Optimization method of winding ratio used in production of direct yarn cake by using wire drawing machine

Abstract

The invention discloses a method for optimizing a winding ratio used when a wire drawing machine is used for producing a direct yarn cake, and relates to the technical field of direct yarn production. The invention provides a set of winding ratio design method suitable for products with different linear densities, meanwhile, when the product forming quality and degradation problems occur, the winding ratio can be scientifically and fundamentally adjusted in a targeted mode, and on the premise that the product forming quality and degradation performance are guaranteed, the production efficiency can be improved, the energy consumption can be reduced, and the production cost can be reduced. And the problem is fundamentally solved.

Description

Technical Field

[0001] The present invention relates to the technical field of direct yarn production, and particularly to an optimization method for the winding ratio used in the production of direct yarn cakes by a wire drawing machine. Background Art

[0002] During the wire drawing and winding process of direct yarn, the winding ratio, as a core process parameter, is defined as the number of turns that the head of the wire drawing machine rotates when the traversing shuttle completes one reciprocating motion cycle during the winding of the tow. This parameter is not only a key control point in the production process, but also has a direct and profound impact on key indicators such as the forming quality and unwinding performance of the final product.

[0003] Specifically, the magnitude of the winding ratio directly determines the packing density and uniformity of the tow during the winding process. A suitable winding ratio can ensure that the tow maintains a stable tension during the winding process, avoiding problems such as looseness, overlap, or breakage, thereby guaranteeing the forming quality of the product. At the same time, the winding ratio also affects the unwinding performance of the product, that is, the ability of the tow to be smoothly unwound from the wound state. If the winding ratio is set improperly, problems such as jamming, wire breakage, and adhesion may occur during unwinding, seriously affecting subsequent processing and use.

[0004] However, currently in the industry when producing direct yarn, most of the winding ratios adopted are a limited number of values fixed based on long-term production practice verification. Although these winding ratios can meet the production requirements to a certain extent, there is still a lack of systematic winding ratio design and optimization methods. When encountering forming or unwinding problems caused by an inappropriate winding ratio during production, it is often impossible to quickly and accurately determine the root cause of the problem and make scientific and effective adjustments and optimizations accordingly.

[0005] In the past, when solving such problems, it was usually necessary to rely on the production experience of technicians and find a suitable winding ratio through multiple winding ratio enumeration tests. This method is not only inefficient, consuming a large amount of human and material resources, but also may produce a large number of unqualified products during the test, causing greater economic losses. In addition, due to the lack of systematic theoretical guidance, the test results often have a certain degree of randomness and uncertainty, making it difficult to guarantee a fundamental solution to the problem.

[0006] Therefore, aiming at the problem of optimizing the winding ratio during the wire drawing and winding process of direct yarn, it is urgent to carry out systematic research and exploration, establish scientific and effective winding ratio design and optimization methods, and provide strong theoretical support and practical guidance for the adjustment and optimization of the winding ratio during the production process. Summary of the Invention

[0007] The technical problem to be solved by the present invention is: to overcome the shortcomings of the prior art and provide a method for optimizing the winding ratio used in producing direct yarn cakes using a wire drawing machine, which is suitable for products with different linear densities, and when encountering problems with product molding quality and debonding, the winding ratio can be scientifically and purposefully adjusted, which can improve production efficiency and reduce energy consumption while ensuring product molding quality and debonding performance, thereby fundamentally solving the problem.

[0008] The technical solution of the present invention is:

[0009] The optimization method of the winding ratio used in the production of direct yarn cakes by a wire drawing machine is to calculate the winding ratio according to the following formula:

[0010] X=I+(N+O / 360) / M

[0011] Wherein, X-winding ratio; O-offset angle (refers to the relative offset angle of the folding points in the two adjacent layers of mesh structure on the end surface when the silk cake is wound), °; I, N, M are all integers, and the values ​​of I, N, M are as follows:

[0012] When the direct yarn density is ≤300tex, I=8-10, M=15-30, O=-0.75-0.75;

[0013] When 300tex<direct yarn density<600tex, I=7~9, M=15~20, O=-1~1;

[0014] When 600tex≤direct yarn density<2400tex, I=5~8, M=10~25, O=-1.5~1.5;

[0015] When 2400tex≤direct yarn density<4800tex, I=3~7, O=-2~2;

[0016] When the direct yarn density is ≥4800tex, I = 2 to 5, O = -3 to 3;

[0017] When the direct yarn density is ≥2400tex, M=10-20;

[0018] N and M are relatively prime, and (M / 3-1)≤N≤(M / 3+1) or (2M / 3-1)≤N≤(2M / 3+1), and N is the integer rounded off after calculation.

