Machine for treating fabrics with an adjustable air flow
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Solution Overview
Problem
Existing fabric treatment machines with air flow diverters face issues with inaccurate stopping and positioning due to high starting forces and compressible control air, leading to potential damage and variable fabric treatment effects.
Innovation Solution
The machine employs dual pneumatic solenoid valves with different flow rates to control the air flow diverter valve, using a high-flow rate for initial movement and a low-flow rate for precise stopping, combined with an angular position sensor and control unit for accurate positioning, and a simpler setup for the lower deflector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pneumatic cylinder is used to control the air flow diverter valve, then the device complexity is reduced, but the positioning precision and stopping accuracy deteriorate due to high starting forces and compressible control air
Solution Approach 1:
The control system is segmented into two independent pneumatic cylinders: a first pneumatic cylinder for moving the deflector from the rest position to intermediate positions, and a second pneumatic cylinder for precise positioning at extreme positions. This segmentation allows each cylinder to be optimized for its specific function, resolving the contradiction between system simplicity and positioning precision.
Solution Approach 2:
The control system transitions from a static single-cylinder design to a dynamic two-cylinder system where each cylinder operates in specific phases. The first cylinder handles the initial movement phase requiring high force, while the second cylinder handles the final positioning phase requiring high precision, allowing the system to adapt its characteristics to the requirements of each operational phase.
2Productivity
If high pressure air is used to move the deflector quickly, then the productivity is improved, but the manufacturing precision deteriorates due to violent impact at limit stops and variable positioning
Solution Approach 1:
The air flow control is segmented into two phases: a first phase using high pressure air from the first pneumatic cylinder for rapid movement (improving productivity), and a second phase using low pressure air from the second pneumatic cylinder for precise positioning (improving manufacturing precision). This eliminates the compromise between speed and accuracy.
Solution Approach 2:
The second pneumatic cylinder acts as a cushioning mechanism before the deflector reaches the extreme positions. By taking over control in the final positioning phase, it prevents violent impacts at limit stops and ensures repeatable positioning, cushioning the transition from high-speed movement to precise stopping.
3Adaptability or versatility
If the deflector partially blocks air channels to divide air flow, then the adaptability is improved for variable fabric treatment, but the device complexity increases due to the need for precise positioning control
Solution Approach 1:
The system dynamically adjusts the deflector position to three distinct states: rest position (full air flow to one channel), intermediate positions (partial blocking for divided air flow), and extreme positions (full blocking for reversed air flow). The dual-cylinder control system enables this dynamic adaptability while maintaining manageable complexity through functional segmentation.
Solution Approach 2:
The system changes the air flow parameters by adjusting the deflector position. The first pneumatic cylinder handles the gross parameter change (moving from rest to intermediate position), while the second pneumatic cylinder handles the fine parameter adjustment (precise positioning at extreme points), enabling versatile air flow distribution without excessive system complexity.
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 solution ensures accurate and repeatable positioning of the air flow diverter valve, reducing the risk of damage and improving the consistency of fabric treatment by maintaining precise control over air flow distribution.
Implementation Method 1
a first pneumatic cylinder (20) connected to the deflector (17) and adapted to move the deflector (17) from the rest position to the intermediate positions
Implementation Method 2
The device comprises a pneumatic cylinder (20) connected to the deflector (17) and actuated by two pneumatic solenoid valves (22, 24) arranged in parallel
Data Source
Figure 1~2
Figure 3a~3d
Figure 4
AI summary
A machine for treating a fabric (T) with air comprises a duct (10) for pneumatic transfer of the fabric, which has a diverter valve (16) located substantially halfway of the duct and equipped with an angularly adjustable deflector (17) adapted to completely or partially block air access in two channels (16a, 16b) oriented to direct the air flow (F) introduced into the duct in one direction or the other. A control unit (UC) instantaneously detects the angular position of the deflector (17) by means of an electronic sensor (26) and actuates a pneumatic cylinder (20) for controlling the deflector (17) via two pneumatic solenoid valves (22, 24) arranged in parallel and having different flow rates.