Suction Blower Static Pressure Control in Automatic Winders

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Solution Overview

Problem

Automatic winders face challenges in maintaining consistent static pressure in suction airflow, leading to increased power consumption and potential failures in yarn joining operations due to accumulated yarn waste, which existing feedback control methods struggle to address effectively.

Innovation Solution

A static pressure control method that includes a startup process to initially set and maintain higher static pressure, followed by an initial feedback process with shorter control periods and higher acceleration/deceleration rates to rapidly adjust the suction blower frequency, and a normal feedback process to maintain the set pressure, reducing power consumption and ensuring reliable yarn joining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the static pressure is set high from the beginning to compensate for pressure lowering, then the suction force is maintained, but the power consumption of the suction blower increases

Engineering Contradiction:

Improvesuction forceVSAvoidpower consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The suction blower operates in two dynamic modes: a startup mode with high static pressure to ensure reliable yarn joining, and a normal operation mode with lower static pressure to reduce power consumption. The system dynamically transitions between these modes based on operational phase, resolving the contradiction between maintaining suction force and minimizing energy use.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The suction blower employs periodic control with distinct phases: a startup process that maintains high static pressure for a predetermined period, followed by a normal operation process with reduced pressure. This periodic action ensures reliable yarn joining during startup while minimizing power consumption during extended operation periods.

Inventive Principle:

Principle #19Periodic action

2Use of energy by moving object

If feedback control is used to maintain static pressure, then power consumption is reduced, but the static pressure hunches (vibrates) and may become higher than the set value, causing power consumption to increase

Engineering Contradiction:

Improvepower consumptionVSAvoidstatic pressure stability

Core Design Contradiction:

Use of energy by moving objectVSStability of the object's composition

Solution Approach 1:

The system performs preliminary high-pressure operation during the startup process to ensure all winding units are properly initialized before transitioning to normal operation. This preliminary action prevents pressure instability by establishing a stable baseline state before feedback control takes over.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A feedback control mechanism continuously monitors static pressure and adjusts the suction blower operation accordingly. During normal operation, feedback maintains pressure at the set value while preventing excessive pressure buildup, thereby stabilizing pressure and minimizing power consumption.

Inventive Principle:

Principle #23Feedback

3Use of energy by moving object

If feedback control is used to maintain static pressure, then power consumption is suppressed, but a long time is required to match the static pressure to the set value at startup

Engineering Contradiction:

Improvepower consumptionVSAvoidstartup time

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The control system implements a two-stage periodic operation: an initial startup process that rapidly establishes high static pressure to ensure immediate yarn joining capability, followed by a normal operation process with feedback control that maintains pressure at the set value. This periodic structure reduces startup time while minimizing overall power consumption through the extended normal operation phase.

Inventive Principle:

Principle #19Periodic action

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 method effectively reduces power consumption by minimizing the duration of high static pressure states and ensures consistent yarn joining operations by rapidly matching static pressure to the set value, preventing failures during startup and normal operation.

Implementation Method 1

a suction blower adapted to supply the suction airflow... a static pressure of the suction airflow becomes higher than a predetermined set value

Methodology Applied

Scientific EffectPressure difference: Pressure Gradient

Implementation Method 2

a static pressure detecting section adapted to detect a static pressure of the suction airflow

Methodology Applied

Scientific EffectStatic pressure detection:

Data Source

PatentEP3511274B1Static pressure control method in automatic winder and automatic winder

Publication Date: 2021.02.03 MURATA MASCH LTD

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AI summary

A static pressure control method includes a startup process of activating a suction blower (41) so that a static pressure of a suction airflow becomes higher than a predetermined set value (P1) at a time of startup of a plurality of winding units (2); an initial feedback process of feedback controlling a frequency of the suction blower (41) to lower the static pressure of the suction airflow to the set value (P1) after the startup process; and a normal feedback process of feedback controlling the frequency of the suction blower to maintain the static pressure of the suction airflow at the set value (P1) after the initial feedback process. A control period in the initial feedback process is shorter than a control period in the normal feedback process.