[0019] Preferably, when the formed saddle problem occurs in the produced silk cake, it is solved by the following method: Among increasing the I value by 1, decreasing the M value by 2, and decreasing the absolute value of O by 0.25, any one or more of the solutions are selected, substituted into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, the new winding ratio is maintained; if not, the winding ratio is adjusted repeatedly according to the above solutions; and when adjusting M, the N value is also adjusted accordingly.

[0020] Preferably, when the produced silk cake has an excessive winding diameter resulting in the whole tray being unable to be packed, it is solved by the following method: Among increasing the M value by 2 and increasing the absolute value of O by 0.25, any one or two of the solutions are selected, substituted into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, the new winding ratio is maintained; if not, the winding ratio is adjusted repeatedly according to the above solutions; and when adjusting the M value, the N value is also adjusted accordingly.

[0021] Preferably, when the growth rate after drying of the produced silk cake > 7%, it is solved by the following method: Decrease the I value by 1, substitute it into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, the new winding ratio is maintained; if not, the winding ratio is adjusted repeatedly according to the above solutions.

[0022] Preferably, when the produced silk cake has a small unwinding tension and the silk bundle slides down and knots, it is solved by the following method: Among decreasing the M value by 2 and increasing the absolute value of O by 0.25, any one or two of the solutions are selected, substituted into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, the new winding ratio is maintained; if not, the winding ratio is adjusted repeatedly according to the above solutions; and when adjusting the M value, the N value is also adjusted accordingly.

[0023] Preferably, when the silk bundle adheres and is lifted during the unwinding of the produced silk cake, it is solved by the following method: Increase the absolute value of O by 0.25, substitute it into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, the new winding ratio is maintained; if not, the winding ratio is adjusted repeatedly according to the above solutions.

[0024] Preferably, when the ratio of the water extraction time to the total drying time of the produced silk cake > 80%, it is solved by the following method: Decrease the M value by 2, substitute it into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, the new winding ratio is maintained; if not, the winding ratio is adjusted repeatedly according to the above solutions; and when adjusting the M value, the N value is also adjusted accordingly.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] The present invention conducts in-depth research and innovative design on the key process parameter winding ratio in the direct yarn drawing winding process, aiming to solve the long-standing problems in the industry such as the solidification of winding ratio and the lack of system optimization methods. The present invention first proposes a set of winding ratio design methods suitable for products with different line densities based on actual production needs. At the same time, when encountering problems with product molding quality and debonding, the winding ratio can be scientifically and rationally adjusted. Under the premise of ensuring product molding quality and debonding performance, it can improve production efficiency and reduce energy consumption, thus fundamentally solving the problem. DETAILED DESCRIPTION

[0027] In order to enable persons skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention.

[0028] Example 1

[0029] In this embodiment, a direct yarn product with a linear density of 300 tex is produced. Taking I=8, N=7, M=17, and O=1, the formula X=I+(N+O / 360) / M is substituted to calculate the winding ratio X=8.411928.

[0030] It was found that the produced silk cakes had a forming saddle problem. After increasing the I value by 1 and reducing O by 0.25, it was found that the problem was not solved. After reducing O by 0.25 again, the winding ratio X=9.411846 was calculated, and it was found that the forming saddle problem was solved.

[0031] Example 2

[0032] In this embodiment, a direct yarn product with a linear density of 2400 tex is produced. Taking I=6, N=4, M=15, O=1.5, and substituting into the formula X=I+(N+O / 360) / M, the winding ratio X=6.266944 is calculated.

[0033] It was found that the produced silk cakes had a problem of too large a coil diameter, which made it impossible to pack the entire tray. After increasing the M value by 2, O by 0.25, and N by 1, it was found that the problem was not solved. After increasing O by 0.25 again, the winding ratio X=6.294444 was calculated, and it was found that the coil diameter was reduced, solving the problem of large coil diameter.

[0034] Example 3

[0035] In this embodiment, a direct yarn product with a linear density of 2000tex is produced. Taking I=6, N=7, M=17, and O=1, the formula X=I+(N+O / 360) / M is substituted to calculate the winding ratio X=6.411928.

[0036] It was found that the problem of the growth rate of the silk cakes after drying being > 7% occurred. After reducing the I value by 1, the winding ratio X = 5.411928 was calculated, and it was found that the growth rate decreased, thus solving the problem of large growth rate.

[0037] Example 4

[0038] In this example, a direct yarn product with a linear density of 300 tex was produced. Taking I = 9, N = 12, M = 19, O = 0.25, and substituting them into the formula X = I + (N + O / 360) / M, the winding ratio X = 9.631616 was calculated.

[0039] It was found that the problems of small unwinding tension and the silk bundle slipping and knotting occurred in the produced silk cakes. After reducing the M value by 2, increasing the O value by 0.25, and reducing the N value by 1, the winding ratio X = 9.647141 was calculated, and it was found that the unwinding tension increased, thus solving the problems of small unwinding tension and the silk bundle slipping and knotting.

