction to enhance cyclone flow generation and prevent yarn waste from remaining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the duct has a polygonal cross-sectional shape (as disclosed in Japanese Unexamined Patent Publication No. 9-53766), then the duct can be easily manufactured by stacking configuring pieces, but air flow stagnates at the bottom or corner of the duct causing yarn waste to remain
Solution Approach 1:
The patent applies curvature by forming the inner side surface of the duct as a curved surface rather than a polygonal shape. This curved configuration prevents air flow stagnation at corners and bottom surfaces, enabling effective cyclone flow generation that continuously removes yarn waste without accumulation, while still maintaining ease of manufacture through appropriate shaping methods
2Productivity
If the duct inner side surface is formed to a curved shape (as disclosed in Japanese Examined Utility Model Publication No. 49-10328), then eddying flow is generated to convey waste material effectively, but the duct requires complicating steps of processing sheet metal to curved surface and welding spliced points
Solution Approach 1:
The patent divides the curved duct into multiple configurable pieces that can be stacked. Each piece has a curved inner side surface configuration that collectively forms the complete curved duct structure. This segmentation enables effective cyclone flow generation while simplifying manufacturing through modular assembly of pre-formed curved sections
3Productivity
If the duct is formed to a cylindrical shape, then eddying flow can be generated effectively, but piping and the like for supplying suction force needs to be attached to the curved surface making connection difficult
Solution Approach 1:
The patent applies local quality by providing a planar connecting surface at specific locations on the duct structure. This planar surface is specifically designed for attaching piping and suction force supply components, while the rest of the duct maintains its curved configuration for effective cyclone flow. This localized planar region enables easy connection without compromising the overall curved structure's waste removal efficiency
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 configuration effectively removes yarn waste with reduced energy consumption and simplifies the connection of suction paths, enhancing the efficiency of yarn waste removal and manufacturing ease.
Implementation Method 1
a cyclone flow is generated in the duct
Implementation Method 2
an inner wall facing the air inflow hole is formed inclined with respect to the duct wall surface. the air flowed in from the air inflow hole is guided in the constant direction by the inclined inner wall
Implementation Method 3
supplying a suction force to each part of the textile machine
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A blower duct is formed such that a cross-sectional shape cut at a plane perpendicular to a suctioning direction by a blower box (negative pressure source) is a polygon. The blower duct (20) includes a first wall surface formed to a planar shape so as to become one surface that configures the cross-sectional shape. The first wall surface is formed with a first air inflow hole (31) for supplying suction force to each winding unit of an automatic winder (10). An opposing surface wall facing the first air inflow hole (31) is formed inclined with respect to the first wall surface. A cyclone flow generates in the blower duct (20) by the first air inflow hole (31) and the suction force of the blower box.