Staggered Workstation Start for Textile Machine Overload Prevention
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Solution Overview
Problem
Textile machines producing cross-wound bobbins face disruptions and overloads during mass starts of workstations, particularly after a lot change or power failure, due to high energy and suction air demands, leading to inefficiencies and mechanical issues like vibrations and communication overloads.
Innovation Solution
Implementing a method where the start of workstations is staggered by delaying the switch-on pulse for each job by a minimum period, initially 1 ms, and up to 15 ms, to ensure all conditions are met before subsequent starts, preventing simultaneous overloads and allowing for staggered communication and energy provision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all workstations are started simultaneously after a batch change or power failure, then the resumption of production is fastest, but the suction air system and energy supply become overloaded
Solution Approach 1:
The patent segments the simultaneous start-up of all workstations into sequential start-up groups. The control unit divides the plurality of workstations into multiple groups and activates them in sequence rather than simultaneously, preventing overload of the suction air system and energy supply while still achieving rapid resumption of production.
2Reliability
If workstations are started sequentially with delays, then system overload is prevented, but the resumption time increases
Solution Approach 1:
The patent implements dynamic control of the start-up process by using a control unit that automatically manages the sequential activation of workstation groups. The system dynamically adjusts the timing and grouping of start-ups based on system capacity, optimizing both reliability and resumption time through automated decision-making rather than fixed delays.
3Quantity of substance
If the suction air motor speed is increased to meet high demand, then suction air availability improves, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by pre-planning and pre-sequencing the activation of workstations before the actual start-up occurs. The control unit determines the optimal sequence and timing of group activations in advance, ensuring that suction air demand is distributed over time rather than peaking simultaneously, thereby avoiding the need to increase motor speed and reducing energy consumption.
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 approach prevents bottlenecks and overloads, ensuring smooth operation by equalizing energy and suction air supply, reducing mechanical vibrations, and allowing for controlled ramp-up of workstations, thereby enhancing production efficiency and reliability.
Implementation Method 1
suction air is constantly required during operation to extract the fiber dust that continuously accumulates during the rewinding process
Implementation Method 2
a so-called spinning vacuum must be maintained constantly in the rotor housing of the open-end spinning unit
Data Source
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AI summary
The invention relates to a method or device for operating a textile machine (5) producing cross-wound bobbins, which has a plurality of individually driveable, autonomously operating workstations (1) and a central control unit (10). According to the invention, it is provided that the workstations (1) affected by a mass start of all workstations (1) of the textile machine (5) or by a start of a plurality of the workstations (1) of the textile machine (5) are started successively by delaying the start-up pulse for the workstations following the first workstation by a minimum time interval of 1 ms compared to the previously started workstation.