[0040] Example 5

[0041] In this example, a direct yarn product with a linear density of 600 tex was produced. Taking I = 8, N = 6, M = 17, O = 0.25, and substituting them into the formula X = I + (N + O / 360) / M, the winding ratio X = 8.352982 was calculated.

[0042] It was found that the problem of the silk bundle sticking and being lifted occurred during the unwinding of the produced silk cakes. After increasing the O value by 0.25, it was found that the winding ratio X = 8.353023, thus solving the problem of unwinding adhesion.

[0043] Example 6

[0044] In this example, a direct yarn product with a linear density of 300 tex was produced. Taking I = 9, N = 15, M = 23, O = -0.7, and substituting them into the formula X = I + (N + O / 360) / M, the winding ratio X = 9.652089 was calculated.

[0045] It was found that the ratio of the drying water extraction time of the produced silk cakes to the total drying time reached 85%. After reducing the M value by 2 and reducing the N value by 1, the winding ratio X = 9.666574 was calculated, and it was found that the drying water extraction rate increased, thus solving the problem of difficult drying.

Claims

1. An optimization method for the winding ratio used in the production of direct yarn cakes by a drawing machine, characterized in that, Calculate the winding ratio according to the following formula: X = I + (N + O / 360) / M Wherein, X - winding ratio; O - offset angle, °; I, N, and M are all integers, and the values of I, N, and M are as follows: When the direct yarn density ≤ 300 tex, I = 8 - 10, M = 15 - 30, O = -0.75 - 0.75; When 300 tex < direct yarn density < 600 tex, I = 7 - 9, M = 15 - 20, O = -1 - 1; When 600 tex ≤ direct yarn density < 2400 tex, I = 5 - 8, M = 10 - 25, O = -1.5 - 1.5; When 2400 tex ≤ direct yarn density < 4800 tex, I = 3 - 7, O = -2 - 2; When the direct yarn density ≥ 4800 tex, I = 2 - 5, O = -3 - 3; When the direct yarn density ≥ 2400 tex, M = 10 - 20; N and M are relatively prime, and (M / 3 - 1) ≤ N ≤ (M / 3 + 1) or (2M / 3 - 1) ≤ N ≤ (2M / 3 + 1), and N takes the integer after rounding off the calculation.

2. The optimization method of the winding ratio used when producing a direct yarn cake by a wire drawing machine as described in claim 1, characterized in that, When the formed saddle problem appears in the produced silk cake, solve it in the following way: Among increasing the I value by 1, decreasing the M value by 2, and decreasing the absolute value of O by 0.25, select one or more solutions, substitute them into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, keep the new winding ratio; if not, repeat adjusting the winding ratio according to the above solutions; And when adjusting M, also adjust the N value accordingly.

3. The optimization method of the winding ratio used in the production of direct yarn cakes by a wire drawing machine as described in claim 1, characterized in that, When the produced silk cake has a too large winding diameter resulting in the entire tray being unable to be packed, solve it in the following way: Among increasing the M value by 2 and increasing the absolute value of O by 0.25, select one or two solutions, substitute them into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, keep the new winding ratio; if not, repeat adjusting the winding ratio according to the above solutions; and when adjusting the M value, also adjust the N value accordingly.

4. The optimization method of the winding ratio used in the production of direct yarn cakes by a wire drawing machine as described in claim 1, characterized in that, When the growth rate after drying of the produced silk cake > 7%, solve it in the following way: Decrease the I value by 1, substitute it into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, keep the new winding ratio; If not, repeat adjusting the winding ratio according to the above solutions.

5. The optimization method of the winding ratio used in the production of direct yarn cakes by a wire drawing machine as described in claim 1, characterized in that, When the produced silk cake has a small unwinding tension and the silk bundle slides down and knots, solve it in the following way: Among decreasing the M value by 2 and increasing the absolute value of O by 0.25, select one or two solutions, substitute them into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, keep the new winding ratio; if not, repeat adjusting the winding ratio according to the above solutions; and when adjusting the M value, also adjust the N value accordingly.

6. The optimization method of the winding ratio used in the production of direct yarn cakes by a wire drawing machine as described in claim 1, characterized in that, When the produced silk cake has the silk bundle sticking and being lifted during unwinding, solve it in the following way: Increase the absolute value of O by 0.25, substitute it into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, keep the new winding ratio; If not, repeat adjusting the winding ratio according to the above solutions.

7. The optimization method of the winding ratio used in the production of direct yarn cakes by a wire drawing machine as described in claim 1, characterized in that, When the ratio of the drying and water extraction time of the produced silk cake to the total drying time > 80%, it is solved in the following way: reduce the M value by 2, substitute it into the above formula to calculate the new winding ratio for actual production verification. If the problem is solved, maintain the new winding ratio; If not, repeat to adjust the winding ratio according to the above plan; and when adjusting the M value, adjust the N value accordingly.