Modular Conveyor System for Yarn Production Energy Reduction
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Solution Overview
Problem
Current yarn production systems face challenges in efficiently transporting full wraps and empty sleeves between machines, leading to operational disruptions, inflexible layout designs, and high energy consumption.
Innovation Solution
An automatic full wrap and empty sleeve transport system is introduced, featuring modular design with handover and buffer modules, coordinated interfaces, and independent funding for efficient transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional conveyor belt system is used to transport full laps and empty tubes, then the system can maintain continuous operation, but the entire conveyor belt must be moved at any one time which results in high energy consumption and requires perfect coordination between ejection and removal
Solution Approach 1:
The conveyor belt system is divided into multiple independent conveyor sections (first conveyor section, second conveyor section, third conveyor section) that can be operated independently. Each section has its own drive mechanism, allowing selective operation of only the sections needed for current transport tasks, thereby reducing overall energy consumption while maintaining continuous operation capability.
Solution Approach 2:
The system employs dynamic control where conveyor sections are activated or deactivated based on real-time production needs. The coordination between ejection from combing preparation machines and removal at combing machines is maintained through independent control of each conveyor section, allowing the system to adapt to varying loads and reduce energy usage during partial operation.
2Device complexity
If a fixed ratio transport system is used where one combing preparation machine is followed by a specific number of combing machines, then the system can be simplified, but the layout cannot be designed flexibly when space or production requirements change
Solution Approach 1:
The transport system is segmented into independent conveyor sections that can be individually configured and controlled. This allows the system to adapt to different numbers of combing machines and preparation machines by activating or deactivating specific sections, providing layout flexibility without increasing overall system complexity.
Solution Approach 2:
The system can operate in different periodic modes depending on production requirements. Conveyor sections can be activated in sequences that match varying production rhythms, allowing the same physical infrastructure to support different machine ratios and production scenarios.
3Extent of automation
If the conveyor belt is long enough to accommodate approximately two batches, then full laps can be transported automatically, but the system comes to a standstill when the transfer point is occupied and coordination between ejection and removal is not perfect
Solution Approach 1:
The conveyor system is divided into multiple sections that can operate independently. When one section is occupied or experiencing delays, other sections can continue transporting laps, preventing complete system standstill and maintaining higher productivity while preserving automatic transport capability.
Solution Approach 2:
The segmented conveyor sections act as intermediaries between the combing preparation machines and combing machines. Each section can buffer and coordinate transport independently, allowing the system to maintain automatic operation even when coordination challenges arise at specific transfer points.
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to an automatic full-winding and empty-core transport system (1) for combing preparation, comprising at least one transfer module (2) and at least one buffer module (3), wherein both the at least one transfer module (2) and the at least one buffer module (3) comprise a frame (4), the respective frame (4) comprising a first and second cooperating side (5.1, 5.2), and wherein the frame (4) of the at least one transfer module (2) additionally comprises a first and/or second production-cooperating side (6.1, 6.2). Furthermore, the at least one transfer module (2) and the at least one buffer module (3) comprise two conveying means (7, 8).The transport system (1) is designed such that the individual modules (2, 3) are arranged one after the other in a conveying direction (9) starting with a transfer module (2) and interfaces (10) are formed between the modules (2, 3) which in turn are designed such that at least one full coil (11) to be transported and/or at least one empty sleeve (12) to be transported pass through these interfaces (10) in a coordinated manner.