Leather Drying Tension Control via Feedback Actuation
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Solution Overview
Problem
Current leather drying and conditioning methods in the tannery industry lack precise control over leather tension, leading to uneven tension across batches, damage from excessive tension, and reduced quality due to variability in operator force and leather properties.
Innovation Solution
Implementing a method with actuation means that measure and adjust tension in real-time using a supply circuit to maintain a predetermined nominal tension value, compensating for initial differences and ensuring consistent fiber tension throughout the drying process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual stretching by operators is used to expand leathers before drying, then the leathers can be loaded onto support frames, but the tension applied is variable and inconsistent leading to uneven tension across batches and reduced quality
Solution Approach 1:
The patent replaces the manual mechanical stretching operation with an automated actuation system that applies controlled mechanical force through pneumatic or hydraulic actuators. These actuators are connected to support frames and automatically adjust the tension applied to leathers during drying, eliminating the variability inherent in manual operations while maintaining ease of loading.
Solution Approach 2:
The patent implements a feedback control system that uses tension sensors to monitor the force applied to leathers during drying. The measured tension values are fed back to a control unit that adjusts the actuation means to maintain the desired tension level, ensuring uniform tension across all leathers in a batch regardless of initial variations.
2Extent of automation
If fixed expansion distance is used by actuation means, then the drying process can be automated, but excessive tension may be applied causing damage to leather fibers
Solution Approach 1:
The patent employs real-time feedback control where tension sensors continuously monitor the force applied to leathers during the automated drying process. When the measured tension approaches or exceeds the maximum safe threshold, the control unit automatically adjusts the actuation means to reduce the applied force, preventing fiber damage while maintaining automation benefits.
Solution Approach 2:
The patent transitions from a static fixed-expansion-distance system to a dynamic system where the expansion distance and applied tension are continuously adjusted based on real-time feedback from tension sensors. This allows the automation to adapt to variations in leather properties and drying conditions, preventing excessive tension while maintaining high automation levels.
3Device complexity
If no tension control is applied during drying, then the drying process is simple, but the leathers suffer from uneven tension and increased damage leading to higher waste
Solution Approach 1:
The patent introduces feedback control through tension sensors and control units that automatically monitor and adjust the tension applied to leathers during drying. This maintains relatively simple drying system operation while significantly improving leather quality consistency by preventing both excessive and insufficient tension conditions that lead to damage and variability.
Solution Approach 2:
The patent implements a self-regulating drying system where the control unit automatically adjusts the actuation means based on real-time tension measurements without requiring manual intervention. The system serves itself by detecting tension deviations and automatically correcting them, maintaining quality consistency while keeping the operational interface simple.
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
Achieves uniform surface expansion and tension across leather batches, reducing damage and waste, while maintaining optimal tension levels, thus enhancing product quality and efficiency.
Implementation Method 1
actuation means, overall numbered with 5, operatively connected with the support frames 4 and suitable to be operated in such a way as to stretch the leathers to the prefixed standard value
Implementation Method 2
detection means 7, generally indicated with 7, operatively connected with the actuation means 5 and having the function of measuring the tension value of the fibres of the leathers expanded
Implementation Method 3
air conditioning devices, (such as, for example, fans of axial type) and/or traction organs (such as pneumatic organs installed in the operative tunnel), suitable to work on the leathers so as to respectively dry and/or stretched them
Implementation Method 4
air conditioning devices, (such as, for example, fans of axial type) and/or traction organs (such as pneumatic organs installed in the operative tunnel), suitable to work on the leathers so as to respectively dry and/or stretched them
Data Source
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AI summary
Leathers, particularly tannery leathers, drying and/or conditioning method comprising the operations of establishing a prefixed standard expansion value of the leathers, loading at least one leather on at least one side face (4c, 4d) of support frames (4), conveying the support frames (4), provided with at least one leather, towards an operative tunnel (2) of a drying and/or conditioning plant (1), operating actuation means (5) in order to mechanically work on the support frames (4) in such a way as to stretch the leathers to the prefixed standard expansion value. In particular, the method comprises a step of controlling the level of expansion of the leathers which includes the operations of establishing a predetermined nominal tension value of the leathers, detecting the tension value of the fibres of the leathers expanded following the operation of the actuation means (5) on the support frames (4) at the operative tunnel (2), comparing the measured tension value with the predetermined nominal tension value, measuring tension deviation thereof and adjusting operation of the actuation means depending on such a measured tension deviation in such a way so as to keep the leathers spread and/or tensioned substantially to the predetermined nominal tension value.