The Research On Modeling And Optimization Of The Stenter Charmber

The Stenter is a wildly used machine in the finishing process in the textile industry.As a key component of the stenter,the chamber consume more than 85%energy of the machine.Therefore,it is of great significance to do the optimiztion of the chamber system to reduce the energy consumption of the heat setting process.By summarizes the relevant theoretical research and application of the chamber system in the heat setting process,this paper found that the current stenter chamber systems has two following critical problems:There are some defaults in the chamber system,such as unstable internal flow field and uneven temperature distribution;There are few mathematical models on the heat setting process,the process parameters are mainly dependence on experience,therefore,the quality of the heating was unstable and the energy consumption was high.In view of the above two problems,this paper focused on the research on the modeling and optimization of the chamber system,the main work are as follows:1)Designing the vortex crushing device and the backflow structure.Firstly,a 3D model of the stenter chamber was established base on the existing production schemes.Then,the numerical simulation analysis of the chamber was carried out by using the hydrodynamics software,the distributions of temperature field and velocity field were analyzed.According to the analysis,this paper found that the flow inside the chamber runs poorly and the existence of the vortex,then a kind of vortex breakdown structure was proposed,it effectively improved the flow field performance inside the chamber and increased the utilization rate of energy.Furthermore a back:flow structure which solve the problem of flow disorder above the air duct in the chamber was designed and had achieved good results.2)Building the mathematic models of the heat-setting process.By analyzing the heat setting process of the dry fabric in the chamber system of the stenter,a real-time temperature mathematic model was built,and well verified by compassion with experimental results.For wet fabric heat setting process,the temperature model,the water evaporation model and the water content model were established based on the basic principles of heat and mass transfer and evaporation characteristics.Then the influence of various factors on the heat setting of the fabrics,such as oven temperature,initial moisture content and oven humidity were analyzed.3)Building the energy consumption models of the heat setting process.Based on the mathematical analysis of the above two kinds of fabrics heat setting process,the mathematical model of the total heat consumption of chamber is established.And the mathematic models of fabric heating,air heating,evaporation,exhaust and cooling energy consumption of heat setting process were respectively established.Then,the energy consumption data were calculated through a polyester fabric heat setting process,and the energy flow diagram was drawn.By comparing with the statistical data mentioned in the literature,the results verify the accuracy of the model.4)Optimizing the setting parameters of the heat setting process.Taking fabric production energy consumption minimization as the objective function,this paper used the temperature of each chamber,the fabric speed as the optimization variables,an improved PSO algorithm as optimization strategy,and the optimization in the heat setting process was done.Several cases results proved that the optimization algorithm proposed can effectively reduce process energy consumption and improve production efficiency.5)Designing the chamber control system based on DSC.The paper designed the stenter chamber control system which combine with electric control cabinet and DCS configuration software,was used in the cooperative company.The system shows a good precision and fast response speed in the control of key parameters.