Yarn Winding Tray Transport Segmentation
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Solution Overview
Problem
The existing yarn winding equipment faces issues with tray congestion and reduced processing efficiency due to trays staying on the bobbin processing device's discharge path, leading to a 'bridge phenomenon' where trays push each other and become stuck, causing operational halts and reduced productivity.
Innovation Solution
The equipment incorporates a tray detecting system that determines when trays are stuck on the discharge path and stops the conveyor mechanism, allowing the second conveyor mechanism to operate independently, preventing tray accumulation and resolving congestion by adjusting transport speeds and paths to prevent re-sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If trays are transported continuously along the discharge path by a shared conveyor belt, then cost is reduced, but tray congestion and bridge phenomenon occur leading to reduced processing efficiency
Solution Approach 1:
The patent divides the previously shared conveyor belt system into two independent conveyor belts: a first conveyor belt for transporting discharged trays from the discharge path, and a second conveyor belt for transporting trays within the bobbin processing device. This segmentation allows independent control of each conveyor, preventing tray congestion and bridge phenomenon while maintaining the cost-effective shared transport approach.
Solution Approach 2:
The patent implements independent drive sources for the first and second conveyor mechanisms, enabling dynamic and independent speed control. When tray congestion is detected on the discharge path, the control section can adjust the speed of the first conveyor belt independently of the second conveyor belt, allowing flexible response to congestion conditions while maintaining overall system productivity.
2Loss of time
If trays stay on the shared belt due to processing delays, then other trays accumulate in a bead-like state, but the bridge phenomenon causes operational halts
Solution Approach 1:
The patent employs a tray detecting section that continuously monitors the discharge path for tray congestion. When congestion is detected, the control section receives feedback and automatically adjusts the operation of the first conveyor mechanism, stopping or slowing it to prevent bridge phenomenon. This feedback loop ensures operational continuity by preventing congestion-related halts.
Solution Approach 2:
The patent prevents bridge phenomenon by taking preliminary action: when tray congestion is detected on the discharge path, the control section proactively stops or slows the first conveyor mechanism before the congestion can propagate to cause bridge phenomenon at the junction with individual paths. This preventive approach maintains operational reliability.
3Productivity
If the discharge path is congested, then individual paths get clogged and winding units cannot discharge trays, but the shared conveyor cannot clear the congestion
Solution Approach 1:
By segmenting the conveyor system into two independently controlled mechanisms, the patent enables differential control strategies. The first conveyor mechanism can be slowed or stopped to clear congestion on the discharge path, while the second conveyor mechanism continues operating to maintain processing within the bobbin processing device. This segmentation resolves the contradiction between maintaining discharge rate and managing congestion without requiring complex multi-conveyor coordination.
Solution Approach 2:
The patent changes the operational parameters (speed, stop/start state) of the first conveyor mechanism based on congestion conditions detected on the discharge path. When congestion is present, the control section adjusts the speed parameter of the first conveyor to clear the backlog, thereby maintaining overall productivity while managing the increased device complexity through parameter adjustment rather than structural complexity.
Data Source
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AI summary
A tray transport device (8) includes a first conveyor mechanism (50) that transports trays (T) along a first discharge path (43). A bobbin processing device (3) includes a second conveyor mechanism (60) that transports trays (T) along a second discharge path (32). A yarn winding equipment (1) includes a tray detecting section (38) that detects the trays (T) that are being transported along the second discharge path (32) and a determining section (5) that determines whether the tray (T) stays on the second discharge path (32) based on a detection result obtained in the tray detecting section. A control section (5), when the determining section (5) determines that the tray (T) stays on the second discharge path (32), stops operation of the first conveyor mechanism (50) in a state that the second conveyor mechanism (60) is operating.